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Atlas Copco QAS+ 250 Instruction Manual
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Atlas Copco QAS+ 250 Instruction Manual

Atlas Copco QAS+ 250 Instruction Manual

Ac generators
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Instruction Manual
for AC Generators
English
QAS+ 250
DC9 320A
QAS+ 325
DC9 320A
QAS+ 450
DC13520
Instruction Manual

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Summary of Contents for Atlas Copco QAS+ 250

  • Page 1 Instruction Manual Instruction Manual for AC Generators English QAS+ 250 DC9 320A QAS+ 325 DC9 320A QAS+ 450 DC13520...
  • Page 3 QAS+ 250-450 Sd ESF Instruction Manual for AC Generators Instruction manual .................. 5 Circuit diagrams .................. 139 Original instructions Printed matter N° 2960 7400 00 ATLAS COPCO - POWER AND FLOW DIVISION www.atlascopco.com 02/2022...
  • 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 2022, Grupos Electrógenos Europa, S.A.U., Zaragoza, Spain. 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 Measuring the valve clearance ..79 9.2.1 Dual frequency (DF) .......103 Technical specifications..111 Engine consumable 9.2.2 Engine electrical coolant heater..103 specifications........81 9.2.3 Automatic battery charger.....103 10.1 Technical specifications for 5.6.1 Engine fuel specifications....81 QAS+ 250 ........111 9.2.4 Transformer Maintenance (TM) - 6 -...
  • Page 7 10.1.1 Specifications of the engine/ alternator/unit.........111 10.2 Technical specifications for QAS+ 325 ........117 10.2.1 Specifications of the engine/ alternator/unit.........117 10.3 Technical specifications for QAS+ 450 ........123 10.3.1 Specifications of the engine/ alternator/unit.........123 10.4 Conversion list of SI units into British units ........129 10.5 Data plate ........129 10.6...

  • 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 Pressure and temperature gauges shall be checked General safety precautions damage arising from the use of non-original parts and for regularly with regard to their accuracy. They shall The owner is responsible for maintaining the unit in modifications, additions or conversions made without be replaced whenever outside acceptable tolerances.

  • 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

    Tool applications safety Battery safety precautions Apply the proper tool for each job. With the knowledge When servicing batteries, always wear protecting of correct tool use and knowing the limitations of tools, clothing and glasses. along with some common sense, many accidents can be The electrolyte in batteries is a sulphuric acid prevented.

  • Page 15: Main Parts

    General description The QAS+ 250-450 Sd 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, 400/480V 3 phase line-to-line with neutral. The QAS+ generator is driven by a fluid-cooled diesel engine, manufactured by Scania. An overview of the main parts is given in the diagram below.
  • Page 16 Alternator Air filter Coupling Diesel exhaust fluid tank Drain flexible engine oil Drain and access hole (in the frame) Data plate Diesel particulate filter Engine Filler cap engine oil Filler cap coolant Fuel filter Intercooler Oil filter Engine oil level dipstick Pre-fuel filter Radiator Catalytic converter...
  • Page 17 QAS+ 450 Lifting beam Guiding rod Side doors Engine exhaust Data plate Door, access to control and indicator panel Forklift slots Earthing rod Drain and access hole (in the frame) Filler cap DEF (AdBlue) Filler cap fuel - 17 -...
  • Page 18 Alternator Air filter Coupling Diesel exhaust fluid tank Drain flexible engine oil Drain and access hole (in the frame) Data plate Diesel particulate filter Engine Filler cap engine oil Filler cap coolant Fuel filter Intercooler Oil filter Engine oil level dipstick Pre-fuel filter Radiator Catalytic converter...

  • Page 19: Markings

    Markings Indicates that the guiding rods may not Indicates the battery switch. Markings provide instructions and information. They be used to lift the generator. Always also warn of hazards. For convenience and safety, use the lifting rod in the roof of the generator to lift it.
  • Page 20 Indicates a risk of fire. This label is required for On Road transport into the Indicates to not switch off European Union according to the the battery when the switch European agreement concerning light is ON. It can cause international carriage of Dangerous severe damages to the goods by Road, Annex A.

  • Page 21: Mechanical Features

    Mechanical features 2.3.2 Engine and alternator 2.3.6 Bodywork The alternator is driven by a coolant-cooled diesel The alternator, the engine, the cooling system, etc. are 2.3.1 Compartments engine. The engine’s power is transmitted through a enclosed in a sound-insulated bodywork that can be direct disc coupling.

  • Page 22: Drain Plugs And Filler Caps

    Drain plugs and filler caps 2.3.9 Spillage free skid View inside - QAS+ 250 The drain holes for the engine oil, the coolant and the A Spillage free skid with forklift slots allows the plug for the fuel, are located and labelled on the customer to transport the generator easily with a frame.

  • Page 23: 2.3.11 Manual Oil Drain Pump

    When using this option, make sure to connect the fuel 2.3.12 Engine-after treatment 2.3.12.1 Diesel particulate filter supply line as well as the fuel return line. Connections Diesel particulate filter (DPF) is a device designed to The exhaust gas after-treatment system is activated to fuel lines ought to be air-tight to prevent air from remove diesel particulate matter or soot from the immediately after the engine is started and remains...
  • Page 24 2.3.12.2 Engine after-treatment flow diagram The illustration provides an overview of exhaust gas after-treatment management system components. NOx sensor with control unit Differential pressure sensor Exhaust gas temperature sensor Exhaust gas temperature sensor Oxidation catalytic converter (DOC) Particulate filter (DPF) Exhaust gas temperature sensor Reductant doser NOx sensor with control unit...

  • Page 25: Electrical Features

    A1 ..Qc1212™ Controller controller The electrical features described in this chapter are S10..On/Off switch QAS+ 250 standard provided on this generator. For all other Put the starter switch in position I (ON). The electrical features, see “Overview of the electrical control cubicle receives voltage.
  • Page 26 Qc4004™ controller. This X1 ..Terminal board General description Qc4004™ control panel controller is located inside the control QAS+ 250 cubicle, and communicates via a display Qd0701 located at the front. The controller will carry out all necessary tasks to control and protect the generator, which allows operation in many different applications.

  • Page 27: Output Terminal Board

    Output terminal board looks like this: The cubicle provides a terminal board for easier connection of cables. It is situated below the control and indicator panel. QAS+ 250 QAS+ 450 Connector - TM controls Connector - TM sensing - 27 -...
  • Page 28 A1 ..Display F10..Fuse S10 ..ON/OFF switch X25 ..Terminal X1 ..Terminal board (400 V AC) Terminals L1, L2, L3, N (= neutral) and PE (= earthing), hidden behind the control panel door and behind a small transparent door. Q1 ..

  • Page 29: Installation And Connection

    Installation and connection To be able to lift the generator by means of a forklift, Lifting Installation rectangular slots 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 30: Precautions For Non-Linear And Sensitive Loads

    Wire section Max. current (A) Consult Atlas Copco for measures against the adverse ² Multiple core Single core H07 RN-F operating generator influence of non-linear loads.

  • Page 31: Connecting The Load

    The lowest acceptable wire section and the 3.3.3 Connecting the load corresponding maximum cable or conductor length for multiple core cable or H07 RN-F, at rated current 3.3.3.1 Site distribution panel (20 A), for a voltage drop e lower than 5% and at a If outlet sockets are provided, they must be mounted power factor of 0.80, are respectively 2.5 mm²...

  • Page 32: Operating Instructions

    Operating instructions Before starting In your own interest, always strictly 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 excess of the limitations mentioned on the engine oil level dipstick.

  • Page 33: Operating And Setting Qc1212

    Operating and setting To start up the unit from a remote location, 4.2.2 During operation proceed as follows: Qc1212™ Regularly carry out following checks: – Put the starter switch S10 in position 1. – Check the controller display for normal readings. 4.2.1 Starting –...

  • Page 34: Stopping

    4.2.3 Stopping 4.2.4 Qc1212 control module AUTO: Allows to put the control description module in Automatic mode. Do not switch off the battery when the switch light is ON. It can cause The Qc1212 control module is integrated in the severe damage to the emissions control panel.
  • Page 35 4.2.4.2 Qc1212 LEDs 4.2.4.3 Qc1212 menu overview DOWN: Allows to scroll to the next item below. Decreases the value of Status page the selected set point in the editor This is the ‘home’ page, the page that is displayed menu. when no other page has been selected, and the page PREVIOUS PAGE: Allows to that is automatically displayed after a period of...
  • Page 36 If no buttons are pressed upon entering an – After-treatment Exhaust Inlet (°C/°F) Instrument pages instrumentation page, the instruments will be It is possible to scroll to display the different pages of – After-treatment Exhaust Outlet (°C/°F) displayed automatically. information by repeatedly operating the NEXT / –...
  • Page 37 Depending on configuration and instrument function, Serial port page Event log some of the instrumentation items may include a tick This section is included to give information about the The Qc1212 module maintains a log of past alarms icon beside them. currently selected serial port and external modem (if and/or selected status changes.
  • Page 38 4.2.4.4 Scheduler AUTO Mode The Qc1212 contains a scheduler, capable of – Scheduled runs will operate ONLY if the module is in AUTO mode with no Shutdown or Electrical automatically starting and stopping the set. Trip alarm present. Up to 16 scheduled start/stop sequences can be –...

  • Page 39: Operating And Setting Qc4004™ - Qd0701

    Operating and setting Qc4004™ - Qd0701 4.3.2 During operation 4.3.3 Stopping Before setting the controller make Regularly carry out following checks: Do not switch off the battery when sure that the Qc4004™ is NOT in the switch light is ON. It can cause –...

  • Page 40: Setting Qc4004™ + Qd0701

    4.3.4 Setting Qc4004™ + Qd0701 Close GB: Closes breaker. Scroll up. 4.3.4.1 Interface Following buttons are used on the Qd0701 Open GB: Opens breaker. Scroll down. CAN ID / Shows the CAN ID ant the priority Controller settings: Opens number in power management Controller settings (Shortcut*).
  • Page 41 Tap Alarms to view or acknowledge the active 4.3.4.2 Qc4004™ + Qd0701 menu alarms. overview Main view The display mainly shows information about the power unit. Control buttons for the power unit are embedded in the screen. At the top of the screen, some general information such as time and display language can be found.
  • Page 42 Supervision Additional operator panel (AOP) Setup Views the state of the system in real-time. The system Additional operator panels (AOPs) provide you with In the Setup menu, the controller settings can be shown depends upon your plant configuration. LED indication and button actions. You can found.

  • Page 43: Changing Settings

    Edit settings Consult the Qc4004™ user manual for all customer level parameters. In order to receive the default parameters for your unit, please contact Atlas Copco Service staff. The actual controller settings shown depend upon the type of setting that you are configuring.

  • Page 44: Dual Frequency

    – Select the correct voltage and frequency, in this 4.3.4.6 Standard modes Write Writes the settings to the controller. example 480/277 V at 60 Hz. Output Selects an output terminal. The unit has four different running modes. Failclass Selects a Failclass. Auto mode Cancel Cancels the changes.

  • Page 45: Standard Applications

    Manual mode 4.3.4.7 Standard applications Island operation When manual mode is selected, the generator In the Qc4004™ module 10 application types can be Generator frequency and voltage can be controlled with external selected. A combination of each application type with breaker LOAD inputs.
  • Page 46 – For Remote Start operation: Installation wirings Peak Shaving (PS) operation • wire the RS switch between X25.9 & X25.10. – The link between X25.10/X25.11 has to be Generator Mains removed. – For Paralleling applications with other generators: breaker breaker LOAD •...
  • Page 47 – Make sure the connections between X25.33 & Installation wirings Fixed Power (FP) operation X25.3; X25.34 & X25.4; X25.35 & X25.5; – The link between X25.10/X25.11 has to be X25.36 & X25.6 are removed. removed. Generator Mains breaker breaker LOAD –...
  • Page 48 Installation wirings Mains power export (MPE) operation Installation wirings – The link between X25.10 & X25.11 has to be – The link between X25.10 & X25.11 has to be Generator Mains removed. removed. breaker breaker LOAD – Mains breaker feedback lines have to be wired to –...
  • Page 49 Installations are possible with stand-alone generators Example: Installation with 3 gensets Multiple gen-sets with load sharing or with the Mains (extra Qc4004™ Mains is then In this application the units are enabled to share the G1 = 300 kW; G2 = 200 kW; G3 = 200 kW. needed).
  • Page 50 The priority on starting and stopping the generators Installation wirings 4.3.4.8 Paralleling can be chosen on priority settings or on the amount of Prior to starting parallel operation of two generators, running hours. In manual mode the start and stop Genset 1 Genset 2 Genset 3...
  • Page 51 3. Select Application 2 (Easy connect). 4.3.4.9 Paralleling machines with Easy connect on the Qd0701 display UNIT 1 1. Connect load cables and switch on all Qd0701 without connecting communication cables X30. DISREGARD ANY MESSAGES AND DO UNIT 1 UNIT 2 NOT PRESS ANY BUTTON.
  • Page 52 5. Mount splitters on X30 connectors with end 6. Confirm Start New Plant. resistors joining across the PMS cables. UNIT 1 8. UNIT 1 is ready: ID 1, Priority 1. UNIT 1 Splitters PMS cable 7. Wait for the application setup to be completed. End resistors UNIT 1 UNIT 1...
  • Page 53 9. Confirm Add Generator to Plant. 12. Verify the plant is created. Go to settings. UNIT 2 11. UNIT 2 is ready: ID 2, Priority 2. 13. Verify the plant is created. Go to Supervision. 10. Wait for the application setup to be completed. UNIT 2 Repeat points 9, 10 and 11 in case of power plant is larger than 2 units (UNIT 3, UNIT 4, ...).
  • Page 54 14. Verify the plant is created. See Diagram with 4.3.4.10 Removing one unit with Easy right number of units. connect on the Qd0701 display 1. To remove one unit from the plant (example UNIT 1) - unplug the X30 cable in UNIT 1 and get the Setup Stand Alone message on UNIT 1.
  • Page 55 4. Select AOP and disable Easy connect by changing to Application 1 on UNIT 1. UNIT 1 - 55 -...
  • Page 56 Only with Transformer Maintenance Box (*) 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 Qc4004™ module. For details, please contact Atlas Copco. - 56 -...
  • Page 57 The installation can contain up to 16 Qc4004™ modules. If the Mains is included in the installation, then an extra Qc4004™ module is required. The installation can be monitored and controlled via the PMS Software Package. For details on this application, please contact Atlas Copco. - 57 -...
  • Page 58 Do not put this value above 60 seconds to avoid any possible damage. 4. For more information on the Qc4004™ module and its applications, we refer to the Qc4004™ User manual and the Qc4004™ Application data sheets. If you need more assistance, please contact Atlas Copco. - 58 -...

  • Page 59: Overview Of Applications

    Overview of applications Required material Mode Configuration Description for N generator sets This configuration is used to connect one 1 x Qc controller for Single generator set as stand-by power with the mains. synchronizing with mains Stand-by Single Parallel to The generator set will synchronize with the and AMF function Genset...
  • Page 60 Required material Mode Configuration Description for N generator sets This configuration is used to connect several generator sets in parallel as prime power island supply. The generator set synchronize together N x Qc controllers for and supply power to the load. The generator paralleling Prime Power sets will share the load and the power...

  • Page 61: Maintenance

    Atlas Copco Parts List (ASL). It guarantees that all necessary parts are replaced at the same time keeping down time to a minimum. The order number of the Service Packs are listed in the Atlas Copco Parts List (ASL). - 61 -...
  • Page 62 To determine the maintenance intervals, use service hours, or calendar time, whichever occurs first. 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 administration costs and are offered at a reduced price, compared to individual components.
  • Page 63 500 hrs Every Every Every Every Every 2 Maintenance schedule Daily after 1000 2000 4500 Yearly Years start-up hours hours hours hours Clean radiator (1) Clean intercooler (1) Drain condensate and water from spillage-free frame or catch basin (8) Check for leaks in engine-, air-, oil-, or fuel system Hoses and clamps - Inspect/Replace Check electrical system cables for wear Check torque on critical bolt connections (12)

  • Page 64: Use Of Maintenance Schedule

    (9) Replace all rubber flexibles every 5 years. The order number of the Service Packs are listed in the Atlas Copco Parts list (ASL). Order Service Packs (10)See section “Battery care”. at your local Atlas Copco dealer.

  • Page 65: Preventing Low Loads

    Low boost pressure will cause oil comes first. leakage over the turbo shaft seal. It is recommended that a unit is always used with a For more info, please contact your Atlas Copco load > 30% of nominal. Corrective actions should be Service Center. 5.2.2...

  • Page 66: Alternator Maintenance Procedures

    1. Remove the oil dipstick (1) and check the oil lev- Alternator maintenance Engine maintenance el. The correct level is between the minimum and procedures procedures maximum marks on the oil dipstick. Check that Refer to the engine’s operator manual for full the correct level has been achieved.
  • Page 67 4. If the engine is drained via the valve, the oil 3. Detach the old filter from the cover by holding the Notes: should be hot. Alternatively, use a pump. This so cover and carefully tapping the entire filter Renew the oil filter and clean the centrifugal oil that draining occurs more quickly.

  • Page 68: Coolant Check

    A sudden release of – A refractometer can be ordered from Atlas Copco pressure from a heated cooling with part number 2913 0028 00. system can result in personal injury from the splash of hot coolant.

  • Page 69: Air Filter Check

    – Run the engine for about 1 minute, in order to 5.4.4.1 Main parts purge the air from the cavities of the engine block. – From the Atlas Copco Instruction book, determine the amount of PARCOOL Green required and – Stop the engine. pour into the radiator top tank.

  • Page 70: Replacing Fuel Filter

    – Always select the service point according to the Fluid escaping under pressure can vacuum indicator or display message. penetrate the skin causing serious – Atlas Copco always recommends exchanging injury. Therefore: rather than cleaning the filter element in order to – Relieve...
  • Page 71 To ensure that the filter housings are drained 5.4.5.1 Removing the fuel filters using a 5.4.5.2 Removing the fuel filters using a properly, the filter covers must be removed as draining nipple suction tool follows: To ensure that the filter housings are drained 2.
  • Page 72 5. Make a mark on the main filter cover (B). It is important to remove remaining Unscrew the cover 3 to 4 turns with the socket. fuel and particles from the filter Draw out fuel which may drain into the water housings to prevent fuel system separating prefilter housing when the main filter is contamination.

  • Page 73: Bleeding The Fuel System

    6. Tighten the filter housings to 25 Nm (18 lb/ft). 5.4.6 Bleeding the fuel system 5.4.6.1 Bleeding the fuel system using a suction tool Every time the fuel system has been opened up for 7. Bleed the fuel system as per the following section. service (lines disconnected or filters), it is necessary to bleed air from the system.
  • Page 74 5.4.6.2 Bleeding the fuel system using a hand pump 1. Attach a clear plastic hose to the bleed nipple (1) on the fuel filter housing. Let the plastic hose drop into a container that holds at least 5 litres (1.3 US gallons).

  • Page 75: Adjustments And Service Procedures

    – Steam cleaning in combination with a cleansing Adjustments and service 5.5.2 Cleaning fuel tank agent may be applied (do not use jet at max. procedures power). Observe all relevant environmental and safety precautions. 5.5.1 Cleaning coolers To avoid damaging the coolers, angle between jet and coolers should be Never leave spilled liquids such as approx.

  • Page 76: Battery Care

    the battery voltage every three to six months. Charge Alternators are NOT chargers. Don't rely on engine 5.5.3 Battery care the battery if it falls below 12.4 volts alternator to do the work of a charger. If a battery is Before handling batteries, read the discharged to the point where it cannot start the relevant safety precautions and act...

  • Page 77: Checking Belt Tensioner Spring Tension And Belt Wear

    3. Check drive belt wear. Renew the drive belt if it is 5.5.4 Checking belt tensioner spring too worn. If the drive belt is only starting to become tension and belt wear worn (8) it can be refitted. If the belt is worn down Belt drive systems equipped with automatic (spring) to the cord (9) then he must be renewed.
  • Page 78 – Remove the belt guard. – Block the tensioner. 5.5.4.2 Checking tensioner spring tension Automatic belt tensioner must not be readjusted, opened or modified. If belt tensioner does not provide the right tension to the belt it will have to be replaced. In case to be needed consult the engine manufacturer manual.

  • Page 79: Measuring The Valve Clearance

    The reference information UP TDC, DOWN TDC 5.5.5 Measuring the valve clearance and the angle indications listed in the table below are Block the starting device. If the engraved on the flywheel. Depending on the engine engine starts unexpectedly, installation, this information is visible in one of the there is a serious risk of injury.
  • Page 80 flywheel from the underside of the engine and tool 8. Mark the rocker arm with the felt-tip pen and then Reading in the Rotation Valve transition Adjust valves 2 402 509 is used from the top side. continue with the next cylinder according to the upper window on cylinder on cylinder...

  • Page 81: Engine Consumable Specifications

    (AdBlue) is required. Stage V and newer standards and are equipped with exhaust after-treatment systems. fluids that recommended by Atlas Copco can Misfueling with fuels of higher sulfur level can Do not use old diesel or oil result numerous...

  • Page 82: Engine Oil Specifications

    Engine oil specifications Specifications PAROIL Do not replace diesel exhaust fluid PAROIL from Atlas Copco is the ONLY oil tested (AdBlue) by a water/urea solution. It is strongly recommended to use and approved for use in all engines built into Atlas...

  • Page 83: Engine Coolant Specifications

    It is strongly recommended to use index. Atlas Copco PAROIL E Mission Green is To set correct oil levels, follow the Atlas Copco branded coolant.
  • Page 84 The use of distilled water is recommended. If you currently used in Atlas Copco compressors and Liquid-cooled engines are factory-filled with this have exceptionally soft water it would be acceptable, generators.

  • Page 85: Checks And Trouble Shooting

    Checks and trouble Engine troubleshooting Not enough power – Restriction in a fuel pipe. shooting The list below gives an overview of the possible engine problems and their possible causes. – Fault in fuel lift pump. Never perform a test run with For more details, please check the engine –...
  • Page 86 – Incorrect valve tip clearances. – Fault in cold start system. The pressure of the lubricating oil is too low – Wrong grade of lubricating oil. – Engine overload. – Restriction in fuel tank vent. – Not enough lubricating oil in sump. –...
  • Page 87 Crankcase pressure – Restriction in breather pipe. – Vacuum pipe leaks or fault in exhaust. Bad compression – Restriction in air filter/cleaner or induction system. – Incorrect valve tip clearances. The engine starts and stops – Dirty fuel filter element. –...

  • Page 88: Alternator Troubleshooting

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

  • Page 89: Solving Controller Alarms

    In the event of a warning alarm, the LCD will display In the event of an alarm the LCD will jump to the Solving controller alarms the appropriate text. If a shutdown then occurs, the Alarm page, and scroll through all active warnings module will again display the appropriate text.

  • Page 90: High Current Shutdown / Electrical Trip Alarm

    The alarm must be accepted and cleared, and the fault 6.3.1.4 Shutdowns IDMT alarm removed to reset the module. Shutdowns are latching alarms and stop the generator The aim of the IDMT alarm is to prevent the alternator windings being overload (heated) too set.
  • Page 91 6.3.1.8 Short circuit alarm Display Reason If the Short Circuit alarm is enabled, the controller Alarms Amber Warning The CAN ECU has detected a begins following the IDMT ‘curve’. If the Trip is Amber warning. ECU Amber surpassed for an excess amount of time the Alarm Red Shutdown The CAN ECU has detected a triggers (Shutdown or Electrical trip as selected in...
  • Page 92 DPF Active SCR Inducement 1/10 ECU Prev. DTCs The module received a fault The module received a fault indication from the engine ECU indication from the engine ECU Water Level Low informing that the Diesel Particulate informing that the Selective Filter is active.

  • Page 93: Protections Disabled

    6.3.1.11 Overview displayed alarm messages Warnings Display Reason CHARGE FAILURE The auxiliary charge alternator voltage is low as measured from the W/L terminal. BATTERY UNDER VOLTAGE The DC supply has fallen below the low volts setting level for the duration of the low battery volts timer. BATTERY OVER VOLTAGE The DC supply has risen above the high volts setting level for the duration of the high battery volts timer.
  • Page 94 Display Reason LOW OIL PRESSURE The module detects that the engine oil pressure has fallen below the low oil pressure pre-alarm setting level after the Safety On timer has expired. ENGINE HIGH TEMPERATURE The module detects that the engine coolant temperature has exceeded the high engine temperature pre-alarm setting level after the Safety On timer has expired.
  • Page 95 Shutdowns Display Reason FAIL TO START The engine has not fired after the preset number of start attempts. EMERGENCY STOP The emergency stop button has been depressed. This a failsafe (normally closed to battery positive) input and will immediately stop the set should the signal be removed. Removal of the battery positive supply from the emergency stop input will also remove DC supply from the Fuel and Start outputs of the controller.

  • Page 96: Auxiliary Inputs

    Display Reason AUXILIARY INPUTS An active auxiliary input configured as a shutdown will cause the engine to shut down. The display shows the text as configured by the user. LOSS OF SPEED SIGNAL The speed signal from the magnetic pickup is not being received by the DSE controller. ECU DATA FAIL The module is configured for CAN operation and does not detect data on the engine CAN data link, the engine shuts down.
  • Page 97 Electrical trips Display Reason GENERATOR HIGH CURRENT If a generator set output in excess of the high current alarm point, a warning alarm occurs. If this high current condition continues for an excess period, then the alarm escalates to either a shutdown or electrical trip condition (depending upon module configuration).

  • Page 98: Qc4004™ Alarms And Remedies

    6.3.2 Qc4004™ alarms and remedies 6.3.2.1 Fail Classes Engine stopped: 6.3.2.2 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 99 6.3.2.3 DPF regeneration alarms: ECU Amber Alarm Shows an engine warning. ECU Red Alarm Shows an engine shut-down. DPF Active Shows that a regeneration is needed. DPF Inhibited The module received a fault condition from the engine ECU informing that the Diesel Particulate Filter has been inhibited.
  • Page 100 6.3.2.4 Solving alarms Menu flow - 100 -...

  • Page 101: 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 102: 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 103: Options Available

    S12. – “Electricité de France” (EDF) It can accept multiple AC voltage connections. QAS+ 250 – Outlet sockets The LED indicator on the front shows when the charger is in a normal or overload condition: –...

  • Page 104: Transformer Maintenance (Tm)

    The battery charger provides multi-stage charging: 9.2.4 Transformer Maintenance (TM) Installation wiring connections – Constant current: maximum current available – The link between X25.10 & X25.11 has to be during charge recovery phase. removed. – Constant voltage. – Plug the Transformer Maintenance Box cables into Transformer Maintenance Box connectors –...

  • Page 105: Fleetlink Corebox

    9.2.5 Fleetlink CoreBox 9.2.7 “Electricité de France” (EDF) 9.2.8 Outlet sockets Fleetlink is an intelligent telematics system that helps When the EDF-option is installed, the unit operates as A brief description of all outlet sockets and circuit optimize fleet usage, reduce maintenance cost, a standard unit when the neutral and the PE terminals breakers available on the generator is given hereafter.

  • Page 106: Power Locks

    9.2.9 Power locks Powerlock - single - QAS+ 250 Powerlock - double - QAS+ 250 Powerlock connectors are plastic bodied single pole electrical connectors withstanding 660 Amps nominal intensity. They are moisture and impact resistant and feature insulated contact tips to prevent accidental touching of electrically live parts.

  • Page 107: Individual Earth Leakage Protection For Sockets, Rcbo Or Vigi Depending On The Socket

    The option provides a detector that will trip the socket detected. breaker when an earth fault current is detected. This option replaces the standard earth leakage relay Type A and B protections available. with a RCMA420 which is type B. QAS+ 250 ELR ..Earth leakage relay - 107 -...

  • Page 108: Terminal Board Plates Extensions

    QAS+ 450 9.2.12 Terminal board plates extensions QAS+ 250 Terminal board plates extensions can be added on the terminal connection plates. As a result, the connection cable doesn’t not need to have terminals. They can be connected with a locking screw.

  • Page 109: Overview Of The Mechanical Options

    9.4.1 Cold weather ons. – Cold weather Includes synthetic oil, engine coolant heater diesel QAS+ 250 – Special Application Equipment: inlet shutdown antifreeze additive and fluid systems special valve (ISV) isolations. It grants generator operation below -15ºC. – Galvanized traction bar add-on, one per side 9.4.2...

  • Page 110: Transport Bumpers

    9.4.4 Transport bumpers 9.4.5 Special colour Two side rubbers (1) are present above the forklift Special colours are available for the canopy and the slots. frame. Contact your generator set supplier for available configurations. 9.4.6 External fuel tank quick couplings The option Quick couplings allows to bypass the internal fuel tank and to connect an external fuel tank to the unit.

  • Page 111: Technical Specifications

    Technical specifications 10.1 Technical specifications for QAS+ 250 10.1.1 Specifications of the engine/alternator/unit 50 Hz 60 Hz Rated frequency 50 Hz 60 Hz Reference conditions Rated speed 1500 rpm 1800 rpm Generator service duty Absolute air inlet pressure 1 bar(a)
  • Page 112 Fuel consumption at full load (100%) 41.4 kg/h 45.6 kg/h Specific fuel consumption at full load (100%) 0.209 kg/kWh 0.210 kg/kWh Capacity of standard fuel tank 1240 l 1240 l Capacity of 24h fuel tank Fuel autonomy at full load with standard tank 25.5 h 23.1 h Fuel autonomy at 75% load with standard tank...
  • Page 113 Rated net output 223 kW 223 kW rating type acc. ISO 3046-7 ICXN ICXN Coolant Parcool EG Parcool EG Combustion system direct injection direct injection Aspiration turbo charged turbo charged Number of cylinders Swept volume 9.3 l 9.3 l Speed governing electronic electronic Capacity of oil sump (initial fill)
  • Page 114 Notes Reference conditions for engine performance to ISO 3046-1. See derating diagram below 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 115 Derating factor (%) Temperature Height PRP 1800 - 480V (°C) 1000 1500 2000 2500 3000 Derating factor (%) Temperature Height ESP 1500 - 400V (°C) 1000 1500 2000 2500 3000 - 115 -...
  • Page 116 Derating factor (%) Temperature Height ESP 1800 - 480V (°C) 1000 1500 2000 2500 3000 For use of generator outside these conditions, please contact Atlas Copco. - 116 -...

  • Page 117: Technical Specifications For Qas+ 325

    10.2 Technical specifications for QAS+ 325 10.2.1 Specifications of the engine/alternator/unit 50 Hz Rated frequency 50 Hz Reference conditions Rated speed 1500 rpm Generator service duty Absolute air inlet pressure 1 bar(a) Relative air humidity Air inlet temperature 25°C Maximum ambient temperature 35°C Limitations 2) Altitude capability...
  • Page 118 Fuel autonomy at full load with standard tank 19.8 h Fuel autonomy at 75% load with standard tank 26.4 h Max. oil consumption at full load 0.05 l/h Capacity of standard fuel tank 1240 l Capacity of 24h fuel tank Urea consumption at 50% load 2.8 kg/h Urea consumption at 75% load...
  • Page 119 Coolant Parcool EG Combustion system direct injection Aspiration turbo charged Number of cylinders Swept volume 9.3 l Speed governing electronic Capacity of oil sump (initial fill) 36 l Electrical system 24 Vdc Maximum permissible load factor of PRP during 24h period Standard IEC 34-1 Alternator 4)
  • Page 120 Notes Reference conditions for engine performance to ISO 3046-1. See derating diagram below 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 121 Derating factor (%) Temperature Height PRP 1800 - 480V (°C) 1000 1500 2000 2500 3000 Derating factor (%) Temperature Height ESP 1500 - 400V (°C) 1000 1500 2000 2500 3000 - 121 -...
  • Page 122 Derating factor (%) Temperature Height ESP 1800 - 480V (°C) 1000 1500 2000 2500 3000 For use of generator outside these conditions, please contact Atlas Copco. - 122 -...

  • Page 123: Technical Specifications For Qas+ 450

    10.3 Technical specifications for QAS+ 450 10.3.1 Specifications of the engine/alternator/unit 50 Hz Rated frequency 50 Hz Reference conditions Rated speed 1500 rpm Generator service duty Absolute air inlet pressure 1 bar(a) Relative air humidity Air inlet temperature 25°C Maximum ambient temperature 35°C Limitations 2) Altitude capability...
  • Page 124 Fuel autonomy at full load with standard tank 14.2 h Fuel autonomy at 75% load with standard tank 19.6 h Max. oil consumption at full load 0.08 l/h Capacity of standard fuel tank 1240 l Urea consumption at 50% load 4.1 kg/h Urea consumption at 75% load 3.9 kg/h...
  • Page 125 Combustion system direct injection Aspiration turbo charged Number of cylinders Swept volume 12.7 l Speed governing electronic Capacity of oil sump (initial fill) 45 l Electrical system 24 Vdc Maximum permissible load factor during 24h period Standard IEC 34-1 Alternator 4) ISO 8528-3 Make Leroy Sommers...
  • Page 126 Notes Reference conditions for engine performance to ISO 3046-1. See derating diagram below 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 127 Derating factor (%) Temperature Height PRP 1800 - 480V (°C) 1000 1500 2000 2500 3000 Derating factor (%) Temperature Height ESP 1500 - 400V (°C) 1000 1500 2000 2500 3000 - 127 -...
  • Page 128 Derating factor (%) Temperature Height ESP 1800 - 480V (°C) 1000 1500 2000 2500 3000 For use of generator outside these conditions, please contact Atlas Copco. - 128 -...

  • Page 129: Conversion List Of Si Units Into British Units

    10.4 Conversion list of SI units 10.5 Data plate Name of manufacturer into British units EEC or national type approved number 1 bar 14.504 psi Vehicle identification number Maximum permitted total weight of the vehicle 0.035 oz Maximum permitted load on towing eye (fixed 1 kg 2.205 lbs towbar)

  • Page 130: 10.6 Critical Bolt Connections - Torque Values

    10.6 Critical bolt connections - torque values Screw/Bolt/Nut Applications Type Class Torque (Nm) Lifting beam - frame (horizontal) 83 + Loctite 2400 Lifting beam - frame (vertical) 83 + Loctite 2400 Fan box - roof 24.3 Alternator - alternator vibration damper 125 (+/- 10%) Alternator vibration damper - beam 83 (+/- 10%)

  • Page 131: 10.7 Dimension Drawings

    10.7 Dimension drawings QAS+ 250-325 - 131 -...
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  • Page 139 Circuit diagrams - 139 -...
  • Page 140 1640 0127 02 Applicable to Qc1212 Table 5 - Circuit breaker & power cables info Table 8 - Component list Table 8 - Component list Table 1 - Index Description Q1 (In) Description Description Sheet T1-T2-T3 Wire size X Wire size Z Location * Location * Index...
  • Page 141 POSITION OF RELAY CONTACTS DSENet 02.F1 03.F3 02.D8 02.C9 03.F4 02.B1 02.C1 02.D4 03.B1 04.B3 O2 - Dual Frequency 4-20 mA ECU - S8 ECU - C4002 ECU-C4071 M 24V 4-20 mA O9 - Inlet shutdown valve O8 - Coolant heater - 141 -...
  • Page 142 Alternator X52, X53 X50, X51 Gen. Current Generator Voltage RS485 D350 9/15 10/14 12/16 O8 - Coolant O7 - Battery charger O13 - heater To GPS Fleetlink SmartBox antenna O2 - Dual Frequency connector PIN2 PIN1 GNSS CELL 1_PW 3_ON/OFF 5_IO2 2_GND 4_IO1...
  • Page 143 O12 - Sockets 03.F5 03.F5 03.F5 03.F5 03.F5 O2 - Dual frequency U > U > U > U > U > I>> I>> I>> 16 A 16 A 16 A 30 mA 30 mA 30 mA (canopy) O11 - Power Locks 30 mA Table 9 - Wire marking Socket...
  • Page 144 1640 0727 80 Applicable to Qc1212 Table 1 - Index Table 5 - Circuit breaker & power cables info Table 8 - Component list Table 8 - Component list Description Q1 (In) Description Description Sheet T1-T2-T3 Wire size X Wire size Z Location * Location * Index...
  • Page 145 POSITION OF RELAY CONTACTS DSENet 02.F1 03.F3 02.D8 02.C9 03.F4 02.B1 02.C1 02.D4 03.B1 04.B3 O2 - Dual Frequency 4-20 mA ECU - S8 ECU - C4002 ECU-C4071 M 24V 4-20 mA O9 - Inlet shutdown valve O8 - Coolant heater - 145 -...
  • Page 146 Alternator X52, X53 X50, X51 Gen. Current Generator Voltage RS485 D350 9/15 10/14 12/16 O8 - Coolant O7 - Battery charger O13 - heater To GPS Fleetlink SmartBox antenna O2 - Dual Frequency connector PIN2 PIN1 GNSS CELL 1_PW 3_ON/OFF 5_IO2 2_GND 4_IO1...
  • Page 147 O11 - Power Locks 1 Row of Power Locks 660A 2 Rows of Power Locks 400A CONFIGURATION POWER METER AT 660A CONFIGURATION POWER METERS AT 400A (canopy) (canopy) (canopy) - 147 -...
  • Page 148 1640 0531 31 Applicable to Qc4004 Fleetlink CoreBox / SmartBox - 148 -...
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  • Page 150 Fleetlink SmartBox - 150 -...
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  • Page 154 1640 0235 71 Applicable to Qc4004 Table 1 - Index Table 5 - Circuit breaker & power cables info Table 8 - Component list Table 8 - Component list Sheet Description Q1 (In) T1-T2-T3 Wire size X Wire size Z Description Location * Description...
  • Page 155 Open MB Close MB Open GB Close GB Pulse Starter General CAN Engine Stop Coil CAN1 - PMS CAN2 - PMS Alarm Relay relay Relay Relay Output Relay 126 127 128 129 130 131 132 133 119 120 121 122 123 124 O9 - Inlet O8 - Coolant shutdown...
  • Page 156 Digital inputs Load Tacho Display Modbus Ethernet MI - 102 MI - 105 MI - 108 Ext. setpoint Digital inputs Digital inputs sharing Power input (D-SUB) supply 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 -XA1.15 -XA1.17 O13 -...
  • Page 157 O8 - Coolant O7 - Battery charger O14 - Transformer maintenance heater Bus voltage PE N Table 9 - CONNECTOR X25 - 10/11/12 STATUS WITH MB WITHOUT MB 220-230V REMOTE 50-60Hz APPLICATION 10-11 10-12 10-11 10-12 START (Open) (Close) (Open) (Close) Island Link P...
  • Page 158 (Alternator) POSITION OF RELAY CONTACTS GOVERNOR Generator current Generator voltage D350 9/15 10/14 03.D3 03.C2 03.D2 12/16 03.D2 O2 - Dual Frequency O4 - ELR O5 - RCMA420 -T23 -T22 +24V Id> Id> U < I>> I>> I>> 07.A1 07.A1 07.A1 07.A1 07.A1...
  • Page 159 O11 - Power Locks 1 Row of Power Locks 660A 2 Rows of Power Locks 400A Notas: (*)Conectar las referencias de tensión de las bornas CONFIGURATION POWER METER AT 660A CONFIGURATION POWER METERS AT 400A L1, L2, L3 y N de los Analizadores V1 y V2, en los terminales del X1 (Terminal Board).
  • Page 160 O12 - Sockets 05.F8 05.F8 05.F8 05.F8 05.F8 O2 - Dual frequency U > U > U > U > U > I>> I>> I>> 16 A 16 A 16 A 30 mA 30 mA 30 mA 30 mA Table 10 - Wire marking Socket L1 L2 L1 L2...
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  • Page 162 A company within the Atlas Copco Group Postal address Phone: +34 902 110 316 V.A.T A50324680 Poligono Pitarco II, Parcela 20 Fax: +34 902 110 318 50450 Muel ZARAGOZA For info, please contact your local Atlas Copco representative Spain www.atlas copco.com p.1(10) - 162 -...
  • Page 163 A company within the Atlas Copco Group Postal address Phone: +34 902 110 316 V.A.T A50324680 Poligono Pitarco II, Parcela 20 Fax: +34 902 110 318 50450 Muel ZARAGOZA For info, please contact your local Atlas Copco representative Spain www.atlas copco.com p.2(10) - 163 -...
  • Page 165 www.atlascopco.com...

This manual is also suitable for:

Qas+ 325Qas+ 450