Atlas Copco: XC 3003/4003 Controllers Scott Ellinger

Agenda Introduction Basic Functionality DPF interfacing Resetting Overhaul Timers Fault Codes Settings Programming

1. Introduction Type of controllers Xc 3003 Xc 4003 Is replacing the former S2 controller No oiltronix, no airXpert AC Part number: 1626 6000 00 Xc 4003 Is replacing the former S2 Drillair controller Including the Oiltronix and or AirXpert modules AC Partnumber Oiltronix: 1626 6002 00 AC Part number Oiltronix + AirXpert: 1626 6004 00

2. Basic Functionality Xc3003 v1.00.0 (r7307)

2. Basic Functionality: Buttons START BUTTON  This button will initiate the starting sequences if the controller is in Ready To Start Sequence, or will re-enter the normal running sequence when in Cool down Sequence. STOP BUTTON  This button will initiate the cool down/stopping sequences if the controller is in normal running sequence. LOAD BUTTON  This button will: - initiate the Auto Load function when the controller is in normal running sequence, but not ready to be loaded. - initiate the loading sequences when the controller is ready to be loaded. - initiate the not loaded sequence when the controller is running in Loaded Sequence. MEASUREMENTS VIEW BUTTON  This button will enter the Measurements View when not already in the Measurements View, or when already in the Measurements View it will enter the Main View. SETTINGS VIEW BUTTON  This button will enter the Settings View when not already in the Settings View, or when already in the Settings View it will enter the Main View. ALARMS VIEW BUTTON  This button will enter the Alarms View when not already in the Alarms View, or when already in the Alarms View it will enter the Main View. NAVIGATION BUTTONS  These buttons are used to navigate through the display menu’s. ENTER BUTTON  Confirms/stores the selection/change. BACK BUTTON  Moves back one level or ignores the change.

2. Basic Functionality: Main View Overhaul Indication Auto Load Indication DPF Regeneration Indication Preset Indication Main View Indication Main View Active Operation Mode Active Sequence LOADED Analog Vessel Pressure Indication 22.4 Fuel Level Value Vessel Pressure Value 41% 1286h 1300rpm 22.4bar Running Hours Value Engine rpm Value Alarm Indication

2. Basic Functionality: Measuring View Overhaul Indication Auto Load Indication DPF Regeneration Indication Preset Indication Measuring View Indication Measurements Active Operation Mode Active Sequence LOADED Running Hours 1286h ECU Engine rpm 1300 rpm ECU Requested Speed 1300 rpm Measured Values ECU DPF Soot Load 24 % Vessel Pressure 22.4 bar HP Element Temperature 101°C Ambient Temperature 27°C Fuel Level Value Vessel Pressure Value 41% 1286h 1300rpm 22.4bar Running Hours Value Engine rpm Value Alarm Indication Use the Up and Down navigation buttons to scroll through the full list of measurements.

2. Basic Functionality: Set Up View Auto Load Indication Overhaul Indication Preset Indication DPF Regeneration Indication Active Operation Mode Settings View Indication Settings Active Sequence LOADED 1000 GENERAL SETTINGS 2000 DIGITAL INPUTS 3000 VOLTAGE INPUTS 4000 TEMPERATURE INPUTS Parameter Menu’s 5000 RELAY OUTPUTS 5300 SEMICONDUCTOR OUTPUTS 6000 SYSTEM SETTINGS Vessel Pressure Value Fuel Level Value 41% 1286h 1300rpm 22.4bar Engine rpm Value Running Hours Value Alarm Indication Use the Up and Down navigation buttons to scroll through the full list of settings. Use the Enter button to enter the selected submenu. Use the Back button to leave the entered (sub) menu.

DPF Regeneration Indication 2. Basic Functionality: Alarm View Overhaul Indication Auto Load Indication DPF Regeneration Indication Preset Indication Alarm View Indication Alarms Active Operation Mode Active Sequence LOADED 3450 BATTERY LOW ALARM 2070 COOLANT LEVEL LOW 3010 FUEL LEVEL LOW ECU DM1 LIST Alarms & Alarm Menu’s ECU DM2 LIST EVENT LOG LIST ALARM LOG LIST Fuel Level Value Vessel Pressure Value 41% 1286h 1300rpm 22.4bar Running Hours Value Engine rpm Value Alarm Indication Use the Up and Down navigation buttons to scroll through the full list of alarms. The DM Lists and the Log Lists can be selected and entered to access the sub list.

2. Basic Functionality: Icons DPF REGENERATION ICON  High Exhaust System Temperature. Means that the Diesel Particle Filter is being regenerated. DPF REGENERATION ICON  Diesel Particle Filter Regeneration Forced. Means that there is a request to regenerate the DPF, which will start as soon as all criteria to do so is met. DPF REGENERATION ICON  Diesel Particle Filter Regeneration Inhibited. Means that the DPF regeneration is inhibited, even if all criteria to activate a regeneration is met. If the Xc controller has been powered down, it will automatically go to automatic DPF regeneration again and disable the DPF Regeneration Inhibit. OVERHAUL ICON  Initial Overhaul required. OVERHAUL ICON  Minor Overhaul required. OVERHAUL ICON  Major Overhaul required. AUTO LOAD ICON  This icon will be shown if the Auto Load function is enabled by pressing the load button before the machine is ready to be loaded. PRESET ICONS Depending of which Pressure (and/or Flow) setting is active, the controller will show its dedicated icon. OPERATION MODE ICONS  Local Remote PC Control Automatic Block Automatic Mode is active, but the Auto Start and Auto Stop functions are both inactive.

2. Basic Functionality: Icons ALARM ICON  Active & not-acknowledged Shutdown Alarm. ALARM ICON  Active & not-acknowledged Non-Shutdown Alarm. ALARM ICON  Active & acknowledged Alarm. FUEL TANK ICON  Running @ Internal Fuel tank. FUEL TANK ICON  Running @ Internal Fuel tank & Fuel pump is energized. FUEL TANK ICON  Running @ External Fuel tank, but Internal Fuel tank level is shown. FUEL TANK ICON  Running @ External Fuel tank, but Internal Fuel tank level is shown & Fuel pump is energized.

Switch on the battery switch. 2. Basic Functionality: Power ON Switch on the battery switch. Switch the controller on by switching the Xc3003/4003 Power Switch to the “ON” position. The instrument panel will now perform a self test and enter the INITIALIZING SEQUENCE.

2. Basic Functionality: Initializing Sequence Except for a power down, nothing can interrupt the INITIALIZING SEQUENCE before it has finished.   All buttons/inputs/outputs/alarms are inactive. Note: This view will be shown for at least 2s., this means that the INITIALIZING SEQUENCE will last for at least 2s.. Xc3003 v1.00.0 (r7307)

2. Basic Functionality: Vessel Blow Down Sequence As long as the measured Vessel Pressure is higher then 1.5bar, (22 psi) the controller will be locked in the VESSEL BLOW DOWN SEQUENCE. It is usually after the Stopping Sequence, that this sequence can be seen. At initial start up, the Vessel Pressure is normally low enough to skip this sequence. Note: If the Power Switch is turned to the “OFF” position while the Xc3003/4003 is in the Vessel Blow Down Sequence, it will not power down as long as the Vessel Pressure is higher than 1.5bar (22psi). MAIN VIEW VESSEL BLOWING DOWN 3.9 41% 1286h --RPM 3.9bar Active Buttons: Measurement View Button Settings View Button Alarms View Button

2. Basic Functionality: Ready To Start Sequence The machine is now ready to be started and is waiting for a start command. MAIN VIEW READY TO START 0.0 41% 1286h --RPM 0.0bar Active Buttons: Start Button (to initiate Start command) Load Button (to activate Automatic Load) Measurement View Button Settings View Button Alarms View Button

2. Basic Functionality: Prestart Sequence MAIN VIEW The horn will activate and the light will flash for 5s., to alert that the start sequence has begun. PREPARING FOR START 0.0 41% 1286h --RPM 0.0bar Active Buttons: Stop Button (to cancel Start command) Load Button (to activate Automatic Load) Measurement View Button Settings View Button Alarms View Button

2. Basic Functionality: Reading Engine Data Sequence MAIN VIEW READING ENGINE DATA The engine electronics (ECU) will be powered up. As soon as communication between Xc and ECU is established, the machine will preheat if the ECU decides to and for as long the ECU decides to. 0.0 41% 1286h --RPM 0.0bar MAIN VIEW Active Buttons: Stop Button (to cancel Start command) Load Button (to activate Automatic Load) Measurement View Button Settings View Button Alarms View Button ENGINE PREHEATING 0.0 41% 1286h --RPM 0.0bar

2. Basic Functionality: Cranking Sequence MAIN VIEW The engine cranks until 800rpm is reached. A Start Failure is generated if 800rpm is not reached within 30s.. When a Start Failure occurs, or if the Start command gets cancelled, the engine will go into Resting (time depends on the cranked time). ENGINE CRANKING 0RPM 800RPM 324RPM 41% 1286h 324RPM 0.0bar MAIN VIEW Active Buttons: Stop Button (to cancel Start command) Load Button (to activate Automatic Load) Measurement View Button Settings View Button Alarms View Button ENGINE RESTING 0s. 120s. 54s. 41% 1286h --RPM 0.0bar

2. Basic Functionality: Warming Up Sequence MAIN VIEW The engine will run at minimum rpm, until the engine’s coolant temperature reaches 40°C, (105F) with a minimum time of 15s. and a maximum time of 300s.. ENGINE WARMING UP 13°C 40°C 25°C 0s 300s 76s 41% 1286h 1200RPM 3.3bar MAIN VIEW Active Buttons: Stop Button (to cancel Start command) Load Button (to activate Automatic Load) Measurement View Button Settings View Button Alarms View Button ENGINE WARMING UP 0s. 15s. 7s. 41% 1286h 1200RPM 2.9bar

2. Basic Functionality: Not Loaded Sequence MAIN VIEW The machine is now ready to be loaded and is waiting for a load command. READY TO LOAD 4.6 41% 1286h 1200RPM 4.6bar Active Buttons: Stop Button (to cancel Start command) Load Button (to initiate Load command) Measurement View Button Settings View Button Alarms View Button

2. Basic Functionality: LOAD Prevention Sequence MAIN VIEW On two-stage units, when a load command is initiated, and the measured Vessel Pressure is lower then 4.5bar (65psi), the controller will run through a short sequence to try to reach the requested 4.5bar, in order to be able to load the machine. BUILDING UP VESSEL PRESSURE 3.9 41% 1286h 1200RPM 3.9bar Active Buttons: Stop Button (to cancel Start command) Load Button (to cancel Load command) Measurement View Button Settings View Button Alarms View Button

2. Basic Functionality: Preload Sequence MAIN VIEW The Load Valve is energized. The engine goes to maximum rpm and keeps running at maximum rpm during the rest of the Preload Sequence (7s.). PREPARING TO LOAD 4.7 41% 1286h 1800RPM 4.7bar Active Buttons: Stop Button (to cancel Start command) Load Button (to cancel Load command) Measurement View Button Settings View Button Alarms View Button

2. Basic Functionality: Loaded Sequence MAIN VIEW The Xc controls the speed of the engine in order to meet the requested working pressure, at the most economical fuel consumption. LOADED 18.6 41% 1286h 1424RPM 18.6bar Active Buttons: Stop Button (to cancel Start command) Load Button (to cancel Load command) Measurement View Button Settings View Button Alarms View Button

2. Basic Functionality: Cool down Sequence MAIN VIEW After a Stop command, or in case of a controlled stop alarm, the machine will go to Cool down Sequence and run at minimum rpm for 3 minutes before it will go to Stop Sequence. When in Cool down Sequence, if the DPF Soot Load is above 30%, the controller may ask the user if it is allowed to perform a complete DPF Regeneration cycle before stopping. ENGINE COOLING DOWN 0s 180s 1s Press ENTER to allow DPF regen before stop DPF Soot Load level 50 41% 1286h 1200RPM 19.4bar MAIN VIEW Active Buttons: Start Button (to initiate Start command) Measurement View Button Settings View Button Alarms View Button ENGINE COOLING DOWN 0s 180s 84s 41% 1286h 1200RPM 6.0bar

2. Basic Functionality: Stop Sequence MAIN VIEW The engine is stopped, and the Xc controller will double check to see if the engine is really stopped. ENGINE STOPPING 41% 1286h --RPM 5.3bar Active Buttons: Start Button (to initiate Start command) Measurement View Button Settings View Button Alarms View Button

2. Basic Functionality: Shutdown Sequence MAIN VIEW The machine is in shutdown, due to a critical alarm. SHUTDOWN 0.0 2000 EMERGENCY STOP Active Buttons: Measurement View Button Settings View Button Alarms View Button Enter Button (to acknowledge the shown alarm)

2. Basic Functionality: Power Off Switch the controller off by switching the Xc3003/4003 Power Switch to the “OFF” position. The compressor is equipped with a battery switch inside the canopy access doors. When the compressor is not in use, this switch must always be in the “OFF” position. Do not use this switch as an emergency switch or for stopping the compressor, it can cause damage to the Xc3003/4003 or the engine’s Electronic Control Unit. Always, shut the Xc3003/4003 off first and wait until the display is dark before switching the battery switch to the “OFF” position.

DPF Regeneration Indication 3. DPF: Automatic DPF Regeneration (default) When the Diesel Particle Filter Regeneration process is kept at its default ‘AUTOMATIC’ setting, the DPF Regeneration will be performed automatically when the Soot Load exceeds 60%. The Xc3003/4003 display will indicate an ongoing DPF Regeneration by showing the HEST Lamp Icon (High Exhaust System Temperature Lamp): DPF Regeneration Indication MAIN VIEW LOADED 18.6 41% 1286h 1424RPM 18.6bar The DPF Regeneration process will continue, until the Soot Load has become as low as possible, or until the engine is stopped. When the DPF Regeneration process is stopped, the HEST Lamp Icon will disappear from the display.

3. DPF: Automatic DPF Regeneration (default) In specific cases, when the engine speed is at a constant Minimum RPM, the DPF Regeneration could start at 30% Soot Load instead of the normal 60% (LSR = Low Speed Regeneration). This can happen in the following sequences: - Warming Up - Not Loaded - Unloaded (machine is loaded not making air) @ minimum RPM - Cool down When an LSR is in process and the soot load is less then 60%, and the engine speed changes (engine is stopped, machine gets loaded, …), the DPF Regeneration process will be stopped. If the Soot Load is higher then 30%, and the Cool down Sequence starts, the Xc may ask if you want to proceed with an LSR: MAIN VIEW If the Enter button is pressed within 10s. the Xc controller will allow the DPF Regeneration to be completed before the engine is stopped. Note: A full DPF Regeneration can take up to an hour. If the Enter button is not pressed (within 10s.), the engine will be stopped after the normal cool down sequence. ENGINE COOLING DOWN 0s 180s 1s Press ENTER to allow DPF regen before stop DPF Soot Load level 50 41% 1286h 1200RPM 19.4bar

3. DPF: Inhibit DPF Regeneration At Service Level, it is possible to change from Automatic DPF Regeneration to Inhibit DPF Regeneration. This might be necessary when running in an environment where an elevated exhaust temperatures is not allowed. To inhibit DPF Regeneration: Press the Settings View Button Enter the ‘1000 GENERAL SETTINGS’ menu Scroll one line down and Enter the ‘1140 ECU DPF REGENERATION’ menu Enter the ‘ENABLE’ parameter (only visible @ Service Level) Scroll up and change to ‘OFF’ setting Scroll down and Enter the ‘MODE’ parameter Scroll up and change to ‘FORCED OFF’ setting Press the Back button 3 times to get back to the Main View MAIN VIEW

DPF Regeneration Indication 3. DPF: Inhibit DPF Regeneration The Xc controller has now changed the DPF Regeneration to FORCED OFF mode, which will Inhibit DPF Regeneration. The Xc controller will now show the Inhibit DPF Icon: DPF Regeneration Indication MAIN VIEW READING ENGINE DATA 0.0 41% 1286h 0RPM 0.0bar When the Xc controller is powered down, and then turned back on it will reset back to the default settings of AUTOMATIC DPF MODE.

DPF Regeneration Indication 3. DPF: Increasing Soot Load When the DPF Regeneration is Inhibited, and the engine is not able to automatically perform a full DPF Regeneration, the Soot Load % will exceed the normal levels. This will be shown in different ways on the Xc display at different Soot Load % levels. SOOT LOAD reaches 80% The engine will communicate that a DPF REGENERATION IS NEEDED, and the Xc controller will show the DPF Regeneration Needed Icon: DPF Regeneration Indication If in DPF Regeneration Inhibited mode, the DPF Regeneration Needed Icon will overwrite the DPF Inhibited Icon. MAIN VIEW LOADED Required Action: Turn Inhibit DPF status off. Give the engine opportunity to perform a DPF Regeneration. When a DPF Regeneration is started, the DPF Regeneration Needed Icon will disappear and the HEST Lamp will pop-up. 18.6 41% 1286h 1424RPM 18.6bar

3. DPF: Increasing Soot Load SOOT LOAD reaches 85% The engine will communicate that a DPF REGENERATION IS NEEDED, in addition a ‘ECU DPF SOOT LOAD HIGH’ warning alarm will pop-up: DPF Regeneration Indication If in DPF Regeneration Inhibited mode, the DPF Regeneration Needed Icon will overwrite the DPF Inhibited Icon. MAIN VIEW LOADED Required Action: Acknowledge the ‘ECU DPF SOOT LOAD HIGH’ warning (press Enter while in the Main View). Turn Inhibit DPF status off. Give the engine opportunity to perform a DPF Regeneration. When a DPF Regeneration is started, the DPF Regeneration Needed Icon will disappear and the HEST Lamp will pop-up. 18.6 7100 ECU DPF SOOT LOAD HIGH DPF Soot Load High Warning

3. DPF: Increasing Soot Load SOOT LOAD reaches 90% The engine will communicate that a DPF REGENERATION IS NEEDED The ‘ECU DPF SOOT LOAD HIGH’ warning alarm will still be active. In addition a ‘PLEASE FORCE DPF REGENERATION !’ warning alarm will pop-up: The DPF Regeneration Needed Icon will overwrite the DPF Inhibited Icon. DPF Regeneration Indication MAIN VIEW Required Action: Acknowledge the ‘PLEASE FORCE DPF REGENERATION !’ warning (press Enter while in the Main View). Turn Inhibit DPF status off. Give the engine opportunity to perform a DPF Regeneration. When a DPF Regeneration is started, the DPF Regeneration Needed Icon will disappear and the HEST Lamp will pop-up. LOADED 18.6 7130 PLEASE FORCE DPF REGENERATION ! DPF Soot Load High Warning

3. DPF: Increasing Soot Load SOOT LOAD reaches 92% The engine will communicate that a DPF REGENERATION IS NEEDED. The ‘ECU DPF SOOT LOAD HIGH’ warning alarm will still be active. The ‘PLEASE FORCE DPF REGENERATION !’ warning alarm will still be active. In addition a ‘LOAD PREVENTION – HIGH DPF SOOT LOAD’ alarm will pop-up, preventing the machine from entering the Loaded Sequence: The DPF Regeneration Needed Icon will overwrite the DPF Inhibited Icon. DPF Regeneration Indication MAIN VIEW Required Action: Acknowledge the ‘LOAD PREVENTION – HIGH DPF SOOT LOAD’ inhibit load alarm (press Enter while in the Main View). Turn Inhibit DPF status off. Give the engine opportunity to perform a DPF Regeneration. When a DPF Regeneration is started, the DPF Regeneration Needed Icon will disappear and the HEST Lamp will pop-up. LOADED 18.6 7110 LOAD PREVENTION - HIGH DPF SOOT LO… DPF Soot Load High Warning

DPF Soot Load High Alarm 3. DPF: Increasing Soot Load SOOT LOAD reaches 95% The engine will communicate that a DPF REGENERATION IS NEEDED. The ‘ECU DPF SOOT LOAD HIGH’ warning alarm will still be active. The ‘PLEASE FORCE DPF REGENERATION !’ warning alarm will still be active (@ Inhibited DPF Regen). The ‘LOAD PREVENTION – HIGH DPF SOOT LOAD’ inhibit load alarm will still be active. In addition a ‘SOOT LOAD TOO HIGH – CALL ATLAS COPCO’ controlled stop alarm will pop-up, which will stop the machine after cool down: MAIN VIEW As soon as the engine is stopped, the DPF Regeneration Needed Icon will disappear. SHUTDOWN Note: At this point the machine will not load and will only run at idle. When it reaches 101% Soot Load the engine will shut down (engine electronics will powered down). . 18.6 7120 SOOT LOAD TOO HIGH – CALL ATLAS CO… DPF Soot Load High Alarm

3. DPF: Force DPF Regeneration If DPF Regeneration is Inhibited Machine is not running: Power the Xc controller down. At next power up, the DPF Regeneration settings will be back to default, and an Automatic DPF Regeneration will take place at the soonest appropriate moment. Machine is running: Press the Settings View Button Enter the ‘1000 GENERAL SETTINGS’ menu Scroll one line down and Enter the ‘1140 ECU DPF REGENERATION’ menu Scroll down and Enter the ‘MODE’ parameter Scroll down and Enter the ‘AUTOMATIC’ setting Press the Back button 3 times to get back to the Main View MAIN VIEW

3. DPF: Service Regeneration When the ‘SOOT LOAD TOO HIGH – CALL ATLAS COPCO’ controlled stop alarm is active, a technician needs to be called to perform a Service Regeneration. Following sequence needs to be followed (only possible with Service Level key 1626624500 inserted): Press the Settings View Button Scroll down and Enter the ‘7000 COMMUNICATIONS’ menu Scroll down to the ‘7100 DPF Soot Load’ setting, and change it to Off Scroll down to the ‘7140 Service Regen’ setting, and change it to On Back out and scroll up; enter the 1000 menu Scroll down to the ‘1130 ECU Station Regen’ setting, and change it to On Scroll down to the ‘1140 ECU DPF Regen’ setting, and change it to Forced Press the Back button 3 times to get back to the Main View Start the unit up and allow it to run; it will run a regeneration cycle and the soot load should be decreasing on the monitored parameter. The ‘SOOT LOAD TOO HIGH – CALL ATLAS COPCO’ controlled stop alarm is suppressed, and a technician can perform a Service DPF Regeneration. The machine will run in Not Loaded Sequence until the DPF Regeneration cycle is completely finished. This may take several hours depending on conditions. MAIN VIEW

4. Resetting Service Timers

4. Resetting Service Timers

4. Resetting Service Timers

5. Fault Codes: Acknowledging Alarms

5. Fault Codes: List

5. Fault Codes: List

6. Settings

7.Programing: Start-up PARUS After installation of PARUS, connect PC to Xc Hardware key Service 1626 6245 00 Start PARUS via the application launcher First start–up, select correct communication port via ‘connection settings’ Click ‘Ok’ and ‘Connect’, the application launcher will connect via the selected port to the controller with the proper PARUS version (PARUS 3 for Xc3003 and Xc4003) MAIN VIEW

7. Programming: Flash and download Flash file = Firmware Project file = unique per unit type and controller variant Flash and download MAIN VIEW

7. Programming: Flash and download Update machine info via ‘Production’ tab Machine data Denomination selection (l/s or cfm) Compressor serial number Engine serial number Construction date Machine options MAIN VIEW

7. Programming: Resetting Start PARUS 3 Click the yellow lightning (Write a firmware to the device) Click ‘YES’ Select ‘Xc4003’ or ‘Xc3003, depending on the controller type and click ‘OK’. Neglect message ‘communication error’ Select the required Firmware. Click ‘Open’ MAIN VIEW

7. Programming: Resetting Click ‘Yes’ Wait 1 to 2 minutes while the application software is loaded Click ‘OK’ 9. Click ‘YES’ ‘OK’ , neglect message ‘communication error’ 10. The controller is reset and connected

Contact Numbers Main Number Atlas Copco Technical Support: 800-732-6762 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) Nicholas Ihnat – Generators 623-879-3718 direct Brandon Hobbs – Hydraulic Attachments /Handheld Construction Tools – Supervisor 303-287-8822 direct & 913-424-4039 mobile Jim Richmeier – Hydraulic attachments/Handheld Construction Tools 303-217-2802 direct & 720-670-7189 mobile Al Eckenfels – Hydraulic Attachments/Handheld Construction Tools 800-760-4049 & 216-816-6264 mobile

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