Atlas Copco QAS 150-200 Cud Instruction Manual
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Atlas Copco QAS 150-200 Cud Instruction Manual

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for AC Generators
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QAS 150-200 Cud
QAS 170-220 Cud

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  • Page 1 Instruction Manual for AC Generators English QAS 150-200 Cud QAS 170-220 Cud...
  • Page 3 QAS 150-200 Cud QAS 170-220 Cud Instruction Manual for AC Generators Instruction manual .................. 5 Circuit diagrams ..................73 Printed matter N° 1092 30 00 ATLAS COPCO - PORTABLE AIR DIVISION www.atlascopco.com 12/2011...
  • Page 4 While every effort has been made to ensure that the information in this manual is correct, Atlas Copco does not assume responsibility for possible errors. Copyright 2011, Atlas Copco Any unauthorized use or copying of the contents or any part thereof is prohibited.

  • Page 5: Table Of Contents

    Please read the following instructions carefully before starting to use your machine. While every effort has been made to ensure that the information in this manual is correct, Atlas Copco does not assume responsibility for possible errors. Atlas Copco reserves the right to make changes without prior notice.

  • Page 6: Safety Precautions For Portable Generators

    The policy of Atlas Copco is to provide the users of their Atlas Copco equipment. It is the responsibility of unsafe operating conditions. Take necessary steps to equipment with safe, reliable and efficient products.

  • Page 7: General Safety Precautions

    The manufacturer does not accept any liability for any Normal ratings (pressures, temperatures, speeds, 14 When working on the unit, wear safety clothing. damage arising from the use of non-original parts and for etc.) shall be durably marked. Depending on the kind of activities these are: safety modifications, additions or conversions made without glasses, ear protection, safety helmet (including Operate the unit only for the intended purpose and...
  • Page 8 - check the towbar, the brake system and the Atlas Copco. towing eye. Also check the coupling of the To lift heavy parts, a hoist of ample capacity, tested...
  • Page 9 Atlas Copco Instruction - above 85 dB(A): room to be classified as a noise- Book (AIB). Keep fuel away from hot parts such as direct an air or gas stream at people.
  • Page 10 Replace the damaged wires or correct the dangerous invisible particles will almost certainly be present Parts shall only be replaced by genuine Atlas Copco condition before restarting. Make sure that all too; but the fact that no dust can be seen is not a replacement parts.
  • Page 11 18 Maintenance and repair work should be recorded in in or on the machine. Never leave rags or loose or approved by Atlas Copco or the machine an operator’s logbook for all machinery. Frequency clothing near the engine air intake.
  • Page 12 When connecting an auxiliary battery (AB) in Tool applications safety parallel to the unit battery (CB) with booster cables: Apply the proper tool for each job. With the knowledge connect the + pole of AB to the + pole of CB, then of correct tool use and knowing the limitations of tools, connect the - pole of CB to the mass of the unit.

  • Page 13: Leading Particulars

    The QAS 150-200 Cud/QAS 170-220 Cud is an AC generator, built for continuous running at sites where no electricity is available or as stand-by in cases of interruption of the mains. The QAS 150-200 Cud operates at 50 Hz, 400 V-3 phase. The QAS 170-220 Cud operates at 60 Hz, 480 V-3 phase/220 V-3 phase lower voltage. The generator is driven by a Parcool-cooled diesel engine, manufactured by CUMMINS.
  • Page 14 Alternator Air filter Battery switch Coupling Coolant filter Drain flexible engine oil OF CF Drain and access hole (in the frame) Drain plug fuel Engine Engine exhaust outlet Filler cap fuel Filler cap engine oil Filler cap coolant Fuel filter Fuel filter (secondary) with water separator Battery Intercooler (only for QAS 200/220 Cud)

  • Page 15: Bodywork

    Bodywork Markings Indicates the drain for the coolant. The alternator, the engine, the cooling system, etc. are A brief description of all markings provided on the enclosed in a sound-insulated bodywork that can be generator is given hereafter. opened by means of side doors (and service plates). Indicates the drain plug for the engine This symbol indicates the presence of fuel.

  • Page 16: Drain Plugs And Filler Caps

    Drain plugs and filler caps QAS 150 Cud, QAS 170 Cud QAS 200 Cud, QAS 220 Cud Indicates the partnumbers of The drain holes for the engine oil, the coolant and the the different service packs Every 250h xxxx xxxx xx plug for the fuel, are located and labelled on the (Yearly) Every 1000h...

  • Page 17: Control And Indicator Panel Qc1002

    F10 ..Fuse Qc1002™ Module Control and indicator panel The fuse activates when the current from the Qc1002™ battery to the engine control circuit exceeds General description Qc1002™ control its setting. The fuse can be reset by pushing the button. panel S2 ..
  • Page 18 Pushbutton and LED functions Following LEDs are used on the Qc1002™ Menu Overview Qc1002™ At Qc1002™, the LCD will show following Following pushbuttons are used on information: the Qc1002™ – in Normal condition (scroll through the information using UP and DOWN): Power Qc 1002 ENTER: Is used to select and...
  • Page 19 Controller type and version display LOG list display Battery Voltage display Qc1002 LOG List Battery 13.2 V v1.00.0 00168.1h This view shows the controller type and the ASW This view shows the alarm memory and gives access This view shows the Battery voltage and the running version number.
  • Page 20 Fuel level display Qc1002™ Menu Description Status Display (pop-up window) DIAGNOSTIC Fuel 00168.1h If a special status has elapsed, the active view will be This view shows the Fuel level and the running hours. entered again automatically. If an Alarm comes up, the Alarm Display is shown. Voltage - frequency - running hours In case special statuses are entered, a pop-up window display...
  • Page 21 Parameter list – Unit Menu The Parameter Menu's are pre-programmed! This menu is used to select whether tempreature and pressure should appear in °C/bar or °F/psi. A password will be asked for when an attempt to change a setting is about to be done (user password = –...
  • Page 22 Alarm Display (pop-up window) Following general groups of Alarms exist: – Warning: Alarm LED lights up + Alarm pop-up LOW FUEL LEVEL appears on the display + Alarm relay is empowered (if configured) – Trip of GB: ‘Warning’ actions + Generator Contactor opens LOW COOLANT –...
  • Page 23 LOG list Remote start operation The unit will keep an event log of the latest 30 events. Installation wirings: SERVICE TIMER 1 Events are: – X25.1 & X25.2 to be wired for the remote start switch. – shutdowns – X25.3 & X25.4 to be wired for the remote –...

  • Page 24: Control And Indicator Panel Qc2002

    F10 ..Fuse Qc2002™ Module Control and indicator panel The fuse activates when the current from the Qc2002™ battery to the engine control circuit exceeds General description Qc2002™ control its setting. The fuse can be reset by pushing the button. panel S20 ..
  • Page 25 Pushbutton and LED functions Following LEDs are used on the Qc2002™ START: Is used to start the unit in Following pushbuttons are used on manual operation. the Qc2002™ Power Qc2002 STOP: Is used to stop the unit in Automatic Alarm ENTER: Is used to select and manual or automatic operation Start...
  • Page 26 Qc2002™ Menu Overview – in Alarm condition (scroll through Mains Green LED indicates that it is information using UP and DOWN): contactor possible to close the Mains At Qc2002™, the LCD will show following • a list of all active Alarms Contactor (only in AMF mode), if information: the Generator contactor is open.
  • Page 27 Parameter display Service timer 1 & Service timer 2 RPM display display Parameter Service 1 00168.1h Service 2 This view shows a number of Parameter settings and This view shows the Battery voltage and the running gives access to them. hours.
  • Page 28 Fuel level display One line voltage - frequency - active Phase voltages mains display power display Fuel M L1-N 230V G L1-L2 400V M L2-N 230V 00168.1h M L3-N 230V G f L1 50Hz 80kW This view shows the Fuel level and the running hours. This view shows the phase voltages of the mains (is only shown in AMF mode).
  • Page 29 Qc2002™ Menu Description Parameter list The Parameter Menu's are pre-programmed ! Status Display (pop-up window) DIAGNOSTIC A password will be asked for when an attempt to change a setting is about to be done (user password = 2003). entering parameter list, pushbutton If a special status has elapsed, the active view will be...
  • Page 30 Island operation Automatic Mains Failure (AMF) operation Running hours adjust – This operation type is selected for local/remote – This application is only possible in combination start applications, without the Mains (= stand- with the Auto mode. If the Manual Operation Running Time alone).
  • Page 31 Diagnostic menu Language selection M frequency delay Diagnostics Language M freq delay English 9900s This menu is used to power up the engine electronics Icons is the default factory set language, but 6 other This menu is used to set the delay, which defines how without starting the engine.
  • Page 32 MF high voltage MF voltage delay Overvoltage delay > Volt Delay MF high volt MF volt delay 1.0s 990.0s 100% 120% This menu is used to set the maximum limit for the This menu is used to set the delay, which defines how Overvoltage setpoint mains voltage, in % of the nominal voltage (in AMF- long the mains voltage may be above the max limit or...
  • Page 33 Undervoltage delay Overfrequency delay Underfrequency delay < Volt Delay > Freq Delay < Freq Delay Undervoltage setpoint Overfrequency setpoint Underfrequency setpoint < Volt > Freq < Freq Overfrequency enable Underfrequency enable > Freq enable < Freq enable Enable enable disable Enable enable disable...
  • Page 34 Alarm Display (pop-up window) Following general groups of Alarms exist: – Warning: Alarm LED lights up + Alarm pop-up LOW FUEL LEVEL appears on the display + Alarm relay is empowered (if configured) – Trip of GB: ‘Warning’ actions + Generator Contactor opens LOW COOLANT –...
  • Page 35 LOG list The unit will keep an event log of the latest 30 events. SERVICE TIMER 1 HZ/V FAILURE Events are: – shutdowns – service timer 1/2 reset Together with each event, the real time of the event SERVICE TIMER 2 OIL LEVEL will be stored.

  • Page 36: Output Terminal Board

    Fail classes Q1 ..Main circuit breaker Output terminal board Interrupts the power supply to X1 when a All the activated alarms of the Qc2002™ have their The output terminal board option is situated below the short-circuit occurs at the load side, or when own pre-defined fail class.

  • Page 37: Operating Instructions

    IEC 364-3, i.e. one point in – Leave enough space for operation, inspection and Consult Atlas Copco for measures against the adverse the power source directly earthed - maintenance (at least 1 meter at each side).
  • Page 38 Quality, minimum section and Protection The lowest acceptable wire section and the maximum length of cables corresponding maximum cable or conductor length For safety reasons, it is necessary to for multiple core cable or H07 RN-F, at rated current The cable connected to the terminal board of the provide an isolating switch or circuit (20 A), for a voltage drop e lower than 5% and at a generator must be selected in accordance with local...

  • Page 39: Before Starting

    During operation Qc1002™ Before starting Operating Qc1002™ Following points should be carried out regularly: – With the generator standing level, check the Starting Qc1002™ engine oil level and top up if necessary. The oil – Check the engine gauges and the lamps for normal level must be near to, but not exceed the high mark readings.

  • Page 40: Operating Qc2002

    Stopping Qc1002™ To start up the unit from a remote Operating Qc2002™ location, proceed as follows: To stop the unit locally, proceed as Starting Qc2002™ – Put the starter switch S20 in position I (ON). follows: Voltage is applied to the Qc2002™ module. To start up the unit locally, proceed –...
  • Page 41 During operation Qc2002™ Stopping Qc2002™ – Cooldown period default 15 sec. Following points should be carried out regularly: – Put the starter switch S20 in position O (OFF) to To stop the unit , proceed as follows: shut down the voltage apply towards the –...

  • Page 42: Maintenance

    3002 6070 30 For the most important subassemblies, Atlas Copco has developed service kits that combine all wear parts. These service kits offer you the benefits of genuine parts, save on administration costs and are offered at reduced price, compared to the loose components. Refer to the parts list for more information on the contents of the service kits.
  • Page 43 Generators in standby application have to be tested on a regular basis. At least once a month the engine should run Inspection by Atlas Copco Service technician for minimum 30 minutes at a high load (50%-70%) that the engine reaches its operating temperature.

  • Page 44: Engine Maintenance

    Specifications PAROIL Engine maintenance Engine oil specifications PAROIL from Atlas Copco is the ONLY oil tested Refer to the engine’s operator manual for full It is strongly recommended to use and approved for use in all engines built into Atlas maintenance, including instructions for changing the Atlas Copco branded lubrication oils.

  • Page 45: Engine Oil Level Check

    It is strongly recommended to use Engine oil and oil filter change low as -25°C. Atlas Copco branded coolant. See section “Maintenance schedule” on page 42. The use of the correct coolant is important for good Order Liter cu.ft...

  • Page 46: Coolant Check

    – Check the pH value of the coolant using a pH- engine overheating and possible failure. measuring device. It reduces water pump seal wear and has excellent – The pH-meter can be ordered from Atlas Copco stability when subjected to sustained high operating with part number 2913 0029 00. temperatures.

  • Page 47: Storage Of The Generator

    – Flush twice with clean water. Used coolant must – A refractometer can be ordered from Atlas Copco • Consult the engine’s operator manual. be disposed or recycled in accordance with laws with part number 2913 0028 00.

  • Page 48: Preparing For Operation After Storage

    Preparing for operation after Checks and trouble shooting Checking voltmeter P4 storage – Put a voltmeter in parallel with voltmeter P4 on Never perform a test run with the control panel. Before operating the generator again, remove the connected power cables. Never touch wrapping, VCI paper and silica gel bags and check the an electrical connector without a –...

  • Page 49: Alternator Troubleshooting

    Alternator troubleshooting Symptom Possible cause Corrective action Alternator gives 0 Volt Blown fuse. Replace fuse. Excite the alternator by applying a 12V battery voltage with a 30  No residual voltage. resistor in series on the + and - terminals of the electronic regulator, respecting the polarities.

  • Page 50: Engine Trouble Shooting

    Engine trouble shooting Not enough power The table below gives an overview of the possible – Incorrect valve tip clearances. engine problems and their possible causes. – Restriction in a fuel pipe. The pressure of the lubricating oil is The starter motor turns the engine –...
  • Page 51 Black exhaust smoke The engine runs erratically The pressure of the lubricating oil is too high – Restriction in air filter/cleaner or induction – Fault in fuel control. system. – Wrong grade of lubricating oil. – Restriction in a fuel pipe. –...

  • Page 52: Options Available For Qas 150-200 And Qas 170-220 Units

    – Bad connection towards oil pressure switch/ Power circuit coolant temperature switch. – Dual voltage (2V) Unit Circuit – Earth leakage relay QAS 150-200 Cud & – IT-relay QAS 170-220 Cud 9829 3000 28 – COSMOS™ QAS 150-200 Cud & QAS 170-220 Cud - 2V...

  • Page 53: Description Of The Electrical Options

    Battery switch Setting: Description of the electrical The battery switch is situated inside the sound- options – Lower output voltage = Counterclockwise insulated bodywork. It allows to open or to close the rotation The positioning of the components electrical connection between the battery and the –...
  • Page 54 Low voltage (LV) Q1 ..Circuit breaker for low voltage, high Dual voltage (2V) current The dual voltage option is only The Low voltage option allows to run the unit at low Interrupts the low voltage power supply available 60 Hz units with voltage (= high current).
  • Page 55 Q1.1 ..Circuit breaker for low voltage, high Earth leakage relay Depending on which mode the generator is running current in, circuit breaker Q1.1 or Q1.2 will be operational. The Earth relay option provides a detector that will Interrupts the low voltage power supply Circuit breakers Q1.1 and Q1.2 cannot be switched on trip the main circuit breaker Q1 when an earth fault towards X1 when a short-circuit occurs at...
  • Page 56 Q1 ..Main circuit breaker IT-relay Position O will only be used in The generator is wired for an IT network i.e. no N13 ..Earth leak detector conjunction with an external earth supply lines of the power supply are directly earthed. fault protection unit (e.g.
  • Page 57 When activated, Q1 interrupts the three For information about COSMOS™, consult your phases towards X1. It must be reset local Atlas Copco dealer. manually after eliminating the problem. - 57 -...

  • Page 58: Overview Of The Mechanical Options

    View outside When using this option, make sure to connect the fuel Overview of the mechanical supply line as well as the fuel return line. Connections options to fuellines ought to be air-tight to prevent air from The following mechanical options are available for entering the fuel system.
  • Page 59 Undercarriage (axle, towbar, towing To maintain the undercarriage Integrated spark arrestor eyes) The integrated spark arrestor option is included in the – Check the tightness of the towbar bolts, the axle refinery equipment pack. The undercarriage is equipped with a fixed towbar bolts and the wheel nuts at least twice a year and with brakes, with BNA-, NATO-, DIN-, ITA-, ISO- after the initial 50 hours of operation.

  • Page 60: Technical Specifications

    Technical specifications Technical specifications for QAS 150/170 units Readings on gauges Gauge Reading Unit Ammeter L3 (P3) Below max. rating Voltmeter (P4) Below max. rating Settings of switches Switch Function Activates at Engine oil pressure Shut down 1.0 bar Engine coolant temperature Shut down 99°C Specifications of the engine/alternator/unit...
  • Page 61 Rated PRP power 3ph 150 kVA 170 kVA Rated voltage 3ph line to line 400 V 480 V Rated voltage 3ph line to line lower voltage 220 V Rated current 3ph 216,5 A 204,5 A Rated current 3ph lower voltage 446,1 A Performance class (acc.ISO 8528-5:1993) Single step load acceptance (0-PRP)
  • Page 62 Status of neutral (ELR config.) (optional) earthed earthed Status of neutral (IT config.) (optional) insulated insulated Alternator 4) Standard IEC34-1 IEC34-1 ISO 8528-3 ISO 8528-3 Make Leroy Somer Leroy Somer Model LSA44.2M95 LSA44.2M95 Rated output, class H temperature rise 150 kVA 188 kVA rating type acc.
  • Page 63 Circuit-breaker, 3ph., lower voltage Number of poles (optional) Thermal release It (thermal release is higher at 25°C) 446 A Magnetic release Im 3..5xIn Fault current protection Residual current release IDn (optional) 0.030-30 A 0.030-30 A Insulation resistance (optional) 10-100 kOhm 10-100 kOhm Unit Dimensions (LxWxH) (standard)
  • Page 64 Derating factor (%) Temperature Height (°C) 1000 1500 2000 2500 3000 3500 4000 For use of generator outside these conditions, please contact Atlas Copco. - 64 -...

  • Page 65: Technical Specifications For Qas 200/220 Units

    Technical specifications for QAS 200/220 units Readings on gauges Gauge Reading Unit Ammeter L3 (P3) Below max. rating Voltmeter (P4) Below max. rating Settings of switches Switch Function Activates at Engine oil pressure Shut down 1.0 bar Engine coolant temperature Shut down 99°C Specifications of the engine/alternator/unit...
  • Page 66 Rated voltage 3ph line to line lower voltage 220 V Rated current 3ph 288.7 A 264.6 A Rated current 3ph lower voltage 577.4 A Performance class (acc.ISO 8528-5:1993) Single step load acceptance (0-PRP) 128 kW 158 kW Frequency droop (as ISO 8528) isochronous isochronous Fuel consumption at no load (0%)
  • Page 67 Alternator 4) Standard IEC34-1 IEC34-1 ISO 8528-3 ISO 8528-3 Make Leroy Somer Leroy Somer Model LSA46.2M5 LSA46.2M5 Rated output, class H temp. rise 200 kVA 250 kVA rating type acc. ISO 8528-3 Degree of protection IP 23 IP 23 Insulation stator class Insulation rotor class Number of wires Engine 4)
  • Page 68 Circuit-breaker, 3ph., lower voltage Number of poles (optional) Thermal release It (thermal release is higher at 25°C) 400 A Magnetic release Im 3..5xIn Fault current protection Residual current release IDn (optional) 0.030-30 A 0.030-30 A Insulation resistance (optional) 10-100 kOhm 10-100 kOhm Unit Dimensions (LxWxH) (standard)
  • Page 69 Derating factor (%) Temperature Height (°C) 1000 1500 2000 2500 3000 3500 4000 For use of generator outside these conditions, please contact Atlas Copco. - 69 -...

  • Page 70: Conversion List Of Si Units Into British Units

    Conversion list of SI units into Dataplate Maximum permitted total weight of the vehicle British units Maximum permitted front axle load Maximum permitted load on towing eye 1 bar 14.504 psi Company code 0.035 oz ★★★★★ Product code -YA3- ★★★★★ ★★★★★...

  • Page 71: Disposal

    Your Atlas Copco generator consists for the most part Remove the batteries. Do not throw batteries into the of metallic materials, that can be remelted in fire (explosion risk) or into the residual waste.
  • Page 72 - 72 -...
  • Page 73 Circuit diagrams - 73 -...
  • Page 74 9829 3000 28/00 Applicable for QAS 150-200 Cud & QAS 170-220 Cud - Power circuit Speed sensor Earth leakage relay (O) Emergency stop F1-3 Fuses 4A IT relay (O) (S2a see engine circuit) Alternator Actuator ELR disable switch (O) Relay...
  • Page 75 See Note 1: Do NOT connect (N) to (PE) Notes Note 1: The PE-N connection has to be made at the alternator-side of main Circuit Breaker Q1. See Note 1 R< 31 34 y54 y54 U> Legend Wire size : Colour code : a = 1 mm²...
  • Page 76 9829 3006 39/00 Applicable for QAS 150-200 Cud & QAS 170-220 - Engine Circuit Qc1002™ Generator control unit Battery 24 Vdc Relay Fuel level sensor Charging alternator Starter motor Coolant temperature sensor Panel light P1-P3 A-meter Oil pressure sensor Starter solenoid...
  • Page 77 F G H I J K a3 a3 to Circ.Diagr POWER to Circ.Diagr POWER a3 50 Legend Wire size : Colour code : a = 1 mm² 0 = black b = 1.5 mm² 1 = brown c = 2.5 mm² 2 = red d = 4 mm²...
  • Page 78 9829 3006 40/00 Applicable for QAS 150-200 Cud & QAS 170-220- Engine Circuit Qc2002™ Generator control unit Battery 24 Vdc Relay Fuel level sensor Charging alternator Starter motor Coolant temperature sensor Panel light Fuel feed pump Oil pressure sensor Starter solenoid...
  • Page 79 F G H J K L M N O P Q to Circ.Diagr POWER a3 a3 a6 a3 a3 50 Legend Wire size : Colour code : a = 1 mm² 0 = black b = 1.5 mm² 1 = brown c = 2.5 mm²...
  • Page 80 - 80 -...
  • Page 82 www.atlascopco.com...

This manual is also suitable for:

Qas 170-220 cudQas 60 cudQas 70 cud

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