KTC COMPACK 2 ECO User manual

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 1of 63
OPERATION AND MAINTENANCE MANUAL FOR
COMPACK 2 ECO / SPECIAL COMPRESSORS
ENGLISH VERSION

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 2of 63
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.

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 3of 63
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.

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 4of 63
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

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 5of 63
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

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 6of 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

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 7of 63
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.

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 8of 63
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.

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 9of 63
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

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 10 of 63
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.