Download - QAS 60 Pd S2A APP EN - flexihire.com.au
QAS 60 Pd S2A APP
Instruction Manual for AC Generators English
ATLAS COPCO - PORTABLE ENERGY DIVISIONwww.atlascopco.com04/2012
QAS 60 PdInstruction Manual for AC Generators
Instruction manual ..................................................................................5
Circuit diagrams ...................................................................................111
Printed matter N°2954 6280 00
Original instructions
Warranty and Liability Limitation
Use only authorized parts. Any damage or malfunction caused b yWarranty or Product Liability.The manufacturer does not accept any s,additions or conversions made without Neglecting maintenance or making cha orhazards, including fire risk.While every effort has been made to e t,Atlas Copco does not assume responsib
Copyright 2012, Atlas Copco Airpower n
Any unauthorized use or copying of the This applies in particular to trademarks,
- 4 -
y the use of unauthorized parts is not covered b
liability for any damage arising from modificationthe manufacturer's approval in writing.nges to the setup of the machine can result in maj
nsure that the information in this manual is correcility for possible errors.
.v., Antwerp, Belgium.
contents or any part thereof is prohibited. model denominations, part numbers and drawings.
888
9
99012
3
3
3
33
4
4
45
4 Operating instructions............. 26
4.1 Before starting..................................26
4.2 Operating and setting Qc1002™ ....26
4.2.1 Starting..............................................264.2.2 During operation ..............................274.2.3 Stopping............................................274.2.4 Setting the Qc1002™ .......................284.2.4.1 Pushbutton and LED functions ........284.2.4.2 Qc1002™ menu overview................284.2.4.3 Qc1002™ menu description ............294.2.4.4 Parameter list....................................314.2.4.5 LOG list..............................................334.2.4.6 Remote start operation....................33
4.3 Operating and setting Qc2002™ ....34
4.3.1 Starting..............................................344.3.2 During operation ..............................344.3.3 Stopping............................................354.3.4 Setting the Qc2002™ .......................354.3.4.1 Pushbutton and LED functions ........354.3.4.2 Qc2002™ menu overview................374.3.4.3 Qc2002™ menu description ............374.3.4.4 Parameter list....................................404.3.4.5 LOG list..............................................45
ing to the latest technology. Follow the instructions in thislly before starting to use your machine.not assume responsibility for possible errors. Atlas Copco
- 5 -
Contents
1 Safety precautions for on-
site generators ............................ 8
1.1 Introduction........................................8
1.2 General safety precautions ...............9
1.3 Safety during transport and
installation........................................10
1.4 Safety during use and
operation ..........................................11
1.5 Safety during maintenance
and repair..........................................12
1.6 Tool applications safety ..................14
1.7 Battery safety precautions..............14
2 Main parts ................................. 15
2.1 General description .........................15
2.2 Markings ...........................................17
2.3 Mechanical features.........................17
2.3.1 Engine and alternator ......................172.3.2 Cooling system.................................172.3.3 Safety devices ..................................182.3.4 Bodywork..........................................182.3.5 Control panel ....................................18
2.3.6 Data plate and serial number ..........12.3.7 Drain plugs and filler caps...............12.3.8 Spillage free skid ..............................1
2.4 Electrical features.............................1
2.4.1 Control and indicator panels ...........12.4.1.1 Qc1002™ controller..........................12.4.1.2 Qc2002™ controller..........................22.4.1.3 Qc4002™ MkII controller .................22.4.2 Output terminal board .....................2
3 Installation and
connection .................................2
3.1 Lifting ................................................2
3.2 Installation........................................2
3.2.1 Indoor installation ............................23.2.2 Outdoor installation .........................2
3.3 Connecting the generator ...............2
3.3.1 Precautions for non-linear and sensitive loads ..................................2
3.3.2 Quality, minimum section and maximum length of cables..............2
3.3.3 Connecting the load.........................2
Congratulations on the purchase of your AC generator. It is a solid, safe and reliable machine, built accordbooklet and we guarantee you years of troublefree operation. Please read the following instructions carefuWhile every effort has been made to ensure that the information in this manual is correct, Atlas Copco does reserves the right to make changes without prior notice.
3
33444444555556
6
668
9
9
99
9
2
3
6.4.1 Qc1002™ and Qc2002™ alarms and remedies .......................83
6.4.1.1 Alarm overview ................................836.4.1.2 Fail classes........................................846.4.1.3 Solving alarms..................................846.4.2 Qc4002™ MkII alarms and
remedies ...........................................876.4.2.1 Fail Classes .......................................876.4.2.2 Diagnostics menu.............................876.4.2.3 Solving alarms..................................88
7 Storage of the generator......... 89
7.1 Storage..............................................89
7.2 Preparing for operation after
storage ..............................................89
8 Disposal..................................... 90
8.1 General..............................................90
8.2 Disposal of materials .......................90
9 Options available for
QAS 60 units............................. 91
9.1 Circuit diagrams...............................91
9.2 Overview of the electrical options .91
9.3 Description of the electrical
options ..............................................92
9.3.1 Automatic battery charger...............929.3.2 Battery switch...................................929.3.3 Engine coolant heater ......................929.3.4 Outlet sockets (S) - Set 1..................93
- 6 -
4.4 Operating and setting
Qc4002™ MkII ..................................46
4.4.1 Starting .............................................464.4.2 During operation ..............................464.4.3 Stopping ...........................................464.4.4 Setting the Qc4002™ MkII ...............474.4.4.1 Pushbutton and LED functions ........474.4.4.2 Qc4002™ MkII menu
overview ...........................................494.4.4.3 Changing settings ............................524.4.4.4 Standard modes...............................534.4.4.5 Standard applications......................544.4.4.6 Paralleling .........................................604.4.4.7 Overview of applications.................61
5 Maintenance.............................. 64
5.1 Maintenance schedule.....................64
5.1.1 Use of maintenance schedule.........695.1.2 Use of service paks ..........................69
5.2 Preventing low loads.......................70
5.3 Alternator maintenance
procedures........................................70
5.3.1 Measuring the alternator insulation resistance ........................70
5.4 Engine maintenance procedures....70
5.4.1 Engine oil level check ......................705.4.2 Engine oil and oil filter change .......715.4.3 Coolant check ...................................715.4.3.1 Monitoring coolant condition .........715.4.3.2 Topping up of coolant .....................725.4.3.3 Replacing the coolant ......................72
5.5 Adjustments and service
procedures........................................7
5.5.1 Cleaning coolers...............................75.5.2 Cleaning the fuel tank ......................75.5.3 Battery care.......................................75.5.3.1 Electrolyte .........................................75.5.3.2 Activating a dry-charged battery ....75.5.3.3 Recharging a battery........................75.5.3.4 Make-up distilled water ...................75.5.3.5 Periodic battery service ...................75.5.4 Servicing air filter engine ................75.5.4.1 Main parts.........................................75.5.4.2 Recommendation.............................75.5.4.3 Cleaning the dust trap......................75.5.4.4 Replacing the air filter element .......75.5.5 Replacing fuel filter element ...........7
5.6 Engine consumable specifications .7
5.6.1 Engine fuel specifications................75.6.2 Engine oil specifications ..................75.6.3 Engine coolant specifications..........7
6 Checks and trouble
shooting.....................................7
6.1 Checks...............................................7
6.1.1 Checking voltmeter P4.....................76.1.2 Checking ammeters P1, P2 and P3 .7
6.2 Engine troubleshooting...................7
6.3 Alternator troubleshooting.............8
6.4 Solving controller alarms ................8
0
0
- 7 -
9.3.5 Outlet sockets (S) - Set 2 .................949.3.6 Outlet sockets (S) - Set 3 .................959.3.7 Single frequency with
electronic speed control (SF) ..........969.3.8 Dual frequency with
electronic speed control (DF) ..........969.3.9 Electronic speed regulator ..............969.3.10 Dual voltage (2V)..............................979.3.11 Earth leakage relay...........................989.3.12 IT-relay ..............................................999.3.13 “Electricité de France” (EDF).........1019.3.14 COSMOS™ .....................................1019.3.15 COC box ..........................................101
9.4 Overview of the mechanical
options ............................................102
9.5 Desciption of the mechanical
options ............................................102
9.5.1 External fueltank connection (with/without quick couplings) ......102
9.5.2 Undercarriage (axle, towbar, towing eyes) ...................................103
9.5.3 Integrated spark arrestor ...............1039.5.4 Air inlet shut-off valve ...................103
10 Technical specifications
for QAS 60 units...................... 104
10.1 Readings on gauges ......................104
10.2 Settings of switches ......................104
10.3 Specifications of the engine/
alternator/unit................................104
10.4 Conversion list of SI units into
British units ....................................11
10.5 Dataplate.........................................11
or repairing the generator.
dnf
te
itty
ealdistye
ealys
al
tse
In general it is recommended that not more than twopeople operate the unit, more operators could lead tounsafe operating conditions. Take necessary steps tokeep unauthorized persons away from the unit andeliminate all possible sources of danger at the unit.When handling, operating, overhauling and/orperforming maintenance or repair on Atlas Copcoequipment, the mechanics are expected to use safeengineering practices and to observe all relevant localsafety requirements and ordinances. The following list isa reminder of special safety directives and precautionsmainly applicable to Atlas Copco equipment.Neglecting the safety precautions may endanger peopleas 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 resultingfrom neglecting these precautions or by non-observanceof ordinary caution and due care required in handling,operating, maintenance or repair, also if not expresslymentioned in this instruction manual, is disclaimed byAtlas Copco.
- 8 -
1 Safety precautions for on-site generators
To be read attentively and acted accordingly before towing, lifting, operating, performing maintenance
1.1 Introduction
The policy of Atlas Copco is to provide the users of theirequipment 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 areexpected 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 therelevant instruction manual. Besides giving detailedoperating instructions, it also gives specific informationabout safety, preventive maintenance, etc.Keep the manual always at the unit location, easyaccessible to the operating personnel.See also the safety precautions of the engine andpossible other equipment, which are separately sentalong or are mentioned on the equipment or parts of theunit.These safety precautions are general and somestatements will therefore not always apply to a particularunit.
Only people that have the right skills should be alloweto operate, adjust, perform maintenance or repair oAtlas Copco equipment. It is the responsibility omanagement to appoint operators with the appropriatraining and skill for each category of job.Skill level 1: OperatorAn operator is trained in all aspects of operating the unwith the push-buttons, and is trained to know the safeaspects.Skill level 2: Mechanical technicianA mechanical technician is trained to operate the unit thsame as the operator. In addition, the mechanictechnician is also trained to perform maintenance anrepair, as described in the instruction manual, and allowed to change settings of the control and safesystem. A mechanical technician does not work on livelectrical components.Skill level 3: Electrical technicianAn electrical technician is trained and has the samqualifications as both the operator and the mechanictechnician. In addition, the electrical technician macarry out electrical repairs within the various enclosureof the unit. This includes work on live electriccomponents.Skill level 4: Specialist from the manufacturerThis is a skilled specialist sent by the manufacturer or iagent to perform complex repairs or modifications to thequipment.
s,
de,
n,er
e,s,e
eyf
dlls.e
ton.e
rr
e
14 When working on the unit, wear safety clothing.Depending on the kind of activities these are: safetyglasses, ear protection, safety helmet (includingvisor), safety gloves, protective clothing, safetyshoes. Do not wear the hair long and loose (protectlong hair with a hairnet), or wear loose clothing orjewellery.
15 Take precautions against fire. Handle fuel, oil andanti-freeze with care because they are inflammablesubstances. Do not smoke or approach with nakedflame when handling such substances. Keep a fire-extinguisher in the vicinity.
16a On-site generators (with earthing pin):Earth the generator as well as the load properly.
16b On-site generators IT:Note: This generator is built to supply a sheeralternating current IT network.Earth the load properly.
- 9 -
The manufacturer does not accept any liability for anydamage arising from the use of non-original parts and formodifications, additions or conversions made withoutthe manufacturer’s approval in writing.If any statement in this manual does not comply withlocal legislation, the stricter of the two shall be applied.Statements in these safety precautions should not beinterpreted as suggestions, recommendations orinducements that it should be used in violation of anyapplicable laws or regulations.
1.2 General safety precautions
1 The owner is responsible for maintaining the unit ina safe operating condition. Unit parts andaccessories must be replaced if missing orunsuitable for safe operation.
2 The supervisor, or the responsible person, shall atall times make sure that all instructions regardingmachinery and equipment operation andmaintenance are strictly followed and that themachines with all accessories and safety devices, aswell as the consuming devices, are in good repair,free of abnormal wear or abuse, and are nottampered with.
3 Whenever there is an indication or any suspicionthat an internal part of a machine is overheated, themachine shall be stopped but no inspection coversshall be opened before sufficient cooling time haselapsed; this to avoid the risk of spontaneousignition of oil vapour when air is admitted.
4 Normal ratings (pressures, temperatures, speedetc.) shall be durably marked.
5 Operate the unit only for the intended purpose anwithin its rated limits (pressure, temperaturspeeds, etc.).
6 The machinery and equipment shall be kept cleai.e. as free as possible from oil, dust or othdeposits.
7 To prevent an increase in working temperaturinspect and clean heat transfer surfaces (cooler finintercoolers, water jackets, etc.) regularly. See thmaintenance schedule.
8 All regulating and safety devices shall bmaintained with due care to ensure that thefunction properly. They may not be put out oaction.
9 Pressure and temperature gauges shall be checkeregularly with regard to their accuracy. They shabe replaced whenever outside acceptable tolerance
10 Safety devices shall be tested as described in thmaintenance schedule of the instruction manual determine that they are in good operating conditio
11 Mind the markings and information labels on thunit.
12 In the event the safety labels are damaged odestroyed, they must be replaced to ensure operatosafety.
13 Keep the work area neat. Lack of order will increasthe risk of accidents.
e,ot
k,ftde,
e
ggrrgng
ds,
eiren
gsad
11 A hoist has to be installed in such a way that theobject will be lifted perpendicular. If that is notpossible, the necessary precautions must be taken toprevent load-swinging, e.g. by using two hoists,each at approximately the same angle not exceeding30° from the vertical.
12 Locate the unit away from walls. Take allprecautions to ensure that hot air exhausted from theengine and driven machine cooling systems cannotbe recirculated. If such hot air is taken in by theengine or driven machine cooling fan, this maycause overheating of the unit; if taken in forcombustion, the engine power will be reduced.
13 Generators shall be stalled on an even, solid floor,in a clean location with sufficient ventilation. If thefloor is not level or can vary in inclination, consultAtlas Copco.
14 The electrical connections shall correspond to localcodes. The machines shall be earthed and protectedagainst short circuits by fuses or circuit breakers.
15 Never connect the generator outlets to aninstallation which is also connected to a publicmains.
16 Before connecting a load, switch off thecorresponding circuit breaker, and check whetherfrequency, voltage, current and power factorcomply with the ratings of the generator.
17 Before transportation of the unit, switch off all thecircuit breakers.
- 10 -
1.3 Safety during transport and
installation
To lift a unit, all loose or pivoting parts, e.g. doors andtowbar, shall first be securely fastened.Do not attach cables, chains or ropes directly to thelifting eye; apply a crane hook or lifting shackle meetinglocal safety regulations. Never allow sharp bends inlifting cables, chains or ropes.Helicopter lifting is not allowed. It is strictly forbidden to dwell or stay in the risk zoneunder a lifted load. Never lift the unit over people orresidential areas. Lifting acceleration and retardationshall be kept within safe limits.1 Before towing the unit:
- check the towbar, the brake system and thetowing eye. Also check the coupling of thetowing vehicle,
- check the towing and brake capability of thetowing vehicle,
- check that the towbar, jockey wheel or stand legis safely locked in the raised position,
- ascertain that the towing eye can swivel freely onthe hook,
- check that the wheels are secure and that thetyres are in good condition and inflated correctly,
- connect the signalisation cable, check all lightsand connect the pneumatic brake couplers,
- attach the safety break-away cable or safetychain to the towing vehicle,
- remove wheel chocks, if applied, and disengagethe parking brake.
2 To tow a unit use a towing vehicle of amplecapacity. Refer to the documentation of the towingvehicle.
3 If a unit is to be backed up by a towing vehicldisengage the overrun brake mechanism (if it is nan automatic mechanism).
4 In case of transporting a non-trailer unit on a trucfasten it to the truck by attaching straps via fork liholes, via the holes in the frame at the front anback or via the lifting beam. To prevent damagnever put straps on the roof surface of the unit.
5 Never exceed the maximum towing speed of thunit (mind the local regulations).
6 Place the unit on level ground and apply the parkinbrake before disconnecting the unit from the towinvehicle. Unclip the safety break-away cable osafety chain. If the unit has no parking brake ojockey wheel, immobilize the unit by placinchocks in front of and/or behind the wheels. Whethe towbar can be positioned vertically, the lockindevice must be applied and kept in good order.
7 To lift heavy parts, a hoist of ample capacity, testeand approved according to local safety regulationshall be used.
8 Lifting hooks, eyes, shackles, etc., shall never bbent and shall only have stress in line with thedesign load axis. The capacity of a lifting devicdiminishes when the lifting force is applied at aangle to its load axis.
9 For maximum safety and efficiency of the liftinapparatus all lifting members shall be applied anear to perpendicular as possible. If required, lifting beam shall be applied between hoist anload.
10 Never leave a load hanging on a hoist.
tokrr
g
lle
totod,
ne,f
re
ldg
r
e-ertlyar
- above 95 dB(A): the warning(s) at theentrance(s) shall be completed with therecommendation that also occasional visitorsshall wear ear protectors,
- above 105 dB(A): special ear protectors that areadequate for this noise level and the spectralcomposition of the noise shall be provided and aspecial warning to that effect shall be placed ateach entrance.
10 The unit has parts of which the temperature can bein exess of 80 °C (176 °F), and which may beaccidentally touched by personnel when openingthe machine during or just after operation.Insulation or safety guards protecting these partsshall not be removed before the parts have cooleddown sufficiently, and must be re-installed beforeoperating the machine. As it is not possible toinsulate or protect all hot parts by guards (e.g.exhaust manifold, exhaust turbine), the operator /service engineer must always be aware not to touchhot parts when opening a machine door.
11 Never operate the unit in surroundings where thereis a possibility of taking in flammable or toxicfumes.
12 If the working process produces fumes, dust orvibration hazards, etc., take the necessary steps toeliminate the risk of personnel injury.
13 When using compressed air or inert gas to cleandown equipment, do so with caution and use theappropriate protection, at least safety glasses, forthe operator as well as for any bystander. Do notapply compressed air or inert gas to your skin ordirect an air or gas stream at people. Never use it toclean dirt from your clothes.
- 11 -
1.4 Safety during use and
operation
1 When the unit has to operate in a fire-hazardousenvironment, each engine exhaust has to beprovided with a spark arrestor to trap incendiarysparks.
2 The exhaust contains carbon monoxide which is alethal gas. When the unit is used in a confinedspace, conduct the engine exhaust to the outsideatmosphere by a pipe of sufficient diameter; do thisin such a way that no extra back pressure is createdfor the engine. If necessary, install an extractor.Observe any existing local regulations. Make sure that the unit has sufficient air intake foroperation. If necessary, install extra air intake ducts.
3 When operating in a dust-laden atmosphere, placethe unit so that dust is not carried towards it by thewind. Operation in clean surroundings considerablyextends the intervals for cleaning the air intakefilters and the cores of the coolers.
4 Never remove a filler cap of the cooling watersystem of a hot engine. Wait until the engine hassufficiently cooled down.
5 Never refill fuel while the unit is running, unlessotherwise stated in the Atlas Copco InstructionBook (AIB). Keep fuel away from hot parts such asair outlet pipes or the engine exhaust. Do not smokewhen fuelling. When fuelling from an automaticpump, an earthing cable should be connected to theunit to discharge static electricity. Never spill norleave oil, fuel, coolant or cleansing agent in oraround the unit.
6 All doors shall be shut during operation so as not disturb the cooling air flow inside the bodyworand/or render the silencing less effective. A dooshould be kept open for a short period only e.g. foinspection or adjustment.
7 Periodically carry out maintenance works accordinto the maintenance schedule.
8 Stationary housing guards are provided on arotating or reciprocating parts not otherwisprotected and which may be hazardous personnel. Machinery shall never be put inoperation, when such guards have been removebefore the guards are securely reinstalled.
9 Noise, even at reasonable levels, can cause irritatioand disturbance which, over a long period of timmay cause severe injuries to the nervous system ohuman beings.When the sound pressure level, at any point whepersonnel normally has to attend, is:- below 70 dB(A): no action needs to be taken,- above 70 dB(A): noise-protective devices shou
be provided for people continuously beinpresent in the room,
- below 85 dB(A): no action needs to be taken fooccasional visitors staying a limited time only,
- above 85 dB(A): room to be classified as a noishazardous area and an obvious warning shall bplaced permanently at each entrance to alepeople entering the room, for even relativeshort times, about the need to wear eprotectors,
g.e
ct
syree.sll
isde
soleis
lsre
rer
s
to
1.5 Safety during maintenance
and repair
Maintenance, overhaul and repair work shall only becarried 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 goodcondition.
2 Parts shall only be replaced by genuine Atlas Copcoreplacement 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 tothe starting equipment. On engine-driven units the battery shall bedisconnected and removed or the terminals coveredby insulating caps. On electrically driven units the main switch shall belocked in open position and the fuses shall be takenout. A warning sign bearing a legend such as “workin progress; do not supply voltage” shall be attachedto the fuse box or main switch.
4 Prior to stripping an engine or other machine orundertaking major overhaul on it, prevent allmovable parts from rolling over or moving.
- 12 -
14 When washing parts in or with a cleaning solvent,provide the required ventilation and use appropriateprotection such as a breathing filter, safety glasses,rubber apron and gloves, etc.
15 Safety shoes should be compulsory in anyworkshop and if there is a risk, however small, offalling objects, wearing of a safety helmet should beincluded.
16 If there is a risk of inhaling hazardous gases, fumesor dust, the respiratory organs must be protected anddepending on the nature of the hazard, so must theeyes and skin.
17 Remember that where there is visible dust, the finer,invisible particles will almost certainly be presenttoo; but the fact that no dust can be seen is not areliable indication that dangerous, invisible dust isnot present in the air.
18 Never operate the generator in excess of its limits asindicated in the technical specifications and avoidlong no-load sequences.
19 Never operate the generator in a humid atmosphere.Excessive moisture causes worsening of thegenerator insulation.
20 Do not open electrical cabinets, cubicles or otherequipment while voltage is supplied. If such cannotbe avoided, e.g. for measurements, tests oradjustments, have the action carried out by aqualified electrician only, with appropriate tools,and ascertain that the required bodily protectionagainst electrical hazards is applied.
21 Never touch the power terminals during operationof the machine.
22 Whenever an abnormal condition arises, e.excessive vibration, noise, odour, etc., switch thcircuit breakers to OFF and stop the engine. Correthe faulty condition before restarting.
23 Check the electric cables regularly. Damaged cableand insufficient tightening of connections macause electric shocks. Whenever damaged wires odangerous conditions are observed, switch thcircuit breakers to OFF and stop the enginReplace the damaged wires or correct the dangeroucondition before restarting. Make sure that aelectric connections are securely tightened.
24 Avoid overloading the generator. The generator provided with circuit breakers for overloaprotection. When a breaker has tripped, reduce thconcerned load before restarting.
25 If the generator is used as stand-by for the mainsupply, it must not be operated without contrsystem which automatically disconnects thgenerator from the mains when the mains supply restored.
26 Never remove the cover of the output terminaduring operation. Before connecting odisconnecting wires, switch off the load and thcircuit breakers, stop the machine and make suthat the machine cannot be started inadvertently othere is any residual voltage on the power circuit.
27 Running the generator at low load for long periodwill reduce the lifetime of the engine.
28 When operating the generator in Remote or Aumode, observe all relevant local legislation.
detss,df
al
r,tog.t,g-
r
llrr
aleg
tok
18 Maintenance and repair work should be recorded inan operator’s logbook for all machinery. Frequencyand nature of repairs can reveal unsafe conditions.
19 When hot parts have to be handled, e.g. shrinkfitting, special heat-resistant gloves shall be usedand, if required, other body protection shall beapplied.
20 When using cartridge type breathing filterequipment, ascertain that the correct type ofcartridge is used and that its useful service life is notsurpassed.
21 Make sure that oil, solvents and other substanceslikely to pollute the environment are properlydisposed of.
22 Before clearing the generator for use aftermaintenance or overhaul, submit it to a testrun,check that the AC power performance is correct andthat the control and shutdown devices functioncorrectly.
- 13 -
5 Make sure that no tools, loose parts or rags are leftin or on the machine. Never leave rags or looseclothing near the engine air intake.
6 Never use flammable solvents for cleaning (fire-risk).
7 Take safety precautions against toxic vapours ofcleaning liquids.
8 Never use machine parts as a climbing aid.9 Observe scrupulous cleanliness during maintenance
and repair. Keep away dirt, cover the parts andexposed openings with a clean cloth, paper or tape.
10 Never weld on or perform any operation involvingheat near the fuel or oil systems. Fuel and oil tanksmust be completely purged, e.g. by steam-cleaning,before carrying out such operations. Never weld on,or in any way modify, pressure vessels. Disconnectthe alternator cables during arc welding on the unit.
11 Support the towbar and the axle(s) securely ifworking underneath the unit or when removing awheel. Do not rely on jacks.
12 Do not remove any of, or tamper with, the sound-damping material. Keep the material free of dirt andliquids such as fuel, oil and cleansing agents. If anysound-damping material is damaged, replace it toprevent the sound pressure level from increasing.
13 Use only lubricating oils and greases recommendeor approved by Atlas Copco or the machinmanufacturer. Ascertain that the selected lubricancomply with all applicable safety regulationespecially with regard to explosion or fire-risk anthe possibility of decomposition or generation ohazardous gases. Never mix synthetic with mineroil.
14 Protect the engine, alternator, air intake filteelectrical and regulating components, etc., prevent moisture ingress, e.g. when steam-cleanin
15 When performing any operation involving heaflames or sparks on a machine, the surroundincomponents shall first be screened with nonflammable material.
16 Never use a light source with open flame foinspecting the interior of a machine.
17 When repair has been completed, the machine shabe barred over at least one revolution foreciprocating machines, several revolutions forotary ones to ensure that there is no mechanicinterference within the machine or driver. Check thdirection of rotation of electric motors when startinup the machine initially and after any alteration the electrical connection(s) or switch gear, to checthat the oil pump and the fan function properly.
ins:n
it.
- 14 -
1.6 Tool applications safety
Apply the proper tool for each job. With the knowledgeof correct tool use and knowing the limitations of tools,along with some common sense, many accidents can beprevented.Special service tools are available for specific jobs andshould be used when recommended. The use of thesetools will save time and prevent damage to parts.
1.7 Battery safety precautions
When servicing batteries, always wear protectingclothing and glasses.1 The electrolyte in batteries is a sulphuric acid
solution which is fatal if it hits your eyes, and whichcan cause burns if it contacts your skin. Therefore,be careful when handling batteries, e.g. whenchecking the charge condition.
2 Install a sign prohibiting fire, open flame andsmoking at the post where batteries are beingcharged.
3 When batteries are being charged, an explosive gasmixture forms in the cells and might escape throughthe vent holes in the plugs.Thus an explosive atmosphere may form around thebattery if ventilation is poor, and can remain in andaround the battery for several hours after it has beencharged. 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) parallel to the unit battery (CB) with booster cableconnect the + pole of AB to the + pole of CB, theconnect the - pole of CB to the mass of the unDisconnect in the reverse order.
tand-by in cases of interruption of the mains. The generator0 Pd generator is driven by a fluid-cooled diesel engine,
Lifting beamGuiding rodSide doorsEngine exhaustData plateDoor, access to control and indicator panelOutput terminal boardHole for forkliftEarthing rod
H Drain and access hole (in the frame)F Filler cap fuel
- 15 -
2 Main parts
2.1 General description
The QAS 60 Pd is an AC generator, built for continuous running at sites where no electricity is available or as soperates at 50/60 Hz, 230/240 V in line-to-neutral mode and 400/480 V in line-to-line mode. The QAS 6manufactured by PERKINS. An overview of the main parts is given in the diagram below.
123456789
DFC
AlternatorF Air filter
CouplingFO Drain flexible engine oilH Drain and access hole (in the frame)PF Drain plug fuel
EngineFan
F Filler cap fuelO Filler cap engine oilW Filler cap coolant
Fuel filter1 BatteryF Oil filterLD Engine oil level dipstick
Pre fuel filterRadiator
- 16 -
AACDDDEFFCFCFCFFGOOPFR
DPF, DH
C
2.3 Mechanical features
The mechanical features described in this chapter arestandard provided on this generator. For all othermechanical features, see “Overview of themechanical options” on page 102.
2.3.1 Engine and alternator
The alternator is driven by a fluid-cooled dieselengine. The engine’s power is transmitted through adirect disc coupling.The generator houses a single bearing alternator witha dedicated voltage regulator.The synchronous brushless alternator has Class Hrotor and stator windings in an IP23 housing.
2.3.2 Cooling system
The engine is provided with a water cooler. Thecooling air is generated by a fan, driven by the engine.
Indicates the partnumbers of the different service packs and of the engine oil. These parts can be ordered to the factory.
XXXXXXXXXXXXXXX
Engine oil PAROIL E PAROIL Extra
Engine coolant PARCOOL EG
XXXXXXXXX XXXX XXXX XXXXXXXXXXX XXXX XXXX XX
XX XXXXXXX XXXX XXXX XX XXXX XXXX XXXX XXXXXXX XXXX XXXX XX XXXX XXXX XXXX XXXXXXX XXXX XXXX XX
XX XXXXXXX XXXX XXXX XXXX XXXXXXX XXXX XXXX XXXX XXXXXXX XXXX XXXX XX
- 17 -
2.2 Markings
A brief description of all markings provided on thegenerator is given hereafter.
Indicates the presence of electric shock hazards. Enclosures marked with these symbols should only be opened by trained or instructed people.
Indicates that the engine exhaust is a hot and harmful gas, which is toxic in case of inhalation. Always make sure that the unit is operated outside or in a well-ventilated room.
Indicates that these parts can become very hot during operation (e.g. engine, cooler, etc.). Always make sure that these parts are cooled down before touching them.
Indicates that the guiding rods may not be used to lift the generator. Always use the lifting rod in the roof of the generator to lift it.
Indicates a lifting point of the generator.
Indicates that the generator may be refuelled with diesel fuel only.
Indicates the drain for the engine oil.
diesel
Indicates the drain for the coolant.
Indicates the drain plug for the enginefuel.
Use PAROIL E only.
Indicates the different earthing connections on the generator.
Indicates that the alternator should notbe cleaned with high pressurised water.
Indicates the battery switch.
Indicates that the unit may start automatically and that the instruction book has to be consulted prior to use.
Read the instruction manualbefore using the lifting eye.
Indicates the 3-way valve.
eeee
e
ian
eas
s,d
d,
- 18 -
2.3.3 Safety devices
The engine is equipped with low oil pressure and highoil temperature shut-down switches.
2.3.4 Bodywork
The alternator, the engine, the cooling system, etc. areenclosed in a sound-insulated bodywork that can beopened by means of side doors (and service plates).The generator can be lifted by using the lifting eyeintegrated in the bodywork (roof). To be able to liftthe QAS 60 by means of a forklift, rectangular holesare provided in the frame.The earthing rod, connected to the generator’s earthterminal is located at the bottom of the frame on theoutside.
2.3.5 Control panel
The control panel grouping volt and amp meters,control switch etc., is placed at the rear end.
2.3.6 Data plate and serial number
The generator is furnished with a data plate showingthe product code, the unit number and the poweroutput (see “Dataplate” on page 110).The serial number is located on the right-hand frontside of the frame.
2.3.7 Drain plugs and filler caps
The drain holes for the engine oil, the coolant and thplug for the fuel, are located and labelled on thframe. The fuel drain plugs are located; one at thbottom of the frame and the other at the cubicle sidof the frame.The drain flexible for engine oil can be brought to thoutside of the generator through the drain hole.
The filler cap for the engine coolant is accessible van opening in the roof. The fuel filler cap is located ithe side panel.
2.3.8 Spillage free skid
A Spillage free skid with forklift slots allows thcustomer to transport the generator easily with forklift. It avoids accidental spilling of engine fluidand thus helps to protect the environment.The leaking fluid can be removed via drain holesecured by drain plugs. Tighten the plugs firmly ancheck for leakages. When removing the leaking fluiobserve all relevant local legislation.
The drain hole can also be used toguide external fueltank connections.When connecting an externalfueltank, use the 3-way valves. Referto External fueltank connection(with/without quick couplings).
!
esg
eiseydd
Qc1002™ Module
The Qc1002™ module is located inside the controlpanel. This control module will carry out allnecessary tasks to control and protect a generator,regardless of the use of the generator.This means that the Qc1002™ module can be used forseveral applications.
Qc 1002
145
- 19 -
2.4 Electrical features
The electrical features described in this chapter arestandard provided on this generator. For all otherelectrical features, see “Overview of the electricaloptions” on page 91.
2.4.1 Control and indicator panels
To operate the generator, one of the following controlpanels is installed.
2.4.1.1 Qc1002™ controller
General description Qc1002™ control panel
A1 .......Qc1002™ display
F10......Fuse
The fuse activates when the current from thbattery to the engine control circuit exceedits setting. The fuse can be reset by pushinthe button.
H0 .......Panel light
S2 .......Emergency stop button
Push the button to stop the generator in casof an emergency. When the button pressed, it must be unlocked, before thgenerator can be restarted. The emergencstop button can be secured in the lockeposition with the key, to avoid unauthorizeuse.
S20 .....ON/OFF/REMOTE switch
To start up the unit (locally or remote).
X25 .....Terminal strip
Qc 1002145
X25
S20
F10
A1
S2
S4
H0
eiseydd
et
ep
Qc2002™ Module
The Qc2002™ module is located inside the controlpanel. This control module will carry out allnecessary tasks to control and protect a generator,regardless of the use of the generator.This means that the Qc2002™ module can be used forseveral applications.
- 20 -
2.4.1.2 Qc2002™ controller
General description Qc2002™ control panel
A1 .......Qc2002™ display
F10...... Fuse
The fuse activates when the current from thebattery to the engine control circuit exceedsits setting. The fuse can be reset by pushingthe button.
H0 .......Panel light
S2 .......Emergency stop button
Push the button to stop the generator in casof an emergency. When the button pressed, it must be unlocked, before thgenerator can be restarted. The emergencstop button can be secured in the lockeposition with the key, to avoid unauthorizeuse.
S20 .....ON/OFF switch
Position O: No voltage is applied to thQc2002™ module, the generator will nostart.Position I: Voltage is applied to thQc2002™ module, it is possible to start uthe generator.
X25 .....Terminal strip
G
X25
S20
F10
A1
S2
S4
H0
tity
eiseydd
t
ell
eo
X25 .....Connection block
Inside the cubicle. Allows customerconnections.
X30 .....Connector X30
Connector for communication with othergenerators with Qc4002™ MkII whenparalleling, both in ALS and PMS mode. Anadapter can be plugged in. See page 58.
Refer to circuit diagram for thecorrect connection.!
- 21 -
2.4.1.3 Qc4002™ MkII controller
General description Qc4002™ MkII control panel
A2 .......Qc4002™ MkII display
F10......Fuse
The fuse (10 A) activates when the currenfrom the battery to the engine control circuexceeds its setting. The fuse can be reset bpushing the button.
S2 .......Emergency stop button
Push the button to stop the generator in casof an emergency. When the button pressed, it must be unlocked, before thgenerator can be restarted. The emergencstop button can be secured in the lockeposition with the key, to avoid unauthorizeuse.
S12 .....Frequency selector switch (50 Hz/60 Hz)
Allows to choose the frequency of the outpuvoltage: 50 Hz or 60 Hz.
S20 .....ON/OFF switch
Position O: No voltage is applied to thQc4002™ MkII module, the generator winot start.Position I: Voltage is applied to thQc4002™ MkII module, it is possible tstart up the generator.
T1 T2 T3
M3
Q1
X30
50Hz - 60Hz
X1
Qc4002
G
!
OK
LOG
S20F10
S12S2A2
X25X30
Changing the output frequency isonly allowed when the unit hasstopped.
!
rl
S2........Emergency stop button
Push the button to stop the generator in caseof an emergency. When the button ispressed, it must be unlocked, by turning itanti-clockwise, before the generator can berestarted. The emergency stop button can besecured in the locked position with the key,to avoid unauthorized use.
Q1 .......Main circuit breaker
Interrupts the power supply to X1 when ashort-circuit occurs at the load side, or whenthe earth leak detector (30 mA) or theovercurrent protection (100 A) is activatedor when the shunt trip is energized. It mustbe reset manually after eliminating theproblem.
X1 .......Main power supply (400 V AC)
Terminals L1, L2, L3, N (= neutral) and PE(= earthing), hidden behind the control paneldoor and behind a small transparent door.
- 22 -
Qc4002™ MkII module
The Qc4002™ MkII module is located inside thecontrol panel, and communicates with a display unit,located in front of the control panel. This controlmodule will carry out all necessary tasks to controland protect a generator, regardless of the use of thegenerator. This means that the Qc4002™ MkII module can beused for several applications.
2.4.2 Output terminal board
The cubicle provides a terminal board for easieconnection of cables. It is situated below the controand indicator panel.
www.atlascopco.com
Qc400
2
G
!
OK
LOG
X1
Q1
S2
t,e
3.2 Installation
3.2.1 Indoor installation
If the generator is operated indoors, install an exhaustpipe of sufficient diameter to duct the engine exhausttowards the outside. Check for sufficient ventilationso that the cooling air is not recirculated.
3.2.2 Outdoor installation
– Place the generator on a horizontal, even and solidfloor. The generator can operate in a slant positionnot exceeding 15° (in both senses: front/rear andleft/right).
– The generator should be kept with the doorsclosed, in order to avoid the ingress of water anddust. Dust ingress reduces the lifetime of filtersand may reduce your generator's performance.
– Check that the engine exhaust is not directedtowards people.
– Locate the rear end of the generator upwind, awayfrom contaminated windstreams and walls. Avoidrecirculation of exhaust air from the engine. Thiscauses overheating and engine power decrease.
For more information about indoorinstallation, consult your local AtlasCopco dealer.
!
- 23 -
3 Installation and connection
3.1 Lifting
The lifting eye, to lift the generator by means of ahoist, is integrated in the bodywork and easilyaccessible from the outside. The recesses in the roofhave guiding rods at both sides.When lifting the generator, the hoist has to be placedin such a way that the generator, which must beplaced level, will be lifted vertically.
To be able to lift the generator by means of a forklifrectangular holes are provided at the bottom of thframe.
Never use the guiding rods to lift thegenerator.
Lifting acceleration and retardationmust be kept within safe limits (max.2 g).Helicopter lifting is not allowed.
!
!
erss,
-k
e-
e
3.3.2 Quality, minimum section and
maximum length of cables
The cable connected to the terminal board of thegenerator must be selected in accordance with locallegislation. The type of cable, its rated voltage andcurrent carrying capacity are determined byinstallation conditions, stress and ambienttemperature. For flexible wiring, rubber-sheathed,flexible core conductors of the type H07 RN-F(Cenelec HD.22) or better must be used.The following table indicates the maximum allowable3-phase currents (in A), in an ambient temperature of40°C, for cable types (multiple and single core PVCinsulated conductors and H07 RN-F multiple coreconductors) and wire sections as listed, in accordancewith VDE 0298 installation method C3. Localregulations remain applicable if they are stricter thanthose proposed below.
Wire section Max. current (A) (mm²) Multiple core Single core H07 RN-F
2.5 22 25 214 30 33 286 38 42 36
10 53 57 5016 71 76 6725 94 101 8835 114 123 11050 138 155 13870 176 191 17095 212 228 205
- 24 -
– Leave enough space for operation, inspection andmaintenance (at least 1 meter at each side).
– Check that the inner earthing system is incompliance with the local legislation.
– Use coolant for the engine cooling system. Referto the Engine instruction book for the propercoolant mixture.
– Check the tightness of the bolts and nuts.
– Install the earthing rod as near as possible to thegenerator and make sure not to have a contactvoltage higher than 25 V.
– Check that the cable end of the earthing rod isconnected to the earth terminal.
3.3 Connecting the generator
3.3.1 Precautions for non-linear and
sensitive loads
The most common non-linear, 3-phase loads arthyristor/rectifier-controlled loads, such as convertosupplying voltage to variable speed motoruninterruptable power supplies and Telecomsupplies. Gas-discharge lighting arranged in singlephase circuits generate high 3rd harmonics and risfor excessive neutral current.Loads most sensitive to voltage distortion includincandescent lamps, discharge lamps, computers, Xray equipment, audio amplifiers and elevators.Consult Atlas Copco for measures against the adversinfluence of non-linear loads.
The generator is wired for a TN-system to IEC 364-3, i.e. one point inthe power source directly earthed -in this case the neutral. The exposedconductive parts of the electricinstallation must be directlyconnected to the functional earth.If operating the generator inanother power system, e.g. an IT-system, other protective devicesrequired for these types must beinstalled. In any case only a qualifiedelectrician is authorized to removethe connection between the neutral(N) and earth terminals in theterminal box of the alternator.
!
Non-linear loads draw currents withhigh contents in harmonics, causingdistortion in the wave form of thevoltage generated by the alternator.
!
dalal.
t
h,s.
– Open the door of the control and indicator paneland the transparent door in front of the terminalboard X1.
– Provide the wire ends with cable lugs suited forthe cable terminals.
– Loosen the cable clamp and push the wire ends ofthe load cable through the orifice and clamp.
– Connect the wires to the proper terminals (L1, L2,L3, N and PE) of X1 and tighten the boltssecurely.
– Tighten the cable clamp.– Close the transparent door in front of X1.
- 25 -
The lowest acceptable wire section and thecorresponding maximum cable or conductor lengthfor multiple core cable or H07 RN-F, at rated current(20 A), for a voltage drop e lower than 5% and at apower factor of 0.80, are respectively 2.5 mm² and144 m. In case electric motors must be started,oversizing the cable is advisable.The voltage drop across a cable can be determined asfollows:
e = Voltage drop (V)I = Rated current (A)
L = Length of conductors (m)R = Resistance (/km to VDE 0102)X = Reactance (/km to VDE 0102)
3.3.3 Connecting the load
3.3.3.1 Site distribution panel
If outlet sockets are provided, they must be mounteon a site distribution panel supplied from the terminboard of the generator and in compliance with locregulations for power installations on building sites
3.3.3.2 Protection
– Check whether frequency, voltage and currencomply with the ratings of the generator.
– Provide a load cable, without excessive lengtand lay it out in a safe way without forming coil
e 3 I L R cos X sin+ 1000
--------------------------------------------------------------------------------=
For safety reasons, it is necessary toprovide an isolating switch orcircuit breaker in each load circuit.Local legislation may impose the useof isolating devices which can belocked.
!
eilk
fstif
-y.’sy
er
e
e
e
t
4.2 Operating and setting
Qc1002™
4.2.1 Starting
To start up the unit locally, proceed as follows:
– Switch on the battery switch, if applicable.
– Switch off circuit breaker Q1. This is notnecessary when a plant contactor is installedbetween Q1 and the load.
– Put the starter switch S20 in position I (ON). Theunit starts a preheating cycle which takes 12seconds.
– The unit will start.In cold conditions the unit might not start from thefirst attempt. The controller will take 3 startattempts.
– Switch on circuit breaker Q1 in case no contactoris installed.
- 26 -
4 Operating instructions
4.1 Before starting
– With the generator standing level, check thengine oil level and top up if necessary. The olevel must be near to, but not exceed the high maron the engine oil level dipstick.
– Check the coolant level in the expansion tank othe engine cooling system. The coolant level mube near to the FULL mark. Add coolant necessary.
– Drain any water and sediment from the fuel prefilter. Check the fuel level and top up if necessarIt is recommended to fill the tank after the dayoperation to prevent water vapor in a nearly empttank from condensing.
– Drain leaking fluid from the frame.– Check the vacuum indicator of the air filter. If th
red part shows completely, replace the filteelement.
– Press the dust evacuator of the air filter to removdust.
– Check the generator for leakage, tightness of wirterminals, etc. Correct if necessary.
– Check that circuit breaker Q1 is switched off.
– Check that fuse F10 has not tripped and that themergency stop is in the OUT position.
– Check that the load is switched off.
– Check that the earth fault protection (N13) has notripped (reset if necessary).
In your own interest, always strictlyobserve all relevant safetyinstructions.Do not operate the generator inexcess of the limitations mentionedin the Technical Specifications.Local rules concerning the settingup of low voltage power installations(below 1000 V) must be respectedwhen connecting site distributionpanels, switch gear or loads to thegenerator.At each start-up and at any time anew load is connected, the earthingand protections (GB trip and earthleakage relay) of the generator mustbe verified. Earthing must be doneeither by the earthing rod or, ifavailable, by an existing, suitableearthing installation. The protectivesystem against excessive contactvoltage is not effective unless asuitable earthing is made.
!
eat
el-
n,k
0
To stop the unit when the starter switch is in
position , proceed as follows:
– Switch off the load.– Stop the engine by putting the remote start/stop
switch in position stop or by putting the starterswitch S20 in position O.
– Lock all doors to avoid unauthorized access.
- 27 -
To start up the unit from a remote location,
proceed as follows:
– Put the starter switch S20 in position .– Switch on circuit breaker Q1.– Put the remote start/stop switch in position start.
The unit starts a preheating cycle which takes 12seconds.
– The unit will start.In cold conditions the unit might not start from thefirst attempt. The controller will take 3 startattempts.
– An external contactor can be connected andcontrolled by the Qc1002™.
4.2.2 During operation
Regularly carry out following checks:– Check the analogue meters (P1-P4) and the
controller display for normal readings.
– Check for leakage of oil, fuel or coolant.
– Check, by means of the generator gauges, that thvoltage between the phases is identical and ththe rated current is not exceeded.
– When single-phase loads are connected to thgenerator output terminals, keep all loads welbalanced.
– If circuit breakers have tripped during operatioswitch off the load and stop the generator. Checand, if necessary, decrease the load.
4.2.3 Stopping
To stop the unit locally, proceed as follows:
– Switch off the load.– Switch off circuit breaker Q1.– Stop the engine by putting the starter switch S2
in position O.– Lock all doors to avoid unauthorized access.
Avoid to let the engine run out offuel. If it happened, priming willspeed up the starting.
Avoid long low-load periods(< 30%). In this case, an outputdrop and higher oil consumption ofthe engine could occur. Refer to‘Preventing low loads’.
!
!
The generator’s doors may onlyremain opened for short periodsduring operation, to carry outchecks for example.
!
4.2.4.2 Qc1002™ menu overview
At Qc1002™, the LCD will show followinginformation:– in Normal condition (scroll through the
information using UP and DOWN):• Status (eg: preheat, crank, run, cooldown,
extended stop time, …)• Controller type & version• Parameter list• Alarm list• LOG list• Service Timer 1 & Service Timer 2• Battery Voltage• Coolant temperature• Oil pressure• Fuel level• Voltage - frequency - running hours
– in Alarm condition (scroll through theinformation using UP and DOWN):• a list of all active Alarms
It's possible to scroll through the views, using the UPand DOWN buttons. The scrolling is continuous.If a Special status comes up, the Status Display isshown. If an Alarm comes up, the Alarm Display is shown.
t
- 28 -
4.2.4 Setting the Qc1002™
4.2.4.1 Pushbutton and LED functions
Following pushbuttons are used on the
Qc1002™:
Following LEDs are used on the Qc1002™:
1 ENTER: Is used to select and confirm changed settings in the Parameter list.
2 UP: Is used to scroll through the display information and to adjust parameter value upwards.
3 DOWN: Is used to scroll through the display information and to adjust parameter value downwards.
4 BACK: Is used to leave the Alarm pop-up window, to leave the Parameter list and to leave menu's without change.
Qc 1002145
12
4
3
1 Power Green LED indicates that the unit ispowered up.
2 Remote Green LED indicates that the RemoteMode is selected.
4 Alarm Flashing red LED indicates that an alarm is present. A continuous red LED indicates that the alarm has beenacknowledged by the user. The exacalarm is shown on the display.
2
1
3Qc 1002
145
e
Parameter display
This view shows a number of Parameter settings andgives access to them.An overview is given in “Parameter list” on page 31.
Alarm list display
This view shows the number of active alarms andgives access to them.An overview is given in “Solving alarms” on page 84.
Parameter
Alarm List0 Alarm(s)
- 29 -
4.2.4.3 Qc1002™ menu description
Status display (pop-up window)
In case special statuses are entered, a pop-up windowwill automatically be entered for as long as the statusis active.The background screen is not updated when the statuspop-up window is active.
These special statuses are:
If a special status has elapsed, the active view will bentered again automatically.If an Alarm comes up, the Alarm Display is shown.
Controller type and version display
This view shows the controller type and the ASWversion number.
PREHEAT
START OFF/EXTENDED STOP TIMER
COOLDOWN
DIAGNOSTIC
Qc1002vX.XX.X
g
e
n
Oil pressure display
This view shows the Oil pressure and the runninghours.See also “Parameter list” on page 31 for selectionbetween bar and psi.
Fuel level display
This view shows the Fuel level and the running hours.
3.2barOil00168.1h
75%Fuel00168.1h
- 30 -
LOG list display
This view shows the alarm memory and gives accessto it.An overview is given in “LOG list” on page 33.
Service timer 1 & Service timer 2 display
This view shows both Service timers. The servicetimer indication is shown when service time has runout. It can be removed by resetting the timers oracknowledging the Service timer indication.The service timer indications count and give an alarmwhen value is reached.
Resetting the Service Timers can be done through theParameter display.
Battery Voltage display
This view shows the Battery voltage and the runninhours.
Coolant temperature display
This view shows the Coolant temperature and thrunning hours.See also “Parameter list” on page 31 for selectiobetween °C and °F.
LOG List
Service 1Service 2
59h59h
13.2 VBattery00168.1h
62˚CWater00168.1h
o=
gd,
s.iset
eiseag
– Unit Menu
This menu is used to select whether tempreatureand pressure should appear in °C/bar or °F/psi.
– Language selection
Icons is the default factory set language, but 6other languages can be selected: English, French,German, Italian, Spanish and Cyrillic (Russian).All information in the Parameter List display isalways in English.
– Generator Underfrequency: failclass, enable,delay, setpoint
– Generator Overfrequency: failclass, enable, delay,setpoint
– Generator Undervoltage: failclass, enable, delay,setpoint
– Generator Overvoltage: failclass, enable, delay,setpoint
– Engine CAN communication
This menu is used to select the type of engineelectronics, the Qc1002™ controller shouldcommunicate with via the Canbus.
It's possible to scroll between configuration menu'sby using the pushbuttons UP and DOWN.Pushing the ENTER button activates theconfiguration menu which is shown at the display.
- 31 -
Voltage - frequency - running hours display
This view shows the voltage, frequency and runninghours.
4.2.4.4 Parameter list
The Parameter Menu's are pre-programmed!
A password will be asked for when an attempt tchange a setting is about to be done (user password 2003).Menu's shown on the Parameter list LCD:– Running hours adjust
This menu is used to adjust the amount of runninhours. The running hours can only be higherenot lowered.
– Unit Type
– Service Timer 2 reset
– Service Timer 1 reset
These menus are used to reset the service timerWhen a service timer alarm occurs and acknowledged, the service timer will be resautomatically.
– Diagnostic Menu
This menu is used to power up the enginelectronics without starting the engine. When thsetting is switched on, electric power will bsupplied to the engine electronics after half minute delay. The unit can not be started as lonas this parameter is switched on.
50Hz400V00168.1h
Unit type 2 for QAS 60!!
Unit type
Unit type2
- 32 -
This is the described menu flow for changing the unit type:
Qc 1002145
Qc1002145
Parameter Running time
Unit type
rt
te
- 33 -
4.2.4.5 LOG list
The unit will keep an event log of the latest 30 events.
Events are:– shutdowns– service timer 1/2 reset– unit type changesTogether with each event, the running hours at thetime of the event will be stored.
4.2.4.6 Remote start operation
Installation wirings:
– X25.1 & X25.2 to be wired for the remote staswitch.
– X25.3 & X25.4 to be wired for the remocontactor (open/close).
1 Controller type2 Event number3 Event4 Running hours
Time: 00001h
EVENT LOG #04 WaterQc1002
1
3
4
2
).
eh
ert
e
ert
4.3.2 During operation
Regularly carry out following checks:
– Check the analogue meters (P1-P4) and thecontroller display for normal readings.
– Check for leakage of oil, fuel or coolant.
– Check, by means of the generator gauges, that thevoltage between the phases is identical and thatthe rated current is not exceeded.
– When single-phase loads are connected to thegenerator output terminals, keep all loads well-balanced.
– If circuit breakers have tripped during operation,switch off the load and stop the generator. Checkand, if necessary, decrease the load.
Avoid to let the engine run out offuel. If it happened, priming willspeed up the starting.
Avoid long low-load periods(< 30%). In this case, an outputdrop and higher oil consumption ofthe engine could occur. Refer to‘Preventing low loads’.
The generator’s doors may onlyremain opened for short periodsduring operation, to carry outchecks for example.
!
!
!
- 34 -
4.3 Operating and setting
Qc2002™
4.3.1 Starting
To start up the unit locally, proceed as follows:
– Switch on the battery switch.– Switch off circuit breaker Q1. This is not
necessary when a plant contactor is installedbetween Q1 and the load.
– Put the starter switch S20 in position I (ON).Voltage is applied to the Qc2002™ module.
– The unit can be started manually by pressing theSTART button on the Qc2002™ module.
– The unit will start. In cold conditions the unit might not start from thefirst attempt. The controller will take 3 startattempts.
– Switch on circuit breaker Q1 in case no contactoris installed.
To start up the unit from a remote location,
proceed as follows:
– Put the starter switch S20 in position I (ONVoltage is applied to the Qc2002™ module.
– Switch on circuit breaker Q1.– For remote start:
• Put the unit in Island mode. Push thAUTOMATIC button. Use an external switcto start the machine.
or• Put the unit in AMF mode. Push th
AUTOMATIC button. The machine will staautomatically when Mains fails.
See also ‘Genset mode’ on page 41 for mordetailed information on Island and AMF mode.
– The unit will start. In cold conditions the unit might not start from thfirst attempt. The controller will take 3 staattempts.
oe
4.3.4 Setting the Qc2002™
4.3.4.1 Pushbutton and LED functions
Following pushbuttons are used on the
Qc2002™:
1 ENTER: Is used to select and confirm changed settings in the Parameter list.
2 UP: Is used to scroll through the display information and to adjust parameter value upwards.
3 DOWN: Is used to scroll through the display information and to adjust parameter value downwards.
4 BACK: Is used to leave the Alarm pop-up window, to leave the Parameter list and to leave menu's without change.
Qc20021.00.1
G
6
5
8
9 3
124
7
- 35 -
4.3.3 Stopping
To stop the unit , proceed as follows:
– Switch off the load.
– Switch off circuit breaker Q1.– Stop the engine by using the STOP button on the
Qc2002™ module.
– Put the starter switch S20 in position O (OFF) toshut down the voltage apply towards theQc2002™ module.
– Lock all doors to avoid unauthorized access.
To stop the unit when the Qc2002™ module is in
AUTOMATIC operation mode, proceed as
follows:
– Switch off the load.
– For remote start: • When operating in Island mode, use the
external switch to stop the machine.• When operating in AMF mode, the machine
will automatically stop when the Mainsreturns.
– Cooldown period default 15 sec.– Put the starter switch S20 in position O (OFF) t
shut down the voltage apply towards thQc2002™ module.
– Lock all doors to avoid unauthorized access.
When the unit is stopped with theSTOP button in Automaticoperation, it will automatically go toManual Mode.
!
6 Mains contactor
Green LED indicates that it is possible to close the Mains Contactor (only in AMF mode), if the Generator contactor is open.
7 Mains voltage
LED is green, if the mains is present and OK.LED is red when a mains failure is detected. LED is flashing green when the mains returns during the ‘mains OK delay’ time.
8 Alarm Flashing red LED indicates that an alarm is present. A continuous red LED indicates that the alarm has been acknowledged by the user. The exact alarm is shown on the display.
- 36 -
Following LEDs are used on the Qc2002™:5 AUTOMATIC: Is used to put the unit in manual or automatic operation.
6START: Is used to start the unit in manual operation.
7 STOP: Is used to stop the unit in manual or automatic operation (without cooldown). When the unit is stopped with the STOP button in automatic operation, it will automatically go to manual operation.
8 GENERATOR CONTACTOR: Is used to open or close the Generator contactor, if the Qc2002™ is in manual operation
9 MAINS CONTACTOR: Is used to open or close the Mains contactor, if the Qc2002™ is in manual operation.
G
1 Power Green LED indicates that the unit is powered up.
2 Automatic Green LED indicates that the Qc2002™ is in automatic operation.
3 Start/Stop Green LED indicates that the Qc2002™ receives running feedback (via the W/L input, via the RPM value at the Canbus, orvia the AC frequency).
4 U/F OK Green LED indicates that the voltage/frequency is present and OK.
5 Generator contactor
Green LED indicates that the voltage and the frequency of the alternator are within certain limits for a certain time. It will be possible to close the Generator Contactor (both in Island and in AMF mode), if the Mains contactor is open.
Qc20021.00.1
G
1
83
2
4
5 7
6
e
e
P
is
4.3.4.3 Qc2002™ menu description
Status Display (pop-up window)
In case special statuses are entered, a pop-up windowwill automatically be entered for as long as the statusis active.The background screen is not updated when the statuspop-up window is active.
These special statuses are:
PREHEAT
START OFF/EXTENDED STOP TIMER
COOLDOWN
- 37 -
4.3.4.2 Qc2002™ menu overview
At Qc2002™, the LCD will show followinginformation:– in Normal condition (scroll through the
information using UP and DOWN):• Status (eg: preheat, crank, cooldown, extended
stop time, …)• Line voltages of the generator• Controller type & version• Parameter list• Alarm list• LOG list• Service Timer 1 & Service Timer 2• Battery Voltage• RPM (speed)• Coolant temperature• Oil pressure• Fuel level• kWh counter• Power factor, the frequency of the generator
and the frequency of the mains • Line voltage, frequency and active power of
the generator
• Active, reactive and apparent power of thgenerator
• Generator currents• Phase voltages of the mains• Line voltages of the mains• Phase voltages of the generator
– in Alarm condition (scroll through thinformation using UP and DOWN):• a list of all active Alarms
It's possible to scroll through the views, using the Uand DOWN buttons. The scrolling is continuous. If a Special status comes up, the Status Display shown. If an Alarm comes up, the Alarm Display is shown.
d
.
d
n
LOG list display
This view shows the alarm memory and gives accessto it.An overview is given in “LOG list” on page 45.
Service timer 1 & Service timer 2 display
This view shows both Service timers. The servicetimer indication is shown when service time has runout. It can be removed by resetting the timers oracknowledging the Service timer indication.The service timer indications count and give an alarmwhen value is reached.
Resetting the Service Timers can be done through theParameter display.
LOG List
Service 1Service 2
59h59h
- 38 -
If a special status has elapsed, the active view will beentered again automatically.If an Alarm comes up, the Alarm Display is shown.
Line voltages generator display
This view shows the line voltages of the generator.
Controller type and version display
This view shows the controller type and the ASWversion number.
Parameter display
This view shows a number of Parameter settings angives access to them.An overview is given in “Parameter list” on page 40
Alarm list display
This view shows the number of active alarms angives access to them.An overview is given in “Alarm overview” opage 83.
DIAGNOSTIC
G L1-L2G L2-L3G L3-L1
400V400V400V
Qc20021.00.1
Parameter
Alarm List0 Alarm(s)
g
n
s.
kWh counter display
This view shows the kWh counter.
Power factor - frequency generator - frequency
mains display
This view shows the PF, the frequency of thegenerator and the frequency of the mains (M f L1:only in AMF mode).
E 4860kWh
PFG f L1M f L1
0.0050Hz50Hz
- 39 -
Battery voltage display
This view shows the Battery voltage and the runninghours.
RPM display
This view shows the engine speed and the runninghours.
Coolant temperature display
This view shows the Coolant temperature and therunning hours.See also “Parameter list” on page 40 for selectionbetween °C and °F.
Oil pressure display
This view shows the Oil pressure and the runninhours.See also “Parameter list” on page 40 for selectiobetween bar and psi.
Fuel level display
This view shows the Fuel level and the running hour
13.2 VBattery00168.1h
0RPM00168.1h
62˚CWater00168.1h
3.2barOil00168.1h
75%Fuel00168.1h
is
is
r.
4.3.4.4 Parameter list
The parameter menu's are pre-programmed !
A password will be asked for when an attempt tochange a setting is about to be done (user password =2003).By entering the parameter list, pushbuttonAUTOMATIC is disposed of its normal operationsand will not perform any functionality.
It's possible to scroll between configuration menu'sby using the pushbuttons UP and DOWN.Pushing the ENTER button activates theconfiguration menu which is shown at the display.
- 40 -
One line voltage - frequency - active power
display
This view shows one line voltage, frequency andactive power of the generator.
Active - reactive - apparent power display
This view shows the active, reactive and apparentpower of the generator.
Generator current display
This view shows the generator current.
Phase voltages mains display
This view shows the phase voltages of the mains (only shown in AMF mode).
Line voltages mains display
This view shows the line voltages of the mains (only shown in AMF mode).
Phase voltages generator display
This view shows the phase voltages of the generato
G L1-L2G f L1P
400V50Hz80kW
PQS
80kW0kVAr80kVA
G I1G I2G I3
100A100A100A
M L1-NM L2-NM L3-N
230V230V230V
M L1-L2M L2-L3M L3-L1
400V400V400V
G L1-NG L2-NG L3-N
230V230V230V
/e
dde
d
:e
Horn delay
This menu is used to set the delay, how long thegeneral alarm relay stays energized (if present). If setto 0.0s, the general alarm relay will stay energizedcontinuously.
Running hours adjust
This menu is used to adjust the amount of runninghours. The running hours can only be highered, notlowered.
Service timer 2 reset
Horn Delay0.0s 20.0s 990.0s
Running TimeCur. 168 20000
St 2 ResetNo No Yes
- 41 -
Menu's shown on the parameter list LCD:
Genset mode
This menu is used to change the mode of the machine.In the Qc2002™ module 2 application modes can beselected:
Island operation
– This operation type is selected for local/remotestart applications, without the Mains (= stand-alone).• Combined with Manual Operation mode =
Local Start operation.• The sequences start / stop / close Generator
Contactor / open Generator Contactor can beactivated manually.
• Combined with Automatic Operation mode =Remote Start operation.
– The remote start signal can be given with anexternal switch. After the generator has beenstarted, the Generator Contactor will closeautomatically.
– Installation wirings for Remote Start operation:wire the RS switch between X25.9 & X25.10.
Automatic Mains Failure (AMF) operation
– When the Mains exceeds the defined voltagefrequency limits for a defined delay time, thgenerator will take over the load automatically.
– When the mains is restored within the definelimits for a defined time, the generator will unloabefore disconnecting and switching back to thMains.
– The generator will then go into cooldown anstop. It will stay stanby for the next event.
– Installation wirings for Remote Start operationrefer to circuit diagram 9822 0996 06/01 for thcorrect connections.
Genset ModeIsland Island AMF
This application is only possible incombination with the AUTO mode.If the Manual Operation mode isselected the AMF operation willNOT function!
To operate the unit in AMF mode,make sure that the COC (ChangeOver Contactors) box is properlyinstalled, see page 101. Refer tocircuit diagram 9822 0773 55 for thecorrect connections.
!
!
h
rn,lln
Engine CAN communication
This menu is used to select the type of engineelectronics, the Qc2002™ controller shouldcommunicate with via the Canbus.
MF high frequency
This menu is used to set the maximum limit for themains frequency, in % of the nominal frequency (inAMF-Auto).
MF low frequency
This menu is used to set the minimum limit for themains frequency, in % of the nominal frequency (inAMF-Auto).
Engine I CommOFF
MF high freq100% 110 120%
MF low freq80% 90 100%
- 42 -
Service timer 1 reset
These menus are used to reset the service timers.When a service timer alarm occurs and isacknowledged, the service timer will be resetautomatically.
Diagnostic menu
This menu is used to power up the engine electronicswithout starting the engine. When this setting isswitched on, electric power will be supplied to theengine electronics after half a minute delay. The unitcan not be started as long as this parameter is swichedon.
Unit menu
This menu is used to select the units into whicpressures and temperatures will be shown.
Language selection
Icons is the default factory set language, but 6 othelanguages can be selected: English, French, GermaItalian, Spanish and Cyrillic (Russian). Ainformation in the Parameter List display is always iEnglish.
St 1 ResetNo No Yes
DiagnosticsOff Off On
UnitC/bar C/bar F/psi
LanguageEnglish
e-
e-
wtsss
MF voltage delay
This menu is used to set the delay, which defines howlong the mains voltage may be above the max limit orbelow the min limit before there will be switchedfrom mains to generator (in AMF-Auto). During thisdelay, the Mains LED flashes in red.
Overvoltage enable
Overvoltage failclass
MF volt delay1.0s 2.0 990.0s
> Volt enableEnable enable disable
> Volt FCwarning warning shutdown
- 43 -
M frequency delay
This menu is used to set the delay, which defines howlong the mains frequency has to be back within thelimits before there will be switched from generator tomains again (in AMF-Auto). During this delay, theMains LED flashes in green.
MF frequency delay
This menu is used to set the delay, which defines howlong the mains frequency may be above the max limitor below the min limit before there will be switchedfrom mains to generator (in AMF-Auto). During thisdelay, the Mains LED flashes in red.
MF high voltage
This menu is used to set the maximum limit for thmains voltage, in % of the nominal voltage (in AMFAuto).
MF low voltage
This menu is used to set the minimum limit for thmains voltage, in % of the nominal voltage (in AMFAuto).
M voltage delay
This menu is used to set the delay, which defines holong the mains voltage has to be back within the limibefore there will be switched from generator to mainagain (in AMF-Auto). During this delay, the MainLED flashes in green.
M freq delay10s 30 9900s
MF freq delay1.0s 2.0 990.0s
MF high volt100% 110 120%
MF low volt80% 90 100%
M volt delay10s 30 9900s
Overfrequency delay
Overfrequency setpoint
Underfrequency enable
Underfrequency failclass
> Freq Delay0 1 99
> Freq SP0 38 70
< Freq enableEnable enable disable
< Freq FCwarning warning shutdown
- 44 -
Overvoltage delay
Overvoltage setpoint
Undervoltage enable
Undervoltage failclass
Undervoltage delay
Undervoltage setpoint
Overfrequency enable
Overfrequency failclass
> Volt Delay0 1 99
> Volt SP0 450 999
< Volt enableEnable enable disable
< Volt FCwarning warning shutdown
< Volt Delay0 1 99
< Volt SP0 450 999
> Freq enableEnable enable disable
> Freq FCwarning warning shutdown
s.
t
- 45 -
Underfrequency delay
Underfrequency setpoint
4.3.4.5 LOG list
The unit will keep an event log of the latest 30 event
Events are:– shutdowns– service timer 1/2 resetTogether with each event, the real time of the evenwill be stored.
< Freq Delay0 1 99
< Freq SP0 38 70
1 Controller type2 Event number3 Event4 Date and hour of the event
Time: 27/6 14:27
EVENT LOG #04 WaterQc2002
4
1
3
2
el-
n,k
4.4.3 Stopping
– When in SEMI-AUTO mode:• Press the GB open/close button to open the
generator breaker. • Press the STOP button once to stop the
generator. The unit will go into cooldown andstop after the cooldown period.
• Press the STOP button twice to stop thegenerator immediately, without going intocooldown.
– When in AUTO mode:• The generator shuts down automatically
depending on the selected application.• If you want to stop the generator manually, go
first to SEMI-AUTO mode and follow theprocedure for stopping in SEMI-AUTO mode.
Not allowing the unit to cooldownproperly can lead to severe damageto the engine!
!
- 46 -
4.4 Operating and setting Qc4002™ MkII
4.4.1 Starting
– Turn the battery switch to ON.– Turn the S20 button to the ON position to activate
the Qc4002™ MkII controller.– Select the correct application type and the correct
mode on the Qc4002™ MkII module (see“Overview of applications” on page 61 for thepossible selections).
– Make the correct wirings and program theapplicable parameters (see “Standardapplications” on page 54 for more details).
– When in SEMI-AUTO mode:• Use the START button to start-up the
generator. • Allow the generator to start-up till voltage and
frequency are OK (LED U/F OK lights up).• Press the GB open/close button to close the
generator breaker.– When in AUTO mode:
• The generator will start-up automatically andclose the contactors depending on the selectedapplication.
4.4.2 During operation
Regularly carry out following checks:– Check the display for normal readings.
– Check for leakage of oil, fuel or cooling water.
– When single-phase loads are connected to thgenerator output terminals, keep all loads welbalanced.
– If circuit breakers have tripped during operatioswitch off the load and stop the generator. Checand, if necessary, decrease the load.
Before setting the controller makesure that the Qc4002™ MkII isNOT in AUTO mode. This willprevent the unit to start upautomatically without prior notice.Also, in AUTO mode someparameters are unavailable.
!Avoid letting the engine run out offuel. If this happens, priming willspeed up the starting.
Avoid long low-load periods(< 30%). In this case, an outputpower drop and higher oilconsumption of the engine couldoccur. Refer to ‘Preventing lowloads’.
Never turn the battery switch toOFF during operation.
The generator’s doors may onlyremain opened for short periodsduring operation, to carry outchecks for example.
!
!
!
!
-
r
r
11 SEL: Is used to select the underscored entry in the fourth line of the display.
12 UP: Increases the value of the selected set point (in the setup menu). In the daily use display, this button function is used for scrolling the View lines in V1 or the second line (in the setup menu) displaying of generator values.
13 DOWN: Decreases the value of the selected set point (in the setup menu). In the daily use display, this button function is used for scrolling the View lines in V1 or the second line (in the setup menu) displaying of generator values.
14 LEFT: Moves the cursor left for manoeuvring in the menus.
15 RIGHT: Moves the cursor right for manoeuvring in the menus.
- 47 -
4.4.4 Setting the Qc4002™ MkII
4.4.4.1 Pushbutton and LED functions
Following pushbuttons are used on the
Qc4002™ MkII
1 INFO: Shifts the display 3 lower lines to show the alarm list.
2 JUMP: Enters a specific menu number selection. All settings have a specific number attached to them. The JUMP button enables the user to select and display any setting without having to navigate through the menus.
3 START: Start of the gen-set if SEMI-AUTO or MANUAL is selected.
Qc4002
G
!
OK
LOG
1
23
4
5 6 9
7 12
8 14
10
1115
13
4 STOP: Stop of the gen-set if SEMIAUTO or MANUAL is selected.
5 GB: Manual activation of close breaker and open breakesequence if SEMI-AUTO is selected.
6 MB: Manual activation of close breaker and open breakesequence if SEMI-AUTO is selected.
7 VIEW: Shifts the first line displaying in the setup menus.
8 LOG: Displays the LOG SETUP window where you can choose between the Event, Alarm and Battery logs. The logs are not deletedwhen the auxiliary supply is switched off.
9 BACK: Jumps one step backwardsin the menu (to previous display or tothe entry window).
10 MODE: Changes the menu line (line4) in the display to mode selection.
G
The main Qc4002™ MkII control unit includes 5
LEDs
o
g
r
t
s
1 Power Green LED indicates that the voltage supply is switched on.
2 Self check OK
Green LED indicates that the unit is OK.
3 Alarm inhibit
Green LED indicates that the inhibit input is ON.
4 CAN 25 CAN 1
32
1
5
4
- 48 -
Following LEDs are used on the Qc4002™ MkII
1 Alarm LED flashing indicates that unacknowledged alarms are present.LED fixed light indicates that ALL alarms are acknowledged.
2 Power LED indicates that the auxiliary supply is switched on.
3 Self check OK
LED indicates that the self check is OK.
4 Alarm inhibit
LED indicates that one of the alarm inhibit functions is active. LED switches off automatically. No action should be taken.
5 Run LED indicates that the generator is running.
6 U/F OK LED green light indicates that the voltage/frequency is present and OK.
Qc4002
G
!
OK
LOG
5
1
6 7 8
234
10
9
7 (GB) ON LED green light indicates that the generator breaker is closed.LED yellow light indicates that the generator breaker has received a command to close on a black BUS, but the breaker is not yet closed due tinterlocking of the GB.LED is flashing orange if the ‘Sprinload time’ signal from the breaker ismissing.
8 (MB) ON LED indicates that the mains breakeis closed.
9 Mains voltage
LED is green, if the mains is presenand OK.LED is red when a mains failure is detected.LED is flashing green when the mainreturns during the ‘mains OK delay’time.
10 Auto LED indicates that auto mode is selected.
ll
e
ega
– The V2 view shows some generatormeasurements.
– In the V1 view the user can scroll up and down to15 configurable screens showing differentmeasurements of the generator, the bus and theMains.
SETUP menu
The control and protection parameters can beprogrammed according the application. This can bedone by scrolling through the setup menu to theappropriate parameter. Each parameter has a specificchannel number and is listed in one of the 4 mainSETUP menus:
– Protection Setup (PROT): Channels from 1000 to1999 (steps of 10).
– Control Setup (CTRL): Channels from 2000 to2999 (steps of 10).
– Input/Output Setup (I/O): Channels from 3000 to5999 (steps of 10).
– System Setup (SYST): Channels from 6000 andup (steps of 10).
- 49 -
4.4.4.2 Qc4002™ MkII menu overview
Main View
The display has 4 different lines. The information onthese lines can change, depending on which view isused. There are 4 different main views possible:SETUP / V3 / V2 / V1.Setup view
V3 view
V2 view
V1 view
The user can scroll through these views with the scrobuttons:– The SETUP view shows the module name, th
software version, the date and the time.
– The V3 view shows the application type and thmode, and some generator measurements. Durinsynchronisation the V3 view will show synchronoscope in the first line.
n
d
is
et
The user can scroll through this list and select one setpoint with the SEL button. After selection of SP the following view will bevisible:
If the correct password is entered, the following viewappears:
Now the user can change the SP of parameter “G-P>1”. This can be done with the scroll buttons. Thenthe user has to select SAVE to save the new settings.To exit the user has to press the BACK button severaltimes, until the main view appears.
- 50 -
If you select SETUP then you get the following view:
The fourth line is the entry selection for the Menusystem. If the SEL button is pressed, the menuindicated with an underscore will be entered.If PROT is selected, the following view will appear(example of parameter):
For a protective function the first entry shows the“Generator reverse power (G-P>1)” setting.
Scrolling down will give all the protectioparameters:– The first line shows some generator data.– The second line shows the channel number an
the name of the parameter.– The third line shows the value of a set point of th
parameter.– The fourth line shows the different possible s
points. In this example:
SP SET POINT, the alarm set point is adjusted in the set point menu. The setting is a percentage of the nominal values.
DEL DELAY, the timer setting is the time that must expire from the alarm level is reached until the alarm occurs.
OA OUTPUT A, a relay can be activated by output A.
OB OUTPUT B, a relay can be activated by output B.
ENA ENABLE, the alarm can be activated or deactivated. ON means always activated, RUN means that the alarm has run status. This means it is activated when the running signal is present.
FC FAIL CLASS, when the alarm occurs the unit will react depending on the selected fail class.
- 51 -
The JUMP button
Instead of navigating through the entire menu, theuser can jump directly to the required parameter, if heknows the channel number of that specific parameter.If the JUMP button is pushed the password view willappear. Not all parameters can be changed by the end-user. The required password level for each parameteris given in the set point list.The following menus can only be reached using theJUMP button:– 9000 Software version– 9020 Service port– 911X User password
Level 2 and Level 3 passwords can only be setthrough the Atlas Copco Utility Software PCSoftware.
– 9120 Service menu– 9130 Single/Split/Three phase– 9140 Angle comp. BB/GUse the UP and DOWN buttons to change the settingsand the SEL button to store the new setting.
- 52 -
4.4.4.3 Changing settings
Menu flow:
The menu flow is similar in the CONTROL SETUP, I/O SETUP and SYSTEM SETUP.
For more details on the Setup menu we refer to the Qc4002™ MkII User Manual.!
eiann
E
etde
llnnn
Test mode
Enables the user to test the generator on a regularbasis. The generator will follow a predefinedsequence of actions.In this mode it is possible to perform the followingtests:
– Simple test– Load test– Full test
Manual mode
When manual mode is selected, the generatorfrequency and voltage can be controlled with externalinputs.
MAN mode cannot be selected,when AUTO mode is selected. To gofrom AUTO to MAN it is necessaryto go to SEMI-AUTO to make MANavailable.
!
- 53 -
Passwords
Changing different parameters requires differentpassword levels. Some parameters cannot be changedby the end-customer because of safety reasons.There are 3 different password levels:– User password (default setting 2003)– Service password– Master passwordOnce the password has been entered, the user canchange all the accessible set points.The user can change the User password (go withJUMP button to channel 9116).
Languages
English is the default language ex-factory.
Changing parameters
Consult the Qc4002™ MkII user manual for allcustomer level parameters, which can be accessedusing password "2003".
In order to receive the default parameters for yourunit, please contact Atlas Copco Service staff.
4.4.4.4 Standard modes
The unit has four different running modes and onblock mode. The required mode can be selected vthe MODE puhbutton. Repeat pushing the buttountil the required mode appears on the display, thepress SEL to select or BACK to cancel. This screen appears when pressing the MODpuhbutton.
Auto mode
In this mode the Qc4002™ MkII controls the gen-sand the circuit breakers (generator breaker GB anmains breaker MB) automatically according to thoperational state.
Semi-Auto mode
In semi-auto mode the operator has to initiate asequences. This can be done via the pushbuttofunctions, modbus commands or digital inputs. Whestarted in semi-automatic mode, the gen-set will ruat nominal values.
When operating in AUTO mode theSTOP and GB Open/Close buttonwill not function.
!
ne
ic
ctal-2
Island operation
This application is possible in combination withSEMI-AUTO mode or AUTO mode. The internal realtime clock timer can only be used in AUTO This operation type is selected for installations withone or more generators, but always without the Mains(= stand-alone). In practice up to 16 generators can beinstalled in parallel.
Installation wirings
– Terminals X25.10/X25.11 have to be linked. Themodule always needs a feedback signal from theMains Breaker MB. In Island mode there is noMB in the system. In this case the MB openedsignal is simulated with this link.
– The busbar sensing lines have to be wired to thecorresponding control module inputs. Placebridge between:• X25.33 (L1) => X25.3• X25.34 (L2) => X25.4• X25.35 (L3) => X25.5• X25.36 (N) => X25.6
(The busbar = power cables between GB and load)
G
Qc4002
LOADGenerator
breaker
- 54 -
Block mode
When the block mode is selected, the unit is lockedfor certain actions. This means that it cannot start thegen-set or perform any breaker operations.To change the running mode from the display, theuser will be asked for a password before the changecan be made. It is not possible to select ‘block mode’when running feedback is present.The purpose of the block mode is to make sure thatthe gen-set does not start for instance duringmaintenance work. If the digital inputs are used tochange the mode, then it is important to know that theinput configured to block mode is a constant signal.So, when it is ON the unit is in a blocked state, andwhen it is OFF, it returns to the mode it was in beforeblock mode was selected.
4.4.4.5 Standard applications
In the Qc4002™ MkII module 9 application types cabe selected. A combination of each application typwith the running mode results in a specifapplication.
Depending on the application the user has to conneextra wirings to terminal blocks X25. These terminblocks can be found inside the control box on a DINrail. We refer to the circuit diagram 9822 0996 18/0for the correct connections.
Gen-set mode Running modeAuto Semi Test Man Block
Automatic Mains Failure (no back sync.)
X (X) X X X
Automatic Mains Failure (with back sync.)
X (X) X X X
Island operation X X X XFixed power/base load X X X X XPeak shaving X X X X XLoad take over X X X X XMains power export X X X X XMultiple gen-sets, load sharing
X X X X
Multiple gen-sets, power management
X (X) X X X
es
ls
e
o
olsBc//
e
;
re
Peak Shaving (PS) operation
This application is normally used in combination withthe AUTO mode. Installation with the Mains.The generator will start up when the mains importedpower (measured through an optional PowerTransducer = PT) exceeds a defined level. Thegenerator will synchronise with the bus, and will takeload until the defined allowable mains importedpower level is reached.When the mains imported power decreases below thedefined mains imported power level for a definedtime, the generator will unload and disconnect fromthe bus. Then the generator will go into cool down.
G
Qc4002
PT
LOADGeneratorbreaker
Mainsbreaker
- 55 -
– For Remote Start operation:• wire the RS switch between X25.9 & X25.10.
– For Paralleling applications with other generators:• See “Paralleling” to set up generator for
paralleling.
Automatic Mains Failure (AMF) operation
This application is only possible in combination withthe AUTO mode. If the SEMI-AUTO mode isselected the AMF operation will NOT function!
The unit automatically starts the gen-set and switchesto generator supply at a mains failure after anadjustable delay time.– AMF no back synchronisation:
When the mains returns, the unit will switch backto mains supply and cool down and stop the gen-set. The switching back to mains supply is donewithout back synchronisation when the adjusted‘Mains OK delay’ has expired.
– AMF with back synchronisation:
When the mains returns, the unit will synchronisthe mains breaker to the busbar when the ‘MainOK delay’ has expired. Then the gen-set coodown and stops.
Installation wirings
– The link between X25.10/X25.11 has to bremoved.
– Mains breaker feedback lines have to be wired tX25.10/X25.11/X25.12.
– Mains breaker control lines have to be wired tX25.13/X25.14/X25.15/X25.16. These terminaare voltage free contacts. The power for the Mhas to be supplied by the customer (24 Vd230 Vac) (max. contact rating K11, K12 = 250 V16 A).
– The Mains sensing lines L1/L2/L3/N have to bwired to terminals X25.3/X25.4/X25.5/X25.6.
– Make sure the connections between X25.33 &X25.3; X25.34 & X25.4; X25.35 & X25.5X25.36 & X25.6 are removed.
– If back synchronisation is enabled, all settings foparalleling set up (see “Paralleling”) must bverified also.
G
Qc4002
LOADGeneratorbreaker
Mainsbreaker
hisne
o
e
o
– Mains breaker control lines have to be wired toX25.13/X25.14/X25.15/X25.16. These terminalsare voltage free contacts. The power for the MBhas to be supplied by the customer (24 Vdc/230 Vac) (max. contact rating K11, K12 = 250 V/16 A).
– The Mains sensing lines L1/L2/L3/N have to bewired to terminals X25.3/X25.4/X25.5/X25.6.
– Make sure the connections between X25.33 &X25.3; X25.34 & X25.4; X25.35 & X25.5;X25.36 & X25.6 are removed.
– Verify all settings for paralleling set up (see“Paralleling”).
- 56 -
Installation wirings
– The link between X25.10/X25.11 has to beremoved.
– Mains breaker feedback lines have to be wired toX25.10/X25.11/X25.12.
– Mains breaker control lines have to be wired toX25.13/X25.14/X25.15/X25.16. These terminalsare voltage free contacts. The power for the MBhas to be supplied by the customer (24 Vdc/230 Vac) (max. contact rating K11, K12 = 250 V/16 A).
– The Mains sensing lines L1/L2/L3/N have to bewired to terminals X25.3/X25.4/X25.5/X25.6.
– Make sure the connections between X25.33 &X25.3; X25.34 & X25.4; X25.35 & X25.5;X25.36 & X25.6 are removed.
– Power Transducer lines have to be wired toX25.21 (input) and X25.22 (GND).
– Verify all settings for paralleling set up (see“Paralleling”).
Fixed Power (FP) operation
This application is possible in combination witSEMI-AUTO mode or AUTO mode. Normally it used in combination with SEMI-AUTO mode iinstallations with the Mains. The internal real timclock timer can only be used in AUTO mode.
The generator will deliver a defined fixed power tthe load or to the Mains.
Installation wirings
– The link between X25.10/X25.11 has to bremoved.
– Mains breaker feedback lines have to be wired tX25.10/X25.11/X25.12.
G
Qc4002
LOADGeneratorbreaker
Mainsbreaker
Mains Power Export (MPE) operation
This application is possible in combination withSEMI-AUTO mode or AUTO mode. The internal realtime clock timer can only be used in AUTO mode.Installation is with the Mains.The mains power export mode can be used tomaintain a constant level of power through the mainsbreaker. The power can be exported to the mains orimported from the mains, but always at a constantlevel.
G
Qc4002
PT
LOADGeneratorbreaker
Mainsbreaker
- 57 -
Load Take Over (LTO) operation
This application is normally used in combination withSEMI-AUTO mode or AUTO mode in installationswith the Mains.
The purpose of the load take over mode is to transferthe load imported from the mains to the gen-set foroperation on generator supply only.The generator will start-up, synchronise and take overthe load from the Mains gradually, before opening theMains Breaker. To know if the load is completelytaken over from the mains, an optional PowerTransducer is necessary.
Installation wirings
– The link between X25.10 & X25.11 has to beremoved.
– Mains breaker feedback lines have to be wired toX25.10/X25.11/X25.12.
– Mains breaker control lines have to be wired toX25.13/X25.14/X25.15/X25.16. These terminalsare voltage free contacts. The power for the MBhas to be supplied by the customer (24 Vdc/230 Vac) (max. contact rating K11, K12 = 250 V/16 A).
– The Mains sensing lines L1/L2/L3/N have to bewired to terminals X25.3/X25.4/X25.5/X25.6.
– Make sure the connections between X25.33 &X25.3; X25.34 & X25.4; X25.35 & X25.5;X25.36 & X25.6 are removed.
– Power Transducer lines have to be wired toX25.21 (input) and X25.22 (GND).
– Verify all settings for paralleling set up (see“Paralleling”).
G
Qc4002
PT
LOADGeneratorbreaker
Mainsbreaker
eehr
atnhts
hd,eoce,
Installations are possible with stand-alone generatorsor with the Mains (extra Qc4002™ MkII Mains isthen needed). A number of Qc4002™ MkII units arebeing used in the power management application, i.e.one for each mains breaker (Qc4002™ MkII mainscontroller), if installed, and one for each generator(Qc4002™ MkII genset controller). All unitscommunicate by means of an internal CANbusconnection.In an application with PMS it is important to programcorrectly the Start and Stop signals between thedifferent generators because of the following reasons:– The maximum load step needs to be programmed
in the Qc4002™ MkII controllers. This never mayexceed the power reserve of the runninggenerators. Otherwise the gensets will go inoverload with a sudden max. load increase beforethe next generator is started up and connected tothe busbar.
– To prevent the gensets to run in a start - stop loop.
The start signal is the value of the maximum requiredload step.The stop signal is the value when the generator shouldbe stopped automatically.
- 58 -
Installation wirings
– The link between X25.10 & X25.11 has to beremoved.
– Mains breaker feedback lines have to be wired toX25.10/X25.11/X25.12.
– Mains breaker control lines have to be wired toX25.13/X25.14/X25.15/X25.16. These terminalsare voltage free contacts. The power for the MBhas to be supplied by the customer (24 Vdc/230 Vac) (max. contact rating K11, K12 = 250 V/16 A).
– The Mains sensing lines L1/L2/L3/N have to bewired to terminals X25.3/X25.4/X25.5/X25.6.
– Make sure the connections between X25.33 &X25.3; X25.34 & X25.4; X25.35 & X25.5;X25.36 & X25.6 are removed.
– Power Transducer lines have to be wired toX25.21 (input) and X25.22 (GND).
– Verify all settings for paralleling set up (see“Paralleling”).
Multiple gen-sets with load sharing
In this application the units are enabled to share thactive and reactive load equally in percentage of thnominal power. The load sharing is active when eacgen-set is running in island mode and the generatobreaker is closed.
Multiple gen-sets with power management
(PMS)
PMS (= Power Management System) is a system thwill automatically start and stop generators based othe actual load dependency. This will be done througa PMS communication between the different uniconnected.PMS applications are always in combination witAUTO mode. If the SEMI-AUTO mode is selectethe PMS operation will NOT function! ThQc4002™ MkII controllers from the gensets need tbe programmed as PMS in AUTO mode. When a QMains controller is installed this needs to bprogrammed in the application that is required (AMFLTO, FP, MPE) and AUTO mode.
By programming the parameters inAUTO mode, the generator canstart up immediately. It isrecommended to place the generatorin SEMI-AUTO mode whileprogramming all the PMSparameters !
!
rsfpystsrtalst
Installation wirings
1 Splitter (1626 6901 00)2 Cable (1626 6906 00)3 End resistor (male) (1626 6926 00)4 End resistor (female) (1626 6927 00)
Genset 1
X30
Genset 2
X30
Genset 3
X30
Genset 4
X30
1
234
- 59 -
Example: Installation with 3 gensetsG1 = 300 kW; G2 = 200 kW; G3 = 200 kW.
– Start signal is set at 90 kW (maximum load step <90 kW).
Start signal if:
Total Power needed > (total available power ofrunning gensets -set point start signal).• Only G1 is running; at 210 kW load (300 kW
- 90 kW) => G2 will be started.• G1 & G2 are running; at 410 kW load (200 kW
+ 300 kW - 90 kW) => G3 will be started.– Stop signal is set at 100 kW and priority is set as
(high) G1 > G2 > G3 (low).
Stop signal if:
Total Power needed < (Total available power ofrunning gensets - Power of generator with lowestpriority - set point stop signal).• G1 & G2 & G3 are running; at 400 kW
(700 kW - 200 kW - 100 kW) => G3 will bestopped.
• G1 & G2 are running; at 200 kW (500 kW -200 kW - 100 kW) => G2 will be stopped.
The priority on starting and stopping the generatocan be chosen on priority settings or on the amount orunning hours. In manual mode the start and stosequence is determined by the chosen prioritbetween the generators. The generator with the lowepriority will start as the latest genset and will stop afirst. If running hours are chosen as priority the staand stop sequence will be defined based on the acturunning hours of the different generators. The lowerunning hours will get the highest priority.
When paralleling generators withPMS, it is no longer necessary to usethe analogue load sharing lines. Thiswill be done through the PMScommunication lines. Use a screenedCAN communication cable with amaximum total distance of200 meters. Do not connect the cablescreen to the ground! Use a120 Ohm resistor at both endcontrollers of the PMS.
For more information on thisoption, see User Manual Qc4002™MkII and dedicated PMS manual.
!
!
- 60 -
4.4.4.6 Paralleling
Prior to starting parallel operation of two generators,following connections need to be made:– Connect the communication cable between the
generators by plugging the adapter into socketX30.
– Connect the load with the generator.
Go via the site distribution panel (to be installedby the customer) to connect the generator(s) withthe load. Always connect generator with the load,and never directly with second generator.
When paralleling, make sure todisable the Earth leakage relay byputting switch S13 into off position.
QAS 1 QAS 2
Site distributionpanel
Load
CORRECT
QAS 1 QAS 2
Load
WRONG
!
a 4...20 mA signal towards the Qc4002™ MkII module. For
properly !
re
- 61 -
4.4.4.7 Overview of applications
Installations with only 1 generator
(*) A Power Transducer is a device that measures the actual power of the mains and which translates this into details, please contact Atlas Copco.
Application type Mode Comments
Island operationSEMI-AUTO mode = Local start
AUTO mode = Remote start
AMF operation(SEMI-AUTO mode) AMF operation will not function
AUTO mode = Emergency start @ Mains Failu
Peak shavingSEMI-AUTO mode Only with Power Transducer (*)
AUTO mode Only with Power Transducer (*)
Fixed PowerSEMI-AUTO mode
AUTO mode
Load Take OverSEMI-AUTO mode Only with Power Transducer (*)
AUTO mode Only with Power Transducer (*)
Mains Power ExportSEMI-AUTO mode Only with Power Transducer (*)
AUTO mode Only with Power Transducer (*)
CAN-bus. It has a fully intelligent system, which will start/contain up to 16 Qc4002™ MkII modules. If the Mains isd and controlled via the PMS Software Package. For details
nerators
nerators
properly !
odule (**)
odule (**)
odule (**)
odule (**)
odule (**)
odule (**)
odule (**)
odule (**)
odule (**)
odule (**)
odule (**)
- 62 -
Installations with more generators
(**) The power management system (PMS) allows communication between the Qc4002™ MkII modules overload/stop the generator according to the actual load and to the status of each generator. The installation can included in the installation, then an extra Qc4002™ MkII module is required. The installation can be monitoreon this application, please contact Atlas Copco.
Application type Mode Comments
Island operationSEMI-AUTO mode = Manual paralleling between ge
AUTO mode = Remote paralleling between ge
AMF operation(SEMI-AUTO mode) AMF operation will not function
AUTO mode PMS + Qc4002™ MkII Mains m
Peak shavingSEMI-AUTO mode PMS + Qc4002™ MkII Mains m
AUTO mode PMS + Qc4002™ MkII Mains m
Fixed PowerSEMI-AUTO mode PMS + Qc4002™ MkII Mains m
AUTO mode PMS + Qc4002™ MkII Mains m
Load Take OverSEMI-AUTO mode PMS + Qc4002™ MkII Mains m
AUTO mode PMS + Qc4002™ MkII Mains m
Main Power ExportSEMI-AUTO mode PMS + Qc4002™ MkII Mains m
AUTO mode PMS + Qc4002™ MkII Mains m
Power Management System(SEMI-AUTO mode) PMS + Qc4002™ MkII Mains m
AUTO mode PMS + Qc4002™ MkII Mains m
g or incomplete wirings can damage the
LTO can be combined with AMF).
hanged to a higher value to have some
he Qc4002™ MkII User manual and theco.
- 63 -
1. Each installation has to be prepared and reviewed very carefully before start-up. Wroninstallation brutally !
2. Each application requires a specific combination of the following parameters:- Auto/ Semi-auto / Test / Manual / Block mode.- Island / AMF / PS / FP / LTO / MPE / PMS application type (in AUTO mode PS / FP / - Back synchronising enabled/disabled (parameter channel 7080).Wrong parameter settings can damage the installation brutally !
3. To be able to start up in cold conditions, parameter 6181 (Start prepare) can be cpreheating. Do not put this value above 60 seconds to avoid any possible damage.
4. For more information on the Qc4002™ MkII module and its applications, we refer to tQc4002™ Application data sheets. If you need more assistance, please contact Atlas Cop
!
d that no electrical power is present on the terminals.
Every 1000
hours
Every 2000
hoursYearly
r - -
hese service kits offer you the benefits of genuine parts, e parts list for more information on the contents of the
x
x
x x
x x
x x
x x
- 64 -
5 Maintenance
5.1 Maintenance schedule
Before carrying out any maintenance activity, check that the start switch is in position O an
Maintenance schedule Daily
50 hrs
after initial
start-up
Every 500
hours
Service pak -2912 4412 05 o
2912 4546 05*
For the most important subassemblies, Atlas Copco has developed service kits that combine all wear parts. Tsave on administration costs and are offered at reduced price, compared to the loose components. Refer to thservice kits.Drain water from fuel filter x
Check/Fill fuel level (3) x
Empty air filter vacuator valves x
Check air intake vacuum indicators x
Check engine oil level (if necessary top up) x
Check coolant level x
Check control panel for alarms and warnings x
Check on abnormal noise x
Check function of coolant heater (option) x
Replace air filter element (1) x
Check/Replace safety cartridge x
Change engine oil (2) (6) x
Replace engine oil filter (2) x
Replace fuel (primary)filter(s) (5) x
!
x x
x x
x
x x
x x
x x
x x
x x
x x
x x
x x
x x
x x
x x
x x
x x
x x
x x
x x
x x
Every 1000
hours
Every 2000
hoursYearly
r - -
- 65 -
Replace fuel (secondary)filter(s) (5) x
Inspect/Adjust fan/alternator belt x x
Replace fan/alternator belt
Measure alternator insulation resistance (11)
Test Earth Leakage Relay (12) x
Check emergency stop (12) x
Clean radiator (1) x
Check for obstructions on crankcase breather system / filter and hoses x
Replace crankcasecbreather filter x
Drain condensate and water from spillage-free frame or catch basin (8) x
Check for leaks in engine-, air-, oil-, or fuel system x
Hoses and clamps - Inspect/Replace x
Check electrical system cables for wear
Check/Test glow plugs - grid heater
Check torque on critical bolt connections
Check electrolyte level and terminals of battery (10) x
Analyse coolant (4) (7) x
Check external fuel connection (option)
Grease locks and hinges x
Check rubber flexibles (9)
Drain/Clean fuel tank water and sediments (1) (13) x
Maintenance schedule Daily
50 hrs
after initial
start-up
Every 500
hours
Service pak -2912 4412 05 o
2912 4546 05*
x
x x
x x
x x
x x
x xn have to be tested on a regular basis. At least once a one hour. If possible a high load (> 30%) should be
s its operating temperature.
Every 1000
hours
Every 2000
hoursYearly
r - -
- 66 -
Adjust engine inlet and outlet valves (2) x
Check fuel injectors (2)
Check engine protective devices
Inspect starter motor
Inspect turbocharger
Inspect waterpump
Inspection by Atlas Copco service technician xGenerators in standby applicatiomonth the engine should run forapplied so that the engine reache
Maintenance schedule Daily
50 hrs
after initial
start-up
Every 500
hours
Service pak -2912 4412 05 o
2912 4546 05*
!
Every 1000
hours
Every 2000
hoursYearly
r - -
hese service kits offer you the benefits of genuine parts, e parts list for more information on the contents of the
x x x
x x
x x
x x
x
x x
x x
x x
x x
x x
x x
x x
x x
x
x
- 67 -
Maintenance schedule Daily
50 km
after initial
start-up
Every 500
hours
Service pak -2912 4412 05 o
2912 4546 05*
For the most important subassemblies, Atlas Copco has developed service kits that combine all wear parts. Tsave on administration costs and are offered at reduced price, compared to the loose components. Refer to thservice kits.Check tyre pressure x
Check tyres for uneven wear
Check torque of wheel nuts x
Check coupling head x
Check height of adjusting facility x
Check towbar handbrake lever spring actuator, reversing lever, linkage and all movable parts for ease of movement
x x x
Grease coupling head, towbar bearings at the housing of the overrun brake x
Check brake system (if installed) and adjust if necessary x
Oil or grease brake lever and moving parts such as bolts and joints x
Grease sliding points on height adjusting parts
Check safety cable for damage
Check Bowden cable on height adjustable connection device for damage
Lubricate torsion bar axle trailing arm
Check brake lining wear
Change wheel hub bearing grease
x x
n have to be tested on a regular basis. At least once a one hour. If possible a high load (> 30%) should be
s its operating temperature.
Every 1000
hours
Every 2000
hoursYearly
r - -
- 68 -
Check/Adjust lateral play of wheel bearing (conventional bearing) x
Generators in standby applicatiomonth the engine should run forapplied so that the engine reache
Maintenance schedule Daily
50 km
after initial
start-up
Every 500
hours
Service pak -2912 4412 05 o
2912 4546 05*
!
d
fis
5.1.1 Use of maintenance schedule
The maintenance schedule contains a summary of themaintenance instructions. Read the respective sectionbefore taking maintenance measures.When servicing, replace all disengaged packings, e.g.gaskets, O-rings, washers.For engine maintenance refer to Engine OperationManual.The maintenance schedule has to be seen as aguideline for units operating in a dusty environmenttypical to generator applications. Maintenanceschedule can be adapted depending on application,environment and quality of maintenance.
5.1.2 Use of service paks
Service Paks include all genuine parts needed fornormal maintenance of both generator and engine.Service Paks minimize downtime and keep yourmaintenance budget low.The order number of the Service Paks are listed in theAtlas Copco Parts list (ASL). Order Service Paks atyour local Atlas Copco dealer.
- 69 -
Notes:
In highly dusty environments, these service intervalsdo not apply. Check and/or replace filters and cleanradiator on a regular basis.
* Service pak 500 hours - 2912 4412 05:For units with a Perkins breather filter
Service pak 500 hours - 2912 4546 05:For units with an Atlas Copco breather filter
(1) More frequently when operating in a dustyenvironment.
(2) Refer to engine operation manual.
(3) After a days work.
(4) Yearly is only valid when using PARCOOL.Change coolant every 5 years.
(5) Gummed or clogged filters means fuel starvationand reduced engine performance. Reduce serviceinterval in heavy duty application.
(6) See section “Engine oil specifications”.
(7) The following part numbers can be ordered fromAtlas Copco to check on inhibitors and freezingpoints:
• 2913 0028 00: refractometer• 2913 0029 00: pH meter
(8) See section “Before starting”.
(9) Replace all rubber flexibles every 5 years,according to DIN20066.
(10)See section “Battery care”.
(11)See section “Measuring the alternator insulationresistance”.
(12)The function of this protection should be testeminimum on every new installation.
(13)Water in fuel tank can be detected by means o2914 8700 00. Drain fuel tank when water detected.
r
,l.
de
e
5.4 Engine maintenance
procedures
Refer to the Engine Operation Manual for a fullmaintenance schedule.
5.4.1 Engine oil level check
Consult the Engine Operation Manual for the oilspecifications, viscosity recommendations and oilchange intervals. For the intervals, see also section“Maintenance schedule” on page 64.
– Check the engine oil level by using the oil leveldipstick (OLD).
– Top up with oil (FCO), if necessary. Refer to the Engine Operation Manual for moredetailed instructions.
- 70 -
5.2 Preventing low loads
To avoid cylinder glazing, high oil consumption orother damages to the engine, it is recommended that aunit is always used with a load > 30% of nominal.Corrective actions should be taken if due tocircumstances this minimum load capacity cannot beobtained. Operate the unit at full load capacity afterany low load operating period. Therefore, connect theunit periodically to a load bank. Increase the load insteps of 25% every 30 minutes and allow the unit torun for 1 hour in full load condition. Gradually returnthe unit to the operating load.The interval between load bank connections may varyaccording to the conditions present on site and theamount of load. However, a rule of thumb is toconnect a unit to a load bank after every maintenanceoperation. Units equipped with Qc4002™ MkII and operating inparallel with the Mains may be placed in Fixed Poweror Test mode without the requirement of a load bank. For more info on this operation, please contact yourAtlas Copco Service Center.
5.3 Alternator maintenance
procedures
5.3.1 Measuring the alternator
insulation resistance
A 500 V megger is required to measure the alternatoinsulation resistance.If the N-terminal is connected to the earthing systemit must be disconnected from the earth terminaDisconnect the AVR.Connect the megger between the earth terminal anterminal L1 and generate a voltage of 500 V. Thscale must indicate a resistance of at least 5 M.Refer to the alternator operating and maintenancinstructions for more details.
ilry
il
5.4.3 Coolant check
5.4.3.1 Monitoring coolant condition
In order to guarantee the lifetime and quality of theproduct, thus to optimise engine protection, regularcoolant-condition-analysis is advisable.The quality of the product can be determined by threeparameters.
Visual check
– Verify the outlook of the coolant regarding colourand make sure that no loose particles are floatingaround.
pH measurement
– Check the pH value of the coolant using a pH-measuring device.
– The pH-meter can be ordered from Atlas Copcowith part number 2913 0029 00.
– Typical value for EG = 8.6.– If the pH-level is below 7 or above 9.5, the coolant
should be replaced.
Long service intervals5-year drain interval to minimizeservice costs (when used inaccordance with the instructions).
!
- 71 -
5.4.2 Engine oil and oil filter change
Replacing the oil filter element
– Place an appropriate drain pan under the oil drainflexible.
– Remove the drain plug from the oil drain flexibleto drain the oil.
– Replace the seal of the drain plug.
– Install and thighten the drain plug on the oil drainflexible.
– Unscrew the oil filter element (OF) from theadapter head.
– Clean the adapter head sealing surface. Lightly othe gasket of the new element and screw the latteonto the adapter head until the gasket is properlseated, then tighten with both hands.
– Top up the engine oil level.– Run the engine for 1 minute and check the o
level using the oil level dipstick.
Observe all relevant environmentaland safety precautions.
Never leave spilled liquids such asfuel, oil, water and cleansing agentsin or around the generator.
n
sts
er
rr
sst’
Fill
– To assure proper operation and the release oftrapped air, run the engine until normal engineoperation temperature is reached. Turn off theengine and allow to cool.
– Recheck coolant level and add if necessary.
- 72 -
Glycol concentration measurement
– To optimise the unique engine protection featuresof the PARCOOL EG the concentration of theGlycol in the water should be always above33 vol.%.
– Mixtures with more than 68 vol.% mix ratio inwater are not recommended, as this will lead tohigh engine operating temperatures.
– A refractometer can be ordered from Atlas Copcowith part number 2913 0028 00.
5.4.3.2 Topping up of coolant
– Verify if the engine cooling system is in a goodcondition (no leaks, clean,...).
– Check the condition of the coolant.– If the condition of the coolant is outside the limits,
the complete coolant should be replaced (seesection “Replacing the coolant”).
– Always top-up with PARCOOL EG.– Topping up the coolant with water only, changes
the concentration of additives and is therefore notallowed.
5.4.3.3 Replacing the coolant
Drain
– Completely drain the entire cooling system.– Used coolant must be disposed or recycled i
accordance with laws and local regulations.
Flush
– Flush twice with clean water. Used coolant mube disposed or recycled in accordance with lawand local regulations.
– From the Atlas Copco Instruction book, determinthe amount of PARCOOL EG required and pouinto the radiator top tank.
– It should be clearly understood that the risk focontamination is reduced in case of propecleaning.
– In case a certain content of ‘other’ coolant remainin the system, the coolant with the loweproperties influences the quality of the ‘mixedcoolant.
In case of a mix of different coolantproducts this type of measurementmight provide incorrect values.
!
e
e
g
5.5.2 Cleaning the fuel tank
– Place an appropriate drain pan under the drainplug of the fuel tank.
– Remove the flange (2) and the drain plug (1).
– Slope the unit. approx. 15° to remove all fuel, dirtand water.
– Clean the fuel tank and fix the drain plug andflange handtight.
– Refill the fuel tank with clean fuel.
Observe all relevant environmentaland safety precautions.
Never leave spilled liquids such asfuel, oil, water and cleansing agentsin or around the generator.
!
!
- 73 -
5.5 Adjustments and service procedures
5.5.1 Cleaning coolers – Keep the water cooler clean to maintain thcooling efficiency.
– The engine water cooler is accessible via thservice door (1) at the front of the unit.
– Steam cleaning in combination with a cleansinagent may be applied.
– Close the service door(s).
Remove any dirt from the coolerswith a fibre brush. Never use a wirebrush or metal objects.
To avoid damaging the coolers, anglebetween jet and coolers should beapprox. 90°.Protect the electrical and controllingequipment, air filters, etc. againstpenetration of moisture.Make sure to not steam clean thealternator.
Never leave spilled liquids such asfuel, oil, water and cleansing agentsin or around the generator.
!
!
!
ired
ehh
dg0
ise.n
r,er
If a battery does not need any make-up water at allover a considerable time of operation, anundercharged battery condition may be caused bypoor cable connections or a too low voltage regulatorsetting.
5.5.3.5 Periodic battery service
– 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 withdistilled water only. Never overfill, as this willcause poor performance and excessice corrosion.
– Record the quantity of distilled water added.
– Keep the terminals and clamps tight, clean, andlightely covered with petroleum jelly.
– Carry out periodic condition tests. Test intervalsof 1 to 3 months, depending on climate andoperating conditions, are recommended.
– If doubtful conditions are noticed or malfunctionsarise, keep in mind that the cause may be in theelectical system, e.g. loose terminals, voltageregulator maladjusted, poor performance ofgenerator, etc...
- 74 -
5.5.3 Battery care
If the battery is still dry, it must be activated asdescribed in section “Activating a dry-chargedbattery”.The battery must be in operation within 2 monthsfrom being activated; if not, it needs to be rechargedfirst.
5.5.3.1 Electrolyte
Electrolyte in batteries is a sulphuric acid solution indistilled water.The solution must be made up before beingintroduced into the battery.
5.5.3.2 Activating a dry-charged battery
– Take out the battery.– 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 thelevel marked on the battery.
– Rock the battery a few times so that possible abubbles can escape; wait 10 minutes and check thlevel in each cell once more; if required, adelectrolyte.
– Refit plugs and/or cover.
– Place the battery in the generator.
5.5.3.3 Recharging a battery
Before and after charging a battery, always check thelectrolyte level in each cell; if required, top up witdistilled water only. When charging batteries, eaccell must be open, i.e. plugs and/or cover removed.
Apply with preference the slow charging method anadjust the charge current according to the followinrule of thumb: battery capacity in Ah divided by 2gives safe charging current in Amp.
5.5.3.4 Make-up distilled water
The amount of water evaporating from batteries largely dependant on the operating conditions, i.temperatures, number of starts, running time betweestart and stop, etc...
If a battery starts to need excessive make-up watethis points to overcharging. Most common causes arhigh temperatures or a too high voltage regulatosetting.
Before handling batteries, read therelevant safety precautions and actaccordingly.
Read the safety instructionscarefully.
!
!Use a commercial automatic batterycharger according to itsmanufacturer’s instructions.
!
r
od
ae
st
5.5.4.4 Replacing the air filter element
– Release the snap clips (1) and remove the dust trap(2). Clean the trap.
– Remove the element (4) from the housing (5).– Reassemble in reverse order of dismantling.
– Inspect and tighten all air intake connections.– Reset the vacuum indicator.
7 Air filter contamination indicator8 Reset button9 Yellow indicator
8
7
9
- 75 -
5.5.4 Servicing air filter engine
5.5.4.1 Main parts
5.5.4.2 Recommendation
– New elements must also be inspected for tears opunctures before installation.
– Discard the filter element (4) when damaged.– In heavy duty applications it is recommended t
install a safety cartridge which can be orderewith part no.: 2914 9307 00.
– A dirty safety cartridge (3) is an indication of malfunctioning air filter element (4). Replace thelement and the safety cartridge in this case.
– The safety cartridge (3) cannot be cleaned.
5.5.4.3 Cleaning the dust trap
To remove dust from the dust trap (2) pinch the duevacuator (6) several times.
1 Snap clips2 Dust trap3 Safety cartridge4 Filter element5 Filter housing6 Dust evacuator
1
6 2 3 4 5
The Atlas Copco air filters arespecially designed for theapplication. The use of non-genuineair filters may lead to severedamage of engine and/or alternator.Never run the generator without airfilter element.
!
s
ds,.t
Specifications PAROIL
PAROIL from Atlas Copco is the ONLY oil testedand approved for use in all engines built into AtlasCopco compressors and generators.Extensive laboratory and field endurance tests onAtlas Copco equipment have proven PAROIL tomatch all lubrication demands in varied conditions. Itmeets stringent quality control specifications toensure your equipment will run smoothly andreliably.The quality lubricant additives in PAROIL allow forextended oil change intervals without any loss inperformance or longevity.
Never mix synthetic with mineraloil.When changing from mineral tosynthetic oil (or the other wayaround), you will need to do anextra rinse.After doing the complete changeprocedure to synthetic oil, run theunit for a few minutes to allow goodand complete circulation of thesynthetic oil. Then drain thesynthetic oil again and fill againwith new synthetic oil. To set correctoil levels, proceed as in normalinstruction.
!
- 76 -
5.5.5 Replacing fuel filter element
Replacing the filter element:– Unscrew the filter element (FF) from the adapter
head.
– Clean the adapter head sealing surface. Lightly oilthe gasket of the new element and screw the latteronto the header until the gasket is properly seated,then tighten with both hands.
Check for fuel leaks once the engine has beenrestarted.
5.6 Engine consumable
specifications
5.6.1 Engine fuel specifications
For fuel specifications, please contact your AtlaCopco Customer Center.
5.6.2 Engine oil specifications
High-quality, mineral, hydraulic or synthesizehydrocarbon oil with rust and oxidation inhibitoranti-foam and anti-wear properties is recommendedThe viscosity grade should correspond to the ambientemperature and ISO 3448, as follows:
It is strongly recommended to useAtlas Copco branded lubricationoils.
Engine Type of lubricant
between -10°C and 50°CPAROIL E or
PAROIL E Mission Green
between -25°C and 50°C PAROIL Extra
!
eses
es
elt
PAROIL E Mission Green
PAROIL E Mission Green is a mineral based highperformance diesel engine oil with a high viscosity-index. Atlas Copco PAROIL E Mission Green isdesigned to provide a high level of performance andprotection in standard ambient conditions as from-10°C (14°F).
LiterUS
gal
Imp
galcu.ft
Order
number
can 5 1.3 1.1 0.175 1630 0471 00
can 20 5.3 4.4 0.7 1630 0472 00
barrel 209 55.2 46 7.32 1630 0473 00
- 77 -
PAROIL provides wear protection under extremeconditions. Powerful oxidation resistance, highchemical stability and rust- inhibiting additives helpreduce corrosion, even within engines left idle forextended periods.PAROIL contains high quality anti-oxidants tocontrol deposits, sludge and contaminants that tend tobuild up under very high temperatures.PAROIL's detergent additives keep sludge formingparticles in a fine suspension instead of allowing themto clog your filter and accumulate in the valve/rockercover area.PAROIL releases excess heat efficiently, whilstmaintaining excellent bore-polish protection to limitoil consumption.PAROIL has an excellent Total Base Number (TBN)retention and more alkalinity to control acidformation.PAROIL prevents Soot build-up.PAROIL is optimized for the latest low emissionEURO -3 & -2, EPA TIER II & III engines running onlow sulphur diesel for lower oil and fuel consumption.
PAROIL Extra
PAROIL Extra is a synthetic ultra high performancdiesel engine oil with a high viscosity-index. AtlaCopco PAROIL Extra is designed to providexcellent lubrication from start-up in temperatures alow as -25°C (-13°F).
PAROIL E
PAROIL E is a mineral based high performancdiesel engine oil with a high viscosity-index. AtlaCopco PAROIL E is designed to provide a high levof performance and protection in standard ambienconditions as from -10°C (14°F).
LiterUS gal
Imp gal
cu.ftOrder
number
can 5 1.3 1.1 0.175 1630 0135 00
can 20 5.3 4.4 0.7 1630 0136 00
LiterUS gal
Imp gal
cu.ftOrder
number
can 5 1.3 1.1 0.175 1615 5953 00
can 20 5.3 4.4 0.7 1615 5954 00
barrel 209 55.2 46 7.32 1615 5955 00
barrel 1000 264 220 35 1630 0096 00
nrsd
isdGn.llt
l0o
itser
tg
cteg
To ensure protection against corrosion, cavitation andformation of deposits, the concentration of theadditives in the coolant must be kept between certainlimits, as stated by the manufacturer's guidelines.Topping up the coolant with water only, changes theconcentration and is therefore not allowed.Liquid-cooled engines are factory-filled with thistype of coolant mixture.
LiterUS gal
Imp gal
cu.ftOrder
number
can 5 1.3 1.1 0.175 1604 5308 00
can 20 5.3 4.4 0.7 1604 5307 01
barrel 210 55.2 46 7.35 1604 5306 00
- 78 -
5.6.3 Engine coolant specifications
The use of the correct coolant is important for goodheat transfer and protection of liquid-cooled engines.Coolants used in these engines must be mixtures ofgood quality water (distilled or de-ionised), specialcoolant additives and if necessary freeze protection.Coolant that is not to manufacturer's specification willresult in mechanical damage of the engine.The freezing point of the coolant must be lower thanthe freezing point that can occur in the area. Thedifference must be at least 5°C. If the coolant freezes,it may crack the cylinder block, radiator or coolantpump.
Consult the engine's operation manual and follow themanufacturer's directions.
Specifications PARCOOL EG
PARCOOL EG is the only coolant that has beetested and approved by all engine manufacturecurrently in use in Atlas Copco compressors angenerators.Atlas Copco's PARCOOL EG extended life coolant the new range of organic coolants purpose designeto meet the needs of modern engines. PARCOOL Ecan help prevent leaks caused by corrosioPARCOOL EG is also fully compatible with asealants and gasket types developed to join differenmaterials used within an engine.
PARCOOL EG is a ready to use Ethylene Glycobased coolant, premixed in an optimum 50/5dilution ratio, for antifreeze protection guaranteed t-40°C.Because PARCOOL EG inhibits corrosion, deposformation is minimized. This effectively eliminatethe problem of restricted flow through the engincoolant ducts and the radiator, minimizing the risk foengine overheating and possible failure.
It reduces water pump seal wear and has excellenstability when subjected to sustained high operatintemperatures.PARCOOL EG is free of nitride and amines to proteyour health and the environment. Longer service lifreduces the amount of coolant produced and needindisposal to minimise environmental impact.
Never remove the cooling systemfiller cap while coolant is hot.The system may be under pressure.Remove the cap slowly and onlywhen coolant is at ambienttemperature. A sudden release ofpressure from a heated coolingsystem can result in personal injuryfrom the splash of hot coolant.It is strongly recommended to useAtlas Copco branded coolant.
Never mix different coolants andmix the coolant components outsidethe cooling system.
!
!
n
e
r
y
te
6.2 Engine troubleshooting
The table below gives an overview of the possibleengine problems and their possible causes.
The starter motor turns the engine too slowly
– Battery capacity too low.– Bad electrical connection.– Fault in starter motor.– Wrong grade of lubricating oil.
The engine does not start or is difficult to start
– Starter motor turns engine too slowly.– Fuel tank empty.– Fault in fuel control solenoid.
– Restriction in a fuel pipe.– Fault in fuel lift pump.– Dirty fuel filter element.– Air in fuel system.– Fault in atomisers.– Cold start system used incorrectly.
– Fault in cold start system.– Restriction in fuel tank vent.– Wrong type or grade of fuel used.– Restriction in exhaust pipe.
- 79 -
6 Checks and trouble
shooting
6.1 Checks
6.1.1 Checking voltmeter P4
– Put a voltmeter in parallel with voltmeter P4 othe control panel.
– Check that the read-out of both voltmeters is thsame.
– Stop the generator and disconnect one terminal.– Check that the internal resistance of the voltmete
is high.
6.1.2 Checking ammeters P1, P2 and
P3
– Measure the outgoing current during the load, bmeans of a clamp-on probe.
– Compare the measured current with the currenindicated on ammeter. Both readings should bthe same.
Never perform a test run withconnected power cables. Nevertouch an electrical connectorwithout a voltage check.When a failure occurs, alwaysreport what you experienced before,during and after the failure.Information with regard to the load(type, size, power factor, etc.),vibrations, exhaust gas colour,insulation check, odours, outputvoltage, leaks and damaged parts,ambient temperature, daily andnormal maintenance and altitudemight be helpful to quickly locatethe problem. Also report anyinformation regarding the humidityand location of the generator (e.g.close to sea).
!
n
ct
n
ct
– Incorrect valve tip clearances.– Engine overload.
Blue or white exhaust smoke
– Wrong grade of lubricating oil.
– Fault in cold start system.– Engine temperature is too low.
The engine knocks
– Fault in fuel lift pump.– Fault in atomisers or atomisers of an incorrect
type.– Fault in cold start system.– Wrong type or grade of fuel used.– Engine temperature is too high.– Incorrect valve tip clearances.
The engine runs erratically
– Fault in fuel control.
– Restriction in a fuel pipe.– Fault in fuel lift pump.– Dirty fuel filter element.– Restriction in air filter/cleaner or induction
system.– Air in fuel system.– Fault in atomisers or atomisers of an incorrect
type.
- 80 -
Not enough power
– Restriction in a fuel pipe.– Fault in fuel lift pump.
– Dirty fuel filter element.– Restriction in air filter/cleaner or induction
system.
– Air in fuel system.– Fault in atomisers or atomisers of an incorrect
type.
– Restriction in fuel tank vent.– Wrong type or grade of fuel used.– Restricted movement of engine speed control.– Restriction in exhaust pipe.– Engine temperature is too high.– Engine temperature is too low.
Misfire
– Restriction in a fuel pipe.– Fault in fuel lift pump.– Dirty fuel filter element.– Air in fuel system.– Fault in atomisers or atomisers of an incorrect
type.– Fault in cold start system.– Engine temperature is too high.– Incorrect valve tip clearances.
The pressure of the lubricating oil is too low
– Wrong grade of lubricating oil.– Not enough lubricating oil in sump.
– Defective gauge.– Dirty lubricating oil filter element.
High fuel consumption
– Restriction in air filter/cleaner or inductiosystem.
– Fault in atomisers or atomisers of an incorretype.
– Fault in cold start system.– Wrong type or grade of fuel used.– Restricted movement of engine speed control.– Restriction in exhaust pipe.– Engine temperature is too low.– Incorrect valve tip clearances.
Black exhaust smoke
– Restriction in air filter/cleaner or inductiosystem.
– Fault in atomisers or atomisers of an incorretype.
– Fault in cold start system.– Wrong type or grade of fuel used.– Restriction in exhaust pipe.
– Engine temperature is too low.
n
n
/
- 81 -
– Fault in cold start system.– Restriction in fuel tank vent.
– Restricted movement of engine speed control.– Engine temperature is too high.– Incorrect valve tip clearances.
Vibration
– Fault in atomisers or atomisers of an incorrecttype.
– Restricted movement of engine speed control.– Engine temperature is too high.– Fan damaged.– Fault in engine mounting or flywheel housing.
The pressure of the lubricating oil is too high
– Wrong grade of lubricating oil.
– Defective gauge.
The engine temperature is too high
– Restriction in air filter/cleaner or inductionsystem.
– Fault in atomisers or atomisers of an incorrecttype.
– Fault in cold start system.– Restriction in exhaust pipe.
– Fan damaged.– Too much lubricating oil in sump.– Restriction in air or coolant passages of radiator.
Crankcase pressure
– Restriction in breather pipe.– Vacuum pipe leaks or fault in exhauster.
Bad compression
– Restriction in air filter/cleaner or inductiosystem.
– Incorrect valve tip clearances.
The engine starts and stops
– Dirty fuel filter element.
– Restriction in air filter/cleaner or inductiosystem.
– Air in fuel system.
The engine shuts down after approx. 15 sec.
– Bad connection towards oil pressure switchcoolant temperature switch
action
.ternator by applying a 12V battery voltage with a 30 ries on the + and - terminals of the electronic regulator, e polarities.ction cables, measure winding resistances and compare entioned in the alternator manual.
e.ncy/voltage regulator.
ngs.e.gulator.
e potentiometer.igh, power factor lower than 0.8; speed lower than 10% d.
gulator.s, disconnect cables.e potentiometer.gulator.rity of rotation.ility of regulator by acting on STABILITY r.
- 82 -
6.3 Alternator troubleshooting
Symptom Possible cause Corrective
Alternator gives 0 Volt Blown fuse. Replace fuseNo residual voltage. Excite the al
resistor in serespecting th
After being excited the alternator still gives 0 Volt.
Connections are interrupted. Check connewith values m
Low voltage at no load Voltage potentiometer out of setting. Reset voltagIntervention of protection. Check frequeWinding failure. Check windi
High voltage at no load Voltage potentiometer out of setting. Reset voltagFailed regulator. Substitute re
Lower than rated voltage at load Voltage potentiometer out of setting. Reset voltagIntervention by protection. Current too h
of rated spee
Failed regulator. Substitute reRotating bridge failure. Check diode
Higher than rated voltage at load Voltage potentiometer out of setting. Reset voltagFailed regulator. Substitute re
Unstable voltage Speed variation in engine. Check regulaRegulator out of setting. Regulate stab
potentiomete
START FAILURE
STOP FAILURE
HZ/V FAILURE(Qc2002™ alarm)
OIL LEVEL(Qc2002™ alarm)
OIL TEMPERATURE(Qc2002™ alarm)
- 83 -
6.4 Solving controller alarms
6.4.1 Qc1002™ and Qc2002™ alarms
and remedies
6.4.1.1 Alarm overview
Possible alarms appearing in the alarm list:
LOW OIL PRESSURE
HIGH COOLANT TEMPERATURE
CHARGING ALTERNATOR
LOW FUEL LEVEL
GENERATOR OVERVOLTAGE
GENERATOR UNDER-VOLTAGE
GENERATOR OVER-FREQUENCY
GENERATOR UNDER-FREQUENCY
SERVICE TIMER 1
SERVICE TIMER 2
ENGINE ALARM
EMERGENCY STOP
llisge
x.
-d
d
odd
at
- 84 -
General groups of Alarms
– Warning: Alarm LED lights up + Alarm pop-upappears on the display + Alarm relay isempowered (if configured)
– Trip of GB: ‘Warning’ actions + GeneratorContactor opens
– Trip and Stop: ‘Trip of GB’ actions + unit stopsafter Cooldown
– Shutdown: ‘Trip of GB’ actions + unit stopsimmediately
6.4.1.2 Fail classes
All the activated alarms have their own pre-definedfail class.All alarms are enabled according to one of these threestatuses:– disabled alarm, no supervision of alarm (OFF).– enabled alarm, supervision of alarm all the time
(ON).– running alarm, only supervision when the
machine is running (RUN).
6.4.1.3 Solving alarms
In case an Alarm occurs, a pop-up window wiautomatically be displayed for as long as the alarm active, no matter which view is active. The flashinred alarm LED will light up. The alarm icons will bshown together with an acknowledgement check-boPush the ENTER button to acknowledge the alarm.When the alarm has been acknowledged, a Vmarking will appear in the check-box and the realarm LED will light up continuously.
The Alarm Display can always be left or entereagain by pushing the BACK button.
If more than one alarm comes up, it is possible tscroll through the alarm messages with the UP anDOWN pushbuttons. The newest alarm will be placeat the bottom of the list (meaning that the older alarmstays at the display when a newer alarm comes up).If one or more than one alarm is present, an arrow the right of the display will be shown.
An alarm should always beacknowledged before solving theproblem that causes the alarm. !
Alarm List0 Alarm(s)
OR
- 85 -
Menu flow
This is the described menu flow for solving alarms:
Qc1002v x.xx.xx
Alarm List1 Alarm(s)
Alarm List0 Alarm(s)
SOLVE PROBLEMSee next page
n problems as an example.
rrective action
place sensor.
l coolant till appropriate level.eck for leaks.
eck air inlets / outlet.an radiator.
eck wiring.
arge battery.tall battery charger (depending on situation).
asure battery voltage during running.place charging alternator if battery voltage is not OK.
place battery.
eck wiring.
l oil till appropriate level.eck for leaks.
place sensor.
eck or contact Atlas Copco.
eck wiring.
- 86 -
Solving problems
The troubleshooting table below shows how to solve problems causing controller alarms. It uses three commo
Alarm display Symptom Possible cause Co
High coolant temperature Sensor broken Re
Not enough coolant FilCh
Obstructed airflow ChCle
Bad connection Ch
Low battery voltage Battery drained ChIns
Charging alternator broken MeRe
Battery broken Re
Bad connection Ch
Low oil pressure Not enough oil FilCh
Sensor broken Re
Oil sump broken Ch
Bad connection Ch
B
B
B
6.4.2.2 Diagnostics menu
The diagnostics menu can be entered via channel6700. It is used for engine diagnostics situations.If diagnostics is selected in this menu, the fuelsolenoid relay output will be de-energized for 30seconds (to make sure that the unit is completelystopped), and then gets energized again. Then enginediagnostics can take place.To leave this status, disable diagnostics in channel6700, or press stop, or start the machine (not duringthe first 30 s).
It's only possible to start thegenerator when Normal is selected.!
- 87 -
6.4.2 Qc4002™ MkII alarms and remedies
6.4.2.1 Fail Classes
All the activated alarms of the module are configuredwith a fail class. The fail class defines the category ofthe alarm and the subsequent action.6 different fail classes can be used:
Engine running:
– Alarm: Alarm Horn Relay, Alarm Display.– Warning: Alarm Horn Relay, Alarm Display.– Trip of GB: Alarm Horn Relay, Alarm Display,
GB Trip.– Trip & Stop: Alarm Horn Relay, Alarm Display,
(Deload), GB Trip, Gen-Set cooling down, Gen-Set stop.
– Shutdown: Alarm Horn Relay, Alarm Display,GB Trip, Gen-Set stop.
– Trip of MB: Alarm Horn Relay, Alarm Display,MB Trip.
Engine stopped:
– Alarm: Block engine start.
– Warning: -– Trip of GB: Block engine start, Block G
sequence.
– Trip & Stop: Block engine start, Block Gsequence.
– Shutdown: Block engine start, Block Gsequence.
– Trip of MB: Block MB sequence.All alarms can be disabled or enabled as following:
– OFF: disabled alarm, inactive supervision.– ON: enabled alarm.
002
002 Qc4002
OR
- 88 -
6.4.2.3 Solving alarms
Menu flow
Qc4
Qc4
Qc4002
G
!
OK
LOG
SOLVE PROBLEMSee page 86
r
eest
e
t
y
- 89 -
7 Storage of the generator
7.1 Storage
– Store the generator in a dry, frost-free room whichis well ventilated.
– Run the engine regularly, e.g. once a week, until itis warmed up. If this is impossible, extraprecautions must be taken:• Consult the engine’s operator manual.• Remove the battery. Store it in a dry, frost-free
room. Keep the battery clean and its terminalslightly covered with petroleum jelly. Rechargethe battery regularly.
• Clean the generator and protect all electricalcomponents against moisture.
• Place silica gel bags, VCI paper (VolatileCorrosion Inhibitor) or another drying agentinside the generator and close the doors.
• Stick sheets of VCI paper with adhesive tapeon the bodywork to close off all openings.
• Wrap the generator, except the bottom, with aplastic bag.
7.2 Preparing for operation afte
storage
Before operating the generator again, remove thwrapping, VCI paper and silica gel bags and check thgenerator thoroughly (go through the checkli“Before starting” on page 26).– Consult the engine’s operator manual.
– Check that the insulation resistance of thgenerator exceeds 5 M.
– Replace the fuel filter and fill the fuel tank. Venthe fuel system.
– Reinstall and connect the battery, if necessarafter being recharged.
– Submit the generator to a test run.
8.2 Disposal of materials
Dispose contaminated substances and materialseparately, according to local applicableenvironmental legislations.
Before dismantling a machine at the end of itsoperating lifetime drain all fluids and dispose ofaccording the applicable local disposal regulations.Remove the batteries. Do not throw batteries into thefire (explosion risk) or into the residual waste.Separate the machine into metal, electronics, wiring,hoses, insulation and plastic parts.Dispose all components according to the applicabledisposal regulations.Remove spilled fluid mechanically; pick up the restwith absorbing agent (for example sand, sawdust) anddispose it according the applicable local disposalregulations. Do not drain into the sewage system orsurface water.
rgtosne
s
- 90 -
8 Disposal
8.1 General
When developing products and services, Atlas Copcotries to understand, address, and minimize thenegative environmental effects that the products andservices may have, when being manufactured,distributed, and used, as well as at their disposal.Recycling and disposal policy are part of thedevelopment of all Atlas Copco products. AtlasCopco company standards determine strictrequirements.Selecting materials the substantial recyclability, thedisassembly possibilities and the separability ofmaterials and assemblies are considered as well as theenvironmental perils and dangers to health during therecycling and disposal of the unavoidable rates of notrecyclable materials.
Your Atlas Copco generator consists for the most partof metallic materials, that can be remelted insteelworks and smelting works and that is thereforealmost infinite recyclable. The plastic used islabelled; sorting and fractioning of the materials forrecycling in the future is forseen.
This concept can only succeed with youhelp. Support us by disposinprofessionally. By assuring a correcdisposal of the product you help tprevent possible negative consequencefor environment and health, that caoccur with an inappropriate wasthandling.Recycling and re-usage of material helpto preserve natural resources.
!
l
)
- 91 -
9 Options available for QAS 60 units
9.1 Circuit diagrams
The engine control circuit diagrams and the powercircuit diagrams for the standard QAS 60 units, forthe units with options and for the units with combinedoptions are:
Power circuit
Unit Circuit
QAS 60 Pd 9822 0996 10QAS 60 Pd - 2V-50Hz 1ph 9822 0996 11QAS 60 Pd - 2V-50 Hz 9822 0996 12
Controller circuit
Unit CircuitQAS 60 Pd Qc1002™ 9822 0996 05QAS 60 Pd Qc2002™ 9822 0996 06QAS 60 Pd Qc4002™ MkII 9822 0996 18
9.2 Overview of the electrical
options
The following electrical options are available:– Automatic battery charger
– Battery switch– Engine coolant heater– Outlet sockets (S) - Set 1– Outlet sockets (S) - Set 2– Outlet sockets (S) - Set 3– Single frequency with electronic speed contro
(SF)– Dual frequency with electronic speed control (DF– Electronic speed regulator
– Dual voltage (2V)– Earth leakage relay– IT-relay– “Electricité de France” (EDF)– COSMOS™– COC box
n
fe
9.3.2 Battery switch
The battery switch is situated inside the sound-insulated bodywork. It allows to open or to close theelectrical connection between the battery and theengine circuits.
9.3.3 Engine coolant heater
To make sure that the engine can start and accept loadimmediately, an external cooling water heater(1000 W, 240 V) is provided which keeps the enginetemperature between 38°C and 49°C.
Never turn the battery switch toOFF during operation.!
- 92 -
9.3 Description of the electrical
options
9.3.1 Automatic battery charger
The automatic battery charger charges the batterycompletely and is disconnected once the unit startsup.Besides the output terminals (secondary side) theautomatic battery charger has a trim potentiometer forsetting of the output voltage. By means of an insulatedslotted screwdriver or adjusting pin the output voltagecan be set in the range.
The LED on the front indicates that the unit isoperational.
Setting:– Lower output voltage = counterclockwise rotatio
– Higher output voltage = clockwise rotationTo use the batery charger: – Provide the X25 connector, located at the side o
the power cubicle, with external power to use thbattery charger.
DEIF-power in control
xxxx xxxx xxxxxxxxxx
xxxx
xxxxxxxx
xxxxxxxxxxxxxxx
xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx!
d
d
anistsne
anised
anised
Q6 .......Circuit breaker for X6
Interrupts the power supply to X6 when ashort-circuit occurs at the load side, or whenthe overcurrent protection (16 A) isactivated. When activated, Q6 interrupts thethree phases towards X6. It can be activatedagain after eliminating the problem.
Circuit breaker Q1 does not onlyinterrupt the power supply towardsX1, but also towards X2, X4, X5 andX6.Make sure to switch on circuitbreakers Q1, Q2, Q4, Q5 and Q6after starting the generator whenpower supply is done by means ofX2, X4, X5 or X6.
!
- 93 -
9.3.4 Outlet sockets (S) - Set 1
A brief description of all outlet sockets and circuitbreakers provided on the generator is given hereafter:
X2 .......1-phase outlet socket (230 V AC)
Provides phase L3, neutral and earthing.
X4 .......3-phase outlet socket (400 V AC)
Provides phases L1, L2 and L3, neutral andearthing.
X5 .......3-phase outlet socket (400 V AC)
Provides phases L1, L2 and L3, neutral anearthing.
X6 .......3-phase outlet socket (400 V AC)
Provides phases L1, L2 and L3, neutral anearthing.
Q2 .......Circuit breaker for X2
Interrupts the power supply to X2 when short-circuit occurs at the load side, or whethe overcurrent protection (16 A) activated. When activated, Q2 interrupphase L3 and the neutral towards X2. It cabe activated again after eliminating thproblem.
Q4 .......Circuit breaker for X4
Interrupts the power supply to X4 when short-circuit occurs at the load side, or whethe overcurrent protection (63 A) activated. When activated, Q4 interrupts ththree phases towards X4. It can be activateagain after eliminating the problem.
Q5 .......Circuit breaker for X5
Interrupts the power supply to X5 when short-circuit occurs at the load side, or whethe overcurrent protection (32 A) activated. When activated, Q5 interrupts ththree phases towards X5. It can be activateagain after eliminating the problem.
Q1
Q2
Q6
Q5
Q4
X5
X6
X4
X2
d
d
d
anistsne
anised
anise
three phases towards X4. It can be activatedagain after eliminating the problem.
Q5 .......Circuit breaker for X5
Interrupts the power supply to X5 when ashort-circuit occurs at the load side, or whenthe overcurrent protection (32 A) isactivated. When activated, Q5 interrupts thethree phases towards X5. It can be activatedagain after eliminating the problem.
Q6 .......Circuit breaker for X6
Interrupts the power supply to X6 when ashort-circuit occurs at the load side, or whenthe overcurrent protection (16 A) isactivated. When activated, Q6 interrupts thethree phases towards X6. It can be activatedagain after eliminating the problem.
Circuit breaker Q1 does not onlyinterrupt the power supply towardsX1, but also towards X2, X3, X4, X5and X6.Make sure to switch on circuitbreakers Q1, Q2, Q3, Q4, Q5 and Q6after starting the generator whenpower supply is done by means ofX2, X3, X4, X5 or X6.
!
- 94 -
9.3.5 Outlet sockets (S) - Set 2
A brief description of all outlet sockets and circuitbreakers provided on the generator is given hereafter:
X2 .......1-phase outlet socket (230 V AC)
Provides phase L3, neutral and earthing.
X3 .......3-phase outlet socket (400 V AC)
Provides phases L1, L2 and L3, neutral andearthing.
X4 .......3-phase outlet socket (400 V AC)
Provides phases L1, L2 and L3, neutral anearthing.
X5 .......3-phase outlet socket (400 V AC)
Provides phases L1, L2 and L3, neutral anearthing.
X6 .......3-phase outlet socket (400 V AC)
Provides phases L1, L2 and L3, neutral anearthing.
Q2 .......Circuit breaker for X2
Interrupts the power supply to X2 when short-circuit occurs at the load side, or whethe overcurrent protection (16 A) activated. When activated, Q2 interrupphase L3 and the neutral towards X2. It cabe activated again after eliminating thproblem.
Q3 .......Circuit breaker for X3
Interrupts the power supply to X3 when short-circuit occurs at the load side, or whethe overcurrent protection (63 A) activated. When activated, Q3 interrupts ththree phases towards X3. It can be activateagain after eliminating the problem.
Q4 .......Circuit breaker for X4
Interrupts the power supply to X4 when short-circuit occurs at the load side, or whethe overcurrent protection (63 A) activated. When activated, Q4 interrupts th
Q1
Q2
Q6
Q5
Q4
Q3
X5
X6
X4
X3
X2
d
d
d
d
anistsne
anised
Q5 .......Circuit breaker for X5
Interrupts the power supply to X5 when ashort-circuit occurs at the load side, or whenthe overcurrent protection (32 A) isactivated. When activated, Q5 interrupts thethree phases towards X5. It can be activatedagain after eliminating the problem.
Q6 .......Circuit breaker for X6
Interrupts the power supply to X6 when ashort-circuit occurs at the load side, or whenthe overcurrent protection (16 A) isactivated. When activated, Q6 interrupts thethree phases towards X6. It can be activatedagain after eliminating the problem.
Circuit breaker Q1 does not onlyinterrupt the power supply towardsX1, but also towards X2, X3, X4, X5and X6.Make sure to switch on circuitbreakers Q1, Q2, Q4, Q5 and Q6after starting the generator whenpower supply is done by means ofX2, X3, X4, X5 or X6.
!
- 95 -
9.3.6 Outlet sockets (S) - Set 3
A brief description of all outlet sockets and circuitbreakers provided on the generator is given hereafter:
X2 .......1-phase outlet socket (230 V AC)
Provides phase L3, neutral and earthing.
X3 .......3-phase outlet socket (400 V AC)
Provides phases L1, L2 and L3, neutral anearthing.
X4 .......3-phase outlet socket (400 V AC)
Provides phases L1, L2 and L3, neutral anearthing.
X5 .......3-phase outlet socket (400 V AC)
Provides phases L1, L2 and L3, neutral anearthing.
X6 .......3-phase outlet socket (400 V AC)
Provides phases L1, L2 and L3, neutral anearthing.
Q2 .......Circuit breaker for X2
Interrupts the power supply to X2 when short-circuit occurs at the load side, or whethe overcurrent protection (16 A) activated. When activated, Q2 interrupphase L3 and the neutral towards X2. It cabe activated again after eliminating thproblem.
Q4 .......Circuit breaker for X4
Interrupts the power supply to X4 when short-circuit occurs at the load side, or whethe overcurrent protection (63 A) activated. When activated, Q4 interrupts ththree phases towards X4. It can be activateagain after eliminating the problem.
Q1
Q2
Q6
Q5
Q4
X5
X6
X4
X3
X2
laty
t
9.3.9 Electronic speed regulator
The electronic speed regulator makes sure that theoutput frequency of the generator is 50 Hz/60 Hz,independent of the amount of load.
Changing the output frequency isonly allowed when the unit hasstopped.After changing the outputfrequency, adjust the output voltageby means of potentiometer R12 tothe required value.Dual frequency with electronicspeed control is standard for unitswith Qc4002™ MkII controller.
!
- 96 -
9.3.7 Single frequency with
electronic speed control (SF)
The Single frequency option provides an electricspeed controller which improves the output frequencyof the generator at 50 Hz/60 Hz at constant load.
R11 ..... Supply voltage adjust potentiometer
See “Electronic speed regulator”.
R12 ..... Voltage adjustment
Allows to adjust the output voltage.
9.3.8 Dual frequency with electronic
speed control (DF)
The Dual frequency with electronic speed controoption allows the unit to work at 50 Hz or at 60 Hz constant load. The frequency selection is done bmeans of switch S12.
R11 .....Speed adjustment
See “Electronic speed regulator”.
R12 .....Voltage adjustment
Allows to adjust the output voltage.
S12 .....Frequency selector switch (50 Hz/60 Hz)
Allows to choose the frequency of the outpuvoltage: 50 Hz or 60 Hz.
Single frequency with electronicspeed control is not available forunits with Qc4002™ MkIIcontroller.
R11
R12
!
R11
S12
R12
yatt/
Ite
Q1.2 ....Circuit breaker for high voltage, low current
Interrupts the high voltage power supplytowards X1 when a short-circuit occurs atthe load side or when the overcurrentprotection (100 A) is activated. It must bereset manually after eliminating theproblem.
R12......Voltage adjustment
Allows to adjust the output voltage.
Depending on which mode the generator is runningin, circuit breaker Q1.1 or Q1.2 will be operational.Circuit breakers Q1.1 and Q1.2 cannot be switched onat the same time. This is prevented by means of theauxiliary voltage selection relays K11 and K12 (referto circuit diagram 9822 0996 11/01) or S10b and S10c(refer to circuit diagram 9822 0996 12/00).The selection between the two modes is done bymeans of S10.
.2
AMF operation is not possible with adual voltage generator.!
- 97 -
9.3.10 Dual voltage (2V)
1 phase - 3 phase
The generator can run in two different modes:
1 phase, lower voltage
When using this selection, the generator provides a230 V output voltage.
3 phase, higher voltage
When using this selection, the generator provides a400 V output voltage.
3 phase - 3 phase
The generator can run in two different modes:
3 phase, lower voltage
When using this selection, the generator provides a230 V output voltage. (IT = active)
3 phase, higher voltage
When using this selection, the generator provides a400 V output voltage. (ELR = active)
Q1.1 ....Circuit breaker for low voltage, high current
Interrupts the low voltage power suppltowards X1 when a short-circuit occurs the load side or when the overcurrenprotection (1 phase - 3 phase: 175 A 3 phase - 3 phase: 152 A) is activated. must be reset manually after eliminating thproblem.
The dual voltage option is onlyavailable on 50 Hz units withQc1002™ controller.
!Hz V
Q1Q1.1
R12
lllt
N13 .....Earth leak detector
Detects and indicates an earth fault currentand activates the main circuit breaker Q1.The detection level can be set at 30 mA fixedwith instantaneous trip but can also beadjusted between 0.1 A and 1 A with timedelayed (0 - 0.5 sec) trip. N13 has to be resetmanually after eliminating the problem(reset button marked R). It can be overriddenby means of the earth leak switch (S13,labelled IN) but has to be tested monthlyby pushing test button T13.
S13......Lock-out switch for earth fault protection (N13)
This switch is located inside the cubicle andis labelled IN.
Position O: No de-energising of the maincircuit breaker Q1 when an earth faultoccurs.Position 1: De-energising of the main circuitbreaker Q1 when an earth fault occurs.
- 98 -
S10 ..... Output voltage selection switch
Allows to select a 3 phase high outputvoltage or a 1 phase / 3 phase low outputvoltage. Selector switch S10 is located onthe alternator.
9.3.11 Earth leakage relay
The Earth relay option provides a detector that witrip the main circuit breaker Q1 when an earth faucurrent is detected.
Q1 .......Main circuit breaker
Changing the output voltage is onlyallowed when the unit has stopped.After changing the output voltage bymeans of the selection switch S10,adjust the output voltage by means ofpotentiometer R12 to the requiredvalue.
!
X1
Q1
N13N14
S13
o.ng
Q1 .......Circuit breaker for X1
Interrupts the power supply X1 when ashort-circuit occurs at the load side, or whenthe overcurrent protection is activated.When activated, Q1 interrupts the threephases towards X1. It must be resetmanually after eliminating the problem.
X1
Q1
N13N14
S13
- 99 -
9.3.12 IT-relay
The generator is wired for an IT network i.e. nsupply lines of the power supply are directly earthedA failure in insulation resulting in a too low insulatioresistance, is detected by the insulation monitorinrelay.
Position O will only be used inconjunction with an external earthfault protection unit (e.g. integratedin a distribution board).If S13 is in position O, properearthing is of the utmost importancefor the safety of the user.Eliminating any earth faultprotection can lead to serious injuryor even death for anybody touchingthe unit or the load.
!
The generator shall not be operatedwith other networks (such as TT orTN). Doing so will cause tripping ofthe insulation monitoring relay. The generator is wired for an ITnetwork i.e. no supply lines of thepower supply are directly earthed.A failure in insulation resulting intoo low an insulation resistance, isdetected by the insulationmonitoring relay.At each start-up and any time a newload is connected, the insulationresistance must be verified. Checkfor the correct setting of theinsulation monitoring relay (factoryset at 13 kΩ).
!
slsisatr.
sFeehe
Changing the operation mode fromstandard unit to EDF-unit or viceversa has to be carried out by aqualified person from “Electricitéde France”.
L1 L2 L3N PE EDF
PE
!
- 100 -
X1 .......Main power supply (400 Vac)
Terminals L1, L2, L3, N (= neutral) and PE(= earthing), hidden behind the control paneldoor and behind a small transparent door.
N14 ..... Insulation monitoring relay
Checks the insulation resistance andactivates Q1 when the insulation resistanceis too low.
S2 .......Emergency stop button
Push the button to stop the generator in caseof an emergency. When the button ispressed, it must be unlocked, by turning itanti-clockwise, before the generator can berestarted. The emergency stop button can besecured in the locked position with the key,to avoid unauthorized use.
9.3.13 “Electricité de France” (EDF)
When the EDF-option is installed, the unit operates aa standard unit when the neutral and the PE terminaare connected to each other (see figure below). In thcase, an earth leakage at the side of the generator or the side of the load will switch off the circuit breake
When EDF-option is installed, the unit operates aEDF-unit when the earthing, the PE and the PE EDterminals are connected to each other (see figurbelow). In this case, an earth leakage at the side of thgenerator will switch off the circuit breaker. An eartleakage at the side of the load will not switch off thcircuit breaker.
L1 L2 L3N PE EDF
PE
F
)
r8
5.
- 101 -
9.3.14 COSMOS™
COSMOS™ is a web-based global remotemonitoring system that electronically tracks everyaspect of equipment from its location to its operatingparameters. The Cosmos system can send e-mails orSMS messages to the contractor or owner in real time,with all critical and non-critical events and datainvolving your compressors and generators. It allowsoptimal servicing.
If no LEDs light up when the generator is running, theCosmos module (1) has not been installed correctly.Consult the Cosmos manual for a descprition of LEDindications.For information about COSMOS™, consult yourlocal Atlas Copco dealer.
9.3.15 COC box
When operating the Qc2002™ control panel in AMmode, the installation of a COC box is required.
PC .......Plant contactor (generator contactor
MC ......Mains contactor
X25 .....Customer wiring
To connect the COC box to the generatoequipped with Qc2002™ controller connections have to be made on X2Connect 1 to 1, 2 to 2,... 8 to 8.
The COC box (Change overcontactor) is only available incombination with the Qc2002™control panel.
!
X25
COC box
MCPC
When using this option, make sure to connect the fuelsupply line as well as the fuel return line. Connectionsto fuellines ought to be air-tight to prevent air fromentering the fuel system. Turn the handle of 3-wayvalve to desired condition.
Internal fuel: Indicates that the fuel supply line to the engine is connected to the internal fueltank.
External fuel: Indicates that the fuel supply line to the engine is connected to the external fueltank.
- 102 -
9.4 Overview of the mechanical
options
The following mechanical options are available:– External fueltank connection (with/without quick
couplings)– Undercarriage (axle, towbar, towing eyes)– Skid fueltank– Integrated spark arrestor– Air inlet shut-off valve
9.5 Desciption of the
mechanical options
9.5.1 External fueltank connection
(with/without quick couplings)
The option external fueltank connection allows tobypass the internal fueltank and to connect anexternal fueltank to the unit.
View outside
View inside
EFT External fuel tank feed connectionEFR External fuel tank return connection
EFT EFR
EFREFT
led
elellte
rs
g
nr
9.5.3 Integrated spark arrestor
The integrated spark arrestor option is included in therefinery equipment pack.
9.5.4 Air inlet shut-off valve
The engine air inlet shut-off valve option is includedin the refinery equipment pack. It will prevent over-speeding of the engine due to combustible gasesbeing traced within the normal engine air intake.
- 103 -
9.5.2 Undercarriage (axle, towbar,
towing eyes)
The undercarriage is equipped with an adjustabletowbar with brakes, with BNA-, NATO-, DIN-, ITA-,ISO-eye and Ball coupling and with roadsignalisation which is approved by EC legislation.
When using this option
– Make sure that the towing equipment of thevehicle matches the towing eye (1) before towingthe generator.
– Never move the generator while electrical cablesare connected to the unit.
– Always apply the hand brake (2) when parking thegenerator.
– Leave enough space for operation, inspection andmaintenance (at least 1 meter at each side).
To maintain the undercarriage
– Check the tightness of the towbar bolts, the axbolts and the wheel nuts at least twice a year anafter the initial 50 hours of operation.
– Grease the wheel axle suspension bearings, thdrawbar to the steering gear shaft and the spindof the brake handle at least twice a year. Use babearing grease for the wheel bearings and graphigrease for the drawbar and spindle.
– Check the brake system twice a year.– Check the condition of the vibration dampe
twice a year.
– Repack the wheel hub bearings once a year usingrease.
– Wheel chocks allows to park the generator osloping ground. Place wheel chocks in front of obehind the wheels to immobilize the generator.
1
2
> 1 m
> 1 m
50 Hz 60 Hz
50 Hz 60 Hz1500 rpm 1800 rpm
PRP PRP100 bar(a) 100 bar(a)
30% 30%25°C 25°C
50°C 50°C4000 m 4000 m
85% 85%-18°C -18°C-25°C -25°C
48 kW 53.6 kW35 kW 39 kW
0.8 cos 0.8 cos 1 cos 1 cos
- 104 -
10 Technical specifications for QAS 60 units
10.1 Readings on gauges
10.2 Settings of switches
10.3 Specifications of the engine/alternator/unit
Gauge Reading UnitAmmeter L1-L3 (P1-P3) Below max. rating AVoltmeter (P4) Below max. rating V
Switch Function Activates atEngine oil pressure Shut down 0.5 barEngine coolant temperature Shut down 103°C
Reference conditions 1) 4)
Rated frequencyRated speedGenerator service dutyAbsolute air inlet pressureRelative air humidityAir inlet temperature
Limitations 2) Maximum ambient temperatureAltitude capabilityMaximum relative air humidityMinimum starting temperatureMinimum starting temperature aided with coldstart equipment (optional)
Performance data 2) 3) 4) 5)
Rated active power (PRP) 3phRated active power (PRP) 1phRated power factor (lagging) 3phRated power factor (lagging) 1ph
60 kVA 67 kVA35 kVA 39 kVA400 V 480 V230 V 240 V230 V 240 V86.6 A 80.6 A150.6 A 161.2 A152.2 A 162.5 A
G2 G2100% 100%48 kW 53.6 kW
< 5% / isochronous < 5% / isochronous1.7 kg/h 2.4 kg/h6.1 kg/h 7.6 kg/h8.9 kg/h 10.6 kg/h11.7 kg/h 13.7 kg/h
0.233 kg/kWh 0.245 kg/kWh16.9 h 14.4 h40.1 h 34.2 h
0.020 l/h 0.024 l/h87 dB(A) 90 dB(A)
230 l 230 l545 l 545 l100% 100%48 kW 53.6 kW
PRP PRPland use land use
single/parallel single/parallelmanual/automatic manual/automatic
unspecified unspecifiedtransportable/D transportable/D
mobile/E mobile/Efully resilient fully resilient
- 105 -
Rated apparent power (PRP) 3phRated apparent power (PRP) 1phRated voltage 3ph line to lineRated voltage 3ph line to line lower voltageRated voltage 1phRated current 3phRated current 3ph lower voltageRated current 1phPerformance class (acc.ISO 8528-5:1993)
Single step load acceptance
Frequency droopFuel consumption at no load (0%)Fuel consumption at 50% loadFuel consumption at 75% loadFuel consumption at full load (100%)Specific fuel consumption at full load (100%)Fuel autonomy at full load with standard tankFuel autonomy at full load with optional skid fueltankMax. oil consumption at full loadMaximum sound power level (Lw) complies with 2000/14/ECCapacity of fuel tankCapacity of optional skid fuel tankSingle step load capability
Application data Mode of operationSiteOperationStart-up and control modeStart-up timeMobility/Config. acc. to ISO 8528-1:1993
(optional)Mounting
open air open airearthed earthed
insulated insulated
ISO 3046 ISO 3046ISO 8528-2 ISO 8528-2
1104C-44TG3/TG2 1104C-44TG3/TG254 kW 60 kWICXN ICXN
coolant coolantdirect injection direct injectionturbo charged turbo charged
4 44.41 l 4.41 l
echanical / electronic mechanical / electronicelectronic with TG2 electronic with TG2
8.5 l 8.5 l12.6 l 12.6 l
12 Vdc 12 VdcEU stage II EU stage II
80% 80%
IEC34-1 IEC34-1ISO 8528-3 ISO 8528-3
Leroy Somer Leroy SomerLSA43.2 M45 LSA43.2 M45
60 kVA 71 kVABR 125/40°C BR 125/40°C
IP 23 IP 23H HH H12 12
- 106 -
Climatic exposureStatus of neutral (TT or NT)Status of neutral (IT) (optional)
Engine 4) Standard
Type PERKINSRated net output
rating type acc. ISO 3046-7CoolantCombustion systemAspirationNumber of cylindersSwept volumeSpeed governing mGovernor type (optional)Capacity of oil sump (initial fill)Capacity of cooling systemElectrical systemEmission complianceMaximum premissible load factor of PRP during 24h period
Alternator 4) Standard
MakeModelRated output, class H temperature rise
rating type acc. ISO 8528-3Degree of protection (IP index acc. NF EN 60-529)Insulation stator classInsulation rotor classNumber of wires
4 4100 A 100 A3..5xIn 3..5xIn
3 4152 A 175 A3..5xIn 3..5xIn
3 4175 A 187.5 A3..5xIn 3..5xIn
0.030-30 A 0.030-30 A10-100 kOhm 10-100 kOhm
i) domestic2p + PE
16 A/230 V
ii) CEE form3p + N + PE16 A/400 V
iii) CEE form3p + N + PE32 A/400 V
iv) CEE form3p + N + PE63 A/400 V
- 107 -
Power circuit Circuit-breaker, 3ph.Number of polesThermal release It (thermal release is higher at 25°C)Magnetic release Im
Circuit-breaker, 3ph., lower voltageNumber of poles (optional)Thermal release It (thermal release is higher at 25°C)Magnetic release Im
Circuit-breaker, 1ph.Number of poles (optional)Thermal release It (thermal release is higher at 25°C)Magnetic release Im
Fault current protectionResidual current release IDnInsulation resistance (optional)
Outlet sockets (optional)Following three socket configuration is possible:
1. i + ii + iii + iv2. i + ii + iii + iv (2x)3. i + ii + iii + iv + v
v) CEE form3p + N + PE125 A/400 V
50 x 1100 x 1635 mm 2850 x 1100 x 1635 mm50 x 1100 x 1751 mm 2850 x 1100 x 1751 mm19 x 1665 x 2201 mm 5019 x 1665 x 2201 mm80 x 1665 x 2201 mm 4780 x 1665 x 2201 mm
1535 kg 1535 kg1756 kg 1756 kg1601 kg 1601 kg2128 kg 2128 kg1930 kg 1930 kg2151 kg 2151 kg
- 108 -
Unit Dimensions without undercarriage (LxWxH) 28Dimensions without undercarriage, with optional 24h fuel tank (LxWxH) 28Dimensions with undercarriage (adj. towbar, DIN eye) (LxWxH) 50Dimensions with undercarriage (fixed towbar, DIN eye) (LxWxH) 47Weight net mass - without undercarriage Weight wet mass - without undercarriage Weight net mass - without undercarriage, with optional 24h fuel tankWeight wet mass - without undercarriage, with optional 24h fuel tankWeight net mass - with undercarriage Weight wet mass - with undercarriage
delivering (at variable load), in the event of a s running). No overload is permitted on these
y be run for an unlimited number of hours per load is permitted for 1 hour in 12 hours. The ndicated in the ‘Technical specifications’
35 40 45 5098 92 85 7598 97 87 7597 96 86 7596 95 85 7394 93 82 7188 88 77 6688 88 77 6682 82 72 6282 82 72 62
- 109 -
For use of generator outside these conditions, please contact Atlas Copco.
Notes
1) Reference conditions for engine performance to ISO 3046-1.
2) See derating diagram below or consult the factory for other conditions.3) At reference conditions unless otherwise stated.4) Rating definition (ISO 8528-1):
LTP: Limited Time Power is the maximum electrical power which a generating set is capable of utility power failure (for up to 500 hours per year of which a maximum of 300 hours is continuouratings. The alternator is peak continuous rated (as defined in ISO 8528-3) at 25°C.PRP: Prime Power is the maximum power available during a variable power sequence, which mayear, between stated maintenance intervals and under the stated ambient conditions. A 10% overpermissible average power output during a 24h period shall not exceed the stated load factor as iabove.
5) Specific mass fuel used: 0.86 kg/l.
DeratingHeight
(m)
Temperature(°C)
0 5 10 15 20 25 300 100 100 100 100 100 100 100
500 100 100 100 100 100 100 991000 100 100 100 100 100 99 981500 97 97 97 97 97 97 972000 94 94 94 94 94 94 942500 88 88 88 88 88 88 883000 88 88 88 88 88 88 883500 82 82 82 82 82 82 824000 82 82 82 82 82 82 82
A Maximum permitted total weight of the vehicleB Maximum permitted axle loadC Maximum permitted load on towing eye1 Company code2 Product code3 Unit serial number4 Name of manufacturer5 EEC or national type approved number6 Vehicle identification number7 Model number8 Frequency9 Apparant power - PRP10 Active power - PRP11 Nominal rated voltage12 Nominal rated current13 Power factor14 Manufacturing year15 EEC mark in accordance witt Machine Directive
89/392E16 Mode of operation17 Winding connections
- 110 -
10.4 Conversion list of SI units
into British units
A temperature difference of 1°C = a temperaturedifference of 1.8°F.
10.5 Dataplate
1 bar = 14.504 psi1 g = 0.035 oz1 kg = 2.205 lbs1 km/h = 0.621 mile/h1 kW = 1.341 hp (UK and US)1 l = 0.264 US gal1 l = 0.220 lmp gal (UK)1 l = 0.035 cu.ft1 m = 3.281 ft1 mm = 0.039 in1 m³/min = 35.315 cfm1 mbar = 0.401 in wc1 N = 0.225 lbf1 Nm = 0.738 lbf.ftt°F = 32 + (1.8 x t°C)
t°C = (t°F - 32)/1.8
ATLAS COPCO AIRPOWER n.v.
MADE BY ATLAS COPCO AIRPOWER n.v. WILRIJK, BELGIUM
1615 6945 00
-YA3--- kg
kg kg
Model/Modell/Modèle
cos phi
f NP NP NU NI N
Manuf. year/Baujahr/Année de fabrication
Hz
kW
V
A
kVA
A
B
C
- 111 -
Circuit diagrams
G H I J K L M N O
6A 6A
1 2 3 4 5 6PE
to A
1.18
442
b0
441
b6
18
a3
to Circ.Diagr POWER
38
a0
12
a6
to G
ener
ator
Con
tact
or A
1 <-
-
to G
ener
ator
Con
tact
or A
2 <-
-
(see Instruction Manual)
Sx=RemoteStart/Stop-switch
to A
1.17
19
a3
(*)
(*)= Connect L2 to X25.5with 230Vd-systems
Generator ContactorOutput: 12Vdc, max.8Adc1
4
a3
14
a3
5
a3
15
a3
Fx Fx
N L1PE
X25 X25 X25X25
MAINS SUPPLY (1P+N)Customer's Installation
Sx
9 = white8 = grey7 = purple6 = blue5 = green4 = yellow3 = orange2 = red
0 = black
h = 25 mm²g = 16 mm²f = 10 mm²e = 6 mm²d = 4 mm²c = 2.5mm²b = 1.5mm²a = 1 mm²
Colour code :Wire size :
1 = brown
54= green/yellow
i = 35 mm²j = 50 mm²k = 70 mm²
lx = 95 mm² EPR-CSP (BS6195-4C)l = 95 mm²
bx = 1.5mm² NSGAFOeU
Legend
- 112 -
A B C D E F
Com
mon
(12
Vdc
)
Engi
ne C
AN
-bus
Inte
rfac
eG
ND
CA
N-L
CA
N-H
Mag
netic
Pic
k-up
(Tac
ho)
Inpu
t
Inpu
tFu
el L
evel
(VD
O)
Coo
lant
Tem
p (V
DO
)
W/L
-Inpu
t D+
Oil
Pres
sure
(VD
O)
Inpu
t
GN
D
Inpu
t
Com
mon
for V
DO-in
puts
(0 V
dc)
12/2
4 V
dc (B
att+
)
Gen
erat
or V
olta
ge L
2
Gen
erat
or V
olta
ge L
1
NO
Com
Fuel
Con
trol
Rel
ayC
om NO
Rem
ote
Sta
rt
Com
mon
for R
elay
Out
puts
Cen
tral
Ala
rm H
orn
Low
Oil
Pres
sure
Hig
h C
oola
nt T
empe
ratu
re
Preh
eat R
elay
Gen
erat
or C
onta
ctor
0 V
dc (B
att-
)
Inpu
t
Inpu
t
Inpu
t
Inpu
t
Inpu
t
Inpu
t
Spa
re <
Low
Coo
lant
Lev
el>
Sta
rt R
elay
Out
put
Sta
rt/S
top
NO
NO
Com NO
135
79
11 12
26104
8
129
a0
128
a0
17
a2
12
a6
125
a0
126
a0
17
a2
12
a6
141
c8
142
c8
143
c8
140
c8
to C
irc.
Dia
gr P
OW
ERC
urre
nt T
rans
fo T
1-T3
127
a0
124
a6
126
a0
125
a0
125
a0
126
a0
Cir
c.D
iagr
PO
WER
Fuse
s F1
-F3
12
a6
17
a2
5
a3
14
a3
14
a3
4
a3
38
a0
15
a3
12
a6
876 159 12 13 14 16 17
252726 32 33 3424 36
1 2 3 4
3521 2319
18
A1
5
S4
V
P4
A
P3
A
P2
A
P1
Qc1002
9822 0996 05/01
Applicable for QAS 60 Pd - Engine Circuit Qc1002™
G H I J K L M N O
C2
C2
B1
B1
B2
B2
A4
A4
B5
B5
f2 d2 d2
21
12
a6
12
a6
4
a3
7
a3
6
a3
6
a3
P
10
a3
12
a6
4
a3
7
a3
6
a3
10 19
a3
18
a3
17
a2
14
a3
5
a3
15
a3
12
a6
12
a6
5
a3
10
a3
12
a6
7
a3
K5
K1
X10
X10 X10
X10
10
S8
K1 K5
X25X25
S98
H0
Position of Relay Contacts
- 113 -
A B C D E F
C1
C1
C3
C3
B4
B4
A5
A5
A2
A2
A3
A3
A1
A1
Can
opy
Cub
icle
CanopyCubicle
a3
14
CD
A
-
+
12
a611
a3
9
a3
17
a3
a3
9
a3
11
a3
12
a6
12
a6
17
a2
3
c2
1
j0
12
j6
17
a2
12
a6
M
5a3
12
a6
5
a3
5
a3
5
a3
B+
GND
D+W
2
a3
2
a3
12
a6
12
a6
1
e2
9
a3
11
a3
1
e2
16
e2
12
j6
1
j0
1
e2
1
c2
3
c2
1
c2
3
c2
13
a2
1c2
1
c2
13
a2
12
a6
5
a3
5
a3to Circ.Diagr POWER
to Circ.Diagr POWER
19
a3
18
a3
17
a2
a3
1412
a6
F10
10A
X10X10 XX10X10X10
X10X10
Y1B7
S2a
BB9+
-
G1
M1
M
K0
K0
M6G2
K1
E1
K5
S20
V2
R2
- 114 -
A1 Generator control unit(set A1 in UNIT-type 2)
B7 Fuel level sensorB8 Coolant temperature sensorB9 Oil pressure sensorE1 Preheat resistorF10 Fuse 10A DCG1 Battery 12 VdcG2 Charging alternatorH0 Panel lightK0 Starter solenoidK1 Preheat relayK5 Starter relayM1 Starter motorM6 Fuel feed pumpP1-P3 A-meterP4 V-meterR2 Excitation resistor 47ohmS2a Emergency stop
(S2b: see Power circuit)S4 V-meter change-over switchS8 High coolant temperature switchS9 Low oil pressure switchS20 ON/OFF/REMOTE switchV2 Excitation diodeX10 Connector wire harnessX25 Customer’s terminal stripY1 Fuel stop solenoid
- 115 -
J K L M N O P
Fuel
Con
trol
Rel
ay
NO
Com
NO
Gen
erat
or C
urre
nt T
rans
fo L
2s2
Gen
erat
or C
urre
nt T
rans
fo L
1s2s1
Cen
tral
Ala
rm H
orn
6A 250mA6A 250mA250mA
to A
1.18
to M
ains
Con
tact
or A
1 <-
-
to G
ener
ator
Con
tact
or A
1 <-
-
to G
ener
ator
Con
tact
or A
2 <-
-
(see Instruction Manual)
9 101 2 4 5 63 7 8PE
to A
1.38
445
a0
444
a0
443
a0
442
b0
441
b6
Sx=RemoteStart/Stop-switch
441
a6
442
a0
447
a0
446
a0
124
a6
18
a3
12
a6
to Circ.Diagr POWER
141
c8
140
8
140
c8
124
a6towardsX25.8
3635
585756
34
Fx FxFx FxFx
N L1 L1 L2 L3
MAINS SUPPLY (3P+N+PE)Customer's Installation
PE
X25X25
Sx
9 = white8 = grey7 = purple6 = blue5 = green4 = yellow3 = orange2 = red
0 = black
h = 25 mm²g = 16 mm²f = 10 mm²e = 6 mm²d = 4 mm²c = 2.5mm²b = 1.5mm²a = 1 mm²
Colour code :Wire size :
1 = brown
54= green/yellow
i = 35 mm²j = 50 mm²k = 70 mm²
lx = 95 mm² EPR-CSP (BS6195-4C)l = 95 mm²
bx = 1.5mm² NSGAFOeU
Legend
- 116 -
Qc2002
A B C D E F G H I
Com
mon
(12
Vdc
)
Gen
erat
or C
urre
nt T
rans
fo L
3
Engi
ne C
AN
-bus
Inte
rfac
eG
ND
CA
N-L
CA
N-H
Mag
netic
Pic
k-up
(Tac
ho)
Inpu
t
Inpu
tFu
el L
evel
(VD
O)
Coo
lant
Tem
p (V
DO
)
W/L
-Inpu
t D+
Oil
Pres
sure
(VD
O)
Inpu
t
GN
D
Inpu
t
Com
mon
for V
DO-in
puts
(0 V
dc)
Com
mon
for
Rel
ay O
utpu
ts
Preh
eat R
elay
Gen
erat
or V
olta
ge N
eutr
al
12/2
4 V
dc (B
att+
)
Sta
rt R
elay
Out
put
Gen
erat
or V
olta
ge L
2
Gen
erat
or V
olta
ge L
1
Gen
erat
or V
olta
ge L
3
NO
Com
ComN
C
Gen
erat
or C
onta
ctor
NO
Com
Rem
ote
Sta
rt
Mai
ns V
olta
ge L
3
Mai
ns C
onta
ctor
Low
Oil
Pres
sure
Spa
re O
utpu
t
Hig
h C
oola
nt T
empe
ratu
re
Mai
ns V
olta
ge L
2
Mai
ns V
olta
ge N
eutr
al
0 V
dc (B
att-
)
Inpu
t
Inpu
t
Inpu
t
Inpu
t
Inpu
t
Inpu
t
Spa
re <
Low
Coo
lant
Lev
el>
NO
NO
Com
Mai
ns V
olta
ge L
1
s2s1 s1
2nd
Para
met
er S
et
142
c8
143
c8
140
c8 c
17
a2
12
a6
124
a6
126
a0
127
a0
125
a0
444
a0
441
a6
445
a0
443
a0
447
a0
446
a0
442
a0
125
a0
17
a2
12
a6
12
a6
17
a2
142
c8
143
c8
141
c8
140
c8
12
a6
135
79
11 12
26104
8
129
a0
128
a0
127
a0
124
a6
126
a0
125
a0
125
a0
126
a0
127
a0
124
a6
Cir
c.D
iagr
PO
WER
Fuse
s F1
-F3
141
c8
142
c8
143
c8
140
c8
to C
irc.
Dia
gr P
OW
ERC
urre
nt T
rans
fo T
1-T3
876 159 12 13 14 16 17
462726 47 49 5045 52
1 2 3 4
555453513837 41 4339
25 32 3318 23 24
A1
5
S4
V
P4
A
P3
A
P2
A
P1
9822 0996 06/01
Applicable for QAS 60 Pd - Engine Circuit Qc2002™
Position of Relay Contacts
J K L M N O P
C2
C2
B1
B1
B2
B2
A4
A4
f2 d2 d2
9
12
a6
12
a6
4
a3
7
a3
6
a3
4
a3
7
a3
6
a3
6
a3
26
a3
18
a3
14
a3
17 14
a3
5
a3
15
a3
12
a6
12
a6
7
a3
12
a6
K5
K1
X10X10 X10 X10
S8
K1 K5
X25
S9
H0
- 117 -
A B C D E F G H I
a3
14
C1
C1
C3
C3
B5
B5
B4
B4
A5
A5
A2
A2
A3
A3
A1
A1C
anop
yC
ubic
le
CanopyCubicle
a3
14CD
A
-
+P
12
a611
a3
9
a3
10
a3
17
a3
10
a3
9
a3
11
a3
12
a6 a2
12
a6
17
a2
3
c2
1
j0
12
j6
17
a2
12
a6
M
5a3
12
a6
5
a35
a3
5
a3
B+
GND
D+W
2
a3
5
a3
2
a3
12
a6
17
a2
12
a6
26
a3
26
a3
1
e2
10
a3
9
a3
11
a3
1
e2
16
e2
12
j6
1
j0
1
e2
1
c2
3
c2
1
c2
3
c2
13
a2
26
a3
1
c2
1
c2
13
a2
to Circ.Diagr POWER50/60Hz-switch S12
5
a3
12
a6
to Circ.Diagr POWER 5
a3
S20F10
10A
X10X10 X10X10X10X10
X10X10
Y1B7
S2a
B8B9
V2
R2
+
-
G1
M1
M
K0
K0
M6G2
K1
E1
K5
- 118 -
A1 Generator control unitB7 Fuel level sensorB8 Coolant temperature sensorB9 Oil pressure sensorE1 Preheat resistorF10 Fuse 10A DCG1 Battery 12 VdcG2 Charging alternatorK0 Starter solenoidK1 Preheat relayK5 Starter relayM1 Starter motorM6 Fuel feed pumpP1-P3 A-meterP4 V-meterR2 Excitation resistor 47ohmS2a Emergency stop
(S2b: see Power circuit)S4 V-meter change-over switchS8 High coolant temperature switchS9 Low oil pressure switchS20 ON/OFF-switchV2 Excitation diodeX10 Connector wire harnessX25 Customer’s terminal stripY1 Fuel stop solenoid
- 119 -
GF H I
F2
F1
N
F3
T3
U1
2
V1
T12
N1
PE
400V/480V
T9T12
T2T5
T8T11
T1T4
T7T10
U1
a0
V1
a0
124
a6
126
a0
142
c8to Circ.Diagr ENGINEAmpere-meter
V1
0
W1
x0
N1
x6 y54
127
a0
to C
irc.
Dia
gr E
NG
INE
V-m
eter
& C
ontr
ol M
odul
e
N1
a6
125
a0
to Circ.Diagr ENGINEAmpere-meter
143
c8
151
c8
T2 T3
141
c8
W1
a0
Cub
icle
Alte
rnat
or
- 120 -
B C DA E
QAS60
Wire Size x Wire Size y35mm² 16mm²
T1 Q1100/5A 100A
400V/480V
G3
T1
U1
T
T3T6
N12
See Note 2 VoltageAdjustm.
R438R250
Frequency Selection
NO
NE
60Hz50Hz
(O)(O)
U1
x0 x(O)
(O)
(O)
T1
50H
z
60H
z
S12
50H
z
60H
z
60H
z
50H
z
12
a6
N11
1 2 3
912 811 710
4 5 6
B11
5
a3
26
a3
R11 R12
20
a3
29
a0
28
a2
24
a3
27
a3
47
a0
46
a2
to Circ.Diagr ENGINEQc2002 - A1.17
to K7.85
70
a3
Cub
icle
Can
opy
12
a6
12
a6
12
a65
a3
47
a0
46
a2
12
a6
5
a3
35
a3
37
a3
36
a3
9 = white8 = grey7 = purple6 = blue5 = green4 = yellow3 = orange2 = red
0 = black
h = 25 mm²g = 16 mm²f = 10 mm²e = 6 mm²d = 4 mm²c = 2.5mm²b = 1.5mm²a = 1 mm²
LegendColour code :Wire size :
1 = brown
54= green/yel.
i = 35 mm²j = 50 mm²k = 70 mm²
lx = 95 mm² EPR-CSP (BS6195-4C)l = 95 mm²
bx =1.5mm² NSGAFOeU
The PE-N connection has to be made at thealternator-side of main Circuit Breaker Q1.
Link N12.1 to N12.2 on gen-sets without ElectronicSpeed Regulation (= no potentiometer R12).
With "TB EDF", do NOT connect (N) to (PE) at Q1.T13 is to be mounted on the (PE)-conductor, instead of on the PE-N connection in the cubicle.
Note 1:
Note 2:
Note 3:
Notes
9822 0996 10/01_A
Applicable for QAS 60 Pd - Power Circuit
T13
2
1
y54y54
L1 L2 L3 N PE
L1
x0
L2
x0
L3
x0
N
x6 y54
PE
Sheet2-a1L2
Sheet2-a1L1
Sheet2-a1L3
Sheet2-a1N
Sheet2-a1PE
DF
g54PE
1
L1 L2 L3 N PE PE-EDF
L1
x0
L2
x0
L3
x0
N
x6
y54
PE
h54
PE
PE
See Note 3
T1321
See Note 1
Cub
icle
Can
opy
E F G H I
- 121 -
to C
irc.
Dia
gr E
NG
INE 5
a3
13
a2
12
a6
5
a3
13
a2
12
a6
102
a3
12
a6
13
a2
118
a3
118
a3
N1
a6b54
5
a3
13
a2
12
a6
S2b
3431A2A1T2T1I n
N13N14R T PE L
R<
A2A1
12
a6
12
a6
13
a2
to C
irc.
Dia
gr E
NG
INE
441
b6
442
b0
X1
(O)(O)
(O)
(O) (O) N-E(O)
c2
c1
Q1
U>44
2
b0
442
b0
441
b6
441
b6
R5
Cub
icle
Can
opy
S13
X
U1
PE
NL
B+B-
K7
85
86
12
a6
70a3
K7
Can
opy
Y7
Cub
icle
13
a2
71
a3
V7
12
a6
to N
11.7
0
KT1
KT1
73
a3
5
a3
B C DA
- 122 -
B11 Speed sensor MPU (O)F1-F3 Fuses 4 AG3 AlternatorK7 Auxiliary relay for Y7 (O)N11 Speed controller (O)N12 Automatic voltage regulatorN13 Earth leakage relay (O)N14 IT-relay (O)Q1 Circuit breakerR5 Coolant heater (O)R11 Speed adjustment 5K (O)R12 Voltage adjustment 1K (O)S2b Emergency stop
(S2a: see Engine circuit)S12 50/60 Hz-switch (O)S13 E.L.R. disable switch (O)T1-T3 Current transformersT13 Torus earth leakage (O)U1 Battery charger (O)V7 Free-wheeling diode Y7X1 Terminal boardY7 Air inlet shutdown valve (O)(O) Optional equipment
c54
PE
6
16A
L1
c0
L2
c0
L3
c0
N
c6
L3 N
L2L116A
X6
6L3
c0
6L1
c0
6L2
c0
(O)
c54
PE
16A30mA
Q2
L3
c0
N
c6
X2
16AL N
2L3
c0 2Nc6
L3N
PE
54= green/yellow9 = white8 = grey7 = purple6 = blue5 = green4 = yellow3 = orange2 = red1 = brown0 = blackColour code :
SP to BS6195 4C-CSP to BS6195 4C
SP to BS6195 4C
-CSP to BS6195 4C
SP to BS6195 4CSP to BS6195 4C
- 123 -
L1L2
L3N
PE
hx54
PE
125A
Q3
L1
hx0
L2
hx0
L3
hx0
N
hx6
3L3
hx0
3L1
hx0
3L2
hx0L3 N
L2L1125A
X3
g54
PE
63A
Q3
L1
g0
L2
g0
L3
g0
N
g6
3L3
g03L
1
g0
3L2
g0L3 N
L2L163A
X3
g54
PE
63A
Q4
L1
g0
L2
g0
L3
g0
N
g6
4L3
g0
4L1
g0
4L2
g0L3 N
L2L163A
X4
e54
PE
32A
Q5
L1
e0
L2
e0
L3
e0
N
e6
5L3
e0
5L1
e0
5L2
e0L3 N
L2 L132A
X5
Q
L1L2
L3N
PE
L1L2
L3N
PE
Circuit Breaker 16A
c4-c2 Outlet Socket 63A or 125A
Outlet Socket 16A
Optional Equipment
Q6
X3
X6
(O)
NameGridMark
c3-c1 Circuit Breaker 63A or 125AQ3
Outlet Socket 32AX5
Circuit Breaker 32AQ5Circuit Breaker 63AQ4
Outlet Socket 63AX4
c7c5c4
c7c6c5
c9 Circuit Breaker 16A/30mAQ2
c9 Outlet Socket 16A 1phX2
j = 50 mm²k = 70 mm²
n = 150 mm²
i = 35 mm²h = 25 mm²g = 16 mm²f = 10 mm²e = 6 mm²d = 4 mm²c = 2.5mm²b = 1.5mm²a = 1 mm²aa = 0.5mm²
LegendWire size :
lx = 95 mm² EPR-Cmx = 120 mm² EPR
kx = 70 mm² EPR-C
l = 95 mm²
nx = 150 mm² EPR
ix = 35 mm² EPR-Chx = 25 mm² EPR-C
Sheet1 - e6Sheet1 - e6Sheet1 - e6Sheet1 - e6Sheet1 - e6
9822 0996 10/01_B
Applicable for QAS 60 Pd - Power Circuit
- 124 -
Q2 Circuit Breaker 16A/30mAQ3 Circuit Breaker 63A or 125AQ4 Circuit Breaker 63AQ5 Circuit Breaker 32AQ6 Circuit Breaker 16AX2 Outlet Socket 16A 1phX3 Outlet Socket 63A or 125AX4 Outlet Socket 63AX5 Outlet Socket 32AX6 Outlet Socket 16A(O) Optional equipment
11
6
12(7) (11)
(10)
W5
x0
z54
W6
x0
V2
x0
U5
x0
U5
x0
V2
x0
W6
x0
W2
a0
W6
a0
W5
a0
z54
106
a0
105
a0
107
a0
N1
x6
N1
x6
N1
x6
z54
W5
x0
Cub
icle
Alte
rnat
or
K11 K12
F4
F5
F6
- 125 -
A B C D E
(1)1 2
L1
4 5 10
L2 8
9 7
3(8)
(12) (4) (2)
(L1)(5)U
1
x0
U2
x0
V1
x0
W2
x0
U6
x0
V6
x0
W1
x0
V5
x0
V5
x0
V6
x0
12
a6
5
12
1 2 3
912 811 710
4 5 6
5
a3
20
a3
29
a0
28a2
24
a3
47
a0
46
a2
to K7.85
70
a3
Cub
icle
Can
opy
12
a6
12
a6
12
a6
5
a3
47
a0
46
a2
70
27
27
a3
(O)
(O)
Frequency Selection
NONE
60Hz50Hz
(O)(O)
U5
x0
V2
x0
W1
x0
V6
x0
W1
x0
Uy0
V
y0
PE
T1
U1
U2
V6
U6
T4 T11 T10
V1
W2
W1
T2 T6 T3
V5
U5
V2
T8 T7 T5T9
W5
T2T5
T8T11
T1T4
T7T10
T3T6
T9T12
T12
W6
Cub
icle
Alte
rnat
or
S10
See Note 3X9
X9
N11
B11R11
R12
X9
X9
SeeNote
2
N12
R438R250
The PE-N connection has to be made at thealternator-side of main Circuit Breaker Q1.
Note 1:
Link N12.1 to N12.2 on gen-sets without ElectronicSpeed Regulation (= no potentiometer R12).
Note 2:
Contacts on S10 indicated between brackets, e.g.(6)aren't to be connected. They are linked internally.
Note 3:
G3
Notes
9822 0996 11/01
Applicable for QAS 60 Pd - Power Circuit, dual voltage, 50 Hz, 1 ph
g54
PE
U
a0
V
a0
127
a0
125
a0
to Circ.D
iagr ENG
INE
V-meter &
Control M
odule
N1
a6
124
a6
126
a0
W1
a0
13
12
12
b6
70
a3
Can
opy
Cub
icle
13
b2
71
b3
12
b6
to X
9.70
(O)
E
F2
F1
N
F3
9 = white8 = grey7 = purple6 = blue5 = green4 = yellow3 = orange2 = red
0 = black
h = 25 mm²g = 16 mm²f = 10 mm²e = 6 mm²d = 4 mm²c = 2.5mm²b = 1.5mm²a = 1 mm²
Colour code :Wire size :
1 = brown
54= green/yel.
i = 35 mm²j = 50 mm²k = 70 mm²
lx = 95 mm² EPR-CSP (BS6195-4C)l = 95 mm²
bx = 1.5mm² NSGAFOeUgx = 16mm² EPR-CSP to BS6195 4Chx = 25mm² ERP-CSP to BS6195 4Cix = 35mm² ERP-CSP to BS6195 4Cjx = 50mm² ERP-CSP to BS6195 4Ckx = 70mm² ERP-CSP to BS6195 4C
See Note 1
K7
X9
X9
K7
Y7V7
Legend
- 126 -
A B C D E
to C
irc.
Dia
gr E
NG
INE
12a6
13
a2
12
a6 12
13
PE
NL
B+B-
12
a6
13
a2
to C
irc.
Dia
gr E
NG
INE
441
b6
442
b0
441
442
442
b0
442
b0
441
b6
441
b6
Cub
icle
Can
opy
c2
c1
U>
118
a3
13
a2
12
a6
102
a3
L1 L2 L3 N PE
1ph
103
a3
104
a3
U
y0
V
y0
L1
x0
L2
x0
12
a6
13
a2
118
a3
13
a2
3431A2A1T2
T1
(O)
(O)
5
5
a3
L1
y0
L2y0
L3
x0
N
x6
z54x54
N1
x6
U
x0
V
x0
W1
x0
L1
y0
L2
y0
L3
x0 z54
N
x6
2
114
1
c8
151
c8
141
c8
151
c8
143
c8
142
c8
143
c8
142
c8
to C
irc.
Dia
gr E
NG
INE
Am
pere
-met
er
s1
s2
SHT
X9
X9
U1
X9
X9
R5
PQ1.2
X1
K12 K11
I nN13
S2bX9 S13
T3T2T1
T13
QAS T1 Q1.1 Wire Size x Wire Size yQ1.2 Wire Size z
60 300/5A 175A 100A gxhx ix
Q1.1
- 127 -
B11 Speed sensor MPU (O)F1-F6 Fuses 4 AG3 AlternatorK7 Auxiliary relay for Y7 (O)K11 Auxiliary relay select 230 Vzz (LV)K12 Auxiliary relay select 400 Vy (HV)N11 Speed controller (O)N12 Automatic voltage regulatorN13 Earth leakage relayQ1.1 Circuit breaker 230 Vzz (LV)Q1.2 Circuit breaker 400 Vy (HV)R5 Coolant heater (O)R11 Speed adjustment 5K (O)R12 Voltage adjustment 1K (O)S2b Emergency stop
(S2a: see Engine circuit)S10 Voltage selector switchS13 E.L.R. disable switch (O)T1-T3 Current transformersT13 Torus earth leakage (O)U1 Battery charger (O)V7 Free-wheeling diode Y7X1 Terminal boardX9 Terminal stripY7 Air inlet shutdown valve (O)(O) Optional equipment
- 128 -
J K L
U6
T1
U1
T11
V6
T2
V1
T12
W6
T3
W1
T2T5
T8T11
T1T4
T7T10
T3T6
T9T12
z54
Cub
icle
Can
opy
z54
to Circ.D
iagr ENG
INE
V-meter &
Control M
odule
U1 V6 V1
(U6)
W6 W1
(V6)(W6)
A
PE
1 8 5 12 9
B
U6
0
U1
x0
V6
x0
V1
x0
W6
x0
W1
x0
U1
a0
V1
a0
126
a0
125
a0
N1
a6
124
a6
127
a0
W1
a0
g54
Note 1:The PE-N connection has to bemade at the alternator-side.Inspection of switch/connectionrequired before each start-up.
Note 2:Link N12.1 to N12.2 ongen-sets without ElectronicSpeed Regulation(= no potentiometer R12).
Note 3:Contacts on S10 indicatedbetween brackets, e.g.(U6)aren't to be connected.They are linked internally.
F2
F1
N
F3
See Note 3
F2
F1
N
F3
Notes
- 129 -
A B C D E F G H I
T10
U64
x
125
a0
124
a6
b54
to C
irc.
Dia
gr E
NG
INE
Am
pere
-met
er
143
c8
151
c8
141
c8
140
c8
143
c8
142
c8
141
c8
142
c829
a0
28
a2
12
a6
5
12
1 2 3
912 811 710
4 5 6
5
a3
20
a3
24
a347
a0
46
a2
to K7.85
70
a3
Cub
icle
Can
opy
12
a6
12
a6
12
a6
5
a3
47
a0
46
a2
70
27
(O)
(O)
X11.8
X11.9Frequency Selection
NO
NE
60Hz50Hz
(O)(O)
G3
S10aT3T2T1
R12
Settings N13
response value overcurrent I1 (alarm) 50% of I2response value overcurrent I2 (alarm) 60mAHysteresis: 15%Fault memory M: onOperating mode K1/K2: NOStarting delay: t= 1sResponse delay ton1 = 0s ton2 = 0sDelay on release: toff = 1sPassword: 0; off
Settings N14
response value 1/2 (alarm 1/2) 10 KOhmFault memory M: onOperating mode K1/K2: NOStarting delay: t= 1sResponse delay ton = 0sPassword: off
X9.28
X9.29
X9
X9
N11
B11
R11
X9
X9
SeeNote
2
N12
R438R250
9822 0996 12/00
Applicable for QAS 60 Pd - Power circuit - Dual voltage, 50 Hz
J K L
z54
L1
y0
L2
y0
L3
y0
g54
z54
PEN
x6
L1 L2 L3 N PE
118
4
1Twisted Pair
N1
x6
c2
c1
U>
U1
x0
V1
x0
W1
x0104
a3
L1
x0
L2
x0
L3
x0
12L1
L2L3
5co118
104
13
X11.7
Cub
icle
Can
opyPE
X1
y Wire Size z
gx
T13
Q1.2
S10c
X9
- 130 -
A B C D E F G H I
to C
irc.
Dia
gr E
NG
INE
12
a6
5
a3
13
a2
12
a6
PE
NL
B+B-12
a6
13
a2
to C
irc.
Dia
gr E
NG
INE
441
b6
442
b0
442
b0
442
b0
441
b6
441
b6
Cub
icle
Can
opy
118
a3
13
a2
12
a6
102
a3
1114A2A1
I
K
13
a2
a3
118
a320
2a3
13
a2
12
a6
T/R KE L1 L2
A2A1
E
14 11
95
a3
c2
c1
U>
103
a3
U1
y0
V1
y0
W1
y0
a6
y0
y0
y0
5co 118
103
a2
4
2
1
CubicleAlt.
X11.1
X11.2
X11.3
X11.4
X11.5
X11.6
CubicleAlt.
S2b
U1
R5
9 = white8 =grey 7 = purple6 = blue5 = green 4 = yellow 3 = orange2 = red
0 = black
h = 25 mm²g = 16 mm²f = 10 mm²e = 6 mm²d = 4 mm²c = 2.5mm²b = 1.5mm²a = 1 mm²aa = 0.5mm²
Colour code :Wire size :
1 = brown
54 = green/yel. i = 35 mm²j = 50 mm²k = 70 mm²bx = 1.5mm² NSGAFOeUgx = 16mm² EPR-CSP to BS6195 4Chx = 25mm² EPR-CSP to BS6195 4Cix = 35mm² EPR-CSP to BS6195 4Cjx = 50mm² EPR-CSP to BS6195 4C
I n
N13
N14
R<X
9
QAS T1 Q1.1 Wire Size x Wire SizeQ1.2
60 150/5A 152A 100A hx hx
Q1.1
S10b
X9
X9
X9X9
S13 S10d
X9
Legend
- 131 -
B11 Speed sensor MPU (O)F1-F3 Fuses 4 AG3 AlternatorN11 Speed controller (O)N12 Automatic voltage regulatorN13 Earth leakage relay (O)N14 IT relayQ1.1 Circuit breaker 230Vd (lower voltage)Q1.2 Circuit breaker 400Vy (higher voltage)R5 Coolant heater (O)R11 Speed adjustment 5K (O)R12 Voltage adjustment 1K (O)S2b Emergency stop
(S2a: see Engine circuit)S10a-d Voltage selector switchS13 E.L.R. disable switch (O)T3 Current transformersT13 Torus earth leakage (O)U1 Battery charger (O)V7 Free-wheeling diode Y7X1 Terminal boardX9 Terminal stripX11 Connector(O) Optional equipment
- 132 -
2
Cub
icle
Alte
rnat
or
(O)
60Hz50Hz
FrequencySelection
35
a3
37
a3
36
a3
60H
z
50H
z
438 (O)
12a
- 133 -
w x y z 1
T1
U1
T3
U1
T2
V1
T12
N1
PE
400V/480V
T3T6T9
T12T2T5
T8T11
T1T4
T7T10
U1
a0
V1
a0
124
a6
126
a0
142
c8
127
a0
N1
a6
125
a0
143
c8
140
c8
141
c8
W1
a0
CubicleAlternator
U1
x0
V1
x0
W1
x0
N1
x6 y54
U1
x0V
1x0
W1
x0
N1
x6 y54
VoltageAdjustm.
28
a3
29
a3
VoltageAdjustm.
28
a3
29
a3
F2
F1
N
F3
G3
T1 T2 T3
N12 RR250 (O) N12
S
9822 0996 18/02
Applicable for QAS 60 Pd - Engine Circuit Qc4002™ MkII
i j k l m n o p q r
13
12
12
b6
70
a3
Can
opy
Cub
icle
13
b2
71
b3
12
b6
to X
9.70
17
a3
link "M" whene mains. case of mainsins-sensing
sed by theA).d connect 5.5ultiple
-mode,ry.
link "P" whenAND-mode. (O)
PMS
CAN-
bus I
nter
face
CA
N-L
GN
D
CA
N-H
Engi
ne C
AN-b
us In
terfa
ce
CA
N-L
GN
D
CA
N-H
Air S
hutd
own
Valv
e Re
lay
NO
ComN
O
ComN
O
ComN
O
Com
Com
mon
(12/
24 V
dc) f
or 4
3-55
Fuel
Pum
p Re
lay
Rela
y Ou
tput
59
Rela
y Ou
tput
57
Conf
igur
able
Conf
igur
able
Conf
igur
able
Conf
igur
able
Conf
igur
able
Conf
igur
able
Conf
igur
able
Emer
genc
y St
op -
Com
for 1
19-1
20
Fuel
Con
trol R
elay
NO
Com
NO
Com
NO
Star
t Ena
ble
W/L
-Inpu
t D+
Inpu
t
Inpu
t
Preh
eat R
elay
NO
Star
ter R
elay
Star
ter R
elay
Stop
Coi
l Rel
ay
Stop
Coi
l Rel
ay
Inpu
t
Inpu
t
Inpu
t
Inpu
t
Inpu
t
Inpu
t
Inpu
t
70
a3
70
12
a6
12
K7
X9
X9
K7
Y7V7
(O)
57 58 63 6461 6259 6055 5649 50 51 52 53 54
116 117 120 121 122 123118 119 124 B3 B2 B1A3 A2 A1
Displayrt
X9 X9(O)
AirShutdown
Valve
- 134 -
A B C D E F G H I J K L M N O P Q R S T U V W X Y Z a b c c e f g h
134
a3
133
a3
17
a2
12
a6
17
a2
12
a6
17
a2
109
a317
a2
110
a3
12a6
12
a6
17
a2
17
a2
12
a6
112
a3
111
a3
6
a3
7
a3
111
a3
112
a3
12
a6
6A 6A
Sx=RemoteStart/Stop-switch12
a6
13
a2
PE
NL
B+B-
9 10 10 11 12 13 14 15 16
-->
Clo
se M
ains
CB
-->
Ope
n M
ains
CB
to A1.115
18
a3
<-- M
CB
Clo
sed
(N
O to
X25
.10)
<-- M
CB
Ope
ned
(N
O to
X25
.10)
445
a0
444
a0
443
a0
to F4-F6
3 4 5 33 34 35 366
L3
a0
L2
a0
L1
a0
to Q1/X1
1 2
Can
opy
Cub
icle
Can
opy
Cub
icle
442
b0
441
b6
441
442
441
b6
442
b0
12 13
441
b6
442
b0
<--
<--
<--
<--
(see
Inst
ruct
ion
Man
ual)
(see
Inst
ruct
ion
Man
ual)
Note "M": Removeparallelling with thIn AMF-mode or inparallelling, the Malines need to be fucustomer (3x 250mFuse L1, L2 & L3 anto X25.3, X25.4 & 2When parallelling mgen-sets in ISLANDlink "M" is necessa
Note "P": Remove NOT running in ISL
N
a6
446
a6
113
a3
114
a3
115
a3
116
a3
130
a0
132
a0
131
a0
132
a0
130
a0
131
a0
132
a0
(O)
138
a3
137
a3
139
a3
31 2
Gene
rato
r Vol
tage
Neu
tral
0 Vd
c (Ba
tt-)
0pen
Mai
ns C
B
0pen
Gen
erat
or C
B
Gene
rato
r Cur
rent
Tran
sfo
L1
Gene
rato
r Vol
tage
L2
Gene
rato
r Vol
tage
L1
Gene
rato
r Vol
tage
L3
Gene
rato
r Cur
rent
Tran
sfo
L2
Gene
rato
r Cur
rent
Tran
sfo
L3s2s1 s2 s1 s2 s1
Com N
C
Com N
C
NO
Com N
O
ComN
O
NO
Activ
e Lo
ad S
harin
g Li
ne
2nd
Para
met
er S
et (6
0Hz)
Repl
y: M
ains
CB
open
ed
Repl
y: G
ener
ator
CB
close
d
Repl
y: G
ener
ator
CB
open
ed
Repl
y: M
ains
CB
close
d
Com
mon
(12/
24 V
dc) f
or 2
3-27
Alar
m In
hibi
t
kWh
coun
ter (
pulse
out
put)
kVAr
h co
unte
r (pu
lse o
utpu
t)
Reac
tive
Load
Sha
ring
Line
Com
mon
for #
37 &
#39
NC
Clos
e Ge
nera
tor C
B
NC
Clos
e M
ains
CB
Com
mon
for k
Wh/
kVAr
h-co
unte
rs
Cent
ral A
larm
HOR
NC
om NC
NO
Stat
us R
elay
NC
Com
Mai
ns/B
usba
r Vol
tage
L2
Mai
ns/B
usba
r Vol
tage
L1
AVR
Volta
ge se
t-poi
nt:
anal
og o
utpu
t (+/
- 25
mA)
Spee
d Go
vern
or se
t-poi
nt:
anal
og o
utpu
t (+/
- 25
mA)
Out
p
GN
D
Out
p
GN
D
3rd
Para
met
er S
et
4th
Para
met
er S
et
Low
Oil
Pres
sure
12/2
4 Vd
c (Ba
tt+)
Conf
igur
able
High
Coo
lant
Tem
pera
ture
A B
Com
mon
(12-
24Vd
c) fo
r 112
-117
Conf
igur
able
C(+)
(-)
Mag
netic
Pick
-up
(Tac
ho)
Inpu
t
GN
D
Mai
ns/B
usba
r Vol
tage
Neu
tral
Mai
ns/B
usba
r Vol
tage
L3
0 Vd
c (Ba
tt-)
12/2
4 Vd
c (Ba
tt+)
Oil p
ress
ure
(VDO
)
A B C
Cool
ant T
emp
(VDO
)
A B C
Fuel
Lev
el (4
-20m
A)
Conf
igur
able
ALS
PID
inhi
bit
Rem
ote
Star
t/Sto
p
Inpu
t
Inpu
t
Inpu
t
Inpu
t
(+)
(-)
Inpu
t
Inpu
t
Inpu
t
Inpu
t
Inpu
t
Inpu
t26
a3
(O)
12
a6 17
a2
V11
K11
V12
K12
Fx Fx SxU1
N L1 L1 L2 L3
X25 X25 X25 X25P
X25
MAINS SUPPLY (3P+N+PE)
X25R5
X9X9
X9 X9
Cust
omer
's In
stal
latio
n
Cust
omer
's In
stal
latio
n
MM
MM
N
K11 K12
K6
X30
757473 8176 77 78 79 83 84
921 1610 11 12 15 17 18 38 39378 14
66 67 70 71
4844 45 4643 4724 25 26 27 282321 2220191343 6 75
85 87 88
A1
103 115102 105104 106 107 108 109 110 111 11411311298 99 10110089
Service po
S12c
Qc4002 MkII
t
u
v
c54
PE
SHT
L3
c0
N
c6
L N
2L3
c0
2N
c6
12
12
a6
22
a3
5
5
a3
50 60Hz Hz
16A30mA
Q2
X2
16A
X9 X9
S12d(O)
(O) 1-Phase Socket
- 135 -
w x y z 1 2
102
a3
12
a6
117
a0
119
a0
y54
U1
x0V
1x0
W1
x0
N1
x6
3231A2A1T2T1
L1 L2 L3 N PE
L1
x0
L2
x0
L3
x0
N
x6 y54
PE
g54
L1
a0
L2
a0
L3
a0
3
4
5
33
34
35
2
1
y54
445
a0
444
a0
443
a0
UVT
d2(+)
d1(-)
14
11
12 P1(+)
P2(-)
OFFRESET
ON
COMPE
6A
N1
a6
W1
a0
5
a3
118
a0
12
a6
120
a6
120
a6
118
a0
117
a0
120
a6
12
a6
118
a0
117
a0
125
y54
PE
y54
PE
y54
PE
118
a0
M
M
M
M
133
a3
134
a3
130
a0
132
a013
1
a0
N
a6 636
446
a6
I n
N13
X1
PE
X25
X25
X25
X25
X25
X25
T13
SeeNote 1
Q1 M3
Q13
S2aS13
X9X9
X25X25
M
i j k l m n o p q rh
C2C2
A4A4
A5A5
Cub
icle
Can
opy
Cub
icle
Can
opy
g5 a10f5 f5 e7 b5 a6 a6
151
a2
GN
D
153
a0
12
a6
4
a3
12
a6
M
15
a3
25
a3
4
a3
14
a3
12
a6
5
a3
5
a3
12
a6
12
a6
4
a3
9
18
a3
14
a3
1212
6
X10X100
K1 K7K5 K6 K11 K12Wire Size x Wire Size y1
25mm² 16mm²7A
9 = white8 = grey7 = purple6 = blue5 = green4 = yellow3 = orange2 = red
0 = black
h = 25 mmg = 16 mmf = 10 mme = 6 mmd = 4 mmc = 2.5mmb = 1.5mma = 1 mm
Colour code :Wire size :
1 = brown
54 = green/yellow
i = 35 mmj = 50 mmk = 70 mm
lx = 95 mm EPR-CSP (BS6195-4C)l = 95 mm
bx = 1.5mm NSGAFOeU
K5
K1
V6
K6AOP-1 ML2
CAN1 CAN2
Qc4002 DisplayA2
25
Position of Relay Contacts
Legend
PEPE
PE
a54
X3054PE
151
a2
GN
D
153
a0
- 136 -
A B C D E F G H I J K L M N O P Q R S T U V W X Y Z a b c c e f g
t
u
v
124
a6
126
a0
127
a0
125
a0
142
c8
143
c8
141
c8
140
c8
140
c8
140
c8
13
c2
B1B1
B2B2
A2A2
C1C1
C3C3
B5B5
B4B4
A3A3
A1A1
a6
12
9
a3
12
a6
10
a3
11
a3
10
a3
9
a3
9
a3
10
a3
12
a6
11
a3
a2
17
400V/480V
3
c2
1
j0
1
j0
1
e2
2a3
6
a3
7
a3
12
a6
1
e2
PB+GND
D+W
3c2
17
a2
CD
A
-
+
12
a6
11
a3
10
a3
9
a3
17
a3
a3
25
2
a3
16
e2
3
c2
12
j6
12
j6
1
c2
1 2 3
912 811 710
4 5 6
20
a3
24
a3
46
a2
70
a3
5
a3
47
a0
70
a3
12
a6
20
a3
24
a3
27
a3
24
a3
5
70 12 27
to K7.85
12
a6
24
a3
29
a0
28
a2
1
c2
1
c2
5
a31
c2
5
a3
25
a3
14
b3
17
b2
6
a3
7
a3
14
b3
17
a2
17
a2
12
a6
12
a6
13
5
a3
17
a2
12a6
13
a2
12
a6
5
a3
12
a6
5
a3
454
a0
456
a6
453
a0
446
a6
444
a0
443
a0
455
a0
445
a0
(O)
12
a6
12
a6
17
a2
17
a2
27
a3
5
a3
(O)
a6
a6
K
X10 X10X10 X10 X1X10 X10 X10X10X10
The PE-N connection has to be madeat the alternator-side of Circuit Breaker Q1.
With "TB EDF", do NOT connect (N) to (PE) at Q1.T13 is t be mounted on the (PE)-conductor insteadof on the PE-N connection in the cubicle.
Note 1:
Note 2:
QAS T1 Q60 150/5A 8
S8
+
-
G1
S9
K1
E1
M1
MK0
K0
M6G2 B7
B9B8
V2
R2K5
N11
B11
X9
X9 X9 X9
R6 R7
F10
10A
S2bS20
X9
F4 F5 N F6
X
S12b
S31
Notes
Cub
icle
Can
opy
Can
opy
Cub
icle
V11,V12 Free-wheeling diode K11,K12X1 Terminal boardX2 1phase socket (16 A)X9 Terminal stripX10 Connector wire harnessX25 Customer's terminal stripX30 PMS/ALS interface connectorY7 Air inlet shutdown valve(O) Optional equipment
- 137 -
A1 Generator control unit N11 Speed controllerA2 LCD display N12 Automatic voltage regulatorA3 PMS CAN-communication N13 Earth leakage relayB7 Fuel level sensor Q1 Circuit breakerB8 Coolant temperature sensor Q2 Circuit breaker 16 AB9 Oil pressure sensor Q13 Circuit breaker 6 AB11 Speed sensor MPU R2 Excitation resistor 47 ohmE1 Preheat resistor R5 Coolant heater (O)F1-6 Fuse 250mA R6 Resistor 120 Ohm (speed adj)F10 Fuse 10A DC R7 Resistor 47 Ohm (volt adj)G1 Battery 12Vdc S2 Emergency stopG2 Charging alternator S8 High coolant temperature switchG3 Alternator S9 Low oil pressure switchK0 Starter solenoid S12 Dual frequency switchK1 Prehaet relay S13 Earth leak. disable switchK5 Starter relay S20 ON/OFF switchK6 Fuel solenoid relay S31 ASL PID inhibit switchK7 Aux.relay for Y7 (O) T1-T3 Current transformersK11 Aux.relay open MCB T13 Torus earth leakageK12 Aux.relay close MCB U1 Battery chargerM1 Starter motor V2 Excitation diodeM3 Motor drive for Q1 V6 Free-wheeling diode K6M6 Fuel feed pump V7 Free-wheeling diode Y7 (O)
NOTE 1X25.2 is mains L1 towards thepower supply-input of the MC,X25.3 is the mains L1-sensingsignal on the AMF-board.
NOTE 2X7.1, X7.2, X7.3 towards batterycharger & coolant heater.
to ter
mina
ls X2
5(g
ener
ator /
remo
te AM
F)
X256
X7
X25
X7
X25
X7
X25
X25
X25
X25
2
1
3
2
1
3
4
5
7
X258
F0 Fuse 6A (see note 1)F1 Fuse 6A (see note 2)F2-4 Fuse 0.25A (see note 1)MC Contactor mains supplyPC Contactor generatorX1 Terminal stripX2 Terminal stripX3 Terminal stripX25 Terminal strip
- 138 -
from 3Ph generator from 3Ph mains supply
to 3Ph load
X1 X1 X1 X1 X1 X2 X2 X2 X2 X2 PC
PC
MC
MC
N
1N 1L1
1L2
1L3
2N 2L1
2L2
2L3
L1 L2 L3 N L1 L2 L3
PC MC1 3 5 7
2 4 6 8 2 4 6 8
1 3 5 7
9691
2N
2N
92PE
9394
9597
39
97
2L1
2L1
2L2
2L3
PE
96
b0
b0
b0
b54
b0
b6
b6
b6
b54
b6
b0
b0
b0
b0
b0
b0
b0
b0
3N 3L1
3L2
3L3
X3 X3 X3 X3 X3N L1 L2 L3
A1
A2
A1
A2
F0
F1
F2
F3
F4
9822 0773 55
Applicable for QAS 60 Pd - COC box
- 139 -
- 140 -
Following documents are provided with this unit:
– Test Certificate– EC Declaration of Conformity:
Atlas Copco Airpower n.v. puorG ocpoC saltA eht nihtiw ynapmoc A
Postal address Visitors address Phone: +32 (0)3 870 21 11 Com. Reg. Antwerp 44651 P.O. Box 100 Boomsesteenweg 957 Fax: +32 (0)3 870 24 43 V.A.T. 403.992.231 B-2610 Wilrijk-Antwerp B-2610 Wilrijk-Antwerp
tcatnoc esaelp ,ofni roF muigleB muigleB your local Atlas Copco representative www.atlascopco.com
p.1(2)
Form
5009
060
0 03
ed. 0
8, 2
010-
01-0
1
1 EC DECLARATION OF CONFORMITY2 We, Atlas Copco Airpower n.v., declare under our sole responsibility, that the product 3 Machine name : Power generator (< 400 kW) 4 Commercial name : 5 Serial number :
Which falls under the provisions of article 12.2 of the EC Directive 2006/42/EC on the approximation of the laws of the Member States relating to machinery, is in conformity with the relevant Essential Health and Safety Requirements of this directive.
The machinery complies also with the requirements of the following directives and their amendments as indicated.
Directive on the approximation of laws of the Member States relating to
Harmonized and/or Technical Standards used
Attmnt
b. Machinery safety 2006/42/EC EN ISO 12100-1 EN ISO 12100-2
EN 1012-1
d. Electromagnetic compatibility 2004/108/EC EN 61000-6-2 EN 61000-6-4
e. Low voltage equipment 2006/95/EC EN 60034
EN 60204-1 EN 60439
f. Outdoor noise emission 2000/14/EC ISO 3744 x
6
7
8.a The harmonized and the technical standards used are identified in the attachments hereafter 8.b Atlas Copco Airpower n.v. is authorized to compile the technical file
9
10 Conformity of the specification to the Directives
Conformity of the product to the specification and by implication to the
directives11
12
13
Issued by Product engineering Manufacturing
14 Name15 Signature
16 Place , Date
Pri
nte
d i
n B
elg
ium
04
/2012
- 2
95
4 6
28
0 0
0
www.atlascopco.com