Atlas Copco PTS 1600 Cud S3A/T3 APP Instruction Manual Download Page 115

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Summary of Contents for PTS 1600 Cud S3A/T3 APP

Page 1: ...Instruction Manual for Portable Compressors English PTS 1600 Cud S3A T3 APP QSX15 ...

Page 2: ......

Page 3: ... PORTABLE ENERGY DIVISION www atlascopco com Printed matter N 2954 7430 01 12 2013 PTS 1600 Cud S3A T3 APP Instruction Manual for Portable Compressors Instruction manual 5 Circuit diagrams 89 Original instructions ...

Page 4: ...er 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 2013 Atlas Copco Airpower n v Antwerp Belgium Any unauthorized use or copying of the contents o...

Page 5: ...1 1 Transporting 30 4 1 2 Lifting 30 4 2 Parking 31 5 Operating instructions 32 5 1 Before starting 32 5 2 Operating 33 5 2 1 Starting 33 5 2 2 During operation 33 5 2 3 Stopping 33 5 3 Setting the compressor control module 34 5 3 1 Control 34 5 3 2 Functionality 35 5 3 3 A closer look at some operating procedure blocks 37 5 4 Operation via User Interface 40 5 4 1 General 40 5 4 2 Ready for Start ...

Page 6: ... 4 2 2 Cleaning the dust trap 62 6 4 2 3 Replacing the air filter element and the safety cartridge 62 6 4 2 4 Cleaning the filter element 63 6 4 3 Fuel system 64 6 4 3 1 Draining primary fuel filters 64 6 4 3 2 Priming the system 64 6 4 3 3 Cleaning fuel tanks 65 6 4 4 Cleaning coolers 65 6 4 5 Poly V belt tension adjustment 66 6 4 6 MP safety valve adjustment 66 6 4 7 Checking intercooler relief ...

Page 7: ...posal 83 10 1 General 83 10 2 Disposal of materials 83 11 Technical specifications 84 11 1 Torque values 84 11 2 Settings of shutdowns and safety valves 84 11 3 Compressor engine specifications 85 11 4 Conversion list of SI units into British units 88 11 5 Dataplate 88 ...

Page 8: ...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 9: ...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 10: ...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 11: ... 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 12: ...he 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 or...

Page 13: ...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 14: ...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 15: ...d pressure setpoint buttons are situated Technician AC personnel allowed to change settings of the control and safety system 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 positio...

Page 16: ...or a nominal effective working pressure of 0 5 10 3 bar 7 150 psi at 1650 rpm 0 5 9 3 bar 7 135 psi at 1750 rpm and 0 5 6 9 bar 7 100 psi at 1850 rpm An overview of the main parts is given in the diagram below AL Alarm lamp AOV Air outlet valve BH Brake handle CP Control panel EP Exhaust pipe ES Emergency stop FCF Filler cap fuel IL Indicator lamps TB Towbar ...

Page 17: ... element E Engine EP Exhaust pipe F1 Cooling fan 1 F2 Cooling fan 2 FCW Filler cap cooling water FC Fuel cooler FFPC Primary coarse fuel filter Water separator FT Fuel tank GC Gear casing IC Intercooler IH Air inlet housing compressor M Muffler MSA Muffler Integrated Spark Arrestor OC Oil cooler OFC Oil filters compressor OFE Oil filter engine PH Pre heater optional RAD Radiator VI Vacuum indicato...

Page 18: ...he battery On Off button Prohibition to open air valves without connected hoses Airfilter Rotation direction Inlet Outlet Compressor oil drain Read the instruction manual before starting Service every 24 hours Warning Part under pressure Do not stand on outlet valves Start Stop indication of switch Do not run the motor with open doors Use diesel fuel only Sound power level in accordance with Direc...

Page 19: ... bearings The leak air from 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 c...

Page 20: ...automatic fire suppression system This installation will respond automatically to a fire in the engine compartment by switching of the engine and spreading extinguishing powder throughout the engine compartment In case of an extinguishing powder release by the fire suppression system please be carefull when opening the doors of the compressor Although this fire suppression system is designed and t...

Page 21: ...r Interface 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 3 4 2 Indicator lamps 1 Running hours and warning bar When warnings occur they swap with the running hours on this bar showing the next message every 3 seconds 2 Setpressure bar 3 Additional information bar 4 Compressor status bar 5...

Page 22: ...e maintenance should be performed The lamp is used by the following features Maintenance Monitor Real Time Clock RTC 3 4 2 4 Wait to Start Lamp The Wait to Start lamp 4 indicates that the pre start intake manifold heater warm up sequence is active An OEM supplied grid heater will automatically heat the intake manifold when needed prior to engine starting Intake manifold heating improves engine sta...

Page 23: ...on UP when the working pressure reaches its preset maximum The pressure of the MP compressor element is then released to the atmosphere through the unloading valve and the blow off silencers BOS resulting in closing of the check valve The throttle 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 ...

Page 24: ... element SC Safety cartridge SV MP safety valve TV Throttle valve unloader assembly UA Unloader assembly UP Unloader piston unloader assembly UV Unloading valve unloader assembly VI Vacuum indicator VV Vacuator valve dust ejector WS Water separator Compressor sensor inputs Compressor Unloaded Compressor Loaded ECM CCM Data link ON OFF Setpoint RPM Engine sensor inputs Compressor outputs CAN bus CA...

Page 25: ...he 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 drop over the filter ...

Page 26: ... DPOS Drain plug oil sump F1 Cooling fan 1 RAD IC AC1 OC GC Gear casing OC Oil cooler OFC Compressor oil filter with bypass valve OGLP Oil gallery LP compressor element OGMP Oil gallery MP compressor element OP Oil pump OS Oil sump TS Temperature sensor CELP CEMP OC DPOC F1 GC DPOS OGMP CELP CEMP GC OS OP BVOS BVOC t BVOF OGLP DPOS TS OS OFC LUBRICATING CIRCUIT COOLING CIRCUIT ...

Page 27: ...electrical priming pump EPP is comprised in the system to fill up filters and fuellines after maintenance and servicing A description of this procedure can be found on page 64 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 are...

Page 28: ...pling 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 back 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: ...section 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 wet weight of unit is 8560 kg 18875 lbs 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 expe...

Page 31: ...exhaust air from the engine This causes overheating and engine power decrease Park the unit on solid level ground 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 1 2 3 ...

Page 32: ... 2 2 Check the air filter vacuum indicators VI If the yellow piston reaches the red 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...

Page 33: ...ion Regularly carry out following checks Check alarm lamp at the front and alarm lamp and horn at the back of the unit When starting up the unit and also when a shutdown occurs the alarm lamps and the horn will be activated But when a warning occurs only the lamps will be activated Check the air filter service indicator If the yellow signal shows in the window of the indicator see section 6 4 2 3 ...

Page 34: ...he Options status PC control mode The CCM is controlled by means of a PC This control mode can only be selected with the Connect button on the PC When the button is clicked the Control Mode parameter becomes remote PC regardless of the state of the Remote parameter Changing the Remote parameter will not effect the Control Mode parameter until the Disconnect button is clicked When the PC mode is ac...

Page 35: ...n status When the cooldown time has elapsed the stopping procedure begins The engine stops and the compressor will automatically return to the Ready for Start status 5 3 2 2 Automatic start automatic stop When switching on the power the compressor goes to the Ready for Start status From this status more information about all system configuration settings can be got or the automatic start can be im...

Page 36: ...Noload Load Stop Stop System Info Stop Stop if No Unload timer running if Automatic Start Start OK Stop Start Failure Not Loaded Load Unload System Info Ready for Start Permissive Start Cranking Warmup Cooldown Shutdown Options Standby Stopping operator action automatic action ...

Page 37: ... to the System Info status When all the parameters are within limits the engine starts cranking The starter motor runs for a preset time and then the engine rests for some time before trying to start again This cycle is repeated for a number of times When the engine does not start the starting procedure is ended and the operator is prompted to the Start Failure status after several failed attempts...

Page 38: ...e operator can leave the Shutdown status at any time and go to the Ready for Start status or to the Process Info status by pressing the reset button Restarting before the parameter is back within its limits is impossible because of the parameter check in the cranking procedure 5 3 3 9 Emergency stop When an emergency stop button is hit this message appears on the screen Until the emergency stop bu...

Page 39: ... When the compressor is in the Ready for Start status and the Remote start button is pressed the CCM will come out of Powerdown and go directly to the Permissive Start or Standby status Pressing any other Remote control button except Remote ON will only result in deactivating the Powerdown also when the CCM is in any other status When the Remote ON input is not active none of the Remote inputs can...

Page 40: ...etric pressure environments high altitude Cummins compensates the diesel injection 5 4 Operation via User Interface 5 4 1 General In this section an overview is given of all statuses of the CCM The reactions of the compressor to actions of the operator and to signals from the compressor itself are also shown 5 4 2 Ready for Start status 5 4 2 1 Manual start Other actions and signals have no effect...

Page 41: ...R To system info status see section 5 4 14 A OK button or Remote start input if Remote control mode R To standby status see section 5 4 3 S Warnings R Are shown on the screen A Emergency stop button R To emergency stop status see section 5 4 13 A button press once R Set pressure 0 1 bar A button press once R Set pressure 0 1 bar A button press continuously R Set pressure 0 1 bar second A button pr...

Page 42: ...1 bar second A Power OFF switch R To stopping status see section 5 4 10 A Stop command To stopping status see section 5 4 10 If cranking S Crank time elapsed S The starter motor output is desactivated for the duration of the crank time resting Crank counter 1 If resting S Crank time elapsed S The starter motor is reactivated the screen shows Crank attempt X with X being the Crank counter S Warning...

Page 43: ...d status see section 5 4 7 or Load Unload status see section 5 4 8 A Emergency stop button R To emergency stop status see section 5 4 13 A button press once R Set pressure 0 1 bar A button press once R Set pressure 0 1 bar A button press continuously R Set pressure 0 1 bar second A button press continuously R Set pressure 0 1 bar second A Stop command R To stopping status see section 5 4 10 A Powe...

Page 44: ...ion 5 4 10 A Power OFF switch R To Stopping status see section 5 4 10 A Load command R To Load Unload status see section 5 4 8 S Warnings R Are shown on the screen A Shutdowns R To Shutdown status see section 5 4 12 A Emergency stop button R To emergency stop status see section 5 4 13 A button press once R Set pressure 0 1 bar A button press once R Set pressure 0 1 bar A button press continuously ...

Page 45: ...Power OFF switch R To Cooldown status see section 5 4 9 A Noload command R To Not Loaded status see section 5 4 7 If Loaded S Unload pressure reached R Unload appears on the screen Autostop timer activated If Unloaded A Reload pressure reached R Load appears on the screen Autostop timer reset S Autostop time elapsed R To stopping status see section 5 4 10 S Warnings R Are shown on the screen A Shu...

Page 46: ... Standby status see section 5 4 3 If Power OFF End of operation A Emergency Stop button R To emergency Stop status see section 5 4 13 A button press once R Set pressure 0 1 bar A button press once R Set pressure 0 1 bar A button press continuously R Set pressure 0 1 bar second A button press continuously R Set pressure 0 1 bar second S Warnings R Are shown on the screen A Emergency Stop button R T...

Page 47: ...on press continuously R Set pressure 0 1 bar second A button press continuously R Set pressure 0 1 bar second A Power OFF switch R End of operation A Reset button R To Ready for Start status see section 5 4 2 S Warnings R Are shown on the screen A button press once R Set pressure 0 1 bar A button press once R Set pressure 0 1 bar A button press continuously R Set pressure 0 1 bar second A button p...

Page 48: ...hich he has clearance The Rental companies can deny access to the gray parameters for the operator In that case the parameters are not shown on the screen With the arrow buttons a parameter is selected Parameters which toggle between different settings e g Pressure Units can be changed by pressing the Toggle button Other parameters e g Display Luminosity can be changed by pressing the Edit button ...

Page 49: ...ing on the setting of the Infobutton parameter the operator has access to the Process Info status by pressing a single named function key the Process Info button In that case the Infobutton parameter is enable When the Infobutton parameter is disable the access to the Process Info status is made by a two button function While pressing the unnamed function button which otherwise would be the Proces...

Page 50: ...el level Engine fuel consumption Battery voltage Loading valve status Engine power contact Starter engine status Oiler valve status Blow off valve status Flap lock solenoid Engine load Engine boost pressure Air inlet temperature Other actions and signals have no effect in this status S Shutdowns R To Shutdown status see section 5 4 12 A Time out R Back to active compressor status A Emergency Stop ...

Page 51: ...suppression system 5 5 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 52: ... Control module The automatic fire suppression installation is constantly monitored by a control module It is powered by the machine s batteries but also fitted with an internal battery guaranteeing power supply should the batteries fail A number of LED s indicate the system status 5 5 3 1 Indicators 1 POWER LED pulses every three seconds when indicating normal power If the power drops below an ac...

Page 53: ...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 5 4 Daily check The LED s status on the ANSUL control module should be checked daily prior to starting up the compress...

Page 54: ... 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 55: ...air 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 crancase 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 drive...

Page 56: ... 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 sytem 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 57: ...ality 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 guar...

Page 58: ...il Level warning This warning is not immediately displayed on the screen of the User Interface but is held back for the duration of the Engine Oil Level Warning Time When the warning is generated the oil level maintainer valve is opened Oil flows from the oil tank into the oil sump of the engine and into the small oil tank The warning condition will disappear The oil level rises until the oil reac...

Page 59: ...ocated 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 3 Compressor maintenance procedures 6 3 1 Compressor oil level check Close the outlet valve s and stop the unit Before checking the compressor oi...

Page 60: ...lot 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 r...

Page 61: ...r 6 4 1 3 Testing coolant inhibitor level Use coolant test strips to measure chloride nitrite and glycol concentrations Cavitation corrosion protection is indicated on the strip by the level of nitrite concentration Freeze boilover 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 f...

Page 62: ... 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 63: ...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 64: ...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 65: ...ce doors The CAC Charge air 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 to the c...

Page 66: ...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 67: ...ged 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 to...

Page 68: ...ry 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 Yel...

Page 69: ...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 suppression system Preventive maintenance To p...

Page 70: ...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 71: ...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 72: ...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 73: ...e and inspect Replace parts where necessary Compressor does not deliver air or not immediatly 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 co...

Page 74: ...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 75: ... 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 76: ... 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 77: ...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 78: ...leak between LP and MP compressor element Inspect pipe connections and intercooler Replace leaking O rings gaskets or intercooler if necessary LP compressor element not in order Have LP compressor element inspected by Atlas Copco Intercooler clogged internally Consult Atlas Copco Intercooler pressure above normal Aftercooler clogged internally Consult Atlas Copco MP compressor element not in order...

Page 79: ...Communication Link Shutdown CAN Communication Link Shutdown Starter Relay Shutdown Compressor Intercooler Pressure 1 Sensor Warning Compressor Intercooler Pressure 2 Sensor Warning Compressor Oil Temperature Sensor Warning Air Discharge Temperature Sensor Warning Air Inlet Temperature Sensor Warning Oil Level Maintainer Valve Output Warning Flasher Lights Output Warning Horn Output Warning Blow of...

Page 80: ...w Engine Coolant Temperature 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 switch Engine oil level overfill shutdown switch LP element temperature shutdown MP element temperature shutdown Compress...

Page 81: ...The heating kit is a cold start option It consists of heater plugs that are to be installed in engine and gearbox making sure that the engine starts at temperatures as low as 25 C 13 F 8 3 Anti frost device The anti frost device is a kind of cover plate that makes the first aftercooler to cool down the compressed air less and prevents the formed condensate from freezing ...

Page 82: ...e used in ambient conditions as low as 25 C 13 F 9 Storage of the compressor 9 1 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 83: ... materials for recycling in the future is forseen 10 2 Disposal of materials Dispose contaminated substances and material separately according to local applicable environmental legislations 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 84: ...0 Bolts towbar turntable 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 yok...

Page 85: ...C 50 50 50 Minimum starting temperature C 25 25 25 Performance data 1 Engine shaft speed normal and maximum r min 1850 1750 1650 Engine shaft speed compressor unloaded r min 1200 1200 1200 Free air delivery 2 l s 762 718 663 Fuel consumption at full load kg h 75 74 4 73 2 Fuel consumption at unload kg h 12 6 12 6 12 6 Specific fuel consumption g m 27 34 28 78 30 67 Typical oil content of compresse...

Page 86: ...5 Load factor 100 Capacity of oil sump Initial fill l 84 Refill max 4 l TBD Capacity of cooling system intercooler Capacity of cooling system engine jackets l 120 Unit Capacity of compressor oil system l 84 Capacity of fuel tanks l 900 Air volume at inlet grating approx 3 m s 15 Unit dimensions Length mm 5240 with towbar in towing position mm 6770 Width mm 2210 Height mm 2350 Weight ready to opera...

Page 87: ...e 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 compression 4 With filter change ...

Page 88: ...S 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 lad...

Page 89: ... 89 Circuit diagrams ...

Page 90: ... K G1 DC DC G2 G3 _ _ S1 O M M1 SEE E C C OR USA VARIAN TS SCHE M ATIC 25M a2 441 03 4 05 1 b6 19U 19U 19U k0 19 k0 19 f6 19 f6 87 30 3 c3 03 5 K1 08 2 25M a2 24M a2 24 f2 24 f2 24 a2 24 k0 24 c2 9822 0900 20 00 Applicable for PTS 1600 T3 Circuit diagram Engine and Controller ...

Page 91: ...9 X2 06 X2 05 A1 A2 X1 06 X1 16 X1 05 X1 04 15 a3 8 a3 6 a3 306 a3 1002 b3 1003 b3 X2 27 X2 11 C LS5 N4 ENGINE CONT ROL MODULE B A D b2 b2 b2 b2 a3 99 19 b6 X1 50 X1 40 X1 39 X1 30 X1 29 X1 18 X1 20 X1 07 X1 08 X1 17 X1 38 19 b6 19 b6 19 b6 19 b6 X10 A H2 H3 H5 H7 B C D E 28 a3 20 a8 21 a7 03 9 25M a2 03 9 19 c6 ...

Page 92: ...241M a2 241M a2 10A 24 b2 24 d2 24 a2 a2 a0 24 03 9 03 3 19U a6 04 8 04 8 04 1 1000 a3 1001 a3 19 c6 19 c6 24M a2 IL a3 39 a3 19 b6 08 1 03 9 10A b2 28 a3 26 d2 conne ctorfor DDRreader USER INTER FACE SEE E CC OR USA VARIAN TS SCHE MATIC 20 a8 21 a3 18 a8 15 16 8 4 5 6 7 P A C S6 H1 3 S3 S2 Y7 F7 S7 N1 N2 N3 F8 R1 K4 F4 F3 Can H Can L Sig gnd A B C E 04 1 06 1 07 2 04 1 06 1 04 1 06 1 06 1 p ...

Page 93: ...L L E VEL SENSOR COMPRESSOR OIL TEMPE R ATURE SENSOR LOW PRESSURE ELEMENT TEMPE R ATURE SENSOR MEDIUM PRESSURE ELEMENT TEMPE R ATURE SENSOR HIGH PRESSURE ELEMENT TEMPE R ATURE SENSOR AMBIENT TEMPE R ATURE SENSOR AIR DISCHA RGE TEMPE R ATURE SENSOR AIR DISCHA RGE PRESSURE SENSOR COMPRESSOR INTE RCOOLER 2 PRESSURE SENSOR COMPRESSOR INTE RCOOLER 1 PRESSURE SENSOR COMPRESSOR OIL PRESSURE SENSOR ENGINE...

Page 94: ... 1 06 1 06 1 06 1 06 1 06 1 06 1 06 1 06 1 05 10 72 a7 52 a5 42 a9 73 a7 58 a5 59 a5 60 a5 61 a5 57 a5 62 a5 a7 78 a7 79 a7 80 a7 81 a7 77 a7 82 53 a5 43 a9 83 a7 63 a5 28 a3 LT2 U V V U P L L U P L L U P L L U P L L PT4 TT1 TT2 TT3 TT4 TT5 TT6 PT3 PT2 PT1 71 a7 51 a5 41 a9 70 a7 50 a5 40 a3 ...

Page 95: ...6 19 a6 1 a3 2 a3 7 a3 4 a3 SH6 a3 5X3 D1 D2 Y2 H6 H4 5 Y4 Y1 K1 LS4 LS3 LS2 LS1 S5 Y6 9 a3 19 a6 39 a3 18 85 86 87 30 03 5 A1 A2 A1 A2 A1 A2 A1 A2 1 2 06 1 06 1 06 1 06 1 06 1 06 1 06 1 06 1 06 1 06 1 06 1 30 a5 35 a5 36 a5 37 a5 34 a5 18 a6 18 a6 18 a6 18 a6 18 a6 ...

Page 96: ...amp Internal Lights PT2 Pressure Sensor Compressor Intercooler Pressure 2 TT6 Temperature Sensor Air Discharge Temperature H2 Lamp Engine Stop H3 Lamp Engine Warning PT3 Pressure Sensor Compressor Intercooler Pressure 1 Y1 Solenoid Loading Valve H4 5 Lamp Engine Warning Y2 Solenoid Oil Level Maintainer Valve H5 Lamp Maintenance PT4 Pressure Sensor Compressor Oil Pressure Y3 Refinery Equipment Air ...

Page 97: ... 97 ...

Page 98: ... C1 L1 C1 X3 D X3 E X1 B X1 A TS3 TS2 TS1 C6 N1 C6 N1 A3 C1 A2 C1 A1 C1 L1 C1 L2 C1 L2 C1 C6 N2 PE C54 PE C54 PE C54 C6 C6 PE C54 N2 N1 C6 C6 PE C54 N2 N1 N PE C54 N C6 C6 R3 R2 R1 X3 A X3 B X3 C X1 E X1 C X1 D k 95 mm 2 54 green yellow 2 ab 0 75 mm 9 white 2 j 50 mm 2 2 2 2 2 2 2 2 2 Wire size Colour code Legend aaa 0 35mm aa 0 5mm a 1 mm b 1 5mm c 2 5mm d 4 mm e 6 mm f 10 mm h 16 mm 0 black 1 br...

Page 99: ...eater R2 Engine oil heater R3 Compressor oil heater S1 Heater switch TS1 Temperature switch TS2 Temperature switch TS3 Temperature switch X1 Connector rear mains wiring X2 Connector user interface X3 Connector main mains wiring X4 Connector rear wiring X5 Power socket X7 Terminal strip ...

Page 100: ... LB X6 L2 C1 L1 C1 PE C54 C1 LA X5 L2 C1 L1 C1 X3 D X3 E X1 B X1 A TS3 TS2 TS1 C6 N1 C6 N1 A3 C1 A2 C1 A1 C1 L1 C1 L2 C1 L2 C1 C6 N2 PE C54 PE C54 PE C54 C6 C6 PE C54 N2 N1 C6 C6 PE C54 N2 N1 NB PE C54 NA C6 C6 R3 R2 R1 X3 A X3 B X3 C X1 E X1 C X1 D k 95 mm2 54 green yellow 2 ab 0 75 mm 9 white 2 j 50 mm 2 2 2 2 2 2 2 2 2 Wire size Colour code Legend aaa 0 35mm aa 0 5mm a 1 mm b 1 5mm c 2 5mm d 4 ...

Page 101: ... heater R2 Engine oil heater R3 Compressor oil heater S1 Heater switch TS1 Temperature switch TS2 Temperature switch TS3 Temperature switch X1 Connector rear mains wiring X2 Connector user interface X3 Connector main mains wiring X4 Connector rear wiring X5 Power socket X6 Power socket X7 Terminal strip ...

Page 102: ...E INTERNAL LIGHT 1 BATTERY SWITCH CONTINUOUS GROUND FOR INTERNAL LIGHTS ENGINE OIL LEVEL SWITCHES RELAY AND CIRCUIT BREAKER ENGINE HEATER SD W OVER FULL C C M ALT B D D START ENGINE STARTER RELAY PRIMING PUMP ELECTRICAL ENGINE HEATER TEMP SWITCH MOTOR ECM REFINERY EQUIPMENT COMP HEATER t SW THIS WIRE IS PLACED BENEATH THE ELEMENT CAT LEVEL SW COMP OIL HEATER BLOW OFF LOAD SOL FLAP LOCK SOL EM ST F...

Page 103: ... 103 ...

Page 104: ... AL C 15 SH C 16 SH NC 1 2 1 2 241M 19UM 241M 39 44 241M 241M 19UM 100 130 130 130 100 100 825 824 Diodes integrated into wiring 831 832 830 39 5H6 5X3 12 14 27MK4 19UM 150 1 0 0 24 19 150 74 76 100 350 STARTER ENGINE 40 0 73 25M 8 750 16 19B 13 7 24 305 9 25 306 13 26 in this area 400 See note 65 in this area Splices 3 75 200 CIRCUIT BREAKER CONTROLLER CIRCUIT BREAKER ECM 24 24 81 823 150 ADDITIO...

Page 105: ... 11 35 53 77 73 57 37 34 43 18 18 36 30 40 41 62 58 63 70 71 42 61 79 50 72 59 60 80 81 82 78 83 52 51 27M 19 2 10 1 19 21 9 27M 28 99 212 213 215 216 217 219 220 221 214 223 224 307 308 309 310 312 313 314 315 318 319 320 321 323 324 201 203 204 205 218 207 208 209 210 211 first digit is connector number Cavity 126 111 122 113 131 120 118 121 128 129 130 136 X2 X3 X1 15 16 25 26 2 3 1 4 5 6 7 8 9...

Page 106: ...1800 300 1700 1400 2200 BLOW OFF VALVE 7 19 See note 14 in this area Splice 2 1 1 2 3 50 TO PAGE 2 300 301 308 901 902 304 306 307 305 FLASHER LIGHT EMERGENCY STOP COOLANT LEVEL 150 1000 1005 900 See note 40 See note 21 105 1007 918 B A C D PAGE 3 ...

Page 107: ... see note 3 23 see note 2 15 1 orange 62 see note 9 73 splice 18 1 blue 63 see note 9 18 1 blue 65 see note 9 18 1 blue 67 see note 9 18 1 blue 159 see note 11 18 1 blue 158 see note 11 18 1 grey 18 see note 2 18 1 grey 31 see note 2 74 see note 18 19 4 blue 60 AMP 165034 0 74 see note 18 19 10 blue 189 see note 13 74 see note 18 19 1 5 blue 193 see note 13 74 see note 18 19 1 5 blue 205 see note ...

Page 108: ...31 805 splice 20 1 grey 191 see note 13 31 20 1 grey 933 see note 30 31 20 1 grey 4 see note 1 31 806 splice 21 1 purple 194 see note 13 31 21 1 purple 932 see note 30 31 21 1 purple 19 see note 2 100 splice IL 1 orange 106 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 ...

Page 109: ...117 2 24M 1 5 red 118 AMP 3 520117 2 8 see note 1 25M 1 5 red 30 see note 2 306 terminal end 26 4 red 307 terminal end 105 splice 27M 4 red 188 see note 13 27M 1 5 red 183 see note 13 27M 1 red 196 see note 13 27M 1 5 red 823 insulated faston 6 3x0 8 821 faston AMP 160913 4 24MF4 4 red 820 faston AMP 160913 4 840 see note 2 27MK4 4 red 20 see note 2 197 see note 13 28 1 orange 5 see note 1 161 see...

Page 110: ...e note 1 151 see note 11 57 1 green 165 see note 12 223 see note 8 58 1 green 174 see note 12 218 see note 8 59 1 green 175 see note 12 221 see note 8 60 1 green 170 see note 12 215 see note 8 61 1 green 10 see note 1 164 see note 12 62 1 green 6 see note 1 166 see note 12 63 1 green 51 see note 7 167 see note 12 70 1 green 168 see note 12 234 see note 7 71 1 purple 173 see note 12 212 see note 7 ...

Page 111: ...e note 19 945 see note 34 1002 1 5 orange 57 see note 19 946 see note 34 1003 1 5 orange 949 see note 34 902 see note 40 1004 1 red 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 112: ... 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 929939 1 Wire seal AMP 828904 1 Seal grommet Bosch 1280 703 26026 Note 9 Connector Deutsch DTM 06 2S Terminals Deutsch 1062 20 01221 Wedge Deutsch WM 2S Note 11 Connector Deutsch DRC 16 40S Terminals Deutsch 0462 201 ...

Page 113: ...ch 100mm 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 12110293 Terminals Packard Electric 12048074 Wire Seals Packard Electric 12048087 Secondary lock Packard Electric 12052845 Note 41 Relay socket Housing E T A R20 4B5 0 BS 01 Faston 6 3 x 0 8 Note 51 Protection cap 1612 0846...

Page 114: ...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 Note 66 2 shrinkable sleeve color blue Note 67 Label indicating AC part Nr and edition testing and or production date supplier reference Black ...

Page 115: ... 115 ...

Page 116: ...this area Splice 77 FUEL FILTER HEATER See note 7 See note 2 2 1 See note 2 1 2 24 87 16 49 24 84 Male Female 280 350 95 10 19 2 1 94 OUTLET TEMP REG VALVE See note 3 13 96 7 83 63 1 2 3 4 signal ground 1 2 28 supply 99 24VDC See note 11 100 4 30 1 101 102 61 62 63 17 18 19 20 21 23 22 25 26 200 50 See note 12 21 24M 19 28 20 A B C D E A B E D C 103 107 106 104 105 COSMOS 1001 1000 49 50 1000 27 1...

Page 117: ... 3 19 1 Blue 10 See note 2 19 1 Blue 21 See note 1 19 1 5 Blue 73 See note 1 19 4 Blue 95 See note 3 19 1 Blue 107 See note 12 19 1 Blue 202 eye M10 210 splice 19U inline fuse see note 2 201 socket Deutsch 1062 12 0166 19UM 1 blue 7 See note 2 52 Splice 22 1 Orange 47 See note 1 22 1 Orange 22 See note 1 22 1 5 Orange 9 See note 2 31 See note 4 9 1 Orange 84 See note 7 87 See note 4 24 4 Red 44 Se...

Page 118: ...n 68 See note 6 42 See note 4 77 1 Purple 76 AMP 160136 0 77 Splice See note 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 4 62 1 Green 79 See note 6 40 See note 4 82 1 Purple 94 See note 3 58 See note 1 10 1 Orange 72 See note 1 63 See note 5 A1 1 Orange 24 See note 1 49 See note 1 1001 1 Orange 27 See note 1 50 ...

Page 119: ...113 See note 15 306 1 Orange 65 See note 1 114 See note 15 313 1 Orange 66 See note 1 115 See note 15 314 1 Orange 69 See note 1 117 See note 15 315 1 Orange 90 See note 9 88 See note 4 54 1 Orange 91 See note 9 89 See note 4 55 1 Orange TERMINAL END A TERMINAL END B WIRE nr terminal nr terminal nr mm color ...

Page 120: ... 26026 Note 7 Terminals 84 85 shall be equipped with a label with printing ALWAYS INSULATE WIRE Label and printing must be water oil and coolant resistant Terminals 84 85 86 shall be equipped with a shrinkable sleeve with a layer of glue as in drawing below and strapped to the harness with nylon straps 1 Wire 2 Sleeve 3 Squeezed tight when hot Note 9 Connector Deutsch DT06 2S Terminals 1062 16 014...

Page 121: ...ness finishing black braiding unless stated otherwise Note 25 Diodes positioned as on drawing Note 26 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 26 1 shrinkable sleeve color red Note 26 2 shrinkable sleeve color blue Note 27 All wire type H05V K H07V K according to A...

Page 122: ... F D CUBICLE CONNECTOR See Note 1 See Note 2 900 50 150 1626 9917 00 01 Applicable for PTS 1600 Wire harness add on TERMINAL END A WIRE TERMINAL END B nr terminal nr mm color nr terminal 1 See note 1 15 1 orange 11 See note 2 2 See note 1 13 1 orange 12 See note 2 3 See note 1 305 1 orange 13 See note 2 4 See note 1 306 1 orange 14 See note 2 5 See note 1 313 1 orange 15 See note 2 6 See note 1 31...

Page 123: ... 123 ...

Page 124: ...he 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 125: ...yd s Register Verification 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 o...

Page 126: ... 126 ...

Page 127: ......

Page 128: ...Printed in Belgium 12 2013 2954 7430 01 ...

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