Related Manuals for Atlas Copco XATS 138 PE Stage V APP
Summary of Contents for Atlas Copco XATS 138 PE Stage V APP
- Page 1 Instruction Manual Instruction Manual for Portable Compressors English XATS 138 PE Stage V APP XATS 250 PE Stage V APP Engine XAHS 108 PE Stage V APP Kubota V2403-CR-T-E5B XAHS 190 PE Stage V APP...
- Page 3 Instruction Manual for Portable Compressors XATS 138 PE Stage V APP XATS 250 PE Stage V APP XAHS 108 PE Stage V APP XAHS 190 PE Stage V APP Original instructions Printed matter No. 2960 5790 00 ATLAS COPCO - PORTABLE ENERGY DIVISION www.atlascopco.com...
- Page 4 Neglecting maintenance or making changes to the setup of the machine can result in major hazards, including fire risk. 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.
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Page 5: Table Of Contents
Table of contents Preface Starting/Stopping ........31 Emergency stop.......... 31 Follow the instructions in this booklet and we guarantee you years of troublefree operation. It is a Safety precautions ........7 Basic operation of the machine....32 solid, safe and reliable machine, built according to 5.6.1 Control panel ......... - Page 6 Available options ........62 Problem solving ........63 Technical specifications ......65 Compressor / engine specifications.... 65 9.1.1 Reference conditions......65 9.1.2 Limitations ..........65 9.1.3 Performance Data (3) (4) ....... 66 9.1.4 Design data..........67 Altitude unit performance curves ....69 Dimension drawing........
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Page 7: Safety Precautions
An electrical technician is trained and has the same These safety precautions are general and some The policy of Atlas Copco is to provide the users of qualifications as both the operator and the mechanical statements will therefore not always apply to a their equipment with safe, reliable and efficient technician. -
Page 8: General Safety Precautions
Atlas Copco GENERAL SAFETY PRECAUTIONS Care shall be taken to avoid damage to safety equipment. valves other pressure-relief devices, The owner is responsible for maintaining the unit especially to avoid plugging by paint, oil coke or These safety precautions apply to machinery in a safe operating condition. -
Page 9: Safety During Transport And Installation
SAFETY DURING TRANSPORT AND on the hook, Lifting hooks, eyes, shackles, etc., shall never be bent and shall only have stress in line with their INSTALLATION - check that the wheels are secure and that the design load axis. The capacity of a lifting device tyres are in good condition and inflated diminishes when the lifting force is applied at an Transport of the unit has to be done by authorized/... -
Page 10: Safety During Use And Operation
13 Never refill fuel while the unit is running, unless injury. to alert people entering the room, for even otherwise stated in the Atlas Copco instruction relatively short times, about the need to wear The air line end connected to the outlet valve book. -
Page 11: Safety During Maintenance And Repair
18 The unit has parts, which may be accidentally 25 Remember that where there is visible dust, the SAFETY DURING MAINTENANCE AND touched by personal, of which the temperature finer, invisible particles will almost certainly be REPAIR can be in excess of 80°C (176°F). The insulation present too;... -
Page 12: Tool Applications Safety
Atlas Copco or the applied. machine manufacturer. Ascertain that the 22 When using cartridge type breathing filter selected lubricants comply with all applicable equipment, ascertain that the correct type of... -
Page 13: Specific Safety Precautions
Bolts of cover and flanges may not be used for as the battery can spit electrolyte while gassing. extra fixation. Once the battery has been charged, ensure that the (Pressure) vessel maintenance is to be performed battery is unplugged before disconnecting the by Atlas Copco. - 13 -... - Page 14 If the set pressure must be altered then use only Inhalation: If dust is inhaled, the person should be correct parts supplied by Atlas Copco and in provided with fresh air immediately. Seek medical accordance with the instructions available for the attention.
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Page 15: Leading Particulars
Leading particulars SAFETY PICTOGRAMS USED GENERAL DESCRIPTION Engine The compressor is driven by a liquid-cooled diesel This symbol draws your attention to engine. dangerous situations. The operation The engine's power is transmitted to the compressor concerned may endanger persons and through a gear box. - Page 16 Regulation Fuel system Lifting eye The compressor is provided with a continuous The fuel feed lines and fuel filtration are designed in A lifting eye is accessible through a rubber covered regulating system and a blow-down valve which is such a way that after running the fuel tank dry, air hole at the top of the unit.
- Page 17 Lubricator A tool lubricator is a reservoir that can keep 2.4 l of lubricant. The lubricant is picked up by the outgoing air and delivered to the pneumatic tool on the other end of the air hose. Data plate The compressor is furnished with a data plate (D) showing the product code, the unit number and the working pressure (see chapter Dataplate).
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Page 18: Main Parts
Main Parts - 18 -... - Page 19 Reference Name Reference Name Aftercooler OFce Oil Filter (compressor element) Air Filter (compressor) Oil Filter (engine) Air Filter (engine) Oil Level Gauge Air Receiver Oil Separator Air Outlet Valves Pressure Sensor Battery Starting Motor Brake Handle Safety Valve Cooler Towbar Compressor Element Tool Box Coupling Housing...
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Page 20: Overview
Overview - 20 -... - Page 21 Reference Name Air Filter (engine) Air Filter Element Air Filter (compressor) Air Outlet Valve AR/OS Air Receiver/Oil Seprator By Pass Valve (oil filter) Blow Off Valve Compressor Element Cooling Fan Coupling Housing Control Panel Drain Plug Engine Electrical Wiring Oil Cooler Oil Filter (compressor) Oil Separator Element Oil Stop Valve...
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Page 22: Markings And Information Labels
Atlas Copco synthetic engine oil. Service every 24 hours. Flammable substances. Do not tow with the support in rest Atlas Copco low sulphur engine oil. Warning! Part under pressure. position. Check the maximum pressure of the Manual. -
Page 23: Operating Instructions
Operating instructions PARKING, TOWING AND LIFTING PARKING INSTRUCTIONS INSTRUCTIONS Safety precautions The operator is expected to apply all relevant Safety precautions. Attention After the first 100 km travel: Check and retighten the wheel nuts and towbar bolts to the specified torque. -
Page 24: Towing Instructions
TOWING INSTRUCTIONS Label on towbar, towing instructions Adjustable towbar with jockey wheel and brakes Towing position of jockey wheel For both non-adjustable and adjustable towbar, the Before towing the compressor, ensure towbar should be as level as possible and the that the towing equipment of the vehicle compressor and towing eye end in a level position. - Page 25 HEIGHT ADJUSTMENT (with adjustable towbar) Remove spring pin (1). Release locking nut (2). Adjust required height of the towbar. Tighten locking nut (2) by hand. Secondly tighten locking nut (2) using an extension tube (3). ...
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Page 26: Lifting Instructions
BALL COUPLING (OPTION) LIFTING INSTRUCTIONS Coupling: Open coupling jaw by pulling the lever vigorously upwards in the direction of the arrow. Lower the opened coupling onto the ball of the vehicle coupling and the lever will automatically be lowered. Closing and locking are carried out automatically. -
Page 27: Shipping The Compressor
SHIPPING THE COMPRESSOR Specified shipping vehicle Use only these shipping vehicles to transport the unit to the required location: 1. Curtain Trailers 2. Open Trailers 3. Winch Trucks - 27 -... -
Page 28: Fixation Tools
FIXATION TOOLS Removing the Lashing belts Use only CE-approved lashing belts (ratchet straps). The lashing belt set has two separate belts, the fixed 1. Open the ratchet handle (3). The lashing belts (ratchet straps) must be of type LC belt and the adjusting belt. 2000 daN and Stf 350 daN. -
Page 29: Securing The Unit To The Shipping Vehicle
SECURING THE UNIT TO THE SHIPPING VEHICLE 1. Place the unit in centre position into the shipping vehicle so that the canopy is parallel to the edges of the shipping vehicle. 2. For tie points 1 to 4, hook the four adjusting belts to the eyes of the unit and four fixed belts to the eyes on the shipping vehicle. -
Page 30: Operating The Compressor
OPERATING THE COMPRESSOR BEFORE STARTING Overall checks Preparing the battery for operation 1. Before initial start-up, prepare battery for PREVENT LOW LOADS operation if not already done. Also see section Follow the relevant safety instructions Recharging a battery. Low loads may lead to: during battery use according to section 2. -
Page 31: Starting/Stopping
STARTING/STOPPING EMERGENCY STOP 5. Drain any water and sediment from the fuel filters Always use low sulphur diesel and low until clean fuel flows from the drain cock. SAP engine oils. Sulphur poisons the catalytic coating of the Diesel Oxidation 6. -
Page 32: Basic Operation Of The Machine
BASIC OPERATION OF THE MACHINE CONTROL PANEL The compressor can be controlled in 4 different modes: Local Operation Mode: locally at the Operating Panel, Remote Operation Mode: via remote switch inputs located at the bottom of the Control panel, ... - Page 33 Reference Name Load button. Pressing this button will: initiate the Auto Load function, or commands the compressor to load (depending on actual status). command the compressor to switch to Not Loaded (when in Load). Measurements View button By pressing this button you can toggle between Measurements View and Main View.
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Page 34: Overview Icons
OVERVIEW ICONS Reference Name View, Overhaul, Auto load, Preset and Active operation mode indication Active compressor status Navigation, toggle between main view and engine view Engine information Vessel pressure indication or information text Alarm indication and compressor information Main View Indication MAIN VIEW LOADED Measuring View Indication... - Page 35 Block Mode Contact Atlas Copco. LED flashing: the diesel particulate Alarm filter urgently needs to be Active & not-acknowledged regenerated. Contact Atlas Copco. Shutdown Alarm. Regeneration of the diesel Alarm particulate filter is inhibited. Active & not-acknowledged Non- LED steady on: the regeneration of Shutdown Alarm.
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Page 36: Possible Views
POSSIBLE VIEWS Main View Measurements View Main view is the default view. In the main view the operator can view the most important information on MEASUREMENTS the actual compressor operation, like: READY TO START Active Sequence Vessel pressure Clock 2013-12-5 20:23 ... - Page 37 Settings View Alarm View SETTINGS ALARMS READY TO LOAD LOADED LOADED 1000 GENERAL SETTINGS 3450 BATTERY LOW ALARM 2000 DIGITAL INPUTS 2070 COOLANT LEVEL LOW Fuel rate 4 l/h 3000 VOLTAGE INPUTS 3010 FUEL LEVEL LOW Engine coolant temp. 87°C 4000 TEMPERATURE INPUTS ECU DM1 LIST Engine inlet temperature...
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Page 38: Starting
STARTING The display will change to During initializing all buttons/inputs/outputs/alarms are inactive. MAIN VIEW This view will be shown for about 2 seconds, after POWERING UP e-XTENSION which the display will show the Main View. MAIN VIEW VESSEL BLOWING OFF 1286h --RPM 0.0bar... - Page 39 The display will change to The display will change to The engine starts crancking, the display shows MAIN VIEW MAIN VIEW MAIN VIEW READING ENGINE DATA ENGINE PREHEATING ENGINE CRANKING 0RPM 800RPM 324RPM 1286h --RPM 0.0bar 1286h --RPM 0.0bar 1286h 324RPM 0.0bar The engine electronics (ECU) will be powered up.
- Page 40 The display now shows The engine starts running at idle speed. The display When warming up temperature is reached within shows 30 seconds the display will show MAIN VIEW MAIN VIEW MAIN VIEW ENGINE RESTING ENGINE WARMING UP ENGINE WARMING UP 13°C 40°C 120s...
- Page 41 After warming up the machine is ready to be loaded Press the load button, the display will show The engine will now run at maximum rpm, the display and is waiting for a load command; the display shows will show MAIN VIEW MAIN VIEW MAIN VIEW...
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Page 42: Pressure Setting
During loading the following display is shown PRESSURE SETTING (default display) To change the pressure setting there are two By pressing the left or the right arrow button the possibilities. operator will be notified to: MAIN VIEW 1. Choosing between presets “Press enter to go to other pressure setting X Y”... -
Page 43: During Operation
2. Changing the pressure of a preset DURING OPERATION The operator can adjust the active preset as follows. The doors must be closed during operation and may be opened for short periods only. MAIN VIEW Be aware not to touch hot parts when the LOADED door is open. -
Page 44: Stopping
STOPPING SHUTDOWN Press the stop button. Open the air outlet valves to After cooling down the engine will stop and the When the machine is shutdown due to a critical alarm avoid that part of the system will remain pressurized. display will show or an emergency stop the display will show After pressing the Stop button the display will show:... -
Page 45: Power Off
POWER OFF SETTINGS Switch the controller off by pressing the Power For buttons to be used see section Control panel. As long as there is an alarm icon in the middle of the button. bottom part of the view, all active acknowledged / un- Acknowledge an Alarm acknowledged alarms can be seen by pressing the When the compressor is not in use, the battery must... - Page 46 Set Language Change Display Settings Set the AutoLoad Function Press the Settings View button Press the Settings View button Press the Settings View button scroll to 1000 GENERAL SETTINGS scroll to 1000 GENERAL SETTINGS scroll to 1000 GENERAL SETTINGS ...
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Page 47: Eco Mode
ECO MODE Overview ECO mode feature is a simplification for the 'Automatic functions'. The common settings of the automatic functions are grouped in the ECO mode pop-up menu, to make it easier for the end user to modify the settings. A single pop-up menu avoids to go into four different menu’s of the Settings Menu. - Page 48 When the ECO mode is active, an icon is displayed in Auto start Auto no-load / auto re-load the right upper corner of the controller display as The auto start function is used to have the compressor The auto no-load function is used for saving fuel shown below.
- Page 49 Auto stop The auto stop function is used to stop the compressor, After setting-up the necessary parameters when there is no air demand over an extended time. for each mode, click on ‘OK’ to This function can be combined with the Auto Start acknowledge.
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Page 50: Fault Codes
AMBIENT TEMP ALARM INDICATION 7100 ECU DPF SOOT LOAD HIGH WARNING 7110 PLEASE FORCE DPF REGENERATION ! INHIBIT LOAD 7120 LOAD PREVENTION - HIGH DPF SOOT LOAD CONTROLLED STOP 7130 SOOT LOAD TOO HIGH - CALL ATLAS COPCO WARNING - 50 -... -
Page 51: Maintenance
Maintenance QR CODE Unauthorised modifications can result Scan the QR code to access into the Atlas Copco in injuries or machine damage. Spare Part list (ASL). Always keep the machine tidy to prevent fire hazard. Poor maintenance void warranty claims. -
Page 52: Storage
Control panel The compressor can be equipped with the FleetLink as an option, an intelligent smartbox system for fleet monitoring. Atlas Copco developed both hardware and DAILY MAINTENANCE UNDERCARRIAGE BEFORE A ROADGOING software to provide you with insights of the compressor performance. - Page 53 MAINTENANCE SCHEDULE ENGINE AND COMPRESSOR Maintenance schedule (running hrs) Notes Daily 50 hrs after Every 250 Every 500 Every Yearly 2 Yearly initial start-up 1000 hrs Drain water from fuel filter Drain/Clean fuel tank water and sediments Drain condensate and water from spillage-free frame or catch basin Empty air filter vacuator valves Check engine oil level (if necessary top up)
- Page 54 Clean oil cooler(s) Clean radiator Analyse coolant (4)(8) Replace air filter element Check/Replace safety cartridge Inspection by Atlas Copco service technician Check engine & compressor anti-vibration pads Check valve in the fuel return line (for mechanical injection system) - 54 -...
- Page 55 MAINTENANCE SCHEDULE UNDERCARRIAGE Maintenance schedule (km) Notes Daily 50 km after Every 2000 Yearly 2 Yearly initial start-up Check tyre pressure Check tyres for uneven wear Check torque of wheel nuts Check towbar handbrake lever spring actuator, reversing lever, linkage and all movable parts for ease of movement.
- Page 56 6. Gummed or clogged filters means fuel starvation and reduced engine performance. 7. See section Oil specification. 8. The following part numbers can be ordered from Atlas Copco to check on inhibitors and freezing points: • 2913 0028 00 refractometer •...
- Page 57 OIL SPECIFICATION ENGINE OIL COMPRESSOR OIL It is strongly recommended to use Atlas Copco branded lubrication oils for both compressor and engine. If you want to use another brand of oil, consult Atlas Copco. Never mix synthetic with mineral oil. Choose your engine oil based on the ambient Choose your compressor oil based on the ambient temperatures in the actual operating area.
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Page 58: Compressor Oil Level Check
COMPRESSOR OIL LEVEL CHECK DAILY CHECK CHECK AFTER A LONGER PERIOD WITHOUT RUNNING THE COMPRESSOR Check the compressor oil level daily, after running 1. Check the oil level via the oil level indicator (3). the compressor. The pointer must register in the green area. The compressor oil level needs to be 2. -
Page 59: Engine Oil Level Check
ENGINE OIL LEVEL CHECK COOLANT COOLANT LEVEL CHECK Check the coolant level at the level gauge on the Never mix oils of different brands or It is strongly recommended to use Atlas radiator. If necessary top up with coolant. See types. -
Page 60: Air Filter Engine/Compressor
AIR FILTER ENGINE/COMPRESSOR CLEANING COOLERS PERIODIC BATTERY SERVICE Always keep the batteries clean and dry. Keep the coolers clean to maintain the cooling Refill batteries with distilled water only. Using tap efficiency. Open the hood and clean the coolers with or mineral water, acid, or electrolyte will alter the a fibre brush and compressed air. -
Page 61: Spillage-Free Frame
SPILLAGE-FREE FRAME The compressor is fitted with a leak-proof undercarriage in order to protect the environment. Any leaking fluid is collected in case of malfunctions. This fluid can be removed via a drain (1), normally secured by caps. Tighten the cap firmly and check for leakages. Please observe the locally applicable environmental regulations when removing the leaked liquid. -
Page 62: Available Options
Available options Towbar: Adjustable with brakes (A) Fixed with brakes (A) Fixed with low rider Without towbar: Support (without undercarriage) Towing eyes: NATO Ball coupling Loose ball coupling Towbar support: Support leg Jockey wheel Road lights system: Full (B) Refinary equipment: Spark arrestor Inlet shutdown valve Air quality Aftercooler + water separator... -
Page 63: Problem Solving
Problem solving It is assumed that the engine is in good condition. If it’s not possible to solve the problem with this problem solving table, please consult Atlas Copco. Problem: Engine loses power, compressor cannot be loaded. Possible faults Corrective actions High soot load in Diesel Particulate Filter causes engine to run in safety Contact Atlas Copco. - Page 64 Problem: Air and oil mist expelles from air filters immediately after stopping. Possible faults Corrective actions Plunger of oil stop valve jammed. Contact Atlas Copco. Problem: Compressor overheating. Possible faults Corrective actions Insufficient compressor cooling. Locate compressor away from walls; when banked with other compressors, leave space between them.
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Page 65: Technical Specifications
Technical specifications COMPRESSOR / ENGINE SPECIFICATIONS REFERENCE CONDITIONS Designation Unit XATS 138 PE XATS 138 PE/XATS 250 PE XAHS 108 PE XAHS 108 PE/XAHS 190 PE XATS 250 PE with aftercooler XAHS 190 PE with aftercooler Absolute inlet pressure bar(a) 14.5 14.5 14.5... -
Page 66: Performance Data (3) (4)
PERFORMANCE DATA (3) (4) Designation Unit XATS 138 PE XATS 138 PE/XATS 250 PE XAHS 108 PE XAHS 108 PE/XAHS 190 PE XATS 250 PE with aftercooler XAHS 190 PE with aftercooler Engine shaft speed, normal and maximum At pressure setting (bar(g)) 7 2700 2700 At pressure setting (bar(g)) 8.6... -
Page 67: Design Data
DESIGN DATA Compressor Number of compression stages XATS 138 PE XATS 138 PE/XATS 250 PE XAHS 108 PE XAHS 108 PE/XAHS 190 PE XATS 250 PE with aftercooler XAHS 190 PE with aftercooler Engine Designation Unit XATS 138 PE XATS 138 PE/XATS 250 PE XAHS 108 PE XAHS 108 PE/XAHS 190 PE XATS 250 PE... - Page 68 Unit Designation Unit XATS 138 PE XATS 138 PE/XATS 250 PE XAHS 108 PE XAHS 108 PE/XAHS 190 PE XATS 250 PE with aftercooler XAHS 190 PE with aftercooler Capacity of compressor oil system US gal Net capacity of air receiver US gal Air volume at inlet grating (approx.) (1) m³/s...
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Page 69: Altitude Unit Performance Curves
ALTITUDE UNIT PERFORMANCE CURVES Maximum allowable working pressure as a function of altitude and ambient temperature. XATS 138 PE/XATS 250 PE XAHS 108 PE/XAHS 190 PE Graphic represents working conditions. For starting conditions, please contact your Atlas Copco service centre. - 69 -... -
Page 70: Dimension Drawing
Dimension drawing DIMENSIONS DRAWING- 9822 0179 00 - 70 -... - Page 71 DIMENSIONS DRAWING- 9822 0180 00 - 71 -...
- Page 72 DIMENSIONS DRAWING- 9822 0181 00 - 72 -...
- Page 73 DIMENSIONS DRAWING- 9822 0205 00 - 73 -...
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Page 74: Electrical Diagram
Electrical diagram CIRCUIT DIAGRAM - 9822 1111 48-01 - 74 -... - Page 75 CIRCUIT DIAGRAM - 9822 1111 48-02 - 75 -...
- Page 76 CIRCUIT DIAGRAM - 9822 1111 48-03 - 76 -...
- Page 77 CIRCUIT DIAGRAM - 9822 1111 48-04 - 77 -...
- Page 78 CIRCUIT DIAGRAM - 9822 1111 48-05 - 78 -...
- Page 79 CIRCUIT DIAGRAM - 9822 1111 48-06 - 79 -...
- Page 80 CIRCUIT DIAGRAM - 9822 1111 48-07 - 80 -...
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Page 81: Dataplate
D Maximum permitted load on rear axle (on dual axle units) Wheel bolt torque S/N: Manuf. Year: (12) Model MADE IN BELGIUM lbf.ft Atlas Copco Airpower n.v. Working pressure Ingberthoeveweg 7 B-2630 Aartselaar 10 Speed 11 Engine power (13) (14) 12 Manufacturing year... -
Page 82: Disposal
(for example sand, sawdust) non-recyclable materials. and dispose of it in accordance with applicable local Your Atlas Copco compressor consists for the most For more information check with your local waste disposal regulations. Do not drain into the sewage part of metallic materials, that can be remelted in authority, customer center or distributor. -
Page 83: Maintenance Log
Maintenance Log Compressor ......................Customer ........................Serial number................................................Service hours Maintenance action Date By: initials - 83 -... - Page 84 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 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 laws of the Member States relating to machinery, is in conformity with the relevant Essential Health and Safety Requirements of this directive.
- Page 86 Scan the QR code to access into the Atlas Copco Spare Part list (ASL). XATS 138 PE XAHS 108 PE XATS 250 PE...