KTC KME 18-22-30-37 Operation And Maintenance Manual
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KTC KME 18-22-30-37 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
KME 18-22-30-37 COMPRESSORS
ENGLISH VERSION
OPERATION AND INSTALLATION MANUAL
pag.1 of 68
COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016

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Summary of Contents for KTC KME 18-22-30-37

  • Page 1 K.T.C. shall safeguard its rights to the full extent of the law. OPERATION AND MAINTENANCE MANUAL FOR KME 18-22-30-37 COMPRESSORS ENGLISH VERSION OPERATION AND INSTALLATION MANUAL pag.1 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...

  • Page 2: Table Of Contents

    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 OPERATION AND INSTALLATION MANUAL pag.2 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...
  • Page 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 OPERATION AND INSTALLATION MANUAL pag.3 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...
  • Page 4 TROUBLESHOOTING ..................64 10 COMMERCIAL PARTS, SPARE PARTS AND PERTINENT DOCUMENTATION ..................66 11 APPENDIX ......................67 11.1 MAINTENANCE CHECK SHEET ................67 OPERATION AND INSTALLATION MANUAL pag.4 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...

  • Page 5: General Warnings And Information For The User

    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. OPERATION AND INSTALLATION MANUAL pag.5 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...

  • Page 6: Warranty

    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.

  • Page 7: Applicable Standards

     Serial number  Maximum working pressure  Power supply voltage and frequency  Nominal power  Weight  Manufacture year Figure 1 OPERATION AND INSTALLATION MANUAL pag.7 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...

  • Page 8: Cautions And Safety Warnings

    6. Work Clothing Do not wear inappropriate clothing or accessories. If necessary, wear a cap that covers the hair. OPERATION AND INSTALLATION MANUAL pag.8 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...
  • Page 9 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. OPERATION AND INSTALLATION MANUAL pag.9 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...
  • Page 10 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! OPERATION AND INSTALLATION MANUAL pag.10 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...

  • Page 11: Contacts And Useful Addresses

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

  • Page 12: Description Of The Machine And Operating Principle

    38- Air outlet line lever cock 9- Low pressure valve 17- Oil filter 32- Control panel 10- Power button 22- Oil recovery window OPERATION AND INSTALLATION MANUAL pag.12 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...

  • Page 13: Operating Principle

    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). OPERATION AND INSTALLATION MANUAL pag.13 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...

  • Page 14: Presentation Of The Manual: Content And Consultation

    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. OPERATION AND INSTALLATION MANUAL pag.14 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...

  • Page 15: Data And Technical Specifications

    ** 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. OPERATION AND INSTALLATION MANUAL pag.15 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...
  • 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. OPERATION AND INSTALLATION MANUAL pag.16 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...

  • Page 17: Installation

    The user must dispose of packaging in compliance with current national regulations. The machine must be unpacked by qualified personnel using suitable tools. OPERATION AND INSTALLATION MANUAL pag.17 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...

  • Page 18: Handling

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

  • Page 19: Location

    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). OPERATION AND INSTALLATION MANUAL pag.19 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...
  • Page 20 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 OPERATION AND INSTALLATION MANUAL pag.20 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...

  • Page 21: Connection And Start-Up

    Directive 98/37/EEC. Check the label on the compressor and at the beginning of this manual for indication of your model. OPERATION AND INSTALLATION MANUAL pag.21 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...

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

  • Page 23: Connecting The Compressor To The Electrical Power Supply

    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. OPERATION AND INSTALLATION MANUAL pag.23 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...
  • Page 24 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. OPERATION AND INSTALLATION MANUAL pag.24 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...

  • Page 25: Information On Thermal Relay Calibration

    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 OPERATION AND INSTALLATION MANUAL pag.25 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...

  • Page 26: Wiring Diagram Kme 18-22-30-37 400V

    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. 5.7.5 WIRING DIAGRAM KME 18-22-30-37 400V OPERATION AND INSTALLATION MANUAL pag.26 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...
  • Page 27 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 INSTALLATION MANUAL pag.27 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...
  • Page 28 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 INSTALLATION MANUAL pag.28 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...
  • Page 29 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 INSTALLATION MANUAL pag.29 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...
  • 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. OPERATION AND INSTALLATION MANUAL pag.30 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...
  • Page 31 MORSETTO PORTAFUSIBILE SIEMENS 8WA1011-1SF12 / 5X20 8WA1011-1SF12 / 5X20 8WA1011-1SF12 / 5X20 8WA1011-1SF12 / 5X20 FUSE-HOLDER TERMINAL MORSETTO PORTAFUSIBILE SIEMENS FUSE-HOLDER TERMINAL OPERATION AND INSTALLATION MANUAL pag.31 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...

  • Page 32: Compressor Connection To Electrical Power Supply

    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. OPERATION AND INSTALLATION MANUAL pag.32 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...

  • Page 33: First Start-Up

    WARNING! Always carefully follow the SAFETY WARNINGS regarding use of the machine. This is extremely important. OPERATION AND INSTALLATION MANUAL pag.33 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...

  • Page 34: Cleaning And Disinfection

    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. OPERATION AND INSTALLATION MANUAL pag.34 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...

  • Page 35: Operation And Use

    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). OPERATION AND INSTALLATION MANUAL pag.35 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...

  • Page 36: Safety Devices And Signals

    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 OPERATION AND INSTALLATION MANUAL pag.36 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...

  • Page 37: Dangers And Risks That Can Be Eliminated

    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.

  • Page 38: Compressor Lubrication

    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. OPERATION AND INSTALLATION MANUAL pag.38 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...

  • Page 39: Using The Compressor With Synthetic Oils

    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. OPERATION AND INSTALLATION MANUAL pag.39 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...

  • Page 40: Instructions For The User

    K.T.C. shall safeguard its rights to the full extent of the law. 7 INSTRUCTIONS FOR THE USER DESCRIPTION OF THE CONTROL DEVICES ELECTRONIC CONTROLLER Ktronic ¹º OPERATION AND INSTALLATION MANUAL pag.40 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...

  • Page 41: Button Layout

    STOP BUTTON when pressed, this button stops the compressor after a set period of time ALARM IN PROGRESS WARNING REMOTE CONNECTION WARNING OPERATION AND INSTALLATION MANUAL pag.41 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...

  • Page 42: Alarms List

    Mushroom head emergency stop button "Emergency SWITCH" pressed "ANOMALIA FASI " Phase sequence inverted "AC. Phase ERROR " "ALLARME SISTEMA!" General alarm "SISTEM ALARM !!!" OPERATION AND INSTALLATION MANUAL pag.42 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...

  • Page 43: Description Of The Operations To Be Performed

    ALARMS HISTORY page 16/16 Description of pressure calibration for Set Reset Scroll history using ) and STOP START to continue scrolling through the screens OPERATION AND INSTALLATION MANUAL pag.43 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...
  • Page 44 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). OPERATION AND INSTALLATION MANUAL pag.44 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...

  • Page 45: Start, Stop And Emergency Stop Functions

    RESET CONDITIONS To reset emergency button functions, turn the button clockwise; this will enable the compressor to start. OPERATION AND INSTALLATION MANUAL pag.45 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...

  • Page 46: Compressor Maintenance

    2000 hours Air filter cartridge KME 30 N11L0104 KME 37 N11L0104 CAUTION!!! USE ONLY ORIGINAL SPARE PARTS!!! CAUTION!!! HOT PARTS INSIDE!!! OPERATION AND INSTALLATION MANUAL pag.46 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...

  • Page 47: Belt Tensioning

    EXCESSIVE BELT TENSION DECREASES THE LIFE OF THE SCREW BEARINGS. WHEN THE MACHINE IS RUNNING, THE DRIVE MUST BE PROTECTED TO PREVENT INJURY. OPERATION AND INSTALLATION MANUAL pag.47 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...
  • Page 48 K.T.C. shall safeguard its rights to the full extent of the law. 1- Loosen the screws (1) and open the panel (2) 2- Loosen the screws (3) OPERATION AND INSTALLATION MANUAL pag.48 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...
  • Page 49 K.T.C. shall safeguard its rights to the full extent of the law. 3- Remove the panel (4). 4- Loosen the electric motor fixing screws (5) and (6). OPERATION AND INSTALLATION MANUAL pag.49 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...
  • Page 50 WITHDRAW THE BELT FROM THE PULLEYS AND REPLACE IT. THEN, LOOSEN SCREWS (5) AND TIGHTEN THE BELT AS INDICATED AT POINT 4. OPERATION AND INSTALLATION MANUAL pag.50 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...
  • Page 51 85Nm and then tighten screws (6) to a torque of 50Nm. 6- Reposition the protective casing (4) and tighten the screws (3). OPERATION AND INSTALLATION MANUAL pag.51 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...
  • Page 52 K.T.C. shall safeguard its rights to the full extent of the law. 7- Close the panel (2) and tighten screws (1). OPERATION AND INSTALLATION MANUAL pag.52 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...

  • Page 53: Using An Optikrik Tension Gauge

    5-Read the tension on the indicator arm as shown in figure 13. OPERATION AND INSTALLATION MANUAL pag.53 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...

  • Page 54: Suction Pre-Filter Maintenance

    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. OPERATION AND INSTALLATION MANUAL pag.54 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...
  • Page 55 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). OPERATION AND INSTALLATION MANUAL pag.55 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...

  • Page 56: Replacing The Oil Filter

    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 OPERATION AND INSTALLATION MANUAL pag.56 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...

  • Page 57: Changing The Oil

    Always clean the container paying particular attention not to let any material fall into the suction valve. Figure 20 OPERATION AND INSTALLATION MANUAL pag.57 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...

  • Page 58: Maintenance Schedule

    - Kit valvola minima pressione /Minimum pressure valve KIT - Kit valvola termostatica/Thermostatic valve - Kit paraolii vite/ Screw Shaft seal - Kit cuscinetti MOTORE/Motor bearing OPERATION AND INSTALLATION MANUAL pag.58 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...
  • Page 59 - Filtro Separatore / Separator KME 22 / PLUS N11L0233 400/50/3 4000 Filter € 8-10Bar - Olio / Oil - Cinghia /Belt - Prefiltro / Prefilter OPERATION AND INSTALLATION MANUAL pag.59 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...
  • Page 60 - Olio / Oil € 8-10Bar - Cinghia /Belt - Prefiltro / Prefilter - Kit ricambi cuscinetti vite / Screw bearing kit OPERATION AND INSTALLATION MANUAL pag.60 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...
  • Page 61 - Kit valvola minima pressione /Minimum pressure valve KIT - Kit valvola termostatica/Thermostatic valve - Kit paraolii vite/ Screw Shaft seal - Kit cuscinetti MOTORE/Motor bearing OPERATION AND INSTALLATION MANUAL pag.61 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...
  • Page 62 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. OPERATION AND INSTALLATION MANUAL pag.62 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...

  • Page 63: Unscheduled Maintenance

    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. OPERATION AND INSTALLATION MANUAL pag.63 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...

  • Page 64: Troubleshooting

    If machine to stop. High temperature. necessary, have the motor repaired or replaced. Magnetothermal switch failure, fuse blown, replace the damaged fuse. OPERATION AND INSTALLATION MANUAL pag.64 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...
  • Page 65 Clean or replace oil recovery viewer. clogged. Top up oil until it reaches the level indicated Oil level too high. in the manual. OPERATION AND INSTALLATION MANUAL pag.65 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...

  • Page 66: 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. OPERATION AND INSTALLATION MANUAL pag.66 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...

  • Page 67: 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. 11 APPENDIX MAINTENANCE CHECK SHEET 11.1 OPERATION AND INSTALLATION MANUAL pag.67 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...
  • Page 68 (even minor modifications) and by tampering and use of non original spare parts. OPERATION AND INSTALLATION MANUAL pag.68 of 68 COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016...

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