XAS 400 JD7 iT4 Compressor Scott Malm Committed to sustainable productivity

Air/Oil System Overview - XAS 400 JD iT4

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 J D Capacity (FAD) Liter/sec CFM (US-version) Working pressure : standard pressure 102psi T : “ten” pressure 150psi H : high pressure 175psi

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 system Air filter Compressor Element (AFCE) (with vacuator valve VV, Safety Cartridge SC and vacuum indicator VI) Unloading Valve (UV) Compressor Element (CE) Temperature Switch (TS) Check Valve (CV) Air Receiver (AR) Non Return Valve Minimum Pressure Valve (MPV) Air Outlet Valve (AOV)

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.

Regulating valve Adjusting receiver pressure by changing spring tension Spring loaded Pressure gauge to speed regulator to unloading valve Regulating pressure Receiver pressure to blow-down valve Regulating Valve Service Kit – 2911 0111 00

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 58-60 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 Compressor element Oil separator Scavenge line 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 Classic Reasons For Oil Carryover Over filled receiver Plugged scavenge line Wrong type of oil (no anti foam agent) Scavenge tube installed improperly Being used improperly for application (Sandblasting) Separator Element Service Kit – 2911 0075 00

Control System

Control Panel – XC2002 Controller Stop Button

XC2002 Status

XC2002 Menus Software Level 1.70.0 for XAS 400 JD iT4 Unit Type 15 For XAS 400 JD iT4

Basic Operations

Shutdown

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 keep flashing. The Alarm will be shown with the phrase “Unack”. Push the Enter button to acknowledge the alarm. Once the alarm is acknowledged if it is still active then the red LED in the triangle will stay on solid. 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 alarm code will be shown.

XC2002 Event Log XC2002 keeps an event log of the last 30 events. Shutdowns Warnings Service timer resets Unit type changes Running hours at time of event logged

Engine Faults

Compressor/Engine Faults

Electrical System

Wiring Diagram

Legend – Wiring Diagram

Wiring Diagram - Engine

Wiring Diagram – Legend - Engine

Maintenance

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

Maintenance – XA(T,V)S 400 JD 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 Check and adjust fan belts Replace compressor oil filter

Maintenance – XA(T,V)S 400 JD IT4 500 Hour service pack part number 1310 3004 47 Perform 50 hour service tasks Clean oil cooler, radiator, intercooler Lubricate door hinges Grease towing eye shaft or ball coupling and shaft Analyze coolant Replace/Check air filter elements Replace engine oil and filter Replace fuel filters

Maintenance – XA(T,V)S 400 JD IT4 1000 Hour service pack part number 1310 3004 48 Perform 500 hour service tasks Test safety valve and shut down switches Check all compressor Oil/Air hoses Replace separator element Replace compressor oil and spin on filter Replace blow down valve on unloader Assy. Clean flow restrictor in oil scavenge line

IT4 EXHAUST AFTERTREATMENT

IT4 Exhaust Aftertreatment Diesel Particulate Filter (DPF) Diesel Oxidation Catalyst (DOC)

XC2002 DPF Status Indicators

Stationary DPF Regeneration Go to the “STATION REGEN” screen. For normal operation this should be “OFF”. Press the “Enter” button. This function is not password protected. Use the up/down arrow to change the selection to “ON” and press the “Enter” button. Go to the “DPF” screen. For normal operation this should be in “AUTO” mode. Press the “ENTER” button. This is password protected. Enter “1968” This will set the unit up for manual regeneration; after a few moments, the regeneration icon should appear, confirming the unit is regenerating. After completion, Set both STATION REGEN to “OFF” and DPF to unit to “AUTO” mode. Atlas Copco recommends that the DPF configuration be left in the AUTO mode at all times; however, in the event that a stationary or manual regeneration is desired, the following process should be followed.

Committed to sustainable productivity.