Atlas Copco QAS 600 Volvo Instruction Manual
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Atlas Copco QAS 600 Volvo Instruction Manual

Atlas Copco QAS 600 Volvo Instruction Manual

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Instruction Manual
for AC Generators
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QAS 600 Volvo

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Summary of Contents for Atlas Copco QAS 600 Volvo

  • Page 1 Instruction Manual for AC Generators English QAS 600 Volvo...
  • Page 3 QAS 600 Volvo Instruction Manual for AC Generators Instruction manual ..................5 Circuit diagrams ..................49 Original instructions Printed matter N° 2954 4650 00 ATLAS COPCO - PORTABLE AIR DIVISION www.atlascopco.com 03/2010...
  • 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 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: Safety Precautions For Portable Generators

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

  • Page 7: General Safety Precautions

    The manufacturer does not accept any liability for any Normal ratings (pressures, temperatures, speeds, 14 When working on the unit, wear safety clothing. damage arising from the use of non-original parts and for etc.) shall be durably marked. Depending on the kind of activities these are: safety modifications, additions or conversions made without glasses, ear protection, safety helmet (including Operate the unit only for the intended purpose and...

  • Page 8: Safety During Transport And Installation

    - 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: Safety During Use And Operation

    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: Safety During Maintenance And Repair

    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: 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 13: Leading Particulars

    General description The QAS 600 Volvo 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 60 Hz, 240/480 V - 3 phase. The QAS 600 Volvo generator is driven by a coolant-cooled diesel engine, manufactured by VOLVO PENTA. An overview of the main parts is given in the diagram below.
  • Page 14 Alternator Air filter Coupling Drain flexible engine oil Drain flexible cooling water Engine Filler cap engine oil Filler cap cooling water Fuel filter Battery Oil drain pump Oil filter Engine oil level dipstick Battery switch - 14 -...

  • Page 15: Bodywork

    The earthing rod, connected to the generator’s earth Bodywork Indicates that the generator may be terminal is located at the bottom of the frame on the The alternator, the engine, the cooling system, etc. are refuelled with diesel fuel only. outside.

  • Page 16: Drain Plugs And Filler Caps

    External fuel tank connection Control and indicator panel Qc1002™ The external fuel tank connection allows to bypass Indicates the 3-way valve. the internal fuel tank and to connect an external fuel General description Qc1002™ control tank to the unit. panel Make sure to connect the fuel supply line as well as QAS 600 VoD Indicates the partnumbers of...
  • Page 17 Qc1002™ Module Pushbutton and LED functions S2 ..Emergency stop button Push the button to stop the generator in case Following pushbuttons are used on of an emergency. When the button is the Qc1002™ pressed, it must be unlocked, before the generator can be restarted.
  • Page 18 Following LEDs are used on the Qc1002™ Menu Overview Qc1002™ At Qc1002™, the LCD will show following START: Is used to start the unit in information: Manual Mode. – in Normal condition (scroll through the Power information using UP and DOWN): Qc1002 CAN STOP: Is used to stop the unit in Alarm...
  • Page 19 Controller type and version display Alarm list display Service timer 1 & Service timer 2 display Qc1002 CAN Alarm List Service 1 v1.00.0 0 Alarm(s) Service 2 This view shows the controller type and the ASW This view shows the number of active alarms and version number.
  • Page 20 Coolant temperature display Fuel level display Qc1002™ Menu Description Status Display (pop-up window) Water 62˚C Fuel 00168.1h 00168.1h This view shows the Coolant temperature and the This view shows the Fuel level and the running hours. running hours. Voltage - frequency - running hours In case special statuses are entered, a pop-up window See also “Parameter list”...
  • Page 21 – Generator Overfrequency: failclass, enable, delay, – Unit Type setpoint – Generator Undervoltage: failclass, enable, delay, Unit type 2 for QAS 600 Volvo! setpoint – Generator Overvoltage: failclass, enable, delay, – Service Timer 2 reset setpoint – Service Timer 1 reset These menus are used to reset the service timers.
  • Page 22 This is the described menu flow for changing the unit type: Qc1002 CAN Qc1002 CAN Parameter Running time Unit type Unit type Unit type - 22 -...
  • Page 23 Alarm Display (pop-up window) Following general groups of Alarms exist: – Warning: Alarm LED lights up + Alarm pop-up LOW FUEL LEVEL appears on the display + Alarm relay is empowered (if configured) – Trip of GB: ‘Warning’ actions + Generator Contactor opens LOW COOLANT –...
  • Page 24 Displaying the engine DM1 alarm SPN98 "OIL LEVEL" Besides some engine specific alarms shown in the oil level SERVICE TIMER 1 standard alarm list, also all Diagnostic messages SPN99 "OIL FILTER DIFF P" DM1 (active alarms) can be shown on the display. pressure difference over oil filter Use the UP or DOWN buttons until DM1 is shown on SPN100...
  • Page 25 LOG list Remote start operation SPN190 "SPEED" The unit will keep an event log of the latest 30 events. Installation wirings: speed FMI00 "HIGH LEVEL SHUTDOWN" Events are: – X25.1 & X25.2 to be wired for the remote start high level shutdown switch.

  • Page 26: Outlet Sockets (S)

    Q2 ..Circuit breaker for X2 Q6 ..Circuit breaker for X6 US Outlet sockets (S) Interrupts the power supply to X2 when a Interrupts the power supply to X6 when a A brief description of all outlet sockets and circuit short-circuit occurs at the load side, or when short-circuit occurs at the load side, or when breakers provided on the generator is given hereafter:...

  • Page 27: Camlock Cubicle

    A brief description of all Camlock outlet sockets and Camlock cubicle Circuit breaker Q1 does not only circuit breakers provided on the generator is given interrupt the power supply towards In addition to the US outlet sockets, optional Camlock hereafter: socket X1 but also towards X2, X3, outlet sockets can be ordered.

  • Page 28: Battery Switch

    Q12 ..Circuit breaker for X12 Q15 ..Circuit breaker for X15 Circuit breaker Q1 does not only Interrupts the power supply to X12 when a Interrupts the power supply to X15 when a interrupt the power supply towards short-circuit occurs at the load side, or when short-circuit occurs at the load side, or when socket X1 but also towards X12, the overcurrent protection (400 A) is...

  • Page 29: Operating Instructions

    Atlas possible to the generator and make sure not to Consult Atlas Copco for measures against the adverse Copco dealer. have a contact voltage higher than 25 V. influence of non-linear loads.
  • Page 30 Quality, minimum section and Protection The lowest acceptable wire section and the maximum length of cables corresponding maximum cable or conductor length For safety reasons, it is necessary to for multiple core cable or H07 RN-F, at rated current, The cable connected to the terminal board of the provide an isolating switch or circuit for a voltage drop e lower than 5% and at a power generator must be selected in accordance with local...

  • Page 31: Before Starting

    – Put the remote start/stop switch in position start. Before starting Operating – The unit will start. The starting attempt will take – With the generator standing level, check the Starting maximum 12 seconds. engine oil level and top up if necessary. The oil level must be near to, but not exceed the high mark To start up the unit locally, proceed During operation...
  • Page 32 To stop the unit when the starter The generator’s doors may only switch is in position , proceed as remain opened for short periods follows: during operation, to carry out – Switch off the load. checks for example. – Stop the engine by putting the remote start/stop Stopping switch in position stop or by using the STOP button on the Qc1002™...

  • Page 33: Maintenance

    2912 4507 06 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 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 Inspection by Atlas Copco Service technician possible a high load (> 30%) should be applied so that the engine reaches its operating temperature.

  • Page 35: Engine Maintenance

    It is strongly recommended to use filter on the engine. A 500 V megger is required to measure the alternator Atlas Copco branded lubrication oils. insulation resistance. (2) After the first initial 150 running hours it is High-quality, mineral, hydraulic or synthesized required to check/adjust the valve clearance.

  • Page 36: 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 37: 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 38: Coolant Check

    Flush parameters. high engine operating temperatures. – 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 39: 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 40: 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 an electrical connector without a – Check that the read-out of both voltmeters is the voltage check.

  • Page 41: 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 42: Technical Specifications

    Technical specifications 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 Specifications of the engine/alternator/unit Metric Reference conditions 1) 4) Rated frequency...
  • Page 43 Max. oil consumption at full load 0.03 US gal/h 0.11 l/h Maximum sound power level (LPA) 77 dB(A) 77 dB(A) measured according to Atlas Copco spec. 9822 0877 00 Useful capacity of fuel tank 239 US gal 905 l Single step load capability (O-PRP) 100%...
  • Page 44 Model LSA 47.2 M7 LSA 47.2 M7 Rated output, class H temperature rise 625 kVA 625 kVA rating type acc. ISO 8528-3 “BR” 125/40°C “BR” 125/40°C Degree of protection IP 23 IP 23 Insulation stator class Insulation rotor class Number of wires Engine Standard ISO 3046...
  • Page 45 Fault current protection Residual current release IDn 0.030-30 A 0.030-30 A Insulation resistance (optional) 10-100 kOhm 10-100 kOhm Outlet sockets (optional) GFCI duplex (2x) GFCI duplex (2x) 2p+E 2p+E 20A 125V 20A 125V Temp Power (3x) Temp Power (3x) 2p+N+E 2p+N+E 50A 125/250V 50A 125/250V...
  • Page 46 Specific mass fuel used: 0.86 kg/l. 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. - 46 -...

  • Page 47: 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 1 kg 2.205 lbs Unit serial number 1 km/h 0.621 mile/h...
  • Page 48 - 48 -...
  • Page 49 Circuit diagrams - 49 -...
  • Page 50 9822 0993 25/02 Applicable for QAS 600 - Qc1002™, Engine Circuit X9 X9 S11d ded. 60Hz 12 13 17 18 33 34 Qc1002 canbus to Control Module A1 11 12 8 Sx=Remote Start/Stop-switch max. 24Vdc, 4A Position of Relay Cont. Plant Contactor Output: 24Vdc, max.
  • Page 51 Control module F G H (configure in UNIT-type 2) Fuel level sensor Fuse Battery 24V Panel light Cubicle Aux.relay for Y7 (O) Canopy Starter motor P1-3 A-meters V-meter Resistor 120 ohm Battery switch Emergency stop button (S2b: see Power Circuit) Water in fuel switch (O) Voltmeter change-over switch S11d...
  • Page 52 9822 0993 80/01 Applicable for QAS 600 - Qc1002™, Power Circuit see note Legend Wire size : Colour code : Voltage Adjustm. 5+(field) aa = 0.5 mm² 0 = black 6-(field) Frequency 1 mm² 1 = brown Selection = 1.5 mm² 2 = red 50Hz 60Hz...
  • Page 53 H I J K L M N O P Q R S 400A 400A 400A 400A L1 L2 L3 N L1 L2 L3 N L1 L2 L3 N L1 L2 L3 N L1 L2 L3 Breaker Set. I2=I3 I t² 1375 1,00 x In 0,86 x Io...
  • Page 54 F1-5 Fuses 4A Socket outlet Thermal overload relay Socket outlet Alternator Socket outlet Contactor Flanged inlet Automatic voltage regulator Terminal strip Circuit breaker - 3p Terminal strip Circuit breaker - 2p Camlock outlet socket Circuit breaker - 2p Camlock outlet socket Circuit breaker - 2p Camlock outlet socket Circuit breaker - 1p...
  • Page 55 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) Machine type : Serial number : Which falls under the provisions of article 12.2 of the EC Directive 2006/42/EC on the approximation of the...
  • Page 56 Phone: +32 (0)3 870 21 11 Com. Reg. Antwerp 44651 P.O. Box 100 Boomsesteenweg 957 Fax: +32 (0)3 870 24 43 V.A.T. 403.992.231 B-2610 Wilrijk-Antwerp B-2610 Wilrijk-Antwerp Belgium Belgium For info, please contact your local Atlas Copco representative www.atlascopco.com p.2(2) - 56 -...
  • Page 58 www.atlascopco.com...

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