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

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7.4

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.

When one of these parameters exceeds its specified limit the compressor will react depending the present status of the control box.

Alarm code

Alarm text

Fail class

Trigger

1231

FUEL FILL CHECK

Warning

1503

INITIAL OVERHAUL REQUIRED

Warning

1522

MINOR OVERHAUL WITHIN ** H

Warning

1523

MINOR OVERHAUL WITHIN ** D

Warning

1524

MINOR OVERHAUL REQUIRED

Warning

1552

MAJOR OVERHAUL WITHIN ** H

Warning

1553

MAJOR OVERHAUL WITHIN ** D

Warning

1554

MAJOR OVERHAUL REQUIRED

Warning

2000

EMERGENCY STOP INPUT

Shutdown

2040

REMOTE EMERGENCY STOP

Shutdown

2070

COOLANT LEVEL LOW WARNING

Warning

2080

COOLANT LEVEL LOW SHUTDOWN

Shutdown

2090

∆

P AIRFILTERS HIGH

Warning

2100

NO PROJECTFILE DOWNLOADED

Warning

3000

FUEL LEVEL LOW WARNING

Warning

3010

FUEL LEVEL LOW SHUTDOWN

Controlled Stop

3020

FUEL LEVEL SENSOR CIRCUIT

Warning

3150

AIR DISCHARGE WARNING

Warning

3160

AIR DISCHARGE SHUTDOWN

Shutdown

3170

AIR DISCHARGE PRESSURE SENSOR CIRCUIT

Warning

Summary of Contents for PNS 1250 Cud S3A/T3 APP

Page 1: ...Instruction Manual for Portable Compressors English PNS 1250 Cud S3A T3 APP QSX15 ...

Page 2: ... PORTABLE ENERGY DIVISION www atlascopco com Printed matter N Preliminary 12 2014 PNS 1250 Cud S3A T3 APP Instruction Manual for Portable Compressors Instruction manual 5 Circuit diagrams 89 Original instructions ...

Page 3: ...rer s approval in writing 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 Copyright 2014 Atlas Copco Airpower n v Antwerp Belgium Any unauthoried use or copying of the contents o...

Page 4: ... Operating instructions 33 5 1 Before starting 33 5 2 Operating and setting the Pc4003 controller 34 5 2 1 Pc4003 button overview 34 5 2 2 Pc4003 display icons 35 5 2 3 Possible views 38 5 2 4 Operations overview 39 5 2 5 Starting 39 5 2 6 Stopping 43 5 2 7 Shutdown 45 5 2 8 Power off 45 5 2 9 Settings 46 5 2 9 1 Set Pressure Setpoint 46 5 2 9 2 Acknowledge an Alarm 46 5 2 9 3 Set Clock 46 5 2 9 4...

Page 5: ...y fuel filters 61 6 4 3 2 Priming the system 61 6 4 3 3 Cleaning fuel tanks 62 6 4 4 Cleaning coolers 62 6 4 5 Poly V belt tension adjustment 63 6 4 6 MP safety valve adjustment 63 6 4 7 Checking intercooler relief valves 64 6 4 8 Battery care 64 6 4 8 1 Electrolyte 64 6 4 8 2 Activating a dry charged battery 64 6 4 8 3 Recharging a battery 65 6 4 8 4 Maintaining the battery voltage 65 6 4 9 Servi...

Page 6: ...ecifications 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 ...

Page 7: ...nstruction manual and is allowed to change settings of the control and safety system A mechanical technician does not work on live electrical components Skill level 3 Electrical technician An electrical technician is trained and has the same qualifications as both the operator and the mechanical technician In addition the electrical technician may carry out electrical repairs within the various en...

Page 8: ...eds etc 6 The machinery and equipment shall be kept clean i e as free as possible from oil dust or other deposits 7 To prevent an increase in working temperature inspect and clean heat transfer surfaces cooler fins intercoolers water jackets etc regularly See the maintenance schedule 8 All regulating and safety devices shall be maintained with due care to ensure that they function properly They ma...

Page 9: ...a fork lift holes via the holes in the frame at the front and back or via the lifting beam To prevent damage never put straps on the roof surface of the unit 5 Never exceed the maximum towing speed of the unit mind the local regulations 6 Place the unit on level ground and apply the parking brake before disconnecting the unit from the towing vehicle Unclip the safety break away cable or safety cha...

Page 10: ... end fittings and connections 10 If the compressor is to be used for sand blasting or will be connected to a common compressed air system fit an appropriate non return valve check valve between compressor outlet and the connected sand blasting or compressed air system Observe the right mounting position direction 11 Before removing the oil filler plug ensure that the pressure is released by openin...

Page 11: ...the respiratory organs must be protected and depending on the nature of the hazard so must the eyes and skin 25 Remember that where there is visible dust the finer invisible particles will almost certainly be present too but the fact that no dust can be seen is not a reliable indication that dangerous invisible dust is not present in the air 26 Never operate the unit at pressures or speeds below o...

Page 12: ...and the possibility of decomposition or generation of hazardous gases Never mix synthetic with mineral oil 15 Protect the engine alternator air intake filter electrical and regulating components etc to prevent moisture ingress e g when steam cleaning 16 When performing any operation involving heat flames or sparks on a machine the surrounding components shall first be screened with non flammable m...

Page 13: ...ng fire open flame and smoking at the post where batteries are being charged 3 When batteries are being charged an explosive gas mixture forms in the cells and might escape through the vent holes in the plugs Thus an explosive atmosphere may form around the battery if ventilation is poor and can remain in and around the battery for several hours after it has been charged Therefore never smoke near...

Page 14: ...stem Operator AC personnel or user allowed to operate the compressor unit with the push buttons Load Operating condition with inlet compressor open and engine speed regulated between minimum and maximum Not loaded Operating condition with inlet compressor forced to closed position by operator command The engine speed is held at minimum Unload Operating condition with inlet compressor forced to clo...

Page 15: ... 2 4 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 ...

Page 16: ...rs 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 AL Alarm lamp AOV Air outlet valve BH Brake handle CP Control panel EP Exhaust pipe ES Emergency stop FCF Filler cap fuel TB Towbar ...

Page 17: ...ernal fuel tank connections EP Exhaust pipe F1 Cooling fan 1 F2 Cooling fan 2 FCF Filler cap fuel FCO Filler cap oil FCW Filler cap cooling water FC Fuel cooler FE Fire extinguisher FFPC Primary coarse fuel filter Water separator FT Fuel tank GC Gear casing ICLP MP Intercooler LP MP IH Air inlet housing compressor M Muffler MSA Muffler integrated spark arrestor OC Oil cooler OFC Oil filters compre...

Page 18: ...ir valves without connected hoses Rotation direction Air suction Lifting point 3 The guiding rods may not be used to lift the compressor Always use the indicated lifting points for lifting Forklift slots Release brake and raise locking pad before towing Compressor oil drain Engine oil drain Engine coolant drain Fuel drain Warning Part under pressure Do not stand on outlet valves Switch enable pre ...

Page 19: ...with Directive 84 533 EC expressed in dB A Compressor noise emission control information this compressor conforms to U S E P A regulations for noise emissions applicable for portable compressors US only California Proposition 65 Warning US only Battery conditioner compressor and engine heater EU only Battery conditioner compressor heater US only ...

Page 20: ...the air seals is evacuated to the atmosphere through vent holes Any oil that might gather between the oil and air seals is prevented from entering the compression space as it is drained through the same vent holes 3 3 4 Cooling and lubrication The radiator intercoolers aftercooler and oil cooler are installed side by side in the front of the unit These coolers are air cooled by an axial fan which ...

Page 21: ...Automatic fire suppression system The PNS 1250 is fitted with an automatic fire suppression system This installation will respond automatically to a fire in the engine compartment by switching off the engine and spreading extinguishing powder throughout the engine compartment In case of an extinguishing powder release by the fire suppression system please be careful when opening the doors of the c...

Page 22: ...th for maximum safety during the cranking procedure It communicates with a display unit located in front of the control panel The control module will carry out all necessary tasks to control and protect the compressor regardless of the use of the compressor This means that the Pc4003 module can be used for several applications 3 4 2 Fuses The Pc4003 is equipped with the following three fuses Q1 Fu...

Page 23: ...e valve leaves an air passage in the closed position Thus air remains drawn into the compressor to maintain a reasonable pressure ratio over the elements An air operated balancing piston is fitted behind the male rotor rear thrust bearing of MP and HP compressor element The piston decreases the load on the male rotor front thrust bearing during loaded operation During loading the MP and HP compres...

Page 24: ...mpressor element S2 Air outlet silencer compressor element SC Safety cartridge SVMP MP safety valve SVHP HP safety valve TV Throttle valve unloader assembly UA Unloader assembly UP Unloader piston unloader assembly UV Unloading valve unloader assembly VV Vacuator valve dust ejector WS Water separator BV CV ICLP C2 C1 TV M BOS AFC UV UP LSV D VV SC ICMP CELP CEHP CEMP RV BOV CV S2 S1 AC2 AC1 WS AOV...

Page 25: ...ains to the oil sump The gear casing is vented to the atmosphere through a breather pot assembly The bypass valve BVOF of the oil filter opens when the pressure drop over the filter is above normal due to clogging of the element The oil is then circulated without being filtered For this reason it is imperative to replace the oil filter at regular intervals Bypass valve BVOS opens when the pressure...

Page 26: ...ain oil sump F1 Cooling fan 1 RAD IC AC1 OC GC Gear casing OC Oil cooler OFC Compressor oil filter with bypass valve OGHP Oil gallery HP compressor element OGLP Oil gallery LP compressor element OGMP Oil gallery MP compressor element OP Oil pump OS Oil sump CELP CEHP CEMP OC F1 GC DOS OGMP OGHP CELP CEMP GC OS OP BVOS BVOC BVOF OGLP DOS OS OFC CEHP LUBRICATING CIRCUIT COOLING CIRCUIT ...

Page 27: ...electrical priming pump EPP is comprised in the system to fill up filters and fuel lines after maintenance and servicing A description of this procedure can be found on page 61 Instead of internal fuel supply via the fuel tanks external fuel supply is possible When using external fuel both the supply and the return hose must be connected to the external fuel supply couplings EFC No restrictions ar...

Page 28: ...trical priming pump F2 Cooling fan 2 AC2 CAC FC FC Fuel cooler FFPC Primary coarse fuel filter water separator FFSE Secondary engine fuel filter FPE Engine fuel pump FSC Fuel shut off cock FT Fuel tank TWV 3 way valve VL Venting line fuel selector in horizontal position internal fuel selector in vertical position external ...

Page 29: ... coolant flow to cool the engine s cylinders The coolant is circulated by the engine water pump WPE seated on the front of the engine E When the coolant returns from the engine it passes through the radiator RAD which is air cooled by the cooler fan F1 The radiator top tank TTRAD supplies the coolant to the system and gives the coolant in the system room to expand TT WP RADIATOR ...

Page 30: ...ection 4 2 Lock blockage device in upward position when unit is manoeuvred to its working location Lock all service doors 4 1 2 Lifting To lift the unit use a lift truck or crane with sufficient capacity Use the lifting positions of the unit as shown in the figure below See to it that the unit will be lifted vertically and remains level The operator is expected to apply all relevant safety precaut...

Page 31: ...and engine power decrease Park the unit on solid level ground The compressor can operate in a slant position not exceeding 5 in both senses front rear and left right Engage the parking brake by pulling parking brake handle 1 Place wheel chocks in front of and behind the wheels before the unit is disconnected from the towing or lifting vehicle Lock the towbar 2 in the raised position with catcher 3...

Page 32: ...ed marked service range see section 6 4 2 3 clean or replace the filter elements see sections 6 4 2 3 and 6 4 2 4 Reset the indicator by pushing the reset button Check the electrolyte level in the batteries B Top up if necessary with distilled water see section 6 4 8 1 Put the fuel shut off cock which is seated on the primary fuel filter housing in the back of the unit in the raised position the h...

Page 33: ...on or commands the compressor to load depending on actual status command the compressor to switch to Not Loaded when in Load 5 MEASUREMENTS VIEW button To toggle between Measurements View and Main View 6 SETTINGS VIEW button To toggle between Settings View and Main View 7 ALARMS VIEW button To toggle between Alarms View and Main View 8 NAVIGATION buttons To navigate through the display menus 9 ENT...

Page 34: ... mode indication 2 Active compressor status 3 Navigation toggle between main view and engine view 4 Regulator overrule indication 5 Regulator pressure value or info text 6 Set active pressure setpoint 7 Alarm indication and compressor info Main view indication Measuring view indication Settings view indication Alarm view indication OVERHAUL Initial Overhaul required OVERHAUL Minor Overhaul require...

Page 35: ...ode is active but the Auto Start and Auto Stop function are both inactive OPERATION MODE Block Mode ALARM Active and not acknowledged Shutdown Alarm ALARM Active and not acknowledged Non Shutdown Alarm ALARM Active and acknowledged Alarm FUEL TANK Running at internal fuel tank FUEL TANK Running at internal fuel tank and fuel pump is energized FUEL TANK Running at external fuel tank but internal fu...

Page 36: ...n 2 Active compressor status 3 Navigation toggle between main view and engine view 4 Engine info 5 Alarm indication and compressor info ENGINE WARNING LAMP AMBER LED steady on low alarm LED flashing slow medium alarm LED flashing fast high alarm ENGINE SHUTDOWN LAMP RED LED steady on low alarm LED flashing slow medium alarm LED flashing fast high alarm ...

Page 37: ...and the Log Lists can be selected and entered to access the sublist MAIN VIEW READY TO START 10 3 bar 1300RPM 1286h 0 0 bar SET 9 0 bar 40 MAIN VIEW READY TO START 10 3 bar 1300RPM 1286h 40 LOADED 10 3 bar 1300RPM 1286h SETTINGS 40 1000 GENERAL SETTINGS 2000 DIGITAL INPUTS 3000 VOLTAGE INPUTS 4000 TEMPERATURE INPUTS 5000 RELAY OUTPUTS 5300 SEMICONDUCTOR OUTPUTS 6000 SYSTEM SETTINGS LOADED 10 3 bar...

Page 38: ...g the entire INITIALIZING SEQUENCE which takes about 2 seconds the following view is shown on the PC display This view shows the controller version e g Pc4003 and the application software version e g v1 00 0 When initialization of the controller is finished the INITIALIZING SEQUENCE is ended The display shows the Main View The machine is now ready to be started and is waiting for a start command L...

Page 39: ...rs of the engine controller Active Buttons Start Button to initiate Start command Load Button to activate Automatic Load Measurement View Button Settings View Button Alarms View Button MAIN VIEW READY TO START 0 0 bar RPM 1286h 0 0 bar SET 9 0 bar 40 MAIN VIEW READING ENGINE DATA 0 0 bar RPM 1286h 0 0 bar SET 9 0 bar 40 Active Buttons Stop Button to initiate Stop command Load Button to activate Au...

Page 40: ...nimum RPM until the engine s coolant temperature reaches 40 C with a minimum time of 30 seconds and a maximum time of 300 seconds 800RPM 324RPM 0RPM MAIN VIEW ENGINE CRANKING 0 0 bar 324RPM 1286h 40 Active Buttons Stop Button to initiate Stop command Load Button to activate Automatic Load Measurement View Button Settings View Button Alarms View Button 54s 0s MAIN VIEW ENGINE RESTING 0 0 bar 324RPM...

Page 41: ...uttons Stop Button to initiate Stop command Load Button to activate Automatic Load Measurement View Button Settings View Button Alarms View Button MAIN VIEW ENGINE WARMING UP 2 7 bar 1200RPM 1286h 30s 12s 0s 40 MAIN VIEW AFTERCOOLER WARMING UP 2 7 bar 1200RPM 1286h 40 Active Buttons Stop Button to initiate Stop command Load Button to activate Automatic Load Measurement View Button Settings View Bu...

Page 42: ...he following view is shown MAIN VIEW PREPARING TO LOAD 1 2 bar 1650RPM 1286h 1 2 bar SET 10 3 bar 40 MAIN VIEW LOADED AIR DISCHARGE PRESSURE REGULATION 10 3 bar 1484RPM 1286h 10 3 bar SET 10 3 bar 40 Active Buttons Stop Button to initiate Stop command Load Button to activate Automatic Load Measurement View Button Settings View Button Alarms View Button Active Buttons Start Button to initiate Start...

Page 43: ...ature condition has been met the following view is shown After cooling down the engine enters the STOP SEQUENCE During the STOP SEQUENCE before the ENGINE RPM is being re read the following view is shown MAIN VIEW ENGINE COOLING DOWN 3 3 bar 1200RPM 1286h 180s 1s 0s 480 C 401 C 400 C 40 MAIN VIEW ENGINE COOLING DOWN 6 0 bar 1200RPM 1286h 180s 74s 0s 40 Active Buttons Start Button to initiate Start...

Page 44: ...pressor is equipped with a battery switch When the compressor is not in use this switch must always be in the OFF position MAIN VIEW ENGINE STOPPING DO NOT SWITCH OFF BATTERY 10 3 bar 0RPM 1286h 180s 74s 0s 40 Active Buttons Measurement View Button Settings View Button Alarms View Button Enter Button to acknowledge the shown alarm MAIN VIEW SHUTDOWN 0 0 bar SET 10 3 bar 2000 EMERGENCY STOP Never u...

Page 45: ... the Alarm View button again will bring you back to the Main View 5 2 9 3 Set Clock 1 Press the Settings View button 2 Scroll to the 1000 GENERAL SETTINGS menu 3 Press Enter 4 Scroll to the 1290 DATE TIME menu 5 Enter the Date Time menu 6 Scroll to the parameter you want to change 7 Enter this parameter To change the RTC Month scroll to the preferred month and press Enter To change any other RTC s...

Page 46: ... you would like to change 7 Press ENTER To change a setting the red figure is editable Scroll up down and press ENTER to change Use left right to shift between editable figure 8 Now press BACK until you are back in the Main View or in the menu you require 5 2 9 7 Go To Diagnostics 1 Press the SETTINGS VIEW button 2 Scroll to 1000 GENERAL SETTINGS 3 Press ENTER 4 Scroll to 1150 DIAGNOSTICS 5 ENTER ...

Page 47: ...RRULE ECU function Enable Setting is set to On the OVERRULE ECU timer will start counting When the OVERRULE ECU timer has elapsed the OVERRULE ECU Enable Setting is automatically set to Off To set the OVERRULE ECU timer 1 Press the SETTINGS VIEW button 2 Scroll to 1000 GENERAL SETTINGS 3 Press ENTER 4 Scroll to 1120 OVERRULE ECU 5 ENTER the Overrule ECU menu 6 ENTER the Timer parameter 7 Set the d...

Page 48: ...suppression system 5 3 1 Main components 1 Control module 2 Cylinder with extinguishing powder 3 Large nitrogen cylinder 4 Manual actuator 5 Small nitrogen cylinder 6 Small nitrogen cylinder 7 Nozzles 8 Automatic actuator 1 5 6 7 7 2 3 4 8 ...

Page 49: ...s 5 3 3 Control module The automatic fire suppression installation is constantly monitored by a control module It is powered by an internal battery A number of LED s indicate the system status 5 3 3 1 Indicators 1 POWER LED pulses every three seconds when indicating normal power If the power drops below an acceptable level of either the internal or external power source the green POWER LED will be...

Page 50: ...tons 6 DELAY This button is used during programming and can be used for maintenance checks 7 RESET Pressing this button for more than 1 second will reset the controller after a fault detection or activates the system after restoring power e g after replacing the internal battery 5 3 4 Daily check The LED s status on the ANSUL control module should be checked daily prior to starting up the compress...

Page 51: ... additive and antifreeze concentration x x x x x Check routing and condition of flexible hoses x x x x x x Drain prefilters water separators 30µ x x x x x x Change fuel prefilter 30µ x x x x x x Check fan cooling x x x x x x Check on abnormal noise and smoke x x x x x x Change engine fuel filter x x x x x x Add engine oil x x Change engine oil x 2 x x x x Replace engine oil filters x x x x x Chang...

Page 52: ...ir filter and cartridge x x x Check air intake piping x Check charge air piping x Test safety relief valves x x Check coolant condition x x x Drain air tanks and reservoirs x x x x x Check crankcase breather tube x Replace the crank case breather internal Only Cummins Clean gear casing breather pot x x Replace compressor oil filter x x Inspect Adjust engine valve clearance x Grease engine fan driv...

Page 53: ... x Replace roller diaphragm of unloader cylinder x Replace parts of unloader cylinder x Replace diaphragm of the balancing pistons x Replace check valve in compressed air system x Replace coolant x Maintenance schedule Daily 50 hrs every 250 hrs every 1000 hrs every 1500hrs every 6000 hrs every 10000 hrs Service pak 2912 4580 04 2912 4581 05 2912 4582 06 ...

Page 54: ...lity of maintenance 6 1 2 Service paks and kits 6 1 2 1 Service paks Service paks include all genuine parts needed for normal maintenance of both compressor and engine Service paks minimise downtime and keep your maintenance budget low Order service paks at your local Atlas Copco dealer 6 1 2 2 Service kits A service kit is a collection of parts to fit a specific repair or rebuilding task It guara...

Page 55: ...emove the drain plug located at the right hand side under the unit and open the drain cock 1 Use a proper drain pan The engine oil filters 1 are located at the unit s left hand side Put a proper drain pan under the engine oil filters and replace the oil filters Close the drain cock and tighten all drain plugs before filling the system with fresh oil Reinstall the oil filler cap Check on leakages 6...

Page 56: ... slot at the top Clean the filter seat on the manifold see to it that no dirt drops into the system Oil the gasket of the new filter element Screw the element into place until the gasket contacts its seat then tighten one half turn only Run the unit at Not Loaded for a few minutes to circulate the oil Stop and depressurize the unit Screw out the filler plug add oil if necessary until the oil level...

Page 57: ...lycol concentrations Cavitation corrosion protection is indicated on the strip by the level of nitrite concentration Freeze boil over protection is determined by glycol concentration Use the test strips as follows Dip the strip into coolant for one second Remove and shake briskly to eliminate excess fluid Immediately compare end pad glycol to the color chart Sixty seconds one minute after dipping ...

Page 58: ... be repeated for both air filters engine and air filters compressor Release the snap clips 1 and remove the dust trap cover 2 Clean the inside of the cover Withdraw the filter element 4 and safety cartridge 3 from the housing 5 Discard the filter element when damaged A dirty safety cartridge is an indication of a malfunctioning filter element Replace the filter element and the safety cartridge at ...

Page 59: ...f the element The air pressure may not exceed 5 bar 73 psi and a reasonable distance must be maintained between the hose nozzle and the pleats If the contaminant is oily soak the element for 10 minutes in luke warm water in which a non foaming detergent is dissolved Then move the element to and fro in the solution for 5 minutes Rinse with soft water until the drain water is clear Let the element d...

Page 60: ...n the lubrication system reaches its normal operating pressure increase engine speed to high idle for one or two minutes After the air is purged loosen the vent cap until the fuel level lowers to just above the bottom of the collar Tighten the vent cap by hand only Hand tighten the collar again while the engine is running To avoid damage do not use tools to tighten the collar 1 Two primary coarse ...

Page 61: ...oors The CAC Charge air cooler fuel cooler and aftercooler 2 are located at the rear end of the unit under the air filters Remove any dirt from the coolers with a fibre brush Never use a wire brush or metal objects Then clean by air jet in reverse direction of normal flow If the dirt is oily wash the coolers with fuel or a cleansing agent A spray gun should preferably be used to apply the solvent ...

Page 62: ...rn the adjusting screw clockwise to increase V belt tension or counter clockwise to decrease V belt tension After adjusting the V belt tension retighten the adjusting screw lock nut and the fixing screw 6 4 6 MP safety valve adjustment A check of the opening of the lifting gear once a year A check of the set pressure once a year according to the local regulations This check cannot be done on the u...

Page 63: ...rged first 6 4 8 1 Electrolyte Electrolyte in batteries is a sulphuric acid solution in distilled water The solution must be made up before being introduced into the battery 6 4 8 2 Activating a dry charged battery Take out the battery Battery and electrolyte must be at equal temperature above 10 C Remove cover and or plug from each cell Fill each cell with electrolyte until the level reaches 10 t...

Page 64: ...ery 6 4 8 4 Maintaining the battery voltage To maintain the battery voltage use the unit s automatic battery charger Battery charger EEC AUS 240 VAC 24 VDC 100 VA Battery charger USA 120 VAC 24 VDC 100 VA When power is supplied to the charger the battery voltage will be kept within preset limits Three LEDs on top of the battery charger show the charging condition Green AC supply voltage present Ye...

Page 65: ...Service the filter of the water separator every 500 hours 6 4 11 Servicing electric blow off valve The blow off valve fitted on the MP air inlet pipe is opened to release air when the air inlet throttle valve is closed it closes when the throttle valve is opened Replace the membrane the diaphragm valve assembly 1 and the spring every 2000 hours kit 2906 0568 00 6 4 12 Servicing automatic fire supp...

Page 66: ...xidation resistance high chemical stability and rust inhibiting additives help reduce corrosion even within engines left idle for extended periods PAROIL contains high quality anti oxidants to control deposits sludge and contaminants that tend to build up under very high temperatures PAROIL s detergent additives keep sludge forming particles in a fine suspension instead of allowing them to clog yo...

Page 67: ...ended life coolant is the new range of organic coolants purpose designed to meet the needs of modern engines PARCOOL EG can help prevent leaks caused by corrosion PARCOOL EG is also fully compatible with all sealants and gasket types developed to join different materials used within an engine PARCOOL EG is a ready to use Ethylene Glycol based coolant premixed in an optimum 50 50 dilution ratio for...

Page 68: ...electrical problems It is assumed that the engine is in good condition and that there is adequate fuel flow to the filter and injection equipment Make sure that the wires are not damaged and that they are clamped tight to their terminals 7 2 Battery and alternator precautions Never reverse the polarity of the battery or the alternator Never break any alternator or battery connections while the eng...

Page 69: ...e and inspect Replace parts where necessary Compressor does not deliver air or not immediately after loading solenoid valve has been energized Diaphragm of unloader piston cracked If air blows from venting device open unloader piston cover and replace diaphragm Air intake throttle valve stuck in closed position Disconnect loading solenoid valve from throttle valve housing and connect independent c...

Page 70: ...ve 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 Repeatedly admit air and listen for opening and closing sound of throttle valve If sou...

Page 71: ... cooling 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 Add correct oil if necessary Never overfill Fan blade...

Page 72: ... 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 Add correct oil if necessary Never overfill Compressor oil filter clogged Replace compressor oil filter Bypass valve in oil pump stuck in open position Remove bypass valve clean and inspect Oil pump failure Remo...

Page 73: ...Temperature or pressure sensor missing or malfunctioning Check via the User Interface display and replace sensor After working for some time the unit keeps shutting down Restriction in fuel supply to engine Check fuel lines and fuel filters Air leak in fuel suction line or fuel filters Check suction side of electric fuel pump and fuel filters for air leaks Compressor oil pressure too low See probl...

Page 74: ...ler 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 normal Aftercooler clogged internally Consult Atlas Copco HP compressor element not in order Have HP compressor element inspected by Atlas Copco HP silencer and or chec...

Page 75: ...NITIAL OVERHAUL REQUIRED Warning PC 1522 MINOR OVERHAUL WITHIN H Warning PC 1523 MINOR OVERHAUL WITHIN D Warning PC 1524 MINOR OVERHAUL REQUIRED Warning PC 1552 MAJOR OVERHAUL WITHIN H Warning PC 1553 MAJOR OVERHAUL WITHIN D Warning PC 1554 MAJOR OVERHAUL REQUIRED Warning PC 2000 EMERGENCY STOP INPUT Shutdown PC 2040 REMOTE EMERGENCY STOP Shutdown PC 2070 COOLANT LEVEL LOW WARNING Warning PC 2080 ...

Page 76: ...TURE SENSOR CIRCUIT Warning PC 4150 H P ELEMENT TEMPERATURE ALARM 1 Warning PC 4160 H P ELEMENT TEMPERATURE ALARM 2 Controlled Stop PC 4170 H P ELEMENT TEMPERATURE ALARM 3 Shutdown PC 4190 H P ELEMENT TEMP SENSOR CIRCUIT Shutdown PC 4450 AFTERCOOLER AIR DISCHARGE TEMP WARNING Warning PC 4460 AFTERCOOLER AIR DISCHARGE TEMP SHUTDOWN Shutdown PC 4470 AFTERCOOLER AIR DISCHARGE TEMP SENSOR CIRCUIT Shut...

Page 77: ...UEL FILTER PRESSURE ECU WATER IN FUEL ECU OIL LEVEL ECU OIL FILTER PRESSURE ECU OIL PRESSURE ECU TURBO BOOST PRESSURE ECU TURBO OIL PRESSURE ECU INTAKE MANIFOLD TEMPERATURE ECU AIR INLET PRESSURE ECU COOLANT TEMPERATURE ECU COOLANT LEVEL ECU SUPPLY VOLTAGE ECU AMBIENT AIR TEMPERATURE ECU AIR INLET TEMPERATURE ECU FUEL TEMPERATURE ECU OIL TEMPERATURE ECU ENGINE SPEED ECU INJECTOR 1 ECU INJECTOR 2 E...

Page 78: ...erature Too High Engine Air Inlet Temperature High Engine Oil Pressure Too Low Turbo Boost Pressure High Engine Fuel Pressure Too Low Engine Injector X Failure Fuel Temperature Too High Engine RPM Sensor Failure Fuel level shutdown Engine oil level shutdown Engine oil level overfill shutdown LP element temperature shutdown MP element temperature shutdown HP element temperature shutdown Compressor ...

Page 79: ...s low as 25 C 13 F 8 2 Hot weather pack The hot weather pack option allows the compressor to run in ambient conditions up to 50 C 122 F 45 C 113 F is standard 8 3 Pressure reducer A pressure reducer 1 limits the operating pressure to 7 bar 102 psi and thus allows the operation of hand held pneumatic tools 8 4 Cold climate fuel Cold climate diesel fuel can be used in ambient conditions as low as 25...

Page 80: ... 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: ... materials for recycling in the future is foreseen 10 2 Disposal of materials Dispose contaminated substances and material separately according to local applicable environmental legislation Before dismantling a machine at the end of its operating lifetime drain all fluids and dispose of according the applicable local disposal regulations Remove the batteries Do not throw batteries into the fire ex...

Page 82: ...le Nm 80 10 Bolts front axle frame Nm 80 10 Bolts rear axle frame Nm 205 20 Compressor to frame Bolts elements gear casing Nm 80 10 Bolts gear casing support Nm 205 20 Bolts support buffer Nm 205 20 Bolts buffer frame Nm 80 10 Engine to frame Bolts engine support Nm 205 20 Bolts support buffer Nm 205 20 Bolts buffer frame Nm 80 10 Lifting beam to frame Bolts lifting beams yoke M12 Nm 80 10 Bolts l...

Page 83: ...5 45 0 Minimum starting temperature C 25 25 0 Performance data 1 Engine shaft speed normal and maximum r min 1800 1750 0 Engine shaft speed compressor unloaded r min 1300 1400 0 Free air delivery 2 l s 575 553 0 Fuel consumption at full load Std kg h 83 82 85 62 Fuel consumption at full load Hot Env kg h 85 71 87 24 Fuel consumption at unload Std kg h 13 20 15 60 Fuel consumption at unload Hot Env...

Page 84: ...ake Cummins Type QSX15 Coolant Liquid Number of cylinders 6 Bore mm 137 Stroke mm 169 Swept volume l 15 0 Output according to SAEJ1995 at normal shaft speed kW 406 Load factor intermittent Capacity of oil sump Initial fill l 90 Refill max 4 l 86 Capacity of cooling system intercooler l 0 Capacity of cooling system engine jackets l 90 Unit Capacity of compressor oil system l 92 Net capacity of air ...

Page 85: ...d in normal shaft speed unless otherwise stated 2 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 Swedish SS ISO 1217 American ANSI PTC9 3 Air required for engine and compressor cooling combustion and for...

Page 86: ...AS COPCO AIRPOWER n v WILRIJK BELGIUM 1615 6945 00 YA3 00 kg 1 kg 2 kg p max e working betrieb service Speed Drehzahl Regime p engine motor moteur Manuf year Baujahr Ann e de fabrication bar rpm kw A B C 12 11 10 9 8 6 5 4 3 2 1 7 1 Company code 2 Product code 3 Unit serial number 4 Name of manufacturer 5 EEC or national type approved number 6 Vehicle identification number 7 A Maximum permitted la...

Page 87: ...m g 16 mm h 25 mm 0 black 2 red 3 orange 4 yellow 5 green 6 blue 7 purple 8 grey 9 white Legend K1 K0 K0 G3 M1 M G1 G2 S1 24 k0 24 f2 24 c2 24 f2 3 c3 19U k0 19 k0 19 f6 19 f6 19 b6 04 2 05 5 06 1 06 7 06 10 07 1 08 1 24 a2 04 2 05 1 07 1 08 1 06 7 03 3 03 2 30 87 9822 0900 21 01 Applicable for PNS 1250 T3 Circuit diagram Engine and Controller ...

Page 88: ...5 9 06 4 06 6 06 6 A1 A2 1003 b3 1005 a6 1006 a3 1007 a7 X1 50 X1 40 X1 39 X1 30 X1 29 X2 07 ENGINE CONTROL MODULE X2 19 X2 06 X2 05 X1 06 X1 18 X1 20 X1 07 20A X1 08 X1 17 X1 38 X1 16 X1 05 X1 04 X2 27 X2 11 19 b6 19 b6 19 b6 19 b6 19 c6 24M b2 28 a3 RX a8 TX a7 24OM b2 24OM b2 24OM b2 24OM b2 99 a3 ...

Page 89: ...7 K4 S3 S2 Q3 Q2 F1 N1 R8 24 a2 39 a3 241M a2 241M a2 A1 A2 44 24 a2 03 10 a3 38 a3 24MF4 d2 27MK4 d2 39 a3 38 a3 27M d2 24M b2 26 d2 06 2 04 9 06 10 07 5 08 5 24 d2 24M b2 24 b2 19 a6 a2 a0 03 10 06 10 10A 20A 10A ...

Page 90: ...URE SENSOR 5VDC POWER SUPPLY SENSOR GND EXTERNAL FUEL SUPPLY SWITCH ENGINE STOP LAMP AUXILIARY STARTER RELAY LOADING VALVE OIL LEVEL MAINTAINER VALVE BLOW OFF VALVE OUTLET TEMP REGULATION VALVE HORN POWER SUPPLY 58 a5 C6 C10 C9 B10 D9 B9 A9 C7 B7 A7 D7 B8 C8 B4 D16 B16 D5 C16 D4 A13 D15 D2 D1 C13 B14 C12 C11 D13 D12 D11 A16 C1 B1 59 a5 60 a5 61 a5 57 a5 62 a5 50 a9 51 a5 52 a5 53 a5 29 a9 18 a6 30...

Page 91: ...3 TS2 TS1 X7 X7 X7 X7 CUBICLE HEATERS EU 03 10 24 a2 24 a2 LM c1 LM c1 LM c1 07 3 L c1 L1 c1 L2 c1 L1 c1 L2 c1 N c6 N2 c6 PE c54 19 b6 A1 b2 IL b2 19 b6 19 b6 19 b6 03 10 IL b2 05 9 24M b2 PE c54 PE c54 PE c54 PE c54 A1 c1 L2 c1 L2 c1 L1 c1 A2 c1 A3 c1 N2 c6 N1 c6 N1 c6 N2 c6 N c6 N c6 PE c54 24 a2 ...

Page 92: ...4 X14 X14 X14 X14 X13 LA c2 NA c6 LB c1 LMB c1 PE c54 NB c6 CUBICLE HEATERS USA LMA c1 LMB c1 08 3 L1 c1 L2 c1 L1 c1 L2 c1 24 a2 24 a2 24 b2 19 b6 19 b6 03 10 08 4 2 4 1 3 08 4 05 9 03 10 PE c54 19 b6 IL b2 IL b2 A1 b2 24M b2 PE c54 PE c54 PE c54 PE c54 A1 c1 L2 c1 L2 c1 L1 c1 A2 c1 A3 c1 N2 c6 N1 c6 N1 c6 N2 c6 NA c6 NB c6 PE c54 ...

Page 93: ...ater USA S2 Switch Emergency Stop X14 Connector Terminal Block USA K4 Relay Solid State S3 Switch Emergency Stop X2 Connector Secondary Connector PC4003 LS5 Level Switch Coolant S4 Switch Internal Lights EU X3 Connector Heaters EU LT1 Level Sensor Fuel Level S5 Switch External Fuel Supply X4 Connector To Rear Wiring EU LT2 Level Sensor Oil Level S6 Switch Heaters EU X5 Connector Can Engine M1 Moto...

Page 94: ...HEATER CUBICLE SOCKET RELAY CIRCUIT BREAKER MOTOR ALT B D D START ENGINE ECM LOAD SOL This wire is placed beneath the element COMP OIL HEATER COMP HEATER t SW CAT LEVEL SW TOP TANK RAD BLOW OFF Breakout Connector REFINERY EQUIPMENT STARTER RELAY FUEL SWITCH EXT INT t DISCH t AMB p DISCH pHP IC tHP OUT tLP OUT pLP IC tMP OUT pCOMP OIL tCOMP OIL WS DRAIN HEATER WS DRAIN SWITCH Battery switch continu...

Page 95: ...M 600 400 CIRCUIT BREAKER Emergency stop CIRCUIT BREAKER ECM 24 24 81 823 150 CIRCUIT BREAKER Main 24 96 SOLID STATE RELAY 24MF4 27MK4 821 820 38 19 819 818 2 8 4 6 250 2 8 6 4 24M 95 24MF4 822 240M 82 4 1 1 1 52 99 6 7 13 15 201 192 181 29 162 35 5 150 OIL LEVEL See note 7 19 35 28 156 163 169 50 1 3 2 4 73 805 See note 3 240M 240M 99 240M 240M 240M Cavity 38 17 08 07 28 18 19 37 19 40 19 39 19 3...

Page 96: ...te 9 HP IC PRESSURE HP ELEMENT TEMPERATURE LOADING VALVE COMPRESSOR OIL PRESSURE LP ELEMENT TEMPERATURE MP ELEMENT TEMPERATURE COMPRESSOR OIL TEMPERATURE INTERNAL LIGHT LP IC PRESSURE 50 150 50 50 100 100 29 53 18 2 19 18 59 60 18 See note 7 See note 7 See note 7 See note 8 See note 14 See note 8 See note 8 58 18 IL 19B 18 51 29 18 52 29 61 18 700 1550 550 100 350 800 250 300 1200 250 750 200 600 ...

Page 97: ...te 8 18 1 blue 217 see note 8 18 1 blue 204 see note 7 18 1 blue 18 see note 2 18 1 blue 31 see note 2 74 see note 18 19 4 blue 193 see note 30 954 splice 19 1 blue 145 see note 32 19 1 blue 74 see note 18 19 1 blue 60 AMP 165034 0 74 see note 18 19 10 blue 205 see note 14 74 see note 18 19 1 blue 803 splice 903 see note 3 19 1 5 blue 904 see note 3 19 1 5 blue 74 see note 18 19 2 5 blue 804 splic...

Page 98: ...see note 9 IL 1 orange 232 see note 9 IL 1 orange 15 see note 1 76 see note 18 24 4 red 16 see note 1 76 see note 18 24 4 red 58 AMP 33466 see note 54 76 see note 18 24 10 red 95 AMP 3 520117 2 76 see note 18 24 1 5 red 72 AMP 342145 1 76 see note 18 24 2 5 red 822 insulated faston 6 3 x 0 8 76 see note 18 24 4 red 81 AMP 3 520117 2 76 see note 18 24 2 5 red 908 see note 3 102 splice 240M 1 5 red ...

Page 99: ...rrule AMP 0 925856 1 832 see note 1 39 1 orange 806 splice 162 see note 1 29 53 see note 7 29 1 orange 236 see note 7 29 1 white 214 see note 7 29 1 white 202 see note 7 29 1 white 814 uninsulated wire ferrule AMP 0 925856 1 825 see note 55 44 1 orange 52 see note 7 172 see note 2 50 1 white 182 see note 2 235 see note 7 51 1 green 181 see note 1 213 see note 7 52 1 green 152 see note 2 203 see no...

Page 100: ...950 see note 34 900 see note 40 1005 1 blue 951 see note 34 901 see note 40 1006 1 orange 918 see note 40 948 see note 34 1007 1 purple TERMINAL END A TERMINAL END B WIRE NR TERMINAL NR TERMINAL NR MM COLOR ...

Page 101: ...mm Deutsch 1062 20 0122 Unused cavities shall be sealed with Deutsch 114017 1 mm Deutsch 0413 204 2005 1 5 mm Note 7 Connector G H 17984 000 002 DIN 72585 4 pins Terminals G H 26570 201 184 Wire seal G H 14414 627 626 Unused cavities to be sealed with G H 14416 627 646 Wiring braided until connector and attached to strain relief with nylon strap Note 8 Connector AMP 0 963040 3 Terminals AMP 0 9299...

Page 102: ...dary lock Deutsch W3S 1939 Note 33 Connector Deutsch DT 04 3P P006 Secondary lock Deutsch W3P 1939 Plug for note 32 Note 34 Connector Deutsch HD36 24 31SE 059 Terminals Deutsch 1062 16 0122 Unused cavities to be sealed with Deutsch HD10 114017 Note 40 Connector body Packard Electric 12065298 Terminals Packard Electric 12048074 Wire Seals Packard Electric 12089678 Secondary lock Packard Electric 12...

Page 103: ...n 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 1 Braiding 2 Insulated wires 3 Terminal 4 Non insulated wires 5 Sleeve Note 66 1 shrinkable sleeve color red ...

Page 104: ... 4 Pc4003 See note 16 A D Pc4003 label 61 120 34 18 31 135 30 50 134 117 127 19 57 1 21 110 24M 122 24M 121 58 19 99 9 20 111 82 35 Cavity 142 136 62 52 140 112 128 TX 20 60 118 39 19 RX 27M 19 4 116 141 5x3 28 C1 EMERGENCY STOP C6 FUEL LEVEL C7 AIR DISCHARGE PRESSURE C8 SENSOR GND C9 LP ELEMENT TEMP C10 COMPR OIL TEMP C11 MODBUS RX C12 MODBUS TX C13 MODBUS GND C16 OIL LEVEL MAINTAINER D1 POWER SU...

Page 105: ...1 Blue 21 See note 16 19 1 5 Blue 73 See note 1 19 4 Blue 95 See note 3 19 1 Blue 144 See note 16 19 1 Blue 145 See note 30 19 1 Blue 29 See note 2 19 1 Blue 107 See note 32 19 1 Blue 7 See note 2 52 Splice IL 1 Orange 47 See note 1 IL 1 Orange 22 See note 5 IL 1 5 Orange 9 See note 2 31 See note 16 9 1 Orange 84 See note 7 87 See note 4 24 4 Red 44 See note 4 61 See note 5 24 4 Red 43 See note 4 ...

Page 106: ...26 4 Red 28 See note 2 34 See note 16 30 1 Green 67 See note 6 41 See note 16 57 1 Green 76 AMP 160136 0 77 Splice See note 26 8 See note 2 19B 1 5 Blue 74 See note 1 19B 1 5 Blue 62 See note 5 19B 1 5 Blue 86 See note 7 19B 4 Blue 78 See note 6 39 See note 16 62 1 Green 94 See note 3 58 See note 16 10 1 Orange 99 See note 11 100 Splice 28 1 Orange 25 See note 16 28 1 Orange 48 See note 1 28 1 Ora...

Page 107: ...ote 16 58 1 Green 64 See note 1 114 See note 16 59 1 Green 65 See note 1 115 See note 16 60 1 Green 66 See note 1 116 See note 16 50 1 White 69 See note 1 117 See note 16 51 1 Green 143 See note 4 118 See note 16 52 1 Green 119 See note 4 120 See note 16 61 1 Green 129 See note 16 130 See note 4 99 1 Orange 131 See note 4 132 See note 34 35 1 Green 133 See note 1 66 Splice 27M 4 Red 134 See note 1...

Page 108: ...tsch HD 34 24 19 PN 059 Terminals Size 12 large Deutsch 0460 204 12141 Size 16 small Deutsch 0460 202 16141 Nut Deutsch 11263 90 Lockwasher Deutsch 112264 Unused cavities to be sealed with Deutsch 114017 Wiring braided until connector and attached to strain relief with nylon strap Note 5 Connector Deutsch DTP 06 4S Terminals Deutsch 0462 203 12141 Unused cavities to be sealed with Deutsch 114017 S...

Page 109: ...IP68 mounted over 100 mm shrinkable sleeve Hood entry at row 16 Note 19 Braiding end at connector fitted with label See drawing for text Note 20 Wire harness shall be provided with a marking label with AC part number and edition Note 21 Scan test to be performed on every conductor Note 22 Marking to be printed on each end of all wires Note 23 All plugs seen from wire connecting side Note 24 Wire h...

Page 110: ...34 Insert Tyco 2 1103111 3 HN D 40 Bu C Harting 09 21 040 3101 Socket Tyco 2 1105051 1 0 5mm Harting 09 15 00 6203 Socket Tyco 3 1105051 1 1mm Harting 09 15 000 6202 Socket Tyco 4 1105051 1 1 5mm Harting 09 15 000 6201 Socket Tyco 5 1105051 1 2 5mm Harting 09 15 000 6206 Hood Tyco 0 1106449 5 HB 16 STS GR 1 M32 G Harting 19 30 016 1542 Metal cable gland M32 IP68 mounted over 100 mm shrinkable slee...

Page 111: ...the Member States relating to machinery is in conformity with the relevant Essential Health and Safety Requirements of this directive The machinery complies also with the requirements of the following directives and their amendments as indicated Directive on the approximation of laws of the Member States relating to Harmonized and or Technical Standards used Att mnt a Pressure equipment 97 23 EC x...

Page 112: ...ification ltd 71 Fenchurch street EC3M 4 BF London United Kingdom 2 Description of the pressure equipment constituting the assembly see table T 2 a Equipment subject to the Simple Pressure Vessel directive 2009 105 EC is excluded from 97 23 EC according article I section 3 3 b Equipment of category I according 97 23 EC is integrated into the machine and falls under the exclusion of article I secti...

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