Atlas Copco QAS 150 JD7 T4A HOP Instruction Manual
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Atlas Copco QAS 150 JD7 T4A HOP Instruction Manual

Atlas Copco QAS 150 JD7 T4A HOP Instruction Manual

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Instruction Manual
for AC Generators
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QAS 150 JD7 T4A HOP

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Summary of Contents for Atlas Copco QAS 150 JD7 T4A HOP

  • Page 1 Instruction Manual for AC Generators English QAS 150 JD7 T4A HOP...
  • Page 3 QAS 150 JD7 T4A HOP Instruction Manual for Generators Instruction manual ................5 Circuit diagrams ................53 Original instructions Printed matter Nr 1310 3012 74 ATLAS COPCO - PORTABLE ENERGY DIVISION 12/2012 www.atlascopco.com...
  • Page 4 Neglecting maintenance or making changes to the setup of the machine can result in major hazards, including fire risk. 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.

  • Page 5: Table Of Contents

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

  • Page 6: Safety Precautions For Portable Generators

    Introduction modifications, additions or conversions made without the Skill level 3: Electrical technician The policy of Atlas Copco is to provide the users of their manufacturer’s approval in writing. An electrical technician is trained and has the same equipment with safe, reliable and efficient products.

  • Page 7: Safety During Transport And Installation

    8 All regulating and safety devices shall be maintained 6 To lift heavy parts, a hoist of ample capacity, tested Safety during transport and installation with due care to ensure that they function properly. and approved according to local safety regulations, To lift a unit, all loose or pivoting parts, e.g.

  • Page 8: Safety During Use And Operation

    5 Never refill fuel while the unit is running, unless composition of the noise shall be provided and a otherwise stated in the Atlas Copco Instruction Book 20 Do not open electrical cabinets, cubicles or other special warning to that effect shall be placed at each (AIB).

  • Page 9: Safety During Maintenance And Repair

    2 Parts shall only be replaced by genuine Atlas Copco 25 If the generator is used as stand-by for the mains prevent the sound pressure level from increasing.

  • Page 10: Tool Applications Safety

    20 When using cartridge type breathing filter equipment, Battery safety precautions ascertain that the correct type of cartridge is used and Batteries that its useful service life is not surpassed. When servicing batteries, always wear protecting 21 Make sure that oil, solvents and other substances clothing and glasses.

  • Page 11: Leading Particulars

    Leading particulars General description The QAS 150 John Deere 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 can run in 3 different modes: 60Hz, 480 V - 3 phase, 60Hz, 208 V - 3 phase lower voltage and 60 Hz, 240 V - 1 phase. The QAS 150 generator is driven by an EPA interim tier 4 compiant watercooled diesel engine, manufactured by John Deere.
  • Page 12 Alternator Air filter Coupling Drain flexible engine oil Engine Fuel Cooler Filler cap engine oil FCW Filler cap cooling water Fuel filter Battery Intercooler Oil filter Engine oil level dipstick Pre-Filter Radiator Battery switch Coolant tank - 12 -...

  • Page 13: Bodywork

    Bodywork Markings The alternator, the engine, the cooling system, etc. are A brief description of all markings provided on the Use PAROIL E Mission green. enclosed in a sound-insulated bodywork that can be generator is given hereafter. opened by means of side doors (and service plates). Indicates the external fueltank.

  • Page 14: Drain Plugs And Filler Caps

    Drain plugs and filler caps External fuel tank connection Exhaust Filter and Stop The drain holes for the engine oil, the coolant and the plug The external fuel tank connection allows to bypass the Indicator for the fuel, are located and labelled on the frame, the fuel internal fuel tank and to connect an external fuel tank to drain plug at the front, the others at the service side.

  • Page 15: Control And Indicator Panel Qc1002

    Qc1002™ Module Pushbutton and LED functions Control and indicator panel Qc1002™ Following pushbuttons are used on the General description Qc1002™ control panel Qc1002™ ENTER: Is used to select and confirm changed settings in the Parameter list. L1L2 L1-N L2L3 L2-N L3L1 L3-N Q5 Q6...
  • Page 16 Following LEDs are used on the Qc1002™ Qc1002™ Menu Overview This view shows a number of Parameter settings and gives access to them. At Qc1002™, the LCD will show following information: An overview is given in “Parameter list” on page 18. –...
  • Page 17 Battery Voltage display Station Regen. Battery 25.2 V 00168.1h This view shows the voltage, frequency and running Stationary or manual DPF regeneration. This view shows This view shows the Battery voltage and the running hours. the stationary regeneration mode selected. When OFF is hours.
  • Page 18 Parameter list Qc1002™ Menu Description This menu is used to select the type of engine electronics, the Qc1002™ controller should communicate with via the The Parameter Menu's are pre-programmed! Status Display (pop-up window) Canbus. A password will be asked for when an attempt to change a It's possible to scroll between configuration menu's by setting is about to be done (user password = 2003).
  • Page 19 This is the described menu flow for changing the unit type: - 19 -...
  • Page 20 Alarm Display (pop-up window) LOW OIL SERVICE TIMER 1 PRESSURE HIGH COOLANT SERVICE TIMER 2 In case an Alarm occurs, a pop-up window will TEMPERATURE automatically be displayed for as long as the alarm is active, no matter which view is active. The flashing red alarm LED will light up.
  • Page 21 LOG list Displaying the engine DM1 alarm turbo boost pressure The unit will keep an event log of the latest 30 events. Besides some engine specific alarms shown in the SPN104 "TURBO OIL PRESS" standard alarm list, also all Diagnostic messages DM1 turbo oil pressure Events are: (active alarms) can be shown on the display.
  • Page 22 (RUN). Stationary Regeneration Procedure Atlas Copco recommends that the DPF configuration be left in the AUTO mode at all times, however in the event that a stationary or manual regeneration in desired the following process should be followed. – Go to the "STATION REGEN" screen. For normal operation this should be in OFF mode.

  • Page 23: Dpf Information - Indicators

    DPF INFORMATION - INDICATORS Indicators Discription Operator Action Exhaust Filter Cleaning Indicator Active when: Machine can be operated as normal. If operating in an area where high 1. Exhaust gas temperature is high. exhaust temperature may be an issue, abort exhaust filter cleaning by using the 2.

  • Page 24: Output Terminal Board

    Q1.1 . Main circuit breaker Output terminal board Make sure to switch on circuit breakers Interrupts the voltage power supply towards X1 The cubicle provides a terminal board for easier Q1.1 or Q2, Q3, Q4 and Q5 after starting when a short-circuit occurs at the load side or when connection of cables.

  • Page 25: Triple Voltage (3V)

    The selection between the three modes is done by means Triple voltage (3V) of S10. The generator can run in three different modes: – 1 phase S10 .. Output voltage selection switch Allows to select a 1 phase output voltage, a 3 phase When using this selection, the generator provides a 120/240 V output voltage.

  • Page 26: Connecting The Generator

    – Loosen the cable clamp and push the wire ends of the load follows: cable through the orifice and clamp. Consult Atlas Copco for measures against the adverse influence of non-linear loads.   ...

  • Page 27: Operating Instructions

    If system against excessive contact voltage – Check the generator for leakage, tightness of wire necessary, consult Atlas Copco. is not effective unless a suitable earthing terminals, etc. Correct if necessary.

  • Page 28: Exhaust Filter

    EXHAUST FILTER / DIESEL PARTICULATE 3. Use Atlas Copco “PAROIL E mission Green Low EXHAUST FILTER SAPS” engine oil. FILTER ASH HANDLING AND DISPOSAL 4. Use only ultra low sulfur fuel. Under federal, state, and/or local laws or regulations, Diesel Particulate Filter ash In addition to soot, ash deposits will also slowly build up may be classified as a hazardous waste.

  • Page 29: Fuel System

    DRAINING INSTRUCTIONS FUEL SYSTEM PRIMING INSTRUCTIONS Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the “ON/ OFF” switch in position “OFF” when changing fuel filters or water separator elements.
  • Page 30 FUEL FILTER REPLACEMENT Fill the fuel tank at the end of each working day to reduce condensation & moisture build-up in the fuelsystem. Replace fuel filter elements anytime audible alarm sounds and trouble codes indicate plugged fuel filters (low fuel pressure). If no alarm sounds during the 12 month service interval, replace elements at that time, or after 500 hours operation, whichever comes...

  • Page 31: Brake Adjustment

    BRAKE ADJUSTMENT Before jacking up the Generator, connect it to a towing vehicle or attach a weight of minimum 50 kg (110 lb) to the towbar. BRAKE SHOE ADJUSTMENT Check the thickness of the brake lining. • Remove both black plastic plugs (3) one on each wheel.
  • Page 32 Stopping Qc1002™ – Check for leakage of oil, fuel or coolant. Operating Qc1002™ – Avoid long low-load periods (< 30%). In this case, an To stop the unit locally, proceed as follows: Starting Qc1002™ output drop and higher oil consumption of the engine –...

  • Page 33: Maintenance

    1310 3130 83 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 34 Clean turbocharger impeller casing and turbocharger generator casing Check valve clearance (5) Inspection by Atlas Copco Service technician Notes: In highly dusty environments, these service intervals do not apply. Check and/or replace filters and clean radiator on a regular basis.

  • Page 35: Engine Maintenance

    Engine fuel specifications procedure to synthetic oil, run the unit for a few minutes to allow good and For fuel specifications, please contact your Atlas Copco complete circulation of the synthetic oil. Customer Center. Then drain the synthetic oil again and fill again with new synthetic oil.
  • Page 36 Powerful oxidation resistance, high chemical PAROIL has an excellent Total Base Number (TBN) PAROIL from Atlas Copco is the ONLY oil tested and stability and rust- inhibiting additives help reduce retention and more alkalinity to control acid formation.

  • Page 37: Engine Oil Level Check

    PARCOOL EG is the only coolant that has been tested and approved by all engine manufacturers currently in use in Atlas Copco generators. Atlas Copco's PARCOOL EG extended life coolant is the new range of organic coolants purpose designed to meet the needs of modern engines. PARCOOL EG can help prevent leaks caused by corrosion.

  • Page 38: Coolant Check

    Flush PARCOOL EG is free of nitride and amines to protect – The pH-meter can be ordered from Atlas Copco with part your health and the environment. Longer service life number 2913 0029 00. – Flush twice with clean water. Used coolant must be...

  • Page 39: Air Filter Engine

    Never beat or knock the element as this will damage it and Remove dust daily. The Atlas Copco air filters are specially there will be a danger of damage to the engine. To remove dust from the dust trap pinch the vacuator designed for the application.

  • Page 40: Storage

    Storage of the generator Storage – Store the generator in a dry, frost-free room which is well ventilated. – Run the engine regularly, e.g. once a week, until it is warmed up. If this is impossible, extra precautions must be taken: •...

  • Page 41: Checks And Trouble Shooting

    Checks and trouble shooting Never perform a test run with connected power cables. Never touch an electrical connector without a voltage check. When a failure occurs, always report what you experienced before, during and after the failure. Information with regard to the load (type, size, power factor, etc.), vibrations, exhaust gas colour, insulation check, odours, output voltage, leaks and damaged parts,...

  • Page 42: 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  resistor in series on the + No residual voltage. and - terminals of the electronic regulator, respecting the polarities. After being excited the alternator still gives 0 Volt.

  • Page 43: Battery Switch

    Options available for QAS 150 T4A John Deere units EFT - Quick Coupling Circuit diagrams The option Quick couplings allows to bypass the internal The engine control circuit diagrams and the power circuit fueltank and to connect an external fueltank to the unit. diagrams for the standard QAS 150 T4A John Deere units, for the units with options and for the units with combined options are:...

  • Page 44: Technical Specifications

    Technical specifications Technical specifications for QAS 150 JD T4i Readings on gauges Gauge Reading Unit Ammeter L1-L3 (P1-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 45 Technical specifications for QAS 150 JD T4i Metric Rated voltage 3ph line to line lower voltage 208 V 208 V Rated voltage 1ph 240 V 240 V Rated current 3 ph 480V 180 A 180 A Rated current 3 ph 240V 361 A 361 A Rated current 3 ph 208V...
  • Page 46 Technical specifications for QAS 150 JD T4i Metric Degree of protection IP 23 IP 23 Insulation - stator H class H class -rotor H class H class Number of wires Excitation AREP AREP Engine Standard ISO 3046 ISO 3046 ISO 8528-2 ISO 8528-2 Make John Deere...
  • Page 47 (b) thermal release is higher at 25°C Derating table (in %, 100% is declarated power at “Performance data”) Temperature Height (°C) 1000 1500 2000 2500 3000 3500 4000 For use of generator outside these conditions, please contact Atlas Copco. - 47 -...

  • Page 48: Conversion List Of Si Units Into British Units

    Conversion list of SI units into British units 1 bar 14.504 psi 0.035 oz 1 kg 2.205 lbs 1 km/h 0.621 mile/h 1 kW 1.341 hp (UK and US) 0.264 US gal 0.220 lmp gal (UK) 0.035 cu.ft 3.281 ft 1 mm 0.039 in 1 m³/min...

  • Page 49: Dataplate

    Dataplate - 49 -...

  • Page 50: Disposal

    (for example sand, sawdust) and dispose recyclable materials. it according the applicable local disposal regulations. Do Your Atlas Copco generator consists for the most part of not drain into the sewage system or surface water. metallic materials, that can be remelted in steelworks and smelting works and that is therefore almost infinite recyclable.
  • Page 51 Circuit diagrams - 53 -...
  • Page 52 1310 3200 00/00 Applicable for QAS 150 - Qc1002™, Engine Circuit - 54 -...
  • Page 53 - 55 -...
  • Page 54 Mark Grid Name Control Module (Configure in UNIT-type 6) Fuel Level Sensor Engine controller Fuse Fuse Battery 12V Panel Light e1-f5 Engine connector Starter Relay Starter Motor P1-3 c9-10 A-Meters V-meter Emergency Stop Button (S2b: see Power Circuit) Voltmeter change-over switch Coolant Level Switch Low Fuel Level Switch Low Fuel Level Switch, Warning...
  • Page 55 1310 3200 29/00 Applicable for QAS 150 - Qc2002™, Power Circuit - 57 -...
  • Page 56 - 58 -...
  • Page 57 Mark Name F1,,4 Fuse 4A Alternator Contactor Automatic Voltage Regulator Optional Equipment Over Load Relay Q1,1 Circuit breaker 3pole Circuit breaker 1pole Circuit breaker 1pole Circuit breaker 2pole Circuit breaker 2pole Coolant Heater Battery Charger Voltage Adjustnent Potmeter Emergency stop (S2a see Engine Circ.) Supply voltage switch CT1..6 Current transforner...
  • Page 58 - 60 -...
  • Page 60 www.atlascopco.com...

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