Atlas Copco QAS 275-325 Instruction Manual Download Page 3

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ATLAS COPCO - PORTABLE AIR DIVISION

www.atlascopco.com

Printed matter N°

2954 3880 01

11/2010

QAS 275-325 Volvo

Instruction Manual for AC Generators

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

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

Summary of Contents for QAS 275-325

Page 1: ...QAS 275 325 Volvo S2A APP Instruction Manual for AC Generators English...

Page 2: ......

Page 3: ...ATLAS COPCO PORTABLE AIR DIVISION www atlascopco com Printed matter N 2954 3880 01 11 2010 QAS 275 325 Volvo Instruction Manual for AC Generators Instruction manual 5 Circuit diagrams 91...

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 informa...

Page 5: ...Checks and trouble shooting 72 Checking voltmeter P4 72 Checking ammeters P1 P2 and P3 72 Engine troubleshooting 72 Alternator troubleshooting 73 Options available for QAS 275 325 Volvo units 74 Circ...

Page 6: ...chanical technician is also trained to perform maintenance and repair as described in the instruction manual and is allowed to change settings of the control and safety system A mechanical technician...

Page 7: ...c 6 The machinery and equipment shall be kept clean i e as free as possible from oil dust or other deposits 7 To prevent an increase in working temperature inspect and clean heat transfer surfaces coo...

Page 8: ...and or behind the wheels When the towbar can be positioned vertically the locking device must be applied and kept in good order 6 To lift heavy parts a hoist of ample capacity tested and approved acco...

Page 9: ...s have been removed before the guards are securely reinstalled 9 Noise even at reasonable levels can cause irritation and disturbance which over a long period of time may cause severe injuries to the...

Page 10: ...connections are securely tightened 24 Avoid overloading the generator The generator is provided with circuit breakers for overload protection When a breaker has tripped reduce the concerned load befo...

Page 11: ...r mix synthetic with mineral oil 14 Protect the engine alternator air intake filter electrical and regulating components etc to prevent moisture ingress e g when steam cleaning 15 When performing any...

Page 12: ...n 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...

Page 13: ...3 phase 50 Hz 230 V 3 phase and 60 Hz 480 V 3 phase The QAS 275 325 Volvo generator is driven by a water cooled diesel engine manufactured by VOLVO PENTA An overview of the main parts is given in the...

Page 14: ...DFO Drain flexible engine oil DFW Drain flexible cooling water E Engine F Fan FCO Filler cap engine oil FCW Filler cap cooling water FF Fuel filter G1 Battery ODP Oil drain pump OF Oil filter OLD Eng...

Page 15: ...tric terminals during operation Indicates that the engine exhaust is a hot and harmful gas which is toxic in case of inhalation Always make sure that the unit is operated outside or in a well ventilat...

Page 16: ...setting The fuse can be reset by pushing the button H0 Panel light Indicates the 3 way valve Indicates the partnumbersof the different service packs and of the engine oil These parts can be ordered t...

Page 17: ...his control module will carry out all necessary tasks to control and protect a generator regardless of the use of the generator This means that the Qc1002 module can be used for several applications P...

Page 18: ...the UP and DOWN buttons The scrolling is continuous If a Special status comes up the Status Display is shown If an Alarm comes up the Alarm Display is shown START Is used to start the unit in Manual M...

Page 19: ...ives access to it An overview is given in LOG list on page 25 Service timer 1 Service timer 2 display This view shows both Service timers The service timer indication is shown when service time has ru...

Page 20: ...age frequency running hours display This view shows the voltage frequency and running hours Engine speed display This view shows the engine speed and running hours Qc1002 Menu Description Status Displ...

Page 21: ...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...

Page 22: ...22 This is the described menu flow for changing the unit type Qc1002 CAN 145 Parameter Running time Unit type Unit type Unit type Qc1002 CAN 145...

Page 23: ...buttons The newest alarm will be placed at the bottom of the list meaning that the older alarm stays at the display when a newer alarm comes up If one or more than one alarm is present an arrow at the...

Page 24: ...IMER 2 ENGINE ALARM EMERGENCY STOP START FAILURE STOP FAILURE SPN16 FUEL FILTER DIFF P pressure difference over fuel filter SPN51 THROTTLE POS throttle position SPN52 INTERCOOL TEMP intercooler temper...

Page 25: ...heir own pre defined fail class All alarms are enabled according to one of these three statuses disabled alarm no supervision of alarm OFF enabled alarm supervision of alarm all the time ON running al...

Page 26: ...tton can be secured in the locked position with the key to avoid unauthorized use S20 ON OFF switch Position O No voltage is applied to the Qc2002 module the generator will not start Position I Voltag...

Page 27: ...d with the STOP button in automatic operation it will automatically go to manual operation MAINS CONTACTOR Is used to open or close the Mains contactor if the Qc2002 is in manual operation GENERATOR C...

Page 28: ...ages of the mains Phase voltages of the generator in Alarm condition scroll through the information using UP and DOWN a list of all active Alarms It s possible to scroll through the views using the UP...

Page 29: ...shown when service time has run out It can be removed by resetting the timers or acknowledging the Service timer indication The service timer indications count upwards and give an alarm when the set...

Page 30: ...F the frequency of the generator and the frequency of the mains M f L1 only in AMF mode One line voltage frequency active power display This view shows one line voltage frequency and active power of t...

Page 31: ...e If a special status has elapsed the active view will be entered again automatically If an Alarm comes up the Alarm Display is shown Parameter list The Parameter Menu s are pre programmed A password...

Page 32: ...MF operation will NOT function When the Mains exceeds the defined voltage frequency limits for a defined delay time the generator will take over the load automatically When the mains is restored withi...

Page 33: ...es can be selected English French German Italian Spanish and Cyrillic Russian All information in the Parameter List display is always in English Engine CAN communication This menu is used to select th...

Page 34: ...used to set the minimum limit for the mains voltage in of the nominal voltage in AMF Auto M voltage delay This menu is used to set the delay which defines how long the mains voltage has to be back wi...

Page 35: ...y delay Overfrequency setpoint Underfrequency enable Underfrequency failclass Volt Delay 0 1 99 Volt SP 0 450 999 Volt enable Enable enable disable Volt FC warning warning shutdown Volt Delay 0 1 99 V...

Page 36: ...to scroll through the alarm messages with the UP and DOWN pushbuttons The newest alarm will be placed at the bottom of the list meaning that the older alarm stays at the display when a newer alarm com...

Page 37: ...LEVEL GENERATOR OVERVOLTAGE GENERATOR UNDER VOLTAGE GENERATOR OVER FREQUENCY GENERATOR UNDER FREQUENCY SERVICE TIMER 1 SERVICE TIMER 2 ENGINE ALARM EMERGENCY STOP START FAILURE STOP FAILURE HZ V FAIL...

Page 38: ...P 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...

Page 39: ...led alarm supervision of alarm all the time ON running alarm only supervision when the machine is running RUN Control and indicator panel Qc4002 General description Qc4002 control panel A2 Qc4002 disp...

Page 40: ...Allows customer connections X30 Connector X30 Connector for communication with other generators with Qc4002 when paralleling X31 Connector X31 Connector for communication with other generators with Q...

Page 41: ...UP window where you can choose between the Event Alarm and Battery logs The logs are not deleted when the auxiliary supply is switched off BACK Jumps one step backwards in the menu to previous display...

Page 42: ...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 du...

Page 43: ...oscope in the first line The V2 view shows some generator measurements In the V1 view the user can scroll up and down to 15 configurable screens showing different measurements of the generator the bus...

Page 44: ...election of SP the following view will be visible If the correct password is entered the following view appears Now the user can change the SP of parameter G P 1 This can be done with the scroll butto...

Page 45: ...he 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 9000 Software version 9020 Service port 911X Use...

Page 46: ...46 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 47: ...tlas Copco Service staff Fail Classes All the activated alarms of the module are configured with a fail class The fail class defines the category of the alarm and the subsequent action 6 different fai...

Page 48: ...s mode it is possible to perform the following tests Simple test Load test Full test Manual mode When manual mode is selected the gen set can be controlled with digital inputs Block mode When the bloc...

Page 49: ...TO This operation type is selected for installations with one or more generators but always without the Mains stand alone In practice up to 16 generators can be installed in parallel Installation wiri...

Page 50: ...X25 3 X25 34 X25 4 X25 35 X25 5 X25 36 X25 6 are removed If back synchronisation is enabled all settings for paralleling set up see Paralleling must be verified also Peak Shaving PS operation This app...

Page 51: ...or will start up synchronise and take over the load from the Mains gradually before opening the Mains Breaker To know if the load is completely taken over from the mains an optional Power Transducer i...

Page 52: ...e If the SEMI AUTO mode is selected the PMS operation will NOT function The Qc4002 controllers from the gensets need to be programmed as PMS in AUTO mode When a Qc Mains controller is installed this n...

Page 53: ...nset and will stop as first If running hours are chosen as priority the start stop sequence will be defined based on the actual running hours of the different generators The lowest running hours will...

Page 54: ...operation SEMI AUTO mode Local start AUTO mode Remote start AMF operation SEMI AUTO mode AMF operation will not function properly AUTO mode Emergency start Mains Failure Peak shaving SEMI AUTO mode On...

Page 55: ...ase contact Atlas Copco Application type Mode Comments Island operation SEMI AUTO mode Manual paralleling between generators AUTO mode Remote paralleling between generators AMF operation SEMI AUTO mod...

Page 56: ...AUTO mode PS FP LTO can be combined with AMF Back synchronising enabled disabled parameter channel 7080 Wrong parameter settings can damage the installation brutally 3 To be able to start up in cold c...

Page 57: ...nside the cubicle and is labelled I N Position O No de energising of the main circuit breaker Q1 when an earth fault occurs Position 1 De energising of the main circuit breaker Q1 when an earth fault...

Page 58: ...d 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...

Page 59: ...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 ment...

Page 60: ...e and single core PVC insulated conductors and H07 RN F multiple core conductors and wire sections as listed in accordance with VDE 0298 installation method C3 Local regulations remain applicable if t...

Page 61: ...lace 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 circuit breaker Q1 is...

Page 62: ...doors and the door of the indicators and control panel to avoid unauthorized access To stop the unit when the starter switch is in position proceed as follows Switch off the load Stop the engine by pu...

Page 63: ...uring operation switch off the load and stop the generator Check and if necessary decrease the load Stopping Qc2002 To stop the unit proceed as follows Switch off the load Switch off circuit breaker Q...

Page 64: ...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...

Page 65: ...sts and are offered at reduced price compared to the loose components Refer to the parts list for more information on the contents of the service kits Check air fuel coolant oil leakage x x x Check oi...

Page 66: ...mechanical links x x Check condition of vibration dampers x x Measure alternator insulation resistance x x Check glycol level in coolant 4 x x Check PH level of engine coolant 4 x x Clean turbocharger...

Page 67: ...resistance If the N terminal is connected to the earthing system it must be disconnected from the earth terminal Disconnect the AVR Connect the megger between the earth terminal and terminal L1 and g...

Page 68: ...imized for the latest low emission EURO 3 2 EPA TIER II III engines running on low sulphur diesel for lower oil and fuel consumption PAROIL Extra and PAROIL E Synthetic engine oil PAROIL Extra PAROIL...

Page 69: ...sit 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...

Page 70: ...he 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...

Page 71: ...er 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 generat...

Page 72: ...s operator manual for the engine troubleshooting An extensive Engine troubleshooting manual is available at Volvo Penta For more information contact Volvo Penta Never perform a test run with connecte...

Page 73: ...tection 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 rat...

Page 74: ...utomatic battery charger charges the battery completely and is disconnected once the unit starts up Besides the output terminals secondary side the automatic battery charger has a trim potentiometer f...

Page 75: ...he overcurrent protection 63 A is activated When activated Q4 interrupts the three phases towards X4 It can be activated again after eliminating the problem Q5 Circuit breaker for X5 Interrupts the po...

Page 76: ...vercurrent protection QAS 275 690 A QAS 325 800 A is activated It must be reset manually after eliminating the problem Q1 2 Circuit breaker for high voltage low current Interrupts the high voltage pow...

Page 77: ...see figure below In this case an earth leakage at the side of the generator will switch off the circuit breaker An earth leakage at the side of the load will not switch off the circuit breaker COSMOS...

Page 78: ...g size coupling is used for the inlet the small size coupling is used for the outlet Integrated spark arrestor The integrated spark arrestor option is included in the refinery equipment pack Air inlet...

Page 79: ...Reference conditions 1 4 Rated frequency 50 Hz 60 Hz Rated speed 1500 rpm 1800 rpm Generator service duty PRP PRP Absolute air inlet pressure 100 kPa 100 kPa Relative air humidity 30 30 Air inlet tem...

Page 80: ...fic fuel consumption at full load 100 0 21 kg kWh 0 22 kg kWh Fuel autonomy at full load with standard tank 10 h 9 h Fuel autonomy at full load with optional 24 hrs tank 30 h 28 h Max oil consumption...

Page 81: ...Volvo TAD940 GE TAD940 GE Rated net output 241 kW 248 kW rating type acc ISO 3046 7 ICXN ICXN Coolant water water Combustion system direct injection direct injection Aspiration turbocharged turbochar...

Page 82: ...ional domestic 1x 2p E 16 A 230 V CEE form 1x 3p N PE 16 A 400 V CEE form 1x 3p N PE 32 A 400 V CEE form 1x 3p N PE 63 A 400 V CEE form 1x 3p N PE 125 A 400 V Unit Dimensions LxWxH 4020 x 1390 x 2016...

Page 83: ...rated as defined in ISO 8528 3 at 25 C PRP Prime Power 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...

Page 84: ...1500 rpm 1800 rpm Generator service duty PRP PRP Absolute air inlet pressure 100 kPa 100 kPa Relative air humidity 30 30 Air inlet temperature 25 C 25 C Limitations 2 Maximum ambient temperature 50 C...

Page 85: ...with standard tank 9 h 8 h Fuel autonomy at full load with optional 24 hrs tank 25 h 22 h Max oil consumption at full load 0 04 l h 0 04 l h Maximum sound power level LWA measured according to 2000 14...

Page 86: ...ype Volvo TAD941 GE TAD941 GE Rated net output 280 kW 296 kW rating type acc ISO 3046 7 ICXN ICXN Coolant water water Combustion system direct injection direct injection Aspiration turbocharged turboc...

Page 87: ...ional domestic 1x 2p E 16 A 230 V CEE form 1x 3p N PE 16 A 400 V CEE form 1x 3p N PE 32 A 400 V CEE form 1x 3p N PE 63 A 400 V CEE form 1x 3p N PE 125 A 400 V Unit Dimensions LxWxH 4020 x 1390 x 2016...

Page 88: ...us rated as defined in ISO 8528 3 at 25 C PRP Prime Power is the maximum power available during a variable power sequence which may be run for an unlimited number of hours per year between stated main...

Page 89: ...lbf ft t F 32 1 8 x t C t C t F 32 1 8 A Maximum permitted total weight of the vehicle B Maximum permitted front axle load C Maximum permitted rear axle load 1 Company code 2 Product code 3 Unit seria...

Page 90: ...terials for recycling in the future is forseen Disposal of materials Dispose contaminated substances and material separately according to local applicable environmental legislations Before dismantling...

Page 91: ...91 Circuit diagrams...

Page 92: ...3 14 b3 14 b2 17 b2 17 a6 12 a6 12 a6 12 a6 12 a6 12 3 4 2 1 b2 13 Qc1002 canbus CAN L GND CAN H Air Shutdown Valve Relay Fuel Control Relay Com Com NO NO 0 Vdc Batt Load Contactor Preheat Relay Commo...

Page 93: ...O not needed for dedicated 60Hz units Note with X11 Connect wires b only if S11 is required or connect wire 35 to X11 2 if S11 is not required O b d S11 a X10 10 1 12 12 S1 M1 8 7 6 5 4 3 2 1 M G1 1 K...

Page 94: ...S1 Battery switch S2a Emergency stop button S2b see Power Circuit S3 Water in fuel switch O S4 Voltmeter change over switch S11d Selector switch 50 60Hz S11a b see Power Circuit S20 ON OFF switch V7 F...

Page 95: ...95...

Page 96: ...ins and Generator Contactor Output 24Vdc max 8Adc1 to Circ Diagr POWER X9 441 X9 442 a6 12 a3 18 a6 124 a0 446 a0 447 a0 442 a6 441 Sx Remote Start Stop switch max 24Vdc 4A b6 441 b0 442 a0 443 a0 444...

Page 97: ...1 4 X11 3 X11 2 See also Circ Diagr Power X11 a3 36 X11 1 b6 12 a3 172 a3 172 10 l0 1 l0 c2 1 b3 171 12 l0 12 l0 aa9 CH aa0 CL c6 12 S1 M1 8 7 6 5 4 3 2 1 CANBUS M G1 1 l0 b3 171 d5 d5 K8 c8 K7 K5 d3...

Page 98: ...esistor 470 ohm 7W O S1 Battery switch S2a Emergency stop S2b see Power Circuit S2c Emergency stop O S3 Water in fuel switch S4 Voltmeter change over switch S10d Supply voltage switch S11d Selector sw...

Page 99: ...99...

Page 100: ...l Relay Stop Coil Relay Starter Relay Starter Relay NO Preheat Relay Input Input Input Input Input Input W L Input D Start Enable Remote Start Stop Configurable Configurable Fuel Level VDO C B A Coola...

Page 101: ...CANBUS a6 446 36 6 a6 N 12 a6 Hz Hz 60 50 a3 5 5 a3 22 8 7 a6 12 12 PE L1 L2 L3 N c6 2N c0 2L3 N L c6 N c0 L3 SHT PE c54 b6 12 5 b3 171 a3 11 17 a2 12 a2 13 13 b2 1 b2 13 b2 1 a3 172 b6 12 a2 17 a6 12...

Page 102: ...S CAN bus R5 Coolant heater O R7 Resistor 47ohm volt adj R9 Resistor 120ohm PMS CAN bus S1 Battery switch S2 Emergency stop S11a b d Selector switch 50 60Hz S13 Earth leak disable switch S20 ON OFF sw...

Page 103: ...103...

Page 104: ...ator side of main Circuit Breaker Q1 The PE N connection has to be made at the nx 0 600A QAS325 470A 600 5A kx lx 0 400A QAS275 400A 400 5A jx 2x lx 0 800A QAS500 720A 800 5A lx X Wire size Q1 T1 3 P1...

Page 105: ...13 12 a3 5 a6 12 5 12 Hz Hz 60 50 a3 22 1 2 PE PE h54 PE z54 x6 N x0 L3 x0 L2 x0 L1 L1 L2 N L3 hx0 3L2 hx0 3L1 hx0 3L3 hx6 N hx0 L3 hx0 L2 hx0 L1 PE hx54 L1 L2 N L3 e0 5L2 e0 5L1 e0 5L3 e6 N e0 L3 e0...

Page 106: ...er 1kOhm S2b Emergency stop S2a see Engine Circuit S11a b Selector switch 50 60Hz S11c see Engine Circuit S13 Earth relay lock out switch T1 3 Current transformer T13 Torus earth relay U1 Static batte...

Page 107: ...107...

Page 108: ...a0 29 Canopy Cubicle Alternator Cubicle a0 29 a2 28 Voltage Adjustm 1 2 2 9 1 Hz 50 a3 37 a3 36 a3 35 Frequency Selection 1 2 3 T1 T4 T12 400Vy 230Vd T12 T9 T6 T3 T2 T5 T8 T11 T10 T7 T4 T1 T7 T10 T2 T...

Page 109: ...9 S10c S10b Q1 2 Q1 1 See Note 1 X9 ELR Relay O X9 X9 X9 PE S13 S2b X1 A B C D E T13 N13 I n See Circ Diagr Engine 442 441 13 12 13 441 a6 a0 442 12 a6 a2 PE N L B B Canopy Cubicle 118 Alternator Cubi...

Page 110: ...heater R12 Voltage adjustment potentiometer S2b Emergency stop S2a see engine circuit diagram S10abc Supply voltage switch S10d see engine circuit diagram S13 Earth relay lock out switch T1 3 Current...

Page 111: ...of the laws of the Member States relating to machinery is in conformity with the relevant Essential Health and Safety Requirements of this directive The machinery complies also with the requirements...

Page 112: ...112...

Page 113: ......

Page 114: ...Printed in Belgium 11 2010 2954 3880 01 www atlascopco com...

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