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1
XA(T,V)S 400 CD7 iT4 Compressors
Scott Ellinger
Committed tosustainable productivity
2
Systems Overview XAS 400 CD
Product Designation Oil Injected Compressors
X A T S 400 C D
Product rangeX : Oil injected portable compressor
Working principleA : Single stage compressorR : Two stage compressor
Working pressure
: std pressure 102psiM : 125psiT : 150psiH : 175psiV : 200psi
Silencing : Un-silencedS : Silenced
Capacity (FAD)Liter/secCFM (US-version)
Engine supplierC : CaterpillarD : DeutzJ : John DeereY : YanmarK : Kubota
Prime moverD : diesel engineE : electric motor
XAS 400 CD7 IT4 Machine Specifications
4
XAS 400 CD7 IT4 Machine Specifications (2)
5
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
10
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.
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.
12
Unloading Valve or Air System Inlet Valve
Spring loaded in the open 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
15
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
Oil stop valve
Oil injected screw compressors
Compressor element
Oil
Oil
Air/Oil
Lubrication to the bearings
Air inlet
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 injected screw compressors
Oil is injected in the bottom of the rotor housing,
on the bearings and gears
Compression principle
Com
pres
sion
sta
rt
Com
pres
sion
Suc
tion
Del
iver
y
Oil separator
Air/Oil
Centrifugal separation
Separator element
Oil
Scavenge line
Oil Separator filter element should be replaced
Every 1,000 hours or yearly.
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
25
Control Panel
XC2002 Status
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XC2002 Menus
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Basic Operations
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Shutdown
30
XC2002 Service Timer Reset
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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
XC2002 Alarms
32
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.
33
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 logged34
35
Engine Faults
Compressor Faults
36
Electrical System
37
Wiring Diagram XAS 400 CD
38
Maintenance
39
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
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
41
Maintenance – XA(T,V)S 400 CD IT4500 Hour service pack part number 1310 3004 52 (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
42
Maintenance – XA(T,V)S 400 CD IT4
1000 Hour service pack part number 1310 3004 53 (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
43
IT4 Exhaust Aftertreatment
44
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
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
51
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.
1
2
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
55
Contact Numbers
•Main Number Atlas Copco Technical Support 800-732-6762 Option 3
•Ed Kukfisz – Compressors – Supervisor 281-542-2562 direct & 832-385-4697 mobile
•Andrew Stevenson – Compressors: Low Pressure720-479-2486 direct & 404-751-6717 mobile
•Andrew Calendar – Compressors: High Pressure720-479-2487 direct & 404-242-6203 mobile
•Scott Ellinger – Compressors720-479-2476 direct & 720-375-1795 mobile
•Robert Walsh – Generators – Supervisor 803-487-0256 direct (mobile)
•Will Hudson – Generators/Compressors 800-732-6762 Ext. 12920 & 832-454-8123 mobile
•Brandon Hobbs – Hydraulic Attachments /Handheld Construction Tools – Supervisor 303-287-8822 direct & 913-424-4039 mobile
•Al Eckenfels – Hydraulic Attachments/Handheld Construction Tools800-760-4049
Committed tosustainable productivity.