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KTC COMPACK 2 - User Manual

KTC COMPACK 2
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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.
USER MANUAL AND INSTALLATION
COD. 091052 - REV. 07 - DATE 11/2016
Pag.1 di 45
OPERATION AND MAINTENANCE MANUAL FOR
COMPACK 2 COMPRESSOR
(SOLUTION FOR BUS)
ENGLISH VERSION

Questions and Answers

  • K
    Kevin GentryAug 14, 2025
    Why does my KTC COMPACK 2 Air Compressor motor thermal sensor cause the machine to stop?
    • E
      Elizabeth MartinAug 14, 2025
      If the motor thermal sensor causes your KTC Air Compressor to stop and indicates the main motor is overloaded, ensure the electric power supply is correct and that the 3 power phases are at approximately the same value with cables firmly secured. Also, check for damaged cables and ensure the main motor ventilation is free of obstructions. If the motor is running in two phases, have it checked by a qualified technician. The oil separator differential pressure may be above 1.0 bar, causing high system absorption; have the unit checked by qualified personnel. High environmental temperature can also be a factor, so ensure the room is well-ventilated. To restart, reset the machine using the button on the control panel.
  • Y
    yvetteherreraAug 17, 2025
    What to do if the safety valve group vented air when KTC COMPACK 2 is running?
    • C
      craig33Aug 18, 2025
      If your KTC Air Compressor's safety valve group is venting air while the compressor is running, it means the pressure has exceeded the safety valve's opening limit. Replace the safety valve. It could also indicate that the separator cartridge air/oil filter is clogged, in which case you should replace the air/oil separator cartridge. If the problem persists, it is recommended to contact an authorized service centre.
  • D
    Douglas GordonAug 20, 2025
    How to fix KTC COMPACK 2 stop for oil thermostat intervention?
    • A
      Anna CooperAug 20, 2025
      If your KTC Air Compressor stops due to oil thermostat intervention, first check the oil level. Also, make sure the cooler is clean and that the fan is working when the machine is running. To restart the machine, switch it off and press the reset thermostat button located under the thermostat cover. If the issue persists, contact a service center.
  • F
    floresraymondAug 25, 2025
    Why KTC Air Compressor has excessive oil consumption?
    • A
      andrewhughesAug 25, 2025
      If your KTC Air Compressor is experiencing excessive oil consumption, the oil may not be suitable for the compressor's operation. Replace the oil with the type indicated by the manufacturer. Also, the air-oil separator cartridge may be spent or defective, so replace it. Check for a clogged oil recovery viewer and clean or replace it if necessary. Finally, ensure the oil level is not too high and top it up to the level indicated in the manual.
  • M
    Matthew JensenAug 27, 2025
    What to do if KTC Air Compressor stop machine intervention thermal compressor motor?
    • D
      Diana JohnsonAug 27, 2025
      If your KTC Air Compressor stops due to thermal compressor motor intervention, and the intervention happens when the compressor is on, check that the phases are stable. If it happens when the compressor is running, make sure the internal pressure of the group and replace the separator cartridge. If the motor draws a current higher than the rated current, contact an authorized service technician. Avoid excessive starts, as they can damage the compressor's electrical plant.
  • T
    tonyaleeAug 31, 2025
    Why is there oil leakage from the air filter of my KTC Air Compressor?
    • S
      Susan JohnstonAug 31, 2025
      If you notice oil leakage from the air filter of your KTC Air Compressor, it could be due to a few reasons. First, check if the oil level is too high and remove any excess oil, referring to the oil sight glass. Another cause might be a dirty oil recovery viewer, which you should remove and clean. Lastly, the separator cartridge could be exhausted, so replace the air/oil separator cartridge, ensuring you clean its nipple.
  • D
    derekcooperSep 3, 2025
    What to do if KTC COMPACK 2 runs but the pressure remains low?
    • M
      Mr. Charles Richard DVMSep 3, 2025
      If your KTC Air Compressor runs but the pressure remains low, start by checking if the intake valve opens. When the machine is off and safely depressurized, remove the air filter and see if the shutter moves. Next, check for any air leaks from the pipes. Finally, inspect the coupling between the screw and engine to ensure the motor transmits motion to the screw; if not, contact a service center.
  • A
    Andrew TaylorSep 6, 2025
    Why is the safety valve opening on my KTC COMPACK 2?
    • J
      John LewisSep 7, 2025
      If the safety valve on your KTC Air Compressor is opening, it's likely because the pressure switch isn't working, causing the pressure to exceed the safety valve's set value. Remove the cover and check the pressure switch for oxide or dirt. If present, remove them with a mild antioxidant. Also, check that the intake valve is not locked and closes properly.
  • C
    chasetiffanySep 10, 2025
    What to do if KTC COMPACK 2 Air Compressor does not start and shows phase anomaly alarm?
    • C
      Christian HoSep 10, 2025
      If your KTC Air Compressor doesn't start and shows a phase anomaly alarm when starting up for the first time, the line phases are likely incorrect. To fix this, invert two power supply phases on the main switch. Ensure to unplug the machine before doing this (only for 3 phases version).

Summary

GENERAL WARNINGS AND INFORMATION FOR THE USER

REGULATED RELATIONSHIPS AND DECLARATIONS

Defines user responsibilities and manufacturer declarations regarding compressor usage and compliance.

WARRANTY AND RETURNS

Covers warranty terms, exclusions, and the RMA procedure for product returns.

RULES APPLY AND MANUAL USAGE

Explains rules, general info, manual symbols, and CE marking.

INSTRUCTIONS FOR SAFE OPERATION

MAINTENANCE AND SUPPORT INFORMATION

Offers support services and emphasizes using original spare parts for optimal performance and warranty.

SAFETY SYMBOLS AND WARNINGS

TECHNICAL DATA COMPRESSOR

DIMENSIONS

UNPACKING AND LOCATION

UNPACKING PROCEDURES

Instructions for safely unpacking the compressor unit using appropriate tools and procedures.

INSTALLATION SITE REQUIREMENTS

Guidelines for selecting an appropriate installation site, considering environmental conditions and safety.

CONNECTION AND START UP

GENERAL CONNECTION WARNINGS

Key checks required before initial compressor start-up, including voltage and oil level.

USE OF THE COMPRESSOR

Defines the intended use of the compressor and highlights critical safety warnings for operation.

COMPRESSOR LUBRICATION

Provides detailed instructions for filling and maintaining the compressor oil level and type.

USING SYNTHETIC OILS

Procedure for using synthetic lubricants, including oil filter replacement and cleaning cycles.

CONNECTING POWER CABLE

Instructions for connecting the compressor's power cable, including wiring details.

ELECTRICAL CONNECTION DETAILS

FUSE AND BREAKER SPECIFICATIONS

Recommended specifications for fuses and circuit breakers for different voltage and power ratings.

GROUND CONNECTION AND CABLE SIZING

Procedures for grounding and selecting appropriate electric cable sections for safety and performance.

AIR CONNECTION OF COMPRESSOR

FIRST START PROCEDURE

CONTROL PANEL OPERATION

COMPRESSOR ELECTRIC DIAGRAM

Schematic representation of the compressor's electrical system, including power supply and control signals.

CONNECTOR INSTALLATION

OIL HEATING RESISTANCE

PNEUMATIC SCHEME AND MACHINE DESCRIPTION

ORDINARY MAINTENANCE

MAINTENANCE SCHEDULE AND PARTS

Provides a schedule for routine maintenance tasks and emphasizes using genuine parts.

FILTER REPLACEMENT PROCEDURES

Step-by-step instructions for replacing oil, separator, and air filter cartridges.

OIL CHANGE PROCEDURE

Instructions for changing compressor oil, including checking level, running time, and filter replacement.

DETAILED MAINTENANCE SCHEDULE

TROUBLESHOOTING GUIDE

APPENDIX

MAINTENANCE CONTROL BOARD

A log sheet for recording maintenance operations, dates, and technician signatures.

COMMERCIAL PARTS AND DOCUMENTATION

KTC COMPACK 2 Specifications

General IconGeneral
BrandKTC
ModelCOMPACK 2
CategoryAir Compressor
LanguageEnglish

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