Instruction Manual
for Portable Compressors
XAS 67 DD
XATS 67 DD
XAS 77 DD
XAS 97 DD
Printed matter N°
2954 2150 03
07/2007
-
XAS 130 DD7
XATS 125 DD7
XAS 150 DD7
XAS 185 DD7
ATLAS COPCO - PORTABLE AIR DIVISION
www.atlascopco.com
Instruction Manual
Warranty and Liability Limitation
Use only authorized parts.
Any damage or malfunction caused by the use of unauthorized parts is not
covered by Warranty or Product Liability.
The manufacturer does not accept any liability for any damage arising for
modifications, additions or conversions made without the manufacturer's approval
in writing.
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 2007, Atlas Copco Airpower n.v., Antwerp, Belgium.
Any unauthorized use or copying of the contents or any part thereof is prohibited.
This applies in particular to trademarks, model denominations, part numbers and
drawings.
4
Instruction Manual
Follow the instructions in this booklet and we guarantee you years
of troublefree operation. Please read the following instructions
carefully before starting to use your machine.
Always keep the manual available near the machine.
In all correspondence always mention the compressor type and
serial number, shown on the data plate.
The company reserves the right to make changes without prior
notice.
CALIFORNIA
CONTENTS
PAGE
Proposition 65 Warning
Diesel engine exhaust and some of its
constituents are known to the State of
California to cause cancer, birth defects,
and other reproductive harm.
1
2
Safety precautions for portable compressors
(with generator) .......................................................................7
1.1
Introduction .................................................................7
1.2
General safety precautions ..........................................7
1.3
Safety during transport and installation ......................8
1.4
Safety during use and operation ..................................9
1.5
Safety during maintenance and repair.......................10
1.6
Tool applications safety ............................................10
1.7
Specific safety precautions........................................11
Leading particulars ...............................................................12
2.1
Description of safety pictograms
used in this manual....................................................12
2.2
General description ...................................................12
2.3
Markings and information labels...............................14
2.4
Main Parts .................................................................15
2.5
Air flow .....................................................................17
2.6
Oil system..................................................................17
2.7
Continuous regulating system ...................................17
2.8
Electrical system .......................................................18
2.8.1
Circuit diagram (standard) ........................................18
2.8.2
Circuit diagram XAS 67 DDG - XAS 130 DD7G,
XAS 97 DDG - XAS 185 DD7G (Generator
DDG 110V without automatic control system).........20
2.8.3
Circuit diagram XAS 67 DDG - XAS 130 DD7G,
XAS 97 DDG - XAS 185 DD7G (Generator DDG
110V with automatic control system) .......................22
2.8.4
Circuit diagram XAS 67 DDG - XAS 130 DD7G,
XAS 97 DDG - XAS 185 DD7G (Generator DDG
IT 230/400V, 6 kVA without automatic control
system) ......................................................................24
2.8.5
Circuit diagram XAS 67 DDG - XAS 130 DD7G,
XAS 97 DDG - XAS 185 DD7G (Generator DDG
IT 230/400V, 6 kVA with automatic control
system) ......................................................................26
2.8.6
Circuit diagram XAS 67 DDG - XAS 130 DD7G,
XAS 97 DDG - XAS 185 DD7G (Generator DDG
IT 230V, 6 kVA) .......................................................28
5
Instruction Manual
CONTENTS
2.8.7
2.8.8
2.8.9
3
4
CONTENTS
PAGE
Circuit diagram XAS 67 DDG - XAS 130 DD7G,
XAS 97 DDG - XAS 185 DD7G (Generator DDG
IT 230/400V, 12.5 kVA without automatic control
system) ...................................................................... 30
4.5.2
Compressor oil and oil filter change......................... 50
4.6
Cleaning coolers ....................................................... 51
4.7
Cleaning fuel tank ..................................................... 51
Circuit diagram XAS 67 DDG - XAS 130 DD7G,
XAS 97 DDG - XAS 185 DD7G (Generator DDG
IT 230/400V, 12.5 kVA with automatic control
system) ...................................................................... 32
4.8
Cleaning hardhat ....................................................... 51
4.9
Battery care ............................................................... 51
4.9.1
Electrolyte ................................................................. 51
4.9.2
Activating a dry-charged battery .............................. 52
4.9.3
Recharging a battery ................................................. 52
4.9.4
Battery maintenance ................................................. 52
Circuit diagram XAS 67 DDG - XAS 130 DD7G,
XAS 97 DDG - XAS 185 DD7G (Generator DDG
IT 230V, 12.5 kVA).................................................. 34
2.8.10
Circuit diagram cold start (all types) ........................ 36
4.10
Changing tyres .......................................................... 52
2.8.11
Circuit diagram refinary equipment (all types)......... 37
4.11
Storage ...................................................................... 52
4.12
Service paks .............................................................. 52
Operating instructions .......................................................... 38
4.13
Service kits................................................................ 52
3.1
Parking, towing and lifting instructions.................... 38
4.14
Compressor element overhaul .................................. 52
3.1.1
Parking instructions .................................................. 38
4.15
Liability..................................................................... 52
3.1.2
Towing instructions .................................................. 39
3.1.3
Spillage-Free Instruction........................................... 39
3.1.4
Height adjustment (with adjustable towbar)............. 39
5.1
Adjustment of the continuous regulating system...... 53
3.1.5
Lifting instructions.................................................... 40
5.2
Air filter engine/compressor ..................................... 54
3.1.6
Anti-Frost Device (option)........................................ 40
5.2.1
Main parts ................................................................. 54
3.2
Starting/Stopping ...................................................... 40
5.2.2
Recommendations..................................................... 54
3.2.1
Before starting........................................................... 40
5.2.3
Cleaning the dust trap ............................................... 54
3.2.2
Starting procedure (with cold start; option).............. 41
5.2.4
Replacing the air filter element................................. 54
3.2.3
Starting procedure (without cold start) ..................... 42
5.3
Air receiver ............................................................... 54
3.2.4
During operation ....................................................... 43
5.4
Safety valve............................................................... 54
3.2.5
Stopping procedure ................................................... 43
5.5
Fuel system ............................................................... 55
3.2.6
Fault situations and protective devices: .................... 43
5.6
Brake (= option) adjustment ..................................... 55
3.3
Function of generator (option).................................. 44
5.6.1
Brake shoe adjustment .............................................. 55
3.3.1
Function of generator DDG 110V without
automatic control system - Functional description ... 44
5.6.2
Test procedure of brake cable adjustment ................ 56
3.3.2
Function of generator DDG 110V with automatic
control system (option) - Functional description...... 45
5.6.3
Brake cable adjustment ............................................. 56
5.7
3.3.3
Function of generator DDG 230/400V and 230V 3ph without automatic control system Functional description............................................... 46
Drive Belt (XAS 67 DD - XAS 130 DD7,
XATS 67 DD - XATS 125 DD7) ............................. 56
3.3.4
Function of generator DDG 230/400V and 230V 3ph with automatic control system (option) Functional description............................................... 47
Maintenance ........................................................................... 48
4.1
Use of service paks ................................................... 48
4.2
Preventive maintenance schedule
for the compressor .................................................... 48
5
6
Adjustments and servicing procedures .............................. 53
Problem solving ..................................................................... 57
6.1
7
8
Alternator precautions............................................... 57
Available options ................................................................... 59
Technical specifications ........................................................ 60
8.1
Torque values............................................................ 60
8.1.1
For general applications............................................ 60
For important assemblies .......................................... 60
4.3
Lubrication oils ......................................................... 49
8.1.2
4.4
Oil level check .......................................................... 49
8.2
Settings of shutdown switches and safety valves ..... 60
4.4.1
Check engine oil level............................................... 49
8.3
Compressor/Engine specifications............................ 61
Check compressor oil level....................................... 50
8.4
Conversion list of SI units into British units............. 68
4.4.2
6
PAGE
4.5
Oil and oil filter change ............................................ 50
4.5.1
Engine oil and oil filter change................................. 50
9
Data plate ............................................................................... 69
Instruction Manual
1.
SAFETY PRECAUTIONS FOR PORTABLE COMPRESSORS (WITH GENERATOR)
To be read attentively and acted accordingly before towing, lifting, operating, performing maintenance or repairing the unit
1.1
INTRODUCTION
The policy of Atlas Copco is to provide the users of their equipment with
safe, reliable and efficient products. Factors taken into account are among
others:
- the intended and predictable future use of the products, and the
environments in which they are expected to operate,
- applicable rules, codes and regulations,
- the expected useful product life, assuming proper service and
maintenance,
- providing the manual with up-to-date information.
Before handling any product, take time to read the relevant instruction
manual. Besides giving detailed operating instructions, it also gives specific
information about safety, preventive maintenance, etc.
Keep the manual always at the unit location, easy accessible to the operating
personnel.
The manufacturer does not accept any liability for any damage arising from
the use of non-original parts and for modifications, additions or conversions
made without the manufacturer’s approval in writing.
If any statement in this manual does not comply with local legislation, the
stricter of the two shall be applied.
Statements in these safety precautions should not be interpreted as
suggestions, recommendations or inducements that it should be used in
violation of any applicable laws or regulations.
1.2
GENERAL
SAFETY PRECAUTIONS
See also the safety precautions of the engine and possible other equipment,
which are separately sent along or are mentioned on the equipment or parts
of the unit.
1
The owner is responsible for maintaining the unit in a safe operating
condition. Unit parts and accessories must be replaced if missing or
unsuitable for safe operation.
These safety precautions are general and some statements will therefore not
always apply to a particular unit.
2
The supervisor, or the responsible person, shall at all times make sure
that all instructions regarding machinery and equipment operation and
maintenance are strictly followed and that the machines with all
accessories and safety devices, as well as the consuming devices, are in
good repair, free of abnormal wear or abuse, and are not tampered with.
3
Whenever there is an indication or any suspicion that an internal part of
a machine is overheated, the machine shall be stopped but no inspection
covers shall be opened before sufficient cooling time has elapsed; this to
avoid the risk of spontaneous ignition of oil vapour when air is admitted.
4
Normal ratings (pressures, temperatures, speeds, etc.) shall be durably
marked.
5
Operate the unit only for the intended purpose and within its rated limits
(pressure, temperature, speeds, etc.).
6
The machinery and equipment shall be kept clean, i.e. as free as possible
from oil, dust or other deposits.
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.
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 may not be put out of action.
Skill level 4:
Specialist from the manufacturer
This is a skilled specialist sent by the manufacturer or its agent to perform
complex repairs or modifications to the equipment.
9
Care shall be taken to avoid damage to safety valves and other pressurerelief devices, especially to avoid plugging by paint, oil coke or dirt
accumulation, which could interfere with the functioning of the device.
In general it is recommended that not more than two people operate the unit,
more operators could lead to unsafe operating conditions. Take necessary
steps to keep unauthorized persons away from the unit and eliminate all
possible sources of danger at the unit.
10 Pressure and temperature gauges shall be checked regularly with regard
to their accuracy. They shall be replaced whenever outside acceptable
tolerances.
Only people that have the right skills should be allowed to operate, adjust,
perform maintenance or repair on Atlas Copco equipment. It is the
responsibility of management to appoint operators with the appropriate
training and skill for each category of job.
Skill level 1:
Operator
An operator is trained in all aspects of operating the unit with the pushbuttons, and is trained to know the safety aspects.
Skill level 2:
Mechanical technician
A mechanical technician is trained to operate the unit the same as the
operator. In addition, the mechanical technician is also trained to perform
maintenance and repair, as described in the instruction manual, and is
allowed to change settings of the control and safety system. A mechanical
technician does not work on live electrical components.
When handling, operating, overhauling and/or performing maintenance or
repair on Atlas Copco equipment, the mechanics are expected to use safe
engineering practices and to observe all relevant local safety requirements
and ordinances. The following list is a reminder of special safety directives
and precautions mainly applicable to Atlas Copco equipment.
These safety precautions apply to machinery processing or consuming air.
Processing of any other gas requires additional safety precautions typical to
the application and are not included herein.
Neglecting the safety precautions may endanger people as well as
environment and machinery:
- endanger people due to electrical, mechanical or chemical influences,
- endanger the environment due to leakage of oil, solvents or other
substances,
- endanger the machinery due to function failures.
All responsibility for any damage or injury resulting from neglecting these
precautions or by non-observance of ordinary caution and due care required
in handling, operating, maintenance or repair, also if not expressly
mentioned in this instruction manual, is disclaimed by Atlas Copco.
11 Safety devices shall be tested as described in the maintenance schedule
of the instruction manual to determine that they are in good operating
condition.
12 Mind the markings and information labels on the unit.
13 In the event the safety labels are damaged or destroyed, they must be
replaced to ensure operator safety.
14 Keep the work area neet. Lack of order will increase the risk of
accidents.
15 When working on the unit, wear safety clothing. Depending on the kind
of activities these are: safety glasses, ear protection, safety helmet
(including visor), safety gloves, protective clothing, safety shoes. Do not
wear the hair long and loose (protect long hair with a hairnet), or wear
loose clothing or jewelry.
16 Take precautions against fire. Handle fuel, oil and anti-freeze with care
because they are inflammable substances. Do not smoke or approach
with naked flame when handling such substances. Keep a fireextinguisher in the vicinity.
7
Instruction Manual
17a Portable compressors with generator (with earthing pin):
Earth the generator as well as the load properly.
17b Portable compressors with generator IT:
Note: This generator is built to supply a sheer alternating current IT
network.
Earth the load properly.
1.3
SAFETY
DURING TRANSPORT AND
INSTALLATION
To lift a unit, all loose or pivoting parts, e.g. doors and towbar, shall first be
securely fastened.
Do not attach cables, chains or ropes directly to the lifting eye; apply a crane
hook or lifting shackle meeting local safety regulations. Never allow sharp
bends in lifting cables, chains or ropes.
Helicopter lifting is not allowed.
It is strictly forbidden to dwell or stay in the risk zone under a lifted load.
Never lift the unit over people or residential areas. Lifting acceleration and
retardation shall be kept within safe limits.
1
Before towing the unit:
- ascertain that the pressure vessel(s) is (are) depressurized,
- check the towbar, the brake system and the towing eye. Also check
the coupling of the towing vehicle,
- check the towing and brake capability of the towing vehicle,
- check that the towbar, jockey wheel or stand leg is safely locked in
the raised position,
- ascertain that the towing eye can swivel freely on the hook,
- check that the wheels are secure and that the tyres are in good
condition and inflated correctly,
- connect the signalisation cable, check all lights and connect the
pneumatic brake couplers,
- attach the safety break-away cable or safety chain to the towing
vehicle,
- remove wheel chocks, if applied, and disengage the parking brake.
2
To tow a unit use a towing vehicle of ample capacity. Refer to the
documentation of the towing vehicle.
3
If the unit is to be backed up by the towing vehicle, disengage the
overrun brake mechanism (if it is not an automatic mechanism).
4
Never exceed the maximum towing speed of the unit (mind the local
regulations).
5
Place the unit on level ground and apply the parking brake before
disconnecting the unit from the towing vehicle. Unclip the safety breakaway cable or safety chain. If the unit has no parking brake 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 line with their design load axis. The capacity of a lifting
device diminishes when the lifting force is applied at an angle to its load
axis.
8
For maximum safety and efficiency of the lifting apparatus all lifting
members shall be applied as near to perpendicular as possible. If
required, a lifting beam shall be applied between hoist and load.
9
Never leave a load hanging on a hoist.
10 A hoist has to be installed in such a way that the object will be lifted
perpendicular. If that is not possible, the necessary precautions must be
taken to prevent load-swinging, e.g. by using two hoists, each at
approximately the same angle not exceeding 30° from the vertical.
8
11 Locate the unit away from walls. Take all precautions to ensure that hot
air exhausted from the engine and driven machine cooling systems
cannot be recirculated. If such hot air is taken in by the engine or driven
machine cooling fan, this may cause overheating of the unit; if taken in
for combustion, the engine power will be reduced.
12 The electrical connections shall correspond to local codes. The
machines shall be earthed and protected against short circuits by fuses or
circuit breakers.
13 Never connect the generator outlets to an installation which is also
connected to a public mains.
14 Before connecting a load, switch off the corresponding circuit breaker,
and check whether frequency, voltage, current and power factor comply
with the ratings of the generator.
Instruction Manual
1.4
SAFETY
DURING USE AND OPERATION
1
When the unit has to operate in a fire-hazardous environment, each
engine exhaust has to be provided with a spark arrestor to trap
incendiary sparks.
2
The exhaust contains carbon monoxide which is a lethal gas. When the
unit is used in a confined space, conduct the engine exhaust to the
outside atmosphere by a pipe of sufficient diameter; do this in such a
way that no extra back pressure is created for the engine. If necessary,
install an extractor. Observe any existing local regulations. Make sure
that the unit has sufficient air intake for operation. If necessary, install
extra air intake ducts.
3
When operating in a dust-laden atmosphere, place the unit so that dust is
not carried towards it by the wind. Operation in clean surroundings
considerably extends the intervals for cleaning the air intake filters and
the cores of the coolers.
4
Close the compressor air outlet valve before connecting or
disconnecting a hose. Ascertain that a hose is fully depressurized before
disconnecting it. Before blowing compressed air through a hose or air
line, ensure that the open end is held securely, so that it cannot whip and
cause injury.
5
The air line end connected to the outlet valve must be safeguarded with
a safety cable, attached next to the valve.
6
No external force may be exerted on the air outlet valves, e.g. by pulling
on hoses or by installing auxiliary equipment directly to a valve, e.g. a
water separator, a lubricator, etc. Do not step on the air outlet valves.
17 Noise, even at reasonable levels, can cause irritation and disturbance
which, over a long period of time, may cause severe injuries to the
nervous system of human beings.
When the sound pressure level, at any point where personnel normally
has to attend, is:
below 70 dB(A): no action needs to be taken,
above 70 dB(A): noise-protective devices should be provided for
people continuously being present in the room,
below 85 dB(A): no action needs to be taken for occasional visitors
staying a limited time only,
above 85 dB(A): room to be classified as a noise-hazardous area and
an obvious warning shall be placed permanently at
each entrance to alert people entering the room, for
even relatively short times, about the need to wear
ear protectors,
above 95 dB(A): the warning(s) at the entrance(s) shall be completed
with the recommendation that also occasional
visitors shall wear ear protectors,
above 105 dB(A): special ear protectors that are adequate for this noise
level and the spectral composition of the noise shall
be provided and a special warning to that effect shall
be placed at each entrance.
18 Insulation or safety guards of parts the temperature of which can be in
excess of 80 °C (175 °F) and which may be accidentally touched by
personnel shall not be removed before the parts have cooled to room
temperature.
19 Never operate the unit in surroundings where there is a possibility of
taking in flammable or toxic fumes.
7
Never move a unit when external lines or hoses are connected to the
outlet valves, to avoid damage to valves, manifold and hoses.
20 If the working process produces fumes, dust or vibration hazards, etc.,
take the necessary steps to eliminate the risk of personnel injury.
8
Do not use compressed air from any type of compressor, without taking
extra measures, for breathing purposes as this may result in injury or
death. For breathing air quality, the compressed air must be adequately
purified according to local legislation and standards. Breathing air must
always be supplied at stable, suitable pressure.
21 When using compressed air or inert gas to clean down equipment, do so
with caution and use the appropriate protection, at least safety glasses,
for the operator as well as for any bystander. Do not apply compressed
air or inert gas to your skin or direct an air or gas stream at people.
Never use it to clean dirt from your clothes.
9
Distribution pipework and air hoses must be of correct diameter and
suitable for the working pressure. Never use frayed, damaged or
deteriorated hoses. Replace hoses and flexibles before the lifetime
expires. Use only the correct type and size of hose end fittings and
connections.
22 When washing parts in or with a cleaning solvent, provide the required
ventilation and use appropriate protection such as a breathing filter,
safety glasses, rubber apron and gloves, etc.
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 sandblasting or compressed-air system. Observe the right mounting position/
direction.
11 Before removing the oil filler plug, ensure that the pressure is released
by opening an air outlet valve.
12 Never remove a filler cap of the cooling water system of a hot engine.
Wait until the engine has sufficiently cooled down.
13 Never refill fuel 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 All doors shall be shut during operation so as not to disturb the cooling
air flow inside the bodywork and/or render the silencing less effective.
A door should be kept open for a short period only e.g. for inspection or
adjustment.
15 Periodically carry out maintenance works according to the maintenance
schedule.
16 Stationary housing guards are provided on all rotating or reciprocating
parts not otherwise protected and which may be hazardous to personnel.
Machinery shall never be put into operation, when such guards have
been removed, before the guards are securely reinstalled.
23 Safety shoes should be compulsory in any workshop and if there is a
risk, however small, of falling objects, wearing of a safety helmet should
be included.
24 If there is a risk of inhaling hazardous gases, fumes or dust, the
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 in excess of its
limits as indicated in the technical specifications.
27 Never operate the generator in excess of its limits as indicated in the
technical specifications and avoid long no-load sequences.
28 Never operate the generator in a humid atmosphere. Excessive moisture
causes worsening of the generator insulation.
29 Do not open electrical cabinets, cubicles or other equipment while
voltage is supplied. If such cannot be avoided, e.g. for measurements,
tests or adjustments, have the action carried out by a qualified electrician
only, with appropriate tools, and ascertain that the required bodily
protection against electrical hazards is applied.
30 Never touch the power terminals during operation of the machine.
31 Whenever an abnormal condition arises, e.g. excessive vibration, noise,
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 condition before restarting. Make sure that all
electric connections are securely tightened.
9
Instruction Manual
33 Do not use aerosol types of starting aids such as ether. Such use could
result in an explosion and personal injury.
34 Avoid overloading the generator. The generator is provided with circuit
breakers for overload protection. When a breaker has tripped, reduce the
concerned load before restarting.
35 If the generator is used as stand-by for the mains supply, it must not be
operated without control system which automatically disconnects the
generator from the mains when the mains supply is restored.
36 Never remove the cover of the output terminals during operation. Before
connecting or disconnecting wires, switch off the load and the circuit
breakers, stop the machine and make sure that the machine cannot be
started inadvertently or there is any residual voltage on the power
circuit.
37 Running the generator at low load for long periods will reduce the
lifetime of the engine.
16 When performing any operation involving heat, flames or sparks on a
machine, the surrounding components shall first be screened with nonflammable material.
17 Never use a light source with open flame for inspecting the interior of a
machine.
18 When repair has been completed, the machine shall be barred over at
least one revolution for reciprocating machines, several revolutions for
rotary ones to ensure that there is no mechanical interference within the
machine or driver. Check the direction of rotation of electric motors
when starting up the machine initially and after any alteration to the
electrical connection(s) or switch gear, to check that the oil pump and
the fan function properly.
19 Maintenance and repair work should be recorded in an operator’s
logbook for all machinery. Frequency and nature of repairs can reveal
unsafe conditions.
20 When hot parts have to be handled, e.g. shrink fitting, special heatresistant gloves shall be used and, if required, other body protection
shall be applied.
1.5
SAFETY
DURING MAINTENANCE AND REPAIR
Maintenance, overhaul and repair work shall only be carried out by
adequately trained personnel; if required, under supervision of someone
qualified for the job.
1
Use only the correct tools for maintenance and repair work, and only
tools which are in good condition.
2
Parts shall only be replaced by genuine Atlas Copco replacement parts.
3
All maintenance work, other than routine attention, shall only be
undertaken when the unit is stopped. Steps shall be taken to prevent
inadvertent starting. In addition, a warning sign bearing a legend such as
”work in progress; do not start” shall be attached to the starting
equipment.
On engine-driven units the battery shall be disconnected and removed or
the terminals covered by insulating caps.
On electrically driven units the main switch shall be locked in open
position and the fuses shall be taken out. A warning sign bearing a
legend such as ”work in progress; do not supply voltage” shall be
attached to the fuse box or main switch.
4
Before dismantling any pressurized component, the compressor or
equipment shall be effectively isolated from all sources of pressure and
the entire system shall be relieved of pressure. Do not rely on non-return
valves (check valves) to isolate pressure systems. In addition, a warning
sign bearing a legend such as ”work in progress; do not open” shall be
attached to each of the outlet valves.
5
Prior to stripping an engine or other machine or undertaking major
overhaul on it, prevent all movable parts from rolling over or moving.
6
Make sure that no tools, loose parts or rags are left in or on the machine.
Never leave rags or loose clothing near the engine air intake.
7
Never use flammable solvents for cleaning (fire-risk).
8
Take safety precautions against toxic vapours of cleaning liquids.
9
Never use machine parts as a climbing aid.
10 Observe scrupulous cleanliness during maintenance and repair. Keep
away dirt, cover the parts and exposed openings with a clean cloth,
paper or tape.
11 Never weld on or perform any operation involving heat near the fuel or
oil systems. Fuel and oil tanks must be completely purged, e.g. by
steam-cleaning, before carrying out such operations. Never weld on, or
in any way modify, pressure vessels. Disconnect the alternator cables
during arc welding on the unit.
12 Support the towbar and the axle(s) securely if working underneath the
unit or when removing a wheel. Do not rely on jacks.
13 Do not remove any of, or tamper with, the sound-damping material.
Keep the material free of dirt and liquids such as fuel, oil and cleansing
agents. If any sound-damping material is damaged, replace it to prevent
the sound pressure level from increasing.
14 Use only lubricating oils and greases recommended or approved by
Atlas Copco or the machine manufacturer. Ascertain that the selected
lubricants comply with all applicable safety regulations, especially with
regard to explosion or fire-risk 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.
10
21 When using cartridge type breathing filter equipment, ascertain that the
correct type of cartridge is used and that its useful service life is not
surpassed.
22 Make sure that oil, solvents and other substances likely to pollute the
environment are properly disposed of.
23 Before clearing the unit for use after maintenance or overhaul, check
that operating pressures, temperatures and speeds are correct and that
the control and shutdown devices function correctly. Submit the
generator to a testrun, check that the AC power performance is correct.
1.6
TOOL
APPLICATIONS SAFETY
Apply the proper tool for each job. With the knowledge of correct tool use
and knowing the limitations of tools, along with some common sense, many
accidents can be prevented.
Special service tools are available for specific jobs and should be used when
recommended. The use of these tools will save time and prevent damage to
parts.
Instruction Manual
1.7
SPECIFIC
SAFETY PRECAUTIONS
Batteries
When servicing batteries, always wear protecting clothing and glasses.
1
The electrolyte in batteries is a sulphuric acid solution which is fatal if it
hits your eyes, and which can cause burns if it contacts your skin.
Therefore, be careful when handling batteries, e.g. when checking the
charge condition.
2
Install a sign prohibiting 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 batteries being, or having recently been, charged,
- never break live circuits at battery terminals, because a spark usually
occurs.
4
When connecting an auxiliary battery (AB) in parallel to the unit battery
(CB) with booster cables: connect the + pole of AB to the + pole of CB,
then connect the - pole of CB to the mass of the unit. Disconnect in the
reverse order.
Pressure vessels
(according to directive 87/404/EEC annex II § 2)
Maintenance/installation requirements:
1
The vessel can be used as pressure vessel or as separator and is designed
to hold compressed air for the following application:
- pressure vessel for compressor,
- medium AIR/OIL,
and operates as detailed on the data plate of the vessel:
- the maximum working pressure ps in bar,
- the maximum working temperature Tmax in °C,
- the minimum working temperature Tmin in °C,
- the capacity of the vessel V in l.
2
The pressure vessel is only to be used for the applications as specified
above and in accordance with 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, safety
valve, etc.
6
Draining of condensate shall be performed regularly when vessel is in
use.
7
Installation, design and connections should not be changed.
8
Bolts of cover and flanges may not be used for extra fixation.
Safety valves
All adjustments or repairs are to be done by an authorized representative of
the valve supplier (see maintenance schedule 4.2).
11
Instruction Manual
2.
LEADING PARTICULARS
2.1
DESCRIPTION
OF SAFETY PICTOGRAMS USED IN THIS MANUAL
This symbol draws your attention to dangerous
situations. The operation concerned may endanger
persons and cause injuries.
This symbol is followed by supplementary information.
Fig. 2.1.a
2.2
General view metal canopy
GENERAL
DESCRIPTION
The compressors type XAS 67 DD - XAS 130 DD7,
XATS 67 DD - XATS 125 DD7, XAS 77 DD - XAS 150 DD7 and
XAS 97 DD - XAS 185 DD7 are silenced, single-stage, oil-injected
screw compressors, built for a nominal effective working pressure,
ranging from 7 bar up to 10.3 bar (see chapter 8, technical
specifications).
The compressor is available with metal or PE canopy (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 DD - XAS 130 DD7,
XATS 67 DD - XATS 125 DD7) or a heavy-duty coupling
(XAS 77 DD - XAS 150 DD7, XAS 97 DD - XAS 185 DD7).
–
Compressor element
The compressor casing houses two screw-type rotors, mounted on
ball and roller bearings. The male rotor, driven by the engine, drives
the female rotor. The element delivers pulsation-free air.
Injected oil is used for sealing, cooling and lubricating purposes.
–
Compressor oil system
The oil is boosted by air pressure. The system has no oil pump.
The oil is removed from the air, in the air/oil vessel at first by
centrifugal force, secondly through the oil separator element.
The vessel is provided with an oil level indicator.
12
Fig. 2.1.b
General view HardHat
Instruction Manual
–
Regulation
The compressor is provided with a continuous regulating system and
a blow-down valve which is integrated in the unloader assembly. The
valve is closed during operation by outlet pressure of the compressor
element and opens by air receiver pressure when the compressor is
stopped.
When the air consumption increases, the air receiver pressure will
decrease and vice versa.
This receiver pressure variation is sensed by the regulating valve
which, by means of control air to the unloader and engine speed
regulator, matches the air output to the air consumption. The air
receiver pressure is maintained between the pre-selected working
pressure and the corresponding unloading pressure.
–
Generator (option for XAS 67 DD - XAS 130 DD7 and
XAS 97 DD - XAS 185 DD7)
The built-in generator is driven by a multi V-belt drive. The generated
current can be drawn via 3 sockets (see chapter 8, Technical
Specifications).
The compressor and the generator of the XAS 67 DDG XAS 130 DD7G / DDG IT may be used simultaneously. The
compressor and the generator of the XAS 97 DDG XAS 185 DD7G / DDG IT may not be used simultaneously.
As an option the generator can be equipped with an automatic control
system to save fuel when no electric power is used.
–
Cooling system
Engine and compressor are provided with an oil cooler.
The cooling air is generated by a fan, driven by the engine.
–
Safety devices
A thermal shut-down switch protects the compressor against
overheating. The air receiver is provided with a safety valve.
The engine is equipped with low oil pressure and high oil
temperature shut-down switches.
–
Frame and axle
The compressor/engine unit is supported by rubber buffers in the
frame. The standard unit has a none adjustable towbar with support
leg and one of the following towing eyes AC, DIN, ball, ITA, GB or
NATO.
As an option the unit can be equipped with an adjustable towbar, a
jockey wheel and/or overrun parking brake (for options see chapter
7).
The braking system consists of an integrated parking brake and
overrunbrake. When driving backwards the overrunbrake is not
engaged automatically.
–
Bodywork
The bodywork has openings at the shaped front and rear end for the
intake and outlet of cooling air and a hood for maintenance and
service operations. The bodywork is internally lined with soundabsorbing material.
–
Lifting eye
A lifting eye is accessible when the small door at the top of the unit
is unlocked.
–
Control panel
The control panel grouping the air pressure gauge, control switch
etc., is placed in the center at the rear end.
–
Data plate
The compressor is furnished with a data plate showing the product
code, the unit number and the working pressure (see chapter 9).
–
Serial number
The serial number is located on the right-hand front side of the
frame.
13
Instruction Manual
2.3
MARKINGS
AND INFORMATION LABELS
Compressor outlet temperature too high.
Inlet.
Compressor outlet temperature.
Outlet.
Compressor outlet pressure.
Compressor oil drain.
Dangerous outlet.
Read the instruction manual before starting.
Danger, heat flat.
Service every 24 hours.
Electrocution hazard.
Warning!
Part under pressure.
Atlas Copco mineral compressor oil.
Do not stand on outlet valves.
Atlas Copco synthetic compressor oil.
Start-Stop indication of switch.
Atlas Copco mineral engine oil.
Do not run the motor with open doors.
Manual.
Lifting permitted.
Read the instruction manual
before working on the battery.
Use diesel fuel only.
Reset fuse.
2.7 bar / 39 psi
On / off button.
Manual override switch.
Hours, time.
98
100
Tyre pressure.
Sound power level in accordance with
Directive 2000/14/EC (expressed in dB (A)).
Sound power level in accordance with
Directive 2000/14/EC (expressed in dB (A)).
Prohibition to open air valves without connected hoses.
Horizontal towbar position required
in case of coupling.
Compressor loaded.
Earthing connections.
Runlamp.
Airfilter.
0 = OFF
Generator
Compressor temperature too high.
Insulation fault.
Rotation direction.
14
1 = ON
Instruction Manual
2.4
MAIN PARTS
EP
H
OF E
A
F
BH
CPG
VI
G
S
AFD
E
TB
AR
RV
SV
JW
FP
OLG
SN
D
DP
EC
FC1
FC
AOV
DS
2
E
CP
FU
OFCE
CE
DB/C
Fig. 2.2
A
AF
AFD
AOV
AR
BH
C
CE
CP
CPG
D
DB
FT
DP
FT
FF
AF
VV
Main parts with some options
Alternator
DPEC
Air Filter
DPFT
Anti-Frost Device (option)
DSE
Air outlet valves
E
Air Receiver
EP
Brake Handle
F
Coupling (XAS 77 DD - XAS 150 DD7, FC1
XAS 97 DD - XAS 185 DD7)
Compressor Element
FC2
Control Panel
FF
Control Panel (generator), (option)
FP
Data plate
FT
Drive Belt (XAS 67 DD - XAS 130 DD7, FU
XATS 67 DD - XATS 125 DD7)
Drain Plug Engine Oil Cooler
Drain Plug Fuel Tank
Engine Oil Level Dipstick
Engine
Exhaust Pipe
Fan
Filler Cap (engine oil)
H
JW
OFCE
OFE
OLG
RV
S
Hood
Jockey wheel
Oil Filter (compressor element)
Oil Filter (engine)
Oil Level Gauge (compressor element)
Regulating Valve
Starting Motor
Filler Cap (fuel tank)
Fuel Filter
Filler Plug (compressor oil)
Fuel Tank
Fuel Pump
SN
SV
TB
VI
VV
Serial Number
Safety Valve
Towbar
Vacuum Indicator
Vacuator Valve
15
Instruction Manual
COMPRESSOR REGULATING SYSTEM
Without generator
With generator
67 DDG 6.5 kVA
67 DDG 12 kVA
97 DDG 6.5 kVA
With generator
97 DDG 12 kVA
Fig. 2.3
AF
AR
AOV
BDV
C
CE
CV
16
Air Filter
Air Receiver
Air Outlet Valves
Blow Down Valve
Coupling
(XAS 77 DD - XAS 150 DD7,
XAS 97 DD - XAS 185 DD7)
Compressor Element
Check Valve
DB
DP
E
F
FN
FP
FR
Drive Belt
(XAS 67 DD - XAS 130 DD7,
XATS 67 DD - XATS 125 DD7)
Drain Plug
Engine
Fan
Flow nozzle
Filler Plug
Flow Restrictor
OCCE
OF
OLG
OS
PG
RV
SL
SR
SV
Oil Cooler
(compressor element)
Oil Filter
Oil Level Gauge
Oil Separator
Pressure Gauge
Regulating Valve
Scavenge Line
Speed Regulator
Safety Valve
SVSR
TS
UA
UV
VH
VI
VV
Solenoid Valve
(Speed regulator)
Temperature Switch
Unloader Assembly
Unloader Valve
Vent Hole
Vacuum Indicator
Vacuator Valve
Instruction Manual
2.5
AIR
FLOW (SEE
FIG. 2.3)
The system comprises:
AF
AR/OS
CE
UA/UV
BDV
FN
Air filter
Air receiver/oil separator
Compressor element
Unloader assembly with unloader valve
Blow-down valve
Flow nozzle
Air drawn through the airfilter (AF) into the compressor element
(CE) is compressed. At the element outlet, compressed air and oil
pass into the air receiver/oil separator (AR/OS).
The check valve (CV) prevents blow-back of compressed air when
the compressor is stopped. In the air receiver/oil separator (AR/OS),
most of the oil is removed from the air/oil mixture; the remaining oil
is removed by the separator 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 8.3), even when the air outlet valves
are open. This ensures adequate oil injection and prevents oil
consumption.
A temperature switch (TS) and a working pressure gauge (PG) are
comprised in the system.
A blow-down valve (BDV) is fitted in the unloader assembly to
automatically depressurise the air receiver (AR) when the
compressor is stopped.
2.6
OIL
SYSTEM (SEE
FIG. 2.3)
The system comprises:
AR/OS
OCCE
OF
Air receiver/oil separator
Oil cooler
Oil filter
The lower part of the air receiver (AR) serves as oil tank.
Air pressure forces the oil from the air receiver/oil separator (AR/
OS) through the oil cooler (OCCE) and oil filter (OF) to the
compressor element (CE).
The compressor element has an oil gallery in the bottom of its casing.
The oil for rotor lubrication, cooling and sealing is injected through
holes in the gallery.
Lubrication of the bearings is ensured by oil injected into the bearing
housings.
The injected oil, mixed with the compressed air, leaves the
compressor element and re-enters the air receiver, where it is
separated from the air as described in section 2.5. The oil that
collects in 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 bypasses the filter without being filtered. For this reason, the oil filter
must be replaced at regular intervals (see section 4.2).
When cold start equipment is installed; a thermostatic valve will
bypass the compressor oil (oil will not pass through oil cooler
OCCE), until the working temperature is reached.
2.7
CONTINUOUS REGULATING
(SEE FIG. 2.3)
SYSTEM
The system comprises:
RV
UA
SR
Regulating valve
Unloader assembly
Speed regulator
The compressor is provided with a continuous regulating system.
This system is provided with a blow-down valve which is integrated
in the unloader assembly (UA). The valve is closed during operation
by outlet pressure of the compressor element and opens by air
receiver pressure when the compressor is stopped.
When the air consumption increases, the air receiver pressure will
decrease and vice versa. This receiver pressure variation is sensed by
the regulating valve which, by means of control air to the unloader,
matches the air output to the air consumption. The air receiver
pressure is maintained between the pre-selected working pressure
and the corresponding unloading pressure.
When starting the compressor, the unloader valve (UV) is kept open
by spring force, the engine runs at maximum speed. The compressor
element (CE) takes in air and pressure builds up in the receiver (AR).
The air output is controlled from maximum output (100%) to no
output (0%) by:
1. Speed control of the engine between maximum load speed and
unloading speed (the output of a screw compressor is
proportional to the rotating speed).
2. Air inlet throttling.
If the air 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
of approx. 1.5 bar above the normal working pressure.
When the air consumption is resumed, the unloader valve (UV)
gradually opens the air intake and the speed regulator (SR) increases
the engine speed.
The construction of the regulating valve (RV) is such that any
increase (decrease) of the air receiver pressure above the pre-set
valve opening pressure results in a proportional increase (decrease)
of the control pressure to the unloading valve and the speed
regulator.
Part of the control air is vented to the atmosphere, and any
condensate discharged, through the vent holes (VH).
Generator
When the generator is switched on, the solenoid valve (SVSR) via the
speed regulator (SR) controls the engine and allows it to reach
maximum speed (the normal control system is switched off).
17
Instruction Manual
2.8
ELECTRICAL
2.8.1 CIRCUIT
SYSTEM
DIAGRAM (STANDARD)
The compressor is equipped with a negative earthed system.
3
2
S1
1
12V DC
S1
F1
10A
22
23
5
30
0
1
2
3
31
33
32
0
1
2
3
4
13
10
K3
11
S5
18
15
K4 19
15«
16
8
3
3
3
17
G2
+
5«
G1
B+
6
14«
q
K4
3
S2
V1
35
p
9
11
K0
13«
7«
S3
Auxiliary
9
8«
q
7
D- D+ 6«
9
13
1«
2«
K0
P1
34
14
27
12«
h
Y1
V2
3«
4«
26
K3 14
12
15
1
4
12
12
12
12
9
K2
25
H1
24 Temp
7
10
2
K2
K1
12
8
6
12
20
21
29
H2
28 General
alarm
K1 5
3
S4
(Lamptester)
12
12
12
9´,10´,11´
Fig. 2.4
F1
G1
G2
H1
H2
K0
K1
K2
K3
K4
18
Circuit diagram (No. 9822 0797 01)
Circuit Breaker (10 A)
Alternator
Battery
Temperature Alarm Lamp
General Alarm Lamp
Starter Solenoid (part of M1)
Shut-down Relay
Blocking Relay
Override Start Relay
Start Relay
M1
P1
S1
S2
S3
S4
S5
Y1
V1
V2
Starter Motor
Hourmeter
Contact Switch (Off-On-Override-start)
Temperature Switch Engine
Oil Pressure Switch Engine
Lamptest Switch
Temperature Switch Compressor
Fuel Solenoid Valve
Diode
Diode
M1
M
Instruction Manual
Engine is running normally:
Oil pressure contact S3 opens, K3 no longer excited. K3 changes
over (13-11), engine cuts out because fuel solenoid Y1 no longer
excited and lamp H2 goes on simultaneously.
Thermocontact S2 opens, K3 no longer excited. K3 changes over
(13-11), engine cuts out because fuel solenoid Y1 no longer
excited and lamp H2 goes on simultaneously.
Thermocontact S5 opens, K1 no longer excited. Contact K1
changes over (4-2). K3 no longer excited. K3 changes over (1311), 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 (8-6).
Fig. 2.5
Location of relais K1-K4
Operation of the electric circuit in detail
Start switch S1 position 1:
Thermocontact S5 cools off and closes, K1 excited again and
contact K1 changes over (4-1). However, lamp H1 remains on
across line 9 and contact K2 (6-8).
A fault in the alternator part causes terminal D+ to go to 0V and
K4 to be excited. Contact K4 changes over to (18-15), engine
cuts out because fuel solenoid Y1 no longer excited and lamp H2
goes on simultaneously.
Line 2 on 12V contact K3 closed (13-11), lamp H2 is on. K4
excites contact K4 (18-15). Thermocontact element S5 normally
closed, K1 excites contact K1 (1-4).
Use of lamp test:
Start switch S1 position 1 press lamp test S4, across K3 and line
9 lamp H1 and relay K2 are excited. After releasing lamp test
button S4, lamp H1 remains on, S4 taken over by contact K2.
Start switch S1 position 2:
Line 3 on 12V (overwrite function) 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 (13-10). Relay K2 no
longer excited, contact K2 opens, lamp H1 goes out. Alternator
also commences supplying voltage and K4 is no longer excited
and contact K4 changes over to (18-16). Lamp H2 goes out, one
can release start switch S1 and it returns to position 1. Exciting
the safety devices occurs no longer across line 3 but across line 2
to line 4 and this way to line 3.
19
Instruction Manual
2.8.2 CIRCUIT DIAGRAM XAS 67 DDG - XAS 130 DD7G, XAS 97 DDG - XAS 185 DD7G
(GENERATOR DDG 110V WITHOUT AUTOMATIC CONTROL SYSTEM)
(Not on HardHat)
3
2
S1
1
0
1
2
3
S1
12V DC
10A
22
5
F1 23
0
1
2
3
4
31
33
32
30
13
10
K3
11
S5
18
14'
K4
K4
G2
+
B+
D+
D-
8
3
3
3
0
Auxiliary
To Circuit diagram
9822 1055 27
9
13'
11
K0
7'
35
6'
9
8'
S2
V1
7
9
3
17
6
5'
G1
19
15'
16
15
13
S3
p
1'
2'
K3
14
9
12
7
34
K0
P1
27
Y1
12'
h
3'
4'
26
25
H1
1
4
12
12
24 Temp
10
15
12
K2
29
H2
K1
5
V2
12
3
28 General
alarm
M1 M
2
K2
K1
12
8
20
6
21
12
S4
(Lamptester)
12
12
12
9',10',11'
X2
X3
e54
e0 e0
Q2
c0 c0
e54
c0 c0
e54
Q4
Q3
16A
32A
3L2
L1 L2
16A
2L2
16A
2L1
L1 L2
1L2
32A
1L1
L1 L2
3L1
X1
16A
L1
L2
e0
e0
e0 e0 e0 e0
1 3 5 7
2 4 6 8
e0 e0
K5
S7
3
W1
f0
V1
f0
1
2
3
4
N13
T13
1
4
10
5 30mA
6 I n
11
40msec
7
3
b6
Q1
12
50A
b3 13
b3 14
D1A1 K5
A2
b6
12
V
b3
b3
13
13
PR
Y2
B
b6
12
b3
34
To Circuit diagram
9822 0797 01
H3
b6
12
35
b6
12
W
f0
V
f0
G3
52 51
b3
13
W
e54
EARTHING PIN
G
The compressor is equipped with a negative earthed system
For location of relais K1, K2, K3, K4, see paragraph 2.8.1
Fig. 2.6
D1
F1
G1
G2
G3
H1
H2
H3
K0
K1
20
Circuit diagram (No. 9822 0797 01 + No. 9822 1055 27)
Diode
Circuit Breaker (10A)
Alternator
Battery
Generator
Temperature Alarm Lamp
General Alarm Lamp
Lamp (Power ON)
Starter Solenoid (part of M1)
Shut-down Relay
K2
K3
K4
K5
M1
N13
P1
Q1
Q2
Q3
Blocking Relay
Override Start Relay
Start Relay
Contactor
Starter Motor
Earth faultcurrent relay
Hourmeter
Main circuit breaker 2-pole
Circuit breaker 2-pole
Circuit breaker 2-pole
Q4
S1
S2
S3
S4
S5
S7
T13
Circuit breaker 2-pole
Contact Switch (Off-OnOverride-start)
Temperature Switch Engine
Oil Pressure Switch Engine
Lamptest Switch
Temperature Switch
Compressor
Switch (Generator-compressor)
Current transformer for N13
V1
V2
X1
X2
X3
Y1
Y2
Diode
Diode
Socket outlet
Socket outlet
Socket outlet
Fuel solenoid Valve
Solenoid valve (Generator
action)
Instruction Manual
Operation of the electric circuit in detail
Start switch S1 position 1:
Line 2 on 12V contact K3 closed (13-11), lamp H2 is on. K4
excites contact K4 (18-15). Thermocontact element S5 normally
closed, K1 excites contact K1 (1-4).
Engine is running normally:
Oil pressure contact S3 opens, K3 no longer excited.
K3 changes over (13-11), engine cuts out because fuel solenoid
Y1 no longer excited and lamp H2 goes on simultaneously.
Thermocontact S2 opens, K3 no longer excited.
K3 changes over (13-11), engine cuts out because fuel solenoid
Y1 no longer excited and lamp H2 goes on simultaneously.
Use of lamp test:
Start switch S1 position 1 press lamp test S4, across K3 and line
9 lamp H1 and relay K2 are excited. After releasing lamp test
button S4, lamp H1 remains on, S4 taken over by contact K2.
Start switch S1 position 2:
Line 3 on 12V (overwrite function) hourmeter P1 and fuel
solenoid Y1 excited. Thermocontact engine S2 normally closed,
oil pressure contact S3 open.
Thermocontact S5 opens, K1 no longer excited. Contact K1
changes over (4-2). K3 no longer excited. K3 changes over (1311), 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 (8-6).
Thermocontact S5 cools off and closes, K1 excited again and
contact K1 changes over (4-1). However, lamp H1 remains on
across line 9 and contact K2 (6-8).
A fault in the alternator part causes terminal D+ to go to 0V and
K4 to be excited. Contact K4 changes over to (18-15), engine
cuts out because fuel solenoid Y1 no longer excited and lamp H2
goes on simultaneously.
Generator function:
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 (13-10). Relay K2 no
longer excited, contact K2 opens, lamp H1 goes out. Alternator
also commences supplying voltage and K4 is no longer excited
and contact K4 changes over to (18-16). Lamp H2 goes out, one
can release start switch S1 and it returns to position 1. Exciting
the safety devices occurs no longer across line 3 but across line 2
to line 4 and this way to line 3.
Turn switch S7 to position 1. The solenoid valve Y2 via the speed
regulator SR 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.
21
Instruction Manual
2.8.3 CIRCUIT DIAGRAM XAS 67 DDG - XAS 130 DD7G, XAS 97 DDG - XAS 185 DD7G
(GENERATOR DDG 110V WITH AUTOMATIC CONTROL SYSTEM)
(Not on HardHat)
3
2
S1
1
0
1
2
3
S1
12V DC
10A
22
5
F1 23
0
1
2
3
4
31
33
32
30
13
10
K3
11
S5
18
14'
K4
K4
G2
+
G1
19
8
3
3
3
0
Auxiliary
To Circuit diagram
9822 1055 91
9
13'
11
K0
7'
35
6'
9
8'
S2
V1
7
9
3
17
6
5'
B+
D+
D-
15'
16
15
13
S3
p
1'
2'
K3
14
9
12
7
34
K0
P1
27
Y1
12'
h
3'
4'
1
4
12
12
12
5
20
21
S4
(Lamptester)
12
12
12
L1 L2
c0 c0
e54
c0 c0
e54
Q4
Q3
32A
8
6
12
3L1
2L1
1L2
e54
M1 M
3
16A
16A
1L1
K1
28 General
alarm
X3
L1 L2
32A
K2
K1
X2
L1 L2
e0 e0
H2
29
3L2
12
X1
Q2
H1
24 Temp
2
2L2
9',10',11'
25
10
15
12
K2
V2
26
16A
16A
L1
e0
E1
e0
7
K5
6
5
4
3 2 1
b3 b3 b6 b3
b6
e0 e0 e0 e0
1 3 5 7
2 4 6 8
e0 e0
9
11
S8
W1
V1
f0
1
2
3
4
N13
T13
b3
13
1
4
10
5 30mA
6 I n
11
40msec
7
3
b6
Q1
12
50A
b3 13
A1
b3 14
A1
K7
b3 A2
D1
A1
A2
K5
b6
b6
12
3
52 51
13
b3
13
b3
K8
b3
PR
Y2
B
b6
12
b3
34
To Circuit
diagram
9822 0797 01
A2
b3
15
b6
S7
b3
f0
H4
b3
3 4
L2
H3
b6
12
35
b6
b6
12
12
12
V
G3
W
f0
V
f0
W
e54
EARTHING PIN
G
The compressor is equipped with a negative earthed system.
For location of relais K1, K2, K3, K4, see paragraph 2.8.1
Fig. 2.7
D1
E1
F1
G1
G2
G3
H1
H2
H3
H4
K0
22
Circuit diagram (No. 9822 0797 01 + No. 9822 1055 91)
Diode
Ecologiser
Circuit Breaker (10A)
Alternator
Battery
Generator
Temperature Alarm Lamp
General Alarm Lamp
Lamp (Power ON)
Lamp automatic control system
Starter Solenoid (part of M1)
K1
K2
K3
K4
K5
K7
K8
M1
N13
P1
Q1
Shut-down Relay
Blocking Relay
Override Start Relay
Start Relay
Contactor
Time relais
Time relais
Starter Motor
Earth faultcurrent relay
Hourmeter
Main circuit breaker 2-pole
Q2
Q3
Q4
S1
S2
S3
S4
S5
S7
Circuit breaker 2-pole
Circuit breaker 2-pole
Circuit breaker 2-pole
Contact Switch (Off-OnOverride-start)
Temperature Switch Engine
Oil Pressure Switch Engine
Lamptest Switch
Temperature Switch
Compressor
Switch (Generator-compressor)
S8
T13
V1
V2
X1
X2
X3
Y1
Y2
Switch automatic control
system
Current transformer for N13
Diode
Diode
Socket outlet
Socket outlet
Socket outlet
Fuel solenoid Valve
Solenoid valve
(Generator action)
Instruction Manual
Operation of the electric circuit in detail
Start switch S1 position 1:
Line 2 on 12V contact K3 closed (13-11), lamp H2 is on. K4
excites contact K4 (18-15). Thermocontact element S5 normally
closed, K1 excites contact K1 (1-4).
Engine is running normally:
Oil pressure contact S3 opens, K3 no longer excited.
K3 changes over (13-11), engine cuts out because fuel solenoid
Y1 no longer excited and lamp H2 goes on simultaneously.
Thermocontact S2 opens, K3 no longer excited.
K3 changes over (13-11), engine cuts out because fuel solenoid
Y1 no longer excited and lamp H2 goes on simultaneously.
Use of lamp test:
Start switch S1 position 1 press lamp test S4, across K3 and line
9 lamp H1 and relay K2 are excited. After releasing lamp test
button S4, lamp H1 remains on, S4 taken over by contact K2.
Start switch S1 position 2:
Line 3 on 12V (overwrite function) hourmeter P1 and fuel
solenoid Y1 excited. Thermocontact engine S2 normally closed,
oil pressure contact S3 open.
Thermocontact S5 opens, K1 no longer excited. Contact K1
changes over (4-2). K3 no longer excited. K3 changes over (1311), 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 (8-6).
Thermocontact S5 cools off and closes, K1 excited again and
contact K1 changes over (4-1). However, lamp H1 remains on
across line 9 and contact K2 (6-8).
A fault in the alternator part causes terminal D+ to go to 0V and
K4 to be excited. Contact K4 changes over to (18-15), engine
cuts out because fuel solenoid Y1 no longer excited and lamp H2
goes on simultaneously.
Generator function:
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 (13-10). Relay K2 no
longer excited, contact K2 opens, lamp H1 goes out. Alternator
also commences supplying voltage and K4 is no longer excited
and contact K4 changes over to (18-16). Lamp H2 goes out, one
can release start switch S1 and it returns to position 1. Exciting
the safety devices occurs no longer across line 3 but across line 2
to line 4 and this way to line 3.
Turn switch S7 to position 1. The solenoid valve Y2 via the speed
regulator SR controls the motor and allows it to reach maximum
speed (the normal control system is switched off). Lamp H3 is
activated. Time relay K7 disconnects the sockets from the
generator during 4 sec, after which the sockets 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 system. When
in this condition E1 senses current to the sockets, the solenoid
valve Y2 is re-activated immediately by K8. Time relay K7
disconnects the sockets from the generator during 4 sec, after
which the sockets X1, X2, X3 are under tension.
23
Instruction Manual
2.8.4 CIRCUIT DIAGRAM XAS 67 DDG - XAS 130 DD7G, XAS 97 DDG - XAS 185 DD7G
(GENERATOR DDG IT 230/400V, 6 KVA WITHOUT AUTOMATIC CONTROL SYSTEM)
(Not on HardHat)
3
2
S1
1
0
1
2
3
S1
12V DC
10A
22
5
F1 23
0
1
2
3
4
31
33
32
30
13
10
K3
11
S5
18
14'
K4
K4
G2
+
B+
D+
D-
19
8
3
3
3
0
Auxiliary
To Circuit diagram
9822 1055 25
S3
9
13'
11
K0
7'
35
6'
9
8'
S2
V1
7
9
3
17
6
5'
G1
15'
16
15
13
p
1'
2'
K3
14
9
12
7
34
P1
K0
27
Y1
12'
h
3'
4'
26
25
H1
1
4
12
12
12
24 Temp
10
15
12
K2
29
H2
K1
5
V2
3
28 General
alarm
M1 M
2
K2
K1
12
8
20
6
21
12
S4
(Lamptester)
12
12
12
9',10',11'
X1.3
X1.2
X1.1
L2 L1
L2
N
L2
K5
1
2
3
4
5
6
c54
L2
N
L2
N
L3
L2
L1
c0 c0 c0 c6
N
16A
16A
c54
c0 c6
N
16A
L3 N
c54
c0 c6
7
8
N
W1
V1
U1
C0 C0 C0 C6
Q1
S7
b0
16
b3
52 51
3
EA
b0
W1
b6
16
b0 b3
16 13
10A 16A 10A 16A
K6
14 12 11 A1
b3
b3
b3
13
13
13
H3 D1 K5
A1
b6
34
To Circuit diagram
9822 0797 01
PR
Y2
B
b6
b6
12
12
R<
N
b0
W1
R T PE L
A2
b6
b54 b54
b0
W1
b6
12
A2
b6
12
b3
35
12
b54
G3
N
W
V
U
b0
N
U1 V1 W1 N
G
S6
u
Fig. 2.8
D1
F1
G1
G2
G3
H1
H2
H3
K0
K1
24
The compressor is equipped with a negative earthed system.
For location of relais K1, K2, K3, K4, see paragraph 2.8.1
Circuit diagram (No. 9822 0797 01 + No. 9822 1055 25)
Diode
Circuit Breaker (10 A)
Alternator
Battery
Generator
Temperature Alarm Lamp
General Alarm Lamp
Lamp (Power Control)
Starter Solenoid (part of M1)
Shut-down Relay
K2
K3
K4
K5
K6
M1
P1
Q1
Blocking Relay
Override Start Relay
Start Relay
Contactor/4-pole
Insulation monitoring relay
Starter Motor
Hourmeter
Main circuit breaker 4-pole +
shunt tripcoil
S1
S2
S3
S4
S5
S6
S7
V1
V2
Contact Switch
(Off-On-Override-start)
Temperature Switch Engine
Oil Pressure Switch Engine
Lamptest Switch
Temperature Switch Compressor
Thermalcontact
Switch (Generator-compressor)
Diode
Diode
X1.1
X1.2
X1.3
Y1
Y2
Socket outlet
Socket outlet
Socket outlet
Fuel solenoid Valve
Solenoid valve
(Generator action)
Instruction Manual
Operation of the electric circuit in detail
Start switch S1 position 1:
Line 2 on 12V contact K3 closed (13-11), lamp H2 is on. K4
excites contact K4 (18-15). Thermocontact element S5 normally
closed, K1 excites contact K1 (1-4).
Engine is running normally:
Oil pressure contact S3 opens, K3 no longer excited.
K3 changes over (13-11), engine cuts out because fuel solenoid
Y1 no longer excited and lamp H2 goes on simultaneously.
Thermocontact S2 opens, K3 no longer excited.
K3 changes over (13-11), engine cuts out because fuel solenoid
Y1 no longer excited and lamp H2 goes on simultaneously.
Use of lamp test:
Start switch S1 position 1 press lamp test S4, across K3 and line
9 lamp H1 and relay K2 are excited. After releasing lamp test
button S4, lamp H1 remains on, S4 taken over by contact K2.
Start switch S1 position 2:
Line 3 on 12V (overwrite function) hourmeter P1 and fuel
solenoid Y1 excited. Thermocontact engine S2 normally closed,
oil pressure contact S3 open.
Thermocontact S5 opens, K1 no longer excited. Contact K1
changes over (4-2). K3 no longer excited. K3 changes over (1311), 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 (8-6).
Thermocontact S5 cools off and closes, K1 excited again and
contact K1 changes over (4-1). However, lamp H1 remains on
across line 9 and contact K2 (6-8).
A fault in the alternator part causes terminal D+ to go to 0V and
K4 to be excited. Contact K4 changes over to (18-15), engine
cuts out because fuel solenoid Y1 no longer excited and lamp H2
goes on simultaneously.
Generator function:
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 (13-10). Relay K2 no
longer excited, contact K2 opens, lamp H1 goes out. Alternator
also commences supplying voltage and K4 is no longer excited
and contact K4 changes over to (18-16). Lamp H2 goes out, one
can release start switch S1 and it returns to position 1. Exciting
the safety devices occurs no longer across line 3 but across line 2
to line 4 and this way to line 3.
Turn switch S7 to position 1. The solenoid valve Y2 via the speed
regulator SR controls the 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 halting
and restarting the assembly.
25
Instruction Manual
2.8.5 CIRCUIT DIAGRAM XAS 67 DDG - XAS 130 DD7G, XAS 97 DDG - XAS 185 DD7G
(GENERATOR DDG IT 230/400V, 6 kVA WITH AUTOMATIC CONTROL SYSTEM)
(Not on HardHat)
3
2
S1
1
0
1
2
3
S1
12V DC
10A
22
5
F1 23
0
1
2
3
4
31
33
32
30
13
10
K3
11
S5
18
14'
K4
K4
G2
+
G1
19
8
3
3
3
0
Auxiliary
To Circuit diagram
9822 1055 90
S3
9
13'
11
K0
7'
35
6'
9
8'
S2
V1
7
9
3
17
6
5'
B+
D+
D-
15'
16
15
13
p
1'
2'
K3
14
9
12
7
34
P1
K0
27
Y1
12'
h
3'
4'
H1
25
H2
29
1
4
12
12
12
24 Temp
10
15
12
K2
K1
5
V2
26
M1 M
3
28 General
alarm
2
K2
K1
12
8
20
6
21
12
S4
(Lamptester)
12
12
12
9',10',11'
X1.1
X1.2
X1.3
L2 L1
L2
L3 N
N
L2
c54
L2
N
L2
N
L3
L2
L1
c0 c0 c0 c6
N
16A
16A
c54
c0 c6
N
16A
c0 c6
c54
N
L3
7
6
5
4
9
11
S8
N
W1
V1
U1
C0 C0 C0 C6
Q1
3 2 1
b3 b3 b6 b3
b6
c0 c0 c0 c6
1 3 5 7
2 4 6 8
b0
16
b3
b3
EA
b0
W1
b6
16
10A 16A 10A 16A
K6
b0 b3
16 13
14 12 11A1
b3
A1
13
A2
K7
b3
H3 D1 K5
A1
3
K8
R T PE L A2
b6
b54 b54
b0
W1
b54
b6
12
A2
b6
b6
12
12
b3
34
To Circuit
diagram
9822 0797 01
15
b3
b3
PR
Y2
B
b6
b6
b6
12
12
12
A2
R<
N
b6
A1
b6
S7
52 51
13
b3
13
b3
H4
b3
3 4
K5
L2
L1
E1
35
12
N
N
W
V
U
b0
b0
W1
U1 V1 W1 N
G3
G
The compressor is equipped with a negative earthed system.
S6
u
Fig. 2.9
D1
E1
F1
G1
G2
G3
H1
H2
H3
H4
K0
K1
26
For location of relais K1, K2, K3, K4, see paragraph 2.8.1
Circuit diagram (No. 9822 0797 01 + No. 9822 1055 90)
Diode
Ecologiser
Circuit Breaker (10 A)
Alternator
Battery
Generator
Temperature Alarm Lamp
General Alarm Lamp
Lamp (Power Control)
Lamp automatic control system
Starter Solenoid (part of M1)
Shut-down Relay
K2
K3
K4
K5
K6
K7
K8
M1
P1
Q1
Blocking Relay
Override Start Relay
Start Relay
Contactor/4-pole
Insulation monitoring relay
Time relais
Time relais
Starter Motor
Hourmeter
Main circuit breaker 4-pole +
shunt tripcoil
S1
S2
S3
S4
S5
S6
S7
S8
Contact Switch
(Off-On-Override-start)
Temperature Switch Engine
Oil Pressure Switch Engine
Lamptest Switch
Temperature Switch
Compressor
Thermalcontact
Switch (Generatorcompressor)
Switch automatic control
system
V1
V2
X1.1
X1.2
X1.3
Y1
Y2
Diode
Diode
Socket outlet
Socket outlet
Socket outlet
Fuel solenoid Valve
Solenoid valve
(Generator action)
Instruction Manual
Operation of the electric circuit in detail
Start switch S1 position 1:
Line 2 on 12V contact K3 closed (13-11), lamp H2 is on. K4
excites contact K4 (18-15). Thermocontact element S5 normally
closed, K1 excites contact K1 (1-4).
Engine is running normally:
Oil pressure contact S3 opens, K3 no longer excited.
K3 changes over (13-11), engine cuts out because fuel solenoid
Y1 no longer excited and lamp H2 goes on simultaneously.
Thermocontact S2 opens, K3 no longer excited.
K3 changes over (13-11), engine cuts out because fuel solenoid
Y1 no longer excited and lamp H2 goes on simultaneously.
Use of lamp test:
Start switch S1 position 1 press lamp test S4, across K3 and line
9 lamp H1 and relay K2 are excited. After releasing lamp test
button S4, lamp H1 remains on, S4 taken over by contact K2.
Start switch S1 position 2:
Line 3 on 12V (overwrite function) hourmeter P1 and fuel
solenoid Y1 excited. Thermocontact engine S2 normally closed,
oil pressure contact S3 open.
Thermocontact S5 opens, K1 no longer excited. Contact K1
changes over (4-2). K3 no longer excited. K3 changes over (1311), 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 (8-6).
Thermocontact S5 cools off and closes, K1 excited again and
contact K1 changes over (4-1). However, lamp H1 remains on
across line 9 and contact K2 (6-8).
A fault in the alternator part causes terminal D+ to go to 0V and
K4 to be excited. Contact K4 changes over to (18-15), engine
cuts out because fuel solenoid Y1 no longer excited and lamp H2
goes on simultaneously.
Generator function:
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 (13-10). Relay K2 no
longer excited, contact K2 opens, lamp H1 goes out. Alternator
also commences supplying voltage and K4 is no longer excited
and contact K4 changes over to (18-16). Lamp H2 goes out, one
can release start switch S1 and it returns to position 1. Exciting
the safety devices occurs no longer across line 3 but across line 2
to line 4 and this way to line 3.
Turn switch S7 to position 1. The solenoid valve Y2 via the speed
regulator SR controls the motor and allows it to reach maximum
speed (the normal control system is switched off). Lamp H3 is
activated. Time relay K7 disconnects the sockets from the
generator during 4 sec, after which the sockets X1.1, 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 system. When
in this condition E1 senses current to the sockets, the solenoid
valve Y2 is re-activated immediately by K8. Time relay K7
disconnects the sockets from the generator during 4 sec, after
which the sockets X1, X2, X3 are under tension.
27
Instruction Manual
2.8.6 CIRCUIT DIAGRAM XAS 67 DDG - XAS 130 DD7G, XAS 97 DDG - XAS 185 DD7G
(GENERATOR DDG IT 230V, 6 kVA)
(Not on HardHat)
3
2
S1
1
0
1
2
3
S1
12V DC
10A
22
5
F1 23
0
1
2
3
4
31
33
32
30
13
10
K3
11
S5
18
14'
K4
K4
G2
+
B+
D+
D-
8
3
3
3
0
Auxiliary
To Circuit diagram
9822 1055 26
S3
9
13'
11
K0
7'
35
6'
9
8'
S2
V1
7
9
3
17
6
5'
G1
19
15'
16
15
13
p
1'
2'
K3
14
9
12
7
34
K0
P1
27
Y1
12'
h
3'
4'
25
H1
29
1
4
12
12
9',10',11'
12
H2
K1
5
3
28 General
alarm
M1 M
2
K2
K1
12
X1.2
24 Temp
10
15
12
K2
V2
26
8
20
6
21
12
S4
(Lamptester)
12
12
12
X1.3
X1.1
L1
L1 L2
L3
e54
c0 c0
L1
1L2
16A
1L1
L3
L2
L1
c0 c0 c0
L1 L2
16A
32A
L2
L2
c54
c0 c0
c54
L1 c0
L2 c0
K5
1
2
3
4
5
6
1W1
1V1
1U1
c0 c0 c0
S7
b0
16
Q1
3
52 51
EA
b0
16A 16A 16A
b6
b0
K6
V1
16 13
13
11 A1
H3 D1 K5
R<
16
R T PE L A2
b6
b54 b54
b0
V1
U1
V1
W1
V1
W1
U2
V2
13
A2
b6
12
To Circuit diagram
9822 0797 01
P R
Y2
B
b6
b6
12
12
35
12
b0
W1
c0 c0 c0
U1
b6
12
34
b3
13
A1
b54
W2
b3
b3
14 12
W1
b0
V1
G3
b0 b3
b3
G
S6
u
Fig. 2.10
D1
F1
G1
G2
G3
H1
H2
H3
K0
K1
28
The compressor is equipped with a negative earthed system.
For location of relais K1, K2, K3, K4, see paragraph 2.8.1
Circuit diagram (No. 9822 0797 01 + No. 9822 1055 26)
Diode
Circuit Breaker (10 A)
Alternator
Battery
Generator
Temperature Alarm Lamp
General Alarm Lamp
Lamp (Power Control)
Starter Solenoid (part of M1)
Shut-down Relay
K2
K3
K4
K5
K6
M1
P1
Q1
Blocking Relay
Override Start Relay
Start Relay
Contactor/4-pole
Insulation monitoring relay
Starter Motor
Hourmeter
Main circuit breaker 3-pole +
shunt tripcoil
S1
S2
S3
S4
S5
S6
S7
Contact Switch
(Off-On-Override-start)
Temperature Switch Engine
Oil Pressure Switch Engine
Lamptest Switch
Temperature Switch Compressor
Thermalcontact
Switch
(Generator-compressor)
V1
V2
X1.1
X1.2
X1.3
Y1
Y2
Diode
Diode
Socket outlet
Socket outlet
Socket outlet
Fuel solenoid Valve
Solenoid valve
(Generator action)
Instruction Manual
Operation of the electric circuit in detail
Start switch S1 position 1:
Line 2 on 12V contact K3 closed (13-11), lamp H2 is on. K4
excites contact K4 (18-15). Thermocontact element S5 normally
closed, K1 excites contact K1 (1-4).
Engine is running normally:
Oil pressure contact S3 opens, K3 no longer excited.
K3 changes over (13-11), engine cuts out because fuel solenoid
Y1 no longer excited and lamp H2 goes on simultaneously.
Thermocontact S2 opens, K3 no longer excited.
K3 changes over (13-11), engine cuts out because fuel solenoid
Y1 no longer excited and lamp H2 goes on simultaneously.
Use of lamp test:
Start switch S1 position 1 press lamp test S4, across K3 and line
9 lamp H1 and relay K2 are excited. After releasing lamp test
button S4, lamp H1 remains on, S4 taken over by contact K2.
Start switch S1 position 2:
Line 3 on 12V (overwrite function) hourmeter P1 and fuel
solenoid Y1 excited. Thermocontact engine S2 normally closed,
oil pressure contact S3 open.
Thermocontact S5 opens, K1 no longer excited. Contact K1
changes over (4-2). K3 no longer excited. K3 changes over (1311), 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 (8-6).
Thermocontact S5 cools off and closes, K1 excited again and
contact K1 changes over (4-1). However, lamp H1 remains on
across line 9 and contact K2 (6-8).
A fault in the alternator part causes terminal D+ to go to 0V and
K4 to be excited. Contact K4 changes over to (18-15), engine
cuts out because fuel solenoid Y1 no longer excited and lamp H2
goes on simultaneously.
Generator function:
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 (13-10). Relay K2 no
longer excited, contact K2 opens, lamp H1 goes out. Alternator
also commences supplying voltage and K4 is no longer excited
and contact K4 changes over to (18-16). Lamp H2 goes out, one
can release start switch S1 and it returns to position 1. Exciting
the safety devices occurs no longer across line 3 but across line 2
to line 4 and this way to line 3.
Turn switch S7 to position 1. The solenoid valve Y2 via the speed
regulator SR controls the 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 halting
and restarting the assembly.
29
Instruction Manual
2.8.7 CIRCUIT DIAGRAM XAS 67 DDG - XAS 130 DD7G, XAS 97 DDG - XAS 185 DD7G
(GENERATOR DDG IT 230/400V, 12.5 kVA WITHOUT AUTOMATIC CONTROL SYSTEM)
(Not on HardHat)
3
2
S1
1
0
1
2
3
S1
12V DC
10A
22
5
F1 23
0
1
2
3
4
31
33
32
30
13
10
K3
11
S5
18
14'
K4
K4
G2
+
B+
D+
D-
19
8
3
3
3
0
V1
Auxiliary
To Circuit diagram
9822 1055 28
9
13'
11
K0
7'
35
7
9
8'
S2
6'
9
3
17
6
5'
G1
15'
16
15
13
S3
p
1'
2'
K3
14
9
12
7
34
P1
K0
27
Y1
12'
h
3'
4'
26
25
H1
1
4
12
12
24 Temp
10
15
12
K2
29
H2
K1
5
V2
3
28 General
alarm
M1 M
2
K2
K1
12
12
8
20
6
21
12
S4
(Lamptester)
12
12
12
9',10',11'
X1.1
X1.2
L2 L1
16A
L3 N
X1.3
L2 L1
16A
L3 N
L3
N
1
2
3
4
5
6
7
8
V1
W1
N
K5
U1
c0 c0 c0 c6
c54
c54
N
L2
N
L3
c0 c0 c0 c6
c0 c6
c54
S7
b0
16
C0 C0 C0 C6
Q1
L2
L1
N
L3
L2
L1
16A
3
52 51
EA
b0
W1
b6
16
b0 b3
16 13
b3
b3
13
16A 16A 16A 16A
14 12 11A1
K6
A1
13
To Circuit diagram
9822 0797 01
PR
Y2
B
b6
b6
12
12
R<
N
b6
34
b3
13
H3 D1 K5
b0
W1
R T PE L
A2
b6
b54 b54
b0
W1
b6
12
A2
b6
12
b3
35
12
b54
b0
N
N
W
V
U
C0 C0 C0 C6
U1 V1 W1 N
G3
G
S6
u
Fig. 2.11
D1
F1
G1
G2
G3
H1
H2
H3
K0
K1
30
The compressor is equipped with a negative earthed system.
For location of relais K1, K2, K3, K4, see paragraph 2.8.1
Circuit diagram (No. 9822 0797 01 + No. 9822 1055 28)
Diode
Circuit Breaker (10 A)
Alternator
Battery
Generator
Temperature Alarm Lamp
General Alarm Lamp
Lamp (Power Control)
Starter Solenoid (part of M1)
Shut-down Relay
K2
K3
K4
K5
K6
M1
P1
Q1
Blocking Relay
Override Start Relay
Start Relay
Contactor/4-pole
Insulation monitoring relay
Starter Motor
Hourmeter
Main circuit breaker 4-pole +
shunt tripcoil
S1
S2
S3
S4
S5
S6
S7
V1
V2
Contact Switch
(Off-On-Override-start)
Temperature Switch Engine
Oil Pressure Switch Engine
Lamptest Switch
Temperature Switch Compressor
Thermalcontact
Switch (Generator-compressor)
Diode
Diode
X1.1
X1.2
X1.3
Y1
Y2
Socket outlet
Socket outlet
Socket outlet
Fuel solenoid Valve
Solenoid valve
(Generator action)
Instruction Manual
Operation of the electric circuit in detail
Start switch S1 position 1:
Line 2 on 12V contact K3 closed (13-11), lamp H2 is on. K4
excites contact K4 (18-15). Thermocontact element S5 normally
closed, K1 excites contact K1 (1-4).
Engine is running normally:
Oil pressure contact S3 opens, K3 no longer excited.
K3 changes over (13-11), engine cuts out because fuel solenoid
Y1 no longer excited and lamp H2 goes on simultaneously.
Thermocontact S2 opens, K3 no longer excited.
K3 changes over (13-11), engine cuts out because fuel solenoid
Y1 no longer excited and lamp H2 goes on simultaneously.
Use of lamp test:
Start switch S1 position 1 press lamp test S4, across K3 and line
9 lamp H1 and relay K2 are excited. After releasing lamp test
button S4, lamp H1 remains on, S4 taken over by contact K2.
Start switch S1 position 2:
Line 3 on 12V (overwrite function) hourmeter P1 and fuel
solenoid Y1 excited. Thermocontact engine S2 normally closed,
oil pressure contact S3 open.
Thermocontact S5 opens, K1 no longer excited. Contact K1
changes over (4-2). K3 no longer excited. K3 changes over (1311), 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 (8-6).
Thermocontact S5 cools off and closes, K1 excited again and
contact K1 changes over (4-1). However, lamp H1 remains on
across line 9 and contact K2 (6-8).
A fault in the alternator part causes terminal D+ to go to 0V and
K4 to be excited. Contact K4 changes over to (18-15), engine
cuts out because fuel solenoid Y1 no longer excited and lamp H2
goes on simultaneously.
Generator function:
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 (13-10). Relay K2 no
longer excited, contact K2 opens, lamp H1 goes out. Alternator
also commences supplying voltage and K4 is no longer excited
and contact K4 changes over to (18-16). Lamp H2 goes out, one
can release start switch S1 and it returns to position 1. Exciting
the safety devices occurs no longer across line 3 but across line 2
to line 4 and this way to line 3.
Turn switch S7 to position 1. The solenoid valve Y2 via the speed
regulator SR controls the 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 halting
and restarting the assembly.
31
Instruction Manual
2.8.8
CIRCUIT DIAGRAM XAS 67 DDG - XAS 130 DD7G, XAS 97 DDG - XAS 185 DD7G
(GENERATOR DDG IT 230/400V, 12.5 kVA WITH AUTOMATIC CONTROL SYSTEM)
(Not on HardHat)
3
2
S1
1
0
1
2
3
S1
12V DC
10A
22
5
F1 23
0
1
2
3
4
31
33
32
30
13
10
K3
11
S5
18
14'
K4
K4
G2
+
G1
19
8
3
3
3
0
Auxiliary
To Circuit diagram
9822 1055 92
9
13'
11
K0
7'
35
6'
9
8'
S2
V1
7
9
3
17
6
5'
B+
D+
D-
15'
16
15
13
S3
p
1'
2'
K3
14
9
12
7
34
P1
K0
27
Y1
12'
h
3'
4'
26
H1
25
H2
29
1
4
12
12
24 Temp
10
15
12
K2
K1
5
V2
M1 M
3
28 General
alarm
2
K2
K1
12
12
8
20
6
21
12
S4
(Lamptester)
12
12
12
9',10',11'
X1.2
X1.3
c0 c0 c0 c6
c54
L3
N
L2
16A
N
L3
L2
L1
L2 L1
16A
L3 N
N
L3
L2
L1
L1
16A
L3 N
c0 c0 c0 c6
c54
N
X1.1
L2
c0 c6
c54
5
6
W1
7
7
8
6
5
4
9
Q1
11
b0
16
C0 C0 C0 C6
3 2 1
b3 b3 b6 b3
b6
S8
b3
EA
b0
W1
b6
16
b0 b3
16 13
16A 16A 16A 16A
K6
R<
N
b6
14 12 11 A1
b0
W1
R T PE L
b0
W1
A2
b6
b54 b54
12
3
b3
34
b3
A1
13
b3 A2
15
b3
b3
K5
PR
Y2
B
b6
b6
b6
12
12
12
H3
b6
12
b54
b6
S7
52 51
13
b3
13
b3
H4
b3
3 4
3
4
N
1
2
V1
K5
U1
E1
D1
A1
A2
K7
b6
b6
12
12
A1
A2
K8
To Circuit
diagram
9822 0797 01
35
b0
N
N
W
V
U
C0 C0 C0 C6
U1 V1 W1
N
G3
G
S6
u
Fig. 2.12
D1
E1
F1
G1
G2
G3
H1
H2
H3
H4
K0
K1
32
The compressor is equipped with a negative earthed system.
For location of relais K1, K2, K3, K4, see paragraph 2.8.1
Circuit diagram (No. 9822 0797 01 + No. 9822 1055 92)
Diode
Ecologiser
Circuit Breaker (10 A)
Alternator
Battery
Generator
Temperature Alarm Lamp
General Alarm Lamp
Lamp (Power Control)
Lamp automatic control system
Starter Solenoid (part of M1)
Shut-down Relay
K2
K3
K4
K5
K6
K7
K8
M1
P1
Q1
Blocking Relay
Override Start Relay
Start Relay
Contactor/4-pole
Insulation monitoring relay
Time relais
Time relais
Starter Motor
Hourmeter
Main circuit breaker 4-pole +
shunt tripcoil
S1
S2
S3
S4
S5
S6
S7
S8
Contact Switch
(Off-On-Override-start)
Temperature Switch Engine
Oil Pressure Switch Engine
Lamptest Switch
Temperature Switch
Compressor
Thermalcontact
Switch (Generatorcompressor)
Switch automatic control
system
V1
V2
X1.1
X1.2
X1.3
Y1
Y2
Diode
Diode
Socket outlet
Socket outlet
Socket outlet
Fuel solenoid Valve
Solenoid valve
(Generator action)
Instruction Manual
Operation of the electric circuit in detail
Start switch S1 position 1:
Line 2 on 12V contact K3 closed (13-11), lamp H2 is on. K4
excites contact K4 (18-15). Thermocontact element S5 normally
closed, K1 excites contact K1 (1-4).
Engine is running normally:
Oil pressure contact S3 opens, K3 no longer excited.
K3 changes over (13-11), engine cuts out because fuel solenoid
Y1 no longer excited and lamp H2 goes on simultaneously.
Thermocontact S2 opens, K3 no longer excited.
K3 changes over (13-11), engine cuts out because fuel solenoid
Y1 no longer excited and lamp H2 goes on simultaneously.
Use of lamp test:
Start switch S1 position 1 press lamp test S4, across K3 and line
9 lamp H1 and relay K2 are excited. After releasing lamp test
button S4, lamp H1 remains on, S4 taken over by contact K2.
Start switch S1 position 2:
Line 3 on 12V (overwrite function) hourmeter P1 and fuel
solenoid Y1 excited. Thermocontact engine S2 normally closed,
oil pressure contact S3 open.
Thermocontact S5 opens, K1 no longer excited. Contact K1
changes over (4-2). K3 no longer excited. K3 changes over (1311), 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 (8-6).
Thermocontact S5 cools off and closes, K1 excited again and
contact K1 changes over (4-1). However, lamp H1 remains on
across line 9 and contact K2 (6-8).
A fault in the alternator part causes terminal D+ to go to 0V and
K4 to be excited. Contact K4 changes over to (18-15), engine
cuts out because fuel solenoid Y1 no longer excited and lamp H2
goes on simultaneously.
Generator function:
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 (13-10). Relay K2 no
longer excited, contact K2 opens, lamp H1 goes out. Alternator
also commences supplying voltage and K4 is no longer excited
and contact K4 changes over to (18-16). Lamp H2 goes out, one
can release start switch S1 and it returns to position 1. Exciting
the safety devices occurs no longer across line 3 but across line 2
to line 4 and this way to line 3.
Turn switch S7 to position 1. The solenoid valve Y2 via the speed
regulator SR controls the motor and allows it to reach maximum
speed (the normal control system is switched off). Lamp H3 is
activated. Time relay K7 disconnects the sockets from the
generator during 4 sec, after which the sockets X1.1, 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 system. When
in this condition E1 senses current to the sockets, the solenoid
valve Y2 is re-activated immediately by K8. Time relay K7
disconnects the sockets from the generator during 4 sec, after
which the sockets X1.1, X1.2, X1.3 are under tension.
33
Instruction Manual
2.8.9 CIRCUIT DIAGRAM XAS 67 DDG - XAS 130 DD7G, XAS 97 DDG - XAS 185 DD7G
(GENERATOR DDG IT 230V, 12.5 kVA)
(Not on HardHat)
3
2
S1
1
0
1
2
3
S1
12V DC
10A
22
5
F1 23
0
1
2
3
4
31
33
32
30
13
10
K3
11
S5
18
14'
K4
K4
G2
+
8
3
3
3
0
6'
Auxiliary
To Circuit diagram
9822 1055 29
9
13'
11
K0
7'
35
7
9
8'
S2
V1
B+
D+
D-
9
3
17
6
5'
G1
19
15'
16
15
S3
13
p
1'
2'
K3
14
9
12
7
34
K0
P1
27
Y1
12'
h
3'
4'
26
25
H1
29
1
4
12
12
12
24 Temp
10
15
12
K2
H2
K1
5
V2
3
28 General
alarm
M1 M
2
K2
K1
12
8
20
6
21
12
S4
(Lamptester)
12
12
12
9',10',11'
X1.2
L3
K5
3
4
e54
1L2
c0 c0
L1 c0
16A
L2 c0
16A
1L1
16A
1L1
L3
L2
L1
Q2
e0 e0 e0
L1 L2
16A
32A
1
2
X1.3
L1 L2
1L2
X1.1
L1
L2
c0 c0
c54
c54
5
6
1W1
1V1
1U1
e0 e0 e0
S7
b0
16
Q1
3
52 51
EA
32A 32A 32A
b6
b0
K6
b0
b0
b3
b3
b3
b3
V1
16
13
13
13
13
14 12 11
R T PE L
b0
V1
U1
V1
W1
V1
W1
V2
b6
12
b54 b54
b6
A2
b6
12
34
To Circuit diagram
9822 0797 01
PR
Y2
B
b6
b6
12
12
35
12
b0
W1
e0 e0 e0
W2 U2
A2
A1
16
b54
U1
H3 D1 K5
R<
b0
V1
G3
A1
W1
b3
G
S6
u
Fig. 2.13
D1
F1
G1
G2
G3
H1
H2
H3
K0
K1
34
The compressor is equipped with a negative earthed system.
For location of relais K1, K2, K3, K4, see paragraph 2.8.1
Circuit diagram (No. 9822 0797 01 + No. 9822 1055 29)
Diode
Circuit Breaker (10 A)
Alternator
Battery
Generator
Temperature Alarm Lamp
General Alarm Lamp
Lamp (Power Control)
Starter Solenoid (part of M1)
Shut-down Relay
K2
K3
K4
K5
K6
M1
P1
Q1
Q2
Blocking Relay
Override Start Relay
Start Relay
Contactor/4-pole
Insulation monitoring relay
Starter Motor
Hourmeter
Main circuit breaker 3-pole +
shunt tripcoil
Circuit breaker 2-pole
S1
S2
S3
S4
S5
S6
S7
Contact Switch
(Off-On-Override-start)
Temperature Switch Engine
Oil Pressure Switch Engine
Lamptest Switch
Temperature Switch Compressor
Thermalcontact
Switch
(Generator-compressor)
V1
V2
X1.1
X1.2
X1.3
Y1
Y2
Diode
Diode
Socket outlet
Socket outlet
Socket outlet
Fuel solenoid Valve
Solenoid valve
(Generator action)
Instruction Manual
Operation of the electric circuit in detail
Start switch S1 position 1:
Line 2 on 12V contact K3 closed (13-11), lamp H2 is on. K4
excites contact K4 (18-15). Thermocontact element S5 normally
closed, K1 excites contact K1 (1-4).
Engine is running normally:
Oil pressure contact S3 opens, K3 no longer excited.
K3 changes over (13-11), engine cuts out because fuel solenoid
Y1 no longer excited and lamp H2 goes on simultaneously.
Thermocontact S2 opens, K3 no longer excited.
K3 changes over (13-11), engine cuts out because fuel solenoid
Y1 no longer excited and lamp H2 goes on simultaneously.
Use of lamp test:
Start switch S1 position 1 press lamp test S4, across K3 and line
9 lamp H1 and relay K2 are excited. After releasing lamp test
button S4, lamp H1 remains on, S4 taken over by contact K2.
Start switch S1 position 2:
Line 3 on 12V (overwrite function) hourmeter P1 and fuel
solenoid Y1 excited. Thermocontact engine S2 normally closed,
oil pressure contact S3 open.
Thermocontact S5 opens, K1 no longer excited. Contact K1
changes over (4-2). K3 no longer excited. K3 changes over (1311), 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 (8-6).
Thermocontact S5 cools off and closes, K1 excited again and
contact K1 changes over (4-1). However, lamp H1 remains on
across line 9 and contact K2 (6-8).
A fault in the alternator part causes terminal D+ to go to 0V and
K4 to be excited. Contact K4 changes over to (18-15), engine
cuts out because fuel solenoid Y1 no longer excited and lamp H2
goes on simultaneously.
Generator function:
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 (13-10). Relay K2 no
longer excited, contact K2 opens, lamp H1 goes out. Alternator
also commences supplying voltage and K4 is no longer excited
and contact K4 changes over to (18-16). Lamp H2 goes out, one
can release start switch S1 and it returns to position 1. Exciting
the safety devices occurs no longer across line 3 but across line 2
to line 4 and this way to line 3.
Turn switch S7 to position 1. The solenoid valve Y2 via the speed
regulator SR controls the 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 halting
and restarting the assembly.
35
Instruction Manual
2.8.10 CIRCUIT
DIAGRAM COLD START (ALL TYPES)
S1
12V DC
5
10A
F1
0
1
2
3
1
2
3
4
2
3
4
30
87
K3
87a
S5
30
K4
87a
30
87a
87
2
K4
1
86
8
3
3
3
85
K5
G2
6
87
30
3
S2
9
9
9
2
87
30
30
7
K0
0
G1
B+
D+
D-
11
87a
V1
S6
13
S3
17
p
Auxiliary
87
30
16
14
P2
P1
K0
K3
Y1
V2
K2
86
85
15
87
30
12
Fig. 2.14
F1
G1
G2
H1
H2
K0
M1
P1
P2
36
12
12
12
12
12
86
85
H1
Temp
10
H2
K5
86
85
12
12
12
87a
K1
12
S1
S2
S3
S4
S5
S6
Y1
V1
V2
86
General
alarm
K2
30
S4
87
(Lamptester)
12
12
Circuit diagram (No. 9822 0864 00)
Circuit breaker (10 A)
Alternator
Battery
Temperature alarm lamp
General alarm lamp
Starter solenoid (part of M1)
Starter motor
Hourmeter
Glowplug
K1
85
Contact switch (Off-On-Override-start)
Temperature switch engine
Oil pressure switch engine
Temperature lamptest switch
Temperature switch compressor
Push button glowplug
Fuel solenoid valve
Diode
Diode
M1
M
Instruction Manual
2.8.11 CIRCUIT
DIAGRAM REFINARY EQUIPMENT (ALL TYPES)
0
1
2
3
S1
12V DC
5
10A
1
2
3
4
2
3
4
F1
30
K3
87
87a
S5
30
87
30
87a
K9
30
K4
2
86
8
87
9
9
9
86
30
11
S2
V1
87a
u
20
7
3
See Note 1
G1
B+
D+
D- W
K0
3A 1
3
85
6
G2
87a
u
K4
3
4
1
8
2
5
6
7
S3
30
13
87a
p
N1
21
K9
22
30
23
14
P1
K0
86
h
85
S32
87
12
Y1
86
K3
86
86
85
85
15
87
85
12
12
30
12
12
K2
H1
H2
K1
86
M1
M
85
Y20 86
30
12
V2
12
Temp
10
General
alarm
85
87a
K1
12
K2
S4
30
87
87
30 (Lamptester)
12
12
12
12
See Note 1
Fig. 2.15
F1
G1
G2
H1
H2
K0
K9
M1
N1
P1
Circuit diagram (No. 9822 0909 00)
Circuit breaker (10 A)
Alternator
Battery
Temperature alarm lamp
General alarm lamp
Starter solenoid (part of M1)
Aux. relay safety circuit
Starter motor
Overspeed module
Hourmeter
S1
S2
S3
S4
S5
S32
Y1
Y20
V1
V2
Contact switch (Off-On-Override-start)
Temperature switch engine
Oil pressure switch engine
Temperature lamptest switch
Temperature switch compressor
Test button overspeed
Fuel solenoid valve
Solenoid for overspeed protection valve
Diode
Diode
37
Instruction Manual
3.
OPERATING INSTRUCTIONS
3.1
PARKING,
TOWING AND LIFTING INSTRUCTIONS
Safety precautions.
The operator is expected to apply all relevant safety
precautions, including those mentioned on the pages
7 - 11 of this book.
Attention:
–
Before putting the compressor in to use, check the brake system
as described in section 5.6.
–
After the first 100 km travel:
– Check and retighten the wheel nuts and towbar bolts to the
specified torque. See section 3.1.4 and 8.1.
– Check the brake adjustment. See section 5.6.
3.1.1 PARKING
When parking a compressor, secure support leg (1) or jockey wheel
(2) to support the compressor in a level position. Be sure that the
jockey wheel (2) is blocked by the blocking pin (6).
Apply parking brake by pulling parking brake handle (3) upwards.
Place the compressor as level as possible; however, it can be
operated temporarily in an out-of-level position not exceeding 15°. If
the compressor is parked on sloping ground, immobilize the
compressor by placing wheel chocks (available as option) in front of
or behind the wheels. Locate the rear-end of the compressor upwind,
(see Fig. 3.4), away from contaminated wind-streams and walls.
Avoid recirculation of exhaust air from the engine. This causes
overheating and engine power decrease.
6
6
INSTRUCTIONS
2
2
Fig. 3.3
Parking position of jockey wheel
Fig. 3.4
Rear-end of compressor upwind
4
1
5
Fig. 3.1
Non-adjustable towbar with standard support leg without brakes
2
3
7
4
5
6
Fig. 3.2
38
Adjustable towbar with jockey wheel and brakes
Instruction Manual
3.1.2 TOWING
3.1.4 HEIGHT
ADJUSTMENT (WITH ADJUSTABLE
TOWBAR)
INSTRUCTIONS
Before towing the compressor, ensure that the towing
equipment of the vehicle matches the towing eye or ball
connector, and ensure that the hood is closed and locked
properly.
Before towing the compressor, make sure that the joints
of the towbar are secured with maximum strength
without damaging the towbar. Be sure that there is no
clearance between the teeth of the joints.
For specific instruction see below!
B
A
3
2
1
Label on towbar, towing instructions
For both non-adjustable - and adjustable towbar, the towbar should
be as level as possible and the compressor and towing eye end in a
level position.
Push the hand brake lever (3) completely downwards and connect
breakaway cable (5) to the vehicle. Secure jockey wheel (2) or
support leg (1) in the highest possible position. The jockey wheel is
prevented from turning.
6
XX
X
Fig. 3.5
Fig. 3.7
Table
Type (XXX)
MA [Nm]
”A“ [mm]
”B“ [N]
ZV 2000
250 - 300
600
420 - 500
ZV 2500
350 - 400
600
580 - 660
6
Fig. 3.8
–
2
Fig. 3.6
2
Towing position of jockey wheel
–
Release locking nut (2) with support tools (Extension tube 3).
–
Adjust required height of the towbar.
–
Tighten locking nut (2) by hand first.
–
Secondly tighten locking nut (2) with a tightening torque
corresponding to table (Fig. 3.8). With an extension tube (3) (”A“
corresponding to table) and handforce (”B“ corresponding to
table) easy tightening is possible.
–
Fix locking nut (2) with spring pin (1).
3.1.3 SPILLAGE-FREE INSTRUCTION
This compressor is fitted with a leak-proof undercarriage in order to
protect the environment.
Remove spring pin (1).
Any leaking fluid is collected in case of malfunctions. This fluid can
be removed via outlets, normally secured by caps.
Attention:
Tighten the caps firmly and check for leakages.
Please observe the locally applicable environmental regulations
when removing the leaking liquid.
–
Height adjustment should be undertaken on levelled ground and
in coupled condition.
–
When readjusting, make sure that the front point of the towbar is
horizontal to the coupling point.
–
Before starting a trip, make sure that the adjustment shaft is
secure, so that the stability and safety is guaranteed while
driving. If necessary tighten the locking nut (2) corresponding to
table (Fig. 3.8).
39
Instruction Manual
3.1.5 LIFTING
3.2
INSTRUCTIONS
STARTING/STOPPING
3.2.1 BEFORE
1
STARTING
1. Before initial start-up, prepare battery for operation if not already
done. See section 4.9.
2. With the compressor standing level, check the level of the engine
oil. Add oil, if necessary, to the upper mark on dipstick. Consult
the Engine Operation Manual for the type and viscosity grade of
the engine oil.
3. Check the level of the compressor oil. The pointer of oil level
gauge (Fig. 2.3, OLG) should register in the green range. Add oil
if necessary. See section 4.3 for the oil to be used.
Before removing oil filler plug (Fig. 2.3, FP), ensure that
the pressure is released by opening an air outlet valve.
Fig. 3.9
Lifting eye
When lifting the compressor, the hoist has to be placed in such a way
that the compressor, which must be placed level, will be lifted
vertically. Keep lifting acceleration and retardation within safe
limits.
Use the lifting eye after opening the small door (1).
Lifting acceleration and retardation must be kept
within safe limits (max. 2g).
Helicopter lifting is not allowed.
Lifting is not allowed when the unit is running.
The anti-frost device consist of a manualy operated by-pass valve (1)
on the oil cooler to prevent freezing of the pneumatic tools at low
ambient temperatures (partial by-pass).
As soon as the ambient temperature drops below 20° C it is
recommended to open the valve and by-pass the oil cooler. The outlet
air temperature will increase with 13-16° C and condensation in the
air will be reduced.
It is also recommend to use the by-pass valve in case the compressor
is used at partial load for a long time.
1
40
Anti-frost device
5. In case of start up of the unit, after running out of fuel, pump up
the fuel manually with the fuel hand pump before starting.
6. Drain any water and sediment from the fuel filter until clean fuel
flows from the drain cock.
7. Drain leaking fluid from the frame.
8. Press vacuator valves (Fig. 2.3, VV) of the air filter to remove
dust.
9. Check the air filter vacuum indicators (Fig. 2.3, VI). If the yellow
piston reaches the red marked service range, replace the filter
element. Reset the indicator by pushing the reset button.
10. Open air outlet valve to allow air flow to the atmosphere.
3.1.6 ANTI-FROST DEVICE (OPTION)
Fig. 3.10
4. Check that the fuel tank contains sufficient fuel. Top up, if
necessary. Consult the Engine Operation Manual for the type of
fuel.
Instruction Manual
3.2.2 STARTING
PROCEDURE (WITH COLD START; OPTION)
P1
P1
F1
PG
H1
H2
S1
S4
S6
Fig. 3.11
PG
Hourmeter
Circuit breaker button
Working pressure gauge
Temperature alarm lamp (red)
General alarm lamp (red)
Start switch
Lamp test button
Cold start button
H1 F1
H2
S1
S4
0 1 2 3
S6
Control panel (with cold start; option)
The control panel indicates receiver pressure (PG) and
accumulated operating hours (P1).
Before starting open the air outlet valve(s) (Fig. 2.3, AOV) and push
circuit breaker button (F1) once (open hood first). To preheat if
necessary, first push the cold start button S6 for a short period.
A
Fig. 3.12
B
Positions of circuit breaker button
Circuit breaker button should now be in position B.
The circuit breaker button is a protection against
unintended starting of the compressor.
Fig. 3.13
Starting procedure
1. To start, turn start switch S1 clockwise to position 1, lamp H2
(general alarm lamp) will go on.
2. Check correct operation of alarm lamps H1 and H2 by pushing
lamp test button S4. Both alarm lamps (red) should go on.
3. Turn start switch S1 further clockwise 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 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.
4. The start switch automatically springs back to position 1.
Lamp H1 only will go on when the compressor outlet
temperature is too high.
5. Close the air outlet valve(s) (Fig. 2.3, AOV).
41
Instruction Manual
3.2.3 STARTING
PROCEDURE (WITHOUT COLD START)
P1
P1
F1
PG
H1
H2
S1
S4
Fig. 3.14
PG
Hourmeter
Circuit breaker button
Working pressure gauge
Temperature alarm lamp (red)
General alarm lamp (red)
Start switch
Lamp test button
H1 F1
H2
S1
0 1 2 3
S4
Control panel (without cold start)
The control panel indicates receiver pressure (PG) and
accumulated operating hours (P1).
Before starting open the air outlet valve(s) (Fig. 2.3, AOV) and push
circuit breaker button (F1) once (open hood first).
A
Fig. 3.15
B
Positions of circuit breaker button
Circuit breaker button should now be in position B.
The circuit breaker button is a protection against
unintended starting of the compressor.
Fig. 3.16
Starting procedure
1. To start, turn start switch S1 clockwise to position 1, lamp H2
(general alarm lamp) will go on.
2. Check correct operation of alarm lamps H1 and H2 by pushing
lamp test button S4. Both alarm lamps (red) should go on.
3. Turn start switch S1 further clockwise 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 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.
42
4. The start switch automatically springs back to position 1.
Lamp H1 only will go on when the compressor outlet
temperature is too high.
5. Close the air outlet valve(s) (Fig. 2.3, AOV).
Instruction Manual
3.2.4 DURING
3.2.6 FAULT
OPERATION
When the engine is running, the air outlet valves (ball
valves) must always be put in a fully opened or fully
closed position.
–
A fault which occurs with the engine, either: oil 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, it
can be determined what it was that caused the engine to fail: 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 will also switch off the group immediately. Both
control lamps H1 and H2 will light up. Both control lamps will
remain on until the group has been restarted (start switch to
position 3) or the contact is turned off (start switch to position 0);
also when, due to cooling off, the thermocontact has closed again
(= memory function).
The hood must be closed during operation and may be
opened for short periods only.
Regularly carry out following checks:
1. That the regulating valve (RV) is correctly adjusted, i.e. starts
decreasing the engine speed when reaching the preset working
pressure in the receiver.
SITUATIONS AND PROTECTIVE DEVICES:
2. Check the air filter vacuum indicator (VI - Fig. 2.3). If the yellow
piston reaches the red marked service range, replace the filter
element. Reset the indicator by pushing the reset button.
3. On compressors with aftercooler, check that the automatic drain
of the water separator is operative without air leakage.
3.2.5 STOPPING
PROCEDURE
3 min
Fig. 3.17
Stopping procedure
1. Close the air outlet valves (Fig. 2.3, AOV).
2. Run unloaded for 3 minutes.
3. Turn the start switch S1 counterclockwise (CCW) to position 0.
4. Push the circuit breaker button (F1) once (open hood first).
A
Fig. 3.18
B
Positions of circuit breaker button
Circuit breaker button should now be in position A.
43
Instruction Manual
3.3
FUNCTION
OF GENERATOR (OPTION)
3.3.1 FUNCTION
OF GENERATOR DDG 110V
WITHOUT AUTOMATIC CONTROL SYSTEM
FUNCTIONAL DESCRIPTION
-
Start the unit in accordance with the normal procedure (see section
3.2). Let the motor warm up until it reaches operational temperature.
Turn the green switch S7 to position 1.
The normal control system is switched off and the motor speed
increases to reach the maximum.
The green lamp H3 in the switch S7 is activated, showing that sockets
X1, X2 and X3 are under tension.
The generator can be switched off by turning the green switch S7 to
position 0.
X1
Fig. 3.19
H3
S7
X1
X2
X3
GND
X2
X3
H3/S7
GND
Control panel (generator)
Lamp (green, power ON)
Switch (generator - compressor)
Socket 110 V/ 32 A
Socket 110 V/ 16 A
Socket 110 V/ 16 A
Terminal earth cable
min 400
Fig. 3.21
Q1
Q2
Q3
Q4
Generator control box
Main circuit breaker 2-pole
Circuit breaker 2-pole
Circuit breaker 2-pole
Circuit breaker 2-pole
Before connecting an electrical device, always check the
data listed on the rating plate.
Fig. 3.20
Earth pin
Before switching on the generator, always place the
earth pin in position. Check the cable connection
between earth pin and the GND-terminal on the unit.
44
Fault situations and protective devices:
–
When switching on the generator by means of the switch S7,
there is no voltage available at the sockets.
Open the hood and check if the circuit breakers are down.
If so, put them up (switch them on). If the circuit breakers are up,
it can be indicative of a serious electrical fault.
–
When the electrical device is connected, the circuit breakers
switch always off. This indicates a fault in the electrical device.
Instruction Manual
3.3.2 FUNCTION
OF GENERATOR DDG 110V WITH
AUTOMATIC CONTROL SYSTEM (OPTION) FUNCTIONAL DESCRIPTION
Operation with automatic control switch S8 “OFF”
–
Switch generator main switch S7 “ON”.
–
Generator is disconnected from socket.
–
Engine reaches nominal speed.
–
Generator is re-connected after 4 secs.
–
Power is now available until the generator main switch S7 is
turned “OFF”.
Operation with automatic control switch S8 “ON”
X1
Fig. 3.22
H3
S7
H4
S8
X1
X2
X3
GND
X2
X3
H4/S8
H3/S7
GND
Control panel (generator)
Lamp (green, power ON)
Switch (generator - compressor)
Lamp automatic control system
Switch automatic control system
Socket 110 V/ 32 A
Socket 110 V/ 16 A
Socket 110 V/ 16 A
Terminal earth cable
–
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 routine is repeated from step 2.
As soon as the generator is switched 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 safety mechanism to protect generator and engine
below nominal speed.
Fig. 3.24
Main circuit breaker 2-pole
Circuit breaker 2-pole
Circuit breaker 2-pole
Circuit breaker 2-pole
min 400
Q1
Q2
Q3
Q4
Generator control box
Before connecting an electrical device, always check the
data listed on the rating plate.
Fig. 3.23
Earth pin
Fault situations and protective devices:
–
When switching on the generator by means of the switch S7,
there is no voltage available at the sockets.
Open the hood and check if the circuit breakers are down.
If so, put them up (switch them on). If the circuit breakers are up,
it can be indicative of a serious electrical fault.
–
When the electrical device is connected, the circuit breakers
switch always off. This indicates a fault in the electrical device.
Before switching on the generator, always place the
earth pin in position. Check the cable connection
between earth pin and the GND-terminal on the unit.
45
Instruction Manual
3.3.3 FUNCTION OF GENERATOR DDG 230/400V
AND 230V - 3PH WITHOUT AUTOMATIC
CONTROL SYSTEM - FUNCTIONAL DESCRIPTION
X1.1
Fig. 3.25
X1.2
X1.3
H3/S7
GND
Control panel (generator)
Generator DDG 230/400V:
S7
Switch
H3
Lamp (green)
X1.1 Socket 400 V/ 16A
X1.2 Socket 230 V/ 16 A*
X1.3 Socket 230 V/ 16 A
GND Terminal earth cable
Generator DDG 230V:
S7
Switch
H3
Lamp (green)
X1.1 Socket 230 V/ 16A**
X1.2 Socket 230 V/ 16 A
X1.3 Socket 230 V/ 16 A
GND Terminal earth cable
*
For 6 kVA.
For 12.5 kVA: Socket 400V / 16A.
Fig. 3.26
Generator DDG 230/400V:
Q1
Main circuit breaker 4-pole + shunt trip coil
K6
Insulation monitoring relay
Generator DDG 230V:
Q1
Main circuit breaker 3-pole + shunt trip coil
Q2
Circuit breaker 2-pole (for 12.5 kVA only)
K6
Insulation monitoring relay
Before connecting an electrical device, always check the
data listed on the rating plate.
Fault situations and protective devices:
–
When switching on the generator by means of the switch S7,
there is no voltage available at the sockets. Open the hood and
check if the circuit breakers are up. If the circuit breakers are
down, put them up (switch them on). Circuit breakers in the up
position can be indicative of a serious electrical fault.
–
When the electrical device is connected, the circuit breakers
always switch off. This indicates a fault in the electrical device.
–
When the yellow LED on the insulation monitoring relay K6 is
activated, it means that a serious insulation fault has occured.
Reset by first switching off the engine, then restart it.
–
The insulation monitoring relay K6 must be adjusted to 10 kΩ.
This adjustment may not be changed.
–
The thermal contact S6 closes when the temperature in the
generator becomes too high.
** For 6 kVA.
For 12.5 kVA: socket 230V / 32A.
Start the unit in accordance with the normal procedure (see section
3.2). Let the motor warm up until it reaches operational temperature.
Turn the green switch S7 to position 1.
The normal control system is switched off and the engine speed
increases to reach the maximum.
The green lamp H3 in the switch S7 is activated, showing that sockets
X1.1, X1.2 and X1.3 are under tension.
The generator can be switched off by turning the green switch S7 to
position 0.
46
Generator control box
Instruction Manual
3.3.4 FUNCTION OF GENERATOR DDG 230/400V
AND 230V - 3PH WITH AUTOMATIC CONTROL
SYSTEM (OPTION) - FUNCTIONAL DESCRIPTION
X1.1
Fig. 3.27
X1.2
X1.3
H4/S8
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 routine is repeated from step 2.
H3/S7 GND
Control panel (generator)
Generator DDG 230/400V:
H3
Lamp (green, power ON)
S7
Switch (generator - compressor)
H4
Lamp automatic control system
S8
Switch automatic control system
X1.1 Socket 400 V/ 16A
X1.2 Socket 230 V/ 16 A*
X1.3 Socket 230 V/ 16 A
GND Terminal earth cable
Generator DDG 230V:
H3
Lamp (green, power ON)
S7
Switch (generator - compressor)
H4
Lamp automatic control system
S8
Switch automatic control system
X1.1 Socket 230 V/ 16A**
X1.2 Socket 230 V/ 16 A
X1.3 Socket 230 V/ 16 A
GND Terminal earth cable
*
Fig. 3.28
Generator DDG 230/400V:
Q1
Main circuit breaker 4-pole + shunt trip coil
K6
Insulation monitoring relay
Generator DDG 230V:
Q1
Main circuit breaker 3-pole + shunt trip coil
Q2
Circuit breaker 2-pole (for 12.5 kVA only)
K6
Insulation monitoring relay
Before connecting an electrical device, always check the
data listed on the rating plate.
For 6 kVA.
For 12.5 kVA: Socket 400V / 16A.
** For 6 kVA.
For 12.5 kVA: socket 230V / 32A.
As soon as the generator is switched 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 safety mechanism to protect generator and engine
below nominal speed.
Operation with automatic control switch S8 “OFF”
–
Switch generator main switch S7 “ON”.
–
Generator is disconnected from socket.
–
Engine reaches nominal speed.
–
Generator is re-connected after 4 secs.
–
Power is now available until the generator main switch S7 is
turned “OFF”.
Generator control box
Fault situations and protective devices:
–
When switching on the generator by means of the switch S7,
there is no voltage available at the sockets. Open the hood and
check if the circuit breakers are up. If the circuit breakers are
down, put them up (switch them on). Circuit breakers in the up
position can be indicative of a serious electrical fault.
–
When the electrical device is connected, the circuit breakers
always switch off. This indicates a fault in the electrical device.
–
When the yellow LED on the insulation monitoring relay K6 is
activated, it means that a serious insulation fault has occured.
Reset by first switching off the engine, then restart it.
–
The insulation monitoring relay K6 must be adjusted to 10 kΩ.
This adjustment may not be changed.
–
The thermal contact S6 closes when the temperature in the
generator becomes too high.
47
Instruction Manual
4.
MAINTENANCE
4.1
USE
OF SERVICE PAKS
Service Paks include all genuine parts needed for normal
maintenance of both compressor and engine.
Service Paks minimize downtime and keep your maintenance budget
low.
Order Service Paks at your local Atlas Copco dealer.
4.2
PREVENTIVE MAINTENANCE SCHEDULE FOR THE
COMPRESSOR
The schedule contains a summary of the maintenance instructions.
Read the respective section before taking maintenance measures.
When servicing, replace all disengaged packings, e.g. gaskets,
O-rings, washers.
For engine maintenance refer to Engine Operation Manual.
The maintenance schedule has to be seen as a guideline for units
operating in a dusty environment typical to compressor applications.
Maintenance schedule can be adapted depending on application,
environment and quality of maintenance.
Maintenance schedule
Daily
Service pak XAS 67 DD - XAS 130 DD7, XATS 67 DD - XATS 125 DD7,
XAS 77 DD - XAS 150 DD7
Service pak XAS 97 DD - XAS 185 DD7
Engine oil level
Compressor oil level
Fuel level
Air filter vacuator valves
Fuel filter water drain
Air intake vacuum indicators
For spillage free, drain water out of frame
General conditions (leaks, damaged parts, loose bolts, trouble in previous operation)
During operation (meters and lamps, noise, colour exhaust fumes)
Electrolyte level and terminals of battery
Tyre pressure
Leaks in air-, oil- or fuel system
Oil coolers
Engine minimum and maximum speeds
Torque of wheel nuts
Brake system (if installed)
Safety valve
Door hinges
Coupling head and all its moving parts / shaft
Joints of height adjustment adjustable towbar
Shutdown switches
Pressure drop over separator element (2)
Fan V-belt (3)
Fuel tank
Compressor oil
Compressor oil filter
Air filter element (1)
Safety cartridges (1) (option)
Engine oil (3) (4) (5)
Engine oil filter (3)
Fuel filter (3) (6) (8)
Engine inlet and outlet valves (3)
PD / QD filter (option)
(1) More frequently when operating in a dusty environment.
(2) Replace the element after 1000 running hours or when the pressure
drop exceeds 0.8 bar.
(3) Refer to the Deutz operation manual.
(4) 500 hours only valid when using PAROIL SAE 15 W 40.
(5) Also drain engine oil from engine oil cooler
(see Fig. 2.2 DPEC = Drain plug engine oil cooler).
Yearly
or every 500 hours
2912 4392 06
–
2912 4393 06
Check
Check
Check
Check
Check
Check
Clean
Check
Check
Check/Adjust
Test
Grease
Grease
Grease
Check
Replace
Adjust
Clean
Change
Replace
Replace
Replace
Change
Replace
Replace
Adjust (7)
Replace
Check
Check
Check/Fill
Empty
Drain
Check
Check/Drain
Check
Check
Check
Check
Check/Adjust
Check
(6) In case of poor fuel quality, replace fuel filter more frequently.
(7) The valves need to be adjusted for the first time before 500 running
hours.
(8) Option, additional fuel filter: heavy duty filter element
2914 8092 00, to be ordered separately.
Keep the bolts of the housing, the lifting eye, the towbar and the axle securely tightened.
Refer to section 8 ’Technical specifications’ and section 3.1.4 for the torque values.
48
Initially
50 hours after
initial start-up
–
Instruction Manual
4.3
LUBRICATION
OILS
High-quality, mineral, hydraulic or synthesized hydrocarbon oil with
rust and oxidation inhibitors and anti-foam and anti-wear properties
is recommended. The viscosity grade should correspond to the
ambient temperature and ISO 3448, as follows:
Type of lubricant
Compressor**
Engine*
between 30°C and 40°C
PAROIL S
PAROIL 15W40
between 30°C and -5°C
PAROIL M
PAROIL S
PAROIL 15W40
between -5°C and -20°C
PAROIL S
PAROIL 5W40
PAROIL from Atlas Copco is the ONLY oil tested and approved for
use in all engines built into Atlas Copco compressors and generators.
Extensive laboratory and field endurance tests on Atlas Copco
equipment have proven PAROIL to match all lubrication demands in
varied conditions. It meets stringent quality control specifications to
ensure your equipment will run smoothly and reliably.
The quality lubricant additives in PAROIL allow for extended oil
change intervals without any loss in performance or longevity.
Mineral compressor oil PAROIL M:
- 5 liter can:
order number 1615 5947 00
- 20 liter can:
order number 1615 5948 00
- 210 liter barrel:
order number 1615 5949 00
Synthetic compressor oil PAROIL S:
- 5 liter can:
order number 1615 5950 01
- 20 liter can:
order number 1615 5951 01
- 210 liter barrel:
order number 1615 5952 01
Mineral engine oil PAROIL 15W40:
- 5 liter can:
order number 1615 5953 00
- 20 liter can:
order number 1615 5954 00
- 210 liter barrel:
order number 1615 5955 00
Synthetic engine oil PAROIL 5W40:
- 5 liter can:
order number 1604 6060 01
- 20 liter can:
order number 1604 6059 01
Never mix synthetic with mineral oil.
PAROIL provides wear protection under extreme conditions.
Powerful oxidation resistance, high chemical stability and rustinhibiting additives help reduce corrosion, even within engines left
idle for extended periods.
Remark:
When changing from mineral to synthetic oil (or the
other way around), you will need to do an extra rinse:
After doing the complete change procedure to synthetic
oil, run the unit for a few minutes to allow good and
complete circulation of the synthetic oil. Then drain the
synthetic oil again and fill again with new synthetic oil.
To set correct oil levels, proceed as in normal
instruction.
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 your filter 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 sulphur diesel for lower oil and
fuel consumption.
PAROIL 5W40 is a Synthetic ultra high performance diesel engine oil
with a high viscosity- index. Atlas Copco PAROIL 5W40 is designed
to provide excellent lubrication from start-up in temperatures as low
as -20°C.
PAROIL 15W40 is a mineral based high performance diesel engine oil
with a high viscosity- index. Atlas Copco PAROIL 15W40 is designed
to provide a high level of performance and protection in 'standard'
ambient conditions as from -5°C.
4.4
OIL
LEVEL CHECK
Never mix oils of different brands or types.
Use only non-toxic oils where there is a risk of inhaling
delivered air.
4.4.1 CHECK
ENGINE OIL LEVEL
Consult also the Engine Operation Manual for the oil specifications,
viscosity recommendations and oil change intervals.
See schedule 4.2.
Check engine oil level according to the instructions in the Engine
Operation Manual and top up with oil if necessary.
*
If you want to use another brand of oil, consult the
engine instruction manual.
**
It is strongly recommended to use Atlas Copco branded
lubrication oils for the compressor. If you want to use
another brands of oil, consult Atlas Copco.
49
Instruction Manual
4.4.2 CHECK
COMPRESSOR OIL LEVEL
4.5.1 ENGINE
OIL AND OIL FILTER CHANGE
See section 4.2.
2
4.5.2 COMPRESSOR
OIL AND OIL FILTER CHANGE
The quality and the temperature of the oil determine the oil change
interval.
1
The prescribed interval (see section 4.2) is based on an oil
temperature of up to 100 °C and normal operating conditions.
When operating in high ambient temperatures, in very dusty or high
humidity conditions, it is recommended to change the oil more
frequently.
In this case, contact Atlas Copco.
1. Run the compressor until warm. Close the outlet valve(s) (5) and
stop the compressor. Wait until the pressure is released through
the automatic blow-down valve. Unscrew the oil filler plug (2)
one turn. This uncovers a vent hole, which permits any pressure
in the system to escape.
3
Fig. 4.1
Check compressor oil level
With the unit standing level, check the level of the compressor oil.
The pointer of the oil level gauge (1) must register in the upper
extremity of the green range. Add oil if necessary.
4.5
2. Drain the oil by removing all relevant drain plugs. Drain plugs
are located at the air receiver and compressor element. Catch the
oil in a drain pan. Screw out the filler plug to speed up draining.
Tighten the plugs after draining.
3. Remove the oil filter (3), e.g. by means of a special tool. Catch
the oil in a drain pan.
Before removing the oil filler plug (2), ensure that the
pressure is released by opening an air outlet valve (3).
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.
OIL
5. Fill the air receiver until the pointer of the oil level gauge (4)
registers in the upper extremity of the green range. Take care that
no dirt drops into the system. Reinstall and tighten the filler plug.
AND OIL FILTER CHANGE
1
3
2
4
6. Run the unit at no load for a few minutes to circulate the oil and
to evacuate the air trapped in the oil system.
7. Stop the compressor. Let the oil settle for a few minutes. Check
that the pressure is released by opening an air outlet valve (5).
Screw out filler plug (2) and add oil until the pointer of the oil
level gauge (4) again registers in the upper extremity of the green
range. Reinstall and tighten the filler plug.
Never add more oil. Overfilling results in oil
consumption.
5
Fig. 4.2
50
Oil filters
Instruction Manual
4.6
CLEANING
4.7
COOLERS
CLEANING
FUEL TANK
Observe all relevant environmental and safety
precautions.
1
2
Place an appropriate drain pan under the drainplug (Fig. 2.2, DPEC)
of the fuel tank.
Remove the drain plug.
Lift the towbar (Fig. 2.2, TB) and tilt the compressor approx. 15° to
remove all fuel, dirt and water.
Clean the fuel tank and fix the drain plug handtight.
Never leave spilled liquids such as fuel, oil, water and
cleansing agents in or around the compressor.
Refill the fuel tank with clean fuel.
Fig. 4.3
Compressor oil cooler (1) and engine oil cooler (2)
Keep the oil-coolers (1) and (2) clean to maintain the cooling
efficiency.
The fan side surface of compressor- and engine oil cooler is
accessible by removing the fan cowl upper part.
The opposite surface of compressor- and engine oil cooler is
accessible by removing the centre part of the front baffles.
Remove any dirt from the coolers with a fibre brush.
Never use a wire brush or metal objects.
Steam cleaning in combination with a cleansing agent may be
applied in order to remove also the dirt sticking to the cooler fins.
To avoid damaging the coolers, angle between jet and
coolers should be approx. 90 °.
Protect the electrical and controlling equipment, air
filters, etc. against penetration of moisture.
Close the service door(s).
Never leave spilled liquids such as fuel, oil, water and
cleansing agents in or around the compressor.
4.8
CLEANING
HARDHAT
Optimal cleaning of the HardHat can be obtained by applying high
pressure cleaning in combination with liquid soap.
4.9
BATTERY
CARE
Before handling batteries, read the relevant safety
precautions and act accordingly.
If the battery is still dry, it must be activated as described in section
4.9.2.
The battery must be in operation within 2 months from being
activated; if not, it needs to be recharged first.
4.9.1 ELECTROLYTE
Read the safety instructions carefully.
Electrolyte in batteries is a sulphuric acid solution in distilled water.
The solution must be made up before being introduced into the
battery.
51
Instruction Manual
4.9.2 ACTIVATING
A DRY-CHARGED BATTERY
4.11 STORAGE
–
Take out the battery.
Run the compressor regularly, e.g. twice a week, until warm.
–
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 15 mm
above the plates, or to the level marked on the battery.
Load and unload the compressor a few times to operate the
unloading and regulating components. Close the air outlet valves
after stopping.
–
Rock the battery a few times so that possible air bubbles can
escape; wait 10 minutes and check the level in each cell once
more; if required, add electrolyte.
–
Refit plugs and/or cover.
–
Place the battery in the compressor.
4.9.3 RECHARGING
A BATTERY
Before and after charging a battery, always check the electrolyte
level in each cell; if required, top up with distilled water only. When
charging batteries, each cell must be open, i.e. plugs and/or cover
removed.
If the compressor is going to be stored without running
from time to time, protective measures must be taken.
4.12 SERVICE
PAKS
A Service Pak is a collection of parts to be used for a specific
maintenance measure.
It guarantees that all necessary parts are replaced at the same time
keeping down time to a minimum.
The order number of the Service Paks are listed in the Atlas Copco
Parts List (ASL).
Use a commercial automatic battery charger according
to its manufacturer’s instructions.
Apply with preference the slow charging method and adjust the
charge current according to the following rule of thumb:
battery capacity in Ah divided by 20 gives safe charging current in
Amp.
4.13 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.
4.9.4 BATTERY
MAINTENANCE
–
Keep the battery clean and dry.
–
Keep the electrolyte level at 10 to 15 mm above the plates or at
the indicated level; top up with distilled water only.
–
Keep the terminals and clamps tight, clean, and lightely covered
with petroleum jelly.
The order numbers of the Service Kits are listed in the Atlas Copco
Parts List (ASL).
Contact Atlas Copco.
4.14 COMPRESSOR
4.10 CHANGING
TYRES
When changing a tyre, please observe that the arrow on the tyre in
top position points in the driving direction (to the towbar).
ELEMENT OVERHAUL
When a compressor element is due for overhaul, it is recommended
to have it done by Atlas Copco. This guarantees the use of genuine
parts and correct tools with care and precision.
4.15 LIABILITY
The manufacturer does not accept any liability for any damage
arising from the use of non-original parts and for modifications,
additions or conversions made without the manufacturer’s approval
in writing.
Fig. 4.4
52
Position of arrow on tyre
Instruction Manual
5.
ADJUSTMENTS AND SERVICING PROCEDURES
5.1
ADJUSTMENT
OF THE CONTINUOUS REGULATING SYSTEM
Without generator
Fig. 5.1
The working pressure is determined by the tension of the spring in
the regulating valve (RV). This tension can be increased to raise the
pressure and decreased to lower it by turning the adjusting wheel
clockwise and anti-clockwise respectively.To adjust the normal
working pressure, proceed as follows:
With generator
1. Start and warm up the engine (see section 3.2).
2. With the outlet valves (AOV) closed, pull out the knob, adjust the
regulating valve (RV) until a pressure of X bar(e) is reached (see
table).
3. Check the minimum speed of the engine. Adjust minimum speed
stop screw if necessary.
4. Open an outlet valve (AOV) just enough to let the engine (E) run
at maximum speed. The working pressure must be Y bar(e) (see
table); adjust if necessary with regulating valve (RV).
5. Check the engine maximum speed. Adjust the maximum speed
by means of adjusting eccentric nut on top of speed regulator
(SR).
6. Close the outlet valves (AOV), check that the pressure is between
Z1 and Z2 bar(e) (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.
Table
X
bar(e)
Y
bar(e)
Z1 – Z2
bar(e) bar(e)
XAS 67 DD XAS 130 DD7
8.5
7
8.3 – 8.7
XATS 67 DD XATS 125 DD7
11.8
10.3
11.6 – 12
XAS 77 DD XAS 150 DD7
8.5
7
8.3 – 8.7
XAS 97 DD XAS 185 DD7
8.5
7
8.3 – 8.7
53
Instruction Manual
5.2
AIR
FILTER ENGINE/COMPRESSOR
5.2.1 MAIN
5.2.3 CLEANING
PARTS
THE DUST TRAP
To remove dust from the dust trap pinch the vacuator valve (6)
several times.
1
5.2.4 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 (Fig. 5.3).
8
6
2
Fig. 5.2
1
2
3
4
5
6
3
4
5
7
Air filter
Snap clips
Dust trap
Safety cartridge (option)
Filter element
Filter housing
Vacuator valve
9
Fig. 5.3
7
8
9
Vacuum indicator
Air filter contamination indicator
Reset button
Yellow indicator
5.2.2 RECOMMENDATIONS
The Atlas Copco air filters are specially designed for
the application. The use of non-genuine air filters may
lead to severe damage of engine and/or compressor
element.
5.3
AIR
RECEIVER
The air receiver is tested according to official standards. Regularly
have inspections carried out in conformity with local regulations.
Never run the compressor without air filter element.
New elements must also be inspected for tears or punctures before
installation.
5.4
Discard the element (4) when damaged.
In heavy duty applications it is recommended to install a safety
cartridge which can be ordered with
XAS 67 DD - XAS 130 DD7, XATS 67 DD - XATS 125 DD7,
XAS 77 DD - XAS 150 DD7 - part no.: 2914 9309 00
XAS 97 DD - XAS 185 DD7 - part no.: 2914 9311 00
A dirty safety cartridge (3) is an indication of a malfunctioning air
filter element. Replace the element and the safety cartridge in this
case.
The safety cartridge cannot be cleaned.
54
SAFETY
VALVE
All adjustments or repairs are to be done by an
authorized representative of the valve supplier.
Following checks must be carried out:
–
a check of the opening of the lifting gear, twice a year.
This can be done by screwing the cap of the valve anti-clockwise.
–
a check of the set pressure once a year according to the local
regulations. This check cannot be done on the machine and must
be carried out on a proper test bench.
Instruction Manual
5.5
FUEL
5.6.1 BRAKE
SYSTEM
SHOE ADJUSTMENT
Check the thickness of the brake lining. Remove both black plastic
plugs (5), one on each wheel. When the brake lining has been worn
to a thickness of 2 mm or less, the brake shoes have to be replaced.
After inspection and/or replacement re-insert both plugs.
4
2
5
Fig. 5.5
1
Fig. 5.4
Fuel filter
1
2
3
4
5
1
3
Brake shoe adjustment
Adjusting bolt
Axle
Brake cable
Pin ∅ 4 mm
Plug
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 has been restarted.
5.6
BRAKE (=
OPTION) ADJUSTMENT
Before jacking up the compressor, connect it to a towing
vehicle or attach a weight of minimum 50 kg to the
towbar.
Brake shoe adjustment re-establishes the brake lining-to-drum
clearance and compensates for lining wear.
Lift and support the compressor. Make sure that all brakes are off
(overrunbrake and hand brake lever). The brake cables must be free
from tension. Lock the swivel cams of the wheel brake from the
outside by means of a pin ∅ 4 mm (4) through the hole as shown in
Fig. 5.5.
Turn the adjusting bolt (1) clockwise with a wrench till the wheel
locks up. Center the brake shoes by actuating the parking brake
several times.
Turn the adjusting bolt anti-clockwise until the wheel is running free
in direction of travel (approx. 1 full turn of the adjusting bolt).
Check the position of the equalizer (Fig. 5.7, 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 (Fig. 5.7, 2).
55
Instruction Manual
5.6.2 TEST
PROCEDURE OF BRAKE CABLE
ADJUSTMENT
5.6.3 BRAKE
CABLE ADJUSTMENT
1
1. Check if the towing eye rod of the overrun brake mechanism is
in the outmost position.
6
4
2
2. Check if the adjustable towbar (= option) is in the actual towing
position.
3. Apply the hand brake lever.
4. Push the compressor a few centimeters backwards so that the
brake lever is automatically pulled further up.
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 Fig. 5.6 A,B,C,D.
1
Fig. 5.7
1
2
A. Adjusted correctly
1
2
3
4
5
6
2
3
4
2
5
Brake cable arrangement
Brake cable
Lock nut
Adjusting nut
Brake cable nut
Main brake cable
Equalizer
1. With the towing eye pulled out in the outmost position and the
hand brake lever in the downward position (Fig. 5.8), loosen the
lock nuts (Fig. 5.7, 2). Turn adjusting nuts and brake cable nuts
(Fig. 5.7, 4) clockwise until there is no slack in the brake
mechanism.
The equalizer (Fig. 5.7, 6) must remain perpendicular to main
brake cable (Fig. 5.7, 5).
2. Apply the hand brake lever several times and repeat the
adjustment. Tighten the nuts with their lock nuts (Fig. 5.7, 2).
Remove the jack and the blocks.
3. Road test the compressor and brake several times. Check brake
shoe and brake cable adjustment and if necessary adjust.
B. Acceptable
Fig. 5.8
Hand brake lever downward - brake not operated
C. Too loose;
adjust brake cables
(Section 5.6.3)
5.7
DRIVE BELT (XAS 67 DD - XAS 130 DD7,
XATS 67 DD - XATS 125 DD7)
Never retense or reuse the drive belt between engine
and compressor.
Consult Atlas Copco for replacement of drive belt.
D. Too tight;
adjust brake cables
(Section 5.6.3)
Fig. 5.6
56
Correct and wrong position of markings
Instruction Manual
6.
PROBLEM SOLVING
It is assumed that the engine is in good condition and that there is
adequate fuel flow to the filter and injection equipment.
6.1
ALTERNATOR
PRECAUTIONS
1. Never reverse the polarity of the battery or the alternator.
An electrical fault must be traced by an electrician.
Make sure that the wires are not damaged and that they are clamped
tight to their terminals.
If it’s not possible to solve the problem with this
problem solving table, please consult Atlas Copco.
2. Never break any alternator or battery connections while the
engine is running.
3. When recharging the battery, disconnect it from the alternator.
Before using booster cables to start the engine, be sure of the
polarity and connect the batteries correctly.
4. Never operate the engine without the main or voltage sensing
cables connected in the circuit.
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.
a. Check electrolyte level and charge battery. If
no cells are shorted and battery is discharged,
trace cause and correct.
b. Check and correct if necessary.
c. Check wiring and connections; correct if
necessary.
d. With (S1) switched in ”I”, check voltage
between earth and respectively each of the
terminals of (S1).Voltage must register at each
of the terminals; if not, replace (S1).
e. Replace circuit breaker.
b. Loose battery cable(s) or oxidised terminals.
c. Loose connection or damaged wiring.
d. Contact switch (S1) defective.
e. Circuit breaker (F1) defective.
2. General alarm lamp (H2)
does not light up when
switching (S1) to „ I“; lamp
(H1) lights up when applying
lamptest.
a. Lamp (H2) blown.
b. Alternator (A)/regulator defective.
a. Replace lamp.
b. Disconnect the wire from alternator terminal
D+ and connect it to terminal D–. If (H1) lights
up, replace the alternator; if not, test (S1); see
remedy 1d.
3. Temperature alarm lamp (H1)
does not light up when
switching (S1) to „ I“ and
applying lamp test.
a. Lamp (H1) blown
b. See fault 1d.
a. Replace lamp.
b. See 1d.
4. Starter motor (S) does not
crank engine (E) after
switching startbutton (S1) to
”
”.
a. Low battery output.
a. See remedy 1a.
5. Starter motor cranks engine
when switching start switch
(S1) to ”
”, but engine
does not fire.
a. Contact switch (S1) defective.
b. Fuel solenoid (Y1) defective.
c. Low battery output.
a. See remedy 1d.
b. Check solenoid and its valve, correct or
replace if necessary.
c. See 1a.
6. Engine fires, but general
alarm lamp (H2) remains
alight; engine stops when
releasing start switch (S1).
a. Alternator drive belt broken or slipping.
b. Alternator (A)/regulator defective.
a. Check and correct if necessary.
b. Have assembly repaired.
7. Engine is running, but shuts
down immediately after (S1)
has been released.
a. Contact switch (S1) released too soon.
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.
a. Insufficient engine oil pressure or too high engine
oil temperature.
b. Engine oil pressure switch (S3), or compressor
temperature switch (S5) defective.
c. Relay (K1) defective.
a. Stop at once, consult Engine Operation
Manual.
b. Stop at once, test switches, replace as
necessary.
c. Replace (K1).
8. General alarm lamp (H2)
remains alight for over 5
seconds after starting.
b. Insufficient engine oil pressure.
57
Instruction Manual
Problem
Possible faults
Corrective actions
9. Hourmeter (P1) does not
count running time.
a. Hourmeter (P1) defective.
a. Replace.
10. Compressor does not unload
and engine keeps running at
maximum speed when
closing the air outlet valves;
safety valve blows.
a. Air leaks in regulating system.
b. Regulating valve (RV) incorrectly set or defective.
a. Check and repair.
b. Adjust or repair regulating valve; see section
5.1.
c. Repair unloading valve assembly.
11. Compressor capacity or
pressure below normal.
a. Air consumption exceeds capacity of compressor.
b. Choked air filter elements (AF).
c. Unloading valve (UV) not completely open.
c. Unloading valve (UV) or its actuating piston stuck.
d. Engine does not run at max. speed.
e. Oil separator element (OS) clogged.
a. Check equipment connected.
b. Replace air filter element (AF).
c. Speed regulation cable maladjusted; see
section 5.1.
d. Check the maximum speed, service the fuel
filter.
e. Have element removed and inspected by an
Atlas Copco Service representative.
12. Working pressure rises during
operation and causes safety
valve to blow.
a. See faults 10.
b. Safety valve (SV) opens too soon.
a. See remedies 10.
b. Have safety valve adjusted;
consult Atlas Copco.
13. Excessive compressor oil
consumption. Oil mist being
discharged from air outlet
valve(s).
a. Restrictor 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.
b.
c.
d.
a.
b.
c.
d.
15. Air and oil mist expelled from
air filter after stopping.
a. Unloader valve (UV) defective.
b. Wrong oil type (without foam-retarding additives).
a. Repair valve.
b. Consult Atlas Copco.
16. Compressor overheating.
a.
b.
c.
d.
a.
b.
c.
d.
Alternator V-belt broken or slipping.
Compressor overheating.
Engine oil pressure too low.
Engine temperature too high.
Insufficient compressor cooling.
Oil cooler (OC) clogged externally.
Oil system clogged internally.
Oil level too low.
Re-tense or replace V-belt.
See condition 16.
Check lubricating system.
Check engine oil system; see Engine
Operation Manual.
Relocate compressor.
Clean cooler; see section 4.6.
Consult Atlas Copco.
See section 4.4.
XAS 67 DD - XAS 130 DD7,
XATS 67 DD - XATS 125 DD7:
17. No air output.
a. Drive belt broken.
a. See section 5.7.
18. Circuit breakers are off
(down).
a. Short circuit or overload.
b. Circuit breakers switched off.
a. Remedy fault. Switch on circuit breakers.
b. Switch on circuit breakers.
19. Green lamp H3 is
deactivated.
a. Circuit breakers are off.
b. Serious electrical fault.
a. Switch on circuit breakers.
b. Consult Atlas Copco.
20. Circuit breakers Q1 are off
(down).
a. Short circuit.
b. Temperature in generator too high.
a. Remedy fault. Switch on circuit breakers.
b. Check generator cooling.
21. Green lamp H3 is
deactivated.
a. Circuit breakers are off.
b. Serious electrical fault.
a. Switch on circuit breakers.
b. Consult Atlas Copco.
Generator DDG 110V:
Generator DDG IT 230/400V:
58
Instruction Manual
7.
AVAILABLE OPTIONS
Pressure vessel approval:
CE
ASME
Undercarriage:
Adjustable towbar with brakes
Fixed towbar with brakes
Support (without undercarriage) 1)
Simplified bumper 1)
Towing eyes:
Loose ball coupling
Towbar support:
Jockey wheel
Road lights system:
Reflectors only
Road lights system
24 V adaptor
Air quality equipment:
Aftercooler + water 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)
Inlet shutdown valve 1)
Spillage free frame
Exhaust particle filter 1)
Non return valve
Additional literature set
Fueltank with metal fillerneck
Additional fuel filter
Cold start:
Cold start – 20 °C
Generator 4):
230/400 V - 6.5 kVA
230/400 V - 6.5 kVA Automatic
230 V - 3 ph - 6.5 kVA
110 V - 6 kVA
110 V - 6 kVA Automatic
230 V - 3 ph - 12.5 kVA
230/400 V - 12.5 kVA
230/400 V - 12.5 kVA Automatic
Canopy colour:
single
double 1)
1)
Not in combination with HardHat
2)
Not on XATS 67 DD - XATS 125 DD7.
3)
In order to obtain a spare key at the local ABUS dealer, the key code card must be presented.
Please keep this card available.
4)
Only for XAS 67 DD - XAS 130 DD7 and XAS 97 DD - XAS 185 DD7 with metal canopy.
59
Instruction Manual
8.
TECHNICAL SPECIFICATIONS
8.1
TORQUE
8.1.1 FOR
VALUES
GENERAL APPLICATIONS
The following tables list the recommended torques applied for
general applications at assembly of the compressor.
For hexagon screws and nuts with strength grade 8.8
Thread size
M6
M8
M10
M12
Nm
9
23
46
80
M14
125
M16
205
For hexagon screws and nuts with strength grade 12.9
Thread size
M6
M8
M10
M12
Nm
15
39
78
135
M14
210
M16
345
8.1.2 FOR
IMPORTANT ASSEMBLIES
Assemblies
Unit
Wheel nuts
Bolts, axle/beams
Bolts, towbar/axle
Bolts, towbar/bottom
Bolts, towing eye/towbar
Bolts, lifting eye/flywheel housing
Bolts, engine/drive housing (M12)
Bolts, engine/drive housing (M14)
Bolts, compressor element/drive housing
Safety switches
Joints adjustable towbar (M24)
(M32)
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Torque values
80
80
80
80
80
205
80
125
80
35
275
375
+10/-0
+/- 10
+/- 10
+/- 10
+/- 10
+ 20
+/- 10
+/- 10
+/- 5
+/- 5
+/- 25
+/- 25
Note:
Secure the tank cap and drain plug of the fuel tank handtight.
8.2
SETTINGS
OF SHUTDOWN SWITCHES AND SAFETY VALVES
XAS 67 DD XAS 130 DD7
XATS 67 DD XATS 125 DD7
XAS 77 DD XAS 150 DD7
XAS 97 DD XAS 185 DD7
Unit
Value
Value
Value
Value
bar(e)
°C
°C
1.2
127 - 133
116 - 120
1.2
127 - 133
116 - 120
1.2
127 - 133
116 - 120
1.2
127 - 133
116 - 120
bar(e)
psi
10.5
160
14.5
210
10.5
160
10.5
160
Compressor type
Designation
Engine oil pressure
Engine oil temperature
Compressor temperature
Safety valve opening pressure
EC type
ASME type
60
Instruction Manual
8.3
COMPRESSOR/ENGINE
SPECIFICATIONS
XAS 67 DD XAS 130 DD7
Compressor type
Designation
Reference conditions
1. Absolute inlet pressure
2. Relative air humidity
3. Air inlet temperature
4. Nominal effective working
pressure
The inlet conditions are specified
at the air inlet grating outside the
canopy
Limitations
1. Minimum effective receiver
pressure
2. Maximum effective receiver
pressure, compressor unloaded
3. Maximum ambient temperature at
sealevel 6)
no aftercooler
with aftercooler
4. Minimum starting temperature
5. Minimum starting temperature,
with coldstart equipment 5)
6. Altitude capability
Unit
XAS 67 DDG - XATS 67 DD XAS 130 DD7G / XATS 125 DD7
DDG IT
Value
Value
XAS 77 DD XAS 150 DD7
XAS 97 DD XAS 185 DD7
Value
Value
Value
bar(e)
%
°C
1
0
20
1
0
20
1
0
20
1
0
20
1
0
20
bar(e)
7
7
10.3
7
7
bar(e)
2.9
3
4
3.3
4
bar(e)
8.7
8.7
11.8
8.7
9
°C
°C
°C
45
40
- 10
45
40
- 10
45
40
- 10
45
40
- 10
45
40
- 10
°C
m
- 20
- 20
- 20
See separate curves below
- 20
- 20
61
Instruction Manual
ALTITUDE
UNIT PERFORMANCE CURVES
XAS 67 DD - XAS 130 DD7
Max. allowable working pressure as a function altitude and ambient temperature.
TEMPERATURE °F
14
32
50
68
86
104
122
5000
16 405
5.0 bar(e)
73 psi
4000
13 124
3000
7.0 bar(e)
87 psi
9 843
102 psi
2000
6 562
1000
3 281
0
ALTITUDE ft
ALTITUDE m
6.0 bar(e)
0
-10
0
10
20
30
40
50
TEMPERATURE °C
ALTITUDE
UNIT PERFORMANCE CURVES
XAS 67 DDG - XAS 130 DD7G 6KVA
Max. allowable working pressure as a function altitude and ambient temperature.
TEMPERATURE °F
14
32
50
68
86
104
122
5000
16 405
4000
13 124
5.0 bar(e)
3000
58 psi
73 psi
6.0 bar(e)
87 psi
7.0 bar(e)
2000
9 843
102 psi
6 562
1000
3 281
0
0
-10
0
10
20
30
TEMPERATURE °C
62
40
50
ALTITUDE ft
ALTITUDE m
4.0 bar(e)
Instruction Manual
ALTITUDE
UNIT PERFORMANCE CURVES
XAS 67 DDG - XAS 130 DD7G 12KVA
Max. allowable working pressure as a function altitude and ambient temperature.
TEMPERATURE °F
14
32
50
68
86
104
122
5000
16 405
102 psi
4000
13 124
3000
9 843
2000
6 562
1000
3 281
0
ALTITUDE ft
ALTITUDE m
7.0 bar(e)
0
-10
0
10
20
30
40
50
TEMPERATURE °C
ALTITUDE
UNIT PERFORMANCE CURVES
XATS 67 DD - XATS 125 DD7
Max. allowable working pressure as a function altitude and ambient temperature.
TEMPERATURE °F
14
32
50
68
86
104
122
5000
16 405
7.3 bar(e)
106 psi
4000
13 124
9.3 bar(e)
3000
10.3 bar(e)
121 psi
135 psi
9 843
150 psi
2000
6 562
1000
3 281
0
ALTITUDE ft
ALTITUDE m
8.3 bar(e)
0
-10
0
10
20
30
40
50
TEMPERATURE °C
63
Instruction Manual
ALTITUDE
UNIT PERFORMANCE CURVES
XAS 77 DD - XAS 150 DD7
Max. allowable working pressure as a function altitude and ambient temperature.
TEMPERATURE °F
14
32
50
68
86
104
122
5000
16 405
4.0 bar(e)
58 psi
4000
13 124
5.0 bar(e)
3000
9 843
6.0 bar(e)
87 psi
2000
6 562
ALTITUDE ft
ALTITUDE m
73 psi
7.0 bar(e)
102 psi
1000
3 281
0
0
-10
0
10
20
30
40
50
TEMPERATURE °C
ALTITUDE
UNIT PERFORMANCE CURVES
XAS 97 DD - XAS 185 DD7
Max. allowable working pressure as a function altitude and ambient temperature.
TEMPERATURE °F
14
32
50
68
86
104
122
5000
16 405
4000
13 124
4.0 bar(e)
3000
9 843
5.0 bar(e)
73 psi
6.0 bar(e)
2000
6 562
87 psi
7.0 bar(e)
1000
3 281
102 psi
0
0
-10
0
10
20
30
TEMPERATURE °C
64
40
50
ALTITUDE ft
ALTITUDE m
58 psi
Instruction Manual
XAS 67 DD - XAS 67 DDG - XATS 67 DD XAS 130 DD7 XAS 130 DD7G/ XATS 125 DD7
DDG IT
Compressor type
Designation
Unit
Value
Value
Value
XAS 77 DD XAS 150 DD7
XAS 97 DD - XAS 97 DDG XAS 185 DD7 XAS 185 DD7G/
DDG IT
Value
Value
Value
Performance data 1)
1. Engine shaft speed, normal and
maximum
r/min
2,400
2,750
2,750
2,300
2,750
2,750
2. Engine shaft speed, compressor
unloaded
r/min
1,850
1,850
1,850
1,850
1,850
1,850
3. Engine shaft speed, generator at
maximum load
r/min
-
2,700
-
-
-
2,700
no aftercooler
l/s
62
58
58
72
89
89
with aftercooler
l/s
57
53
53
67
84
84
5. Typical oil content of compressed
mg/m3
air
<5
<5
<5
<5
<5
<5
g/h
17
20
37
17
37
37
no aftercooler
°C
89
94
90
89
90
90
with aftercooler
°C
30
30
30
30
30
30
- 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(A)
98
98
98
98
98
100
4. Free air delivery 2)
free air
6. Engine oil consumption
(maximum)
7. Compressed air temperature at
outlet valves
8. Noise level
65
Instruction Manual
Compressor type
Designation
Unit
XAS 67 DD XAS 130 DD7
XAS 67 DDG XAS 130 DD7G/
DDG IT
XATS 67 DD XATS 125 DD7
XAS 77 DD XAS 150 DD7
XAS 97 DD XAS 185 DD7
XAS 97 DDG XAS 185 DD7G/
DDG IT
Value
Value
Value
Value
Value
Value
Design data
Compressor
1. Number of compression stages
1
1
1
1
1
1
1. Make
Deutz
Deutz
Deutz
Deutz
Deutz
Deutz
2. Type
D2011L03
D2011L03
D2011L03
D2011L03
D2011L03
D2011L03
Oil
Oil
Oil
Oil
Oil
Oil
3
3
3
3
3
3
Engine
3. Coolant
4. Number of cylinders
5. Bore
mm
94
94
94
94
94
94
6. Stroke
mm
112
112
112
112
112
112
l
2.332
2.332
2.332
2.332
2.332
2.332
kW
32.5
36
36
31.5
36
36
%
50
50
50
50
50
50
l
8.5
8.5
8.5
8.5
8.5
8.5
l
6
6
6
6
6
6
l
-
-
-
-
-
-
1. Capacity of compressor oil system
l
8
8
8
8
8
8
2. Net capacity of air receiver
l
16.7
16.7
16.7
16.7
16.7
16.7
3. Capacity of fuel tank
l
80
80
80
80
80
80
m3/s
0.85
0.85
0.85
0.93
1.2
0.81
7. Swept volume
8. Output according to ISO 9249 G at
normal shaft speed
- Load factor
9. Capacity of oil sump:
- Initial fill
- Refill (max.)
4)
10. Capacity of cooling system
Unit
4. Air volume at inlet grating
(approx.) 3)
1) At reference conditions, if applicable, and at normal shaft speed,
unless otherwise stated.
2) Data
Free air delivery
Measured according to
Tolerance
ISO 1217 ed.3
+/- 5%
1996 annex D
+/- 4% 250 l/s <FAD
25 l/s <FAD<250 l/s
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
5) Coldstart: compressor oil DTE22 instead of DTE25
6) For Hose Reel application: maximum ambient temperature 30°C
66
Instruction Manual
Generator type
DDG 110V - 6 kW
DDG IT 230V 3 ph - 6 kVA
DDG IT 230V 3 ph - 12.5 kVA
DDG IT 230/400V 3 ph - 6 kVA
DDG IT 230/400V 3 ph - 12.5 kVA
(XAS 67 DDG (XAS 67 DDG (XAS 67 DDG (XAS 67 DDG (XAS 67 DDG XAS 130 DD7G/ DDG IT XAS 130 DD7G/ DDG IT XAS 130 DD7G/ DDG IT XAS 130 DD7G/ DDG IT XAS 130 DD7G/ DDG IT
XAS 97 DDG XAS 97 DDG XAS 97 DDG XAS 97 DDG XAS 97 DDG XAS 185 DD7G/DDG IT)XAS 185 DD7G/DDG IT)XAS 185 DD7G/DDG IT) XAS 185 DD7G/DDG IT) XAS 185 DD7G/DDG IT)
Designation
Unit
Value
Value
Value
Value
Value
Alternator
1. Standard
IEC 34-1
IEC 34-1
IEC 34-1
IEC 34-1
IEC 34-1
2. Make
MECC ALTE
MECC ALTE
MECC ALTE
MECC ALTE
MECC ALTE
3. Model
MR-1 -180/2
TR-1 -160/2
TR-2 -200/2
TR-1 -160/2
TR-2 -200/2
kVA
6
6
12.5
6
12.5
4. Rated output
5. Degree of protection
6. Insulation
IP
23
23
23
23
23
- stator
class
H
H
H
H
H
- rotor
class
H
H
H
H
H
7. Number of phases
1
3
3
3
3
8. Number of leads
4
6
6
6
6
5.5
4.8
9.6
4.8
9.6
1
0.8
0.8
0.8
0.8
Electrical power circuit
1. Rated continuous active power
COP
kW
2. Rated power factor (lagging)
3. Rated continuous apparent power 1 ph
4. Rated voltage 1ph
COP
line to line
5. Rated current 1ph
6. Frequency droop
5.5
4
V
110
230
230
230
4
230
A
50
16
16
16
16
%
<5
<5
<5
<5
<5
kVA
-
6
12
6
12
V
-
230
230
400
400
A
-
15
30.1
8.7
17.4
2
3
3
4
4
1ph
A
50
In 1ph/3ph
A
16/16
16/32
16/10
16/16
7. Rated continuous apparent power 3 ph
8. Rated voltage 3ph
kVA
COP
line to line
9. Rated current 3ph
Circuit breaker
1. Number of poles
2. Rated current
3. Thermal release
4. Magnetic release
In
1ph
A
It 1ph/3ph
It
A
Im
A
50
3..5 In
16/16
16/32
16/10
16/16
3..5 In
3..5 In
3..5 In
3..5 In
10-80
10-80
10-80
10-80
Fault current protection
Insulation resistance
Residual current release
kOhm
Idn
A
0.03
67
Instruction Manual
Compressor type
Designation
Unit
XAS 67 DD - XAS 130 DD7
XATS 67 DD - XATS 125 DD7
XAS 77 DD - XAS 150 DD7
XAS 97 DD - XAS 185 DD7
Value
Value
Value
Value
Unit dimensions
towbar
without brakes
fixed
Length
Width
Height
Weight (ready to operate)
mm
mm
mm
kg
towbar
adjustable
2,827
1,410
1,258
880
fixed
N.A.
1,410
1,258
N.A.
towbar
with brakes
fixed
Length
Width
Height
Weight (ready to operate)
8.4
CONVERSION
mm
mm
mm
kg
LIST OF
SI
UNITS INTO
BRITISH
UNITS
1 bar
= 14.504 psi
1g
= 0.035 oz
1 kg
= 2.205 lb
1 km/h = 0.621 mile/h
1 kW
= 1.341 hp (UK and US)
1l
= 0.264 US gal
1l
= 0.220 Imp gal (UK)
1l
= 0.035 cu.ft
1m
= 3.281 ft
1 mm
= 0.039 in
1 m3/min = 35.315 cfm
1 mbar = 0.401 in wc
1N
= 0.225 lbf
1 Nm
= 0.738 lbf.ft
t °F
= 32 + (1.8 x t °C)
t °C
= (t °F- 32)/1.8
– A temperature difference of 1 °C = a temperature difference of 1.8 °F
68
N.A.
1,410
1,258
N.A.
towbar
adjustable
2,970
1,410
1,258
915
adjustable
2,827
1,410
1,258
890
3,302-3,470
1,410
1,258
930
fixed
adjustable
2,970
1,410
1,258
925
3,302-3,470
1,410
1,258
940
Instruction Manual
9.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
DATA PLATE
Company code
Product code
Unit serial number
Name of manufacturer
EEC or national type approval number
Vehicle identification number
A Maximum permitted total weight of the vehicle
B Maximum permitted axle load
C Maximum permitted load on the towing eye
Model
Working pressure
Speed
Engine power
Manufacturing year
CE-mark in accordance with Machine Directive 89/392 EEC
Register number or number of notified body
69
Instruction Manual
Notes
70
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