Komptec KT-90A User manual

Komptec GmbH. KT-90A User Manual v1.0a; 8 May, 2016
Page 1 of 52
KT-90A
HIGH PRESSURE AIR COMPRESSOR
User Manual

KT 90
Komptec GmbH. KT-90A User Manual Page 2 of 52 v1.0a; 8 May 2016
Index
1.!Introduction................................................................................................................................5!
1.1.!Quick Start Guide ...................................................................................................................5!
1.2.!Foreword.................................................................................................................................6!
1.3.!Documentation........................................................................................................................6!
1.4.!Warranty for within the European Union...............................................................................7!
1.5.!Disclaimer...............................................................................................................................7!
1.6.!Required Operator Training....................................................................................................8!
1.7.!Information for the User.........................................................................................................8!
1.8.!Obligations and notes for you as an operator .........................................................................8!
1.9.!Customer service ....................................................................................................................9!
1.10.!Serial Number .....................................................................................................................9!
1.11.!Instructional and training aids.............................................................................................9!
1.11.1.!Instruction for the operator.............................................................................................9!
1.11.2.!Examples of training topics..........................................................................................10!
1.12.!Symbols Used....................................................................................................................10!
2.!Product Description .................................................................................................................12!
2.1.!Intended Use.........................................................................................................................12!
2.2.!Construction..........................................................................................................................12!
2.2.1.!Air Filter............................................................................................................................12!
2.3.!Optional Equipment..............................................................................................................13!
2.3.1.!Block Heater for operation below +5°C.......................................................................13!
2.4.!Functional Description .........................................................................................................13!
3.!General safety ..........................................................................................................................15!
3.1.!Obligation of diligence .........................................................................................................15!
3.2.!Basic safety measures...........................................................................................................15!
3.2.1.!Principle; Intended Use ................................................................................................15!
3.2.2.!Responsibility ...............................................................................................................15!
3.2.3.!Personnel selection and qualification; fundamental obligations ..................................16!
3.2.4.!Safety instructions for certain operating phases...........................................................16!
3.2.5.!Notes on special types of hazard ..................................................................................18!
4.!EG-Konformitätserklärung ......................................................................................................20!
5.!Technical Specifications ..........................................................................................................21!
5.1.!Compressor System ..............................................................................................................21!
5.2.!Compressor Block ................................................................................................................21!

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5.3.!compressor oil.......................................................................................................................21!
5.4.!Connections ..........................................................................................................................21!
5.5.!Pneumatic Flow Diagram .....................................................................................................22!
6.!Transport and Installation ........................................................................................................23!
6.1.!Transport...............................................................................................................................23!
6.1.1.!Dimensions and Weight................................................................................................23!
6.1.2.!Transport to the Site .....................................................................................................23!
6.2.!Installation ...........................................................................................................................23!
6.2.1.!Conditions for Set-up....................................................................................................23!
6.3.!Placement..............................................................................................................................24!
7.!Start-up.....................................................................................................................................26!
7.1.!Checks before initial Start-up...............................................................................................26!
8.!Operation..................................................................................................................................27!
8.1.!Description of the controls ...................................................................................................27!
8.1.1.!Compressor...................................................................................................................27!
8.1.2.!Filling Hose ..................................................................................................................27!
8.2.!Adjusting and Setting ...........................................................................................................28!
8.2.1.!Operation ......................................................................................................................28!
8.2.1.1.!Starting the Motor....................................................................................................28!
8.2.1.2.!pressure buildup.......................................................................................................29!
8.2.1.3.!To Fill the pressure cylinder ....................................................................................29!
8.2.1.4.!Condensate Drain.....................................................................................................30!
8.2.1.5.!Turning off...............................................................................................................30!
8.2.1.6.!Complete the Filling process ...................................................................................31!
8.3.!Extended Storage..................................................................................................................31!
8.3.1.!Waste Disposal .............................................................................................................31!
9.!Troubleshooting .......................................................................................................................32!
9.1.!Tabular overview of possible malfunctions and suggestions to help eliminate the fault.....32!
9.1.1.!List of Faults.................................................................................................................32!
10.!Maintenance.............................................................................................................................34!
10.1.!Maintenance Plan ..............................................................................................................34!
10.2.!Filter changing log ............................................................................................................36!
10.3.!Maintenance Work ............................................................................................................37!
10.3.1.!Checking the Oil Level ................................................................................................37!
10.3.2.!Filter Change................................................................................................................38!
10.3.3.!Oil Change ...................................................................................................................39!
10.3.4.!Final pressure gauge check ..........................................................................................40!

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1. Introduction
1.1. Quick Start Guide
SAFETY NOTICE!
• Read the User Manual before using the compressor
• The KT-90A should not be run continuously for more than 45 minutes
Before First Use
• Check that the Combi-Filter is installed
o KT-90A is shipped with the filter packed separately to maximize filter service life
• Insure the oil level is between top and bottom mark
o Clean dipstick, insert without treading
Before Turning On
• Check oil level
• If compressor is cold (less than 5°C), run for 5 minutes with output open, with no pressure
vessel attached, then turn off.
• Open Condensate Screws and drain condensate. Close Output Fill Valve
• Attach Pressure Vessel to be filled
Turn On Power
• Close both condensate screws
• Once output pressure rises to about 1500 psi (100 bar), slowly open the fill valve.
Finish Filling
• The Auto Shut off will turn off the compressor when target pressure is reached. Close the Fill
Valve.
• Slowly open the drain screws on the filling hose (if so configured) until the pressure is released
• Open Intermediate Condensate screw slowly, capture condensate and dispose of accordingly
• Open Final Condensate screw slowly, capture condensate and dispose of accordingly
• Unscrew pressure vessel

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1.2. Foreword
Dear Customer,
Thank you for choosing the KT 90A. The KT-90A includes an Auto Shut off
and an Hour Counter. The Auto Shut off will turn the compressor off when
the target cylinder reached the specified pressure, 200bar or 300bar. The hour
counter is useful in keeping to the maintenance schedule.
This manual is an aid to successful and safe operation of the compressor.
These materials are only for information purposes. Changes may be made
without prior notice. Please refer to the manual for compliance to regulations,
for accident prevention and environmental protection.
Keep this manual available where the compressor is in use. Any person who
is authorized to work on the compressor must have read the operating instruc-
tions.
The compressor has been built according to state of the art and recognized
safety regulations. Nevertheless, it can be hazardous.
Read this manual before using the compressor is in operation. It helps you:
• Prevent risks to the operator,
• Become familiar with the compressor,
• To avoid interference due to improper operation,
• To increase the life of the compressor,
• To avoid repair costs and downtime,
• To effectively use the compressor.
Komptec Kompressoren Technik GmbH
Gutenbergring 3, D-63110 Rodgau Germany
Phone. [phone]
email: [email protected]
1.3. Documentation
To avoid errors in operation and to ensure trouble-free operation of the com-
pressor, the user guide must always be accessible.
The copyright in this manual and the material in this manual is owned by
Komptec Kompressoren Technik GmbH.
Copyright
©
2016 by Komptec Kompressoren Technik GmbH

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1.4. Warranty for within the European Union.
We warranty to the original owner of the KT 90A purchased from Komptec as new will
be free from manufacturing defects in materials and workmanship under normal use
within a period of (2) two years from date of purchase for an end user, or (90) ninety days
for a commercial user, provided it is operated and maintained according to instructions
and the user manual.
Our obligation under this warranty is limited, at our election expressly to the replacement
or repair of such parts from the manufacturer, or at a service center designated by us, who
have been found by the audit to be defective.
DISCLAIMERS:
This warranty does not cover damage due to negligence or improper use, including faulty
repairs by others and failure to implement reasonable and necessary maintenance. We
are not liable for any special, indirect, incidental or consequential damages of any kind,
including wage and transport costs in connection with the repair or replacement of defec-
tive parts.
NO WARRANTY, ORAL OR WRITTEN, EXPRESED OR IMPLIED, OTHER THAN
THE ABOVE WARRANTY IS MADE WITH REGARD TO THIS KOMPTEC PROD-
UCT. KOMTEC DISCLAIMS ANY IMPLIED WARRANTY OF MERCHATABIL-
ITY OR FITNESS FOR A PARTICUALR USE OR PURPOSE, AND ALL OTHER
WARRANTIES. IN NO EVENT SHALL KOMPTEC BE LIABLE FOR ANY INCI-
DENTAL, SPECIAL, CONSEQUENTIAL OR PUNITIVE DAMAGES OR FOR ANY
COSTS, ATTORNEY FEES, EXPENSES, LOSSES OR DELAYS ALLEGED TO BE
AS A CONSEQUENCE OF ANY DAMAGE TO, FAILURE OF, OR DEFECT IN ANY
PRODUCT INCLUDING, BUT NOT LIMITED TO, ANY CLAIMS FOR LOSS OF
PROFITS.
1.5. Disclaimer
Based upon the Law on Technical Equipment (Product Safety Act) of 6 January 2004 (I,
p. 2, over p. 219), as amended on 8 November 2011 (I, p. 2178, calc. 2012 I, p 131)) the
following applies:
• Operation of the KT90A requires expertise and training, and is limited to applica-
tions defined by Komptec in this user manual.
• In the event of improper maintenance (servicing) or of ignoring the operating in-
structions, the owner assumes full responsibility for the functioning of the appli-
ance.
• For safety reasons, the device should be maintained and tested by an authorized
agent annually.
• The device must be serviced by experts. During maintenance (service) only orig-
inal spare parts may be used. The maintenance must be recorded.

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• In the event of damage caused by not complying with the above listed points,
Komptec GmbH is not liable. The warranty and liability claims or general terms
and conditions of Komptec GmbH are not changed by the guidelines listed above.
1.6. Required Operator Training
This manual must be read carefully:
• all compressor operators’ / maintenance personnel must read this entire manual with
due care and attention and observe the instructions/information contained herein.
• the operator must possess the required training for operation of the compressor and
read the manual.
1.7. Information for the User
The instruction manual must be read and used as follows:
• read this manual carefully, treat it as an essential part of the compressor;
• the instruction manual must be kept where it can readily be consulted by compressor
operators and maintenance staff
• keep the manual for the working life of the compressor
• make sure updates are incorporated in the manual
• make sure the manual is given to other users or subsequent owners in the event of
resale
• keep the manual in good condition and ensure its contents remain undamaged
• do not remove, tear or re-write any part of the manual for any reason
• keep the manual protected from dampness and heat
• if the manual is lost or partially damaged and its contents cannot be read, please request
a copy from the manufacturer.
1.8. Obligations and notes for you as an operator
The instruction manual is an integral part of the compressor. The operator shall ensure
that this manual is always available on the compressor and that the operator follows the
instructions.
In order to protect personnel against health hazard or other safety hazards, the operator is
obliged to inform his/her self on the safe and proper operation, maintenance and the
proper operation of the compressor.
The operator must arrange for the execution of a test run with testing of all safety equip-
ment in order to satisfy itself of the operational safety of the compressor.
The compressor has been built according to the prior art and the recognized safety regu-
lations. As an operator, you are obliged to adapt the compressor to the applicable current
safety regulations.

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It should be bourn in mind that the User Manual can never replace proper experience;
some maintenance jobs are particularly difficult and in this regard the manual only offers
general guidelines on the most important tasks, which must be carried out by personnel
with proper training (e.g. acquired during training courses run by the manufacturer).
1.9. Customer service
For technical information about Komptec’s products and their systematic application,
please contact customer service.
Should you have any questions about our products, please call our customer service de-
partment.
1.10. Serial Number
Please include the serial number from the nameplate on any inquiries. Specifying this
data ensures that you receive the correct information or the required spare parts.
1.11. Instructional and training aids.
1.11.1. Instruction for the operator
Any failure to comply with the safety instructions in this manual or on
the compressor can result in injury or death.
Read the KOMPTEC Instruction Manual. All compressor operators’ / mainte-
nance personnel must read this entire manual with due care and attention and
observe the instructions/ information contained herein.- the operator must
possess the required training for operation of the compressor and that he/she
has read the manual.
In addition to the operating instructions, applicable statutory and other regu-
lations for accident prevention and environmental protection and basic health
and safety requirements must be observed.
Such requirements may also include the handling of hazardous substances,
which affect provision / wearing of personal protective equipment.
Consider:
Operation of this compressor poses danger to life and limb when operated by
untrained personnel, or when operated when improperly mounted, maintained
or used.
The training of the operating personnel must be repeated every year!
Operator seminars, and art workshops are offered regularly by the manufac-
turer.

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The following are examples of topics for training as well as a form for con-
firmation of instruction.
1.11.2. Examples of training topics
1. For safety
• Accident prevention regulations
• General legislation
• General safety
• Measures in case of emergency
• Personal protective equipment
• Safety instructions for the operation of the plant
• Dealing with the safety devices of the system
• Safety devices in the vicinity of the plant
• Meaning of symbols and signs
• ________________________________
• ________________________________
2. To operate the plant
• Use the operating elements
• Explanation of the operating instructions for the operating personnel
• Special experience of the operator in handling the compressor
• The use of input materials, tools and auxiliary equipment
• ________________________________
• ________________________________
3. Servicing and maintenance requirements
• Regulative handling cleaning agents and lubricants
• Special experience of the operator for maintenance, servicing, cleaning
and maintenance of plant
• ________________________________
• ________________________________
1.12. Symbols Used
In the manual, the following terms and symbols for particularly important
information are used:
information
Special information regarding the economical use of the machine
Warning
Particular specifications or instructions and prohibitions to prevent damage
i