Documente Academic
Documente Profesional
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Original instructions
Printed matter N°
2954 5440 02 ATLAS COPCO - PORTABLE ENERGY DIVISION
07/2013 www.atlascopco.com
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INTRODUCTION
The policy of Atlas Copco is to provide the users of It is the responsibility of management to appoint Take necessary steps to keep unauthorized persons
their equipment with safe, reliable and efficient operators with the appropriate training and skill for away from the unit and eliminate all possible sources
products. Factors taken into account are among each category of job. of danger at the unit.
others:
Skill level 1: Operator When handling, operating, overhauling and/or
- the intended and predictable future use of the performing maintenance or repair on Atlas Copco
products, and the environments in which they are An operator is trained in all aspects of operating the
unit with the push-buttons, and is trained to know the equipment, the mechanics are expected to use safe
expected to operate, engineering practices and to observe all relevant local
- applicable rules, codes and regulations, safety aspects.
safety requirements and ordinances. The following
- the expected useful product life, assuming proper Skill level 2: Mechanical technician list is a reminder of special safety directives and
service and maintenance, A mechanical technician is trained to operate the unit precautions mainly applicable to Atlas Copco
- providing the manual with up-to-date the same as the operator. In addition, the mechanical equipment.
information. technician is also trained to perform maintenance and These safety precautions apply to machinery
Before handling any product, take time to read the repair, as described in the instruction manual, and is processing or consuming air. Processing of any other
relevant instruction manual. Besides giving detailed allowed to change settings of the control and safety gas requires additional safety precautions typical to
operating instructions, it also gives specific system. A mechanical technician does not work on the application and are not included herein.
information about safety, preventive maintenance, live electrical components.
etc. Neglecting the safety precautions may endanger
Skill level 3: Electrical technician people as well as environment and machinery:
Keep the manual always at the unit location, easy An electrical technician is trained and has the same - endanger people due to electrical, mechanical or
accessible to the operating personnel. qualifications as both the operator and the mechanical chemical influences,
See also the safety precautions of the engine and technician. In addition, the electrical technician may - endanger the environment due to leakage of oil,
possible other equipment, which are separately sent carry out electrical repairs within the various solvents or other substances,
along or are mentioned on the equipment or parts of enclosures of the unit. This includes work on live - endanger the machinery due to function failures.
the unit. electrical components. All responsibility for any damage or injury resulting
These safety precautions are general and some Skill level 4: Specialist from the manufacturer from neglecting these precautions or by non-
statements will therefore not always apply to a This is a skilled specialist sent by the manufacturer or observance of ordinary caution and due care required
particular unit. its agent to perform complex repairs or modifications in handling, operating, maintenance or repair, also if
Only people that have the right skills should be to the equipment. not expressly mentioned in this instruction manual, is
allowed to operate, adjust, perform maintenance or disclaimed by Atlas Copco.
In general it is recommended that not more than two
repair on Atlas Copco equipment. people operate the unit, more operators could lead to
unsafe operating conditions.
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The XAMS 527 - XAMS 1150 is a silenced, single- Engine Compressor oil system
stage, oil-injected screw compressor, built for a
The compressors are driven by a 6 cilinder in-line The oil is boosted by air pressure. The system has no
nominal effective working pressure of 8.6 bar liquid-cooled diesel engine. oil pump.
(125 psi).
The engine’s power is transmitted to the compressor The oil is removed from the air, in the air/oil vessel at
The XATS 487 - XATS 1050 is a silenced, single- element through a heavy-duty coupling. first by centrifugal force, secondly by the oil separator
stage, oil-injected screw compressor, built for a
element.
nominal effective working pressure of 10.3 bar Compressor
(150 psi). The vessel is provided with an oil level indicator.
The compressor casing houses two screw-type rotors,
The XAHS 447 - XAHS 950 is a silenced, single- mounted on ball and roller bearings. The male rotor, Regulation
stage, oil-injected screw compressor, built for a driven by the engine, drives the female rotor. The
nominal effective working pressure of 12 bar The compressor is provided with a continuous
compressor delivers pulsation-free air. pneumatic regulating system and a blow-off valve
(175 psi).
Injected oil is used for sealing, cooling and which is integrated in the unloader assembly. The
The XAVS 407 - XAVS 900 is a silenced, single- lubricating purposes. valve is closed during operation by air receiver
stage, oil-injected screw compressor, built for a pressure and opens by air receiver pressure via the
nominal effective working pressure of 14 bar compressor element when the compressor is stopped.
(200 psi).
When the air consumption increases, the air receiver
pressure will decrease and vice versa.
This receiver pressure variation is sensed by the
regulating valve which, by means of control air to the
unloader and an electronic engine speed regulator,
matches the air output to the air consumption. The air
receiver pressure is maintained between the pre-
selected working pressure and the corresponding
unloading pressure.
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(SV)
(WPS)
(ATS)
(AR) (TB)
(H)
(IC)
(FL)
(MPV) (SN)
(CU) (ES)
(CP)
(FLG) (AFS)
(RV)
(LV)
(ES)
(AOV)
(F)
(CE) (A)
(FT) (E)
(DPar)
(DPce) (FLS)
(FPco) (ETS) (FCft) (FFac)
(DPeo)
(F1)
(DPoc) (RPS)
(DPr)
(OLG) (RS) (CB)
(CBE)
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OVERVIEW
(CY)
Reference Name
AFce Air Filter (compr. element)
AFe Air Filter (engine)
(SC)
AFS Air Filter Switch
(AFce) AOV Air Outlet Valves
AR Air Receiver
BOV Blow Off Valve
(AFe) (AFS)
BVof Bypass Valve oil filter
(SV)
(CU) C Coupling
(VV) (BVof)
(WPS) (OFce)
CBE Cubicle for Electrical devices
(AR) (OC)
(FR) CE Compressor Element
CU Control Unit
(DP)
CV Check Valve
(SL)
CY Cylinder (EC)
(WPG) (OS) (TBV)
(F) DP Drain Plug
(MPV) (UA)
(FPco) (TV) E Engine
(OLG) F Fan
(RV) (BOV) F1 Fuse
(LV) FPco Filler Plug (oil compressor element)
(RPS)
(E) FR Flow Restrictor
(CV) (C) LV Loading Valve
(TS) (VH) (DP)
(TS) MPV Minimum Pressure Valve
(AOV)
(CE) OC Oil Cooler
(DP) OFce Oil Filter (compressor element)
(PS) (F1)
(OSV)
(CBE) (DP)
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Air drawn through the airfilter (AFce) into the When the compressor is stopped and / or there is no
Reference Name compressor element (CE) is compressed. At the pressure in the system, the oil stop valve (OSV)
OLG Oil Level Gauge element outlet, compressed air and oil pass into the air prevents the oil from flowing back into the
receiver/oil separator (AR/OS). compressor element.
OS Oil Separator
OSV Oil Stop Valve The check valve (CV) prevents blow-back of The thermostatic by-pass valve (TBV) starts opening
compressed air when the compressor is stopped. In when the oil temperature is 80°C (176°F).
PS Pressure Sensor the air receiver/oil separator (AR/OS), most of the oil
The compressor element has an oil gallery in the
RPS Regulating Pressure Sensor is removed from the air/oil mixture. bottom of its casing. The oil for rotor lubrication,
RV Regulating Valve The oil collects in the receiver and on the bottom of cooling and sealing is injected through holes in the
the separator element. gallery.
SC Safety Cartridge
The air leaves the receiver via a minimum pressure Lubrication of the bearings is ensured by oil injected
SL Scavenge Line
valve (MPV) which prevents the receiver pressure into the bearing housings.
SV Safety Valve from dropping below the minimum working pressure,
The injected oil, mixed with the compressed air,
TBV Thermostatic Bypass Valve even when the air outlet valves are open (specified in
leaves the compressor element and re-enters the air
section Limitations). This ensures adequate oil receiver, where it is separated from the air as
TS Temperature Sensor injection and prevents oil consumption. The
described in section Air flow. The oil that collects on
TV Throttle Valve minimum pressure valve (MPV) also functions as a
the bottom of the oil separator element is returned to
check valve. the system through a scavenging line (SL), which is
UA Unloader Assembly
The system comprises temperature sensors (TS), provided with a flow restrictor (FR).
VH Vent Hole
pressure sensors (PS) and a working pressure sensor The oil filter by-pass valve opens when the pressure
VV Vacuator Valve (WPS).
drop over the filter is above normal because of a
WPG Working Pressure Gauge clogged filter. The oil then by-passes the filter
WPS Working Pressure Sensor without being filtered. For this reason, the oil filter
OIL SYSTEM must be replaced at regular intervals (see section
Preventive maintenance schedule).
The lower part of the air receiver (AR) serves as an oil
tank.
Air pressure forces the oil from the air receiver/oil
separator (AR/OS) through the oil cooler (OC), the oil
filters (OF) and the oil stop valve (OSV) to the
compressor element (CE).
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(AFce)
(BVof)
(WPS) (OFce) (OC)
(AR)
(FR)
(SL)
(TBV)
(OS)
(MPV) (UA)
(TV)
(RV) (BOV)
(CV)
(TS) (VH)
(TS)
(CE)
(PS) (OSV)
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Tag Desc. 1 Desc. 2 Location Sheet/ Tag Desc. 1 Desc. 2 Location Sheet/
Col. Col.
B1 Namur sensor Bypass Optional 07/6 PS1 Pressure switch Air filter 05/3
B2 Namur sensor Closed Optional 07/6 PT1 Pressure sensor Vessel pressure Machine 05/2
B3 Combo sensor Optional 07/4 PT2 Pressure sensor Regulating pressure Machine 05/3
G1 Battery Machine 03/1 PT3 Pressure sensor Oil Stop valve pressure Machine 05/4
G2 Battery Machine 03/1 PT4 Pressure sensor Interstage pressure Machine 05/5
G3 Alternator Engine 03/3 PT5 Pressure sensor Air discharge pressure Optional 06/5
H1 Horn Machine 05/2 Q1 Circuit breaker 15A Main Machine 03/8
H2 Lamp Flasher light Machine 05/2 Q13 Circuit breaker 60A Alternator Machine 03/2
K0 Relay Starter motor Engine 03/2 Q2 Circuit breaker 10A Engine Machine 03/3
K1 Relay Auxilary starter 05/1 Q3 Circuit breaker 10A Engine Machine 03/4
K10 Relay Remote control Option box 06/7 Q4 Circuit breaker 10A Engine Machine 03/4
K3 Relay Refuel pump Optional 06/2 Q5 Circuit breaker 10A Engine Machine 03/4
K4 Relay Etherstart Optional 06/6 Q6 Circuit breaker 10A Refuel pump Machine 06/1
K5 Relay Refinary equipment Optional 06/4 Q9 Circuit breaker 10A Preheater Optional 07/1
K8 Relay Heater Optional 07/3 R1 Resistor 120 Ohm Can J1939 Machine 03/6
LS1 Level switch Coolant level warning Machine 05/6 R2 Resistor Preheater Optional 07/2
LS2 Level switch Coolant level shutdown Machine 05/7 S1 Switch Battery Machine 03/1
LT1 Level sensor Fuel level Machine 05/5 S2 Switch Emergency Machine 03/9
M1 Motor Engine 03/2 TT1 Temperature sensor LP Element temperature Machine 05/5
M2 Pump Refueling Optional 06/1 TT2 Temperature sensor HP Element temperature Machine 05/6
M4 Pump Preheater Optional 07/3 TT3 Temperature sensor Ambient temperature Machine 05/7
M5 Stepper motor Oiltronix Optional 07/7 TT4 Temperature sensor Aftercooler air discharge Optional 07/5
temperature
N1 Connector ECU Machine 03/3
TT5 Temperature sensor Air discharge temperature Optional 06/6
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1 2 3 4 5 6 7 8 9 10
9822 0963 49
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1 2 3 4 5 6 7 8 9 10
9822 0963 49
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1 2 3 4 5 6 7 8 9 10
9822 0963 49
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1 2 3 4 5 6 7 8 9 10
9822 0963 49
G
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1 2 3 4 5 6 7 8 9 10
9822 0963 49
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Atlas Copco mineral engine oil. Warning! Part under pressure. Filler cap coolant.
4 bar
Rotation direction. (58 psi) Tyre pressure.
6 bar
Inlet. (87 psi) Tyre pressure.
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Safety precautions
(2)
The operator is expected to apply all
relevant Safety precautions.
(3)
(4)
Attention
(5)
Before putting the compressor into use, (6)
check the brake system as described in (1)
section Brake shoe adjustment (no ABS).
After the first 100 km travel:
Uncouple vehicle. At compressors equipped with Locate the rear-end of the compressor upwind, away
Check and retighten the wheel nuts and ABS brakes the brakes will be activated. from contaminated wind-streams and walls. Do not
towbar bolts to the specified torque. See obstruct air evacuation from the cooling system.
section Torque values. It is not allowed to leave ABS-equipped Avoid recirculation of exhaust air from the engine.
compressors parked for a long period This can cause overheating and engine power
Check the brake adjustment. See section with pressure engaged brakes only. Also
Brake shoe adjustment (no ABS). decrease.
use the parking brake.
Apply parking brake by moving the lever (1) in the
When towing, lifting or transporting the direction of the arrow.
compressor in any way, the battery
switch must always be switched off. Connect the safety chain (2) to the eyes (3) on the
towbar (4). You can move the towbar (4) upwards and
Also switch off the preheater as this unit secure it by connecting the chain (5) to the eye (6).
is directly connected to the batteries.
Place the compressor as level as possible; however, it
can be operated temporarily in an out-of-level
position not exceeding 15°. If the compressor is
parked on sloping ground, immobilize the compressor
by placing wheel chocks (available as option) in front
of or behind the wheels.
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(1)
10˚
(2) 10˚
+
(1)
-
(2)
Before towing the compressor, ensure When equipped with ABS: The towbar of the wagon is equipped with an
that the towing equipment of the vehicle Before moving the unit without connecting the adjustable spring loaded levelling device.
matches the towing eye. The height of brake pressure lines, pressure has to be released To adjust:
the towing device of the vehicle must be from the ABS brake system by pushing button (3).
815 - 845 mm (31.8 - 33 in). 1. Slide back the rubber bellows (1).
If the ABS vessel is under pressure it is possible to
2. Turn the nut (2) clockwise to increase the spring
1. Attach the compressor to the towing vehicle. put pressure back on the brakes by pulling button
load for lifting the towbar; turn the nut (2) counter
(3). clockwise to decrease the spring load for lowering
2. Connect the brake pressure lines (when equipped
with ABS). When towing a compressor equipped the towbar.
with tandem axles, take care that the 3. Slide the bellows (1) over the nut.
3. Move hand brake lever (1) in the direction of the angle between compressor and towing
arrow till stop and connect the breakaway chain vehicle does not exceed 10° (see picture)
(2) to the towing vehicle.
Never move the compressor with air hoses connected
to the air outlet valves.
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Reference Name
Start button
Pressing this button will start the compressor.
Stop button
Pressing this button will stop the compressor in a controlled way.
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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.
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During operation
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Reference Name
1 Compressor status
2 Vessel pressure indication or info
text
3 Compressor info
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Use the Up and Down navigation buttons to scroll Use the Up and Down navigation buttons to scroll
through the full list of settings. through the full list of alarms.
Measuring View
Use the Enter button to enter the selected submenu. The DM Lists and the Log Lists can be selected and
entered to access the sublist.
Use the Back button to leave the entered (sub)menu.
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The actual vessel pressure is shown. If the measured The machine is now ready to be started and is waiting
vessel pressure is higher than 1.5 bar, the unit will not for a start command.
Xc3003 start. The vessel pressure has to be lowered by
v1.00.0 (r7307) opening the blow down valve. After power up, the Active Buttons
vessel pressure normally is low enough to proceed
with the starting procedure. Start Button
(to initiate Start command)
If the Power switch is turned to the
During initializing all buttons/inputs/outputs/alarms “OFF” position while the vessel is
are inactive. blowing down, it will not power down for Load Button
This view will be shown for about 2 seconds, after as long as the vessel pressure is higher (to activate Automatic Load)
which the display will show the Main View. than 1.5 bar.
Measurement View Button
Active Buttons
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After pressing the Start button the machine will The engine electronics (ECU) will be powered up.
activate its horn and flasher light for 5 seconds, to Active Buttons
As soon as communication between compressor
notify that it will start. controller and engine controller is established, the
Stop Button
machine will preheat according to the parameters of
Active Buttons (to cancel Start command)
the engine controller.
Stop Button Load Button
(to cancel Start command) (to activate Automatic Load)
Load Button
(to activate Automatic Load) Measurement View Button
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The engine cranks until 800 rpm is reached. The engine will run at minimum rpm, until the
Active Buttons engine’s coolant temperature reaches 40°C, with a
If 800 rpm is not reached within 30 seconds, the
starting procedure is cancelled and the engine will minimum time of 15 seconds and a maximum time of
Stop Button 300 seconds.
rest for some time. (Resting time depends on cranking
(to cancel Start command)
time).
Load Button
(to activate Automatic Load)
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When the load button is pressed and the measured The loading valve will be energized and pressure The controller controls the speed of the engine in
vessel pressure is lower then 4.5 bar, the controller starts building up. order to meet the requested working pressure, at the
will run a specific program to reach the requested most economical fuel usage.
4.5 bar, in order to be able to load the machine. (Only Active Buttons
applicable for 2-stage machines). Active Buttons
Stop Button
Active Buttons (to cancel Start command) Stop Button
(to cancel Start command)
Stop Button
(to cancel Start command) Load Button
(to cancel Load command) Load Button
(to cancel Load command)
Load Button
(to cancel Load command) Measurement View Button
Measurement View Button
Measurement View Button
Settings View Button
Settings View Button
Settings View Button
Alarms View Button
Alarms View Button
Alarms View Button
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5 4 3
To use remote control, the controller must be set for
remote operation and the power switch on the control
panel must be off.
1. On / off
2. Control light
3. Start engine
4. Stop engine
5. Load/unload compressor
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0.0
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Details of ECU triggered alarms can be monitored via the ECU DM1 LIST menu
In case of ECU AMBER LAMP or ECU PROTECT For following alarms, the Xc controller also shows full ECU - AMBIENT AIR TEMPERATURE
LAMP: text next to the SPN code: ECU - AIR INLET TEMPERATURE
Only possible when engine is running or if ECU - FUEL FILTER PRESSURE ECU - FUEL TEMPERATURE
Diagnostics Mode is active. ECU - INTERCOOLER TEMPERATURE ECU - OIL TEMPERATURE
Access the ECU DM1 LIST menu via Alarm View. ECU - FUEL PRESSURE ECU - ENGINE SPEED
ECU - FUEL FILTER PRESSURE ECU - INJECTOR 1
In case of ECU RED LAMP: ECU - WATER IN FUEL ECU - INJECTOR 2
Do NOT acknowledge the ECU RED LAMP alarm. ECU - OIL LEVEL ECU - INJECTOR 3
DM1 alarms are automatically copied into the ECU - OIL FILTER PRESSURE ECU - INJECTOR 4
Alarm View, and can be read there. ECU - OIL PRESSURE ECU - INJECTOR 5
ECU - TURBO BOOST PRESSURE ECU - INJECTOR 6
For all ECU triggered alarms, the respective SPN code ECU - TURBO OIL PRESSURE ECU - INJECTOR 7
is shown in the ECU DM1 LIST ECU - INTAKE MANIFOLD TEMPERATURE ECU - INJECTOR 8
A full list of supported SPN codes is provided by the ECU - AIR INLET PRESSURE
engine manufacturer. ECU - SOOT LOAD
ECU - COOLANT TEMPERATURE
ECU - COOLANT LEVEL
ECU - SUPPLY VOLTAGE
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The order number of the Service Paks are listed in the Run the compressor regularly, e.g. twice a week, until
Atlas Copco Parts List (ASL). warm.
Load and unload the compressor a few times to
operate the unloading and regulating components.
Use of service paks
Close the air outlet valves after stopping.
Service Paks include all genuine parts needed for
normal maintenance of both compressor and engine. If the compressor is going to be stored
without running from time to time,
Service Paks minimize downtime and keep your protective measures must be taken.
maintenance budget low.
Order Service Paks at your local Atlas Copco dealer.
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Notes
1. More frequently when operating in a dusty environment. Keep the bolts of the housing, the lifting
2. Refer to engine operation manual. eye, the towbar and the axle securely
tightened.
3. After a day’s work.
Refer to section Technical specifications
4. Yearly is only valid when using PARCOOL. Change coolant every 5 years. for the torque values.
5. Use Atlas Copco oil filters, with by-pass valve as specified in the parts list.
6. Gummed or clogged filters means fuel starvation and reduced engine performance.
7. See section Oil specifications.
8. The following part numbers can be ordered from Atlas Copco to check on inhibitors and freezing
points:
2913 0028 00 : refractometer
2913 0029 00 : pH meter.
9. See section Safety valve.
10. See section Before starting.
11. Replace all rubber flexibles every 6 years.
12. For other specific engine and alternator requirements refer to specific manuals.
13. 250 hours is only valid when using PAROIL E or PAROIL E xtra.
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It is strongly recommended to use Atlas PAROIL from Atlas Copco is the ONLY oil tested PAROIL releases excess heat efficiently, whilst
Copco branded lubrication oils for both and approved for use in all engines built into Atlas maintaining excellent bore-polish protection to limit
compressor and engine. Copco compressors and generators. oil consumption.
Extensive laboratory and field endurance tests on PAROIL has an excellent Total Base Number (TBN)
Atlas Copco equipment have proven PAROIL to retention and more alkalinity to control acid
Only use synthetic compressor oil. match all lubrication demands in varied conditions. It formation.
meets stringent quality control specifications to
PAROIL prevents Soot build-up
ensure your equipment will run smoothly and
High-quality, mineral, hydraulic or synthesized reliably. PAROIL is optimized for the latest low emission
hydrocarbon oil with rust and oxidation inhibitors, EURO -3 & -2, EPA TIER II & III engines running on
The quality lubricant additives in PAROIL allow for
anti-foam and anti-wear properties is recommended. low sulphur diesel for lower oil and fuel consumption.
extended oil change intervals without any loss in
The viscosity grade should correspond to the ambient PAROIL E xtra is a Synthetic ultra high performance
performance or longevity.
temperature and ISO 3448, as follows: diesel engine oil with a high viscosity- index. Atlas
PAROIL provides wear protection under extreme Copco PAROIL E xtra is designed to provide
conditions. Powerful oxidation resistance, high
Never mix synthetic with mineral oil. excellent lubrication from start-up at temperatures
chemical stability and rust- inhibiting additives help
as low as -25°C (-13°F).
Remark: reduce corrosion, even within engines left idle for
extended periods. PAROIL E is a mineral based high performance
After a complete change over to diesel engine oil with a high viscosity- index. Atlas
synthetic oil (or the other way around), PAROIL contains high quality anti-oxidants to Copco PAROIL E is designed to provide a high level
you will need to do an extra rinse: control deposits, sludge and contaminants that tend to
of performance and protection under 'standard'
build up under very high temperatures. PAROIL's
After doing the complete change ambient conditions from -15°C (5°F) onward.
detergent additives keep sludge forming particles in a
procedure to synthetic oil, run the unit fine suspension, instead of allowing them to clog your
for a few minutes to allow proper and filter and accumulate in the valve/rocker cover area.
complete circulation of the synthetic oil.
Then drain the synthetic oil again and
fill again with new synthetic oil. To set
correct oil levels, follow the normal
instructions.
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PAROIL S xtreme
PAROIL S
10˚ C 50˚ F
Synthetic compressor oil PAROIL S xtreme
-0˚ C 32˚ F
Liter US gal Order number
-10˚ C 14˚ F
can 20 5.3 1630 0180 00
-20˚ C -4˚ F
barrel 210 55.2 1630 0181 00
-30˚ C -22˚ F
-40˚ C -40˚ F
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PAROIL EXTRA
PAROIL E
PAROIL E
-40˚ C -40˚ F
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(3)
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(1)
(2)
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Not respecting compressor oil changing 4. Check the interior of the oil vessel (see pictures).
intervals in accordance with the If varnish deposits are discovered, contact Atlas
maintenance schedule, can lead to Copco Service dept. and do not continue.
serious problems, including fire hazard! 5. Put in a new oil separator, screw on new
The manufacturer does not accept any compressor oil filter(s) and close the oil vessel
liability for damage arising from not according to the instructions.
following the maintenance schedule or
not using genuine parts. 6. Fill the oil vessel with the minimum amount of
replacement oil, run the compressor under light
To avoid problems when changing over to a new type load conditions for 30 minutes.
of oil (see table) a special Compressor Oil Flushing 7. Thoroughly drain the system when the oil is
Procedure has to be followed. The procedure is only warm, leaving as little oil in the system as
valid in case the replaced oil has not exceeded its possible, especially in dead areas, if possible blow
lifetime. For more information consult Atlas Copco Vessel cover
out remaining oil by pressurising the oil. contaminated clean
Service dept.
8. Fill the system with the final oil charge.
Aged oil can be recognized best by using an oil
sampling analysis program. Indicators for aged oil are 9. Run the compressor under light load conditions
strong smell, or contamination such as sludge and for 15 minutes and check for leakage.
varnish inside the oil vessel and oil stop valve or a 10. Check the oil level and top up if necessary.
brownish colour of the oil.
11. Collect all waste lubricant used during the
Whenever aged oil is discovered, eg. when changing flushing process and dispose of it in accordance
the oil separator, contact Atlas Copco Service dept. to with the applicable procedures for managing
have your compressor cleaned and flushed. waste lubricant.
1. First thoroughly drain the system when the oil is
warm, leaving as little oil in the system as
possible, especially in dead areas, if possible blow
out remaining oil by pressurising the oil system. Vessel
Check the instruction manual for detailed contaminated clean
description.
2. Remove the compressor oil filter(s). PAROIL M PAROIL S PAROIL S xtreme
3. Open the oil vessel and remove the oil separator PAROIL M draining * flushing flushing
element. PAROIL S draining ** draining * draining
Instructions on replacing the oil PAROIL S xtreme draining ** draining draining *
separator element are available from
* When changing over to the same oil within the oil changing interval, draining is sufficient
Atlas Copco Service dept.
** Change over not recommended
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PARCOOL EG is the only coolant that has been Because PARCOOL EG inhibits corrosion, deposit
Never remove the cooling system filler tested and approved by all manufacturers of formation is minimized. This effectively eliminates
cap while coolant is hot. engines currently used in Atlas Copco flow restriction problems through the engine coolant
The system may be under pressure. compressors and generators. ducts and the radiator, minimizing the risk of engine
Remove the cap slowly and only when overheating and possible failure.
Atlas Copco's PARCOOL EG extended life coolant is
coolant is at ambient temperature. A the new range of organic coolants purpose-designed It reduces water pump seal wear and has excellent
sudden release of pressure from a heated to meet the needs of modern engines. PARCOOL EG stability when subjected to sustained high operating
cooling system can result in personal can help prevent leaks caused by corrosion. temperatures.
injury from the splash of hot coolant. PARCOOL EG is also fully compatible with all
PARCOOL EG is free of nitride and amines to protect
sealants and gasket types developed to join different
your health and the environment. Longer service life
It is strongly recommended to use Atlas materials used within an engine. reduces the amount of coolant produced and needing
Copco branded coolant. PARCOOL EG is a ready to use Ethylene Glycol disposal to minimise environmental impact.
based coolant, premixed in an optimum 50/50
The use of the correct coolant is important for proper dilution ratio, for antifreeze protection guaranteed to
heat transfer and protection of liquid-cooled engines. -40°C (-40°F).
Coolants used in these engines must be mixtures of
good quality water (distilled or de-ionised), special
coolant additives and anti-freeze, if required. Coolant
that is not to manufacturer's specification will result PARCOOL EG
in mechanical damage of the engine.
Liter US gal Order number
The freezing point of the coolant must be lower than
the freezing point that can occur in the area. The can 5 1.3 1604 5308 00
difference must be at least 5°C (9°F). If the coolant can 20 5.3 1604 5307 01
freezes, it may crack the cylinder block, radiator or
coolant pump. barrel 210 55.2 1604 5306 00
Consult the engine's operation manual and follow the To ensure protection against corrosion, cavitation and formation of deposits, the concentration of the additives
manufacturer's directions. in the coolant must be kept to certain limits, as stated by the manufacturer's guidelines. Topping up the coolant
with water only, changes the concentration and is therefore not allowed.
Never mix different coolants and mix the
Liquid-cooled engines are factory-filled with this type of coolant mixture.
coolant components outside the cooling
system.
PARCOOL EG Concentrate
Liter US gal Order number
can 5 1.3 1604 8159 00
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- 70 -
Corrections concentrate in measured system towards 50% volume by using PARCOOL EG Concentrate
5,5 1
5,0 2
4,5
Top-up volume (liter)
4,0
3,5
3
3,0
2,5
2,0
4 1. Refractometer indication -20° C (33%)
1,5
2. Refractometer indication -22° C
1,0
3. Refractometer indication -25° C
0,5 4. Refractometer indication -30° C
5
0,0 5. Refractometer indication -36° C
4 5 6 7 8 9 10 11 12 13 14 15 16
Engine coolant capacity (liter)
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100- 33 = 67
In case of expansion tank at normal level, this quantity is to
be drained from the cooling system.
Top-up volume PARCOOL EG Concentrate with drainage
25,0
22,5 1
20,0 2
17,5
Top-up volume (liter)
15,0 3
12,5
10,0
4
7,5
1. Refractometer indication -20° C (33%)
5,0 2. Refractometer indication -22° C
3. Refractometer indication -25° C
2,5
5 4. Refractometer indication -30° C
0,0 5. Refractometer indication -36° C
4 8 12 16 20 24 28 32 36 40 44 48 52 56 60 64 68 72 76 80 84
Engine coolant capacity (liter)
- 72 -
Used coolant must be disposed or recycled in (2) To avoid damaging the coolers, angle
accordance with laws and local regulations. between jet and coolers should be
(3) approx. 90 °.
Flush
Close the service door(s).
Flush twice with clean water. Used coolant must
be disposed or recycled in accordance with laws Protect the electrical and controlling
and local regulations. equipment, air filters, etc. against
Using the Atlas Copco Instruction book, penetration of moisture.
determine the amount of PARCOOL EG required (4) Never leave spilled liquids such as fuel,
and pour into the radiator top tank. oil, coolant and cleansing agents in or
It should be clearly understood that proper around the compressor.
cleaning reduces contamination risks.
In case of "other" coolant residues inside the
system, the coolant with the lowest properties
influences the quality of the ‘mixed’ coolant. Keep the coolers (1), (2) and (3) clean to maintain the
cooling efficiency.
Fill
Service doors (4) are provided on both sides of the fan
To assure proper operation and the release of cowl to allow easy access to the fan side surface of the
trapped air, run the engine until normal engine coolers.
operation temperature is reached. Turn off the
engine and allow to cool. Remove any dirt from the coolers with a
fibre brush. Never use a wire brush or
Recheck coolant level and add if necessary. metal objects.
Caution: do not top up when the engine Clean by air jet in the direction of the arrow.
is hot.
- 73 -
Before handling batteries, read the Take out the battery. The amount of water evaporating from batteries is
largely dependant on the operating conditions, i.e.
relevant safety precautions and act Battery and electrolyte must be at equal
accordingly. temperature above 10°C (50°F). temperatures, number of starts, running time between
start and stop, etc...
If the battery is still dry, it must be activated as Remove cover and/or plug from each cell.
If a battery starts to need excessive make-up water,
described in section Activating a dry-charged Fill each cell with electrolyte until the level this points to overcharging. Most common causes are
battery. reaches the mark on the battery. If there is no mark high temperatures or a too high voltage regulator
The battery must be in operation within 2 months on the battery, the level must be above the plates setting.
from being activated; if not, it needs to be recharged for at least 10 mm (0.4 in) to 15 mm (0.6 in).
If a battery does not need any make-up water at all
first. Rock the battery a few times so that possible air over a considerable time of operation, an
bubbles can escape; wait 10 minutes and check the undercharged battery condition may be caused by
level in each cell once more; if required, add poor cable connections or a too low voltage regulator
electrolyte. setting.
ELECTROLYTE
Refit plugs and/or cover.
Place the battery in the compressor.
Read the safety instructions carefully.
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- 75 -
- 76 -
MAIN PARTS REPLACING THE FILTER ELEMENT AND THE SAFETY CARTRIDGE
1. Release the snap clips (1) and remove the dust trap
cover (2). Clean the inside of the cover.
2. Withdraw the filter element (4) and safety
(3) cartridge (3) from the housing (5).
Discard the filter element when damaged.
(2)
(1) A dirty safety cartridge (3) is an indication of a
(5) malfunctioning filter element.
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- 78 -
- 79 -
- 80 -
(3)
(2) (1) (2)
"1"
"23"
"16"
- 81 -
"Y"
"Z"
"1"
"14" "6"
- 82 -
(1)
(l)
- 83 -
"Z"
- 84 -
- 85 -
Problem: After working some time, the unit stops through a shutdown switch.
Problem: Air and oil mist expelles from air filters immediately after stopping.
- 86 -
Alternator precautions
1. Never reverse the polarity of the battery or the
alternator.
2. Never break any alternator or battery connections
while the engine is running.
3. When recharging the battery, disconnect it from
the alternator. Before using booster cables to start
the engine, be sure of the polarity and connect the
batteries correctly.
4. Never operate the engine without the main or
voltage sensing cables connected in the circuit.
- 87 -
- 88 -
The undercarriage makes it possible to move the With the option “Support mounted” it is possible to
compressor on the site with a truck to the location fix the compressor to a truck for more flexibility or to
where it is needed. This option exits of rubber damped a frame when it is to be used permanently in an
axles, four wheels and a tow bar. The wheels are also installation.
equipped with brakes operated from the brake handle
In combination with the support mounted it is also
on the tow bar. possible to integrate larger fuel tank to get larger
intervals between two fuel supply actions.
- 89 -
For extra safe parking on slopes. In dusty environments or in situations where the fuel The preheater is a device for preheating the cooling
quality is not up to the normal standard, this fluid before starting when operating at low
additional fuel filter gives an extra protection to the temperatures. The engine will start more easy.
fuel/combustion system. Additionally the preheater will lengthen the life span
of the engine as there are no cold starts (see also
section Preheater (option)).
- 90 -
The cold start option consists of larger batteries The inlet shut down valve is a safety device This is a control module that regulates engine speed
and a blow off valve to be able to start the engine preventing the engine from over speeding when and the air inlet to optimise fuel consumption
at temperatures between -10°C (14°F) and -25°C sucking in combustible fumes. When the engine max. depending on the working conditions, and the output
(-13°F). It also includes a preheater. RPM is exceeded a pneumatically controlled solenoid required.
valve closes off the air inlet and the fuel supply to the
engine is cut.
- 91 -
- 92 -
Improves braking stability from higher transport The tow bar levelling device is an ergonomic device
speeds compliant to 98/12/EC. making it easier for the operating personnel to couple
the compressor to a towing vehicle. As the tow bar
itself is rather heavy, the levelling device
compensates most of this weight so the operator has
The compressor controls can be handled remotely if less weight to carry, saving his back.
required, thereby allowing the compressor to work at
some distance from the actual drilling application. It’s
easy-to-use in all kinds of applications and it saves
fuel with an additional no-load function.
The remote start allows the user to start, stop the
compressor and switch to load/noload by radiosignal.
This is particularly comfortable when the compressor
can not be positioned directly at the job site because
of blocking by buildings or other obstacles.
- 93 -
To fasten the compressor to the vehicle it is On-road bumper bars and lights can be specified in For quality dry air, a reheater can be fitted in
transported with tie down loops are attached to the accordance with local legislation. combination with the aftercooler. This allows air
axle of the compressor. quality to be delivered at ambient +60°C.
- 94 -
For applications were the air outlet temperature is For more flexibility it is possible to have additional
important additional sensors can be installed in the outlets installed.
manifold.
- 95 -
The following tables list the recommended torques applied for general applications
during assembly of the compressor. Assemblies Torque value (Nm / lbf.ft)
Axles to frame:
Wheel nuts 270 (200) +10/-0 %
For hexagon screws and nuts with strength grade 8.8 Bolts, front axle/frame 205 (152) +/- 10 %
Bolts, rear axle/frame 205 (152) +/- 10 %
Thread size Torque value (Nm / lbf.ft)
Compressor to frame:
M6 8 (6) +/-25 %
Bolts, elements/gear casing 46 (34) +/- 10 %
M8 20 (15) +/-25 %
Bolts, elements/support 80 (60) +/- 10 %
M10 41 (30) +/-25 %
Bolts, support/buffer 205 (152) +/- 10 %
M12 73 (54) +/-25 %
Bolts, buffer/frame 80 (60) +/- 10 %
M14 115 (85) +/-25 %
Engine to frame:
M16 185 (137) +/-25 %
Bolts, engine/support 205 (152) +/- 10 %
For hexagon screws and nuts with strength grade 12.9 Bolts, support/buffer 46 (34) +/- 10 %
Bolts, buffer/frame 23 (17) +/- 10 %
Thread size Torque value (Nm / lbf.ft) Lifting beams to frame:
M6 14 (10) +/-21 % Bolts, lifting beams/yoke (M12) 125 (93) +/- 10 %
M8 34 (25) +/-23 % Bolts, lifting beams/yoke (M16) 205 (152) +/- 10 %
M10 70 (52) +/-24 % Bolts, lifting beams/A-Frames 205 (152) +/- 10 %
M12 120 (89) +/-25 % Bolts, A-Frames/frame 205 (152) +/- 10 %
M14 195 (144) +/-23 % Hose clamps:
M16 315 (233) +/-23 % Pebra hose clamps on all IC/radiator 12 (9) +/- 10 %
hoses
Secure the drain cock and tank cap of the fuel tank handtight.
- 96 -
REFERENCE CONDITIONS
Designation XAMS 527 - XAMS 1150 XATS 487 - XATS 1050 XAHS 447 - XAHS 950 XAVS 407 - XAVS 900
LIMITATIONS
Designation XAMS 527 - XAMS 1150 XATS 487 - XATS 1050 XAHS 447 - XAHS 950 XAVS 407 - XAVS 900
- 97 -
At reference conditions, if applicable, and at normal shaft speed, unless otherwise stated.
Designation XAMS 527 - XAMS 1150 XATS 487 - XATS 1050 XAHS 447 - XAHS 950 XAVS 407 - XAVS 900
Engine shaft speed, normal and maximum r/min 1800 1800 1800 1800
Engine shaft speed, compressor unloaded r/min 1300 1300 1300 1300
Free air delivery 1) without aftercooler l/s 520 482 443 406
cfm 1102 1020 938 860
with aftercooler l/s 510 472 433 396
cfm 1001 1000 918 840
Fuel consumption
- at 100% FAD Fuel expert kg/h 45.0 45.2 44.8 45.1
lb/h 100.7 101.1 100.3 101.0
No kg/h 45.0 45.2 44.8 45.1
Fuel expert lb/h 100.7 101.1 100.3 101.0
- at 75% FAD Fuel expert kg/h 35.1 35.5 35.3 35.7
lb/h 78.7 79.4 79.1 79.8
No kg/h 40.2 40.4 40.3 40.7
Fuel expert lb/h 89.9 90.5 90.3 91.1
- at 50% FAD Fuel expert kg/h 30.3 30.7 30.7 31.1
lb/h 67.9 68.8 68.8 69.7
No kg/h 34.5 34.9 34.9 35.3
Fuel expert lb/h 77.1 78.1 78.2 79.0
- at 25% FAD Fuel expert kg/h 27.7 28.0 28.0 28.2
lb/h 62.0 62.7 62.7 63.1
No kg/h 28.5 28.9 29.0 29.3
Fuel expert lb/h 63.7 64.8 64.9 65.5
- 98 -
- 99 -
TEMPERATURE °F TEMPERATURE °F
ALTITUDE m
ALTITUDE ft
ALTITUDE ft
0 0 ft 0 0 ft
-10 0 10 20 30 40 50 -10 0 10 20 30 40 50
TEMPERATURE °C TEMPERATURE °C
- 100 -
12 bar 14 bar
ALTITUDE m
ALTITUDE m
ALTITUDE ft
ALTITUDE ft
0 0 ft 0 0 ft
-10 0 10 20 30 40 50 -10 0 10 20 30 40 50
TEMPERATURE °C TEMPERATURE °C
- 101 -
Compressor
Designation
Number of compression stages 1
Engine
- 102 -
Compressor dimensions
Electric refuel pump
Designation Wagon Tandem
Designation All units Length mm 6045 5640
Flow rate *) l/m 50 inch 238.0 222.1
US gal/m 13 Width mm 2150 2140
Self priming *) from dry up to m 2.4 inch 84.7 84.3
ft 7.8 Height mm 2479 2474
*) inch 97.6 97.4
Fuel temperature max 40°C (104°F)
Weight (ready-to-operate) see indication on data plate
- 103 -
- 104 -
Designation XAMS 527 - XAMS 1150 XATS 487 - XATS 1050 XAHS 447 - XAHS 950 XAVS 407 - XAVS 900
- 105 -
- 106 -
- 107 -
- 108 -
1
EC DECLARATION OF CONFORMITY
2 We, Atlas Copco Airpower n.v., declare under our sole responsibility, that the product
3 Machine name : Compressor (< 350 kW)
4 Commercial name ::
5 Serial number :
6 Which falls under the provisions of article 12.2 of the EC Directive 2006/42/EC on the approximation of the
laws of the Member States relating to machinery, is in conformity with the relevant Essential Health and
Safety Requirements of this directive.
The machinery complies also with the requirements of the following directives and their amendments as
indicated.
EN ISO 12100-1
b. Machinery safety 2006/42/EC EN ISO 12100-2
EN 1012-1
c. Simple pressure vessel 87/404/EEC X
EN 61000-6-2
d. Electromagnetic compatibility 2004/108/EC
EN 61000-6-4
EN 60034
e. Low voltage equipment 2006/95/EC EN 60204-1
EN 60439
f. Outdoor noise emission 2000/14/EC ISO 3744 X
8.a The harmonized and the technical standards used are identified in the attachments hereafter
8.b Atlas Copco Airpower n.v. is authorized to compile the technical file
16 Place , Date
Form 5009 0600 06
ed. 07, 2010-03-15
Atlas Copco Airpower n.v. A company within the Atlas Copco Group
Postal address Visitors address Phone: +32 (0)3 870 21 11 Com. Reg. Antwerp 44651
P.O. Box 100 Boomsesteenweg 957 Fax: +32 (0)3 870 24 43 V.A.T. 403.992.231
B-2610 Wilrijk-Antwerp B-2610 Wilrijk-Antwerp
Belgium Belgium For info, please contact your local Atlas Copco representative
www.atlascopco.com
p.1(1)
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