Prebena KT-3500 Installation instructions

PREBENA Wilfried Bornemann GmbH & Co. KG
Seestraße 20 –26, 63679 Schotten, Germany
Tel.: [phone] / 96 01 –0, Fax: [phone]
Email: [e-mail]
www.prebena.de, www.kartuschen-tausch.de
Original Operating Manual for the
Cartridge
PREBENA KT-3500
PREBENA KT-300
PREBENA KT-470
PREBENA KT-690
PREBENA KT-900
98678703

Preamble
This operating manual helps you with the
intended,
safe and
economic
use of the cartridges KT-3500, KT-300, KT-470, KT-690 and KT-900,
short cartridge.
We assume that every cartridge user possesses knowledge in
handling pressure containers and compressed air-driven devices.
Persons without such knowledge must be instructed in cartridge
usage by an experienced user.
Every person who
uses,
fills,
cleans
or disposes of
the cartridge, must take note of this operating manual.
This operating manual is part of the product. Always keep it near the
cartridge. Pass this operating manual on if you sell the cartridge or
hand it down in another way.

3
Table of Contents
Design Elements..............................................................................4
General design elements .............................................................4
Safety information features ..........................................................4
Basic Safety Information ................................................................5
Intended use.................................................................................5
Avoiding explosion hazards..........................................................6
Avoid damaging the cartridge.......................................................6
Description.......................................................................................7
Scope of delivery..........................................................................7
Specification on the type label for KT-3500 .................................7
Specifications on the type label for KT-300, KT-470, KT-690 and
KT-900..........................................................................................8
Using the Cartridge .........................................................................9
Checking the condition.................................................................9
Connecting the cartridge..............................................................9
Separating the cartridge from the device...................................10
Transporting and Storing the Cartridge......................................11
Servicing the Cartridge.................................................................11
Cleaning the cartridge ................................................................11
Filling the cartridge.....................................................................12
Having the cartridge checked.....................................................13
Troubleshooting ............................................................................14
Cartridge Disposal.........................................................................15
Technical Data ...............................................................................15
Manufacturer Address ..................................................................18
Warranty.........................................................................................19

Design Elements
4
Design Elements
General design elements
Various elements of the operating manual are furnished with defined
design elements. This way you can easily differentiate if it is a
normal text,
A list or
Action step.

These notes contain additional information such as special
details about the economic use of the cartridge.
Safety information features
All safety information in this operating manual is structured in the
same way. On the left you find a hazard symbol. Right next to it you
see a signal word indicating the severity of danger. Below this, you
see a description about the source of danger and information about
how you can avoid this hazard.
WARNING
Information with the word WARNING warns of
hazards that could possibly lead to severe or
fatal injuries.
CAUTION
Information with the word CAUTION warns of
hazards that could possibly lead to minor or
moderate injury as well as damage to property
or the environment.

Basic Safety Information
5
Basic Safety Information
Note and observe all warnings and information in this operating
manual and on the cartridge when handling the cartridge. The
attached Declaration of Conformity is part of this operating manual.
Intended use
The cartridges are solely for supplying those types of PREB ENA
devices with compressed air that are expressly stipulated in their
respective cartridge operating manual. The use of other devices is
only permitted after consulting with the manufacturer. Part of the
intended use is observing the accident prevention regulations and
the provisions and standards applicable on site. Any other use is
deemed as not intended and can lead to damage to property and
even to damage to persons.
The following items are particularly deemed as not intended
Operation on not permitted devices,
Operation with oxygen or other flammable gases or gas mixtures
or
Operation by persons without knowledge of the use of pressure
containers and devices driven by compressed air.
The PREBENA WILFRIED BORNEMANN GMBH & CO. KG is not
liable for damages that occur due to non-intended use.

Basic Safety Information
6
Avoiding explosion hazards
Fill the cartridge with the PREBENA compressors of the PKT
FILLMASTER series only.
Fill the cartridge with compressed air only.
Fill the cartridge only to the maximum filling pressure of 300 bar.
Do not fill a damaged cartridge.
Do not expose the cartridge to temperatures above 60 °C or
direct sunlight.
Use the cartridge only up to the date of the maximum operating
life specified on the type label.
Separate the cartridge from the fastener driving tool and the
controller before transport.
Keep the cartridge inaccessible for children and other
unauthorised persons.
Do not use a cartridge if its periodic check dates back more than
5 years.
Avoid damaging the cartridge
Never open the cartridge. Always leave repair works to qualified
experts.
Do not use the cartridge if it has been dropped or damaged. Have
the cartridge checked by qualified experts before putting it into
service again.
Avoid contact of the cartridge with the following substances:
-Aggressive solvents
-Fuel and lubricants
-Acids
-Cleaning agents
-Chemicals of all kinds.

Description
7
Description
Scope of delivery
The cartridge is delivered in a metal transport case for two cartridges
(KT-3500-S) and one cartridge (KT-300-S,
KT-470-S, KT-690-S and KT-900-S) respectively or is enclosed to
the device. The scope of delivery includes protective caps for the
valves on the cartridge, the operating manual and the conformity.
Specification on the type label for KT-3500
A label is attached to the cartridge. You can find the following
important information about the cartridge on it:
No.
Explanation
1
End of operating life
2
Serial number of the cartridge
3
Manufacturing date (month and year)
4
Year of the first periodic check
5
Type designation of the cartridge
6
Country of origin
7
Company name
8
Date of the last periodic check that was carried out

Description
8
Specifications on the type label for KT-300, KT-470,
KT-690 and KT-900
A label is attached to the cartridge. You can find the following
important information about the cartridge on it:
No.
Explanation
1
End of operating life
2
Serial number of the cartridge
3
Manufacturing date (month and year)
4
Year of the first periodic check
5
Type designation of the cartridge
6
Country of origin
7
Company name
8
Date of the last periodic check that was carried out
Do not remove or cover the type label.

Using the Cartridge
9
Using the Cartridge
Checking the condition
WARNING
There is risk of explosion when using a
damage cartridge.
Check the cartridge’s condition before
every single connection.
Connect the cartridge in sound condition
only.
Particularly check the following items:
-The valve must not be damaged or contaminated or loose.
-The cartridge must not show any external damage such as
scrapes or dents.
-The last periodic check of the cartridge must not date back
more than five years.
-The cartridge’s operating life must not be exceeded.
Do not connect a damaged cartridge to a device.
Have the damaged cartridge repaired by PREBENA experts
before connecting it.
Connecting the cartridge
Take the cartridge from the transport case.
Keep the transport case for transporting the cartridge.

Transport of the cartridge is only permitted in the transport
case.

Using the Cartridge
10
WARNING
There is risk of explosion when exceeding the
maximum operating pressure (see operating
manual of the fastener driving tool).
In this case, separate the cartridge from
the device immediately.
Unscrew the sealing cap from the valve.
Check the valve for foreign objects and contamination.
Clean the valve, if necessary (see page Fehler! Textmarke nicht
definiert.).
Check the condition of the cartridge (see page 9).
WARNING
Operation on unsuitable devices can cause
damage to the cartridge and the device.
Connect the cartridge to devices approved
by the manufacturer only.
Slide the cartridge with the valve at the head into the brackets on
the device.
Screw the cartridge hand-tight into the thread at the device
connection.
Separating the cartridge from the device
Conduct the following steps after the operation or after service
interruption:
Unscrew the cartridge from the connection thread.
Pull the cartridge back from the brackets on the device.
Screw the sealing cap onto the cartridge’s valve.
Store the cartridge in the delivered transport case protected
against shock and blows.

Transporting and Storing the Cartridge
11
Transporting and Storing the
Cartridge
CAUTION
Damage due to chemicals or shock possible.
Transport and store the cartridge protected
against shock.
Transport and store the cartridge protected
against chemicals.
Leave a little pressure on the cartridge (between 2 and 3 bar).
Pack the cartridge in the transport case or a durable shipping
carton before transport or storage.
Transport the cartridge to the desired location.
Store the cartridge at room temperature in a dry and dust-proof
location.
Servicing the Cartridge
The cartridge must only be serviced by persons having the required
knowledge, skills and experience for that. All works not described
here must only be conducted by the manufacturer’s customer service
or at the manufacturer’s premises.
Cleaning the cartridge
Clean the hull and the valve of the cartridge after every single
use.
CAUTION
Damage to the cartridge due to wrong cleaning
agents.
Use a dry or slightly moistened cloth or a
cloth slightly moistened with mild soap
solution for cleaning only.

Servicing the Cartridge
12
In order to remove slight contamination on the hull, proceed as
follows:
Wipe the cartridge with a cloth slightly moistened with mild soap
solution.
Then wipe the cartridge with a cloth slightly moistened with tap
water.
Then scrub it with a soft and dry cloth.
To clean the valve, proceed as follows:
WARNING
Risk of explosion if the valve is damaged.
Do not clean the valve with hard or pointed
objects.
Blow out the inside of the valve.
Wipe the outside of the valve with a cloth slightly moistened with
soap solution.
Then wipe the outside of the valve with a cloth slightly moistened
with tap water.
Then scrub it with a soft and dry cloth.
It is not permitted to clean the cartridge with means other than the
stated means.
If you are unable to clean the cartridge as described, send it to
the manufacturer.
Filling the cartridge
You can fill the cartridge with the compressor of the PKT
FILLMASTER series available as accessory.
Observe the compressor operating manual here.
You can also buy a full cartridge at a specialist shop in exchange for
an empty cartridge.

Servicing the Cartridge
13
Having the cartridge checked
WARNING
Risk of explosion due to unchecked cartridges.
Use properly checked cartridges only.
The cartridge must be inspected at Prebena at intervals specified in
national regulations every five years. This check must be
documented in the intended field on the label of the cartridge.
Check the date of the last periodic check on the type label.
If it dates back 5 years or more, proceed as follows:
Pack the cartridge in a sturdy shipping carton (see page 11).
Send the cartridge to PREBENA for inspection.

Troubleshooting
14
Troubleshooting
Symptom
Possible cause
Remedy
Air escapes audibly at the
fastener driving tool’s
safety valve.
The operating pressure
is too high; the fastener
driving tool is damaged.
Separate the cartridge from
the fastener driving tool
(see page 10).
Send cartridge and device
to PREBENA via a
specialist dealer
(see page 18).
Air escapes audibly at the
connection for the
cartridge.
The cartridge was
loosened by shock.
Screw the cartridge hand-
tight into the connection
(see page 9).
The gaskets on the
connections for the
cartridge are defective.
Connect new cartridge
(see page 9).
Send cartridge to
PREBENA via a specialist
dealer (see page 18).
If the problem persists:
Send the fastener driving
tool to PREBENA via a
specialist dealer
(see page 18).
No release possible
The operating pressure
is too low.
Connect new cartridge (see
page 9).
If the malfunction still cannot be remedied, contact your specialist
dealer or the manufacturer (see page 18).

Cartridge Disposal
15
Cartridge Disposal
CAUTION
Damage to the environment if disposed of
incorrectly.
Clean the cartridge before disposal.
Observe applicable regulations for
disposing of oil.

Never throw the cartridge into the normal
household waste.
Send the cartridge to the manufacturer for
disposal (see page 18).
Technical Data
KT-3500
Length:
410 mm
Diameter:
87 mm
Packaging dimensions (L × W × H):
KT-3500-S: 270 × 115 × 435 mm
Weight, empty cartridge:
1.3 kg
Weight, full cartridge:
1.7 kg
Weight KT-3500-S,
with transport case:
7 kg
Content:
1.5 l compressed air
Maximum container air pressure:
300 bar
Operating temperature:
–5 to +45 °C
Storage / transport temperature:
Room temperature, maximum of 60 °C
Maximum operating life:
15 years from the date of manufacture

Technical Data
16
KT-300
Length:
465 mm
Diameter:
115 mm
Packaging dimensions (L × W × H):
KT-300-S: 600 x 290 x 195 mm
Weight, empty cartridge:
2.0 kg
Weight, full cartridge:
3.06 kg
Weight KT-3500-S,
with transport case:
9.52 kg
Content:
3.0 l compressed air
Maximum container air pressure:
300 bar
Operating temperature:
–5 to +45 °C
Storage / transport temperature:
Room temperature, maximum of 60 °C
Maximum operating life:
15 years from the date of manufacture
KT-470
Length:
505 mm
Diameter:
140 mm
Packaging dimensions (L × W × H):
KT-470-S: 600 x 290 x 195 mm
Weight, empty cartridge:
2.9 kg
Weight, full cartridge:
4.54 kg
Weight KT-3500-S,
with transport case:
11.1 kg
Content:
4.7 l compressed air
Maximum container air pressure:
300 bar
Operating temperature:
–5 to +45 °C
Storage / transport temperature:
Room temperature, maximum of 60 °C
Maximum operating life:
15 years from the date of manufacture

Technical Data
17
KT-690
Length:
540 mm
Diameter:
160 mm
Packaging dimensions (L × W × H):
KT-690-S: 675 x 310 x 235 mm
Weight, empty cartridge:
3.9 kg
Weight, full cartridge:
6.22 kg
Weight KT-3500-S,
with transport case:
14.04 kg
Content:
6.9 l compressed air
Maximum container air pressure:
300 bar
Operating temperature:
–5 to +45 °C
Storage / transport temperature:
Room temperature, maximum of 60 °C
Maximum operating life:
15 years from the date of manufacture
KT-900
Length:
575 mm
Diameter:
175 mm
Packaging dimensions (L × W × H):
KT-900-S: 675 x 310 x 235 mm
Weight, empty cartridge:
5.0 kg
Weight, full cartridge:
8.1 kg
Weight KT-3500-S,
with transport case:
15.94 kg
Content:
9.0 l compressed air
Maximum container air pressure:
300 bar
Operating temperature:
–5 to +45 °C
Storage / transport temperature:
Room temperature, maximum of 60 °C
Maximum operating life:
15 years from the date of manufacture

Manufacturer Address
18
Manufacturer Address
PREBENA
Wilfried Bornemann GmbH & Co. KG
Fastening technology
Seestraße 20–26
D-63679 Schotten
Telephone: [phone] / 96 01 - 0
Telefax: +49 (0) 60 44 / 96 01 - 820
Email: [email protected]
Homepage: www.prebena.de
www.kartuschen-tausch.de

Warranty
19
Warranty
PREBENA warrants 1 year of warranty for the specified device from
the date of purchase according to the following warranty conditions.
PREBENA warrants the corrections of defects attributable to material
or fabrication defects free of charge. Functional defects and
damages caused by improper handling are not considered within the
scope of this free warranty.
Furthermore, only original PREBENA fixtures must be used and
product liability and thereby the warranty claim does not apply upon
non-compliance. The warranty does not extend to wear parts such
as O-rings, etc. It is at PREBENA’s discretion to undertake the
warranty by exchanging the defective part or by substitute delivery.
There are no further claims.
In order to make claims under the warranty, the properly filled out
warranty certificate with dealer stamp and date of purchase or an
invoice stating the data and specifications to be executed according
to the warranty certificate must be attached.
Shipping: The faulty device must be packed carefully and shock-
proved and sent to PREBENA sufficiently stamped.

Warranty certificate
Model designation:
Date of purchase:
Dealer:
(stamp)

PREBENA Wilfried Bornemann GmbH & Co. KG
Seestraße 20 –26, 63679 Schotten, Germany
Tel.: [phone] / 96 01 –0, Fax: [phone]
Email: [e-mail]
www.prebena.de, www.kartuschen-tausch.de