2954 2960 03_QAS 125-150_EN

QAS 125-150 Volvo

Instruction Manual for AC Generators English

ATLAS CO

QAS 125-150Instruction Manual for AC Generators

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

Circuit diagrams ............................................. ....................91

Orig...................

...................PCO - PORTABLE AIR DIVISIONwww.atlascopco.comPrinted matter NPreliminary

06/2010

inal instructions

Warranty and Liability Limitation

Use only authorized parts. Any damage or malfunction caused by the use of unauthoWarranty or Product Liability.The manufacturer does not accept any liability for any damagadditions or conversions made without the manufacturer's appNeglecting maintenance or making changes to the setup of thhazards, including fire risk.While every effort has been made to ensure that the informaAtlas Copco does not assume responsibility for possible errors.

Copyright 2010, Atlas Copco Airpower n.v., Antwerp, Belgium.

Any unauthorized use or copying of the contents or any part theThis applies in particular to trademarks, model denominations, - 4 -

rized parts is not covered by

e arising from modifications,roval in writing.e machine can result in major

tion in this manual is correct,

reof is prohibited.part numbers and drawings.

Contents

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

Leading particulars .....................................13General descripBodywork .........Markings...........Drain plugs andExternal fuel tanControl and indControl and indControl and indOutput terminalBattery switch ..Spillage free ski

Operating instructInstallation........Connecting the Before starting .Operating Qc10Operating Qc20Operating Qc40

Maintenance ................................................63Maintenance schedule ...........................63Engine maintenance...............................65(*) Measuring the alternator

Options available for QAS 125-150 Volvo units ...................................................71

Circuit diagrams......................................71Overview of the electrical options.........71

the electrical options .....71e mechanical options ....76he mechanical options...76

ations .............................77ifications for .........................................77ifications for .........................................83 of SI units into .........................................89.........................................89

.........................................90

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 thisbooklet 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 Copcoreserves the right to make changes without prior notice.- 5 -

tion ................................13.......................................15.......................................15 filler caps .....................16k connection ................16

icator panel Qc1002..16icator panel Qc2002..25icator panel Qc4002..38 board ...........................55.......................................56d ....................................56

ions...............................57.......................................57generator ......................57.......................................5902 ...............................5902 ...............................6002 ...............................62

insulation resistance...............................65Engine fuel specifications ......................65Engine oil specifications ........................65Engine oil level check .............................66Engine oil and oil filter change..............66Engine coolant specifications ................66Coolant check..........................................67

Storage of the generator ...........................68Storage ....................................................68Preparing for operation after storage ...69

Checks and trouble shooting....................69Checking voltmeter P4 ...........................69Checking ammeters P1, P2 and P3........69Engine troubleshooting..........................69Alternator troubleshooting ....................70

Description of Overview of thDesciption of t

Technical specificTechnical specQAS 125 unitsTechnical specQAS 150 unitsConversion listBritish units ....Dataplate ........

Disposal ...............

Safety precautions for portable generatorsTo be read attentively and acted accordingly before towing, lifting, operating, performing maintenance or repairing the generator.

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

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

- applicable rules, codes and regulations,- the expected usefu

service and mainten- providing the manuBefore handling any prelevant instruction maoperating instructions, itabout safety, preventive Keep the manual alwaaccessible to the operatinSee also the safety ppossible other equipmealong or are mentioned unit.These safety precautistatements will thereforeunit.

Only people that have the right skills should be allowedto operate, adjust, perform maintenance or repair onAtlas Copco equipment. It is the responsibility ofmanagement to appoint operators with the appropriatetraining and skill for each category of job.Skill level 1: OperatorAn operator is trained in all aspects of operating the unitwith the push-buttons, and is trained to know the safetyaspects.

In general it is recommended that not more than twopeople operate the unit, more operators could lead tounsafe operating conditions. Take necessary steps tokeep unauthorized persons away from the unit andeliminate all possible sources of danger at the unit.When handling, operating, overhauling and/orperforming maintenance or repair on Atlas Copcoequipment, the mechanics are expected to use safeengineering practices and to observe all relevant local

ordinances. The following list issafety directives and precautionstlas Copco equipment.recautions may endanger people

and machinery:due to electrical, mechanical ors,

ironment due to leakage of oil,ubstances,inery due to function failures.any damage or injury resulting

precautions or by non-observanced due care required in handling,e or repair, also if not expresslyruction manual, is disclaimed by- 6 -

l product life, assuming properance,al with up-to-date information.roduct, take time to read thenual. Besides giving detailed also gives specific informationmaintenance, etc.ys at the unit location, easyg personnel.

recautions of the engine andnt, which are separately sent

on the equipment or parts of the

ons are general and some not always apply to a particular

Skill level 2: Mechanical technicianA mechanical technician is trained to operate the unit thesame as the operator. In addition, the mechanicaltechnician is also trained to perform maintenance andrepair, as described in the instruction manual, and isallowed to change settings of the control and safetysystem. A mechanical technician does not work on liveelectrical components.Skill level 3: Electrical technicianAn electrical technician is trained and has the samequalifications as both the operator and the mechanicaltechnician. In addition, the electrical technician maycarry out electrical repairs within the various enclosuresof the unit. This includes work on live electricalcomponents.Skill level 4: Specialist from the manufacturerThis is a skilled specialist sent by the manufacturer or itsagent to perform complex repairs or modifications to theequipment.

safety requirements anda reminder of special mainly applicable to ANeglecting the safety pas well as environment- endanger people

chemical influence- endanger the env

solvents or other s- endanger the machAll responsibility for from neglecting these of ordinary caution anoperating, maintenancmentioned in this instAtlas Copco.

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

General safety precautions1 The owner is respon

a safe operating accessories must unsuitable for safe o

2 The supervisor, or all times make surmachinery and maintenance are smachines with all awell as the consumfree of abnormal tampered with.

3 Whenever there is that an internal partmachine shall be stshall be opened beelapsed; this to aignition of oil vapou

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

5 Operate the unit only for the intended purpose andwithin 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 otherdeposits.

7 To prevent an increase in working temperature,inspect and clean heat transfer surfaces (cooler fins,intercoolers, coolant jackets, etc.) regularly. See themaintenance schedule.

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

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

16a Portable generators (with earthing pin):r as well as the load properly.rs IT:ator is built to supply a sheer IT network.perly.- 7 -

sible for maintaining the unit incondition. Unit parts and

be replaced if missing orperation.the responsible person, shall ate that all instructions regarding

equipment operation andtrictly followed and that theccessories and safety devices, asing devices, are in good repair,wear or abuse, and are not

an indication or any suspicion of a machine is overheated, theopped but no inspection coversfore sufficient cooling time hasvoid the risk of spontaneousr when air is admitted.

8 All regulating and safety devices shall bemaintained with due care to ensure that theyfunction properly. They may not be put out ofaction.

9 Pressure and temperature gauges shall be checkedregularly with regard to their accuracy. They shallbe replaced whenever outside acceptable tolerances.

10 Safety devices shall be tested as described in themaintenance schedule of the instruction manual todetermine that they are in good operating condition.

11 Mind the markings and information labels on theunit.

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

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

Earth the generato16b Portable generato

Note: This generalternating currentEarth the load pro

Safety during transport and installationTo lift a unit, all loose or pivoting parts, e.g. doors andtowbar, shall first be securely fastened.Do not attach cables, chains or ropes directly to thelifting eye; apply a crane hook or lifting shackle meetinglocal safety regulations. Never allow sharp bends inlifting cables, chains or ropes.Helicopter lifting is not allowed. It is strictly forbidden to dwell or stay in the risk zoneunder a lifted load. Never lift the unit over people orresidential areas. Lifting acceleration and retardationshall be kept within safe1 Before towing the u

- check the towbtowing eye. Alstowing vehicle,

- check the towintowing vehicle,

- check that the tois safely locked i

- ascertain that thethe hook,

- check that the wtyres are in good

- connect the signand connect the p

- attach the safetchain to the towi

- remove wheel chthe parking brake

2 To tow a unit use a towing vehicle of amplecapacity. Refer to the documentation of the towingvehicle.

3 If the unit is to be backed up by the towing vehicle,disengage the overrun brake mechanism (if it is notan automatic mechanism).

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

5 Place the unit on level ground and apply the parkingbrake before disconnecting the unit from the towingvehicle. Unclip the safety break-away cable orsafety chain. If the unit has no parking brake or

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

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

e stalled on an even, solid floor, with sufficient ventilation. If ther can vary in inclination, consult

nections shall correspond to locales shall be earthed and protected

its by fuses or circuit breakers.the generator outlets to an is also connected to a public

g a load, switch off thecuit breaker, and check whethere, current and power factortings of the generator.ion of the unit, switch off all the- 8 -

limits.nit:ar, the brake system and theo check the coupling of the

g and brake capability of the

wbar, jockey wheel or stand legn the raised position, towing eye can swivel freely on

heels are secure and that the condition and inflated correctly,alisation cable, check all lightsneumatic brake couplers,

y break-away cable or safetyng vehicle,ocks, if applied, and disengage.

jockey wheel, immobilize the unit by placingchocks in front of and/or behind the wheels. Whenthe towbar can be positioned vertically, the lockingdevice must be applied and kept in good order.

6 To lift heavy parts, a hoist of ample capacity, testedand approved according to local safety regulations,shall be used.

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

8 For maximum safety and efficiency of the liftingapparatus all lifting members shall be applied asnear to perpendicular as possible. If required, alifting beam shall be applied between hoist andload.

9 Never leave a load hanging on a hoist.

12 Generators shall bin a clean locationfloor is not level oAtlas Copco.

13 The electrical concodes. The machinagainst short circu

14 Never connect installation whichmains.

15 Before connectincorresponding cirfrequency, voltagcomply with the ra

16 Before transportatcircuit breakers.

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

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

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

3 When operating in the unit so that dustwind. Operation in extends the intervafilters and the cores

4 Never remove a fillhot engine. Wait ucooled down.

5 Never refill fuel wotherwise stated inBook (AIB). Keep fair outlet pipes or thwhen fuelling. Whpump, an earthing cunit to discharge sleave oil, fuel, coaround the unit.

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

7 Periodically carry out maintenance works accordingto the maintenance schedule.

8 Stationary housing guards are provided on allrotating or reciprocating parts not otherwiseprotected and which may be hazardous topersonnel. Machinery shall never be put intooperation, when such guards have been removed,before the guards are securely reinstalled.

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

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

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

unit in surroundings where theref taking in flammable or toxic

rocess produces fumes, dust or etc., take the necessary steps toof personnel injury.pressed air or inert gas to cleando so with caution and use thetion, at least safety glasses, forell as for any bystander. Do not air or inert gas to your skin or stream at people. Never use it to

ur clothes.rts in or with a cleaning solvent,ed ventilation and use appropriate a breathing filter, safety glasses,loves, etc.- 9 -

unit has sufficient air intake forary, install extra air intake ducts.a dust-laden atmosphere, place is not carried towards it by theclean surroundings considerablyls for cleaning the air intake

of the coolers.er cap of the coolant system of antil the engine has sufficiently

hile the unit is running, unless the Atlas Copco Instructionuel away from hot parts such ase engine exhaust. Do not smokeen fuelling from an automaticable should be connected to the

tatic electricity. Never spill norolant or cleansing agent in or

9 Noise, even at reasonable levels, can cause irritationand disturbance which, over a long period of time,may cause severe injuries to the nervous system ofhuman beings.When the sound pressure level, at any point wherepersonnel 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 beingpresent in the room,

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

- above 85 dB(A): room to be classified as a noise-hazardous area and an obvious warning shall beplaced permanently at each entrance to alertpeople entering the room, for even relativelyshort times, about the need to wear earprotectors,

room temperature.11 Never operate the

is a possibility ofumes.

12 If the working pvibration hazards,eliminate the risk

13 When using comdown equipment, appropriate protecthe operator as wapply compresseddirect an air or gasclean dirt from yo

14 When washing paprovide the requirprotection such asrubber apron and g

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

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

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

18 Never operate the gindicated in the teclong no-load sequen

19 Never operate the gExcessive moisturgenerator insulation

20 Do not open electrequipment while vobe avoided, e.g. adjustments, have qualified electricianand ascertain that against electrical ha

21 Never touch the poof the machine.

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

23 Check the electric cables regularly. Damaged cablesand insufficient tightening of connections maycause electric shocks. Whenever damaged wires ordangerous conditions are observed, switch thecircuit breakers to OFF and stop the engine.Replace the damaged wires or correct the dangerouscondition before restarting. Make sure that allelectric connections are securely tightened.

24 Avoid overloading the generator. The generator is

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

repair work, and only tools which are in goodcondition.

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

3 All maintenance work, other than routine attention,rtaken when the unit is stopped.n to prevent inadvertent starting.ing sign bearing a legend such as

; do not start shall be attached toent. units the battery shall be

removed or the terminals covered. ven units the main switch shall besition and the fuses shall be takenn bearing a legend such as work supply voltage shall be attachedmain switch. an engine or other machine orr overhaul on it, prevent all rolling over or moving.- 10 -

enerator in excess of its limits ashnical specifications and avoidces.enerator in a humid atmosphere.e causes worsening of the.ical cabinets, cubicles or otherltage is supplied. If such cannotfor measurements, tests orthe action carried out by a only, with appropriate tools,the required bodily protectionzards is applied.wer terminals during operation

provided with circuit breakers for overloadprotection. When a breaker has tripped, reduce theconcerned load before restarting.

25 If the generator is used as stand-by for the mainssupply, it must not be operated without controlsystem which automatically disconnects thegenerator from the mains when the mains supply isrestored.

26 Never remove the cover of the output terminalsduring operation. Before connecting ordisconnecting wires, switch off the load and thecircuit breakers, stop the machine and make surethat the machine cannot be started inadvertently orthere is any residual voltage on the power circuit.

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

shall only be undeSteps shall be takeIn addition, a warnwork in progressthe starting equipmOn engine-drivendisconnected and by insulating capsOn electrically drilocked in open poout. A warning sigin progress; do notto the fuse box or

4 Prior to strippingundertaking majomovable parts from

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

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

7 Take safety precautions against toxic vapours ofcleaning liquids.

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

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

10 Never weld on or perform any operation involvingheat near the fuel omust be completelybefore carrying out or in any way modithe alternator cables

11 Support the towbaworking underneathwheel. Do not rely o

12 Do not remove anydamping material. Kliquids such as fuel,sound-damping maprevent the sound p

13 Use only lubricating oils and greases recommendedor approved by Atlas Copco or the machinemanufacturer. Ascertain that the selected lubricantscomply with all applicable safety regulations,especially with regard to explosion or fire-risk andthe possibility of decomposition or generation ofhazardous gases. Never mix synthetic with mineraloil.

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

15 When performing any operation involving heat,flames or sparks on a machine, the surrounding

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

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

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

21 Make sure that oil, solvents and other substances the environment are properly

the generator for use afterverhaul, submit it to a testrun,power performance is correct andand shutdown devices function- 11 -

r oil systems. Fuel and oil tanks purged, e.g. by steam-cleaning,such operations. Never weld on,fy, pressure vessels. Disconnect during arc welding on the unit.r and the axle(s) securely if the unit or when removing an jacks. of, or tamper with, the sound-eep the material free of dirt and oil and cleansing agents. If anyterial is damaged, replace it toressure level from increasing.

components shall first be screened with non-flammable material.

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

17 When repair has been completed, the machine shallbe barred over at least one revolution forreciprocating machines, several revolutions forrotary ones to ensure that there is no mechanicalinterference within the machine or driver. Check thedirection of rotation of electric motors when startingup the machine initially and after any alteration tothe electrical connection(s) or switch gear, to checkthat the oil pump and the fan function properly.

likely to pollutedisposed of.

22 Before clearing maintenance or ocheck that the AC that the control correctly.

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

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

solution which is facan cause burns if ibe careful when checking the charge

2 Install a sign prosmoking at the pcharged.

3 When batteries are mixture forms in thethe vent holes in theThus an explosive abattery if ventilationaround the battery fcharged. Therefore:- never smoke ne

recently been, ch- never break live

because a spark u

4 When connecting an auxiliary battery (AB) inparallel to the unit battery (CB) with booster cables:connect the + pole of AB to the + pole of CB, thenconnect the - pole of CB to the mass of the unit.Disconnect in the reverse order.- 12 -

batteries is a sulphuric acidtal if it hits your eyes, and whicht contacts your skin. Therefore,handling batteries, e.g. when condition.hibiting fire, open flame andost where batteries are being

being charged, an explosive gas cells and might escape through plugs.tmosphere may form around the is poor, and can remain in and

or several hours after it has been

ar batteries being, or havingarged, circuits at battery terminals,sually occurs.

Leading particulars

General descriptionThe QAS 125-150 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. Thegenerator operates at 50 Hz, 400 V - 3 phase, 50 Hz, 230 V-400 V - 3 phase and 60 Hz, 480 V - 3 phase. Some parts of the unit are different, depending on which version.The QAS 125-150 Volvo generator is driven by a water-cooled diesel engine, manufactured by VOLVO PENTA. An overview of the main parts is given in the diagrambelow.

1 Lifting eye2 Guiding rod3 Side doors4 Engine exhaust

control and indicator panelrd

ater

FCW 42 1- 13 -

5 Data plate6 Side door, access to 7 Output terminal boa8 Hole for forklift9 Earthing rod

FCF Filler cap fuelFCW Filler cap cooling w

9

5

3

8

7

8

FCF

6

A AlternatorAF Air filterC CouplingDFO Drain flexible engine oilDFW Drain flexible cooling waterDH Drain and access hole (in the frame)E EngineF FanFCO Filler cap engine oilFCW Filler cap cooling waterFF Fuel filterG1 BatteryODP Oil drain pump

tick

A

AF

S1

G1

FCW FFCODFW- 14 -

OF Oil filterOLD Engine oil level dipsS1 Battery switch

DHODP

DFO

OFOLD

E

C FF

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

The lifting beam access, provided to lift the generatorby means of a hoist, is integrated in the bodywork andeasily accessible from outside. The recesses in theroof have guiding rods at both sides.

To be able to lift the gerectangular holes are pframe.

The earthing rod, connterminal is located at toutside.

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

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

Indicates the drain for the coolant.

Indicates the drain plug for the engine fuel.

Use PAROIL E only.

Indicates the different earthing connections on the generator.

tes that the alternator should not aned with high pressurised

tes 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.- 15 -

nerator by means of a forklift,rovided at the bottom of the

ected to the generators earthhe bottom of the frame on the

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.

Indicabe clewater.

Indica

Drain plugs and filler capsThe drain holes for the engine oil, the coolant and theplug for the fuel, are located and labelled on the frameat the service side.

The drain flexibles forcoolant can be broughtthrough the drain hole.

External fuel tank connectionThe external fuel tank connection allows to bypassthe internal fuel tank and to connect an external fueltank to the unit.

Make sure to connect the fuel supply line as well asthe fuel return line. Connections to fuellines ought tobe air-tight to prevent air from entering the fuelsystem.

Control and indicator panel Qc1002

General description Qc1002 control panel

isplay

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

The drainguide exteWhen cfueltank, u

XXXXXXXXXXXXXXX

Engine oil PAROIL E PAROIL Extra

Engine coolant PARCOOL EG

XXXXXXXXXXXX XXXX XXXX XXXXXXXXXXX XXXX XXXX XXXXXXXXXXX XXXX XXXX XX

XX XXXXXXX XXXX XXXX XX XXXX XXXX XXXX XXXXXXX XXXX XXXX XX XXXX XXXX XXXX XXXXXXX XXXX XXXX XX XX XXXXXXX XXXX XXXX XX

XX XXXXXXX XXXX XXXX XXXX XXXXXXX XXXX XXXX XXXX XXXXXXX XXXX XXXX XX

Position 1: Indicates that the fuel supply line to the engine is

N13 Q1

L1 L2 L3 N PE

H0X25

L1L2OFF

L1-N

L2L3 L2-N

L3L1

LL LN

L3-N- 16 -

the engine oil and the engine to the outside of the generator

A1 .......Qc1002 d

hole can also be used tornal fueltank connections.onnecting an externalse the 3-way valves.

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.

S2

A1S20F10

F10...... Fuse

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

H0 ....... Panel light

S2 ....... Emergency stop button

Push the button to stop the generator in caseof an emergency. When the button ispressed, it must be unlocked, before thegenerator canstop button cposition with use.

S20 ..... ON/OFF swi

Position O: NQc1002 mostart.Position I: Qc1002 mothe generator.

X25 ..... Terminal str

Qc1002 Module Pushbutton and LED functions

Following pushbuttons are used on the Qc1002

Qc100

2 CAN

145

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

UP: Is used to scroll through the ay information and to adjust

eter value upwards.

N: Is used to scroll through the ay information and to adjust

eter value downwards.

K: Is used to leave the Alarm up window, to leave the meter list and to leave menu's out change.

OTE MODE: Is used to ate the remote mode. The LED ates if the gen-set is put in ote Mode.- 17 -

be restarted. The emergencyan be secured in the lockedthe key, to avoid unauthorized

tch

o voltage is applied to thedule, the generator will not

Voltage is applied to thedule, it is possible to start up

ip

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

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

displparam

DOWdisplparam

BACpop-Parawith

REMactivindicRem

Following LEDs are used on the Qc1002

Qc1002 Menu Overview

At Qc1002, the LCD will show followinginformation:

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

extended stop time, ) (pop-up: this display isonly shown when a Special status comes up)

Controller type & version Parameter list

1 & Service Timer 2erature

ency - running hours

dition (scroll through the UP and DOWN):ive Alarmshrough the views, using the UPThe scrolling is continuous.mes up, the Status Display is

, 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 (without cooldown). When the unit is stopped with the STOP button in Remote mode, it will automatically go to Manual Mode.

Remote

Power

Alarm

Start/Stop

Qc1002 CAN145- 18 -

Alarm list LOG list Service Timer Battery Voltag Coolant tempe Oil pressure RPM (speed) Fuel level Voltage - frequ

in Alarm coninformation using a list of all act

It's possible to scroll tand DOWN buttons. If a Special status coshown. If an Alarm comes up

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.

Controller type and version display

This view shows the controller type and the ASWversion number.

Parameter display

This view shows a numgives access to them.

An overview is given i

Alarm list display

This view shows the number of active alarms andgives access to them.An overview is given in Alarm Display (pop-upwindow) on page 23.

Service timer 1 & Service timer 2 display

This view shows both Service timers. The servicetimer indication is shown when service time has runout. It can be removed by resetting the timers oracknowledging the Service timer indication.

cations count and give an alarm.

Timers can be done through the

display

Battery voltage and the running

Qc1002 CANv1.00.0

Para

Alarm List0 Alarm(s)

Service 1Service 2

59h59h

13.2 Vy- 19 -

ber of Parameter settings and

n Parameter list on page 21.

LOG list display

This view shows the alarm memory and gives accessto it.An overview is given in LOG list on page 24.

The service timer indiwhen value is reached

Resetting the Service Parameter display.

Battery Voltage

This view shows the hours.

meterLOG List

Batter00168.1h

Coolant temperature display

This view shows the Coolant temperature and therunning hours.See also Parameter list on page 21 for selectionbetween C and F.

Oil pressure disp

This view shows the hours.See also Parameter lbetween bar and psi.

Fuel level display

This view shows the Fuel level and the running hours.

Voltage - frequency - running hours display

Qc1002 Menu Description

Status Display (pop-up window)

In case special statuses are entered, a pop-up windowwill automatically be entered for as long as the statusis active.

n is not updated when the statusive.

tuses are:

62CWater00168.1h

Oil00168.1h

75%Fuel00168.1h- 20 -

lay

Oil pressure and the running

ist on page 21 for selection

This view shows the voltage, frequency and runninghours.

Engine speed display

This view shows the engine speed and running hours.

The background screepop-up window is act

These special sta4.0bar50Hz400V

00168.1h

1500RPM00168.1h

PREHEAT

START OFF/EXTENDED STOP TIMER

COOLDOWN

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

Parameter list

The Parameter Menu's A password will be achange a setting is abou2003).Menu's shown on the P

Running hours adju

This menu is used thours. The runninglowered.

Unit Type

Service Timer 2 res

Service Timer 1 res

These menus are usWhen a service acknowledged, theautomatically.

Diagnostic Menu

This menu is used to power up the engineelectronics without starting the engine. When thissetting is switched on, electric power will besupplied to the engine electronics after half aminute delay. The unit can not be started as longas this parameter is switched on.

Unit Menu

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

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

DIAGNOSTIC

Unit type 7- 21 -

are pre-programmed!sked for when an attempt tot to be done (user password =

arameter list LCD:

st

o adjust the amount of running hours can only be raised, not

et

et

ed to reset the service timers.timer alarm occurs and is service timer will be reset

Language selection

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

Generator Underfrequency: failclass, enable,delay, setpoint

Generator Overfrequency: failclass, enable, delay,setpoint

Generator Undervoltage: failclass, enable, delay,setpoint

Generator Overvoltage: failclass, enable, delay,setpoint

Engine CAN communication

This menu is used to select the type of engineelectronics, the Qc1002 controller shouldcommunicate with via the Canbus.

for QAS 125-150 Volvo!

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

Qc1002 CAN145

Parameter Running time

Unit type7

Unit type

Qc1002 CAN145- 22 -

Unit type

Alarm Display (pop-up window)

In case an Alarm occurs, a pop-up window willautomatically be displayed for as long as the alarm isactive, no matter which view is active. The flashingred alarm LED will light up. The alarm icons will beshown together with an acknowledgement check-box.Push the ENTER buttoWhen the alarm hasmarking will appear ialarm LED will light u

The Alarm Display canBACK button.

If more than one alarm through the alarm messpushbuttons. The newebottom of the list (meaat the display when a nIf one or more than onthe right of the display

Following general groups of Alarms exist:

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

Trip of GB: Warning actions + GeneratorContactor opens

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

Shutdown: Trip of GB actions + unit stopsimmediately

An alaracknowledproblem th

LOW FUEL LEVEL

LOW COOLANT LEVEL- 23 -

n to acknowledge the alarm. been acknowledged, a V-n the check-box and the redp continuously.

always be left by pushing the

comes up, it's possible to scrollages with the UP and DOWNst alarm will be placed at thening that the older alarm staysewer alarm comes up).e alarm is present, an arrow at will be shown.

List of possible alarms:

m should always beged before solving theat causes the alarm.

LOW OIL PRESSURE

HIGH COOLANT TEMPERATURE

CHARGING ALTERNATOR

GENERATOR OVERVOLTAGE

GENERATOR UNDER-VOLTAGE

GENERATOR OVER-FREQUENCY

GENERATOR UNDER-FREQUENCY

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 thetime of the event will be stored.

Remote start operation

Installation wirings:

X25.1 & X25.2 to be wired for the remote startswitch.

X25.3 & X25.4 to be wired for the remotecontactor (open/close).

Fail classes

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

according to one of these three

supervision of alarm (OFF).

pervision of alarm all the time

only supervision when theg (RUN).

SERVICE TIMER 1

SERVICE TIMER 2

ENGINE ALARM

EMERGENCY STOP

START FAILURE

STOP FAILURE

1 2- 24 -

All alarms are enabledstatuses:

disabled alarm, no

enabled alarm, su(ON).

running alarm, machine is runnin

1 Controller type2 Event number3 Event4 Running hours

Time: 00001h

EVENT LOG #04 WaterQc1002

3

4



A1 ....... Qc2002 di

F10......Fuse

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

H0 .......Panel light

S2 .......Emergency stop button

Push the button to stop the generator in caseof an emergency. When the button ispressed, it must be unlocked, before the

Qc2002 Module

le is located inside the control module will carry out allntrol and protect a generator,f the generator.

c2002 module can be used for

N

G

H0X25

S2

A1S20F10

L1L2OFF

L1-N

L2L3 L2-N

L3L1

LL LN

L3-N- 25 -

splay

generator can be restarted. The emergencystop button can be secured in the lockedposition with the key, to avoid unauthorizeduse.

S20 .....ON/OFF switch

Position O: No voltage is applied to theQc2002 module, the generator will notstart.Position I: Voltage is applied to theQc2002 module, it is possible to start upthe generator.

X25 .....Terminal strip

The Qc2002 modupanel. This controlnecessary tasks to coregardless of the use o

This means that the Qseveral applications.

13 Q1

L1 L2 L3 N PE

Pushbutton and LED functions



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

UP: Is used to scroll through the displaparam

DOWdisplaparam

BACKpop-upParamwithou

AUTOunit inoperat

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

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

n LED indicates that the unit is ered up.

n LED indicates that the 002 is in automatic operation.

n LED indicates that the 002 receives running back (via the W/L input, via the value at the Canbus, or via the requency).

n LED indicates that the ge and the frequency of the nator are within certain limits certain time. It will be possible ose the Generator Contactor in Island and in AMF mode), Mains contactor is open.

Qc2002 CAN145

G

Power

AlarmStart

Automatic

GeneratorContactor

MainsContactor

Stop- 26 -

y information and to adjust eter value upwards.

N: Is used to scroll through the y information and to adjust eter value downwards.

: Is used to leave the Alarm window, to leave the

eter list and to leave menu's t change.

MATIC: Is used to put the manual or automatic ion.

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

.

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

G

Power Greepow

Automatic GreeQc2

Start/Stop GreeQc2feedRPMAC f

Generator contactor

Greevoltaalterfor ato cl(bothif the

Qc2002 Menu Overview

At Qc2002, the LCD will show followinginformation:

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

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

Line voltages of the generator Controller type & version

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

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

Line voltages generator display

ine voltages of the generator.

and version display

controller type and the ASW

Mains contactor

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

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

400V400V400V

02 CAN1.00.1- 27 -

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

This view shows the l

Controller type

This view shows theversion number.

G L1-L2G L2-L3G L3-L1

Qc20

Parameter display

This view shows a number of Parameter settings andgives access to them.An overview is given in Parameter list on page 31.

Alarm list display

This view shows the gives access to them.An overview is givenwindow) on page 35.

LOG list display

This view shows the alarm memory and gives accessto it.An overview is given in LOG list on page 37.

Service timer 1 & Service timer 2

Battery voltage display

This view shows the Battery voltage and the runninghours.

RPM display

engine speed and the running

ature display

Coolant temperature and the

list on page 31 for selection

Parameter

Alar

LOG List 13.2 VBattery00168.1h

0

62C- 28 -

number of active alarms and

in Alarm Display (pop-up

display

This view shows both Service timers. The servicetimer indication is shown when service time has runout. It can be removed by resetting the timers oracknowledging the Service timer indication.The service timer indications count and give an alarmwhen value is reached.Resetting the Service Timers can be done through theParameter display.

This view shows thehours.

Coolant temper

This view shows therunning hours.See also Parameter between C and F.

m List0 Alarm(s)

Service 1Service 2

59h59h

RPM00168.1h

Water00168.1h

Oil pressure display

This view shows the Oil pressure and the runninghours.See also Parameter list on page 31 for selectionbetween bar and psi.

Fuel level displa

This view shows the Fu

kWh counter display

This view shows the kWh counter.

Power factor - frequency generator - frequency mains display

One line voltage - frequency - active power display

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

Active - reactive - apparent power

active, reactive and apparentr.

nt display

enerator current.

4.0barOil00168.1h

Fuel00168.1h

E 4860kWhG L1-L2G f L1P

400V50Hz80kW

80kW0kVAr80kVA

100A100A100A- 29 -

y

el level and the running hours.

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

display

This view shows thepower of the generato

Generator curre

This view shows the g

75%

PFG f L1M f L1

0.0050Hz50Hz P

QS

G I1G I2G I3

Phase voltages mains display

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

Line voltages mains display

This view shows the lonly shown in AMF m

Phase voltages g

This view shows the ph

Qc2002 Menu Description

Status Display (pop-up window)

In case special statuses are entered, a pop-up windowwill automatically be entered for as long as the statusis active.

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

M L1-NM L2-NM L3-N

230V230V230V

M L1-L2M L2-L3M L3-L1

G L1-NG L2-NG L3-N

DIAGNOSTIC- 30 -

ine voltages of the mains (isode).

enerator display

ase voltages of the generator.

The background screen is not updated when the statuspop-up window is active.

These special statuses are:

400V400V400V

230V230V230V

PREHEAT

START OFF/EXTENDED STOP TIMER

COOLDOWN

Parameter list

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

Menu's shown on the P

Genset mode

This menu is used to chIn the Qc2002 moduselected:

Island operation

This operation type is selected for local/remotestart applications, without the Mains (= stand-alone). Combined with Manual Operation mode =

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

Contactor/open Generator Contactor can beactivated manually.

Combined with Automatic Operation mode =Remote Start operation.

Automatic Mains Failure (AMF) operation

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

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

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

ll then go into cooldown and

s: we refer to circuit diagramor the correct connections.

o set the delay, how long theays energized (if present). If setlarm relay will stay energized

GensIsland

n Delay 20.0s 990.0s- 31 -

R button activates theich is shown at the display.

arameter list LCD:

ange the mode of the machine.le 2 application modes can be

The remote start signal can be given with anexternal switch. After the generator has beenstarted, the Generator Contactor will closeautomatically.

Installation wirings for Remote Start operation:wire the RS switch between X25.9 & X25.10.

Mains.

The generator wistop.

Installation wiring9822 0993 05/02 f

Horn delay

This menu is used tgeneral alarm relay stto 0.0s, the general acontinuously.

et Mode Island AMF

Hor0.0s

Running hours adjust

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

Service timer 2 reset

Service timer 1 res

These menus are usedWhen a service timacknowledged, the sautomatically.

Diagnostic menu

This menu is used to power up the engine electronicswithout starting the engine. When this setting isswitched on, electric power will be supplied to theengine electronics after half a minute delay. The unitcan not be started as long as this parameter is swiched

Language selection

Icons is the default factory set language, but 6 otherlanguages can be selected: English, French, German,Italian, Spanish and Cyrillic (Russian). Allinformation in the Parameter List display is always inEnglish.

unication

to select the type of enginec2002 controller should the Canbus.

Running TimeCur. 168 20000

St 2No

St 1No

DiagnosticsOff Off On

LanguageEnglish

e I CommOFF- 32 -

et

to reset the service timers.er alarm occurs and is

ervice timer will be reset

on.

Unit menu

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

Engine CAN comm

This menu is used electronics, the Qcommunicate with via

Reset No Yes

Reset No Yes

UnitC/bar C/bar F/psi

Engin

MF high frequency

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

MF low frequency

This menu is used to smains frequency, in %AMF-Auto).

M frequency delay

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

MF high voltage

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

MF low voltage

set the minimum limit for thef the nominal voltage (in AMF-

et the delay, which defines how has to be back within the limitsitched from generator to mains

). During this delay, the Mains

MF high freq100% 110 120%

MF l80%

M freq delay10s 30 9900s

MF high volt100% 110 120%

low volt 90 100%

olt delay 30 9900s- 33 -

et the minimum limit for the of the nominal frequency (in

MF frequency delay

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

This menu is used tomains voltage, in % oAuto).

M voltage delay

This menu is used to slong the mains voltagebefore there will be swagain (in AMF-AutoLED flashes in green.

ow freq 90 100% MF freq delay

1.0s 2.0 990.0s

MF80%

M v10s

MF voltage delay

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

Overvoltage enable

Overvoltage failcla

Overvoltage delay

Overvoltage setpoint

Undervoltage delay

Undervoltage setpoint

able

ilclass

MF volt delay1.0s 2.0 990.0s

> VoltEnable e

> Volt warning w

> Volt Delay0 1 99

> Volt SP

< Volt Delay0 1 99

< Volt SP450 999

enableenable disable

FCwarning shutdown- 34 -

ss

Undervoltage enable

Undervoltage failclass

Overfrequency en

Overfrequency fa

enablenable disable

FCarning shutdown

0 450 999

< Volt enableEnable enable disable

< Volt FCwarning warning shutdown

0

> FreqEnable

> Freqwarning

Overfrequency delay

Overfrequency setpoint

Underfrequency en

Underfrequency fa

Underfrequency delay

Underfrequency setpoint

Alarm Display (pop-up window)

In case an Alarm occurs, a pop-up window willautomatically be displayed for as long as the alarm isactive, no matter which view is active. The flashingred alarm LED will light up. The alarm icons will beshown together with an acknowledgement check-box.

ton to acknowledge the alarm.s been acknowledged, a V-in the check-box and the red

up continuously.

n always be left by pushing the

comes up, it's possible to scrollssages with the UP and DOWNest alarm will be placed at theaning that the older alarm staysnewer alarm comes up).ne alarm is present, an arrow aty will be shown.

> Freq Delay0 1 99

> Freq SP0

< FreqEnable e

< Freq warning w

< Freq Delay0 1 99

< Freq SP

rm should always beedged before solving the that causes the alarm. - 35 -

able

ilclass

Push the ENTER butWhen the alarm hamarking will appear alarm LED will light

The Alarm Display caBACK button.

If more than one alarmthrough the alarm mepushbuttons. The newbottom of the list (meat the display when a If one or more than othe right of the displa

38 70

enablenable disable

FCarning shutdown

0 38 70

An alaacknowlproblem

Following general groups of Alarms exist:

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

Trip of GB: Warning actions + GeneratorContactor opens

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

Shutdown: Trip of GB actions + unit stopsimmediately

List of possible alaz

LOW OIL PRESSURE

HIGH COOLANT TEMPERATURE

CHARGING ALTERNATOR

LOW FUEL LEVEL

LOW COOLANT LEVEL

SERVICE TIMER 1

SERVICE TIMER 2- 36 -

rms:GENERATOR OVERVOLTAGE

GENERATOR UNDER-VOLTAGE

GENERATOR OVER-FREQUENCY

GENERATOR UNDER-FREQUENCY

ENGINE ALARM

EMERGENCY STOP

START FAILURE

STOP FAILURE

LOG list

The unit will keep an event log of the latest 30 events.Events are:

shutdowns

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

Fail classes

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

All alarms are enabled according to one of these threestatuses:

disabled alarm, no supervision of alarm (OFF).

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

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

HZ/V FAILURE

OIL LEVEL

OIL TEMPERATURE

1 2- 37 -

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

Time: 27/6 14:27

EVENT LOG #04 WaterQc2002

4

3



A2 ....... Qc4002 di

F10......Fuse

The fuse (10 A) activates when the currentfrom the battery to the engine control circuitexceeds its setting. The fuse can be reset bypushing the button.

S2 .......Emergency stop button

Push the button to stop the generator in caseof an emergency. When the button ispressed, it must be unlocked, before thegenerator can be restarted. The emergencystop button can be secured in the locked

X25 .....Connection block

Inside the cubicle. Allows customerconnections.

X30 .....Connector X30

Connector for communication with othergenerators with Qc4002 when paralleling.

X31 .....Connector X31

or communication with otherith Qc4002 when paralleling.

X32

or PMS communication withators with Qc4002 when

X25 X32S11S2

X30 X31

A2 S20 F10

0 I

S20S11

A2

N

X30 X31

X2

50Hz 60Hz

F10

Qc4002

G

!

OK

LOG

Refer to circuit diagram for thecorrect connection.- 38 -

splay

position with the key, to avoid unauthorizeduse.

S11 .....Frequency selector switch (50 Hz/60 Hz)

Allows to choose the frequency of the outputvoltage: 50 Hz or 60 Hz.

S20 .....ON/OFF switch

Position O: No voltage is applied to theQc4002 module, the generator will notstart.Position I: Voltage is applied to theQc4002 module, it is possible to start upthe generator.

Connector fgenerators w

X32 .....Connector

Connector fother generparalleling.

13

X1

Q2

Changing the output frequency isonly allowed after shutdown.

Qc4002 module

The Qc4002 modulepanel, and communicain front of the control pcarry out all necessarygenerator, regardless o

This means that the Qc4several applications.

Pushbutton and LED functions


www.a

tlasco

pco.c

om

Qc400

2

!

OK

LOG

INFO: Shifts the display 3 lower lines to show the alarm list.

JUMP: Enters a specific menu number selection. All settings have a

MB: Manual activation of close breaker and open breaker sequence if SEMI-AUTO is selected.

VIEW: Shifts the first line displaying in the setup menus.

LOG: Displays the LOG SETUP window where you can choose

een the Event, Alarm and Battery . The logs are not deleted when auxiliary supply is switched off.

CK: Jumps one step backwards in menu (to previous display or to the y window).

DE: Changes the menu line (line n the display to mode selection.

: Is used to select the underscored y in the fourth line of the display.- 39 -

is located inside the controltes with a display unit, locatedanel. This control module will tasks to control and protect af the use of the generator.

002 module can be used for

G specific number attached to them. The JUMP button enables the user to select and display any setting without having to navigate through the menus.

START: Start of the gen-set if SEMI-AUTO or MANUAL is selected.

STOP: Stop of the gen-set if SEMI-AUTO or MANUAL is selected.

GB: Manual activation of close breaker and open breaker sequence if SEMI-AUTO is selected.

G

betwlogsthe

BAthe entr

MO4) i

SELentr


UP: Increases the value of the selected set point (in the setup menu). In the daily use display, this button function is used for scrolling the View lines in V1 or the second line (in the setup menu) displaying of generator values.

DOWN: Decreases the value of the selected set point (in the setup menu). In the daily use display, this button function is used for scrolling the View lines in V1 or the second line (in the setupvalue

LEFmano

RIGHmano

1 Alarm LED flashing indicates that

Qc4002

G

!

OK

LOG

5

1

6 7 8

234

10

9

7 (GB) ON LED green light indicates that the generator breaker is closed.LED yellow light indicates that the generator breaker has received a command to close on a black BUS, but the breaker is not yet closed due to interlocking of the GB.LED is flashing orange if the Spring load time signal from the breaker is missing.

8 (MB) ON LED indicates that the mains breaker is closed.

is green, if the mains is present OK. is red at a measured mains re. is flashing green when the mains

rns during the mains OK delay . indicates that auto mode is

cted.- 40 -

menu) displaying of generator s.

T: Moves the cursor left for euvring in the menus.

T: Moves the cursor right for euvring in the menus.

unacknowledged alarms are present.LED fixed light indicates that ALL alarms are acknowledged.

2 Power LED indicates that the auxiliary supply is switched on.

3 Self check OK

LED indicates that the self check is OK.

4 Alarm inhibit

Please refer to Alarm inhibit in the chapter Additional functions.

5 Run LED indicates that the generator is running.

6 Generator voltage

LED green light indicates that the voltage/frequency is present and OK.

9 Mains voltage

LEDand LEDfailuLEDretutime

10 Auto LEDsele

The main Qc4002 control unit includes 5 LEDs

Qc4002 menu overview

Main View

The display has 4 different lines. The information onthese lines can change, depending on which view isused. There are 4 different main views possible:SETUP / V3 / V2 / V1.

Setup view

V2 view

V1 view

ough these views with the scroll

shows the module name, thethe date and the time.

ws the application type and theenerator measurements. Duringthe V3 view will show a the first line.

shows some generator

user can scroll up and down to screens showing differentthe generator, the bus and the

1 Power Greensuppl

2 Self check OK

GreenOK.

3 Alarm inhibit

Greeninput

4 CAN 25 CAN 1

32

1

5

4- 41 -

V3 view

The user can scroll thrbuttons:

The SETUP viewsoftware version,

The V3 view shomode, and some gsynchronisation synchronoscope in

The V2 viewmeasurements.

In the V1 view the15 configurablemeasurements of Mains.

LED indicates that the voltage y is switched on. LED indicates that the unit is

LED indicates that the inhibit is ON.

SETUP menu

The control and protection parameters can beprogrammed according the application. This can bedone by scrolling through the setup menu to theappropriate parameter. Each parameter has a specificchannel number and is listed in one of the 4 mainSETUP menus:

Protection Setup (PROT): Channels from 1000 to1999 (steps of 10).

Control Setup (CTRL): Channels from 2000 to2999 (steps of 10).

Input/Output Setup5999 (steps of 10).

System Setup (SYSup (steps of 10).

If you select SETUP th

The fourth line is the system. If the SEL bindicated with an unde

If PROT is selected, the following view will appear(example of parameter):

For a protective function the first entry shows theThe user can scroll to these choices and select onechoice with the SEL button.

P the following view will be

ENA ENABLE, the alarm can be activated or deactivated. ON means always activated, RUN means that the alarm has run status. This means it is activated when the running signal is present.

FC FAIL CLASS, when the alarm occurs the unit will react depending on the selected fail class.- 42 -

(I/O): Channels from 3000 to

T): Channels from 6000 and

en you get the following view:

entry selection for the Menuutton is pressed, the menu

rscore will be entered.

Generator reverse power (G-P>1) setting.

Scrolling down will give all the protectionparameters:

The first line shows some generator data.

The second line shows the channel number andthe name of the parameter.

The third line shows the value of a set point of thisparameter.

The fourth line shows the different possible setpoints. In this example:

After selection of Svisible:

SP SET POINT, the alarm set point is adjusted in the set point menu. The setting is a percentage of the nominal values.

DEL DELAY, the timer setting is the time that must expire from the alarm level is reached until the alarm occurs.

OA OUTPUT A, a relay can be activated by output A.

OB OUTPUT B, a relay can be activated by output B.

If the correct password is entered, the following viewappears:

Now the user can change the SP of parameter G-P>1. This can be donethe user has to select STo exit the user has to ptimes, until the main vi

The JUMP button

Instead of navigating through the entire menu, theuser can jump directly to the required parameter, if heknows the channel number of that specific parameter.If the JUMP button is pushed the password view willappear. Not all parameters can be changed by the end-user. The required password level for each parameteris given in the set point list.The following menus can only be reached using theJUMP button:

9000 Software version- 43 -

with the scroll buttons. ThenAVE to save the new settings.ress the BACK button severalew appears.

9020 Service port

911X User password

Level 2 and Level 3 passwords can only be setthrough the Atlas Copco Utility Software PCSoftware.

9120 Service menu

9130 Single/Split/Three phase

9140 Angle comp. BB/GUse the UP and DOWN buttons to change the settingsand the SEL button to store the new setting.

This is the described menu flow:

The menu flow is simil

Qc4002 v1.00.0Qc4002 v1.00.02007-01-02 16:08:11SETUP MENUSETUP V3 V2 V1

G 0,00I PF 0kWG 0,00I PF 0kWI-L1 0APROTECTION SETUPPROT CTRL I/O SYST

G 0,00I PF 0kWG 0,00I PF 0kWI-L1 0ACONTROL SETUPPROT CTRL I/O SYST

G 0,00I PF 0kWG 0,00I PF 0kW

G 0,00I PF 0kWG 0,00I PF 0kW1000 G -P> 1Set point -5,0%LIM DEL OA OB ENA FC

G 0,00I PF 0kWG 0,00I PF 0kW1010 G -P> 2Set point -20,0%LIM DEL OA OB ENA FC

G 0,00I PF 0kWG 0,00I PF 0kWCONTROL SETUPSYNCHRONISE SETUPSYNC REG

G 0,00I PF 0kWG 0,00I PF 0kWCONTROL SETUPREGULATION SETUPSYNC REG

G 0,00I PF 0kW

G 0,00I PF 0kWG 0,00I PF 0kWENTER PASSWORD 1999

ENTER

G 0,00I PF G 0,00I PF 0kW1001 G -P> 1001 G -P> 1-50,0 -5,0 -50,0 -5,0 0,0%RESET RESET SAVE

PARAMETERS 1000 1999



For more - 44 -

ar in the CONTROL SETUP, I/O SETUP and SYSTEM SETUP.

I-L1 0AINPUT/OUTPUT SETUPPROT CTRL I/O SYST

G 0,00I PF 0kWI-L1 0ASYSTEM SETUPPROT CTRL I/O SYST

INPUT/OUTPUT SETUPBINARY INPUT SETUPBIN AIN OUT

G 0,00I PF 0kWG 0,00I PF 0kWINPUT/OUTPUT SETUPANALOGUE INPUT SETUPBIN AIN OUT

G 0,00I PF 0kWG 0,00I PF 0kWINPUT/OUTPUT SETUPOUTPUT SETUPBIN AIN OUT

G 0,00I PF 0kWSYSTEM SETUPGENERAL SETUPGEN MAINS COMM PM

G 0,00I PF 0kWSYSTEM SETUPMAINS SETUPGEN MAINS COMM PM

G 0,00I PF 0kWG 0,00I PF 0kWSYSTEM SETUPCOMMUNICATION SETUPGEN MAINS COMM PM

G 0,00I PF 0kWG 0,00I PF 0kWSYSTEM SETUPPOWER MANAG. SETUPGEN MAINS COMM PM








details on the Setup menu we refer to the Qc4002 User Manual.

Languages

English is the default language ex-factory.

Passwords

Changing different parameters requires differentpassword levels. Some parameters cannot be changedby the end-customer because of safety reasons.

There are 4 different password levels:

No password

User password (default setting 2003)

Service password

Master password

Once the password hachange all the accessibThe user can change JUMP button to channe

Changing param

Consult the Qc4002level parameters, whpassword "2003".

In order to receive theunit, please contact Atl

Fail Classes

All the activated alarms of the module are configuredwith a fail class. The fail class defines the category ofthe alarm and the subsequent action.6 different fail classes can be used:Engine running:

Alarm: Alarm Horn Relay, Alarm Display.

Warning: Alarm Horn Relay, Alarm Display.

Trip of GB: Alarm Horn Relay, Alarm Display,GB Trip.

Engine stopped:

Alarm: Block engine start.

Warning: -

Trip of GB: Block engine start, Block GBsequence.

Trip & Stop: Block engine start, Block GBsequence.

Shutdown: Block engine start, Block GBsequence.

Trip of MB: Block MB sequence.bled or enabled as following:

rm, inactive supervision.

.- 45 -

s been entered, the user canle set points.the User password (go withl 9116).

eters

user manual for all customerich can be accessed using

default parameters for youras Copco Service staff.

Trip & Stop: Alarm Horn Relay, Alarm Display,(Deload), GB Trip, Gen-Set cooling down, Gen-Set stop.

Shutdown: Alarm Horn Relay, Alarm Display,GB Trip, Gen-Set stop.

Trip of MB: Alarm Horn Relay, Alarm Display,MB Trip.

All alarms can be disa

OFF: disabled ala

ON: enabled alarm

Standard modes

The unit has four different running modes and oneblock mode. The required mode can be selected viathe MODE puhbutton. Repeat pushing the buttonuntil the required mode appears on the display, thenpress SEL to select or BACK to cancel.

This screen appears when pressing the MODEpuhbutton.

Auto mode

In this mode the Qc40the circuit breakers (gebreaker MB) automoperational state.

Semi-Auto mode

In semi-auto mode thsequences. This can functions, modbus comstarted in semi-automaat nominal values.

Test mode

Enables the user to test the generator on a regularbasis. The generator will follow a predefinedsequence of actions.In this mode it is possible to perform the followingtests:

Simple test

Load test

Full test

Block mode

When the block mode is selected, the unit is lockedfor certain actions. This means that it cannot start thegen-set or perform any breaker operations.To change the running mode from the display, theuser will be asked for a password before the changecan be made. It is not possible to select block modewhen running feedback is present.The purpose of the block mode is to make sure thatthe gen-set does not start for instance duringmaintenance work. If the digital inputs are used to

it is important to know that thelock mode is a constant signal.e unit is in a blocked state, andrns to the mode it was in beforeted.- 46 -

02 controls the gen-set andnerator breaker GB and mainsatically according to the

e operator has to initiate allbe done via the pushbuttonmands or digital inputs. Whentic mode, the gen-set will run

Manual mode

When manual mode is selected, the gen-set can becontrolled with digital inputs.

change the mode, theninput configured to bSo, when it is ON thwhen it is OFF, it retublock mode was selecMAN mode cannot be selected,

when AUTO mode is selected. To gofrom AUTO to MAN it is necessaryto go to SEMI-AUTO to make MANavailable.

Diagnostics menu

This diagnostics menu can be entered via channel6700. This menu is used for engine diagnosticssituations.If diagnostics is selected in this menu, the fuelsolenoid relay output will be de-energized for 30seconds (to make sure that the unit is completelystopped), and then gets energized again. Then enginediagnostics can take place.

To leave this status, disable diagnostics in channel6700, or press stop, or start the machine (not duringthe first 30 s).

Standard applications

In the Qc4002 module 9 application types can beselected. A combination of each application type withthe running mode results in a specific application.

Island operation

This application is possible in combination withSEMI-AUTO mode or AUTO mode. The internal realtime clock timer can only be used in AUTO This operation type is selected for installations withone or more generators, but always without the Mains(= stand-alone). In practice up to 16 generators can beinstalled in parallel.

Installation wirings

Terminals X25.10/X25.11 have to be linked. Theeds a feedback signal from theB. In Island mode there is no. In this case the MB opened with this link.

g lines have to be wired to thentrol module inputs. Place

> X25.3> X25.4> X25.5 X25.6

er cables between GB and load)

operation:itch between X25.9 & X25.10.

plications with other generators:ng to set up generator for

It's onlygenerator

Gen-set mode Running modeAuto Semi Test Man Block

Automatic Mains Failure (no back sync.)

X (X) X X X

Automatic Mains Failure (with back sync.)

X (X) X X X- 47 -

Depending on the application the user has to connectextra wirings to terminal blocks X25. These terminalblocks can be found inside the control box on a DIN-rail. We refer to the circuit diagram 9822 0993 09/00for the correct connections.

module always neMains Breaker MMB in the systemsignal is simulated

The busbar sensincorresponding cobridge between: X25.33 (L1) = X25.34 (L2) = X25.35 (L3) = X25.36 (N) =>

(The busbar = pow

For Remote Start wire the RS sw

For Paralleling ap See Paralleli

paralleling.

possible to start the when Normal is selected.

Island operation X X X XFixed power/base load X X X X XPeak shaving X X X X XLoad take over X X X X XMains power export X X X X XMultiple gen-sets, load sharing

X X X X

Multiple gen-sets, power management

X (X) X X X

Automatic Mains Failure (AMF) operation

This application is only possible in combination withthe AUTO mode. If the SEMI-AUTO mode isselected the AMF operation will NOT function!The unit automatically starts the gen-set and switchesto generator supply at a mains failure after anadjustable delay time.

AMF no back synchronisation:

When the mains returns, the unit will switch backto mains supply and cool down and stop the gen-set. The switching without back synchMains OK delay h

AMF with back syn

When the mains retthe mains breaker tOK delay has expdown and stops.

Installation wiring

The link betweenremoved.

Mains breaker feedX25.10/X25.11/X2

Mains breaker control lines have to be wired toX25.13/X25.14/X25.15/X25.16. These terminalsare voltage free contacts. The power for the MBhas to be supplied by the customer (24 Vdc/230 Vac) (max. contact rating K11, K12 = 250 V/16 A).

The Mains sensing lines L1/L2/L3/N have to bewired to terminals X25.3/X25.4/X25.5/X25.6.

Make sure the connections between X25.33 &X25.3; X25.34 & X25.4; X25.35 & X25.5;X25.36 & X25.6 are removed.


The link between X25.10/X25.11 has to beremoved.

Mains breaker feedback lines have to be wired toX25.10/X25.11/X25.12.


g lines L1/L2/L3/N have to be X25.3/X25.4/X25.5/X25.6.

nnections between X25.33 && X25.4; X25.35 & X25.5;re removed.

r lines have to be wired tod X25.22 (GND).

s for paralleling set up (see- 48 -

back to mains supply is doneronisation when the adjustedas expired.

chronisation:

urns, the unit will synchroniseo the busbar when the Mainsired. Then the gen-set cools

s

X25.10/X25.11 has to be

back lines have to be wired to5.12.

If back synchronisation is enabled, all settings forparalleling set up (see Paralleling) must beverified also.

Peak Shaving (PS) operation

This application is normally used in combination withthe AUTO mode. Installation with the Mains.The generator will start up when the mains importedpower (measured through an optional PowerTransducer = PT) exceeds a defined level. Thegenerator will synchronise with the bus, and will takeload until the defined allowable mains importedpower level is reached.When the mains imported power decreases below thedefined mains imported power level for a definedtime, the generator will unload and disconnect fromthe bus. Then the generator will go into cool down.

The Mains sensinwired to terminals

Make sure the coX25.3; X25.34 X25.36 & X25.6 a

Power TransduceX25.21 (input) an

Verify all settingParalleling).

Fixed Power (FP) operation

This application is possible in combination withSEMI-AUTO mode or AUTO mode. Normally it isused in combination with SEMI-AUTO mode ininstallations with the Mains. The internal real timeclock timer can only be used in AUTO mode.

The generator will deliver a defined fixed power tothe load or to the Mains.


The link between X25.10/X25.11 has to beremoved.

Mains breaker feedX25.10/X25.11/X2

Mains breaker conX25.13/X25.14/X2are voltage free cohas to be supplie230 Vac) (max. con16 A).

The Mains sensingwired to terminals X

Make sure the conX25.3; X25.34 &X25.36 & X25.6 ar

Verify all settingsParalleling).

Load Take Over (LTO) operation

This application is normally used in combination withSEMI-AUTO mode or AUTO mode in installationswith the Mains.The purpose of the load take over mode is to transferthe load imported from the mains to the gen-set foroperation on generator supply only.The generator will start-up, synchronise and take overthe load from the Mains gradually, before opening theMains Breaker. To know if the load is completelytaken over from the mains, an optional Power


Power Transducer lines have to be wired toX25.21 (input) and X25.22 (GND).

Verify all settings for paralleling set up (seeParalleling).

Mains power export (MPE) operation

This application is possible in combination withSEMI-AUTO mode or AUTO mode. The internal real

only be used in AUTO mode. Mains.xport mode can be used tovel of power through the mainsan be exported to the mains orains, but always at a constant

s

X25.10 & X25.11 has to be

dback lines have to be wired to25.12.- 49 -

back lines have to be wired to5.12.

trol lines have to be wired to5.15/X25.16. These terminalsntacts. The power for the MBd by the customer (24 Vdc/tact rating K11, K12 = 250 V/

lines L1/L2/L3/N have to be25.3/X25.4/X25.5/X25.6.

nections between X25.33 & X25.4; X25.35 & X25.5;e removed.

for paralleling set up (see

Transducer is necessary.


The link between X25.10 & X25.11 has to beremoved.

Mains breaker feedback lines have to be wired toX25.10/X25.11/X25.12.



time clock timer canInstallation is with theThe mains power emaintain a constant lebreaker. The power cimported from the mlevel.

Installation wiring

The link betweenremoved.

Mains breaker feeX25.10/X25.11/X




Power TransducerX25.21 (input) and

Verify all settingsParalleling).

Multiple gen-set

In this application the active and reactive loanominal power. The logen-set is running in ibreaker is closed.

Multiple gen-sets with power management (PMS)

PMS (= Power Management System) is a system thatwill automatically start & stop generators based onthe actual load dependency. This will be done througha PMS communication between the different unitsconnected.PMS applications are always in combination withAUTO mode. If the SEMI-AUTO mode is selected,the PMS operation will NOT function! TheQc4002 controllers from the gensets need to be

Installations are possible with stand-alone generatorsor with the Mains (extra Qc4002 Mains is thenneeded). A number of Qc4002 units are being usedin the power management application, i.e. one foreach mains breaker (Qc4002 mains controller), ifinstalled, and on

Documents

2954 2960 03_QAS 125-150_EN