Transcript
USER MANUAL
TuranairÔ K-150 User Manual Turanair System with 0-150 psi Output Pressure
May 2017 Version 2.00
Komptec Kompressoren Technik GmbH Gutenbergring 3, D-63110 Rodgau Telefon. +49 6106 2661787 E-Mail:
[email protected]
Turanair K-150 Users Manual
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USER GUIDE
Symbols The following symbols are found throughout this Instruction Manual to alert the reader to the relative danger that may result from non-observance.
This indicates a situation in which a hazard is imminent and will result in a high probability of serious injury or death.
This indicates a potentially hazardous situation, which could result in minor to moderate injury.
This indicates a potentially hazardous situation or unsafe practice which could result in product or property damage.
CAUTION
This symbol indicates a general statement to assist the user in the operation or maintenance of the equipment.
IMPORTANT
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USER GUIDE Table of Contents Glossary .......................................................................................................................................................................................... 4 WARNINGS ................................................................................................................................................................................... 5 GENERAL SAFETY PRECAUTIONS ..................................................................................................................................... 6 TURANAIR SYSTEMS SAFETY PRECAUTIONS .............................................................................................................. 7 1
Introduction ................................................................................................................................................................. 9 1.1 ... Scope and Purpose .......................................................................................................................................................... 9
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Work Bottle Kit Description ................................................................................................................................ 10 2.1 ... REGULATOR DIAGRAM (FRONT VIEW) .............................................................................................................. 11 2.2 ... REGULATOR DIAGRAM (REAR VIEW) ................................................................................................................. 12
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Regulator Specifications ....................................................................................................................................... 14
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Description of Cylinder ......................................................................................................................................... 14
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Operating Instructions .......................................................................................................................................... 15
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Air Tool and Shot Count Notes ........................................................................................................................... 15
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Refill Options and Instructions .......................................................................................................................... 16
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Regulator Maintenance and Repair ................................................................................................................. 18 8.1 ... Maintenance. ................................................................................................................................................................... 18 8.2 ... REPAIR ............................................................................................................................................................................... 18
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Cylinder Maintenance ............................................................................................................................................ 18 9.1 ... HYDROSTAT RETESTING INFORMATION: ......................................................................................................... 18 9.2 ... RETESTING THE Turanair System: ....................................................................................................................... 19 9.3 ... Cylinder Visual Maintenance ................................................................................................................................... 19 1.1.1 ........................................................................................................................................................................................................ 20
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Copyright, Trademarks, and Intellectual Property ................................................................................... 20
10.1 . Copyright: ......................................................................................................................................................................... 20 10.2 . Trademarks and Logos: .............................................................................................................................................. 20 11
Appendix A: Troubleshooting ........................................................................................................................... 21
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Appendix B: Komptec Limited Warranty ..................................................................................................... 22
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Contact Information ............................................................................................................................................... 24
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USER MANUAL Glossary Become familiar with these terms before operating our products: Air-Knife: Pressurized air that is rapidly leaking through a small hole or port (such as the Pressure Vent Hole on the Regulator) that could act as a sharp knife and cut your finger.
Never cover any hole or port that is leaking with your finger. Composite Pressure Vessel/Cylinder/Tank/Bottle: Terms used interchangeably to mean a fiberglass wrapped or carbon-fiber wrapped cylinder with either an aluminum liner or steel liner that holds pressurized gas i.e., air, nitrogen, helium, argon, etc. Depressurize: To release leftover moisture and air pressure in the system after filling up a Cylinder/Vessel/Bottle/Tank. Fastener: A general term used for any type of fastener that shoots from a pneumatic tool. Fill Adapter: An apparatus used to fill a Turanair System at a Dive Shop, Paintball Field, or any other high pressure compressor that uses a CGA fitting. Full Fill: When the Turanair System is refilled to its designated psi rating, i.e., 4500 psi equivalent at 70°F (full capacity). High Pressure Air (HPA): A general term for compressed air at pressures of 3000 psi or greater. Quick Connect Coupler: Used to connect two parts or products together so that compressed air/gas can be transferred. Rapid-Fill: Filling at greater than 600 psi / minute. Under pressure or pressurized: Means the system is "ON" and/or there is compressed air of some capacity in the Cylinder/Vessel/Bottle/Tank, hoses and/or Regulator. Unraveling of Fibers: Means that the Cylinder/Vessel/Bottle/Tank has been extensively damaged, and the fibers are unraveling from the exterior of the Cylinder / Vessel / Bottle / Tank. If this occurs, then you must IMMEDIATELY STOP USING THE CYLINDER / VESSEL / BOTTLE / TANK. It must be inspected by a Hydro-Static Testing Facility before it can be used again (See Bottle/Tank Maintenance.) If you use a faulty Cylinder / Vessel / Bottle / Tank then you WILL RUN THE RISK OF PROPERTY OR BODILY DAMAGE. (SEE WARNINGS)
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USER GUIDE WARNINGS
Using KOMPTEC products with respect and caution, will considerably lessen the possibility of personal injury. However, if normal safety precautions are overlooked or completely ignored, personal injury to operator can occur.
WARNING! Read the KOMPTEC Instruction Manual. Read, understand and follow the Safety and Maintenance Instructions found in these Manuals. Know the limitations and hazards associated with the Turanair System and all other KOMPTEC products. WARNING! POWER ON: Remember the "power" is always ON when the Turanair System is under pressure and the low pressure gauge is set at a psi higher than zero. WARNING! DO NOT attempt to modify or use any generic parts to replace a broken part of the Regulator or any other KOMPTEC product. Remember that all parts are specified to be used in accordance with "HighPressure" requirements. Any use of generic parts could cause serious bodily injuries. Please contact KOMPTEC for parts and the proper procedure to remove the broken part and replace it with the new part. (Some parts can only be changed by a KOMPTEC representative.) WARNING! The Hose and Connectors were specifically chosen for the Turanair System. Do not
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attempt to change the hose, fittings, or connectors unless they were purchased from KOMPTEC. WARNING! Never adjust the output pressure above the ratings of the output hose or the tool. Exceeding the ratings of the output hose or the tool could result in damage to those items. WARNING! Never use Locktite or any other adhesive product to try to secure the Regulator in the Cylinder / Vessels / Bottles / Tanks. This will void your Warranty. WARNING! Never under any circumstances attempt to take apart the Regulator or to separate the Regulator from the cylinder. It will void the Warranty. WARNING! DO NOT put your finger over any hole or product part that is leaking. The air could act as an air knife and instantly cut your finger. WARNING! Rapidly filling a Turanair System results in heating of the compressed air and the Cylinder. If filled too fast, this heat could become excessive, resulting in
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USER GUIDE eventual failure of the Cylinder/Vessel. WARNING! Never remove the Regulator from the Cylinders / Vessels. The Cylinders have been cleaned and are free from debris. This will void your Warranty. WARNING! DO NOT allow any of our products or product parts or any other tools to be used by children as a toy or in any other manner. No tool
should be used in close proximity to children. KEEP OUT OF REACH OF CHILDREN. WARNING! DO NOT operate any of our products near toxic substances, flammable or combustible liquids, such as gasoline, or operate in the presence of explosive or flammable fumes.
GENERAL SAFETY PRECAUTIONS
CAUTION
General Safety Precautions should always be followed when using our products or any other tools to reduce the risk of personal injury and/or property damage. All manuals that come with your pneumatic tools or one of our products should be read and adhered to.
1. USE SAFETY GLASSES. To prevent eye injuries, the operator and all persons working in the area must wear safety glasses with permanently attached, rigid, plastic side shields. 2. WEAR EAR PROTECTION to safeguard against possible hearing loss. 3. NEVER USE ANY PNEUMATIC TOOL OR OUR PRODUCTS IF SAFETY PARTS ARE INOPERABLE, MISSING OR DAMAGED. Do not alter or remove safety parts. Make daily inspections on all mechanisms of all tools and Turanair System kits. 4. ALWAYS ASSUME THE PNEUMATIC TOOL IS LOADED AND READY TO USE. Keep the tool pointed away from you and others at all times. No horseplay. Respect the tool as a serious device. 5. DO NOT EXCEED THE MAXIMUM RATED PRESSURE OF THE TOOL. Know and follow the recommendations of the tool, exceeding the maximum rated pressure of the tool can damage the tool or cause injury. 6. DO NOT OVERREACH. Keep proper footing and balance at all times when using or handling our products or any other tool.
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USER GUIDE 7. KEEP HANDS AND BODY PARTS away from the pneumatic tool’s shooting range to avoid injury. 8. DO NOT ATTEMPT TO USE ANY OF OUR PRODUCTS other than for its intended and specific use as stated in KOMPTEC manuals. 9. DO NOT ATTEMPT TO USE ANY OF OUR PRODUCTS FOR BREATHING OR SCUBA DIVING. OUR PRODUCTS DO NOT HAVE THE PROPER EQUIPMENT ON THEM FOR BREATHING USE. 10. DO NOT ATTEMPT TO FILL ANY OF OUR PRODUCTS with any form of liquid. 11. DO NOT ATTEMPT TO MODIFY OR DISASSEMBLE ANY OF OUR PRODUCTS. Contact our Service Department for service or repair. Incorrect reassembly may result in the risk of further damage & will void your warranty. 12. DO NOT OPERATE ANY PNEUMATIC TOOL OR ANY OF OUR PRODUCTS while under the influence of medication, drugs or alcohol. 13. DO NOT OPERATE ANY PNEUMATIC TOOL faster than its intended use. Set the air pressure on your Turanair System to the least amount of air needed to efficiently operate the tool.
TURANAIR SYSTEMS SAFETY PRECAUTIONS 1. DO NOT TRY TO FILL THE Turanair System with a standard compressor or any compressor that does not compress air up to 3000 PSI or higher (4500 psi recommended). 2. DO NOT REMOVE THE REGULATOR from the high pressure cylinder under any circumstance 3. DO NOT ALTER OR CHANGE ANY FITTING on the Regulator. 4. DO NOT EXCEED THE MAXIMUM RATED PRESSURE OF THE TOOL. Know and follow the recommendations of the tool, exceeding the maximum rated pressure of the tool can damage the tool or cause injury. 5. DO NOT ATTEMPT TO REMOVE THE REGULATOR from the Turanair System while it is under pressure. 6. DO NOT ATTEMPT TO CHANGE ANY EXTERNAL PART on the Regulator while under pressure.
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USER GUIDE 7. DO NOT ATTEMPT TO CONNECT THE REGULATOR to any other type of cylinder (whether carbon fiber, steel, fiberglass, aluminum, etc.) other than the KOMPTEC Cylinder that the Regulator came on. 8. ALWAYS DISCONNECT YOUR PNEUMATIC TOOL from your Turanair System before doing any maintenance or clearing a jammed fastener on your air tool. 9. ALWAYS LEAVE THE Turanair System in its protective pouch to help eliminate unnecessary nicks and scratches that may occur on the surface of the bottle/tank. 10. CHECK YOUR Turanair System REGULARLY for visual defects before filling. NEVER use a bottle / tank that is leaking air, has missing or damaged parts, visible signs of wear and tear, deep scratches or requires repair. (See page titled, "Cylinder / Vessel / Bottle / Tank Visual Damage Evaluation") 11. NEVER FAST FILL OR "RAPID FILL" The Turanair System. Excessive Cylinder heat due to "fast filling" could damage a cylinder. 12. NEVER USE TOOLS TO TIGHTEN OR LOOSEN the parts on the Regulator. Always manipulate by hand. Do not over tighten. 13. DO NOT HABITUALLY EMPTY THE Turanair System because it will gradually lessen the life span of the bottle/tank. 14. IT IS SAFE TO KEEP IN A CAR under most temperatures from 60°C to 54°C / 140°F to -65°F. The most that would happen is the gauges or another port would safely release the air. (See Regulator Repair & Maintenance if this happens.) 15. ALWAYS ATTACH THE AIR TOOL TO THE AIR HOSE AFTER the air hose has been connected to the Turanair system. NOT BEFORE! 16. DO NOT FILL THE Turanair System with a pneumatic tool attached. 17. DO NOT OPERATE THE TURANAIR SYSTEM IF THE CYLINDER HYDROSTAT TESTING IS OUT OF DATE.
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USER GUIDE 1 Introduction 1.1 Scope and Purpose Thank you for purchasing a TuranairÔ Work BottleÔ from Komptec. It is our objective to provide our customers with the best possible information on Operating Instructions, Safety, Maintenance and Troubleshooting Issues. This Manual provides a permanent reference to any issue you may have. Please keep it available and in good condition. This Manual has been prepared for the owner and those responsible for the operation of a Work Bottle System. Its purpose, aside from explaining how to operate the Work Bottle System, is to promote safety through the use of KOMPTEC accepted correct Operating and Maintenance Procedures. Before operating or servicing your Work Bottle System, it is important to thoroughly read this Manual. In order to obtain maximum life and efficiency, and aid in operating and maintaining the Work Bottle System safely, follow all Safety and Maintenance Instructions. The specifications set forth in this Manual were in effect at the time of publication. However, due to KOMPTEC’s policy of continuous improvement, change to these specifications may be made at any time without obligation on the part of KOMPTEC. The information and recommendations contained in this publication come from sources believed to be reliable and to represent the best current practice. KOMPTEC does not intend for this Manual to be a complete course of instructions on how to safely use these systems and does not guarantee or represent that the information is absolutely correct or sufficient. In addition, it cannot be assumed that all acceptable safety measures are listed or that other additional measures are not needed under particular or exceptional circumstances or conditions.
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2 Work Bottle Kit Description Work Bottle System KIT INCLUDES:
B
C
A. Carbon fiber wrapped cylinder that holds 4500 psi compressed air. B. Dual-stage 4500 psi Regulator that regulates the amount of pressure going out of the Turanair System to your pneumatic tool. This Regulator is made ONLY to fit and be used on properly labeled Turanair Cylinders.
A D
C. Pressure Regulator Knob. “Off” is fully extended. Rotating the knob clockwise will increase the output pressure. Output pressure is indicated on the gauge on the right. The knob should be returned to “Off” when the tool is not in use to prevent unintended air leakage anywhere in the system. Never adjust the output pressure above the rated maximum pressure of 150 psi.
E
D. 6’ coiled hose with a quick connect coupler on the end. E. Heavy-Duty Pouch with a belt loop on the back to wear on user’s tool belt. We recommend you leave the Work Bottle System in the pouch to help protect it and keep it clean. Configuration Options This manual is for the K-150 Turanair system. The following configuration options are covered by this manual: •
Gauge Units. The Gauge is labeled using English Units, in PSI
•
Cylinder size. 114 ci cylinders are covered by this manual. The ordering number includes the cylinder size, for example K-150E-114 would be for a 114 ci cylinder. Actual cylinder size may vary slightly due to sourcing, please check the label on the cylinder for actual volume. Future revisions will include larger size cylinders such as 4.7, 6.7 and 9 liters.
•
Certification. Cylinders will be certified to DOT and Transport Canada.
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MISSING PARTS 1. Each box has been inspected for completeness. If parts are missing call KOMPTEC. Have the serial number, part number, or model number handy when calling.
2.1 REGULATOR DIAGRAM (FRONT VIEW) A. High-Pressure Indicator: Located on the LEFT side of the Regulator and indicates the amount of pressure inside the cylinder. Note that these small indicators have +/- 10% accuracy, so are best used for relative measures. B. Low-Pressure Indicator: Located on the RIGHT side of the Regulator and indicates the amount of pressure that is being delivered through the air hose to the pneumatic tool. Note that these small indicators have +/- 10% accuracy, so are best used for relative measures. C. Output Pressure Adjustment Knob: Located on the TOP of the Regulator. Using the arrows, turn the Pressure Adjustment Knob SLOWLY, either way to get the correct psi. To Increase Pressure: SLOWLY turn the Pressure Adjustment Knob (C) CLOCKWISE. As you are turning it, you will see the Low-Pressure Gauge (B) needle move. Stop turning just before the gauge needle reaches the desired pressure. To Decrease Pressure: SLOWLY turn the Pressure Adjustment Knob (C) COUNTERCLOCKWISE. You will need to release the leftover air pressure as you are setting it. To see the gauge needle come down, attach and operate a tool to release the pressure (E). The knob should be returned to “Off” when the tool is not in use to prevent unintended air leakage anywhere in the system.
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D. Male Fill Port: Located on the LEFT side of the Regulator and attaches to the quick connect coupler on a Fill Adapter (not supplied), to fill the Work Bottle System. This Port has a rubber cover on it called a "cap". ALWAYS leave this cap on when not using this Port. This is the only Port through which dirt and debris can enter your Regulator. E. Low-Pressure Output: Located on the RIGHT side of the Regulator with a quick connect couple on the end which attaches to the air hose. Make sure the Low Pressure Gauge (B) is 0 PSI when connecting the air hose. Once the air hose is connected, then connect the pneumatic tool safely.
C B
A D
E 2.2 REGULATOR DIAGRAM (REAR VIEW) F. Relief Port Plug: To de-pressurize the Turanair System, use a 3mm Hex Wrench to turn the Relief Port Plug one-half turn counter-clockwise and allow to de-pressurize. Quickly releasing pressure will result in a cooling of the regulator, potentially forming ice. De-pressurization should take at least 2 ½ to 3 minutes for a full tank.
Never remove the Relief Port Plug while under pressure.
Be sure to re-tighten the Relief Port Plug with hand tools before re-pressurizing. Turanair K-150 Users Manual
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F
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3 Regulator Specifications Description: 4500 psi, Dual Stage Regulator for use with ONLY KOMPTEC supplied cylinders. • Physical Size and Weight of the regulator with all fittings included: 5.25" L x 2.25" W x 3.50" H, Weight 1.18 Lbs • Regulator: Fully Re-buildable (not a throwaway Regulator) • Input Pressure: 5000 psi maximum • Output Pressure: 0-150 PSI (+/- 10%). • High Pressure Fill Port: G 1/8 BSP female with Stainless Steel Quick Connect Coupling and Attached Protective Dust Cap • Low Pressure Output Port: G 1/4 Female BSP with Quick Connect Coupling • High and Low Pressure Gauges: 7/8” Gauges with Venting Polycarbonate Bezel Plated Brass Housing, 1/8-27 NPT Back Connection • Output Pressure Knob: Fine Adjustment for Precise Control (slight variances may occur) • Body: Lightweight Aluminum • Internal components: Durable Stainless Steel • O-Rings: Viton throughout Regulator for long service life • Regulator Thread (Connection to cylinder): 5/8-18 UNF 19mm L, O-Ring Seal, 14x1,8, NBR 90° and Safety Bleed Hole
4 Description of Cylinder The example shown is for the DOT certified 4500 psi rated bottles. Hydrostat testing is required every 5 years. For more information, see section titled "Bottle / Tank Maintenance"
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All carbon fiber composite Cylinders/Vessels/Bottles/Tanks must be retested every FIVE (5) years to insure safe operation by a certified Retest Facility. Please return the Work Bottle system to KOMPTEC for this retesting. Any Hydrostat test must be performed on or before the last day of the month preceding (before) the month of “Next Periodic Retesting” The example above requires retesting prior to Feburary, 2020.
5 Operating Instructions 1. Make sure your Turanair System is full or has air in it by checking the HighPressure Gauge (A) on the left. If you need to fill it, refer to the section titled "Refill Options and Need to Know" and have it filled. 2. Attach the included air hose to the Low-Pressure Output (E). (NEVER use an alternate hose or fitting unless it was purchased from KOMPTEC) 3. Refer to the tool operating manual for the input pressure requirements for the pneumatic tool that will be connected to the output of the Turanair System. Damage to the tool may occur if the output of the Turanair System exceeds the tool’s recommended maximum input pressure. 4. Start with your Turanair System set to 0 PSI (or off). Slowly turn the Output Pressure Adjustment Knob (C) clockwise using half turns to increase the psi. The needle on the Low Pressure Gauge (B) will start to move. 5. Using the arrows on the Output Pressure Adjustment Knob (C), slowly turn it in half turn increments, either way, to get the correct PSI. If you turn the PSI up (higher), the Low Pressure Gauge (B) will register the correct PSI immediately. If you turn the PSI down (lower), the Low Pressure Gauge (B) will reflect it only when some of the air is released. (To release air, cycle the air tool.) 6. Check for tool adjustments, for example on a nailer, depth adjustment and then, if necessary, turn the PSI higher. If it is countersinking the nail, turn the PSI lower.
6 Air Tool and Shot Count Notes • • • •
Our Turanair System is so highly efficient that you should experiment with your pneumatic tools to find the right psi for each tool – you might be able to reduce operating pressure. The Turanair System can be used with almost any pneumatic tool that is normally run by standard compressors. The air in the Turanair System is dry, clean air. This system can be used with spray guns needing no other moisture filters. Many air tools require lubrication. Since the Turanair system does not include an in-line lubricator, be sure to lubricate your tool as described in the tool’s operating manual.
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•
The following suggestions are listed below to better aid you in receiving the best possible shot count with your pneumatic tools.
1. Air Pressure For Pneumatic Tools Vary. Standard air pressure to run most tools is 90 PSI-120 PSI. There are several factors that can affect the PSI amount and shot count such as: • Age of the Tool • Tool Maintenance • Material that you are shooting into • Hot Climates/More Shots & Cold Climates/Less Shots (±10%) • High Altitude Areas • Air Leaks in the Tool 2. To Find the Proper PSI for your tool, simply take a few shots and see how the fastener is sinking. The Regulator is set at 0 PSI and must be adjusted from there. 3. To Better Conserve Your Air and Shot Count, leave your tool attached to the system (ONLY if the tool has a safety on it) as often as possible. It is NOT necessary to disconnect the tool every time you take the System off.
IMPORTANT
If your Tool is leaking and you leave it connected to the Turanair system, then your air supply will leak out through your air tool and empty the cylinder.
4. Lubricate and Maintain Your Tools Regularly if you are interested in a high shot count. Remember that you are used to having a constant and wasteful supply of air for your tool from your old low-pressure compressor. If your tool was not working efficiently or leaking air, you would have never realized it. 5. It Is Extremely Beneficial to the life span of the Turanair System and your shot count if you don’t let your Turanair System drop below 500-1000 PSI before you refill again. By maintaining at least 500 – 1000 PSI in your Cylinder, you maintain pressure on all o-rings and seats. 6. You Are Likely to Waste Shots by having an "Itchy Trigger Finger". Certain kinds of pneumatic tools have a particular trigger that is called an "Air Release Contact Trip Trigger". If your tool has this kind of trigger then keeping your finger on the trigger allows air to escape which reduces your shot count.
7 Refill Options and Instructions NOTE: YOUR Turanair System HAS BEEN INSPECTED AND TESTED PRIOR TO DELIVERY. YOUR Work Bottle System MUST BE FILLED PRIOR TO FIRST USE.
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1. Fill Adapter (Used for any size Cylinder): The standard male quick connect on the fill port should permit the Turanair System to be filled by any dive shop, or any other location that has a 4500 psi or higher, high pressure compressor. The fill adapter will be required if you’re working with your own High-Pressure Compressor without a quick disconnect. Item is sold separately. 2. High-Pressure Compressor: KOMPTEC offers compressors that fill to 4500 psi such as the KOMPTEC® KT-90 High Pressure Portable Compressor (Gas or Electric). Be sure that whichever compressor you use has a Fill Adapter with a standard high-pressure quick disconnect. 3. Other Options: There are several other options for refilling your Turanair System’s cylinder including dive shops and paintball arenas. NEED TO KNOW: • KOMPTEC recommends filling to no more than the rated pressure 4500 psi at 70°F. The cylinders are either DOT or TC Certified for North America and PI for Europe. • Normal fill rates are up to 600 psi / min. Fast fill rates of up to 6000 psi / min can be employed. • Cylinders are rated for 4500psi at 70°F. Gas pressure and temperature are directly related. That same 4500psi at 70°F will increase 13.2% at 140°F to 5100psi (The ratio needs to be on the Rankine scale, with 460 being added to both numbers). • DO NOT FILL the Turanair System with the pneumatic tool attached to the hose. • It is NORMAL for the Turanair System to get WARM when filling! You may use the Turanair System warm; it will cool off pretty quickly. However a cylinder filled to 4500 psi at a fast fill rate will cool, reducing the pressure of the cylinder after cooling. • Cylinders may be filled to pressures above 4500 psi as long as when the cylinder cools to 70F the pressure does not exceed 4500 psi • The Turanair System was designed to hold the air in until it is used with an air tool. Therefore, the air should not leak out as long as there is no leaking air tool attached. However it is a good practice to return the Output Pressure Adjustment Knob to “off” when the system is not in use. • The Turanair System can be stored in a car or truck under temperatures from 140°F to -65°F. The most that could happen is that the gauges or another port would safely release the air. (See Regulator Repair and Regulator Maintenance Sections if this happens.) • Always keep the dust cap on the fill port of the Regulator. It is the only opening that micro-particles can enter the Regulator. Even the smallest particles can affect its performance.
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8 Regulator Maintenance and Repair 8.1 Maintenance. • •
The Regulator is virtually maintenance free. It does not require any oil, lubricants or adhesives. Keep the Regulator clean at all times. Wash clean using a hose or under a faucet.
Keep the "Male Fill Port Cap" on at all times. This is the only port where dust and debris could enter the Regulator. CAUTION •
We recommend you keep your Work Bottle System in its pouch to protect it from dings and scratches. If you are experiencing any or all of the following problems with your system, it might be time to service your Regulator. (See Troubleshooting) • Sluggish response time • Losing air too quickly • Not working at all There may be some debris inside the Regulator or the internal O-Rings may need to be replaced. The Regulator can only be serviced by KOMPTEC. Call our Service Department for further information. Always keep your receipt or a copy of it with your original box and this manual so that the System can be tracked by the product serial numbers.
8.2 REPAIR 1. There are no customer serviceable parts on the Turanair system. Contact Komptec in the event the Turanair System requires repair.
9 Cylinder Maintenance 9.1 HYDROSTAT RETESTING INFORMATION: When you purchase a Turanair System, the bottle/tank is already hydrostat tested and DOT and TC approved with the date shown on the label and can be
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filled as long as it does not show visible signs of damage. (See "Cylinder Visual Maintenance" Section). It is your responsibility to hydrostat test your Cylinder when it is required. Please return to KOMPTEC for hydrostat testing.
9.2 RETESTING THE Turanair System: The Turanair System is made from a Type III carbon fiber wrapped cylinder for the ability to sustain a working pressure of 4500 psi. Any Hydrostat test must be performed on or before the last day of the month preceding (before) the month of manufacture (as shown on cylinder label).
9.3 Cylinder Visual Maintenance
Scratches in the outer protective coating are a result of regular use. NB: Scratches are not a concern if they don’t expose any fibers.
Abrasion has exposed fibers. NB: This cylinder must be inspected and tested before filling or use. The cylinder might be repairable at an approved DOT inspection facility.
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Impact damage may appear as dull white dimples in the protective coating. NB: Have the cylinder inspected if the dimples measure more than 7/16" or expose any fibers.
Severe impact has chipped the protective outer coating and exposed fibers. NB: This cylinder must be inspected and tested before filling or use.
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Composite cylinders are safe and durable products. But like any pressurized product, misuse or abuse can end in failure and possible personal injury or death.
Unraveling of fibers is a potentially dangerous situation! NB: Never fill or use a cylinder with signs of unraveling! As a rule, any composite cylinder that has damage that penetrates the protective outer coating or that cuts, unravels, or in any way exposes the fibers underneath should be taken out of service immediately and inspected at an approved PI/DOT facility.
10 Copyright, Trademarks, and Intellectual Property 10.1 Copyright: This manual is Copyright Komptec Kompressorentechnik GmbH.
10.2 Trademarks and Logos: The stylized Turanair Logo, Turanair, Turanair Systems and Work Bottle are copyright Turanair Systems Inc., and are used with permission.
All other trademarks cited herein are the property of their respective owners.
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11 Appendix A: Troubleshooting PROBLEM
No Air to Pneumatic Tool
POSSIBLE CAUSES 1. Turanair System is empty. 2. Regulator pressure set too low. 3. Gauge is damaged. 4. Debris Inside Regulator body.
Too much Air Pressure. Counter-sinking the Fastener.
1. Regulator pressure too high. 2. Check tool depth. 3. Malfunction of Regulator.
If you hear or feel Air Leaking From the Regulator
1. O-Ring inside Quick Disconnect coupler is loose. 2. Gauges or connections loose. 3. Interior O-Rings need to be replaced. 4. Base O-Ring needs to be replaced.
Losing Air Too Quickly from the Cylinder
1. If connected to a Tool that is Leaking, it will deplete air supply. 2. Regulator needs to be rebuilt.
Not Getting Good Shot Count
2. Check Tool being used. 3. Regulator Pressure set too high. 4. Air might be leaking out.
Inaccurate or inconsistent reading from High Pressure gauges
1. The small indicator gauges have 5% tolerances 2. Cylinder pressure will rise or fall with temperature
Low Pressure gauge pegged to the left
1. Contamination within the regulator
Can’t insert nipple into coupler
1. Residual pressure in low pressure side
SOLUTION 1. Check Gauge. If Bottle is empty, refill. 2. Using the Output Pressure Adjustment Knob, raise the air pressure. 3. If Gauge Needle doesn’t move after it is filled, replace Gauge. See Regulator Repair. 4. Call Komptec. 1. Using the Output Pressure Adjustment Knob, reduce air pressure. 2. Call Komptec. 1. See Regular Maintenance Section 2. If Gauges or connections are leaking air, call Komptec. 3. Call Komptec. 4. See Regulator Maintenance Section.
1. Test Tool for leaks. If it is leaking, repair or replace the Tool. 2. Call Komptec. 1. Using Output Pressure Adjustment Knob, lower air pressure. 2. Call Komptec.
1. Call Komptec 1. Turn adjustment knob to off, then release pressure by backing out coupler with wrench.
If you have any problems that cannot be easily overcome, call Komptec’s Customer Service Department before continuing use.
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12 Appendix B: Komptec Limited Warranty WHAT YOUR WARRANTY COVERS: • This Komptec product is warranted by Komptec Kompressoren Technik GmbH. (referred to hereinafter as “Komptec”) against defective materials or workmanship. • This warranty of the Komptec product extends to the original purchase of the Komptec product This warranty is void if: defects in materials or workmanship or damages result from repairs or alterations which have been made or attempted by others or the unauthorized use of nonconforming parts; the damage is due to normal wear and tear, the damage is due to use of the Komptec product after partial failure or use with improper accessories. FOR HOW LONG AFTER YOUR PURCHASE: • Cylinders lifetime as documented on the Cylinder. (Only if there has been proof of all hydrostat tests as required by the label on the Vessel). • For End Users: 1-Year for the Regulator against defects in workmanship or materials; excludes serviceable parts as listed below. • For Commercial Users: 90 days for the Regulator against defects in workmanship or materials; excludes serviceable parts as listed below.. HOW YOU GET SERVICE: • To identify the Authorized Service Center nearest you, contact Komptec. • A copy of your sales receipt or other evidence of date of purchase is required. WHAT YOUR WARRANTY DOES NOT COVER: • Hydrostat testing for the bottles / tanks. • Replacement of bottle / tank if it is rejected for a hydrostat test approval based on damage from misuse, abuse or neglect. • Adjustments related to using the product(s) with other tools. • Damage from misuse, abuse, improper service or neglect. • Customer modification for uses other than for what it is intended. • Regulator damage caused by unauthorized persons (including Customer/Owner) attempting to repair, modify or alter in any way. • A Work Bottle System that has been modified or incorporated into other products for institutional or other commercial purposes. • Acts of nature, such as but not limited to lightning damage or other circumstances beyond Komptec control. • Transportation to and from the Authorized Service Center. (We recommend that you use the same box it came in.) • Merchandise sold as reconditioned, used as rental equipment and floor or display models. • Repair or transportation costs of merchandise determined not to be defective or under warranty.
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RESPONSIBILITY OF THE ORIGINAL PURCHASER: • Repairs or service which do not involve defective materials or workmanship, are not covered by this warranty. Costs of such service calls are the sole responsibility of the purchaser. • Problems with tools that can be attached to the Work Bottle System are not the responsibility of KOMPTEC. If there is a problem with that tool, then you must contact the tool manufacturer’s rep. • During the above warranty period, should your Komptec product exhibit a defect in materials or workmanship, such defect will be repaired when the complete Komptec product is returned, postage prepaid and insured, to a Komptec Authorized Service Center. Other than the postage and insurance requirement, no charge will be made for repairs covered by this warranty. A Return Material Authorization is required prior to returning materials. • KOMPTEC is not responsible for products sent out for repair that do not contain a return label and a RMA number. It is the owner’s sole responsibility to make sure the product is sent and returned properly and safely. We recommend the owner to insure their package and retain the tracking information. Warranty Disclaimer • 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. All decisions of KOMPTEC with regards to this Limited Warranty shall be final.
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13 Contact Information Komptec Kompressoren Technik GmbH Gutenbergring 3 D-63110 Rodgau Germany Telefon. +49 6106 2661787 E-Mail:
[email protected] Distributed in North America by Komptec Air Systems, Inc. 725 Crystal Ln. Pleasanton, CA 94566 Phone 925 596-1096 E-Mail:
[email protected]
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