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Maintenance

Maintenance schedule

Before carrying out any maintenance activity, check that the start switch is in position O and that no electrical power is present on the terminals.

!

Maintenance schedule

Daily

Every 500 hours or

yearly

Every 1000 hours or 24

months

Service pak

-

2912 6382 05

2912 6383 06

For the most important subassemblies, Atlas Copco has developed service kits that combine all wear parts. These service kits offer you the benefits of genuine parts,
save on administration costs 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 for air, fuel, coolant and oil leakage

x

x

x

Check oil and coolant level

x

x

x

Check or drain water in fuelfilter/waterseparator

x

x

x

Clean air cleaner and dust bowl

x

x

x

Check vaccuum indicator

x

x

x

Visual walk around the unit

x

x

x

Replace engine oil (1)

x

x

Replace engine oil filter (1)

x

x

Check/clean radiator/cooler fins

x

x

Check tension and condition of the drive belt/Replace

x

x

Grease door hinges and locks

x

x

Replace fuel filter element

x

x

Replace fuel prefilter element

x

x

Check electrolyte level and terminals of battery

x

x

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Содержание QAS 14

Страница 1: ...QAS 14 20 Kd Instruction Manual for AC Generators English...

Страница 2: ......

Страница 3: ...LAS COPCO PORTABLE AIR DIVISION www atlascopco com Printed matter N 2954 3380 04 11 2010 QAS 14 20 Kd Instruction Manual for AC Generators Instruction manual 5 Circuit diagrams 81 Original instruction...

Страница 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...

Страница 5: ...eter P4 48 Checking ammeter P3 48 Alternator troubleshooting 49 Engine trouble shooting 50 Options available for QAS 14 and QAS 20 units 52 Circuit diagrams 52 Overview of the electrical options 52 De...

Страница 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...

Страница 7: ...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 cool...

Страница 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...

Страница 9: ...ave 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 ner...

Страница 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...

Страница 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...

Страница 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...

Страница 13: ...V in line to line mode The QAS 14 and QAS 20 generators are driven by a fluid cooled diesel engine manufactured by KUBOTA An overview of the main parts is given in the diagram below 1 Lifting beam 2...

Страница 14: ...lexible coolant DH Drain and access hole in the frame DPF Drain plug fuel E Engine F Fan FCF Filler cap fuel FCO Filler cap engine oil FCW Filler cap coolant FF Fuel filter G1 Battery OF Oil filter OL...

Страница 15: ...e engine fuel Use PAROIL E only Indicates the different earthing connections on the generator Indicates that the alternator should not be cleaned with high pressurised water Indicates the battery swit...

Страница 16: ...he engine control circuit exceeds its setting The fuse can be reset by pushing the button H0 Panel light S20 ON OFF REMOTE switch To start up the unit locally or remote X25 Terminal strip Qc1002 Modul...

Страница 17: ...s 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 ENTER Is used to select and confirm changed settings in the Param...

Страница 18: ...2 display This view shows both Service timers The service timer indication is shown when service time has run out It can be removed by resetting the timers or acknowledging the Service timer indicatio...

Страница 19: ...rvice Timer 1 reset These menus are used to reset the service timers When a service timer alarm occurs and is acknowledged the service timer will be reset automatically Unit Menu This menu is used to...

Страница 20: ...20 This is the described menu flow for changing the unit type Qc 1002 145 Qc1002 145 Parameter Running time Unit type Unit type...

Страница 21: ...est alarm will be placed at the bottom of the list meaning that the older alarm stays at the display when a newer alarm comes up If one or more than one alarm is present an arrow at the right of the d...

Страница 22: ...4 to be wired for the remote contactor open close Fail classes All the activated alarms of the Qc1002 have their own pre defined fail class All alarms are enabled according to one of these three stat...

Страница 23: ...carry out all necessary tasks to control and protect a generator regardless of the use of the generator This means that the Qc2002 module can be used for several applications Pushbutton and LED functi...

Страница 24: ...c Operation Start Stop Green LED indicates that the Qc2002 receives running feedback via the W L input via the RPM value at the Canbus or via the AC frequency Generator contactor Green LED indicates t...

Страница 25: ...voltages of the generator in Alarm condition scroll through the information using UP and DOWN a list of all active Alarms It s possible to scroll through the views using the UP and DOWN buttons The s...

Страница 26: ...be done through the Parameter display Battery voltage display This view shows the Battery voltage and the running hours Fuel level display This view shows the Fuel level and the running hours kWh coun...

Страница 27: ...mode Phase voltages generator display This view shows the phase voltages of the generator Qc2002 Menu Description Status Display pop up window In case special statuses are entered a pop up window wil...

Страница 28: ...nerator Contactor can be activated manually Combined with Automatic Operation mode Remote Start operation The remote start signal can be given with an external switch After the generator has been star...

Страница 29: ...guage selection Icons is the default factory set language but 6 other languages can be selected English French German Italian Spanish and Cyrillic Russian All information in the Parameter List display...

Страница 30: ...ominal voltage in AMF Auto MF low voltage This menu is 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 whic...

Страница 31: ...ay Undervoltage setpoint Overfrequency enable Overfrequency failclass Volt enable Enable enable disable Volt FC warning warning shutdown Volt Delay 0 1 99 Volt SP 0 450 999 Volt enable Enable enable d...

Страница 32: ...will appear in the check box and the red alarm LED will light up continuously The Alarm Display can always be left by pushing the BACK button If more than one alarm comes up it s possible to scroll t...

Страница 33: ...Stop Trip of GB actions unit stops after Cooldown Shutdown Trip of GB actions unit stops immediately List of possible alarms z LOW OIL PRESSURE HIGH COOLANT TEMPERATURE CHARGING ALTERNATOR LOW FUEL LE...

Страница 34: ...nning RUN Output terminal board The output terminal board option is situated below the control and indicator panel S2 Emergency stop button Push the button to stop the generator in case of an emergenc...

Страница 35: ...switch S13 labelled I N but has to be tested monthly by pushing test button T S13 Lock out switch for earth fault protection N13 This switch is located inside the cubicle and is labelled I N Position...

Страница 36: ...e high 3rd harmonics and risk for excessive neutral current Loads most sensitive to voltage distortion include incandescent lamps discharge lamps computers X ray equipment audio amplifiers and elevato...

Страница 37: ...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...

Страница 38: ...he starter switch S20 in position I ON The unit starts a preheating cycle which takes 12 seconds After the preheating period the unit will start The starting attempt will take maximum 12 seconds Switc...

Страница 39: ...t necessary when a plant contactor is installed between Q1 and the load Put the starter switch S20 in position I ON Voltage is applied to the Qc2002 module The unit can be started manually by pressing...

Страница 40: ...tton on the Qc2002 module Put the starter switch S20 in position O OFF to shut down the voltage apply towards the Qc2002 module Lock the side doors and the door of the indicators and control panel to...

Страница 41: ...s 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 for air fuel coolant and oil leakage x x x Ch...

Страница 42: ...eck PH level of engine coolant 4 x x Monitor Insulation Resistance of the main alternator x x Replace safety cartridge x Check alternator and starter motor x Check electrical system for security of ca...

Страница 43: ...nal and terminal L1 and generate a voltage of 500 V The scale must indicate a resistance of at least 5 M Refer to the alternator operating and maintenance instructions for more details Engine fuel spe...

Страница 44: ...ention and more alkalinity to control acid formation PAROIL prevents Soot build up PAROIL is optimized for the latest low emission EURO 3 2 EPA TIER II III engines running on low sulphur diesel for lo...

Страница 45: ...ranteed to 40 C 40 F 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 m...

Страница 46: ...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...

Страница 47: ...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...

Страница 48: ...readings should be the same 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 be...

Страница 49: ...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...

Страница 50: ...ion system Air in fuel system Fault in atomisers or atomisers of an incorrect type Restriction in fuel tank vent Wrong type or grade of fuel used Restricted movement of engine speed control Restrictio...

Страница 51: ...stem Fault in atomisers or atomisers of an incorrect type Fault in cold start system Restriction in fuel tank vent Restricted movement of engine speed control Engine temperature is too high Incorrect...

Страница 52: ...ircuit QAS 14 20 Kd 9822 0992 65 QAS 14 20 Kd 1ph 9822 0992 66 QAS 14 20 Kd 2V 50Hz 9822 0992 67 QAS 14 20 Kd 2V 50 Hz 1ph 9822 0992 73 Engine circuit Unit Circuit QAS 14 20 Kd 9822 0992 77 Controller...

Страница 53: ...keeps the engine temperature between 38 C and 49 C Outlet sockets S 3 phase A brief description of all outlet sockets and circuit breakers provided on the generator is given hereafter X3 3 phase outle...

Страница 54: ...the load side or when the overcurrent protection 16 A is activated When activated Q5 interrupts phase L and the neutral towards X5 It can be activated again after eliminating the problem Circuit brea...

Страница 55: ...ting the problem Single phase The Single phase option provides single phase output voltage e g 230 V X1 Main power supply 230 240 V AC Terminals L1 L2 and PE earthing hidden behind the control panel d...

Страница 56: ...stment Allows to adjust the output voltage Depending on which mode the generator is running in circuit breaker Q1 1 or Q1 2 will be operational Circuit breakers Q1 1 and Q1 2 cannot be switched on at...

Страница 57: ...fter eliminating the problem R12 Voltage adjustment Allows to adjust the output voltage Depending on which mode the generator is running in circuit breaker Q1 1 or Q1 2 will be operational Circuit bre...

Страница 58: ...stop button Push the button to stop the generator in case of an emergency When the button is pressed it must be unlocked by turning it anti clockwise before the generator can be restarted The emergenc...

Страница 59: ...ot switch off the circuit breaker COSMOS COSMOS is a web based global remote monitoring system that electronically tracks every aspect of equipment from its location to its operating parameters The Co...

Страница 60: ...connect an external fuel tank to the unit View outside View inside When using this option make sure to connect the fuel supply line as well as the fuel return line Connections to fuellines ought to b...

Страница 61: ...carriage Check the tightness of the towbar bolts the axle bolts and the wheel nuts at least twice a year and after the initial 50 hours of operation Grease the wheel axle suspension bearings the drawb...

Страница 62: ...construction sites where no electricity nor lighting is available EC Elevation cable FS Foot HHF Handle to adjust the height of the foot HLF Handle to lock unlock the foot HLS Handle to lock unlock t...

Страница 63: ...the generator mounted on the light ing tower Locate the rear end of the generator upwind see figure below away from contaminated wind streams and walls Avoid recirculation of exhaust air from the eng...

Страница 64: ...e mast Unlock the mast by raising the lever LTF situated at the back of the transport frame TF Raise the mast M from the horizontal resting position to the vertical position by turning the lever of th...

Страница 65: ...its horizontal position tighten the elevation cable EC by turning on the lever of the winding mechanisme WM Make sure ALWAYS to retract the stabilizers ST After retracting check that the stabilizers...

Страница 66: ...r Engine coolant temperature Shut down 103 C 50 Hz 60 Hz Reference conditions 1 Rated frequency 50 Hz 60 Hz Rated speed optional 1500 rpm 1800 rpm Generator service duty PRP PRP Absolute air inlet pre...

Страница 67: ...93 G2 G2 Single step load acceptance 0 PRP 10 9 kW 13 0 kW 100 100 Frequency droop 5 5 isochronous isochronous Fuel consumption at no load 0 0 9 kg h 1 3 kg h Fuel consumption at 50 load 2 0 kg h 2 2...

Страница 68: ...y Somer Model LSA40 S3 LSA40 S3 Rated output class H temp rise 15 0 kVA 19 0 kVA rating type acc ISO 8528 3 BR BR Degree of protection IP 23 IP 23 Insulation stator class H H Insulation rotor class H...

Страница 69: ...0 A Magnetic release Im 3 5xIn 3 5xIn Circuit breaker 1 ph optional Number of poles 2 2 Thermal release It thermal release is higher at 25 C 40 A 40 A Magnetic release Im 3 5xIn 3 5xIn Fault current p...

Страница 70: ...hours per year of which a maximum of 300 hours is continuous running No overload is permitted on these ratings The alternator is peak continuous rated as defined in ISO 8528 3 at 25 C PRP Prime Power...

Страница 71: ...30 35 40 45 50 0 100 100 100 100 100 100 100 95 95 90 90 500 100 100 100 95 95 95 90 90 85 85 85 1000 95 90 90 90 90 85 85 85 80 80 75 1500 85 85 85 85 80 80 80 75 75 75 70 2000 80 80 80 75 75 75 75 7...

Страница 72: ...ional 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...

Страница 73: ...Fuel consumption at 75 load 3 3 kg h 4 1 kg h Fuel consumption at full load 100 4 2 kg h 4 6 kg h Specific fuel consumption at full load 100 0 262 kg kWh 0 237 kg kWh Fuel autonomy at full load with...

Страница 74: ...BR BR Degree of protection IP 23 IP 23 Insulation stator class H H Insulation rotor class H H Number of wires 12 12 Engine 4 Standard ISO 3046 ISO 3046 ISO 8528 2 ISO 8528 2 Type KUBOTA V2403M BG V240...

Страница 75: ...n 3 5xIn Circuit breaker 1 ph optional Number of poles 2 2 Thermal release It thermal release is higher at 25 C 63 A 63 A Magnetic release Im 3 5xIn 3 5xIn Fault current protection Residual current re...

Страница 76: ...hours per year of which a maximum of 300 hours is continuous running No overload is permitted on these ratings The alternator is peak continuous rated as defined in ISO 8528 3 at 25 C PRP Prime Power...

Страница 77: ...30 35 40 45 50 0 100 100 100 100 100 100 100 95 95 90 90 500 100 100 100 95 95 95 90 90 85 85 85 1000 95 90 90 90 90 85 85 85 80 80 75 1500 85 85 85 85 80 80 80 75 75 75 70 2000 80 80 80 75 75 75 75 7...

Страница 78: ...BELGIUM 1615 6945 00 YA3 kg kg kg Model Modell Mod le cos phi f N P N P N U N I N Manuf year Baujahr Ann e de fabrication Hz kW V A kVA A B C A Maximum permitted total weight of the vehicle B Maximum...

Страница 79: ...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...

Страница 80: ...80...

Страница 81: ...81 Circuit diagrams...

Страница 82: ...ter Control Module bx0 bx0 b0 b0 E E 110 0V a0 127 y54 x6 N1 x0 W1 x0 V1 x0 U1 to Circ Diagr ENGINE Ampere meter c8 142 y54 y54 a0 126 a6 124 a0 V1 a0 U1 6 5 T8 T11 T10 T7 T4 T1 T11 T8 T5 T2 T12 T9 T6...

Страница 83: ...AS See Note 3 PE X1 Note 3 Note 2 Note 1 With TB EDF do NOT connect N to PE at Q1 T13 is to be mounted on the PE conductor in stead of on the PE N connection in the cubicle Link N12 1 to N12 2 on gen...

Страница 84: ...0V N12 y54 x0 W1 x0 U1 to Circ Diagr ENGINE Ampere meter y54 y54 a0 126 a0 W a0 U S13 S2b R N14 N13 I n T1 T2 9822 0992 66 00 Applicable for QAS 14 20 Compact Power circuit Single phase F1 F2 Fuses 4...

Страница 85: ...0 0 Coolant Heater to Circ Diagr CONTROLLER b6 441 b0 442 b0 442 b6 441 b0 442 b6 441 a6 12 a2 13 1ph ZZ 1ph ZZ 230V 240V 230V 50Hz 63A 60 5A 16mm 16mm 20 40A Q1 60 5A T1 10mm Wire Size y 10mm Wire Si...

Страница 86: ...ter 143 c8 151 c8 141 c8 140 c8 143 c8 142 c8 141 c8 142 c8 R12 29 a0 28 a2 U1 a0 V1 a0 126 a0 125 a0 F2 F1 N F3 N1 a6 124 a6 127 a0 W1 a0 X9 28 X9 29 U1 y0 V1 y0 W1 y0 U1 x0 V1 x0 W1 x0 U1 y0 V1 y0 W...

Страница 87: ...y0 L1 x0 L2 x0 L3 x0 12 a6 13 a2 L1 y L2 y L3 y 30 100 5A 80A 50A 25mm2 16mm2 10mm2 40 100 5A 100A 63A 35mm2 16mm2 16mm2 QAS T3 Q1 1 Wire Size x Wire Size y Q1 2 Wire Size z 14 20 30 5A 32A 20A 6mm2 6...

Страница 88: ...irc Diagr ENGINE Ampere meter c8 142 c8 143 c8 142 c8 143 c8 151 c8 141 c8 151 c8 141 c8 141 c8 142 T1 T2 T3 c8 151 c8 143 x0 T9 z54 x6 N1 x0 T5 x0 T7 bx0 T3 a0 126 a6 124 bx6 N1 to Circ Diagr ENGINE...

Страница 89: ...side of main Circuit Breaker Q1 x6 N PE z54 x0 L3 y0 L2 y0 L1 x0 W x0 V x0 U x6 N1 x54 z54 x6 N x0 L3 y0 L2 y0 L1 S13 a3 5 S2b N13 I n T1 T2 a2 13 a3 118 a2 13 a6 12 x0 L2 x0 L1 y0 V y0 U a3 104 K11...

Страница 90: ...1 c2 1 d2 16 d2 1 c2 3 a3 4 a2 17 a2 17 a3 26 a3 5 a3 5 a3 7 a3 6 a3 11 a3 50 a2 49 a3 46 a3 7 a3 6 b3 48 b3 47 a6 12 a6 12 a6 12 b6 12 a6 12 C4 C4 X10 A1 A1 X10 A3 A3 X10 C3 C3 X10 C1 C1 X10 B1 B1 B2...

Страница 91: ...K0 Starter solenoid K1 Preheat relay M1 Starter motor M6 Fuel feed pump S1 Battery switch O N11 Engine controller unit O S8 High coolant temperature switch S9 Low oil pressure switch S10 Coolant temp...

Страница 92: ...put Input Input Input Input Input 5 A1 18 19 23 21 35 4 3 2 1 36 24 0 Vdc Batt 34 33 32 26 27 25 17 16 14 13 12 9 15 6 7 8 Generator Contactor Preheat Relay High Coolant Temperature Low Oil Pressure C...

Страница 93: ...15 C5 C5 X10 Dual Frequency a6 12 a3 26 C4 C4 X10 0 60Hz 50Hz S12b e2 K5 e2 Position of Relay Contacts a6 12 a3 4 a3 5 X25 C2 C2 X10 A4 A4 X10 A5 A5 X10 a3 15 a6 12 a3 5 a6 12 a6 12 to Circ Diagr POWE...

Страница 94: ...rator Contactor A1 to Mains Contactor A1 L3 L2 L1 L1 N to A1 18 250mA 250mA 6A 250mA 6A a2 17 a6 12 a2 17 Central Alarm Horn 2nd Parameter Set s1 s2 Generator Current Transfo L1 s1 s2 Generator Curren...

Страница 95: ...C4 C4 X10 a6 12 a6 12 a3 15 C5 C5 Dual Frequency a6 12 a3 26 C4 C4 X10 0 60Hz 50Hz S12b a3 4 S20 a2 13 a2 13 c2 1 a3 5 a3 15 a3 14 a3 14 a3 14 a3 4 a3 5 a6 12 a3 7 a3 6 a3 11 X25 9 C4 C4 X10 A1 A1 X1...

Страница 96: ...96...

Страница 97: ...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 o...

Страница 98: ...98...

Страница 99: ......

Страница 100: ...Printed in Belgium 11 2010 2954 3380 04 www atlascopco com...

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