User Manual KT-70E KT-90E KT-70SE

KT-70E/KT-90E/KT-70SE
HIGH PRESSURE AIR COMPRESSOR
User Manual
(60Hz Version)
KT-70E / KT-90E / KT-70SE User Manual
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23 October 2017
KT-70E / KT-90E / KT-70SE
Index
1.
Introduction ................................................................................................................................ 5
1.1. Quick Start Guide ................................................................................................................... 5
1.2. Foreword................................................................................................................................. 7
1.3. Documentation........................................................................................................................ 7
1.4. Warranty ................................................................................................................................. 8
1.5. Disclaimer............................................................................................................................... 8
1.6. Required Operator Training.................................................................................................... 9
1.7. Information for the User ......................................................................................................... 9
1.8. Obligations and notes for you as an operator ......................................................................... 9
1.9. Customer service .................................................................................................................. 10
1.10.
Serial Number ................................................................................................................... 10
1.11.
Instructional and training aids. .......................................................................................... 10
1.11.1. Instruction by the operator ........................................................................................... 10
1.11.2. Examples of training topics .......................................................................................... 11
1.12.
2.
Symbols Used.................................................................................................................... 11
Product Description ................................................................................................................. 13
2.1. Intended Use ......................................................................................................................... 13
2.2. Construction.......................................................................................................................... 14
2.3. Optional Equipment.............................................................................................................. 14
2.3.1.
Automatic shut-off........................................................................................................ 15
2.3.2.
Hour counter. ................................................................................................................ 15
2.3.3.
Minimum Pressure Valve. ............................................................................................ 15
2.3.4.
Automatic Condensate Drain........................................................................................ 15
2.4. Functional Description ......................................................................................................... 16
2.5. Pneumatic Air Flow .............................................................................................................. 17
3.
2.5.1.
Intermediate Stage Condensate Collector and Drain. ................................................... 17
2.5.2.
Final Condensate Collector, Drain and Filter. .............................................................. 17
General safety .......................................................................................................................... 18
3.1. Obligation of diligence ......................................................................................................... 18
3.2. Basic safety measures ........................................................................................................... 18
3.2.1.
Principle; Intended Use ................................................................................................ 18
3.2.2.
Responsibility ............................................................................................................... 18
3.2.3.
Personnel selection and qualification; fundamental obligations .................................. 19
3.2.4.
Safety instructions for certain operating phases ........................................................... 19
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3.2.5.
Notes on special types of hazard .................................................................................. 21
4.
EG-Konformitätserklärung ...................................................................................................... 23
5.
Technical Specifications .......................................................................................................... 24
5.1. Compressor System .............................................................................................................. 24
5.2. Compressor Block ................................................................................................................ 24
5.3. compressor oil....................................................................................................................... 24
5.4. Connections .......................................................................................................................... 24
5.5. Pneumatic Flow Diagram – Base Configuration .................................................................. 26
6.
Transport and Installation ........................................................................................................ 27
6.1. Transport............................................................................................................................... 27
6.1.1.
6.2.
Transport to the Site ..................................................................................................... 27
Installation ........................................................................................................................... 27
6.2.1.
Conditions for Set-up.................................................................................................... 27
6.3. Placement.............................................................................................................................. 28
7.
Start-up..................................................................................................................................... 29
7.1. Power .................................................................................................................................... 29
7.2. Checks before initial Start-up ............................................................................................... 30
8.
Operation.................................................................................................................................. 31
8.1. Description of the controls ................................................................................................... 31
8.1.1.
Compressor ................................................................................................................... 31
8.1.2.
Filling Hose .................................................................................................................. 32
8.2. Adjusting and Setting ........................................................................................................... 33
8.2.1.
Operation ...................................................................................................................... 33
8.2.1.1. Starting the Motor .................................................................................................... 33
8.2.1.2. pressure buildup ....................................................................................................... 34
8.2.1.3. To Fill the pressure cylinder. ................................................................................... 34
8.2.1.4. Condensate Drain ..................................................................................................... 35
8.2.1.5. Turning off ............................................................................................................... 35
8.2.1.6. Complete the Filling process ................................................................................... 36
8.3. Filter...................................................................................................................................... 36
8.3.1. Breathing Air Filter ........................................................................................................... 36
8.3.2. Non-Breathing Air Filter ................................................................................................... 36
8.4. Extended Storage .................................................................................................................. 37
8.4.1.
9.
Waste Disposal ............................................................................................................. 37
Troubleshooting ....................................................................................................................... 38
9.1. Tabular overview of possible malfunctions and suggestions to help eliminate the fault. .... 38
9.1.1.
List of Faults ................................................................................................................. 38
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10.
Maintenance ............................................................................................................................. 40
10.1.
Consumable Parts .............................................................................................................. 40
10.2.
Maintenance Plan .............................................................................................................. 41
10.3.
Filter changing log. Please top off the crankcase oil each time the air filter is changed. 43
10.4.
Maintenance Work ............................................................................................................ 44
10.4.1. Checking the Oil Level ................................................................................................ 44
10.4.2. Filter Change. Please top off the crankcase oil each time the air filter is changed. ... 45
10.4.3. Oil Change ................................................................................................................... 46
10.4.4. Final pressure gauge check .......................................................................................... 47
10.4.5. Check final pressure safety valve ................................................................................. 47
10.4.6. Other Maintenance Notes ............................................................................................. 47
11.
Break-out Drawings ................................................................................................................. 48
Figure A.
Figure B.
Figure C.
Figure D.
Figure E.
Figure F.
Figure G.
Figure H.
Exploded View ................................................................................................................. 48
Crankshaft with Piston Rods ............................................................................................ 49
First Stage Cylinder .......................................................................................................... 50
Second Stage Cylinder...................................................................................................... 51
Third Stage Cylinder ......................................................................................................... 52
Oil filler tube and housing pressure equalization .............................................................. 53
Filter Housing ................................................................................................................... 54
Casing ............................................................................................................................... 55
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1. Introduction
1.1. Quick Start Guide
Note this manual is for the US type configuration with 115V or 230V 60Hz supplies. For
230V 50Hz units, please refer to the appropriate manual.
SAFETY NOTICE!
• Read the User Manual before using the compressor
• Disconnect the power and depressurize the filter housing before removing the housing
• The compressor should not be run continuously for more than 45 minutes after which it needs
15 minutes rest.
Prior to operation
• Verify the plug meets local codes, and that the electrical outlet is able to supply the required
current at the required voltage.
• Place the compressor on a flat stable surface or solid surface. Keep a safe distance from wall.
A pitch of up to 20° from Horizontal is permissible.
• Check the oil level is at the mid point of the dipstick or higher, and if necessary top off the
oil.
• For the first time it is operated, run the compressor for 5 minutes with the condensate drains
open.
• Connect the pressure vessel.
• Close the output fill valve if present, or the valve on the pressure vessel.
Running the compressor
• Turn on Compressor.
• Residual high pressure within the compressor may prevent the motor (either gas or electric)
from turning over. If so, open condensate drain valves or output fill valve and vent some of
the residual pressure.
• For the first time it is operated or after an extended period of non-operation, run the compressor for 5 minutes with the condensate drains or output open.
• Insure both condensate screws are closed
• Once output pressure rises to1500 psi (100 bar), slowly open the fill valve.
• Drain the condensate every 15 to 25 minutes while operating by opening the final and intermediate drain screws briefly until the accumulated condensate is released.
• Supervise compressor during filling.
Finish filling
• Turn off the compressor
• Close the filling valve
• Slowly open the bleed screws on the filling hose (if so configured) until the pressure within
the fill hose is released, then the pressure vessel can be removed.
• Open final Condensate screw slowly, capture condensate and dispose of accordingly. Repeat
for intermediate Condensate Drain.
• If the compressor will be out of use for an extended period, run the compressor with both
condensate fill valves open for a minimum of 1 minute.
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Maintenance
• Filter cartridges should be changed on the interval described in 8.3, or once per year.
• Top off the crankcase oil each time the filter is changed.
• Once a year or every 500 operating hours change the crankcase oil.
• Check the oil level before each use.
ATTENTION in case of malfunction, depressurize compressor and remove power
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1.2. Foreword
Dear Customer,
Thank you for choosing the KT-70E / KT-90E / KT-70SE
This manual is an aid to successful and safe operation of the compressor.
These materials are only for information purposes. Changes may be made
without prior notice. Please refer to the manual for compliance to regulations,
for accident prevention and environmental protection.
Keep this manual available where the compressor is in use. Any person who
is authorized to work on the compressor must have read the operating instructions.
The compressor has been built according to state of the art and recognized
safety regulations. Nevertheless, it can be hazardous.
Read this manual before using the compressor is in operation. It helps you:
•
•
•
•
•
•
Prevent risks to the operator,
Become familiar with the compressor,
To avoid interference due to improper operation,
To increase the life of the compressor,
To avoid repair costs and downtime,
To effectively use the compressor.
1.3. Documentation
To avoid operating errors and to ensure trouble-free operation of the compressor, the user guide the operator must always be accessible.
All documents are protected within the meaning of the copyright law.
Violations are an offense and liable to compensation. All rights to exercise
intellectual property rights We reserve the right.
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1.4. Warranty
We warranty to the original owner of the KT-70E / KT-90E purchased from Komptec as
new will be free from manufacturing defects in materials and workmanship under normal
use within a period of (1) one year from date of purchase for an end user, or (90) ninety
days for a commercial user, provided it is operated and maintained according to instructions and the user manual. Contact Komptec for the warranty policy inside the European
Union..
Our obligation under this warranty is limited, at our election expressly to the replacement
or repair of such parts from the manufacturer, or at a service center designated by us, who
have been found by the audit to be defective.
DISCLAIMERS:
This warranty does not cover damage due to negligence or improper use, including faulty
repairs by others and failure to implement reasonable and necessary maintenance. We
are not liable for any special, indirect, incidental or consequential damages of any kind,
including wage and transport costs in connection with the repair or replacement of defective parts.
NO WARRANTY, ORAL OR WRITTEN, EXPRESED OR IMPLIED, OTHER THAN
THE ABOVE WARRANTY IS MADE WITH REGARD TO THIS KOMPTEC PRODUCT. KOMTEC DISCLAIMS ANY IMPLIED WARRANTY OF MERCHATABILITY OR FITNESS FOR A PARTICUALR USE OR PURPOSE, AND ALL OTHER
WARRANTIES. IN NO EVENT SHALL KOMPTEC BE LIABLE FOR ANY INCIDENTAL, SPECIAL, CONSEQUENTIAL OR PUNITIVE DAMAGES OR FOR ANY
COSTS, ATTORNEY FEES, EXPENSES, LOSSES OR DELAYS ALLEGED TO BE
AS A CONSEQUENCE OF ANY DAMAGE TO, FAILURE OF, OR DEFECT IN ANY
PRODUCT INCLUDING, BUT NOT LIMITED TO, ANY CLAIMS FOR LOSS OF
PROFITS.
1.5. Disclaimer
Based upon the Law on Technical Equipment (Product Safety Act) of 6 January 2004 (I,
p. 2, over p. 219), as amended on 8 November 2011 (I, p. 2178, calc. 2012 I, p 131)) the
following applies:
•
Operation of the KT-70E / KT-90E / KT-70SE requires expertise and training,
and is limited to applications defined by Komptec in this user manual.
•
In the event of improper maintenance (servicing) or of ignoring the operating instructions, the owner assumes full responsibility for the functioning of the appliance.
•
For safety reasons, the device should be maintained and tested by an authorized
agent annually.
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•
The device must be serviced by experts. During maintenance (service) only original spare parts may be used. The maintenance must be recorded.
•
In the event of damage caused by not complying with the above listed points,
Komptec GmbH is not liable. The warranty and liability claims or general terms
and conditions of Komptec GmbH are not changed by the guidelines listed above.
1.6. Required Operator Training
This manual must be read carefully:
• all compressor operators’ / maintenance personnel must read this entire manual with
due care and attention and observe the instructions/information contained herein.
• the operator must possess the required training for operation of the compressor and
read the manual.
1.7. Information for the User
The instruction manual must be read and used as follows:
• read this manual carefully, treat it as an essential part of the compressor;
• the instruction manual must be kept where it can readily be consulted by compressor
operators and maintenance staff
• keep the manual for the working life of the compressor
• make sure updates are incorporated in the manual
• make sure the manual is given to other users or subsequent owners in the event of
resale
• keep the manual in good condition and ensure its contents remain undamaged
• do not remove, tear or re-write any part of the manual for any reason
• keep the manual protected from dampness and heat
• if the manual is lost or partially damaged and its contents cannot be read, please request a copy from the manufacturer.
1.8.
Obligations and notes for you as an operator
The instruction manual is an integral part of the compressor. The operator shall ensure
that this manual is always available on the compressor and that the operator assumes the
guidelines note.
In order to protect personnel against health hazard or other safety hazards, the operator is
obliged to inform his/her self on the safe and proper operation, maintenance and the
proper operation of the compressor.
The operator must arrange for the execution of a test run with testing of all safety equipment in order to satisfy itself of the operational safety of the compressor and to be able to
properly and safely operating on the ability of the staff, the operation after completing the
installation and before using the compressor.
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The compressor has been built according to the prior art and the recognized safety regulations. As an operator, you are obliged to adapt the compressor to the applicable current
safety regulations.
It should be born in mind that the User Manual can never replace proper experience; some
maintenance jobs are particularly difficult and in this regard the manual only offers general guidelines on the most important tasks, which must be carried out by personnel with
proper training (e.g. acquired during training courses run by the manufacturer).
1.9.
Customer service
For technical information about Komptec’s products and their systematic application,
please contact customer service.
Should you have any questions about our products, please call our customer service department.
1.10. Serial Number
Please include the serial number from the nameplate on any inquiries. Specifying this
data ensures that you receive the correct information or the required spare parts.
1.11. Instructional and training aids.
1.11.1. Instruction by the operator
Any failure to comply with the safety instructions in this manual or on
the compressor can result in injury or death.
Read the KOMPTEC Instruction Manual. All compressor operators’ / maintenance personnel must read this entire manual with due care and attention and
observe the instructions/ information contained herein. - the operator must
possess the required training for operation of the compressor and that he/she
has read the manual.
In addition to the operating instructions, applicable statutory and other regulations for accident prevention and environmental protection and basic health
and safety requirements must be observed.
Such requirements may also include the handling of hazardous substances,
which affect provision / wearing of personal protective equipment.
Consider:
Operation of this compressor poses danger to life and limb when operated by
untrained personnel, or when operated when improperly mounted, maintained
or used.
The training of the operating personnel must be repeated every year!
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Operator seminars, and art workshops are offered regularly by the manufacturer.
The following are examples of topics for training as well as a form for confirmation of instruction.
1.11.2. Examples of training topics
1. For safety
•
Accident prevention regulations
•
General legislation
•
General safety
•
Measures in case of emergency
•
Personal protective equipment
•
Safety instructions for the operation of the plant
•
Dealing with the safety devices of the system
•
Safety devices in the vicinity of the plant
•
Meaning of symbols and signs
•
________________________________
•
________________________________
2.
•
•
•
•
•
•
3.
•
•
•
•
To operate the plant
Use the operating elements
Explanation of the operating instructions for the operating personnel
Special experience of the operator in handling the compressor
The use of input materials, tools and auxiliary equipment
________________________________
________________________________
Servicing and maintenance requirements
Regulative handling cleaning agents and lubricants
Special experience of the operator for maintenance, servicing, cleaning
and maintenance of plant
________________________________
________________________________
1.12. Symbols Used
In the manual, the following terms and symbols for particularly important
information are used:
i
information
Special information regarding the economical use of the machine
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Warning
Particular specifications or instructions and prohibitions to prevent damage
Danger
Specifications or instructions and prohibitions to prevent personal injury or
substantial property damage
F
●
Mark
for performing an action by the operator
Enumeration
Hint
Useful hints and tips for the operator
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2.
Product Description
2.1.
Intended Use
i
The compressor is exclusively for compressing air at an operating pressure of 4500 psi
with a maximum pressure of plus 10%. The compressor block is designed for intermittent
operation. The maximum duration must not exceed 45 minutes. After a rest time of 15
minutes is necessary. This represents a total investment of 4 Nm. Any other use or extended use is considered improper. The manufacturer is not liable for any resulting damage. The risk is borne solely by the user.
It is expressly prohibited to draw gases other than air. Operation in a Nitrox environment
up to 36% oxygen concentration is permitted.
Intended use also includes observing the operating instructions and compliance with the
inspection and maintenance conditions.
The 2.5 CFM KT-70E and KT-70SE are tailored to the specific requirements of filling
air tanks of up to 20L. The 3.2 CFM KT-90E is suited for filling air tanks of up to 45L.
Their construction has been designed for this purpose.
The KT-70E and KT-90E are targeted at SCUBA and other markets using DIN 200 or
DIN 300 couplers. The KT-70SE “Shooter’s Edition” is intended for Air Gunners and
Paintball enthusiasts using a foster style Quick Disconnect on their air cylinders.
Figure 1. KT-90E
Figure 2. KT-70SE
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Figure 3. KT-90E Configuration 1 and 2
2.2.
Construction
The main structure of the compressor is made up of the following components:
Standard equipment high pressure compressor:
•
•
•
•
•
housing
drive
Compressor block
filter unit
filling unit
Standard accessories:
•
•
•
•
2.3.
Filling hose for 4500 psi (300 bar DIN connector) or 3000 psi (200 bar DIN connector)
for “E” series compressors, or Quick Disconnect for “SE” series.
an intake filter (in housing)
a high-pressure compressed air filter with filter cartridge
On-off switch
Optional Equipment
The KT-70E and KT-90E are offered as one of three configurations, based on the intended
use, and the user’s budget.
•
Base Configuration: (Base Option) The base configuration groups together the pressure gauge, safety valve, and DIN connector on the end of the fill hose. After filling,
pressure is relieved in the fill hose as part of the process of draining the condensate,
by opening the final condensate drain.
•
Configuration 1 (C1 Option): C1 adds a Minimum Pressure Valve (also called a Priority Valve), as well as a fill valve and bleed valve to the end of the fill hose, and
moves the safety valve to the Compressor housing.
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•
Configuration 2 (C2 Option): C2 builds on the C1 configuration, and adds the Automatic Shut-Off and Hour Counter.
The KT-70SE is configured with a fill valve with bleed, and a fill hose with a Quick Disconnect coupling. The Automatic Shut-Off and Hour Counter are optional on the KT-70SE
2.3.1. Automatic shut-off.
If configured with the automatic shut-off, the compressor will fill the target cylinder to
the maximum rated pressure of the compressor, then turn off the motor.
2.3.2. Hour counter.
If configured with the Hour counter, the operating hours will be displayed on the hour
counter, mounted on top of the electrical motor.
2.3.3. Minimum Pressure Valve.
If configured with the Minimum Pressure Valve, air will not flow out of the filter until
the minimum pressure is achieved (150 bar, or 2200 psi, minimum), and when a large
cylinder is being filled, the pressure within the filter will be maintained at the minimum
pressure or above.
2.3.4. Automatic Condensate Drain.
If configured, the Automatic Condensate Drain (ACD) will bleed off the condensate
into a separate container on a defined interval.
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2.4.
Functional Description
Standard Equipment
The housing consists of the
base plate with the cover.
Most components are
mounted on the base plate.
The drive consists of a 230V
motor, a pulley and drive
belt. See 115V photo below
The drive can also be a gas
motor with a V-belt pulley
and V-belts.
The compressor block consists of 3 compressor stages.
The filter unit consists of a
high-definition filter and the
condensate drain.
The intake filter is incorporated in the housing for the
KT-70E / KT-90E.
In the gasoline version of the The intake filter for the gasoKT-70E / KT-90E, a snorkel line version of the compresmay be fitted.
sor must be mounted at least
1 m above the compressor.
The filling unit (base configuration) consists of: pressure
gauge, safety valve and fill
port. See optional filling
unit description in sec. 8.1.2
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KT-70E 115V On/Off
switch and Hour Counter
configuration
2.5.
Fill block for Configuration 1
or 2, showing attachment
point for fill hose, safety
valve, MPV, and Auto ShutOff sensor
Fill valve for KT-70SE with
fill whip attached
Pneumatic Air Flow
The compressor has two elements where moisture and / or condensate is removed.
2.5.1. Intermediate Stage Condensate Collector and Drain.
A condensate drain is positioned after the first stage intercooler, prior to the intake for
the second stage.
2.5.2. Final Condensate Collector, Drain and Filter.
The filter housing contains both the Final Condensate Collector as well as the air filter.
One key element used in the condensate collector is the sintered filter. A conical synthetic sintered filter is installed in the base of the filter housing. Air enters the housing
after the 3rd stage and the aftercooler, and flows through the sintered filter where oil and
moisture condense on the interior surface of the sintered filter, and fall to the base of the
condensate collector. The moisture and oil that is captured here are contaminants that
need not be captured by the filter, extending its effective service life.
An additional benefit of using the sintered filter
prior to the filter cartridge is that the air that exits
the sintered filter and flows thru the molecular sieve
filter has an even velocity across the surface of the
filter as it enters the filter. This avoids the creation
of a high velocity path thru the filter material. Constant air velocity permits optimum effectiveness of
and utilization of the molecular sieve material
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3.
General safety
3.1.
Obligation of diligence
To ensure maximum working efficiency, Komptec has constructed the compressor with
carefully selected components and materials. The compressor is tested prior to delivery.
Continued compressor efficiency over time will also depend on proper use and maintenance as per the instructions contained in this manual.
However, this safety can only be achieved in operational practice if all necessary
measures are taken. It is the obligation of diligence of the operator to plan these measures
and to monitor their implementation.
The operator must in particular ensure that
the compressor is only used as intended (see chapter description)
the compressor is operated only in perfect working condition and safety equipment
in particular is checked regularly for proper functioning,
required personal protective equipment for the operating, maintenance and repair
personnel are available and are in use,
the user manual is always in a legible condition, is complete and is available at the
site of the compressor,
only sufficiently qualified and authorized personnel operate the compressor and perform maintenance and repairs,
the personnel are regularly instructed in all applicable questions regarding occupational safety and environmental protection and knows the operating instructions and
particularly the safety instructions contained therein,
safety instructions and warnings are all mounted on the compressor are not removed
and remain legible.
3.2.
Basic safety measures
3.2.1. Principle; Intended Use
The compressor has been built according to the prior art and the recognized safety regulations. Nevertheless, danger to life and limb to the user and to third parties, or damage
to the compressor or other tangible assets can arise. The following table shows how this
manual is organized and when and what the individual sections are needed.
The compressor must be maintained in good working condition. In particular, faults that
can impair safety must be rectified immediately!
The compressor is intended exclusively for filling compressed air cylinders. Any other
use or extended use is considered improper. The manufacturer is not liable for any resulting damage. The risk is borne solely by the user.
Intended use also includes complying with the operating instructions and compliance with
the inspection and maintenance conditions.
3.2.2. Responsibility
The operating instructions must remain accessible and kept at hand at the compressor!
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In addition to the operating instructions are generally applicable statutory and other binding regulations for accident prevention and environmental protection which must be observed.
All safety instructions and warnings at / on the compressor must be kept complete in a
legible condition!
Any changes to the compressor or its operating behavior must be immediately reported
to the appropriate authority!
Changes, additions or conversions to the compressor, which could impair safety must not
be carried out without the supplier's approval
Spare parts must meet the technical requirements specified by the manufacturer. This is
always guaranteed with original spare parts!
3.2.3. Personnel selection and qualification; fundamental obligations
Working with the compressor may only be carried out by qualified personnel.
Responsibilities of the personnel for operation, maintenance, repair must be clearly defined!
Only authorized personnel should operate the compressor!
Make sure that training must be performed by an experienced person!
Work on electrical equipment of the compressor may only be performed by a qualified
electrician or by instructed persons under the direction and supervision of a qualified
electrician in accordance with regulations.
3.2.4. Safety instructions for certain operating phases
Normal operation
Insure that the compressor is operated only in safe and reliable state! The compressor may
only be operated when all protective devices and safety-related equipment, sound insulation and intake devices are in place and functioning!
Check for externally visible damage in pressure vessels and filling hoses before operating
the compressor! Immediately report any changes (including the operating performance)
to the competent authority / person! Stop the machine immediately if there are any concerns!
In case of malfunction, the compressor must be shut down immediately and secured!
Faults must be eliminated immediately!
Before switching on / starting the compressor, make sure that nobody can be endangered
by the compressor.
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special works
The ECC Machinery Directive provides the following definitions
•
“Dangerous Zone”: any zone in side and/or near a machine in which the presence
of an exposed person constitutes a risk for his/her security and health
•
“Exposed Person”: any person wholly or partially inside a Dangerous Zone
•
“Operator”: the person(s) charged with the task of installing, running, maintaining,
cleaning, repairing and transporting the machine
Removing or tampering with any safety device is strictly forbidden
Maintenance and inspection must be performed in accordance with this manual! These
activities may only carry out by qualified personnel.
Before doing any work concerning the operation, production adjustment, upgrading or
setting of the compressor and its safety equipment and inspection, maintenance and repair, the unit must be turned off in accordance with the operating manual and instructions
for maintenance work!
Disconnect the electrical supply prior to performing maintenance and repair work.
Cleaning of flexible hoses, connections and fittings at the beginning of maintenance is
important. Aggressive or flammable cleaning agents should not be used!
Before cleaning the compressor, cover all openings so that cleaning agents do not penetrate. Particularly at risk are electric motors and control boxes.
After cleaning the covers / seals must be removed completely!
If safety devices are removed during maintenance and repair, they must be replaced immediately after completion of the maintenance and repair work, and all safety devices
must be checked.
Never place hands or introduce screwdrivers, keys or other tools into moving parts
Periodically check the info plates / labels and restore / replace them where necessary
The workplace must be clean, tidy and free from objects that might hinder movement
Operators must avoid carrying out “awkward” tasks in uncomfortable positions that might
result in imbalance.
Operators should be aware of the risks of entrapment caused by clothes or hair getting
caught up in moving parts; wear a cap to contain long hair.
Necklaces, bracelets and rings can be a source of danger
Workplace lighting must be adequate for the work in progress. Insufficient or excessive
lighting can generate risks.
KT-70E / KT-90E / KT-70SE User Manual
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23 October 2017
3.2.5. Notes on special types of hazard
Electric power
In case of faults in the electrical power supply, the system must be switched off immediately!
Work on electrical systems or equipment must be per local codes, and carried out by a
qualified electrician or by instructed persons under the direction and supervision of a
qualified electrician.
The electrical equipment must be regularly inspected / checked. Defects such as loose
connections or scorched cables must be rectified immediately.
Pneumatics
All lines, hoses and fittings must be checked regularly for leaks and externally visible
damage! Damage must be eliminated immediately! Splashed oil may cause injury and
fire.
Insure that the system and any hoses are depressurized before starting any repair work!
Compressed air lines must be professionally installed and mounted! Do not interchange
connections! Fittings, length and quality of the hoses must comply with the requirements.
Hazard statements for dealing with the filter and pressure vessels
Never remove reservoir cap or pipe connection parts under pressure.
The KT-70E / KT-90E has a container (filter) for dynamic load. This pressure vessel may
be operated under varying operating pressure. The pressure may vary between the atmospheric and the maximum operating pressure.
We recommend replacing aluminum containers at least every 15 years.
This measure should observe to ensure your own safety and that of your employees and
customers unconditionally and obey!
Check your pressure vessels regularly inside and outside for damage from corrosion.
Residual Risk Zones
DANGER: In some compressor zones there remain residual risks that were not possible
to eliminate at the design stage or for which safety guards could not be provided without
compromising the functionality of the compressor. To prevent accidents all operators
must be aware of the residual risks on this compressor.
There is a danger of polluting the intake air due to the possibility of mixing exhaust fumes
or lubricating oil vapors with the compressed air being produced.
KT-70E / KT-90E / KT-70SE User Manual
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23 October 2017
Electrical danger. Install electrical connections to local codes and do not use in wet locations
Danger from use of an Internal Combustion Engine. Observe the instructions in the manual for the engine used.
Danger from heat generated by the exhaust of the Internal Combustion Engine. Wait 30
minutes after switching off the engine before carrying out maintenance work.
Danger derived from the noise emitted by the compressor
Fire Risk
Risk from contact with the drive belt
Risk from contact with the cooling fan
Danger of contact with the hose should the hose break during cylinder refill.
KT-70E / KT-90E / KT-70SE User Manual
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4. EG-Konformitätserklärung
nach Anhang II A der EG-Maschinenrichtlinie 2006/42/EG
ANHANG II A sinngemäß der EG-Druckgeräterichtlinie 97/23/EG Anhang VII
Der Hersteller
KompTec Kompressoren Technik GmbH
Gutenbergring 3
D-63110 Rodgau
erklärt, dass der Hochdruckkompressor Typ
Komptec KT-70E / KT-90E / KT-70SE
die Sicherheits- und Gesundheitsanforderungen der EG - Maschinenrichtlinie 2006/42/EG erfüllt.
Angewendete harmonisierte Normen:
- EN ISO 12100:2010
- DIN EN 12021:2014
- DIN EN 1012-1:2010
- DIN EN ISO 13850:2008
- DIN EN ISO 13857:2008
- DIN EN 60204-1:2006
Angewendete nationale Normen und technische Spezifikationen:
- AD 2000
Merkblätter
- TRG 400
Technische Regeln - Druckgase Abs. Füllanlagen
- TRG 401
Technische Regeln - Druckgase Abs. Einrichten von Füllanlagen
- TRG 402
Technische Regeln - Druckgase Abs. Betreiben von Füllanlagen
- TRG 790
Technische Regeln - Druckgase Abs. Prüfen von Füllanlagen
durch einen Sachkundige
Konstruktive Änderungen, die Auswirkungen auf die in der Betriebsanleitung angegebenen technischen Daten und den bestimmungsgemäßen Gebrauch haben, die Maschine also wesentlich verändern, machen diese Konformitätserklärung ungültig!
Rodgau, Januar 2015
Ort, Datum
(Unterschrift)
Michael Wittmann, Technische Betriebsleitung
KT-70E / KT-90E / KT-70SE User Manual
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23 October 2017
5.
Technical Specifications
5.1.
Compressor System
Dimensions
LxBxH
LxWxH
Weight
Operating Pressure
Air Delivery
KT-70E
KT-90E
Set pressure, final
pressure, safety valve
or
5.2.
4500
70
90
4950
psi
l/min
l/min
psi
3300
psi
3
3
65
22
10
17
0.5
7.2
48
mm
mm
mm
mm
m/sec
bar
bar
compressor oil
Compressor oil capacity
Oil type
5.4.
Mm
Inches
Compressor Block
Number of Stages
Number of Cylinders
Cylinder bore 1st stage
Cylinder bore 2nd stage
Cylinder bore 3rd stage
Piston Stroke
Piston Speed
Intermediate pressure 1st stage
Intermediate pressure 2nd stage
5.3.
700 x 330 x 460
27 x 13 x 18
39 kg / 86 lbs
300
CL751
ml
Komptec
Connections
AC Electrical Motor
KT-70E/KT-70SE KT-70E/KT-70SE
Voltage
115V 60Hz
230V 60Hz
Current Requirement 20 A
13A
Drive Power
2 HP
2 HP
Supply
According to local regulations
Rotation
Left
Left
Noise Level
81 dB (A)
81 dB (A)
KT-70E / KT-90E / KT-70SE User Manual
Page 24 of 60
KT-90E
230V 60 Hz
16 A
3 HP
Left
81 dB (A)
23 October 2017
Gasoline Engine
Fuel Type
KT-90G
Gasoline,
Premium
6.5 HP
Left
Power
Rotation
For further details, refer to the
Motor’s operating manual
Noise level
86 dB (A)
Note, supplier for Gasoline Engine may vary.
KT-70E / KT-90E / KT-70SE User Manual
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23 October 2017
5.5.
Pneumatic Flow Diagram – Base Configuration
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
Air Intake Filter
Air Intake Hose
1st Compressor Stage
Intercooler
1st Stage Pressure Relief Valve
2nd Compressor Stage
Intercooler
2nd Stage Pressure Relief Valve
3rd Compressor Stage
Aftercooler
Condensation Discharge
Condensation Absorber
Active Coal Granulate
Felt Disk
Moisture Absorption Granulate
Filling Armature
Safety Valve
Intermediate Condensate Collector and Drain
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23 October 2017
6.
Transport and Installation
6.1.
Transport
To avoid damage or serious injury during transportation of the compressor, the following
points must be observed:
•
•
•
WARNING: Manual lifting of the compressor requires at least two workers and in any
case no individual worker should lift more than 30kg (66 lbs).
Transport work may only be carried out in compliance with the safety instructions.
Also read the chapter "General safety instructions"
6.1.1. Transport to the Site
i
6.2.
Transport damage must be reported immediately.
For transportation, if necessary, appropriate lifting tools are to be used.
Installation
To avoid damage or serious injury when installing the compressor, the following
points must be observed:
-
Manual lifting of the compressor requires at least two workers and in any case no individual worker should lift more than 30 Kg (66lbs).
The preparation work - assembly and installation of the compressor - may only be carried
out by qualified staff in compliance with the safety.
Before starting the installation work, the compressor must be checked for transport damage.
Also read the chapter "General safety instructions".
6.2.1. Conditions for Set-up
i
The base plate of the compressor is equipped with anti-vibration pads. A foundation or
special mounting is not required.
Installation in enclosed spaces:
l
l
l
Ensure adequate ventilation
Intake air must be free of harmful gases, eg Fumes, solvent fumes
If possible, install system so that the fan of the compressor may suck in fresh air for
cooling from the outside, for example, through a wall opening. Distance from the
wall is at least 0.5 m.
Outdoor Installation:
l
l
Provide aggregate on firm surface and up horizontally
Make sure that near the intake point are no motor vehicles with the engine running.
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l
6.3.
Physical Do not operate near open flames (fumes!)
Placement
i
Place the unit on a firm surface
Place the unit horizontally. A maximum pitch of 20° from Horizontal is permitted
Space required for the Compressor. Note that accessories may extend beyond
the dimensions shown below to accommodate motor configurations or optional accessories.
F
The compressor must not be placed directly on the wall. Minimum distance from the wall is 0.5m.
F
The ambient temperature must be no higher than + 35 ° C and not lower
than + 5 ° C.
F
When operated below + 10 ° C, warm-up the compressor with the condensate drain valves open for a few minutes.
To prevent fire hazards and to ensure adequate ventilation, place the
compressor in operation in at least 0.5m from buildings and other equipment. Do not bring any flammable materials are Nourish the compressor.
Superstructures or operation in crates or the like is not permitted.
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7.
Start-up
To avoid damage or serious injury during startup of the compressor, the following points
must be observed:
-
The commissioning of the compressor may only be carried out by qualified staff in
compliance with the safety.
Check before the first start that all tools and foreign objects were removed from the
compressor.
Check before commissioning the motor rotation direction.
Also read the chapter "General safety instructions".
7.1.
Power
Electrical connection
.
Observe the following for the electrical connections;
-
Comply with local electrical codes.
Installation of electrical receptacles should be performed by licensed electricians.
KT-70E/KT-70SE
KT-90E
230 V AC
230 V AC
3-wire Supply
3-wire Supply
L1, N, and PE
L1, N, and PE
Current Requirement
20 A
13 A
16 A
Motor power
1.5kW (2HP)
1.5kW (2HP)
2.2kW (3HP)
Frequency
60Hz
60Hz
60Hz
Plug
NEMA 5-20P
Not provided (see Not provided (see
Note)
Note)
Rotation
Counter clockwise
Counter clockwise
Counter clockwise
Note: NEMA 5-20P is keyed to not fit into 115V 15A household plugs, but will fit into 115V
20A household receptacles. Most homes have multiple NEMA 5-20R receptacles. Be sure no
other appliances are connected to the same circuit to provide the full 20A capability to the
compressor.
Note: 230V electrical receptacles vary, and may include NEMA 6-20, L6-20, 14-30, L14-30,
14-50, 14-60, 10-30, 6-30 or others. Please determine what receptacle you have and purchase
the appropriate plug, rated at or above the 230V / 16A requirement for the compressor.
Voltage
KT-70E/KT-70SE
115 V AC
Gasoline Engine
Note: Supplier for Gasoline Engine may vary.
Fuel
Motor power
Rotation
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Gasoline - Premium
4 kW
Counter clockwise
23 October 2017
7.2.
Checks before initial Start-up
F Remove all packing used in transport
F Check that all screws and bolts are secure
F Check all cables and connectors.
F Check the oil level
The oil level should be at the middle mark on the dipstick, or higher.
F Check filter system for damage and completeness. Insert the filter cartridge.
All protective devices must be correctly fitted.
i
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8.
Operation
To avoid damage to property or life-threatening injuries in the operation of
the compressor, the following points must be observed:
-
8.1.
The compressor must only be used according to its intended use.
Also read the chapter "General safety instructions".
Description of the controls
8.1.1. Compressor
Base Configuration
5
4
1
2
3
4
5
6
Filter Unit
Condensate drain pipe
Drain Screw
Filling Hose Connection
Drive Motor (Electric)
Bleed screw / Intermediate stage condensate drain
1
2
3
4
Fill Hose Connection
Safety Valve
Minimum Pressure Valve
Auto Shut-Off
6
5
4
3
Configurations 1 and 2
1
2
3
2
3
2
1
4
1
KT-70SE
2
1. Fill Valve
2. Safety Valve
3. Bleed Screw
1
3
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8.1.2. Filling Hose
Base Configuration
1 Final pressure safety
valve
2 Pressure Gauge
3 Filling connection
DIN 200 bar or DIN 300
bar
2
1
3
Configurations 1 or 2
4
3
2
1 Filling connection, DIN
200 bar or DIN 300 bar
2 Bleed Valve
3 Fill Valve
4 Gauge
1
KT-70SE
KT-70E / KT-90E / KT-70SE User Manual
Fill Hose connects to output
of Fill Valve and has a
Quick Disconnect fitting
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23 October 2017
8.2.
Adjusting and Setting
8.2.1. Operation
Before you turn on the system, make sure that there are no persons in
the danger zone of the equipment.
i
8.2.1.1.
F
Set up compressor according to Chapter 6.2
F
Carry out the instructions as described in Chapter 7.2
F
Connect the Spark Plug and add gasoline (for gas motor version)
F
Note the speed of the gas motor is set by Komptec and is not adjustable
Pay attention to the condition of the cylinders, pressure vessels and valves!
Cylinders and pressure vessels which have defects, which can endanger
third parties may be endangered, shall not be filled.
Only approved and current air receivers and air tanks (DOT / TÜV etc.)
should be filled.
Only compressed air containers and bottles that are approved for the intended operating pressure (filling pressure) may be filled.
Only compressed air containers and bottles that have a fill port / valve
may be filled
Starting the Motor
Inspect the intermediate and condensate drains and confirm they are open
prior to turning on the motor
1. Switch to "I" or "ON"
2. Close condensate drain
screw
3. Close intermediate condensate drain.
Note: Under certain conditions you should warm up the compressor and clear residual condensate by operating the compressor for 5 minutes with intermediate and condensate drain
plugs and the fill port in their open condition:
• On initial use
• After extended non-usage
• After being moved
KT-70E / KT-90E / KT-70SE User Manual
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23 October 2017
•
8.2.1.2.
After moving a cold compressor to a warm environment (requires a 15 minute warm
up period)
pressure buildup
Note: Units with MPV will
not show pressure until minimum pressure is achieved.
1. Build up pressure to 100 bar
8.2.1.3.
To Fill the pressure cylinder.
i
1. Open filling valve slowly
(on compressor, on hose or
on target cylinder)
KT-70E / KT-90E / KT-70SE User Manual
The filling process is to be
monitored !!
Page 34 of 60
Units with Minimum Pressure Valves should open filling valve prior to pressure
reaching MPV setting
23 October 2017
8.2.1.4.
Condensate Drain
i
1. Drain the condensate after The compressor condensate
every 15 to 25 minutes of consists of a mixture of water
operation
and compressor oil. Cloth and
condensate must be disposed of
in accordance with local laws
and regulations to ensure appropriate places.
8.2.1.5.
Opening the condensate drain
plug too quickly may cause
icing in the condensate drain
and potentially dangerous air
velocities. Therefore, open
the drain extremely cautiously.
Turning off
For units configured with the
Auto Shut-Off, compressor
will stop when target pressure
is reached
1. Upon reaching the set air
pressure, switch to “O” or
“OFF”
KT-70E / KT-90E / KT-70SE User Manual
2. The compressor stops.
Page 35 of 60
.
23 October 2017
8.2.1.6.
1.
8.3.
•
•
•
•
•
Complete the Filling process
Close the filling valve (on
compressor, fill valve or
on target cylinder)
2.
Slowly open the Condensate Drain and drain the
condensate. Bleed residual pressure in fill hose or
system.
3.
Remove the pressure vessel at the filling valve
Filter
ONLY the filter cartridges provided by Komptec may be used!
Filter part numbers are listed in section 10.1
Modifying the filter system in any way is prohibited!
Use of non-authorized filter materials, even if they are used by other filter manufacturers,
may lead to severe impairment of filter efficiency, including total loss of filter effect.
Filters must be changed at least once per year
8.3.1. Breathing Air Filter
Filters configured for Breathing Air usage include both molecular sieve and activated
carbon materials. The filter lifetime is 60 m3 of air at 30°C. These filter lifetimes
have been specified to be in compliance with DIN EN12021.
Filter Change Interval
Temperature
30°C
70 LPM
13 hours
Capacity
90 LPM
10 hours
8.3.2. Non-Breathing Air Filter
Filters configured for Non-Breathing Air usage replace the activated carbon with additional molecular sieve material. The filter lifetime is 90 m3 of air at 30°C. Examples
of applications where the Non-Breathing Air Filter can be considered include shooting
sports and industrial / construction applications.
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23 October 2017
Filter Change Interval
Temperature
30°C
8.4.
70 LPM
19 hours
Capacity
90 LPM
15 hours
Extended Storage
If the compressor will not be used for an extended period:
• Run the compressor for a few minutes with the fill valve open to flush out the
residual condensate. Stop the compressor, disassemble the intake filter, and add a
few drops of oil so that a light film of lubricant is aspirated and penetrates the
interior of the compressor. Stop the compressor and refit the intake filter.
• Clean the external parts, eliminate any moisture, salt or oil deposits.
• Store the compressor in a clean, dry location.
8.4.1. Waste Disposal
Use of the compressor generates waste that is classified as special. Wastes not classified as urban waste must be treated as special waste. Deteriorated or obsolete machines are also classified as special waste.
Waste oil must be disposed of in compliance with local ordinances.
KT-70E / KT-90E / KT-70SE User Manual
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23 October 2017
9.
Troubleshooting
To avoid damage to property or life-threatening injuries during the removal of faults
on the compressor, the following points must be observed:
-
Eliminate the fault only if you also have the specified qualifications.
Protect the compressor against accidental restart by pulling the power plug.
Also read the chapter "General safety instructions".
9.1.
Tabular overview of possible malfunctions and suggestions to help eliminate the fault.
If faults occur during operation of the compressor, check for possible causes using the
following table If the fault can not be resolved by one of the measures listed, please
notify a service technician or the manufacturer.
9.1.1. List of Faults
Error
Possible Cause
Corrective Action
Compressor does not reach pres- Leaking pipe or condensate Retighten screw
sure
drain
Cartridge defective
Check
Reduced air deliver
Dirty intake filter
Leaking pipes or drain
Worn piston rings
1st stage inlet valve does not
seal
Faulty seal on Cartridge
Faulty o-ring on female
Quick Disconnect
Clean intake filter
Retighten screw
Change piston rings
Change intake valve
Change gasket
Replace with 010-70 o-ring
1st or 2nd stage overpressure Pressure between stages is Check inlet valve of follow-on
valves release air
too high
stage
Leaking relief valve
Replace valve
Condensate oil leaking onto base Residual pressure in filter af- Bleed residual pressure in complate
ter motor is off forcing resid- pressor to zero after completing
ual condensate out of pres- operation
sure relief valves
Final pressure valve releases air
Leaking valve
Compressor does not start
Excess residual pressure in Open intermediate and final conthe compressor
densate drains to reduce back pressure on motor before starting motor. Verify gasket on intermediate
drain screw did not create blockage.
KT-70E / KT-90E / KT-70SE User Manual
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Replace valve
23 October 2017
Tripped circuit breaker
Engine failure
Temperature under +10°C
System does not turn on
Interrupted power supply
Engine failure
Reset circuit breaker mounted
above electric motor
Warm up compressor to +10°C.
Check plug and cable
Check fuse or circuit breaker
Replace motor
Fuse or circuit breaker blows Wrong size fuses / circuit Replace fuses, check with a liwhen engine turned on
breaker, or time delay not censed electrician
correct
Short circuit in electrical sys- Have it checked by a licensed electem
trician
Compressor becomes noisy
v-belt not tightened
Gas motor does not start
See manual for Gas Motor
Tighten belts
Contact the manufacturer for issues not listed.
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23 October 2017
10.
Maintenance
In the maintenance of the compressor, the following safety instructions must be observed
– to avoid life-threatening injuries to persons, damage to machinery and other damage to
property and environmental damage.
-
Cleaning, lubricating and maintenance work must be performed only by authorized service personnel - operating instructions must be strictly observed.
The repairs must be performed only by qualified service personnel - the accident prevention regulations must be observed.
The specified sequence of operations shall be followed precisely.
All work on the electrical equipment of the compressor may be basically carried out only
by trained electrical specialists.
All non-recycled fuels, lubricants and additives must be disposed of in an environmentally friendly manner.
Also read the chapter "General safety instructions".
10.1. Consumable Parts
Description
Item Number
Air Filter – Breathing Air
K310100
Air Filter – Non-Breathing Air, for Construction or Air Gunners
K319100
Oil, CL751, 1 liter
K320400
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23 October 2017
10.2. Maintenance Plan
For the first time after 25 operating
Chapter
hours
Check function and tightness of the filling
-hose valve
Check O-ring seal
--
Check V-belt tension
--
Oil change
Signature
Date
Signature
Date
Signature
Date
Signature
10.4.3
Check tightness of all cooler and connecting lines
--
Check fastening of the cooler
--
Final pressure gauge must be located in the
unpressurized state to the 0 position
Date
10.4.4
Tighten valve cap screws and valve pin
screws.
Daily
Check oil level
After 10 Hours (See 8.3)
Change filter
Check O-rings on the filter
Every 500 Operating Hours
Oil change
Chapter
10.4.1
Chapter
10.4.2
-Chapter
10.4.3
Change O-rings on the filter
--
Change O-rings on the cylinder cover
--
Clean the filter unit
--
Check safety valve
10.4.5
check exhaust
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23 October 2017
Check all operation and leaks
--
Change intake filter
--
Replace separator in base of filter housing
--
Replace piston rings in 3rd stage
--
Check tightness of all cooler and connecting lines
--
Every 1000 Operating Hours
Replace v-belt
Every 2000 Operating Hours
Replace piston rings on 1st and 2nd stages
At least once per year
Oil Change
Change O-rings on the filter
Chapter
Date
Signature
Date
Signature
Date
Signature
-Chapter
-Chapter
10.4.3
--
Change the filter
Clean the filter unit
Check the safety valve
Check exhaust
Check all operation and check for leaks
KT-70E / KT-90E / KT-70SE User Manual
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23 October 2017
10.3.
Date
Filter changing log. Please top off the crankcase oil each time the air filter is changed.
Hours
KT-70E / KT-90E / KT-70SE User Manual
Sum
Date
Page 43 of 60
Hours
Sum
23 October 2017
10.4. Maintenance Work
10.4.1. Checking the Oil Level
Check the oil level on the dipstick in the oil fill cap daily before operation. Clean the
dipstick, reinsert without rethreading. Oil should be between the upper and lower lines,
it is good to top off the oil if the level is below the middle line. Each line on the dipstick
represents about 50ml of oil, it takes about 100ml to raise the oil from the bottom to the
top lines. Avoid overfilling of the compressor when refilling the oil.
If the compressor is operated with too little or too much oil, this can cause serious damage
to the compressor.
Only use the recommended oil (section 5.3), because other oils have an adverse effect on
the service life, and can destroy the compressor.
1. Open drain valves, bleed
the system completely
2. Remove oil fill cap
4. Oil level must be within the
upper and lower marks. If
below middle level, top off
oil.
5. Replace oil fill cap with
dipstick
3. Remove dipstick
Pouring oil directly into the fill hose can create a mess if the oil spills while filling, and it is hard to
estimate the amount of oil that was added. A simple technique to avoid the mess is to use a syringe,
in the range of 50ml to 100ml, with a short length of hose attached. Such syringes are readily available from medical supply stores, or on-line. Measuring 50ml of oil with this technique both lets
you know how much oil was added, and prevents spilling oil onto the compressor.
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23 October 2017
10.4.2. Filter Change. Please top off the crankcase oil each time the air filter is changed.
1. Open drain valves,
bleed system completely
2. Remove AC power
3. Unscrew the air filter cover,
possibly with filter wrench.
Filter wrench not included in
the delivery.
4. Extraction Tool for filter cartridge screw.
5. Remove filter cartridge
6. Insert new filter cartridge
7. Check O-rings for
damage, replace if necessary
8. Clean the thread on the filter
lid and and lubricate with
silicone grease.
9. Tighten the filter cover by
hand
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23 October 2017
10.4.3. Oil Change
1. Run about 1-2 minutes before changing the oil the
compressor
2. Turn off the compressor
and unplug
3. Let the compressor rest for
a few minutes.
4. Compressor carefully put
aside.
5. Open oil drain plug (with
6mm Allen key)
6. Screw in oil drain pipe
7. Place a container underneath
8. Raise compressor slowly
9. Raise compressor slowly.
10. Unscrew oil fill cap
(with dipstick)
11. Drain oil into collection
basin
12. Remove oil drain pipe
13. Replace oil drain plug
14. Add new oil through the
oil filler neck slowly
(300ml)
15. Check oil level with the
dipstick.
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10.4.4. Final pressure gauge check
1. The end of the pressure
gauge must be located in
the unpressurized state to
the 0 position.
10.4.5. Check final pressure safety valve
Check the functionality of the
final pressure safety valve before using the compressor.
1. Operate the compressor 2. When operating pressure
with the filling valve
reaches 3300 psi or 4950 psi
closed. If configured with
the safety valve must blow
Auto Shut-off, hold the
off..
“on” button to override the
auto shut off.
10.4.6. Other Maintenance Notes
•
When replacing heads on the compressor cylinders, re-torque the bolts to a torque of 10nm.
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11. Break-out Drawings
80
79
77
87
79
87
86
87
Figure 4. Exploded View
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Figure E. Crankshaft with Piston Rods
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Figure F. First Stage Cylinder
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86
87
Figure 7. Second Stage Cylinder
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Figure 8. Third Stage Cylinder
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80
81
0
79
78
87
77
0
6
78
0
5
87
87
79
0
Figure 9. Oil filler tube and housing pressure equalization
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Figure 10. Filter Housing
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Figure K. Casing
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Overview:
A
B
C
D
E
F
Exploded view
Crankshaft with piston rod
1st compressor stage
2nd compressor stage
3rd compressor stage
G
Oil filler tube and housing pressure
equalization
Intercooler, aftercooler and Safety
valves
Engine and cooling fan. See figure B
H
Casing
KT-70E / KT-90E / KT-70SE User Manual
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23 October 2017
A
001
002
004
004a
005
005
006
007
007a
008
009
010
Qty
1
4
1
1
1
1
1
2
8
2
2
2
B
1
012
014
015
016
017
018
1
2
4
3
1
2
C
1
1
2
1
1
1
1
1
4
1
1
1
1
1
1
1
1
910080
910090
910100
Crank arm (drive side) with
Crank axle
Crank arm (fan side)
Dowel pins
Spacers (0.3 - 0.5mm thickness)
Roller bearings
Piston rod - 1st stage
Piston rods - 2nd & 3rd stages
910110
910120
910140
910150
910160
910170
910180
Piston - 1st stage
Piston pin
Piston pin snap ring
Gasket with O-ring
Wiper ring with O-ring
Cylinder
Cylinder housing O-ring
Cylinder cover
Cylinder head bolts
Vent connection
Threaded elbow joint
Valve seat
Cylinder - cylinder head O-ring
Valve seat O-ring
Intake valve
Exhaust valve
Exhaust valve spring
910190
910200
910210
910220
910230
910240
910250
910270
910490
910280
910290
910320
910330
910340
910350
910360
910370
2nd Compressor stage
1
1
1
1
1
1
1
1
1
1
4
1
1
1
1
1
1
1
E
057
910010
910020
910040
910041
910050
910051
910061
910070
1st Compressor stage
D
038
039
040
041
042
044
045
046
047
048
049
050
051
052
053
054
055
056
Crankcase
Screws
Oil drain plug
Copper seal
Oil tube holder
Gasket
O-ring
Bearing cover
Screws
O-rings for bearing cover
Crankshaft seals
Crankshaft ball bearings
Part Number
Crankshaft with piston rod
011
019
020
021
022
023
024
025
027
027a
028
029
032
033
034
035
036
037
Overview
Piston - 2nd stage
Piston pin
Piston pin snap ring
Gasket with O-ring
Cylinder
Housing - cylinder head O-ring
Cylinder cover
Intake threaded elbow joint
Wiper ring with O-ring
Exhaust threaded elbow joint
Cylinder head bolts
Valve seat
Intake valve
Intake valve spring
Exhaust valve
Exhaust valve spring
Cylinder - cylinder head O-ring
Cylinder - valve seat O-ring
910380
910390
910400
910410
910420
910440
910450
910460
910470
910290
910490
910500
910510
910520
910530
910540
910550
910560
3rd Compressor stage
1
Piston - 3rd stage
KT-70E / KT-90E / KT-70SE User Manual
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058
059
060
061
063
064
065
066
067
068
069
070
071
072
073
074
075
1
1
1
1
1
1
1
1
1
4
1
1
1
1
1
1
1
Piston pin
Piston pin snap ring
Gasket with O-ring
Cylinder
Housing - cylinder head O-ring
Cylinder cover
Wiper ring with O-ring
Intake threaded elbow joint
Exhaust threaded elbow joint
Cylinder head bolts
Valve seat
Intake valve
Intake valve spring
Exhaust valve
Exhaust valve spring
Cylinder - cylinder head O-ring
Cylinder - valve seat O-ring
910580
910400
910600
910610
910440
910640
910650
910460
910670
910490
910690
910700
910710
910720
910730
910740
910750
1
1
1
1
1
Oil filler tube and housing
pressure equalization
Oil filler neck
Connector, straight
Ventilation tubing
dipstick
Rubber ring
Intercooler and aftercooler
Safety valves
910760
910780
910790
910800
910810
F
077
078
079
080
081
G
082
083
084
085
086
087
090
091
092
095
096
097
098
099
100
101
102
104
105
H
1
1
1
1
1
3
1
1
1
1
1
1
1
1
1
1
1
1
3
Intercooler 1st to 2nd stage
Intercooler 2nd to 3rd stage
Aftercooler 3rd stage
Safety valve 1st stage 10-16 bar
condensate separator
Connector, angle
Safety valve 2nd stage 30-60bar
Threaded elbow joint
Connecting pipe Filter
Engine and cooling fan. See
figure B
Flywheel disk
Allen stud screw
Adjustment spring
Flange disk
Set screw
Cooling fan
Adapter cooling fan
Adjustment spring
Sink bolt
Hex screws
910820
910830
910840
910850
910860
910870
910900
910910
910920
910950
910960
910970
910980
910990
911000
911010
911020
911040
911050
Casing
106
1
Cover fan
107
1
Cover pulley
108
1
Side panel filter
109
2
Hose clamps
110
1
Baseplate
111
4
feet
112
4
Spacer tube
113
4
Nuts M6 x 10
113a
4
Washer
114
8
Screw M6 x 10
115
1
stiffening profile
116
1
handle
117
1
Side panel motor
118
1
Cover motor
119
4
Screw M8 x 80
119a
4
Washer
120
13
Screw M5 x 10
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121
121a
2
2
Screw M8 x 10
Washer
Attention!
Not all parts are available separately. Please contact Customer Service for information on parts sets that are supported.
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US Distributor:
Komptec Air Systems
725 Crystal Lane
Pleasanton California 94566
Phone: +1 925-596-1056
Email: sales@komptec.com
Manufacturer:
Komptec
Kompressoren Technik GmbH
Gutenbergring 3
63110 Rodgau
Telefon: + 49 (0) 6106 2661787
Telefax: + 49 (0) 6106 2662829
Email: kontakt@komptec.de
Service:
Komptec
Kompressoren Technik GmbH
Gutenbergring 3
63110 Rodgau
Telefon: + 49 (0) 6106 2661787
Telefax: + 49 (0) 6106 2662829
Email: technik@komptec.de
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