XA(T,V)S 400 CD7 iT4 Compressors Scott Ellinger Committed to sustainable productivity

Systems Overview XAS 400 CD

Product Designation Oil Injected Compressors Engine supplier C : Caterpillar D : Deutz J : John Deere Y : Yanmar K : Kubota Working principle A : Single stage compressor R : Two stage compressor Product range X : Oil injected portable compressor Silencing : Un-silenced S : Silenced Prime mover D : diesel engine E : electric motor X A T S 400 C D Capacity (FAD) Liter/sec CFM (US-version) Working pressure : std pressure 102psi M : 125psi T : 150psi H : 175psi V : 200psi

XAS 400 CD7 IT4 Machine Specifications

XAS 400 CD7 IT4 Machine Specifications (2)

Compressor systems Air system Oil system Control system Four major components : Air system Oil system Control system Electrical system

Air system The following slides explain how the regulating system of the XA(H)S 146-186 works. They will give you an overview of the different parts and their function.

Air filter centrifugal dust separation paper filter element Filtration of the inlet air in 3 stages : centrifugal dust separation paper filter element safety cartridge (optional) Vacuum indicator gives an indication when the pressure drop over the filter element is too high  filter element needs to be replaced

Air filter Centrifugal separation Air inlet Vacuum indicator Filter element Dust to compressor element

REGULATING SYSTEM REG VALVE Spring loaded Adjusting receiver pressure by changing spring tension to pressure gauge and loading valve to speed regulator to unloading valve Regulating pressure: Receiver pressure In order to regulate the pressure inside the reciever tank of our compressor, the air intake and the engine speed have to be controlled. This is done pneumatically. For that reason, we need regulating pressure. The regulating valve reduces the pressure inside the tank, thus providing the regulating pressure. This regulating pressure is then supplied to the unloader valve and the speed regulator or RPS. The air receiver pressure can be set to another value by adjusting the spring tension of the regulating valve. This is done by turning the handle on top the valve. Increasing the spring tension, by turning in, will increase the regulating pressure and consequently the pressure inside the vessel. Turning out will decrease the pressure.

Unloading valve Open position at load condition => Air consumption Opens and closes the air inlet to the compressor element. Open position at load condition => Air consumption Closed position at no load condition => No air consumption. Control of the valve by regulating pressure.

Unloading Valve or Air System Inlet Valve Legend Receiver Pressure From Pressure Regulator right now very low to zero pressure Spring loaded in the open position Control Air closes the inlet Also serves as check valve Unloading valve service kit – 2911 0074 00

No-Load Condition Load Condition

Unload Condition Blow- Down Condition

AIR SYSTEM MIN PRESS VALVE Maintains a minimum pressure of 58 PSI for oil flow Also contains the final check valve

Oil System The following slides explain how the regulating system of the XA(H)S 146-186 works. They will give you an overview of the different parts and their function.

Oil System Air receiver Oil cooler Oil filter/TBV Compressor element Oil separator Scavenge line Oil stop valve The following slides explain how the regulating system of the XA(H)S 146-186 works. They will give you an overview of the different parts and their function.

Oil injected screw compressors

Compressor element Lubrication to the bearings Air inlet Oil Air/Oil

Oil injected screw compressors Oil is used for : Cooling : compression heat is absorbed by the oil Lubrication of rotors, bearings, gears Sealing between rotors and rotor and housing Corrosion protection of the internal metal parts

Oil injected screw compressors Oil is injected in the bottom of the rotor housing, on the bearings and gears

Compression principle Suction Compression start Delivery Compression

Oil separator Scavenge line Separator element Centrifugal separation Oil Separator filter element should be replaced Every 1,000 hours or yearly. Centrifugal separation Oil Air/Oil

Oil Separator Separator Element Service Kit – 2911 0075 00 Classic Reasons For Oil Carryover Over filled receiver Plugged scavenge line Wrong type of oil (no anti foam agent) Shut down with air outlet valves open Scavenge tube installed improperly Separator Element Service Kit – 2911 0075 00

Control System

Control Panel

XC2002 Status

XC2002 Menus

Basic Operations

Shutdown

XC2002 Service Timer Reset Scroll through the controller menu to “Parameters” (on some units “Parameters” may be a submenu under “Extra Views”) Press Enter to select Parameters Scroll to ST1 Reset or ST2 Reset as needed (ST1 = 500 hours, ST2 = 1000 hours) Press Enter to select to reset the appropriate timer Prompt for Password: change to 2003 and press Enter Center option will highlight; up/down to change to “Yes” and press Enter Service timer is reset

XC2002 Alarms

XC2002 Alarms If an Alarm occurs, a pop-up window will display for as long as the alarm is active, in any view. The flashing red Alarm LED will light up. The Alarm icon(s) will be shown with an acknowledgement check box. Push the Enter button to acknowledge the alarm. An acknowledged Alarm will mark the check box and light the red Alarm LED. An Alarm should always be acknowledged before solving the cause of the Alarm. The Alarm display can be left by pushing the Back button. If more than one Alarm occurs, the Up and Down arrows may be used to scroll through the list. Newest Alarms will be at the bottom of the list. If a Shutdown occurs, the Shutdown Display will be shown.

XC2002 Event Log XC2002 keeps an event log of the last 15 events. Shutdowns Warnings Service timer resets Unit type changes Running hours at time of event logged

Engine Faults

Compressor Faults

Electrical System

Wiring Diagram XAS 400 CD

Maintenance

Maintenance – XA(T,V)S 400 CD IT4 Daily: Check engine oil level Check compressor oil level Check coolant level Drain water from fuel filter Empty air filter vaccuator valve Check tire pressure

Maintenance – XA(T,V)S 400 CD IT4 Initial Service at 50 Hours Check electrolyte level and terminals of battery Check for leaks in Air, Oil, and Fuel systems Check wheel nut torque (if equipped) Check and adjust brakes (if equipped) Check and adjust fan belts Replace compressor oil filter

Maintenance – XA(T,V)S 400 CD IT4 500 Hour service pack part number 1310 3004 52 (typical 6 months) Perform 50 hour service tasks Clean oil cooler, radiator, intercooler Grease door hinges Grease towing eye shaft or ball coupling and shaft Analyze coolant Replace air filter elements Replace engine oil and filter Replace fuel primary filter and prefilter

Maintenance – XA(T,V)S 400 CD IT4 1000 Hour service pack part number 1310 3004 53 (typical 12 months) Perform 500 hour service tasks Test safety valve and shut down switches Check rubber flexibles Replace separator element Replace compressor oil and filter Replace bleed off valve unloader Replace filter element from regulating valve Clean flow restrictor in oil scavenge line Inspection by Atlas Copco service technician Check/adjust engine valves every 2000 hours or per Caterpillar

IT4 Exhaust Aftertreatment

Tier 4: Terms and Key Words Regeneration: The process of eliminating built up soot from the exhaust system Two types of Regeneration Active Regeneration: Using a hydrocarbon (fuel) to elevate exhaust gas temperatures above 1100 F (600 C) in order to remove built up soot from the exhaust filter Passive (Natural) Regeneration: Using temperature alone to burn soot by elevated exhaust temperature Can be controlled by temperature management of the exhaust stream Can be achieved by maintaining exhaust gas temperature Can also be achieved by control valves including VGT that effect exhaust backpressure

Tier 4: Terms and Key Words Soot Incomplete combustion of hydro carbons in the exhaust stream Can be purged from the DPF by re-generation Ash Incomplete combustion of some hydrocarbon by-products CANNOT be purged from the DPF by re-generation EPA Mandated that DPF must withstand 4500 hrs before ash cleaning is needed HPCR High Pressure Common Rail fuel system System pressures up to 30,000 psi Allows multiple injection events to take place reducing emissions VGT Variable Geometry Turbocharger Inlet guide vanes can adjust to provide exact boost pressure to work in conjunction with the EGR

Tier 4: Terms and Key Words NOx Nitrogen Oxides Highly reactive gasses that form from emissions EGR Exhaust Gas Recirculation Recycles a portion of exhaust gas back to the engine ULSD Ultra low sulfur fuel (less than 15 ppm) Must be used on all IT4 machines Normal diesel fuel will kill an EGR and DOC within a few tanks Low ash Engine oil Must be used on all IT4 machines to reduce the formation of ash accumulating in the DPF CANbus – Method of communication between controllers or networks. All Atlas Copco controllers use SAE J1939 CANbus communication

Tier 4: DOC and DPF Diesel Particulate Filter (DPF) Diesel Oxidation Catalyst (DOC) CEM- Cleaning Emission Module

Tier 4: Diesel Oxidation Catalyst (DOC) Open cell substrate flow though device Reduces HC and CO significantly Reduces Pm 10 to 30% Converts NO to NO2 for passive regeneration of the DPF Oxidizes HC (diesel fuel) as part of active regeneration strategy No servicing required Requires use of low sulfur diesel or ULSD Typically element is =100% of engine displacement in size 49

Tier 4: Diesel Particulate Filter (DPF) Wall flow, high filtration efficiency (95%+) Traps ash, soot and any particles Needs periodic regeneration / cleaning Periodic ash cleaning required No muffler required in the vast majority of applications 50

XC2002 DPF Status Indicators

Xc2002 – DPF Information Manual Regeneration Parameter DPF – Diesel Particulate filter – can change from AUTO to ON or turn OFF completely (not recommended!) STATION REGEN. – Stationary (manual) Regeneratoin – OFF or ON Both need to be set to “ON” for manual regeneration Both are password protected Unit will not regenerate until soot level is ~70%

Procedure: Stationary/Forced DPF Regeneration Atlas Copco recommends that the DPF configuration be left in the AUTO mode at all times however in the event that a stationary or forced regeneration in desired the following process should be followed.. Unit WILL NOT regenerate until soot level is above 72% Go to the "STATION REGEN" screen. For normal operation this should be in OFF mode. Press the enter button (1), a password window will appear. Enter 1968 and press the enter button. Use the up or down (2) arrow to change the selection to ON and press the enter button. Go to the "DPF" screen. For normal operation this should be in the AUTO mode. Press the enter button (1) This will set the unit up for regeneration, after a few moments the regeneration icon should appear confirming the unit is regenerating. The stationary/forced regeneration can take in excess of 3 hours to complete. 1 2

Procedure: Stationary/Forced DPF Regeneration Upon completion of the stationary/forced regeneration it is highly recommended to reset the unit to automatically regenerate to prevent engine derate & shutdown due to high soot load. Go to the "STATION REGEN" screen. (For normal operation this should be in OFF mode). Press the enter button, a password window will appear. Enter 1968 and press the enter button. Use the up or down arrow to change the selection to OFF and press the enter button. Go to the "DPF" screen. For normal operation this should be in the AUTO mode. Press the enter button, Use the up or down arrow to change the selection to AUTO and press the enter button. The unit is now ready for normal operation.

Contact Numbers Main Number Atlas Copco Technical Support 800-732-6762 Option 3 Ed Kukfisz – Compressors – Supervisor 281-542-2562 direct & 832-385-4697 mobile Andrew Stevenson – Compressors: Low Pressure 720-479-2486 direct & 404-751-6717 mobile Andrew Calendar – Compressors: High Pressure 720-479-2487 direct & 404-242-6203 mobile Scott Ellinger – Compressors 720-479-2476 direct & 720-375-1795 mobile Robert Walsh – Generators – Supervisor 803-487-0256 direct (mobile) Will Hudson – Generators/Compressors 800-732-6762 Ext. 12920 & 832-454-8123 mobile Brandon Hobbs – Hydraulic Attachments /Handheld Construction Tools – Supervisor 303-287-8822 direct & 913-424-4039 mobile Al Eckenfels – Hydraulic Attachments/Handheld Construction Tools 800-760-4049

Committed to sustainable productivity.