KTC COMPACK 2 User manual

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USER MANUAL AND INSTALLATION
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OPERATION AND MAINTENANCE MANUAL FOR
COMPACK 2 COMPRESSOR
(SOLUTION FOR BUS)
ENGLISH VERSION

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SUMMARY
1GENERAL WARNINGS AND INFORMATION FOR THE USER...................4
1.1 DEFINITION OF REGULATED RELATIONSHIPS...................................................4
1.1.1 DECLARATIONS..............................................................................................4
1.1.2 WARRANTY......................................................................................................5
1.1.3 RETURNS ..........................................................................................................5
1.2 RULES APPLY ..............................................................................................................6
1.3 GENERAL INFORMATION.........................................................................................6
1.3.1 WARNINGS AND PRECAUTIONS.................................................................6
1.4 HOW TO SEE THE MANUAL .....................................................................................6
1.5 CE MARKING ...............................................................................................................7
1.6 MAINTENANCE AND SUPPORT INFORMATION OF THE MACHINE................8
1.7 INSTRUCTIONS FOR SAFE OPERATION.................................................................8
1.8 LABELS POSITION ....................................................................................................11
2TECHNICAL DATA COMPRESSOR................................................................14
3DIMENSIONS......................................................................................................15
4UNPACKING.......................................................................................................17
5LOCATION..........................................................................................................17
6CONNECTION AND START UP......................................................................19
6.1 GENERAL WARNINGS .............................................................................................19
6.2 USE OF THE COMPRESSOR.....................................................................................20
6.3 COMPRESSOR LUBRICATION................................................................................21
6.4 USING THE COMPRESSOR WITH SYNTHETIC OILS..........................................22
6.5 CONNECTION AND START UP...............................................................................23
6.5.1 GENERAL WARNINGS .................................................................................23
6.5.2 CONNECTING OF THE POWER CABLE OF COMPRESSOR...................23
6.6 ELECTRICAL CONNECTION OF COMPRESSOR..................................................24
6.6.1 FUSE AND BREAKER....................................................................................24
6.6.2 GROUND CONNECTION...............................................................................25
6.6.3 SIZING OF ELECTRIC CABLE .....................................................................25

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6.7 AIR CONNECTION OF COMPRESSOR...................................................................26
7FIRST START......................................................................................................27
8CONTROL PANEL .............................................................................................28
8.1 ELECTRIC DIAGRAM ...............................................................................................29
9HEATING RESISTANCE OF OIL .....................................................................33
10 PNEUMATIC SCHEME AND MACHINE DESCRIPTION.............................34
11 ORDINARY MAINTENANCE OF COMPRESSOR.........................................35
11.1 REPLACEMENT OF OIL FILTER.............................................................................37
11.2 REPLACEMENT OF SEPARATOR FILTRE.............................................................37
11.3 CHANGING OIL..........................................................................................................38
11.4 REPLACEMENT OF AIR FILTER.............................................................................39
12 MAINTENANCE SCHEDULE...........................................................................40
13 TROUBLESHOOTING.......................................................................................42
14 APPENDIX ..........................................................................................................44
14.1 MAINTENANCE CONTROL BOARD ......................................................................44
15 COMMERCIAL PARTS, SPARE PARTS AND RELATED
DOCUMENTATION..........................................................................................45

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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 solely 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.
When making any requests, always indicate model and serial number.
TEST CERTIFICATE
We hereby declare that the compressor has passed testing.
The following checks were performed:
-All parts have been assembled correctly and are functioning properly;
-The unit has passed electrical testing;
-The pressurized parts have passed testing;
-There are no leakages in the oil and air circuits;
-The outside of the machine is not defective;
-The air yield, power consumption and operating temperature parameters are all within normal
ranges;
The Tester
________________
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
2009/105/CE - 2014/35/CE –2006/42/CE –2014/30/CE - EN60204-1 - EN1012-1
K.T.C. S.r.l. holds the relevant technical dossier.

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1.1.2 WARRANTY
The KTC S.R.L guarantees its products from manufacturing or design defects for a period of 24
months from the date of commissioning, which must be communicated to KTC S.R.L, filling out
the form within the technical documentation supplied with the machine.
Not getting no communication, the guarantee will be recognized for 24 months by referring to the
following shipment date on the sales invoice KTC S.R.L.
Are excluded from the warranty the components for their specific use is subject to usury.
Interventions under warranty can be made exclusively by KTC SR.L. or technical assistance centres
authorized by KTC SR.L. shipment of any product made to KTC S.R.L, for Interventions under
warranty must be authorized in advance in writing by KTC S.R.L, which decides in its sole
discretion whether to authorise or use of its own Authorized technical assistance Center.
In both cases, the expedition to KTC S.R.L will be prepaid with the charge of the shipping invoice.
Repair or replacement under warranty includes free replacement of machine components, defective
recognized.
The warranty lapses for damage caused by negligence, incorrect installation, use and or do not
comply with the instructions described in "use and maintenance booklet"; in the case of alterations
or repairs carried out with non-original spare parts or by KTC S.R.L personnel not authorized by
KTC S.R.L.
Defective items replaced under warranty, are withdrawn from the authorized service center. Are
excluded from any warranty repair or compensation for damages occurring during transport (one-
way or return from an authorized technical assistance Center). Is any type of compensation for
damage caused to persons or things, resulting from a failure and inappropriate use of purchased and
downtime (the customer must protect itself for this case).
Warranty service is provided only to buyer in compliance with contractual and administrative rules
that present the specification documentation attesting to the purchase period.
This is the only valid warranty recognized by KTC S.R.L JURISDICTION.
Any dispute will be exclusively the competence of the courts of Vicenza.
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 KTC.

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1.2 RULES APPLY
As expressed in the declaration of conformity (chap. 1.1.1), the air compressor is identified by the
label on the front of this document complies with the essential requirements of DIRECTIVE - LAW
2009/105/CE - 2014/35/CE –2006/42/CE –2014/30/CE - EN60204-1 - EN1012-1
1.3 GENERAL INFORMATION
The compressor should be used only as indicated in this manual, which should be stored carefully in
a place easily accessible and familiar, since it will follow the entire life of the machine.
For any requests always specify model and serial number.
1.3.1 WARNINGS AND PRECAUTIONS
Before each operation, read carefully this user manual. Failure of the information and instructions
contained in it can cause damage to property and injury to persons.
• The machine was designed and built for the following functions. Any other commitment is not
allowed.
• Installation and maintenance must be performed by qualified personnel. Always follow the safety
rules.
• The manufacturer disclaims any liability for damage to persons or things to the machine in
question, caused by incorrect use of the same, failure or superficial compliance with security
policies in this manual, by even slight changes, from use of non-original spare parts.
1.4 HOW TO SEE THE MANUAL
Symbols have been identifying situations requiring extra attention. These symbols may appear next
to a text, a picture next to or on top of the page. Give full attention to the meaning of the symbols:
their function is to avoid repeating the key terms or notices of darkness, to be considered
"reminders". See the page below whenever doubts arise about their meaning.
WARNING: This highlights an important description regarding hazardous
conditions, safety warnings, information of utmost importance.
MACHINE STOPS: Each operation must be performed with the machine stopped
ATTENTION MACHINE IN PRESSURE: every operation must be performed for a
machine without pressure in the air/oil separator tank (0 bar).

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REMOVE POWER: every operation must be performed on the machine when the
power is turned off.
QUALIFIED: any intervention highlighted by this symbol is the exclusive competence
of a technician
1.5 CE 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:
CE marking
Compressor model
Serial number
Maximum working pressure
Power supply voltage and frequency
Nominal power
Weight
Manufacture year

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1.6 MAINTENANCE AND SUPPORT INFORMATION OF THE MACHINE
Our assistant service is at your disposal to provide all information necessary to resolve any
problems that might arise.
For further information please contact customer service or your local dealer.
Only with the use of original spare parts can guarantee the best performance of the our
compressor.
Please observe the instructions given in chapter maintenance and use only original spare parts.
The use of the non original spare parts will automatically make void the warranty.
1.7 INSTRUCTIONS FOR SAFE OPERATION
WARNING!
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 injury to the user.
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 compressor.
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.
8. Personnel Intervention
Before performing any form of intervention, the personnel must be aware of all compressor
functions and controls.

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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.
Contact an Authorized Service Centre if necessary.
14. Check for Defective Parts and Air Leaks
Check the alignment of moving parts, hoses, pressure gauges, pressure reducers, tyre 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 turning it off 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.
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.

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21. 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.
22. Spare Parts
Use only original spare parts which can be purchased from our distributors. Use of non original
spare parts voids the warranty and can lead to compressor malfunction. Repairs must be carried out
by an Authorized Service Centre.
23. Pneumatic Circuit
Use hoses, connections and pneumatic tools rated to handle pressures above the operating pressure.
24. 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.
25. 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.
26. 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.
THE TERMINALS OF THE ELECTRIC MOTOR ARE STILL LIVE EVEN
WHEN THE COMPRESSOR IS OFF, DISCONNECT THE PLUG FROM THE
ELECTRICAL SOCKET
KEEP THIS MANUAL INTACT AND ON HAND, AVAILABLE TO ANYONE
USING THE COMPRESSOR!
WE RESERVE THE RIGHT TO MAKE ANY MODIFICATIONS WE DEEM
NECESSARY WITHOUT PRIOR NOTICE!

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1.8 LABELS POSITION

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ATTENTION:
Do not perform any
maintenance on this
machine before:
• have stopped all moving
parts
• disconnect the power
supply
• you have downloaded all
air pressure.
Maintenance and repairs
are performed by
authorized personnel!
ATTENTION:
Hot surface
ATTENTION:
Component or system
under pressure
High oil temperature
safety thermostat

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2TECHNICAL DATA COMPRESSOR
• When the environmental temperature is below 5 ° C is necessary to choose a lubricant ISO VG 32.
• For temperatures below 0° adopt a heater for the specific oil. If necessary, contact an authorized service center KTC.
** Value detected at the maximum operating pressure
*** Sound level measured in free field at 1 meter ± 3 dB (A) at maximum operating pressure.
Model
COMPACK 2 V230/3/50
10 bar
COMPACK 2 V400/3/50
10 bar
Machine type
Oil injected screw compressor
Oil injected screw compressor
Drive
Direct coupling
Direct coupling
Type of screw
ADAM S60 C
ADAM S60 C
Flow rate (ISO 1217 annex B 1996)
0.29 m3/min - 10.24 cfm
0.29 m3/min - 10.24 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**
3.0 kW - 4 hp
3.0 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 - 88.2 lb
40 kg - 88.2 lb
Power Supply Voltage
230/3/50
400/3/50
Max. current consumption
11,5 A
6 A
Degree of electrical motor protection
IP 54
IP 54
Class of insulation
F
F
Service Factor
S1
S1
Oil Quantity
1.5 lt
1.5 lt
Air Outlet connection
3/8”
3/8”
Oil residue in air
< 3 ppm
< 3 ppm
Electrical Motor
MEC90
MEC90
Heating Oil Resistance
24 V / 35 W / 1,5 A
24 V / 35 W / 1,5 A
Sound Level***
< 70 dBA
< 70 dBA
Air Tank Capacity
/
/

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3DIMENSIONS

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4UNPACKING
The machine must be unpacked by qualified personnel using suitable tools.
The compressor is to be lifted with a forklift truck rated for the weight of the unit.
Check that the outside packaging is intact.
Unpack the machine carefully.
Check that the outside of the machine is intact.
Dispose of the packaging in compliance with current environmental regulations.
5LOCATION
Install the compressor at the site point indicated at the time the order was placed. If the unit is
installed at a different site, the manufacturer cannot be held responsible for any ensuing
problems.
Unless specified otherwise at the time the order is placed, the compressor must run normally under
the environmental conditions indicated below.
The room where the compressor is installed must comply with current accident prevention
standards and must meet the following requirements:
Protected from rain and frost.
Relatively free of dust. In time, a dusty environment can lead to damage and operating problems.
Adequately ventilated and of such size that environmental temperature remains steady (min. 5°C,
max. 45°C) when the machine is running. At the maximum admissible environmental temperature
(45°C) and with a relative humidity above 80% machine performance can reduce. Likewise,
machine performance may be reduced when the unit is installed at an altitude of 1000 m above
sea level.
If hot air exhaust is inadequate, install exhaust fans at the highest position possible (see figure 4).
Lighting: the compressor is built considering current standards and seeking to reduce shadow
zones to the barest minimum, thus facilitating operator intervention; as the compressor room
lighting system is deemed important for personnel safety, there must not be any shadows, glaring
lights or stroboscopic effects due to the lighting.
Potentially explosive and/or flammable atmospheres: in its standard configuration, the compressor
is not designed to work in environments where there is the risk of explosion and/or fire;

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In this version, the compressor must be set between a floor and legs of the compressor,
through no.4 M8 screws.
If necessary, refer to ch. 3 DIMENSIONS to assess the interests of a puncture.

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6CONNECTION AND START UP
6.1 GENERAL WARNINGS
Before starting compressor for the first time it is compulsory to make sure that:
Incoming voltage is the same as indicated on the number plate .
Main automatic switch on the wall, must follow the engineering data (see chapter 6.6.1).
Check that oil level is correct (see chapter 11.3).
The electrical connection are made using cables with adequate section (see chapter 6.6.3).
CAUTION!
Carefully comply with the SAFETY WARNINGS regarding use of the machine.
For the European market, the tanks are complaint with Directive 87/404/EEC while
the compressors are built in compliance with Directive 98/37/EEC.
Check the label on the compressor and at the beginning of this manual for indication
of your model.

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6.2 USE OF THE COMPRESSOR
The compressor is designed and manufactured exclusively to produce compressed air.
The compressor is not suitable for use in explosion-proof and flammable products.
ANY OTHER USE OTHER THAN EXPECTED FROM THE MANUFACTURER
TO RISE FROM LIABILITY 'LINKED TO RISK THAT SHOULD BE INCURRED.
USING THE COMPRESSOR AS OTHERWISE AGREED UPON PURCHASE BY
THE MANUFACTURER DISCLAIMS ANY RESPONSIBILITY 'FOR ANY
DAMAGE TO PROPERTY, AND PERSONS TO THE MACHINE.
WARNING!
NEVER POINT THE JET OF AIR ON PEOPLE OR PETS.
DO NOT USE THE AIR FOR A RESPIRATORY OR FOOD OR
PHARMACEUTICAL MANUFACTURING PROCESS WHERE THE AIR
PRODUCED PRIOR TO BE TREATED TO MAKE APPROPRIATE USE THAT IS
REQUIRED.