Atlas Copco QAS 30 Kd Instruction Manual
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Atlas Copco QAS 30 Kd Instruction Manual

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Instruction Manual
for AC Generators
English
QAS 30-35-40-45 Kd

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Summary of Contents for Atlas Copco QAS 30 Kd

  • Page 1 Instruction Manual for AC Generators English QAS 30-35-40-45 Kd...
  • Page 3 QAS 30-35-40-45 Kd Instruction Manual for AC Generators Instruction manual ..................5 Circuit diagrams ..................71 Printed matter N° 9829 3096 61 ATLAS COPCO - PORTABLE AIR DIVISION www.atlascopco.com 01/2011...
  • 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 2010, Atlas Copco Any unauthorized use or copying of the contents or any part thereof is prohibited.

  • Page 5: Table Of Contents

    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 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 Never refill fuel while the unit is running, unless occasional visitors staying a limited time only, otherwise stated in the Atlas Copco Instruction apply compressed air or inert gas to your skin or - above 85 dB(A): room to be classified as a noise- Book (AIB).
  • 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

    Leading particulars General description The QAS 30 and QAS 40 are AC generators, 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 30 and QAS 40 generators are driven by a fluid-cooled diesel engine, manufactured by KUBOTA.
  • Page 14 Alternator Air filter Battery switch Coupling Drain flexible engine oil Drain flexible coolant 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 Vacuum indicator - 14 -...

  • Page 15: Bodywork

    Bodywork Indicates that the unit may The alternator, the engine, the cooling system, etc. are start automatically and that Indicates a lifting point of the the instruction book has to generator. enclosed in a sound-insulated bodywork that can be be consulted prior to use. opened by means of side doors (and service plates).

  • Page 16: Drain Plugs And Filler Caps

    H0 ..Panel light Drain plugs and filler caps Control and indicator panel Qc1002™ The drain holes for the engine oil, the coolant and the S20..ON/OFF/REMOTE switch plug for the fuel, are located and labelled on the To start up the unit (locally or remote). General description Qc1002™...
  • Page 17 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 •...
  • Page 18 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 19 Qc1002™ Menu Description If a special status has elapsed, the active view will be – Language selection entered again automatically. Icons is the default factory set language, but 6 Status Display (pop-up window) If an Alarm comes up, the Alarm Display is shown. other languages can be selected: English, French, German, Italian, Spanish and Cyrillic (Russian).
  • Page 20 This is the described menu flow for changing the unit type: Qc1002 Qc 1002 Parameter Running time Unit type Unit type - 20 -...
  • Page 21 Alarm Display (pop-up window) Following general groups of Alarms exist: – Warning: Alarm LED lights up + Alarm pop-up LOW COOLANT appears on the display + Alarm relay is LEVEL empowered (if configured) – Trip of GB: ‘Warning’ actions + Generator Contactor opens –...
  • Page 22 LOG list Remote start operation The unit will keep an event log of the latest 30 events. Installation wirings: SERVICE TIMER 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 23: Control And Indicator Panel Qc2002

    Pushbutton and LED functions S20 ..ON/OFF switch Control and indicator panel Position O: No voltage is applied to the Qc2002™ Following pushbuttons are used on Qc2002™ module, the generator will not the Qc2002™ General description Qc2002™ control start. panel Position I: Voltage is applied to the Qc2002™...
  • Page 24 Following LEDs are used on the Alarm Flashing red LED indicates that an Qc2002™ alarm is present. A continuous red START: Is used to start the unit in LED indicates that the alarm has manual operation. been acknowledged by the user. The exact alarm is shown on the display.
  • Page 25 Qc2002™ Menu Overview Parameter display – in Alarm condition (scroll through DOWN information using At Qc2002™, the LCD will show following • a list of all active Alarms information: Parameter It's possible to scroll through the views, using the UP –...
  • Page 26 LOG list display Battery voltage display Power factor - frequency generator - frequency mains display Battery 13.2 V LOG List 0.00 00168.1h G f L1 50Hz M f L1 50Hz This view shows the Battery voltage and the running This view shows the alarm memory and gives access hours.
  • Page 27 Active - reactive - apparent power Line voltages mains display Qc2002™ Menu Description display Status Display (pop-up window) M L1-L2 400V M L2-L3 400V 80kW M L3-L1 400V 0kVAr 80kVA This view shows the line voltages of the mains (is only shown in AMF mode).
  • Page 28 Island operation Automatic Mains Failure (AMF) operation If a special status has elapsed, the active view will be entered again automatically. – This operation type is selected for local/remote – This application is only possible in combination If an Alarm comes up, the Alarm Display is shown. start applications, without the Mains (= stand- with the Auto mode.
  • Page 29 Running hours adjust Unit menu MF high frequency Running Time Unit MF high freq Cur. 20000 C/bar C/bar F/psi 100% 120% This menu is used to adjust the amount of running This menu is used to select the units into which This menu is used to set the maximum limit for the hours.
  • Page 30 M frequency delay MF high voltage M voltage delay M volt delay M freq delay MF high volt 9900s 9900s 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 31 Overvoltage enable Overvoltage setpoint Undervoltage delay > Volt enable > Volt < Volt Delay Enable enable disable Overvoltage failclass Undervoltage enable Undervoltage setpoint > Volt < Volt enable < Volt warning warning shutdown Enable enable disable Overvoltage delay Undervoltage failclass Overfrequency enable >...
  • Page 32 Alarm Display (pop-up window) Overfrequency delay Underfrequency delay > Freq Delay < Freq Delay Overfrequency setpoint Underfrequency setpoint In case an Alarm occurs, a pop-up window will automatically be displayed for as long as the alarm is active, no matter which view is active. The flashing >...
  • Page 33 Following general groups of Alarms exist: – Warning: Alarm LED lights up + Alarm pop-up LOW COOLANT SERVICE TIMER appears on the display + Alarm relay is LEVEL empowered (if configured) – Trip of GB: ‘Warning’ actions + Generator Contactor opens –...
  • Page 34 LOG list Fail classes The unit will keep an event log of the latest 30 events. All the activated alarms of the Qc2002™ have their OIL LEVEL own pre-defined fail class. Events are: All alarms are enabled according to one of these three –...

  • Page 35: Output Terminal Board

    Q1 ..Main circuit breaker S13..Lock-out switch for earth fault Output terminal board protection (N13) Interrupts the power supply to X1 when a The output terminal board is situated below the short-circuit occurs at the load side, or when This switch is located inside the cubicle and control and indicator panel.

  • Page 36: Operating Instructions

    If necessary, The generator is wired for a TN- consult Atlas Copco. system to IEC 364-3, i.e. one point in – Leave enough space for operation, inspection and the power source directly earthed - maintenance (at least 1 meter at each side).

  • Page 37: Connecting The Generator

    3rd harmonics and risk for excessive neutral current. Loads most sensitive to voltage distortion include incandescent lamps, discharge lamps, computers, X- ray equipment, audio amplifiers and elevators. Consult Atlas Copco for measures against the adverse influence of non-linear loads. - 37 -...

  • Page 38: Before Starting

    Connecting the load – Connect the wires to the proper terminals (L1, L2, Before starting L3, N and PE) of X1 and tighten the bolts – With the generator standing level, check the Site distribution panel securely. engine oil level and top up if necessary. The oil If outlet sockets are provided, they must be mounted –...

  • Page 39: Operating Qc1002

    During operation Qc1002™ Stopping Qc1002™ Operating Qc1002™ Following points should be carried out regularly: To stop the unit locally, proceed as Starting Qc1002™ – Check the engine gauges and the lamps for normal follows: readings. To start up the unit locally, proceed –...

  • Page 40: Operating Qc2002

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

  • Page 42: Maintenance

    1625 0010 73 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

    To set correct It is strongly recommended to use oil levels, proceed as in normal Atlas Copco branded lubrication oils. instruction. High-quality, mineral, hydraulic or synthesized hydrocarbon oil with rust and oxidation inhibitors, anti-foam and anti-wear properties is recommended.

  • Page 45: Engine Oil Level Check

    Engine oil level check EURO -3 & -2, EPA TIER II & III engines running on PAROIL from Atlas Copco is the ONLY oil tested Consult the Engine Operation Manual for the oil low sulphur diesel for lower oil and fuel consumption.

  • Page 46: Engine Coolant Specifications

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

  • Page 47: Coolant Check

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

  • Page 48: Storage Of The Generator

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

  • Page 49: Checks And Trouble Shooting

    Checks and trouble shooting Checking voltmeter P4 – Put a voltmeter in parallel with voltmeter P4 on Never perform a test run with the control panel. connected power cables. Never touch – Check that the read-out of both voltmeters is the an electrical connector without a same.

  • Page 50: 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 51: Engine Trouble Shooting

    Engine trouble shooting Not enough power The pressure of the lubricating oil is The table below gives an overview of the possible engine problems and their possible causes. too low – Restriction in a fuel pipe. – Wrong grade of lubricating oil. –...
  • Page 52 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 53: Options Available For Qas 30 35And Qas 40 45Units

    The engine starts and stops Options available for Overview of the electrical options – Dirty fuel filter element. The following electrical options are available for the QAS 30 35 and QAS 30 35 and QAS 40 45 units: – Restriction in air filter/cleaner or induction QAS 40 45 units system.

  • Page 54: Description Of The Electrical Options

    Outlet sockets (S) To use the batery charger: Description of the electrical – Provide the X25 connector, located at the side of options A brief description of all outlet sockets and circuit the power cubicle, with external power to use the breakers provided on the generator is given hereafter: Automatic battery charger battery charger.
  • Page 55 Low voltage (LV) Q4 ..Circuit breaker for X4 Interrupts the power supply to X4 when a The Low voltage option allows to run the unit at low short-circuit occurs at the load side, or when voltage (= high current). overcurrent protection (16 A)
  • Page 56 IT-relay X1 ..Main power supply (400 V AC) Terminals L1, L2, L3, N (= neutral) and PE The generator is wired for an IT network i.e. no (= earthing), hidden behind the control panel supply lines of the power supply are directly earthed. door and behind a small transparent door.

  • Page 57: Overview Of The Mechanical Options

    When starting up the generator, the green Power Led (1) of the Cosmos module will light up when the installation has been carried out correctly. For information about COSMOS™, consult your local Atlas Copco dealer. External fuel tank connection External fuel tank return connection - 57 -...
  • Page 58 Undercarriage (axle, towbar, towing To maintain the undercarriage When using this option, make sure to connect the fuel supply line as well as the fuel return line. Connections eyes) – Check the tightness of the towbar bolts, the axle to fuellines ought to be air-tight to prevent air from bolts and the wheel nuts at least twice a year and The undercarriage is equipped with an adjustable entering the fuel system.

  • Page 59: Technical Specifications

    Technical specifications Technical specifications for QAS 30 35 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 0.5 bar Engine coolant temperature Shut down 103°C...
  • Page 60 0.8 cos  0.8 cos  Rated power factor (lagging) 3ph 1.0 cos  1.0 cos  Rated power factor (lagging) 1ph Rated PRP power 3ph 30.0 kVA 34.5 kVA 21.3 kVA Rated PRP power 1ph 18.5 kVA Rated voltage 3ph line to line 400 V 480 V Rated voltage 3ph line to line lower voltage...
  • Page 61 Start-up time unspecified unspecified Mobility/Config. acc. to ISO 8528-1:1993 transportable/D transportable/D (optional) mobile/E mobile/E Mounting fully resilient fully resilient Climatic exposure open air open air Degree of protection IP 54 IP 54 Status of neutral (TT or NT) earthed earthed Status of neutral (IT) (optional) insulated insulated...
  • Page 62 Emission compliance EU STAGE II EU STAGE II Power circuit Circuit-breaker, 3ph. Number of poles Thermal release It (thermal release is higher at 25°C) 50 A 50 A Magnetic release Im 3..5xIn 3..5xIn Circuit-breaker, 3ph., lower voltage Number of poles Thermal release It 100 A Magnetic release Im...
  • Page 63 Notes Reference conditions for engine performance to ISO 3046-1. See derating diagram or consult the factory for other conditions. At reference conditions unless otherwise stated. Rating definition (ISO 8528-1): LTP: Limited Time Power is the maximum electrical power which a generating set is capable of delivering (at variable load), in the event of a utility power failure (for up to 500 hours per year of which a maximum of 300 hours is continuous running).

  • Page 64: Technical Specifications For Qas 40 45Units

    Technical specifications for QAS 40 45 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 0.5 bar Engine coolant temperature shut down 105°C QAS45...
  • Page 65 Rated PRP power 3ph 40.0 kVA 48.3 kVA 31 kVA Rated PRP power 1ph 28 k Rated voltage 3ph line to line 400 V 480 V Rated voltage 3ph line to line lower voltage 220 V Rated voltage 1ph 230V 240V Rated current 3ph 57.7 A...
  • Page 66 (optional) mobile/E mobile/E Mounting fully resilient fully resilient Climatic exposure open air open air Degree of protection IP 54 IP 54 Status of neutral (TT or TN) earthed earthed Status of neutral (IT) (optional) insulated insulated Alternator 4) Standard IEC34-1 IEC34-1 ISO 8528-3 ISO 8528-3...
  • Page 67 Power circuit Circuit-breaker, 3ph. Number of poles Thermal release It (thermal release is higher at 25°C) 63 A 63 A Magnetic release Im 3..5xIn 3..5xIn Circuit-breaker, 3ph., lower voltage Number of poles Thermal release It 125 A Magnetic release Im 3..5xIn Circuit-breaker, 1h.
  • Page 68 Notes Reference conditions for engine performance to ISO 3046-1. See derating diagram or consult the factory for other conditions. At reference conditions unless otherwise stated. Rating definition (ISO 8528-1): LTP: Limited Time Power is the maximum electrical power which a generating set is capable of delivering (at variable load), in the event of a utility power failure (for up to 500 hours per year of which a maximum of 300 hours is continuous running).

  • Page 69: Conversion List Of Si Units Into British Units

    Conversion list of SI units into Dataplate British units Maximum permitted total weight of the vehicle Maximum permitted front axle load Maximum permitted rear axle load 1 bar 14.504 psi Company code 0.035 oz Product code -YA3- 1 kg 2.205 lb Unit serial number 1 km/h 0.621 mile/h...

  • Page 70: 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 71 Circuit diagrams - 71 -...
  • Page 72 9822 0992 65/00 Applicable for QAS 30-35-40-45 Power circuit See Note 2 400V/480V 240V-60Hz to Circ.Diagr ENGINE Ampere-meter F1-F3 Fuses 4 A Alternator to Circ.Diagr ENGINE Automatic voltage regulator Ampere-meter Earth leakage relay (O) IT-relay (O) Circuit breaker (O) Circuit breaker 32 A (O) ELR-Relay Circuit breaker 16 A (O) Circuit breaker 16 A/30 mA (O)
  • Page 73 Outlet socket 32 A (O) Outlet socket 16 A (O) C D E Outlet socket 16 A (O) Terminal strip Optional equipment Coolant Heater 14-20 16A-1ph (Q1) 16A/30mA 30-40 16A-1ph (Q1) 16A/30mA Notes Note 1: The PE-N connection has to be made at the Wire Size x Wire Size y alternator-side of main Circuit Breaker Q1.
  • Page 74 9822 0992 77/01 Applicable for QAS 30-35-40-45 Engine circuit 20 1 19 Legend Position of Relay Contacts Wire size : Colour code : a = 1 mm h = 25 mm 0 = black 6 = blue b = 1.5mm i = 35 mm 1 = brown 7 = purple...
  • Page 75 Fuel level sensor Speed sensor Preheat resistor Battery 12 Vdc Charging alternator Starter solenoid Preheat relay Starter motor Fuel feed pump Battery switch (O) Engine controller unit (O) High coolant temperature switch Low oil pressure switch Coolant temperature sensor Connector wire harness (see Controller circuit) Fuel solenoid Optional equipment...
  • Page 76 9822 0992 78/01 Applicable for QAS 30-35-40-45 Controller circuit Qc1002™ Generator control unit (configure in unit type 1) Fuse 10 A DC Panel light a6 a2 a0 a0 a3 a3 a3 a3 Starter relay 26 27 P1-P3 Amperemeter a0 a0 Voltmeter Emergency stop *only on QAS14/20...
  • Page 77 to Circ.Diagr POWER X9.441 & X9.442 b6 b0 Sx=Remote Start/Stop-switch (*)= Connect L2 to X25.5 with 230Vd-systems MAINS SUPPLY (1P+N) Generator Contactor Customer's Installation Output: 12Vdc, max.8Adc1 S12b (see Instruction Manual) Note: with dedicated 60Hz-cubicles, DO NOT connect wire 12/a6 to X10.C4 Position of Relay Contacts Dual Frequency to Circ.Diagr POWER...
  • Page 78 9822 0992 79/02 Applicable for QAS 30-35-40-45 Controller circuit Qc2002™ towards to Circ.Diagr POWER X25.8 X9.441 & X9.442 a6 a2 b6 b0 a0 a0 a0 a0 a0 26 27 37 38 53 54 57 58 Fx Fx Fx Fx Sx=Remote Start/Stop-switch MAINS SUPPLY (3P+N+PE) Customer's Installation...
  • Page 79 E F G H I J K L M N a3 a3 to Circ.Diagr POWER X9.12 to A1.17 to Circ.Diagr POWER S12b X9.13 to Circ.Diagr POWER Dual Frequency X9.5 Legend Note: With dedicated 60Hz-cubicles, Position of Relay Contacts to A1.17 to A1.16 Wire size : Colour code :...
  • Page 80 - 80 -...
  • Page 82 www.atlascopco.com...

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