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Atlas Copco PTS 1600 Cud S3A/T3 APP Instruction Manual

Portable compressors
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PTS 1600 Cud S3A/T3 APP
QSX15

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Summary of Contents for Atlas Copco PTS 1600 Cud S3A/T3 APP

  • Page 1 Instruction Manual for Portable Compressors English PTS 1600 Cud S3A/T3 APP QSX15...
  • Page 3 PTS 1600 Cud S3A/T3 APP Instruction Manual for Portable Compressors Instruction manual .................. 5 Circuit diagrams ..................89 Original instructions Printed matter N° 2954 7430 01 ATLAS COPCO - PORTABLE ENERGY DIVISION www.atlascopco.com 12/2013...
  • Page 4 While every effort has been made to ensure that the information in this manual is correct, Atlas Copco does not assume responsibility for possible errors. Copyright 2013, Atlas Copco Airpower n.v., Antwerp, Belgium. Any unauthorized use or copying of the contents or any part thereof is prohibited.

  • Page 5: Table Of Contents

    Congratulations on the purchase of your AC compressor. It is a solid, safe and reliable machine, built according to the latest technology. Follow the instructions in this booklet and we guarantee you years of troublefree operation. Please read the following instructions carefully before starting to use your machine. Always keep the manual available near the machine.
  • Page 6 5.4.9 Cooldown status ......45 6.3.3 Compressor element 6.4.9 Servicing air inlet shut-down overhaul ..........60 valve ..........69 5.4.10 Stopping status ........46 6.4.10 Servicing water separator ....69 5.4.11 Start failure status......46 Adjustment and servicing 6.4.11 Servicing electric blow-off valve..69 5.4.12 Shutdown status ......47 procedures ........61 6.4.12 Servicing automatic fire 5.4.13 Emergency stop status ....47...
  • Page 7 Storage of the compressor ..82 Storage instructions ......82 Disposal ........83 10.1 General..........83 10.2 Disposal of materials .......83 Technical specifications ... 84 11.1 Torque values........84 11.2 Settings of shutdowns and safety valves........84 11.3 Compressor/engine specifications........85 11.4 Conversion list of SI units into British units ........88 11.5 Dataplate ..........88...

  • Page 8: Safety Precautions For Portable Compressors

    An operator is trained in all aspects of operating the unit The policy of Atlas Copco is to provide the users of their unsafe operating conditions. Take necessary steps to with the push-buttons, and is trained to know the safety equipment with safe, reliable and efficient products.
  • Page 9 The manufacturer does not accept any liability for any Normal ratings (pressures, temperatures, speeds, 13 In the event the safety labels are damaged or damage arising from the use of non-original parts and for etc.) shall be durably marked. destroyed, they must be replaced to ensure operator modifications, additions or conversions made without safety.
  • Page 10 To tow a unit use a towing vehicle of ample 10 Never leave a load hanging on a hoist. Safety during transport and capacity. Refer to the documentation of the towing 11 A hoist has to be installed in such a way that the installation vehicle.
  • Page 11 13 Never refill fuel while the unit is running, unless people entering the room, for even relatively be safeguarded with a safety cable, attached next to otherwise stated in the Atlas Copco Instruction short times, about the need to wear ear the valve.
  • Page 12 Insulation or safety guards protecting these parts or dust, the respiratory organs must be protected and Parts shall only be replaced by genuine Atlas Copco shall not be removed before the parts have cooled depending on the nature of the hazard, so must the replacement parts.
  • Page 13 14 Use only lubricating oils and greases recommended 20 When hot parts have to be handled, e.g. shrink undertaking major overhaul on it, prevent all or approved by Atlas Copco or the machine fitting, special heat-resistant gloves shall be used movable parts from rolling over or moving.
  • Page 14 When connecting an auxiliary battery (AB) in Tool applications safety parallel to the unit battery (CB) with booster cables: Apply the proper tool for each job. With the knowledge connect the + pole of AB to the + pole of CB, then of correct tool use and knowing the limitations of tools, connect the - pole of CB to the mass of the unit.

  • Page 15: About This Manual

    CCM. Atlas Copco push-buttons. At this max. setpoint the engine Atlas Copco Instruction Book speed will be regulated between Load Operating condition with inlet Service Bulletin max. and min. speed when running in...

  • Page 16: Main Parts

    Main parts General description The PTS 1600 Cud is a portable, two-stage screw compressor unit, which delivers oil-free air. The PTS 1600 Cud is built for a nominal effective working pressure of 0.5- 10.3 bar (7-150 psi) at 1650 rpm, 0.5-9.3 bar (7-135 psi) at 1750 rpm and 0.5-6.9 bar (7-100 psi) at 1850 rpm. An overview of the main parts is given in the diagram below. Alarm lamp Air outlet valve Brake handle...
  • Page 17 Aftercooler 1 Aftercooler 2 Air intake filter (compressor) Air intake filter (engine) Air outlet valve Battery Battery Switch Charge air cooler LP compressor element MP compressor element Engine Exhaust pipe Cooling fan 1 Cooling fan 2 Filler cap cooling water Fuel cooler Primary coarse fuel filter / Water separator Fuel tank...

  • Page 18: Markings

    Inlet with Directive 84/533/EC (expressed in dB (A)) Danger, heat flat Outlet Electrocution hazard Compressor oil drain Atlas Copco engine oil Read the instruction manual before starting Manual Service every 24 hours Read the instruction manual Warning! before working on the battery...

  • Page 19: Mechanical Features

    Mechanical features The male rotors have four lobes and the female rotors Water condensate from the water separator is drained 3.3.1 Engine six flutes. Thus, the male rotors revolve at 1 1/2 times through a nipple in the bottom of the frame in the back The compressor is driven by a liquid-cooled diesel the speed of the female rotors.

  • Page 20: Frame And Axles

    Repairs and maintenance must be 3.3.10 Control panel done by authorized personnel only. The control panel is located behind a small door at the Please contact Atlas Copco if the rear right-hand side of the unit. fire suppression system shows any irregularities.

  • Page 21: Electrical Features

    Electrical features 3.4.2 Indicator lamps The electrical features described in this chapter are standard provided on this compressor. 3.4.1 User Interface and Compressor Control Module General description of the User Interface The User Interface consists of a color LCD display which gives the user the essential process information feedback.

  • Page 22: Fuses

    3.4.2.1 Stop lamp 3.4.2.4 Wait-to-Start Lamp 3.4.3 Fuses The Stop lamp (1) provides critical operator messages. The Wait-to-Start lamp (4) indicates that the pre-start These messages require immediate and decisive operator intake manifold heater warm-up sequence is active. An response. The Stop lamp is also used to flash out OEM-supplied grid heater will automatically heat the Diagnostics fault codes.

  • Page 23: Operation Flows

    Operation flows An air-operated balancing piston is fitted behind the 3.5.1 Air flow system male rotor rear thrust bearing of MP compressor Description element. The piston decreases the load on the male rotor front thrust bearing during loaded operation. Air drawn through the air intake filters (AF ), and During loading the MP compressor element unloader (UA) into LP compressor element (CE...
  • Page 24 Overview Aftercooler 1 Aftercooler 2 Air intake filter (compressor) Air outlet valve Engine Blow-off silencer sensor Compressor Blow-off valve inputs Unloaded By-pass valve Chamber (unloader assembly) Chamber (unloader assembly) LP compressor element MP compressor element Check valve Data Setpoint Diaphragm (unloader assembly) link Intercooler Throttle...

  • Page 25: Cooling And Lubricating Oil System

    3.5.2 Cooling and lubricating oil system Description Oil from the oil sump (OS) of gear casing (GC) is Bypass valve (BV ) opens when the pressure rise circulated by an oil pump (OP), mounted on the front over the oil cooler is above normal. This will happen of the gear casing.
  • Page 26 Overview Bypass valve (oil cooler) LUBRICATING Bypass valve (oil filter) CIRCUIT Bypass valve (oil sump) LP compressor element MP compressor element Drain plug (oil cooler) Drain plug (oil sump) Cooling fan 1 (RAD, IC, AC , OC) Gear casing Oil cooler Compressor oil filter (with bypass valve) Oil gallery (LP compressor element) Oil gallery (MP compressor element)

  • Page 27: Fuel System

    3.5.3 Fuel system Description The unit must be stopped before In case of internal fuel supply, fuel from the fuel tanks switching from the internal to an (FT) is circulated by the engine fuel pump (FP ). The external fuel source. fuel is pumped through a 3-way valve (TWV) to two When using external fuel, both the supply and the primary coarse fuel filters (FF...
  • Page 28 Overview Bypass valve Filler cap (fuel tank) Check valve Engine External fuel supply coupling Cooling fan 2 (AC , CAC/FC) Fuel cooler Primary coarse fuel filter / water separator Secondary engine fuel filter Engine fuel pump Fuel shut-off cock Fuel tank 3-way valve Venting line fuel selector in...

  • Page 29: Water System

    3.5.4 Water system Overview Engine RADIATOR Cooling fan 1 (RAD, IC, AC , OC) Radiator Top tank (radiator) Engine water pump (radiator) Description The water system contains a coolant flow to cool the engine’s cylinders. The coolant is circulated by the engine water pump ), seated on the back of the engine (E).

  • Page 30: Installation

    Installation 4.1.2 Lifting The operator is expected to apply all relevant safety precautions, To lift the unit, use a lift truck or crane with sufficient including those mentioned capacity (wet weight of unit is 8560 kg (18875 lbs)). pages 7-10 of this book. Use the lifting positions of the unit as shown in the figure below.

  • Page 31: Parking

    Parking – Locate the wind direction and place the rear end of – Place wheel chocks in front of and behind the – Lock the towbar (2) in the raised position with the unit upwind, away from contaminated wind wheels before the unit is disconnected from the catcher (3).

  • Page 32: Operating Instructions

    Operating instructions – Move the power switch on the control panel (CP) Before starting Make sure that nobody is in the unit to the ON position and read the fuel level on the – With the unit standing level, check the engine and and all doors are closed prior to display.

  • Page 33: Operating

    Operating When the unit is in the standby status for a long time, 5.2.1 Starting The pressure is not immediately the following action should be performed: – Move the control panel power switch to ON. The relieved from the unit, when the –...

  • Page 34: Setting The Compressor Control Module

    When the PC mode is active, monitoring the Setting the compressor operation on the UI stays possible. Further, the UI can control module only be used for looking at the System information and the Process information. 5.3.1 Control 5.3.1.3 Control commands 5.3.1.1 Arrow buttons The arrow buttons are generally used to increase or Start command...

  • Page 35: Functionality

    When the cooldown time has elapsed, the stopping 5.3.1.4 Enable parameters 5.3.2 Functionality procedure begins. The engine stops and the There are six enable parameters with four possible The start and stop function can be set to manual or compressor will automatically return to the Ready for conditions.
  • Page 36 Emergency Stop Emergency Stop Shutdown Reset Reset System Info Options Return Return System Info Power ON Ready for Start Standby Start Stop Automatic Start Permissive Start Reset Start Failure Cranking Stop Not Loaded Warmup Stop Stop if No/Unload timer running Cooldown Stopping Noload...

  • Page 37: A Closer Look At Some Operating Procedure Blocks

    5.3.3 A closer look at some operating procedure blocks At any time the operator can leave the Options status 5.3.3.1 Process information 5.3.3.5 Warming up and go to the Ready for Start status by pressing the While the compressor is running, the operator can When the engine starts, the compressor enters the Return button.
  • Page 38 When less air is needed, the pressure rises and the PID 5.3.3.8 Shutdowns 5.3.3.11Loading Valve Control will decrease the engine RPM. There are several parameters which are continuously When the compressor is going to the load condition, When the engine RPM is at its minimum, and the air watched.
  • Page 39 5.3.3.13Poweroff 5.3.3.14Powerdown PC control mode When an action is performed via the PC, demanding When the power is switched on, a Wrong Poweroff To save the batteries, the CCM and UI are equipped a response from the CCM or UI (Start signal, flag is set.

  • Page 40: Operation Via User Interface

    Air Discharge Temperature Control parameter Operation via User Interface 5.4.2 Ready for Start status “Enable” 5.4.2.1 Manual start When the parameter is enable or enable lock, the PID 5.4.1 General will regulate the Air Discharge Temperature to the In this section an overview is given of all statuses of Air Discharge Temperature Setting.

  • Page 41: Standby Status

    5.4.2.2 Automatic start 5.4.3 Standby status 5.4.4 Permissive start status In this status the CCM checks if the parameters are out of range and checks all sensor inputs for sensor faults. This status does not require any action from the operator, and is therefore not visible on the screen.

  • Page 42: Cranking Status

    5.4.5 Cranking status 5.4.6 Warmup status If cranking: Crank time elapsed The starter motor output 5.4.6.1 Manual start is desactivated for the duration of the crank time (resting). Crank counter +1 The starter motor output is activated when the CCM enters this status.
  • Page 43 5.4.6.2 Automatic start A Auto load button R After the Warmup status, A Manual load button R After the Warmup status, or Remote Load input the CCM will skip the or Remote Load input the CCM will go to the if Remote control mode Not Loaded status and go if Remote control mode...

  • Page 44: Not Loaded Status

    5.4.7 Not Loaded status 5.4.8 Load/Unload status A Noload command R To Not Loaded status (see section 5.4.7) 5.4.8.1 Manual stop If Loaded: Unload pressure reached R “Unload” appears on the screen If Unloaded: A Reload pressure reached R “Load” appears on the screen Other actions and signals have no effect in this status.

  • Page 45: Cooldown Status

    5.4.8.2 Automatic stop 5.4.9 Cooldown status If Loaded: Unload pressure reached R “Unload” appears on the screen Autostop timer activated If Unloaded: A Reload pressure reached R “Load” appears on the screen Autostop timer reset Autostop time elapsed R To stopping status (see section 5.4.10) Other actions and signals have no effect in this status.

  • Page 46: Stopping Status

    Sreen B: Start failure, origin in Cranking status. 5.4.10 Stopping status 5.4.11 Start failure status First a stopping procedure is executed, and the operator has to wait. Warnings R Are shown on the screen Warnings R Are shown on the screen A Shutdowns R To shutdown status (see A Emergency Stop button...

  • Page 47: Shutdown Status

    Screen B: Emergency Stop is unlocked. 5.4.12 Shutdown status Warnings R Are shown on the screen First a stopping procedure is executed. A Emergency Stop button R To emergency Stop status (see section 5.4.13) A ↓-button, press once R Set pressure - 0.1 bar A ↑-button, press once R Set pressure + 0.1 bar A ↓-button, press...

  • Page 48: System Info Status

    – Battery Voltage 5.4.14 System info status 5.4.15 Options status – Software version UI – Software version CCM A ↓-button, press once R Set pressure - 0.1 bar A ↑-button, press once R Set pressure + 0.1 bar A Return button R To Ready for Start status (see section 5.4.2) A Options button...

  • Page 49: Process Info Status

    The parameters the operator can change are: 5.4.16 Process Info status 5.4.16.2Process Info status function This status is not an active status, but can be entered – Display Luminosity 5.4.16.1Two key access from the following statuses: – Pressure Units (Metric/Imperial) Depending on the setting of the Infobutton parameter, –...
  • Page 50 These parameters are: – Compressor oil temperature Shutdowns R To Shutdown status (see section 5.4.12) – Air discharge temperature A Time-out R Back to active – Air discharge temp. setting compressor status A Emergency Stop button R To Emergency Stop –...

  • Page 51: Operating The Automatic Fire Suppression System

    Operating the automatic fire suppression system 5.5.1 Main components Control module Cylinder with extinguishing powder Large nitrogen cylinder Manual actuator Small nitrogen cylinder Small nitrogen cylinder Nozzles Automatic actuator - 51 -...

  • Page 52: Operation

    5.5.2 Operation 5.5.3 Control module Staff that are not familiar with this The fire suppression system is equipped with a The automatic fire suppression installation is system are not allowed to run checks manual and automatic activation. constantly monitored by a control module. It is on the system.

  • Page 53: Buttons

    4. DETECTION 5.5.4 Daily check The detection LED and the audio pulse once every 10 The LED’s status on the ANSUL control module seconds when the control module detects a problem in should be checked daily prior to starting up the the detection circuit.

  • Page 54: Maintenance

    Maintenance Maintenance schedule every every every every every Maintenance schedule Daily 50 hrs 250 hrs 1000 hrs 1500hrs 6000 hrs 10000 hrs Service pak 2912 4580 04 2912 4581 05 2912 4582 06 Check engine oil level Check compressor oil level Check coolant levels (radiator) Check coolant additive and antifreeze concentration...
  • Page 55 every every every every every Maintenance schedule Daily 50 hrs 250 hrs 1000 hrs 1500hrs 6000 hrs 10000 hrs Service pak 2912 4580 04 2912 4581 05 2912 4582 06 Clean service filter water separator Grease turntable Check tension and condition of poly V-belts Check electrolyte and terminals on batteries Drain water and sediment in fuel tanks Clean air filters elements (1)
  • Page 56 every every every every every Maintenance schedule Daily 50 hrs 250 hrs 1000 hrs 1500hrs 6000 hrs 10000 hrs Service pak 2912 4580 04 2912 4581 05 2912 4582 06 Grease fan drive Replace cooler system water temperature regulator Change compressor oil Replace silencers glasswool and insert (every 2 years) Replace roller diaphragm of unloader cylinder...

  • Page 57: Use Of Preventive Maintenance Schedule

    Cummins support for more information and Atlas Copco service kits offer you all the benefits of make sure to have their agreement genuine Atlas Copco parts, save on administration to increase oil change interval. costs and are offered at a reduced price compared to the loose components.

  • Page 58: Engine Maintenance Procedures

    Engine maintenance procedures Refer to the engine’s operator manual for full When the warning is generated, the oil level maintenance schedule. maintainer valve is opened. Oil flows from the oil tank into the oil sump of the engine and into the small oil tank.

  • Page 59: Engine Oil And Oil Filter Change

    6.2.2 Engine oil and oil filter change Compressor maintenance procedures 6.3.1 Compressor oil level check The engine oil filters (1) are located at the unit’s left- hand side. – Consult, besides the maintenance schedule, the – Put a proper drain pan under the engine oil filters Engine Operation Manual as well for oil and oil and replace the oil filters.

  • Page 60: Compressor Oil And Oil Filter Change

    6.3.3 Compressor element overhaul When a compressor element is due for overhaul, it is recommended to have it done by Atlas Copco. This guarantees the use of genuine parts and correct tools with care and precision. – Run the compressor until warm. Close the outlet –...

  • Page 61: Adjustment And Servicing Procedures

    Adjustment and servicing procedures 6.4.1 Coolant 6.4.1.2 Adding coolant for units with 6.4.1.3 Testing coolant inhibitor level optional preheater Use coolant test strips to measure, chloride nitrite and 6.4.1.1 Coolant level check glycol concentrations. Cavitation/corrosion This instruction is only applicable protection is indicated on the strip by the level of for units equipped with an optional nitrite concentration.

  • Page 62: Replacing The Coolant

    – Before filling the system, close the drain cocks Vacuator valve (dust ejector) and tighten all plugs. The safety cartridge cannot be cleaned. The Atlas Copco air filters are specially designed application. The use of non-genuine air filters may lead to severe damage...

  • Page 63: Cleaning The Filter Element

    – Reassemble in reverse order of dismantling. – Carefully knock the end faces of the filter element on a flat surface to remove the dry contaminant. – Inspect and tighten all air intake connections. Never strike on a hard surface. Then blow dry air –...

  • Page 64: Fuel System

    6.4.3 Fuel system 6.4.3.2 Priming the system – Check to make sure the drain valve at the base of 6.4.3.1 Draining primary fuel filters the fuel filter is closed. – Remove the vent cap from the top of the clear cover.

  • Page 65: Cleaning Fuel Tanks

    6.4.3.3 Cleaning fuel tanks 6.4.4 Cleaning coolers Keep all coolers clean to maintain the cooling efficiency. The fan side surface of the radiator, intercooler, aftercooler 1 and oil cooler is accessible by opening the service doors. The CAC/Charge air cooler and aftercooler 2 are located at the rear end of the unit, under the air filters.

  • Page 66: Poly V-Belt Tension Adjustment

    Correct the V-belt tension by loosening the fixing 6.4.5 Poly V-belt tension adjustment 6.4.6 MP safety valve adjustment screw (1) of V-belt tensioner (2). Loosen the lock nut To check the cooler fan poly V-belt tension, measure on the adjusting screw (3). Turn the adjusting screw the belt frequency.

  • Page 67: Checking Intercooler Relief Valves

    6.4.7 Checking intercooler relief valves 6.4.8 Battery care Before handling batteries, read the relevant safety precautions and act accordingly. If the battery is still dry, it must be activated as described in section 6.4.8.2. The battery must be in operation within 2 months from being activated;...

  • Page 68: Recharging A Battery

    – Rock the battery a few times so that possible air 6.4.8.4 Maintaining the battery voltage 6.4.8.5 Battery maintenance bubbles can escape; wait 10 minutes and check the To maintain the battery voltage, use the unit’s – Keep the battery clean and dry. level in each cell once more;...

  • Page 69: Servicing Air Inlet Shut-Down Valve

    Connect Maintenance must be performed by authorized a drain hose to the nipple and make sure that the personnel only. Please contact Atlas Copco. condensate is properly disposed of. All maintenance activities are to be recorded in a Service the filter of the water separator every 500 logbook.

  • Page 70: Engine Consumable Specifications

    Specifications PAROIL oils for both compressor and engine. retention and more alkalinity to control acid PAROIL from Atlas Copco is the ONLY oil tested formation. High-quality, mineral, hydraulic or synthesized and approved for use in all engines built into Atlas hydrocarbon oil with rust and oxidation inhibitors, Copco compressors and generators.

  • Page 71: Engine Coolant Specifications

    Atlas Copco PAROIL E Mission Green is currently in use in Atlas Copco compressors and The system may be under pressure.

  • Page 72: Checks And Trouble

    PARCOOL EG is free of nitride and amines to protect Checks and trouble Battery and alternator your health and the environment. Longer service life precautions shooting reduces the amount of coolant produced and needing – Never reverse the polarity of the battery or the disposal to minimise environmental impact.

  • Page 73: Trouble Shooting

    Trouble shooting Symptom Possible cause Corrective action Compressor loaded automatically Loading solenoid valve stuck in loaded position. Remove and check loading solenoid valve. to full capacity after starting Replace valve if necessary. Air intake throttle valve in open position. Check position throttle valve. Disconnect loading solenoid valve from throttle valve housing and connect independent compressed-air line to throttle valve housing.
  • Page 74 Replace valve, if necessary. Compressor element(s) not in order. Check interstage pressure and have compressor element(s) inspected by Atlas Copco. Air intake throttle valve remains partially closed. Disconnect loading solenoid valve from throttle valve housing and connect independent compressed-air line to throttle valve housing.
  • Page 75 Move unit away from walls; when banked with other units, leave space between them. Oil cooler clogged externally. Clean oil cooler. Oil cooler clogged internally. Consult Atlas Copco. Compressor oil filter clogged. Replace oil filter. Compressor oil level too low. Before checking compressor oil level, wait approx. 10 minutes after unit has stopped.
  • Page 76 If in order, check piston for free axial movement by hand. If jammed, remove throttle valve housing, dismantle and replace defective parts. Control panel ‘Load’ button inoperative. Consult Atlas Copco. Compressor oil pressure too low Compressor oil level too low. Before checking compressor oil level, wait approx. 10 minutes after unit has stopped.
  • Page 77 See Engine Operation Manual. Compressor overheating. See “Compressor overheating” Engine overheating. See Engine Operation Manual. Excessive oil fumes or air flow Compressor element(s) seals defective. Have compressor element(s) inspected by Atlas Copco. coming from breather pot assembly on gear casing. - 77 -...
  • Page 78 Air leak between LP and MP compressor element. Inspect pipe connections and intercooler. Replace leaking O-rings, gaskets or intercooler, if necessary. LP compressor element not in order. Have LP compressor element inspected by Atlas Copco. Intercooler clogged internally. Consult Atlas Copco. Intercooler pressure above normal Aftercooler clogged internally.

  • Page 79: Compressor Control Module Trouble Shooting

    Compressor control module trouble shooting 7.4.1 Process information Process warnings Effect Apparatus warnings Effect Fuel Level Warning While the compressor is running, the operator can Fuel Level Sensor Shutdown take a brief look at all the incoming compressor and Engine Oil Level Low Warning Air Discharge Pressure Sensor Shutdown...

  • Page 80: Shutdowns

    – Fuel level shutdown 7.4.3 Shutdowns The unit comprises several shutdown sensors: – Engine oil level shutdown (switch) – Engine shutdowns (by ECM): – Engine oil level overfill shutdown (switch) • Engine Coolant Level Sensor Failure – LP element temperature shutdown •...

  • Page 81: Available Options

    Available options Preheater Heating kit Anti-frost device The anti-frost device is a kind of cover plate that The preheater option allows setting a higher outlet The heating kit is a cold start option. makes the first aftercooler to cool down the temperature of the compressed air via the compressor It consists of heater plugs that are to be installed in compressed air less and prevents the formed...

  • Page 82: Hot Weather Pack

    Hot weather pack Cold climate fuel Storage of the compressor Cold climate diesel fuel can be used in ambient conditions as low as -25°C (-13°F). Storage instructions Run the compressor regularly, e.g. twice a week, until warm. Load and unload the compressor a few times to operate the unloading and regulating components.

  • Page 83: Disposal

    (for example sand, sawdust) and recyclable materials. dispose it according the applicable local disposal Your Atlas Copco compressor consists for the most regulations. Do not drain into the sewage system or part of metallic materials, that can be remelted in surface water.

  • Page 84: Technical Specifications

    Technical specifications 11.1 Torque values 11.1.2 For important assemblies 11.2 Settings of shutdowns and safety valves Assemblies Unit Torque 11.1.1 For general applications values Designation Value Axles to frame: The following tables list the recommended torques Engine shutdowns (see EOM) applied for general applications at assembly of the Wheel nuts + 10/- 0...

  • Page 85: Compressor/Engine Specifications

    11.3 Compressor/engine specifications Designation Unit Value Reference conditions Absolute inlet pressure bar(e) Relative air humidity Air inlet temperature °C Normal effective working pressure bar(e) 10.3 The inlet conditions are specified at the air inlet grating outside the canopy Limitations Minimum effective receiver pressure bar(e) Maximum effective receiver pressure, compressor unloaded bar(e)
  • Page 86 Design data Compressor Number of compressor stages 2 in serial Engine Make Cummins Type QSX15 Coolant Liquid Number of cylinders Bore Stroke Swept volume 15.0 Output according to SAEJ1995 at normal shaft speed Load factor Capacity of oil sump: Initial fill Refill (max.) Capacity of cooling system (intercooler) Capacity of cooling system (engine jackets)
  • Page 87 Notes At reference conditions, if applicable, and in normal shaft speed, unless otherwise stated. Data Measured according to Tolerance Free air delivery ISO 1217 ed. 3 1996 annex D ± 5% 25 l/s <FAD<250 l/s ± 4% 250 l/s <FAD The international standard ISO 1217 corresponds to following national standards: British BSI 1571 part 1 German DIN 1945 part 1...

  • Page 88: Conversion List Of Si Units Into

    1 m³/min 35.315 cfm Speed 1 mbar 0.401 in wc 10 Engine power MADE BY ATLAS COPCO AIRPOWER n.v. WILRIJK, BELGIUM 0.225 lbf 11 Manufacturing year 1 Nm 0.738 lbf.ft 12 EC mark in accordance with Machine Directive 1615 6945 00 32 + (1.8 x t...
  • Page 89 Circuit diagrams - 89 -...
  • Page 90 9822 0900 20/00 Applicable for PTS 1600 T3, Circuit diagram Engine and Controller 04.1, 05.1 08.2 25M (a2) 03.5 04.1 03.4 (b6 19U) 05.1 04.1, 05.1, 05.1, 05.1, 05.5, 05.6, 06.1, 06.1, 08.1 - 90 -...
  • Page 91 24 (c2) 03.9 20 A 06.1 X1-18 X1-20 X1-07 X1-08 X1-17 X1-38 15 (a3) X1-06 1004 (a2) 8 (a3) X1-16 X2-17 6 (a3) X1-05 1005 (a6) X2-19 306 (a3) X1-04 1006 (a3) X2-06 1002 (b3) X2-27 1007 (a7) X2-05 ENGINE CONT ROL MODULE 1003 (b3) X2-11 X1-50 X1-40 X1-39 X1-30 X1-29...
  • Page 92 03.9 SEE E C C OR USA 38 (a3) VARIAN TS SCHE M ATIC 27M (d2) 06.1 44 (a3) 241M (a2) USER INTER FACE 26 (d2) 19 (c6) 24MK4 (d2) 241M (a2) 39 (a3) 241M (a2) 19UM (a6) 28 (a3) 04.1, 06.1, 07.2 P.A.C 20 (a8)
  • Page 93 19 (b6) 03.9 19 (b6) X1 (CONT ROLLER) 03.9 - 93 -...
  • Page 94 - 94 -...
  • Page 95 06.1 H4-5 19 (b6) 03.9 39 (a3) 05.1 30 03.5 - 95 -...
  • Page 96 Diode Level Switch - Engine Oil Level Overfill Temperature Sensor - Compressor Oil Shutdown Temperature Diode Fuse ECM Level Switch - Coolant Temperature Sensor - Low Pressure Element Temperature Fuse User Interface Level Sensor - Fuel Level Fuse Controller Starter Motor Temperature Sensor - Medium Pressure Element Temperature Fuse Flap Lock Solenoid...
  • Page 97 - 97 -...
  • Page 98 9822 0899 97/01 Applicable for PTS 1600 T3 - Circuit diagram (EC) Cubicle X3:E X1:B X7:4 X3:D X1:A X7:5 X7:3 X4:1 X7:6 TO MAIN X4:2 X7:7 X7:2 CIRCUIT DIAGRAM X7:8 X2:1 USER INTERFACE X2:2 X4:3 X7:1 X3:C X1:C X3:B X1:D X3:A X1:E Legend...
  • Page 99 Battery charger Relay Circuit breaker Water separator drain nozzle heater Engine oil heater Compressor oil heater Heater switch Temperature switch Temperature switch Temperature switch Connector rear mains wiring Connector user interface Connector main mains wiring Connector rear wiring Power socket Terminal strip - 99 -...
  • Page 100 9822 0899 98/01 Applicable for PTS 1600 T3 - Circuit diagram (USA) Cubicle X3:E X1:B X7:4 X3:D X1:A X7:5 X4:1 X7:3 X7:6 TO MAIN CIRCUIT X4:2 X7:7 X7:2 DIAGRAM X2:1 X7:8 USER X7:9 INTERFACE X2:2 X4:3 X7:1 X3:C X1:C X3:B X1:D X3:A X1:E...
  • Page 101 Battery charger Relay Circuit breaker Circuit breaker Water separator drain nozzle heater Engine oil heater Compressor oil heater Heater switch Temperature switch Temperature switch Temperature switch Connector rear mains wiring Connector user interface Connector main mains wiring Connector rear wiring Power socket Power socket Terminal strip...
  • Page 102 9822 0899 30/02 Applicable for PTS 1600 T3 - Circuit wiring TOPTANK BATTERY SWITCH ENGINE CONTINUOUS HEATER GROUND FOR INTERNAL LIGHTS MOTOR COMP ENGINE HEATER TEMP. SWITCH OILER REFINERY VALVE EQUIPMENT FLASHER INTERNAL LIGHT FLASHER START LIGHT LIGHT ENGINE STARTER RELAY COMP PRIMING...
  • Page 103 - 103 -...
  • Page 104 1626 8282 00/00 (page1/2/3) Applicable for PTS 1600 T3 - Wire harness front See note 53 See note 51 CIRCUIT ALTERNATOR BREAKER ADDITIONAL CIRCUIT CIRCUIT USER CIRCUIT BREAKER BREAKER See note 54 SOLID STATE RELAY INTERFACE BREAKER CONTROLLER See note 19 Cavity: AIR INLET See note 19...
  • Page 105 6 7 8 9 10 1 2 3 4 5 6 1 2 3 4 5 6 See note 11 See note 12 See note 13 CONTROLLER LP-IC PRESSURE See note 7 31 32 33 34 35 36 37 38 39 40 19 20 21 22 23 24 19 20 21...
  • Page 106 See note 21 FLASHER LIGHT See note 19 COOLANT LEVEL See note 40 901 902 BLOW OFF VALVE See note 14 1800 1400 EMERGENCY STOP TO PAGE 2 Splice: in this area PAGE 3 - 106 -...
  • Page 107 TERMINAL END A TERMINAL END B WIRE TERMINAL TERMINAL MM² COLOR see note 19 see note 13 orange see note 13 see note 14 orange AMP 342145-1 AMP 130090-0 orange see note 13 splice orange see note 19 orange see note 1 orange see note 13 see note 14...
  • Page 108 TERMINAL END A TERMINAL END B WIRE TERMINAL TERMINAL MM² COLOR Splice faston AMP 5-160446-2 blue see note 19 blue see note 18 blue Splice see note 18 blue see note 14 blue see note 19 blue see note 2 splice blue see note 9...
  • Page 109 TERMINAL END A TERMINAL END B WIRE TERMINAL TERMINAL MM² COLOR see note 3 Splice 240M see note 3 240M AMP 3-520117-2 240M see note 3 240M purple see note 3 240M purple see note 3 240M purple eye M12 splice inline fuse;...
  • Page 110 TERMINAL END A TERMINAL END B WIRE TERMINAL TERMINAL MM² COLOR uninsulated wire ferrule AMP 0-925856-1 splice orange splice diode 1N5402 (3A, 100V) see note 1 orange splice diode 1N5402 (3A, 100V) see note 13 orange see note 7 see note 12 orange see note 12 see note 7...
  • Page 111 TERMINAL END A TERMINAL END B WIRE TERMINAL TERMINAL MM² COLOR see note 3 see note 13 orange see note 3 see note 2 orange see note 3 See note 2 orange see note 19 see note 34 1002 orange see note 19 see note 34 1003...
  • Page 112 NOTES Note 1: Connector: Deutsch HD N 36 - 24-19 SN Note 11:Connector: Deutsch DRC 16-40S - 059 Terminals: Deutsch 0462-201-16141 Terminals: Size 12 (large): Deutsch Unused cavities to be sealed with: 0462-203-12141 Deutsch 11407 Size 16 (small): Deutsch 0462-201-16141 Note 12:Connector: Deutsch DRC 16-24S Unused cavities to be sealed with: Terminals: Deutsch 0462-201-16141...
  • Page 113 Note 18:AMP 133544-4 Note 22:Wire insulation should be resistant to oil, Shrinkable sleeve to be attached as in fuel and coolant. drawing. Wall thickness: min. 1 mm. Note 27: All wire type H05V-K/H07V-K according Wires may be devided over two terminals if to AC standard 0995 2000 00 unless necessary.
  • Page 114 Note 61: Scan test to be performed on every conductor Note 62:Marking to be printed on each end of all wires Note 63:All plugs seen from wire connecting side Note 64:Wire harness finishing: black braiding, unless stated otherwise Note 65:Diodes positioned as on drawing Note 66:Terminal and shrinkable sleeve to be mounted as in drawing Wire number printed on shrinkable sleeve...
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  • Page 116 1626 9916 00/02 Applicable for PTS 1600 T3 - Wire harness rear See note 2 USER INTERFACE OILER VALVE See note 1 7 11 CONTINUOUS GROUND OUTLET TEMP. REG. VALVE 17 18 19 20 21 25 26 FOR INTERNAL LIGHTS See note 3 COSMOS (Male)
  • Page 117 TERMINAL END A TERMINAL END B WIRE terminal terminal mm² color See note 11 See note 11 Green See note 11 See note 11 Purple See note 2 See note 4 Orange See note 4 Splice Orange See note 1 Orange See note 3 Orange...
  • Page 118 TERMINAL END A TERMINAL END B WIRE terminal terminal mm² color See note 1 Splice Grey See note 4 Grey See note 12 Grey See note 1 Splice Grey See note 4 Grey See note 12 Grey See note 1 Splice Blue See note 2...
  • Page 119 TERMINAL END A TERMINAL END B WIRE terminal terminal mm² color See note 1 See note 15 Orange See note 1 See note 15 Orange See note 1 See note 15 Orange See note 1 See note 15 Orange See note 1 See note 15 Orange See note 1...
  • Page 120 NOTES Note 1: Connector: Deutsch HD 36 - 24-19 SN - Note 5: Connector: Deutsch DTP 06 - 4S Note 10:Wire insulation should be resistant to oil, diesel Terminals: Deutsch 0460-204-12141 fuel and coolant. Terminals: Size 12 (large): Deutsch Unused Cavities to be sealed with: 0462-203-12141 Deutsch 114017 Note 11:Connector according to DIN 72585 4 pins.
  • Page 121 Note 15:Connector: Deutsch HD16-9-16S Deutsch HD16-9-96S Terminals: Deutsch 0462-209-16141 Deutsch 0462-209-16141 Note 20: Wire harness shall be provided with a marking label with AC part number and 1: Braiding edition. 2: Insulated wires 3: Terminal Note 21: Scan test to be performed on every 4: Non-insulated wires conductor 5: Sleeve...
  • Page 122 1626 9917 00/01 Applicable for PTS 1600 - Wire harness (add-on) SELECTION SWITCHES CUBICLE INDICATOR LIGHTS CONNECTOR See Note 2 See Note 1 TERMINAL END A WIRE TERMINAL END B terminal mm² color terminal See note 1 orange See note 2 See note 1 orange See note 2...
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  • Page 124 Following documents are provided with this unit: – Test Certificate – EC Declaration of Conformity: EC DECLARATION OF CONFORMITY We, Atlas Copco Airpower n.v., declare under our sole responsibility, that the product Machine name : Compressor (≥ 350 kW) Commercial name : Serial number Which falls under the provisions of article 12.2 of the EC Directive 2006/42/EC on the approximation of the...
  • Page 125 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.2(2) - 125 -...
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