operation and maintenance manual for kle d 55

CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written
authorization. K.T.C. shall safeguard its rights to the full extent of the law.
OPERATION AND MAINTENANCE MANUAL FOR
KLE D 55 COMPRESSOR
ENGLISH VERSION
OPERATION AND INSTALLATION MANUAL
COD. 091087 – KLE D 55 - REV. 02 - DATE 11/2016
pag.1 di 57
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SUMMARY
1
GENERAL WARNINGS AND INFORMATION FOR THE USER ................... 5
1.1
DEFINITION OF REGULATED RELATIONSHIPS ................................................... 5
1.1.1
1.1.2
1.1.3
1.2
APPLICABLE STANDARDS ....................................................................................... 7
1.2.1
1.3
2
INSTRUCTIONS FOR USE IN SAFETY .......................................................................... 8
CONTACTS AND USEFUL ADDRESSES ................................................................ 11
DESCRIPTION OF THE MACHINE AND OPERATING PRINCIPLE........... 12
2.1
3
CE MARKING..................................................................................................................... 7
CAUTIONS AND SAFETY WARNINGS .................................................................... 8
1.3.1
1.4
DECLARATIONS ............................................................................................................... 5
WARRANTY....................................................................................................................... 6
RETURNS ........................................................................................................................... 6
OPERATING PRINCIPLE ........................................................................................... 13
PRESENTATION OF THE MANUAL: CONTENT AND CONSULTATION 14
3.1
SYMBOLS, GLOSSARY AND NOTES ON GRAPHIC LAYOUT .......................... 14
4
DATA AND TECHNICAL SPECIFICATIONS ................................................. 15
5
INSTALLATION ................................................................................................. 17
5.1
CHARACTERISTICS AND STORAGE CONDITIONS ............................................ 17
5.2
TRANSPORT ............................................................................................................... 17
5.3
UNPACKING ............................................................................................................... 17
5.4
HANDLING.................................................................................................................. 18
5.5
LOCATION .................................................................................................................. 19
5.6
FOUNDATIONS .......................................................................................................... 19
5.7
CONNECTION AND START UP ............................................................................... 21
5.7.1
5.7.2
5.7.3
5.7.4
5.7.5
5.7.6
GENERAL WARNINGS................................................................................................... 21
CONNECTING THE POWER SUPPLY CORD OF THE COMPRESSOR .................... 22
CONNECTING THE COMPRESSOR TO THE ELECTRICAL POWER SUPPLY ...... 23
ELECTRICAL DIAGRAM ............................................................................................... 25
CONNECTION OF THE COMPRESSOR TO THE AIR SYSTEM ................................ 31
FIRST START-UP ............................................................................................................. 32
5.8
CLEANING AND DISINFECTION ............................................................................ 33
5.9
RECYCLING AND RE-USED .................................................................................... 33
OPERATION AND INSTALLATION MANUAL
COD. 091087 – KLE D 55 - REV. 02 - DATE 11/2016
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5.10
6
DEMOLITION AND DISPOSAL ................................................................................ 33
OPERATION AND USE ..................................................................................... 34
6.1
DESCRIPTION OF THE OPERATION ...................................................................... 34
6.2
RANGE OF APPLICATIONS ..................................................................................... 34
6.3
PROPER AND IMPROPER USE ................................................................................ 34
6.4
OPERATING AND ENVIRONMENTAL LIMITS .................................................... 34
6.5
WORKSTATION AND DANGEROUS AREAS ........................................................ 34
6.6
SAFETY DEVICES AND SIGNALS .......................................................................... 35
6.6.1
6.7
DANGERS AND RISKS THAT CAN BE ELIMINATED ......................................... 36
6.8
PERSONAL PROTECTIVE EQUIPMENT, SAFE WORKING PROCEDURES AND
TRAINING ................................................................................................................... 36
6.9
COMPRESSOR LUBRICATION ............................................................................... 37
6.9.1
6.9.2
7
DESCRIPTION OF THE CONTROL DEVICES ........................................................ 39
7.1.1
BUTTON LAYOUT .......................................................................................................... 40
7.2
ALARM LIST ............................................................................................................... 41
7.3
DESCRIPTION OF THE OPERATIONS TO BE PERFORMED .............................. 42
7.4
START, STOP AND EMERGENCY STOP FUNCTIONS ........................................ 44
7.5
RESET CONDITIONS ................................................................................................. 44
COMPRESSOR MAINTENANCE ..................................................................... 45
8.1
SCHEDULED MAINTENANCE................................................................................. 45
8.1.1
8.1.2
8.1.3
8.1.4
8.1.5
8.1.6
8.2
9
GENERAL RECOMMENDATIONS................................................................................ 37
USING THE COMPRESSOR WITH SYNTHETIC OILS ............................................... 38
INSTRUCTIONS FOR THE USER .................................................................... 39
7.1
8
POSITION OF THE LABELS........................................................................................... 35
SUCTION PRE-FILTER MAINTENANCE ..................................................................... 46
REPLACING THE OIL FILTER ...................................................................................... 48
REPLACING THE OIL FILTER ...................................................................................... 48
CHANGING THE OIL ...................................................................................................... 49
REPLACING THE AIR FILTER ...................................................................................... 50
MAINTENANCE SCHEDULE......................................................................................... 51
UNSCHEDULED MAINTENANCE ........................................................................... 52
TROUBLESHOOTING ....................................................................................... 53
OPERATION AND INSTALLATION MANUAL
COD. 091087 – KLE D 55 - REV. 02 - DATE 11/2016
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10 COMMERCIAL PARTS, SPARE PARTS AND PERTINENT
DOCUMENTATION .......................................................................................... 55
11 APPENDIX .......................................................................................................... 56
11.1
MAINTENANCE CHECK LIST ................................................................................. 56
OPERATION AND INSTALLATION MANUAL
COD. 091087 – KLE D 55 - REV. 02 - DATE 11/2016
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1
1.1
GENERAL WARNINGS AND INFORMATION FOR THE USER
DEFINITION OF REGULATED RELATIONSHIPS
1.1.1 DECLARATIONS
The compressor must be used solely as indicated in this manual. This manual must be kept
on hand in a known, easily accessible place because it should be used throughout the
machine's entire working life.
When making any requests, always indicate model and serial number.
TEST CERTIFICATE
We hereby declare that the compressor has passed testing.
The following checks were performed:
-All parts have been assembled correctly and are functioning properly;
-The unit has passed electrical testing;
-The pressurized parts have passed testing;
-There are no leakages in the oil and air circuits;
-The outside of the machine is not defective;
-The air yield, power consumption and operating temperature parameters are all within normal
ranges.
The Tester
________________
DECLARATION OF CONFORMITY
K.T.C. S.r.l., the manufacturer, on its own responsibility, declares that the air compressor identified
by the label on the front page of this document, complies with the essential requirements laid out in
the following DIRECTIVES – STANDARDS
2009/105/CE - 2014/35/CE – 2006/42/CE – 2014/30/CE - EN60204-1 - EN1012-1
K.T.C. S.r.l. holds the relevant technical dossier.
OPERATION AND INSTALLATION MANUAL
COD. 091087 – KLE D 55 - REV. 02 - DATE 11/2016
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1.1.2 WARRANTY
KTC S.r.l. guarantees its products from manufacturing or design defects for a period of 24 months
from the date of initial start-up. To inform K.T.C.S.r.l. of this date, fill out the special form supplied
with the machine technical documentation and send it in.
If no communication is received, the warranty shall be recognized for 24 months starting from the
date on which the unit was shipped; that is the date indicated on the K.T.C. S.r.l. invoice.
The warranty does not cover parts subject to wear.
Repair works covered under the warranty can only be performed by K.T.C. S.r.l. or a K.T.C. S.r.l.
Authorized Service Centre.
Shipment of any product being returned for service under the warranty must be authorized in
advance, and in writing, by K.T.C. S.r.l. Moreover, K.T.C. S.r.l., in its unquestionable wisdom, can
decide whether to authorize such shipment or have one of its Authorized Service Centres do the
work.
In both cases, shipment to K.T.C. S.r.l. must be made carriage paid with shipping costs charged in
the invoice. Repairs or replacements covered by the warranty include free replacement of parts of
the machine that are recognized as defective.
The warranty does not cover damages caused by negligence, by incorrect use or installation or by
non compliance with the warnings indicated in the “Operation and Maintenance Manual”.
Moreover the warranty is voided if modifications or repairs are made with non original K.T.C. S.r.l.
spare parts or performed by anyone not authorized to do so by K.T.C. S.r.l.
Defective parts replaced under the warranty are retained by the Authorized Service Centre. The
warranty does not cover repairs or reimbursement for damage due to shipping (to or from the
Authorized Service Centre). The warranty does not cover any type of reimbursement for injuries or
damages to people or things derived from improper use of the model purchased or due to machine
down time (the customer must take steps to prevent this). Service covered under the warranty is
guaranteed only to purchasers who have met their contractual and administrative obligations and
who are able to show the documentation certifying the purchase period. This is the only valid
warranty recognized by K.T.C. S.r.l. COURT HAVING JURISDICTION.
For any disputes the competent court is that of Vicenza, Italy.
1.1.3 RETURNS
Returns are made using the RMA (return material authorization) procedure.
To open said procedure, the customer must send a request to K.T.C.
OPERATION AND INSTALLATION MANUAL
COD. 091087 – KLE D 55 - REV. 02 - DATE 11/2016
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authorization. K.T.C. shall safeguard its rights to the full extent of the law.
1.2
APPLICABLE STANDARDS
As outlined in the declaration of conformity (chap. 1.1.1.), the air compressor identified by the label
on the front page of this document complies with the essential requirements outlined in the
following DIRECTIVES – STANDARDS
2009/105/CE - 2014/35/CE – 2006/42/CE – 2014/30/CE - EN60204-1 - EN1012-1
1.2.1 CE MARKING
The CE marking certifies that the compressor complies with the health and safety requirements
outlined in the European Directives indicated in the EC declaration of conformity.
The marking is printed with silver lettering on a black polyester adhesive label (L:90mm H:80mm).
The label is placed as indicated in figure 1 and bears the following information:
CE marking
Compressor model
Serial number
Maximum working pressure
Power supply voltage and frequency
Nominal power
Weight
Manufacture year
Figure 1
OPERATION AND INSTALLATION MANUAL
COD. 091087 – KLE D 55 - REV. 02 - DATE 11/2016
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1.3
CAUTIONS AND SAFETY WARNINGS
Read this operation manual carefully before performing any operations. Non-compliance with the
instructions contained herein can lead to injury and property damage.
 The machine has been designed and built to operate as reported below. Any other use is
considered unacceptable.
 Only qualified personnel can install and service the machine. Always follow accident prevention
standards.
 The manufacturer is relieved of any responsibility for injuries and machine or property damage
caused by incorrect use of the compressor, non-compliance or inadequate compliance with the
safety criteria reported herein, modifications (even minor modifications) and by use of non
original spare parts.
1.3.1 INSTRUCTIONS FOR USE IN SAFETY
CAUTION!
Below is a list of important instructions for safe use of the compressor. Follow
these instructions carefully. Improper use or maintenance of the compressor can
cause user injury.
1. Never Touch any Moving Parts
Never allow parts of the body to come near moving parts of the machine.
2. Never Use the Compressor if the Protection Guards have been Removed
Never use the compressor unless all guards are assembled. If maintenance requires removing any of
the guards, make sure that they are properly reinstalled before starting up the unit. Never bypass the
safety devices installed on the compressor. This is strictly forbidden.
3. Protective Grids
Never insert objects or body parts into protective grids as this can cause injury and can damage the
compressor.
4. Use the Compressor Correctly
Always operate the compressor following the instructions given in this manual. Never allow
children or unauthorized persons to use the machine.
5. Always Wear Eye Protection
Always wear goggles or other equivalent form of eye protection. Do not direct air toward parts of
the body, your own or others.
6. Work Clothing
Do not wear inappropriate clothing or accessories. If necessary, wear a cap that covers the hair.
OPERATION AND INSTALLATION MANUAL
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7. Use the Compressor Sensibly
Never use the compressor while under the effect of alcohol, drugs or medications that can cause
drowsiness.
8. Personnel Intervention
Before performing any form of intervention, the personnel must be aware of all compressor
functions and controls.
9. Compressor Usage
Never use the compressor for any purpose other than those specified in the user's manual.
10. Air Jets
Never direct air jet toward persons or animals.
11. Hot Parts
To prevent burns, never touch the hoses, motor or other hot parts.
12. Work Area
Keep the compressor work area clean and well ventilated. Never use the compressor in a place
containing paints, solvents or combustible/explosive materials.
13. Compressor Maintenance
Check the outside of the compressor. If the power supply cord is damaged, repair or replace it. If
necessary, contact an Authorized Service Centre.
14. Check for Defective Parts and Air Leaks
Check alignment of moving parts, hoses, pressure gauges, pressure reducers, pneumatic connections
or other parts important to compressor function. Make certain that all screws, bolts and lids are
thoroughly secured. Any damaged parts must be repaired by an Authorized Service Centre.
15. Protect yourself against Thermal Shocks
Prevent accidentally coming into contact with metal parts of the compressor such as hoses, tanks or
grounded parts. Never use the compressor if water or moisture is present in the area.
16. Disconnect the Compressor
When servicing the compressor or when it is not running, always disconnect it from the power
supply and completely vent the pressure in the tank.
17. Handling
Never move the compressor while it is connected to the power supply or when the tank is
pressurized. Before unplugging the compressor make certain that the switch is set to OFF.
18. Precautions for the Power Supply Cord
Never unplug the unit by pulling on the cord. Never step on or crush the power supply cord.
Keep it away from heat, oil or sharp surfaces. Never turn off the compressor by pulling on the
power supply cord. Use the red emergency button to stop the compressor.
19. Electrical Extension Cords
If the compressor is used outdoor, use power supply cords rated for outdoor use.
OPERATION AND INSTALLATION MANUAL
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20. Cleaning of the Intake Grid and Plastic Parts
Keep the ventilation grid clean. If the unit is used in a particularly dirty environment, clean the grid
regularly. Never use solvents, thinners or other substances containing hydrocarbons as they can
damage the plastic parts. Clean with soapy water or an appropriate liquid cleaner.
21. Compressor Rated Voltage
Use the compressor at the voltage indicated on the label. Using the compressor at a different voltage
can burn out or damage the electric motor.
22. Compressor Defects
If the compressor makes strange noises or vibrates excessively during operations, check that it is
functioning properly and, if necessary, contact an Authorized Service Centre.
23. Spare Parts
Use only original spare parts which can be purchased from our distributors. Use of non original
spare parts voids the warranty and can lead to compressor malfunction. Repairs must be carried out
by an Authorized Service Centre.
24. Pneumatic Circuit
Use hoses, connections and pneumatic tools rated to handle pressures above the operating pressure.
25. Tank
Never unscrew any tank connections without first checking to ensure that the pressure has been
vented. Never make holes, welds or modifications on the tank.
26. Compressor Modifications
Never make any unauthorized modifications to the compressor. Such modifications can cause
damage and serious injury. Consult an Authorized Service Centre for any operations.
27. Using the Compressor for Painting
Never use the compressor in confined spaces or near open flames. Make certain that the work area
is adequately ventilated. In addition, wear a special mask to protect nose and mouth.
KEEP THIS MANUAL INTACT AND ON HAND, AVAILABLE TO ANYONE
USING THE COMPRESSOR!
WE RESERVE THE RIGHT TO MAKE ANY MODIFICATIONS WE DEEM
NECESSARY WITHOUT PRIOR NOTICE!
OPERATION AND INSTALLATION MANUAL
COD. 091087 – KLE D 55 - REV. 02 - DATE 11/2016
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1.4
CONTACTS AND USEFUL ADDRESSES
Our technical services department is at your disposal, ready to provide any information you may
need and to help you resolve any problems that may arise.
For any information, please log onto our website www.ktc-air.com.
For any clarifications you may require, contact our customer services department or your area
retailer.
Only original spare parts can guarantee best performance of our compressors.
We recommend carefully following the instructions given in the chapter on maintenance and
always use only original spare parts.
Using non original parts automatically voids the warranty.
OPERATION AND INSTALLATION MANUAL
COD. 091087 – KLE D 55 - REV. 02 - DATE 11/2016
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2
DESCRIPTION OF THE MACHINE AND OPERATING PRINCIPLE
OPERATION AND INSTALLATION MANUAL
COD. 091087 – KLE D 55 - REV. 02 - DATE 11/2016
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2.1
OPERATING PRINCIPLE

During the initial phase of start up, the electric motor ref. 4 (with "star" power supply),
rotates slowly. The solenoid valve ref. 11 is not powered and thus the suction valve ref. 6 it
controls remains closed. The time of this phase can be set.

During the second phase, the "delta" power supply accelerates the motor to reach the set
operating r.p.m. The solenoid valve ref. 11 is powered and the suction valve ref. 6 is opened,
thus allowing air to pass through the suction filter ref. 5 and enter in the screw compressor
ref. 7. This starts the compression phase.

The air/oil mixture delivered by the screw compressor ref. 7 is conveyed into the air/oil
separator tank ref. 19.

An initial portion of the oil is separated from the air mechanically and deposits at the bottom
of the tank while the air collects at the top.

By force of pressure the air is forced to flow through the air/oil separator filter ref. 16 and,
after further separation of the oil, it is sent on to the minimum pressure valve ref. 20. This
allows the passage of the air only after the pressure set point has been reached. When this
happens, the air passes through the air cooler ref. 21, where it is cooled, and then continues
on to the operating tank ref. 22.
The oil removed from the air inside the oil separator filter is sent, through the oil return from
separator line ref. 15, into the screw compressor. The amount of oil can be monitored
through oil recovery viewer ref. 14.

In the version with dryer, the air passes through the dryer before reaching the operating tank.

Unless the unit has an automatic drainage, the condensate accumulated inside the tank must
be eliminated manually through the condensate drainage ref. 28.

The pressure sends oil at the bottom of the tank to the thermostatic valve ref. 10. This valve
sends the oil with a temperature above the set point to the oil cooler ref. 9 where it is cooled.
Once cooled, the oil returns to the thermostatic valve, is mixed with hot oil coming from the
tank and is again checked by the thermostatic valve. Once the temperature set point (low) is
exceeded, the oil is sent to the oil filter ref. 8 and then into the screw compressor.

When the set maximum working pressure is reached, the pressure switch ref. 13 remove
power from the solenoid valve ref. 11 and trips the circuit. The suction valve ref. 6 closes air
flow and the compressor enters in "no-load" operating mode. This situation remains in force
until the system minimum pressure setting is reached.
If consumption is low or has stopped unit will continue operate in no-load mode for a set amount of
time and then reverts to stand-by mode. (see chapter 7).
OPERATION AND INSTALLATION MANUAL
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3
3.1
PRESENTATION OF THE MANUAL: CONTENT AND
CONSULTATION
SYMBOLS, GLOSSARY AND NOTES ON GRAPHIC LAYOUT
This manual uses symbols to highlight situations that require utmost attention. These symbols can
be located beside a text, a figure or at the top of a page.
Pay utmost attention to the meaning of the symbols: They are used to avoid redundant repetition of
technical concepts or safety warnings and must be considered as “reminders”. Always refer to this
page whenever you have any doubts as to their meaning.
CAUTION: indicates an important note regarding hazardous conditions, safety
warnings, information of primary importance.
MACHINE DOWN: all operations must be performed with the machine down.
CAUTION: MACHINE PRESSURIZED: all operations must be performed with the
machine depressurized, with no pressure in oil separator tank.
UNPLUG: all operations must be performed with the machine unplugged from the
power supply.
QUALIFIED PERSONNEL: all operations indicated with this symbol must be
performed only by specially trained personnel.
OPERATION AND INSTALLATION MANUAL
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4
DATA AND TECHNICAL SPECIFICATIONS
Model
Machine type
Drive
Type of screw
Type of fluid handled
Flow rate (ISO 1217 annex B 1996)
Max. working pressure
Min. working presure
Maximum power consumption**
Max. air/oil outlet temperature
Max. environmental temperature
Min. environmental temperature*
Weight
Power supply voltage
Max. current consumption
Degree of motor protection
Insulation class
Service factor
Oil charge
Air outlet connection
Maximum fan flow rate
Oil residue in air
Electric motor
Max. start-ups per hours
Noise level***
Tank
OPERATION AND INSTALLATION MANUAL
COD. 091087 – KLE D 55 - REV. 02 - DATE 11/2016
KLE D 55
Oil injected screw compressor
Direct drive with joint coupling
PSV150
air
0-6.75 m3/min - 0-238.5 cfm
10 bar g - 145 psi g
5 bar g - 72.5 psi g
55 kW - 75 hp
105 °C - 221°F
45 °C - 113 °F
5 °C - 41 °F
1220 kg - 2690 lb
Vedi targhetta macchina
88 A
IP 55
F
S1
20 litri
1-1/2”
10000 m3/h
<3 ppm
MEC 250
69
-
pag.15 di 57
* When the environmental temperature is below 5°C, an ISO VG
32 lubricant must be used
** Value detected with working pressure: 10 bar g
*** Noise measured in an open field at 1 metre from the unit
±3 dB(A) at maximum working pressure.
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OPERATION AND INSTALLATION MANUAL
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5
5.1
INSTALLATION
CHARACTERISTICS AND STORAGE CONDITIONS
During periods of inactivity, before being unpacked (storage), the compressor must be kept at a
temperature of between +5 °C and +45 °C and in a dry place sheltered from the weather.
Once unpacked, when the unit is not going to be used (prior to start-up or when production is
interrupted), the compressor should be protected with a tarpaulin to protect dust from gathering on
the mechanical and electric mechanisms.
If the compressor has remained inactive for a long period of time, before starting it up again, change
the oil and check function.
5.2
TRANSPORT
To ensure that the unit is protected and does not incur shipping damages, the compressor is screwed
onto a wooden pallet and covered with a cardboard box.
All shipping information is printed on the compressor package (data and pictograms).
5.3
UNPACKING
When unpacking the unit, carefully check that the contents match what is indicated in the shipping
documents.
The user must dispose of packaging in compliance with current national regulations.
The machine must be unpacked by qualified personnel using suitable tools.
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5.4
HANDLING
The compressor is to be lifted with a fork lift truck rated for the weight of the unit.
 Check that the outside packaging is intact.
 Unpack the machine carefully.
 Check that the outside of the machine is intact.
 Dispose of the packaging in compliance with current environmental regulations.
The compressor should be handled as indicated in figures 2.
Figure 2
THE COMPRESSOR CAN BE LEFT ON THE PALLET WHICH MAKES SUBSEQUENT MOVEMENT
EASIER.
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5.5
LOCATION
Install the compressor at the site point indicated at the time the order was placed. If the unit is
installed at a different site, the manufacturer cannot be held responsible for any ensuing
problems.
Unless specified otherwise at the time the order is placed, the compressor must run normally under
the environmental conditions indicated below.
The room where the compressor is installed must comply with current accident prevention
standards and must meet the following requirements:
 Protected from rain and frost.
 Relatively free of dust. In time, a dusty environment can lead to damage and operating problems.
 Adequately ventilated and of such size that environmental temperature remains steady (min. 5°C,
max. 45°C) when the machine is running. At the maximum admissible environmental temperature
(45°C) and with a relative humidity above 80% machine performance can reduce. Likewise,
machine performance may be reduced when the unit is installed at an altitude of 1000 m above
sea level.
 If hot air exhaust is inadequate, install exhaust fans at the highest position possible (see figure 4).
 Lighting: the compressor is built considering current standards and seeking to reduce shadow
zones to the barest minimum, thus facilitating operator intervention; as the compressor room
lighting system is deemed important for personnel safety, there must not be any shadows, glaring
lights or stroboscopic effects due to the lighting.

Potentially explosive and/or flammable atmospheres: in its standard conFiguretion, the
compressor is not designed to work in environments where there is the risk of explosion and/or
fire;
5.6
FOUNDATIONS
Once the position for the compressor has been identified, check that it is set on a flat surface. The
machine does not require foundations or any specific preparation of the support surface (foundation
works).
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CAUTION!!
Do not insert any check valves between the compressor and the tank.
 The ducting must not exceed 3 metres in length; if this proves necessary, install
a fan on the outlet side (see figure 4).
 The ducting must have a uniform section of 0.3 m².
 Condensation must not be discharged into the environment or into the sewers.
The well must be fit with a valve and removable container, or it must be
connected to a special unit to separate the air from the water.
Figure 4
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5.7
CONNECTION AND START UP
5.7.1 GENERAL WARNINGS
When starting up the unit for the first time, make certain that:
 The power supply matches the requirements indicated on the label.
 The wall-mounted general switch is proportioned according to the indications in the technical data
table (see chapter 5.7.3.3).
 The oil is at the correct level (see chapter 8.1.4).
 The electrical connections have been made using cables of adequate section (see chapter 5.7.3.2)
CAUTION!
Carefully comply with the SAFETY WARNINGS regarding use of the machine.
For the European market, the tanks are complaint with Directive 87/404/EEC while
the compressors are built in compliance with Directive 98/37/EEC.
Check the label on the compressor and at the beginning of this manual for indication
of your model.
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5.7.2 CONNECTING THE POWER SUPPLY CORD OF THE COMPRESSOR
1- Insert the power supply cord through the cable seal and run it as indicated by the red arrow in
figure 5.
Connect L1 L2 L3 to the disconnecting switch as indicated in figure 5.
Figure 5
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5.7.3 CONNECTING THE COMPRESSOR TO THE ELECTRICAL POWER SUPPLY
The machine is connected to the electrical power network by the customer, at his own
expense and responsibility, using qualified personnel and in compliance with accident
prevention standard EN 60204
5.7.3.1 Ground connection
To protect the operator from electric shocks, the compressor must be grounded during use. The
ground connection must be carried out by a qualified technician or by a specialized service centre.
The ground connection on the compressor power supply cord must be connected only to the
terminal on the compressor itself.
Before replacing the plug of the power supply cord, make certain that the ground is connected.
5.7.3.2 Sizing of Electrical cable
Never use cable that show signs of damage. Always make certain that the cable is in good
condition. When a cable is used, make certain that the section is adequate for the current absorbed
by the compressor. If the cable is too thin, there will be a drop in voltage, power loss and the unit
will overheat. The section of the cable must be proportional to its length, as indicated in the table
below:
KW
220/240 V
50/60 Hz
380/415 V
50/60 Hz
55
185 mm²
70 mm²
Avoid all risks of electric discharges. Never use the compressor if the power supply
cord or extension cord are damaged. Check the electrical cables regularly. Never use
the compressor in dangerous environments where electrical discharges can occur.
Installation must be performed by a qualified technician.
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5.7.3.3 Fuses and circuit breaker
It is advisable to install the outlet, the circuit breaker and fuses near the compressor (not more than
3 metres away). The circuit breaker and fuses must have the characteristics indicated in the table
below:
Power
kW
55
Rated voltage
220/240 V
Magnetothermic
250 A
Rated voltage
380/415 V
Fuse
Magnetothermic
200 aM
250 A
The values refer to AM (time-lag) fuses.
The values refer to "D-type" switches.
Fuse
160 aM
 Always check that the installed power, in kW, is at least double the absorbed power rating of the
electric motor.
 The line voltage must match the electrical parameters indicated on the machine label; the
acceptable variation must not exceed 6%.
 The power supply plug must not be used as a switch; it must be plugged into a power outlet
controlled by an adequate differential switch (circuit breaker).
Never use the ground in place of the neutral. Ground connection must be performed
in compliance with accident prevention standards (EN 60204). Make certain that the
line voltage matches that required for good compressor function.
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5.7.4 ELECTRICAL DIAGRAM
The electrical diagrams shown below are approximate. The specific diagram of the machine is specifically contained within the cabinet.
KME 55kW
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5.7.5 CONNECTION OF THE COMPRESSOR TO THE AIR SYSTEM
Be sure to use the pneumatic hoses for air compressed with features and cross section
appropriate to the compressor. Do not repair a faulty hose, but proceed with the
replacement.
Connect the compressor to the pneumatic system using the special 1-1/2” female connection
arranged on the compressor and indicated in the figure.
It is recommended to use a hose having a diameter equal to or greater than the 1-1/2" compressor
outlet.
1”-1/2
Figure 8
A check valve is already installed inside the compressor.
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5.7.6 FIRST START-UP
The first start of the compressor (operational testing) must be compulsorily performed by a
qualified technician.
It is recommended that the compilation of the report R.C.R. included in the product, to the effect of
technical warrant (see notes on the terms of sale).
After following all steps of assembly of the compressor illustrated in Chapter 5, you can proceed
with the operation of preparing the car for the first start.
• it has to be verified only the direction of rotation of the electric fan (see arrow above the fan) and
the warm air will be extracted from the compressor.
• If the fan turns in the wrong direction, exchange the connections of two phases of, then restart the
compressor.
Figura 9
WARNING!
The reverse rotation of the screw than the direction of the arrow shown in relief in
the body (see Figure 9) may damage the screw!
WARNING!
In case of replacement of the electric motor, at the time of restart it is absolutely
necessary to visually check the direction of rotation of the screw unit (see the
transmission joint, or the direction of rotation of the electric motor fan and will have
to turn in the same direction indicated by the arrow this group lives Fig.9)
WARNING!
It's absolutely necessary to strictly follow the SAFETY INFORMATION on the use
of the machine.
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5.8
CLEANING AND DISINFECTION
Keeping the installation site and the compressor clean is essential to good machine operation and
keeps operating and maintenance costs down (see chap. 5.5).
Installation site and compressor disinfection is essential to guarantee good air quality in the
compressor room and in the area where the compressed air is used (workshop).
5.9
RECYCLING AND RE-USED
The re-installation and re-used of the machine must be performed by qualified personnel, subject to
control by the state of the machine itself. The same as in previous chapters.
5.10 DEMOLITION AND DISPOSAL
In the case of demolition and dismantling of the compressor must dispose of all materials in full
compliance with the regulations. In any case, always contact the structures responsible for disposal
and recycling of waste.
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6
6.1
OPERATION AND USE
DESCRIPTION OF THE OPERATION
For the machine functions, see chap. 2.
6.2
RANGE OF APPLICATIONS
The machine is suited to all those applications requiring compressed air at the flow rate and
pressure outlined in the technical data sheet (see chap. 4).
6.3
PROPER AND IMPROPER USE
CAUTION!
The compressor is designed and built solely to produce compressed air.
The manufacturer is relieved of any responsibility for risks ensuing from any other
use.
CAUTION!
Any use of the compressor that differs from the agreements made at the time of
purchase relieves the manufacturer of any responsibility for ensuing injury or
property damage or damage to the machine itself.
CAUTION!
The electrical system cannot be used in flame-proof areas and with flammable
products.
CAUTION!
Never direct air jet toward persons or animals.
Never use compressed air for breathing or in production processes where the air
produced is in direct contact with foodstuffs, unless previously treated and filtered.
6.4
OPERATING AND ENVIRONMENTAL LIMITS
The operating and environmental limits are indicated in the table containing the technical data and
characteristics (see chap.4).
6.5
WORKSTATION AND DANGEROUS AREAS
During normal operation of the machine, the operator works on the side where the electronic
controller is located. Once correctly connected to the electrical and pneumatic system (see chap. 5),
the machine is completely protected on the outside and thus there are no dangerous areas accessible
during normal operation.
When scheduled and unscheduled maintenance is performed, the machine is completely open.
These operations must be performed under safe conditions by qualified personnel (see chap. 8).
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6.6
SAFETY DEVICES AND SIGNALS
The machine is equipped with safety devices and signals to prevent situations dangerous for the
operator and the machine itself.
These devices and signals come in the form of labels placed at dangerous points, and alarms that are
displayed on the electronic controller.
6.6.1 POSITION OF THE LABELS
Figure 10
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SIGNAL
MEANING
CAUTION:
Never perform any maintenance
on this machine without having
unplugged it from the power
supply and completed vented the
air pressure
CAUTION:
Hot surface
CAUTION:
pressurized part or system
6.7
DANGERS AND RISKS THAT CAN BE ELIMINATED
See chap. 6.6.
6.8
PERSONAL PROTECTIVE EQUIPMENT, SAFE WORKING PROCEDURES AND
TRAINING
Use of the compressor does not require any PPE.
Our technical services department is at your disposal, ready to provide any information you may
need and to help you resolve any problems that may arise.
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For any information, please log onto our website www.ktc-air.com. For any clarifications you may
require, contact our customer services department or your area retailer.
6.9
COMPRESSOR LUBRICATION
6.9.1 GENERAL RECOMMENDATIONS
CAUTION!
Before performing any operation involving draining or topping up compressor oil,
unplug the compressor and wait until the system has reached atmospheric pressure.
Use adequate protection when handling lubricants.
We recommend a lubricant compatible with the ISO VG 46 oil (mineral-based oil) used during
testing. The pour point must be at least -8+10°C and the flash point higher than +200°C.
KTC Oilscrew plus 46
For use of incompatible oils, follow the procedure described in chapter 6.9.2
Never mix different types of oil
We recommend using oil with a VG32 rating for cold climates and VG68 for tropical climates.
Before starting up compressors without oil, feed approximately 1 l of lubricant in through the
regulator intake opening while keeping the suction valve shutter lowered and manually turning the
screw rotors in the right direction.
CAUTION!
When lowering the suction valve shutter be careful not to damage the throttle valve Oring.
Feed the mineral-based lubricant into the oil tank using the special top-up hole and fill until the
right level is read on the window. The correct quantity of oil is indicated in the ch. 4
Start up the compressor, initially switching it on and off sequentially and quickly and then starting it
up.
Once initially filled with oil, turn off the compressor, vent the pressure and, if necessary, top up the
lubricant from the top-up hole until the right level is read on the window.
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6.9.2 USING THE COMPRESSOR WITH SYNTHETIC OILS
If you wish to use a synthetic lubricant, carefully follow the procedure below.

Drain all mineral oil from the compressor circuit using the oil drain cock.

Feed the synthetic lubricant or detergent oil into the oil tank through the top-up hole and fill
up to the correct level.

Before starting up the compressor or the first time after installation, feed approximately 1 l
of lubricant in through the regulator intake opening while keeping the suction valve shutter
lowered and manually turning the screw rotors in the right direction.
CAUTION!
When lowering the suction valve shutter be careful not to damage the throttle valve Oring.
 Start up the compressor, initially switching it on and off sequentially and quickly and then
starting it up.

Then turn off the compressor and drain all lubricant from the system using the cock.

Through the oil top-up hole, feed new synthetic lubricant in until it reaches the set level;
then start up the compressor and run it steady for about 10 minutes.

Turn off the compressor, vent the pressure and, if necessary, top up by feeding the
lubricant through the top-up hole until the right level is read on the window.
CAUTION!
If the above-mentioned “washing” cycle is not performed, the mixing of incompatible
lubricants may cause problems in lubrication. Use adequate protection when handling
lubricants.
Dispose of mineral lubricants in compliance with current environmental regulations.
CAUTION!
Before performing any operation involving draining or topping up compressor oil,
unplug the compressor and wait until the system has reached atmospheric pressure.
Use adequate protection when handling lubricants.
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7
7.1
INSTRUCTIONS FOR THE USER
DESCRIPTION OF THE CONTROL DEVICES
ELECTRONIC CONTROLLER
Ktronic¹º
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7.1.1 BUTTON LAYOUT
START BUTTON
if there is no active alarm, pressing this button starts the compressor
STOP BUTTON
when pressed, this button stops the compressor after a set period of time
ALARM IN PROGRESS WARNING
REMOTE CONNECTION WARNING
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7.2
ALARM LIST
TYPE OF ALARM
DESCRIPTION
"ALLARME NTC > "
"NTC alarm"
Temperature probe failure
"ALTA T. OLIO"
"OIL HIGH TEMP.AL"
T. MAX setting exceeded
"BASSA T. OLIO"
"OIL LOW TEMP."
T. MIN setting exceeded
"TERMICO COMPRES."
"MOTOR TH. SWITCH "
Main motor thermal relay setting exceeded
"TERMICO VENTIL."
"FUN TH. SWITCH AL"
Electric fan thermal relay setting exceeded
"ALLARME TRASDUT."
"PRESSURE TRD AL."
Transducer failure
"EMERGENZA ATTIVA"
"Emergency SWITCH"
Mushroom head emergency stop button
pressed
"ANOMALIA FASI "
"AC. Phase ERROR "
Phase sequence inverted
"ALLARME SISTEMA!"
"SISTEM ALARM !!!"
General alarm
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7.3
DESCRIPTION OF THE OPERATIONS TO BE PERFORMED
MAIN PAGE
OIL
TEMPERATURE
COMPRESSOR
PRESSURE
DISPLAY OF
ALARMS, IF ANY
MACHINE STATUS
INDICATOR
OFF: machine not running
STOP: request to stop machine
START: request to start machine
LOAD: machine loaded
EMPTY: machine empty
PAUSE: machine in stand-by mode
ALARMS HISTORY page 16/16
Scroll history using
TOTAL MACHINE
HOURS
Description of pressure calibration
for Set ( STOP ) and Reset (START)
to continue scrolling through the screens
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PROGRAMMING KEYPAD
Key:




MULTIFUNCTION
Reset currently saved alarms.
Switches from main page of the current menu to a subpage.
In data entry mode, this key selects the setting subfield in maintenance mode and, if kept
pressed for 4 sections, cancels and resets the time on the maintenance timer.
When pressed on any page, after a 5 second delay, it returns to the main menu.

Key:



ENTER
This key activates the data change mode and saves the modifications.
When in data entry mode, the value to be modified flashes on the screen.
If the page selected has several fields that can be modified, using
move between fields.
makes it possible to
key :


Normally used in data entry mode to change page.
These keys are used to modify the selected value, keeping them pressed for more than 1
second automatically increases or decreases the value (rapid modification).
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7.4
START, STOP AND EMERGENCY STOP FUNCTIONS
EMERGENCY
BUTTON
Figure 11
START
STOP
See chap. 7.1
See chap. 7.1
EMERGENCY STOP
Achieved by pressing the Emergency button (see figure).
This mechanically engaged button immediately stops the compressor if an emergency arises. When
this button is engaged, the compressor cannot perform any operation.
7.5
RESET CONDITIONS
To reset emergency button functions, turn the button clockwise; this will enable the compressor to
start.
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8
8.1
COMPRESSOR MAINTENANCE
SCHEDULED MAINTENANCE
K10
K11
K12
Figure 12
The table below reports the compressor maintenance schedule.
The hours of operation indicated in the table refer to optimal use of the machine and can thus vary
depending on the work site and number of cycles.
KIT
MACHINE
CODE
DESCRIPTION
WORK HOURS
N11L0126
Air/Oil separator filter
Oil filter
Air filter cartdrige
Oil
every 2000 hours
N11L0128
Air/Oil separator filter
Oil filter
Air filter cartdrige
Oil
Environmental filter 473x708 sp.10mm
every 4000 hours
K10
K11
KLE 55
K12
K10
K11
KLE 55
K12
K14
WARNING! USE ONLY GENUINE PARTS
CAUTION!!! HOT PARTS INSIDE!!!
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8.1.1 SUCTION PRE-FILTER MAINTENANCE
Figure 16
1 Raise the protection grid (1) aligning the tabs (see part 1) with the openings on the panel (3).
2
Withdraw the protection grid (1) and remove the pre-filter panel (2) so it can be cleaned or
replaced.
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CLEAN THE PANEL WITH A JET OF AIR OR WASH IT WITH WATER.
DO NOT USE SOLVENTS.
THE PRE-FILTER PANEL MUST BE CLEANED OR REPLACED
WITH THE MACHINE OFF AND WITH THE UNIT AT ATMOSPHERIC
PRESSURE.
OIL LEVEL CHECKS AND TOP UPS MUST BE PERFORMED WITH THE
MACHINE OFF AND WITH THE UNIT AT ATMOSPHERIC PRESSURE.
THE OIL REMOVED MUST BE DISCARDED IN COMPLIANCE WITH
CURRENT LAW.
IN SEVERE WORKING ENVIRONMENTS (e.g.: PARTICULARLY DUSTY
WORK SITES), THE MAINTENANCE INTERVAL MUST BE SHORTER.
INCORRECT MAINTENANCE OF THE OIL FILTER, AIR FILTER AND OIL
SEPARATOR CAN DAMAGE THE UNIT.
LEAVING CARTRIDGES IN OPERATION FOR LONGER THAN THE
INDICATED TIME CAN DAMAGE THE COMPRESSOR.
ALWAYS CAREFULLY COMPLY WITH THE SAFETY WARNINGS
REGARDING USE OF THE MACHINE. THIS IS ABSOLUTELY ESSENTIAL.
MAINTENANCE MUST BE CARRIED OUT BY SPECIALISED PERSONNEL.
ALWAYS FOLLOW CURRENT ACCIDENT PREVENTION STANDARDS (USE
ADEQUATE PROTECTION).
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8.1.2 REPLACING THE OIL FILTER
Perform all maintenance as described in this manual or following the indications provided by the
retailer or Authorized Service Centre. Open the rear panel and remove the filter cartridge using the
special spanner. Then replace the spent cartridge with a new one.
Before screwing down the filter cartridge, oil the gasket.
Manually screw down the new cartridge.
Figure 17
8.1.3 REPLACING THE OIL FILTER
Perform all maintenance as described in this manual or following the indications provided by the
retailer or Authorized Service Centre. Open the rear panel and remove the filter cartridge using the
special spanner. Then replace the spent cartridge with a new one.
Before screwing down the filter cartridge, oil the gasket.
Manually screw down the new cartridge.
Figure 18
OPERATION AND INSTALLATION MANUAL
COD. 091087 – KLE D 55 - REV. 02 - DATE 11/2016
pag.48 di 57
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authorization. K.T.C. shall safeguard its rights to the full extent of the law.
8.1.4 CHANGING THE OIL
Change the oil as indicated in the table point 8.1.6. Extending the number of hours before
replacement depends on the type of oil used but in no case can oil be used for more than one year.
If the compressor is not used frequently (a couple of hours a day), we recommend changing the oil
every 6 months and periodically opening the oil drain cock to check for condensation residues.
When the oil drain cock is opened, oil starts flowing out of the screw assembly.
Always keep on all necessary equipment to collect the oil.
Unscrew the oil filling cap on the oil separator tank and open the drain cock.
Once emptied, close the drain cock.
Then top up the oil until the right level is read on the window (see figure 19). Then tighten the oil
filling cap once more.
After having replaced the oil and oil filter, run the compressor for about 10 minutes, turn it off and
check the oil level. If necessary, top up.
Figure 19
Never mix different types of oil. Make certain that the oil circuit is completely empty
before performing any maintenance. Always replace the filter at each oil change.
OPERATION AND INSTALLATION MANUAL
COD. 091087 – KLE D 55 - REV. 02 - DATE 11/2016
pag.49 di 57
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authorization. K.T.C. shall safeguard its rights to the full extent of the law.
8.1.5 REPLACING THE AIR FILTER
Replace the cartridge following the indications in the maintenance table; in dusty environments we
recommend replacing the filter early, contact an Authorized Service Centre for information.
To replace the cartridge, unscrew the upper lid. Always clean the container paying particular
attention not to let any material fall into the suction valve.
Figure 20
OPERATION AND INSTALLATION MANUAL
COD. 091087 – KLE D 55 - REV. 02 - DATE 11/2016
pag.50 di 57
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authorization. K.T.C. shall safeguard its rights to the full extent of the law.
8.1.6 MAINTENANCE SCHEDULE
Codice/Code Modello/Type
N11L0126
N11L0128
MOTOR ORE/HOURS
KLE D/KLE 55 /
PLUS
400/50/3
8-10-13Bar
KLE D/KLE 55 /
PLUS
400/50/3
8-10-13Bar
Contenuto / Content
LISTINO/LIST
2000
- Filtro Aria / Air Filter
- Filtro Olio / Oli Filter
- Filtro Separatore / Separator
Filter
- Olio / Oil
€
550
4000
- Filtro Aria / Air Filter
- Filtro Olio / Oli Filter
- Filtro Separatore / Separator
Filter
- Olio / Oil
- Prefiltro / Prefilter
€
600
N11L0278
KLE D/KLE 55 /
PLUS
400/50/3
8-10-13Bar
8000
N11L0279
KLE D/KLE 55 /
PLUS
400/50/3
8-10-13Bar
16000
OPERATION AND INSTALLATION MANUAL
COD. 091087 – KLE D 55 - REV. 02 - DATE 11/2016
- Filtro Aria / Air Filter
- Filtro Olio / Oli Filter
- Filtro Separatore / Separator
Filter
- Olio / Oil
- Prefiltro / Prefilter
- Kit ricambi valvola aspirazione/
Intake valve KIT
€
- Kit valvola minima pressione
/Minimum pressure valve KIT
- Kit valvola
termostatica/Thermostatic valve
- Kit paraolio vite/ Screw Shaft seal
KIT
- Anello elastico trasmissione
/Elastic ring of trasmission
- Filtro Aria / Air Filter
- Filtro Olio / Oli Filter
- Filtro Separatore / Separator
Filter
- Olio / Oil
- Prefiltro / Prefilter
- Kit ricambi valvola aspirazione/
Intake valve KIT
- Kit valvola minima pressione
€
/Minimum pressure valve KIT
- Kit valvola
termostatica/Thermostatic valve
- Kit paraolii vite/ Screw Shaft seal
KIT
- Anello elastico trasmissione
/Elastic ring of trasmission
- Cuscinetti MOTORE / Motor
bearing
pag.51 di 57
1.040
1.310
CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written
authorization. K.T.C. shall safeguard its rights to the full extent of the law.
N11L0280
KLE D/KLE 55 /
PLUS
400/50/3
8-10-13Bar
20000
- Filtro Aria / Air Filter
- Filtro Olio / Oli Filter
- Filtro Separatore / Separator
Filter
- Olio / Oil
- Prefiltro / Prefilter
- Anello elastico di trasmissione /
Elastic ring of trasmission
- Kit ricambi cuscinetti vite / Screw
bearing kit
€
1.340
The maintenance program is set considering all installation and operating parameters recommended
by the Manufacturer.
The Manufacturer recommends keeping a log of the maintenance works performed on the
compressor.
8.2
UNSCHEDULED MAINTENANCE
Unscheduled maintenance must be performed by an Authorized Service Centre.
For any information, please log onto our website www.ktc-air.com.
For any clarifications you may require, contact our customer services department or your area
retailer.
OPERATION AND INSTALLATION MANUAL
COD. 091087 – KLE D 55 - REV. 02 - DATE 11/2016
pag.52 di 57
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authorization. K.T.C. shall safeguard its rights to the full extent of the law.
9
TROUBLESHOOTING
Problem
High oil
temperature limit
trips causing
machine to stop.
Cause
Low oil level, too high
environmental temperature,
air oil exchanger clogged,
temperature probe failure.
Resolution
Top up oil level and check that exchanger
is clean and the electric fan is functioning
properly.
Check environmental temperature
parameters.
Replace temperature probe.
Make certain that electric power supply is
correct.
Check that the 3 power phases are at
approximately the same value and that the
cables are firmly secured to the terminal.
Check that the cables are not damaged.
Make certain the main motor ventilation is
free of any fouling or foreign objects.
Motor thermal trip
causes machine to
stop. Main motor
overloaded.
Fan motor or
electric cooling fan
thermal trip
causing the
machine to stop.
Low line voltage.
Phase missing.
High oil separator pressure.
If the motor is running in two phases, have
it checked by a qualified technician. If
necessary, have the motor repaired or
replaced.
The oil separator differential pressure is
above 1.0 bar causing high system
absorption. Have the unit checked by
qualified personnel.
Environmental temperature too high: air
the room.
To start up the machine again, reset it
using the special button on the control
panel.
The thermal trip for electric
fan motor has tripped.
High power absorption.
High temperature.
OPERATION AND INSTALLATION MANUAL
COD. 091087 – KLE D 55 - REV. 02 - DATE 11/2016
Make certain that electric power supply is
correct.
Make certain that the 3 power phases are
at approximately the same value. Make
certain that the power cords are firmly
tightened to the terminal.
Make certain that the power supply cords
are not damaged.
Make certain the cooling fan air intake grid
is free of any fouling or foreign objects.
If the motor is running in two phases, have
it checked by a qualified technician. If
necessary, have the motor repaired or
replaced.
Circuit breaker failure, fuse blown, replace
the damaged fuse.
pag.53 di 57
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authorization. K.T.C. shall safeguard its rights to the full extent of the law.
Problem
Cause
High pressure safety
has tripped causing
the machine to stop.
The pressure exceeds the
alarm set point.
Transducer does not detect
pressure properly.
Low temperature
safety has tripped
causing machine to
stop.
Environmental
temperature below the
electronic controller
setting.
Resolution
Check line pressure, vent pressure and
return to operating set point.
In this phase, if the start button is pressed
intermittently, the machine starts in DELTA
mode and the temperature should return to
above the setting. As soon as it does, the
machine will automatically start running
again.
Check the environmental temperature and, if
necessary, use a heating resistance on the
oil circuit. Contact an authorized Service
Centre.
Make certain that the transducer is connected
both electrically and pneumatically.
Compressor runs
but does not
charge.
Suction valve does not
open.
Auxiliary power
disconnected, solenoid
valve fuse blown.
Check that the solenoid valve installed on the
suction regulator is functioning properly.
Check valve or minimum pressure valve
failure. Contact an Authorized Service
Centre.
Check the fuses for the solenoid valve
installed on the terminal inside the starter
itself.
When starting up the
unit for the first time,
the machine does not The line phases are not
start. Phase anomaly correct.
alarm
Invert two power supply phases on the main
switch. CAUTION!! UNPLUG THE MACHINE.
Oil leaking from air
filter.
High oil level, defective
suction valve.
Drain the oil until the correct level is
reached. For the valve, contact an
Authorized Service Centre.
Pressure relief
safety valve vented.
During no-load operation the
machine is not depressurized.
Oil separator cartridge
clogged.
Contact an Authorized Service Centre.
Excessive oil
consumption.
Oil not suitable for the
compressor operation.
Air-oil separator cartridge
spent or defective.
Oil recovery window clogged.
Oil level too high.
OPERATION AND INSTALLATION MANUAL
COD. 091087 – KLE D 55 - REV. 02 - DATE 11/2016
Replace oil, fill machine with the oil
indicated by the manufacturer. Replace oil
separator cartridge. Clean or replace oil
recovery window.
Top up oil until it reaches the level indicated
in the manual.
pag.54 di 57
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authorization. K.T.C. shall safeguard its rights to the full extent of the law.
10 COMMERCIAL PARTS, SPARE PARTS AND PERTINENT
DOCUMENTATION
For any information, please log onto our website www.ktc-air.com.
For any clarifications you may require, contact our customer services department or your area
retailer.
OPERATION AND INSTALLATION MANUAL
COD. 091087 – KLE D 55 - REV. 02 - DATE 11/2016
pag.55 di 57
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authorization. K.T.C. shall safeguard its rights to the full extent of the law.
11 APPENDIX
11.1 MAINTENANCE CHECK LIST
OPERATION AND INSTALLATION MANUAL
COD. 091087 – KLE D 55 - REV. 02 - DATE 11/2016
pag.56 di 57
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authorization. K.T.C. shall safeguard its rights to the full extent of the law.
CAUTION!

Never touch moving parts while the compressor is running.

All compressor maintenance operations must be performed with the machine off (at
environmental pressure and temperature) and with the unit unplugged.

Maintenance must be carried out by qualified personnel. Always follow current accident
prevention standards (use adequate protection).
The manufacturer reserves the right to make any modifications to the present manual it
deems fit and to do so without prior notice.
The manufacturer is relieved of any responsibility for injuries and property damage caused
by incorrect use of the compressor assembly, non-compliance or inadequate compliance
with the safety criteria indicated herein, modifications (even minor modifications) and by
tampering and use of non original spare parts.
OPERATION AND INSTALLATION MANUAL
COD. 091087 – KLE D 55 - REV. 02 - DATE 11/2016
pag.57 di 57
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