Koci Elektromaschinen KC 100 User manual

Kontakt:
Zittauer Straße 12 Tel. + 49 35844/ 70234 www.elektromaschinen-koci.de
D – 02796 Kurort Jonsdorf Fax + 49 35844/ 72103 [email protected]
O R I G I N A L
Operating Instruction
Compressor unit with direct current motor
KC 100 and KC 200
Manufacturer:
Koci Elektromaschinen GbR
Zittauer Straße 12
02796 Kurort Jonsdorf
Germany
Edition: 07.2016

Kontakt:
Zittauer Straße 12 Tel. + 49 35844/ 70234 www.elektromaschinen-koci.de
D – 02796 Kurort Jonsdorf Fax + 49 35844/ 72103 [email protected]
List of content
1. Introduction .................................................................................................................................. 1
1.1 Owner’s responsibility .............................................................................................................. 1
1.2 Copyright .................................................................................................................................. 1
1.3 General advices ....................................................................................................................... 1
EC – Declaration of Conformity ..................................................................................................... 1
2. Warranty and complaints ............................................................................................................ 2
3. Reference of utilization ................................................................................................................ 2
3.1 conventional utilization ............................................................................................................. 2
3.2 unconventional utilization ......................................................................................................... 2
4. Technical information about the compressor unit ................................................................... 3
4.1 Components account ............................................................................................................... 3
4.2 Technical description ............................................................................................................... 3
4.3 Technical Data ......................................................................................................................... 4
5. Commissioning ............................................................................................................................ 5
5.1 Location and assembly references .......................................................................................... 5
5.2 Installation – electrical ............................................................................................................. 6
6. Maintenance.................................................................................................................................. 8
General reference notes ................................................................................................................ 9
Compressor block .......................................................................................................................... 9
Cylinder head and valves .............................................................................................................. 9
Clean and replace air filter ............................................................................................................. 9
Maintenance of the bearings and carbon brushes of the DC motor .............................................. 9
Checking the safety valve ............................................................................................................ 10
Pressure container (accessory if requested) ............................................................................... 10
Performance check ...................................................................................................................... 10
Torque specification ..................................................................................................................... 10
Reference notes to anti-freeze pump .......................................................................................... 11
7. Safety regulations – environment protection .......................................................................... 11
7.1 Safety regulations .................................................................................................................. 11
7.2 Environment protection .......................................................................................................... 11
8. Troubleshooting ......................................................................................................................... 12
9. Storing & Transport ................................................................................................................... 13
10. Replacement parts ................................................................................................................... 13

Kontakt:
Zittauer Straße 12 Tel. + 49 35844/ 70234 www.elektromaschinen-koci.de
D – 02796 Kurort Jonsdorf Fax + 49 35844/ 72103 [email protected]
1
1. Introduction
These operating instructions are applicable for the compressor units KC 100 and KC 200.
Description: compressor unit with direct current motor
Type: ___________________________________
Machine no.: ___________________________________
Please read these operating instructions carefully to enable a safe operation.
1.1 Owner’s responsibility
These operating instructions are part of the product. The owner/ operator has to consider on own authority:
 Operating and maintenance staff has access to these operating instructions always.
 All advices and safety regulations have to be fulfilled during shutdown and operating.
 These operating instructions have to be retained for further utilization.
1.2 Copyright
The duplication of text, technical data, drawings or similar is prohibited and demands the agreement of the
manufacturer.
Technical changes at the compressor unit stay reserved for the manufacturer.
1.3 General advices
The company Koci Elektromaschinen GbR determined that requirements regarding to spare parts and their
delivery, information for reparation or questions about technical issues of the compressor can be handled
only with the correct type or machine number.
If you did not purchase the compressor directly from the manufacturer please first contact your provider.
Additionally it is prohibited to remove the appliance rating plate.
EC – Declaration of Conformity

Kontakt:
Zittauer Straße 12 Tel. + 49 35844/ 70234 www.elektromaschinen-koci.de
D – 02796 Kurort Jonsdorf Fax + 49 35844/ 72103 [email protected]
2
2. Warranty and complaints
The legal foundation of our guarantee management is the German Civil Code. But please consider the
following regulations:
 Work carried out on our compressors under guarantee is only done in our workshop as a matter of
principle because the machines are classified as easy to transport. In case of contact by others any
guarantee claim cannot be asserted.
 Equally guarantee does not apply, if the compressor has been modified or altered without
consultation and approval by our company.
 The guarantee is limited to the compressor only and includes material and manufacturing faults.
 Faults resulting from natural wear and tear, improper use, installation or insufficient maintenance are
disregarded. Wear and tear elements are:
 Solenoid discharge valve
 Non-return valve
 Pressure switch
 Air filter
 Fuse
Furthermore the tube cooler is excluded from guarantee in case of traceable use as carry handle,
what is not allowed and results destruction of itself.
 We reserve the right to determine how and by whom the repairs are to be made.
 Costs that may arise as an after-effect of the compressor’s breakdown will not be accepted by our
company.
3. Reference of utilization
3.1 conventional utilization
The compressor units with DC motor are designed for versatile applications in which a compressed air
supply is needed to permanent disposition.
The compressor is provided solely for production of compressed air. Any other use is considered improper.
The manufacturer is not responsible for any damages resulting from improper utilization – the risk carries
the operator by himself.
Correct use includes also the compliance with the manufacturer’s regulations of installation, operating and
maintenance.
3.2 unconventional utilization
The compressor unit must not be used in hazardous areas - it is not protected against explosions.
Without additional air treatment compressed air from oil lubricated compressors is not suitable for the filling
of breathing air equipment and use in dentistry or for operations where compressed air comes directly into
contact with food.
Compressed air must never be directed at people. The concentrated energy causes a life-threatening
situation.

Kontakt:
Zittauer Straße 12 Tel. + 49 35844/ 70234 www.elektromaschinen-koci.de
D – 02796 Kurort Jonsdorf Fax + 49 35844/ 72103 [email protected]
3
4. Technical information about the compressor unit
4.1 Components account
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
4.2 Technical description
The compressor unit with DC motor and control unit is a compact, powerful unit in block manner, which is
composed of two main parts, the single cylinder – compressor and the DC motor as a drive source.
Furthermore, we would like to mention following principal technical details that are integrated into the
compressor and contribute to increased safety and functionality.
General area: Area control block: Field electric machine:
 intake silencer with air filter
 4 rubber mounts for vibration
damping
 tube cooler
 compressed air tank/ pressure
container (delivery on request)
 solenoid discharge valve1
 pressure switch
 non-return valve
 safety valve
 silencer for the discharge air
 antifreeze pump with
antifreeze reservoir(installation
on request)
 power relay
 suppression equipment
 thermostats
 low voltage protection
 operating voltage independent
of the control voltage
 ensure a low control current
 security protection by circuit
board against false engaging
from the outside of the
compressor
To ensure the electrical connection security and the corresponding control over the compressor, a control
light outside the device signals the respective operating.
An integrated momentum balance in the engine reduces vibration and provides a quiet and low-wear run.
For further noise reduction the compressor units are fixed on four rubber mounts and completed with an
intake silencer and an exhaust box on the discharge valve.
1 only compressors with antifreeze pump
1 oil filler neck
2 oil drain plug
3 oil level eye
4 air filter and intake manifold
5 pressure – adjustment screw
6 pressure switch
7 solenoid discharge valve1
8 antifreeze reservoir1
9 switch summer/ winter operation of
the antifreeze pump1
10 safety valve
11 adjustment screw for antifreeze1
12 non-return valve
13 cable entry for battery 31 -
14 main terminal negative 30 +
15 cable entry
16 fine-wire fuse 12 V or 24 V

Kontakt:
Zittauer Straße 12 Tel. + 49 35844/ 70234 www.elektromaschinen-koci.de
D – 02796 Kurort Jonsdorf Fax + 49 35844/ 72103 [email protected]
4
4.3 Technical Data
Compressor Unit KC 100/1.2.1
12 V 24 V 48 V 80 V 110 V
Max. working pressure: bar 10 10 10 10 10
Inlet volume: l/min 75 75 75 75 75
Effect. capacity 6 bar: l/min 52 52 52 52 52
Compressor speed: rpm 1500 1500 1500 1600 1600
Motor rating: kW 0,5 0,5 0,53 0,53 0,55
Power consumption: A 48 24 13 8 5,5
System of protection: IP 66 66 66 66 66
Shielded: yes yes yes yes yes
Oil filling: l 0,13 0,13 0,13 0,13 0,13
Weight: kg 20 20 20 20 20
Noise level: dB(A) 84 84 84 84 84
Dimension (LxWxH): mm 390x255x320 390x265x320
Compressor Unit KC 200/1.2.1
12 V 24 V 48 V 80 V 110 V
Max. working pressure: bar 10 10 10 10 10
Inlet volume: l/min 150 150 150 150 150
Effect. capacity 6 bar: l/min 104 105 105 106 106
Compressor speed: rpm 2400 2500 2500 2600 2600
Motor rating: kW 1 1 1 1,2 1,2
Power consumption: A 96 48 24 16 5,5
System of protection: IP 66 66 66 66 66
Shielded: yes yes yes yes yes
Oil filling: l 0,13 0,13 0,13 0,13 0,13
Weight: kg 25 25 25 25 25
Noise level: dB(A) 84 84 84 84 84
Dimension (LxWxH): mm 440x255x320 440x285x320

Kontakt:
Zittauer Straße 12 Tel. + 49 35844/ 70234 www.elektromaschinen-koci.de
D – 02796 Kurort Jonsdorf Fax + 49 35844/ 72103 [email protected]
5
5. Commissioning
5.1 Location and assembly references
 Before the initial start-up the compressor unit must be screwed tightly on its location
 The compressor unit must be protected from dust and dirt to ensure the conventional functionality.
 The connection of the compressor should be chosen in accordance to the guidelines for the
installation of compressed-air lines with a slight incline towards the boiler.
 Enough cooling should be provided.
 In case of installation in a vehicle, the cooling direction must no work against the airflow.
 The connection of the compressor unit should be done with a flexible hose connection.
 Please use the rubber mounts for placement and storing.
 The device has IP66 (splash-proof). So please protect the air supply (flexible hose connection
towards air filter) and all the other parts from intensive water contact.
 The environment is not allowed to be humid or wet and no gases or liquids should be places nearby
the compressor.
under voltage protection and control light
1. Under voltage protection
The operator should provide an operating voltage between -10 % and +20 % of the rated voltage.
The following faults occur, when the operating voltage does not lie correctly:
a) The compressor cannot be switched on – Fault: operating voltage under -10% of rated voltage.
b) The compressor turns off automatically – Fault: operating voltage under -25% of rated voltage.
c) The compressor turns off automatically and can be switched on again only after the control
switched was turned off and a waiting time of about 10 seconds. – Fault: short interruption of
operating voltage or control line (loose connection).
A correct and safe operation is only guaranteed, when the connection follows the description of the
manufacturer or a confirmed (by the manufacturer) compliant circuit.
You have to be able to switch off the compressor at any time.
Any self-made changes in the original circuit during the legal warranty period cause an immediate
loss of any claims.
2. Control light
The control switch and light have to be installed within the operator’s viewing area.
An illumination of the control light indicates:
 Loose connection – Motor turns off automatically
 excess temperature – Motor turns off automatically and can be switched on after its cooling (ca. 45
min).
Please always investigate the reason of an occurring fault or glowing control light and arrange quick
remedy to avoid consequential damages.

Kontakt:
Zittauer Straße 12 Tel. + 49 35844/ 70234 www.elektromaschinen-koci.de
D – 02796 Kurort Jonsdorf Fax + 49 35844/ 72103 [email protected]
6
5.2 Installation – electrical
It is the responsibility of the operator/ owner to ensure that the compressor is wired professionally. Any
electrical work should be carried out by a competent electrician and installed to meet all applicable local
and national codes and regulations.
Therefore please read the following regulations carefully:
 Current, voltage and polarity of the power system must match the information on the appliance rating
plate of the motor.
 The fuse regarding to the control lead should have (61) 2A.
 safety fuse in the lead-in:
12 V 24 V 48 V 80 V 110 V
KC100/1.21 80 A 40 A 16 A 10 A 10
KC200/1.21 150 A 80 A 40 A 20 A 16
 The cross-sectional area of the lead-in must be chosen in such a way that, when the compressor is
operating, the voltage on the terminal board or power relay does not fall below the necessary
operating voltage. (12, 24, 48 or 80 V)
 Cu wire in mm²:
Cu wire Cu wire > 1m length
KC100/1.21 12V 10,0 16,0
KC100/1.21 24V 6,0 10,0
KC200/1.21 12V 25,0 35,0
KC200/1.21 24V 10,0 16,0
KC100/1.21 48V 2,5 4,0
KC100/1.21 80V 1,5 2,5
KC200/1.21 48V 2,5 4,0
KC200/1.21 80V 2,5 4,0
KC100/1.21 110V 1,5 2,5
KC200/1.21 110V 2,5 2,5
 The control 61 and KK can have at maximum a 0,75mm² Cu wire.
 The oil level on the compressor block must be checked. The oil level must be within/ at the red circle
of the oil level eye.
Regulation:
The compressor is regulated automatically by means of a pressure switch depending on the compressed
air requirements. After the system has been switched on for the first time, the pressure switch controls the
compressor’s operating corresponding to the set pressure.
Pressure switch settings made at the factory
max. operational
excess pressure
pressure switch - off
excess pressure
pressure switch – on
excess pressure
10 bar 8 – 9 bar ca. 7 bar

Kontakt:
Zittauer Straße 12 Tel. + 49 35844/ 70234 www.elektromaschinen-koci.de
D – 02796 Kurort Jonsdorf Fax + 49 35844/ 72103 [email protected]
7
Connection plug – cable installation – control line
view of cable or solder side
BLUE
YELLOW
GREEN
RED
control switch with control lamp
anti-rotation
element
31a ground for control
lamp, etc.
KK
compressor control
normal operation – dimly illuminated
case of fault – brightly illuminated (low voltage)
61
feed of the control voltage from the
alternator control lamp cable.
Or, if no alternator control lamp cable is used,
from ignition lock switch via control switch.
D
feed to the control switch if the
alternator control lamp cable is not used
D
(RED)
or optional if D is
not used, the cable must
be insulated as it carries
voltage from the
compressor
D+ (RED)
control lamp
cable from
vehicle
alternator
61 (GREEN)
feed of the control voltage to the
compressor
31a (BLUE) ground for compressor control
KK
(YELLOW)
compressor control carries
voltage during operation in case of fault

Kontakt:
Zittauer Straße 12 Tel. + 49 35844/ 70234 www.elektromaschinen-koci.de
D – 02796 Kurort Jonsdorf Fax + 49 35844/ 72103 [email protected]
8
KC 100 and KC 200 48 V and more
jack in compressor for main cable entry
jack in compressor for control lead
anti
-
rotation
negative max. 4mm² (blue, black or brown)
positive max. 4mm² (red)
anti
-
rotation element
D carries voltage during operation (red)
31a ground for control lamp, etc. (blue)
KK
control lamp (yellow)
carries voltage during normal operation
and in case of fault
61 feed of the voltage to the switch (green)