2954 4650 00_qas 600_en

QAS 600 Volvo

Instruction Manual for AC Generators English

ATLAS COPCO - PORTABLE AIR DIVISION

www.atlascopco.com03/2010

QAS 600 VolvoInstruction Manual for AC Generators

Instruction manual ..................................................................................5

Circuit diagrams ....................................................................................49

Printed matter N°2954 4650 00

Original instructions

Warranty and Liability Limitation

Use only authorized parts.

Any damage or malfunction caused b y

Warranty or Product Liability.

The manufacturer does not accept any s,

additions or conversions made without

Neglecting maintenance or making cha or

hazards, including fire risk.

While every effort has been made to e ct,

Atlas Copco does not assume responsib

Copyright 2010, Atlas Copco Airpower n

Any unauthorized use or copying of the

This applies in particular to trademarks,

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y the use of unauthorized parts is not covered b

liability for any damage arising from modification

the manufacturer's approval in writing.

nges to the setup of the machine can result in maj

nsure that the information in this manual is corre

ility for possible errors.

.v., Antwerp, Belgium.

contents or any part thereof is prohibited.

model denominations, part numbers and drawings.

335

5556678

999

00001

Technical specifications .............................42Readings on gauges ...............................42Settings of switches ...............................42Specifications of the engine/alternator/unit .........................................42Conversion list of SI units into British units .............................................47Dataplate .................................................47

ing to the latest technology. Follow the instructions in thisy before starting to use your machine.not assume responsibility for possible errors. Atlas Copco

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Contents

Safety precautions for portable

generators ......................................................6

Leading particulars .....................................13General description ................................13Bodywork ................................................15Markings..................................................15Drain plugs and filler caps .....................16External fuel tank connection ................16Control and indicator panel Qc1002™..16US Outlet sockets (S) .............................26Camlock cubicle......................................27Battery switch .........................................28Spillage free skid ....................................28Engine coolant heater ............................28

Operating instructions...............................29Installation...............................................29Connecting the generator ......................29Before starting ........................................31Operating ................................................31

Maintenance ................................................3Maintenance schedule ...........................3Engine maintenance...............................3(*) Measuring the alternator insulation resistance...............................3Engine fuel specifications ......................3Engine oil specifications ........................3Engine oil level check .............................3Engine oil and oil filter change..............3Engine coolant specifications ................3Coolant check..........................................3

Storage of the generator ...........................3Storage ....................................................3Preparing for operation after storage ...3

Checks and trouble shooting....................4Checking voltmeter P4 ...........................4Checking ammeters P1, P2 and P3........4Engine troubleshooting..........................4Alternator troubleshooting ....................4

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 carefullWhile 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.

or repairing the generator.

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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.

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Safety precautions for portable generators

To be read attentively and acted accordingly before towing, lifting, operating, performing maintenance

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.

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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 Portable generators (with earthing pin):Earth the generator as well as the load properly.

16b Portable generators IT:Note: This generator is built to supply a sheeralternating current IT network.Earth the load properly.

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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.

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.

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10 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.

11 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.

12 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.

13 The electrical connections shall correspond to localcodes. The machines shall be earthed and protectedagainst short circuits by fuses or circuit breakers.

14 Never connect the generator outlets to aninstallation which is also connected to a publicmains.

15 Before connecting a load, switch off thecorresponding circuit breaker, and check whetherfrequency, voltage, current and power factorcomply with the ratings of the generator.

16 Before transportation of the unit, switch off all thecircuit breakers.

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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 ampcapacity. Refer to the documentation of the towinvehicle.

3 If the unit is to be backed up by the towing vehicldisengage the overrun brake mechanism (if it is nan automatic mechanism).

4 Never exceed the maximum towing speed of thunit (mind the local regulations).

5 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.

6 To lift heavy parts, a hoist of ample capacity, testeand approved according to local safety regulationshall be used.

7 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.

8 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.

9 Never leave a load hanging on a hoist.

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- 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 Insulation or safety guards of parts the temperatureof which can be in excess of 80°C (175°F) andwhich may be accidentally touched by personnelshall not be removed before the parts have cooled toroom temperature.

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.

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.

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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,

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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.

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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.

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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.

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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-cleaning

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.

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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.

Battery safety precautions

BatteriesWhen 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 uniDisconnect in the reverse order.

le or as stand-by in cases of interruption of the mains. Theled diesel engine, manufactured by VOLVO PENTA. An

Lifting beamGuiding rodSide doorsEngine exhaustData plateDoor, access to control and indicator panelOutput terminal boardHole for forklift

H Drain and access hole (in the frame)F Filler cap fuel

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Leading particulars

General description

The QAS 600 Volvo is an AC generator, built for continuous running at sites where no electricity is availabgenerator operates at 60 Hz, 240/480 V - 3 phase. The QAS 600 Volvo generator is driven by a coolant-coooverview of the main parts is given in the diagram below.

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DFC

AlternatorF Air filter

CouplingFO Drain flexible engine oilFW Drain flexible cooling water

EngineFan

O Filler cap engine oilW Filler cap cooling water

Fuel filter1 BatteryDP Oil drain pumpF Oil filterLD Engine oil level dipstick

Battery switch

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Indicates that the generator may be refuelled with diesel fuel only.

Indicates the drain for the engine oil.

Indicates the drain for the coolant.

Indicates the drain plug for the engine fuel.

Use PAROIL E only.

Indicates the external fueltank.

Indicates that the alternator should not be 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.

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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 lifting beam, to lift the generator by means of acrane, is integrated in the bodywork and easilyaccessible from the outside. The recesses in the roofhave guiding rods at both sides.

To be able to lift the generator by means of a forklift,rectangular holes are provided at the bottom of theframe.

The earthing rod, connected to the generator’s eartterminal is located at the bottom of the frame on thoutside.

Markings

A brief description of all markings provided on thgenerator is given hereafter.

Never use the guiding rods to lift thegenerator.

Indicates that an electric voltage, dangerous to life, is present. Never touch the electric terminals during operation.

Indicates that the engine exhaust is a hot and harmful gas, which is toxic incase of inhalation. Always make sure that the unit is operated outside or in awell-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 notbe 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.

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Control and indicator panel

Qc1002™

General description Qc1002™ control

panel

A1 .......Qc1002™ 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

H0

A1

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S2

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X4

X5 X3

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Q3Q2 Q4 Q5 Q6

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L2L3 L2-N

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Drain plugs and filler caps

The drain holes for the engine oil, the coolant and theplug for the fuel, are located and labelled on theframe, the fuel drain plug at the front, the others at theservice side. The drain flexibles for the engine oil and the enginecoolant can be brought to the outside of the generatorthrough the drain hole.

External fuel tank connection

The external fuel tank connection allows to bypasthe internal fuel tank and to connect an external futank to the unit.

Make sure to connect the fuel supply line as well athe fuel return line. Connections to fuellines ought tbe air-tight to prevent air from entering the fusystem.

Indicates the 3-way valve.

Indicates the partnumbers of the different service packs and of the engine oil. These parts can be ordered to the factory.

The drain hole can also be used toguide external fueltank connections.When connecting an externalfueltank, use the 3-way valves.

QAS 600 VoD

Engine oil PAROIL E PAROIL Extra

Engine coolant PARCOOL EG Engine coolant PARCOOL EG Engine coolant PARCOOL EG Engine coolant PARCOOL EG Engine coolant PARCOOL EG Engine coolant PARCOOL EG Engine coolant PARCOOL EG Engine coolant PARCOOL EG Engine coolant PARCOOL EG Engine coolant PARCOOL EG Engine coolant PARCOOL EG Engine coolant PARCOOL EG Engine coolant PARCOOL EG Engine coolant PARCOOL EG Engine coolant PARCOOL EG Engine coolant PARCOOL EG Engine coolant PARCOOL EG Engine coolant PARCOOL EG Engine coolant PARCOOL EG Engine coolant PARCOOL EG Engine coolant PARCOOL EG Engine coolant PARCOOL EG Engine coolant PARCOOL EG

XXXXXXXX XXXX XXXX XXXXXXXXXXX XXXX XXXX XXXXXXXXXXXX XXXX XXXX XX

XX XXXXXXX XXXX XXXX XX XXXX XXXX XXXX XXXXXXX XXXX XXXX XX XXXX XXXX XXXX XXXXXXX XXXX XXXX XXXXX XXXXXXX XXXX XXXX XX

XX XXXXXXX XXXX XXXX XXXX XXXXXXX XXXX XXXX XXXX XXXXXXX XXXX XXXX XX Position 1: Indicates that the

fuel supply line to the engine is connected to the internal fueltank.

Position closed: Indicates that the fuel supply line to the engine is closed.

Position 2: Indicates that the fuel supply line to the engine is connected to the external fueltank.

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Pushbutton and LED functions

Following pushbuttons are used on the Qc1002™

ENTER: Is used to select and confirm changed settings in the Parameter list.

UP: Is used to scroll through the display information and to adjust parameter value upwards.

DOWN: Is used to scroll through the display information and to adjust parameter value downwards.

BACK: Is used to leave the Alarm pop-up window, to leave the Parameter list and to leave menu's without change.

REMOTE MODE: Is used to activate the remote mode. The LED indicates if the gen-set is put in Remote Mode.

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S2 ....... Emergency stop button

Push the button to stop the generator in caseof an emergency. When the button ispressed, it must be unlocked, before thegenerator can be restarted. The emergencystop button can be secured in the lockedposition with the key, to avoid unauthorizeduse.

S20 ..... ON/OFF switch

Position O: No voltage is applied to theQc1002™ module, the generator will notstart.

Position I: Voltage is applied to theQc1002™ module, it is possible to start upthe generator.

X25 ..... Terminal strip

Qc1002™ Module

The Qc1002™ module is located inside the contropanel. This control module will carry out anecessary tasks to control and protect a generatoregardless of the use of the generator.

This means that the Qc1002™ module can be used foseveral applications.

Qc1002 CAN

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Qc1002™ Menu Overview

At Qc1002™, the LCD will show followinginformation:

– in Normal condition (scroll through theinformation 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• RPM (speed)• 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.

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Following LEDs are used on the

Qc1002™START: Is used to start the unit in Manual Mode.

STOP: Is used to stop the unit in Manual or Remote Mode (always with shutdown!). When the unit is stopped with the STOP button in Remote mode, it will automatically go to Manual Mode.

Power Green LED indicates that the unit is powered up.

Remote Green LED indicates that the RemoteMode is selected.

Start/Stop Green LED indicates that the engineis running.

Alarm Flashing red LED indicates that an alarm is present. A continuous red LED indicates that the alarm has beenacknowledged by the user. The exact alarm is shown on the display.

Remote

Powe

Alarm

Start/Stop

Qc1002 CAN145

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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 runninghours.

Service 1Service 2

59h59h

25.2 VBattery00168.1h

- 19 -

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 andgives access to them.

An overview is given in “Parameter list” on page 21.

Alarm list display

This view shows the number of active alarms angives access to them.An overview is given in “Alarm Display (pop-uwindow)” on page 23.

LOG list display

This view shows the alarm memory and gives accesto it.An overview is given in “LOG list” on page 25.

Qc1002 CANv1.00.0

Parameter

Alarm List0 Alarm(s)

LOG List

s.

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s.

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:

PREHEAT

START OFF/EXTENDED STOP TIMER

COOLDOWN

- 20 -

Coolant temperature display

This view shows the Coolant temperature and therunning hours.See also “Parameter list” on page 21 for selectionbetween °C and °F.

Oil pressure display

This view shows the Oil pressure and the runninghours.See also “Parameter list” on page 21 for selectionbetween bar and psi.

Fuel level display

This view shows the Fuel level and the running hour

Voltage - frequency - running hours

display

This view shows the voltage, frequency and runninhours.

Engine speed display

This view shows the engine speed and running hour

62˚CWater00168.1h

3.2barOil00168.1h

75%Fuel00168.1h

50Hz400V00168.1h

1500RPM00168.1h

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,

,

– 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.

- 21 -

If a special status has elapsed, the active view will beentered again automatically.If an Alarm comes up, the Alarm Display is shown.

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).Menu's shown on the Parameter list LCD:

– Running hours adjust

This menu is used to adjust the amount of runninghours. The running hours can only be highered,not lowered.

– Unit Type

– Service Timer 2 reset

– 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 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.

– Unit Menu

This menu is used to select whether tempreaturand pressure should appear in °C/bar or °F/psi.

– Language selection

Icons is the default factory set language, but other languages can be selected: English, FrenchGerman, Italian, Spanish and Cyrillic (RussianAll information in the Parameter List display always in English.

– Generator Underfrequency: failclass, enabldelay, setpoint

– Generator Overfrequency: failclass, enable, delasetpoint

– Generator Undervoltage: failclass, enable, delaysetpoint

– Generator Overvoltage: failclass, enable, delaysetpoint

DIAGNOSTIC

Unit type 2 for QAS 600 Volvo!

Unit type2

Unit type

- 22 -

This is the described menu flow for changing the unit type:

Qc1002 CAN145

Parameter Running time

Unit type

Qc1002 CAN145

:

pis

r

s

s

LOW FUEL LEVEL

LOW COOLANT LEVEL

GENERATOR OVERVOLTAGE

GENERATOR UNDER-VOLTAGE

GENERATOR OVER-FREQUENCY

GENERATOR UNDER-FREQUENCY

- 23 -

Alarm Display (pop-up window)

In case an Alarm occurs, a pop-up window willautomatically be displayed for as long as the alarm isactive, no matter which view is active. The flashingred alarm LED will light up. The alarm icons will beshown together with an acknowledgement check-box.Push the ENTER button to acknowledge the alarm.When the alarm has been acknowledged, a V-marking will appear in the check-box and the redalarm LED will light up continuously.

The Alarm Display can always be left or enteredagain by pushing the BACK button.If more than one alarm comes up, it's possible to scrollthrough the alarm messages with the UP and DOWNpushbuttons. The newest alarm will be placed at thebottom of the list (meaning that the older alarm staysat the display when a newer alarm comes up).If one or more than one alarm is present, an arrow atthe right of the display will be shown.

Following general groups of Alarms exist

– Warning: Alarm LED lights up + Alarm pop-uappears on the display + Alarm relay empowered (if configured)

– Trip of GB: ‘Warning’ actions + GeneratoContactor opens

– Trip and Stop: ‘Trip of GB’ actions + unit stopafter Cooldown

– Shutdown: ‘Trip of GB’ actions + unit stopimmediately

List of possible alarms:

An alarm should always beacknowledged before solving theproblem that causes the alarm.

LOW OIL PRESSURE

HIGH COOLANT TEMPERATURE

CHARGING ALTERNATOR

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SPN98 "OIL LEVEL"oil level

SPN99 "OIL FILTER DIFF P"pressure difference over oil filter

SPN100 "OIL PRESSURE"oil pressure

SPN101 "CRANKCASE PRESS"crankcase pressure

SPN102 "TURBO BOOST PRESS"turbo boost pressure

SPN104 "TURBO OIL PRESS"turbo oil pressure

SPN105 "INTAKE MANIF TEMP"intake manifold temperature

SPN106 "AIR INLET PRESSURE"air inlet pressure

SPN110 "COOLANT TEMP"coolant temperature

SPN111 "COOLANT LEVEL"coolant level

SPN158 "BATT VOLTAGE"battery voltage

SPN171 "AMBIENT AIR TEMP"ambient air temperature

SPN172 "AIR IN TEMP"air in temperature

SPN174 "FUEL TEMP"fuel temperature

SPN175 "OIL TEMP"oil temperature

- 24 -

Displaying the engine DM1 alarm

Besides some engine specific alarms shown in thstandard alarm list, also all Diagnostic messageDM1 (active alarms) can be shown on the display.Use the UP or DOWN buttons until DM1 is shown othe display and press ENTER. The DM1 alarm lowill be shown on the display. Use the UP and DOWN buttons to scroll through thlist.

The DM1 alarm log will always show the SPN cod(Diagnostics Codes) and the FMI code (FailurModes) of every engine failure.

For example, the error code for “Low Coolant LevShutdown” will be 111/01 (111 for “Coolant leveand 01 for “Low level shutdown”).

The list below shows the most common error codeThe DM1 alarm log for these codes will also show thalarm text:

SERVICE TIMER 1

SERVICE TIMER 2

ENGINE ALARM

EMERGENCY STOP

START FAILURE

STOP FAILURE

SPN16 "FUEL FILTER DIFF P"pressure difference over fuel filter

SPN51 "THROTTLE POS"throttle position

SPN52 "INTERCOOL TEMP"intercooler temperature

SPN94 "FUEL PRESS"fuel pressure

SPN95 "FUEL FILTER DIFF P"pressure difference over fuel filter

SPN97 "WATER IN FUEL"water in fuel

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Remote start operation

Installation wirings:

– X25.1 & X25.2 to be wired for the remote startswitch.

– X25.3 & X25.4 to be wired for the remotecontactor (open/close).

Fail classes

All the activated alarms of the Qc1002™ have theirown pre-defined fail 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 themachine is running (RUN).

- 25 -

LOG list

The unit will keep an event log of the latest 30 eventEvents are:

– shutdowns

– service timer 1/2 reset

– unit type changes

Together with each event, the running hours at thtime of the event will be stored.

SPN190 "SPEED"speed

FMI00 "HIGH LEVEL SHUTDOWN"high level shutdown

FMI01 "LOW LEVEL SHUTDOWN"low level shutdown

FMI15 "HIGH LEVEL WARNING"high level warning

FMI16 "HIGH LEVEL ALARM"high level alarm

FMI17 "LOW LEVEL WARNING"low level warning

FMI18 "LOW LEVEL ALARM"low level alarm

1 Controller type2 Event number3 Event4 Running hours

Time: 00001h

EVENT LOG #04 WaterQc1002

1

3

4

2

anised

anised

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 (20 A) isactivated. When activated, Q6 interrupts onephase (L2) towards X6. It can be activatedagain after eliminating the problem.

X1 .......Main power supply (480 V AC)

Terminals L1, L2, L3, N (= neutral) and PE(= earthing), hidden behind the control paneldoor and behind a small transparent door.

X2 .......2-phase outlet socket

Provides phase L1, L2, neutral and earthing.






Provides phase L1, neutral and earthing.


Provides phase L2, neutral and earthing.

X7 .......Flanged inlet

F6 ........Thermal overload relay (480 V)

Causes the main breaker to trip when theovercurrent protection is activated (480 V).

- 26 -

US Outlet sockets (S)

A brief description of all outlet sockets and circuitbreakers provided on the generator is given hereafter:

Q1 ....... Circuit breaker for X1

Interrupts the power supply to X1 when ashort-circuit occurs at the load side (240/480 V), or when the overcurrent protectionis activated (240 V). When activated, Q1interrupts the three phases towards X1. Itmust be reset manuallly after eliminating theproblem.


Interrupts the power supply to X2 when short-circuit occurs at the load side, or whethe overcurrent protection (50 A) activated. When activated, Q2 interrupts thtwo phases towards X2. It can be activateagain after eliminating the problem.






Interrupts the power supply to X5 when short-circuit occurs at the load side, or whethe overcurrent protection (20 A) activated. When activated, Q5 interrupts onphase (L1) towards X5. It can be activateagain after eliminating the problem.

Q3 X7 X5 X2Q1 F6 Q4 Q5 Q6Q2 S2

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Q1

Q3Q2 Q4 Q5 Q6

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L1L2OFF

L1-N

L2L3 L2-N

L3L1

LL LN

L3-N

X6 X4X1 X3

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A brief description of all Camlock outlet sockets andcircuit breakers provided on the generator is givenhereafter:


See US outlet sockets.

;�;�

;�

;� ;�

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Q12 Q13 Q14 Q15

X12 X13 X14 X15

- 27 -

Camlock cubicle

In addition to the US outlet sockets, optional Camlocoutlet sockets can be ordered. An extra Camloccubicle, containing both US as Camlock outlsockets will be attached to the unit.

The 4 Camlock circuits, enclosed in this extra cubiclprovide 3 phases, neutral and eathing each. Followincable coulours are used:

L1........black

L2........ red

L3........blue

N .........white

PE .......green

Circuit breaker Q1 does not onlyinterrupt the power supply towardssocket X1 but also towards X2, X3,X4, X5 and 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 and X6.

anistsee

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d

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d

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.

Spillage free skid

A Spillage free skid with forklift slots allows thecustomer to transport the generator easily with aforklift.It avoids accidental spilling of engine fluids.

Engine coolant heater

To make sure that the engine can start and accept loadimmediately, an external cooling water heater(2000 W, 240 V) is provided which keeps the enginetemperature between 38°C and 49°C.

Circuit breaker Q1 does not onlyinterrupt the power supply towardssocket X1 but also towards X12,X13, X14 and X15.Make sure to switch on circuitbreakers Q1, Q12, Q13, Q14 andQ15 after starting the generatorwhen power supply is done by meansof X12, X13, X14 and X15.

Never turn the battery switch toOFF during operation.

- 28 -

Q12 ..... Circuit breaker for X12

Interrupts the power supply to X12 when ashort-circuit occurs at the load side, or whenthe overcurrent protection (400 A) isactivated. When activated, Q12 interruptsthe three phases towards X12. It can beactivated again after eliminating theproblem.





Q15 .....Circuit breaker for X15

Interrupts the power supply to X15 when short-circuit occurs at the load side, or whethe overcurrent protection (400 A) activated. When activated, Q15 interrupthe three phases towards X15. It can bactivated again after eliminating thproblem.

X1 .......Main power supply (480 V AC)

See US outlet sockets.

X12 .....3-phase Camlock outlet socket

Provides phases L1, L2, L3, neutral anearthing.







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Connecting the generator

Precautions for non-linear and

sensitive loads

The most common non-linear, 3-phase loads arethyristor/rectifier-controlled loads, such as convertorssupplying voltage to variable speed motors,uninterruptable power supplies and Telecomsupplies. Gas-discharge lighting arranged in single-phase circuits generate high 3rd harmonics and riskfor excessive neutral current.Loads most sensitive to voltage distortion includeincandescent lamps, discharge lamps, computers, X-ray equipment, audio amplifiers and elevators.Consult Atlas Copco for measures against the adverseinfluence of non-linear loads.

Non-linear loads draw currents withhigh contents in harmonics, causingdistortion in the wave form of thevoltage generated by the alternator.

- 29 -

Operating instructions

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 directetowards people. If the generator is operateindoors, install an exhaust pipe of sufficiendiameter to duct the engine exhaust towards thoutside. Check for sufficient ventilation so that thcooling air is not recirculated. If necessaryconsult Atlas Copco.

– Leave enough space for operation, inspection anmaintenance (at least 1 meter at each side).

– Check that the inner earthing system is icompliance with the local legislation.

– Use coolant for the engine cooling system. Refeto the Engine instruction book for the propecoolant mixture.

– Check the tightness of the bolts and nuts.

– Install the earthing rod (not included in the unit, tbe provided by the end user, if desired) as near apossible to the generator and make sure not thave a contact voltage higher than 25 V.

– Check that the cable end of the earthing rod connected to the earth terminal.

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.

For information about indoorinstallation, consult your local AtlasCopco dealer.

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dalal.

Protection

– Check whether frequency, voltage and currentcomply with the ratings of the generator.

– Provide for the load cable, without excessivelength, and lay it out in a safe way withoutforming coils.

– 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.

For safety reasons, it is necessary toprovide an isolating switch or circuitbreaker in each load circuit. Locallegislation may impose the use ofisolating devices which can be locked.

- 30 -

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.

The lowest acceptable wire section and thcorresponding maximum cable or conductor lengtfor multiple core cable or H07 RN-F, at rated currenfor a voltage drop e lower than 5% and at a powefactor of 0.80, are respectively 120 mm² and 370 mIn case electric motors must be started, oversizing thcable is advisable.

The voltage drop across a cable can be determined afollows:

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)

Connecting the load

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

Wire section Max. current (A) (mm²) Multiple core Single core H07 RN-F

25 94 101 8835 114 123 11050 138 155 13870 176 191 17095 212 228 205120 245 273 239150 282 314 275185 323 358 313240 379 421 371300 429 477 428

e 3 I L R cos X sin+ 1000

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– Put the remote start/stop switch in position start.

– The unit will start. The starting attempt will takemaximum 12 seconds.

During operation

Following points should be carried out regularly:

– Check the engine gauges and the lamps for normalreadings.

– Check for leakage of oil, fuel or coolant.

– Avoid long low-load periods (< 30%). In this case,an output drop and higher oil consumption of theengine could occur.

– Check, by means of the generator gauges, that thevoltage between the phases is identical and thatthe rated current in the third phase (L3) is notexceeded.

– When single-phase loads are connected to thegenerator output terminals, keep all loads well-balanced.

If circuit breakers are activated during operation,switch off the load and stop the generator. Checkand, if necessary, decrease the load.

Avoid to let the engine run out of fuel.If it happened, priming will speed upthe starting.

- 31 -

Before starting

– With the generator standing level, check theengine oil level and top up if necessary. The oillevel must be near to, but not exceed the high markon the engine oil level dipstick.

– Check the coolant level in the expansion tank ofthe engine cooling system. The coolant level mustbe near to the FULL mark. Add coolant ifnecessary.

– Drain any coolant and sediment from the fuel pre-filter. Check the fuel level and top up if necessary.It is recommended to fill the tank after the day’soperation to prevent coolantdamp in a nearlyempty tank from condensing.

– Check the vacuum indicator of the air filter. If thered part shows completely, replace the filterelement.

– Press the vacuator valve of the air filter to removedust.

– Check the generator for leakage, tightness of wireterminals, etc. Correct if necessary.

– Check that circuit breaker Q1 is switched off.

– Check that fuse F10 has not tripped and that theemergency stop is in the OUT position.

– Check that the load is switched off.

– Check that the earth fault protection (N13) has nottripped (reset if necessary).

Operating

Starting

To start up the unit locally, proceed as follows:

– Switch on the battery switch.

– Switch off circuit breaker Q1. This is nonecessary when a plant contactor is installebetween Q1 and the load.

– Put the starter switch S20 in position I (ONVoltage is applied to the Qc1002™ module.

– The unit can be started manually by pressing thSTART button on the Qc1002™ module.

– The unit will start. The starting attempt will takmaximum 12 seconds.

– Switch on circuit breaker Q1 in case no contactois 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 Qc1002™ module.

– The unit can be started from a remote location bpressing the remote mode button on thQc1002™ module.

– Switch on circuit breaker Q1.

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- 32 -

Stopping

To stop the unit locally, proceed as

follows:

– Switch off the load.

– Switch off circuit breaker Q1.

– Let the engine run for about 5 minutes.

– Stop the engine by using the STOP button on theQc1002™ module.

– Put the starter switch S20 in position O (OFF) toshut down the voltage apply towards theQc1002™ module.

– Lock the side doors and the door of the indicatorsand control panel to avoid unauthorized access.

To stop the unit when the starter

switch is in position , proceed asfollows:

– Switch off the load.

– Stop the engine by putting the remote start/stoswitch in position stop or by using the STObutton on the Qc1002™ module. When the unit stopped with the STOP button in Remote Mode, will automatically go to Manual Mode.

– Put the starter switch S20 in position O (OFF) tshut down the voltage apply towards thQc1002™ module.

– Lock the side doors and the door of the indicatoand control panel to avoid unauthorized access.

The generator’s doors may onlyremain opened for short periodsduring operation, to carry outchecks for example.

that no electrical power is present on the terminals.

Small

Yearly

Every 500

hours

Normal

Every 1000

hours

Every 2

years

Every 2000

hours

2912 4505 04 2912 4506 05 2912 4507 06

These service kits offer you the benefits of genuine parts, the 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

x x

x

x

- 33 -

Maintenance

Maintenance schedule

Before carrying out any maintenance activity, check that the start switch is in position O and

Maintenance schedule

Daily Initially

Every 50

hours

Service pak - -

For the most important subassemblies, Atlas Copco has developed service kits that combine all wear parts.save on administration costs and are offered at reduced price, compared to the loose components. Refer to service kits.

Check coolant level (1) x x

Check oil level in sump x x

Check oil pressure on gauge x x

Check vacuum indicator x x

Check and drain fuel pre-filter/Water separator x x

Check and clean radiator and intercooler fins x

Clean air cleaner and dust bowl x

Check oil, fuel and water leaks x

Check level battery electrolyte x

Check condition of vibration dampers x

Check tension and condition of drive belt(s) x

Check and adjust valve clearance (2) x

Check fuel injectors 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

standby application have to be tested on a regularnce a month the engine should run for one hour. If

load (> 30%) should be applied so that the engineating temperature.

- 34 -

Check tightness of nuts and bolts x

Grease door hinges and locks x

Change lubrication oil (3)

Replace oil filter(s) (3)

Replace air filter element (4)

Grease mechanical links (e.g. fuel solenoid link)

Measure alternator insulation resistance (See (*) Measuring the alternator insulation resistance)

Check glycol level in coolant

Check pH level of coolant

Replace and drain fuel pre-filter/Water separator

Replace fuel filter element

Check crankcase pressure

Check fixation of hoses, cables and pipes

Replace drive belt(s)

Replace safety cartridge

Clean and inspect turbocharger impeller and housing

Lubricate fan hub bearings

Check fueltank for water (5)

Inspection by Atlas Copco Service technician

Generators in basis. At least opossible a highreaches its oper

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Engine fuel specifications

For fuel specifications, please contact your AtlasCopco Customer Center.

Engine oil specifications

High-quality, mineral, hydraulic or synthesizedhydrocarbon oil with rust and oxidation inhibitors,anti-foam and anti-wear properties is recommended.The viscosity grade should correspond to the ambienttemperature and ISO 3448, as follows.

It is strongly recommended to useAtlas Copco branded lubrication oils.

Engine Type of lubricant

between -15°C and 40°C PAROIL E

between -25°C and 40°C PAROIL Extra

- 35 -

Notes:

In highly dusty environments, these service intervalsdo not apply. Check and/or replace filters and cleanradiator on a regular basis.

(1) Drain and replace after 10.000 hours or 5 yearswhichever comes first. Never change the coolantfilter on the engine.

(2) After the first initial 150 running hours it isrequired to check/adjust the valve clearance.When opening the rocker cover it is necessary toreplace the gasket. This gasket can be orderedwith AC partnumber 2914 6978 00.

Valve Clearance:• Inlet: 0.30+/-0.05 mm• Exhaust: 0.60+/-0.05 mm

(3) Change oil and oil filters after 150 hours.

Oil filters:• 2 x 2914 9847 00• 1 x 2914 9603 00

Bad fuel may request earlier change of filters, seepage 36.

(4) More frequently when operating in a dustyenvironment. Evacuate dust from the air filtervalve daily.

(5) Use water finding paste 2914 8700 00.

Engine maintenance

Refer to the engine’s operator manual for fumaintenance schedule.

(*) 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 2 M.Refer to the alternator operating and maintenancinstructions for more details.

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elt

Engine oil level check

Consult the Engine Operation Manual for the oilspecifications, viscosity recommendations and oilchange intervals.

For intervals, see section “Maintenance schedule” onpage 33.Check engine oil level according to the instructions inthe Engine Operation Manual and if necessary top upwith oil.

Engine oil and oil filter change

The table below shows the oil change intervalaccording to the sulfur content in the fuel.

Sulfur content in fuel, by weight

<0.5% 0.5-1.0% >1.0%

Oil change interval, reached first in operation

500h / 12 months

250h / 12 months

125h / 12 months

- 36 -

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.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 emissioEURO -3 & -2, EPA TIER II & III engines running olow sulphur diesel for lower oil and fuel consumptio

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 temperatureas low as -25°C.

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 -15°C.

LiterUS gal

Imp gal

cu.ftOrder

number

can 5 1.3 1.1 0.175 1630 0135 00

barrel 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

- 37 -

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 system fillercap while coolant is hot.The system may be under pressure.Remove the cap slowly and only whencoolant is at ambient temperature. Asudden release of pressure from aheated cooling system can result inpersonal injury from the splash of hotcoolant.It is strongly recommended to useAtlas Copco branded coolant.

Never mix different coolants andmix the coolant components outsidethe cooling system.

see

no

o

d

s,e

st

Replacing the coolant

Drain

– Completely drain the entire cooling system.

– Used coolant must be disposed or recycled inaccordance with laws and local regulations.

Flush

– Flush twice with clean water. Used coolant mustbe disposed or recycled in accordance with lawsand local regulations.

– From the Atlas Copco Instruction book, determinethe amount of PARCOOL EG required and pourinto the radiator top tank.

– It should be clearly understood that the risk forcontamination is reduced in case of propercleaning.

– In case a certain content of ‘other’ coolant remainsin the system, the coolant with the lowestproperties influences the quality of the ‘mixed’coolant.

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.

tt

- 38 -

Coolant check

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 coolantshould be replaced.

Glycol concentration measurement

– To optimise the unique engine protection featureof the PARCOOL EG the concentration of thGlycol in the water should be always abov33 vol.%.

– Mixtures with more than 68 vol.% mix ratio iwater are not recommended, as this will lead thigh engine operating temperatures.

– A refractometer can be ordered from Atlas Copcwith part number 2913 0028 00.

Topping up of coolant

– Verify if the engine cooling system is in a goocondition (no leaks, clean,...).

– Check the condition of the coolant.

– If the condition of the coolant is outside the limitthe complete coolant should be replaced (sesection “Replacing the coolant”).

– Always top-up with PARCOOL EG.

– Topping up the coolant with water only, changethe concentration of additives and is therefore noallowed.

Long service intervals5-year drain interval to minimizeservice costs (when used in accordancewith the instructions).

In case of a mix of different coolanproducts this type of measuremenmight provide incorrect values.

eest

e

t

y

- 39 -

Storage of the generator

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.

Preparing for operation after

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 31).

– Consult the engine’s operator manual.

– Check that the insulation resistance of thgenerator exceeds 2 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.

n

e

r

3

y

te

eeoa.

- 40 -

Checks and trouble shooting 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 voltmeteis high.

Checking ammeters P1, P2 and P

– 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.

Engine troubleshooting

– Refer to the engine’s operator manual for thengine troubleshooting. An extensive Engintroubleshooting manual is available at VolvPenta. For more information contact Volvo Pent

Never perform a test run withconnected power cables. Never touchan electrical connector without avoltage check.When a failure occurs, always reportwhat you experienced before, duringand after the failure. Information withregard to the load (type, size, powerfactor, etc.), vibrations, exhaust gascolour, insulation check, odours,output voltage, leaks and damagedparts, ambient temperature, daily andnormal maintenance and altitudemight be helpful to quickly locate theproblem. Also report any informationregarding the humidity and locationof the generator (e.g. close to sea).

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.

- 41 -

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 voltag

Intervention by protection. Current too hof rated spee

Failed regulator. Substitute re

Rotating bridge failure. Check diodeHigher than rated voltage at load Voltage potentiometer out of setting. Reset voltag

Failed regulator. Substitute re

Unstable voltage Speed variation in engine. Check regulaRegulator out of setting. Regulate stab

potentiomete

US Metric

60 Hz 60 Hz1800 rpm 1800 rpm

PRP PRP100 kPa 100 kPa

30% 30%77°F 25°C

122°F 50°C13124 ft 4000 m

85% 85%5°F -15°C

-13°F -25°C

613 hp 457 kW0.8 cos 0.8 cos 571 kVA 571 kVA571 kVA 571 kVA

- 42 -

Technical specifications

Readings on gauges

Settings of switches

Specifications of the engine/alternator/unit

Gauge Reading Unit

Ammeter L1-L3 (P1-P3) Below max. rating AVoltmeter (P4) Below max. rating V

Switch Function Activates at

Engine 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 temperature unaidedMinimum starting temperature with coolant heater

Performance data 2) 3) 4) 5) Rated active power (PRP) 3phRated power factor (lagging) 3phRated apparent power (PRP) 3phRated apparent power (PRP) 3ph, lower voltage

480 V 480 V240 V 240 V687 A 687 A1374 A 1374 A

G2 G272% 72%

441 hp 329 kW<5% <5%

isochronous isochronous29.1 lb/h 13.2 kg/h117.3 lb/h 53.2 kg/h162.5 lb/h 73.7 kg/h221.4 lb/h 100.4 kg/h

0.48 lb/kWh 0.219 kg/kWh7.8 h 7.8 h

0.03 US gal/h 0.11 l/h77 dB(A) 77 dB(A)

239 US gal 905 l100% 100%613 hp 457 kW

PRP PRPland use land use

single/parallel single/parallelmanual/automatic manual/automatic

unspecified unspecifiedtransportable/D transportable/Dfully resilient fully resilient

open air open airearthed earthed

IEC34-1 IEC34-1ISO 8528-3 ISO 8528-3

LEROY SOMER LEROY SOMER

- 43 -

Rated voltage 3ph line to lineRated voltage 3ph line to line lower voltageRated current 3phRated current 3ph lower voltagePerformance class (acc.ISO 8528-5:1993)

Single step load acceptance (0-PRP)

Frequency droop

Fuel consumption at 0% loadFuel 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 tankMax. oil consumption at full loadMaximum sound power level (LPA) measured according to Atlas Copco spec. 9822 0877 00Useful capacity of fuel tankSingle step load capability (O-PRP)

Application data Mode of operationSiteOperationStart-up and control modeStart-up timeMobility/Config. acc. to ISO 8528-1:1993MountingClimatic exposureStatus of neutral

Alternator Standard

Make

LSA 47.2 M7 LSA 47.2 M7625 kVA 625 kVA

“BR” 125/40°C “BR” 125/40°CIP 23 IP 23

H HH H12 12

ISO 3046 ISO 3046ISO 8528-2 ISO 8528-2

TAD1641 GE TAD1641 GE650 hp 485 kWICXN ICXN

coolant coolantdirect injection direct injectionturbocharged turbochargedintercooled intercooled

6 64.26 US gal 16.12 lelectronic electronic

EMS 2 EMS 211 US gal 42 l16 US gal 60 l

24 Vdc 24 VdcUS TIER II US TIER II

3 3690 A 690 A8 x In 8 x In

3 31375 A 1375 A4 x In 4 x In

- 44 -

ModelRated output, class H temperature rise

rating type acc. ISO 8528-3Degree of protectionInsulation stator classInsulation rotor classNumber of wires

Engine Standard

Type VolvoRated net output

rating type acc. ISO 3046-7CoolantCombustion systemAspiration

Number of cylindersSwept volumeSpeed governing

Capacity of oil sumpCapacity of cooling systemElectrical systemEmission compliance

Power circuit Circuit-breaker, 3ph.Number of polesThermal release It (thermal release is higher at 25°C)Magnetic release Im

Circuit-breaker, 3ph., lower voltage (optional)Number of polesThermal release It (thermal release is higher at 25°C)Magnetic release Im

0.030-30 A 0.030-30 A10-100 kOhm 10-100 kOhm

GFCI duplex (2x) GFCI duplex (2x)2p+E 2p+E

20A 125V 20A 125V

Temp Power (3x) Temp Power (3x)2p+N+E 2p+N+E

50A 125/250V 50A 125/250V

amlocks (4x) (optional) Camlocks (4x) (optional)3p+N+E 3p+N+E

400A 240/480V 400A 240/480V

87.2 x 60.45 x 89.7 in 4800 x 1550 x 2300 mm11797 lb 5350 kg13781 lb 6250 kg

- 45 -

Fault current protectionResidual current release IDnInsulation resistance (optional)

Outlet sockets (optional)

C

Unit Dimensions (LxWxH) 1Weight net massWeight wet mass

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 0%.

35 40 45 50100 95 85 75100 95 85 75100 95 85 7595 95 85 7595 90 85 7585 85 80 7585 85 80 7565 65 65 6550 50 50 50

- 46 -

Derating table (in %, 100% is declarated power at “Performance data”)

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 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 of 7

5) Specific mass fuel used: 0.86 kg/l.

Height(m)

Temperature(°C)

0 5 10 15 20 25 300 100 100 100 100 100 100 100

500 100 100 100 100 100 100 1001000 100 100 100 100 100 100 1001500 100 100 100 100 100 100 1002000 95 95 95 95 95 95 952500 90 90 90 90 90 90 903000 85 85 85 85 85 85 853500 65 65 65 65 65 65 654000 50 50 50 50 50 50 50

A Maximum permitted total weight of the vehicleB Maximum permitted front axle loadC Maximum permitted rear axle load1 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

- 47 -

Conversion list of SI units into

British units

A temperature difference of 1°C = a temperaturedifference of 1.8°F.

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

- 48 -

- 49 -

Circuit diagrams

Position of Relay Cont.

Sx

Air S

hutd

own

Valve

(O)

X9

V7 Y7

K7

X9

X9

K7

Customer’s Installation(see Instruction Manual)

X25X25

K7

S4

A

P1P2

A

P3

A

P4

V

to A

1.35

to A

1.36

70

b6

12

b3

71

b2

13

Cubic

leCa

nopy

a3

70

b6

12

12

13

Plant ContactorOutput: 24Vdc,max. 8Adc1

3

to Control Module A1

1 42

Sx=RemoteStart/Stop-switchmax. 24Vdc, 4A

to P

lant C

onta

ctor A

2 <-

-to

Plan

t Con

tacto

r A1

<--

19

a3

12

a3

12

a6

38

a0

a8

97

5111 12 8

4106

23

a0

129

a0

128

2

12

X95

X912

X913

See C

irc.Dia

gr Po

wer

See C

irc.Dia

gr Po

wer

13

(O)

(O) ded. 60Hz

- 50 -

A B C D E F G H I

X9 X9

(O)

R3

H0

S20

X25X25

S2a

10AF10

A1

262524 27232119

3632 3533 3414 161512 13 17 18

6 75431 2

b3

14

b3

14 12

a6

12

70

a3

70

Cubic

leCa

nopy

a0

126

a0

126

a3

5

to C

irc.D

iagr P

ower

F1-N

to C

irc.D

iagr P

ower

T1-T

3

a8140

a8141

a8142

a8143

a0

126a0

125

a0

127

a6

124

a0

125

a3

5

a3

5

a3

5

a3

11

b6

12

aa0

CL

aa9

CH

a2

b2

17

a0

38a6

12

a2

13

a2

13

a2

17

a2

17

b2

1

b3

14

a0

125

a3

5

a6

12

a314

a3

14

b3

14

b2

17b2

17

a6

12

a6

12

a6

12

a6

12

a6

12

3

4

b2

13

Qc1002 canbus

CAN-

LGN

DCA

N-H

Air Sh

utdow

n Valv

e Rela

y

Fuel

Cont

rol R

elay

Com

Com

NONO

0 Vd

c (Ba

tt-)

Load

Con

tacto

rPr

ehea

t Rela

yCo

mmon

for R

elay O

utputs

12/2

4 Vd

c (Ba

tt+)

Gene

rato

r Volt

age

L1Ge

nera

tor V

oltag

e L2

NONONOSt

art R

elay O

utpu

t

Inpu

tIn

put

Inpu

t

Inpu

tIn

put

Com

mon

High C

oolan

t Tem

perat

ureLo

w Oi

l Pre

ssur

e

W/L

Inpu

t

Rem

ote

Star

tSt

art/S

top

50/6

0Hz

Inpu

t

Inpu

tIn

put

Inpu

t

(VDO

) Coo

lant T

emp.

(VDO

) Coo

lant le

vel S

witch

Engin

e CAN

-bus I

nterfa

ce

(VDO

) Fue

l Lev

elCo

mmon

for V

DO inp

ut (0V

dc)

X251

2X2519

a317

60

a3

S11dX113

X114

12

a6 (O) (O)

Dual f

reque

ncy

Dedic

ated 6

0Hz

S3

15

X9

X9

12

15a3

(O)2

2 a6a2

9822 0993 25/02

Applicable for QAS 600 - Qc1002™, Engine Circuit

low

pycle

A1 Control module (configure in UNIT-type 2)

B7 Fuel level sensorF10 FuseG1 Battery 24VH0 Panel lightK7 Aux.relay for Y7 (O)M1 Starter motorP1-3 A-metersP4 V-meterR3 Resistor 120 ohmS1 Battery switchS2a Emergency stop button

(S2b: see Power Circuit)S3 Water in fuel switch (O)S4 Voltmeter change-over switchS11d Selector switch 50/60Hz

(S11a,b see Power Circuit)S20 ON/OFF switchV7 Free-wheeling diode Y7 (O)X9 Terminal strip (See Power Circuit)X10 15-Pole connectorX11 Terminal strip (See Power Circuit)X25 Terminal stripY7 Air inlet shutdown valve (O)(O) Optional equipment

- 51 -

A B C D E F G H I

Terminal strip X11

Legend

Wire size :

aa = 0.5mm†a = 1 mm†b = 1.5mm†c = 2.5mm†d = 4 mm†e = 6 mm†f = 10 mm†g = 16 mm†h = 25 mm†i = 35 mm†j = 50 mm†k = 70 mm†l = 95 mm†bx = 1.5 mm† NSGAFOeU

Note with X11

Connect wires..b only if S11is requiredorconnect wire 35to X11-2 if S11is not required

(O)b dS11 a

X10

101

1212

S1

M1

87

65

43

21

M

-+

G1

-+

1

Colour code :

0 = black1 = brown2 = red3 = orange4 = yellow5 = green6 = blue7 = purple8 = grey9 = white54= green/yel

X10

B7

CanoCubi

a6

12b

a3

22b

a6

12

a3

22X1

1-8

X11-

7

a6

35

a6

35X1

1-9

a3

37

a3

36

a3

37b

a3

36b

X11-

2X1

1-1

a3

60b

a6

12b

a3

60

a6

12X1

1-4

X11-

3

See also Circ.Diagr PowerX11

a3

5

C5

C5 PE

PE

b3

14

c6

12

aa0CL

aa9

CH

c2

1

C4

C4 B1

B1A1

A1

B2

B2

C2

C2

a3

5

l0

l0

c2

1b3

14

l0l0

aa9

CHaa0

CLc6

12CANB

US

l0

a2

17

A5

A5

a6

12

+-

2

4 3a3

11

b6

12

C1

C1

2

(O) not needed for dedicated 60Hz units

P Q R S T U V W X Y

441

6

2 x lx

Z

Cu 80x104 x lx0-1500AAS 600 1385A 1500/5A

YXWire sizeQ1 T1-3 P1-3

Colour code :

0 = black1 = brown2 = red3 = orange4 = yellow5 = green6 = blue7 = purple8 = grey9 = white54 = green/yellow

Legend

Wire size :

aa = 0.5 mm²a = 1 mm²b = 1.5 mm²c = 2.5 mm²d = 4 mm²e = 6 mm²f = 10 mm²g = 16 mm²h = 25 mm²i = 35 mm²j = 50 mm²k = 70 mm²l = 95 mm²bx = 1.5 mm² NSGAFOeUjx = 50 mm² NSGAFOeUlx = 95 mm² EPR-CSP to BS6195 4C (or equal)mx = 120 mm² EPR-CSP to BS6195 4C (or equal)

- 52 -

A B C D E F G H I J K L MN O

a3

103

a6

12

Y0

L1

Y0

L2

Y0

L3

Y6

N

Z54

Z54

Can

opy

Cub

icle

g54

98

97

s1

s2

SHT

a6

12a2

13

a3

103

See

Cir

c.D

iagr

amEn

gine

24

23

1

2

3

4

5

6

to C

irc.

Dia

gr E

ngin

eP1

-P3

a8140a8141a8142a8143

to C

irc.

Dia

gr E

ngin

eS

4a0

126a0

125

a0

127

a6

124

a0

U1

a0

V1

a0

W1

a6

N

5 6

7 8

3 4

1 2

442

cc0

a0

110

a3

35

a0

29

a2

28

Can

opy

Cub

icle

Alte

rnat

orC

ubic

le

T8

T5

see note

T10T7

T4T1

T11T8

T5T2

T12T9

T6T3

T10T7

T4T1

T11T8

T5T2

T12T9

T6T3

PMG

5+(field)

6-(field)

T2

T5 T3T12T11T10T514

16T2

15

FrequencySelection

110V

X2

VoltageAdjustm.ST4

50Hz 60Hz

X1

Z2

E+

E-

0V

bx0

109

bx0

105

a0

106

3 4

1 2

A2

A1

1L31L2

jx0jx0jx0

1L1

h54PEjx6NL3L2

jx0jx0jx0

L1

6 5

4 3

2 1

NW1

V1

U1

X0 X0 X0 X6 Z54

PE

K13

F6 Q1S2b

2,3A

F6

T3T2T1

F3

F2

F1

X7

R5S10

G3N12

F5

F4

K13

K13

Q

R12

9822 0993 80/01

Applicable for QAS 600 - Qc1002™, Power Circuit

P Q R S T U V W X Y

PE N

f64

c0

1L2

c0

1

2

N

c54 c6

6L2

c0

1L1c0

1

2

N

c54 c6

5L1

20A

Q6

X6

20A

Q5

X5

- 53 -

A B C D E F G H I J K L MN O

a3

103

a6

12

a6

12

2,3

OFF0,11040,86 x Io1,00 x In1375QAS600

s1

s2SHT

5

6

3

4

1

2

PEZ5

4N

lx6

L3lx

0L2

lx0

L1lx

0

10L3

lx0

10L2

lx0

10L1

lx0

s1

s2SHT

5

6

3

4

1

2

s1

s2SHT

5

6

3

4

1

2

s1

s2SHT

5

6

3

4

1

2

PEZ5

4N

lx6

L3lx

0L2

lx0

L1lx

0

PEZ5

4N

lx6

L3lx

0L2

lx0

L1lx

0

9L3

lx0

9L2

lx0

9L1

lx0

8L3

lx0

8L2

lx0

8L1

lx0

7L3

lx0

7L2

lx0

7L1

lx0

PEZ5

4N

lx6

L3lx

0L2

lx0

L1lx

0

PEPE

3

4

1

2

f0f0

f5

4L2

1L2

f0f0

4L3

1L3

3

4

1

2

f0f0N

f6f54

3L3

1L3

f0f0

3L1

1L1

3

4

1

2

f0f0

Nf6f54

2L1

1L1

f0f0

2L2

1L2

Y0L1

Y0

L2

Y0

L3

Y6

N

Z54

F6

I t²T2T1I2=I3I1IoQ1Breaker Set.

(O)

400AQ15

PEL1 L2 L3 NX15

400AQ12

400AQ13

400AQ14

PEL1 L2 L3 NX14

PEL1 L2 L3 NX13

PEL1 L2 L3 NX12

50A

Q4

X4

50A

Q3

X3

50A

Q2

X2

PE

X1

L1 L2 L3 N

- 54 -

F1-5 Fuses 4A X4 Socket outletF6 Thermal overload relay X5 Socket outletG3 Alternator X6 Socket outletK13 Contactor X7 Flanged inletN12 Automatic voltage regulator X9 Terminal stripQ1 Circuit breaker - 3p X10 Terminal stripQ2 Circuit breaker - 2p X12 Camlock outlet socketQ3 Circuit breaker - 2p X13 Camlock outlet socketQ4 Circuit breaker - 2p X14 Camlock outlet socketQ5 Circuit breaker - 1p X15 Camlock outlet socketQ6 Circuit breaker - 1p X25 Terminal stripQ12 Circuit breaker - 3p Sx Remote start/stopQ13 Circuit breaker - 3p Kx Contactor generator readyQ14 Circuit breaker - 3p (15s. delayed)Q15 Circuit breaker - 3p (O) Optional equipmentR5 Coolant heaterR12 Voltage adjustment potmeterS2b Emergency stop

(S2a, see Engine Circuit)S10 Supply voltage switchT1-3 Current transformerX1 Terminal boardX2 Socket outletX3 Socket outlet

- 55 -

Following documents are provided with this unit:

– Test Certificate

– EC Declaration of Conformity:

Atlas Copco Airpower n.v. A company within the Atlas Copco Group

Postal address Visitors address Phone: +32 (0)3 870 21 11 Com. Reg. Antwerp 44651P.O. Box 100 Boomsesteenweg 957 Fax: +32 (0)3 870 24 43 V.A.T. 403.992.231B-2610 Wilrijk-Antwerp B-2610 Wilrijk-AntwerpBelgium Belgium For info, please contact your local Atlas Copco representativewww.atlascopco.com

p.1(2)

Form

500

906

0301

ed. 0

6,20

10-0

1-01

1

2

EC DECLARATION OF CONFORMITYWe, Atlas Copco Airpower n.v., declare under our sole responsibility, that the product

3 Machine name : Power generator ( 400 kW)4 Machine type :5 Serial number :

6

7

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

Att�mnt

b. Machinery safety 2006/42/ECEN ISO 12100-1EN ISO 12100-2

EN 1012-1

d. Electromagnetic compatibility 2004/108/EC EN 61000-6-2EN 61000-6-4

e. Low voltage equipment 2006/95/ECEN 60034

EN 60204-1EN 60439

f. Outdoor noise emission 2000/14/EC ISO 3744 x

8.a The harmonized and the technical standards used are identified in the attachments hereafter8.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 Date

- 56 -

– Outdoor Noise EmissionDirective 2000/14/EC

Atlas Copco Airpower n.v. A company within the Atlas Copco Group

Postal address Visitors address Phone: +32 (0)3 870 21 11 Com. Reg. Antwerp 44651P.O. Box 100 Boomsesteenweg 957 Fax: +32 (0)3 870 24 43 V.A.T. 403.992.231B-2610 Wilrijk-Antwerp B-2610 Wilrijk-AntwerpBelgium Belgium For info, please contact your local Atlas Copco representativewww.atlascopco.com

p.2(2)

Form

500

906

0301

ed. 0

6,20

10-0

1-01

Outdoor Noise Emission Directive 2000/14/EC

1. Conformity assessment procedure followed : Internal control of production

2. Name and address of the notified body : Notified body number 0088

3. Measured sound power level :

Lloyd�s Register Quality Assurance,71, Fenchurch street,EC3M �4 BF, LondonUnited Kingdom

4. Guaranteed sound power level : dB(A)

dB(A)

Pri

nte

d in

Bel

giu

m 0

3/2

01

0 -

29

54

46

50

00

www.atlascopco.com

2954 4650 00_qas 600_en

Documents

volvoinstruction manual

engine maintenance

maintenance schedule

atlas copco airpower

portable generators

liability limitationuse

product liability

atlas copcoreserves