Atlas Copco QAS 250-330 JD T4i Instruction Manual
QAS 250-330 JD T4i
Instruction Manual
for AC Generators
English
ATLAS COPCO - PORTABLE ENERGY DIVISION
www.atlascopco.com
Printed matter Nr
1310 3012 57
03/2012
QAS 250-330 JD T4i
Instruction Manual for AC Generators
Instruction manual .............................................................................5
Circuit diagrams ...............................................................................65
Original instructions
- 4 -
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 2012, Atlas Copco Compressors LLC, RockHill SC USA.
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.
- 5 -
Contents
Safety precautions for portable
generators
......................................................... .................. 6
Leading particulars
.................................... ...................... 11
General description ................................................... 11
Bodywork ................................................................... 13
Markings .................................................................... 13
Drain plugs and filler caps ........................................ 14
External fuel tank connection .................................... 14
Control and indicator panel Qc1002™..................... 14
Control and indicator panel Qc4002™..................... 24
DPF Information - Indicators.................................... 23
Output terminal board ............................................... 35
Battery switch ............................................................ 35
Spillage free frame..................................................... 35
Operating instructions............................ ............. ......... 36
Installation................................................................. 36
EXHAUST FILTER SYSTEM..................................... 37
Before starting ........................................................... 39
Operating Qc1002™ ................................................. 40
Operating Qc4002™ ................................................. 41
Maintenance ................................................... ................ 42
Maintenance schedule ............................................... 42
Engine maintenance................................................... 44
(*) Measuring the alternator insulation resistance ... 44
Engine fuel specifications.......................................... 44
Engine oil level check ................................................ 46
Engine oil and oil filter change ................................. 46
Engine coolant specifications .................................... 46
Coolant check ............................................................ 47
Storage of the generator ...................... ...................... 48
Storage........................................................................48
Preparing for operation after storage ........................48
Checks and trouble shooting............. ...................... 49
Checking voltmeter P4 ...............................................49
Checking ammeters P1, P2 and P3 ............................49
Engine troubleshooting ..............................................49
Alternator troubleshooting .........................................50
Options available for QAS 250-330 John
Deere units
........................................................ ...................... 51
Circuit diagrams.........................................................51
Overview of the electrical options..............................51
Description of the electrical options ..........................51
Overview of the mechanical options...........................53
Desciption of the mechanical options.........................53
Technical specifications......................... .......... ............ 54
Technical specifications for QAS 250 JD T4i ............54
Technical specifications for QAS 330 JD T4i ............58
Conversion list of SI units into British units............... 62
Dataplate ....................................................................63
Disposal..................................................... .................. 64
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 troublefree 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.
- 6 -
Safety precautions for portable generators
To be read attentively and acted accordingly before towing, lifting, operating, performing maintenance or repairing the generator.
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.
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.
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.
- 7 -
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.
16aPortable generators (with earthing pin):
Earth the generator as well as the load properly.
16bPortable generators IT:
Note: This generator is built to supply a sheer
alternating current IT network.
Earth the load properly.
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 retardation
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 the unit is to be backed up by the towing vehicle,
disengage the overrun brake mechanism (if it is not an
automatic mechanism).
4 Never exceed the maximum towing speed of the unit
(mind the local regulations).
5 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.
6 To lift heavy parts, a hoist of ample capacity, tested
and approved according to local safety regulations,
shall be used.
7 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.
8 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.
9 Never leave a load hanging on a hoist.
10 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.
11 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.
12 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.
13 The electrical connections shall correspond to local
codes. The machines shall be earthed and protected
against short circuits by fuses or circuit breakers.
14 Never connect the generator outlets to an installation
which is also connected to a public mains.
15 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.
16 Before transportation of the unit, switch off all the
circuit breakers.
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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 Insulation or safety guards of parts the temperature of
which can be in excess of 80°C (175°F) and which
may be accidentally touched by personnel shall not be
removed before the parts have cooled to room
temperature.
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.
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 causes worsening of 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
- 9 -
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.
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.
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.
- 10 -
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 testrun, check
that the AC power performance is correct and that the
control and shutdown devices function correctly.
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.
Battery safety precautions
Batteries
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.
- 11 -
Leading particulars
General description
The QAS 250-330 is an AC generator, built for continuous running at sites where no electricity is available or as stand-by in cases of interruption of the mains. The generator operates
at 60 Hz, 480 V - 3 phase, 240 V - 3 phase and 240 V 1 phase. The QAS 250-330 generator is driven by a water-cooled diesel engine, manufactured by John Deere.
An overview of
the main parts is given in the diagram below.
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 Hole for forklift
9 Coolant filler access
DH Drain and access hole (in the frame)
FCF Filler cap fuel
- 12 -
A Alternator
AF Air filter
C Coupling
DFO Drain flexible engine oil
EEngine
FFan
FC Fuel Cooler
FCO Filler cap engine oil
FCW Filler cap cooling water
FF Fuel filter
G1 Battery
I Intercooler
OF Oil filter
OLD Engine oil level dipstick
PF Pre-Filter
S1 Battery switch
- 13 -
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 lifting beam, to lift the generator by means of a crane,
is integrated in the bodywork and easily accessible from
the outside. The recesses in the roof have guiding rods at
both sides.
To be able to lift the generator by means of a forklift,
rectangular holes are provided at the bottom of the frame.
The earthing rod, connected to the generator’s earth
terminal is located at the bottom of the frame on the
outside.
Markings
A brief description of all markings provided on the
generator is given hereafter.
Never use the guiding rods to lift the
generator.
Indicates that an electric voltage,
dangerous to life, is present. Never
touch the electric terminals during
operation.
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.
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 engine
fuel.
Use PAROIL E only.
Indicates the external fueltank.
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 the partnumbers of
the different service packs
and of the engine oil. These
parts can be ordered to the
factory.
XXXXXXXXXXXXXXX
Engine oil
PAROIL E PAROIL Extra
Engine coolant PARCOOL EG
XXXXXXXXXXXX
XXXX XXXX XX
XXXXXXXXX
XXXX XXXX XX
XXXXXXXXX
XXXX XXXX XX
XX XXXXXXX
XXXX XXXX XX
XXXX XXXX XX
XX XXXXXXX
XXXX XXXX XX
XXXX XXXX XX
XX XXXXXXX
XXXX XXXX XX
XX XXXXXXX
XXXX XXXX XX
XX
XXXXXXX
XXXX XXXX XX
XX XXXXXXX
XXXX XXXX XX
XX XXXXXXX
XXXX XXXX XX
- 14 -
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, the fuel
drain plug at the front, the others 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.
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 fuellines ought to be airtight to prevent air from entering the fuel system.
Control and indicator panel Qc1002™
General description Qc1002™ control panel
A1..... Qc1002™ display
F10 ... Fuse
The fuse activates 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 position with the key, to avoid unauthorized
use.
S20... ON/OFF switch
Position O: No voltage is applied to the Qc1002™
module, the generator will not start.
The drain hole can also be used to guide
external fueltank connections. When
connecting an external fueltank, use the 3way valves.
Position 1: Indicates that the fuel supply
line to the engine is connected to the
internal fueltank.
Position closed: Indicates that the fuel
supply line to the engine is closed.
Position 2: Indicates that the fuel supply
line to the engine is connected to the
external fueltank.
- 15 -
Position I: Voltage is applied to the Qc1002™
module, it is possible to start up the generator.
X7 ... Flanged Inlet
Used to supply power to the available coolant
heater or battery charger (if ordered).
X25 .. Terminal strip
Qc1002™ Module
The Qc1002™ module is located inside the control panel.
This control module will carry out all necessary tasks to
control and protect a generator, regardless of the use of the
generator.
This means that the Qc1002™ module can be used for
several applications.
Pushbutton and LED functions
Following pushbuttons are used on the
Qc1002™
Q
c1002 CA
N
145
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.
REMOTE MODE: Is used to
activate the remote mode. The LED
indicates if the gen-set is put in
Remote Mode.
START: Is used to start the unit in
Manual Mode.
STOP: Is used to stop the unit in
Manual or Remote Mode (always
with shutdown!). When the unit is
stopped with the STOP button in
Remote mode, it will automatically go
to Manual Mode.
- 16 -
Following LEDs are used on the Qc1002™
Qc1002™ Menu Overview
At Qc1002™, the LCD will show following information:
–in Normal condition (scroll through the information 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
• Coolant temperature
• Oil pressure
• RPM (speed)
• Fuel level
• Voltage - frequency - running hours
–in Alarm condition (scroll through the information using
UP and DOWN):
• a list of all active Alarms
It's possible to scroll through the views, using the UP and
DOWN buttons. The scrolling is continuous.
If a Special status comes up, the Status Display is shown.
If an Alarm comes up, the Alarm Display is shown.
Controller type and version display
This view shows the controller type and the ASW version
number.
Parameter display
This view shows a number of Parameter settings and gives
access to them.
An overview is given in “Parameter list” on page 18.
Alarm list display
This view shows the number of active alarms and gives
access to them.
An overview is given in “Control and indicator panel
Qc1002™” on page 14.
LOG list display
This view shows the alarm memory and gives access to it.
An overview is given in “LOG list” on page 21.
Service timer 1 & Service timer 2 display
This view shows both Service timers. The service timer
indication is shown when service time has run out. It can
be removed by resetting the timers or acknowledging the
Service timer indication.
The service timer indications count upwards and give an
alarm when the set value is reached.
Resetting the Service Timers can be done through the
Parameter display.
Power
Green LED indicates that the unit is
powered up.
Remote
Green LED indicates that the Remote
Mode is selected.
Start/Stop
Green LED indicates that the engine is
running.
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.
Remote
Power
Alarm
Start/Stop
Qc1002 CAN
145
Qc1002 CAN
v1.00.0
Parameter
Alarm List
0 Alarm(s)
LOG List
Service 1
Service 2
59h
59h
- 17 -
Battery Voltage display
This view shows the Battery voltage and the running
hours.
Coolant temperature display
This view shows the Coolant temperature and the running
hours.
See also “Parameter list” on page 18 for selection between
°C and °F.
Oil pressure display
This view shows the Oil pressure and the running hours.
See also “Parameter list” on page 18 for selection between
bar and psi.
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 running
hours.
Engine speed display
This view shows the engine speed and running hours.
Diagnostic menu
This menu is used to power up the engine electronics
without starting the engine. When this setting is switched
on, electric power will be supplied to the engine
electronics after half a minute delay. The unit can not be
started as long as this parameter is swiched on.
DPF - Diesel Particulate Filter
This view shows the DPF mode selected. When AUTO is
selected the DPF will regenerate automatically. When
OFF is selected, regeneration is disabled. When ON is
selected manual regeneration is partially enabled (see
STATION REGEN).
It is highly recommended that the genset be left in the
AUTO mode at all times to prevent engine de-rate and
possible shutdown due to high soot level.
Station Regen.
Stationary or manual DPF regeneration. This view shows
the stationary regeneration mode selected. When OFF is
selected, manual regeneration is disabled. When ON is
selected manual regeneration is enabled. The views DPF
and STATION REGEN. must be set to ON for the unit to
perform a stationary (manual) regeneration.
DPF and STATION REGEN. are password protected.
Note: Unit will not regenerate until soot level is ~72%
Soot Load Indicator
Available in EXTRA VIEWS on control panel
Only visible when unit is operating. This screen has been
provided for the operator to monitor the soot load of the
DPF (read in percent of load)
For stationary/manual regeneration instructions See
page 22.
25.2 VBattery
00168.1h
62˚CWater
00168.1h
3.2barOil
00168.1h
75%Fuel
00168.1h
- 18 -
Qc1002™ Menu Description
Status Display (pop-up window)
In case special statuses are entered, a pop-up window will
automatically be entered for as long as the status is active.
The background screen is not updated when the status
pop-up window is active.
These special statuses are:
If a special status has elapsed, the active view will be
entered 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 to change 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 running hours. The
running hours can only be highered, not lowered.
– Unit Type
– Service Timer 2 reset
– Service Timer 1 reset
These menus are used to reset the service timers. When a
service timer alarm occurs and is acknowledged, the service
timer will be reset automatically.
– Diagnostic Menu
This menu is used to power up the engine electronics without
starting the engine. When this setting is switched on, electric
power will be supplied to the engine electronics after half a
minute delay. The unit can not be started as long as this
parameter is switched on.
– Unit Menu
This menu is used to select whether tempreature and pressure
should appear in °C/bar or °F/psi.
– Language selection
Icons is the default factory set language, but 6 other languages
can be selected: English, French, German, Italian, Spanish
and Cyrillic (Russian). All information in the Parameter List
display is always 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
– Engine CAN communication
This menu is used to select the type of engine electronics, the
Qc1002™ controller should communicate with via the
Canbus.
It's possible to scroll between configuration menu's by
using the pushbuttons UP and DOWN.
Pushing the ENTER button activates the configuration
menu which is shown at the display.
PREHEAT
START OFF/
EXTENDED
STOP TIMER
COOLDOWN
DIAGNOSTIC
Unit type 6 for QAS 250-330 John Deere!
- 19 -
This is the described menu flow for changing the unit type:
- 20 -
Alarm Display (pop-up window)
In case an Alarm occurs, a pop-up window will
automatically be displayed for as long as the alarm is
active, no matter which view is active. The flashing red
alarm LED will light up. The alarm icons will be shown
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 red alarm LED will light up
continuously.
The Alarm Display can always be left or entered again by
pushing the BACK button.
If more than one alarm comes up, it's possible to scroll
through the alarm messages with the UP and DOWN
pushbuttons. The newest alarm will be placed at the
bottom of the list (meaning that the older alarm stays at the
display when a newer alarm comes up).
If one or more than one alarm is present, an arrow at the
right of the display will be shown.
Following general groups of Alarms exist:
– Warning: Alarm LED lights up + Alarm pop-up appears
on the display + Alarm relay is empowered (if configured)
– Trip of GB: ‘Warning’ actions + Generator Contactor
opens
– Trip and Stop: ‘Trip of GB’ actions + unit stops after
Cooldown
– Shutdown: ‘Trip of GB’ actions + unit stops immediately
List of possible alarms:
An alarm should always be acknowledged
before solving the problem that causes the
alarm.
LOW OIL
PRESSURE
HIGH COOLANT
TEMPERATURE
CHARGING
ALTERNATOR
LOW FUEL LEVEL
LOW COOLANT
LEVEL
GENERATOR
OVERVOLTAGE
GENERATOR
UNDERVOLTAGE
GENERATOR
OVERFREQUENCY
GENERATOR
UNDERFREQUENCY
SERVICE TIMER 1
SERVICE TIMER 2
ENGINE ALARM
EMERGENCY
STOP
START FAILURE
STOP FAILURE
- 21 -
Displaying the engine DM1 alarm
Besides some engine specific alarms shown in the
standard alarm list, also all Diagnostic messages DM1
(active alarms) can be shown on the display.
Use the UP or DOWN buttons until DM1 is shown on the
display and press ENTER. The DM1 alarm log will be
shown on the display.
Use the UP and DOWN buttons to scroll through the list.
The DM1 alarm log will always show the SPN code
(Diagnostics Codes) and the FMI code (Failure Modes) of
every engine failure.
For example, the error code for “Low Coolant Level
Shutdown” will be 111/01 (111 for “Coolant level” and 01
for “Low level shutdown”).
The list below shows the most common error codes. The
DM1 alarm log for these codes will also show the alarm
text:
LOG list
The unit will keep an event log of the latest 30 events.
Events are:
– shutdowns
– service timer 1/2 reset
– unit type changes
Together with each event, the running hours at the time of
the event will be stored.
SPN16 "FUEL FILTER DIFF P"
pressure difference over fuel filter
SPN51 "THROTTLE POS"
throttle position
SPN52 "INTERCOOL TEMP"
intercooler temperature
SPN94 "FUEL PRESS"
fuel pressure
SPN95 "FUEL FILTER DIFF P"
pressure difference over fuel filter
SPN97 "WATER IN FUEL"
water in fuel
SPN98 "OIL LEVEL"
oil level
SPN99 "OIL FILTER DIFF P"
pressure difference over oil filter
SPN100 "OIL PRESSURE"
oil pressure
SPN101 "CRANKCASE PRESS"
crankcase pressure
SPN102 "TURBO BOOST PRESS"
turbo boost pressure
SPN104 "TURBO OIL PRESS"
turbo oil pressure
SPN105 "INTAKE MANIF TEMP"
intake manifold temperature
SPN106 "AIR INLET PRESSURE"
air inlet pressure
SPN110 "COOLANT TEMP"
coolant temperature
SPN111 "COOLANT LEVEL"
coolant level
SPN158 "BATT VOLTAGE"
battery voltage
SPN171 "AMBIENT AIR TEMP"
ambient air temperature
SPN172 "AIR IN TEMP"
air in temperature
SPN174 "FUEL TEMP"
fuel temperature
SPN175 "OIL TEMP"
oil temperature
SPN190 "SPEED"
speed
FMI00 "HIGH LEVEL SHUTDOWN"
high level shutdown
FMI01 "LOW LEVEL SHUTDOWN"
low level shutdown
FMI15 "HIGH LEVEL WARNING"
high level warning
FMI16 "HIGH LEVEL ALARM"
high level alarm
FMI17 "LOW LEVEL WARNING"
low level warning
FMI18 "LOW LEVEL ALARM"
low level alarm
1 Controller type
2 Event number
3 Event
4 Running hours
Time: 00001h
EVENT LOG #04
Water
Qc1002
1
3
4
2
- 22 -
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 their own
pre-defined fail class.
All alarms are enabled according to one of these three
statuses:
– disabled alarm, no supervision of alarm (OFF).
– enabled alarm, supervision of alarm all the time (ON).
– running alarm, only supervision when the machine is
running (RUN).
Stationary Regeneration Procedure
Atlas Copco recommends that the DPF configuration be left in the AUTO mode at all times, however in the event that a stationary or manual regeneration in desired the
following process should be followed.
– Go to the "STATION REGEN" screen. For normal operation this should be in OFF mode.
§ Press the enter button, this function is password protected contact Atlas Copco service department.
§ Use the up or down arrow to change the selection to ON and press the enter button.
– Go to the "DPF" screen. For normal operation this should be in the AUTO mode.
§ Press the enter button
§ Use the up or down arrow to change the selection to ON and press the enter button.
§ This will set the unit up for regeneration, after a few moments the regeneration icon should appear confirming the unit is regenerating.
Upon completion of the stationary/forced regeneration it is highly recommended to reset the unit to automatically regenerate to prevent engine derate & shutdown due to
high soot load. Follow the process below to return the unit to AUTO mode for normal operation.
– Go to the "STATION REGEN" screen. (For normal operation this should be in OFF mode).
§ Press the enter button, this function is password protected contact Atlas Copco service department.
§ Use the up or down arrow to change the selection to OFF and press the enter button.
– Go to the "DPF" screen. For normal operation this should be in the AUTO mode.
§ Press the enter button,
§ Use the up or down arrow to change the selection to AUTO and press the enter button.
§ The unit is now ready for normal operation.
- 23 -
DPF INFORMATION - INDICATORS
Indicators Discription Operator Action
Exhaust Filter Cleaning Indicator Active when:
1. Exhaust gas temperature is high.
2. Elevated idle is active.
3. Exhaust filter cleaning is in process.
Machine can be operated as normal.
If operating in an area where high
exhaust temperature may be an issue,
abort exhaust filter cleaning by using the
disable feature. Only use disable feature
in emergency situation.
Exhaust Filter Indicator Active when:
Soot level in the exhaust filter indicates
need for an exhaust filter cleaning.
Warning will be present on controller
Enable auto filter cleaning to allow a
cleaning cycle.
OR
Begin a manual cleaning.
Exhaust Filter and Warning Indicators Active when:
Machine performance is reduced due to
moderately high soot level.
Warning will be present on controller
Begin a manual cleaning.
Exhaust Filter and Stop Indicators Active when:
Exhaust filter requires service, Machine
performance is reduced due to Extremely
High soot level and a stop engine request
is made.
Service the exhaust filter.
Contact your servicing dealer.
Auto Cleaning Disabled Indicator Active when:
Auto exhaust filter cleaning is disabled.
If possible, enable auto cleaning.
Always leave machine in auto cleaning mode unless forced to use a manual cleaning.
Do not let machine operate unloaded excessively, exhaust filter performance is reduced.
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