KTC COMPACK 2 ECO Operation And Maintenance Manual
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KTC COMPACK 2 ECO 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. S.r.l. shall safeguard its rights to the full extent of the law.
OPERATION AND MAINTENANCE MANUAL FOR
COMPACK 2 ECO / SPECIAL COMPRESSORS
ENGLISH VERSION
OPERATION AND INSTALLATION MANUAL
COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020
1
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  • Page 1 K.T.C. S.r.l. shall safeguard its rights to the full extent of the law. OPERATION AND MAINTENANCE MANUAL FOR COMPACK 2 ECO / SPECIAL COMPRESSORS ENGLISH VERSION OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...
  • Page 2  Do not remove, tear or rewrite parts of the manual for any reason.  Keep the manual in an environment protected from humidity and heat. OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...
  • Page 3 QUALIFIED PERSONNEL any intervention highlighted by this symbol is the exclusive responsibility of a specialized technician. OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...

  • Page 4: Table Of Contents

    WIRING DIAGRAM ......................31 7.6.4 AIR CIRCUIT CONNECTION ..................31 FIRST START-UP ......................31 CLEANING AND DISINFECTION ................32 REINSTALLATION AND REUSE ................32 OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...
  • Page 5 REPLACING OIL FILTER ..................50 10.3 REPLACING OIL SEPARATOR FILTER ..............51 10.4 CHANGING THE OIL ....................52 10.5 REPLACING THE AIR FILTER ................. 54 OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...
  • Page 6 UNSCHEDULED MAINTENANCE, COMMERCIAL PARTS, SPARE PARTS AND PERTINENT DOCUMENTATION ..............59 11 TROUBLESHOOTING ..................60 12 APPENDIX ......................62 12.1 MAINTENANCE CHECK SHEET ................62 OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...

  • Page 7: General Warnings And Information For The User

    DIRECTIVES – STANDARDS written in the certificate of conformity attached to the machine. K.T.C. S.r.l. holds the relevant technical dossier. OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...

  • Page 8: Warranty

    Returns are made using the RMA (return material authorization) procedure. To open said procedure, the customer must send a request to K.T.C. S.r.l. OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...

  • Page 9: Ce Marking

     Serial number  Maximum working pressure  Power supply voltage and frequency  Nominal power  Weight  Manufacture year OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...

  • Page 10: Cautions And Safety Warnings

    7. Use the Compressor Sensibly Never use the compressor while under the effect of alcohol, drugs or medications that can cause drowsiness. OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...
  • Page 11 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. OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...
  • Page 12 KEEP THIS MANUAL INTACT AND ON HAND, AVAILABLE TO ANYONE USING THE COMPRESSOR! WE RESERVE THE RIGHT TO MAKE ANY MODIFICATIONS DEEMED NECESSARY WITHOUT PRIOR NOTICE! OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...

  • Page 13: 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 COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...

  • Page 14: Description Of The Machine And Operating Principle

    Air/oil delivery hose from screw assembly Air/oil separator tank Suction filter Oil filter Oil recovery window Thermostatic valve Electric motor Oil level Oil discharge OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...

  • Page 15: Operating Principle

     The condensate that accumulates inside the tank must be discharged daily through the special drain in the lower part of the tank. OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...

  • Page 16: Data And Technical Specification

    ** Value detected with the respective max working pressure *** Noise measured in an open field at 1 metre from the unit ±3 dB(A) at maximum working pressure OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...
  • Page 17 ** Value detected with the respective max working pressure *** Noise measured in an open field at 1 metre from the unit ±3 dB(A) at maximum working pressure OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...

  • Page 18: 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. S.r.l. shall safeguard its rights to the full extent of the law. 6 DIMENSIONS OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...
  • Page 19 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. S.r.l. shall safeguard its rights to the full extent of the law. OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...
  • Page 20 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. S.r.l. shall safeguard its rights to the full extent of the law. OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...
  • Page 21 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. S.r.l. shall safeguard its rights to the full extent of the law. OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...
  • Page 22 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. S.r.l. shall safeguard its rights to the full extent of the law. OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...
  • Page 23 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. S.r.l. shall safeguard its rights to the full extent of the law. OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...
  • Page 24 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. S.r.l. shall safeguard its rights to the full extent of the law. OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...
  • Page 25 CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written authorization. K.T.C. S.r.l. shall safeguard its rights to the full extent of the law. OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...

  • Page 26: 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 COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...

  • Page 27: Handling

    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. OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...

  • Page 28: Connection And Start-Up

    Directives in force mentioned in the declaration of conformity attached to the machine Check the label on the compressor and at the beginning of this manual for indication of your model. OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...

  • Page 29: Electrical Connection Of Compressor

    (EN 60204). Verify that the mains voltage corresponds to that required for the proper functioning of the compressor. OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...
  • Page 30 All electrical installations and maintenance on facility must be performed by a qualified technician. OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...

  • Page 31: Wiring Diagram

    If the phases of the supply line are positioned incorrectly, the compressor does not start. Swap the connections of two phases of power line and restart the compressor. Picture 10 OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...

  • Page 32: 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 COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...

  • Page 33: 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. OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...

  • Page 34: Safety Devices And Signals

    Risk of electric shock ATTENTION: Drain condensation ATTENTION: Check the oil level with the machine stopped ATTENTION: See the instruction book for the maintenance OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...

  • Page 35: Position Of The Labels

    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. S.r.l. shall safeguard its rights to the full extent of the law. 8.6.1 POSITION OF THE LABELS OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...

  • Page 36: 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 COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...

  • Page 37: 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 COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...

  • Page 38: Instructions For The User

    K.T.C. S.r.l. shall safeguard its rights to the full extent of the law. 9 INSTRUCTIONS FOR THE USER DESCRIPTION OF THE CONTROL DEVICES ELECTRONIC CONTROLLER Ktronic OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...

  • Page 39: Button Layout

    In working mode, when pressed, it compares system temperature. ALLARM RESET BUTTON (3) In alarm mode, if pressed for more than 2 seconds, it resets the alarms. OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...

  • Page 40: Symbol Layout

    AUTOMATIC RESTART SYMBOL when led is on, compressor is in automatic restart state OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...

  • Page 41: Alarms List

    MAINTENANCE ALARM if needed perform maintenance and reset the maintenance hours by P8 parameter (by entering the security key) "MAINTENANCE ALARM” OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...

  • Page 42: Description Of The Operations To Be Performed

    It appears the value of system pressure. OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...
  • Page 43 K.T.C. S.r.l. shall safeguard its rights to the full extent of the law. By pressing it appears the value of system temperature: ________________________________________________________________________________ By pressing it appears the flashing value of working hours: OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...

  • Page 44: Programming

    ________________________________________________________________________________ By pressing it is possible to modify the selected parameter ________________________________________________________________________________ By pressing the changed parameter is confirmed OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...

  • Page 45: Parameter

    STOPPING THE COMPRESSOR 9.3.4 By pressing for 2 seconds, it appears the following flashing screen: After 10 seconds, the compressor stops. OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...

  • Page 46: Remote Control

    The above-mentioned change is at the discretion of the user, therefore KTC Srl doesn't accept any responsibility for damage to persons and property with this type of use. OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...

  • Page 47: Description Of The Control Devices (Eco Version)

    (ignition light off) and with the system at ambient pressure (see manometer). ATTENTION The compressor's working hours are visible in the COUNTER. OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...

  • Page 48: Compressor Maintenance

    K.T.C. S.r.l. shall safeguard its rights to the full extent of the law. 10 COMPRESSOR MAINTENANCE 10.1 SCHEDULED MAINTENANCE CAUTION!!! USE ONLY ORIGINAL SPARE PARTS!!! CAUTION!!! HOT PARTS INSIDE!!! OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...
  • Page 49 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 COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...

  • Page 50: Replacing Oil Filter

    Then replace the spent cartridge with a new one. Before screwing down the filter cartridge, oil the gasket. Manually screw down the new cartridge. OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...

  • Page 51: Replacing Oil Separator 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. OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...

  • Page 52: Changing The Oil

    Always keep on all necessary equipment to collect the oil. Open filling cap. Open emptying cap. ADAM 50 Filling cap Emptying cap ADAM 60 Filling cap Emptying cap OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...
  • Page 53 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 (chap. 10.6). OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...

  • Page 54: Replacing The Air Filter

    The duration of the air filter and proportionate to the type of environment and air contamination by dust. If the environment is heavily contaminated it is necessary to intensify the replacement of the air filter. OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...

  • Page 55: Maintenance Schedule

    Belt drive (where eventual present) Control of the cooling system Oil cooler Control efficiency and / temperature OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...
  • Page 56 1 year filter Replacing Oil (type Replacement lubricating oil Substitution Mineral) Control belt tensioning control and Belt drive (where eventual present) OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...
  • Page 57 Revision oil thermostatic Thermostatic oil Revision controller with dedicated spare circuit regulator parts kit OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...
  • Page 58 The maintenance intervals / substitution with oil semi-synthetic / synthetic are doubled from 2,000 hours (with mineral oil) to 4,000 hours OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...

  • Page 59: Unscheduled Maintenance, 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 COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...

  • Page 60: Troubleshooting

    Check the fuses for the solenoid valve installed on the terminal inside the starter itself. Check and replace the elements of transmission failures. OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...
  • Page 61 Clean or replace oil recovery window. clogged. Top up oil until it reaches the level indicated Oil level too high. in the manual. OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...

  • Page 62: 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. S.r.l. shall safeguard its rights to the full extent of the law. 12 APPENDIX 12.1 MAINTENANCE CHECK SHEET OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...
  • Page 63 (even minor modifications) and by tampering and use of non original spare parts. OPERATION AND INSTALLATION MANUAL COD. 091114 – COMPACK 2 ECO / SPECIAL - REV. 08 - DATE 10/2020 page...

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