KTC COMPACK 2 ECO 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. 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

OPERATION AND MAINTENANCE MANUAL FOR

COMPACK 2 ECO / SPECIAL COMPRESSORS

ENGLISH VERSION

Summary of Contents for COMPACK 2 ECO

Page 1: ...hird 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 1 of 63 OPERATION AND MAINTENANCE MANUAL FOR COMPACK 2 ECO SPECIAL COMPRESSORS ENGLISH VERSION ...

Page 2: ...ndations contained in it as the good functioning and duration of the compressor depend on the correct use and methodical application of the maintenance instructions given below It should be remembered that should difficulties or inconveniences arise the AUTHORIZED ASSISTANCE CENTERS are at your complete disposal for any clarification or possible intervention The Manufacturer therefore declines any...

Page 3: ...aving to repeat the technical concepts or safety warnings therefore to be considered reminders Consult the table below whenever there are any doubts about their meaning READ THE INSTRUCTION BOOKLET Before positioning operating or working on the compressor read the user and maintenance manual carefully ATTENTION highlights an important description regarding dangerous conditions safety warnings info...

Page 4: ...8 2 CE MARKING 9 3 CAUTIONS AND SAFETY WARNINGS 10 3 1 INSTRUCTIONS FOR SAFE OPERATION 10 3 2 CONTACTS AND USEFUL ADDRESSES 13 4 DESCRIPTION OF THE MACHINE AND OPERATING PRINCIPLE 14 4 1 MACHINE DESCRIPTION 14 4 2 OPERATING PRINCIPLE 15 5 DATA AND TECHNICAL SPECIFICATION 16 6 DIMENSIONS 18 7 INSTALLATION 26 7 1 CHARACTERISTICS AND STORAGE CONDITIONS 26 7 2 TRANSPORT 26 7 3 UNPACKING 26 7 4 HANDLIN...

Page 5: ...TY DEVICES AND SIGNALS 34 8 6 1 POSITION OF THE LABELS 35 8 7 COMPRESSOR LUBRICATION 36 8 7 1 GENERAL RECOMMENDATIONS 36 8 8 USING THE COMPRESSOR WITH SYNTHETIC OILS 37 9 INSTRUCTIONS FOR THE USER 38 9 1 DESCRIPTION OF THE CONTROL DEVICES 38 9 1 1 BUTTON LAYOUT 39 9 1 2 SYMBOL LAYOUT 40 9 2 ALARMS LIST 41 9 3 DESCRIPTION OF THE OPERATIONS TO BE PERFORMED 42 9 3 1 STARTING THE COMPRESSOR 42 9 3 2 P...

Page 6: ... 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 6 of 63 10 6 MAINTENANCE SCHEDULE 55 10 7 UNSCHEDULED MAINTENANCE COMMERCIAL PARTS SPARE PARTS AND PERTINENT DOCUMENTATION 59 11 TROUBLESHOOTING 60 12 APPENDIX 62 12 1 MAINTENANCE CHECK SHEET 62 ...

Page 7: ...essor must be used exclusively as indicated in this manual This manual must be kept on hand in a known easily accessible place because it should be used throughout the machine s entire working life For any request always indicate model and serial number DECLARATION OF CONFORMITY K T C S r l the manufacturer on its own responsibility declares that the air compressor identified by the label on the f...

Page 8: ...carriage 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 not cover damages caused by negligence by incorrect use or installation or by not compliance with the warnings indicated in the Operation and Maintenance Manual Moreover the warranty is voided if...

Page 9: ...ARKING The CE marking certifies that the compressor complies with the health and safety requirements outlined in the European Directives indicated in the EC declaration of conformity The marking is printed with silver lettering on a black polyester adhesive label L 90mm H 80mm The label is placed as indicated in figure 1 and bears the following information Manufacturer name CE marking Compressor m...

Page 10: ...nstructions for safe use of the compressor Follow these instructions carefully Improper use or maintenance of the compressor can cause user injury 1 Never Touch any Moving Parts 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 assembled If maintenance requires ...

Page 11: ...all screws bolts and lids are thoroughly secured Any damaged parts must be repaired by an Authorized Service Centre 15 Protect yourself against Thermal Shocks Prevent accidentally coming 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 servicing the compressor...

Page 12: ... Repairs must be carried out by an Authorized Service Centre 24 Pneumatic Circuit Use hoses connections and pneumatic tools rated to handle pressures above the operating pressure 25 Tank Never unscrew any tank connections without first checking to ensure that the pressure has been vented Never make holes welds or modifications on the tank 26 Compressor Modifications Never make any unauthorized mod...

Page 13: ...rvices 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 Only original spare parts can guarantee best performance of our compressors We recommend carefully...

Page 14: ...63 4 DESCRIPTION OF THE MACHINE AND OPERATING PRINCIPLE 4 1 MACHINE DESCRIPTION 1 Suction valve 2 Screw compressor 3 Air tank if present 5 Pressure relief safety valve 6 Manometer 7 Oil radiator 9 Minimum pressure valve 11 Pressure switch Pressure transmitter 12 Oil return from separator 13 Oil separator filter 14 Air oil delivery hose from screw assembly 15 Air oil separator tank 16 Suction filte...

Page 15: ...s allows passage of the air only after the pressure set point has been reached When this happens the air passes through the air tank ref 3 if present The oil removed from the air inside the oil separator filter is sent through the oil return from separator line ref 12 into the screw compressor The amount of oil can be monitored through oil recovery window ref 22 The pressure sends oil at the botto...

Page 16: ...bar g 145 psi g Min working pressure 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 2 7 kW 3 6 hp 2 7 kW 3 6 hp 3 kW 4 hp 3 6 kW 4 8 hp Max air oil outlet temperature 105 C 221 F 105 C 221 F 105 C 221 F 105 C 221 F Max environmental temperature 45 C 113 F 45 C 113 F 45 C 113 F 45 C 113 F Min environmental temperature 5 C 41 F 5 C 41 F 5 C 41 F...

Page 17: ...Air Flow rate ISO 1217 2009 annex C 0 27 m3 min 9 5 cfm 0 27 m3 min 9 5 cfm Max working pressure 10 bar g 145 psi g 10 bar g 145 psi g Min working pressure 5 bar g 72 5 psi g 5 bar g 72 5 psi g Maximum power consumption 2 7 kW 3 6 hp 3 kW 4 hp Max air oil outlet temperature 105 C 221 F 105 C 221 F Max environmental temperature 45 C 113 F 45 C 113 F Min environmental temperature 5 C 41 F 5 C 41 F W...

Page 18: ...d 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 18 of 63 6 DIMENSIONS ...

Page 19: ...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 19 of 63 ...

Page 20: ...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 20 of 63 ...

Page 21: ...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 21 of 63 ...

Page 22: ...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 22 of 63 ...

Page 23: ...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 23 of 63 ...

Page 24: ...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 24 of 63 ...

Page 25: ...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 25 of 63 ...

Page 26: ...a temperature of between 5 C and 45 C If the compressor has remained inactive for a long period of time before starting it up again change the oil and check function 7 2 TRANSPORT To ensure that the unit is protected and does not incur shipping damages the compressor is covered with a cardboard box All shipping information is printed on the compressor package data and pictograms 7 3 UNPACKING When...

Page 27: ...is installed must comply with current accident prevention standards and must meet the following requirements The unit must be positioned on a horizontal surface and resting on the respective anti vibration mountings Under no circumstances should the compressor be tilted during operation Adequately ventilated and of such size that environmental temperature remains steady min 5 C max 45 C when the m...

Page 28: ...the requirements indicated on the label The wall mounted general switch is proportioned according to the indications in the technical data table see chapter 7 6 2 1 The oil is at the correct level see chapter 10 4 The electrical connections have been made using cables of adequate section see chapter 7 6 2 3 CAUTION Carefully comply with the SAFETY WARNINGS regarding use of the machine For the Euro...

Page 29: ...install the connector the circuit breaker and fuses near the compressor not more than 3 meters The circuit breaker and the fuses must have the characteristics shown in the following table The voltage volts must correspond to that indicated on the nameplate of the electrical machine tolerance must be within the 5 The plug of the power cable should not be used as a switch Do not remove power while u...

Page 30: ...erly equipped with mandatory safety switch 7 6 2 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 compressor A little section of power cable can cause a voltage drop with consequent loss of power and excessive heating of the cable itself which can cause irreparable consequences on the device...

Page 31: ...lified technician Remember for the technical warranty to be valid that the registered test report R C R attached to the documentation must be filled out see notes on sales clauses After having followed all the indications contained in the previous chapters it is possible to proceed with the preparation of the machine for the first start up For the three phase version is present in the compressor a...

Page 32: ...carefully follow the SAFETY WARNINGS regarding use of the machine This is extremely important 7 8 CLEANING AND DISINFECTION Keeping the installation site and the compressor clean is essential to good machine operation and keeps operating and maintenance costs down Installation site and compressor disinfection is essential to guarantee good air quality in the compressor room and in the area where t...

Page 33: ...r of any responsibility 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 air jet toward persons or animals Never use compressed air for breathing or in production processes where the air produced is in direct contact with foodstuffs unless previously treated and f...

Page 34: ...ices and signals come in the form of labels placed at dangerous points and alarms that are displayed on the electronic controller SIGNAL MEANING ATTENTION Do not perform any maintenance operations on this machine before having stopped all moving parts have disconnected the power supply have completely discharged the pressurized air Maintenance and repair must be performed by specialized and author...

Page 35: ... 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 35 of 63 8 6 1 POSITION OF THE LABELS ...

Page 36: ...lus 46 For use of incompatible oils follow the procedure described in chapter 8 8 Never mix different types of oil We recommend using oil with a VG32 10 C 0 C rating for cold climates and VG68 for tropical climates 20 C 50 C Before starting up compressors without oil feed approximately 0 1 lt of lubricant in through the regulator intake opening while keeping the suction valve shutter lowered and m...

Page 37: ...AUTION 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 Then turn off the compressor and drain all lubricant from the system using the ball valve Through the oil top up hole feed new synthetic lubricant in until it reaches the set level then start up ...

Page 38: ...arties 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 38 of 63 9 INSTRUCTIONS FOR THE USER 9 1 DESCRIPTION OF THE CONTROL DEVICES ELECTRONIC CONTROLLER Ktronic 5 ...

Page 39: ...ECO SPECIAL REV 08 DATE 10 2020 page 39 of 63 9 1 1 BUTTON LAYOUT START STOP BUTTON when pressed this button starts and stops the compressor MENU BUTTONS 1 2 In programming mode when pressed those buttons change parameters values BUTTON PROGRAMMING 1 When pressed it shows the total work hours BUTTON PROGRAMMING 2 In working mode when pressed it compares system temperature ALLARM RESET BUTTON 3 In ...

Page 40: ...LATION MANUAL COD 091114 COMPACK 2 ECO SPECIAL REV 08 DATE 10 2020 page 40 of 63 9 1 2 SYMBOL LAYOUT LOAD SYMBOL when LED is on compressor is in load phase STAND BY SYMBOL when led is on compressor is in stand by phase ALARM SYMBOL when led is on compressor is in alarm state REMOTE CONTROL SYMBOL when led is on compressor is in remote control state AUTOMATIC RESTART SYMBOL when led is on compresso...

Page 41: ...ARMS LIST TYPE OF ALARM DESCRIPTION MOTOR THERMAL Main motor thermal relay setting exceeded ALARM TEMP MAX TEMP setting exceeded OVERLOAD PRESSURE P MAX setting exceeded WRONG ROTATION EMERGENCY BUTTON PRESSED or WRONG ROTATION VERSE OF THE MOTOR reversing one of the 3 phases FAN THERMAL PROTECTOR FAN THERMAL CONTACTOR setting exceeded only in the presence of electric fan MAINTENANCE ALARM MAINTEN...

Page 42: ...091114 COMPACK 2 ECO SPECIAL REV 08 DATE 10 2020 page 42 of 63 9 3 DESCRIPTION OF THE OPERATIONS TO BE PERFORMED 9 3 1 STARTING THE COMPRESSOR When machine is powered it appears the following flashing screen for few seconds then ________________________________________________________________________________ By pressing it appears the following flashing screen for few seconds then the machine star...

Page 43: ... 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 43 of 63 By pressing it appears the value of system temperature ________________________________________________________________________________ By pressing it appears the flashing value of working hours ...

Page 44: ...t appear programmable parameters P1 P6 ________________________________________________________________________________ By pressing it is possible to change the parameter to modify ________________________________________________________________________________ By pressing the selected parameter can be changed ________________________________________________________________________________ By pres...

Page 45: ...mperature Above this temperature it appear temperature alarm 100 C P4 Fan temperature Above this value electric fan starts 75 C P5 Maximum system pressure Above this value compressor goes in unload mode 8 barg P6 Minimum system pressure Under this value compressor goes in load mode 7 barg P7 Maintenance hours Is the time setted between one maintenance and the next protected by key parameter that i...

Page 46: ... remote control of the compressor activate SWITCH 1 ON and connect your controller to Pin shown in the picture below 9 5 AUTOMATIC RESTART To activate the AUTOMATIC RESTART of compressor place the SWITCH 2 in the ON position as shown in the picture below ATTENTION The rules stipulate the need for manual reset of the system in case of arrest for the absence of voltage The above mentioned change is ...

Page 47: ...SION ECO VERSION ATTENTION The manual control of the compressor can only be managed by the GENERAL compressor start up and shutdown switch ATTENTION After an emergency stop caused by high oil or engine temperature press the green button I to restart the compressor ATTENTION Before carrying out any type of intervention in the compressor make sure that the machine is off ignition light off and with ...

Page 48: ...thout 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 48 of 63 10 COMPRESSOR MAINTENANCE 10 1 SCHEDULED MAINTENANCE CAUTION USE ONLY ORIGINAL SPARE PARTS CAUTION HOT PARTS INSIDE ...

Page 49: ...HERIC PRESSURE THE OIL REMOVED MUST BE DISCARDED IN COMPLIANCE WITH CURRENT LAW IN SEVERE WORKING ENVIRONMENTS e g PARTICULARLY DUSTY WORK SITES THE MAINTENANCE INTERVAL MUST BE SHORTER INCORRECT MAINTENANCE OF THE OIL FILTER AIR FILTER AND OIL SEPARATOR CAN DAMAGE THE UNIT LEAVING CARTRIDGES IN OPERATION FOR LONGER THAN THE INDICATED TIME CAN DAMAGE THE COMPRESSOR ALWAYS CAREFULLY COMPLY WITH THE...

Page 50: ...AL COD 091114 COMPACK 2 ECO SPECIAL REV 08 DATE 10 2020 page 50 of 63 10 2 REPLACING OIL FILTER Perform all maintenance as described in this manual or following the indications provided by the retailer or Authorized Service Centre Open cover 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 ga...

Page 51: ...PACK 2 ECO SPECIAL REV 08 DATE 10 2020 page 51 of 63 10 3 REPLACING OIL SEPARATOR FILTER Replace the oil separator filter after the number of hours indicated in the manual or after checking its differential pressure To do so open the upper half shell and remove the filter cartridge using the special spanner Then replace the spent cartridge with a new one Before screwing down the oil separator cart...

Page 52: ...p 10 6 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 If the compressor is not used frequently a couple of hours a day we recommend changing the oil every 6 months 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 ...

Page 53: ...page 53 of 63 Once emptied close the emptying cap Then top up the oil until the right level is read on the window see figure 13 Then tighten the oil filling cap once more After having replaced the oil and oil filter run the compressor for about 10 minutes turn it off and check the oil level If necessary top up Figure 13 Never mix different types of oil Make certain that the oil circuit is complete...

Page 54: ...114 COMPACK 2 ECO SPECIAL REV 08 DATE 10 2020 page 54 of 63 10 5 REPLACING THE AIR FILTER Replace the cartridge following the indications in the maintenance table Take particular attention not to let any material fall into the suction valve 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 nece...

Page 55: ...ESCRIPTION OF OPERATION Operator control maintenance compressor Unit Visual Daily General Inspection unit MS Component Verification Maintenance Control Type HOURS DESCRIPTION OF OPERATION Operator control maintenance Oil level Control Weekly level Control MS Prefilter air intake Control General control and cleaning if necessary Oil radiators air Control Cleaning if necessary of the radiators from ...

Page 56: ...V 08 DATE 10 2020 page 56 of 63 Component Verification Maintenance Control Type HOURS DESCRIPTION OF OPERATION Operator control maintenance Air filter Replacement 2000 1 year filter replacement SP Oil filter Replacement Replacing the oil filter and oil recovery level Air separator filter oil Replacement Changing the air oil separator filter Replacing Oil type Mineral Replacement lubricating oil Su...

Page 57: ...eplacement type Minerale2 Replacement lubricating oil Substitution Oil replacement type Semi synthetic Sintetico2 Replacement lubricating oil Substitution main electric motor bearings Control and greasing Grease the motor bearings with grease specification Belt drive Control where present belt tensioning control and eventual Belt drive Replacement only for kpm 3 5 Substitution of the belt and its ...

Page 58: ...itution Oil replacement type Semi synthetic Sintetico2 Replacement lubricating oil Substitution Suction regulator Revision Revision vacuum controller with dedicated spare parts kit Minimum air pressure regulator Revision Revision minimum air pressure controller with dedicated spare parts kit Thermostatic oil circuit regulator Revision Revision oil thermostatic controller with dedicated spare parts...

Page 59: ...N AND INSTALLATION MANUAL COD 091114 COMPACK 2 ECO SPECIAL REV 08 DATE 10 2020 page 59 of 63 10 7 UNSCHEDULED MAINTENANCE COMMERCIAL PARTS SPARE PARTS AND PERTINENT DOCUMENTATION Unscheduled maintenance must be performed by an Authorized Service Centre For any information please log onto our website www ktc air com For any clarifications you may require contact our customer services department or ...

Page 60: ...fferential pressure is above 1 0 bar causing high system absorption Check the unit by qualified personnel Stopping the machine for intervention of the high pressure safety The pressure exceeds the alarm set point Transducer does not detect pressure properly Check the line pressure Check for proper operation of the transducer if necessary replace it Stopping the machine because of the low temperatu...

Page 61: ...el is reached For the valve contact an Authorized Service Centre Opening of the safety valve Working pressure too high Overpressure in the internal circuit The oil separator cartridge is clogged Safety valve is damaged Restore correct working pressure from rating plate Replace oil separator filter Replace any defective safety valve Excessive oil consumption Oil not suitable for the compressor oper...

Page 62: ...produced 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 62 of 63 12 APPENDIX 12 1 MAINTENANCE CHECK SHEET ...

Page 63: ...ne off at 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 The manufacturer reserves the right to make any modifications to the present manual it deems fit and to do so without prior notice The manufacturer is relieved of any responsibility for injuri...

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