Atlas Copco QAS 500 Volvo S2A APP Instruction Manual

QAS 500 Volvo S2A APP

Instruction Manual for AC Generators English

ATLAS COPCO - PORTABLE AIR DIVISION

www.atlascopco.com

Printed matter N°

2954 3870 00

05/2009

QAS 500 Volvo

Instruction Manual for AC Generators

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

Circuit diagrams .................................................................................... 99

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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 for modifications, additions or conversions made without the manufacturer's approval in writing.

This applies in particular to trademarks, model denominations, part numbers and drawings.

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Contents

Safety precautions for portable generators

......................................................6

Leading particulars .....................................13

General description ................................13

Bodywork ................................................15

Markings..................................................15

Drain plugs and filler caps.....................16

External fuel tank connection................16

Control and indicator panel Qc1002™..16 Control and indicator panel Qc2002™..26 Control and indicator panel Qc4002™..39

Output terminal board ...........................70

Dual frequency........................................71

Battery switch.........................................71

Spillage free skid....................................71

Operating instructions...............................72

Installation...............................................72

Connecting the generator......................72

Before starting........................................74

Operating Qc1002™ ...............................74

Operating Qc2002™ ...............................75

Operating Qc4002™ ...............................77

Maintenance ................................................78

Maintenance schedule ...........................78

Engine maintenance...............................80

(*) Measuring the alternator

insulation resistance...............................80

Engine fuel specifications......................80

Engine oil specifications ........................80

Engine oil level check.............................81

Engine oil and oil filter change..............81

Engine coolant specifications................82

Coolant check..........................................83

Storage of the generator...........................84

Storage....................................................84

Preparing for operation after storage ...84

Checks and trouble shooting....................85

Checking voltmeter P4 ...........................85

Checking ammeters P1, P2 and P3........85

Engine troubleshooting..........................85

Alternator troubleshooting ....................86

Options available for QAS 500 Volvo units

...............................................................87

Circuit diagrams......................................87

Overview of the electrical options.........87

Description of the electrical options .....87

Overview of the mechanical options ....91

Desciption of the mechanical options...91

Technical specifications.............................92

Readings on gauges...............................92

Settings of switches ...............................92

Specifications of the engine/

alternator/unit .........................................92

Conversion list of SI units into

British units.............................................98

Dataplate .................................................98

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.

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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.

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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.

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 Portable generators (with earthing pin):

Earth the generator as well as the load properly.

16b Portable generators IT:

Note: This generator is built to supply a sheer alternating current IT network. Earth the load properly.

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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.

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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 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.

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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 testrun, check that the AC power performance is correct and that the control and shutdown devices function correctly.

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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.

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Leading particulars

General description

The QAS 500 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, 50 Hz, 230 V - 3 phase and 60 Hz, 480 V - 3 phase. The QAS 500 Volvo generator is driven by a fluid-cooled diesel engine, manufactured by VOLVO PENTA.

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 Earthing rod

DH Drain and access hole (in the frame) FCF Filler cap fuel

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A Alternator AF Air filter C Coupling DFO Drain flexible engine oil DFW Drain flexible cooling water E Engine 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 S1 Battery switch

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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 15W40 oil 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.

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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 air-tight 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

Indicates the 3-way valve.

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

The drain hole can also be used to guide external fueltank connections. When connecting an external fueltank, use the 3-way valves.

QAS500 VoD

Engine oil

PAROIL 15W40 PAROIL 5W40

Engine coolant PARCOOL EG

XXXXXXXX

XXXX XXXX XX

XXXXXXXXX

XXXX XXXX XX

XXXXXXXXXX

XXXX XXXX XX

XX XXXXXXX

XXXX XXXX XX

XX XXXXXXX

XXXX XXXX XX XXXX XXXX XX

XX XXXXXXX

XXXX XXXX XX

XXXXXXX

XXXX XXXX XX

XX XXXXXXX

XXXX XXXX XX

XX XXXXXXX

XXXX XXXX XX

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.

F10

S20

X25

Q3 Q4 Q5 Q6

N13

L1L2

OFF

L1-N

L2L3 L2-N

L3L1

LL LN

L3-N

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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.

Position I: Voltage is applied to the Qc1002™ module, it is possible to start up the generator.

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™

Qc1002 CAN

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.

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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.

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.

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

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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 21.

Alarm list display

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

An overview is given in “Alarm Display (pop-up window)” on page 23.

LOG list display

This view shows the alarm memory and gives access to it.

An overview is given in “LOG list” on page 25.

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.

Battery Voltage display

This view shows the Battery voltage and the running hours.

Qc1002 CAN

v1.00.0

Parameter

Alarm List

0 Alarm(s)

LOG List

Service 1 Service 2

59h 59h

25.2 VBattery

00168.1h

- 20 -

Coolant temperature display

This view shows the Coolant temperature and the running hours.

See also “Parameter list” on page 21 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 21 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.

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:

62˚CWater

00168.1h

3.2barOil

00168.1h

75%Fuel

00168.1h

50Hz400V

00168.1h

1500RPM

00168.1h

START OFF/ EXTENDED STOP TIMER

COOLDOWN

DIAGNOSTIC

- 21 -

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.

Unit type 2 for QAS 500 Volvo!

- 22 -

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

Qc1002 CAN

145

Parameter Running time

Unit type

Qc1002 CAN

145

- 23 -

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 Vmarking 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

- 24 -

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:

SERVICE TIMER 1

SERVICE TIMER 2

ENGINE ALARM

EMERGENCY STOP

START FAILURE

STOP FAILURE

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

- 25 -

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.

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).

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

- 26 -

Control and indicator panel Qc2002™

General description Qc2002™ control panel

A1 .......Qc2002™ 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

S20 .....ON/OFF switch

Position O: No voltage is applied to the Qc2002™ module, the generator will not start.

Position I: Voltage is applied to the Qc2002™ module, it is possible to start up the generator.

X25 .....Terminal strip

Qc2002™ Module

The Qc2002™ 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 Qc2002™ module can be used for several applications.

F10

S20

X25

Q3 Q4 Q5 Q6

N13

L1L2

OFF

L1-N

L2L3 L2-N

L3L1

LL LN

L3-N

- 27 -

Pushbutton and LED functions

Following pushbuttons are used on the Qc2002™

Following LEDs are used on the Qc2002™

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

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

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

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

AUTOMATIC: Is used to put the unit in manual or automatic operation.

START: Is used to start the unit in manual operation.

STOP: Is used to stop the unit in manual or automatic operation (without cooldown). W hen the unit is stopped with the STOP button in automatic operation, it will automatically go to manual operation.

MAINS CONTACTOR: Is used to open or close the Mains contactor, if the Qc2002™ is in manual operation.

GENERATOR CONTACTOR: Is used to

open or close the Generator contactor, if the Qc2002™ is in manual operation

Power Green LED indicates that the unit is

powered up.

Automatic Green LED indicates that the

Qc2002™ is in automatic operation.

Start/Stop Green LED indicates that the

Qc2002™ receives running feedback (via the W/L input, via the RPM value at the Canbus, or via the AC frequency).

Generator contactor

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

Qc2002 CAN

145

Power

Alarm

Start

Automatic

Generator

Contactor

Mains

Contactor

Stop

- 28 -

Qc2002™ Menu Overview

At Qc2002™, the LCD will show following information:

–in Normal condition (scroll through the

information using UP and DOWN):

• Status (eg: preheat, crank, cooldown, extended stop time, …) (pop-up: this display is only shown when a Special status comes up)

• Line voltages of the generator

• Controller type & version

• Parameter list

•Alarm list

• LOG list

• Service Timer 1 & Service Timer 2

• Battery Voltage

• RPM (speed)

• Coolant temperature

• Oil pressure

• Fuel level

• kWh counter

• Power factor, the frequency of the generator and the frequency of the mains

• Line voltage, frequency and active power of the generator

• Active, reactive and apparent power of the generator

• Generator currents

• Phase voltages of the mains

• Line voltages of the mains

• Phase voltages of the generator

–in Alarm condition (scroll through 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.

Line voltages generator display

This view shows the line voltages of the generator.

Controller type and version display

This view shows the controller type and the ASW version number.

Mains contactor

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

Alarm Flashing red LED indicates that an

alarm is present. A continuous red LED indicates that the alarm has been acknowledged by the use r. The exact alarm is shown on the display.

G L1-L2 G L2-L3 G L3-L1

400V 400V 400V

Qc2002 CAN

1.00.1

- 29 -

Parameter display

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

An overview is given in “Parameter list” on page 31.

Alarm list display

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

An overview is given in “Alarm Display (pop-up window)” on page 36.

LOG list display

This view shows the alarm memory and gives access to it.

An overview is given in “LOG list” on page 39.

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.

Battery voltage display

This view shows the Battery voltage and the running hours.

RPM display

This view shows the engine speed and the running hours.

Coolant temperature display

This view shows the Coolant temperature and the running hours.

See also “Parameter list” on page 31 for selection between °C and °F.

Parameter

Alarm List

0 Alarm(s)

LOG List

Service 1 Service 2

59h 59h

25.2 VBattery

00168.1h

0RPM

00168.1h

62˚CWater

00168.1h

- 30 -

Oil pressure display

This view shows the Oil pressure and the running hours.

See also “Parameter list” on page 31 for selection between bar and psi.

Fuel level display

This view shows the Fuel level and the running hours.

kWh counter display

This view shows the kWh counter.

Power factor - frequency generator frequency mains display

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

One line voltage - frequency - active power display

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

Active - reactive - apparent power display

This view shows the active, reactive and apparent power of the generator.

Generator current display

This view shows the generator current.

3.2barOil

00168.1h

75%Fuel

00168.1h

4860kWh

PF GfL1 Mf L1

0.00 50Hz 50Hz

G L1-L2 G f L1 P

400V 50Hz 80kW

P Q S

80kW 0kVAr 80kVA

G I1 G I2 G I3

100A 100A 100A

+ 84 hidden pages

Atlas Copco QAS 500 Volvo S2A APP Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual