Atlas Copco PAC H64 FSC03 CNP ITH Instruction Manual

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Instruction Manual

Instruction manual

for PAC Series Pump

English

PAC H64 FSC03 CNP ITH

Scania DC0907A

PAC H86 FSC03 CNP ITH

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Summary of Contents for Atlas Copco PAC H64 FSC03 CNP ITH

Page 1 Instruction Manual Instruction manual for PAC Series Pump English PAC H64 FSC03 CNP ITH Scania DC0907A PAC H86 FSC03 CNP ITH...
Page 3 PAC H64 FSC03 CNP ITH PAC H86 FSC03 CNP ITH Instruction Manual for PAC Series Pump Instruction manual .................. 5 Circuit diagrams ..................63 Original instructions Printed matter No ATLAS COPCO - PORTABLE ENERGY DIVISION 2960 7000 00 www.atlascopco.com 07/2021...
Page 4 While every effort has been made to ensure that the information in in this manual is correct, Atlas Copco does not assume responsibility for possible errors. Copyright 2021, Varisco S.r.L, PADOVA, ITALY. 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.
Page 5 Please read the following instructions carefully before starting to use your machine. 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. Atlas Copco reserves the right to make changes without prior notice.
Page 6 5.2.1 Positioning the impeller with General..........59 reference to the wear plate(s)....43 Disposal of materials .......59 5.2.2 Inspection check valve - Valmatic ....43 Engine maintenance procedures Options ....60 Scania DC0907A ......
Page 7 The policy of Atlas Copco is to provide the users of their Atlas Copco equipment. It is the responsibility of unsafe operating conditions. Take necessary steps to equipment with safe, reliable and efficient products.
Page 8 The manufacturer does not accept any liability for any covers shall be opened before sufficient cooling 15 When working on the unit, wear safety clothing. damage arising from the use of non-original parts and for time has elapsed; this to avoid the risk of Depending on the kind of activities these are: spontaneous ignition of oil vapour when air is safety glasses, ear protection, safety helmet...
Page 9 - check the towbar, the brake system and the via the holes in the frame at the front and back or consult Atlas Copco. towing eye. Also check the coupling of the via the lifting beam. To prevent damage, never 15.
Page 10 5. Never refill fuel while the unit is running, unless down equipment, do so with caution and use the noise hazardous area and an obvious warning otherwise stated in the Atlas Copco Instruction appropriate protection, at least safety glasses, for shall be placed permanently at each entrance Book (AIB).
Page 11 15. Safety shoes should be compulsory in any sure that all electric connections are securely inadvertent starting. In addition, a warning sign workshop and if there is a risk, however small, tightened. bearing a legend such as "work in progress; do of falling objects, wearing of a safety helmet not start"...
Page 12 Therefore: recommended or approved by Atlas Copco or 20. Make sure that oil, solvents and other substances -never smoke near batteries being, or having recently the machine manufacturer. Ascertain that the likely to pollute the environment are properly...
Page 13 Main parts General description The PAC H64-H86 dry-prime centrifugal pumps, are suitable for handling clean water or liquids up to 50°C. The PAC H64-H86 pumps are driven by a fluid-cooled diesel engine, manufactured by Scania. An overview of the main parts is given in the diagram below. Air filter Air separator Battery switch...
Page 14 Lifting beam Side doors Engine exhaust Data plate Hole for forklift Drain hole Emergency stop button kit - 14 -...
Page 15 Flow Diagram - 15 -...
Page 16 Markings CHECK Read the instruction manual Markings provide instructions and information. They ENGINE Check engine oil daily. before using the lifting eye. also warn of hazards. For convenience and safety, OIL DAILY keep all markings in legible condition, replacing them when damaged or missing.
Page 17 Despite the pump is able to deal with air in the suction Vacuum created in the suction pipe by the vacuum line, Atlas Copco recommends to avoid this situation pump, forces water to penetrate the pump. When The engine is equipped with the following safety...
Page 18 2.4.5 Control panel 2.4.7 Drain plugs and filler caps Electrical features The control panel grouping the controller, hour meter, The drain holes for the engine oil, the coolant and the The electrical features described in this chapter are fuel level gauge, ON/OFF switch etc., is placed at the plug for the fuel, are located and labelled on the standard provided on this pump.
Page 19 Control panel - PW 500 The PAC H64-H86 range of pumps are fitted with PW 500 controller. This is located inside the canopy and communicates via a display section in the front. It carries out the entire necessary task to control and protect the Pump. Operation Mode Selection key Controller Manual Operation...
Page 20 General description of PW 500 START BUTTON Pressing this button in Manual Mode will start the Pump. STOP BUTTON Pressing this button in manual mode will stop the pump in a controlled way. RESET BUTTON Press Reset Button to reset the controller. ARROW BUTTON Press Briefly to Show the instruments.
Page 21 Led Functions Starter Enable Key The Starter enable key is used to power the controller for starting the machine. Cumulative alarm with Engine stop Once the machine is running the starter key can be flipped Start Float Call Closed. to OFF position. It will not stop the machine. It will not Operation Mode Light - Controller in Manual Mode allow the engine to be re-cranked unless a manual input Operation Mode Light - Controller in Automatic Mode...
Page 22 Control Panel for Automatic Diesel Engine DSE Deep Sea Electronics DSE Deep Sea Electronics 1498 RPM 2.9 Bar Engine Speed Oil Pressure 75 % Engine Temp Fuel Level AUTO STOP CAUTION AUTO STOP ENGINE MAY START WITHOUT WARNING DISCONNECT BATTERY BEFORE SERVICING Pressing this button increases the pump speed.
Page 23 2.8.1 Float switches Operating procedure: • The tank drains: The pump is fitted with two float switches for 1. Connect the float switches as follows: operation in Auto mode. These float switches must be • Connect the Start float to Connector indicated coupled to the connectors, located at the side of the by label “A Start float”.
Page 24 Installation and connection To be able to lift the unit by means of a forklift, Lifting Installation rectangular slots are provided at the bottom of the Before lifting the unit, check its dimensions and frame. 3.2.1 Indoor installation weight, which can be found on the Data plate. If the pump is operated indoors, install an exhaust When lifting the unit, the hoist has to be placed in pipe of sufficient diameter to duct the engine exhaust...
Page 25 – Check that the inner earthing system is in compliance with the local legislation. – Use coolant for the engine cooling system. Refer to the Engine instruction book for the proper coolant mixture. – Check the tightness of the bolts and nuts. - 25 -...
Page 26 In the same casing. way, bends in the suction should be avoided as much as possible. Atlas Copco recommends fluid velocities up to 2 m/s (6 ft/sec) on the suction and 3 m/s (9ft/sec) on the discharge.
Page 27 In this mode, float switches are not 4. Flip the operation mode selection key to glow plugs and starts the engine. used. Atlas Copco recommends using the machine in position 2. 8. In order to avoid fail start, controller makes a automatic mode in order to prevent dry running.
Page 28 Manual operation mode Settings PW 500 Starting 4.3.1 Acknowledge an alarm and faults 1. Switch on the battery switch. When the engine protection device intervenes or when there are fault detections, the controller displays the fault codes or messages (based on settings) with flashing 2.
Page 29 Anomaly Messages Charging alternator anomaly (belt breakage) Warning/shut down* In the event of no communication with the injection control unit of the engine, the Number of start up attempts (staring failure) Shut down anomaly fault activates. Start in case of low battery charge Note: - All the messages or instruments displayed on the display regarding the injection control unit and the CAN bus are identified by the character at the bottom Over speed...
Page 30 Can Bus Instruments: Cumulative Alarms The following parameters read by the injection control unit are displayed on the • POS 10 LED (RED Steady light): Anomaly managed by the injection unit screen when the engine is running. The injection control unit manages all will cause the engine to Stop anomalies regarding these instruments.
Page 31 4.3.2 General feature settings Weekly Automatic Test To use Option D) and E) make sure – With this option, the engine performs a test cycle 1. Press PROG (program) button that the Calendar Clock updated and when operating in Automatic Mode. OPERATION MODE BUTTON panel.
Page 32 4.5.2 Stopping the engine • Press the AUTO button to check the PIN for Operating the PW 600 validity, if the number is correct, the editor is – In manual mode, the engine continues to run until displayed. 4.4.1 Instruments pages the Stop/Rest button is pressed.
Page 33 Front panel configuration editor parameters Section Parameter as shown on display Value Section Parameter as shown on display Value Contrast Smoke Limiting Off - m - s Backlight Level Warm Up Time - m - s Language English Cool Down Time - h - m - s Display Day: month:...
Page 34 Charge Alternator Shut down Delay (When Charge Alternator Shut down Delay (When - h - m - s - h - m - s Enabled) Enabled) Charge Alternator Failure Shut down (When Charge Alternator Failure Shut down (When -.- V -.- V Enabled) Enabled)
Page 35 LCD Page Timer - h - m - s Scroll Delay - h - m - s Engine Pre Heat Timer (When Enabled) - m - s Crank Duration Timer - m - s Crank Rest Timer - m - s Safety On Delay - m - s Smoke Limiting...
Page 36 Maintenance The maintenance schedule contains a summary of the maintenance instructions. Read the respective section before taking maintenance measures. 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 the pump's applications.
Page 37 Every Every Every Every Regular service period Daily Annually 500 hrs 1000 hrs 3000 hrs 2 years Fuel filter Replace Check level (if necessary top up) Coolant Check additive concetration Replace Engine tightness (visual inspection for Check leaks) Exhaust system including exhaust after Check treatment components for leaks Check...
Page 38 Every Every Every Every Regular service period Daily Annually 500 hrs 1000 hrs 3000 hrs 2 years General Control panel Check for alarms and warnings Condensate and water from spillage-free Drain frame or catch basin (if applicable) Locks and hinges Grease Emergency stop Check function...
Page 39 Every Every Every Every Regular service period Daily Annually 500 hrs 1000 hrs 3000 hrs 2 years Pump Check oil level (if necessary top up) Vacuum pump oil Replace Inspect (if necessary replace) Vacuum pump diaphragm and valves Replace Inspect (if necessary tension or replace) Vacuum pump belt Replace...
Page 40 Every Every Every Every Regular service period Daily Annually 500 hrs 1000 hrs 3000 hrs 2 years Check valve Inspect (if necessary replace) Inspect function of floater and valve Separator Clean components Rubber couplings Inspect (if necessary replace) Pump shaft bearings Replace - 40 -...
Page 41 Pump maintenance Residual liquid may be found in the procedures pump casing, head and suction line. Take the necessary precautions if liquid hazardous GENERAL RECOMMENDATIONS (inflammable, corrosive, poisonous, – Handling must be carried out by specialized infected). personnel to avoid damage to the pump and to persons.
Page 42 LUBRIFICATING THE PUMP LUBRIFICATING THE DIAPHRAGM VACUUM PUMP Every month check the oil level using indicators The vacuum pump is of diaphragm type; its (min. oil level, maximum oil level) and if necessary lubrication is oil bath type. to up through the cap (Ref. n°3). Running the vacuum pump with an insufficient MECHANICAL SEAL CHECK amount of oil can damage it.
Page 43 Adjustments and service procedures 5.2.1 Positioning the impeller with 5.2.2 Inspection check valve - Valmatic reference to the wear plate(s) In all models, the distance between the top of the impeller blades and the surface of the wear plate must be between 0.3 - 0.6 mm To achieve this, dimensions A and B must be as nearly as possible equal.
Page 44 Engine maintenance procedures Scania DC0907A 5.3.1 Engine oil level check 5.3.2 Engine oil and oil filter change – Install and tighten the drain plug on the oil drain flexible. Consult the Engine Operation Manual for the oil Refer to the Engine Operation Manual for more –...
Page 45 5.3.4 Servicing air filter engine 5.3.4.2 Recommendation 5.3.4.1 Main parts The Atlas Copco air filters are specially designed application. The use of non-genuine air filters may lead to severe damage of engine and/or alternator. Never run the unit without air filter element.
Page 46 5.3.5 Replacing the filter element New elements must also be inspected for tears or punctures before installation. 1. Release the snap clips (1) and remove the dust trap cover (2). Clean the inside of the cover. 2. Remove the element (3). 3.
Page 47 5.3.6 Cleaning cooler 5.3.7 Cleaning the fuel tank – Steam cleaning in combination with a cleansing agent may be applied. 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.
Page 48 5.3.8 Battery care – Rock the battery a few times so that possible air If a battery does not need any make-up water at all bubbles can escape; wait 10 minutes and check the over considerable time operation, Before handling batteries, read the level in each cell once more;...
Page 49 ISO 3448, as follows: Specifications PAROIL retention and more alkalinity to control acid formation. PAROIL from Atlas Copco is the ONLY oil tested Engine Type of lubricant and approved for use in all engines built into Atlas PAROIL prevents Soot build-up.
Page 50 Remove the cap slowly and only low as -25°C (-13°F). when coolant ambient Atlas Copco's PARCOOL EG extended life coolant is temperature. A sudden release of the new range of organic coolants purpose designed Order pressure from a heated cooling to meet the needs of modern engines.
Page 51 Order Litre cu.ft number 0.175 1604 5308 00 1604 5307 01 barrel 55.2 7.35 1604 5306 00 To ensure protection against corrosion, cavitation and formation of deposits, the concentration of the additives in the coolant must be kept between certain limits, as stated by the manufacturer's guidelines.
Page 52 Checks and trouble shooting Not enough power Engine troubleshooting – Restriction in a fuel pipe. When a failure occurs, always The table below gives an overview of the possible report what you experienced before, engine problems and their possible causes. –...
Page 53 The pressure of the lubricating oil is too low – Incorrect valve tip clearances. – Fault in cold start system. – Wrong grade of lubricating oil. – Engine overload. – Restriction in fuel tank vent. – Not enough lubricating oil in sump. –...
Page 54 Crankcase pressure Pump troubleshooting – Restriction in breather pipe. The paragraph reports the most common problems – Vacuum pipe leaks or fault in exhaust. that may occur during use of the pump and the possible remedies. Bad compression In case operation defects founded in the starting phase –...
Page 55 6.2.1 Overview of possible operating problems Symptom Possible cause Corrective action Pump does not prime 1. Suction tubes or inlet filter clogged. The Remove the obstruction. vacuum gauge indicates a high value. 2. Suction tube collapse. Use reinforced suction tube. 3.
Page 56 Low or no flow 1. The pump does not prime, See causes given in Pump does not prime. 2. Head required by the system is greater Revise system design or select a different pump. than the rated head of the pump. 3.
Page 57 Pump does not provide enough pressure 1. Viscosity of the liquid is higher than Contact the pump manufacturer once you have measured the viscosity expected. of the liquid. Viscosity for centrifugal pumps should not exceed 50 cSt. Check for other possible causes: see Low or no flow. 2.
Page 58 Storage of the pump Storage Preparing for operation after storage – Store the pump in a dry, frost-free room which is well ventilated. Before operating the pump again, remove the wrapping. – Run the engine regularly, e.g. once a week, until it is warmed up.
Page 59 This concept can only succeed with your non-recyclable materials. help. Support disposing Your Atlas Copco pump consists mostly of metallic professionally. assuring correct materials, that can be remelted in steel and melting disposal of the product you help prevent works and are therefore amost infinitely recyclable.
Page 60 Options View inside External fuel tank Shut off valve connection (with/without The valve is designed to provide a shut down of an engine (the solenoid valve is powered to close the quick couplings) airflow). The option external fuel tank connection allows to The shut down signal is generated automatically by bypass the internal fuel tank and to connect an control unit when there is an over speed.
Page 61 Overview Filler cap (fuel tank) Engine External fuel supply coupling Fuel filter engine Primary coarse fuel filter / water separator Fuel tank 3-way valve - 61 -...
Page 62 Suction and discharge pipes Bauer Perrot/Cardan DIN / ASME Discharge DIN / ASME Discharge Bauer Discharge Perrot/Cardan Suction DIN / ASME Suction Bauer Suction Perrot/Cardan - 62 -...
Page 63 Circuit diagrams 10.1 Control Panel - 63 -...
Page 64 10.2 Control Panel + Shut off valve - 64 -...
Page 65 10.3 Harness - 65 -...
Page 66 Technical specifications 11.1 Technical specifications of unit/engine/pump FEATURES Pump model Engine model PAC H64 PAC H86 Product number 8381063540 Connection - Suction (mm/in) 150 / 6 200 / 8 Connection - Discharge (mm/in) 100 / 4 150 / 6 Weight (kg) 4020 4020 Fuel tank capacity (l)
Page 67 FEATURES PAC H64 PAC H86 Vacuum pump oil tank (l) Mechanical seal oil tank (l) Non return check valve Ball type Ball type Pass maximum (kw) Eff maximum (%) Q Eff maximum (m Starting voltage (V) - 67 -...
Page 68 11.2 Dimension Drawing - 68 -...
Page 69 11.3 Torque values 11.3.1 General torque values 11.3.2 Critical torque values The following tables list the recommended torques applied for general applications Assemblies at assembly of the compressor. Axles to frame: For hexagon screws and nuts with strength grade 8.8 Wheel nuts Bolts, axle/frame Thread size...
Page 70 11.4 Data plate QR CODE Every electrically driven pump is equipped with an identification plate which gives the following information: Type of unit TYPE: PROD. NR: Product Number SERIAL: MATERIAL ID: Serial Number ENGINE ID: Weight: Material Id Engine Id Weight (kg) Maximum capacity of the pump (m (10)
Page 71 Spare parts 12.1 Ordering spare parts For spare parts see parts list. To avoid errors in delivery, please give the following information when ordering spare parts: – Pump type. – Pump serial number – Quantity required. – Part number. – Part description.
Page 72 www.atlascopco.com...

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Pac series Pac h86 fsc03 cnp ith