Prebena KT-3500 User manual

PREBENA Wilfried Bornemann GmbH & Co. KG
Seestr. 20 – 26, 63679 Schotten, Germany
Tel.: [phone] / 96 01 – 0, Fax: [phone] / 96 01 – 80
email: [e-mail]
www.prebena.de, www.kartuschen-tausch.de
Operating Manual for the Cartridge
PREBENA KT-3500
98678701

Introduction
This operating manual is provided as an aid for
•proper,
•safe, and
•economical
use of the KT-3500 cartridge, or also referred to as just cartridge.
We assume that every user of the cartridge has experience handling
pressure vessels and devices powered by compressed air. Persons
lacking this knowledge must be instructed in the use of the cartridge
by an experienced user.
Every person who
uses,
fills,
cleans or
disposes
of this cartridge must have read and understood this operating
manual.
This operating manual is considered as a component of the product.
Always keep this operating with the cartridge. If you sell the
cartridge, or provide it to another party, ensure that the operating
manual is included with the cartridge.

3
Table of Contents
Organizational features................................................................... 4
General organizational features ...................................................4
Features of the safety instructions ...............................................4
Basic safety instructions.......................................................5
Proper use ....................................................................................5
Avoid explosion hazards...............................................................6
Avoid damage to the cartridge......................................................6
Description .......................................................................................7
Scope of supply ............................................................................7
Rating plate information................................................................7
Using the cartridge .......................................................................... 8
Check the condition ......................................................................8
Connecting the cartridge ..............................................................8
Disconnecting the cartridge from the pneumatic tool. ..................9
Transporting and storing the cartridge .......................................10
Maintaining the cartridge ..............................................................10
Cleaning the cartridge ................................................................10
Filling the cartridge .....................................................................11
Having the cartridge tested.........................................................12
Troubleshooting ............................................................................12
Cartridge disposal .........................................................................13
Technical data................................................................................14
Manufacturer's address ................................................................14
Guarantee .......................................................................................15

Organizational features
4
Organizational features
General organizational features
Different elements of the operating manual have specific
organizational features. These features make it easy to differentiate
normal text,
listings or
action steps.

These instructions contain additional information, such as
special tips on economical use of the cartridge.
Features of the safety instructions
All safety instructions contained in this operating manual are
structured on the same pattern. To the left is the hazard symbol. To
the right a signal word that indicates the seriousness of the hazard.
Below there is a description of the hazard source and instructions on
how you can avoid this hazard.
WARNING
Instructions with the word WARNING warn of
hazards that could possibly result in serious or
fatal injuries.
CAUTION
Instructions with the word CAUTION warn of
hazards in which light to medium severity
injuries, property damage, or damage to the
environment can possibly occur.

Basic safety instructions
5
Basic safety instructions
When handling the cartridge heed and comply with all warning and
instructions in this operating manual and on the cartridge.
Proper use
The cartridge is used exclusively for supplying compressed air to
those PREBENA pneumatic tools for which this cartridge type is
expressly prescribed in the operating manuals for those pneumatic
tools. Using the cartridge on other devices is only permitted after
consultation with the manufacturer. Proper use also includes
compliance with accident prevention regulations and legal guidelines
and standards applicable at the site of implementation. Any other
use is considered to be improper use and can result in property
damage, or even personal injury.
Operation
on non-approved devices,
with oxygen or with other flammable gasses or gas mixtures, or
operation by persons lacking knowledge of implementation of
pressure vessels and pneumatic tools
particularly constitutes improper use.
PREBENA WILFRIED BORNEMANN GMBH & CO. KG assumes no
liability for damage that occurs due to improper use.

Basic safety instructions
6
Avoid explosion hazards
Only fill the cartridge with the PREBENA PKT-FILLMASTER 350
compressor
Only fill the cartridge with compressed air.
Only fill the cartridge to the maximum filling pressure of 300 bar
Do not fill damaged cartridges.
Never expose the cartridge to temperatures in excess of 60 °C, or
to direct sunlight.
Only use the cartridge until the maximum service life, as specified
on the rating plate, has expired.
Disconnect the cartridge from the pneumatic tool prior to every
transport.
Store the pneumatic tool where it is inaccessible to children and
other unauthorized persons.
Avoid damage to the cartridge
Never open the cartridge. Only have qualified specialists perform
repair work.
Do not use the cartridge if it has fallen or if it is damaged. Have
the cartridge checked by qualified, specialized personnel before
you place it in service again.
Prevent the cartridge from coming into contact with the following
substances:
- Aggressive solvents
- Fuels and lubricants
- Acids
- Cleaning agents
- Chemicals of any type.

Description
7
Description
Scope of supply
The cartridge is supplied in a metal transport case for two cartridges
(KT-3500-S). The scope of supply includes two protective caps for
the valves of the cartridges.
Rating plate information
A sticker is affixed to the cartridge. The following important
information is provided on this sticker:
No.
Explanation
1
Maximum service life:
2
Serial number of the cartridge
3
Date of manufacture (month and year)
4
Year of the first periodic test
5
Type designation of the cartridge
6
Country
of origin
7
Company name
8
Date of the last periodic test performed
Do not remove or cover this rating plate.

Using the cartridge
8
Using the cartridge
Check the condition
WARNING
There is an explosion hazard when operating a
damaged cartridge.
Check the condition of the cartridge before
each connection.
Only connect the cartridge if it is trouble-
free condition.
Check the following points in particular:
- The valve should not be damaged, fouled, or loosely seated.
- The cartridge should not show any external damage such as
scratches or dents.
- The last periodic test of the cartridge should not be more than
five years in the past.
- Do not exceed the service life of the cartridge.
Do not connect a damaged cartridge to a pneumatic tool.
Have PREBENA specialized personnel repair a damaged
cartridge before you connect it.
Connecting the cartridge
Take the cartridge out of the transport case.
Keep the transport case for transport of the cartridge.

Only transport the cartridge in the transport case.

Using the cartridge
9
WARNING
Explosion hazard when exceeding the
maximum operating pressure (see the
operating manual for the pneumatic tool).
In this case immediately disconnect the
cartridge from the pneumatic tool.
Unscrew the sealing cap from the valve.
Check that the valve is free of foreign objects and fouling.
Clean the valve if necessary (see page 11).
Check the condition of the cartridge (see page 8).
WARNING
Operation on unsuitable devices can result in
damage to the cartridge, and to the tool.
Only connect the cartridge to devices that
have been approved by the manufacturer.
Slide the cartridge, with the valve in front, into the pneumatic
tool's holders.
Screw the cartridge hand-tight into the thread on the connection
element of the pneumatic tool.
Disconnecting the cartridge from the pneumatic tool.
Execute the steps described below after operation, or if you
anticipate longer interruptions in operation.
Unscrew the cartridge from the connecting thread.
Pull the cartridge from the rear out of the holder on the pneumatic
tool.
Screw the sealing cap onto the valve of the cartridge.
Keep the cartridge in the supplied transport case where it will be
protected from bumps and impact.

Transporting and storing the cartridge
10
Transporting and storing the cartridge
CAUTION
Damage due to chemicals or impact is
possible.
Pack the cartridge in such a manner that is
protected from impact for transport and
storage.
Protect the cartridge from chemicals during
transport and storage.
Pack the cartridge in the transport case or in a stable shipping
box prior to storage or transport.
Transport the cartridge to the desired location.
Store the cartridge at room temperature in a dry and dust-
protected area.
Maintaining the cartridge
The cartridge should only be maintained by personnel who have the
necessary skill, capability, and experience. All tasks not described
here should only be performed by the manufacturer's customer
service organization, or in the manufacturer's facilities.
Cleaning the cartridge
Clean the shell and the valve of cartridge after each use.
CAUTION
Non-suitable cleaning agents can damage the
cartridge.
Use a dry or slightly damp cloth, or a cloth
that is slightly moistened with a mild soap
solution to clean the cartridge.

Maintaining the cartridge
11
Proceed as follows to remove light fouling from the shell:
Wipe off the cartridge with a cloth that has been slightly
dampened with a mild soap solution.
Then wipe the cartridge with a cloth that has been slightly
dampened with tap water.
Wipe off the pneumatic tool with a dry soft cloth.
Proceed as follows to clean the valve:
WARNING
There is an explosion hazard if the valve is
damaged.
Do not use hard or sharp objects to clean
the valve.
Blow out the inside of the valve.
Wipe the outside with a cloth that has been slightly dampened
with a mild soap solution.
Then wipe the outside of the valve with a cloth that has been
slightly dampened with tap water.
Wipe off the cartridge with a dry soft cloth.
Only use the cleaning agents described to clean the cartridge.
If you cannot clean the cartridge as described, then send the
cartridge to the manufacturer.
Filling the cartridge
You can fill the cartridge with the PKT-FILLMASTER 350
compressor, which is available as an accessory.
Read the operating manual supplied with the compressor.
You can also exchange an empty cartridge when purchasing a full
cartridge from your dealer.

Troubleshooting
12
Having the cartridge tested
WARNING
Explosion hazard due to untested cartridges.
Only use properly tested cartridges.
The cartridge must pass a pressure test at PREBENA every five
years. This test must be documented in the proper field on the label
of the cartridge.
Check the date of the last periodic test on the rating plate.
If the date shows that five years or more have elapsed, proceed as
follows:
Pack the cartridge in a stable shipping box (see page 10).
Send the cartridge in to PREBENA for testing.
Troubleshooting
Symptom
Possible cause:
Reme y
Air audibly escapes
on
the safety valve of the
pneumatic tool.
Operating pressure is
set too high or the
pneumatic tool is
damaged.

Disconnect the cartridge
from the pneumatic tool
(see page 9).
Send the cartridge and
the device to PREBENA
via your dealer (see page
9).

Cartridge disposal
13
Symptom
Possible cause:
Reme y
Air audibly escapes on
the connection for the
cartridge.
The cartridge has
loosened due to
vibration.

Screw the cartridge hand
tight into the connection
(see page 8).
The seals on the
connections for the
cartridge are defective

Connect a new cartridge
(see page 8).
Send the cartridge to
PREBENA via your
dealer (see page 14).
If the problem persists
Send the pneumatic tool
to PREBENA via your
dealer (see page 8).
Release is not possible.
Insufficient operating
pressure.

Connect new cartridge
(see page 9).
If a malfunction cannot be resolved in spite of these instructions,
notify your dealer or the manufacturer (see page 14).
Cartridge disposal
CAUTION
Improper disposal can be harmful to the
environment.
Clean the cartridge prior to disposal.
Comply with the applicable regulations for
disposal of oil.
Never dispose of the cartridge in normal
household waste containers.
Send the cartridge to the manufacturer for
disposal (see page 14).

Technical data
14
Technical data
Length:
410 mm!
Diameter:
87 mm!
Packaging dimensions (L × B × H):
KT
-
3500
-
S: 270 × 115 × 435
mm
Weight empty cartridge
1.3 kg
Weight filled 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
Implementation temperature:
–
5 to +45 °C
Storage/transport temperature:
Room temperature maximum 60°C
Maximum service life:
15 years after manufacturing
Manufacturer's address
PREBENA
Wilfried Bornemann GmbH & Co. KG
Fastening Technology
Seestr. 20–26
D-63679 Schotten
Telephone: [phone] / 01 0-0
Fax: [phone] / 96 01-80
E-mail: [e-mail]
Homepage: www.prebena.de
www.kartuschen-tausch.de

Guarantee
15
Guarantee
For the designated device PREBENA provides a 1-year guarantee
starting from the date of purchase in accordance with the following
guarantee conditions. PREBENA guarantees no-charge resolution of
defects that are attributable to material or manufacturing errors.
Malfunction or damage that has been caused by improper use is not
considered eligible for the no-charge guarantee.
Moreover only original PREBENA fasteners may be used; if this
condition is not complied with, then PREBENA assumes no product
liability, and thus there is no guarantee claim. The guarantee does
not extend to parts subject to wear, such as O-rings, etc. Prebena
will either repair the defective part or ship a replacement at its
discretion. More extensive claims do not exist.
To claim the guarantee, the completely filled- out guarantee card
with dealer stamp and purchase date must be provided, or a receipt
that shows the dates and information in accordance with the
guarantee card must be provided.
Shipping: The device in question must be carefully packed so that it
cannot be damaged during transport, and sent at customer's
expense to PREBENA.

Guarantee card
Model designation: Purchase date:
Dealer: (Stamp)

PREBENA Wilfried Bornemann GmbH & Co. KG
Seestr 20 – 26, 63679 Schotten, Germany
Tel.: [phone] / 96 01 – 0, Fax: [phone] / 96 01 – 80
email: [e-mail]
www.prebena.de, www.kartuschen-tausch.de
Created by
KONTECXT GmbH
www.kx-doku.de
ISO 9001:2000