XA(T,V)S 400 CD7 iT4 Compressors
Scott Ellinger
Committed to
sustainable productivity
1
Systems Overview XAS 400 CD
2
Product Designation Oil Injected Compressors
Product range
X : Oil injected
portable
compressor
Working principle
A : Single stage
compressor
R : Two stage
compressor
Silencing
: Un-silenced
S : Silenced
X A T S 400
Working pressure
: std pressure
M:
T :
H:
V:
102psi
125psi
150psi
175psi
200psi
Engine supplier
C : Caterpillar
D : Deutz
J : John Deere
Y : Yanmar
K : Kubota
Prime mover
D : diesel engine
E : electric motor
C D
Capacity (FAD)
Liter/sec
CFM (US-version)
XAS 400 CD7 IT4 Machine Specifications
4
XAS 400 CD7 IT4 Machine Specifications (2)
5
Compressor systems
 Four major components :
– Air system
– Oil system
– Control system
– Electrical system
Air system
Air filter
 Filtration of the inlet air in 3 stages :
– centrifugal dust separation
– paper filter element
– safety cartridge (optional)
 Vacuum indicator gives an indication when the pressure drop over
the filter element is too high  filter element needs to be replaced
Air filter
Air inlet
Vacuum indicator
Centrifugal separation
Filter element
Dust
to compressor element
REGULATING SYSTEM REG VALVE
Adjusting receiver pressure
by changing spring tension
Spring loaded
In order to regulate the pressure inside the reciever
tank of our compressor, the air intake and the
engine speed have to be controlled. This is done
pneumatically. For that reason, we need regulating
pressure. The regulating valve reduces the pressure
inside the tank, thus providing the regulating
pressure. This regulating pressure is then supplied
to the unloader valve and the speed regulator or
RPS.
Regulating pressure:
• to speed regulator
• to unloading valve
Receiver pressure
• to pressure gauge and loading valve
10
The air receiver pressure can be set to another value
by adjusting the spring tension of the regulating valve.
This is done by turning the handle on top the valve.
Increasing the spring tension, by turning in, will
increase the regulating pressure and consequently the
pressure inside the vessel. Turning out will decrease
the pressure.
Unloading valve
 Opens and closes the air inlet to the compressor element.
– Open position at load condition
=> Air consumption
– Closed position at no load condition
=> No air consumption.
 Control of the valve by regulating pressure.
Unloading Valve or Air System Inlet Valve
Legend
Receiver Pressure
From Pressure Regulator right now very low to zero pressure
Spring loaded in the open
position
Control Air closes the inlet
Also serves as check valve
Unloading valve service kit – 2911 0074 00
12
No-Load Condition
Load Condition
Unload Condition
Blow- Down Condition
AIR SYSTEM MIN PRESS VALVE
Maintains a minimum pressure
of 58 PSI for oil flow
Also contains the final check
valve
15
Oil System
Oil System
 Air receiver
 Oil cooler
 Oil filter/TBV
 Compressor
element
 Oil separator
 Scavenge line
 Oil stop valve
Oil injected screw compressors
Compressor element
Lubrication to the bearings
Air inlet
Oil
Oil
Air/Oil
Oil injected screw compressors
 Oil is used for :
– Cooling : compression heat is absorbed by
the oil
– Lubrication of rotors, bearings, gears
– Sealing between rotors and rotor and
housing
– Corrosion protection of the internal metal
parts
Oil injected screw compressors
Oil is injected in the bottom of the rotor housing,
on the bearings and gears
Suction
Compression start
Compression
Delivery
Compression principle
Oil separator
Scavenge line
Separator element
Oil Separator filter element should be replaced
Every 1,000 hours or yearly.
Centrifugal separation
Oil
Air/Oil
Oil Separator
 Classic Reasons For Oil Carryover
– Over filled receiver
– Plugged scavenge line
– Wrong type of oil (no anti foam agent)
– Shut down with air outlet valves open
– Scavenge tube installed improperly
Separator Element Service Kit – 2911 0075 00
Control System
25
Control Panel
XC2002 Status
27
XC2002 Menus
28
Basic Operations
29
Shutdown
30
XC2002 Service Timer Reset
 Scroll through the controller menu to “Parameters” (on some units
“Parameters” may be a submenu under “Extra Views”)
 Press Enter to select Parameters
 Scroll to ST1 Reset or ST2 Reset as needed (ST1 = 500 hours, ST2
= 1000 hours)
 Press Enter to select to reset the appropriate timer
 Prompt for Password: change to 2003 and press Enter
 Center option will highlight; up/down to change to “Yes” and press
Enter
 Service timer is reset
31
XC2002 Alarms
32
XC2002 Alarms
If an Alarm occurs, a pop-up window will display for as long as the
alarm is active, in any view. The flashing red Alarm LED will light up.
The Alarm icon(s) will be shown with an acknowledgement check box.
Push the Enter button to acknowledge the alarm. An acknowledged
Alarm will mark the check box and light the red Alarm LED.
An Alarm should always be acknowledged before solving the cause of
the Alarm.
The Alarm display can be left by pushing the Back button.
If more than one Alarm occurs, the Up and Down arrows may be used
to scroll through the list. Newest Alarms will be at the bottom of the list.
If a Shutdown occurs, the Shutdown Display will be shown.
33
XC2002 Event Log
XC2002 keeps an event log of the last 15 events.
 Shutdowns
 Warnings
 Service timer resets
 Unit type changes
Running hours at time of event logged
34
Engine Faults
35
Compressor Faults
36
Electrical System
37
Wiring Diagram XAS 400 CD
38
Maintenance
39
Maintenance – XA(T,V)S 400 CD IT4
Daily:
 Check engine oil level
 Check compressor oil level
 Check coolant level
 Drain water from fuel filter
 Empty air filter vaccuator valve
 Check tire pressure
Maintenance – XA(T,V)S 400 CD IT4
Initial Service at 50 Hours
 Check electrolyte level and terminals of battery
 Check for leaks in Air, Oil, and Fuel systems
 Check wheel nut torque (if equipped)
 Check and adjust brakes (if equipped)
 Check and adjust fan belts
 Replace compressor oil filter
41
Maintenance – XA(T,V)S 400 CD IT4
500 Hour service pack part number 1310 3004 52 (typical 6 months)
 Perform 50 hour service tasks
 Clean oil cooler, radiator, intercooler
 Grease door hinges
 Grease towing eye shaft or ball coupling and shaft
 Analyze coolant
 Replace air filter elements
 Replace engine oil and filter
 Replace fuel primary filter and prefilter
42
Maintenance – XA(T,V)S 400 CD IT4
1000 Hour service pack part number 1310 3004 53 (typical 12 months)
 Perform 500 hour service tasks
 Test safety valve and shut down switches
 Check rubber flexibles
 Replace separator element
 Replace compressor oil and filter
 Replace bleed off valve unloader
 Replace filter element from regulating valve
 Clean flow restrictor in oil scavenge line
 Inspection by Atlas Copco service technician
Check/adjust engine valves every 2000 hours or per Caterpillar
43
IT4 Exhaust Aftertreatment
44
Tier 4: Terms and Key Words
Regeneration: The process of eliminating built up soot from the
exhaust system
Two types of Regeneration
 Active Regeneration:
– Using a hydrocarbon (fuel) to elevate exhaust gas temperatures above
1100 F (600 C) in order to remove built up soot from the exhaust filter
 Passive (Natural) Regeneration:
– Using temperature alone to burn soot by elevated exhaust temperature
 Can be controlled by temperature management of the exhaust stream
– Can be achieved by maintaining exhaust gas temperature
– Can also be achieved by control valves including VGT that effect exhaust backpressure
Tier 4: Terms and Key Words
 Soot
– Incomplete combustion of hydro carbons in the exhaust stream
– Can be purged from the DPF by re-generation
 Ash
– Incomplete combustion of some hydrocarbon by-products
– CANNOT be purged from the DPF by re-generation
– EPA Mandated that DPF must withstand 4500 hrs before ash cleaning is needed
 HPCR
– High Pressure Common Rail fuel system
– System pressures up to 30,000 psi
– Allows multiple injection events to take place reducing emissions
 VGT
– Variable Geometry Turbocharger
– Inlet guide vanes can adjust to provide exact boost pressure to work in conjunction
with the EGR
Tier 4: Terms and Key Words
 NOx
– Nitrogen Oxides
– Highly reactive gasses that form from emissions
 EGR
– Exhaust Gas Recirculation
– Recycles a portion of exhaust gas back to the engine
 ULSD
– Ultra low sulfur fuel (less than 15 ppm)
– Must be used on all IT4 machines
– Normal diesel fuel will kill an EGR and DOC within a few tanks
 Low ash Engine oil
– Must be used on all IT4 machines to reduce the formation of ash accumulating in
the DPF
 CANbus – Method of communication between controllers or networks. All Atlas Copco
controllers use SAE J1939 CANbus communication
Tier 4: DOC and DPF
Diesel Particulate
Filter (DPF)
Diesel Oxidation
Catalyst (DOC)
CEM- Cleaning Emission Module
Tier 4: Diesel Oxidation Catalyst (DOC)








Open cell substrate flow though device
Reduces HC and CO significantly
Reduces Pm 10 to 30%
Converts NO to NO2 for passive regeneration of the DPF
Oxidizes HC (diesel fuel) as part of active regeneration strategy
No servicing required
Requires use of low sulfur diesel or ULSD
Typically element is =100% of engine displacement in size
Tier 4: Diesel Particulate Filter (DPF)
 Wall flow, high filtration efficiency
(95%+)
 Traps ash, soot and any particles
 Needs periodic regeneration / cleaning
 Periodic ash cleaning required
 No muffler required in the vast majority
of applications
XC2002 DPF Status Indicators
51
Xc2002 – DPF Information
Manual Regeneration
•
Parameter
• DPF – Diesel Particulate filter – can
change from AUTO to ON or turn OFF
completely (not recommended!)
• STATION REGEN. – Stationary (manual)
Regeneratoin – OFF or ON
• Both need to be set to “ON” for manual
regeneration
• Both are password protected
• Unit will not regenerate until soot level is
~70%
Procedure: Stationary/Forced DPF Regeneration

Atlas Copco recommends that the DPF configuration be
left in the AUTO mode at all times however in the event
that a stationary or forced regeneration in desired the
following process should be followed..

Unit WILL NOT regenerate until soot level is above 72%
– Go to the "STATION REGEN" screen. For normal
operation this should be in OFF mode.
 Press the enter button (1), a password window will
appear. Enter 1968 and press the enter button.
 Use the up or down (2) arrow to change the
selection to ON and press the enter button.
– Go to the "DPF" screen. For normal operation this
should be in the AUTO mode.
 Press the enter button (1)
 Use the up or down (2) arrow to change the
selection to ON and press the enter button.

This will set the unit up for regeneration, after a few
moments the regeneration icon should appear confirming
the unit is regenerating.
– The stationary/forced regeneration can take in excess
of 3 hours to complete.
1
2
Procedure: Stationary/Forced DPF Regeneration

Upon completion of the stationary/forced regeneration it is highly recommended to reset the
unit to automatically regenerate to prevent engine derate & shutdown due to high soot load.
– Go to the "STATION REGEN" screen. (For normal operation this should be in OFF mode).
 Press the enter button, a password window will appear. Enter 1968 and press the enter
button.
 Use the up or down arrow to change the selection to OFF and press the enter button.
– Go to the "DPF" screen. For normal operation this should be in the AUTO mode.
 Press the enter button,
 Use the up or down arrow to change the selection to AUTO and press the enter button.

The unit is now ready for normal operation.
Contact Numbers
•Main Number Atlas Copco Technical Support
800-732-6762 Option 3
•Ed Kukfisz – Compressors – Supervisor
281-542-2562 direct & 832-385-4697 mobile
•Andrew Stevenson – Compressors: Low Pressure
720-479-2486 direct & 404-751-6717 mobile
•Andrew Calendar – Compressors: High Pressure
720-479-2487 direct & 404-242-6203 mobile
•Scott Ellinger – Compressors
720-479-2476 direct & 720-375-1795 mobile
•Robert Walsh – Generators – Supervisor
803-487-0256 direct (mobile)
•Will Hudson – Generators/Compressors
800-732-6762 Ext. 12920 & 832-454-8123 mobile
•Brandon Hobbs – Hydraulic Attachments /Handheld Construction Tools – Supervisor
303-287-8822 direct & 913-424-4039 mobile
•Al Eckenfels – Hydraulic Attachments/Handheld Construction Tools
800-760-4049
55
Committed to
sustainable productivity.