KTC COMPACK 2 ECO User manual

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OPERATION AND INSTALLATION MANUAL
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OPERATION AND MAINTENANCE MANUAL FOR
COMPACK 2 ECO / SPECIAL COMPRESSORS
ENGLISH VERSION

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BACKGROUND
Never use the compressor in an inappropriate way, but only as recommended by the Manufacturer.
The Manufacturer reserves the right to update the technical data contained in this manual without
prior notice. Before using the compressor, carefully read the instructions in the following manual.
IMPORTANCE OF THE MANUAL
This INSTRUCTION MANUAL is your guide to INSTALLATION, USE, MAINTENANCE of
the compressor you purchased. We advise you to strictly follow all the recommendations 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 responsibility for incorrect use or inadequate maintenance of the compressor. The
INSTRUCTION MANUAL is an integral part of the compressor. Keep this manual for the
duration of the compressor.
Ensure that any updates received by the Manufacturer are incorporated into the
manual. Transfer the manual to any other user or subsequent owner of the compressor.
Preservation of the manual:
Use the manual in such a way as not to damage all or part of the contents.
Do not remove, tear or rewrite parts of the manual for any reason.
Keep the manual in an environment protected from humidity and heat.

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SYMBOLS USED
The following SYMBOLS are used throughout the course of this publication to draw the
attention of the operator to the behavior to be adopted in every operating situation
These symbols can be placed next to a text, next to a figure or at the top of the page. Pay the
utmost attention to the meaning of the symbols: their function is that of not having 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,
information of the utmost importance.
STOPPING MACHINE
every operation must be carried out with the machine stopped.
CAUTION MACHINE IN PRESSURE
each operation must be performed with the machine without pressure inside the oil
separator tank (0 bar).
REMOVE TENSION
every operation on the machine must be carried out with the power supply switched
off.
QUALIFIED PERSONNEL
any intervention highlighted by this symbol is the exclusive responsibility of a
specialized technician.

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SUMMARY
1GENERAL WARNINGS AND INFORMATION FOR THE USER...................7
1.1 DEFINITION OF REGULATED RELATIONSHIPS...................................................7
1.1.1 DECLARATIONS............................................................................................................... 7
1.1.2 WARRANTY....................................................................................................................... 8
1.1.3 RETURNS ........................................................................................................................... 8
2CE MARKING.......................................................................................................9
3CAUTIONS AND SAFETY WARNINGS .........................................................10
3.1 INSTRUCTIONS FOR SAFE OPERATION...............................................................10
3.2 CONTACTS AND USEFUL ADDRESSES................................................................13
4DESCRIPTION OF THE MACHINE AND OPERATING PRINCIPLE...........14
4.1 MACHINE DESCRIPTION.........................................................................................14
4.2 OPERATING PRINCIPLE...........................................................................................15
5DATA AND TECHNICAL SPECIFICATION...................................................16
6DIMENSIONS......................................................................................................18
7INSTALLATION.................................................................................................26
7.1 CHARACTERISTICS AND STORAGE CONDITIONS............................................26
7.2 TRANSPORT ...............................................................................................................26
7.3 UNPACKING...............................................................................................................26
7.4 HANDLING..................................................................................................................27
7.5 LOCATION..................................................................................................................27
7.6 CONNECTION AND START-UP...............................................................................28
7.6.1 GENERAL WARNINGS................................................................................................... 28
7.6.2 ELECTRICAL CONNECTION OF COMPRESSOR....................................................... 29
7.6.3 WIRING DIAGRAM......................................................................................................... 31
7.6.4 AIR CIRCUIT CONNECTION......................................................................................... 31
7.7 FIRST START-UP........................................................................................................31
7.8 CLEANING AND DISINFECTION............................................................................32
7.9 REINSTALLATION AND REUSE.............................................................................32

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7.10 DEMOLITION AND DISPOSAL................................................................................32
8OPERATION AND USE.....................................................................................33
8.1 DESCRIPTION OF THE OPERATION......................................................................33
8.2 RANGE OF APPLICATIONS .....................................................................................33
8.3 PROPER AND IMPROPER USE ................................................................................33
8.4 OPERATING AND ENVIRONMENTAL LIMITS ....................................................33
8.5 WORKSTATION AND DANGEROUS AREAS........................................................33
8.6 SAFETY 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
9INSTRUCTIONS 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 PROGRAMMING ............................................................................................................. 44
9.3.3 PARAMETER.................................................................................................................... 45
9.3.4 STOPPING THE COMPRESSOR..................................................................................... 45
9.4 REMOTE CONTROL ..................................................................................................46
9.5 AUTOMATIC RESTART............................................................................................46
9.6 DESCRIPTION OF THE CONTROL DEVICES (ECO VERSION)..........................47
10 COMPRESSOR MAINTENANCE.....................................................................48
10.1 SCHEDULED MAINTENANCE.................................................................................48
10.2 REPLACING OIL FILTER..........................................................................................50
10.3 REPLACING OIL SEPARATOR FILTER..................................................................51
10.4 CHANGING THE OIL.................................................................................................52
10.5 REPLACING THE AIR FILTER.................................................................................54

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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

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1GENERAL WARNINGS AND INFORMATION FOR THE USER
1.1 DEFINITION OF REGULATED RELATIONSHIPS
1.1.1 DECLARATIONS
The compressor 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 front page of this document, complies with the essential requirements laid out in
the following DIRECTIVES –STANDARDS written in the certificate of conformity attached to the
machine.
K.T.C. S.r.l. holds the relevant technical dossier.

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1.1.2 WARRANTY
K.T.C. S.r.l. guarantees its products from manufacturing or design defects for a period of 24 months
from the date of initial start-up. To inform K.T.C. S.r.l. of this date, fill out the special form
supplied with the machine technical documentation and send it in.
If no communication is received, the warranty shall be recognized for 12 months starting from the
date on which the unit was shipped; that is the date indicated on the K.T.C. S.r.l. invoice.
The warranty does not cover parts subject to wear.
Repair works covered under the warranty can only be performed by K.T.C. S.r.l. or a K.T.C. S.r.l.
Authorized Service Centre.
Shipment of any product being returned for service under the warranty must be authorized in
advance, and in writing, by K.T.C. S.r.l. Moreover, K.T.C. S.r.l., in its unquestionable wisdom, can
decide whether to authorize such shipment or have one of its Authorized Service Centres do the
work.
In both cases, shipment to K.T.C. S.r.l. must be made 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 modifications or repairs are made with not original K.T.C. S.r.l. spare parts
or performed by anyone not authorized to do so by K.T.C. S.r.l.
Defective parts replaced under the warranty are retained by the Authorized Service Centre. The
warranty does not cover repairs or reimbursement for damage due to shipping (to or from the
Authorized Service Centre). The warranty does not cover any type of reimbursement for injuries or
damages to people or things derived from improper use of the model purchased or due to machine
down time (the customer must take steps to prevent this). Service covered under the warranty is
guaranteed only to purchasers who have met their contractual and administrative obligations and
who are able to show the documentation certifying the purchase period. This is the only valid
warranty recognized by K.T.C. S.r.l. COURT HAVING JURISDICTION.
For any disputes the competent court is that of Vicenza, Italy.
1.1.3 RETURNS
Returns are made using the RMA (return material authorization) procedure.
To open said procedure, the customer must send a request to K.T.C. S.r.l.

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2CE MARKING
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 model
Serial number
Maximum working pressure
Power supply voltage and frequency
Nominal power
Weight
Manufacture year

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3CAUTIONS AND SAFETY WARNINGS
Read this operation manual carefully before performing any operations. Non-compliance with the
instructions contained herein can lead to injury and property damage.
The machine has been designed and built to operate as reported below. Any other use is
considered unacceptable.
Only qualified personnel can install and service the machine. Always follow accident prevention
standards.
The manufacturer is relieved of any responsibility for injuries and machine or property damage
caused by incorrect use of the compressor, non-compliance or inadequate compliance with the
safety criteria reported herein, modifications (even minor modifications) and by use of not
original spare parts.
3.1 INSTRUCTIONS 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 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 removing any of
the guards, make sure that they are properly reinstalled before starting up the unit. Never bypass the
safety devices installed on the compressor. This is strictly forbidden.
3. Protective Grids
Never insert objects or body parts into protective grids as this can cause injury and can damage the
compressor.
4. Use the Compressor Correctly
Always operate the compressor following the instructions given in this manual. Never allow
children or unauthorized persons to use the machine.
5. Always Wear Eye Protection
Always wear goggles or other equivalent form of eye protection. Do not direct air toward parts of
the body, your own or others.
6. Work Clothing
Do not wear inappropriate clothing or accessories. If necessary, wear a cap that covers the hair.
7. Use the Compressor Sensibly
Never use the compressor while under the effect of alcohol, drugs or medications that can cause
drowsiness.

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8. Personnel Intervention
Before performing any form of intervention, the personnel must be aware of all compressor
functions and controls.
9. Compressor Usage
Never use the compressor for any purpose other than those specified in the user's manual.
10. Air Jets
Never direct air jet toward persons or animals.
11. Hot Parts
To prevent burns, never touch the hoses, motor or other hot parts.
12. Work Area
Keep the compressor work area clean and well ventilated. Never use the compressor in a place
containing paints, solvents or combustible/explosive materials.
13. Compressor Maintenance
Check the outside of the compressor. If the power supply cord is damaged, repair or replace it. If
necessary, contact an Authorized 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 function. Make certain that 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 or when it is not running, always disconnect it from the power
supply and completely vent the pressure in the tank.
17. Handling
Never move the compressor while it is connected to the power supply or when the tank is
pressurized. Before unplugging the compressor make certain that the switch is set to OFF.
18. Precautions for the Power Supply Cord
Never unplug the unit by pulling on the cord. Never step on or crush the power supply cord.
Keep it away from heat, oil or sharp surfaces. Never turn off the compressor by pulling on the
power supply cord. Use the red emergency button to stop the compressor.
19. Electrical Extension Cords
If the compressor is used outdoor, use power supply cords rated for outdoor use.
20. Cleaning of the Intake Grid and Plastic Parts
Keep the ventilation grid clean. If the unit is used in a particularly dirty environment, clean the grid
regularly. Never use solvents, thinners or other substances containing hydrocarbons as they can
damage the plastic parts. Clean with soapy water or an appropriate liquid cleaner.

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21. Compressor Rated Voltage
Use the compressor at the voltage indicated on the label. Using the compressor at a different voltage
can burn out or damage the electric motor.
22. Compressor Defects
If the compressor makes strange noises or vibrates excessively during operations, check that it is
functioning properly and, if necessary, contact an Authorized Service Centre.
23. Spare Parts
Use only original spare parts which can be purchased from our distributors. Use of not original
spare parts voids the warranty and can lead to compressor malfunction. 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 modifications to the compressor. Such modifications can cause
damage and serious injury. Consult an Authorized Service Centre for any operations.
27. Using the Compressor for Painting
Never use the compressor in confined spaces or near open flames. Make certain that the work area
is adequately ventilated. In addition, wear a special mask to protect nose and mouth.
28. Keep the Compressor Horizontal
To ensure correct functioning of the compressor, it is advisable to work in a near-to horizontal
position.
KEEP THIS MANUAL INTACT AND ON HAND, AVAILABLE TO ANYONE
USING THE COMPRESSOR!
WE RESERVE THE RIGHT TO MAKE ANY MODIFICATIONS DEEMED
NECESSARY WITHOUT PRIOR NOTICE!

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authorization. K.T.C. S.r.l. shall safeguard its rights to the full extent of the law.
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3.2 CONTACTS AND USEFUL ADDRESSES
Our technical services 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 following the instructions given in the chapter on maintenance and
always use only original spare parts.
Using non original parts automatically voids the warranty.

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authorization. K.T.C. S.r.l. shall safeguard its rights to the full extent of the law.
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4DESCRIPTION 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 filter
17
Oil filter
22
Oil recovery window
25
Thermostatic valve
29
Electric motor
30
Oil level
31
Oil discharge

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4.2 OPERATING PRINCIPLE
During the initial phase (unload), the electric motor ref. 29 reach the set operating RPM.
The solenoid valve is not powered and thus the suction valve ref. 1 remains closed. The
length of this phase can be set.
During the second phase (load), the solenoid valve is powered and the suction valve ref. 1 is
opened, thus allowing air to pass through the suction filter ref. 16 and enter the screw
compressor ref. 2. This starts the compression phase.
The air/oil mixture delivered by the screw compressor ref. 2 is conveyed into the air/oil
separator tank ref. 15.
An initial portion of the oil is separated from the air mechanically and deposits at the bottom
of the tank while the air collects at the top.
By force of pressure the air is forced to flow through the oil separator filter ref. 13 and, after
further separation of the oil, it is sent on to the minimum pressure valve ref. 9. This 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 bottom of the tank to the thermostatic valve ref. 25. This valve
sends the oil with a temperature above the set point to the oil radiator ref. 7 where it is
cooled. Once cooled, the oil returns to the thermostatic valve, is mixed with hot oil coming
from the tank and is again checked by the thermostatic valve. Once the temperature set point
(low) is exceeded, the oil is sent to the oil filter ref. 17 and then into the screw compressor.
When the set maximum working pressure is reached, the pressure switch ref. 11 remove
power from the solenoid valve and trips the circuit. The suction valve ref. 1 closes air flow
and the compressor enters in "unload" operating mode. This situation remains in force until
the system minimum pressure setting is reached.
If consumption is low or has stopped unit will continue operate in no-load mode for a set
amount of time and then reverts to stand-by mode.
The condensate that accumulates inside the tank must be discharged daily through the
special drain in the lower part of the tank.

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OPERATION AND INSTALLATION MANUAL
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5DATA AND TECHNICAL SPECIFICATION
* When the environmental temperature is below 5°C, an ISO VG 32 lubricant must be used
** Value detected with the respective max working pressure
*** Noise measured in an open field at 1 metre from the unit ±3 dB(A) at maximum working pressure
Model
COMPACK SPECIAL
Machine type
Oil injected screw compressor
Drive
Direct drive
Type of screw
ADAM V50
ADAM V50
ADAM V60
ADAM V60
Type of fluid handled
Air
Air
Air
Air
Flow rate (ISO 1217:2009 annex C)**
0,27 m3/min –9,5 cfm
0,311 m3/min –10,9 cfm
0,29 m3/min –10,2 cfm
0,38 m3/min –13,4 cfm
Max. working pressure
10 bar g - 145 psi g
10 bar g - 145 psi g
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
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
5 °C - 41 °F
Weight
40 kg –88 lb
46 kg –101,4 lb (2,5 lt)
52 kg –114,6 lb (trolley)
78 kg –172 lb (90lt)
40 kg –88 lb
46 kg –101,4 lb (2,5 lt)
52 kg –114,6 lb (trolley)
78 kg –172 lb (90lt)
40 kg –88 lb
46 kg –101,4 lb (2,5 lt)
52 kg –114,6 lb (trolley)
78 kg –172 lb (90lt)
40 kg –88 lb
46 kg –101,4 lb (2,5 lt)
52 kg –114,6 lb (trolley)
78 kg –172 lb (90lt)
Power supply voltage
230V/1ph/50Hz
230V/1ph/60Hz
400V/3ph/50Hz
460V/3ph/60Hz
Max. current consumption**
14,5 A
17 A
5,8 A
6 A
Electric motor protection rating
IP 54
IP 54
IP 54
IP 54
Insulation class
F
F
F
F
Service factor
S1
S1
S1
S1
Oil charge
1 lt
1 lt
1,3 lt
1,3 lt
Air outlet connection
1/4”
1/4”
1/4”
1/4”
Oil residue in air
< 5 ppm
< 5 ppm
< 5 ppm
< 5 ppm
Electric motor
MEC90
MEC90
MEC90
MEC90
Noise level***
< 65 dB(A)***
< 65 dB(A)***
< 65 dB(A)***
< 65 dB(A)***

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OPERATION AND INSTALLATION MANUAL
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* When the environmental temperature is below 5°C, an ISO VG 32 lubricant must
** Value detected with the respective max working pressure
*** Noise measured in an open field at 1 metre from the unit ±3 dB(A) at maximum working pressure
Model
COMPACK ECO
Machine type
Oil injected screw compressor
Drive
Direct drive
Type of screw
ADAM V50
ADAM V50
Type of fluid handled
Air
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
Weight
40 kg –88 lb
46 kg –101,4 lb (2,5 lt)
52 kg –114,6 lb (trolley)
78 kg –172 lb (90lt)
40 kg –88 lb
46 kg –101,4 lb (2,5 lt)
52 kg –114,6 lb (trolley)
78 kg –172 lb (90lt)
Power supply voltage
230V/1ph/50Hz
400V/3ph/50Hz
Max. current consumption**
14,5 A
5,5 A
Electric motor protection rating
IP 54
IP 54
Insulation class
F
F
Service factor
S1
S1
Oil charge
1 litro
1,3 litri
Air outlet connection
1/4”
1/4”
Oil residue in air
< 5 ppm
< 5 ppm
Electric motor
MEC90
MEC90
Noise level***
< 65 dB(A)***
< 65 dB(A)***

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 18 of 63
6DIMENSIONS

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 19 of 63

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 20 of 63