Atlas Copco QAS366 Gd USA User manual
$7/$6&23&23257$%/($,5',9,6,21
ZZZDWODVFRSFRFRP
,QVWUXFWLRQ0DQXDODQG3DUWV/LVW
IRU$&*HQHUDWRUV
4$6*G86$
,QVWUXFWLRQPDQXDO
DQXHOG©LQVWUXFWLRQV
/LEURGHLQVWUXFFLRQHV
DQXDOGHLQVWUXo}HV
&LUFXLWGLDJUDPV¤6FKpPDVGHFLUFXLWV¤(VTXHPDGHFRQH[LRQHV¤
(VTXHPDVHOpFWULFRV
3DUWVOLVW¤/LVWHGHSLqFHV¤/LVWDGHODVSDUWHV¤/LVWDGHSHoDV
*ORVVDU\¤*ORVVDLUH¤*ORVDULR¤*ORVViULR
5HJLVWUDWLRQFRGH
&ROOHFWLRQ $3&4
7DE
3ULQWHG0DWWHU1
2954 0254 00 EN
4$6*G86$
2
,16758&7,21 $18$/
3
&
217(176
6DIHW\ SUHFDXWLRQV IRU SRUWDEOH
JHQHUDWRUV
/HDGLQJSDUWLFXODUV
*HQHUDOGHVFULSWLRQ
%RG\ZRUN
DUNLQJV
&RQWURODQGLQGLFDWRUSDQHO
%DWWHU\VZLWFK
5HPRWHVWDUW56
2XWSXWFRQQHFWLRQV
'LSVZLWFKHV
([WHUQDOIXHOWDQNFRQQHFWLRQ
'UDLQSOXJVDQGILOOHUFDSV
7ULSOHYROWDJHZLWKVZLWFK96:
2SHUDWLQJLQVWUXFWLRQV
,QVWDOODWLRQ
&RQQHFWLQJWKHJHQHUDWRU
%HIRUHVWDUWLQJ
6WDUWLQJ
'XULQJRSHUDWLRQ
6WRSSLQJ
0DLQWHQDQFH
DLQWHQDQFHVFKHGXOH
(QJLQHPDLQWHQDQFH
HDVXULQJWKHDOWHUQDWRULQVXODWLRQ
UHVLVWDQFH
6WRUDJHRIWKHJHQHUDWRU
6WRUDJH
3UHSDULQJIRURSHUDWLRQDIWHUVWRUDJH
&KHFNVDQGWURXEOHVKRRWLQJ
&KHFNLQJYROWPHWHU3
&KHFNLQJIUHTXHQF\PHWHU3
&KHFNLQJDPPHWHUV
$OWHUQDWRUWURXEOHVKRRWLQJ
(QJLQHWURXEOHVKRRWLQJ
7HFKQLFDOVSHFLILFDWLRQV
5HDGLQJVRQJDXJHV
6HWWLQJVRIVZLWFKHV
6SHFLILFDWLRQVRIWKHHQJLQHDOWHUQDWRUXQLW
&RQYHUVLRQOLVWRI6,XQLWVLQWR%ULWLVKXQLWV
'DWDSODWH
&RQJUDWXODWLRQVRQWKHSXUFKDVHRI\RXU4$6$&JHQHUD
WRU,WLVDVROLGVDIHDQGUHOLDEOHPDFKLQHEXLOWDFFRUGLQJWR
WKHODWHVWWHFKQRORJ\)ROOR WKHLQVWUXFWLRQVLQWKLVERRNOHWDQG
HJXDUDQWHH\RX\HDUVRIWURXEOHIUHHRSHUDWLRQ3OHDVHUHDG
WKHIROOR LQJLQVWUXFWLRQVFDUHIXOO\EHIRUHVWDUWLQJWRXVH\RXU
PDFKLQH
:KLOHHYHU\HIIRUWKDVEHHQPDGHWRHQVXUHWKDWWKHLQIRUPDWLRQ
LQWKLVPDQXDOLVFRUUHFW$WODV&RSFRGRHVQRWDVVXPHUHVSRQ
VLELOLW\ IRU SRVVLEOH HUURUV $WODV &RSFR UHVHUYHV WKH ULJKW WR
PDNHFKDQJHV LWKRXWSULRUQRWLFH
4$6*G86$
4
6$)(7<35(&$87,216)253257$%/(*(1(5$7256
7REHUHDGDWWHQWLYHO\DQGDFWHGDFFRUGLQJO\EHIRUHWRZLQJOLIWLQJRSHUDWLQJSHUIRUPLQJPDLQWHQDQFHRUUHSDLULQJWKHJHQHUDWRU
,
1752'8&7,21
The policy of Atlas Copco is to provide the users of their equipment with safe,
reliable and efficient products. Factors taken into account are among others:
- the intended and predictable future use of the products, and the
environments in which they are expected to operate,
- applicable rules, codes and regulations,
- the expected useful product life, assuming proper service and
maintenance,
- providing the manual with up-to-date information.
Before handling any product, take time to read the relevant instruction manual.
Besides giving detailed operating instructions, it also gives specific
information about safety, preventive maintenance, etc.
Keep the manual always at the unit location, easy accessible to the operating
personnel.
See also the safety precautions of the engine and possible other equipment,
which are separately sent along or are mentioned on the equipment or parts of
the unit.
These safety precautions are general and some statements will therefore not
always apply to a particular unit.
Only people that have the right skills should be allowed to operate, adjust,
perform maintenance or repair on Atlas Copco equipment. It is the
responsibility of management to appoint operators with the appropriate
training and skill for each category of job.
6NLOOOHYHO 2SHUDWRU
An operator is trained in all aspects of operating the unit with the push-buttons,
and is trained to know the safety aspects.
6NLOOOHYHO 0HFKDQLFDOWHFKQLFLDQ
A mechanical technician is trained to operate the unit the same as the operator.
In addition, the mechanical technician is also trained to perform maintenance
and repair, as described in the instruction manual, and is allowed to change
settings of the control and safety system. A mechanical technician does not
work on live electrical components.
6NLOOOHYHO (OHFWULFDOWHFKQLFLDQ
An electrical technician is trained and has the same qualifications as both the
operator and the mechanical technician. In addition, the electrical technician
may carry out electrical repairs within the various enclosures of the unit. This
includes work on live electrical components.
6NLOOOHYHO 6SHFLDOLVWIURPWKHPDQXIDFWXUHU
This is a skilled specialist sent by the manufacturer or its agent to perform
complex repairs or modifications to the equipment.
In general it is recommended that not more than two people operate the unit,
more operators could lead to unsafe operating conditions. Take necessary steps
to keep unauthorized persons away from the unit and eliminate all possible
sources of danger at the unit.
When handling, operating, overhauling and/or performing maintenance or
repair on Atlas Copco equipment, the mechanics are expected to use safe
engineering practices and to observe all relevant local safety requirements and
ordinances. The following list is a reminder of special safety directives and
precautions mainly applicable to Atlas Copco equipment.
Neglecting the safety precautions may endanger people as well as environment
and machinery:
- endanger people due to electrical, mechanical or chemical influences,
- endanger the environment due to leakage of oil, solvents or other
substances,
- endanger the machinery due to function failures.
All responsibility for any damage or injury resulting from neglecting these
precautions or by non-observance of ordinary caution and due care required in
handling, operating, maintenance or repair, also if not expressly mentioned in
this instruction manual, is disclaimed by Atlas Copco.
The manufacturer does not accept any liability for any damage arising from the
use of non-original parts and for modifications, additions or conversions made
without the manufacturer’s approval in writing.
If any statement in this manual does not comply with local legislation, the
stricter of the two shall be applied.
Statements in these safety precautions should not be interpreted as suggestions,
recommendations or inducements that it should be used in violation of any
applicable laws or regulations.
*
(1(5$/
6$)(7<
35(&$87,216
1 The owner is responsible for maintaining the unit in a safe operating
condition. Unit parts and accessories must be replaced if missing or
unsuitable for safe operation.
2 The supervisor, or the responsible person, shall at all times make sure that
all instructions regarding machinery and equipment operation and
maintenance are strictly followed and that the machines with all
accessories and safety devices, as well as the consuming devices, are in
good repair, free of abnormal wear or abuse, and are not tampered with.
3 Whenever there is an indication or any suspicion that an internal part of a
machine is overheated, the machine shall be stopped but no inspection
covers shall be opened before sufficient cooling time has elapsed; this to
avoid the risk of spontaneous ignition of oil vapor when air is admitted.
4 Normal ratings (pressures, temperatures, speeds, etc.) shall be durably
marked.
5 Operate the unit only for the intended purpose and within its rated limits
(pressure, temperature, speeds, etc.).
6 The machinery and equipment shall be kept clean, i.e. as free as possible
from oil, dust or other deposits.
7 To prevent an increase in working temperature, inspect and clean heat
transfer surfaces (cooler fins, intercoolers, water jackets, etc.) regularly.
See the maintenance schedule.
8 All regulating and safety devices shall be maintained with due care to
ensure that they function properly. They may not be put out of action.
9 Pressure and temperature gauges shall be checked regularly with regard to
their accuracy. They shall be replaced whenever outside acceptable
tolerances.
10 Safety devices shall be tested as described in the maintenance schedule of
the instruction manual to determine that they are in good operating
condition.
11 Mind the markings and information labels on the unit.
12 In the event the safety labels are damaged or destroyed, they must be
replaced to ensure operator safety.
13 Keep the work area neat. Lack of order will increase the risk of accidents.
14 When working on the unit, wear safety clothing. Depending on the kind of
activities these are: safety glasses, ear protection, safety helmet (including
visor), safety gloves, protective clothing, safety shoes. Do not wear the
hair long and loose (protect long hair with a hairnet), or wear loose
clothing or jewelry.
15 Take precautions against fire. Handle fuel, oil and anti-freeze with care
because they are inflammable substances. Do not smoke or approach with
naked flame when handling such substances. Keep a fire-extinguisher in
the vicinity.
16a
3RUWDEOHJHQHUDWRUVZLWKHDUWKLQJSLQ
Earth the generator as well as the load properly.
16b
3RUWDEOHJHQHUDWRUV,7
1RWH
This generator is built to supply a sheer alternating current IT
network.
Earth the load properly.
,16758&7,21 $18$/
5
6
$)(7<
'85,1*
75$163257
$1'
,167$//$7,21
To lift a unit, all loose or pivoting parts, e.g. doors and towbar, shall first be
securely fastened.
Do not attach cables, chains or ropes directly to the lifting eye; apply a crane
hook or lifting shackle meeting local safety regulations. Never allow sharp
bends in lifting cables, chains or ropes.
Helicopter lifting is not allowed.
It is strictly forbidden to dwell or stay in the risk zone under a lifted load.
Never lift the unit over people or residential areas. Lifting acceleration and
retardation shall be kept within safe limits.
1 Before towing the unit:
- check the towbar, the brake system and the towing eye. Also check the
coupling of the towing vehicle,
- check the towing and brake capability of the towing vehicle,
- check that the towbar, jockey wheel or stand leg is safely locked in the
raised position,
- ascertain that the towing eye can swivel freely on the hook,
- check that the wheels are secure and that the tires are in good condition
and inflated correctly,
- connect the signalisation cable, check all lights and connect the
pneumatic brake couplers,
- attach the safety break-away cable or safety chain to the towing vehicle,
- remove wheel chocks, if applied, and disengage the parking brake.
2 To tow a unit use a towing vehicle of ample capacity. Refer to the
documentation of the towing vehicle.
3 If the unit is to be backed up by the towing vehicle, disengage the overrun
brake mechanism (if it is not an automatic mechanism).
4 Never exceed the maximum towing speed of the unit (mind the local
regulations).
5 Place the unit on level ground and apply the parking brake before
disconnecting the unit from the towing vehicle. Unclip the safety break-
away cable or safety chain. If the unit has no parking brake or jockey
wheel, immobilize the unit by placing chocks in front of and/or behind the
wheels. When the towbar can be positioned vertically, the locking device
must be applied and kept in good order.
6 To lift heavy parts, a hoist of ample capacity, tested and approved
according to local safety regulations, shall be used.
7 Lifting hooks, eyes, shackles, etc., shall never be bent and shall only have
stress in line with their design load axis. The capacity of a lifting device
diminishes when the lifting force is applied at an angle to its load axis.
8 For maximum safety and efficiency of the lifting apparatus all lifting
members shall be applied as near to perpendicular as possible. If required,
a lifting beam shall be applied between hoist and load.
9 Never leave a load hanging on a hoist.
10 A hoist has to be installed in such a way that the object will be lifted
perpendicular. If that is not possible, the necessary precautions must be
taken to prevent load-swinging, e.g. by using two hoists, each at
approximately the same angle not exceeding 30°from the vertical.
11 Locate the unit away from walls. Take all precautions to ensure that hot air
exhausted from the engine and driven machine cooling systems cannot be
recirculated. If such hot air is taken in by the engine or driven machine
cooling fan, this may cause overheating of the unit; if taken in for
combustion, the engine power will be reduced.
12 Generators shall be stalled on an even, solid floor, in a clean location with
sufficient ventilation. If the floor is not level or can vary in inclination,
consult Atlas Copco.
13 The electrical connections shall correspond to local codes. The machines
shall be earthed and protected against short circuits by fuses or circuit
breakers.
14 Never connect the generator outlets to an installation which is also
connected to a public mains.
15 Before connecting a load, switch off the corresponding circuit breaker, and
check whether frequency, voltage, current and power factor comply with
the ratings of the generator.
6
$)(7<
'85,1*
86(
$1'
23(5$7,21
1 When the unit has to operate in a fire-hazardous environment, each engine
exhaust has to be provided with a spark arrestor to trap incendiary sparks.
2 The exhaust contains carbon monoxide which is a lethal gas. When the
unit is used in a confined space, conduct the engine exhaust to the outside
atmosphere by a pipe of sufficient diameter; do this in such a way that no
extra back pressure is created for the engine. If necessary, install an
extractor. Observe any existing local regulations. Make sure that the unit
has sufficient air intake for operation. If necessary, install extra air intake
ducts.
3 When operating in a dust-laden atmosphere, place the unit so that dust is
not carried towards it by the wind. Operation in clean surroundings
considerably extends the intervals for cleaning the air intake filters and the
cores of the coolers.
4 Never remove a filler cap of the cooling water system of a hot engine. Wait
until the engine has sufficiently cooled down.
5 Never refill fuel while the unit is running, unless otherwise stated in the
Atlas Copco Instruction Book (AIB). Keep fuel away from hot parts such
as air outlet pipes or the engine exhaust. Do not smoke when fuelling.
When fuelling from an automatic pump, an earthing cable should be
connected to the unit to discharge static electricity. Never spill nor leave
oil, fuel, coolant or cleansing agent in or around the unit.
6 All doors shall be shut during operation so as not to disturb the cooling air
flow inside the bodywork and/or render the silencing less effective. A door
should be kept open for a short period only e.g. for inspection or
adjustment.
7 Periodically carry out maintenance works according to the maintenance
schedule.
8 Stationary housing guards are provided on all rotating or reciprocating
parts not otherwise protected and which may be hazardous to personnel.
Machinery shall never be put into operation, when such guards have been
removed, before the guards are securely reinstalled.
9 Noise, even at reasonable levels, can cause irritation and disturbance
which, over a long period of time, may cause severe injuries to the nervous
system of human beings.
When the sound pressure level, at any point where personnel normally has
to attend, is:
below 70 dB(A): no action needs to be taken,
above 70 dB(A): noise-protective devices should be provided for people
continuously being present in the room,
below 85 dB(A): no action needs to be taken for occasional visitors
staying a limited time only,
above 85 dB(A): room to be classified as a noise-hazardous area and an
obvious warning shall be placed permanently at each
entrance to alert people entering the room, for even
relatively short times, about the need to wear ear
protectors,
above 95 dB(A): the warning(s) at the entrance(s) shall be completed
with the recommendation that also occasional visitors
shall wear ear protectors,
above 105 dB(A): special ear protectors that are adequate for this noise
level and the spectral composition of the noise shall be
provided and a special warning to that effect shall be
placed at each entrance.
10 Insulation or safety guards of parts the temperature of which can be in
excess of 80 °C (175 °F) and which may be accidentally touched by
personnel shall not be removed before the parts have cooled to room
temperature.
11 Never operate the unit in surroundings where there is a possibility of
taking in flammable or toxic fumes.
12 If the working process produces fumes, dust or vibration hazards, etc., take
the necessary steps to eliminate the risk of personnel injury.
13 When using compressed air or inert gas to clean down equipment, do so
with caution and use the appropriate protection, at least safety glasses, for
the operator as well as for any bystander. Do not apply compressed air or
inert gas to your skin or direct an air or gas stream at people. Never use it
to clean dirt from your clothes.
14 When washing parts in or with a cleaning solvent, provide the required
ventilation and use appropriate protection such as a breathing filter, safety
glasses, rubber apron and gloves, etc.
4$6*G86$
6
15 Safety shoes should be compulsory in any workshop and if there is a risk,
however small, of falling objects, wearing of a safety helmet should be
included.
16 If there is a risk of inhaling hazardous gases, fumes or dust, the respiratory
organs must be protected and depending on the nature of the hazard, so
must the eyes and skin.
17 Remember that where there is visible dust, the finer, invisible particles will
almost certainly be present too; but the fact that no dust can be seen is not
a reliable indication that dangerous, invisible dust is not present in the air.
18 Never operate the generator in excess of its limits as indicated in the
technical specifications and avoid long no-load sequences.
19 Never operate the generator in a humid atmosphere. Excessive moisture
causes worsening of the generator insulation.
20 Do not open electrical cabinets, cubicles or other equipment while voltage
is supplied. If such cannot be avoided, e.g. for measurements, tests or
adjustments, have the action carried out by a qualified electrician only,
with appropriate tools, and ascertain that the required bodily protection
against electrical hazards is applied.
21 Never touch the power terminals during operation of the machine.
22 Whenever an abnormal condition arises, e.g. excessive vibration, noise,
odor, etc., switch the circuit breakers to OFF and stop the engine. Correct
the faulty condition before restarting.
23 Check the electric cables regularly. Damaged cables and insufficient
tightening of connections may cause electric shocks. Whenever damaged
wires or dangerous conditions are observed, switch the circuit breakers to
OFF and stop the engine. Replace the damaged wires or correct the
dangerous condition before restarting. Make sure that all electric
connections are securely tightened.
24 Avoid overloading the generator. The generator is provided with circuit
breakers for overload protection. When a breaker has tripped, reduce the
concerned load before restarting.
25 If the generator is used as stand-by for the mains supply, it must not be
operated without control system which automatically disconnects the
generator from the mains when the mains supply is restored.
26 Never remove the cover of the output terminals during operation. Before
connecting or disconnecting wires, switch off the load and the circuit
breakers, stop the machine and make sure that the machine cannot be
started inadvertently or there is any residual voltage on the power circuit.
27 Running the generator at low load for long periods will reduce the lifetime
of the engine.
6
$)(7<
'85,1*
0$,17(1$1&(
$1'
5(3$,5
Maintenance, overhaul and repair work shall only be carried out by adequately
trained personnel; if required, under supervision of someone qualified for the
job.
1 Use only the correct tools for maintenance and repair work, and only tools
which are in good condition.
2 Parts shall only be replaced by genuine Atlas Copco replacement parts.
3 All maintenance work, other than routine attention, shall only be
undertaken when the unit is stopped. Steps shall be taken to prevent
inadvertent starting. In addition, a warning sign bearing a legend such as
”work in progress; do not start”shall be attached to the starting equipment.
On engine-driven units the battery shall be disconnected and removed or
the terminals covered by insulating caps.
On electrically driven units the main switch shall be locked in open
position and the fuses shall be taken out. A warning sign bearing a legend
such as ”work in progress; do not supply voltage”shall be attached to the
fuse box or main switch.
4 Prior to stripping an engine or other machine or undertaking major
overhaul on it, prevent all movable parts from rolling over or moving.
5 Make sure that no tools, loose parts or rags are left in or on the machine.
Never leave rags or loose clothing near the engine air intake.
6 Never use flammable solvents for cleaning (fire-risk).
7 Take safety precautions against toxic vapors of cleaning liquids.
8 Never use machine parts as a climbing aid.
9 Observe scrupulous cleanliness during maintenance and repair. Keep away
dirt, cover the parts and exposed openings with a clean cloth, paper or
tape.
10 Never weld on or perform any operation involving heat near the fuel or oil
systems. Fuel and oil tanks must be completely purged, e.g. by steam-
cleaning, before carrying out such operations. Never weld on, or in any
way modify, pressure vessels. Disconnect the alternator cables during arc
welding on the unit.
11 Support the towbar and the axle(s) securely if working underneath the unit
or when removing a wheel. Do not rely on jacks.
12 Do not remove any of, or tamper with, the sound-damping material. Keep
the material free of dirt and liquids such as fuel, oil and cleansing agents.
If any sound-damping material is damaged, replace it to prevent the sound
pressure level from increasing.
13 Use only lubricating oils and greases recommended or approved by Atlas
Copco or the machine manufacturer. Ascertain that the selected lubricants
comply with all applicable safety regulations, especially with regard to
explosion or fire-risk and the possibility of decomposition or generation of
hazardous gases. Never mix synthetic with mineral oil.
14 Protect the engine, alternator, air intake filter, electrical and regulating
components, etc., to prevent moisture ingress, e.g. when steam-cleaning.
15 When performing any operation involving heat, flames or sparks on a
machine, the surrounding components shall first be screened with non-
flammable material.
16 Never use a light source with open flame for inspecting the interior of a
machine.
17 When repair has been completed, the machine shall be barred over at least
one revolution for reciprocating machines, several revolutions for rotary
ones to ensure that there is no mechanical interference within the machine
or driver. Check the direction of rotation of electric motors when starting
up the machine initially and after any alteration to the electrical
connection(s) or switch gear, to check that the oil pump and the fan
function properly.
18 Maintenance and repair work should be recorded in an operator’s logbook
for all machinery. Frequency and nature of repairs can reveal unsafe
conditions.
19 When hot parts have to be handled, e.g. shrink fitting, special heat-
resistant gloves shall be used and, if required, other body protection shall
be applied.
20 When using cartridge type breathing filter equipment, ascertain that the
correct type of cartridge is used and that its useful service life is not
surpassed.
21 Make sure that oil, solvents and other substances likely to pollute the
environment are properly disposed of.
,16758&7,21 $18$/
7
22 Before clearing the generator for use after maintenance or overhaul,
submit it to a testrun, check that the AC power performance is correct and
that the control and shut down devices function correctly.
7
22/
$33/,&$7,216
6$)(7<
Apply the proper tool for each job. With the knowledge of correct tool use and
knowing the limitations of tools, along with some common sense, many
accidents can be prevented.
Special service tools are available for specific jobs and should be used when
recommended. The use of these tools will save time and prevent damage to
parts.
%
$77(5<
6$)(7<
35(&$87,216
%DWWHULHV
When servicing batteries, always wear protecting clothing and glasses.
1 The electrolyte in batteries is a sulphuric acid solution which is fatal if it
hits your eyes, and which can cause burns if it contacts your skin.
Therefore, be careful when handling batteries, e.g. when checking the
charge condition.
2 Install a sign prohibiting fire, open flame and smoking at the post where
batteries are being charged.
3 When batteries are being charged, an explosive gas mixture forms in the
cells and might escape through the vent holes in the plugs.
Thus an explosive atmosphere may form around the battery if ventilation
is poor, and can remain in and around the battery for several hours after it
has been charged. Therefore:
- never smoke near batteries being, or having recently been, charged,
- never break live circuits at battery terminals, because a spark usually
occurs.
4 When connecting an auxiliary battery (AB) in parallel to the unit battery
(CB) with booster cables: connect the + pole of AB to the + pole of CB,
then connect the - pole of CB to the mass of the unit. Disconnect in the
reverse order.
4$6*G86$
8
/($',1*3$57,&8/$56
*
(1(5$/
'(6&5,37,21
The QAS366 is an AC generator, built for continuous running at sites
where no electricity is available or as stand-by in cases of interruption
of the mains.
The QAS366 generator is driven by a water-cooled diesel engine, man-
ufactured by DETROIT DIESEL.
The generator can run in 2 different modes:
An overview of the main parts is given in the diagram below.
3 phase - lower voltage 60 Hz 208 V 386.2 hp / 288 kW
3 phase - higher voltage 60 Hz 480 V 386.2 hp / 288 kW
1 Lifting eye A Alternator FCF Filler cap fuel
2 Guiding rod AF Air filter FCO Filler cap engine oil
3 Side doors, access to engine and alternator C Coupling FCW Filter cap cooling water
4 Engine exhaust DFO Drain flexible engine oil FF Fuel filter
5 Data Plate DFW Drain flexible cooling water FPF Fuel pre-filter
6 Grounding rod DH Drain and access hole (in the frame) G1 Battery
7 Side door, access to control and indicator panel DPF Drain plug fuel OF Oil filter
8 Output terminal board DPO Drain pump engine oil OLD Engine oil level dipstick
9 Hole for forklift E Engine S1 Battery switch
F Fan 3WV 3-way valve for external fueltank connection
diesel
ATLASCOPCOAIRPOWER n.v.
1200 Kg
S
1N
N
N
N
N
Hz
kVA
kW
V
COP
COP
3/N/PE
A
P
V
I
1994
49
400/230
27
34
50
cosphi cl. G2.
MADEBYATLASCOPCOAIRPOWERn.v. WILRIJK BELGIUM
1615694500
-YA3-606035-xxxxxx-
97
4
G1DPO
DPF
5
3FCF 3
6 87
2
FCWS1 AF
1
COF 9 9
A 3WV
4
FCW
E FFFCOOLD
DFW DH
,16758&7,21 $18$/
9
%
2'<:25.
The alternator, the engine, the cooling system, etc. are enclosed in a
sound-insulated bodywork that can be opened by means of side doors
(and service plates).
The generator’s lifting eye is located in the middle of the roof. The re-
cesses in the roof have guiding rods at both sides.
To be able to lift the QAS366 by means of a forklift, rectangular holes
are provided in the frame.
0
$5.,1*6
A brief description of all markings provided on the QAS366 is given
hereafter.
&
21752/
$1'
,1',&$725
3$1(/
The control and indicator panel is located behinda door in the side pan-
el. The hinged door is partly transparent and allows easy access to the
parts mounted behind it. Panel light H1 lights up as soon as the starter
switch is turned into position or the remote start/stop switch is put
in position start, indicating that the fuel solenoid is energized.
(QJLQHJDXJHV
3 +RXUPHWHU
3 )XHOOHYHOJDXJH
3 (QJLQHFRRODQWWHPSHUDWXUHJDXJH
3 (QJLQHRLOSUHVVXUHJDXJH
*HQHUDWRUJDXJHV
3 $PPHWHUOLQH/
Indicates the outgoing current in the first line (L1).
3 $PPHWHUOLQH/
Indicates the outgoing current in the second line (L2).
3 $PPHWHUOLQH/
Indicates the outgoing current in the third line (L3).
3 ROWPHWHU
Indicates the voltage selected by means of voltage selector
switch S4.
3 )UHTXHQF\530PHWHU
Indicates the frequency of the supply voltage and the speed of
the engine.
6 ROWPHWHUVHOHFWRUVZLWFK
Allows to measure the voltage between each of the phases and
between each phase and the neutral. It also allows to switch off
the voltmeter.
6HSDUDWHGLDJQRVWLFVRFNHW
;'LDJQRVWLFGDWDVRFNHW
Allows to connect the diagnostic data reader. Refer to chapter
“Checks and trouble shooting - Engine trouble shooting”.
1HYHUXVHWKHJXLGLQJURGVWROLIWWKHJHQHUDWRU
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 harm-
ful gas, which is toxic in case of inhalation. Always
make sure that the unit is operated outside or in a
well-ventilated room.
Indicates that these parts can become very hot dur-
ing operation (e.g. engine, cooler, etc.). Always
make sure that these parts are cooled down before
touching them.
Indicates that the generator may be refuelled with
diesel fuel only.
Indicates the drain for the engine oil.
Indicates the drain for the coolant.
Indicates the drain plug for the engine fuel.
Indicates that the guiding rods may not be used to
lift the generator. Always use the lifting eye in the
roof of the generator to lift it.
Indicates the lifting eye of the generator.
Indicates that the unit may start automati-
cally and that the instruction book has to be
consulted prior to use.
Indicates the 3-way valve.
Indicates the battery switch.
!
diesel
X20 P6S15
F4P7P9P8
60/5A I
ME
L2
A
I
ME
RPM
HZ
60/5A I
ME
L1
A
60/5A I
ME
L3
A
P4 R11
I
ME
V
P5
OFF L1-NL1L2
L2-N
LN
L3L1
L2L3
S4
P1 P2 P3
60 80 100 120
°C
0000 0
bar
0123450
1/2
1/1
H1
V
LL
HZ
L1
SINGLE PARALLEL
45
50
55
6065
0
400
200
200
100
0
200
100
0
200
100
0
4$6*G86$
10
3DUDOOHOLQJ
6 6LQJOHSDUDOOHOVZLWFK
Enables the generator (combined with the SAPE unit) to oper-
ate in parallel mode. For details refer to the SAPE unit instruc-
tion manual.
(QJLQHFRQWUROVDQGODPSV
/ (OHFWULFDOV\VWHPLQGLFDWRU
Lights up when the electrical system of the engine is energized.
/ $OWHUQDWRUFKDUJLQJLQGLFDWRU
Goes out after starting, indicating that the alternator is charg-
ing. A failing alternator however will not shut theengine down.
/ $&VKXWGRZQLQGLFDWRU
Lights up when no AC input (< 75 V) is present.
/ 2YHUVSHHGVKXWGRZQLQGLFDWRU
Lights up when the engine’s speed has exceeded 115 % of the
nominal speed.
/ 6SDUHVKXWGRZQLQGLFDWRU
Can be used to wire an extra shut down.
/ (QJLQHVKXWGRZQ
Lights up when a major fault occurred which shuts down the
engine.
/ 6SDUHVKXWGRZQLQGLFDWRU
Can be used to wire an extra shut down.
/ &KHFNHQJLQHOLJKW
With the starter switch into the P1/P5 position and the engine
running, push and hold the diagnostic request switch to have
the inactive codes flashing on the check engine light.
/ 6WRSHQJLQHOLJKW
With the starter switch into the P1/P5 position and the engine
running, push and hold the diagnostic request switch to have
the active codes flashing on the stop engine light.
/ )XHOOHYHOLQGLFDWRU
Lights up when the fuel level is below 20 % of the maximum
fuel tank capacity.
67 6WDUWHUVZLWFK
3 3RVLWLRQ3
Used to select normal start and to disable remote start. If the
unit fails to start the first time, two more starting attempts will
take place with 12 seconds waiting time in between.
3 3RVLWLRQ3
Used to switch off the power supply from the battery or to reset
after a shutdown due to a failure. The unit will not be able to
start up.
3 3RVLWLRQ3
Used to select remote start.
3 3RVLWLRQ3
The generator will not start. When the starter switch is in this
position, the engine faults can be read out by the diagnostic re-
quest button (DB).
'% 'LDJQRVWLFUHTXHVWVZLWFK
With the ignition switch on and the engine at idle or not run-
ning, push and hold the switch to have the active codes flashing
on the stop engine light (L6), followed by the inactive codes
flashing on the check engine light (L7). For detailed informa-
tion concerning the engine diagnostic codes, see chapter “En-
gine trouble shooting”- “Engine diagnostic codes”on page 19.
) )XVH
The fuse activates when the current from the battery to the en-
gine control circuit exceeds its setting. The fuse can be
switched on and off by pushing the button.
)$ )UHTXHQF\DGMXVWSRWHQWLRPHWHU
Allows to adjust the frequency of the output voltage. This ad-
justment has no influence on the output voltage.
5 2XWSXWYROWDJHDGMXVWSRWHQWLRPHWHU
Allows to adjust the output voltage. R11 is located on the con-
trol and indicator panel.
$IWHUDSSUR[LPDWHO\VHFRQGVLQSRVLWLRQ ZLWK
RXW VWDUWLQJ WKH FRQWURO V\VWHP ZLOO DXWRPDWLFDOO\
VKXWGRZQEDWWHU\VDYLQJSXUSRVHLQGLFDWLQJDORZ
RLOSUHVVXUHIDLOXUH ,QWKLVFDVHDUHVHWRIWKHFRQWURO
V\VWHPE\SXWWLQJWKHVZLWFKLQSRVLWLRQ2LVQHFHV
VDU\
&KDQJLQJWKHRXWSXWIUHTXHQF\LVRQO\DOORZHGDIWHU
GLVFRQQHFWLQJWKHORDG
!
!
,16758&7,21 $18$/
11
%
$77(5<
6:,7&+
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.
5
(027(
67$57
56
"Remote start" allows to switch the unit on or off without using the
control panel located on the unit. The start module of the control panel
provides extra connections for the remote start/stop switch and the
plant contactor (voltage free contact), both to be installed by the cus-
tomer.
2
87387
&211(&7,216
The output connections are situated below the control and indicator
panel.
6 (PHUJHQF\VWRSEXWWRQ
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.
4&LUFXLWEUHDNHUIRUORZYROWDJH
Interrupts the low voltage power supply towards X1 when a
short-circuit occurs at the load side, or when the overcurrent
protection (1000 A) is activated. It must be reset manually after
eliminating the problem.
4&LUFXLWEUHDNHUIRUKLJKYROWDJH
Interrupts the high voltage power supply towards X1 when a
short-circuit occurs at the load side, or when the overcurrent
protection (440 A) is activated. It must be reset manually after
eliminating the problem.
4&LUFXLWEUHDNHU
Interrupts phase L2 towards X2 when a short-circuit occurs at
the load side, or when the overcurrent protection (20 A) is acti-
vated. It must be reset manually after eliminating the problem.
4&LUFXLWEUHDNHU
Interrupts line L1 and L2 towards X3 when a short-circuit oc-
curs at the load side, or when the overcurrent protection (50 A)
is activated. It must be reset manually after eliminating the
problem.
4&LUFXLWEUHDNHU
Interrupts line L1 and L2 towards X4 when a short-circuit oc-
curs at the load side, or when the overcurrent protection (50 A)
is activated. It must be reset manually after eliminating the
problem.
;0DLQSRZHUVXSSO\7HUPLQDOERDUG
Terminals L1, L2, L3, N (=neutral) and PE (= grounding), hid-
den behind the control panel door and behind a small transpar-
ent door.
;6LQJOHSKDVHRXWOHWVRFNHW
Provides lines L2, N (= neutral), and PE (= grounding).
;6LQJOHSKDVHRXWOHWVRFNHW
Provides lines L1, L2, N (= neutral), and PE (= grounding).
;6LQJOHSKDVHRXWOHWVRFNHW
Provides lines L1, L2, N (= neutral), and PE (= grounding).
;&RQQHFWLRQEORFN
Allows easy connection for a remote start switch.
;&RQQHFWRU;
Connector for communication between the generator and the
SAPE unit.For details refer to the SAPE unit instruction manual.
1HYHUWXUQWKHEDWWHU\VZLWFKRIIZKLOHWKHHQJLQHLV
UXQQLQJ
7KHSODQWFRQWDFWRUVKRXOGEHVL]HGDFFRUGLQJWRWKH
ORDG 7KH PD[LPXP FXUUHQW WKURXJK WKH YROWDJH
IUHHFRQWDFWLV$
7KHUHPRWHVWDUWVWRSVZLWFK6[KDVWRPHHWWKHIRO
ORZLQJVSHFLILFDWLRQV9'&$
5HIHUWRWKHFLUFXLWGLDJUDPIRUWKHFRUUHFWFRQQHF
WLRQRIWKHSODQWFRQWDFWRUDQGWKHUHPRWHVWDUWVWRS
VZLWFK
$ VKXQW WULS FRLO ZLOO VZLWFK RII 4 RU 4
GHSHQGLQJRQWKHPRGHWKHJHQHUDWRULVUXQQLQJLQ
LQFDVHRIDQHPHUJHQF\VWRSRUDQHDUWKIDXOW
!
!
S2
Q3
Q1.2
Q4
X33
X4
X2
X2
Q1.1 Q1.2
208-240V 480V
Q4
Q2 Q3
L1 L2 L3 N PE
X1
X25
X3
X25
X1
Q1.1
Q2
X3 X4
5HIHUWRWKHFLUFXLWGLDJUDPVIRUWKHFRUUHFWFRQQHF
WLRQ
!
4$6*G86$
12
'
,3
6:,7&+(6
For correct functioning of the module, the DIP switches at the back of
the control module should be positioned as follows:
(
;7(51$/
)8(/7$1.
&211(&7,21
The "External fueltank connection" allows to bypass the internal
fueltank and to connect an external fueltank to the unit.
When using an external fueltank, make sure to connect the fuel supply
line as well as the fuel return line. Connections to fuellines ought to be
air-tight to prevent air from entering the fuel system.
'
5$,1
3/8*6
$1'
),//(5
&$36
The drain holes for the engine oil, the coolant and the plug for the fuel,
are located and labelled on the frame; the fuel drain plug at the front,
the others at the service side.
The drain flexible for engine oil can be brought to the outside of the
generator through the drain hole.
The filler cap for the engine coolant is accessible via an opening in the
roof. The fuel filler cap is located in the side panel.
7
5,3/(
92/7$*(
:,7+
6:,7&+
96:
The generator can run in two different modes:
–3 phase, lower voltage
–3 phase, higher 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 the same time.
This is prevented by means of the auxiliary voltage selection relays
K11 and K12 (refer to the circuit diagram).
The selection between the three modes is done by means of S10.
6 2XWSXWYROWDJHVHOHFWRUVZLWFK
Allows to select a 3 phase high output voltage, a 3 phase low
output voltage or a 1 phase low output voltage. Selector switch
S10 is located on the alternator.
SKDVHORZHUYROWDJH
When using this selection, the generator provides a 208 V output volt-
age.
SKDVHKLJKHUYROWDJH
When using this selection, the generator provides a 480 V output volt-
age.
Indicatesthe fuel supplyline from the tank to the en-
gine.
Indicates the fuel return line from the engine to the
tank.
Indicates the internal fueltank.
Indicates the external fueltank.
7KH GUDLQ KROH FDQ DOVR EH XVHG WR JXLGH H[WHUQDO
IXHOWDQNFRQQHFWLRQV :KHQFRQQHFWLQJDQH[WHUQDO
IXHOWDQN XVH WKH ZD\ YDOYHV 5HIHU WR ³([WHUQDO
IXHOWDQNFRQQHFWLRQ´
ON
5H
1 2 3 4
!
&KDQJLQJ WKH RXWSXW YROWDJH LV RQO\ DOORZHG DIWHU
VKXWGRZQ
$IWHUFKDQJLQJWKHRXWSXW YROWDJHE\PHDQVRIWKH
VHOHFWLRQ VZLWFK 6 DGMXVW WKH RXWSXW YROWDJH E\
PHDQVRISRWHQWLRPHWHU5WRWKHUHTXLUHGYDOXH
!
,16758&7,21 $18$/
13
23(5$7,1*,16758&7,216
,
167$//$7,21
–Place the generator on a horizontal, even and solid floor.
–Check that the engine exhaust is not directed towards people. If the
generator is operated indoors, install an exhaust pipe of sufficient
diameter to duct the engine exhaust towards the outside. Check for
sufficient ventilation so that the cooling air is not recirculated. If
necessary, consult Atlas Copco.
–Leave enough space for operation, inspection and maintenance (at
least 1 meter at each side).
–Check that the inner earthing system is in compliance with the local
legislation.
–Use coolant for the engine cooling system. Refer to the Engine in-
struction book for the proper coolant mixture.
–Check the tightness of the bolts and nuts.
&
211(&7,1*
7+(
*(1(5$725
3UHFDXWLRQV IRU QRQOLQHDU DQG VHQVLWLYH
ORDGV
The most common non-linear, 3-phase loads are thyristor/rectifier-con-
trolled loads, such as convertors supplying voltage to variable speed
motors, uninterruptable power supplies and Telecom supplies. Gas-
discharge lighting arranged in single-phase circuits generate 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 el-
evators.
Consult Atlas Copco for measures against the adverse influence of
non-linear loads.
4XDOLW\ PLQLPXP VHFWLRQ DQG PD[LPXP
OHQJWKRIFDEOHV
The cable connected to the terminal board of the generator must be se-
lected in accordance with local legislation. The type of cable, its rated
voltage and current carrying capacity are determined by installation
conditions, stress and ambient temperature. For flexible wiring, rub-
ber-sheathed, flexible core conductors must be used.
&RQQHFWLQJWKHORDG
6LWHGLVWULEXWLRQSDQHO
If outlet sockets are required, they must be mounted on a site distribu-
tion panel supplied from the terminal board of the generator and in
compliance with local regulations for power installations on building
sites.
,Q\RXURZQLQWHUHVWDOZD\VVWULFWO\REVHUYHDOOUHOH
YDQWVDIHW\LQVWUXFWLRQV
'RQRWRSHUDWHWKHJHQHUDWRULQH[FHVVRIWKHOLPLWD
WLRQVPHQWLRQHGLQWKH7HFKQLFDO6SHFLILFDWLRQV
/RFDOUXOHVFRQFHUQLQJWKHVHWWLQJXSRIORZYROWDJH
SRZHU LQVWDOODWLRQV EHORZ 9 PXVW EH
UHVSHFWHG ZKHQ FRQQHFWLQJ VLWH GLVWULEXWLRQSDQHOV
VZLWFKJHDURUORDGVWRWKHJHQHUDWRU
$WHDFKVWDUWXSDQGDWDQ\WLPHDQHZORDGLVFRQ
QHFWHGWKHHDUWKLQJRIWKHJHQHUDWRUPXVWEHYHUL
ILHG (DUWKLQJPXVWEHGRQHHLWKHUE\WKHHDUWKLQJ
URGRULIDYDLODEOHE\DQH[LVWLQJVXLWDEOHHDUWKLQJ
LQVWDOODWLRQ 7KHSURWHFWLYHV\VWHPDJDLQVWH[FHVVLYH
FRQWDFW YROWDJH LV QRW HIIHFWLYH XQOHVV D VXLWDEOH
HDUWKLQJLVPDGH
7KHJHQHUDWRULVZLUHGIRUD71V\VWHPWR,(&
L H RQHSRLQWLQWKHSRZHUVRXUFHGLUHFWO\HDUWKHG
LQ WKLV FDVH WKH QHXWUDO 7KH H[SRVHG FRQGXFWLYH
SDUWVRIWKHHOHFWULFLQVWDOODWLRQPXVWEHGLUHFWO\FRQ
QHFWHGWRWKHIXQFWLRQDOHDUWK
,IRSHUDWLQJWKHJHQHUDWRULQDQRWKHUSRZHUV\VWHP
H J DQ,7V\VWHPRWKHUSURWHFWLYHGHYLFHVUHTXLUHG
IRUWKHVHW\SHVPXVWEHLQVWDOOHG ,QDQ\FDVHRQO\D
TXDOLILHGHOHFWULFLDQLVDXWKRUL]HGWRUHPRYHWKHFRQ
QHFWLRQEHWZHHQWKHQHXWUDO1DQGHDUWKWHUPLQDOV
LQWKHWHUPLQDOER[RIWKHDOWHUQDWRU
!
1RQOLQHDU ORDGV GUDZFXUUHQWV ZLWK KLJK FRQWHQWV
LQKDUPRQLFVFDXVLQJGLVWRUWLRQLQWKHZDYHIRUPRI
WKHYROWDJHJHQHUDWHGE\WKHDOWHUQDWRU
!
4$6*G86$
14
3URWHFWLRQ
–Check whether frequency, voltage and current comply with the rat-
ings of the generator.
–Provide for the load cable, without excessive length, and lay it out
in a safe way without forming coils.
–Open the door of the control and indicator panel and the transparent
door in front of the terminal board X1.
–Provide the wire ends with cable lugs suited for the cable terminals.
–Loosen the cable clamp and push the wire ends of the load cable
through the orifice and clamp.
–Connect the wires to the proper terminals (L1, L2, L3, N and PE) of
X1 and tighten the bolts securely.
–Tighten the cable clamp.
–Close the transparent door in front of X1.
%
()25(
67$57,1*
–With the generator standing level, check the engine oil level and top
up if necessary. The oil level must be near to, but not exceed the
high mark on the engine oil level dipstick.
–Check the coolant level in the expansion tank of the engine cooling
system. The water level must be near to the FULL mark. Add cool-
ant if necessary.
–Drain any water and sediment from the fuel pre-filter. Check the
fuel level and top up if necessary. It is recommended to fill the tank
after the day’s operation to prevent watervapour 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 fuse F4 is not activated and that the emergency stop is in
the “OUT”position.
–Check that the load is switched off.
–Check that circuit breakers Q1.1 and Q1.2 are switched off.
–Check the correct position of the voltage selector switch (S10) on
the alternator.
–Turn the battery switch to ON.
6
7$57,1*
7RVWDUWXSWKHXQLWORFDOO\ZLWKRXWXVLQJWKHUH
PRWHVWDUWVWRSVZLWFKSURFHHGDVIROORZV
–Put the starter switch in position P1. The unit starts a preheating cy-
cle which takes 12 seconds.
–After the preheating period, the unit will start. The starting attempt
will take maximum 12 seconds. If the unit does not start immediate-
ly, it will perform another two starting attempts.
–Approximately 15 seconds after starting (stabilization time for the
generator), the timer relay closes the voltage free contact and the
plant contactor is energized (if installed).
–Check that the warning lamps on the control and indicator panel are
out. Refer to “Control and indicator panel”for component locations.
–Run the engine for approximately 5 minutes to warm up.
–Check the engine oil pressure (P9) and the cooling water tempera-
ture (P8).
–Check the voltmeter P4 (with voltmeter selector switch S4 in differ-
ent positions) and the frequency meter P5.
–Switch on circuit breaker Q1.1 or Q1.2, depending on the mode the
generator is running in.
–Switch on theload andcheck the ammeters P1, P2 and P3, voltmeter
P4 (voltmeter selector switch S4 in different positions) and the fre-
quency meter P5.
7RVWDUWXSWKHXQLWIURPDUHPRWHORFDWLRQXVLQJ
WKHUHPRWHVWDUWVWRSVZLWFKSURFHHGDVIROORZV
–Put the starter switch in position P3.
–Switch on circuit breakers Q1.1 or Q1.2, depending on the type of
generator, and the mode the unit is running in.
–Put the remote start/stop switch in position start. 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. If the unit does not start immediate-
ly, it will perform another two starting attempts.
–Approximately 15 seconds after starting (stabilization time for the
generator), the timer relay closes the voltage free contact and the
plant contactor is energized (if installed).
–Check that the warning lamps on the control and indicator panel are
out. Refer to “Control and indicator panel”for component locations.
–Run the engine for approximately 5 minutes to warm up.
–Check the engine oil pressure (P9) and the cooling water tempera-
ture (P8).
–Check the voltmeter P4 (with voltmeter selector switch S4 in differ-
ent positions) and the frequency meter P5.
–Switch on theload andcheck the ammeters P1, P2 and P3, voltmeter
P4 (voltmeter selector switch S4 in different positions) and the fre-
quency meter P5.
)RUVDIHW\UHDVRQVLWLVQHFHVVDU\WRSURYLGHDQLVR
ODWLQJVZLWFKRUFLUFXLWEUHDNHULQHDFKORDGFLUFXLW
/RFDO OHJLVODWLRQ PD\ LPSRVH WKH XVH RI LVRODWLQJ
GHYLFHVZKLFKFDQEHORFNHG
!
,16758&7,21 $18$/
15
'
85,1*
23(5$7,21
Following points should be carried out regularly:
–Check the engine gauges and the lamps for normal readings.
–Check for leakage of oil, fuel or cooling water.
–Avoid long low-load periods (< 30 %). In this case, an output drop
and higher oil consumption 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 per phase is not ex-
ceeded.
–When single-phase loads are connected to the generator output ter-
minals, keep all loads well-balanced (in 3 phase output voltage
mode).
–If circuit breakers are activated during operation, switch off the load
and stop the generator. Check and, if necessary, decrease the load.
–The generator’s side doors may only remain opened for short peri-
ods during operation, to carry out checks for example.
6
7233,1*
7RVWRSWKHXQLWZKHQWKHVWDUWHUVZLWFKLVLQSRVL
WLRQ3 SURFHHGDVIROORZV
–Switch off the load.
–Switch off circuit breakers Q1.1 or Q1.2.
–Let the engine run for about 5 minutes.
–Stop the engine by putting the starter switch in position P2 or P4.
7RVWRSWKHXQLWZKHQWKHVWDUWHUVZLWFKLVLQSRVL
WLRQ3SURFHHGDVIROORZV
–Switch off the load.
–Let the engine run for about 5 minutes.
–Stop the engine by putting the remote start/stop switch in position
stop or by putting the starter switch in position P2 or P4.
$YRLG WR OHW WKH HQJLQH UXQ RXW RI IXHO ,I LW KDS
SHQHGSULPLQJZLOOVSHHGXSWKHVWDUWLQJ
1HYHUWXUQWKHEDWWHU\VZLWFKWR2))GXULQJRSHUD
WLRQ
!
!/RFNWKHVLGH GRRUVDQG WKHGRRURIWKHLQGLFDWRUV
DQGFRQWUROSDQHOWRDYRLGXQDXWKRUL]HGDFFHVV
!
4$6*G86$
16
0$,17(1$1&(
(1) More frequently when operating in a dusty environment. Evacuate
dust from the airfilter valve daily.
(2) A Service Bulletin (ASB) dealing elaborately with batteries and
due care is available on request.
(
1*,1(
0$,17(1$1&(
Refer to the engine’s operator manual for full maintenance, including
instructions for changing the oil and cooling water and replacing the fu-
el, oil and air filters.
0
($685,1*
7+(
$/7(51$725
,168/$7,21
5(6,67$1&(
A 500 V megger is required to measure the alternator insulation resistance.
If the N-terminal is connected to the earthing system, it must be discon-
nected from the earth terminal. Disconnect the AVR. Disconnect the
radio interference suppressor.
Connect the megger between the earth terminal and terminal L1 and
generate a voltage of 500 V. The scale must indicate a resistance of at
least 5 MΩ.
Refer to the alternator operating and maintenance instructions for more
details.
%HIRUH FDUU\LQJRXW DQ\ PDLQWHQDQFH DFWLYLW\ FKHFN WKDW WKH VWDUW VZLWFK LVLQ SRVLWLRQ 2 DQG WKDW QR HOHFWULFDO SRZHULV
SUHVHQWRQWKHWHUPLQDOV
!
0
$,17(1$1&(
6&+('8/(
'DLO\ ,QLWLDO 6PDOO 1RUPDO <HDUO\
KRXUV KRXUV KRXUV KRXUV
6(59,&(3$.
:LWKXQLW
)RUWKHPRVWLPSRUWDQWVXEDVVHPEOLHV$WODV&RSFRKDVGHYHORSHGVHUYLFHNLWVWKDWFRPELQHDOOZHDUSDUWV7KHVHVHUYLFHNLWVRIIHU\RX
WKHEHQHILWVRIJHQXLQHSDUWVVDYHRQDGPLQLVWUDWLRQFRVWVDQGDUHRIIHUHGDWUHGXFHGSULFHFRPSDUHGWRWKHORRVHFRPSRQHQWV5HIHUWR
WKHSDUWVOLVWIRUPRUHLQIRUPDWLRQRQWKHFRQWHQWVRIWKHVHUYLFHNLWV
Coolant level Check Check Check Check Check
Tension and condition of drive belt(s) Check Check Check Replace
Radiator and intercooler fins Check/Clean Check/Clean Check/Clean Check/Clean
Fuel pre-filter/Water separator Check/Drain Replace Replace Replace Replace
Fuel filter element Replace Replace Replace Replace
Fuel injectors Check
Oil level in sump Check Check Check Check Check
Oil pressure on gauge Check Check Check Check Check
Lubrication oil Change Change Change Change
Oil filter(s) Replace Replace Replace Replace
Crankcase pressure (3mm WG at no load) Check Check
Vacum indicator Check Check Check Check Check
Air cleaner and dust bowl Clean Clean Clean Clean
Air filter element (1) Clean Replace Replace
Safety cartridge Replace
Turbocharger impeller and housing Clean/inspect
Fan hub bearings Lubricate
Oil, fuel and water leaks Check Check Check Check
Mechanical links (e.g. fuel solenoid link) Grease Grease Grease
Level battery electrolyte (2) Check Check Check Check
Condition of vibration dampers Check Check Check Check
Alternator insulation resistance (*) Measure
Tightness of nuts and bolts Check Check
Door hinges and locks Grease Grease
Fixation of hoses, cables and pipes Check Check
,QVSHFWLRQE\$WODV&RSFR6HUYLFHWHFKQLFLDQ
!
,16758&7,21 $18$/
17
6725$*(2)7+(*(1(5$725
6
725$*(
–Store the generator in a dry, frost-free room which is well ventilated.
–Run the engine regularly, e.g. once a week, until it is warmed up. If
this is impossible, extra precautions must be taken:
–Consult the engine’s operator manual.
–Remove the battery. Store it in a dry, frost-free room. Keep the
battery clean and its terminals lightly covered with petroleum
jelly. Recharge the battery regularly.
–Clean the generator and protect all electrical components against
moisture.
–Place silica gel bags, VCI paper (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.
3
5(3$5,1*
)25
23(5$7,21
$)7(5
6725$*(
Before operating the generator again, remove the wrapping, VCI paper
and silicagel bags and check the generator thoroughly (go through the
checklist “Before starting”).
–Consult the engine’s operator manual.
–Check that the insulation resistance of the generator exceeds 5 MΩ.
–Replace the fuel filter and fill the fuel tank. Vent the fuel system.
–Reinstall and connect the battery, if necessary after being recharged.
–Submit the generator to a test run.
&+(&.6$1'7528%/(
6+227,1*
&
+(&.,1*
92/70(7(5
3
–Put a voltmeter in parallel with voltmeter P4 on the control panel.
–Check that the read-out of both voltmeters is the same.
–Stop the generator and disconnect one terminal.
–Check that the internal resistance of the voltmeter is high.
&
+(&.,1*
)5(48(1&<
0(7(5
3
–Run the unit at normal speed.
–Put a voltmeter in parallel with frequency meter P5.
–If the measured voltage is higher than 240 V, the frequency meter
has to work properly.
If not, remove the frequency meter, connect it with the mains
(240 V) and check that it indicates 60 Hz.
&
+(&.,1*
$00(7(56
–Measure during the load, by means of a clamp-on probe, the outgo-
ing current in the three phases.
–Compare the measured current with the current indicated on amme-
ters on the corresponding ammeters P1, P2 and P3. Both readings
should be the same.
1HYHU SHUIRUP D WHVW UXQ ZLWK FRQQHFWHG SRZHU
FDEOHV 1HYHUWRXFKDQHOHFWULFDOFRQQHFWRUZLWKRXW
DYROWDJHFKHFN
:KHQDIDLOXUHRFFXUVDOZD\VUHSRUWZKDW\RXH[SH
ULHQFHGEHIRUHGXULQJDQG DIWHU WKHIDLOXUH ,QIRU
PDWLRQ ZLWK UHJDUG WR WKH ORDG W\SH VL]H SRZHU
IDFWRU HWF YLEUDWLRQV H[KDXVW JDV FRORXU LQVXOD
WLRQFKHFNRGRXUVRXWSXWYROWDJHOHDNVDQGGDP
DJHGSDUWVDPELHQWWHPSHUDWXUHGDLO\DQGQRUPDO
PDLQWHQDQFH DQG DOWLWXGH PLJKW EH KHOSIXO WR
TXLFNO\ ORFDWH WKH SUREOHP $OVR UHSRUW DQ\ LQIRU
PDWLRQ UHJDUGLQJWKH KXPLGLW\DQG ORFDWLRQ RIWKH
JHQHUDWRUH J FORVHWRVHD
!
4$6*G86$
18
$
/7(51$725
7528%/(
6+227,1*
6\PSWRP 3RVVLEOHFDXVH &RUUHFWLYHDFWLRQ
$OWHUQDWRUGRHVQRWH[FLWH
Blown fuse. Replace fuse.
Insufficient residual voltage. Increase the speed by 15 %.
No residual voltage. For an instant apply on the + and –terminals of the
electronic regulator a 12 V battery voltage with a
30 Ωresistor in series respecting the polarities.
$IWHUEHLQJH[FLWHGDOWHUQD
WRUGRHVQRWH[FLWH
Connections are interrupted. Check connection cables as per attached drawings.
/RZYROWDJHDWQRORDG
Voltage potentiometer out of setting. Reset voltage.
Intervention of protection. Check rpm.
Winding failure. Check windings.
+LJKYROWDJHDWQRORDG
Voltage potentiometer out of setting. Reset voltage.
Failed regulator. Substitute regulator.
/RZHUWKDQUDWHGYROWDJHDW
ORDG
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 regulator. Substitute regulator.
Rotating bridge failure. Check diodes, disconnect cables.
+LJKHUWKDQUDWHGYROWDJHDW
ORDG
Voltage potentiometer out of setting. Reset voltage potentiometer.
Loose sensing wires on AVR. Check sensing wires on AVR.
Failed regulator. Substitute regulator.
8QVWDEOHYROWDJH
Speed variation in engine. Check regularity of rotation.
Regulator out of setting. Regulate stability of regulator by acting on
“STABILITY”potentiometer.
,16758&7,21 $18$/
19
(
1*,1(
7528%/(
6+227,1*
A first fault diagnose can be read on the check engine light (L7) and the
engine stop light (L6). For more detailed information refer to the En-
gine operating manual. An extensive Engine troubleshooting manual is
available at Detroit Diesel. For more information contact Detroit Die-
sel.
The DDEC reader is a useful tool for troubleshooting.
(QJLQHGLDJQRVWLFFRGHV
To read the engine diagnostic codes, connect the diagnostic data reader
to the diagnostic data socket (X20) or depress and hold the diagnostic
request switch with the ignition on, the engine at idle or not running.
Press and hold the switch.
Active codes will be flashed on the stop engine light, followed by the
inactive codes being flashed on the check engine light. The cycle will
repeat until the diagnostic request switch is released.
The flash code contains 2 digits:
–the first digit is the number of times L6 or L7 flashes slowly
–the second digit is the number of times L6 or L7 flashes fast
)ODVK
FRGH &RGHGHVFULSWLRQ
)ODVK
FRGH &RGHGHVFULSWLRQ
11 VSG input low 47 Fuel pressure high
12 VSG input high 48 Fuel pressure low
13 Coolant level circuit low 52 A/D conversion fail
14 Intercooler, coolant or oil temperature circuit high 53 EEPROM write or nonvolatile checksum fail
15 Intercooler, coolant or oil temperature circuit low 54 Vehicle speed sensor fault
16 Coolant level circuit high 55 J1939 data link fault
17 Bypass position circuit high 56 J1587 data link fault
18 Bypass position circuit low 57 J1922 data link fault
21 TPS circuit high 58 Torque overload
22 TPS circuit low 61 Injector response time long
23 Fuel temperature circuit high 62 Auxiliary output open or short to battery
24 Fuel temperature circuit low 63 PWM open or short to battery
25 No codes 64 Turbo speed circuit failed
26 Auxiliary shutdown #1 or #2 active 67 Coolant pressure circuit high or low
27 Air temperature circuit high 68 IVS switch fault, open or grounded circuit
28 Air temperature circuit low 71 Injector response time short
31 Auxiliary output short or open circuit (high side) 72 Vehicle overspeed
32 SEL short or open circuit 75 Battery voltage high
33 Boost pressure circuit high 76 Engine overspeed with engine brake
34 Boost pressure circuit low 81 Oil level or crankcase pressure circuit high
35 Oil pressure circuit high 82 Oil level or crankcase pressure circuit low
36 Oil pressure circuit low 83 Oil level or crankcase pressure high
37 Fuel pressure circuit high 84 Oil level or crankcase pressure low
38 Fuel pressure circuit low 85 Engine overspeed
41 Too many SRS (missing TRS) 86 Water pump or barometer pressure circuit high
42 Too few SRS (missing SRS) 87 Water pump or barometer pressure circuit low
43 Coolant level low 88 Coolant pressure low
44 Intercooler, coolant or oil temperature high
45 Oil pressure low
46 Battery voltage low
4$6*G86$
20
7(&+1,&$/63(&,),&$7,216
5
($',1*6
21
*$8*(6
6
(77,1*6
2)
6:,7&+(6
6
3(&,),&$7,216
2)
7+(
(1*,1(
$/7(51$725
81,7
*DXJH 5HDGLQJ 86 0HWULF
Ammeter L1 (P1) Below max. rating A A
Ammeter L2 (P2) Below max. rating A A
Ammeter L3 (P3) Below max. rating A A
Voltmeter (P4) Depends upon selector switch V V
Frequency meter (P5) Between 60 and 62.5 Hz Hz
Hourmeter (P6) Adding up h h
Fuel level (P7) Above 0 Fuel tank full Fuel tank full
Engine temperature (P8) Below 221°F or 105 °C°F°C
Engine oil pressure (P9) Below maximum rating psi bar
6ZLWFK )XQFWLRQ $FWLYDWHVDW $FWLYDWHVDW
Engine oil pressure shut down 7.25 psi 0.5 bar
Engine coolant temperature shut down 221 °F 105 °C
86 0HWULF
5HIHUHQFH Absolute air inlet pressure 14.5 psi 1 bar
YDOXHV Air inlet temperature 77 °F25°C
Relative air humidity 30 % 30 %
Generator load Continuous Continuous
/LPLWDWLRQV Maximum ambient temperature 104 °F40°C
ZLWKRXW Maximum altitude 3281 ft 1000 m
GHUDWLQJ Maximum relative air humidity 85 % 85 %
Minimum starting temperature -0.4 °F -18 °C
3HUIRUP Rated continuous active power (COP) 3 ph 386.2 hp 288 kW
DQFH Power factor 3 phase 0.8 0.8
Voltage 3 ph. line-to-line, lower voltage 208 V 208 V
Voltage 3 ph. line-to-line, higher voltage 480 V 480 V
Current 3 ph. line-to-line, lower voltage 1000 A 1000 A
Current 3 ph. line-to-line, higher voltage 433 A 433 A
Frequency 60 Hz 60 Hz
Setting of Q1.1 1000 A 1000 A
Setting of Q1.2 440 A 440 A
Setting of Q2 20 A 20 A
Setting of Q3 50 A 50 A
Setting of Q4 50 A 50 A
Fuses F1, F2, F3 4 A 4 A
Fuse F4 10 A 10 A
(QJLQH Type DETROIT DIESEL S60 S60
Rated net output 415.7 hp 310 kW
Load speed 1800 rpm 1800 rpm
Electrical system 24 V 24 V
Battery 24 V/143 Ah 24 V/143 Ah
Oil circuit capacity 9.5 gal 36 l
Cooling circuit capacity 11.6 gal 44 l
Fuel tank capacity 125.93 gal 447 l
Fuel consumption at full load/no load 131.42/21.83 lb/h 59.6/9.9 kg/h
Maximum run time with fueltank 6.6 h 6.6 h
Other Atlas Copco Inverter manuals
Atlas Copco
Atlas Copco QAS 80 - 100 Pd User manual
Atlas Copco
Atlas Copco QLTS 4 ESF User manual
Atlas Copco
Atlas Copco QAS 200 VoD S3A ESF User manual
Atlas Copco
Atlas Copco QAS108 Pd(S) Mk II User manual
Atlas Copco
Atlas Copco QAS 80 Pd S3A ESF User manual
Atlas Copco
Atlas Copco QAX 12 Dd S2 APP User manual
Atlas Copco
Atlas Copco QAS 250-330 JD T4i User manual
