Atlas Copco SAPE User manual

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Congratulations on the purchase of your SAPE unit. It is asolid,
safe and reliable unit, built according to the latest technology.
Follow the instructions in this booklet and we guarantee you
years of trouble-free operation. Please read the following in-
structions carefully before starting to use your machine.
While every effort has been made to ensure that the information
in this manual is correct, Atlas Copco does not assume respon-
sibility for possible errors. Atlas Copco reserves the right to
make changes without prior notice.

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To be read attentively and acted accordingly before towing, lifting, operating, performing maintenance or repairing the SAPE unit.
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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.
Skill level 1: Operator
An operator is trained in all aspects of operating the unit with the push-buttons,
and is trained to know the safety aspects.
Skill level 2: Mechanical technician
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.
Skill level 3: Electrical technician
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.
Skill level 4: Specialist from the manufacturer
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.
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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 vapour 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 jewellery.
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 Portable generators (with earthing pin):
Earth the generator as well as the load properly.
16b Portable generators IT:
Note:This generator is built to supply a sheer alternating current IT
network.
Earth the load properly.

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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 tyres 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 Units 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.
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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.

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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,
odour, 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.
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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 vapours 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.

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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 shutdown devices function correctly.
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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.
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Batteries
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.

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The “Stand Alone Paralleling Equipment” (SAPE) enables the con-
nection of generators in parallel, provided that the generator is
equipped with a paralleling device on the alternator and has the
connector with the appropriate signals.
Parallel operation is used in those cases where the load exceeds the
nominal load of one generator in operation. Using this option, gen-
erators can be connected in parallel in order to share the load pro-
portionally.
This manual describes the principle of paralleling two generators
with factory setting, using at least one SAPE unit.
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The “Stand Alone Paralleling Equipment” (SAPE) consists of con-
nection cables (1), an optional frame (2) and two cubicles:
– The power control module (3)
– The contactor box (315 A, 500 A or 1000 A) (4)
The two cubicles can be mounted on the generator or on the frame.
An overview of the main parts is given in the diagram below.
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A standard generator must be provided with a 15
pole connector to be able to connect with a SAPE
unit (the master generator as well as each of the
slave generators).
It is possible to convert a standard generator using a
conversion kit. This is necessary for generators built
before may 2000.
The generators do not have to be of the same type
for paralleling: any combination between QAS168,
QAS228, QAS278 or QAS338 generators is possible.
The required number of SAPE units is equal to the
number of generators to be paralleled.
It is also possible to connect a generator plus a SAPE
unit with a dedicated generator (generator provided
with integrated paralleling).
2
3
1
4

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The following features are available with the paralleling control
module:
– Measurement, Annunciation, and Control Setup
The paralleling control module is provided with an integral
Keypad/Display Panel.
Parameters are monitored, and setup performed by means of
this panel.
– Auto-Synchronizing
The paralleling control module incorporates automatic syn-
chronizing to match the frequency and phase of an incoming
generator to the frequency and phase of the bus or another gen-
erator. The synchronizer compares the incoming generator to
the frequency and phase to be matched and controls its speed
and phase to assure synchronization within a minimumof time.
– Isochronous Load Sharing
The object of isochronous load sharing is to proportionally di-
vide a common load between two or more generators in paral-
lel while maintaining a fixed frequency. This means that the
generators inthe parallel connection will deliver equal percent-
ages of their full loadcapacity.This also implies thatdue to the
isochronous load sharing module and the proportional load
sharing, the generators that are connected in parallel do not
need to have the same rated output power.
The paralleling control module compares the load of its gener-
ator unit with the load applied to all other units in operation,
through the paralleling lines, and either decreases or increases
the engine fuel to maintain its proportional share of the total
load.
– Load Commanding/Blending
Blending loads with the paralleling control module allows for
soft loading, unloading and power setting of the controlled
generator.
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This lamp lights when the circuit breaker/contactor of the
SAPE is closed.
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Allows to adjust the frequency of the output voltage.
BREAKER
CLOSED
BREAKER/
CONTACTOR
CLOSEENABLE
BREAKER/
CONTACTOR
CLOSE
BLEND
ILS COMMAND
UNLOAD LOAD
BREAKER/
CONTACTOR
OPEN
FREQUENCY
ADJUST
H19
S18
S20
R1
N14
S6
S5
S22
S19
K20
X31
X30
X33
X32
X32
T4
T5
See the instruction manual of the Pow-R-Con for
details.

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This switch allows for three positions:
–ILS (Isochronous Load Sharing): both connected genera-
tors give their full proportional load immediately
–Blend: the proportional load of the brought in generator is
slowly built up (time adjustable between 2 s and 5 min), af-
ter selector switch S6 has been set to ‘Load’
–Command: allows a fixed power output of the generator,
irrespective of the load
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This switch only applies to the ‘Blend’ mode (selector switch
ILS/Blend/Command in position ‘Blend’).
The central position of the three position selector switch is used
for ‘ILS’ mode. The other two positions are:
–Unload: one generator is enough to supply the full load, but
to prevent the other generator from idling, it still supplies
± 10 % (adjustable value) while the other one supplies
± 90 % of the full load
–Load: both connected generators deliver equal percentages
of their full load capacity
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Allows the circuit breaker/contactor of the second unit to be
closed if all conditions are fulfilled.
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Manually closing of the circuit breaker/contactor of the first
unit, after S18 (Breaker/Contactor close enable) has been
pushed.
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Opens the circuit breaker/contactor of the unit.
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Push the button to stop the unit in case of an emergency. When
the button is pressed, it must be unlocked, by turning it anti-
clockwise, before the unit can be restarted.
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Connector for communication with the power control module
of another SAPE unit or QAS with integrated paralleling.
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Connector for communication with the power control module
of another SAPE unit or QAS with integrated paralleling.
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Connector for communication between the SAPE power con-
trol module and the SAPE contactor.
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Connector for communication between the power control mod-
ule of the SAPE unit and the generator.
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Connector for communication between the SAPE power con-
trol module and the SAPE contactor.
Several SAPE units can be connected to each other,
as the power control module of each SAPE unit has
got two connectors (X30 and X31).

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The following keys are provided for user monitoring and editing:
– ESC - Escape key
This key is used to select Monitor, Program, Review, or Setup
modes. It may be pressed to return to the previous function at any
time.
– SCROLL - Scroll key
From the automatic monitoring mode, pressing the left or right
SCROLL key allows the desired phase-to-phase, phase-to-neutral,
or average set of values to be displayed on the LCD. Press ESC to
return to automatic monitoring.
In the Review, Program, or Setup modes, the Scroll key allows for-
ward or reverse display of the various menu selections.
– SELECT - Select key
Pressing the Select key places the unit in the mode or data entry
point shown on the LCD display.
– INCREASE / DECREASE - Increase and Decrease keys
When a data entry is selected, the value is changed by depressing
the Increase or Decrease key.
– ENTER - Enter key
When a desired data entry value is displayed, pressing the ENTER
key will place the value in the program.
Also, pressing ENTER during the monitor mode will stop the dis-
play from scrolling. Pressing ENTER again causes scrolling to
resume.
During initial power up, the Liquid Crystal Display (LCD) on the
Keypad/Display Panel displays the panel revision level, then re-
verts to automatically scrolling through the measured phase-to-
phase, phase-to-neutral, and average values.
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The following picture gives an overview of the connections to be
made between two SAPE units and two QAS-generators.
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Prior to starting parallel operation of two generators, following con-
nections need to be made:
1. Connect the communication cable between the generator QAS 1
and the stand alone paralleling equipment SAPE 1 (socket X33). Do
the same for QAS 2 and SAPE 2.
2. Connect the communication cable between SAPE 1 and SAPE 2 or
QAS with integrated paralleling (socket X30 or X31).
3. Route the power cables of the QAS through the bottom hole of the
contactor box of the SAPE and connect them with the contactor
(strips L1, L2, L3, N and PE on the left-hand side).
PHASE
KWATT
Barber
Colman
KVAR PF
-180 +180
VOLTS AMPS HERTZ
INC
ESC SCROLL SCROLL
DEC ENTER SELECT
COMMAND MODE
HIGH LIMIT
LOW LIMIT
BLEND MODE
LOAD GENERATOR
UNLOAD GENERATOR
BREAKER TRIP
SYNCH ENABLE
VOLT NOT MATCHED
FREQ NOT MATCHED
PHASE NOT MATCHED
FORWARD POWER ON
FORWARD POWER OFF
REVERSE POWER ON
BREAKER CLOSED
When connecting two standard generators in paral-
lel, two SAPE units must be used.
Each SAPE has two of these connections, to enable
paralleling more than two generators.
Always connect strips L1 with L1, L2 with L2 and
L3 with L3!
PC
CB
SAPE 1
QAS 1 QAS 2
PC
CB
SAPE 2
DP
(5)
(4)
(1) (2) (1)
(3)
(5)
(3)

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4. Connect the load with the output of the contactor (strips 1L1, 1L2,
1L3, N and PE on the right-hand side).
5. Connect the SAPE power control module with the SAPE contactor
(sockets X32).
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If parameters are to be changed in the paralleling control module,
proceed as follows:
1. Select the SETUP mode: press SELECT, press SCROLL until SET-
UP is reached and press SELECT.
2. Enter password: successively press the ENT, DEC, SCROLL (left),
and SELECT keys for the password.
3. Select the SYSTEM screen.
4. Select the desired parameter by using the SCROLL (left or right)
key.
5. Press the SELECT key.
6. If applicable: choose the desired digit by using the SCROLL (left or
right) key.
7. Change the digit by using the INCREASE (up) or DECREASE
(down) key.
8. Press the ENTER key to place the value in the program.
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– Set engine VSG min at 1425 rpm (for 50 Hz) or at 1710 rpm (for 60
Hz).
Set engine VSG max at 1575 rpm (for 50 Hz) or at1810 rpm (for 60
Hz).
Use a DDEC reader to adjust the speed limits of a generator.
– Remove the bridge (between connections 0 and 1) on the AVR (Au-
tomatic Voltage Regulator) to activate the paralleling device.
– Check, and adapt if necessary, the voltage settings on transformers
T4 and T5.
The connection on the primary side of transformer T4 must be con-
nected to the correct terminals, dependent on the generator voltage.
Make sure that the load is connected correctly (to
the strips on the right-hand side of the contactor).
Do NOT connect the load with the generator.
Do NOT connect the output of the contactor with the
second SAPE.
Go via the site distribution panel (to be installed by
the customer) to connect the SAPE units with the
load.
Pressing ESC allows for returning to the previous
function at any time.
60Hz
6
5
4
56
43210B
+-
3
2
1
0
B
+
-
P

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Prior to starting up the system, the paralleling control module needs
to know what size of QAS is going to be connected.
Therefore proceed as follows:
1. Go to ‘SETUP’ ⇒‘PROGRAM’ ⇒
2. Voltage match: set at 5 %
3. Freq match: set at 0.25 Hz
4. Phase match: set at 20 deg
5. Go to ‘SETUP’ ⇒‘SETUP’ ⇒
6. CT ratio A, B, C: primary current divided by secondary current
7. PT ratio: 1
8. Gen Power: xxx kW: see technical specifications for nomi-
nal values
9. Sys Volt: Bus voltage: 208 – 240V ⇒240V
400 – 480V ⇒ 480V
10.Bus Freq: 50 or 60Hz depending on what frequency the
QAS is set up.
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– Put on both generators the selector switch “Single/Parallel” in the
“Parallel” position.
– Start both generators.
– Run the engines for approximately 5 minutes to warm up and stabi-
lize speed and voltage.
– Try to match frequency and voltage of both generators as close as
possible.
– Switch on the main circuit breakers Q1 of both generators.
– Push the button “Breaker/Contactor close enable” on the SAPE of
the first generator (master).
– Push the button “Breaker/Contactor close” on the SAPE of the first
generator.
– Push the button “Breaker/Contactor close enable” on the SAPE of
the second generator (slave).
When both generators are synchronized, the circuit breaker of the
SAPE of the second generator is automatically closed and the sec-
ond generator starts supplying power together with the first one.
The paralleling control modules will share the load evenly between
the generators, according to the capacity of the units. It will also de-
tect a circulating current and will deactivate one of the units if the
circulating current exceeds the value set ontheload sharing module.
It is possible to lower the circulating current by better matching the
voltages of the generators. Therefore adjust the voltage on one or
more generators.
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– Refer to the manuals of the applicable generators for the check ac-
tions to be performed during operation.
– Regularly check the amperemeters on both generators and the
clamp meter which measures the circulating current.
Note that the ratio needs to be entered, not the pri-
mary current rating,
e.g.: current transfo 600/5
→ratio to be entered = 120
Note the difference between 50 and 60Hz,
e.g.: QAS168 50Hz = 120kW
60Hz = 144kW
Make sure that the generators are connected cor-
rectly before starting operation.

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7256
After connecting two generators in parallel, more generators can be
added.
Once two (or more) generators are connected in parallel, they can
be treated as if they were one unit.
– Shut down or disconnect the load or make sure that the load is sta-
ble.
– Shut down the generators that are already in operation. Make sure
not to change the settings on these generators.
– Connect the extra generator to the parallel connection of the first
generators, treating these generators as one unit.
– Make sure that all main circuit breakers Q1 are switched OFF.
– Carry out the actions described in “Before starting parallel opera-
tion” for the extra generator.
– Start up the first generator, close its circuit breaker Q1 and push the
button “Breaker/Contactor close” on the corresponding SAPE.
– Start up the second (possibly third, fourth, ...) generator, close its
circuit breaker(s) Q1 and push the button(s) “Breaker/Contactor
close enable” on the corresponding SAPE unit(s). These units can
now be considered as one unit.
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– Switch off and disconnect the load.
– Push the buttons “Breaker/Contactor open” on both SAPE units.
– Switch off the main circuit breakers Q1 of both generators.
– Let the engines run for about 5 minutes to cool them down.
– Shut down the generators one by one.
Do not connect more than 7 generators in parallel.
Once the extra generator is synchronized, it can be
used as a standby unit. If the load exceeds the nomi-
nal load of the first generator(s), the standby unit
can be put in parallel operation by closing the circuit
breaker of the corresponding SAPE.

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Display does not function. Connection between Pow-R-Con and dis-
play is faulty or absent. Connect correctly.
Measured and actual power do not match. CT ratio not entered correctly. Enter the correct CT ratio.
Connection between power control mod-
ule and contactor box is faulty. Connect the power control module and the contactor correctly (see 5.1 Connecting
Generators and SAPE Units).
Circulating current is too high. Parallel device is not or faultily connected. Check the parallel device and the polarity.
Voltages of the generators are not
matched. Adjust the voltage on one or more genera- tors until the circulating current is mini-
mal.
One generator supplies active power to
the other. Frequencies of the generators are not matched. Adjust the frequency on a generator sothat the power is zero.
One of the connection cables is not con-
nected. Check all connections.
Generator runs in idle speed. Selector switch “Single/Parallel” is in
“Parallel” position, but the SAPE unit is
not connected.
Put the switch in “Single” position if single
mode is needed.
Connect the SAPE unit if parallel mode is
needed.
Potentiometer for frequency adjustment
does not function. Selector switch “Single/Parallel” is in wrong position. Put the switch in single mode if you want to use the frequency adjustment potenti-
ometer on the control panel of the QAS.
Put the switch in parallel mode if you want
to use the frequency adjustment potenti-
ometer on the control panel of the SAPE
unit.

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3DUDOOHOLQJFRQWUROPRGXOH Frequency 50 Hz/60 Hz
Number of phases 3
Voltage input 120-480 VAC ± 15%
Current input 5 A at Max. gen. load
Burden 1.25 VA per phase at 5.0 A
Load Sharing Accuracy Within ± 0.5%
Output full load (Paralleling Lines) 1.5-5.0 VDC
Operating Temperature -20 to 70 °C
Shipping/Storage Temperature -40 to 85 °C
Fuse F6 4 A
Fuse F7 2 A
Dimensions (LxWxH) 600 x 415 x 240 mm
&RQWDFWRUER[ Fuse F1-5 4 A
&RQWDFWRUER[ $ Dimensions (LxWxH) 600 x 635 x 240 mm
&RQWDFWRUER[ $ Dimensions (LxWxH) 1000 x 795 x 330 mm
&RQWDFWRUER[ $ Dimensions (LxWxH) 1000 x 795 x 330 mm
)UDPH Dimensions (LxWxH) 1200 x 700 x 2070 mm
6$3(XQLW $ Weight ± 130 kg
6$3(XQLW $ $ Weight ± 170 kg
*HQHUDWRU4$6  Power (50 Hz/60 Hz) 120 kW/144 kW
*HQHUDWRU4$6  Power (50 Hz/60 Hz) 160 kW/192 kW
*HQHUDWRU4$6  Power (50 Hz/60 Hz) 200 kW/240 kW
*HQHUDWRU4$6  Power (50 Hz/60 Hz) 240 kW/288 kW

195
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196
PHASE
KWATT
COMMAND MODE HIGH LIMIT LOW LIMIT
SYNCH ENABLE VOLT NOT MATCHED FREQ NOT MATCHED PHASE NOT MATCHED FORWARD POWER ON FORWARD POWER OFF REVERSE POWER ON BREAKER CLOSED
BLEND MODE LOAD GENERATOR UNLOAD GENERATOR BREAKER TRIP
ESC
Barber Colman
INC
SCROLL SCROLL
DEC ENTER
SELECT
-180 +180
KVAR PF
VOLTS AMPS HERTZ
4347484698 41 42 44 45
37 24 23
K16
19
X26
PE
21
S22c
22
Par. line
Batt-
Batt+
36 32 31 R1 30 29 28
Par. line
Gov. ref.
Gov. speed set
Remote
Speed
Set
Unload
Blend
Bus
Voltage
Load
Common
Common
Command
Breaker
Trip
a0
201
a0
202
a0
201
a0
202
a0
203
c8
204
c8
205
c8
206
c8
207
aa0
511
aa0
230
aa0
236
aa2 b54
237
aa2
231
aa9
232
aa2
X33 X33
916
A1A2
X30
1
X31
1
X30
233
5A5B5
223
224
B4 A4 PEPEPE
X31 X30 X30 X31 X31 X33 X33 X33
b3
b3
266
b3
b6
242
a0
247
a0
248
a0
S5
246
ILS
a0
209
a0
239
a0
240
a0
253
a0
215
a0
221
a0
253
a0
215
a0
215
a0
263
a0
262
a0
265
a3
265
a3
264
a3
264
a3
22
13 14 14 13
265
a3
252
a0
251
a0
201
a0
202
a0
257
a0
221
a0
256
a0 a0
222
222
a0
250
a0
255
a0
254
a0
261
a0
26
253
a0
253
a0
16 15
253
a0
253
a0
253
a0
17
X26
K18
T4
K19 H19
X32 X32 K19
K25
X26
23
X26
S22b
S22a
K25 S20 S18 K18
X26
25
X26
K15 S19
K20
X32 X32
F6
K18
K16
238
a0
98
X32
MOTOR DRIVE
control
CONTACTOR
control X32
208
a0
208
a0
208
a0
260
a0
209
a0
259
a0
258
a0 19
X26
26
X26
26
X26
25
X26
K19K19
K15
F7
15 15
M
X32
15 15 16 16
X32 X32
K20
24V batt+
230V 230V
T5 24V batt- in genset
(*)
(*) to be linked by the customer
241
a0
243
a0
S6
X33 X33
17
(1) Bridge if motordrive
is used.
X26
19 22 25 26
PE 24V batt+ 24V batt+ 230Vac supply to parall. contactor
23
2
N14a
N14b
X32 123 4 756
4 7 10 11 12 13
23 24 49 50 PE PE
RS-485B
RS-485A
56
CT1 CommonCT2 CT3
Current Transformer
Input Forward Power
ON OFF
12
Generator
Voltage
3
X32X32 X32 X32X32X32
a0
221
a0
222
a0
221
(1)
LEGEND: Wire size: Colour code:  aa = 0.5 mm2 0 = black
 a = 1 mm2 1 = brown
 b = 1.5 mm2 2 = red
 c = 2.5 mm2 3 = orange
 d = 4 mm2 4 = yellow
 e = 6 mm2 5 = green
 f = 10 mm2 6 = blue
 g = 16 mm2 7 = purple  h = 25 mm2 8 = grey  i = 35 mm2 9 = white
 j = 50 mm2 54= green/yellow  k = 70 mm2
 l = 95 mm2  lx = 95 mm2STK
 bx = 1.5 mm2NSGAFOeU
38 39
K19
K18 40
Breaker
Close
Breaker
Trip
Reverse
Power
Aux. Br. contact Synch Enable
22 21 20 19
15 14
L1 L3
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