Atlas Copco QAS 60 Pd Instruction Manual
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Atlas Copco QAS 60 Pd Instruction Manual

Atlas Copco QAS 60 Pd Instruction Manual

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QAS 60 Pd S2A APP

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  • Page 1 Instruction Manual for AC Generators English QAS 60 Pd S2A APP...
  • Page 3 QAS 60 Pd Instruction Manual for AC Generators Instruction manual .................. 5 Circuit diagrams ................... 111 Original instructions Printed matter N° 2954 6280 00 ATLAS COPCO - PORTABLE ENERGY DIVISION www.atlascopco.com 04/2012...
  • 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 2012, Atlas Copco Airpower n.v., Antwerp, Belgium. 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 Operating and setting Adjustments and service 6.4.1 Qc1002™ and Qc2002™ Qc4002™ MkII ........46 procedures ........73 alarms and remedies .......83 4.4.1 Starting ..........46 5.5.1 Cleaning coolers.......73 6.4.1.1 Alarm overview ........83 4.4.2 During operation ......46 5.5.2 Cleaning the fuel tank ......73 6.4.1.2 Fail classes ........84 4.4.3 Stopping ...........46 5.5.3...
  • Page 7 9.3.5 Outlet sockets (S) - Set 2 ....94 10.4 Conversion list of SI units into British units ........110 9.3.6 Outlet sockets (S) - Set 3 ....95 9.3.7 Single frequency with 10.5 Dataplate.........110 electronic speed control (SF) ..96 9.3.8 Dual frequency with electronic speed control (DF) ..96 9.3.9 Electronic speed regulator ....96...

  • Page 8: Safety Precautions For On-Site 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 9: 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 10: Safety During Transport And Installation

    When - check the towbar, the brake system and the Atlas Copco. the towbar can be positioned vertically, the locking towing eye. Also check the coupling of the device must be applied and kept in good order.

  • Page 11: Safety During Use And Operation

    - above 85 dB(A): room to be classified as a noise- vibration hazards, etc., take the necessary steps to otherwise stated in the Atlas Copco Instruction hazardous area and an obvious warning shall be eliminate the risk of personnel injury.

  • Page 12: Safety During Maintenance And Repair

    Replace the damaged wires or correct the dangerous or dust, the respiratory organs must be protected and Parts shall only be replaced by genuine Atlas Copco condition before restarting. Make sure that all depending on the nature of the hazard, so must the replacement parts.
  • Page 13 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 14: Tool Applications Safety

    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 15: Main Parts

    General description The QAS 60 Pd 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 generator operates at 50/60 Hz, 230/240 V in line-to-neutral mode and 400/480 V in line-to-line mode. The QAS 60 Pd generator is driven by a fluid-cooled diesel engine, manufactured by PERKINS.
  • Page 16 Alternator Air filter Coupling Drain flexible engine oil Drain and access hole (in the frame) Drain plug fuel Engine Filler cap fuel Filler cap engine oil Filler cap coolant Fuel filter Battery Oil filter Engine oil level dipstick Pre fuel filter Radiator DPF, DH - 16 -...

  • Page 17: Markings

    Markings Indicates the drain for the coolant. XXXXXXXXXXXXXXX A brief description of all markings provided on the Indicates the partnumbers of generator is given hereafter. the different service packs XXXXXXXXX XXXX XXXX XX XXXXXXXXX XXXX XXXX XX and of the engine oil. These Indicates the drain plug for the engine Engine oil PAROIL E...

  • Page 18: Safety Devices

    2.3.3 Safety devices 2.3.7 Drain plugs and filler caps The engine is equipped with low oil pressure and high The drain holes for the engine oil, the coolant and the oil temperature shut-down switches. plug for the fuel, are located and labelled on the frame.

  • Page 19: Qc1002™ Controller

    Electrical features The electrical features described in this chapter are A1 ..Qc1002™ display Qc1002™ Module standard provided on this generator. For all other F10 ..Fuse electrical features, see “Overview of the electrical options” on page 91. The fuse activates when the current from the battery to the engine control circuit exceeds 2.4.1 Control and indicator panels...

  • Page 20: Qc2002™ Controller

    2.4.1.2 Qc2002™ controller H0 ..Panel light Qc2002™ Module S2 ..Emergency stop button General description Qc2002™ control panel Push the button to stop the generator in case of an emergency. When the button is pressed, it must be unlocked, before the generator can be restarted.

  • Page 21: Qc4002™ Mkii Controller

    2.4.1.3 Qc4002™ MkII controller F10 ..Fuse X25 ..Connection block The fuse (10 A) activates when the current Inside cubicle. Allows customer General description Qc4002™ MkII control panel from the battery to the engine control circuit connections. exceeds its setting. The fuse can be reset by pushing the button.

  • Page 22: Output Terminal Board

    Qc4002™ MkII module 2.4.2 Output terminal board S2..Emergency stop button Push the button to stop the generator in case The cubicle provides a terminal board for easier of an emergency. When the button is connection of cables. It is situated below the control pressed, it must be unlocked, by turning it and indicator panel.

  • Page 23: Installation And Connection

    Installation and connection To be able to lift the generator by means of a forklift, Lifting Installation rectangular holes are provided at the bottom of the The lifting eye, to lift the generator by means of a frame. 3.2.1 Indoor installation hoist, is integrated in the bodywork and easily accessible from the outside.

  • Page 24: Connecting The Generator

    The exposed ray equipment, audio amplifiers and elevators. conductive parts of the electric Wire section Max. current (A) Consult Atlas Copco for measures against the adverse installation must directly ² Multiple core...

  • Page 25: Connecting The Load

    The lowest acceptable wire section and the – Open the door of the control and indicator panel 3.3.3 Connecting the load corresponding maximum cable or conductor length and the transparent door in front of the terminal for multiple core cable or H07 RN-F, at rated current board X1.

  • Page 26: Operating Instructions

    Operating instructions Before starting Operating and setting In your own interest, always strictly Qc1002™ observe relevant safety – With the generator standing level, check the instructions. engine oil level and top up if necessary. The oil Do not operate the generator in level must be near to, but not exceed the high mark 4.2.1 Starting...

  • Page 27: During Operation

    – Check, by means of the generator gauges, that the To start up the unit from a remote location, To stop the unit when the starter switch is in voltage between the phases is identical and that proceed as follows: position , proceed as follows: the rated current is not exceeded.

  • Page 28: Setting The Qc1002

    4.2.4 Setting the Qc1002™ Following LEDs are used on the Qc1002™: 4.2.4.2 Qc1002™ menu overview At Qc1002™, the LCD will show following 4.2.4.1 Pushbutton and LED functions information: – in Normal condition (scroll through the Following pushbuttons are used on the Qc 1002 information using UP and DOWN): Qc1002™:...

  • Page 29: Qc1002™ Menu Description

    4.2.4.3 Qc1002™ menu description Parameter display Status display (pop-up window) DIAGNOSTIC Parameter If a special status has elapsed, the active view will be This view shows a number of Parameter settings and entered again automatically. gives access to them. If an Alarm comes up, the Alarm Display is shown. In case special statuses are entered, a pop-up window An overview is given in “Parameter list”...
  • Page 30 LOG list display Battery Voltage display Oil pressure display LOG List Battery 13.2 V 3.2bar 00168.1h 00168.1h This view shows the alarm memory and gives access This view shows the Battery voltage and the running This view shows the Oil pressure and the running to it.

  • Page 31: Parameter List

    – Unit Menu Voltage - frequency - running hours display 4.2.4.4 Parameter list 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 400V 50Hz change a setting is about to be done (user password =...
  • Page 32 This is the described menu flow for changing the unit type: Qc1002 Qc 1002 Parameter Running time Unit type Unit type Unit type - 32 -...

  • Page 33: Log List

    4.2.4.5 LOG list 4.2.4.6 Remote start operation The unit will keep an event log of the latest 30 events. Installation wirings: 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 34: Operating And Setting Qc2002

    Operating and setting To start up the unit from a remote location, 4.3.2 During operation proceed as follows: Qc2002™ Regularly carry out following checks: – Put the starter switch S20 in position I (ON). – Check the analogue meters (P1-P4) and the Voltage is applied to the Qc2002™...

  • Page 35: Stopping

    4.3.3 Stopping 4.3.4 Setting the Qc2002™ When the unit is stopped with the STOP button Automatic To stop the unit , proceed as follows: 4.3.4.1 Pushbutton and LED functions operation, it will automatically go to – Switch off the load. Following pushbuttons are used on the Manual Mode.
  • Page 36 Following LEDs are used on the Qc2002™: Mains Green LED indicates that it is AUTOMATIC: Is used to put the contactor possible to close the Mains unit in manual or automatic Contactor (only in AMF mode), operation. if the Generator contactor is Qc2002 open.

  • Page 37: Qc2002™ Menu Overview

    • Active, reactive and apparent power of the 4.3.4.2 Qc2002™ menu overview 4.3.4.3 Qc2002™ menu description generator At Qc2002™, the LCD will show following Status Display (pop-up window) • Generator currents information: • Phase voltages of the mains – in Normal condition (scroll through the •...
  • Page 38 Parameter display LOG list display DIAGNOSTIC Parameter LOG List If a special status has elapsed, the active view will be This view shows a number of Parameter settings and This view shows the alarm memory and gives access entered again automatically. gives access to them.
  • Page 39 Battery voltage display Oil pressure display kWh counter display Battery 13.2 V 3.2bar 4860kWh 00168.1h 00168.1h This view shows the Battery voltage and the running This view shows the Oil pressure and the running This view shows the kWh counter. hours.

  • Page 40: Parameter List

    One line voltage - frequency - active power Phase voltages mains display 4.3.4.4 Parameter list display The parameter menu's are pre-programmed ! A password will be asked for when an attempt to M L1-N 230V change a setting is about to be done (user password = G L1-L2 400V M L2-N...
  • Page 41 Menu's shown on the parameter list LCD: Automatic Mains Failure (AMF) operation Horn delay Genset mode This application is only possible in Horn Delay combination with the AUTO mode. If the Manual Operation mode is Genset Mode 0.0s 20.0s 990.0s selected the AMF operation will NOT function! Island...
  • Page 42 Service timer 1 reset Unit menu Engine CAN communication Engine I Comm St 1 Reset Unit C/bar C/bar F/psi These menus are used to reset the service timers. This menu is used to select the units into which This menu is used to select the type of engine When a service timer alarm occurs and is pressures and temperatures will be shown.
  • Page 43 M frequency delay MF high voltage MF voltage delay M freq delay MF high volt MF volt delay 9900s 1.0s 990.0s 100% 120% This menu is used to set the delay, which defines how This menu is used to set the maximum limit for the This menu is used to set the delay, which defines how long the mains frequency has to be back within the mains voltage, in % of the nominal voltage (in AMF-...
  • Page 44 Overvoltage delay Undervoltage delay Overfrequency delay > Volt Delay < Volt Delay > Freq Delay Overvoltage setpoint Undervoltage setpoint Overfrequency setpoint > Volt < Volt > Freq Undervoltage enable Overfrequency enable Underfrequency enable < Volt enable > Freq enable < Freq enable Enable enable...

  • Page 45: Log List

    Underfrequency delay 4.3.4.5 LOG list The unit will keep an event log of the latest 30 events. Events are: < Freq Delay – shutdowns – service timer 1/2 reset Together with each event, the real time of the event Underfrequency setpoint will be stored.

  • Page 46: Operating And Setting Qc4002™ Mkii

    Operating and setting Qc4002™ MkII 4.4.2 During operation 4.4.3 Stopping Before setting the controller make Regularly carry out following checks: – When in SEMI-AUTO mode: sure that the Qc4002™ MkII is • Press the GB open/close button to open the –...

  • Page 47: Setting The Qc4002™ Mkii

    4.4.4 Setting the Qc4002™ MkII STOP: Stop of the gen-set if SEMI- SEL: Is used to select the AUTO or MANUAL is selected. underscored entry in the fourth line 4.4.4.1 Pushbutton and LED functions of the display. Following pushbuttons are used on the UP: Increases the value of the GB: Manual activation of Qc4002™...
  • Page 48 Following LEDs are used on the Qc4002™ MkII The main Qc4002™ MkII control unit includes 5 (GB) ON LED green light indicates that the LEDs generator breaker is closed. LED yellow light indicates that the Qc4002 generator breaker has received a command to close on a black BUS, but the breaker is not yet closed due to interlocking of the GB.

  • Page 49: Qc4002™ Mkii Menu Overview

    V2 view – The view shows some generator 4.4.4.2 Qc4002™ MkII menu overview measurements. Main View – In the V1 view the user can scroll up and down to The display has 4 different lines. The information on 15 configurable screens showing different these lines can change, depending on which view is measurements of the generator, the bus and the used.
  • Page 50 If you select SETUP then you get the following view: Scrolling down will give all the protection The user can scroll through this list and select one set parameters: point with the SEL button. – The first line shows some generator data. After selection of SP the following view will be visible: –...
  • Page 51 – 9000 Software version – 9020 Service port – 911X User password Level 2 and Level 3 passwords can only be set through the Atlas Copco Utility Software PC Software. – 9120 Service menu – 9130 Single/Split/Three phase – 9140 Angle comp. BB/G Use the UP and DOWN buttons to change the settings and the SEL button to store the new setting.

  • Page 52: Changing Settings

    4.4.4.3 Changing settings Menu flow: The menu flow is similar in the CONTROL SETUP, I/O SETUP and SYSTEM SETUP. For more details on the Setup menu we refer to the Qc4002™ MkII User Manual. - 52 -...

  • Page 53: Standard Modes

    "2003". operational state. In order to receive the default parameters for your When operating in AUTO mode the unit, please contact Atlas Copco Service staff. STOP and GB Open/Close button will not function. Semi-Auto mode In semi-auto mode the operator has to initiate all sequences.

  • Page 54: Standard Applications

    Block mode 4.4.4.5 Standard applications Island operation When the block mode is selected, the unit is locked In the Qc4002™ MkII module 9 application types can Generator for certain actions. This means that it cannot start the be selected. A combination of each application type breaker LOAD gen-set or perform any breaker operations.
  • Page 55 – For Remote Start operation: – AMF with back synchronisation: Peak Shaving (PS) operation • wire the RS switch between X25.9 & X25.10. When the mains returns, the unit will synchronise Generator Mains – For Paralleling applications with other generators: the mains breaker to the busbar when the ‘Mains breaker LOAD...
  • Page 56 – Mains breaker control lines have to be wired to Installation wirings Fixed Power (FP) operation X25.13/X25.14/X25.15/X25.16. These terminals – The link between X25.10/X25.11 has to be are voltage free contacts. The power for the MB removed. Generator Mains breaker breaker LOAD has to be supplied by the customer (24 Vdc/...
  • Page 57 Load Take Over (LTO) operation Installation wirings Mains Power Export (MPE) operation – The link between X25.10 & X25.11 has to be Generator Mains Generator Mains removed. breaker LOAD breaker breaker LOAD breaker – Mains breaker feedback lines have to be wired to X25.10/X25.11/X25.12.
  • Page 58 Installations are possible with stand-alone generators Installation wirings Multiple gen-sets with load sharing or with the Mains (extra Qc4002™ MkII Mains is – The link between X25.10 & X25.11 has to be In this application the units are enabled to share the then needed).
  • Page 59 Example: Installation with 3 gensets The priority on starting and stopping the generators Installation wirings can be chosen on priority settings or on the amount of G1 = 300 kW; G2 = 200 kW; G3 = 200 kW. running hours. In manual mode the start and stop Genset 1 Genset 2 Genset 3...

  • Page 60: Paralleling

    4.4.4.6 Paralleling Prior to starting parallel operation of two generators, following connections need to be made: – Connect the communication cable between the generators by plugging the adapter into socket X30. – Connect the load with the generator. Go via the site distribution panel (to be installed by the customer) to connect the generator(s) with the load.

  • Page 61: Overview Of Applications

    Only with Power Transducer (*) (*) A Power Transducer is a device that measures the actual power of the mains and which translates this into a 4...20 mA signal towards the Qc4002™ MkII module. For details, please contact Atlas Copco. - 61 -...
  • Page 62 The installation can contain up to 16 Qc4002™ MkII modules. If the Mains is included in the installation, then an extra Qc4002™ MkII module is required. The installation can be monitored and controlled via the PMS Software Package. For details on this application, please contact Atlas Copco. - 62 -...
  • Page 63 Do not put this value above 60 seconds to avoid any possible damage. 4. For more information on the Qc4002™ MkII module and its applications, we refer to the Qc4002™ MkII User manual and the Qc4002™ Application data sheets. If you need more assistance, please contact Atlas Copco. - 63 -...

  • Page 64: Maintenance

    2912 4546 05 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 65 50 hrs Every 500 Every 1000 Every 2000 Maintenance schedule Daily after initial Yearly hours hours hours start-up 2912 4412 05 or Service pak 2912 4546 05 Replace fuel (secondary)filter(s) (5) Inspect/Adjust fan/alternator belt Replace fan/alternator belt Measure alternator insulation resistance (11) Test Earth Leakage Relay (12) Check emergency stop (12) Clean radiator (1)
  • Page 66 Inspect turbocharger Inspect waterpump Inspection by Atlas Copco service technician Generators in standby application have to be tested on a regular basis. At least once a month the engine should run for one hour. If possible a high load (> 30%) should be applied so that the engine reaches its operating temperature.
  • Page 67 2912 4546 05 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 68 50 km Every 500 Every 1000 Every 2000 Maintenance schedule Daily after initial Yearly hours hours hours start-up 2912 4412 05 or Service pak 2912 4546 05 Check/Adjust lateral play of wheel bearing (conventional bearing) Generators in standby application have to be tested on a regular basis. At least once a month the engine should run for one hour.

  • Page 69: Use Of Maintenance Schedule

    The order number of the Service Paks are listed in the (7) The following part numbers can be ordered from Atlas Copco Parts list (ASL). Order Service Paks at your local Atlas Copco dealer. Atlas Copco to check on inhibitors and freezing points: •...

  • Page 70: Preventing Low Loads

    Mains may be placed in Fixed Power or Test mode without the requirement of a load bank. For more info on this operation, please contact your Atlas Copco Service Center. – Check the engine oil level by using the oil level dipstick (OLD).

  • Page 71: Engine Oil And Oil Filter Change

    – Remove the drain plug from the oil drain flexible – The pH-meter can be ordered from Atlas Copco to drain the oil. with part number 2913 0029 00. – Replace the seal of the drain plug.

  • Page 72: Topping Up Of Coolant

    Flush high engine operating temperatures. – Flush twice with clean water. Used coolant must – A refractometer can be ordered from Atlas Copco be disposed or recycled in accordance with laws with part number 2913 0028 00. and local regulations.

  • Page 73: Adjustments And Service Procedures

    Adjustments and service procedures – Keep the water cooler clean to maintain the 5.5.1 Cleaning coolers 5.5.2 Cleaning the fuel tank cooling efficiency. – The engine water cooler is accessible via the service door (1) at the front of the unit. Remove any dirt from the coolers with a fibre brush.

  • Page 74: Battery Care

    – Rock the battery a few times so that possible air If a battery does not need any make-up water at all 5.5.3 Battery care bubbles can escape; wait 10 minutes and check the over considerable time operation, Before handling batteries, read the level in each cell once more;...

  • Page 75: Servicing Air Filter Engine

    Servicing air filter engine 5.5.4.2 Recommendation 5.5.4.4 Replacing the air filter element – Release the snap clips (1) and remove the dust trap The Atlas Copco air filters are 5.5.4.1 Main parts (2). Clean the trap. specially designed – Remove the element (4) from the housing (5).

  • Page 76: Replacing Fuel Filter Element

    Specifications PAROIL – Clean the adapter head sealing surface. Lightly oil PAROIL from Atlas Copco is the ONLY oil tested the gasket of the new element and screw the latter and approved for use in all engines built into Atlas...
  • Page 77 Copco PAROIL Extra is designed to provide index. Atlas Copco PAROIL E Mission Green is extended periods. excellent lubrication from start-up in temperatures as designed to provide a high level of performance and low as -25°C (-13°F).

  • Page 78: Engine Coolant Specifications

    Never remove the cooling system number tested and approved by all engine manufacturers filler cap while coolant is hot. currently in use in Atlas Copco compressors and The system may be under pressure. 0.175 1604 5308 00 generators. Remove the cap slowly and only...

  • Page 79: Checks And Trouble Shooting

    Checks and trouble Checks Engine troubleshooting shooting The table below gives an overview of the possible 6.1.1 Checking voltmeter P4 engine problems and their possible causes. Never perform a test run with – Put a voltmeter in parallel with voltmeter P4 on connected power cables.
  • Page 80 – Incorrect valve tip clearances. Not enough power The pressure of the lubricating oil is too low – Restriction in a fuel pipe. – Wrong grade of lubricating oil. – Engine overload. – Fault in fuel lift pump. – Not enough lubricating oil in sump. Blue or white exhaust smoke –...
  • Page 81 – Fault in cold start system. Crankcase pressure – Restriction in fuel tank vent. – Restriction in breather pipe. – Vacuum pipe leaks or fault in exhauster. – Restricted movement of engine speed control. – Engine temperature is too high. Bad compression –...

  • Page 82: 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 83: Solving Controller Alarms

    Solving controller alarms GENERATOR UNDER- START FAILURE 6.4.1 Qc1002™ and Qc2002™ alarms VOLTAGE and remedies 6.4.1.1 Alarm overview GENERATOR OVER- STOP FAILURE Possible alarms appearing in the alarm list: FREQUENCY GENERATOR LOW OIL UNDER- HZ/V FAILURE PRESSURE FREQUENCY (Qc2002™ alarm) HIGH COOLANT SERVICE TIMER 1 OIL LEVEL...

  • Page 84: Fail Classes

    General groups of Alarms 6.4.1.3 Solving alarms – Warning: Alarm LED lights up + Alarm pop-up appears on the display + Alarm relay is empowered (if configured) – Trip of GB: ‘Warning’ actions + Generator Contactor opens – Trip and Stop: ‘Trip of GB’ actions + unit stops In case an Alarm occurs, a pop-up window will after Cooldown automatically be displayed for as long as the alarm is...
  • Page 85 Menu flow This is the described menu flow for solving alarms: Qc1002 Alarm List Alarm List v x.xx.xx 1 Alarm(s) 0 Alarm(s) SOLVE PROBLEM See next page Alarm List 0 Alarm(s) - 85 -...
  • Page 86 Battery broken Replace battery. Bad connection Check wiring. Low oil pressure Not enough oil Fill oil till appropriate level. Check for leaks. Sensor broken Replace sensor. Oil sump broken Check or contact Atlas Copco. Bad connection Check wiring. - 86 -...

  • Page 87: Qc4002™ Mkii Alarms And Remedies

    6.4.2 Qc4002™ MkII alarms and remedies 6.4.2.1 Fail Classes Engine stopped: 6.4.2.2 Diagnostics menu – Alarm: Block engine start. All the activated alarms of the module are configured The diagnostics menu can be entered via channel with a fail class. The fail class defines the category of 6700.

  • Page 88: Solving Alarms

    6.4.2.3 Solving alarms Menu flow Qc4002 Qc4002 Qc4002 SOLVE PROBLEM See page 86 Qc4002 - 88 -...

  • Page 89: Storage Of The Generator

    Storage of the generator Storage Preparing for operation after storage – Store the generator in a dry, frost-free room which is well ventilated. Before operating the generator again, remove the wrapping, VCI paper and silica gel bags and check the –...

  • Page 90: Disposal

    (for example sand, sawdust) and recyclable materials. dispose it according the applicable local disposal Your Atlas Copco generator consists for the most part regulations. Do not drain into the sewage system or of metallic materials, that can be remelted in surface water.

  • Page 91: Options Available For Qas 60 Units

    – Outlet sockets (S) - Set 1 QAS 60 Pd 9822 0996 10 – Outlet sockets (S) - Set 2 QAS 60 Pd - 2V-50Hz 1ph 9822 0996 11 – Outlet sockets (S) - Set 3 QAS 60 Pd - 2V-50 Hz 9822 0996 12 –...

  • Page 92: Description Of The Electrical Options

    Setting: Description of the electrical 9.3.2 Battery switch – Lower output voltage = counterclockwise rotation options The battery switch is situated inside the sound- insulated bodywork. It allows to open or to close the – Higher output voltage = clockwise rotation electrical connection between the battery and the 9.3.1 Automatic battery charger...

  • Page 93: Outlet Sockets (S) - Set 1

    9.3.4 Outlet sockets (S) - Set 1 X5 ..3-phase outlet socket (400 V AC) Q6 ..Circuit breaker for X6 Provides phases L1, L2 and L3, neutral and Interrupts the power supply to X6 when a A brief description of all outlet sockets and circuit earthing.

  • Page 94: Outlet Sockets (S) - Set 2

    three phases towards X4. It can be activated 9.3.5 Outlet sockets (S) - Set 2 X4 ..3-phase outlet socket (400 V AC) again after eliminating the problem. Provides phases L1, L2 and L3, neutral and A brief description of all outlet sockets and circuit earthing.

  • Page 95: Outlet Sockets (S) - Set 3

    9.3.6 Outlet sockets (S) - Set 3 X3 ..3-phase outlet socket (400 V AC) Q5 ..Circuit breaker for X5 Provides phases L1, L2 and L3, neutral and Interrupts the power supply to X5 when a A brief description of all outlet sockets and circuit earthing.

  • Page 96: Single Frequency With

    9.3.7 Single frequency with 9.3.8 Dual frequency with electronic Changing the output frequency is electronic speed control (SF) speed control (DF) only allowed when the unit has The Single frequency option provides an electric The Dual frequency with electronic speed control stopped.

  • Page 97: Dual Voltage (2V)

    9.3.10 Dual voltage (2V) Q1.2 ..Circuit breaker for high voltage, low current The dual voltage option is only Interrupts the high voltage power supply available 50 Hz units with towards X1 when a short-circuit occurs at Qc1002™ controller. the load side or when the overcurrent 1 phase - 3 phase protection (100 A) is activated.

  • Page 98: Earth Leakage Relay

    S10 ..Output voltage selection switch 9.3.11 Earth leakage relay N13 ..Earth leak detector Allows to select a 3 phase high output Detects and indicates an earth fault current The Earth relay option provides a detector that will voltage or a 1 phase / 3 phase low output and activates the main circuit breaker Q1.

  • Page 99: It-Relay

    9.3.12 IT-relay Position O will only be used in The generator is wired for an IT network i.e. no conjunction with an external earth supply lines of the power supply are directly earthed. fault protection unit (e.g. integrated A failure in insulation resulting in a too low insulation in a distribution board).

  • Page 100: Electricité De France" (Edf)

    X1 ..Main power supply (400 Vac) 9.3.13 “Electricité de France” (EDF) Terminals L1, L2, L3, N (= neutral) and PE When the EDF-option is installed, the unit operates as PE EDF (= earthing), hidden behind the control panel a standard unit when the neutral and the PE terminals door and behind a small transparent door.

  • Page 101: 9.3.14 Cosmos

    X25 ..Customer wiring For information about COSMOS™, consult your To connect the COC box to the generator local Atlas Copco dealer. equipped with Qc2002™ controller 8 connections have to be made on X25. Connect 1 to 1, 2 to 2,... 8 to 8.

  • Page 102: Overview Of The Mechanical Options

    When using this option, make sure to connect the fuel Overview of the mechanical View outside 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: entering the fuel system.

  • Page 103: Undercarriage (Axle, Towbar, Towing Eyes)

    9.5.2 Undercarriage (axle, towbar, To maintain the undercarriage 9.5.3 Integrated spark arrestor towing eyes) – Check the tightness of the towbar bolts, the axle The integrated spark arrestor option is included in the bolts and the wheel nuts at least twice a year and refinery equipment pack.

  • Page 104: Technical Specifications For Qas 60 Units

    Technical specifications for QAS 60 units 10.1 Readings on gauges Gauge Reading Unit Ammeter L1-L3 (P1-P3) Below max. rating Voltmeter (P4) Below max. rating 10.2 Settings of switches Switch Function Activates at Engine oil pressure Shut down 0.5 bar Engine coolant temperature Shut down 103°C 10.3 Specifications of the engine/alternator/unit...
  • Page 105 Rated apparent power (PRP) 3ph 60 kVA 67 kVA Rated apparent power (PRP) 1ph 35 kVA 39 kVA Rated voltage 3ph line to line 400 V 480 V Rated voltage 3ph line to line lower voltage 230 V 240 V Rated voltage 1ph 230 V 240 V...
  • Page 106 Climatic exposure open air open air Status of neutral (TT or NT) earthed earthed Status of neutral (IT) (optional) insulated insulated Standard ISO 3046 ISO 3046 Engine 4) ISO 8528-2 ISO 8528-2 Type PERKINS 1104C-44TG3/TG2 1104C-44TG3/TG2 Rated net output 54 kW 60 kW rating type acc.
  • Page 107 Circuit-breaker, 3ph. Power circuit Number of poles Thermal release It (thermal release is higher at 25°C) 100 A 100 A Magnetic release Im 3..5xIn 3..5xIn Circuit-breaker, 3ph., lower voltage Number of poles (optional) Thermal release It (thermal release is higher at 25°C) 152 A 175 A Magnetic release Im...
  • Page 108 v) CEE form 3p + N + PE 125 A/400 V Dimensions without undercarriage (LxWxH) 2850 x 1100 x 1635 mm 2850 x 1100 x 1635 mm Unit Dimensions without undercarriage, with optional 24h fuel tank (LxWxH) 2850 x 1100 x 1751 mm 2850 x 1100 x 1751 mm Dimensions with undercarriage (adj.
  • Page 109 24h period shall not exceed the stated load factor as indicated in the ‘Technical specifications’ above. Specific mass fuel used: 0.86 kg/l. Derating Temperature Height (°C) 1000 1500 2000 2500 3000 3500 4000 For use of generator outside these conditions, please contact Atlas Copco. - 109 -...
  • Page 110 35.315 cfm cos phi " Nominal rated current Manuf. year/Baujahr/Année de fabrication 1 mbar 0.401 in wc MADE BY ATLAS COPCO AIRPOWER n.v. WILRIJK, BELGIUM Power factor 0.225 lbf Manufacturing year 1 Nm 0.738 lbf.ft 1615 6945 00 EEC mark in accordance witt Machine Directive 32 + (1.8 x t...
  • Page 111 Circuit diagrams - 111 -...
  • Page 112 9822 0996 05/01 Applicable for QAS 60 Pd - Engine Circuit Qc1002™ to Circ.Diagr POWER a0 a0 a3 a3 Sx=Remote 11 12 Start/Stop-switch Generator Contactor (*)= Connect L2 to X25.5 Output: 12Vdc, max.8Adc1 with 230Vd-systems MAINS SUPPLY (1P+N) Customer's Installation...
  • Page 113 to Circ.Diagr POWER to Circ.Diagr POWER Canopy Position of Relay Contacts d2 d2 - 113 -...
  • Page 114 Generator control unit (set A1 in UNIT-type 2) Fuel level sensor Coolant temperature sensor Oil pressure sensor Preheat resistor Fuse 10A DC Battery 12 Vdc Charging alternator Panel light Starter solenoid Preheat relay Starter relay Starter motor Fuel feed pump P1-P3 A-meter V-meter...
  • Page 115 - 115 -...
  • Page 116 9822 0996 06/01 Applicable for QAS 60 Pd - Engine Circuit Qc2002™ towards to Circ.Diagr POWER X25.8 11 12 Sx=Remote Start/Stop-switch MAINS SUPPLY (3P+N+PE) Customer's Installation (see Instruction Manual) Legend Qc2002 Wire size : Colour code : a = 1 mm²...
  • Page 117 to Circ.Diagr POWER to Circ.Diagr POWER 50/60Hz-switch S12 Canopy Position of Relay Contacts d2 d2 - 117 -...
  • Page 118 Generator control unit Fuel level sensor Coolant temperature sensor Oil pressure sensor Preheat resistor Fuse 10A DC Battery 12 Vdc Charging alternator Starter solenoid Preheat relay Starter relay Starter motor Fuel feed pump P1-P3 A-meter V-meter Excitation resistor 47ohm Emergency stop (S2b: see Power circuit) V-meter change-over switch High coolant temperature switch...
  • Page 119 - 119 -...
  • Page 120 9822 0996 10/01_A Applicable for QAS 60 Pd - Power Circuit Voltage See Note 2 Adjustm. Frequency Selection 400V/480V R250 R438 50Hz 60Hz to Circ.Diagr ENGINE to Circ.Diagr ENGINE Qc2002 - A1.17 Ampere-meter a3 a3 to Circ.Diagr ENGINE Ampere-meter to K7.85...
  • Page 121 R< See Note 1 U> PE-EDF See Note 3 (O) N-EDF - 121 -...
  • Page 122 Speed sensor MPU (O) F1-F3 Fuses 4 A Alternator Auxiliary relay for Y7 (O) Speed controller (O) Automatic voltage regulator Earth leakage relay (O) IT-relay (O) Circuit breaker Coolant heater (O) Speed adjustment 5K (O) Voltage adjustment 1K (O) Emergency stop (S2a: see Engine circuit) 50/60 Hz-switch (O) E.L.R.
  • Page 123 9822 0996 10/01_B Applicable for QAS 60 Pd - Power Circuit Sheet1 - e6 Sheet1 - e6 Sheet1 - e6 Sheet1 - e6 Sheet1 - e6 g0 g0 g0 g6 g0 g0 g0 g6 e0 e0 e0 e6 hx0 hx0 hx0 hx6...
  • Page 124 Circuit Breaker 16A/30mA Circuit Breaker 63A or 125A Circuit Breaker 63A Circuit Breaker 32A Circuit Breaker 16A Outlet Socket 16A 1ph Outlet Socket 63A or 125A Outlet Socket 63A Outlet Socket 32A Outlet Socket 16A Optional equipment - 124 -...
  • Page 125 9822 0996 11/01 Applicable for QAS 60 Pd - Power Circuit, dual voltage, 50 Hz, 1 ph T4 T11 T10 Frequency Selection Note R250 R438 50Hz 60Hz NONE (12) (11) (L1) (10) See Note 3 Notes to K7.85 Note 1: The PE-N connection has to be made at the alternator-side of main Circuit Breaker Q1.
  • Page 126 See Note 1 Legend Wire size : Colour code : a = 1 mm² 0 = black b = 1.5mm² 1 = brown X9 S13 c = 2.5mm² 2 = red 3 = orange d = 4 mm² e = 6 mm² 4 = yellow f = 10 mm²...
  • Page 127 Speed sensor MPU (O) F1-F6 Fuses 4 A Alternator Auxiliary relay for Y7 (O) Auxiliary relay select 230 Vzz (LV) Auxiliary relay select 400 Vy (HV) Speed controller (O) Automatic voltage regulator Earth leakage relay Q1.1 Circuit breaker 230 Vzz (LV) Q1.2 Circuit breaker 400 Vy (HV) Coolant heater (O)
  • Page 128 - 128 -...
  • Page 129 9822 0996 12/00 Applicable for QAS 60 Pd - Power circuit - Dual voltage, 50 Hz X11.8 X9.28 Note Frequency Selection X11.9 X9.29 R250 R438 50Hz 60Hz Notes Note 1: The PE-N connection has to be made at the alternator-side.
  • Page 130 R< Twisted Pair Cubicle Alt. Cubicle X11.2 X11.4 Alt. S10d X11.5 X11.1 X11.3 S10b S10c X11.6 X11.7 Legend Q1.1 Q1.2 Wire size : Colour code : aa = 0.5mm² 0 = black a = 1 mm² 1 = brown b = 1.5mm² 2 = red c = 2.5mm²...
  • Page 131 Speed sensor MPU (O) F1-F3 Fuses 4 A Alternator Speed controller (O) Automatic voltage regulator Earth leakage relay (O) IT relay Q1.1 Circuit breaker 230Vd (lower voltage) Q1.2 Circuit breaker 400Vy (higher voltage) Coolant heater (O) Speed adjustment 5K (O) Voltage adjustment 1K (O) Emergency stop (S2a: see Engine circuit)
  • Page 132 - 132 -...
  • Page 133 9822 0996 18/02 Applicable for QAS 60 Pd - Engine Circuit Qc4002™ MkII R250 (O) R438 (O) Frequency Selection 50Hz 60Hz 400V/480V a3 a3 S12a T1 T2 T3 - 133 -...
  • Page 134 Note "M": Remove link "M" when parallelling with the mains. MAINS SUPPLY (3P+N+PE) In AMF-mode or in case of mains Shutdown N L1 L1 L2 L3 parallelling, the Mains-sensing Sx=Remote Start/Stop-switch lines need to be fused by the Fx Fx Valve customer (3x 250mA).
  • Page 135 Note 1 d2(+) P1(+) RESET d1(-) P2(-) 30mA S12d (O) 1-Phase Socket - 135 -...
  • Page 136 A B C D E F G J K L M N O P Q R S T U V W X Y Z a b c c e f n o p c8 c8 a0 a0 a0 a6 a3 a6 a3 a3 a6 a3 a3 a3 F4 F5 N F6...
  • Page 137 Generator control unit Speed controller V11,V12 Free-wheeling diode K11,K12 LCD display Automatic voltage regulator Terminal board PMS CAN-communication Earth leakage relay 1phase socket (16 A) Fuel level sensor Circuit breaker Terminal strip Coolant temperature sensor Circuit breaker 16 A Connector wire harness Oil pressure sensor Circuit breaker 6 A Customer's terminal strip...
  • Page 138 Fuse 6A (see note 1) 9822 0773 55 Fuse 6A (see note 2) Applicable for QAS 60 Pd - COC box F2-4 Fuse 0.25A (see note 1) Contactor mains supply Contactor generator Terminal strip Terminal strip from 3Ph generator from 3Ph mains supply...
  • Page 139 - 139 -...
  • Page 140 Following documents are provided with this unit: – Test Certificate – EC Declaration of Conformity: EC DECLARATION OF CONFORMITY We, Atlas Copco Airpower n.v., declare under our sole responsibility, that the product Machine name : Power generator (< 400 kW) Commercial name : Serial number Which falls under the provisions of article 12.2 of the EC Directive 2006/42/EC on the approximation of the...
  • Page 142 www.atlascopco.com...

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