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XAS 400 JD7 Compressors

Scott Ellinger

Committed tosustainable productivity

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Systems Overview XAS 400 JD

Product Designation Oil Injected Compressors

X A T S 400 J D

Product rangeX : Oil injected portable compressor

Working principleA : Single stage compressorR : Two stage compressor

Silencing : Un-silencedS : Silenced

Capacity (FAD)Liter/secCFM (US-version)

Engine supplierC : CaterpillarD : DeutzJ : John DeereY : YanmarK : Kubota

Prime moverD : diesel engineE : electric motor

Working pressure Single stage

: standard pressure 7 bar/100psiM : medium pressure 8.6 bar/125psiT : “ten” pressure 10.3 bar/150psiH : high pressure 12 bar/175psiV : very high pressure 14 bar/200psi

Oil injected screw compressors

Compression principle

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Compressor systems

Four major components :

– Air system

– Oil system

– Control system

– Electrical system

Air system

Air filter

Filtration of the inlet air in 3 stages :

– centrifugal dust separation

– paper filter element

– safety cartridge (optional)

Vacuum indicator gives an indication when the pressure drop over the filter element is too high filter element needs to be replaced

Air filter

Air inlet Centrifugal separation

Dust

Filter element

to compressor element

Vacuum indicator

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REGULATING SYSTEM REG VALVE

Spring loaded

Adjusting receiver pressureby changing spring tension

• to pressure gauge and loading valve

• to speed regulator• to unloading valve

Regulating pressure:

Receiver pressure

The air receiver pressure can be set to another value by adjusting the spring tension of the regulating valve. This is done by turning the handle on top the valve. Increasing the spring tension, by turning in, will increase the regulating pressure and consequently the pressure inside the vessel. Turning out will decrease the pressure.

In order to regulate the pressure inside the reciever tank of our compressor, the air intake and the engine speed have to be controlled. This is done pneumatically. For that reason, we need regulating pressure. The regulating valve reduces the pressure inside the tank, thus providing the regulating pressure. This regulating pressure is then supplied to the unloader valve and the speed regulator or RPS.

Regulating Valve Service Kit – 2911 0111 00

Unloading valve

Opens and closes the air inlet to the compressor element.

– Open position at load condition=> Air consumption

– Closed position at no load condition=> No air consumption.

Control of the valve by regulating pressure.

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Unloading Valve or Air System Inlet Valve

Spring loaded in the closed position

Control Air closes the inlet

Also serves as check valve

Legend

Receiver Pressure

From Pressure Regulator right now very low to zero pressure

Unloading valve service kit – 2911 0074 00

No-Load Condition Load Condition

Unload Condition Blow- Down Condition

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Maintains a minimum pressure

of 58 PSI for oil flow

Also contains the final check

valve

AIR SYSTEM MIN PRESS VALVE

Oil System

Oil System

Air receiver

Oil cooler

Oil filter/TBV

Compressor element

Oil separator

Scavenge line

Compressor element

Oil

Oil

Air/Oil

Lubrication to the bearings

Air inlet

Oil injected screw compressors

Oil is injected in the bottom of the rotor housing,

on the bearings and gears

Oil injected screw compressors

Oil is used for :

– Cooling : compression heat is absorbed by the oil

– Lubrication of rotors, bearings, gears

– Sealing between rotors and rotor and housing

– Corrosion protection of the internal metal parts

Oil separator

Air/Oil

Centrifugal separation

Separator element

Oil

Scavenge line

Oil Separator filter element should be replaced

Every 1,000 hours or yearly.

Separator element retainer should be checked and cleaned at the time of separator element service

Oil Separator

Classic Reasons For Oil Carryover– Over filled receiver

– Plugged scavenge line

– Wrong type of oil (no anti foam agent)

– Shut down with air outlet valves open

– Scavenge tube installed improperly

Separator Element Service Kit – 2911 0075 00

Control System

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Control Panel

XC2002 Status

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XC2002 Menus

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Basic Operations

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Shutdown

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XC2002 Alarms

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XC2002 Alarms

If an Alarm occurs, a pop-up window will display for as long as the alarm is active, in any view. The flashing red Alarm LED will light up.

The Alarm icon(s) will be shown with an acknowledgement check box. Push the Enter button to acknowledge the alarm. An acknowledged Alarm will mark the check box and light the red Alarm LED.

An Alarm should always be acknowledged before solving the cause of the Alarm.

The Alarm display can be left by pushing the Back button.

If more than one Alarm occurs, the Up and Down arrows may be used to scroll through the list. Newest Alarms will be at the bottom of the list.

If a Shutdown occurs, the Shutdown Display will be shown.

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XC2002 Event Log

XC2002 keeps an event log of the last 15 events.

Shutdowns

Warnings

Service timer resets

Unit type changes

Running hours at time of event logged31

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Engine Faults

Compressor Faults

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Electrical System

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Wiring Diagram (1)

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Wiring Diagram (2)

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Maintenance

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Maintenance – XA(T,V)S 400 JD IT4

Daily:

Check engine oil level

Check compressor oil level

Check coolant level

Drain water from fuel filter

Empty air filter vaccuator valve

Check tire pressure

Maintenance – XA(T,V)S 400 JD IT4

Initial Service at 50 Hours

Check electrolyte level and terminals of battery

Check for leaks in Air, Oil, and Fuel systems

Check wheel nut torque (if equipped)

Check and adjust brakes (if equipped)

Check and adjust fan belts

Replace compressor oil filter

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Maintenance – XA(T,V)S 400 JD IT4500 Hour service pack part number 1310 3004 47 (typical 6 months)

Perform 50 hour service tasks

Clean oil cooler, radiator, intercooler

Grease door hinges

Grease towing eye shaft or ball coupling and shaft

Analyze coolant

Replace air filter elements

Replace engine oil and filter

Replace fuel primary filter and prefilter

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Maintenance – XA(T,V)S 400 JD IT41000 Hour service pack part number 1310 3004 48 (typical 12 months)

Perform 500 hour service tasks

Test safety valve and shut down switches

Check rubber flexibles

Replace separator element

Replace compressor oil and filter

Replace bleed off valve unloader

Clean oil stop valve

Replace filter element from regulating valve

Clean flow restrictor in oil scavenge line

Inspection by Atlas Copco service technician

Check/adjust engine valves every 2000 hours or per John Deere

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IT4 EXHAUST AFTERTREATMENT

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Tier 4: Terms and Key Words

Regeneration: The process of eliminating built up soot from the exhaust system

Two types of Regeneration

Active Regeneration: – Using a hydrocarbon (fuel) to elevate exhaust gas temperatures above

1100 F (600 C) in order to remove built up soot from the exhaust filter

Passive (Natural) Regeneration:– Using temperature alone to burn soot by elevated exhaust temperature

Can be controlled by temperature management of the exhaust stream– Can be achieved by maintaining exhaust gas temperature

– Can also be achieved by control valves including VGT that affect exhaust backpressure

Tier 4: Terms and Key Words Soot

– Incomplete combustion of hydro carbons in the exhaust stream

– Can be purged from the DPF by re-generation

Ash– Incomplete combustion of some hydrocarbon by-products

– CANNOT be purged from the DPF by re-generation

– EPA Mandated that DPF must withstand 4500 hrs before ash cleaning is needed

HPCR– High Pressure Common Rail fuel system

– System pressures up to 30,000 psi

– Allows multiple injection events to take place reducing emissions

VGT– Variable Geometry Turbocharger

– Inlet guide vanes can adjust to provide exact boost pressure to work in conjunction with the EGR

Tier 4: Terms and Key Words

NOx– Nitrogen Oxides

– Highly reactive gasses that form from emissions

EGR– Exhaust Gas Recirculation

– Recycles a portion of exhaust gas back to the engine

ULSD– Ultra low sulfur fuel (less than 15 ppm)

– Must be used on all IT4 machines

– Normal diesel fuel will kill an EGR and DOC within a few tanks

Low ash Engine oil– Must be used on all IT4 machines to reduce the formation of ash accumulating in

the DPF

CANbus – Method of communication between controllers or networks. All Atlas Copco controllers use SAE J1939 CANbus communication

Tier 4: DOC and DPF

Diesel Oxidation Catalyst (DOC)

Diesel Particulate Filter (DPF)

CEM- Cleaning Emission Module

Tier 4: Diesel Oxidation Catalyst (DOC)

Open cell substrate flow though device Reduces HC and CO significantly Reduces Pm 10 to 30% Converts NO to NO2 for passive regeneration of the DPF Oxidizes HC (diesel fuel) as part of active regeneration strategy No servicing required Requires use of low sulfur diesel or ULSD Typically element is =100% of engine displacement in size

Tier 4: Diesel Particulate Filter (DPF)

Wall flow, high filtration efficiency (95%+)

Traps ash, soot and any particles Needs periodic regeneration / cleaning Periodic ash cleaning required No muffler required in the vast majority

of applications

XC2002 DPF Status Indicators

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Xc2002 – DPF Information

Manual RegenerationManual Regeneration

• ParameterParameter

• DPF – Diesel Particulate filter – can DPF – Diesel Particulate filter – can change from AUTO to ON or turn OFF change from AUTO to ON or turn OFF completely (not recommended!)completely (not recommended!)

• STATION REGEN. – Stationary STATION REGEN. – Stationary (manual) Regeneratoin – OFF or ON(manual) Regeneratoin – OFF or ON

• Both need to be set to “ON” for manual Both need to be set to “ON” for manual regenerationregeneration

• Both are password protectedBoth are password protected

• Unit will not regenerate until soot level is Unit will not regenerate until soot level is ~70%~70%

Procedure: Stationary/Forced DPF Regeneration

Atlas Copco recommends that the DPF configuration be left in the AUTO mode at all times however in the event that a stationary or forced regeneration in desired the following process should be followed..

Unit WILL NOT regenerate until soot level is above 72%– Go to the "STATION REGEN" screen. For normal operation

this should be in OFF mode. Press the enter button (1), a password window will appear.

Enter 1968 and press the enter button. Use the up or down (2) arrow to change the selection to

ON and press the enter button. – Go to the "DPF" screen. For normal operation this should be

in the AUTO mode. Press the enter button (1) Use the up or down (2) arrow to change the selection to

ON and press the enter button.

This will set the unit up for regeneration, after a few moments the regeneration icon should appear confirming the unit is regenerating. – The stationary/forced regeneration can take in excess of 3

hours to complete.

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Upon completion of the stationary/forced regeneration it is highly recommended to reset the unit to automatically regenerate to prevent engine derate & shutdown due to high soot load.– Go to the "STATION REGEN" screen. (For normal operation this should be in OFF mode).

Press the enter button, a password window will appear. Enter 1968 and press the enter button.

Use the up or down arrow to change the selection to OFF and press the enter button. – Go to the "DPF" screen. For normal operation this should be in the AUTO mode.

Press the enter button, Use the up or down arrow to change the selection to AUTO and press the enter button.

The unit is now ready for normal operation.

Procedure: Stationary/Forced DPF Regeneration

Committed tosustainable productivity.