QAS 150-200 CudQAS 170-220 Cud

Instruction Manual for AC Generators English

TLAS COPCO - PORTABLE AIR DIVISIONwww.atlascopco.com

Printed matter N°1092 5230 00

12/2011

QAS 150-200 CudQAS 170-220 CudInstruction Manual for AC Generators

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

Circuit diagrams ....................................................................................73

A

Warranty and Liability Limitation

Use only authorized parts. Any damage or malfunction caused b yWarranty or Product Liability.The manufacturer does not accept any s,additions or conversions made without Neglecting maintenance or making cha orhazards, including fire risk.While every effort has been made to e t,Atlas Copco does not assume responsib

Copyright 2011, Atlas Copco

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 modificationthe manufacturer's approval in writing.nges to the setup of the machine can result in maj

nsure that the information in this manual is correcility for possible errors.

contents or any part thereof is prohibited. model denominations, part numbers and drawings.

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Options available for QAS 150-200 and

QAS 170-220 units ......................................52Circuit diagrams......................................52Overview of the electrical options.........52Description of the electrical options .....53Overview of the mechanical options ....58Description of the mechanical options .58

Technical specifications .............................60Technical specifications for QAS 150/170 units ..................................60Technical specifications for QAS 200/220 units ..................................65Conversion list of SI units into British units .............................................70Dataplate .................................................70

Disposal ........................................................71

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 .....................16Control and indicator panel Qc1002™..17Control and indicator panel Qc2002™..24Output terminal board ...........................36Spillage free ............................................36

Operating instructions...............................37Installation...............................................37Connecting the generator ......................37Before starting ........................................39Operating Qc1002™ ...............................39Operating Qc2002™ ...............................40

Maintenance ................................................4Maintenance schedule ...........................4Engine maintenance...............................4(*) Measuring the alternator insulation resistance...............................4Engine fuel specifications ......................4Engine oil specifications ........................4Engine oil level check.............................4Engine oil and oil filter change..............4Engine coolant specifications ................4Coolant check..........................................4

Storage of the generator ...........................4Storage ....................................................4Preparing for operation after storage ...4

Checks and trouble shooting....................4Checking voltmeter P4 ...........................4Checking ammeters P1, P2 and P3........4Alternator troubleshooting ....................4Engine trouble shooting.........................5

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.

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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 unDisconnect in the reverse order.

lectricity is available or as stand-by in cases of interruptiont 60 Hz, 480 V-3 phase/220 V-3 phase lower voltage. The parts is given in the diagram below.

Lifting beamGuiding rodSide doorsEngine exhaustData plateSide door, access to control and indicator panelOutput terminal boardEarthing rod

H Drain and access hole (in the frame)F Filler cap fuelW Filler cap cooling water

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Leading particulars

General description

The QAS 150-200 Cud/QAS 170-220 Cud is an AC generator, built for continuous running at sites where no eof the mains. The QAS 150-200 Cud operates at 50 Hz, 400 V-3 phase. The QAS 170-220 Cud operates agenerator is driven by a Parcool-cooled diesel engine, manufactured by CUMMINS. An overview of the main

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AlternatorF Air filterS Battery switch

CouplingF Coolant filterFO Drain flexible engine oilH Drain and access hole (in the frame)PF Drain plug fuel

EngineEO Engine exhaust outlet

FanF Filler cap fuelO Filler cap engine oilW Filler cap coolant1 Fuel filter2 Fuel filter (secondary) with water separator

1 BatteryIntercooler (only for QAS 200/220 Cud)

F Oil filterLD Engine oil level dipstick

RadiatorStart motor

I Vacuum indicator

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Indicates the drain for the coolant.

Indicates the drain plug for the engine fuel.

Use PAROIL E only.

Indicates the different earthing connections on the generator.

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.

Read the instruction manual before using the lifting eye.

Indicates the 3-way valve.

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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 access to lift the generator by meansof crane is integrated in the bodywork and easilyaccessible from outside.

The earthing rod, connected to the generator’s earthterminal is located at the bottom of the frame fromoutside.

Markings

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

This symbol indicates the presence ofelectric shock hazards. Enclosures marked with these symbols should only be opened by trained or instructedpeople.

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.

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

Indicates the drain for the engine oil.

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Drain plugs and filler caps

The drain holes for the engine oil, the coolant and thplug for the fuel, are located and labelled on thframe. The fuel drain plugs are located; one at thbottom of the frame and the other at the cubicle sidof the frame.

The drain flexible for engine oil can be brought to thoutside of the generator through the drain hole.

The filler cap for the engine coolant is accessible van opening in the roof. The fuel filler cap is located ithe side panel.

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

QAS 150 Cud, QAS 200 Cud, QAS 220 Cud

Every 250h (Yearly)

QAS 170 Cud

xxxx xxxx xxEvery 1000h xxxx xxxx xx

Engine oil PAROIL E PAROIL Extra

Engine coolant Parcool EG

5 l (1.3 US gal) xxxx xxxx xx xxxx xxxx xx

20 l (5 US gal) xxxx xxxx xx xxxx xxxx xx

210 l (55 US gal) xxxx xxxx xx

5 l (1.3 US gal) xxxx xxxx xx

20 l (5 US gal)

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210 l (55 US gal) xxxx xxxx xx

The drain hole can also be used toguide external fueltank connectionsWhen connecting an externafueltank, use the 3-way valves. Referto External fueltank connection (withwithout quick couplings).

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Qc1002™ Module

The Qc1002™ module is located inside the controlpanel. This control module will carry out allnecessary tasks to control and protect a generator,regardless of the use of the generator.This means that the Qc1002™ module can be used forseveral applications.

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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 thbattery to the engine control circuit exceedits setting. The fuse can be reset by pushinthe button.

S2 .......Emergency stop button

Push the button to stop the generator in casof an emergency. When the button pressed, it must be unlocked, before thgenerator can be restarted. The emergencstop button can be secured in the lockeposition with the key, to avoid unauthorizeuse.

S20 .....ON/OFF/REMOTE switch

To start up the unit (locally or remote).

X25 .....Terminal strip

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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• 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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Pushbutton and LED functions

Following pushbuttons are used on the Qc1002™

Following LEDs 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.

Power Green LED indicates that the unit is powered up.

Remote Green LED indicates that the RemoteMode is selected.

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.

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Battery Voltage display

This view shows the Battery voltage and the runninghours.

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.

13.2 VBattery00168.1h

62˚CWater00168.1h

3.2barOil00168.1h

- 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 andgives access to them.An overview is given in “Alarm Display (pop-upwindow)” on page 22.

LOG list display

This view shows the alarm memory and gives accesto it.An overview is given in “LOG list” on page 23.

Service timer 1 & Service timer 2 display

This view shows both Service timers. The servictimer indication is shown when service time has ruout. It can be removed by resetting the timers oacknowledging the Service timer indication.The service timer indications count and give an alarmwhen value is reached.Resetting the Service Timers can be done through thParameter display.

Qc1002v1.00.0

Parameter

Alarm List0 Alarm(s)

LOG List

Service 1Service 2

59h59h

ws

s

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

DIAGNOSTIC

- 20 -

Fuel level display

This view shows the Fuel level and the running hours.

Voltage - frequency - running hours display

This view shows the voltage, frequency and runninghours.

Qc1002™ Menu Description

Status Display (pop-up window)

In case special statuses are entered, a pop-up windowill automatically be entered for as long as the statuis active.The background screen is not updated when the statupop-up window is active.

These special statuses are:

75%Fuel00168.1h

50Hz400V00168.1h

PREHEAT

START OFF/EXTENDED STOP TIMER

COOLDOWN

e

6h,).is

e,

,

y,

y,

's

e

- 21 -

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 raised, notlowered.

– 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 engineelectronics without starting the engine. When thissetting is switched on, electric power will besupplied to the engine electronics after half aminute delay. The unit can not be started as longas 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, FrencGerman, Italian, Spanish and Cyrillic (RussianAll information in the Parameter List display always in English.

– Generator Underfrequency: failclass, enabldelay, setpoint

– Generator Overfrequency: failclass, enable, delaysetpoint

– Generator Undervoltage: failclass, enable, delasetpoint

– Generator Overvoltage: failclass, enable, delasetpoint

It's possible to scroll between configuration menuby using the pushbuttons UP and DOWN.

Pushing the ENTER button activates thconfiguration menu which is shown at the display.

:

pis

r

s

s

LOW FUEL LEVEL

LOW COOLANT LEVEL

GENERATOR OVERVOLTAGE

GENERATOR UNDER-VOLTAGE

GENERATOR OVER-FREQUENCY

GENERATOR UNDER-FREQUENCY

- 22 -

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 by pushing theBACK 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

s.

e

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).

- 23 -

LOG list

The unit will keep an event log of the latest 30 event

Events are:

– shutdowns

– service timer 1/2 reset

– unit type changesTogether with each event, the running hours at thtime of the event will be stored.

SERVICE TIMER 1

SERVICE TIMER 2

ENGINE ALARM

EMERGENCY STOP

START FAILURE

STOP FAILURE

1 Controller type2 Event number3 Event4 Running hours

Time: 00001h

EVENT LOG #04 WaterQc1002

1

3

4

2

esg

et

ep

Qc2002™ Module

The Qc2002™ module is located inside the controlpanel. This control module will carry out allnecessary tasks to control and protect a generator,regardless of the use of the generator.This means that the Qc2002™ module can be used forseveral applications.

- 24 -

Control and indicator panel

Qc2002™

General description Qc2002™ control panel

A1 .......Qc2002™ display

F10......Fuse

The fuse activates when the current from thbattery to the engine control circuit exceedits setting. The fuse can be reset by pushinthe button.

S20 .....ON/OFF switch

Position O: No voltage is applied to thQc2002™ module, the generator will nostart.Position I: Voltage is applied to thQc2002™ module, it is possible to start uthe generator.

X25 .....Terminal strip

G

X25

S20

F10

A1

S2

S4

Following LEDs are used on the Qc2002™

Power Green LED indicates that the unit is powered up.

Automatic Green LED indicates that the Qc2002™ is in automatic operation.

Start/Stop Green LED indicates that the Qc2002™ receives running feedback (via the W/L input, via the RPM value at the Canbus, or via the AC frequency).

Generator contactor

Green LED indicates that the voltage and the frequency of the alternator are within certain limits for a certain time. It will be possible to close the Generator Contactor (both in Island and in AMF mode), if the Mains contactor is open.

Qc2002145

G

Power

AlarmStart

Automatic

GeneratorContactor

MainsContactor

Stop

- 25 -

Pushbutton and LED functions

Following pushbuttons are used on the Qc2002™

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.

AUTOMATIC: Is used to put the unit in manual or automatic operation.

START: Is used to start the unit in manual operation.

STOP: Is used to stop the unit in manual or automatic operation (without cooldown). When the unit is stopped with the STOP button in automatic operation, it will automatically go to manual operation.

MAINS CONTACTOR: Is used to open or close the Mains contactor, if the Qc2002™ is in manual operation.

.

GENERATOR CONTACTOR: Is used to open or close the Generator contactor, if the Qc2002™ is in manual operation

G

g

e

dy

r

f

e

– 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.

Line voltages generator display

This view shows the line voltages of the generator.

Controller type and version display

This view shows the controller type and the ASWversion number.

G L1-L2G L2-L3G L3-L1

400V400V400V

Qc20021.00.1

- 26 -

Qc2002™ Menu Overview

At Qc2002™, the LCD will show followininformation:

– in Normal condition (scroll through thinformation using UP and DOWN):• Status (eg: preheat, crank, cooldown, extende

stop time, …) (pop-up: this display is onlshown when a Special status comes up)

• Line voltages of the generator• Controller type & version• Parameter list• Alarm list• LOG list• Service Timer 1 & Service Timer 2• Battery Voltage• RPM (speed)• Coolant temperature• Oil pressure• Fuel level• kWh counter• Power factor, the frequency of the generato

and the frequency of the mains • Line voltage, frequency and active power o

the generator• Active, reactive and apparent power of th

generator• Generator currents• Phase voltages of the mains• Line voltages of the mains• Phase voltages of the generator

Mains contactor

Green LED indicates that it is possible to close the Mains Contactor (only in AMF mode), if the Generator contactor is open.

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

enr

d.e

g

RPM display

This view shows the Battery voltage and the runninghours.

Coolant temperature display

This view shows the Coolant temperature and therunning hours.See also “Parameter list” on page 29 for selectionbetween °C and °F.

Oil pressure display

This view shows the Oil pressure and the runninghours.See also “Parameter list” on page 29 for selectionbetween bar and psi.

0RPM00168.1h

62˚CWater00168.1h

3.2barOil00168.1h

- 27 -

Parameter display

This view shows a number of Parameter settings andgives access to them.An overview is given in “Parameter list” on page 29.

Alarm list display

This view shows the number of active alarms andgives access to them.An overview is given in “Alarm Display (pop-upwindow)” on page 34.

LOG list display

This view shows the alarm memory and gives accessto it.An overview is given in “LOG list” on page 35.

Service timer 1 & Service timer 2 display

This view shows both Service timers. The servictimer indication is shown when service time has ruout. It can be removed by resetting the timers oacknowledging the Service timer indication.

The service timer indications count downwards angive an alarm when the set value 0 (zero) is reachedResetting the Service Timers can be done through thParameter display.

Battery voltage display

This view shows the Battery voltage and the runninhours.

Parameter

Alarm List0 Alarm(s)

LOG List

Service 1Service 2

59h59h

13.2 VBattery00168.1h

d

t

Phase voltages mains display

This view shows the phase voltages of the mains (isonly shown in AMF mode).

Line voltages mains display

This view shows the line voltages of the mains (isonly shown in AMF mode).

Phase voltages generator display

This view shows the phase voltages of the generator.

M L1-NM L2-NM L3-N

230V230V230V

M L1-L2M L2-L3M L3-L1

400V400V400V

G L1-NG L2-NG L3-N

230V230V230V

- 28 -

Fuel level display

This view shows the Fuel level and the running hours.

kWh counter display

This view shows the kWh counter.

Power factor - frequency generator - frequency mains display

This view shows the PF, the frequency of thegenerator and the frequency of the mains (M f L1:only in AMF mode).

One line voltage - frequency - active power display

This view shows one line voltage, frequency anactive power of the generator.

Active - reactive - apparent power display

This view shows the active, reactive and apparenpower of the generator.

Generator current display

This view shows the generator current.

75%Fuel00168.1h

E 4860kWh

PFG f L1M f L1

0.0050Hz50Hz

G L1-L2G f L1P

400V50Hz80kW

PQS

80kW0kVAr80kVA

G I1G I2G I3

100A100A100A

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Parameter list

The Parameter Menu's are pre-programmed !

A password will be asked for when an attempt tochange a setting is about to be done (user password =2003).By entering the parameter list, pushbuttonAUTOMATIC is disposed of its normal operationsand will not perform any functionality.

It's possible to scroll between configuration menu'sby using the pushbuttons UP and DOWN.Pushing the ENTER button activates theconfiguration menu which is shown at the display.Menu's shown on the Parameter list LCD:

Genset mode

This menu is used to change the mode of the machine.In the Qc2002™ module 2 application modes can beselected:

Genset ModeIsland Island AMF

- 29 -

Qc2002™ Menu Description

Status Display (pop-up window)

In case special statuses are entered, a pop-up windowwill automatically be entered for as long as the statusis active.The background screen is not updated when the statuspop-up window is active.

These special statuses are:

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

PREHEAT

START OFF/EXTENDED STOP TIMER

COOLDOWN

DIAGNOSTIC

nnT

/e

dde

d

eetd

Running hours adjust

This menu is used to adjust the amount of runninghours. The running hours can only be raised, notlowered.

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.

Running TimeCur. 168 20000

St 2 ResetNo No Yes

St 1 ResetNo No Yes

- 30 -

Island operation

– This operation type is selected for local/remotestart applications, without the Mains (= stand-alone).• Combined with Manual Operation mode =

Local Start operation.• The sequences start/stop/close Generator

Contactor/open Generator Contactor can beactivated manually.

• Combined with Automatic Operation mode =Remote Start operation.

– The remote start signal can be given with anexternal switch. After the generator has beenstarted, the Generator Contactor will closeautomatically.

– Installation wirings for Remote Start operation:wire the RS switch between X25.9 & X25.10.

Automatic Mains Failure (AMF) operation

– This application is only possible in combinatiowith the Auto mode. If the Manual Operatiomode is selected the AMF operation will NOfunction !

– When the Mains exceeds the defined voltagefrequency limits for a defined delay time, thgenerator will take over the load automatically.

– When the mains is restored within the definelimits for a defined time, the generator will unloabefore disconnecting and switching back to thMains.

– The generator will then go into cooldown anstop.

– Installation wirings: we refer to circuit diagram9829 3006 40/00 for the correct connections.

Horn delay

This menu is used to set the delay, how long thgeneral alarm relay stays energized (if present). If sto 0.0s, the general alarm relay will stay energizecontinuously.

Horn Delay0.0s 20.0s 990.0s

rn,lln

en

en

M frequency delay

This menu is used to set the delay, which defines howlong the mains frequency has to be back within thelimits before there will be switched from generator tomains again (in AMF-Auto). During this delay, theMains LED flashes in green.

MF frequency delay

This menu is used to set the delay, which defines howlong the mains frequency may be above the max limitor below the min limit before there will be switchedfrom mains to generator (in AMF-Auto). During thisdelay, the Mains LED flashes in red.

M freq delay10s 30 9900s

MF freq delay1.0s 2.0 990.0s

- 31 -

Diagnostic menu

This menu is used to power up the engine electronicswithout starting the engine. When this setting isswitched on, electric power will be supplied to theengine electronics after half a minute delay. The unitcan not be started as long as this parameter is swichedon.

Unit menu

This menu is used to select the units into whichpressures and temperatures will be shown.

Language selection

Icons is the default factory set language, but 6 othelanguages can be selected: English, French, GermaItalian, Spanish and Cyrillic (Russian). Ainformation in the Parameter List display is always iEnglish.

MF high frequency

This menu is used to set the maximum limit for thmains frequency, in % of the nominal frequency (iAMF-Auto).

MF low frequency

This menu is used to set the minimum limit for thmains frequency, in % of the nominal frequency (iAMF-Auto).

DiagnosticsOff Off On

UnitC/bar C/bar F/psi

LanguageEnglish

MF high freq100% 110 120%

MF low freq80% 90 100%

wrdis

Overvoltage delay

Overvoltage setpoint

Undervoltage enable

Undervoltage failclass

> Volt Delay0 1 99

> Volt SP0 450 999

< Volt enableEnable enable disable

< Volt FCwarning warning shutdown

- 32 -

MF high voltage

This menu is used to set the maximum limit for themains voltage, in % of the nominal voltage (in AMF-Auto).

MF low voltage

This menu is used to set the minimum limit for themains voltage, in % of the nominal voltage (in AMF-Auto).

M voltage delay

This menu is used to set the delay, which defines howlong the mains voltage has to be back within the limitsbefore there will be switched from generator to mainsagain (in AMF-Auto). During this delay, the MainsLED flashes in green.

MF voltage delay

This menu is used to set the delay, which defines holong the mains voltage may be above the max limit obelow the min limit before there will be switchefrom mains to generator (in AMF-Auto). During thdelay, the Mains LED flashes in red.

Overvoltage enable

Overvoltage failclass

MF high volt100% 110 120%

MF low volt80% 90 100%

M volt delay10s 30 9900s

MF volt delay1.0s 2.0 990.0s

> Volt enableEnable enable disable

> Volt FCwarning warning shutdown

Underfrequency delay

Underfrequency setpoint

< Freq Delay0 1 99

< Freq SP0 38 70

- 33 -

Undervoltage delay

Undervoltage setpoint

Overfrequency enable

Overfrequency failclass

Overfrequency delay

Overfrequency setpoint

Underfrequency enable

Underfrequency failclass

< Volt Delay0 1 99

< Volt SP0 450 999

> Freq enableEnable enable disable

> Freq FCwarning warning shutdown

> Freq Delay0 1 99

> Freq SP0 38 70

< Freq enableEnable enable disable

< Freq FCwarning warning shutdown

:

pis

r

s

s

LOW FUEL LEVEL

LOW COOLANT LEVEL

GENERATOR OVERVOLTAGE

GENERATOR UNDER-VOLTAGE

GENERATOR OVER-FREQUENCY

GENERATOR UNDER-FREQUENCY

- 34 -

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 by pushing theBACK 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

LOG list

The unit will keep an event log of the latest 30 events.

Events are:

– shutdowns

– service timer 1/2 resetTogether with each event, the real time of the eventwill be stored.

1 Controller type2 Event number3 Event4 Date and hour of the event

Time: 27/6 14:27

EVENT LOG #04 WaterQc2002

4

1

3

2

- 35 -

SERVICE TIMER 1

SERVICE TIMER 2

ENGINE ALARM

EMERGENCY STOP

START FAILURE

STOP FAILURE

HZ/V FAILURE

OIL LEVEL

OIL TEMPERATURE

e

eisitee

y,

Q1 .......Main circuit breaker

Interrupts the power supply to X1 when ashort-circuit occurs at the load side, or whenthe earth leak detector (30 mA) or theovercurrent protection (QAS 150: 216A,QAS 170: 205A, QAS 200: 289A,QAS 220: 265A) is activated or when theshunt trip is energized. It must be resetmanually after eliminating the problem.

X1 .......Main power supply (400 V AC)

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

Spillage free

A Spillage free skid avoids accidental spilling ofengine fluids.

- 36 -

Fail classes

All the activated alarms of the Qc2002™ 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).

Output terminal board

The output terminal board option is situated below thcontrol and indicator panel.

S2 .......Emergency stop button

Push the button to stop the generator in casof an emergency. When the button pressed, it must be unlocked, by turning anti-clockwise, before the generator can brestarted. The emergency stop button can bsecured in the locked position with the keto avoid unauthorized use.

X1

Q1

S2

d

rsdrs

ddtee,

d

n

rr

– Check the tightness of the bolts and nuts.

– Install the earthing rod as near as possible to thegenerator and make sure not to have a contactvoltage higher than 25 V.

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

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.

!

- 37 -

Operating instructions

Installation

– Place the generator on a horizontal, even and solifloor.

– The generator should be kept with the dooclosed, in order to avoid the ingress of water andust. Dust ingress reduces the lifetime of filteand 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.

In your own interest, always strictlyobserve all relevant safetyinstructions.Do not operate the generator inexcess of the limitations mentionedin the Technical Specifications.Local rules concerning the settingup of low voltage power installations(below 1000 V) must be respectedwhen connecting site distributionpanels, switch gear or loads to thegenerator.At each start-up and at any time anew load is connected, the earthingof the generator must be verified.Earthing must be done either by theearthing rod or, if available, by anexisting, suitable earthinginstallation. The protective systemagainst excessive contact voltage isnot effective unless a suitableearthing is made.The generator is wired for a TN-system to IEC 364-3, i.e. one point inthe power source directly earthed -in this case the neutral. The exposedconductive parts of the electricinstallation must be directlyconnected to the functional earth.

!

If operating the generator inanother power system, e.g. an IT-system, other protective devicesrequired for these types must beinstalled. In any case only aqualified electrician is authorized toremove the connection between theneutral (N) and earth terminals inthe terminal box of the alternator.

eht

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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.

!

- 38 -

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 curren(20 A), for a voltage drop e lower than 5% and atpower factor of 0.80, are respectively 2.5 mm² an144 m. In case electric motors must be startedoversizing the cable 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

2.5 22 25 214 30 33 286 38 42 3610 53 57 5016 71 76 6725 94 101 8835 114 123 11050 138 155 13870 176 191 17095 212 228 205

e 3 I L R cos X sin+ 1000

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During operation Qc1002™

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.

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

!

!

- 39 -

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

– Check that the load is switched off.

– Check that circuit breaker Q1 is switched off.

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

Operating Qc1002™

Starting Qc1002™

To start up the unit locally, proceed as follows:

– Switch on the battery switch, if applicable.

– 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 (ON). Thunit starts a preheating cycle which takes 1seconds.

– After the preheating period, the unit will start. Thstarting attempt will take maximum 12 seconds.

– Switch on circuit breaker Q1.

To start up the unit from a remote location, proceed as follows:

– Put the starter switch S20 in position .

– Switch on circuit breaker Q1.

– Put the remote start/stop switch in position starThe unit starts a preheating cycle which takes 1seconds.

– After the preheating period, the unit will start. Thstarting attempt will take maximum 12 seconds.

– An external contactor can be connected ancontrolled by the Qc1002™.

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To start up the unit from a remote location, proceed as follows:

– Put the starter switch S20 in position I (ON).Voltage is applied to the Qc2002™ module.

– Switch on circuit breaker Q1.

– For remote start: • Put the unit in Island mode. Push the

AUTOMATIC button. Use an external switchto start the machine.

or• Put the unit in AMF mode. Push the

AUTOMATIC button. The machine will startautomatically when Mains fails.

– The unit starts a preheating cycle which takes 12seconds.

– After the preheating period, the unit will start. Thestarting attempt will take maximum 12 seconds.

- 40 -

Stopping Qc1002™

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 putting the starter switch S20in position O.

– 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 as follows:

– Switch off the load.

– Stop the engine by putting the remote start/stopswitch in position stop or by putting the starterswitch S20 in position O.

– Cooldown period default 15 sec.

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

Operating Qc2002™

Starting Qc2002™

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 Qc2002™ module.

– The unit can be started manually by pressing thSTART button on the Qc2002™ module.

– The unit starts a preheating cycle which takes 1seconds.

– After the preheating period, the unit will start. Thstarting attempt will take maximum 12 seconds.

– Switch on circuit breaker Q1 in case no contactois installed.

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– Cooldown period default 15 sec.

– Put the starter switch S20 in position O (OFF) toshut down the voltage apply towards theQc2002™ module.

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

- 41 -

During operation Qc2002™

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.

Stopping Qc2002™

To stop the unit , 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 thQc2002™ module.

– Put the starter switch S20 in position O (OFF) tshut down the voltage apply towards thQc2002™ module.

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

To stop the unit when the Qc2002™ module is in AUTOMATIC operation mode, proceed as follows:

– Switch off the load.

– For remote start: • When operating in Island mode, use th

external switch to stop the machine.• When operating in AMF mode, the machin

will automatically stop when the Mainreturns.

Avoid to let the engine run out offuel. If it happened, priming willspeed up the starting.

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

!

!When the unit is stopped with theSTOP button in Automaticoperation, it will automatically go toManual Mode.

!

that no electrical power is present on the terminals.

very 250 hours or yearly

Every 1000 hours or 24 months

3002 6070 20 3002 6070 30

hese service kits offer you the benefits of genuine parts, e parts list for more information on the contents of the

x x

x x

x x

x x

x x

x x

x x

x x

x x

x x

x x

x x

x x

x x

- 42 -

Maintenance

Maintenance schedule

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

Maintenance schedule DailyE

Service pak -

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

Check for air, fuel, coolant and oil leakage x

Check oil and coolant level x

Check or drain water in fuelfilter x

Clean air cleaner and dust bowl x

Check/clean externally coolers x

Check tension and condition of the drive belt x

Check condition of cooling fan assembly x

Replace engine oil

Replace engine oil filter

Grease door hinges and locks

Replace fuel filter element

Replace fuel-water separator

Replace coolant filter

Check electrolyte level and terminals of battery

ator on a regular basis.

x x

x x

x x

x x

x x

x x

x x

x

x

x

erators in standby application have to be tested on alar basis. At least once a month the engine should run

minimum 30 minutes at a high load (50%-70%) thatengine reaches its operating temperature.

- 43 -

Notes:

In highly dusty environments, these service intervals do not apply. Check and/or replace filters and clean radi

(1) Change coolant every 5 years.

Check fixation of hoses, cables and pipes

Grease mechanical links

Check condition of vibration dampers

Replace air filter element

Measure alternator insulation resistance

Check glycol level in coolant (1)

Check PH level of engine coolant (1)

Check and adjust engine inlet and outlet valves

Check alternator and starter motor

Check electrical system for security of cables and wear

Inspection by Atlas Copco Service technician

Genregufor the

!

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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.

- 44 -

Engine maintenance

Refer to the engine’s operator manual for fullmaintenance, including instructions for changing theoil and coolant and replacing the fuel, oil and airfilters.

(*) Measuring the alternator

insulation resistance

A 500 V megger is required to measure the alternatorinsulation resistance.If the N-terminal is connected to the earthing system,it must be disconnected from the earth terminal.Disconnect the AVR.Connect the megger between the earth terminal andterminal L1 and generate a voltage of 500 V. Thescale must indicate a resistance of at least 5 M.Refer to the alternator operating and maintenanceinstructions for more details.

Engine fuel specifications

For fuel specifications, please contact your AtlasCopco Customer Center.

Engine oil specifications

High-quality, mineral, hydraulic or synthesizehydrocarbon oil with rust and oxidation inhibitoranti-foam and anti-wear properties is recommendedThe viscosity grade should correspond to the ambientemperature and ISO 3448, as follows.

It is strongly recommended to useAtlas Copco branded lubrication oils.

Engine Type of lubricant

between -15°C (5°F) and 40°C (104°F) PAROIL E

between -25°C (-13°F) and 40°C (104°F) PAROIL Extra

Never mix synthetic with mineraloil.When changing from mineral tosynthetic oil (or the other wayaround), you will need to do anextra rinse.After doing the complete changeprocedure to synthetic oil, run theunit for a few minutes to allow goodand complete circulation of thesynthetic oil. Then drain thesynthetic oil again and fill againwith new synthetic oil. To set correctoil levels, proceed as in normalinstruction.

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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 (41°F). If the coolantfreezes, it may crack the cylinder block, radiator orcoolant pump.Consult the engine's operation manual and follow themanufacturer's directions.

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.

!

!

- 45 -

PAROIL is optimized for the latest low emissionEURO -3 & -2, EPA TIER II & III engines running onlow sulphur diesel for lower oil and fuel consumption.

PAROIL Extra and PAROIL E

Synthetic engine oil PAROIL Extra

PAROIL Extra is a Synthetic ultra high performancediesel engine oil with a high viscosity- index. AtlasCopco PAROIL Extra is designed to provideexcellent lubrication from start-up in temperatures aslow as -25°C.

Mineral engine oil PAROIL E

PAROIL E is a mineral based high performancediesel engine oil with a high viscosity- index. AtlasCopco PAROIL E is designed to provide a high levelof performance and protection in standard ambientconditions as from -15°C.

Engine oil level check

Consult the Engine Operation Manual for the ospecifications, viscosity recommendations and ochange intervals.For intervals, see section “Maintenance schedule” opage 42.Check engine oil level according to the instructions ithe Engine Operation Manual and if necessary top uwith oil.

Engine oil and oil filter change

See section “Maintenance schedule” on page 42.

Liter US gal

Imp gal cu.ft Order

number

can 5 1.3 1.1 0.175 1630 0135 00

can 20 5.3 4.4 0.7 1630 0136 00

Liter US gal

Imp gal cu.ft Order

number

can 5 1.3 1.1 0.175 1615 5953 00

can 20 5.3 4.4 0.7 1615 5954 00

barrel 210 55.2 46 7.35 1615 5955 00

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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.

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

!

- 46 -

Specifications PARCOOL EG

PARCOOL EG is the only coolant that has beentested and approved by all engine manufacturerscurrently in use in Atlas Copco compressors andgenerators.

Atlas Copco's PARCOOL EG extended life coolant isthe new range of organic coolants purpose designedto meet the needs of modern engines. PARCOOL EGcan help prevent leaks caused by corrosion.PARCOOL EG is also fully compatible with allsealants and gasket types developed to join differentmaterials used within an engine.PARCOOL EG is a ready to use Ethylene Glycolbased coolant, premixed in an optimum 50/50dilution ratio, for antifreeze protection guaranteed to-40°C (-40°F).Because PARCOOL EG inhibits corrosion, depositformation is minimized. This effectively eliminatesthe problem of restricted flow through the enginecoolant ducts and the radiator, minimizing the risk forengine overheating and possible failure.It reduces water pump seal wear and has excellentstability when subjected to sustained high operatingtemperatures.PARCOOL EG is free of nitride and amines to protectyour health and the environment. Longer service lifereduces the amount of coolant produced and needingdisposal to minimise environmental impact.

To ensure protection against corrosion, cavitation anformation of deposits, the concentration of thadditives in the coolant must be kept between certailimits, as stated by the manufacturer's guidelineTopping up the coolant with water only, changes thconcentration and is therefore not allowed.Liquid-cooled engines are factory-filled with thtype of coolant mixture.

Liter US gal

Imp gal cu.ft Order

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

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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.

- 47 -

Glycol concentration measurement

– To optimise the unique engine protection featuresof the PARCOOL EG the concentration of theGlycol in the water should be always above 33vol.%.

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

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

Topping up of coolant

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

– Check the condition of the coolant.

– If the condition of the coolant is outside the limits,the complete coolant should be replaced (seesection “Replacing the coolant”).

– Always top-up with PARCOOL EG.

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

Replacing the coolant

Drain

– Completely drain the entire cooling system.

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

Flush

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

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

– It should be clearly understood that the risk focontamination is reduced in case of propecleaning.

– In case a certain content of ‘other’ coolant remainin the system, the coolant with the loweproperties influences the quality of the ‘mixedcoolant.

Fill

– To assure proper operation and the release otrapped air, run the engine until normal enginoperation temperature is reached. Turn off thengine and allow to cool.

– Recheck coolant level and add if necessary.

In case of a mix of different coolantproducts this type of measurementmight provide incorrect values.

!

Checking voltmeter P4

– Put a voltmeter in parallel with voltmeter P4 onthe control panel.

– Check that the read-out of both voltmeters is thesame.

– Stop the generator and disconnect one terminal.

– Check that the internal resistance of the voltmeteris high.

Checking ammeters P1, P2 and P3

– Measure the outgoing current during the load, bymeans of a clamp-on probe.

– Compare the measured current with the currentindicated on ammeter. Both readings should bethe same.

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- 48 -

Preparing for operation after

storage

Before operating the generator again, remove thewrapping, VCI paper and silica gel bags and check thegenerator thoroughly (go through the checklist“Before starting” on page 39).

– Consult the engine’s operator manual.

– Check that the insulation resistance of thegenerator exceeds 5 M.

– Replace the fuel filter and fill the fuel tank. Ventthe fuel system.

– Reinstall and connect the battery, if necessaryafter being recharged.

– Submit the generator to a test run.

Checks and trouble shooting

Never perform a test run withconnected power cables. Never touchan electrical connector without avoltage check.When a failure occurs, always reporwhat you experienced before, duringand after the failure. Information withregard to the load (type, size, powefactor, etc.), vibrations, exhaust gacolour, insulation check, odoursoutput voltage, leaks and damagedparts, ambient temperature, daily andnormal maintenance and altitudemight be helpful to quickly locate thproblem. 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.

- 49 -

Alternator troubleshooting

Symptom Possible cause Corrective

Alternator gives 0 Volt Blown fuse. Replace fuseNo residual voltage. Excite the al

resistor in serespecting th

After being excited the alternator still gives 0 Volt.

Connections are interrupted. Check connewith values m

Low voltage at no load Voltage potentiometer out of setting. Reset voltagIntervention of protection. Check frequeWinding failure. Check windi

High voltage at no load Voltage potentiometer out of setting. Reset voltagFailed regulator. Substitute re

Lower than rated voltage at load Voltage potentiometer out of setting. Reset voltagIntervention by protection. Current too h

of rated spee

Failed regulator. Substitute reRotating bridge failure. Check diode

Higher than rated voltage at load Voltage potentiometer out of setting. Reset voltagFailed regulator. Substitute re

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

potentiomete

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– Incorrect valve tip clearances.

The pressure of the lubricating oil is too low

– Wrong grade of lubricating oil.

– Not enough lubricating oil in sump.

– Defective gauge.

– Dirty lubricating oil filter element.

High fuel consumption

– Restriction in air filter/cleaner or inductionsystem.

– Fault in atomisers or atomisers of an incorrecttype.

– Fault in cold start system.

– Wrong type or grade of fuel used.

– Restricted movement of engine speed control.

– Restriction in exhaust pipe.

– Engine temperature is too low.

– Incorrect valve tip clearances.

- 50 -

Engine trouble shooting

The table below gives an overview of the possibleengine problems and their possible causes.

The starter motor turns the engine too slowly

– Battery capacity too low.

– Bad electrical connection.

– Fault in starter motor.

– Wrong grade of lubricating oil.

The engine does not start or is difficult to start

– Starter motor turns engine too slowly.

– Fuel tank empty.

– Fault in fuel control solenoid.

– Restriction in a fuel pipe.

– Fault in fuel lift pump.

– Dirty fuel filter element.

– Air in fuel system.

– Fault in atomisers.

– Cold start system used incorrectly.

– Fault in cold start system.

– Restriction in fuel tank vent.

– Wrong type or grade of fuel used.

– Restriction in exhaust pipe.

Not enough power

– Restriction in a fuel pipe.

– Fault in fuel lift pump.

– Dirty fuel filter element.

– Restriction in air filter/cleaner or inductiosystem.

– Air in fuel system.

– Fault in atomisers or atomisers of an incorretype.

– Restriction in fuel tank vent.

– Wrong type or grade of fuel used.

– Restricted movement of engine speed control.

– Restriction in exhaust pipe.

– Engine temperature is too high.

– Engine temperature is too low.

Misfire

– Restriction in a fuel pipe.

– Fault in fuel lift pump.

– Dirty fuel filter element.

– Air in fuel system.

– Fault in atomisers or atomisers of an incorretype.

– Fault in cold start system.

– Engine temperature is too high.

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The pressure of the lubricating oil is too high

– Wrong grade of lubricating oil.

– Defective gauge.

The engine temperature is too high

– Restriction in air filter/cleaner or inductionsystem.

– Fault in atomisers or atomisers of an incorrecttype.

– Fault in cold start system.

– Restriction in exhaust pipe.

– Fan damaged.

– Too much lubricating oil in sump.

– Restriction in air or coolant passages of radiator.

– Insufficient coolant in system.

Crankcase pressure

– Restriction in breather pipe.

– Vacuum pipe leaks or fault in exhauster.

Bad compression

– Restriction in air filter/cleaner or inductionsystem.

– Incorrect valve tip clearances.

- 51 -

Black exhaust smoke

– Restriction in air filter/cleaner or inductionsystem.

– Fault in atomisers or atomisers of an incorrecttype.

– Fault in cold start system.

– Wrong type or grade of fuel used.

– Restriction in exhaust pipe.

– Engine temperature is too low.

– Incorrect valve tip clearances.

– Engine overload.

Blue or white exhaust smoke

– Wrong grade of lubricating oil.

– Fault in cold start system.

– Engine temperature is too low.

The engine knocks

– Fault in fuel lift pump.

– Fault in atomisers or atomisers of an incorrecttype.

– Fault in cold start system.

– Wrong type or grade of fuel used.

– Engine temperature is too high.

– Incorrect valve tip clearances.

The engine runs erratically

– Fault in fuel control.

– Restriction in a fuel pipe.

– Fault in fuel lift pump.

– Dirty fuel filter element.

– Restriction in air filter/cleaner or inductiosystem.

– Air in fuel system.

– Fault in atomisers or atomisers of an incorretype.

– Fault in cold start system.

– Restriction in fuel tank vent.

– Restricted movement of engine speed control.

– Engine temperature is too high.

– Incorrect valve tip clearances.

Vibration

– Fault in atomisers or atomisers of an incorretype.

– Restricted movement of engine speed control.

– Engine temperature is too high.

– Fan damaged.

– Fault in engine mounting or flywheel housing.

rd

Overview of the electrical options

The following electrical options are available for theQAS 150-200 and QAS 170-220 units:

– Automatic battery charger

– Battery switch

– Engine coolant heater

– Low voltage (LV)

– Electronic speed regulator

– Dual voltage (2V)

– Earth leakage relay

– IT-relay

– COSMOS™

- 52 -

The engine starts and stops

– Dirty fuel filter element.

– Restriction in air filter/cleaner or inductionsystem.

– Air in fuel system.

The engine shuts down after approx. 15 sec.

– Bad connection towards oil pressure switch/coolant temperature switch.

Options available for

QAS 150-200 and QAS 170-

220 units

Circuit diagrams

The engine control circuit diagrams and the powecircuit diagrams for the standard QAS 150-200 anQAS 170-220 units:

Power circuit

Unit CircuitQAS 150-200 Cud &QAS 170-220 Cud 9829 3000 28QAS 150-200 Cud &QAS 170-220 Cud - 2V NA

Controller circuit

Unit CircuitQAS 150-200 Cud &QAS 170-220 Cud Qc1002™ 9829 3006 39QAS 150-200 Cud &QAS 170-220 Cud Qc2002™ 9829 3006 40

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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.

Engine coolant heater

To make sure that the engine can start and accept loadimmediately, an external coolant heater (1000 W,240 V) is provided which keeps the enginetemperature between 38°C and 49°C.

Never turn the battery switch toOFF during operation.!

- 53 -

Description of the electrical

options

Automatic battery charger

The automatic battery charger charges the batterycompletely and is disconnected once the unit startsup.Besides the output terminals (secondsary side) theautomatic battery charger has a trim potentiometer forsetting of the output voltage. By means of an insulatedslotted screwdriver or adjusting pin the output voltagecan be set in the range 23.5-27.5 V.The LED on the front indicates that the unit isoperational.

Setting:

– Lower output voltage = Counterclockwisrotation

– Higher output voltage = Clockwise rotationTo use the batery charger:

– Provide the X25 connector, located at the side othe power cubicle, with external power to use thbattery charger.

The positioning of the componentsmentioned in the description of theQAS 150-200 and QAS 170-220options, may differ slightlydepending on the generator model.

!

DEIF-power in control

xxxx xxxx xxxxxxxxxx

xxxx

xxxxxxxx

xxxxxxxxxxxxxxx

xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx!

The automatic battery charger isstandard on units with Qc2002™controller.

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Dual voltage (2V)

The generator can run in two different modes:

3 phase, lower voltage

When using this selection, the generator provides a220 V output voltage.

3 phase, higher voltage

When using this selection, the generator provides a480 V output voltage.

The dual voltage option is onlyavailable on 60 Hz units withQc1002™ controller.

!

Q1.2Q1.1

- 54 -

Low voltage (LV)

The Low voltage option allows to run the unit at lowvoltage (= high current).

Q1 .......Circuit breaker for low voltage, high current

Interrupts the low voltage power suppltowards X1 when a short-circuit occurs the load side or when the overcurrenprotection (QAS 170: 410A, QAS 220530A) is activated. It must be reset manuallafter eliminating the problem.

Electronic speed regulator

The electronic speed regulator makes sure that thoutput frequency of the generator is 50 Hz/60 Hindependent of the amount of load.

All the cables that are used must besuitable for high current.!

X1

Q1

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Earth leakage relay

The Earth relay option provides a detector that willtrip the main circuit breaker Q1 when an earth faultcurrent is detected.

X1

Q1

N13N14

S13

- 55 -

Q1.1.... Circuit breaker for low voltage, high current

Interrupts the low voltage power supplytowards X1 when a short-circuit occurs atthe load side or when the overcurrentprotection (QAS 170: 410 A, QAS 220:530 A) is activated. It must be resetmanually after eliminating the problem.

Q1.2.... Circuit breaker for high voltage, low current

Interrupts the high voltage power supplytowards X1 when a short-circuit occurs atthe load side or when the overcurrentprotection (QAS 170: 205 A, QAS 220:265 A) is activated. It must be resetmanually after eliminating the problem.

Depending on which mode the generator is runninin, circuit breaker Q1.1 or Q1.2 will be operational.Circuit breakers Q1.1 and Q1.2 cannot be switched oat the same time. This is prevented by means of thauxiliary voltage selection relays S10b and S10(refer to the circuit diagram).The selection between the two modes is done bmeans of S10.

S10 .....Output voltage selection switch

Allows to select a 3 phase high outpuvoltage or a 3 phase low output voltagSelector switch S10 is located on thalternator.

AMF operation is not possible with adual voltage generator.!

Changing the output voltage is onlyallowed when the unit has stopped.!

IT-relay

The generator is wired for an IT network i.e. nosupply lines of the power supply are directly earthed.A failure in insulation resulting in a too low insulationresistance, is detected by the insulation monitoringrelay.

The generator shall not be operatedwith other networks (such as TT orTN). Doing so will cause tripping ofthe insulation monitoring relay. The generator is wired for an ITnetwork i.e. no supply lines of thepower supply are directly earthed.A failure in insulation resulting intoo low an insulation resistance, isdetected by the insulationmonitoring relay.At each start-up and any time a newload is connected, the insulationresistance must be verified. Checkfor the correct setting of theinsulation monitoring relay (factoryset at 13 kΩ).

!

- 56 -

Q1 .......Main circuit breaker

N13 ..... Earth leak detector

Detects and indicates an earth fault currentand activates the main circuit breaker Q1.The detection level can be set at 30 mA fixedwith instantaneous trip but can also beadjusted between 0.1 A and 1 A with timedelayed (0 - 0.5 sec) trip. N13 has to be resetmanually after eliminating the problem(reset button marked R). It can be overriddenby means of the earth leak switch (S13,labelled IN) but has to be tested monthlyby pushing test button T13.

S13 ..... Lock-out switch for earth fault protection (N13)

This switch is located inside the cubicle andis labelled IN.Position O: No de-energising of the maincircuit breaker Q1 when an earth faultoccurs.Position 1: De-energising of the main circuitbreaker Q1 when an earth fault occurs.

Position O will only be used inconjunction with an external earthfault protection unit (e.g. integratedin a distribution board).If S13 is in position O, properearthing is of the utmost importancefor the safety of the user.Eliminating any earth faultprotection can lead to serious injuryor even death for anybody touchingthe unit or the load.

!

COSMOS™

COSMOS™ is a web-based global remotemonitoring system that electronically tracks everyaspect of equipment from its location to its operatingparameters. The Cosmos system can send e-mails orSMS messages to the contractor or owner in real time,with all critical and non-critical events and datainvolving your compressors and generators. It allowsoptimal servicing.

When starting up the generator, the green Power Led(1) of the Cosmos module will light up when theinstallation has been carried out correctly.For information about COSMOS™, consult yourlocal Atlas Copco dealer.

1

- 57 -

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

Interrupts the power supply X1 when ashort-circuit occurs at the load side, or whenthe overcurrent protection is activated.When activated, Q1 interrupts the threephases towards X1. It must be resetmanually after eliminating the problem.

X1 .......Main power supply (400 Vac)

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

N14 ..... Insulation monitoring relay

Checks the insulation resistance andactivates Q1 when the insulation resistanceis too low.

S2 .......Emergency stop button

Push the button to stop the generator in caseof an emergency. When the button ispressed, it must be unlocked, by turning itanti-clockwise, before the generator can berestarted. The emergency stop button can besecured in the locked position with the key,to avoid unauthorized use.

X1

Q1

N13N14

S13

When using this option, make sure to connect the fuelsupply line as well as the fuel return line. Connectionsto fuellines ought to be air-tight to prevent air fromentering the fuel system. Turn the handle of 3-wayvalve to desired condition.

Internal fuel: Indicates that the fuel supply line to the engine is connected to the internal fueltank.

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

- 58 -

Overview of the mechanical

options

The following mechanical options are available forthe QAS 150-200 and QAS 170-220 units:

– External fueltank connection (with/without quickcouplings)

– Undercarriage (axle, towbar, towing eyes)

– Skid fueltank

– Integrated spark arrestor

– Air inlet shut-off valve

Description of the mechanical

options

External fueltank connection (with/without quick couplings)

The option external fueltank connection allows tobypass the internal fueltank and to connect anexternal fueltank to the unit.

View outside

View inside

EFT External fuel tank feed connectionEFR External fuel tank return connection

EFT EFR

EFTEFR

led

elellte

rs

g

nr

Integrated spark arrestor

The integrated spark arrestor option is included in therefinery equipment pack.

Air inlet shut-off valve

The engine air inlet shut-off valve option is includedin the refinery equipment pack. It will prevent over-speeding of the engine due to combustible gasesbeing traced within the normal engine air intake.

- 59 -

Undercarriage (axle, towbar, towing eyes)

The undercarriage is equipped with a fixed towbarwith brakes, with BNA-, NATO-, DIN-, ITA-, ISO-eye and Ball coupling.

When using this option

– Make sure that the towing equipment of thevehicle matches the towing eye (1) before towingthe generator.

– Never move the generator while electrical cablesare connected to the unit.

– Always apply the hand brake (2) when parking thegenerator.

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

To maintain the undercarriage

– Check the tightness of the towbar bolts, the axbolts and the wheel nuts at least twice a year anafter the initial 50 hours of operation.

– Grease the wheel axle suspension bearings, thdrawbar to the steering gear shaft and the spindof the brake handle at least twice a year. Use babearing grease for the wheel bearings and graphigrease for the drawbar and spindle.

– Check the brake system twice a year.

– Check the condition of the vibration dampetwice a year.

– Repack the wheel hub bearings once a year usingrease.

– Wheel chocks allows to park the generator osloping ground. Place wheel chocks in front of obehind the wheels to immobilize the generator.

1

2

> 1 m

> 1 m

QAS 150 QAS 170

50 Hz 60 Hz1500 rpm 1800 rpm

PRP PRP100 kPa 100 kPa

30% 30%25°C 25°C

50°C 50°C4000 m 4000 m

85% 85%-10°C -10°C-25°C -25°C

120 kW 136 kW0.8 cos 0.8 cos

- 60 -

Technical specifications

Technical specifications for QAS 150/170 units

Readings on gauges

Settings of switches

Specifications of the engine/alternator/unit

Gauge Reading UnitAmmeter L3 (P3) Below max. rating AVoltmeter (P4) Below max. rating V

Switch Function Activates atEngine oil pressure Shut down 1.0 barEngine coolant temperature Shut down 99°C

Reference conditions 1) 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 aided (optional)

Performance data 2) 3) 5) Rated active power (PRP) 3phRated power factor (lagging) 3ph

150 kVA 170 kVA400 V 480 V

- 220 V216,5 A 204,5 A

- 446,1 AG2 G2

108 kW 95 kW90% 70%

- -isochronous isochronous

4.2 kg/h 6.1 kg/h14.8 kg/h 18.2 kg/h20.8 kg/h 24.2 kg/h27.3 kg/h 31.6 kg/h

0.228 kg/kWh 0.232 kg/kWh14.5 h 12.5 h42 h 36 h

136.5 g/h 158.0 g/h99 dB(A) 101 dB(A)

497 l 497 l1417 l 1417 l

120.0 kW 122.4 kW100% 90%

PRP PRPland use land usesingle single

anual/automatic manual/automaticunspecified unspecified

ransportable/D transportable/Dmobile/E mobile/E

fully resilient fully resilientopen air open air

- 61 -

Rated PRP power 3phRated 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 (as ISO 8528)

Fuel consumption at no load (0%)Fuel consumption at 50% loadFuel consumption at 75% loadFuel consumption at full load (100%)Specific fuel consumption at full load (100%)Fuel autonomy at full load with standard tankFuel autonomy at full load with optional extended fuel tankMax. oil consumption at full loadMaximum sound power level (LWA) measured according to 2000/14/EC ONDCapacity of fuel tankCapacity of optional skid fuel tankSingle step load capability (0-PRP)

Application data Mode of operationSiteOperationStart-up and control mode mStart-up timeMobility/Config. acc. to ISO 8528-1:1993 t

(optional)MountingClimatic exposure

earthed earthedinsulated insulated

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

Leroy Somer Leroy SomerLSA44.2M95 LSA44.2M95

150 kVA 188 kVABR BR

IP 23 IP 23H HH H12 12

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

GB/T 6072.1 GB/T 6072.1GB/T 2820.0 GB/T 2820.06CTA8.3-G2 6CTA8.3-G2

146.7 kW 153.0 kW±5% ±5%

Parcool Parcoolirect injection direct injection

turbo charged turbo charged6 6

8.3 l 8.3 lelectronic electronic

27.6 l 27.6 l12.3 l 12.3 l

24 Vdc 24 Vdc

4 4216 A 204 A3..5xIn 3..5xIn

- 62 -

Status of neutral (ELR config.) (optional)Status of neutral (IT config.) (optional)

Alternator 4) Standard

MakeModelRated output, class H temperature rise

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

Engine 4) Standard

Type CUMMINSRated net output

production toleranceCoolantCombustion system dAspirationNumber of cylindersSwept volumeSpeed governingCapacity of oil sumpCapacity of cooling system (only in Engine)Electrical system

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

- 4- 446 A- 3..5xIn

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

x 1180 x 1869 mm 3540 x 1180 x 1869 mm2357 kg 2357 kg2950 kg 2950 kg

x 1180 x 2272 mm 3540 x 1180 x 2272 mm2580 kg 2580 kg3890 kg 3890 kg

delivering (at variable load), in the event of a s running). No overload is permitted on these

le load application. Variable load is not to l operating time at 100% Prime Power shall ithin a 12-hour period of operation. Total

- 63 -

Circuit-breaker, 3ph., lower voltageNumber of poles (optional)Thermal release It (thermal release is higher at 25°C)Magnetic release Im

Fault current protectionResidual current release IDn (optional)Insulation resistance (optional)

Unit Dimensions (LxWxH) (standard) 3540Weight net mass (standard)Weight wet mass (standard)Dimensions (LxWxH) (unit with extended fuel tank) 3540Weight net mass (unit with extended fuel tank)Weight wet mass (unit with extended fuel tank)

Notes

1) Reference conditions for engine performance to ISO 3046-1 / GB/T 6072.1.2) See derating diagram or consult the factory for other conditions.3) At reference conditions unless otherwise stated.4) Rating definition (ISO 8528-1 / GB/T 2820.1):

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: Engines with this rating are available for an unlimited number of hours per year in a variabexceed a 70% average of the Prime Power Rating during any operating period of 250 hours. Totanot exceed 500 hours per year. A 10% overload capability is available for a period of one hour woperating time at the 10% overload power shall not exceed 25 hours per year.

5) Specific mass fuel used: 0.85 kg/l.

ure

30 35 40 45 50100 100 100 90 80100 100 100 90 80100 100 100 90 8095 95 95 85 7590 90 90 85 7585 85 85 NA NA85 85 85 NA NA80 NA NA NA NA80 NA NA NA NA

- 64 -

For use of generator outside these conditions, please contact Atlas Copco.

Derating factor (%)

Height(m)

Temperat(°C)

0 5 10 15 20 250 100 100 100 100 100 100

500 100 100 100 100 100 1001000 100 100 100 100 100 1001500 100 100 100 100 100 1002000 95 95 95 95 95 952500 90 90 90 90 90 903000 90 90 90 90 90 903500 80 80 80 80 80 804000 80 80 80 80 80 80

QAS 200 QAS 220

50 Hz 60 Hz1500 rpm 1800 rpm

PRP PRP100 kPa 100 kPa

30% 30%25°C 25°C

50°C 50°C4000 m 4000 m

85% 85%-10°C -10°C-25°C -25°C

160 kW 176 kW0.8 cos 0.8 cos 200 kVA 220 kVA

400 V 480 V

- 65 -

Technical specifications for QAS 200/220 units

Readings on gauges

Settings of switches

Specifications of the engine/alternator/unit

Gauge Reading UnitAmmeter L3 (P3) Below max. rating AVoltmeter (P4) Below max. rating V

Switch Function Activates atEngine oil pressure Shut down 1.0 barEngine coolant temperature Shut down 99°C

Reference conditions 1) 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 aided (optional)

Performance data 2) 3) 5) Rated active power (PRP) 3phRated power factor (lagging) 3phRated PRP power 3phRated voltage 3ph line to line

- 220 V288.7 A 264.6 A

- 577.4 AG2 G2

128 kW 158 kW80% 90%

- -isochronous isochronous

4.0 kg/h 6.6 kg/h18.8 kg/h 22.8 kg/h26.9 kg/h 31.4 kg/h35.2 kg/h 40.9 kg/h

0.220 kg/kWh 0.232 kg/kWh11.0 h 10.0 h33.0 h 28.0 h

176.0 g/h 204.5 g/h99 dB(A) 101 dB(A)

497 l 497 l1417 l 1417 l

100 kW 108 kW100% 100%

PRP PRPland use land usesingle single

anual/automatic manual/automaticunspecified unspecified

ransportable/D transportable/Dmobile/E mobile/E

fully resilient fully resilientopen air open airearthed earthed

insulated insulated

- 66 -

Rated 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 (as ISO 8528)

Fuel consumption at no load (0%)Fuel consumption at 50% loadFuel consumption at 75% loadFuel consumption at full load (100%)Specific fuel consumption at full load (100%)Fuel autonomy at full load with standard tankFuel autonomy at full load with optional extended fuel tankMax. oil consumption at full loadMaximum sound power level (LWA) measured according to 2000/14/EC ONDCapacity of fuel tankCapacity of optional skid fuel tankSingle step load capability (0-PRP)

Application data Mode of operationSiteOperationStart-up and control mode mStart-up timeMobility/Config. acc. to ISO 8528-1:1993 t

(optional)MountingClimatic exposureStatus of neutral (ELR config.) (optional)Status of neutral (IT config.) (optional)

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

Leroy Somer Leroy SomerLSA46.2M5 LSA46.2M5

200 kVA 250 kVABR BR

IP 23 IP 23H HH H12 12

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

GB/T 6072.1 GB/T 6072.1GB/T 2820.2 GB/T 2820.2

6LTAA8.9-G2 6LTAA8.9-G2198.0 kW 211.5 kW

± 5% ± 5%Parcool Parcool

irect injection direct injectionrbo intercooled turbo intercooled

6 68.9 l 8.9 l

electronic electronic27.6 l 27.6 l11.1 l 11.1 l

24 Vdc 24 Vdc

4 4288 A 264 A3..5xIn 3..5xIn

- 67 -

Alternator 4) Standard

MakeModelRated output, class H temp. rise

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

Engine 4) Standard

Type CUMMINSRated net output

production toleranceCoolantCombustion system dAspiration tuNumber of cylindersSwept volumeSpeed governingCapacity of oil sumpCapacity of cooling systemElectrical system

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

- 4- 400 A- 3..5xIn

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

x 1180 x 1869 mm 3540 x 1180 x 1869 mm2607 kg 2607 kg3200 kg 3200 kg

x 1180 x 2272 mm 3540 x 1180 x 2272 mm2838 kg 2838 kg4140 kg 4140 kg

delivering (at variable load), in the event of a s running). No overload is permitted on these

le load application. Variable load is not to l operating time at 100% Prime Power shall ithin a 12-hour period of operation. Total

- 68 -

Circuit-breaker, 3ph., lower voltageNumber of poles (optional)Thermal release It (thermal release is higher at 25°C)Magnetic release Im

Fault current protectionResidual current release IDn (optional)Insulation resistance (optional)

Unit Dimensions (LxWxH) (standard) 3540Weight net mass (standard)Weight wet mass (standard)Dimensions (LxWxH) (unit with extended fuel tank) 3540Weight net mass (unit with extended fuel tank)Weight wet mass (unit with extended fuel tank)

Notes

1) Reference conditions for engine performance to ISO 3046-1 / GB/T 6072.1.2) See derating diagram or consult the factory for other conditions.3) At reference conditions unless otherwise stated.4) Rating definition (ISO 8528-1 / GB/T 2820.1):

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: Engines with this rating are available for an unlimited number of hours per year in a variabexceed a 70% average of the Prime Power Rating during any operating period of 250 hours. Totanot exceed 500 hours per year. A 10% overload capability is available for a period of one hour woperating time at the 10% overload power shall not exceed 25 hours per year.

5) Specific mass fuel used: 0.85 kg/l.

ure

30 35 40 45 50100 100 100 90 80100 100 100 90 80100 100 100 90 8095 95 95 85 7590 90 90 85 7585 85 85 NA NA85 85 85 NA NA80 NA NA NA NA80 NA NA NA NA

- 69 -

For use of generator outside these conditions, please contact Atlas Copco.

Derating factor (%)

Height(m)

Temperat(°C)

0 5 10 15 20 250 100 100 100 100 100 100

500 100 100 100 100 100 1001000 100 100 100 100 100 1001500 100 100 100 100 100 1002000 95 95 95 95 95 952500 90 90 90 90 90 903000 90 90 90 90 90 903500 80 80 80 80 80 804000 80 80 80 80 80 80

A Maximum permitted total weight of the vehicleB Maximum permitted front axle loadC Maximum permitted load on towing eye1 Company code2 Product code3 Unit serial number4 Name of manufacturer5 EEC or national type approved number6 Vehicle identification number7 Model number8 Frequency9 Apparant power - PRP10 Active power - PRP11 Nominal rated voltage12 Nominal rated current13 Power factor14 Manufacturing year15 Mode of operation16 Winding connections

- 70 -

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 lb1 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

-YA3--- kg

kg kg

Model/Modell/ModŁle

cos phi

f NP NP NU NI N

Manuf. year/Baujahr/AnnØe de fabrication

Hz

kW

V

A

kVA

1 2

45

7

89

10

11

1213

14

15 16

A

B

C

6

3

alle

tsf

ee.,

le

stdalr

rgtosne

s

- 71 -

Disposal

General

When developing products and services, Atlas Copcotries to understand, address, and minimize thenegative environmental effects that the products andservices may have, when being manufactured,distributed, and used, as well as at their disposal.Recycling and disposal policy are part of thedevelopment of all Atlas Copco products. AtlasCopco company standards determine strictrequirements.Selecting materials the substantial recyclability, thedisassembly possibilities and the separability ofmaterials and assemblies are considered as well as theenvironmental perils and dangers to health during therecycling and disposal of the unavoidable rates of notrecyclable materials.

Your Atlas Copco generator consists for the most partof metallic materials, that can be remelted insteelworks and smelting works and that is thereforealmost infinite recyclable. The plastic used islabelled; sorting and fractioning of the materials forrecycling in the future is forseen.

Disposal of materials

Dispose contaminated substances and materiseparately, according to local applicabenvironmental legislations.Before dismantling a machine at the end of ioperating lifetime drain all fluids and dispose oaccording the applicable local disposal regulations.Remove the batteries. Do not throw batteries into thfire (explosion risk) or into the residual wastSeparate the machine into metal, electronics, wiringhoses, insulation and plastic parts.Dispose all components according to the applicabdisposal regulations.Remove spilled fluid mechanically; pick up the rewith absorbing agent (for example sand, sawdust) andispose it according the applicable local disposregulations. Do not drain into the sewage system osurface water.

This concept can only succeed with youhelp. Support us by disposinprofessionally. By assuring a correcdisposal of the product you help tprevent possible negative consequencefor environment and health, that caoccur with an inappropriate wasthandling.Recycling and re-usage of material helpto preserve natural resources.

!

- 72 -

- 73 -

Circuit diagrams

Circ.Diagr ENGINEmpere-meter

a0

125

to Circ.Diagr ENGINEV-meter & Control Module

a0

127

Circ.Diagr ENGINEmpere-meter

a0

126

a6

124

220V 60HZ 577A600/5A446A600/5A

Q1T1

220 150mm22*150mm2120mm22*120mm2

Wire Size yWire Size x

170

QAS

480V 60HZ 266A300/5A104A300/5A

Q1T1

220 70mm2150mm250mm295mm2

Wire Size yWire Size x

170

QAS

400V 50HZ 288A300/5A216A300/5A

Q1T1

200 70mm2150mm250mm295mm2

Wire Size yWire Size x

150

QAS

S2b Emergency stop(S2a see engine circuit)

S13 ELR disable switch (O)T1-T3 Current transformers

- 74 -

A

BC

D E F HG

Alte

rnat

orCu

bicle

a0

W1

c8

141

T3T2T1

c8

151

c8

143

toA

a6N1

y54x6N1

x0W

1x0

V1

x0

U1

toAc8

142

a0

V1

a0

U1

U6U5

U2U1

V6V5

V2V1

W6W5

W2W1

400V/480V

PEN1

N

V1

V1

U1

W1

U1

U1

G3

FEDCBA

N11

B11N15

16A

a3

46

a6

47

b3

20

b6

24

b3

27

b6

12

b3

14

X8

K6 F11b335

X10 X10X10 X10

G J

A5 C5 C3 C4A5 C5 C3 C4

F3

N

F1

F2

9829 3000 28/00

Applicable for QAS 150-200 Cud & QAS 170-220 Cud - Power circuit

B11 Speed sensor N13 Earth leakage relay (O)F1-3 Fuses 4A N14 IT relay (O)G3 Alternator N15 ActuatorK6 Relay Q1 Circuit breakerK7 Aux. relay for Y7 (O) R5 Coolant heater (O)N11 ESD5500 speed controller R12 Frequency adjustm. 1K

bx = 1.5 mm² NSGAFOeU

l = 95 mm²lx = 95 mm² EPR-CSP (BS6195-4C)

k = 70 mm²j = 50 mm²i = 35 mm²

54 = green/yel.

1 = brown

Wire size : Colour code :a = 1 mm²b = 1.5 mm²c = 2.5 mm²d = 4 mm²e = 6 mm²f = 10 mm²g = 16 mm²h = 25 mm²

0 = black

2 = red3 = orange4 = yellow5 = green6 = blue7 = purple8 = grey9 = white

Legend

HG

All materials supplied are in compliance with therequirements of the List of Prohibited Substances

Cano

pyCu

bicle

See Note 1

PEg54

Notes

Note 1: The PE-N connection has to be made at thealternator-side of main Circuit Breaker Q1.

PE

y54x6

NL3

y54 y54

PEN

1

2

T13

7 Air inlet shutdown valve (O)) Optional equipment

- 75 -

A

BC

D E F

a3

73

to A

1.36

a6

12V7

a371

a2

13

Cubi

cle

Y7

Cano

py

K7

a3

70

K7

B- B+

L N

PE

U1

S13Ca

nopy

Cubi

cle

R5

b6

441

b6

441

b0

442

b0

442

U>

Q1

c1

c2

See Note 1: Do NOT connect (N) to (PE)

x0x0

L2

x0

L1

X1

b0

442b6

441

to C

irc.D

iagr

ENG

INE

a2

13

a6

12

a6

12

R<

N14 N13

I nT1T2

S2b

a6

12

a2

13

a35

b54a6

N1

a3

118

a3

118

a2

13

a6

12

a3

102

a6

12

b2

13

a3

5

a6

12

a2

13

a3

5

to C

irc.D

iagr

ENG

INE

to A

1.35

X9

X9

86

85

(O)(O)

(O)

(O) (O)

L3L2L1

A1 A2

LPETR

A1 A2 31 34

T13 Torus earth leakage (O) V7 Free-wheeling diode Y7 YU1 Battery charger (O) X1 Terminal board (O

N O

All materials supplied are in compliance with therequirements of the List of Prohibited Substances

SnijbrandenFlame cutting1355K / C

PlaatwerkSheet metal1350:01K1350K / 2

Bew. opp./GatenMach.surf./Holes

LassenWelding1356K / B

K5K1

d2d2f2

Position of Relay Contacts

X25

a3

5

3

14

Customer's InstallationMAINS SUPPLY (1P+N)

X25X25X25

PE L1N

X25

Sx FxFx

Generator ContactorOutput: 24Vdc, max.8Adc1

(*)= Connect L2 to X25.5with 230Vd-systems

(*)

a3

19to

A1.

17

Sx=RemoteStart/Stop-switch

(see Instruction Manual)

to G

ener

ator

Con

tact

or A

2 <-

-

to G

ener

ator

Con

tact

or A

1 <-

-

a6

12

a0

38

to Circ.Diagr POWER

a3

18

b6

441

b0

442

to A

1.18

PE 654321

6A6A

K6 RelayM1 Starter motorP1-P3 A-meterP4 V-meterR2 Excitation resistor 100ohm

- 76 -

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

5 184321 17161413129 156 7 8

Spar

e <Lo

w Co

olant

Leve

l>

Inpu

t

Inpu

t

Inpu

t

Inpu

t

Inpu

t

Inpu

t High

Coo

lant

Tem

pera

ture

Com

mon

for V

DO-in

puts

(0 V

dc)

Inpu

t

GND

Inpu

t

Inpu

t

Inpu

t

Mag

netic

Pick

-up

(Tac

ho)

CAN-

H

CAN-

L

GND

Engi

ne C

AN-b

us In

terfa

ce

Star

t/Sto

p

Low

Oil

Pres

sure

Rem

ote

Star

t

Oil P

ress

ure

(VDO

)

W/L

-Inpu

t D+

Cool

ant T

emp

(VDO

)

Fuel

Lev

el (V

DO)

Com

mon

(12

Vdc)

P1

P2

P3

P4

A

A

A

V

S4

Circ.Diagr POWERFuses F1-F3

a0

126

a0

125

a0

125a0

126

a6

124

a0

127

to Circ.Diagr POWERCurrent Transfo T1-T3

c8

140

c8

143

c8

142

c8

141

a0

128

a0

1298

4106

2

12119

75

3 1 A1 19 2321 35 3624 34333226 27 25

X9

X8a6

12

a3

15

a0

384

b3

14

a3

14

a3

5

a3

15

ba612

a2

17

a0

126

a0

125

a6

12

a2

17

NOCom

NO NOSt

art R

elay

Out

put

0 Vd

c (Ba

tt-)

Gene

rato

r Con

tact

or

Preh

eat R

elay

Air s

hutd

own

valv

e re

lay

Com

mon

for R

elay

Out

puts

NOCom

Fuel

Con

trol R

elay

Com

NO

Gene

rato

r Vol

tage

L1

Gene

rato

r Vol

tage

L2

12/2

4 Vd

c (Ba

tt+)

a3 a3

4

a6

12

a3

70

(o)

Qc1002

9829 3006 39/00

Applicable for QAS 150-200 Cud & QAS 170-220 - Engine Circuit Qc1002™

A1 Generator control unit G1 Battery 24 VdcB7 Fuel level sensor G2 Charging alternatorB8 Coolant temperature sensor H0 Panel lightB9 Oil pressure sensor K0 Starter solenoidE1 Preheat resistor K1 Preheat relayF10 Fuse 20 A DC K5 Starter relay

H0

S9

X25 X25

S8

X10X10

X10

K5

X10

K1

S10

K4

a3

7

a6

12

a3

5

a6

12

a6

12

a3

15

a3

5

b3

14

a2

17

a6

12

a3

18

a3

19

P

a3

6

a3

6

a3

7

a3

6

a3

7

a6

12

1 2

B2B2

B1B1

C2C2

a3

4

a6 12

A4

a3

4

A4

(o)

a3

22

a6

12

B3B3

8

a3

a3

8

a6

12

a6

12

bx = 1.5 mm² NSGAFOeU

l = 95 mm²lx = 95 mm² EPR-CSP (BS6195-4C)

k = 70 mm²j = 50 mm²i = 35 mm²

54 = green/yel.

1 = brown

Wire size : Colour code :a = 1 mm²b = 1.5 mm²c = 2.5 mm²d = 4 mm²e = 6 mm²f = 10 mm²g = 16 mm²h = 25 mm²

0 = black

2 = red3 = orange4 = yellow5 = green6 = blue7 = purple8 = grey9 = white

Legend

E F G H I J K L M N O

- 77 -

S20

G2

K0

K0M

M1

G1

-

+

S2a

B7

X10 X10

X10

20A

F10

E1

K1

R2

V2K4

X10

K6

K5

a6

12 14

b3

b2

17

a3

18

a3

19

to Circ.Diagr POWER

to Circ.Diagr POWERa3

5

a2

17

a6

12

a6

12

b2

13c2

1

c2

1 b2

13

c2

3

c2

1

c2

3

c2

1

e2

1

j0

1

j6

12

a3

11

e2

1

a6

12

a6

12

GNDB+

a3

5

a2

17

j6

12

j0

1

c2

3

a6

12

a6

12

a3

11

a3

1112

14

b3

Cubi

cleCa

nopy

Cubi

cleCa

nopy

A1A1

A3A3

C1C1

a6

e2

16

e2

1

(o)

a6

a3

2

a3

2

D+

a3

2

A2A2

a3 50

A B C D

S2a Emergency stop S20 ON/OFF/REMOTE-switch(S2b: see Power circuit) V2 Excitation diode

S4 V-meter change-over switch X10 Connector wire harnessS8 High coolant temperature switch X25 Customer’s terminal stripS9 Low oil pressure switchS10 Low coolant level switch

K6 RelayM1 Starter motorM6 Fuel feed pumpP1-P3 A-meterP4 V-meterR2 Excitation resistor 100ohm

N O P Q

K5K1

X25 X25

PE

Customer's InstallationMAINS SUPPLY (3P+N+PE)

L3

L2

L1

L1N

33 3432

54 5655 57 58

35 36

SxFx FxFx FxFx

Position of Relay Contacts

towardsX25.8a6

124

c8

140

c8

140

140

c8

141

c8

142

d2d2f2

to Circ.Diagr POWER

a6

12

a3

18

a6

124

a0

446

a0

447

a0

442

a6

441

Sx=RemoteStart/Stop-switch

b6

441

b0

442

a0

443

a0

444

a0

445

to A

1.38

PE 873 65421 109

(see Instruction Manual)

to G

ener

ator

Con

tact

or A

2 <-

-

to G

ener

ator

Con

tact

or A

1 <-

-

to M

ains

Con

tact

or A

1 <-

-

to A

1.18

250mA

250mA

6A

250mA

6A

Air i

nlet

shut

dow

n va

lve

s1 s2Ge

nera

tor C

urre

nt Tr

ansf

o L1

s1 s2Ge

nera

tor C

urre

nt Tr

ansf

o L2

s2

Com

NONO Com

NO

Star

t Rel

ay O

utpu

t

Fuel

Con

trol R

elay

All materials supplied are in compliance with therequirements of the List of Prohibited Substances

SnijbrandenFlame cutting1355K / C

PlaatwerkSheet metal1350:01K1350K / 2

Bew. opp./GatenMach.surf./Holes

LassenWelding1356K / B

- 78 -

9829 3006 40/00

Applicable for QAS 150-200 Cud & QAS 170-220- Engine Circuit Qc2002™

A1 Generator control unit G1 Battery 24 VdcB7 Fuel level sensor G2 Charging alternatorB8 Coolant temperature sensor H0 Panel lightB9 Oil pressure sensor K0 Starter solenoidE1 Preheat resistor K1 Preheat relayF10 Fuse 20A DC K5 Starter relay

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

P1

P2

P3

P4

5

A1

242318 25

39 434137 38 51 53

4321

5245 50494726 27 46

17161413129 156 7 8

A

A

A

V

S4

Qc2002

to C

irc.D

iagr

POW

ERCu

rrent

Tran

sfo

T1-T

3

c8

140

c8

143

c8

142

c8

141

Circ

.Dia

gr P

OWER

Fuse

s F1-

F3

a6

124

a0

127

a0

126

a0

125

a0

125a0

126

a6

124

a0

127

a0

128

a0

1298

4106

2

12119

75

3 1

a6

12

c8

140

c8

141

c8

143

c8

142

a6

12

a2

17

a0

125

a0

442

a0

446

a0

447

a0

443

a0

445

a6

441

a0

444

a0

125

a0

127

a0

126

a6

124

a6

12

a2

17

c8c8

143

2nd

Para

met

er S

et

s1

Mai

ns V

olta

ge L

1

NO

Low

Coo

lant

Lev

el

Inpu

t

Inpu

t

Inpu

t

Inpu

t

Inpu

t

Inpu

t

0 Vd

c (Ba

tt-)

Mai

ns V

olta

ge N

eutra

l

Mai

ns V

olta

ge L

2

High

Coo

lant

Tem

pera

ture

Spar

e Ou

tput

Low

Oil

Pres

sure

Mai

ns C

onta

ctor

Mai

ns V

olta

ge L

3

Rem

ote

Star

t

Com

NOGe

nera

tor C

onta

ctor

NC Com

Com

NO

Gene

rato

r Vol

tage

L3

Gene

rato

r Vol

tage

L1

Gene

rato

r Vol

tage

L2

12/2

4 Vd

c (Ba

tt+)

Gene

rato

r Vol

tage

Neu

tral

Preh

eat R

elay

Com

mon

for R

elay

Out

puts

Com

mon

for V

DO-in

puts

(0 V

dc)

Inpu

t

GND

Inpu

tOi

l Pre

ssur

e (V

DO)

W/L

-Inpu

t D+

Cool

ant T

emp

(VDO

)

Fuel

Lev

el (V

DO)

Inpu

t

Inpu

t

Mag

netic

Pick

-up

(Tac

ho)

CAN-

H

CAN-

L

GND

Engi

ne C

AN-b

us In

terfa

ce

Gene

rato

r Cur

rent

Tran

sfo

L3

Com

mon

(12

Vdc)

bx = 1.5 mm² NSGAFOeU

l = 95 mm²lx = 95 mm² EPR-CSP (BS6195-4C)

k = 70 mm²j = 50 mm²i = 35 mm²

54 = green/yel.

1 = brown

Wire size : Colour code :a = 1 mm²b = 1.5 mm²c = 2.5 mm²d = 4 mm²e = 6 mm²f = 10 mm²g = 16 mm²h = 25 mm²

0 = black

2 = red3 = orange4 = yellow5 = green6 = blue7 = purple8 = grey9 = white

Legend

D E F G H I J K L M N O P Q

S9

X25

S8

X10X10

X10

K5

X10

K1

X9 X9

X8

S10

K4

a3

7

a6

12

a6

12

a3

15

a3

5

a3

14

a2

17

a3

14

a3

1811

P

a3

6

a3

6

a3

7

a3

6

a3

7

a6

12

9

B2B2

B1B1

C2C2

a3

4

a3

4

a6

12

A4A4

(o)

a3

22

a6

12

a6

12

a3

70

(o)

B3B3

a3

8

a3

8

a6

12

a6

12

- 79 -

A B C

G2

K0

K0M

M1

G1

-

+

S2a

X10 X10

X10

20A

F10 S20

B7E1

K1

R2

V2K4

X10

K6

K5

a3

5

to Circ.Diagr POWER

a6

12a3

5

b2

13c2

1

c2

1 a2

13

c2

3

c2

1

c23

c2

1

e21

j0

1

j6

12

a2

17

a3

11

e21

a6

12

a2

17

a6

12

GNDB+

a3

5

a6

12

a2

17

j6

12

j0

1

c2

3

a6

12

a6

12

a3

a3

11

14

a3Cubi

cleCa

nopy

Cubi

cleCa

nopy

A1A1

A3A3

C1C1

14

a3

a6

12

e2

16

e2

1

(o)

a6

12

a3

2

a3

2

D+

a3

2

A2A2

a3 50

S2a Emergency stop S20 ON/OFF-switch(S2b: see Power circuit) V2 Excitation diode

S4 V-meter change-over switch X10 Connector wire harnessS8 High coolant temperature switch X25 Customer’s terminal stripS9 Low oil pressure switch Y1 Fuel stop solenoidS10 Low coolant level switch

- 80 -

Pri

nte

d i

n B

elg

ium

01

/2012

- 1

09

2 5

23

0 0

0

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