KTC KME 18-22-30-37 Operation And Maintenance Manual Download Page 1

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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 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

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

Page 1: ...sued to third parties without written authorization K T C shall safeguard its rights to the full extent of the law OPERATION AND INSTALLATION MANUAL COD 091003 KME 18 22 30 37 REV 07 DATA 11 2016 pag...

Page 2: ...D 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...

Page 3: ...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...

Page 4: ...its rights to the full extent of the law OPERATION AND INSTALLATION MANUAL COD 091003 KME 18 22 30 37 REV 07 DATA 11 2016 pag 4 of 68 8 1 7 REPLACING THE AIR FILTER 57 8 1 8 MAINTENANCE SCHEDULE 58 8...

Page 5: ...l 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...

Page 6: ...age 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...

Page 7: ...s 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 comp...

Page 8: ...IONS 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 use...

Page 9: ...ized 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 func...

Page 10: ...ecessary 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...

Page 11: ...epartment 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...

Page 12: ...ompressor 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...

Page 13: ...et 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...

Page 14: ...most 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...

Page 15: ...psi g Min working presure 5 bar g 72 5 psi g 5 bar g 72 5 psi g 5 bar g 72 5 psi g 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 tem...

Page 16: ...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 COD 091003...

Page 17: ...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 lo...

Page 18: ...ATA 11 2016 pag 18 of 68 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 Che...

Page 19: ...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...

Page 20: ...2016 pag 20 of 68 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 se...

Page 21: ...s 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 s...

Page 22: ...the full extent of the law OPERATION AND INSTALLATION MANUAL COD 091003 KME 18 22 30 37 REV 07 DATA 11 2016 pag 22 of 68 5 7 2 CONNECTING THE POWER SUPPLY CORD OF THE COMPRESSOR 1 Insert the power su...

Page 23: ...ted 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 c...

Page 24: ...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 use...

Page 25: ...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 environmenta...

Page 26: ...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 COD 091003 KME 18 22 30 37 REV 0...

Page 27: ...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 COD 091003...

Page 28: ...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 COD 091003...

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 OPERATION AND INSTALLATION MANUAL COD 091003...

Page 30: ...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 COD 091003...

Page 31: ...1924 2B 3RA1924 2B KY CONTATTORE STELLA STAR CONTACTOR SIEMENS 3RT1024 1AC20 3RT1026 1AC20 3RT1026 1AC20 3RT1034 1AC20 QV SALVAMOTORE VENTILATORE FAN MOTOR PROTECTOR SIEMENS 3RV1011 1CA10 3RV1011 1CA1...

Page 32: ...ON 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 repl...

Page 33: ...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 s...

Page 34: ...ntenance 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 worksh...

Page 35: ...sponsibility 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 ai...

Page 36: ...INSTALLATION MANUAL COD 091003 KME 18 22 30 37 REV 07 DATA 11 2016 pag 36 of 68 6 6 SAFETY DEVICES AND SIGNALS The machine is equipped with safety devices and signals to prevent situations dangerous f...

Page 37: ...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...

Page 38: ...ompatible 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 starti...

Page 39: ...When lowering the suction valve shutter be careful not to damage the throttle valve O ring Start up the compressor initially switching it on and off sequentially and quickly and then starting it up Th...

Page 40: ...hird parties without written authorization K T C shall safeguard its rights to the full extent of the law OPERATION AND INSTALLATION MANUAL COD 091003 KME 18 22 30 37 REV 07 DATA 11 2016 pag 40 of 68...

Page 41: ...hts to the full extent of the law OPERATION AND INSTALLATION MANUAL COD 091003 KME 18 22 30 37 REV 07 DATA 11 2016 pag 41 of 68 7 1 1 BUTTON LAYOUT START BUTTON if there is no active alarm pressing th...

Page 42: ...RIPTION 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...

Page 43: ...g 43 of 68 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 scrol...

Page 44: ...ing 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...

Page 45: ...ag 45 of 68 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 but...

Page 46: ...NANCE 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 var...

Page 47: ...elt 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...

Page 48: ...d 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 COD 091003 KME 18 22 30 37 REV 07 DATA 11 20...

Page 49: ...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 COD 091003 KME 18 22 30 37 REV 07 DATA 11 2016 p...

Page 50: ...REV 07 DATA 11 2016 pag 50 of 68 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 nu...

Page 51: ...en authorization K T C shall safeguard its rights to the full extent of the law OPERATION AND INSTALLATION MANUAL COD 091003 KME 18 22 30 37 REV 07 DATA 11 2016 pag 51 of 68 5 Secure the screws 5 to a...

Page 52: ...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 COD 091003 KME 18 22 30 37 REV 0...

Page 53: ...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...

Page 54: ...ghts to the full extent of the law OPERATION AND INSTALLATION MANUAL COD 091003 KME 18 22 30 37 REV 07 DATA 11 2016 pag 54 of 68 8 1 3 SUCTION PRE FILTER MAINTENANCE Figure 16 1 Raise the protection g...

Page 55: ...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...

Page 56: ...e 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...

Page 57: ...cessary 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 o...

Page 58: ...0 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 4...

Page 59: ...t 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 O...

Page 60: ...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 cuscinet...

Page 61: ...i 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...

Page 62: ...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...

Page 63: ...ll extent of the law OPERATION AND INSTALLATION MANUAL COD 091003 KME 18 22 30 37 REV 07 DATA 11 2016 pag 63 of 68 8 2 UNSCHEDULED MAINTENANCE Unscheduled maintenance must be performed by an Authorize...

Page 64: ...ed 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 re...

Page 65: ...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 functionin...

Page 66: ...its rights to the full extent of the law OPERATION AND INSTALLATION MANUAL COD 091003 KME 18 22 30 37 REV 07 DATA 11 2016 pag 66 of 68 10 COMMERCIAL PARTS SPARE PARTS AND PERTINENT DOCUMENTATION For...

Page 67: ...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 COD 091003 KME 18 22 30 37 REV 0...

Page 68: ...t 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...

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