Doosan 9/274 User manual

AUTOSTART SYSTEM
OPERATION MANUAL
9/274, 9/304, 12/254, 17/244, 21/224
HP915, XP1000, XHP750
This manual contains
important safety information
and must be made available to
personnel who operate and
maintain this machine.
46696687_en_A_11/16

3
TABLE OF CONTENTS
Operation & Maintenance Manual
TITLE PAGE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Operational Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
AutoStart Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Switch Type Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Pressure Type Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
AUTOSTART SETUP AND OPERATION SEQUENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
AutoStart System Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Navigation Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Automatic Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Automatic Stop (if enabled). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
AutoStart Customer Interface Terminal Block Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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TABLE OF CONTENTS
Operation & Maintenance Manual
TITLE PAGE

5
Foreword

Operation & Maintenance Manual Foreword
6
Information
The contents of this manual are considered to be proprietary and confidential to Doosan
Infracore Portable Power (herein referred to as “Portable Power”), and should not be
reproduced without the prior written permission of Portable Power.
Nothing contained in this document is intended to extend any promise, warranty or
representation, expressed or implied, regarding the Portable Power products described
herein. Any such warranties or other terms and conditions of sale of products shall be in
accordance with the standard terms and conditions of sale for such products, which are
available upon request.
This manual contains instructions and technical data to cover all routine operation and
scheduled maintenance tasks by operation and maintenance staff. Major overhauls are
outside the scope of this manual and should be referred to an authorized Portable Power
Service department.
All components, accessories, pipes, and connectors added to the compressed air system
should be:
• of good quality, procured from a reputable manufacturer and, wherever possible, be
of a type approved by Portable Power.
• clearly rated for a pressure at least equal to the compressor safety valve setting.
• compatible with the compressor oil.
• accompanied with instructions for safe installation, operation, and maintenance.
Details of approved equipment are available from the Portable Power Service departments.
The use of repair parts other than those included within the approved parts list may create
hazardous conditions over which Portable Power has no control. Therefore, Portable Power
cannot be held responsible for equipment in which non-approved repair parts are installed.
Portable Power reserves the right to make changes and improvements to products without
notice and without incurring any obligation to make such changes or add such improvements
to products sold previously.
The intended uses of this compressor are outlined below and examples of unapproved usage
are also given. However, Portable Power cannot anticipate every application or work situation
that may arise. If in doubt, consult supervision.
This compressor has been designed and supplied for above ground operation to be used for
compression of normal ambient air containing no additional gases, vapors, or particles within
the ambient temperature range specified in the General Data Section of this manual.

Foreword Operation & Maintenance Manual
7
This compressor should NOT be used:
A. For direct or indirect human consumption of the compressed air.
B. Outside the ambient temperature range specified in the General Data Section
of this manual.
C. When an actual or foreseeable risk of hazardous levels of flammable gases or
vapors exists.
D. With other than Portable Power approved components.
E. With guards, controls, or switches missing or disabled.
F. For storage or transportation of materials inside or on the enclosure.
Portable Power accepts no responsibility for errors in translation of this manual from the
original English version.
You, as the customer, are expected to provide certain service and maintenance items. Your
Portable Power dealer will provide all other more detailed service and maintenance items on
a special preventive maintenance schedule for each compressor. It is very important that the
minimum service and maintenance requirements explained in this manual be performed at the
required intervals. Exceeding these intervals may reduce the reliability of the compressor.
The purpose of this manual is to train the operator with functions, operation, and basic service
and maintenance requirements of the compressor. During the preparation of this manual,
every effort was made to ensure the accuracy and adequacy of the contents.
Your Portable Power dealer will assist with setup and initial startup of the compressor and will
also provide brief operating and service instructions. Before starting the compressor, this
manual and instructions should be carefully read to obtain a thorough knowledge of the duties
to be performed. Please take pride in the compressor, keep it clean and in good mechanical
condition.

Operation & Maintenance Manual Foreword
8

9
Safety

Operation & Maintenance Manual Safety
10
Safety Precautions
Never operate the compressor without first observing all safety warnings and carefully reading
the Operation and Maintenance Manual shipped from the factory with this compressor.
Ensure the operator reads and understands the decals and consults the manuals before
operation or performing maintenance.
Ensure all maintenance personnel are adequately trained, competent, and have read the
manuals.
Ensure all protective covers are in place and the canopy/doors are closed during operation.
The specification of this compressor is such that the compressor is not suitable for use in
flammable gas risk areas. If such an application is required, all local regulations, codes of
practice, and site rules must be observed. To ensure the compressor can operate in a safe
and reliable manner, additional equipment such as gas detection, exhaust spark arrestors,
and intake (shut-off) valves may be required, dependent on local regulations or the degree of
risk involved.
A weekly visual check must be made of all fasteners/fixing screws securing mechanical parts.
In particular, safety-related parts such as coupling hitch, drawbar components, wheels, tires,
and lifting bail should be checked for total security.
All components which are loose, damaged, or unserviceable must be rectified without delay.
Air discharged from this compressor may contain carbon monoxide or other contaminants
which will cause serious injury or death. Do not breathe discharged air.
This compressor produces loud noise with the doors open or service valve vented. Extended
exposure to loud noise can cause hearing loss. Always wear hearing protection when doors
are open or service valve is vented.
Never inspect or service the compressor without first disconnecting battery cable(s) to prevent
accidental starting.
Do not use petroleum products (solvents or fuels) under high pressure as this can penetrate
the skin and result in serious illness. Wear eye protection while cleaning the compressor with
compressed air to prevent debris from injuring eye(s).
Rotating fan blade can cause serious injury. Do not operate without fan guard in place.
Use care to avoid contacting hot surfaces (engine exhaust manifold and piping, air receiver,
and air discharge piping, etc.).
Ether is an extremely volatile, highly flammable gas. When it is specified as a starting aid, use
sparingly. Do not use Ether if the engine has glow plugs or inlet heater starting aids. Engine
damage will result.
Never operate the compressor with guards, covers, or screens removed. Keep hands, hair,
clothing, tools, blow gun tips, etc. well away from moving parts.
Automatic or remote start during service, maintenance or inspection shall be prevented by the
Pad Lock, locking Control Panel doors, to prevent inadvertent automatic starting.

Safety Operation & Maintenance Manual
11
Compressed Air
Compressed air can be dangerous if incorrectly handled. Prior to performing maintenance or
service on the compressor, ensure all pressure is vented from the system and the compressor
cannot be started accidentally.
Ensure the compressor is operating at the rated pressure and the rated pressure is known to
all relevant personnel.
All air pressure equipment installed in, or connected to, the compressor must have safe
working pressure ratings of at least the compressor safety valve setting.
If more than one compressor is connected to one common downstream plant, effective check
valves and isolation valves must be fitted and controlled by work procedures, to ensure one
compressor cannot accidentally be pressurized or over pressurized by another.
Compressed air must NOT be used for a direct feed to any form of breathing apparatus or
mask.
Compressed air can cause serious injury or death. Relieve pressure before removing filler
plugs/caps, fittings, or covers.
Air pressure can remain trapped in air supply line which can result in serious injury or death.
Always carefully vent air supply line at tool or vent valve before performing any service or
maintenance.
Discharged air contains a very small percentage of compressor lubricating oil and care should
be taken to ensure downstream equipment is compatible.
If discharged air is to be ultimately released into a confined space, adequate ventilation must
be provided.
When using compressed air, always use appropriate personal protective equipment.
All pressure containing parts, especially flexible hoses and their couplings, must be regularly
inspected, be free from defects, and be replaced according to the manual instructions.
Avoid bodily contact with compressed air.
The safety valve located in the separator tank must be checked periodically for correct
operation.
Whenever the compressor is stopped, air will flow back into the compressor from downstream
devices or systems unless the service valve is closed. Install a check valve at the compressor
service valve to prevent reverse flow in the event of an unexpected shut down when the
service valve is open.
Disconnected air hoses whip and can cause serious injury or death. Always attach a safety
flow restrictor to each hose at the source of supply or branch line in accordance with OSHA
Regulation 29CFR Section 1926.302(b).
Never allow the compressor to sit stopped with pressure in the separator tank or piping.

Operation & Maintenance Manual Safety
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Decals
Decals are located on the compressor to point out potential safety hazards. Read and follow
these instructions. If you do not understand these instructions, inform your supervisor.
DANGER
!
(Red Background)
Indicates the presence of a hazard which WILL cause serious injury,
death, or property damage, if ignored.
WARNING
!
(Orange Background)
Indicates the presence of a hazard which CAN cause serious injury,
death, or property damage, if ignored.
CAUTION
!
(Yellow Background)
Indicates the presence of a hazard which WILL or CAN cause injury or
property damage, if ignored.
NOTICE
(Blue Background)
Indicates important set-up, operating, or maintenance information.

Safety Operation & Maintenance Manual
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DECALS - 9/274, 9/304, 12/254, 17/244, 21/224

Operation & Maintenance Manual Safety
14
DECALS - HP915, XP1000, XHP750

15
Operating Instructions

Operating & Maintenance Manual Operating Instructions
16
Operational Theory
This AutoStart System is designed to be used with portable air compressors using the View
Port and Titan Electronic System.
The AutoStart System provides the means of automatic start and stop for a portable air
compressor. The AutoStart System has a dedicated controller that connects to the
compressor J1939 CAN network and communicates with the compressor's Titan controller.
The Auto Start controller collects input information from sensors and switches and determines
if the compressor should be started or stopped. It sends commands to the Titan controller to
crank and start the compressor or to stop and initiate a cool down sequence. The two
controllers work together to implement the AutoStart functions.
The Titan controller automatically detects if the AutoStart controller is on the J1939 CAN
network at power up. Once the AutoStart controller is detected, the Titan controller will check
for its presence at each power up. If the Titan cannot detect the AutoStart controller, it will
issue an AutoStart communication ALERT. This will not prohibit the operation of the
compressor in manual mode even with an AutoStart communication ALERT.
AutoStart Controller
The AutoStart controller provides output signals to the Customer Interface Terminal Block,
TB1. These signals provide system status to the customer. These signals include, auto start
enabled, compressor running, and low fuel warning. These signals are 24 VDC level for an
"ON" indication and 0 VDC for an "OFF" indication. These outputs can source 2 amps at 24
VDC. These can be connected to customer provided devices. The AutoStart Controller lights
a red indicator lamp when the system is enabled and ready to start the compressor. The lamp
is located above the compressor control panel. The AutoStart Controller sounds an alarm and
will sound 10 seconds before the auto crank cycle begins.
Inputs
The Auto Start System has two types of customer inputs, Switch type and Pressure type, to
control the automatic start and stopping of the compressor. Only one type of input can be
selected to control start/stop of the compressor.
Switch Type Input
The switch input is connected to a pressure switch supplied by the customer. The pressure
switch can be a normally open (NO) type or normally closed (NC) type. The Auto Start System
can be configured for either. The NO type pressure switch will close upon reaching setpoint
pressure and the NC type pressure switch will open upon reaching setpoint pressure. The
Auto Start Controller provides a 12 volt DC voltage to the pressure switch. The current draw
is approximately 30 milliamps.
The switch input is located on the Customer Interface terminal Block, TB1, on terminal TB1-3
and the 12 volt DC is on terminal TB1-4. The customer pressure switch is connected across
these terminals.

Operating Instructions Operating & Maintenance Manual
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Pressure Type Input
The pressure type input uses a sense line from the plant air system to the compressor. This
input is on the front of the compressor close to the service air valve. This input connects to a
pressure transducer, PT20, on the compressor. The pressure range of this input is 0 psi to 500
psi, ± 2% of full scale. The start pressure can be set using the View Port user interface. Refer
to the Auto Start Setup and Operation Sequence section for instructions on how the setup can
be performed.
Outputs
The Auto Start Controller provides three 24 volt DC outputs. These outputs provide 24 volts
DC at 2 amps and can be used to drive indicator lamps, relay coils, etc. These outputs are
used to provide system status to the customer.
The customer connections are as shown in the table below:
Table 1
Customer Connections
Auto Start mode enabled is connected between TB1-1 and TB1-2, Compressor running
(blinking beacon) between TB1-5 and TB1-6 and Low fuel between TB1-7 and TB1-8. Switch
input for Auto Start Control between TB1-3 and TB1-4.
TB1-1 AutoStart Mode +24 VDC=ON. 0 VDC=OFF
TB1-2 GND
TB1-3 AutoStart Initiate +12 VDC=ON. 0 VDC=OFF
TB1-4 12 Volts DC
TB1-5 Compressor Running +24 VDC=ON. 0 VDC=OFF
TB1-6 GND
TB1-7 Low Fuel +24 VDC=ON. 0 VDC=OFF
TB1-8 GND

Operating & Maintenance Manual Operating Instructions
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19
AutoStart Setup and Operation
Sequence

Operating & Maintenance Manual AutoStart Setup and Operation Sequence
20
AutoStart System Setup
1. Install customer supplied one-way check valve at compressor service outlet.
WARNING
!
Do not connect the air discharge on this unit onto a common header with
any other unit of any description, or any other source of compressed air,
without first making sure a check valve is used between the header and
the unit. If this unit is connected in parallel with another unit of higher
discharge pressure and capacity, a safety hazard could occur in a back-
flow condition.
NOTE: One-way check valve must be installed. This compressor is
equipped with a pressure switch which does not allow cranking if tank
pressure is above 20 psi. Cranking or restart will not occur - AutoStart
enabled or disabled - until tank pressure blows down.
2. Determine which type of input will be used with the Auto Start system, switch
input or a pressure input. If the switch type of input is used, connect the switch
contacts to the customer connection terminal block, TB1, to TB1-3 and TB1-4.
If the pressure input is used, use the View Port to configure it as shown in
Figure 5.
3. Connect the AC power to the 230V socket on the front panel.
4. Connect the AC power to the battery charger, and if equipped, the compressor
AC cold weather kit.
5. Place the main control power switch, on the compressor control panel, in the
ON position.
6. Allow the compressor Electronic Control System to initialize.
7. Place the Main Power Switch to the RUN position.
8. Enable AutoStart in the Setup Screen in the ViewPort.