QAS 14-15-20-24 Kd

Instruction Manual for AC Generators English

ATLAS COPCO - PORTABLE AIR DIVISION

www.atlascopco.com01/2011

QAS 14-15-20-24 KdInstruction Manual for AC Generators

Instruction manual ..................................................................................5

Circuit diagrams ....................................................................................73Printed matter N9829 3096 41

Warranty and Liability Limitation

Use only authorized parts.

Any damage or malfunction caused b y

Warranty or Product Liability.

The manufacturer does not accept any s,

additions or conversions made without

Neglecting maintenance or making cha or

hazards, including fire risk.

While every effort has been made to e ct,

Atlas Copco does not assume responsib

Copyright 2010, Atlas Copco

Any unauthorized use or copying of the

This applies in particular to trademarks,- 4 -

y the use of unauthorized parts is not covered b

liability for any damage arising from modification

the manufacturer's approval in writing.

nges to the setup of the machine can result in maj

nsure that the information in this manual is corre

ility for possible errors.

contents or any part thereof is prohibited.

model denominations, part numbers and drawings.

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445567

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99901

Options available for QAS 14 15 and QAS 20 24 units. ..........................................53

Circuit diagrams......................................53Overview of the electrical options.........53Description of the electrical options .....54Overview of the mechanical options ....58Description of the mechanical options .58

Technical specifications .............................60Technical specifications for QAS 14 15units.......................................60Technical specifications for QAS 20 24units.......................................65Conversion list of SI units into British units .............................................70Dataplate .................................................70

Disposal ........................................................71

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Contents

Safety precautions for portable generators ......................................................6

Leading particulars .....................................13General description ................................13Bodywork ................................................15Markings..................................................15Drain plugs and filler caps .....................16Control and indicator panel Qc1002..16Control and indicator panel Qc2002..23Output terminal board ...........................35Electronic speed regulator.....................36

Operating instructions...............................36Installation...............................................36Connecting the generator ......................37Before starting ........................................38Operating Qc1002 ...............................39Operating Qc2002 ...............................40

Maintenance ................................................4Maintenance schedule ...........................4Engine maintenance...............................4(*) Measuring the alternator insulation resistance...............................4Engine oil specifications ........................4Engine oil level check .............................4Engine oil and oil filter change..............4Engine coolant specifications ................4Coolant check..........................................4

Storage of the generator ...........................4Storage ....................................................4Preparing for operation after storage ...4

Checks and trouble shooting....................4Checking voltmeter P4 ...........................4Checking ammeter P3 ............................4Alternator troubleshooting ....................5Engine trouble shooting.........................5

Congratulations on the purchase of your AC generator. It is a solid, safe and reliable machine, built accordilatest technology. Follow the instructions in this booklet and we guarantee you years of troublefree operationread 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 noresponsibility for possible errors. Atlas Copco reserves the right to make changes without prior notice.

or repairing the generator.

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In general it is recommended that not more than twopeople operate the unit, more operators could lead tounsafe operating conditions. Take necessary steps tokeep unauthorized persons away from the unit andeliminate all possible sources of danger at the unit.When handling, operating, overhauling and/orperforming maintenance or repair on Atlas Copcoequipment, the mechanics are expected to use safeengineering practices and to observe all relevant localsafety requirements and ordinances. The following list isa reminder of special safety directives and precautionsmainly applicable to Atlas Copco equipment.Neglecting the safety precautions may endanger peopleas well as environment and machinery:- endanger people due to electrical, mechanical or

chemical influences,- endanger the environment due to leakage of oil,

solvents or other substances,- endanger the machinery due to function failures.All responsibility for any damage or injury resultingfrom neglecting these precautions or by non-observanceof ordinary caution and due care required in handling,operating, maintenance or repair, also if not expresslymentioned in this instruction manual, is disclaimed byAtlas Copco.- 6 -

Safety precautions for portable generatorsTo be read attentively and acted accordingly before towing, lifting, operating, performing maintenance

IntroductionThe policy of Atlas Copco is to provide the users of theirequipment with safe, reliable and efficient products.Factors taken into account are among others:- the intended and predictable future use of the

products, and the environments in which they areexpected to operate,

- applicable rules, codes and regulations,- the expected useful product life, assuming proper

service and maintenance,- providing the manual with up-to-date information.Before handling any product, take time to read therelevant instruction manual. Besides giving detailedoperating instructions, it also gives specific informationabout safety, preventive maintenance, etc.Keep the manual always at the unit location, easyaccessible to the operating personnel.See also the safety precautions of the engine andpossible other equipment, which are separately sentalong or are mentioned on the equipment or parts of theunit.These safety precautions are general and somestatements will therefore not always apply to a particularunit.

Only people that have the right skills should be alloweto operate, adjust, perform maintenance or repair oAtlas Copco equipment. It is the responsibility omanagement to appoint operators with the appropriatraining and skill for each category of job.Skill level 1: OperatorAn operator is trained in all aspects of operating the unwith the push-buttons, and is trained to know the safeaspects.Skill level 2: Mechanical technicianA mechanical technician is trained to operate the unit thsame as the operator. In addition, the mechanictechnician is also trained to perform maintenance anrepair, as described in the instruction manual, and allowed to change settings of the control and safesystem. A mechanical technician does not work on livelectrical components.Skill level 3: Electrical technicianAn electrical technician is trained and has the samqualifications as both the operator and the mechanictechnician. In addition, the electrical technician macarry out electrical repairs within the various enclosureof the unit. This includes work on live electriccomponents.Skill level 4: Specialist from the manufacturerThis is a skilled specialist sent by the manufacturer or iagent to perform complex repairs or modifications to thequipment.

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14 When working on the unit, wear safety clothing.Depending on the kind of activities these are: safetyglasses, ear protection, safety helmet (includingvisor), safety gloves, protective clothing, safetyshoes. Do not wear the hair long and loose (protectlong hair with a hairnet), or wear loose clothing orjewellery.

15 Take precautions against fire. Handle fuel, oil andanti-freeze with care because they are inflammablesubstances. Do not smoke or approach with nakedflame when handling such substances. Keep a fire-extinguisher in the vicinity.

16a Portable generators (with earthing pin):Earth the generator as well as the load properly.

16b Portable generators IT:Note: This generator is built to supply a sheeralternating current IT network.Earth the load properly.- 7 -

The manufacturer does not accept any liability for anydamage arising from the use of non-original parts and formodifications, additions or conversions made withoutthe manufacturers approval in writing.If any statement in this manual does not comply withlocal legislation, the stricter of the two shall be applied.Statements in these safety precautions should not beinterpreted as suggestions, recommendations orinducements that it should be used in violation of anyapplicable laws or regulations.

General safety precautions1 The owner is responsible for maintaining the unit in

a safe operating condition. Unit parts andaccessories must be replaced if missing orunsuitable for safe operation.

2 The supervisor, or the responsible person, shall atall times make sure that all instructions regardingmachinery and equipment operation andmaintenance are strictly followed and that themachines with all accessories and safety devices, aswell as the consuming devices, are in good repair,free of abnormal wear or abuse, and are nottampered with.

3 Whenever there is an indication or any suspicionthat an internal part of a machine is overheated, themachine shall be stopped but no inspection coversshall be opened before sufficient cooling time haselapsed; this to avoid the risk of spontaneousignition of oil vapour when air is admitted.

4 Normal ratings (pressures, temperatures, speedetc.) shall be durably marked.

5 Operate the unit only for the intended purpose anwithin its rated limits (pressure, temperaturspeeds, etc.).

6 The machinery and equipment shall be kept cleai.e. as free as possible from oil, dust or othdeposits.

7 To prevent an increase in working temperaturinspect and clean heat transfer surfaces (cooler finintercoolers, coolant jackets, etc.) regularly. See thmaintenance schedule.

8 All regulating and safety devices shall bmaintained with due care to ensure that thefunction properly. They may not be put out oaction.

9 Pressure and temperature gauges shall be checkeregularly with regard to their accuracy. They shabe replaced whenever outside acceptable tolerance

10 Safety devices shall be tested as described in thmaintenance schedule of the instruction manual determine that they are in good operating conditio

11 Mind the markings and information labels on thunit.

12 In the event the safety labels are damaged odestroyed, they must be replaced to ensure operatosafety.

13 Keep the work area neat. Lack of order will increasthe risk of accidents.

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10 A hoist has to be installed in such a way that theobject will be lifted perpendicular. If that is notpossible, the necessary precautions must be taken toprevent load-swinging, e.g. by using two hoists,each at approximately the same angle not exceeding30 from the vertical.

11 Locate the unit away from walls. Take allprecautions to ensure that hot air exhausted from theengine and driven machine cooling systems cannotbe recirculated. If such hot air is taken in by theengine or driven machine cooling fan, this maycause overheating of the unit; if taken in forcombustion, the engine power will be reduced.

12 Generators shall be stalled on an even, solid floor,in a clean location with sufficient ventilation. If thefloor is not level or can vary in inclination, consultAtlas Copco.

13 The electrical connections shall correspond to localcodes. The machines shall be earthed and protectedagainst short circuits by fuses or circuit breakers.

14 Never connect the generator outlets to aninstallation which is also connected to a publicmains.

15 Before connecting a load, switch off thecorresponding circuit breaker, and check whetherfrequency, voltage, current and power factorcomply with the ratings of the generator.

16 Before transportation of the unit, switch off all thecircuit breakers.- 8 -

Safety during transport and installationTo lift a unit, all loose or pivoting parts, e.g. doors andtowbar, shall first be securely fastened.Do not attach cables, chains or ropes directly to thelifting eye; apply a crane hook or lifting shackle meetinglocal safety regulations. Never allow sharp bends inlifting cables, chains or ropes.Helicopter lifting is not allowed. It is strictly forbidden to dwell or stay in the risk zoneunder a lifted load. Never lift the unit over people orresidential areas. Lifting acceleration and retardationshall be kept within safe limits.1 Before towing the unit:

- check the towbar, the brake system and thetowing eye. Also check the coupling of thetowing vehicle,

- check the towing and brake capability of thetowing vehicle,

- check that the towbar, jockey wheel or stand legis safely locked in the raised position,

- ascertain that the towing eye can swivel freely onthe hook,

- check that the wheels are secure and that thetyres are in good condition and inflated correctly,

- connect the signalisation cable, check all lightsand connect the pneumatic brake couplers,

- attach the safety break-away cable or safetychain to the towing vehicle,

- remove wheel chocks, if applied, and disengagethe parking brake.

2 To tow a unit use a towing vehicle of ampcapacity. Refer to the documentation of the towinvehicle.

3 If the unit is to be backed up by the towing vehicldisengage the overrun brake mechanism (if it is nan automatic mechanism).

4 Never exceed the maximum towing speed of thunit (mind the local regulations).

5 Place the unit on level ground and apply the parkinbrake before disconnecting the unit from the towinvehicle. Unclip the safety break-away cable osafety chain. If the unit has no parking brake ojockey wheel, immobilize the unit by placinchocks in front of and/or behind the wheels. Whethe towbar can be positioned vertically, the lockindevice must be applied and kept in good order.

6 To lift heavy parts, a hoist of ample capacity, testeand approved according to local safety regulationshall be used.

7 Lifting hooks, eyes, shackles, etc., shall never bbent and shall only have stress in line with thedesign load axis. The capacity of a lifting devicdiminishes when the lifting force is applied at aangle to its load axis.

8 For maximum safety and efficiency of the liftinapparatus all lifting members shall be applied anear to perpendicular as possible. If required, lifting beam shall be applied between hoist anload.

9 Never leave a load hanging on a hoist.

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- above 95 dB(A): the warning(s) at theentrance(s) shall be completed with therecommendation that also occasional visitorsshall wear ear protectors,

- above 105 dB(A): special ear protectors that areadequate for this noise level and the spectralcomposition of the noise shall be provided and aspecial warning to that effect shall be placed ateach entrance.

10 Insulation or safety guards of parts the temperatureof which can be in excess of 80C (175F) andwhich may be accidentally touched by personnelshall not be removed before the parts have cooled toroom temperature.

11 Never operate the unit in surroundings where thereis a possibility of taking in flammable or toxicfumes.

12 If the working process produces fumes, dust orvibration hazards, etc., take the necessary steps toeliminate the risk of personnel injury.

13 When using compressed air or inert gas to cleandown equipment, do so with caution and use theappropriate protection, at least safety glasses, forthe operator as well as for any bystander. Do notapply compressed air or inert gas to your skin ordirect an air or gas stream at people. Never use it toclean dirt from your clothes.

14 When washing parts in or with a cleaning solvent,provide the required ventilation and use appropriateprotection such as a breathing filter, safety glasses,rubber apron and gloves, etc.- 9 -

Safety during use and operation1 When the unit has to operate in a fire-hazardous

environment, each engine exhaust has to beprovided with a spark arrestor to trap incendiarysparks.

2 The exhaust contains carbon monoxide which is alethal gas. When the unit is used in a confinedspace, conduct the engine exhaust to the outsideatmosphere by a pipe of sufficient diameter; do thisin such a way that no extra back pressure is createdfor the engine. If necessary, install an extractor.Observe any existing local regulations. Make sure that the unit has sufficient air intake foroperation. If necessary, install extra air intake ducts.

3 When operating in a dust-laden atmosphere, placethe unit so that dust is not carried towards it by thewind. Operation in clean surroundings considerablyextends the intervals for cleaning the air intakefilters and the cores of the coolers.

4 Never remove a filler cap of the coolant system of ahot engine. Wait until the engine has sufficientlycooled down.

5 Never refill fuel while the unit is running, unlessotherwise stated in the Atlas Copco InstructionBook (AIB). Keep fuel away from hot parts such asair outlet pipes or the engine exhaust. Do not smokewhen fuelling. When fuelling from an automaticpump, an earthing cable should be connected to theunit to discharge static electricity. Never spill norleave oil, fuel, coolant or cleansing agent in oraround the unit.

6 All doors shall be shut during operation so as not disturb the cooling air flow inside the bodyworand/or render the silencing less effective. A dooshould be kept open for a short period only e.g. foinspection or adjustment.

7 Periodically carry out maintenance works accordinto the maintenance schedule.

8 Stationary housing guards are provided on arotating or reciprocating parts not otherwisprotected and which may be hazardous personnel. Machinery shall never be put inoperation, when such guards have been removebefore the guards are securely reinstalled.

9 Noise, even at reasonable levels, can cause irritatioand disturbance which, over a long period of timmay cause severe injuries to the nervous system ohuman beings.When the sound pressure level, at any point whepersonnel normally has to attend, is:- below 70 dB(A): no action needs to be taken,- above 70 dB(A): noise-protective devices shou

be provided for people continuously beinpresent in the room,

- below 85 dB(A): no action needs to be taken fooccasional visitors staying a limited time only,

- above 85 dB(A): room to be classified as a noishazardous area and an obvious warning shall bplaced permanently at each entrance to alepeople entering the room, for even relativeshort times, about the need to wear eprotectors,

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Safety during maintenance and repairMaintenance, overhaul and repair work shall only becarried out by adequately trained personnel; if required,under supervision of someone qualified for the job.1 Use only the correct tools for maintenance and

repair work, and only tools which are in goodcondition.

2 Parts shall only be replaced by genuine Atlas Copcoreplacement parts.

3 All maintenance work, other than routine attention,shall only be undertaken when the unit is stopped.Steps shall be taken to prevent inadvertent starting.In addition, a warning sign bearing a legend such aswork in progress; do not start shall be attached tothe starting equipment. On engine-driven units the battery shall bedisconnected and removed or the terminals coveredby insulating caps. On electrically driven units the main switch shall belocked in open position and the fuses shall be takenout. A warning sign bearing a legend such as workin progress; do not supply voltage shall be attachedto the fuse box or main switch.

4 Prior to stripping an engine or other machine orundertaking major overhaul on it, prevent allmovable parts from rolling over or moving.- 10 -

15 Safety shoes should be compulsory in anyworkshop and if there is a risk, however small, offalling objects, wearing of a safety helmet should beincluded.

16 If there is a risk of inhaling hazardous gases, fumesor dust, the respiratory organs must be protected anddepending on the nature of the hazard, so must theeyes and skin.

17 Remember that where there is visible dust, the finer,invisible particles will almost certainly be presenttoo; but the fact that no dust can be seen is not areliable indication that dangerous, invisible dust isnot present in the air.

18 Never operate the generator in excess of its limits asindicated in the technical specifications and avoidlong no-load sequences.

19 Never operate the generator in a humid atmosphere.Excessive moisture causes worsening of thegenerator insulation.

20 Do not open electrical cabinets, cubicles or otherequipment while voltage is supplied. If such cannotbe avoided, e.g. for measurements, tests oradjustments, have the action carried out by aqualified electrician only, with appropriate tools,and ascertain that the required bodily protectionagainst electrical hazards is applied.

21 Never touch the power terminals during operationof the machine.

22 Whenever an abnormal condition arises, e.excessive vibration, noise, odour, etc., switch thcircuit breakers to OFF and stop the engine. Correthe faulty condition before restarting.

23 Check the electric cables regularly. Damaged cableand insufficient tightening of connections macause electric shocks. Whenever damaged wires odangerous conditions are observed, switch thcircuit breakers to OFF and stop the enginReplace the damaged wires or correct the dangeroucondition before restarting. Make sure that aelectric connections are securely tightened.

24 Avoid overloading the generator. The generator provided with circuit breakers for overloaprotection. When a breaker has tripped, reduce thconcerned load before restarting.

25 If the generator is used as stand-by for the mainsupply, it must not be operated without contrsystem which automatically disconnects thgenerator from the mains when the mains supply restored.

26 Never remove the cover of the output terminaduring operation. Before connecting odisconnecting wires, switch off the load and thcircuit breakers, stop the machine and make suthat the machine cannot be started inadvertently othere is any residual voltage on the power circuit.

27 Running the generator at low load for long periodwill reduce the lifetime of the engine.

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18 Maintenance and repair work should be recorded inan operators logbook for all machinery. Frequencyand nature of repairs can reveal unsafe conditions.

19 When hot parts have to be handled, e.g. shrinkfitting, special heat-resistant gloves shall be usedand, if required, other body protection shall beapplied.

20 When using cartridge type breathing filterequipment, ascertain that the correct type ofcartridge is used and that its useful service life is notsurpassed.

21 Make sure that oil, solvents and other substanceslikely to pollute the environment are properlydisposed of.

22 Before clearing the generator for use aftermaintenance or overhaul, submit it to a testrun,check that the AC power performance is correct andthat the control and shutdown devices functioncorrectly.- 11 -

5 Make sure that no tools, loose parts or rags are leftin or on the machine. Never leave rags or looseclothing near the engine air intake.

6 Never use flammable solvents for cleaning (fire-risk).

7 Take safety precautions against toxic vapours ofcleaning liquids.

8 Never use machine parts as a climbing aid.9 Observe scrupulous cleanliness during maintenance

and repair. Keep away dirt, cover the parts andexposed openings with a clean cloth, paper or tape.

10 Never weld on or perform any operation involvingheat near the fuel or oil systems. Fuel and oil tanksmust be completely purged, e.g. by steam-cleaning,before carrying out such operations. Never weld on,or in any way modify, pressure vessels. Disconnectthe alternator cables during arc welding on the unit.

11 Support the towbar and the axle(s) securely ifworking underneath the unit or when removing awheel. Do not rely on jacks.

12 Do not remove any of, or tamper with, the sound-damping material. Keep the material free of dirt andliquids such as fuel, oil and cleansing agents. If anysound-damping material is damaged, replace it toprevent the sound pressure level from increasing.

13 Use only lubricating oils and greases recommendeor approved by Atlas Copco or the machinmanufacturer. Ascertain that the selected lubricancomply with all applicable safety regulationespecially with regard to explosion or fire-risk anthe possibility of decomposition or generation ohazardous gases. Never mix synthetic with mineroil.

14 Protect the engine, alternator, air intake filteelectrical and regulating components, etc., prevent moisture ingress, e.g. when steam-cleaning

15 When performing any operation involving heaflames or sparks on a machine, the surroundincomponents shall first be screened with nonflammable material.

16 Never use a light source with open flame foinspecting the interior of a machine.

17 When repair has been completed, the machine shabe barred over at least one revolution foreciprocating machines, several revolutions forotary ones to ensure that there is no mechanicinterference within the machine or driver. Check thdirection of rotation of electric motors when startinup the machine initially and after any alteration the electrical connection(s) or switch gear, to checthat the oil pump and the fan function properly.

ins:nt.- 12 -

Tool applications safetyApply the proper tool for each job. With the knowledgeof correct tool use and knowing the limitations of tools,along with some common sense, many accidents can beprevented.Special service tools are available for specific jobs andshould be used when recommended. The use of thesetools will save time and prevent damage to parts.

Battery safety precautionsBatteriesWhen servicing batteries, always wear protectingclothing and glasses.1 The electrolyte in batteries is a sulphuric acid

solution which is fatal if it hits your eyes, and whichcan cause burns if it contacts your skin. Therefore,be careful when handling batteries, e.g. whenchecking the charge condition.

2 Install a sign prohibiting fire, open flame andsmoking at the post where batteries are beingcharged.

3 When batteries are being charged, an explosive gasmixture forms in the cells and might escape throughthe vent holes in the plugs.Thus an explosive atmosphere may form around thebattery if ventilation is poor, and can remain in andaround the battery for several hours after it has beencharged. Therefore:- never smoke near batteries being, or having

recently been, charged,- never break live circuits at battery terminals,

because a spark usually occurs.

4 When connecting an auxiliary battery (AB) parallel to the unit battery (CB) with booster cableconnect the + pole of AB to the + pole of CB, theconnect the - pole of CB to the mass of the uniDisconnect in the reverse order.

ble or as stand-by in cases of interruption of the mains. TheAS 14 and QAS 20 generators are driven by a fluid-cooled

Lifting beamSide doorsEngine exhaustData PlateDoor, access to control and indicator panelOutput terminal boardEarthing rod (not available in combination with an IT-relay)

SB Emergency stop buttonF Filler cap fuelW Filler cap coolant- 13 -

Leading particulars

General descriptionThe QAS 14 and QAS 20 are AC generators, built for continuous running at sites where no electricity is availagenerator operates at 50/60 Hz, 230/240 V in line-to-neutral mode and 400/480 V in line-to-line mode. The Qdiesel engine, manufactured by KUBOTA. An overview of the main parts is given in the diagram below.

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AlternatorF Air filterS Battery switch

CouplingFO Drain flexible engine oilFW Drain flexible coolantH Drain and access hole (in the frame)PF Drain plug fuel

EngineFan

F Filler cap fuelO Filler cap engine oilW Filler cap coolant

Fuel filter1 BatteryF Oil filterLD Engine oil level dipstickI Vacuum indicator- 14 -

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Indicates that the unit may start automatically and that the instruction book has to be consulted prior to use.

Read the instruction manual before using the lifting eye.

Indicates the 3-way valve.

Indicates the partnumbers of the different service packs and of the engine oil. These parts can be ordered to the factory.

Position 1 Closed Position 2- 15 -

BodyworkThe alternator, the engine, the cooling system, etc. areenclosed in a sound-insulated bodywork that can beopened by means of side doors (and service plates).

The recess in the roof has a lifting rod in the middle.

To be able to lift the generator by means of a forklift,rectangular holes are provided in the frame.

The earthing rod, connected to the generators earthterminal is located at the side of the frame.

MarkingsA brief description of all markings provided on thegenerator is given hereafter.

Never use the guiding rods to lift thegenerator.

Indicates that the engine exhaust is a hot and harmful gas, which is toxic in case of inhalation. Always make sure that the unit is operated outside or in a well-ventilated room.

Indicates that these parts can become very hot during operation (e.g. engine, cooler, etc.). Always make sure that these parts are cooled down before touching them.

Indicates that the guiding rods may not be used to lift the generator. Always use the lifting rod in the roof of the generator to lift it.

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Indicates a lifting point of the generator.

Indicates that the generator may be refuelled with diesel fuel only.

Indicates the drain for the engine oil.

Indicates the drain for the coolant.

Indicates the drain plug for the enginefuel.

Use PAROIL E only.

Indicates the different earthing connections on the generator.

Indicates that the alternator should notbe cleaned with high pressurised water.

Indicates the battery switch.

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H0 .......Panel light

S20......ON/OFF/REMOTE switch

To start up the unit (locally or remote).

X25 .....Terminal strip

Qc1002 Module

The Qc1002 module is located inside the controlpanel. This control module will carry out allnecessary tasks to control and protect a generator,regardless of the use of the generator.

This means that the Qc1002 module can be used forseveral applications.

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Drain plugs and filler capsThe drain holes for the engine oil, the coolant and theplug for the fuel, are located and labelled on theframe; the fuel drain plug at the front, the others at theservice side.The drain flexible for engine oil can be brought to theoutside of the generator through the drain hole.

The filler cap for the engine coolant is accessible viaan opening in the roof. The fuel filler cap is located inthe side panel.

Control and indicator panel Qc1002

General description Qc1002 contro

panel

A1 .......Qc1002 display

F10......Fuse

The fuse activates when the current from thbattery to the engine control circuit exceedits setting. The fuse can be reset by pushinthe button.

The drain hole can also be used toguide external fuel tank connections.When connecting an external fueltank, use the 3-way valves. Refer toExternal fuel tank connection (with/without quick couplings).

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400 500

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Qc1002 Menu Overview

At Qc1002, the LCD will show followinginformation:

in Normal condition (scroll through theinformation using UP and DOWN): Status (eg: preheat, crank, run, cooldown,

extended stop time, ) Controller type & version Parameter list Alarm list LOG list Service Timer 1 & Service Timer 2 Battery Voltage Fuel level Voltage - frequency - running hours

in Alarm condition (scroll through theinformation using UP and DOWN): a list of all active Alarms

It's possible to scroll through the views, using the UPand DOWN buttons. The scrolling is continuous. If a Special status comes up, the Status Display isshown. If an Alarm comes up, the Alarm Display is shown.

- 17 -

Pushbutton and LED functions

Following pushbuttons are used on the Qc1002

Following LEDs are used on the

Qc1002

ENTER: Is used to select and confirm changed settings in the Parameter list.

UP: Is used to scroll through the display information and to adjust parameter value upwards.

DOWN: Is used to scroll through the display information and to adjust parameter value downwards.

BACK: Is used to leave the Alarm pop-up window, to leave the Parameter list and to leave menu's without change.

Power Green LED indicates that the unit is powered up.

Remote Green LED indicates that the RemoteMode is selected.

Alarm Flashing red LED indicates that an alarm is present. A continuous red LED indicates that the alarm has beenacknowledged by the user. The exact alarm is shown on the display.

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Battery Voltage display

This view shows the Battery voltage and the runninghours.

Fuel level display

This view shows the Fuel level and the running hours.

Voltage - frequency - running hours

display

This view shows the voltage, frequency and runninghours.

13.2 VBattery00168.1h

75%Fuel00168.1h

50Hz400V00168.1h- 18 -

Controller type and version display

This view shows the controller type and the ASWversion number.

Parameter display

This view shows a number of Parameter settings andgives access to them.

An overview is given in Parameter list on page 19.

Alarm list display

This view shows the number of active alarms andgives access to them.

An overview is given in Alarm Display (pop-upwindow) on page 21.

LOG list display

This view shows the alarm memory and gives accesto it.An overview is given in LOG list on page 22.

Service timer 1 & Service timer 2

display

This view shows both Service timers. The servictimer indication is shown when service time has ruout. It can be removed by resetting the timers oacknowledging the Service timer indication.The service timer indications count and give an alarmwhen value is reached.

Resetting the Service Timers can be done through thParameter display.

Qc1002v1.00.0

Parameter

Alarm List0 Alarm(s)

LOG List

Service 1Service 2

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Language selection

Icons is the default factory set language, but 6other languages can be selected: English, French,German, Italian, Spanish and Cyrillic (Russian).All information in the Parameter List display isalways in English.

Generator Underfrequency: failclass, enable,delay, setpoint

Generator Overfrequency: failclass, enable, delay,setpoint

Generator Undervoltage: failclass, enable, delay,setpoint

Generator Overvoltage: failclass, enable, delay,setpoint

It's possible to scroll between configuration menu'sby using the pushbuttons UP and DOWN.Pushing the ENTER button activates theconfiguration menu which is shown at the display.- 19 -

Qc1002 Menu Description

Status Display (pop-up window)

In case special statuses are entered, a pop-up windowwill automatically be entered for as long as the statusis active.The background screen is not updated when the statuspop-up window is active.

These special statuses are:

If a special status has elapsed, the active view will bentered again automatically.If an Alarm comes up, the Alarm Display is shown.

Parameter list

The Parameter Menu's are pre-programmed!A password will be asked for when an attempt tchange a setting is about to be done (user password 2003).Menu's shown on the Parameter list LCD:

Running hours adjust

This menu is used to adjust the amount of runninhours. The running hours can only be raised, nolowered.

Unit Type

Service Timer 2 reset

Service Timer 1 reset

These menus are used to reset the service timerWhen a service timer alarm occurs and acknowledged, the service timer will be resautomatically.

Unit Menu

This menu is used to select whether tempreaturand pressure should appear in C/bar or F/psi.

PREHEAT

START OFF/EXTENDED STOP TIMER

COOLDOWN

Unit type 1 for QAS 14-20 !!

Unit type- 20 -

This is the described menu flow for changing the unit type:

Qc 1002145

Qc1002145

Parameter Running time

Unit type

pis

r

s

s

GENERATOR OVERVOLTAGE

GENERATOR UNDER-VOLTAGE

GENERATOR OVER-FREQUENCY

GENERATOR UNDER-FREQUENCY

SERVICE TIMER 1

SERVICE TIMER 2

- 21 -

Alarm Display (pop-up window)

In case an Alarm occurs, a pop-up window willautomatically be displayed for as long as the alarm isactive, no matter which view is active. The flashingred alarm LED will light up. The alarm icons will beshown together with an acknowledgement check-box.Push the ENTER button to acknowledge the alarm.When the alarm has been acknowledged, a V-marking will appear in the check-box and the redalarm LED will light up continuously.

The Alarm Display can always be left by pushing theBACK button.

If more than one alarm comes up, it's possible to scrollthrough the alarm messages with the UP and DOWNpushbuttons. The newest alarm will be placed at thebottom of the list (meaning that the older alarm staysat the display when a newer alarm comes up).If one or more than one alarm is present, an arrow atthe right of the display will be shown.

Following general groups of Alarms exist:

Warning: Alarm LED lights up + Alarm pop-uappears on the display + Alarm relay empowered (if configured)

Trip of GB: Warning actions + GeneratoContactor opens

Trip and Stop: Trip of GB actions + unit stopafter Cooldown

Shutdown: Trip of GB actions + unit stopimmediately

List of possible alarms:

An alarm should always beacknowledged before solving theproblem that causes the alarm. !

LOW OIL PRESSURE

HIGH COOLANT TEMPERATURE

CHARGING ALTERNATOR

LOW FUEL LEVEL

s.

e

Remote start operation

Installation wirings: X25.1 & X25.2 to be wired for the remote start

switch. X25.3 & X25.4 to be wired for the remote

contactor (open/close).

Fail classes

All the activated alarms of the Qc1002 have theirown pre-defined fail class.

All alarms are enabled according to one of these threestatuses: disabled alarm, no supervision of alarm (OFF).

enabled alarm, supervision of alarm all the time(ON).

running alarm, only supervision when themachine is running (RUN).- 22 -

LOG list

The unit will keep an event log of the latest 30 eventEvents are:

shutdowns service timer 1/2 reset unit type changes

Together with each event, the running hours at thtime of the event will be stored.

ENGINE ALARM

EMERGENCY STOP

START FAILURE

STOP FAILURE

1 Controller type2 Event number3 Event4 Running hours

Time: 00001h

EVENT LOG #04 WaterQc1002

1

3

4

2

et

ep

lllr,

r

Pushbutton and LED functions

Following pushbuttons are used on the Qc2002

ENTER: Is used to select and confirm changed settings in the Parameter list.

UP: Is used to scroll through the display information and to adjust parameter value upwards.

DOWN: Is used to scroll through the display information and to adjust parameter value downwards.

BACK: Is used to leave the Alarm pop-up window, to leave the Parameter list and to leave menu's without change.

AUTOMATIC: Is used to put the unit in Manual or Automatic Operation.- 23 -

Control and indicator panel Qc2002

General description Qc2002 control

panel

A1 ....... Qc2002 display

F10...... Fuse

The fuse activates when the current from thebattery to the engine control circuit exceedsits setting. The fuse can be reset by pushingthe button.

S20 .....ON/OFF switch

Position O: No voltage is applied to thQc2002 module, the generator will nostart.

Position I: Voltage is applied to thQc2002 module, it is possible to start uthe generator.

X25 .....Terminal strip

Qc2002 Module

The Qc2002 module is located inside the contropanel. This control module will carry out anecessary tasks to control and protect a generatoregardless of the use of the generator.

This means that the Qc2002 module can be used foseveral applications.

S20

F10

Q1

X1 X25

L1 L2 L3 N PE

G

Reset

Test

On

Fault

N13

F10

X25

S20

A1

r

Mains contactor

Green LED indicates that it is possible to close the Mains Contactor (only in AMF mode), if the Generator contactor is open.

Alarm Flashing red LED indicates that an alarm is present. A continuous red LED indicates that the alarm has been acknowledged by the user. The exact alarm is shown on the display.- 24 -

Following LEDs are used on the

Qc2002START: Is used to start the unit in Manual Operation.

STOP: Is used to stop the unit in Manual or Automatic Operation (without cooldown). When the unit is stopped with the STOP button in Automatic Operation, it will automatically go to Manual Operation.

MAINS CONTACTOR: Is used to open or close the Mains contactor, if the Qc2002 is in Manual Operation.

.

GENERATOR CONTACTOR: Is used to open or close the Generator contactor, if the Qc2002 is in Manual Operation

G

Power Green LED indicates that the unit is powered up.

Automatic Green LED indicates that the Qc2002 is in Automatic Operation.

Start/Stop Green LED indicates that the Qc2002 receives running feedback (via the W/L input, via the RPM value at the Canbus, or via the AC frequency).

Generator contactor

Green LED indicates that the voltage and the frequency of the alternator are within certain limits for a certain time. It will be possible to close the Generator Contactor (both in Island and in AMF mode), if the Mains contactor is open.

Qc2002145

G

Powe

AlarmStart

Automatic

GeneratorContactor

MainsContactor

Stop

e

P

is

Parameter display

This view shows a number of Parameter settings andgives access to them.An overview is given in Parameter list on page 28.

Alarm list display

This view shows the number of active alarms andgives access to them.An overview is given in Alarm Display (pop-upwindow) on page 32.

Parameter

Alarm List0 Alarm(s)- 25 -

Qc2002 Menu Overview

At Qc2002, the LCD will show followinginformation:

in Normal condition (scroll through theinformation using UP and DOWN): Status (eg: preheat, crank, cooldown, extended

stop time, ) (pop-up: this display is onlyshown when a Special status comes up)

Line voltages of the generator Controller type & version Parameter list Alarm list LOG list Service Timer 1 & Service Timer 2 Battery Voltage Fuel level kWh counter Power factor, the frequency of the generator

and the frequency of the mains Line voltage, frequency and active power of

the generator Active, reactive and apparent power of the

generator Generator currents Phase voltages of the mains Line voltages of the mains Phase voltages of the generator

in Alarm condition (scroll through thinformation using UP and DOWN): a list of all active Alarms

It's possible to scroll through the views, using the Uand DOWN buttons. The scrolling is continuous. If a Special status comes up, the Status Display shown. If an Alarm comes up, the Alarm Display is shown.

Line voltages generator display

This view shows the line voltages of the generator.

Controller type and version display

This view shows the controller type and the ASWversion number.

G L1-L2G L2-L3G L3-L1

400V400V400V

Qc20021.00.1

g

s.

Power factor - frequency generator -

frequency mains display

This view shows the PF, the frequency of thegenerator and the frequency of the mains (M f L1:only in AMF mode).

One line voltage - frequency - active power display

This view shows one line voltage, frequency andactive power of the generator.

PFG f L1M f L1

0.0050Hz50Hz

G L1-L2G f L1P

400V50Hz80kW- 26 -

LOG list display

This view shows the alarm memory and gives accessto it.An overview is given in LOG list on page 34.

Service timer 1 & Service timer 2

display

This view shows both Service timers. The servicetimer indication is shown when service time has runout. It can be removed by resetting the timers oracknowledging the Service timer indication.The service timer indications count downwards andgive an alarm when the set value 0 (zero) is reached.Resetting the Service Timers can be done through theParameter display.

Battery voltage display

This view shows the Battery voltage and the runninhours.

Fuel level display

This view shows the Fuel level and the running hour

kWh counter display

This view shows the kWh counter.

LOG List

Service 1Service 2

59h59h

13.2 VBattery00168.1h

75%Fuel00168.1h

E 4860kWh

is

r.

Qc2002 Menu Description

Status Display (pop-up window)

In case special statuses are entered, a pop-up windowwill automatically be entered for as long as the statusis active.The background screen is not updated when the statuspop-up window is active.

These special statuses are:

PREHEAT

START OFF/EXTENDED STOP TIMER

COOLDOWN- 27 -

Active - reactive - apparent power

display

This view shows the active, reactive and apparentpower of the generator.

Generator current display

This view shows the generator current.

Phase voltages mains display

This view shows the phase voltages of the mains (isonly shown in AMF mode).

Line voltages mains display

This view shows the line voltages of the mains (only shown in AMF mode).

Phase voltages generator display

This view shows the phase voltages of the generato

PQS

80kW0kVAr80kVA

G I1G I2G I3

100A100A100A

M L1-NM L2-NM L3-N

230V230V230V

M L1-L2M L2-L3M L3-L1

400V400V400V

G L1-NG L2-NG L3-N

230V230V230V

te-

=

re

=

nne

:

Automatic Mains Failure (AMF) operation

This application is only possible in combinationwith the Auto mode. If the Manual Operationmode is selected the AMF operation will NOTfunction !

When the Mains exceeds the defined voltage /frequency limits for a defined delay time, thegenerator will take over the load automatically.

When the mains is restored within the definedlimits for a defined time, the generator will unloadbefore disconnecting and switching back to theMains.

The generator will then go into cooldown andstop.

Installation wirings: we refer to circuit diagram9822 0992 79/02 for the correct connections.

Horn delay

This menu is used to set the delay, how long thegeneral alarm relay stays energized (if present). If setto 0.0s, the general alarm relay will stay energizedcontinuously.

Horn Delay0.0s 20.0s 990.0s- 28 -

If a special status has elapsed, the active view will beentered again automatically.If an Alarm comes up, the Alarm Display is shown.

Parameter list

The Parameter Menu's are pre-programmed !A password will be asked for when an attempt tochange a setting is about to be done (user password =2003).By entering the parameter list, pushbuttonAUTOMATIC is disposed of its normal operationsand will not perform any functionality.It's possible to scroll between configuration menu'sby using the pushbuttons UP and DOWN.Pushing the ENTER button activates theconfiguration menu which is shown at the display.

Menu's shown on the Parameter list LCD:

Genset mode

This menu is used to change the mode of the machine.In the Qc2002 module 2 application modes can beselected:

Island operation

This operation type is selected for local/remostart applications, without the Mains (= standalone). Combined with Manual Operation mode

Local Start operation. The sequences start/stop/close Generato

Contactor / open Generator Contactor can bactivated manually.

Combined with Automatic Operation mode Remote Start operation.

The remote start signal can be given with aexternal switch. After the generator has beestarted, the Generator Contactor will closautomatically.

Installation wirings for Remote Start operationwire the RS switch between X25.9 & X25.10.

Genset ModeIsland Island AMF

h

rn,lln

MF high frequency

This menu is used to set the maximum limit for themains frequency, in % of the nominal frequency (inAMF-Auto).

MF low frequency

This menu is used to set the minimum limit for themains frequency, in % of the nominal frequency (inAMF-Auto).

MF high freq100% 110 120%

MF low freq80% 90 100%- 29 -

Running hours adjust

This menu is used to adjust the amount of runninghours. The running hours can only be raised, notlowered.

Service timer 2 reset

Service timer 1 reset

These menus are used to reset the service timers.When a service timer alarm occurs and isacknowledged, the service timer will be resetautomatically.

Unit menu

This menu is used to select the units into whicpressures and temperatures will be shown.

Language selection

Icons is the default factory set language, but 6 othelanguages can be selected: English, French, GermaItalian, Spanish and Cyrillic (Russian). Ainformation in the Parameter List display is always iEnglish.

Running TimeCur. 168 20000

St 2 ResetNo No Yes

St 1 ResetNo No Yes

UnitC/bar C/bar F/psi

LanguageEnglish

e-

e-

M voltage delay

This menu is used to set the delay,, which defines howlong the mains voltage has to be back within the limitsbefore there will be switched from generator to mainsagain (in AMF-Auto). During this delay, the MainsLED flashes in green.

MF voltage delay

This menu is used to set the delay, which defines howlong the mains voltage may be above the max limit orbelow the min limit before there will be switchedfrom mains to generator (in AMF-Auto). During thisdelay, the Mains LED flashes in red.

M volt delay10s 30 9900s

MF volt delay1.0s 2.0 990.0s- 30 -

M frequency delay

This menu is used to set the delay, which defines howlong the mains frequency has to be back within thelimits before there will be switched from generator tomains again (in AMF-Auto). During this delay, theMains LED flashes in green.

MF frequency delay

This menu is used to set the delay, which defines howlong the mains frequency may be above the max limitor below the min limit before there will be switchedfrom mains to generator (in AMF-Auto). During thisdelay, the Mains LED flashes in red.

MF high voltage

This menu is used to set the maximum limit for thmains voltage, in % of the nominal voltage (in AMFAuto).

MF low voltage

This menu is used to set the minimum limit for thmains voltage, in % of the nominal voltage (in AMFAuto).

M freq delay10s 30 9900s

MF freq delay1.0s 2.0 990.0s

MF high volt100% 110 120%

MF low volt80% 90 100%

Undervoltage delay

Undervoltage setpoint

Overfrequency enable

Overfrequency failclass

< Volt Delay0 1 99

< Volt SP0 450 999

> Freq enableEnable enable disable

> Freq FCwarning warning shutdown- 31 -

Overvoltage enable

Overvoltage failclass

Overvoltage delay

Overvoltage setpoint

Undervoltage enable

Undervoltage failclass

> Volt enableEnable enable disable

> Volt FCwarning warning shutdown

> Volt Delay0 1 99

> Volt SP0 450 999

< Volt enableEnable enable disable

< Volt FCwarning warning shutdown

Alarm Display (pop-up window)

In case an Alarm occurs, a pop-up window willautomatically be displayed for as long as the alarm isactive, no matter which view is active. The flashingred alarm LED will light up. The alarm icons will beshown together with an acknowledgement check-box.Push the ENTER button to acknowledge the alarm.When the alarm has been acknowledged, a V-marking will appear in the check-box and the redalarm LED will light up continuously.

The Alarm Display can always be left by pushing theBACK button.

If more than one alarm comes up, it's possible to scrollthrough the alarm messages with the UP and DOWNpushbuttons. The newest alarm will be placed at thebottom of the list (meaning that the older alarm staysat the display when a newer alarm comes up).If one or more than one alarm is present, an arrow atthe right of the display will be shown.

An alarm should always beacknowledged before solving theproblem that causes the alarm. !- 32 -

Overfrequency delay

Overfrequency setpoint

Underfrequency enable

Underfrequency failclass

Underfrequency delay

Underfrequency setpoint

> FreqDelay0 1 99

> Freq SP0 38 70

< Freq enableEnable enable disable

< Freq FCwarning warning shutdown

< FreqDelay0 1 99

< Freq SP0 38 70

ENGINE ALARM

EMERGENCY STOP

START FAILURE

STOP FAILURE

HZ/V FAILURE

OIL LEVEL- 33 -

Following general groups of Alarms exist:

Warning: Alarm LED lights up + Alarm pop-upappears on the display + Alarm relay isempowered (if configured)

Trip of GB: Warning actions + GeneratorContactor opens

Trip and Stop: Trip of GB actions + unit stopsafter Cooldown

Shutdown: Trip of GB actions + unit stopsimmediately

List of possible alarms:z

LOW OIL PRESSURE

HIGH COOLANT TEMPERATURE

CHARGING ALTERNATOR

LOW FUEL LEVEL

GENERATOR OVERVOLTAGE

GENERATOR UNDER-VOLTAGE

GENERATOR OVER-FREQUENCY

GENERATOR UNDER-FREQUENCY

SERVICE TIMER 1

SERVICE TIMER 2

s.

t

Fail classes

All the activated alarms of the Qc2002 have theirown pre-defined fail class.

All alarms are enabled according to one of these threestatuses: disabled alarm, no supervision of alarm (OFF)

enabled alarm, supervision of alarm all the time(ON)

running alarm, only supervision when themachine is running (RUN)- 34 -

LOG list

The unit will keep an event log of the latest 30 eventEvents are:

shutdowns service timer 1/2 resetTogether with each event, the real time of the evenwill be stored.

OIL TEMPERATURE

1 Controller type2 Event number3 Event4 Date and hour of the event

Time: 27/6 14:27

EVENT LOG #04 WaterQc2002

4

1

3

2

ane,e

et

Eel

t1.dee

et

n3,y

S13......Lock-out switch for earth fault

protection (N13)

This switch is located inside the cubicle andis labelled IN.

Position O: No de-energising of the maincircuit breaker Q1 when an earth faultoccurs.

Position 1: De-energising of the main circuitbreaker Q1 when an earth fault occurs.

Position O will only be used inconjunction with an external earthfault protection unit (e.g. integratedin a distribution board).If S13 is in position O, properearthing is of the utmost importancefor the safety of the user.Eliminating any earth faultprotection can lead to serious injuryor even death for anybody touchingthe unit or the load.

!

- 35 -

Output terminal boardThe output terminal board is situated below thecontrol and indicator panel.

S2 ....... Emergency stop button

Push the button to stop the generator in caseof an emergency. When the button ispressed, it must be unlocked, by turning itanti-clockwise, before the generator can berestarted. The emergency stop button can besecured in the locked position with the key,to avoid unauthorized use.

Q1 .......Main circuit breaker

Interrupts the power supply to X1 when short-circuit occurs at the load side, or whethe earth leak detector (30 mA) or thovercurrent protection (QAS 14: 20 AQAS 20: 32 A) is activated or when thshunt trip is energized. It must be resmanually after eliminating the problem.

X1 .......Main power supply (400 V AC)

Terminals L1, L2, L3, N (= neutral) and P(= earthing), hidden behind the control pandoor and behind a small transparent door.

N13 .....Earth leak detector

Detects and indicates an earth fault currenand activates the main circuit breaker QThe detection level can be set at 0.03 A fixewith instantaneous trip but can also badjusted between 0.1 A and 1 A with timdelayed (0 - 0.5 sec) trip. N13 has to be resmanually after eliminating the problem(reset button marked R). It can be overriddeby means of the earth leak switch (S1labelled IN) but has to be tested monthl(by pushing test button T).

L1 L2 L3 N PE

Reset

Test

On

Fault

H0

S20

F10

Q1

X1

N13

P4 P3

0 0

20

40

80

100

200

VA

300

400 500

Qc 1002145

N13

S13

Q1

X1

S2

Installation Place the generator on a horizontal, even and solid

floor. The generator should be kept with the doors

closed, in order to avoid the ingress of water anddust. Dust ingress reduces the lifetime of filtersand may reduce your generator's performance.

Check that the engine exhaust is not directedtowards people. If the generator is operatedindoors, install an exhaust pipe of sufficientdiameter to duct the engine exhaust towards theoutside. Check for sufficient ventilation so that thecooling air is not recirculated. If necessary,consult Atlas Copco.

Leave enough space for operation, inspection andmaintenance (at least 1 meter at each side).

Check that the inner earthing system is incompliance with the local legislation.

Use coolant for the engine cooling system. Referto the Engine instruction book for the propercoolant mixture.

If operating the generator inanother power system, e.g. an IT-system, other protective devicesrequired for these types must beinstalled. In any case only aqualified electrician is authorized toremove the connection between theneutral (N) and earth terminals inthe terminal box of the alternator.- 36 -

Electronic speed regulatorThe electronic speed regulator makes sure that theoutput frequency of the generator is fixed (50 Hz/60 Hz), independent of the amount of load.

Operating instructions

In your own interest, always strictlyobserve all relevant safetyinstructions.Do not operate the generator inexcess of the limitations mentionedin the Technical Specifications.Local rules concerning the settingup of low voltage power installations(below 1000 V) must be respectedwhen connecting site distributionpanels, switch gear or loads to thegenerator.At each start-up and at any time anew load is connected, the earthingof the generator must be verified.Earthing must be done either by theearthing rod or, if available, by anexisting, suitable earthinginstallation. The protective systemagainst excessive contact voltage isnot effective unless a suitableearthing is made.The generator is wired for a TN-system to IEC 364-3, i.e. one point inthe power source directly earthed -in this case the neutral. The exposedconductive parts of the electricinstallation must be directlyconnected to the functional earth.

!

ealdyt

d,F

lef

Cee

aln

The lowest acceptable wire section and thecorresponding maximum cable or conductor lengthfor multiple core cable or H07 RN-F, at rated current(20 A), for a voltage drop e lower than 5% and at apower factor of 0.80, are respectively 2.5 mm and144 m. In case electric motors must be started,oversizing the cable is advisable.

The voltage drop across a cable can be determined asfollows:

e = Voltage drop (V)

I = Rated current (A)L = Length of conductors (m)R = Resistance (/km to VDE 0102)

X = Reactance (/km to VDE 0102)

e 3 I L R cos X sin+ 1000------------------------------------------------------------------------------=- 37 -

Check the tightness of the bolts and nuts.

Install the earthing rod as near as possible to thegenerator and make sure not to have a contactvoltage higher than 25 V.

Check that the cable end of the earthing rod isconnected to the earth terminal.

Connecting the generator

Precautions for non-linear and

sensitive loads

The most common non-linear, 3-phase loads arethyristor/rectifier-controlled loads, such as convertorssupplying voltage to variable speed motors,uninterruptable power supplies and Telecomsupplies. Gas-discharge lighting arranged in single-phase circuits generate high 3rd harmonics and riskfor excessive neutral current.Loads most sensitive to voltage distortion includeincandescent lamps, discharge lamps, computers, X-ray equipment, audio amplifiers and elevators.Consult Atlas Copco for measures against the adverseinfluence of non-linear loads.

Quality, minimum section and

maximum length of cables

The cable connected to the terminal board of thgenerator must be selected in accordance with loclegislation. The type of cable, its rated voltage ancurrent carrying capacity are determined binstallation conditions, stress and ambientemperature. For flexible wiring, rubber-sheatheflexible core conductors of the type H07 RN-(Cenelec HD.22) or better must be used.The following table indicates the maximum allowab3-phase currents (in A), in an ambient temperature o40C, for cable types (multiple and single core PVinsulated conductors and H07 RN-F multiple corconductors) and wire sections as listed, in accordancwith VDE 0298 installation method C3. Locregulations remain applicable if they are stricter thathose proposed below.

Non-linear loads draw currents withhigh contents in harmonics, causingdistortion in the wave form of thevoltage generated by the alternator.

!

Wire section Max. current (A) (mm) Multiple core Single core H07 RN-F

2.5 22 25 214 30 33 286 38 42 3610 53 57 5016 71 76 6725 94 101 8835 114 123 11050 138 155 13870 176 191 17095 212 228 205

,ts

Before starting With the generator standing level, check the

engine oil level and top up if necessary. The oillevel must be near to, but not exceed the high markon the engine oil level dipstick.

Check the coolant level in the expansion tank ofthe engine cooling system. The coolant level mustbe near to the FULL mark. Add coolant ifnecessary.

Drain any coolant and sediment from the fuel pre-filter. Check the fuel level and top up if necessary.It is recommended to fill the tank after the daysoperation to prevent coolantdamp in a nearlyempty tank from condensing.

Check the vacuum indicator of the air filter. If thered part shows completely, replace the filterelement.

Press the vacuator valve of the air filter to removedust.

Check the generator for leakage, tightness of wireterminals, etc. Correct if necessary.

Check that fuse F10 has not tripped and that theemergency stop is in the OUT position.

Check that the load is switched off. Check that circuit breaker Q1 is switched off.

Check that the earth fault protection (N13) has nottripped (reset if necessary).- 38 -

Connecting the load

Site distribution panel

If outlet sockets are provided, they must be mountedon a site distribution panel supplied from the terminalboard of the generator and in compliance with localregulations for power installations on building sites.

Protection

Check whether frequency, voltage and currentcomply with the ratings of the generator.

Provide for the load cable, without excessivelength, and lay it out in a safe way withoutforming coils.

Open the door of the control and indicator paneland the transparent door in front of the terminalboard X1.

Provide the wire ends with cable lugs suited forthe cable terminals.

Loosen the cable clamp and push the wire ends ofthe load cable through the orifice and clamp.

Connect the wires to the proper terminals (L1, L2L3, N and PE) of X1 and tighten the bolsecurely.

Tighten the cable clamp.

Close the transparent door in front of X1.

For safety reasons, it is necessary toprovide an isolating switch or circuitbreaker in each load circuit. Locallegislation may impose the use ofisolating devices which can be locked.

!

al

e,e

eatt

el-

,k

Stopping Qc1002

To stop the unit locally, proceed as follows:

Switch off the load. Switch off circuit breaker Q1.

Let the engine run for about 5 minutes. Stop the engine by putting the starter switch S20

in position O.

Lock the side doors and the door of the indicatorsand control panel to avoid unauthorized access.

To stop the unit when the starter switch is in position , proceed as

follows:

Switch off the load. Stop the engine by putting the remote start/stop

switch in position stop or by putting the starterswitch S20 in position O.

Cooldown period default 15 sec. Lock the side doors and the door of the indicators

and control panel to avoid unauthorized access.

.

- 39 -

Operating Qc1002

Starting Qc1002

To start up the unit locally, proceed as follows:

Switch on the battery switch, if applicable. Switch off circuit breaker Q1. This is not

necessary when a plant contactor is installedbetween Q1 and the load.

Put the starter switch S20 in position I (ON). Theunit starts a preheating cycle which takes 12seconds.

After the preheating period, the unit will start. Thestarting attempt will take maximum 12 seconds.

Switch on circuit breaker Q1.

To start up the unit from a remote

location, proceed as follows:

Put the starter switch S20 in position .

Switch on circuit breaker Q1. Put the remote start/stop switch in position start.

The unit starts a preheating cycle which takes 12seconds.

After the preheating period, the unit will start. Thestarting attempt will take maximum 12 seconds.

An external contactor can be connected andcontrolled by the Qc1002.

During operation Qc1002

Following points should be carried out regularly: Check the engine gauges and the lamps for norm

readings.

Check for leakage of oil, fuel or coolant. Avoid long low-load periods (< 30%). In this cas

an output drop and higher oil consumption of thengine could occur.

Check, by means of the generator gauges, that thvoltage between the phases is identical and ththe rated current in the third phase (L3) is noexceeded.

When single-phase loads are connected to thgenerator output terminals, keep all loads welbalanced.

If circuit breakers are activated during operationswitch off the load and stop the generator. Checand, if necessary, decrease the load.

Avoid to let the engine run out of fuelIf it happened, priming will speed upthe starting.

The generators doors may onlyremain opened for short periodsduring operation, to carry outchecks for example.

!

!

).

eh

ert

2

e

During operation Qc2002

Following points should be carried out regularly: Check the engine gauges and the lamps for normal

readings.

Check for leakage of oil, fuel or coolant.

Avoid long low-load periods (< 30%). In this case,an output drop and higher oil consumption of theengine could occur.

Check, by means of the generator gauges, that thevoltage between the phases is identical and thatthe rated current in the third phase (L3) is notexceeded.

When single-phase loads are connected to thegenerator output terminals, keep all loads well-balanced.

If circuit breakers are activated during operation,switch off the load and stop the generator. Checkand, if necessary, decrease the load.

Avoid to let the engine run out offuel. If it happened, priming willspeed up the starting.

The generators doors may onlyremain opened for short periodsduring operation, to carry outchecks for example.

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- 40 -

Operating Qc2002

Starting Qc2002

To start up the unit locally, proceed as follows:

Switch on the battery switch. Switch off circuit breaker Q1. This is not

necessary when a plant contactor is installedbetween Q1 and the load.

Put the starter switch S20 in position I (ON).Voltage is applied to the Qc2002 module.

The unit can be started manually by pressing theSTART button on the Qc2002 module.

The unit starts a preheating cycle which takes 12seconds.

After the preheating period, the unit will start. Thestarting attempt will take maximum 12 seconds.

Switch on circuit breaker Q1 in case no contactoris installed.

To start up the unit from a remote

location, proceed as follows:

Put the starter switch S20 in position I (ONVoltage is applied to the Qc2002 module.

Switch on circuit breaker Q1. For remote start:

Put the unit in Island mode. Push thAUTOMATIC button. Use an external switcto start the machine.

or Put the unit in AMF mode. Push th

AUTOMATIC button. The machine will staautomatically when Mains fails.

The unit starts a preheating cycle which takes 1seconds.

After the preheating period, the unit will start. Thstarting attempt will take maximum 12 seconds.

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rs- 41 -

Stopping Qc2002

To stop the unit , proceed as follows:

Switch off the load.

Switch off circuit breaker Q1. Let the engine run for about 5 minutes. Stop the engine by using the STOP button on the

Qc2002 module. Put the starter switch S20 in position O (OFF) to

shut down the voltage apply towards theQc2002 module.

Lock the side doors and the door of the indicatorsand control panel to avoid unauthorized access.

To stop the unit when the Qc2002

module is in AUTOMATIC operation mode, proceed as follows:

Switch off the load.

For remote start: When operating in Island mode, use the external

switch to stop the machine.

When operating in AMF mode, the machine willautomatically stop when the Mains returns.

Cooldown period default 15 sec.

Put the starter switch S20 in position O (OFF) tshut down the voltage apply towards thQc2002 module.

Lock the side doors and the door of the indicatoand control panel to avoid unauthorized access.

When the unit is stopped with theSTOP button in Automaticoperation, it will automatically go toManual Mode.

!

that no electrical power is present on the terminals.

very 250 hours or

yearly

Every 1000 hours or 24

months

2912 6382 05 1625 0010 72

hese service kits offer you the benefits of genuine parts, e parts list for more information on the contents of the

x x

x x

x x

x x

x x

x x

x x

x x

x x

x x

x x

x x

x x

x x

x x- 42 -

Maintenance

Maintenance schedule

Before carrying out any maintenance activity, check that the start switch is in position O and!Maintenance schedule Daily

E

Service pak -

For the most important subassemblies, Atlas Copco has developed service kits that combine all wear parts. Tsave on administration costs and are offered at reduced price, compared to the loose components. Refer to thservice kits.

Check for air, fuel, coolant and oil leakage x

Check oil and coolant level x

Check or drain water in fuelfilter/waterseparator x

Clean air cleaner and dust bowl x

Check vaccuum indicator x

Visual walk around the unit x

Replace engine oil (1)

Replace engine oil filter (1)

Check/clean radiator/cooler fins

Check tension and condition of the drive belt/Replace

Grease door hinges and locks

Replace fuel filter element

Replace fuel prefilter element

Check electrolyte level and terminals of battery

Check engine mounts

x x

x x

x x

x x

x x

x x

x x

x x

x x

x

x

x

x

x

erators in standby application have to be tested on alar basis. At least once a month the engine should run

minimum 30 minutes at a high load (50% - 70%) thatengine reaches its operating temperature.- 43 -

Check crankcase ventilation system

Check condition of cooling fan assembly

Pressure test cooling system

Check engine electrical ground connection

Replace air filter element (2)

Measure alternator insulation resistance

Check glycol level in coolant (4)

Check PH level of engine coolant (4)

Monitor Insulation Resistance of the main alternator

Replace safety cartridge

Check alternator and starter motor

Check electrical system for security of cables and wear

Test thermostats

Test glow plugs

Inspection by Atlas Copco Service technician

Genregufor the

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Engine Type of lubricant

between -15C (5F) and 40C (104F) PAROIL E

between -25C (-13F) and 40C (104F) PAROIL Extra

Never mix synthetic with mineraloil.Remark:When changing from mineral tosynthetic oil (or the other wayaround), you will need to do anextra rinse.After doing the complete changeprocedure to synthetic oil, run theunit for a few minutes to allow goodand complete circulation of thesynthetic oil. Then drain thesynthetic oil again and fill againwith new synthetic oil. To set correctoil levels, proceed as in normalinstruction.

!

- 44 -

Notes:

In highly dusty environments, these service intervalsdo not apply. Check and/or replace filters and cleanradiator on a regular basis.

(1) During engine break-in, change the oil and oilfilter for the first time after max. 50 hours ofoperation.

(2) Air filter should be replaced sooner when the unitis operating in a dusty environment.

(3) Rocker cover gaskets can be re-used after valveclearence.(Rocker cover gasket: QAS 14 - 2913 3074 00 &QAS 20 - 2913 3075 00).

(4) Adjust/replace coolant as necessary.

Engine maintenanceRefer to the engines operator manual for fumaintenance, including instructions for changing thoil and coolant and replacing the fuel, oil and afilters.

(*) Measuring the alternator insulation resistanceA 500 V megger is required to measure the alternatoinsulation resistance.If the N-terminal is connected to the earthing systemit must be disconnected from the earth terminaDisconnect the AVR.Connect the megger between the earth terminal anterminal L1 and generate a voltage of 500 V. Thscale must indicate a resistance of at least 5 M.Refer to the alternator operating and maintenancinstructions for more details.

Engine oil specifications

High-quality, mineral, hydraulic or synthesizehydrocarbon oil with rust and oxidation inhibitoranti-foam and anti-wear properties is recommendedThe viscosity grade should correspond to the ambientemperature and ISO 3448, as follows.

It is strongly recommended to useAtlas Copco branded lubrication oils.!

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Engine oil level checkConsult the Engine Operation Manual for the oilspecifications, viscosity recommendations and oilchange intervals.

For intervals, see section Maintenance schedule onpage 42.Check engine oil level according to the instructions inthe Engine Operation Manual and if necessary top upwith oil.

Engine oil and oil filter changeSee section Maintenance schedule on page 42.- 45 -

Specifications PAROIL

PAROIL from Atlas Copco is the ONLY oil testedand approved for use in all engines built into AtlasCopco compressors and generators.Extensive laboratory and field endurance tests onAtlas Copco equipment have proven PAROIL tomatch all lubrication demands in varied conditions. Itmeets stringent quality control specifications toensure your equipment will run smoothly andreliably.The quality lubricant additives in PAROIL allow forextended oil change intervals without any loss inperformance or longevity.PAROIL provides wear protection under extremeconditions. Powerful oxidation resistance, highchemical stability and rust- inhibiting additives helpreduce corrosion, even within engines left idle forextended periods.

PAROIL contains high quality anti-oxidants tocontrol deposits, sludge and contaminants that tend tobuild up under very high temperatures.PAROIL's detergent additives keep sludge formingparticles in a fine suspension instead of allowing themto clog your filter and accumulate in the valve/rockercover area.PAROIL releases excess heat efficiently, whilstmaintaining excellent bore-polish protection to limitoil consumption.PAROIL has an excellent Total Base Number (TBN)retention and more alkalinity to control acidformation.PAROIL prevents Soot build-up.

PAROIL is optimized for the latest low emissioEURO -3 & -2, EPA TIER II & III engines running olow sulphur diesel for lower oil and fuel consumptio

PAROIL Extra and PAROIL E

Synthetic engine oil PAROIL Extra

PAROIL Extra is a Synthetic ultra high performancdiesel engine oil with a high viscosity- index. AtlaCopco PAROIL Extra is designed to providexcellent lubrication from start-up in temperatures alow as -25C.

Mineral engine oil PAROIL E

PAROIL E is a mineral based high performancdiesel engine oil with a high viscosity- index. AtlaCopco PAROIL E is designed to provide a high levof performance and protection in standard ambienconditions as from -15C.

LiterUS gal

Imp gal

cu.ftOrder

number

can 5 1.3 1.1 0.175 1630 0135 00

can 20 5.3 4.4 0.7 1630 0136 00

LiterUS gal

Imp gal

cu.ftOrder

number

can 5 1.3 1.1 0.175 1615 5953 00

can 20 5.3 4.4 0.7 1615 5954 00

barrel 209 55.2 46 7.35 1615 5955 00

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To ensure protection against corrosion, cavitation andformation of deposits, the concentration of theadditives in the coolant must be kept between certainlimits, as stated by the manufacturer's guidelines.Topping up the coolant with water only, changes theconcentration and is therefore not allowed.Liquid-cooled engines are factory-filled with thistype of coolant mixture.

LiterUS gal

Imp gal

cu.ftOrder

number

can 5 1.3 1.1 0.175 1604 5308 00

can 20 5.3 4.4 0.7 1604 5307 01

barrel 210 55.2 46 7.35 1604 5306 00- 46 -

Engine coolant specifications

The use of the correct coolant is important for goodheat transfer and protection of liquid-cooled engines.Coolants used in these engines must be mixtures ofgood quality water (distilled or de-ionised), specialcoolant additives and if necessary freeze protection.Coolant that is not to manufacturer's specification willresult in mechanical damage of the engine.The freezing point of the coolant must be lower thanthe freezing point that can occur in the area. Thedifference must be at least 5C (41F). If the coolantfreezes, it may crack the cylinder block, radiator orcoolant pump.Consult the engine's operation manual and follow themanufacturer's directions.

Specifications PARCOOL EG

PARCOOL EG is the only coolant that has beetested and approved by all engine manufacturecurrently in use in Atlas Copco compressors angenerators.Atlas Copco's PARCOOL EG extended life coolant the new range of organic coolants purpose designeto meet the needs of modern engines. PARCOOL Ecan help prevent leaks caused by corrosioPARCOOL EG is also fully compatible with asealants and gasket types developed to join differenmaterials used within an engine.

PARCOOL EG is a ready to use Ethylene Glycobased coolant, premixed in an optimum 50/5dilution ratio, for antifreeze protection guaranteed t-40C (-40F).Because PARCOOL EG inhibits corrosion, deposformation is minimized. This effectively eliminatethe problem of restricted flow through the engincoolant ducts and the radiator, minimizing the risk foengine overheating and possible failure.

It reduces water pump seal wear and has excellenstability when subjected to sustained high operatintemperatures.

PARCOOL EG is free of nitride and amines to proteyour health and the environment. Longer service lifreduces the amount of coolant produced and needindisposal to minimise environmental impact.

Never remove the cooling system fillercap while coolant is hot.The system may be under pressure.Remove the cap slowly and only whencoolant is at ambient temperature. Asudden release of pressure from aheated cooling system can result inpersonal injury from the splash of hotcoolant.It is strongly recommended to useAtlas Copco branded coolant.

Never mix different coolants andmix the coolant components outsidethe cooling system.

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Replacing the coolant

Drain

Completely drain the entire cooling system.

Used coolant must be disposed or recycled inaccordance with laws and local regulations.

Flush

Flush twice with clean water. Used coolant mustbe disposed or recycled in accordance with lawsand local regulations.

From the Atlas Copco Instruction book, determinethe amount of PARCOOL EG required and pourinto the radiator top tank.

It should be clearly understood that the risk forcontamination is reduced in case of propercleaning.

In case a certain content of other coolant remainsin the system, the coolant with the lowestproperties influences the quality of the mixedcoolant.

Fill

To assure proper operation and the release oftrapped air, run the engine until normal engineoperation temperature is reached. Turn off theengine and allow to cool.

Recheck coolant level and add if necessary.

tt

- 47 -

Coolant check

Monitoring coolant condition

In order to guarantee the lifetime and quality of theproduct, thus to optimise engine protection, regularcoolant-condition-analysis is advisable.The quality of the product can be determined by threeparameters.

Visual check

Verify the outlook of the coolant regarding colourand make sure that no loose particles are floatingaround.

pH measurement

Check the pH value of the coolant using a pH-measuring device.

The pH-meter can be ordered from Atlas Copcowith part number 2913 0029 00.

Typical value for EG = 8.6. If the pH-level is below 7 or above 9.5, the coolant

should be replaced.

Glycol concentration measurement

To optimise the unique engine protection featureof the PARCOOL EG the concentration of thGlycol in the water should be always above 3vol.%.

Mixtures with more than 68 vol.% mix ratio iwater are not recommended, as this will lead thigh engine operating temperatures.

A refractometer can be ordered from Atlas Copcwith part number 2913 0028 00.

Topping up of coolant

Verify if the engine cooling system is in a goocondition (no leaks, clean,...).

Check the condition of the coolant. If the condition of the coolant is outside the limit

the complete coolant should be replaced (sesection Replacing the coolant).

Always top-up with PARCOOL EG. Topping up the coolant with water only, change

the concentration of additives and is therefore noallowed.

Long service intervals5-year drain interval to minimizeservice costs (when used inaccordance with the instructions).

!

In case of a mix of different coolanproducts this type of measuremenmight provide incorrect values.!

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- 48 -

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, extraprecautions must be taken: Consult the engines operator manual. Remove the battery. Store it in a dry, frost-free

room. Keep the battery clean and its terminalslightly covered with petroleum jelly. Rechargethe battery regularly.

Clean the generator and protect all electricalcomponents against moisture.

Place silica gel bags, VCI paper (VolatileCorrosion Inhibitor) or another drying agentinside the generator and close the doors.

Stick sheets of VCI paper with adhesive tapeon the bodywork to close off all openings.

Wrap the generator, except the bottom, with aplastic bag.

Preparing for operation after storageBefore operating the generator again, remove thwrapping, VCI paper and silica gel bags and check thgenerator thoroughly (go through the checkliBefore starting on page 38). Consult the engines operator manual. Check that the insulation resistance of th

generator exceeds 5 M. Replace the fuel filter and fill the fuel tank. Ven

the fuel system.

Reinstall and connect the battery, if necessarafter being recharged.

Submit the generator to a test run.

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- 49 -

Checks and trouble shooting Checking voltmeter P4 Put a voltmeter in parallel with voltmeter P4 o

the control panel. Check that the read-out of both voltmeters is th

same. Stop the generator and disconnect one terminal. Check that the internal resistance of the voltmete

is high.

Checking ammeter P3