Atlas Copco QAS 200 VoD S3A ESF, QAS 250 VoD S3A ESF Instruction Manual
Instruction Manual
for AC Generators
English
Instruction Manual
QAS 200 Vod S3A ESF
QAS 250 Vod S3A ESF
TAD753 GE
TAD754 GE
Original instructions
Printed matter N°
2954 6640 02
05/2015
QAS 200 VoD S3A ESF
QAS 250 VoD S3A ESF
Instruction Manual for AC Generators
Instruction manual .................................................................................. 5
Circuit diagrams .................................................................................. 135
ATLAS COPCO - PORTABLE ENERGY DIVISION
www.atlascopco.com
Warranty and Liability Limitation
Use only authorized parts.
Any damage or malfunction caused by the use of unauthorized parts is not covered by
Warranty or Product Liability.
The manufacturer does not accept any liability for any damage arising from modifications,
additions or conversions made without the manufacturer's approval in writing.
Neglecting maintenance or making changes to the setup of the machine can result in major
hazards, including fire risk.
While every effort has been made to ensure that the information in this manual is correct,
Atlas Copco does not assume responsibility for possible errors.
Copyright 2015, Grupos Electrógenos Europa, S.A.U., Zaragoza, Spain.
Any unauthorized use or copying of the contents or any part thereof is prohibited. This applies
in particular to trademarks, model denominations, part numbers and drawings.
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Congratulations on the purchase of your AC generator. It is a solid, safe and reliable machine, built according to the latest technology. Follow the instructions in this
booklet and we guarantee you years of trouble free operation. 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.
Contents
1 Safety precautions for on-
site generators............................9
1.1 Introduction........................................9
1.2 General safety precautions .............10
1.3 Safety during transport and
installation........................................11
1.4 Safety during use and
operation ..........................................12
1.5 Safety during maintenance
and repair..........................................13
1.6 Tool applications safety ..................15
1.7 Battery safety precautions..............15
2 Main parts ................................. 16
2.1 General description .........................16
2.2 Markings ........................................... 18
2.3 Mechanical features.........................19
2.3.1 Engine and alternator ......................19
2.3.2 Cooling system.................................19
2.3.3 Safety devices ..................................19
2.3.4 Bodywork..........................................19
2.3.5 Control panel ....................................19
2.3.6 Data plate and serial number..........19
2.3.7 Drain plugs and filler caps...............19
2.3.8 External fuel tank connection..........20
2.4 Electrical features.............................21
2.4.1 Control and indicator panels ...........20
2.4.1.1 Control panel with Qc1002™
controller...........................................21
2.4.1.2 Control panel with Qc2002™
controller...........................................22
2.4.1.3 Control panel with Qc1103™
controller...........................................22
2.4.1.4 Control panel with Qc2103™
controller...........................................23
2.4.1.5 Control panel with Qc4002™
MkII controller...................................24
2.4.2 Output terminal board .....................25
2.4.3 Dual frequency .................................26
2.4.4 Battery switch...................................26
3 Installation and
connection.................................27
3.1 Lifting ................................................27
3.2 Installation........................................27
3.2.1 Indoor installation ............................27
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3.2.2 Outdoor installation .........................27
3.3 Connecting the generator ...............28
3.3.1 Precautions for non-linear and
sensitive loads ..................................28
3.3.2 Quality, minimum section and
maximum length of cables..............28
3.3.3 Connecting the load .........................29
4 Operating instructions............. 30
4.1 Before starting..................................30
4.2 Operating and setting Qc1002™ ....30
4.2.1 Starting..............................................30
4.2.2 During operation ..............................31
4.2.3 Stopping............................................31
4.2.4 Setting the Qc1002™ .......................32
4.2.4.1 Push button and LED
functions ...........................................32
4.2.4.2 Qc1002™ menu overview................33
4.2.4.3 Qc1002™ menu description ............33
4.2.4.4 Parameter list....................................35
4.2.4.5 LOG list..............................................38
4.2.4.6 Remote start operation ....................38
4.3 Operating and setting Qc2002™ ....39
4.3.1 Starting .............................................39
4.3.2 During operation .............................. 39
4.3.3 Stopping ...........................................40
4.3.4 Setting the Qc2002™ .......................40
4.3.4.1 Push button and LED
functions ...........................................40
4.3.4.2 Qc2002™ menu overview ...............42
4.3.4.3 Qc2002™ menu description ............42
4.3.4.4 Parameter list ...................................45
4.3.4.5 LOG list .............................................50
4.4 Operating and setting Qc1103™ ....51
4.4.1 Starting .............................................51
4.4.2 During operation .............................. 51
4.4.3 Stopping ...........................................51
4.4.4 Setting the Qc1103™ .......................52
4.4.4.1 Push button and LED
functions ...........................................52
4.4.4.2 Qc1103™ menu overview ...............53
4.4.4.3 Running modes ................................58
4.4.4.4 Application modes ........................... 58
4.4.4.5 Parameter settings........................... 58
4.4.4.6 LOG list .............................................59
4.5 Operating and setting Qc2103™ ....60
4.5.1 Starting .............................................60
4.5.2 During operation .............................. 60
4.5.3 Stopping ...........................................61
4.5.4 Setting the Qc2103™ .......................62
4.5.4.1 Push button and LED
functions ...........................................62
4.5.4.2 Qc2103™ menu overview................63
4.5.4.3 Running modes ................................68
4.5.4.4 Application modes ...........................68
4.5.4.5 Parameter settings ...........................69
4.5.4.6 LOG list70
4.6 Operating and setting
Qc4002™ MkII...................................71
4.6.1 Starting..............................................71
4.6.2 During operation ..............................71
4.6.3 Stopping............................................71
4.6.4 Setting the Qc4002™ MkII ...............72
4.6.4.1 Push button and LED
functions ...........................................72
4.6.4.2 Qc4002™ MkII menu
overview............................................74
4.6.4.3 Changing settings ............................77
4.6.4.4 Standard modes...............................78
4.6.4.5 Standard applications......................79
4.6.4.6 Paralleling .........................................85
4.6.4.7 Overview of applications .................86
5 Maintenance ............................. 89
5.1 Maintenance schedule.....................89
5.1.1 Use of maintenance schedule .........92
5.1.2 Use of service paks ..........................92
5.2 Preventing low loads .......................93
5.3 Alternator maintenance
procedures ........................................94
5.3.1 Measuring the alternator
insulation resistance ........................94
5.4 Engine maintenance procedures ....94
5.4.1 Engine oil level check.......................94
5.4.2 Engine oil and oil filter change .......94
5.4.3 Coolant check ...................................95
5.4.3.1 Monitoring coolant condition..........95
5.4.3.2 Topping up of coolant......................96
5.4.3.3 Replacing the coolant ......................96
5.5 Adjustments and service
procedures ........................................97
5.5.1 Cleaning coolers...............................97
5.5.2 Battery care.......................................97
5.5.2.1 Electrolyte .........................................97
5.5.2.2 Activating a dry-charged battery ....98
5.5.2.3 Recharging a battery........................98
5.5.2.4 Make-up distilled water ...................98
5.5.2.5 Periodic battery service ...................98
5.5.3 Servicing air filter engine ................99
5.5.3.1 Main parts .........................................99
5.5.3.2 Recommendation .............................99
5.5.3.3 Cleaning the dust trap......................99
5.5.3.4 Replacing the air filter element .......99
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5.5.4 Cleaning the fuel tank ....................100
5.5.5 Draining condensate fuel system .100
5.5.6 Bleeding fuel system .....................100
5.5.7 Replacing the fuel filter element...101
5.5.7.1 Fuel filter ......................................... 101
5.5.7.2 Pre-fuel filter ................................... 101
5.6 Engine consumable
specifications..................................102
5.6.1 Engine fuel specifications..............102
5.6.2 Engine oil specifications................102
5.6.3 Engine coolant specifications .......104
6 Checks and trouble
shooting...................................105
6.1 Checks.............................................105
6.1.1 Checking voltmeter P4...................105
6.1.2 Checking ammeters P1, P2
and P3 .............................................105
6.2 Engine troubleshooting.................105
6.3 Alternator troubleshooting...........106
6.4 Solving controller alarms..............107
6.4.1 Qc1002™ and Qc2002™
alarms and remedies .....................107
6.4.1.1 Alarm overview..............................107
6.4.1.2 Fail classes......................................109
6.4.1.3 Solving alarms ...............................109
6.4.2 Qc1103™ and Qc2103™
alarms and remedies .....................112
6.4.2.1 Alarm handling...............................112
6.4.2.2 Fail classes......................................112
6.4.2.3 Solving alarms................................113
6.4.3 Qc4002™ MkII alarms and
remedies .........................................115
6.4.3.1 Fail Classes .....................................115
6.4.3.2 Diagnostics menu...........................115
6.4.3.3 Solving alarms................................116
7 Storage of the generator........117
7.1 Storage............................................117
7.2 Preparing for operation after
storage ............................................117
8 Disposal ...................................118
8.1 General............................................118
8.2 Disposal of materials .....................118
9 Options available for
QAS 200-250 Volvo units....... 119
9.1 Circuit diagrams.............................119
9.2 Overview of the electrical
options ............................................119
9.3 Description of the electrical
options ............................................119
9.3.1 Automatic battery charger.............119
9.3.2 Engine coolant heater ....................119
9.3.3 Outlet sockets (S) ...........................120
9.3.4 “Electricité de France” (EDF).........121
9.3.5 COSMOS™ .....................................122
9.3.6 Power Transfer Box (PTB) .............122
9.4 Overview of the mechanical
options ............................................123
9.5 Description of the mechanical
options ............................................123
9.5.1 Quick couplings ..............................123
9.5.2 Integrated spark arrestor ...............123
9.5.3 Air inlet shut-off valve....................123
9.5.4 Spillage free skid ............................123
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10 Technical specifications .........124
10.1 Technical specifications for
QAS 200 ..........................................124
10.2 Technical specifications for
QAS 250 ..........................................129
10.3 Conversion list of SI units into
British units ....................................134
10.4 Data plate .......................................134
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1 Safety precautions for on-site generators
To be read attentively and acted accordingly before towing, lifting, operating, performing maintenance or repairing the generator.
1.1 Introduction
The policy of Atlas Copco is to provide the users of their
equipment 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 are
expected 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 the
relevant instruction manual. Besides giving detailed
operating instructions, it also gives specific information
about safety, preventive maintenance, etc.
Keep the manual always at the unit location, easy
accessible to the operating personnel.
See also the safety precautions of the engine and
possible other equipment, which are separately sent
along or are mentioned on the equipment or parts of the
unit.
These safety precautions are general and some
statements will therefore not always apply to a particular
unit.
Only people that have the right skills should be allowed
to operate, adjust, perform maintenance or repair on
Atlas Copco equipment. It is the responsibility of
management to appoint operators with the appropriate
training and skill for each category of job.
Skill level 1: Operator
An operator is trained in all aspects of operating the unit
with the push-buttons, and is trained to know the safety
aspects.
Skill level 2: Mechanical technician
A mechanical technician is trained to operate the unit the
same as the operator. In addition, the mechanical
technician is also trained to perform maintenance and
repair, as described in the instruction manual, and is
allowed to change settings of the control and safety
system. A mechanical technician does not work on live
electrical components.
Skill level 3: Electrical technician
An electrical technician is trained and has the same
qualifications as both the operator and the mechanical
technician. In addition, the electrical technician may
carry out electrical repairs within the various enclosures
of the unit. This includes work on live electrical
components.
Skill level 4: Specialist from the manufacturer
This is a skilled specialist sent by the manufacturer or its
agent to perform complex repairs or modifications to the
equipment.
In general it is recommended that not more than two
people operate the unit, more operators could lead to
unsafe operating conditions. Take necessary steps to
keep unauthorized persons away from the unit and
eliminate all possible sources of danger at the unit.
When handling, operating, overhauling and/or
performing maintenance or repair on Atlas Copco
equipment, the mechanics are expected to use safe
engineering practices and to observe all relevant local
safety requirements and ordinances. The following list is
a reminder of special safety directives and precautions
mainly applicable to Atlas Copco equipment.
Neglecting the safety precautions may endanger people
as 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 resulting
from neglecting these precautions or by non-observance
of ordinary caution and due care required in handling,
operating, maintenance or repair, also if not expressly
mentioned in this instruction manual, is disclaimed by
Atlas Copco.
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The manufacturer does not accept any liability for any
damage arising from the use of non-original parts and for
modifications, additions or conversions made without
the manufacturer’s approval in writing.
If any statement in this manual does not comply with
local legislation, the stricter of the two shall be applied.
Statements in these safety precautions should not be
interpreted as suggestions, recommendations or
inducements that it should be used in violation of any
applicable laws or regulations.
1.2 General safety precautions
1 The owner is responsible for maintaining the unit in
a safe operating condition. Unit parts and
accessories must be replaced if missing or
unsuitable for safe operation.
2 The supervisor, or the responsible person, shall at
all times make sure that all instructions regarding
machinery and equipment operation and
maintenance are strictly followed and that the
machines with all accessories and safety devices, as
well as the consuming devices, are in good repair,
free of abnormal wear or abuse, and are not
tampered with.
3 Whenever there is an indication or any suspicion
that an internal part of a machine is overheated, the
machine shall be stopped but no inspection covers
shall be opened before sufficient cooling time has
elapsed; this to avoid the risk of spontaneous
ignition of oil vapour when air is admitted.
4 Normal ratings (pressures, temperatures, speeds,
etc.) shall be durably marked.
5 Operate the unit only for the intended purpose and
within its rated limits (pressure, temperature,
speeds, etc.).
6 The machinery and equipment shall be kept clean,
i.e. as free as possible from oil, dust or other
deposits.
7 To prevent an increase in working temperature,
inspect and clean heat transfer surfaces (cooler fins,
intercoolers, water jackets, etc.) regularly. See the
maintenance schedule.
8 All regulating and safety devices shall be
maintained with due care to ensure that they
function properly. They may not be put out of
action.
9 Pressure and temperature gauges shall be checked
regularly with regard to their accuracy. They shall
be replaced whenever outside acceptable tolerances.
10 Safety devices shall be tested as described in the
maintenance schedule of the instruction manual to
determine that they are in good operating condition.
11 Mind the markings and information labels on the
unit.
12 In the event the safety labels are damaged or
destroyed, they must be replaced to ensure operator
safety.
13 Keep the work area neat. Lack of order will increase
the risk of accidents.
14 When working on the unit, wear safety clothing.
Depending on the kind of activities these are: safety
glasses, ear protection, safety helmet (including
visor), safety gloves, protective clothing, safety
shoes. Do not wear the hair long and loose (protect
long hair with a hairnet), or wear loose clothing or
jewellery.
15 Take precautions against fire. Handle fuel, oil and
anti-freeze with care because they are inflammable
substances. Do not smoke or approach with naked
flame when handling such substances. Keep a fireextinguisher in the vicinity.
16a On-site generators (with earthing pin):
Earth the generator as well as the load properly.
16b On-site generators IT:
Note: This generator is built to supply a sheer
alternating current IT network.
Earth the load properly.
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1.3 Safety during transport and installation
To lift a unit, all loose or pivoting parts, e.g. doors and
towbar, shall first be securely fastened.
Do not attach cables, chains or ropes directly to the
lifting eye; apply a crane hook or lifting shackle meeting
local safety regulations. Never allow sharp bends in
lifting cables, chains or ropes.
Helicopter lifting is not allowed.
It is strictly forbidden to dwell or stay in the risk zone
under a lifted load. Never lift the unit over people or
residential areas. Lifting acceleration and deceration
shall be kept within safe limits.
1 Before towing the unit:
- check the towbar, the brake system and the
towing eye. Also check the coupling of the
towing vehicle,
- check the towing and brake capability of the
towing vehicle,
- check that the towbar, jockey wheel or stand leg
is safely locked in the raised position,
- ascertain that the towing eye can swivel freely on
the hook,
- check that the wheels are secure and that the
tyres are in good condition and inflated correctly,
- connect the signalisation cable, check all lights
and connect the pneumatic brake couplers,
- attach the safety break-away cable or safety
chain to the towing vehicle,
- remove wheel chocks, if applied, and disengage
the parking brake.
2 To tow a unit use a towing vehicle of ample
capacity. Refer to the documentation of the towing
vehicle.
3 If a unit is to be backed up by a towing vehicle,
disengage the overrun brake mechanism (if it is not
an automatic mechanism).
4 In case of transporting a non-trailer unit on a truck,
fasten it to the truck by attaching straps via fork lift
slots, via the holes in the frame at the front and back
or via the lifting beam. To prevent damage, never
put straps on the roof surface of the unit.
5 Never exceed the maximum towing speed of the
unit (mind the local regulations).
6 Place the unit on level ground and apply the parking
brake before disconnecting the unit from the towing
vehicle. Unclip the safety break-away cable or
safety chain. If the unit has no parking brake or
jockey wheel, immobilize the unit by placing
chocks in front of and/or behind the wheels. When
the towbar can be positioned vertically, the locking
device must be applied and kept in good order.
7 To lift heavy parts, a hoist of ample capacity, tested
and approved according to local safety regulations,
shall be used.
8 Lifting hooks, eyes, shackles, etc., shall never be
bent and shall only have stress in line with their
design load axis. The capacity of a lifting device
diminishes when the lifting force is applied at an
angle to its load axis.
9 For maximum safety and efficiency of the lifting
apparatus all lifting members shall be applied as
near to perpendicular as possible. If required, a
lifting beam shall be applied between hoist and
load.
10 Never leave a load hanging on a hoist.
11 A hoist has to be installed in such a way that the
object will be lifted perpendicular. If that is not
possible, the necessary precautions must be taken to
prevent load-swinging, e.g. by using two hoists,
each at approximately the same angle not exceeding
30° from the vertical.
12 Locate the unit away from walls. Take all
precautions to ensure that hot air exhausted from the
engine and driven machine cooling systems cannot
be recirculated. If such hot air is taken in by the
engine or driven machine cooling fan, this may
cause overheating of the unit; if taken in for
combustion, the engine power will be reduced.
13 Generators shall be stalled on an even, solid floor,
in a clean location with sufficient ventilation. If the
floor is not level or can vary in inclination, consult
Atlas Copco.
14 The electrical connections shall correspond to local
codes. The machines shall be earthed and protected
against short circuits by fuses or circuit breakers.
15 Never connect the generator outlets to an
installation which is also connected to a public
mains.
16 Before connecting a load, switch off the
corresponding circuit breaker, and check whether
frequency, voltage, current and power factor
comply with the ratings of the generator.
17 Before transportation of the unit, switch off all the
circuit breakers.
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1.4 Safety during use and operation
1 When the unit has to operate in a fire-hazardous
environment, each engine exhaust has to be
provided with a spark arrestor to trap incendiary
sparks.
2 The exhaust contains carbon monoxide which is a
lethal gas. When the unit is used in a confined
space, conduct the engine exhaust to the outside
atmosphere by a pipe of sufficient diameter; do this
in such a way that no extra back pressure is created
for the engine. If necessary, install an extractor.
Observe any existing local regulations.
Make sure that the unit has sufficient air intake for
operation. If necessary, install extra air intake ducts.
3 When operating in a dust-laden atmosphere, place
the unit so that dust is not carried towards it by the
wind. Operation in clean surroundings considerably
extends the intervals for cleaning the air intake
filters and the cores of the coolers.
4 Never remove a filler cap of the cooling water
system of a hot engine. Wait until the engine has
sufficiently cooled down.
5 Never refill fuel while the unit is running, unless
otherwise stated in the Atlas Copco Instruction
Book (AIB). Keep fuel away from hot parts such as
air outlet pipes or the engine exhaust. Do not smoke
when fuelling. When fuelling from an automatic
pump, an earthing cable should be connected to the
unit to discharge static electricity. Never spill nor
leave oil, fuel, coolant or cleansing agent in or
around the unit.
6 All doors shall be shut during operation so as not to
disturb the cooling air flow inside the bodywork
and/or render the silencing less effective. A door
should be kept open for a short period only e.g. for
inspection or adjustment.
7 Periodically carry out maintenance works according
to the maintenance schedule.
8 Stationary housing guards are provided on all
rotating or reciprocating parts not otherwise
protected and which may be hazardous to
personnel. Machinery shall never be put into
operation, when such guards have been removed,
before the guards are securely reinstalled.
9 Noise, even at reasonable levels, can cause irritation
and disturbance which, over a long period of time,
may cause severe injuries to the nervous system of
human beings.
When the sound pressure level, at any point where
personnel normally has to attend, is:
- below 70 dB(A): no action needs to be taken,
- above 70 dB(A): noise-protective devices should
be provided for people continuously being
present in the room,
- below 85 dB(A): no action needs to be taken for
occasional visitors staying a limited time only,
- above 85 dB(A): room to be classified as a noisehazardous area and an obvious warning shall be
placed permanently at each entrance to alert
people entering the room, for even relatively
short times, about the need to wear ear
protectors,
- above 95 dB(A): the warning(s) at the
entrance(s) shall be completed with the
recommendation that also occasional visitors
shall wear ear protectors,
- above 105 dB(A): special ear protectors that are
adequate for this noise level and the spectral
composition of the noise shall be provided and a
special warning to that effect shall be placed at
each entrance.
10 The unit has parts of which the temperature can be
in excess of 80 °C (176 °F), and which may be
accidentally touched by personnel when opening
the machine during or just after operation.
Insulation or safety guards protecting these parts
shall not be removed before the parts have cooled
down sufficiently, and must be re-installed before
operating the machine. As it is not possible to
insulate or protect all hot parts by guards (e.g.
exhaust manifold, exhaust turbine), the operator /
service engineer must always be aware not to touch
hot parts when opening a machine door.
11 Never operate the unit in surroundings where there
is a possibility of taking in flammable or toxic
fumes.
12 If the working process produces fumes, dust or
vibration hazards, etc., take the necessary steps to
eliminate the risk of personnel injury.
13 When using compressed air or inert gas to clean
down equipment, do so with caution and use the
appropriate protection, at least safety glasses, for
the operator as well as for any bystander. Do not
apply compressed air or inert gas to your skin or
direct an air or gas stream at people. Never use it to
clean dirt from your clothes.
- 12 -
14 When washing parts in or with a cleaning solvent,
provide the required ventilation and use appropriate
protection such as a breathing filter, safety glasses,
rubber apron and gloves, etc.
15 Safety shoes should be compulsory in any
workshop and if there is a risk, however small, of
falling objects, wearing of a safety helmet should be
included.
16 If there is a risk of inhaling hazardous gases, fumes
or dust, the respiratory organs must be protected and
depending on the nature of the hazard, so must the
eyes and skin.
17 Remember that where there is visible dust, the finer,
invisible particles will almost certainly be present
too; but the fact that no dust can be seen is not a
reliable indication that dangerous, invisible dust is
not present in the air.
18 Never operate the generator in excess of its limits as
indicated in the technical specifications and avoid
long no-load sequences.
19 Never operate the generator in a humid atmosphere.
Excessive moisture reduces the generator
insulation.
20 Do not open electrical cabinets, cubicles or other
equipment while voltage is supplied. If such cannot
be avoided, e.g. for measurements, tests or
adjustments, have the action carried out by a
qualified electrician only, with appropriate tools,
and ascertain that the required bodily protection
against electrical hazards is applied.
21 Never touch the power terminals during operation
of the machine.
22 Whenever an abnormal condition arises, e.g.
excessive vibration, noise, odour, etc., switch the
circuit breakers to OFF and stop the engine. Correct
the faulty condition before restarting.
23 Check the electric cables regularly. Damaged cables
and insufficient tightening of connections may
cause electric shocks. Whenever damaged wires or
dangerous conditions are observed, switch the
circuit breakers to OFF and stop the engine.
Replace the damaged wires or correct the dangerous
condition before restarting. Make sure that all
electric connections are securely tightened.
24 Avoid overloading the generator. The generator is
provided with circuit breakers for overload
protection. When a breaker has tripped, reduce the
concerned load before restarting.
25 If the generator is used as stand-by for the mains
supply, it must not be operated without control
system which automatically disconnects the
generator from the mains when the mains supply is
restored.
26 Never remove the cover of the output terminals
during operation. Before connecting or
disconnecting wires, switch off the load and the
circuit breakers, stop the machine and make sure
that the machine cannot be started inadvertently or
there is any residual voltage on the power circuit.
27 Running the generator at low load for long periods
will reduce the lifetime of the engine.
28 When operating the generator in Remote or Auto
mode, observe all relevant local legislation.
1.5 Safety during maintenance and repair
Maintenance, overhaul and repair work shall only be
carried 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 good
condition.
2 Parts shall only be replaced by genuine Atlas Copco
replacement 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 as
“work in progress; do not start” shall be attached to
the starting equipment.
On engine-driven units the battery shall be
disconnected and removed or the terminals covered
by insulating caps.
On electrically driven units the main switch shall be
locked in open position and the fuses shall be taken
out. A warning sign bearing a legend such as “work
in progress; do not supply voltage” shall be attached
to the fuse box or main switch.
4 Prior to stripping an engine or other machine or
undertaking major overhaul on it, prevent all
movable parts from rolling over or moving.
- 13 -
5 Make sure that no tools, loose parts or rags are left
in or on the machine. Never leave rags or loose
clothing near the engine air intake.
6 Never use flammable solvents for cleaning (fire-
risk).
7 Take safety precautions against toxic vapours of
cleaning liquids.
8 Never use machine parts as a climbing aid.
9 Observe scrupulous cleanliness during maintenance
and repair. Keep away dirt, cover the parts and
exposed openings with a clean cloth, paper or tape.
10 Never weld on or perform any operation involving
heat near the fuel or oil systems. Fuel and oil tanks
must be completely purged, e.g. by steam-cleaning,
before carrying out such operations. Never weld on,
or in any way modify, pressure vessels. Disconnect
the alternator cables during arc welding on the unit.
11 Support the towbar and the axle(s) securely if
working underneath the unit or when removing a
wheel. Do not rely on jacks.
12 Do not remove any of, or tamper with, the sound-
damping material. Keep the material free of dirt and
liquids such as fuel, oil and cleansing agents. If any
sound-damping material is damaged, replace it to
prevent the sound pressure level from increasing.
13 Use only lubricating oils and greases recommended
or approved by Atlas Copco or the machine
manufacturer. Ascertain that the selected lubricants
comply with all applicable safety regulations,
especially with regard to explosion or fire-risk and
the possibility of decomposition or generation of
hazardous gases. Never mix synthetic with mineral
oil.
14 Protect the engine, alternator, air intake filter,
electrical and regulating components, etc., to
prevent moisture ingress, e.g. when steam-cleaning.
15 When performing any operation involving heat,
flames or sparks on a machine, the surrounding
components shall first be screened with nonflammable material.
16 Never use a light source with open flame for
inspecting the interior of a machine.
17 When repair has been completed, the machine shall
be barred over at least one revolution for
reciprocating machines, several revolutions for
rotary ones to ensure that there is no mechanical
interference within the machine or driver. Check the
direction of rotation of electric motors when starting
up the machine initially and after any alteration to
the electrical connection(s) or switch gear, to check
that the oil pump and the fan function properly.
18 Maintenance and repair work should be recorded in
an operator’s logbook for all machinery. Frequency
and nature of repairs can reveal unsafe conditions.
19 When hot parts have to be handled, e.g. shrink
fitting, special heat-resistant gloves shall be used
and, if required, other body protection shall be
applied.
20 When using cartridge type breathing filter
equipment, ascertain that the correct type of
cartridge is used and that its useful service life is not
surpassed.
21 Make sure that oil, solvents and other substances
likely to pollute the environment are properly
disposed of.
22 Before clearing the generator for use after
maintenance or overhaul, submit it to a test run,
check that the AC power performance is correct and
that the control and shutdown devices function
correctly.
- 14 -
1.6 Tool applications safety
Apply the proper tool for each job. With the knowledge
of correct tool use and knowing the limitations of tools,
along with some common sense, many accidents can be
prevented.
Special service tools are available for specific jobs and
should be used when recommended. The use of these
tools will save time and prevent damage to parts.
1.7 Battery safety precautions
When servicing batteries, always wear protecting
clothing and glasses.
1 The electrolyte in batteries is a sulphuric acid
solution which is fatal if it hits your eyes, and which
can cause burns if it contacts your skin. Therefore,
be careful when handling batteries, e.g. when
checking the charge condition.
2 Install a sign prohibiting fire, open flame and
smoking at the post where batteries are being
charged.
3 When batteries are being charged, an explosive gas
mixture forms in the cells and might escape through
the vent holes in the plugs.
Thus an explosive atmosphere may form around the
battery if ventilation is poor, and can remain in and
around the battery for several hours after it has been
charged. 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) in
parallel to the unit battery (CB) with booster cables:
connect the + pole of AB to the + pole of CB, then
connect the - pole of CB to the mass of the unit.
Disconnect in the reverse order.
- 15 -
2 Main parts
2.1 General description
The QAS 200-250 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 50 Hz, 400 V - 3 phase and 60 Hz, 480 V - 3 phase. Some parts of the unit are different, depending on which version.
The QAS 200-250 Volvo generator is driven by a fluid-cooled diesel engine, manufactured by VOLVO PENTA.
below.
An overview of the main parts is given in the diagram
1 Lifting beam
2 Guiding rod
3 Side doors
4 Engine exhaust
5 Data plate
6 Door, access to control and indicator panel
7 Output terminal board
8 Forklift slots
9 Earthing rod
DH Drain and access hole (in the frame)
FCF Filler cap fuel
- 16 -
A Alternator
AF Air filter
C Coupling
DFO Drain flexible engine oil
DFW Drain flexible cooling water
EEngine
FFan
FCO Filler cap engine oil
FCW Filler cap cooling water
FF Fuel filter
G1 Battery
ODP Oil drain pump
OF Oil filter
OLD Engine oil level dipstick
PF1 Pre-fuel filter 1
PF2 Pre-fuel filter 2
S1 Battery switch
- 17 -
2.2 Markings
Markings provide instructions and information. They
also warn of hazards. For convenience and safety,
keep all markings in legible condition, replacing them
when damaged or missing. Replacement markings are
available from the factory.
A brief description of all markings provided on the
generator is given hereafter. The precise location of
all markings can be found in the parts manual of this
generator.
Instruction book label.
Indicates that an electric voltage,
dangerous to life, is present. Never
touch the electric terminals during
operation.
Indicates the sound power level in
accordance with Directive 2000/14/
EC (expressed in dB (A)).
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.
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 external fuel tank.
Indicates that the alternator should not
be cleaned with high pressurised
water.
Indicates the battery switch.
Indicates that the unit may
start automatically and that
the instruction book has to
be consulted prior to use.
Indicates the 3-way valve.
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 the drain for the coolant.
Indicates the drain plug for the engine
fuel.
Use PAROIL E only.
- 18 -
XXXXXXXXXXXXXXX
XXXXXXXXXXXX
XXXXXXXXX
XXXXXXXXX
XX XXXXXXX
XX XXXXXXX
XX XXXXXXX
XX
XXXXXXX
XX XXXXXXX
XX XXXXXXX
PAROIL E PAROIL Extra
XXXX XXXX XX
XXXX XXXX XX
XXXX XXXX XX
XXXX XXXX XX
XXXX XXXX XX
XXXX XXXX XX
Engine oil
Engine coolant PARCOOL EG
Indicates the part numbers
XXXX XXXX XX
XXXX XXXX XX
of the different service
XXXX XXXX XX
packs and of the engine oil.
XXXX XXXX XX
XXXX XXXX XX
These parts can be ordered
to the factory.
2.3 Mechanical features
The mechanical features described in this chapter are
standard provided on this generator. For all other
mechanical features, see “Overview of the
mechanical options” on page 123.
2.3.1 Engine and alternator
The alternator is driven by a fluid-cooled diesel
engine. The engine’s power is transmitted through a
direct disc coupling.
The generator houses a single bearing alternator with
a dedicated voltage regulator.
The synchronous brushless alternator has Class H
rotor and stator windings in an IP23 housing.
2.3.2 Cooling system
The engine is provided with a water cooler. The
cooling air is generated by a fan, driven by the engine.
2.3.3 Safety devices
The engine electronics monitor the engines
parameters and generate warning and shut-down
signals when the parameters reach a preset treshold
value.
2.3.4 Bodywork
The alternator, the engine, the cooling system, etc. are
enclosed in a sound-insulated bodywork that can be
opened by means of side doors (and service plates).
The generator can be lifted by using the lifting eye
integrated in the bodywork (roof). To be able to lift
the QAS 200-250 by means of a forklift, rectangular
slots are provided in the frame.
The earthing rod, connected to the generator’s earth
terminal is located at the bottom of the frame on the
outside.
2.3.5 Control panel
The control panel grouping volt and amp meters,
control switch etc., is placed at the rear end.
2.3.6 Data plate and serial number
The generator is furnished with a data plate showing
the product code, the unit number and the power
output (see “Data plate” on page 134).
The serial number is located on the right-hand front
side of the frame.
2.3.7 Drain plugs and filler caps
The drain holes for the engine oil, the coolant and the
plug for the fuel, are located and labelled on the frame
at the service side.
The drain flexibles for the engine oil and the engine
coolant can be brought to the outside of the generator
through the drain hole.
The drain hole can also be used to
guide external fuel tank
connections. When connecting an
external fuel tank, use the 3-way
valves.
- 19 -
2.3.8 External fuel tank connection
The external fuel tank connection allows to bypass
the internal fuel tank and to connect an external fuel
tank to the unit.
Make sure to connect the fuel supply line as well as
the fuel return line. Connections to fuel lines ought to
be air-tight to prevent air from entering the fuel
system.
Position 1: Indicates that the
fuel supply line to the engine is
connected to the internal fuel
tank.
Position 2: Indicates that the
fuel supply line to the engine is
connected to the external fuel
tank.
- 20 -
2.4 Electrical features
Q2
N13
Q1
H0
S2
A1
S20
F10
L1L2
OFF
L1-N
L2L3 L2-N
L3L1
LL LN
L3-N
X25
Qc1002 CAN
v x.xx.xx
The electrical features described in this chapter are
standard provided on this generator. For all other
electrical features, see “Overview of the electrical
options” on page 119.
2.4.1 Control and indicator panels
To operate the generator, the QAS 200-250 control
panel contains a Qc1002™, Qc2002™, Qc1103™,
Qc2103™ or Qc4002™ MkII controller. This
controller is located inside the control cubicle, and
communicates via a display located at the front. The
controller will carry out all necessary tasks to control
and protect the generator, which allows operation in
many different applications.
2.4.1.1 Control panel with Qc1002™
controller
General description Qc1002™ control panel
A1 .......Qc1002™ display
F10......Fuse
The fuse trips when the current from the
battery to the engine control circuit exceeds
its setting. The fuse can be reset by pushing
the button.
H0 .......Panel light
S2 .......Emergency stop button
Push the button to stop the generator in case
of an emergency. When the button is
pressed, it must be unlocked, before the
generator can be restarted. The emergency
stop button can be secured in the locked
- 21 -
position with the key, to avoid unauthorized
use.
S20......ON/OFF switch
Position O: No voltage is supplied to the
Qc1002™ module, the generator will not
start.
Position I: Voltage is supplied to the
Qc1002™ module, it is possible to start up
the generator.
X25 .....Terminal strip
Qc1002™ Module
2.4.1.2 Control panel with Qc2002™
G
Q2
N13
Q1
H0
S2
A1
S20
F10
L1L2
OFF
L1-N
L2L3 L2-N
L3L1
LL LN
L3-N
X25
S20
F10
S2
X25
A1
controller
General description Qc2002™ control panel
A1 .......Qc2002™ display
F10...... Fuse
The fuse trips when the current from the
battery to the engine control circuit exceeds
its setting. The fuse can be reset by pushing
the button.
H0 .......Panel light
S2 .......Emergency stop button
Push the button to stop the generator in case
2.4.1.3 Control panel with Qc1103™
controller
of an emergency. When the button is
pressed, it must be unlocked, before the
generator can be restarted. The emergency
stop button can be secured in the locked
position with the key, to avoid unauthorized
use.
S20 .....ON/OFF switch
Position O: No voltage is supplied to the
Qc2002™ module, the generator will not
start.
Position I: Voltage is supplied to the
Qc2002™ module, it is possible to start up
the generator.
X25 .....Terminal strip
Qc2002™ Module
A1 .......Qc1103™ display
F10......Thermal circuit breaker
The termal circuit breaker trips when the
current from the battery to the engine control
circuit exceeds its setting. It can be reset by
pushing the button.
v x.xx.xx
- 22 -
S2 .......Emergency stop button
S20
F10
S2
X25
A1
Push the button to stop the generator in case
of an emergency. When the button is
pressed, it must be unlocked, before the
generator can be restarted. The emergency
stop button can be secured in the locked
position with the key, to avoid unauthorized
use.
S20 .....ON/OFF switch
Position O: No voltage is supplied to the
Qc1103™ module, the generator will not
start.
Position I: Voltage is supplied to the
Qc1103™ module, it is possible to start up
the generator.
X25 .....Terminal strip
2.4.1.4 Control panel with Qc2103™
controller
A1 .......Qc2103™ display
F10......Thermal circuit breaker
The thermal circuit breaker trips when the
current from the battery to the engine control
circuit exceeds its setting. It can be reset by
pushing the button.
S2........Emergency stop button
Push the button to stop the generator in case
of an emergency. When the button is
pressed, it must be unlocked, before the
generator can be restarted. The emergency
stop button can be secured in the locked
position with the key, to avoid unauthorized
use.
S20......ON/OFF switch
Position O: No voltage is supplied to the
Qc2103™ module, the generator will not
start.
Position I: Voltage is supplied to the
Qc2103™ module, it is possible to start up
the generator.
X25 .....Terminal strip
- 23 -
2.4.1.5 Control panel with Qc4002™ MkII
X30
X2
N13
Q2
X41
X40
Qc4002
G
!
OK
LOG
0 I
S20
S11
50Hz 60Hz
F10
X30 X41X40
S2
X25S11 A2 S20 F10
controller
General description Qc4002™ MkII control panel
A2 .......Qc4002™ MkII display
F10......Fuse
The fuse (10 A) trips when the current from
the battery to the engine control circuit
exceeds its setting. The fuse can be reset by
pushing the button.
S2 .......Emergency stop button
Push the button to stop the generator in case
of an emergency. When the button is
pressed, it must be unlocked, before the
generator can be restarted. The emergency
stop button can be secured in the locked
position with the key, to avoid unauthorized
use.
S11 .....Frequency selector switch (50 Hz/
60 Hz)
Allows to choose the frequency of the output
voltage: 50 Hz or 60 Hz.
Changing the output frequency is
only allowed when the unit has
stopped.
S20......ON/OFF switch
Position O: No voltage is supplied to the
Qc4002™ MkII module, the generator will
not start.
Position I: Voltage is supplied to the
Qc4002™ MkII module, it is possible to
start up the generator.
X25 .....Connection block
Inside the cubicle. Allows customer
connections.
Refer to circuit diagram for the
correct connection.
X30 .....Connector X30
Connector for communication with other
generators with Qc4002™ MkII when
paralleling, both in ALS and PMS mode. An
adapter can be plugged in. See page 84.
X40 .....Transformer Maintenance controls
connector
X41 .....Transformer Maintenance sensing
connector
- 24 -
Qc4002™ MkII module
N13
Q2
N13
Q1
Q3
Q4Q5Q6
S2
Q1
X1
L1L2
OFF
L1-N
L2L3 L2-N
L3L1
LL LN
L3-N
S13
2.4.2 Output terminal board
The cubicle provides a terminal board for easier
connection of cables. It is situated below the control
and indicator panel.
N13 .....Earth leakage relay
Detects and indicates an earth fault current
and activates the main circuit breaker Q1.
The detection level can be set at 30 mA fixed
with instantaneous trip but can also be
adjusted between 30 mA and 250 mA with
time delayed (0 - 1 sec) trip. N13 has to be
OK
Qc4002
LOG
.atlascopco.com
w
w
!
G
w
reset manually after eliminating the problem
(reset button marked R). It can be overridden
by means of the earth leak switch (S13,
labelled IΔN) but has to be tested monthly by
pushing test button T13.
S13......Earth relay lock-out switch (N13)
This switch is located inside the cubicle and
is labelled IΔN.
Position O: No tripping of the main circuit
breaker Q1 when an earth fault occurs.
Position 1: Tripping of the main circuit
breaker Q1 when an earth fault occurs.
Q1 .......Main circuit breaker
S2 .......Emergency stop button
Push the button to stop the generator in case
of an emergency. When the button is
pressed, it must be unlocked, by turning it
anti-clockwise, before the generator can be
restarted. The emergency stop button can be
Interrupts the power supply X1 when a
short-circuit occurs at the load side, or when
the overcurrent (QAS 200: 290 A /
QAS 250: 360 A) protection is activated.
When activated, Q1 interrupts the three
phases towards X1. It must be reset
manually after eliminating the problem.
secured in the locked position with the key,
to avoid unauthorized use.
- 25 -
X1 .......Main power supply
L1L2
OFF
L1-N
L2L3 L2-N
L3L1
LL LN
L3-N
R12
S11
Terminals L1, L2, L3, N (= neutral) and PE
(= earthing), behind a small transparent
door.
Position O on switch S13 will only
be used in conjunction with an
external earth fault protection unit
(e.g. integrated in a distribution
board) or when the generator is
used in parallel.
The earth fault protection on the
single phase outlet socket is not
affected by the switch S13.
If S13 is in position O, proper
earthing is of the utmost importance
for the safety of the user.
Eliminating any earth fault
protection can lead to serious injury
or even death for anybody touching
the unit or the load.
2.4.3 Dual frequency
Dual frequency allows the unit to work at 50 Hz or at
60 Hz with an accuracy of constant load. The
frequency selection is done by means of switch S11.
R12 .....Voltage adjust potentiometer
Allows to adjust the output voltage
S11 .....Frequency selector switch (50 Hz/
60 Hz)
Allows to choose the frequency of the output
voltage: 50 Hz or 60 Hz.
Changing the output frequency is
only allowed when the unit has
stopped.
After changing the output
frequency, adjust the output voltage
by means of potentiometer R12 to
the required value.
2.4.4 Battery switch
The battery switch is situated inside the soundinsulated bodywork. It allows to open or to close the
electrical connection between the battery and the
engine circuits.
Never turn the battery switch to
OFF during operation.
- 26 -
3 Installation and connection
3.1 Lifting
The lifting eye, to lift the generator by means of a
hoist, is integrated in the bodywork and easily
accessible from the outside. The recesses in the roof
have guiding rods at both sides.
When lifting the generator, the hoist has to be placed
in such a way that the generator, which must be
placed level, will be lifted vertically.
Never use the guiding rods to lift the
generator.
Lifting acceleration and deceration
must be kept within safe limits (max.
2 g).
Helicopter lifting is not allowed.
To be able to lift the generator by means of a forklift,
rectangular slots are provided at the bottom of the
frame.
3.2 Installation
3.2.1 Indoor installation
If the generator is operated indoors, install an exhaust
pipe of sufficient diameter to duct the engine exhaust
towards the outside. Check for sufficient ventilation
so that the cooling air is not recirculated.
For more information about indoor
installation, consult your local Atlas
Copco dealer.
3.2.2 Outdoor installation
– Place the generator on a horizontal, even and solid
floor. The generator can operate in a slant position
not exceeding 15% (in both senses: front/rear and
left/right).
– The generator should be kept with the doors
closed, in order to avoid the ingress of water and
dust. Dust ingress reduces the lifetime of filters
and may reduce your generator's performance.
– Check that the engine exhaust is not directed
towards people.
– Locate the rear end of the generator upwind, away
from contaminated wind streams and walls. Avoid
recirculation of exhaust air from the engine. This
causes overheating and engine power decrease.
- 27 -
– Leave enough space for operation, inspection and
maintenance (at least 1 meter at each side).
– Check that the inner earthing system is in
compliance with the local legislation.
– Use coolant for the engine cooling system. Refer
to the Engine instruction book for the proper
coolant mixture.
– Check the tightness of the bolts and nuts.
– Check that the cable end of the earthing rod is
connected to the earth terminal.
The generator is wired for a TNsystem to IEC 364-3, i.e. one point in
the power source directly earthed in this case the neutral. The exposed
conductive parts of the electric
installation must be directly
connected to the functional earth.
3.3 Connecting the generator
3.3.1 Precautions for non-linear and sensitive loads
Non-linear loads draw currents with
high contents in harmonics, causing
distortion in the wave form of the
voltage generated by the alternator.
The most common non-linear, 3-phase loads are
thyristor/rectifier-controlled loads, such as convertors
supplying voltage to variable speed motors,
uninterruptable power supplies and Telecom
supplies. Gas-discharge lighting arranged in singlephase circuits generate high 3rd harmonics and risk
for excessive neutral current.
Loads most sensitive to voltage distortion include
incandescent lamps, discharge lamps, computers, Xray equipment, audio amplifiers and elevators.
Consult Atlas Copco for measures against the adverse
influence of non-linear loads.
3.3.2 Quality, minimum section and maximum length of cables
The cable connected to the terminal board of the
generator must be selected in accordance with local
legislation. The type of cable, its rated voltage and
current carrying capacity are determined by
installation conditions, stress and ambient
temperature. For flexible wiring, rubber-sheathed,
flexible core conductors of the type H07 RN-F
(Cenelec HD.22) or better must be used.
The following table indicates the maximum allowable
3-phase currents (in A), at an ambient temperature of
40°C, for cable types (multiple and single core PVC
insulated conductors and H07 RN-F multiple core
conductors) and wire sections as listed, in accordance
with VDE 0298 installation method C3. Local
regulations remain applicable if they are stricter than
those proposed below.
Wire section Max. current (A)
2
(mm
Multiple core Single core H07 RN-F
)
25 94 101 88
35 114 123 110
50 138 155 138
70 176 191 170
95 212 228 205
120 245 273 239
150 282 314 275
185 323 358 313
240 379 421 371
300 429 477 428
- 28 -
The lowest acceptable wire section and the
e
3IL R ϕcos⋅ X ϕsin⋅+()⋅⋅ ⋅
1000
------------------------------------------------------------------------------
=
corresponding maximum cable or conductor length
for multiple core cable or H07 RN-F, at rated current,
for a voltage drop e lower than 5% and at a power
factor of 0.80, are respectively 120 mm² and 370 m.
In case electric motors must be started, oversizing the
cable is advisable.
The voltage drop across a cable can be determined as
follows:
e = Voltage drop (V)
I = Rated current (A)
L = Length of conductors (m)
R = Resistance (Ω/km to VDE 0102)
X = Reactance (Ω/km to VDE 0102)
3.3.3 Connecting the load
3.3.3.1 Site distribution panel
If outlet sockets are provided, they must be mounted
on a site distribution panel supplied from the terminal
board of the generator and in compliance with local
regulations for power installations on building sites.
3.3.3.2 Protection
For safety reasons, it is necessary to
provide an isolating switch or
circuit breaker in each load circuit.
Local legislation may impose the use
of isolating devices which can be
locked.
– Check whether frequency, voltage and current
comply with the ratings of the generator.
– Provide a load cable, without excessive length,
and lay it out in a safe way without forming coils.
– Open the door of the control and indicator panel
and the transparent door in front of the terminal
board X1.
– Provide the wire ends with cable lugs suited for
the cable terminals.
– Loosen the cable clamp and push the wire ends of
the load cable through the orifice and clamp.
– Connect the wires to the proper terminals (L1, L2,
L3, N and PE) of X1 and tighten the bolts
securely.
– Tighten the cable clamp.
– Close the transparent door in front of X1.
- 29 -
4 Operating instructions
In your own interest, always strictly
observe all relevant safety
instructions.
Do not operate the generator in
excess of the limitations mentioned
in the Technical Specifications.
Local rules concerning the setting
up of low voltage power installations
(below 1000 V) must be respected
when connecting site distribution
panels, switch gear or loads to the
generator.
At each start-up and at any time a
new load is connected, the earthing
and protections (GB trip and earth
leakage relay) of the generator must
be verified. Earthing must be done
either by the earthing rod or, if
available, by an existing, suitable
earthing installation. The protective
system against excessive contact
voltage is not effective unless a
suitable earthing is made.
4.1 Before starting
– With the generator standing level, check the
engine oil level and top up if necessary. The oil
level must be near to, but not exceed the high mark
on the engine oil level dipstick.
– Check the coolant level in the expansion tank of
the engine cooling system. The coolant level must
be near to the FULL mark. Add coolant if
necessary.
– Drain any water 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 day’s
operation to prevent water vapor in a nearly empty
tank from condensing.
– Drain leaking fluid from the frame.
– Check the vacuum indicator of the air filter. If the
red part shows completely, replace the filter
element.
– Press the dust evacuator of the air filter to remove
dust.
– Check the generator for leakage, tightness of wire
terminals, etc. Correct if necessary.
– Check that circuit breaker Q1 is switched off.
– Check that fuse F10 has not tripped and that the
emergency stop is in the OUT position.
– Check that the load is switched off.
– Check that the earth fault protection (N13) has not
tripped (reset if necessary).
4.2 Operating and setting Qc1002™
4.2.1 Starting
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 installed
between Q1 and the load.
– Put the starter switch S20 in position I (ON).
Voltage is applied to the Qc1002™ module.
– The unit can be started manually by pressing the
START button on the Qc1002™ module.
– The unit will start.
In cold conditions the unit might not start from the
first attempt. The controller will take 3 start
attempts.
– Switch on circuit breaker Q1 in case no contactor
is installed.
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