KTC COMPACK 2 Operation And Maintenance Manual Download

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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.

USER MANUAL AND INSTALLATION
COD. 091052 - REV. 07 - DATE 11/2016

Pag.1 di 45

OPERATION AND MAINTENANCE MANUAL FOR

COMPACK 2 COMPRESSOR

(SOLUTION FOR BUS)

ENGLISH VERSION

Summary of Contents for COMPACK 2

Page 1: ...or issued to third parties without written authorization K T C shall safeguard its rights to the full extent of the law USER MANUAL AND INSTALLATION COD 091052 REV 07 DATE 11 2016 Pag 1 di 45 OPERATIO...

Page 2: ...6 1 3 1 WARNINGS AND PRECAUTIONS 6 1 4 HOW TO SEE THE MANUAL 6 1 5 CE MARKING 7 1 6 MAINTENANCE AND SUPPORT INFORMATION OF THE MACHINE 8 1 7 INSTRUCTIONS FOR SAFE OPERATION 8 1 8 LABELS POSITION 11 2...

Page 3: ...TION OF COMPRESSOR 26 7 FIRST START 27 8 CONTROL PANEL 28 8 1 ELECTRIC DIAGRAM 29 9 HEATING RESISTANCE OF OIL 33 10 PNEUMATIC SCHEME AND MACHINE DESCRIPTION 34 11 ORDINARY MAINTENANCE OF COMPRESSOR 35...

Page 4: ...EST 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 el...

Page 5: ...on to KTC S R L will be prepaid with the charge of the shipping invoice Repair or replacement under warranty includes free replacement of machine components defective recognized The warranty lapses fo...

Page 6: ...ry to persons The machine was designed and built for the following functions Any other commitment is not allowed Installation and maintenance must be performed by qualified personnel Always follow the...

Page 7: ...vention highlighted by this symbol is the exclusive competence of a technician 1 5 CE MARKING The CE marking certifies that the compressor complies with the health and safety requirements outlined in...

Page 8: ...rts 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 assemble...

Page 9: ...ming 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 servic...

Page 10: ...ions and pneumatic tools rated to handle pressures above the operating pressure 24 Tank Never unscrew any tank connections without first checking to ensure that the pressure has been vented Never make...

Page 11: ...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 USER MANUAL AND INSTALLATION COD 091052 REV 0...

Page 12: ...erty 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 USER MANUAL AND INSTALLATION COD 09...

Page 13: ...w USER MANUAL AND INSTALLATION COD 091052 REV 07 DATE 11 2016 Pag 13 di 45 ATTENTION Do not perform any maintenance on this machine before have stopped all moving parts disconnect the power supply you...

Page 14: ...compressor Oil injected screw compressor Drive Direct coupling Direct coupling Type of screw ADAM S60 C ADAM S60 C Flow rate ISO 1217 annex B 1996 0 29 m3 min 10 24 cfm 0 29 m3 min 10 24 cfm Max work...

Page 15: ...f 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 USER MANUAL AND INSTALLATION COD 091052 R...

Page 16: ...erty 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 USER MANUAL AND INSTALLATION COD 09...

Page 17: ...essor 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...

Page 18: ...orization K T C shall safeguard its rights to the full extent of the law USER MANUAL AND INSTALLATION COD 091052 REV 07 DATE 11 2016 Pag 18 di 45 In this version the compressor must be set between a f...

Page 19: ...ncoming voltage is the same as indicated on the number plate Main automatic switch on the wall must follow the engineering data see chapter 6 6 1 Check that oil level is correct see chapter 11 3 The e...

Page 20: ...ir The compressor is not suitable for use in explosion proof and flammable products ANY OTHER USE OTHER THAN EXPECTED FROM THE MANUFACTURER TO RISE FROM LIABILITY LINKED TO RISK THAT SHOULD BE INCURRE...

Page 21: ...ng oil with a VG32 rating for cold climates and VG68 for tropical climates CAUTION for machines without oil or warehouse storage for a long proceed as described below Absence of oil 1 Place the oil in...

Page 22: ...use the same synthetic lubricant that you want to use the machine We recommend two cycles of loading and unloading oil at each cycle will start up the machine for about 5 min and then proceed with the...

Page 23: ...see section 6 6 1 Check for proper oil level see section 11 3 The electrical connections are made using cables of appropriate size see section 6 6 3 ATTENTION Carefully follow the SAFETY PRECAUTIONS...

Page 24: ...ust have the characteristics shown in the following table The voltage volts must correspond to that indicated on the nameplate of the electrical machine the tolerance must be within the 5 The plug of...

Page 25: ...with mandatory safety switch 6 6 3 SIZING OF ELECTRIC CABLE Do not use a damaged cable but make sure it is in good condition This section must be appropriate to the current requested by the compresso...

Page 26: ...or Do not repair a faulty tube but proceed with the replacement Connect the compressor to the pneumatic network by using the special attack female 3 8 arranged on the compressor and illustrated We rec...

Page 27: ...rotation of the screw If the supply phases are correctly positioned the compressor will start as indicated on the arrow on the body of the screw as shown in Figure 10 Check with motor fan If the phas...

Page 28: ...r 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 b...

Page 29: ...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 USER MANUAL AND INSTALLATION COD 091052 REV 0...

Page 30: ...erty 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 USER MANUAL AND INSTALLATION COD 09...

Page 31: ...erty 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 USER MANUAL AND INSTALLATION COD 09...

Page 32: ...D 091052 REV 07 DATE 11 2016 Pag 32 di 45 Heavy duty POWER and CONTROLLER connectors with spring terminal connectors Inserts for section conductors 0 14 2 5 mm2 AWG 26 14 conductors stripping lenght 9...

Page 33: ...nstalled 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 con...

Page 34: ...DATE 11 2016 Pag 34 di 45 10 PNEUMATIC SCHEME AND MACHINE DESCRIPTION 1 Intake valve 2 Screw compressor 3 Air tank 4 Solenoid valve 3 2 5 Safety valve 6 Manometer 7 Oil cooler 9 Minimum pressure valv...

Page 35: ...NANCE OF COMPRESSOR The following table is a plan for maintenance of the compressor The work hours listed in the table refer to the optimal use of the machine and can therefore vary depending on the w...

Page 36: ...PRESSURIZED WASTE LUBRICANT MUST BE DISPOSED IN ACCORDANCE WITH THE REGULATIONS FOR HEAVY ENVIRONMENTAL CONDITIONS ex ESPECIALLY DUSTY PLACES THE MAINTENANCE SCHEDULE WILL BE MORE CLOSE CONSULT AN AUT...

Page 37: ...re attaching the support the mounting is done by hand after tightening the cartridge and placed on the base just around ensure the seal Be careful before you screw the filter cartridge oil the seal Ha...

Page 38: ...and periodically opening the oil drain ball valve to check for condensation residues When the oil drain ball valve is opened oil starts flowing out of the screw assembly Always keep on all necessary...

Page 39: ...D INSTALLATION COD 091052 REV 07 DATE 11 2016 Pag 39 di 45 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 ca...

Page 40: ...Olio Oli Filter Filtro Separatore Separator Filter Olio Oil Anello elastico trasmissione Elastic ring of trasmission 160 N11L0285 8000 Filtro Aria Air Filter Filtro Olio Oli Filter Filtro Separatore S...

Page 41: ...AND INSTALLATION COD 091052 REV 07 DATE 11 2016 Pag 41 di 45 The maintenance program is set considering all installation and operating parameters recommended by the Manufacturer The Manufacturer reco...

Page 42: ...much with the starts because they could cause serious damage to the electrical plant of compressor Opening safety valve Pressure switch doesn t work and the pressure exceeds the value set by the safet...

Page 43: ...ses 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 che...

Page 44: ...nd 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 USER MANUAL AND INSTALLATION COD 091052 REV 07 DATE 11 2...

Page 45: ...aler ATTENTION Do not touch the moving parts when the compressor is running All maintenance of the compressor must be carried off pressure and temperature and circuit switched off Maintenance must be...

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KTC COMPACK 2, Operation And Maintenance Manual

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