1. XA(T,V)S 400 CD7 iT4 Compressors
Scott Ellinger
Committed to sustainable productivity

2. Systems Overview XAS 400 CD

3. Product Designation Oil Injected Compressors
Engine supplier
C : Caterpillar
D : Deutz
J : John Deere
Y : Yanmar
K : Kubota
Working principle
A : Single stage compressor
R : Two stage compressor
Product range
X : Oil injected
portable compressor
Silencing
: Un-silenced
S : Silenced
Prime mover
D : diesel engine
E : electric motor X A T S
400 C D
Capacity (FAD)
Liter/sec CFM (US-version)
Working pressure
: std pressure psi
M : psi
T : psi
H : psi
V : psi

4. XAS 400 CD7 IT4 Machine Specifications

5. XAS 400 CD7 IT4 Machine Specifications (2)

6. Compressor systems Air system Oil system Control system
Four major components :
Air system
Oil system
Control system
Electrical system

7. Air system
The following slides explain how the regulating system of the XA(H)S works. They will give you an overview of the different parts and their function.

8. Air filter centrifugal dust separation paper filter element
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

9. Air filter Centrifugal separation Air inlet Vacuum indicator
Filter element
Dust
to compressor element

10. REGULATING SYSTEM REG VALVE
Spring loaded
Adjusting receiver pressure
by changing spring tension
to pressure gauge and loading valve
to speed regulator
to unloading valve
Regulating pressure:
Receiver 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.
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.

11. Unloading valve Open position at load condition => Air consumption
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.

12. Unloading Valve or Air System Inlet Valve
Legend
Receiver Pressure
From Pressure Regulator right now very low to zero pressure
Spring loaded in the open
position
Control Air closes the inlet
Also serves as check valve
Unloading valve service kit –

13. No-Load Condition Load Condition

14. Unload Condition Blow- Down Condition

15. AIR SYSTEM MIN PRESS VALVE
Maintains a minimum pressure
of 58 PSI for oil flow
Also contains the final check
valve

16. Oil System
The following slides explain how the regulating system of the XA(H)S works. They will give you an overview of the different parts and their function.

17. Oil System Air receiver Oil cooler Oil filter/TBV Compressor element
Oil separator
Scavenge line
Oil stop valve
The following slides explain how the regulating system of the XA(H)S works. They will give you an overview of the different parts and their function.

18. Oil injected screw compressors

19. Compressor element
Lubrication to the bearings
Air inlet
Oil
Air/Oil

20. 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

21. Oil injected screw compressors
Oil is injected in the bottom of the rotor housing,
on the bearings and gears

22. Compression principle
Suction
Compression start
Delivery
Compression

23. Oil separator Scavenge line Separator element Centrifugal separation
Oil Separator filter element should be replaced
Every 1,000 hours or yearly.
Centrifugal separation
Oil
Air/Oil

24. Oil Separator Separator Element Service Kit – 2911 0075 00
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 –

25. Control System

26. Control Panel

27. XC2002 Status

28. XC2002 Menus

29. Basic Operations

30. Shutdown

31. XC2002 Service Timer Reset
Scroll through the controller menu to “Parameters” (on some units “Parameters” may be a submenu under “Extra Views”)
Press Enter to select Parameters
Scroll to ST1 Reset or ST2 Reset as needed (ST1 = 500 hours, ST2 = 1000 hours)
Press Enter to select to reset the appropriate timer
Prompt for Password: change to 2003 and press Enter
Center option will highlight; up/down to change to “Yes” and press Enter
Service timer is reset

32. XC2002 Alarms

33. 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.

34. 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 logged

35. Engine Faults

36. Compressor Faults

37. Electrical System

38. Wiring Diagram XAS 400 CD

39. Maintenance

40. Maintenance – XA(T,V)S 400 CD 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

41. Maintenance – XA(T,V)S 400 CD 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

42. Maintenance – XA(T,V)S 400 CD IT4
500 Hour service pack part number (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

43. Maintenance – XA(T,V)S 400 CD IT4
1000 Hour service pack part number (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
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 Caterpillar

44. IT4 Exhaust Aftertreatment

45. 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 effect exhaust backpressure

46. 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

47. 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

48. Tier 4: DOC and DPF Diesel Particulate Filter (DPF)
Diesel Oxidation Catalyst (DOC)
CEM- Cleaning Emission Module

49. 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 49

50. 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 50

51. XC2002 DPF Status Indicators

52. Xc2002 – DPF Information Manual Regeneration Parameter
DPF – Diesel Particulate filter – can change from AUTO to ON or turn OFF completely (not recommended!)
STATION REGEN. – Stationary (manual) Regeneratoin – OFF or ON
Both need to be set to “ON” for manual regeneration
Both are password protected
Unit will not regenerate until soot level is ~70%

53. 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)
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. 1 2

54. Procedure: Stationary/Forced DPF Regeneration
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.

55. Contact Numbers Main Number Atlas Copco Technical Support
Option 3
Ed Kukfisz – Compressors – Supervisor
direct & mobile
Andrew Stevenson – Compressors: Low Pressure
direct & mobile
Andrew Calendar – Compressors: High Pressure
direct & mobile
Scott Ellinger – Compressors
direct & mobile
Robert Walsh – Generators – Supervisor
direct (mobile)
Will Hudson – Generators/Compressors
Ext & mobile
Brandon Hobbs – Hydraulic Attachments /Handheld Construction Tools – Supervisor
direct & mobile
Al Eckenfels – Hydraulic Attachments/Handheld Construction Tools

56. Committed to sustainable productivity.