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Atlas Copco QAS 250-330 JD T4i Instruction Manual Download Page 71

- 71 -

Mark

F1,,5
G3
K11
K12
K13
N12
P1-3
P4
Q1,1
Q1,2
Q2
Q3
Q4
Q5
R5
R11
S2b
S4
S10
T1,3
X1
X2
X3
X4
X5
X7
X25
Sx
Kx

Name

Fuse 4A
Alternator
Aux, relay (lower volt,)
Aux, relay (higher volt,)
Contactor
Automatic Voltage Regulator
A-Meters
V-meter
Circuit breaker      3pole
Circuit breaker      1pole
Circuit breaker      1pole
Circuit breaker      2pole
Circuit breaker      2pole
Circuit breaker      2pole
Coolant Heater
Voltage Adjustnent Potmeter
Emergency stop (S2a see Engine Circ.)
Voltmeter change-over switch
Supply voltage switch
Current transforner
Terminal board
Socket outlet
Socket outlet
Socket outlet
Socket outlet
Flanged inlet
Terminal strip
Remote Start/Stop
Contactor Generator Ready
(15s. Delayed)

Summary of Contents for QAS 250-330 JD T4i

Page 1: ...QAS 250 330 JD T4i Instruction Manual for AC Generators English ...

Page 2: ......

Page 3: ...COPCO PORTABLE ENERGY DIVISION www atlascopco com Printed matter Nr 1310 3012 57 03 2012 QAS 250 330 JD T4i Instruction Manual for AC Generators Instruction manual 5 Circuit diagrams 65 Original instructions ...

Page 4: ...r s approval in writing Neglecting maintenance or making changes to the setup of the machine can result in major hazards including fire risk While every effort has been made to ensure that the information in this manual is correct Atlas Copco does not assume responsibility for possible errors Copyright 2012 Atlas Copco Compressors LLC RockHill SC USA Any unauthorized use or copying of the contents...

Page 5: ...oltmeter P4 49 Checking ammeters P1 P2 and P3 49 Engine troubleshooting 49 Alternator troubleshooting 50 Options available for QAS 250 330 John Deere units 51 Circuit diagrams 51 Overview of the electrical options 51 Description of the electrical options 51 Overview of the mechanical options 53 Desciption of the mechanical options 53 Technical specifications 54 Technical specifications for QAS 250...

Page 6: ...authorized 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 precauti...

Page 7: ... 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 ma...

Page 8: ...l 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 an...

Page 9: ...g 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 Disco...

Page 10: ...yte 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 a...

Page 11: ... V 3 phase 240 V 3 phase and 240 V 1 phase The QAS 250 330 generator is driven by a water cooled diesel engine manufactured by John Deere An overview of the main parts is given in the diagram below 1 Lifting beam 2 Guiding rod 3 Side doors 4 Engine exhaust 5 Data plate 6 Door access to control and indicator panel 7 Output terminal board 8 Hole for forklift 9 Coolant filler access DH Drain and acce...

Page 12: ...upling DFO Drain flexible engine oil E Engine F Fan FC Fuel Cooler FCO Filler cap engine oil FCW Filler cap cooling water FF Fuel filter G1 Battery I Intercooler OF Oil filter OLD Engine oil level dipstick PF Pre Filter S1 Battery switch ...

Page 13: ...me 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 en...

Page 14: ...y F10 Fuse The fuse activates when the current from the battery to the engine control circuit exceeds its setting The fuse can be reset by pushing the button H0 Panel light S2 Emergency stop button Push the button to stop the generator in case of an emergency When the button is pressed it must be unlocked before the generator can be restarted The emergency stop button can be secured in the locked ...

Page 15: ... 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 withou...

Page 16: ...on page 18 Alarm list display This view shows the number of active alarms and gives access to them An overview is given in Control and indicator panel Qc1002 on page 14 LOG list display This view shows the alarm memory and gives access to it An overview is given in LOG list on page 21 Service timer 1 Service timer 2 display This view shows both Service timers The service timer indication is shown ...

Page 17: ... This view shows the DPF mode selected When AUTO is selected the DPF will regenerate automatically When OFF is selected regeneration is disabled When ON is selected manual regeneration is partially enabled see STATION REGEN It is highly recommended that the genset be left in the AUTO mode at all times to prevent engine de rate and possible shutdown due to high soot level Station Regen Stationary o...

Page 18: ...e 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 ot...

Page 19: ... 19 This is the described menu flow for changing the unit type ...

Page 20: ... 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 ...

Page 21: ...PN51 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 ...

Page 22: ...o change the selection to ON and press the enter button Go to the DPF screen For normal operation this should be in the AUTO mode Press the enter button Use the up or down arrow to change the selection to ON and press the enter button This will set the unit up for regeneration after a few moments the regeneration icon should appear confirming the unit is regenerating Upon completion of the station...

Page 23: ...er Enable auto filter cleaning to allow a cleaning cycle OR Begin a manual cleaning Exhaust Filter and Warning Indicators Active when Machine performance is reduced due to moderately high soot level Warning will be present on controller Begin a manual cleaning Exhaust Filter and Stop Indicators Active when Exhaust filter requires service Machine performance is reduced due to Extremely High soot le...

Page 24: ...with other generators with Qc4002 when paralleling X31 Connector X31 Connector for communication with other generators with Qc4002 when paralleling X32 Connector X32 Connector for PMS communication with other generators with Qc4002 when paralleling Qc4002 module The Qc4002 module is located inside the control panel and communicates with a display unit located in front of the control panel This con...

Page 25: ...FT Moves the cursor left for manoeuvring in the menus RIGHT Moves the cursor right for manoeuvring in the menus 1 Alarm LED flashing indicates that 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 in...

Page 26: ... Setup SYST Channels from 6000 and up steps of 10 If you select SETUP then you get the following view The fourth line is the entry selection for the Menu system If the SEL button is pressed the menu indicated with an underscore will be entered If PROT is selected the following view will appear example of parameter For a protective function the first entry shows the Generator reverse power G P 1 se...

Page 27: ... to the required parameter if he knows the channel number of that specific parameter If the JUMP button is pushed the password view will appear Not all parameters can be changed by the end user The required password level for each parameter is given in the set point list The following menus can only be reached using the JUMP button 9000Software version 9020Service port 911XUser password Level 2 an...

Page 28: ... 28 This is the described menu flow The menu flow is similar in the CONTROL SETUP I O SETUP and SYSTEM SETUP For more details on the Setup menu we refer to the Qc4002 User Manual ...

Page 29: ...g modes and one block mode The required mode can be selected via the MODE puhbutton Repeat pushing the button until the required mode appears on the display then press SEL to select or BACK to cancel This screen appears when pressing the MODE puhbutton Auto mode In this mode the Qc4002 controls the gen set and the circuit breakers generator breaker GB and mains breaker MB automatically according t...

Page 30: ...a mains failure after an adjustable delay time AMF no back synchronisation When the mains returns the unit will switch back to mains supply and cool down and stop the gen set The switching back to mains supply is done without back synchronisation when the adjusted Mains OK delay has expired AMF with back synchronisation When the mains returns the unit will synchronise the mains breaker to the busb...

Page 31: ... to be wired to X25 13 X25 14 X25 15 X25 16 These terminals are voltage free contacts The power for the MB has 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 be wired 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 Power Transducer l...

Page 32: ...kW 100 kW G3 will be stopped G1 G2 are running at 200 kW 500 kW 200 kW 100 kW G2 will be stopped The priority on starting stopping the generators can be chosen on priority settings or on the amount of running hours In manual mode the start stop sequence is determent by the chosen priority between the generators The generator with the lowest priority will start as the latest genset and will stop as...

Page 33: ...ly with Power Transducer Fixed Power SEMI AUTO mode AUTO mode Load Take Over SEMI AUTO mode Only with Power Transducer AUTO mode Only with Power Transducer Mains Power Export SEMI AUTO mode Only with Power Transducer AUTO mode Only with Power Transducer Application type Mode Comments Island operation SEMI AUTO mode Manual paralleling between generators AUTO mode Remote paralleling between generato...

Page 34: ... AUTO mode PMS Qc4002 Mains module 1 Each installation has to be prepared and reviewed very carefully before start up Wrong or incomplete wirings can damage the installation brutally 2 Each application requires a specific combination of the following parameters Auto Semi auto Test Manual Block mode Island AMF PS FP LTO MPE PMS application type in AUTO mode PS FP LTO can be combined with AMF Back s...

Page 35: ... L1 L2 L3 N neutral and PE earthing behind a small transparent door Battery switch The battery switch is situated inside the sound insulated bodywork It allows to open or to close the electrical connection between the battery and the engine circuits Spillage free frame A spillage free frame with forklift slots allows the customer to transport the generator easily with a forklift It avoids accident...

Page 36: ...e end of the earthing rod is connected to the earth terminal In your own interest always strictly observe all relevant safety instructions Do not operate the generator in excess of the limitations mentioned in the Technical Specifications Local rules concerning the setting up of low voltage power installations below 1000 V must be respected when connecting site distribution panels switch gear or l...

Page 37: ...equired will vary depending upon the engine s power category duty cycle and operating conditions engine oil ash content and fuel quality The exhaust filter s dash lamp indicator or the dignostic codes will indicate when the DPF needs ash removal service The removal of DPF ash must be done by removing the DPF from the machine and placing it into specialized equipment Do not remove ash by using wate...

Page 38: ...or of 0 80 are respectively 2 5 mm and 144 m In case electric motors must be started oversizing the cable is advisable The voltage drop across a cable can be determined as follows e Voltage drop V I Rated current A L Length of conductors m R Resistance km to VDE 0102 X Reactance km to VDE 0102 Connecting the load Site distribution panel If outlet sockets are provided they must be mounted on a site...

Page 39: ...p if necessary It is recommended to fill the tank after the day s operation to prevent coolantdamp in a nearly empty tank from condensing Check the vacuum indicator of the air filter If the red part shows completely replace the filter element Press the vacuator valve of the air filter to remove dust Check the generator for leakage tightness of wire terminals etc Correct if necessary Check that cir...

Page 40: ...sumption of the engine could occur Check by means of the generator gauges that the voltage between the phases is identical and that the rated current in the third phase L3 is not exceeded When single phase loads are connected to the generator output terminals keep all loads well balanced If circuit breakers are activated during operation switch off the load and stop the generator Check and if nece...

Page 41: ...oil consumption of the engine could occur It is recommended to operate the generator at full load capacity immediately after any low load operating period When single phase loads are connected to the generator output terminals keep all loads well balanced If circuit breaker Q1 1 trips off during operation switch off the load and stop the generator Check and if necessary decrease the load The gener...

Page 42: ...k oil and coolant level x x x Check coolers x x x Clean coolers externally x x x Check condition of cooling fan assembly x x x Drain water in fuel filter x x x Clean air cleaner and dust bowl x x x Check electrolyte level and terminals of battery x x Check oil and coolant level x x Check tension and condition of the drive belt x x Check conditions of the engine drive belts 1 x x Grease door hinges...

Page 43: ...replace the coolant filter on the engine 5 When opening the rocker cover it is necessary to replace the gasket This gasket can be ordered with AC partnumber 2914 9852 00 Valve Clearance Inlet 0 20 0 05 mm Exhaust 0 50 0 05 mm Control and adjustment of valve clearance is done with an engine oil temperature between 20 C 80 C Measure alternator insulation resistance x x Check glycol level in coolant ...

Page 44: ... oil specifications High quality mineral hydraulic or synthesized hydrocarbon oil with rust and oxidation inhibitors anti foam and anti wear properties is recommended The viscosity grade should correspond to the ambient temperature and ISO 3448 as follows It is strongly recommended to use Atlas copco branded lubrication oils for both compressor and engine Never mix synthetic with mineral oil Remar...

Page 45: ...dle for extended periods PAROIL contains high quality anti oxidants to control deposits sludge and contaminants that tend to build up under very high temperatures PAROIL s detergent additives keep sludge forming particles in a fine suspension instead of allowing them to clog your filter and accumulate in the valve rocker cover area PAROIL releases excess heat efficiently whilst maintaining excelle...

Page 46: ...ol based coolant premixed in an optimum 50 50 dilution ratio for antifreeze protection guaranteed to 40 C Because PARCOOL EG inhibits corrosion deposit formation is minimized This effectively eliminates the problem of restricted flow through the engine coolant ducts and the radiator minimizing the risk for engine overheating and possible failure It reduces water pump seal wear and has excellent st...

Page 47: ...the condition of the coolant is outside the limits the complete coolant should be replaced see section Replacing the coolant Always top up with PARCOOL EG Topping up the coolant with water only changes the concentration of additives and is therefore not allowed Replacing the coolant Drain Completely drain the entire cooling system Used coolant must be disposed or recycled in accordance with laws a...

Page 48: ...per Volatile Corrosion Inhibitor or another drying agent inside the generator and close the doors Stick sheets of VCI paper with adhesive tape on the bodywork to close off all openings Wrap the generator except the bottom with a plastic bag Preparing for operation after storage Before operating the generator again remove the wrapping VCI paper and silica gel bags and check the generator thoroughly...

Page 49: ...perator manual for the engine troubleshooting An extensive Engine troubleshooting manual is available at John Deere Penta For more information contact John Deere Penta Never perform a test run with connected power cables Never touch an electrical connector without a voltage check When a failure occurs always report what you experienced before during and after the failure Information with regard to...

Page 50: ...otection Check frequency voltage regulator Winding failure Check windings High voltage at no load Voltage potentiometer out of setting Reset voltage Failed regulator Substitute regulator Lower than rated voltage at load Voltage potentiometer out of setting Reset voltage potentiometer Intervention by protection Current too high power factor lower than 0 8 speed lower than 10 of rated speed Failed r...

Page 51: ...ger and when the batteries are being charged To use the batery charger Provide external power 120V to the X7 connector located on the side of the power cubicle Engine coolant heater To make sure that the engine can start and accept load immediately an external cooling water heater 1500 W 120 V is provided which keeps the engine temperature between 38 C and 49 C Outlet sockets S A brief description...

Page 52: ...6 480 V output voltage Q1 1 Circuit breaker for low voltage high current Interrupts the low voltage power supply towards X1 when a short circuit occurs at the load side or when the overcurrent protection is activated It must be reset manually after eliminating the problem Q1 2 Circuit breaker for high voltage low current Interrupts the high voltage power supply towards X1 when a short circuit occu...

Page 53: ...ions Quick couplings The option Quick couplings allows to bypass the internal fueltank and to connect an external fueltank to the unit Make sure that the big size coupling is used for the inlet the small size coupling is used for the outlet EFT External fuel tank connection EFR External fuel tank return connection An extra clamp needs to be used to guide the fuellines EFT EFR EFT EFR ...

Page 54: ...mperature 25 C Limitations 2 Maximum ambient temperature 50 C Altitude capability 4000 m Maximum relative air humidity 85 Minimum starting temperature unaided 0 C Minimum starting temperature with coolant heater 25 C Performance data 2 3 4 5 Rated active power PRP 3ph 182 4 kW Rated active power PRP 3ph lower voltage optional 182 4 kW Rated active power PRP 1ph 131 6 kW Rated power factor lagging ...

Page 55: ...o spec 9822087700 74 dB A Useful capacity of fuel tank 450 gal Single step load capability O PRP 100 182 4 kW Application data Mode of operation PRP Site land use Operation single parallel Start up and control mode manual automatic Start up time unspecified Mobility Config acc to ISO 8528 1 1993 transportable D mobile E Mounting fully resilient Climatic exposure open air Degree of protection Cubic...

Page 56: ... Number of poles 3 Thermal release It thermal release is higher at 25 C 275 A Magnetic release Im 3 x In Circuit breaker 3ph lower voltage optional Number of poles 3 Thermal release It thermal release is higher at 25 C 633 A Magnetic release Im 3 5 x In Outlet sockets optional GFCL duplex 2x 2p E 20A 125V Temp Power 2x 2p N E 50A 125 250V Unit Dimensions LxWxH 4020 x 1390 x 2016 8 mm Weight net ma...

Page 57: ...is the maximum power available during a variable power sequence which may be run for an unlimited number of hours per year between stated mainte nance intervals and under the stated ambient conditions A 10 overload is permitted for 1 hour in 12 hours The permissible average power output during a 24h period shall not exceed the stated load factor of 70 5 Specific mass fuel used 0 86 kg l 6 Unless s...

Page 58: ...nt temperature 50 C Altitude capability 4000 m Maximum relative air humidity 85 Minimum starting temperature unaided 0 C Minimum starting temperature with coolant heater 25 C Performance data 2 3 4 5 Rated active power PRP 3ph 264 kW Rated active power PRP 3ph lower voltage optional 259 kW Rated active power PRP 1ph 198 kW Rated power factor lagging 3ph 0 8 cos Rated power factor lagging 1ph 1 0 c...

Page 59: ...ank 430 gal Single step load capability O PRP 100 264 kW Application data Mode of operation PRP Site land use Operation single parallel Start up and control mode manual automatic Start up time unspecified Mobility Config acc to ISO 8528 1 1993 transportable D mobile E Mounting fully resilient Climatic exposure open air Degree of protection Cubicle IP 54 Status of neutral earthed Alternator Standar...

Page 60: ... Thermal release It thermal release is higher at 25 C 400 A Magnetic release Im 3 x In Circuit breaker 3ph lower voltage optional Number of poles 3 Thermal release It thermal release is higher at 25 C 900 A Magnetic release Im 3 5 x In Outlet sockets optional GFCL duplex 2x 2p E 20A 125V Temp Power 2x 2p N E 50A 125 250V Unit Dimensions LxWxH 4020 x 1390 x 2016 8 mm Weight net mass 3628 kg Weight ...

Page 61: ...is the maximum power available during a variable power sequence which may be run for an unlimited number of hours per year between stated mainte nance intervals and under the stated ambient conditions A 10 overload is permitted for 1 hour in 12 hours The permissible average power output during a 24h period shall not exceed the stated load factor of 70 5 Specific mass fuel used 0 86 kg l 6 Unless s...

Page 62: ...ure difference of 1 8 F 1 bar 14 504 psi 1 g 0 035 oz 1 kg 2 205 lbs 1 km h 0 621 mile h 1 kW 1 341 hp UK and US 1 l 0 264 US gal 1 l 0 220 lmp gal UK 1 l 0 035 cu ft 1 m 3 281 ft 1 mm 0 039 in 1 m min 35 315 cfm 1 mbar 0 401 in wc 1 N 0 225 lbf 1 Nm 0 738 lbf ft t F 32 1 8 x t C t C t F 32 1 8 ...

Page 63: ... 63 Dataplate ...

Page 64: ...aterials for recycling in the future is forseen Disposal of materials Dispose contaminated substances and material separately according to local applicable environmental legislations Before dismantling a machine at the end of its operating lifetime drain all fluids and dispose of according the applicable local disposal regulations Remove the batteries Do not throw batteries into the fire explosion...

Page 65: ... 65 Circuit diagrams ...

Page 66: ... 66 1310 3200 12 00 Applicable for QAS 250 330 Qc1002 Engine Circuit ...

Page 67: ... 67 ...

Page 68: ...ontroller Fuse Fuse Battery 24V Panel Light Engine connector Starter Relay Starter Motor A Meters V meter Battery switch Emergency Stop Button S2b see Power Circuit Voltmeter change over switch Coolant Level Switch Low Fuel Level Switch Low Fuel Level Switch Warning ON OFF Switch Diode Terminal strip Fuel Level Unit Connector Motor Diagnostic Plug Terminal strip ...

Page 69: ... 69 1310 3200 11 00 Applicable for QAS 250 330 Qc2002 Power Circuit ...

Page 70: ... 70 ...

Page 71: ... Circuit breaker 3pole Circuit breaker 1pole Circuit breaker 1pole Circuit breaker 2pole Circuit breaker 2pole Circuit breaker 2pole Coolant Heater Voltage Adjustnent Potmeter Emergency stop S2a see Engine Circ Voltmeter change over switch Supply voltage switch Current transforner Terminal board Socket outlet Socket outlet Socket outlet Socket outlet Flanged inlet Terminal strip Remote Start Stop ...

Page 72: ... 72 1310 3200 13 00 Applicable for QAS 250 330 Wiring Diagram Control panel wiring ...

Page 73: ...20 H1 K5 P1 3 P4 S2a S4 S20 X10 X25 Name Control Module Engine controller Fuse Fuse Panel Light Starter Relay A Meters V meter Emergency Stop Button Voltmeter change over switch ON OFF Switch Terminal strip Terminal strip ...

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Page 76: ...www atlascopco com ...

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