KTC KME 18-22-30-37 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. shall safeguard its rights to the full extent of the law.
OPERATION AND INSTALLATION MANUAL
COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016 pag.1 of 68
OPERATION AND MAINTENANCE MANUAL FOR
KME 18-22-30-37 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. shall safeguard its rights to the full extent of the law.
OPERATION AND INSTALLATION MANUAL
COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016 pag.2 of 68
CONTENTS
1GENERAL WARNINGS AND INFORMATION FOR THE USER...................5
1.1 DEFINITION OF REGULATED RELATIONSHIPS...................................................5
1.1.1 DECLARATIONS............................................................................................................... 5
1.1.2 WARRANTY....................................................................................................................... 6
1.1.3 RETURNS ........................................................................................................................... 6
1.2 APPLICABLE STANDARDS .......................................................................................7
1.2.1 CE MARKING..................................................................................................................... 7
1.3 CAUTIONS AND SAFETY WARNINGS....................................................................8
1.3.1 INSTRUCTIONS FOR SAFE OPERATION...................................................................... 8
1.4 CONTACTS AND USEFUL ADDRESSES................................................................11
2DESCRIPTION OF THE MACHINE AND OPERATING PRINCIPLE...........12
2.1 MACHINE DESCRIPTION.........................................................................................12
2.2 OPERATING PRINCIPLE...........................................................................................13
3PRESENTATION OF THE MANUAL: CONTENT AND CONSULTATION 14
3.1 SYMBOLS, GLOSSARY AND NOTES ON GRAPHIC LAYOUT ..........................14
4DATA AND TECHNICAL SPECIFICATIONS.................................................15
5INSTALLATION.................................................................................................17
5.1 CHARACTERISTICS AND STORAGE CONDITIONS............................................17
5.2 TRANSPORT ...............................................................................................................17
5.3 UNPACKING...............................................................................................................17
5.4 HANDLING..................................................................................................................18
5.5 LOCATION..................................................................................................................19
5.6 FOUNDATIONS..........................................................................................................19
5.7 CONNECTION AND START-UP...............................................................................21
5.7.1 GENERAL WARNINGS................................................................................................... 21
5.7.2 CONNECTING THE POWER SUPPLY CORD OF THE COMPRESSOR.................... 22
5.7.3 CONNECTING THE COMPRESSOR TO THE ELECTRICAL POWER SUPPLY ...... 23
5.7.4 INFORMATION ON THERMAL RELAY CALIBRATION .......................................... 25
5.7.5 WIRING DIAGRAM KME 18-22-30-37 400V................................................................ 26
5.7.6 COMPRESSOR CONNECTION TO ELECTRICAL POWER SUPPLY........................ 32
5.7.7 FIRST START-UP............................................................................................................. 33

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. shall safeguard its rights to the full extent of the law.
OPERATION AND INSTALLATION MANUAL
COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016 pag.3 of 68
5.8 CLEANING AND DISINFECTION............................................................................34
5.9 REINSTALLATION AND REUSE.............................................................................34
5.10 DEMOLITION AND DISPOSAL................................................................................34
6OPERATION AND USE.....................................................................................35
6.1 DESCRIPTION OF THE OPERATION......................................................................35
6.2 RANGE OF APPLICATIONS .....................................................................................35
6.3 PROPER AND IMPROPER USE ................................................................................35
6.4 OPERATING AND ENVIRONMENTAL LIMITS ....................................................35
6.5 WORKSTATION AND DANGEROUS AREAS........................................................35
6.6 SAFETY DEVICES AND SIGNALS..........................................................................36
6.6.1 POSITION OF THE LABELS........................................................................................... 36
6.7 DANGERS AND RISKS THAT CAN BE ELIMINATED.........................................37
6.8 PERSONAL PROTECTIVE EQUIPMENT, SAFE WORKING PROCEDURES AND
TRAINING ...................................................................................................................37
6.9 COMPRESSOR LUBRICATION...............................................................................38
6.9.1 GENERAL RECOMMENDATIONS................................................................................ 38
6.9.2 USING THE COMPRESSOR WITH SYNTHETIC OILS............................................... 39
7INSTRUCTIONS FOR THE USER ....................................................................40
7.1 DESCRIPTION OF THE CONTROL DEVICES........................................................40
ELECTRONIC CONTROLLER ............................................................................................40
7.1.1 BUTTON LAYOUT.......................................................................................................... 41
7.2 ALARMS LIST.............................................................................................................42
7.3 DESCRIPTION OF THE OPERATIONS TO BE PERFORMED ..............................43
7.4 START, STOP AND EMERGENCY STOP FUNCTIONS ........................................45
7.5 RESET CONDITIONS.................................................................................................45
8COMPRESSOR MAINTENANCE.....................................................................46
8.1 SCHEDULED MAINTENANCE.................................................................................46
8.1.1 BELT TENSIONING......................................................................................................... 47
8.1.2 USING AN OPTIKRIK TENSION GAUGE.................................................................... 53
8.1.3 SUCTION PRE-FILTER MAINTENANCE..................................................................... 54
8.1.4 REPLACING THE OIL FILTER ...................................................................................... 56
8.1.5 REPLACING THE OIL SEPARATOR FILTER.............................................................. 56
8.1.6 CHANGING THE OIL...................................................................................................... 57

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. shall safeguard its rights to the full extent of the law.
OPERATION AND INSTALLATION MANUAL
COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016 pag.4 of 68
8.1.7 REPLACING THE AIR FILTER...................................................................................... 57
8.1.8 MAINTENANCE SCHEDULE......................................................................................... 58
8.2 UNSCHEDULED MAINTENANCE...........................................................................63
9TROUBLESHOOTING......................................................................................64
10 COMMERCIAL PARTS, SPARE PARTS AND PERTINENT
DOCUMENTATION..........................................................................................66
11 APPENDIX ..........................................................................................................67
11.1 MAINTENANCE CHECK SHEET .............................................................................67

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. shall safeguard its rights to the full extent of the law.
OPERATION AND INSTALLATION MANUAL
COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016 pag.5 of 68
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.