Atlas Copco PNS 1250 Cud S3A/T3 APP Instruction Manual
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Atlas Copco PNS 1250 Cud S3A/T3 APP Instruction Manual

Atlas Copco PNS 1250 Cud S3A/T3 APP Instruction Manual

Portable compressors
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PNS 1250 Cud S3A/T3 APP
QSX15

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Summary of Contents for Atlas Copco PNS 1250 Cud S3A/T3 APP

  • Page 1 Instruction Manual for Portable Compressors English PNS 1250 Cud S3A/T3 APP QSX15...
  • Page 2 PNS 1250 Cud S3A/T3 APP Instruction Manual for Portable Compressors Instruction manual .................. 5 Circuit diagrams ..................89 Original instructions Printed matter N° Preliminary ATLAS COPCO - PORTABLE ENERGY DIVISION www.atlascopco.com 12/2014...
  • Page 3 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 2014, Atlas Copco Airpower n.v., Antwerp, Belgium. Any unauthoried use or copying of the contents or any part thereof is prohibited.

  • Page 4: 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 trouble free operation. Please read the following instructions carefully before starting to use your machine. Always keep the manual available near the machine.
  • Page 5 Operating the automatic fire 6.4.2.1 Main parts .........59 Checks and trouble suppression system......49 6.4.2.2 Cleaning the dust trap......59 shooting ........69 5.3.1 Main components ......49 6.4.2.3 Replacing the air filter Problem solving chart......69 5.3.2 Operation ..........50 element and the safety Battery and alternator precautions 69 cartridge ..........59 5.3.3...
  • Page 6 Technical specifications ... 83 11.1 Torque values........83 11.2 Settings of shutdowns and safety valves........83 11.3 Compressor/engine specifications for standard units ..........84 11.4 Conversion list of SI units into British units ........87 11.5 Data plate .........87 - 7 -...

  • Page 7: 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 8 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 9 Safety during transport and To tow a unit use a towing vehicle of ample 10 Never leave a load hanging on a hoist. capacity. Refer to the documentation of the towing installation 11 A hoist has to be installed in such a way that the vehicle.
  • Page 10 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 11 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 12 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 13 Tool applications safety When connecting an auxiliary battery (AB) in 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 14: About This Manual

    AC personnel or user allowed to is used for speed regulation and for Atlas Copco operate the compressor unit with the the compressor controls (unloading Atlas Copco Instruction Book push-buttons. system, safeties, ...). It can be Service Bulletin operated via PC or User Interface.

  • Page 15: Directions

    Directions The driving direction has always been originated with, when the sides of the unit are denoted. E.g. the towbar is at the front and the User Interface is at the rear right-hand side of the unit. - 16 -...

  • Page 16: Main Parts

    Main parts General description The PNS 1250 Cud is a portable, three-stage screw compressor unit, which delivers oil-free air. The PNS 1250 Cud is built for a nominal effective working pressure of 20 bar at 1800 rpm and 24 bar at 1750 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 Blow off valve Battery Switch Charge air cooler LP compressor element MP compressor element HP compressor element Engine External fuel tank connections Exhaust pipe Cooling fan 1 Cooling fan 2 Filler cap fuel...

  • Page 18: Markings

    Engine oil drain Battery switch. Prohibition to open air valves without connected hoses Engine coolant drain Battery conditioner Rotation direction Fuel drain Atlas Copco engine oil Air suction Warning! Part under pressure Atlas Copco coolant Lifting point - 19 -...
  • Page 19 California Proposition 65 Low sulphur fuel (EU only) Warning (US only) Low sulphur fuel (US only) Battery conditioner / compressor and engine heater (EU only) Battery conditioner / compressor heater (US only) Do not switch the fuel lever while the unit is in operation Sound power level in accordance with Directive 84/533/EC (expressed in dB (A))

  • Page 20: Mechanical Features

    Mechanical features 3.3.1 Engine The male rotors have four lobes and the female rotors Water condensate from the water separator is drained 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 21: Frame And Axles

    3.3.10 Control panel Repairs and maintenance must be 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 22: Electrical Features

    Electrical features 3.4.2 Fuses The electrical features described in this chapter are standard provided on this compressor. 3.4.1 Pc4003™ controller The Pc4003™ module is built in into the side of the rear right corner panel, with an emergency stop button directly underneath, for maximum safety during the cranking procedure.

  • Page 23: Operation Flows

    Operation flows 3.5.1 Air flow system An air-operated balancing piston is fitted behind the male rotor rear thrust bearing of MP and HP Description compressor element. The piston decreases the load on the male rotor front thrust bearing during loaded Air drawn through the air intake filters (AF ), and operation.
  • Page 24 Overview Aftercooler 1 Engine Aftercooler 2 sensor Air intake filter (compressor) inputs Air outlet valve Blow-off silencer Compressor Unloaded Blow-off valve AF C By-pass valve Chamber (unloader assembly) Chamber (unloader assembly) HP compressor element CAN J1939 LP compressor element (RPM, Fault codes,... ) MP compressor element Throttle Check valve...

  • 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) Bypass valve (oil filter) LUBRICATING CIRCUIT Bypass valve (oil sump) OG LP CE HP HP compressor element OG HP CE LP CE MP LP compressor element MP compressor element OG MP Drain (oil sump) Cooling fan 1 (RAD, IC, AC , OC) Gear casing Oil cooler...

  • 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 Electrical priming pump 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...

  • 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 front 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. 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 Before starting – Select fuel source (internal/external) and lock the Make sure that nobody is in the unit selector valve. and all doors are closed prior to – With the unit standing level, check the engine and – Turn ON the battery switch (BS). starting the unit.

  • Page 33: Operating And Setting The Pc4003™ Controller

    Operating and setting the LOAD button. Pressing this button BACK button Pc4003™ controller will: To moves back one level or ignore – initiate Auto Load the change. 5.2.1 Pc4003™ button overview function, or commands the compressor to load (depending on actual status). –...

  • Page 34: Pc4003™ Display Icons

    5.2.2 Pc4003™ display icons Primary Main view View, Overhaul, Auto load, Preset, Active operation mode indication Active compressor status Navigation: toggle between main view and engine view Regulator overrule indication Regulator pressure value or info text Set active pressure setpoint Alarm indication and compressor info MAIN VIEW Main view indication...
  • Page 35 ALARM OIL FILL OVERHAUL Active and not-acknowledged Shutdown Major Overhaul required. The engine oil level as dropped under a Alarm. set level. The oil fill pump will be AUTO LOAD activated. ALARM This icon will be shown if the Auto Load Active and not-acknowledged Non- functionality is enabled, or by means of a Shutdown Alarm.
  • Page 36 Secondary Main view - Engine view View, Overhaul, Auto load, Preset, Active operation mode indication Active compressor status Navigation: toggle between main view and engine view Engine info Alarm indication and compressor info MAIN VIEW ENGINE WARNING LAMP - AMBER LED steady on: low alarm LOADED LED flashing slow: medium alarm...

  • Page 37: Possible Views

    5.2.3 Possible views Setup view Alarm view Main view ALARMS SETTINGS LOADED LOADED MAIN VIEW READY TO START 3450 BATTERY LOW ALARM 1000 GENERAL SETTINGS 2070 COOLANT LEVEL LOW 2000 DIGITAL INPUTS 3010 FUEL LEVEL LOW 3000 VOLTAGE INPUTS ECU DM1 LIST 4000 TEMPERATURE INPUTS ECU DM2 LIST 5000 RELAY OUTPUTS...

  • Page 38: Operations Overview

    Measuring view 5.2.5 Starting Except for a controller power down, nothing interrupt 1. Switch on the battery switch. MEASUREMENTS INITIALIZING SEQUENCE. 2. Switch on the machine by switching the Pc4003™ During INITIALIZING LOADED Power Switch to the ON position. SEQUENCE, all buttons / inputs / While the machine gets powered up, the controller outputs / alarms are inactive.
  • Page 39 The following view is shown. 3. Press the START button. MAIN VIEW The machine activates its horn and flasher light MAIN VIEW for 5 seconds, to notify that it is starting. ENGINE PREHEATING READY TO START MAIN VIEW READING ENGINE DATA 1286h --RPM 0.0 bar...
  • Page 40 The engine starts cranking. The engine starts running at idle speed. MAIN VIEW MAIN VIEW MAIN VIEW ENGINE RESTING ENGINE WARMING UP ENGINE CRANKING 120s 13°C 40°C 25°C 300s 0RPM 800RPM 324RPM 1286h 324RPM 0.0 bar 1286h 1200RPM 3.3 bar 1286h 324RPM 0.0 bar...
  • Page 41 If during the WARMING UP SEQUENCE, all After warming up, the machine is ready to be conditions are met to end the WARMING UP loaded and is waiting for a load command. MAIN VIEW SEQUENCE, WARMING ENGINE WARMING UP SEQUENCE blocked MAIN VIEW TEMPERATURE CONTROL function, the...

  • Page 42: Stopping

    5.2.6 Stopping 4. Press the LOAD button. Active Buttons: Press the STOP button. Stop Button MAIN VIEW The engine will go into COOLDOWN SEQUENCE. (to initiate Stop command) PREPARING TO LOAD The following view is shown. Load Button (to activate Automatic Load) MAIN VIEW ENGINE COOLING DOWN Measurement View Button...
  • Page 43 Following condition is taken into account, before the During the COOLDOWN SEQUENCE, if the After cooling down, the engine enters the STOP COOLDOWN SEQUENCE ended: COOLDOWN ‘MODE’ is set to ‘timer based’, or if SEQUENCE. During the STOP SEQUENCE, before COOLDOWN TIMER ≥...

  • Page 44: Shutdown

    5.2.7 Shutdown 5.2.8 Power off When the controller is waiting for the STOP DETECTION ‘MINIMUM START DELAY’ to When the machine is shut down due to a critical alarm The compressor is equipped with a battery switch. elapse, an additional timer is shown on the display: or an emergency stop, the following view is shown.

  • Page 45: Settings

    5.2.9 Settings 5.2.9.2 Acknowledge an Alarm As soon as the fuel level is higher than the warning level again, the alarm icon will automatically If an alarm becomes active, for example a Low Fuel For buttons to be used see “Pc4003™ button disappear.

  • Page 46: Set Language

    5.2.9.4 Set Language 5.2.9.6 Change Display Settings 8. Now press BACK until you are back in the Main View (or in the menu you require). 1. Press the SETTINGS VIEW button. 1. Press the SETTINGS VIEW button. 9. To leave Diagnostics, press the STOP button. 2.

  • Page 47: Overrule Ecu Alarms

    5.2.9.9 Overrule ECU Alarms 7. Set the desired time schedule (default = 5 minutes) and press ENTER. If the Overrule ECU Alarms function is enabled, the Pc4003™ controller will temporarily ignore all 8. Now press BACK until you are back in the Main received ECU alarms.

  • Page 48: Operating The Automatic Fire Suppression System

    Operating the automatic fire suppression system 5.3.1 Main components Control module Cylinder with extinguishing powder Large nitrogen cylinder Manual actuator Small nitrogen cylinder Small nitrogen cylinder Nozzles Automatic actuator - 49 -...

  • Page 49: Operation

    5.3.2 Operation 5.3.3 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 50: Buttons

    4. DETECTION 5.3.4 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 51: Maintenance

    Maintenance Maintenance schedule every every every every every Maintenance schedule Daily 50 hrs 250 hrs 1000 hrs 1500hrs 6000 hrs 10000 hrs 2912 4580 04 2912 4581 05 2912 4582 06 Service pak Check engine oil level Check compressor oil level Check coolant levels (radiator) Check coolant additive and antifreeze concentration...
  • Page 52 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 53 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 glass wool and insert (every 2 years) Replace roller diaphragm of unloader cylinder...

  • Page 54: 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 55: Engine Maintenance Procedures

    Engine maintenance Compressor maintenance – To drain oil from system, open the oil filler cap, remove the drain plug, located at the right-hand procedures procedures side under the unit and open the drain cock (1). Refer to the engine’s operator manual for full 6.3.1 Compressor oil level check –...

  • Page 56: 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 57: Adjustment And Servicing Procedures

    Adjustment and servicing procedures 6.4.1 Coolant 6.4.1.2 Testing coolant inhibitor level Use coolant test strips to measure, chloride nitrite and 6.4.1.1 Coolant level check glycol concentrations. Cavitation/corrosion protection is indicated on the strip by the level of nitrite concentration. Freeze/boil over protection is determined by glycol concentration.

  • Page 58: 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 59: 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 60: Draining Primary Fuel Filters

    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 61: 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, fuel cooler and aftercooler 2 are located at the rear end of the unit, under the air filters.

  • Page 62: Poly V-Belt Tension Adjustment

    6.4.5 Poly V-belt tension adjustment 6.4.6 MP safety valve adjustment Correct the V-belt tension by loosening the fixing 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 63: Electrolyte

    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 64: Recharging A Battery

    6.4.8.4 Maintaining the battery voltage 6.4.8.5 Battery maintenance – Rock the battery a few times so that possible air 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 65: Servicing Water Separator

    Maintenance must be performed by authorized Water condensate from the water separator is drained personnel only. Please contact Atlas Copco. through a nipple in the bottom of the frame. Connect a drain hose to the nipple and make sure that the All maintenance activities are to be recorded in a condensate is properly disposed of.

  • Page 66: Engine Consumable Specifications

    PAROIL has an excellent Total Base Number (TBN) 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 67: 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 68: Checks And Trouble

    Checks and trouble Battery and alternator PARCOOL EG is free of nitride and amines to protect 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 69: 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 70 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 71 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 72 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 73 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. - 74 -...
  • Page 74 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. LP intercooler pressure above Aftercooler clogged internally.

  • Page 75: Compressor Control Module Trouble Shooting

    Compressor control module trouble shooting 7.4.1 Process information While the compressor is running, the operator can take a brief look at all the incoming compressor and engine data, by pressing the Process Info button. This can be very useful for trouble shooting over the phone. 7.4.2 Fault codes There are several parameters that are continuously watched.
  • Page 76 Alarm code Alarm text Fail class Trigger 3200 ENGINE OIL LEVEL WARNING Warning 3210 ENGINE OIL LEVEL SHUTDOWN Shutdown 3220 ENGINE OIL LEVEL SENSOR CIRCUIT Shutdown 3450 BATTERY LOW ALARM Indication 3460 BATTERY HIGH ALARM Warning 3720 INTERSTAGE PRESSURE SENSOR CIRCUIT Warning 4000 L.P.
  • Page 77 Alarm code Alarm text Fail class Trigger 7002 ECU COMMUNICATION Shutdown 7007 ECU RED LAMP Shutdown 7008 ECU AMBER LAMP Warning 7009 ECU PROTECT LAMP Warning 7010 ECU ENGINE SPEED TOO LOW Shutdown 7020 ECU ENGINE SPEED ALARM 2 Shutdown 7030 ECU ENGINE COOLANT TEMP.

  • Page 78: Shutdown Sensors

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

  • Page 79: Available Options

    Available options Hot weather pack Pressure reducer Heating kit The heating kit is a cold start option. The hot weather pack option allows the compressor to A pressure reducer (1) limits the operating pressure to It consists of heater plugs that are to be installed in run in ambient conditions up to 50°C (122°F) (45°C 7 bar (102 psi) and thus allows the operation of hand engine and gearbox, making sure that the engine starts...

  • Page 80: Storage Of The Compressor

    Storage of the compressor 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. Close the air outlet valves after stopping. If the unit is going to be stored without running from time to time, protective measures must be taken.

  • Page 81: 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 82: 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 83: Compressor/Engine Specifications For Standard Units

    11.3 Compressor/engine specifications for standard units Designation Unit Value Reference conditions Absolute inlet pressure bar(e) Relative air humidity Air inlet temperature °C Normal effective working pressure bar(e) The inlet conditions are specified at the air inlet grating outside the canopy Limitations Minimum effective receiver pressure bar(e)
  • Page 84 Sound pressure level (LP), measured according to EPA with a tolerance of ± 3dB(A) dB(A) under free field conditions at 7 m distance Sound power level (LW) complies with 84/532/533/EEC and 85/406/EEC limits dB(A) Design data Compressor Number of compressor stages 3 in serial Engine Make...
  • Page 85 Unit dimensions Length 5240 (with towbar in towing position) 6770 Width 2210 Height 2350 Weight (ready to operate) TBD* Weight (without fuel) TBD* Notes TBD = Data to be defined At reference conditions, if applicable, and in normal shaft speed, unless otherwise stated. Data Measured according to Tolerance...

  • Page 86: 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 87 9822 0900 21/01 Applicable for PNS 1250 T3, Circuit diagram Engine and Controller 24(a2) 04.2, 05.1, 07.1, 08.1 06.7 Legend Wire sections : Color codes : aaa = 0.35mm² 0 = black 03.3 1 = brown aa = 0.5 mm² 2 = red ab = 0.75mm²...
  • Page 88 24(c2) 03.10 06.7 X1-18 X1-20 X1-07 X1-08 X1-17 X1-38 X1-06 1004(a2) X2-07 X1-16 X1-05 1005(a6) X2-19 X1-04 1006(a3) X2-06 1002(b3) X2-27 1007(a7) X2-05 ENGINE CONTROL MODULE 1003(b3) X2-11 X1-50 X1-40 X1-39 X1-30 X1-29 19(c6) 03.10 - 91 -...
  • Page 89 24(a2) 03.10 38(a3) 241M(a2) 24M(b2) 04.9, 06.10, 07.5, 08.5 27MK4(d2) 26(d2) 27M(d2) 06.2 241M(a2) 39(a3) 39(a3) 06.10 - 92 -...
  • Page 90 19(a6) 03.10 S5 H4-5 39(a3) 05.1 30 03.3 D7 B8 D16 B16 28(a3) 04.9 - 93 -...
  • Page 91 HEATERS EU 24(a2) 03.10 CUBICLE L1(c1) L1(c1) LM(c1) LM(c1) L2(c1) L2(c1) 07.3 LM(c1) L(c1) N2(c6) N(c6) PE(c54) H1-3 N(c6) 19(b6) N(c6) N2(c6) 03.10 - 94 -...
  • Page 92 HEATERS USA 24(a2) 03.10 CUBICLE LMA(c1) L1(c1) L1(c1) LMB(c1) L2(c1) L2(c1) 08.3 LA(c2) NA(c6) LB(c1) LMB(c1) NB(c6) PE(c54) 08.4 3 08.4 H2-3 NB(c6) NA(c6) N2(c6) 19(b6) 03.10 - 95 -...
  • Page 93 Diode Circuit Breaker - ECM, 20A Temperature Sensor - Low Pressure Element Temperature Diode Circuit Breaker - Emergency Stop, 20A Fuse - Fire Extinguisher, 10A Circuit Breaker - Main, 10A Temperature Sensor - Medium Pressure Element Temperature Battery Circuit Breaker - Heater EU, 16A Battery Circuit Breaker - Heater USA, 16A Temperature Sensor - High Pressure...
  • Page 94 9822 1025 07/00 Applicable for PNS 1250 T3 - Circuit wiring ENGINE HEATER Battery switch continuous ground for internal lights MOTOR COMP OILER REFINERY EQUIPMENT VALVE Breakout Engine heater Connector switch FLASHER FLASHER Internal light LIGHT LIGHT START ENGINE STARTER RELAY COMP WS DRAIN HEATER...
  • Page 95 1626 9921 02/00 Applicable for PNS 1250 T3 - Wire harness front See note 51 ALTERNATOR See note 53 See note 54 CIRCUIT CIRCUIT CIRCUIT BREAKER BREAKER BREAKER SOLID STATE RELAY Main Emergency stop 31-PIN BREAKOUT See note 19 Cavity: CONNECTOR See note 55 AIR INLET...
  • Page 96 See note 21 LP-IC PRESSURE FLASHER LIGHT See note 7 See note 19 COOLANT LEVEL See note 40 INTERNAL LIGHT See note 9 901 902 234 235 236 BLOW OFF VALVE See note 14 232 233 1800 1400 EMERGENCY STOP TO PAGE 1 Splice: in this area...
  • Page 97 TERMINAL END A TERMINAL END B WIRE TERMINAL TERMINAL MM² COLOR see note 19 see note 1 orange see note 1 see note 14 orange AMP 342145-1 AMP 130090-0 orange see note 19 see note 1 orange see note 2 see note 14 orange see note 7...
  • Page 98 TERMINAL END A TERMINAL END B WIRE TERMINAL TERMINAL MM² COLOR splice see note 18 blue see note 14 blue see note 19 blue see note 2 splice blue see note 9 blue see note 9 blue see note 1, 31 splice grey see note 30, 31...
  • Page 99 TERMINAL END A TERMINAL END B WIRE TERMINAL TERMINAL MM² COLOR eye M12 splice inline fuse; see notes 56, 57 splice 241M 241M uninsulated wire ferrule AMP 0-925856-1 241M uninsulated wire ferrule AMP 0-925856-1 241M see note 1 AMP 3-520117-2 see note 2 terminal end terminal end...
  • Page 100 TERMINAL END A TERMINAL END B WIRE TERMINAL TERMINAL MM² COLOR see note 34 see note 40 1005 blue see note 34 see note 40 1006 orange see note 40 see note 34 1007 purple - 103 -...
  • Page 101 NOTES Note 1: Connector: Amphenol PT06 A 22-41 S SR Note 1 and 2 need to be from the same supplier and Note 9: Connector: Deutsch DTM 06-2S Terminals: Size 16 (large): the same as on 1626992000. Terminals: Deutsch 1062-20-0122 Amphenol 800 635 Secondary Lock: Size 20 (small):...
  • Page 102 Note 18:AMP 133544-4 Note 27:All wire type H05V-K/H07V-K according Note 40:Connector body: Shrinkable sleeve to be attached as in to AC standard 0995 2000 00 unless Packard Electric 12065298 drawing. specified otherwise Terminals: Packard Electric 12048074 Wall thickness: min. 1 mm. Wire Seals: Packard Electric 12089678 Wires may be devided over two terminals if Note 30:Connector: Deutsch DT 04-3P...
  • Page 103 Note 55:Deutsch DT Series Note 66:Terminal and shrinkable sleeve to be Housing Deutsch DT 06-2S mounted as in drawing Socket Deutsch 0462-201-16141 Wire number printed on shrinkable sleeve Wedge Deutsch W2S Note 56: Fuse holder Multicomp MCCQ-211C (or equal) Note 57:Fuse (10A) Littelfuse 0257010 (or equal) Multicomp MCATQ 10A Fuse holder's wires to be cut to appropriate 1: Braiding...
  • Page 104 1626 9920 02/00 Applicable for PNS 1250 T3 - Wire harness rear OILER VALVE See note 2 Pc4003 label: OUTLET TEMP. REG. VALVE Pc4003 See note 16 See note 3 See note 8 Pc4003 ROW 1-8: LENGTH = 150mm label: ROW 9-16: LENGTH = 100mm Pc4003 See note 34...
  • Page 105 TERMINAL END A TERMINAL END B WIRE TERMINAL TERMINAL MM² COLOR See note 11 See note 16 Green See note 4 Splice Orange See note 16 Orange See note 3 Orange See note 2 Splice Blue See note 11 Blue See note 16 Blue See note 16...
  • Page 106 TERMINAL END A TERMINAL END B WIRE TERMINAL TERMINAL MM² COLOR See note 16 & 29 Splice Grey See note 4 & 29 Grey See note 30 & 29 Grey See note 16 & 29 Splice Purple See note 4 & 29 Purple See note 30 &...
  • Page 107 TERMINAL END A TERMINAL END B WIRE TERMINAL TERMINAL MM² COLOR See note 4 Splice Orange Splice diode 1N5402 (3A, 100V) See note 2 Orange Splice diode 1N5402 (3A, 100V) See note 16 Orange See note 16 See note 32 Grey See note 16 See note 32...
  • Page 108 NOTES Note 1 and 4 need to be from the same supplier and Note 4: Connector: Amphenol PT07 A 22-41 P SR Note 7: - Terminals 84, 85 shall be equipped with a the same as on 1626991900 and 1626992100. Terminals: Size 16 (large): Amphenol label with printing: 800 620...
  • Page 109 Note 11:Connector according to DIN 72585 4 pins Note 19:Braiding end at connector fitted with label Note 26:Terminal and shrinkable sleeve to be Connector: G&H 17984.000.002 See drawing for text mounted as in drawing Terminals: G&H 26570.201.184 Wire number printed on shrinkable sleeve Wire seal: G&H 14414.627.626 Unused cavities to be sealed with:...
  • Page 110 Note 29:Twisted cables 3 turns each 100 mm Note 34:Insert: Tyco 2-1103111-3 (HN.D.40.Bu.C) Terminal A Terminal B Harting 09 21 040 3101 Group 1 splice 100 grey Socket: Tyco 2-1105051-1 (0.5mm²) splice 102 purple Harting 09 15 00 6203 Group 2 splice 100 grey Socket:...
  • Page 111 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 112 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) - 115 -...

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