Atlas Copco XAS 130 DD7 C3 APP Instruction Manual Download Page 40

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GENERATOR 230/400V, 12 kVA WITH AUTOMATIC CONTROL SYSTEM

Circuit diagram (9822 1055 92)

(Not on HardHat)

To Circuit

diagram

9822 0991 34

X1.2

16A

c54

X1.3

16A

c54

X1.1

16A

c54

1
2

3
4

5
6

7
8

16A

16A 16A 16A

b0
W1

b54

b54 b54

52 51

13
b3

14 12 11

2 1

Reference

Name

Diode

Ecologiser

Generator

Lamp (Power Control)

Lamp automatic control system

Contactor/4-pole

Insulation monitoring relay

Time relais

Main circuit breaker 4-pole +

shunt tripcoil

Thermalcontact

Switch (Generator-compressor)

Switch automatic control system

X1.1

Socket outlet

X1.2

Socket outlet

X1.3

Socket outlet

Solenoid valve (Generator action)

The compressor is equipped with a negative earthed

system.
For location of relais K1, K2, K3, K4, see paragraph

Electric system

Summary of Contents for XAS 130 DD7 C3 APP

Page 1: ... C3 APP XAS 130 DD7 C3 APP XATS 67 Dd C3 APP XATS 125 DD7 C3 APP XAS 77 Dd C3 APP XAS 150 DD7 C3 APP XAS 97 Dd C3 APP XAS 185 DD7 C3 APP Instruction Manual for Portable Compressors English Engine Deutz D2011L03 ...

Page 2: ......

Page 3: ...O PORTABLE ENERGY DIVISION www atlascopco com Printed matter N 2954 2150 07 09 2015 Instruction Manual for Portable Compressors XAS 67 XAS 130 XATS 67 XATS 125 XAS 77 XAS 150 XAS 97 XAS 185 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 2015 Atlas Copco Airpower n v Antwerp Belgium Any unauthorized use or copying of the contents o...

Page 5: ... system 28 3 5 3 Generator 110V with automatic control system 30 3 5 4 Generator 230 400V 6 kVA without automatic control system 32 3 5 5 Generator 230 400V 6 kVA with automatic control system 34 3 5 6 Generator 230V 6 kVA 36 3 5 7 Generator 230 400V 12 kVA without automatic control system 38 3 5 8 Generator 230 400V 12 kVA with automatic control system 40 3 5 9 Generator 230V 12 kVA 42 3 5 10 Cir...

Page 6: ...5 15 Service kits 77 5 16 Compressor element overhaul 77 5 17 Liability 77 6 Adjustments and servicing procedures 78 6 1 Adjustment of the continuous pneumatic regulating system 78 6 2 Air filter engine compressor 80 6 3 Air receiver 81 6 4 Drive Belt XAS 67 XAS 130 XATS 67 XATS 125 81 6 5 Safety valve 81 6 6 Fuel system 81 6 7 Brake option adjustment 82 6 8 Wheels 84 6 9 Towbar and overrun brake ...

Page 7: ... 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 enclosures of the unit This includes work on live electrical components Skill level 4 Specialist from the manufacturer This ...

Page 8: ...perature inspect and clean heat transfer surfaces cooler fins intercoolers water jackets etc regularly See the Preventive maintenance schedule 8 All regulating and safety devices shall be maintained with due care to ensure that they function properly They may not be put out of action 9 Care shall be taken to avoid damage to safety valves and other pressure relief devices especially to avoid pluggi...

Page 9: ...e or jockey wheel immobilize the unit by placing chocks in front of and or behind the wheels When the towbar can be positioned vertically the locking device must be applied and kept in good order 6 To lift heavy parts a hoist of ample capacity tested and approved according to local safety regulations shall be used 7 Lifting hooks eyes shackles etc shall never be bent and shall only have stress in ...

Page 10: ...uel while the unit is running unless otherwise stated in the Atlas Copco Instruction Book AIB Keep fuel away from hot parts such as air outlet pipes or the engine exhaust Do not smoke when fuelling When fuelling from an automatic pump an earthing cable should be connected to the unit to discharge static electricity Never spill nor leave oil fuel coolant or cleansing agent in or around the unit 14 ...

Page 11: ...odour etc switch the circuit breakers to OFF and stop the engine Correct the faulty condition before restarting 32 Check the electric cables regularly Damaged cables and insufficient lightening of connections may cause electric shocks Whenever damaged wires or dangerous conditions are observed switch the circuit breakers to OFF and stop the engine Replace the damaged wires or correct the dangerous...

Page 12: ...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 material 17 Never use a ...

Page 13: ...the technical specifications Safety reasons prohibit any other applications 3 National legislation requirements with respect to re inspection must be complied with 4 No welding or heat treatment of any kind is permitted to those vessel walls which are exposed to pressure 5 The vessel is provided and may only be used with the required safety equipment such as manometer overpressure control devices ...

Page 14: ... psi see chapter Technical specifications The compressor is available with metal or PE canopy HardHat General view HardHat Engine The compressor is driven by an oil cooled diesel engine The engine s power is transmitted to the compressor through a heavy duty drive belt XAS 67 XAS 130 XATS 67 XATS 125 or a heavy duty coupling XAS 77 XAS 150 XAS 97 XAS 185 This symbol draws your attention to dangero...

Page 15: ...nd high oil temperature shut down switches Frame and axles The compressor engine unit is supported by rubber buffers in the frame The standard unit has a non adjustable towbar with support leg and one of the following towing eyes AC DIN ball ITA GB or NATO As an option the machine can be delivered with a spillage free frame an adjustable towbar a jockey wheel and or overrun parking brake for optio...

Page 16: ... 16 Main Parts SV A VI AR RV FP G OLG AOV CP DB C AF VV FF FU CE F EP FT D SN FCeo FCft DPec DSe OFe OFce JW BH TB H DPft CPG S E AFD ...

Page 17: ...ec Drain Plug Engine Oil Cooler DPft Drain Plug Fuel Tank DSe Engine Oil Level Dipstick E Engine EP Exhaust Pipe F Fan FCeo Filler Cap engine oil FCft Filler Cap fuel tank Reference Name FF Fuel Filter FP Filler Plug compressor oil FT Fuel Tank FU Fuel Pump G Generator H Hood JW Jockey wheel OFce Oil Filter compressor element OFe Oil Filter engine OLG Oil Level Gauge compressor element RV Regulati...

Page 18: ...DP SV OLG PG SL OF UA UV VH BDV DB C CV CE DP TS SL OCce AF VV FP RV FR SV SVsr PG BDV CV FP RV FR SV SVsr PG SL BDV CV SVuv SL F E VI XAS 67 6 5 kVA XAS 67 12 kVA XAS 97 6 5 kVA XAS 97 12 kVA With generator With generator Without generator ...

Page 19: ...ngine F Fan FN Flow Nozzle FP Filler Plug FR Flow Restrictor OCce Oil Cooler compressor element OF Oil Filter OLG Oil Level Gauge OS Oil Separator Reference Name PG Pressure Gauge RV Regulating Valve SL Scavenge Line SR Speed Regulator SV Safety Valve SVsr Solenoid Valve Speed regulator SVuv Solenoid Valve Unloader valve TS Temperature Switch UA Unloader Assembly UV Unloader Valve VH Vent Hole VI ...

Page 20: ...tor element The oil collects in the receiver and on the bottom of the separator element The air leaves the receiver via a flow nozzle FN which prevents the receiver pressure from dropping below the minimum working pressure specified in section Limitations even when the air outlet valves are open This ensures adequate oil injection and prevents oil consumption The system comprises of a temperature ...

Page 21: ... re enters the air receiver where it is separated from the air as described in section Air flow The oil that collects on the bottom of the oil separator element is returned to the system through a scavenging line SL which is provided with a flow restrictor FR The oil filter by pass valve opens when the pressure drop over the filter is above normal because of a clogged filter The oil then by passes...

Page 22: ... 22 CONTINUOUS PNEUMATIC REGULATING SYSTEM SR RV AR UA UV VH CE SVuv SVsr SVsr XAS 67 6 5 kVA XAS 67 12 kVA XAS 97 6 5 kVA XAS 97 12 kVA With generator With generator Without generator ...

Page 23: ... consumption is equal to or exceeds the maximum air output the engine speed is held at maximum load speed and the unloading valve is fully open If the air consumption is less than the maximum air output the regulating valve supplies control air to unloader valve UV to reduce the air output and holds air receiver pressure between the normal working pressure and the corresponding unloading pressure ...

Page 24: ...4 V1 X1 X1 X1 X1 X3 S5 P1 X1 K1 K0 G2 M1 K0 X1 N1 G1 M 3 b3 2 a3 6 a3 7 a3 2 a3 8 a3 11 a3 1 b2 1 f2 1 j 1 j 87 87a 30 85 86 8 85 86 87 30 02 5 02 9 02 9 02 10 02 10 87 87a 87 30 30 30 02 5 87 87a 86 85 30 87 87a 02 5 02 5 2 A B 6 5 3 8 15 30 50f 31 50e W 4 1 86 85 87a 87 30 02 8 02 8 AUXILIARY 2 a3 7 a3 8 a3 5 b2 9 31 33 32 2 b3 3 b3 4 b3 1 b2 30 02 1 02 3 B B D W 0 1 2 3 3 b3 ENGINE COMPARTIMENT...

Page 25: ... Pressure K4 Relay Charge Fail Protection K5 Relay Heater Plug K6 Relay Heater Plug M1 Starter Motor N1 Starter Protection Relay P1 Digital Hour Meter R1 Heater Plug optional R2 Heater Plug optional S1 Contact Switch Off On Override start S2 Temperature Switch Engine S3 Oil Pressure Switch S4 Temperature Lamptest Switch S5 Temperature Switch Compressor S6 Switch optional V1 Diode Reference Name X1...

Page 26: ...tion hourmeter P1 and fuel solenoid Y1 excited Thermocontact engine S2 normally closed oil pressure contact S3 open Start switch S1 position 3 Start relay K0 is excited and starter motor is running engine builds up oil pressure and oil pressure contact S3 closes K3 excited and contact K3 changes over to 30 87 Relay K2 no longer excited contact K2 opens lamp H1 goes out Alternator also commences su...

Page 27: ...er excited K3 changes over 30 87a engine cuts out because fuel solenoid Y1 no longer excited and lamp H2 and H1 go on simultaneously Take over relay K2 is excited simultaneously with H1 and contact K2 closes 30 87 Thermocontact S5 cools off and closes K1 excited again and contact K1 changes over 30 87 However lamp H1 remains on across line 9 and contact K2 30 87 A fault in the alternator part caus...

Page 28: ...b6 12 b3 I n 30mA 40msec 4 5 6 7 10 11 1 3 N13 D1 e0 e0 1 2 3 4 T13 EARTHING PIN To Circuit diagram 9822 0991 34 Reference Name D1 Diode G3 Generator H3 Lamp Power ON K5 Contactor N13 Earth faultcurrent relay Q1 Main circuit breaker 2 pole Q2 Circuit breaker 2 pole Q3 Circuit breaker 2 pole Q4 Circuit breaker 2 pole S7 Switch Generator compressor T13 Current transformer for N13 X1 Socket outlet X2...

Page 29: ... via the speed regulator controls the motor and allows it to reach maximum speed the normal control system is switched off Lamp H3 is activated and sockets X1 X2 X3 are under tension The generator can be switched off by turning switch S7 to position 0 An insulation fault is detected when a leakage current is flowing Contactor K5 will no longer be exited through the earth faultcurrent relay N13 ...

Page 30: ...3L2 L2 L1 16A e54 c0 c0 X2 L2 L1 L2 L1 16A 1L1 1L2 2L1 2L2 e54 c0 c0 e54 e0 e0 X1 32A Reference Name D1 Diode E1 Ecologiser G3 Generator H3 Lamp Power control H4 Lamp automatic control system K5 Contactor 4 pole K7 Time relais K8 Time relais N13 Earth faultcurrent relay Q1 Main circuit breaker 2 pole Q2 Circuit breaker 2 pole Q3 Circuit breaker 2 pole Q4 Circuit breaker 2 pole S7 Switch Generator ...

Page 31: ... X1 X2 X3 are under tension The generator can be switched off by turning switch S7 to position 0 If switch S7 is turned on lamp H4 and ecologiser E1 are activated E1 senses continuously the current to the sockets If no current is sensed time relay K8 is activated This time relay deactivates the solenoid valve Y2 so that the speed regulator is again controlled by the normal compressor control syste...

Page 32: ... c0 N b6 Q1 W U N V s2 03 03 03 b54 W1 b0 N b6 G3 G S6 16 b0 02 U1 W1 V1 N SHEET 02 Reference Name D1 Diode G3 Generator H3 Lamp Power control K5 Contactor 4 pole K6 Insulation monitoring relay Q1 Circuit breaker 10A 4 pole S6 Thermalcontact S7 Switch Generator compressor X1 1 Socket outlet X1 2 Socket outlet X1 3 Socket outlet Y2 Solenoid valve Generator action The compressor is equipped with a n...

Page 33: ... 3 are under tension The generator can be switched off by turning switch S7 to position 0 In the case of an insulation fault the yellow LED on the insulation monitoring relay K6 of the system is activated When the yellow LED of K6 is active a reset can only occur by halting and restarting the assembly 35 K6 34 To Circuit diagram 9822 0991 34 9822 0827 02 H3 K5 D1 Y2 A2 A1 A2 A1 12 b6 12 b6 12 b0 1...

Page 34: ... b6 b6 PR K7 K8 A1 A2 A1 A2 12 12 12 12 12 12 b3 b3 b3 D1 35 34 S8 S7 13 b3 15 b3 b3 b3 H4 b6 E1 To Circuit diagram 9822 0991 34 b6 b3 b3 b3 b6 11 9 51 52 3 4 3 7 1 2 3 4 5 6 u Reference Name D1 Diode E1 Ecologiser G3 Generator H3 Lamp Power control H4 Lamp Auto function K5 Contactor 4 pole K6 Insulation monitoring relay K7 Time relais K8 Time relais Q1 Main circuit breaker 4 pole shunt trip coil ...

Page 35: ... 1 X1 2 X1 3 are under tension The generator can be switched off by turning switch S7 to position 0 If switch S7 is turned on lamp H4 and ecologiser E1 are activated E1 senses continuously the current to the sockets If no current is sensed time relay K8 is activated This time relay deactivates the solenoid valve Y2 so that the speed regulator is again controlled by the normal compressor control sy...

Page 36: ...c0 e54 c0 c0 c0 c0 c0 c0 c0 c0 c0 b0 L1 L2 b54 b0 b6 12 b54 b54 b3 b0 b0 L A2 A1 PE T R 14 12 11 R K6 D1 c0 c0 To Circuit diagram 9822 0991 34 Reference Name D1 Diode G3 Generator H3 Lamp Power Control K5 Contactor 4 pole K6 Insulation monitoring relay Q1 Main circuit breaker 4 pole shunt tripcoil S6 Thermalcontact S7 Switch Generator compressor X1 1 Socket outlet X1 2 Socket outlet X1 3 Socket ou...

Page 37: ... motor and allows it to reach maximum speed the normal control system is switched off Lamp H3 is activated and sockets X1 1 X1 2 X1 3 are under tension The generator can be switched off by turning switch S7 to position 0 In the case of an insulation fault the yellow LED on the insulation monitoring relay K6 of the system is activated When the yellow LED of K6 is active a reset can only occur by ha...

Page 38: ...W1 H3 S6 u A1 A2 K5 35 52 51 S7 P B R Y2 13 13 12 3 13 b6 b6 12 b6 b3 34 12 b6 12 b3 b3 b3 13 b6 12 b3 L A2 A1 PE T R 14 12 11 R K6 D1 To Circuit diagram 9822 0991 34 Reference Name D1 Diode G3 Generator H3 Lamp Power Control K5 Contactor 4 pole K6 Insulation monitoring relay Q1 Main circuit breaker 4 pole shunt tripcoil S6 Thermalcontact S7 Switch Generator compressor X1 1 Socket outlet X1 2 Sock...

Page 39: ... motor and allows it to reach maximum speed the normal control system is switched off Lamp H3 is activated and sockets X1 1 X1 2 X1 3 are under tension The generator can be switched off by turning switch S7 to position 0 In the case of an insulation fault the yellow LED on the insulation monitoring relay K6 of the system is activated When the yellow LED of K6 is active a reset can only occur by ha...

Page 40: ...2 b3 13 b6 12 b3 13 b3 3 4 S8 H4 A1 A2 K8 13 b3 A1 A2 K7 b6 12 b6 12 b6 9 b3 b3 b3 b3 b3 b3 b6 b6 b3 b3 11 15 L A2 A1 PE T R 14 12 11 R K6 D1 2 1 3 4 5 6 7 E1 Reference Name D1 Diode E1 Ecologiser G3 Generator H3 Lamp Power Control H4 Lamp automatic control system K5 Contactor 4 pole K6 Insulation monitoring relay K7 Time relais K8 Time relais Q1 Main circuit breaker 4 pole shunt tripcoil S6 Therm...

Page 41: ...X1 2 X1 3 are under tension The generator can be switched off by turning switch S7 to position 0 If switch S7 is turned on lamp H4 and ecologiser E1 are activated E1 senses continuously the current to the sockets If no current is sensed time relay K8 is activated This time relay deactivates the solenoid valve Y2 so that the speed regulator is again controlled by the normal compressor control syste...

Page 42: ... b3 b0 b6 b6 b3 V1 13 12 12 b3 16 b0 16 b0 V1 35 34 c0 c0 b54 b0 b6 12 b54 b54 b3 b0 b0 L A2 A1 PE T R 14 12 11 R K6 16A 16A Q2 L1 L2 D1 Reference Name D1 Diode G3 Generator H3 Lamp Power Control K5 Contactor 4 pole K6 Insulation monitoring relay Q1 Main circuit breaker 3 pole shunt tripcoil Q2 Circuit breaker 2 pole S6 Thermalcontact S7 Switch Generator compressor X1 1 Socket outlet X1 2 Socket o...

Page 43: ... motor and allows it to reach maximum speed the normal control system is switched off Lamp H3 is activated and sockets X1 1 X1 2 X1 3 are under tension The generator can be switched off by turning switch S7 to position 0 In the case of an insulation fault the yellow LED on the insulation monitoring relay K6 of the system is activated When the yellow LED of K6 is active a reset can only occur by ha...

Page 44: ...Y1 P1 K0 Y20 S32 K9 N1 V1 K4 K4 V2 K1 K2 86 87a 87a 3 9 9 11 9 30 87 30 87 K3 S5 K0 87a 87a u 30 30 30 86 87 87a 87 30 87 30 85 86 85 86 85 86 85 86 2 8 3 85 6 7 86 85 87 21 20 22 23 30 15 87a 87 10 30 30 14 13 30 S4 12V DC 12 12 12 12 12 h 12 12 12 12 12 12 12 S1 F1 0 1 2 3 2 3 4 5 10A 2 1 3 4 u p 1 4 3 8 6 5 2 7 ...

Page 45: ...erride Start Relay K4 Start Relay K9 Auxilary Relay Safety Circuit M1 Starter Motor N1 Overspeed Module P1 Hourmeter S1 Contact Switch Off On Override start S2 Temperature Switch Engine S3 Oil Pressure Switch Engine S4 Temperature Lamptest Switch S5 Temperature Switch Compressor S32 Test Button Overspeed Y1 Fuel Solenoid Valve Y20 Solenoid for Overspeed Protection Valve V1 Diode V2 Diode ...

Page 46: ...lves without connected hoses Compressor loaded Runlamp Airfilter Compressor temperature too high 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 compressor with open doors Lifting device Use diesel fuel only 2 7 bar 39 psi ...

Page 47: ... in front of or behind the wheels Locate the rear end of the compressor upwind away from contaminated wind streams and walls Avoid recirculation of exhaust air from the engine This causes overheating and engine power decrease Do not obstruct air evacuation from the cooling system The compressor oil lifetime will be shortened when the compressor inlet air is contaminated The operator is expected to...

Page 48: ...sh the hand brake lever 3 completely downwards and connect breakaway cable 4 to the vehicle Secure jockey wheel 2 or support leg 1 in the highest possible position The jockey wheel is prevented from turning Adjustable towbar with jockey wheel and brakes Towing position of jockey wheel Before towing the compressor ensure that the towing equipment of the vehicle matches the towing eye or ball connec...

Page 49: ... guaranteed while driving If necessary tighten the locking nut 2 corresponding with table SPILLAGE FREE INSTRUCTION The compressor is fitted with a leak proof undercarriage in order to protect the environment Any leaking fluid is collected in case of malfunctions This fluid can be removed via outlets normally secured by caps Tighten the caps firmly and check for leakages Please observe the locally...

Page 50: ... breakaway cable and electrical plug Pull the lever vigorously upwards in the direction of the arrow and hold Wind down jockey wheel option and lift the compressor off the ball of the towing vehicle Secure the compressor by means of a wheel chock and or by applying the parking brake LIFTING INSTRUCTIONS When lifting the compressor the hoist has to be placed in such a way that the compressor which ...

Page 51: ...l be lowered Using low SAP oil less sulphur will create longer intervals between cleanings In the bottom bar 4 alarms will be displayed while an additional LED will submit additional information in respect to temperature or backpressure In case of an alarm a triangle shaped LED 6 will start flashing By just touching the sensor 5 the error will be acknowledged and the LED will be off In case an ala...

Page 52: ...l for the type and viscosity grade of the engine oil 3 Check the level of the compressor oil The pointer of the oil level gauge OLG should register in the green range Add oil if necessary See section Compressor oil level check for the oil to be used 4 Check that the fuel tank contains sufficient fuel Top up if necessary Consult the Engine Operation Manual for the type of fuel 5 In case of start up...

Page 53: ...G PROCEDURE WITH COLD START OPTION Reference Name P1 Digital hour meter F1 Circuit breaker button PG Working pressure gauge H1 Temperature alarm lamp red H2 General alarm lamp red S1 Start switch S4 Lamp test button S6 Cold start button P1 PG H1 H2 S1 S6 S4 F1 The control panel indicates receiver pressure PG and accumulated operating hours P1 The circuit breaker button is a protection against unin...

Page 54: ...lockwise into position 3 The starter motor will set the engine in motion The maximum allowed starter time where the starter motor is running continuously is 20 seconds If the engine does not catch a new attempt can be made after waiting 30 seconds The temperature alarm lamp H1 and the general alarm lamp H2 will go out as soon as the engine has been started The start switch automatically springs ba...

Page 55: ...LD START Reference Name P1 Digital hour meter F1 Circuit breaker button PG Working pressure gauge H1 Temperature alarm lamp red H2 General alarm lamp red S1 Start switch S4 Lamp test button P1 PG H1 H2 S1 S4 F1 The control panel indicates receiver pressure PG and accumulated operating hours P1 The circuit breaker button is a protection against unintended starting of the compressor A B F1 ...

Page 56: ...sition 3 The starter motor will set the engine in motion The maximum allowed starter time where the starter motor is running continuously is 20 seconds If the engine does not catch a new attempt can be made after 30 seconds waiting The temperature alarm lamp H1 and the general alarm lamp H2 will go out as soon as the engine has been started The start switch automatically springs back to position 1...

Page 57: ...el particulate filter This will increase the soot load of the filter BEST PRACTICES Reduce low load periods to a minimum This should be achieved by adequately sizing the unit for the application It is recommended that a unit is always used with a load 30 of nominal Actions should be taken if due to circumstances this minimum load capacity cannot be obtained Operate the unit at full load capacity a...

Page 58: ...il pressure too low oil temperature too high or alternator voltage too low will always and immediately cause the engine to cut out and the control lamp H2 will light up By doing some simple checks the cause of the engine failure can be determined low oil level clogged up cooler slack alternator belt tension or broken belt When the outlet temperature of the element becomes too high a thermocontact ...

Page 59: ...ive device The generator is protected by circuit breakers that switch off if a connected electrical device has an electrical fault H3 Lamp green power ON S7 Switch generator compressor X1 Socket 110 V 32 A X2 Socket 110 V 16 A X3 Socket 110 V 16 A GND Terminal earth cable Before switching on the generator always place the earth pin in position Check the cable connection between earth pin and the G...

Page 60: ...le until the generator main switch S7 is turned OFF Operation with automatic control switch S8 ON Switch generator main switch S7 ON Generator is disconnected from socket Engine reaches nominal speed Generator is re connected after 4 secs If a consumer is connected the engine goes on for 60 secs before falling back to idle speed Generator is in standby As soon as any consumer is switched on the ro...

Page 61: ... Socket 230 V 16 A X1 3 Socket 230 V 16 A GND Terminal earth cable Generator 230V S7 Switch H3 Lamp green X1 1 Socket 230 V 16 A X1 2 Socket 230 V 16 A X1 3 Socket 230 V 16 A GND Terminal earth cable 230 400V AND 230V 3PH WITHOUT AUTOMATIC CONTROL SYSTEM X1 3 X1 2 X1 1 H3 S7 GND Generator 230 400V Q1 Main circuit breaker 4 pole shunt trip coil K6 Insulation monitoring relay Generator 230V Q1 Main ...

Page 62: ...d on the automatic control system will continuously check for electric load in order to rev up the engine from idle to nominal speed only when needed This saves fuel and reduces emissions What is more with the current continuously monitored a consumer having just been switched on is temporary disconnected from the generator to be re connected as soon as the engine reaches nominal speed This is a s...

Page 63: ...x Protective device The generator is protected by circuit breakers that switch off if a connected electrical device has an electrical fault The insulation is monitored by relay K6 When the yellow LED on the insulation monitoring relay K6 is activated it means that a serious insulation fault has occured The insulation monitoring relay K6 is adjusted to 10 k This adjustment may not be changed The ge...

Page 64: ... damage Always keep the machine tidy to prevent fire hazard Poor maintenance can void any warranty claims MAINTENANCE SCHEDULE COMPRESSOR To determine the maintenance intervals use service hours or calendar time whichever occurs first Maintenance schedule running hrs Daily 50 hrs after initial start up Every 500 hrs Yearly Service pak XAS 67 XAS 130 XATS 67 XATS 125 XAS 77 XAS 150 2912 4392 06 Ser...

Page 65: ...Drain Clean fuel tank water and sediments 1 x x Check functioning of regulating valve x x Check electrolyte level and terminals of battery x x Check engine minimum and maximum speed x x Replace compressor oil filter s 5 x x Change engine oil 2 x x Replace engine oil filter 2 x x Replace fuel pre filters 6 x x Clean flow restrictor in oil scavenge line x x Grease hinges x x Replace bleed off valve ...

Page 66: ...valve in the fuel return line for mechanical injection system x 1 More frequently when operating in a dusty environment 2 Refer to engine operation manual 3 After a day s work 4 Replace all rubber flexibles every 6 years according to DIN 20066 5 Use Atlas Copco oil filters with by pass valve as specified in the parts list 6 Gummed or clogged filters means fuel starvation and reduced engine perform...

Page 67: ...rs every 1500 hrs Diesel particle filter clean replace Soot is toxic It must be handled according local regulations for toxic waste Cleaning and replacing of the diesel particle filter may only be done by qualified and authorised personnel ...

Page 68: ...x x Check torque of wheel nuts x x x Grease coupling head drawbar bearings at the housing of the overrun brake x x x Check brake system if installed and adjust if necessary x x x Oil or grease brake lever and moving parts such as bolts and joints x x x Check Adjust lateral play of wheel bearing conventional bearing x x Check tyres for uneven wear x x Grease sliding points on height adjusting parts...

Page 69: ...ter and accumulate in the valve rocker cover area PAROIL releases excess heat efficiently whilst maintaining excellent bore polish protection to limit oil consumption PAROIL has an excellent Total Base Number TBN retention and more alkalinity to control acid formation PAROIL prevents Soot build up PAROIL is optimized for the latest low emission EURO 3 2 EPA Tier II III engines running on low sulph...

Page 70: ...e intervals For intervals see Preventive maintenance schedule Check engine oil level in accordance to the instructions in the Engine Operation Manual and if necessary top up with oil ENGINE OIL AND OIL FILTER CHANGE See section Preventive maintenance schedule Liter US gal Order number can 5 1 3 1615 5953 00 can 20 5 3 1615 5954 00 barrel 209 55 2 1615 5955 00 container 1000 265 1630 0096 00 Liter ...

Page 71: ...pressor oil PAROIL M Synthetic compressor oil PAROIL S Liter US gal Order number can 5 1 3 1615 5947 00 can 20 5 3 1615 5948 00 barrel 209 55 2 1615 5949 00 container 1000 265 1630 0310 00 Liter US gal Order number can 5 1 3 1630 0160 00 can 20 5 3 1630 0161 00 barrel 209 55 2 1630 0162 00 container 1000 265 1630 0163 00 ...

Page 72: ... of the oil level gauge 1 The pointer must register in the green area the oil filler plug The level must be between the two markings as indicated in the label on the oil vessel 2 If the oil level is too low remove the oil filler plug 2 and check if there is still oil in the vessel No oil in the vessel Top up the compressor with oil until the pointer of the oil level gauge is in the upper part of t...

Page 73: ...er plug to speed up draining After draining reposition and tighten the drain plugs 3 Remove the oil filters 3 e g by means of a special tool Catch the oil in a drain pan 4 Clean the filter seat on the manifold taking care that no dirt drops into the system Oil the gasket of the new filter element Screw it into place until the gasket contacts its seat then tighten one half turn only 5 Fill the air ...

Page 74: ...w oil separator screw on new compressor oil filter s and close the oil vessel according to the instructions 6 Fill the oil vessel with the minimum amount of replacement oil run the compressor under light load conditions for 30 minutes 7 Thoroughly drain the system when the oil is warm leaving as little oil in the system as possible especially in dead areas if possible blow out remaining oil by pre...

Page 75: ... of the fuel tank Remove the drain plug Lift the towbar see chapter Main Parts TB and tilt the compressor approx 15 to remove all fuel dirt and water Clean the fuel tank and fix the drain plug handtight Refill the fuel tank with clean fuel Remove any dirt from the coolers with a fibre brush Never use a wire brush or metal objects 1 2 To avoid damaging the coolers angle between jet and coolers shou...

Page 76: ...es safe charging current in Amp MAKE UP DISTILLED WATER The amount of water evaporating from batteries is largely dependant on the operating conditions i e temperatures number of starts running time between start and stop etc If a battery starts to need excessive make up water this points to overcharging Most common causes are high temperatures or a too high voltage regulator setting If a battery ...

Page 77: ...ts List ASL SERVICE KITS A Service Kit is a collection of parts to fit a specific repair or rebuilding task It guarantees that all necessary parts are replaced at the same time which improves the uptime of the unit The order numbers of the Service Kits are listed in the Atlas Copco Parts List ASL COMPRESSOR ELEMENT OVERHAUL When a compressor element is due for overhaul it needs to be done by Atlas...

Page 78: ... 78 Adjustments and servicing procedures ADJUSTMENT OF THE CONTINUOUS PNEUMATIC REGULATING SYSTEM SR RV AOV SVsr FP SVsr E SVuv With generator Without generator With generator ...

Page 79: ...k the engine maximum speed Adjust the maximum speed by means of adjustable eccentric nut on top of speed regulator SR 6 Close the outlet valves AOV check that the pressure is between Z1 and Z2 bar see table Lock the regulating valve RV by pushing the knob down 7 Check the operation of the solenoid valve SVsr when equipped with a generator Modifying the set point above the nominal working pressure ...

Page 80: ...eaned REPLACING THE AIR FILTER ELEMENT 1 Release the snap clips 1 and remove the dust trap 2 Clean the trap 2 Remove the element 4 from the housing 5 3 Reassemble in reverse order of dismantling Make sure the vacuator valve 6 points down 4 Inspect and tighten all air intake connections 5 Reset the vacuum indicator 7 1 Snap clips 6 Vacuator valve 2 Dust trap cover 7 Vacuum indicator 3 Safety cartri...

Page 81: ...ck cannot be done on the machine and must be carried out on a proper test bench FUEL SYSTEM Replacing the filter element 1 Unscrew the filter element 1 from the adapter head 2 Clean the adapter head sealing surface Lightly oil the gasket of the new element and screw the latter onto the header until the gasket is properly seated then tighten with both hands 3 Check for fuel leaks once the engine ha...

Page 82: ...ent 6 with the parking brake actuated Perpendicular position of equalizer identical clearance of wheel brakes Re adjust the brake shoes if necessary To test slightly apply the parking brake and check identical brake torque on left and right side Remove locking pin 4 Remove clearance from brake cables Check all lock nuts see section Brake cable adjustment 2 BRAKE CABLE ADJUSTMENT 1 With the towing ...

Page 83: ... Apply the hand brake lever 4 Push the compressor a few centimeters backwards so that the brake lever is automatically pulled up further 5 Check the position of the arrow marking 1 at the catch lock in combination with the arrow marking 2 at the toothed sector according to A B C D 2 1 B Acceptable C Too loose adjust brake cables Section Brake cable adjustment D Too tight adjust brake cables Sectio...

Page 84: ...th taper roller bearings are recognizable by a tapered type hub cap see Figure Remove wheels and wheel hubs Mark dismounted wheel hubs and bearing races so that their identity is not mistaken during reassembly Clean wheel hubs thoroughly inside and outside Remove old grease totally Clean taper roller bearings and seals using diesel oil and check for reuseability Work BPW special longlife grease EC...

Page 85: ...are designed for high mileages Therefore there is no grease change or regreasing necessary WHEEL BOLTS CHECK Wheel bolts tightening Tighten wheel bolts crosswise using a torque wrench and tightening torque in compliance with the table Tightening torques of wheel bolts After the first run likewise after each wheel change Spanner width mm Thread Tightening torque Nm lbf ft 19 M 12 x 1 5 85 63 ...

Page 86: ...t pin from axle nut and tighten so that rotation of the wheel is slightly braked Turn back the axle nut to the next possible split pin hole by a maximum of 30 degrees Insert split pin and bend ends slightly outwards Check wheel rotation fit hub cap Important The grease in the hub cap and bearing must not be contaminated with dirt during this job Compact bearings Compact bearings are recognizable b...

Page 87: ... 250 350 Nm M 32 350 400 Nm Check tight fit of the clamping nuts and correct positioning of the adjustment facility See also Height adjustment Brake play check Brake play check The check is carried out visually on the stroke x of the overrun coupling As soon as this is more than 50 mm when the brakes are applied adjust the wheel brakes Check towbar handbrake lever spring actuator reversing lever l...

Page 88: ...coupling at regular intervals in the specified locations and moving parts Grease the contact surface of the ball of the towing vehicle Greasing towbar Towbar bushes on the housing of the overrun coupling Apply general purpose grease via the grease nipples until fresh grease can be seen emerging from the bushes 50 km after initial start up then every 2 000 kilometres or annually 2 1 At regular inte...

Page 89: ...ubricate all moving parts and pivot pins at the overrun coupling All moving parts of drawbar handbrake lever spring actuator reversing lever linkages etc are to be oiled or greased as required Heigth adjusting device Grease sliding locations on the height adjusting device Oil threaded parts and grease toothed parts 50 km after initial start up then every 2 000 kilometres or annually 1 50 km after ...

Page 90: ...as Copco Problem Possible faults Corrective actions 1 Lamps H1 H2 do not light up when switching S1 to I and applying lamp test a Discharged or defective battery b Loose battery cable s or oxidised terminals c Loose connection or damaged wiring d Contact switch S1 defective e Circuit breaker F1 defective a Check electrolyte level and charge battery If no cells are shorted and battery is discharged...

Page 91: ...leased too soon b Insufficient engine oil pressure c Fuel tank contains insufficient fuel a Release switch after engine oil pressure has built up above the minimum allowed value b Stop at once consult the Engine Operation Manual c Fill fuel tank 8 General alarm lamp H2 remains alight for over 5 seconds after starting a Insufficient engine oil pressure or too high engine oil temperature b Engine oi...

Page 92: ...rictor in oil scavenging line SL clogged b Oil separator element OS defective c Oil level too high a Dismount clean and refit restrictor b Replace element c Check for overfilling Release pressure and drain oil to correct level 14 Compressor shuts down through a shutdown switch a Alternator V belt broken or slipping b Compressor overheating c Engine oil pressure too low d Engine temperature too hig...

Page 93: ...re off b Serious electrical fault a Switch on circuit breakers b Consult Atlas Copco Generator 230 400V 22 No voltage at sockets a Generator not switched on b Circuit breakers are off a Switch generator on b Switch on circuit breakers 23 When the electrical device is connected the circuit breakers switch always off a Electrical device is defective a Have electrical device replaced or repaired 24 C...

Page 94: ...angle shaped flashes Damage of temperature probe Pressure 8 Alarm 1 flash triangle shaped flashes Upper Pressure Limit Switch to full load Alarm 3 flashes triangle shaped flashes No RPM Signal from the generator Alarm 7 flashes triangle shaped flashes Date and Time not correct no recording of data Consult Atlas Copco Alarm 1 flashes triangle shaped flashes Pressure 8 off Error Additive Dosing Cons...

Page 95: ...r separator Aftercooler water separator PD filter Aftercooler water separator PD QD filters Aftercooler water separator reheater 1 Aftercooler water separator PD filter reheater 1 Aftercooler water separator PD QD filters reheater 1 Lubricator 2 Anti frost device 2 By pass 2 Tool box Single Twin Safety Wheel chocks Safety cartridge Spark arrestor 1 Safety chain CE ASME Anti theft 3 Hose reel 1 Inl...

Page 96: ...e Torque value Nm lbf ft M6 14 10 21 M8 34 25 23 M10 70 52 24 M12 120 89 25 M14 195 144 23 M16 315 233 23 Assemblies Torque value Nm lbf ft Wheel bolts see section Wheel bolts check Bolts axle beams 80 59 10 Bolts towbar axle 80 59 10 Bolts towbar bottom 80 59 10 Bolts towing eye towbar 80 59 10 Bolts lifting eye flywheel housing 80 59 10 Bolts engine drive housing M12 80 59 10 Bolts engine drive ...

Page 97: ...e oil pressure bar 1 2 1 2 1 2 1 2 psi 17 4 17 4 17 4 17 4 Engine oil temperature C 127 133 127 133 127 133 127 133 F 260 270 260 270 260 270 260 270 Compressor temperature C 116 120 116 120 116 120 116 120 F 241 248 241 248 241 248 241 248 Safety valve opening pressure EC type bar 10 5 14 5 10 5 10 5 ASME type psi 160 210 160 160 ...

Page 98: ... grating outside the canopy Designation XAS 67 XAS 130 XATS 67 XATS 125 XAS 77 XAS 150 XAS 97 XAS 185 Absolute inlet pressure bar 1 1 1 1 psi 14 5 14 5 14 5 14 5 Relative air humidity 0 0 0 0 Air inlet temperature C 20 20 20 20 F 68 68 68 68 Nominal effective working pressure bar 7 10 3 7 7 psi 102 150 102 102 ...

Page 99: ... 58 48 58 Maximum effective receiver pressure compressor unloaded bar 8 7 11 8 8 7 9 psi 126 171 126 130 Maximum ambient temperature at sea level 1 without aftercooler C 45 45 45 45 F 113 113 113 113 with aftercooler C 40 40 40 40 F 104 104 104 104 Minimum starting temperature C 10 10 10 10 F 14 14 14 14 Minimum starting temperature with coldstart equipment C 20 20 20 20 F 4 4 4 4 Altitude capabil...

Page 100: ...m ALTITUDE ft TEMPERATURE F TEMPERATURE C 5000 4000 3000 2000 1000 0 14 32 50 68 86 104 122 10 0 10 20 30 40 50 16 405 0 XAS 67 XAS 130 13 124 9 843 6 562 3 281 4 0 bar e 58 psi 5 0 bar e 73 psi 6 0 bar e 87 psi 7 0 bar e 102 psi ALTITUDE m ALTITUDE ft TEMPERATURE F TEMPERATURE C Generator 6kVA 5000 4000 3000 2000 1000 0 14 32 50 68 86 104 122 10 0 10 20 30 40 50 16 405 0 XAS 67 XAS 130 13 124 9 8...

Page 101: ...124 9 843 6 562 3 281 7 3 bar e 106 psi 8 3 bar e 121 psi 9 3 bar e 135 psi 10 3 bar e 150 psi ALTITUDE m ALTITUDE ft TEMPERATURE F TEMPERATURE C 5000 4000 3000 2000 1000 0 14 32 50 68 86 104 122 10 0 10 20 30 40 50 16 405 0 XAS 77 XAS 150 13 124 9 843 6 562 3 281 4 0 bar e 58 psi 5 0 bar e 73 psi 6 0 bar e 87 psi 7 0 bar e 102 psi ALTITUDE m ALTITUDE ft TEMPERATURE F TEMPERATURE C ...

Page 102: ...9 843 6 562 3 281 4 0 bar e 58 psi 5 0 bar e 73 psi 6 0 bar e 87 psi 7 0 bar e 102 psi ALTITUDE m ALTITUDE ft TEMPERATURE F TEMPERATURE C 5000 4000 3000 2000 1000 0 14 32 50 68 86 104 122 10 0 10 20 30 40 50 16 405 0 XAS 97 XAS 185 13 124 9 843 6 562 3 281 4 0 bar e 58 psi 5 0 bar e 73 psi 6 0 bar e 87 psi 7 0 bar e 102 psi ALTITUDE m ALTITUDE ft TEMPERATURE F TEMPERATURE C Generator ...

Page 103: ...thout aftercooler l s 62 58 58 72 89 89 cfm 131 123 123 153 189 189 with aftercooler l s 57 53 53 67 84 84 cfm 121 112 112 142 178 178 Fuel consumption 2 at 100 FAD 2 kg h 5 9 7 4 7 5 9 8 1 8 1 lb h 13 16 1 15 4 13 0 17 9 17 9 at 75 FAD 2 kg h 5 2 6 2 5 6 5 1 6 4 6 4 lb h 11 5 13 7 12 3 11 2 14 1 14 1 at 50 FAD 2 kg h 4 3 5 4 2 4 5 5 5 lb h 9 5 11 9 3 9 9 11 11 at 25 FAD 2 kg h 3 4 4 2 3 7 3 9 4 4...

Page 104: ... h 17 20 37 17 37 37 oz h 0 6 0 7 1 3 0 6 1 3 1 3 Compressed air temperature at outlet valves without aftercooler C 89 94 90 89 90 90 F 192 201 194 192 194 194 with aftercooler C 30 30 30 30 30 30 F 86 86 86 86 86 86 Noise level Sound pressure level Lp measured according to ISO 2151 under free field conditions at 7 m distance dB A 70 70 72 70 72 72 Sound power level Lw complies with 2000 14 EC dB ...

Page 105: ... 94 94 94 94 94 in 3 7 3 7 3 7 3 7 3 7 3 7 Stroke mm 112 112 112 112 112 112 in 4 4 4 4 4 4 4 4 4 4 4 4 Swept volume l 2 332 2 332 2 332 2 332 2 332 2 332 cu in 142 3 142 3 142 3 142 3 142 3 142 3 Output acc to ISO 9249 G at normal shaft speed kW 32 5 36 36 31 5 36 36 hp 43 6 48 3 48 3 42 2 48 3 48 3 Load factor 50 50 50 50 50 50 Capacity of oil sump Initial fill l 8 5 8 5 8 5 8 5 8 5 8 5 US gal 2...

Page 106: ...XAS 97 XAS 185 XAS 97 XAS 185 Generator Capacity of compressor oil system l 8 8 8 8 8 8 US gal 2 1 2 1 2 1 2 1 2 1 2 1 Net capacity of air receiver l 16 7 16 7 16 7 16 7 16 7 16 7 US gal 4 4 4 4 4 4 4 4 4 4 4 4 Air volume at inlet grating approx 1 m3 s 0 85 0 85 0 85 0 93 1 2 0 85 cuft s 30 29 30 33 42 4 29 Capacity of fuel tank l 80 80 80 80 80 80 US gal 21 1 21 1 21 1 21 1 21 1 21 1 ...

Page 107: ...lass H H H H H rotor class H H H H H Number of phases 1 3 3 3 3 Number of leads 4 6 6 6 6 Designation XAS 67 XAS 130 XAS 97 XAS 185 110V 6 kW 230V 3 ph 6 kVA 230V 3 ph 12 5 kVA 230 400V 3 ph 6 kVA 230 400V 3 ph 12 5 kVA Rated continuous active power COP kW 5 5 4 8 9 6 4 8 9 6 Rated power factor lagging 1 0 8 0 8 0 8 0 8 Rated continuous apparent power 1 ph COP kVA 5 5 4 3 7 4 3 7 Rated voltage 1ph...

Page 108: ... Rated current In 1ph A 50 In 1ph 3ph A 16 16 16 32 16 10 16 16 Thermal release It 1ph A 50 It 1ph 3ph A 16 16 16 32 16 10 16 16 Magnetic release Im A 3 5 In 3 5 In 3 5 In 3 5 In 3 5 In Designation XAS 67 XAS 130 XAS 97 XAS 185 110V 6 kW 230V 3 ph 6 kVA 230V 3 ph 12 5 kVA 230 400V 3 ph 6 kVA 230 400V 3 ph 12 5 kVA Insulation resistance kOhm 10 80 10 80 10 80 10 80 Residual current release Idn A 0 ...

Page 109: ...djustable fixed adjustable fixed adjustable fixed adjustable Length A 1 mm 2827 2970 3302 3470 2827 2970 3302 3470 in 111 117 130 136 111 117 130 136 Width B mm 1410 1410 1410 1410 1410 1410 in 55 55 55 55 55 55 Height C mm 1258 1258 1258 1258 1258 1258 in 49 49 49 49 49 49 Weight ready to operate 2 3 kg 880 915 930 890 925 940 lbs 1940 2018 2051 1963 2040 2073 Weight dry 2 3 kg 815 850 865 825 86...

Page 110: ...S 77 XAS 150 XAS 97 XAS 185 Length X mm 2018 2018 in 79 79 Width Y mm 1040 1040 in 41 41 Height Z mm 970 1230 970 1230 in 38 48 38 48 Weight ready to operate kg 790 840 800 850 lbs 1742 1852 1763 1873 Weight dry kg 725 775 735 785 lbs 1599 1709 1621 1730 X Y Z ...

Page 111: ...e B Maximum permitted axle load C Maximum permitted load on the towing eye 8 Model 9 Working pressure 10 Speed 11 Engine power 12 Year of manufacture 13 CE mark in accordance with Machine Directive 89 392 EC 14 Register number or number of notified body Atlas Copco Airpower n v Atlas Copco Airpower n v Boomsesteenweg 957 B 2610 WILRIJK 0038 kg kg kg 1 A C B 2 kg D S N Manuf year 1 2 3 4 5 6 7 8 9 ...

Page 112: ...g in the future is foreseen DISPOSAL OF MATERIALS Dispose of contaminated substances and material separately in accordance with locally applicable environmental legislation Before dismantling a machine at the end of its operating lifetime drain and dispose of all fluids of according the applicable local disposal regulations Remove the batteries Do not throw batteries into the fire explosion risk o...

Page 113: ... 113 Maintenance Log Compressor Customer Serial number Service hours Maintenance action Date By initials ...

Page 114: ...mplies 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 b Machinery safety 2006 42 EC EN ISO 12100 1 EN ISO 12100 2 EN 1012 1 c Simple pressure vessel 87 404 EEC X d Electromagnetic compatibility 2004 108 ...

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