Atlas Copco QAS 500 Volvo S2A APP, Instruction Manual

Page 1: ...QAS 500 Volvo S2A APP Instruction Manual for AC Generators English...

Page 2: ......

Page 3: ...ATLAS COPCO PORTABLE AIR DIVISION www atlascopco com Printed matter N 2954 3870 00 05 2009 QAS 500 Volvo Instruction Manual for AC Generators Instruction manual 5 Circuit diagrams 99...

Page 4: ...nufacturer does not accept any liability for any damage arising for modifications addi tions or conversions made without the manufacturer s approval in writing Copyright 2009 Atlas Copco Airpower n v...

Page 5: ...age 84 Checks and trouble shooting 85 Checking voltmeter P4 85 Checking ammeters P1 P2 and P3 85 Engine troubleshooting 85 Alternator troubleshooting 86 Options available for QAS 500 Volvo units 87 Ci...

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

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

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

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

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

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

Page 12: ...n handling batteries e g when checking the charge condition 2 Install a sign prohibiting fire open flame and smoking at the post where batteries are being charged 3 When batteries are being charged an...

Page 13: ...3 phase 50 Hz 230 V 3 phase and 60 Hz 480 V 3 phase The QAS 500 Volvo generator is driven by a fluid cooled diesel engine manufactured by VOLVO PENTA An overview of the main parts is given in the diag...

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

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

Page 16: ...connections When connecting an external fueltank use the 3 way valves QAS500 VoD Engine oil PAROIL 15W40 PAROIL 5W40 Engine coolant PARCOOL EG Engine coolant PARCOOL EG Engine coolant PARCOOL EG Engi...

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

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

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

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

Page 21: ...d to the engine electronics after half a minute delay The unit can not be started as long as this parameter is switched on Unit Menu This menu is used to select whether tempreature and pressure should...

Page 22: ...22 This is the described menu flow for changing the unit type Qc1002 CAN 145 Parameter Running time Unit type Unit type 3 Unit type Qc1002 CAN 145...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Page 38: ...P intercooler temperature SPN94 FUEL PRESS fuel pressure SPN95 FUEL FILTER DIFF P pressure difference over fuel filter SPN97 WATER IN FUEL water in fuel SPN98 OIL LEVEL oil level SPN99 OIL FILTER DIFF...

Page 39: ...OFF enabled alarm supervision of alarm all the time ON running alarm only supervision when the machine is running RUN Control and indicator panel Qc4002 General description Qc4002 control panel A2 Qc4...

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

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

Page 42: ...LED green light indicates that the generator breaker is closed LED yellow light indicates that the generator breaker has received a command to close on a black BUS but the breaker is not yet closed du...

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

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

Page 45: ...he end user The required password level for each parameter is given in the set point list The following menus can only be reached using the JUMP button 9000 Software version 9020 Service port 911X Use...

Page 46: ...46 This is the described menu flow The menu flow is similar in the CONTROL SETUP I O SETUP and SYSTEM SETUP For more details on the Setup menu we refer to the Qc4002 User Manual...

Page 47: ...m 1 Trip MB 6 1141 Setpoint 150 0 350 0 1142 Delay 0 0 s 100 0 s 1143 Output A Not Used Option dependent 1144 Output B Not Used Option dependent 1145 Enable Off On 1146 Failclass Alarm 1 Trip MB 6 105...

Page 48: ...00 0 1332 Delay 0 00 s 99 99 s 1333 Output A Not Used Option dependent 1334 Output B Not Used Option dependent 1335 Enable Off On 1336 Failclass Alarm 1 Trip MB 6 1310 BB U 2 1320 BB U 3 1330 BB U 4 1...

Page 49: ...class Alarm 1 Trip MB 6 1430 Vector jump 1450 G P 1 1470 G P 3 1481 1482 1483 1484 1485 1486 1491 1492 1493 1494 1495 1496 1501 1502 1503 1504 1505 1506 1511 1512 1513 1514 1515 1516 Setpoint Delay Ou...

Page 50: ...dent 2125 Enable Off On 2131 Delay 30 0 s 300 0 s 2132 Output A Not Used Option dependent 2133 Output B Not Used Option dependent 2134 Enable Off On 2135 Failclass Alarm 1 Trip MB 6 2120 Sync window 2...

Page 51: ...0 0 s 60 0 s 2653 Td 0 0 s 2 0 s 2661 Kp 0 0 s 60 0 s 2662 Ti 0 0 s 60 0 s 2663 Td 0 0 s 60 0 s 2664 Qw 0 0 100 0 2671 Offset 0 0 100 0 2681 Deadband 1 0 100 0 2682 Delay 10 0 s 300 0 s 2683 Output A...

Page 52: ...ndent 41 5 Enable Off On 41 6 Failclass Alarm 1 Trip MB 6 41 7 High Alarm Off On 2 3 5 6 42 1 Setpoint 4mA 20mA 42 2 Delay 0 0 s 600 0 s 42 3 Output A Not Used Option dependent 42 4 Output B Not Used...

Page 53: ...able Off On 44 6 Failclass Alarm 1 Trip MB 6 44 7 High Alarm Off On 42 0 VDO water 102 43 0 VDO water 105 44 0 VDO water 108 2 3 5 6 8 9 42 1 Setpoint 0 0 100 0 42 2 Delay 0 0 s 999 0 s 42 3 Output A...

Page 54: ...s 999 0 s 4973 Output A Not Used Option dependent 4974 Output B Not Used Option dependent 4975 Enable Off On 4976 Failclass Alarm 1 Trip MB 6 4981 4982 4983 4984 4985 4986 Setpoint 8 0 V 32 0 V Delay...

Page 55: ...211 Cooldown 0 0 s 990 0 s 6212 Ext stop time 1 0 s 99 0 s 6221 Timer 1 0 s 99 0 s 6231 GB Close Delay 0 0 s 30 0 s 6232 GB Load Time 0 0 s 30 0 s 6261 Input Multi input 102 Multi input 105 Multi inpu...

Page 56: ...rip MB 6 6510 Stp swbd error 6541 Delay 10 0 s 900 0 s 6542 Output A Not Used Option dependent 6543 Output B Not Used Option dependent 6544 Enable Off On 6545 Failclass Alarm 1 Trip MB 6 6540 Not in a...

Page 57: ...g Open MB Start eng 7071 Fail Delay 1 0 s 990 0 s 7072 Mains OK Delay 10 0 s 9900 0 s 7073 f 80 0 100 0 7074 f 100 0 120 0 7031 Setpoint 0 0 80 0 7032 Timer 0 0 s 990 0 s 7041 Setpoint 1 0 100 0 7042...

Page 58: ...m 1 Trip MB 6 7601 Setpoint 0 rpm 2000 rpm 7602 Timer 0 0 s 100 0 s 7603 Output A Not Used Option dependent 7604 Output B Not Used Option dependent 7605 Enable Off On 7606 Failclass Alarm 1 Trip MB 6...

Page 59: ...n running set 2 1 16 8021 DG s available 1 16 8022 Mains available No mains Single mains Multiple mains 8023 PMS active Off On 8024 Start Stop Remote Local Timer 8025 Command Unit Off On 8171 Setpoint...

Page 60: ...subsequent action 6 different fail classes can be used Engine running Alarm Alarm Horn Relay Alarm Display Warning Alarm Horn Relay Alarm Display Trip of GB Alarm Horn Relay Alarm Display GB Trip Tri...

Page 61: ...s mode it is possible to perform the following tests Simple test Load test Full test Manual mode When manual mode is selected the gen set can be controlled with digital inputs Block mode When the bloc...

Page 62: ...TO This operation type is selected for installations with one or more generators but always without the Mains stand alone In practice up to 16 generators can be installed in parallel Installation wiri...

Page 63: ...X25 3 X25 34 X25 4 X25 35 X25 5 X25 36 X25 6 are removed If back synchronisation is enabled all settings for paralleling set up see Paralleling must be verified also Peak Shaving PS operation This app...

Page 64: ...or will start up synchronise and take over the load from the Mains gradually before opening the Mains Breaker To know if the load is completely taken over from the mains an optional Power Transducer i...

Page 65: ...e If the SEMI AUTO mode is selected the PMS operation will NOT function The Qc4002 controllers from the gensets need to be programmed as PMS in AUTO mode When a Qc Mains controller is installed this n...

Page 66: ...nset and will stop as first If running hours are chosen as priority the start stop sequence will be defined based on the actual running hours of the different generators The lowest running hours will...

Page 67: ...operation SEMI AUTO mode Local start AUTO mode Remote start AMF operation SEMI AUTO mode AMF operation will not function properly AUTO mode Emergency start Mains Failure Peak shaving SEMI AUTO mode On...

Page 68: ...ase contact Atlas Copco Application type Mode Comments Island operation SEMI AUTO mode Manual paralleling between generators AUTO mode Remote paralleling between generators AMF operation SEMI AUTO mod...

Page 69: ...AUTO mode PS FP LTO can be combined with AMF Back synchronising enabled disabled parameter channel 7080 Wrong parameter settings can damage the installation brutally 3 To be able to start up in cold c...

Page 70: ...s located inside the cubicle and is labelled I N Position O No de energising of the main circuit breaker Q1 when an earth fault occurs Position 1 De energising of the main circuit breaker Q1 when an e...

Page 71: ...ed inside the sound insulated bodywork It allows to open or to close the electrical connection between the battery and the engine circuits Spillage free skid A Spillage free skid with forklift slots a...

Page 72: ...a contact voltage higher than 25 V at 30 mA leakage current Check that the cable end of the earthing rod is connected to the earth terminal Connecting the generator Precautions for non linear and sen...

Page 73: ...rrent A L Length of conductors m R Resistance km to VDE 0102 X Reactance km to VDE 0102 Connecting the load Site distribution panel If outlet sockets are provided they must be mounted on a site distri...

Page 74: ...d the load Put the starter switch S20 in position I ON Voltage is applied to the Qc1002 module The unit can be started manually by pressing the START button on the Qc1002 module The unit will start Th...

Page 75: ...O OFF to shut down the voltage apply towards the Qc1002 module Lock the side doors and the door of the indicators and control panel to avoid unauthorized access Operating Qc2002 Starting Qc2002 To st...

Page 76: ...t proceed as follows Switch off the load Switch off circuit breaker Q1 Let the engine run for about 5 minutes Stop the engine by using the STOP button on the Qc2002 module Put the starter switch S20 i...

Page 77: ...oil consumption of the engine could occur It is recommended to operate the generator at full load capacity immediately after any low load operating period When single phase loads are connected to the...

Page 78: ...of genuine parts save on administration costs and are offered at reduced price compared to the loose components Refer to the parts list for more information on the contents of the service kits Check...

Page 79: ...place and drain fuel pre filter Water separator x x Replace fuel filter element x x Check crankcase pressure x x Check fixation of hoses cables and pipes x x Replace drive belt s x Replace safety cart...

Page 80: ...o the engine s operator manual for full maintenance schedule Measuring the alternator insulation resistance A 500 V megger is required to measure the alternator insulation resistance If the N terminal...

Page 81: ...tion PAROIL prevents Soot build up PAROIL is optimized for the latest low emission EURO 3 2 EPA TIER II III engines running on low sulphur diesel for lower oil and fuel consumption PAROIL 5W40 PAROIL...

Page 82: ...ranteed to 40 C Because PARCOOL EG inhibits corrosion deposit formation is minimized This effectively eliminates the problem of restricted flow through the engine coolant ducts and the radiator minimi...

Page 83: ...he condition of the coolant is outside the limits the complete coolant should be replaced see section Replacing the coolant Always top up with PARCOOL EG Topping up the coolant with water only changes...

Page 84: ...er Volatile Corrosion Inhibitor or another drying agent inside the generator and close the doors Stick sheets of VCI paper with adhesive tape on the bodywork to close off all openings Wrap the generat...

Page 85: ...s operator manual for the engine troubleshooting An extensive Engine troubleshooting manual is available at Volvo Penta For more information contact Volvo Penta Never perform a test run with connecte...

Page 86: ...tection Check frequency voltage regulator Winding failure Check windings High voltage at no load Voltage potentiometer out of setting Reset voltage Failed regulator Substitute regulator Lower than rat...

Page 87: ...The automatic battery charger charges the battery completely and is disconnected once the unit starts up Besides the output terminals secondary side the automatic battery charger has a trim potentiom...

Page 88: ...the overcurrent protection 63 A is activated When activated Q4 interrupts the three phases towards X4 It can be activated again after eliminating the problem Q5 Circuit breaker for X5 Interrupts the p...

Page 89: ...ards X1 when a short circuit occurs at the load side or when the overcurrent protection 720 A is activated It must be reset manually after eliminating the problem R12 Output voltage adjust potentiomet...

Page 90: ...ure below In this case an earth leakage at the side of the generator will switch off the circuit breaker An earth leakage at the side of the load will not switch off the circuit breaker Integrated spa...

Page 91: ...ption Quick couplings allows to bypass the internal fueltank and to connect an external fueltank to the unit Make sure that the big size coupling is used for the inlet the small size coupling is used...

Page 92: ...1800 rpm Generator service duty PRP PRP Absolute air inlet pressure 100 kPa 100 kPa Relative air humidity 30 30 Air inlet temperature 25 C 25 C Limitations 2 Maximum ambient temperature 50 C 50 C Alt...

Page 93: ...19 kg kWh Fuel autonomy at full load with standard tank 9 4 h 7 8 h Max oil consumption at full load 0 10 l h 0 11 l h Maximum sound power level LWA measured according to 2000 14 EC OND measured at 75...

Page 94: ...TAD1641 GE Rated net output 430 kW 485 kW rating type acc ISO 3046 7 ICXN ICXN Coolant coolant coolant Combustion system direct injection direct injection Aspiration turbocharged turbocharged intercoo...

Page 95: ...ent release IDn 0 030 30 A 0 030 30 A Insulation resistance 10 100 kOhm 10 100 kOhm Outlet sockets optional domestic 1x 2p E 16 A 230 V CEE form 1x 3p N PE 16 A 400 V CEE form 1x 3p N PE 32 A 400 V CE...

Page 96: ...t 25 C PRP Prime Power is the maximum power available during a variable power sequence which may be run for an unlimited number of hours per year between stated maintenance intervals and under the sta...

Page 97: ...0 100 100 100 100 95 85 75 500 100 100 100 100 100 100 100 100 95 85 75 1000 100 100 100 100 100 100 100 100 95 85 75 1500 100 100 100 100 100 100 100 95 95 85 75 2000 95 95 95 95 95 95 95 95 90 85 75...

Page 98: ...lbf ft t F 32 1 8 x t C t C t F 32 1 8 A Maximum permitted total weight of the vehicle B Maximum permitted front axle load C Maximum permitted rear axle load 1 Company code 2 Product code 3 Unit seria...

Page 99: ...99 Circuit diagrams...

Page 100: ...Diagr Power F1 N to Circ Diagr Power T1 T3 a8 140 a8 141 a8 142 a8 143 a0 126 a0 125 a0 129 a0 128 a0 127 a6 124 a0 125 a3 5 a3 5 a3 5 a3 11 a3 60 b6 12 aa0 CL aa9 CH a2 17 b2 17 a3 19 a0 38 a6 12 a2...

Page 101: ...60 a6 12 X11 4 X11 3 See also Circ Diagr Power X11 a3 5 C5 C5 PE PE b3 14 c6 12 aa0 CL aa9 CH c2 1 C4 C4 B1 B1 A1 A1 B2 B2 C2 C2 a3 5 l0 l0 c2 1 b3 14 l0 l0 aa9 CH aa0 CL c6 12 CANBUS l0 a2 17 A5 A5...

Page 102: ...2 a3 18 a6 124 a0 446 a0 447 a0 442 a6 441 Sx Remote Start Stop switch max 24Vdc 4A b6 441 b0 442 a0 443 a0 444 a0 445 to A1 38 PE X25 8 7 3 6 5 4 2 1 X25 10 9 PE MAINS SUPPLY 3P N PE Customer s Insta...

Page 103: ...mm l 95 mm lx 95 mm EPR CSP BS6195 4C bx 1 5 mm NSGAFOeU b2 1 a3 5 b6 12 a2 17 a6 12 2 B7 4 3 a3 11 a2 17 a3 11 a3 14 aa0 CL aa9 CH H0 a3 5 to Circ Diagr POWER X9 5 X9 12 X9 13 a6 12 a3 5 a2 13 b2 1 a...

Page 104: ...c 2 5 mm d 4 mm e 6 mm f 10 mm g 16 mm h 25 mm i 35 mm j 50 mm k 70 mm l 95 mm n 150 mm hx 25 mm EPR CSP to BS6195 4C ix 35 mm EPR CSP to BS6195 4C jx 50 mm EPR CSP to BS6195 4C kx 70 mm EPR CSP to B...

Page 105: ...x 0 400A QAS275 400A 400 5A jx 2x lx 0 800A QAS500 720A 800 5A lx X Wire size Q1 T1 3 P1 3 Z O 8 X11 7 X11 O 1 Phase Socket See Circ Diagr Engine O 3 Phase Sockets O N EDF a3 5 a6 12 5 X9 12 X9 Hz Hz...

Page 106: ...42 12 a6 a2 PE N L U1 B B R5 Canopy Cubicle a8 141 a8 142 a8 143 a8 140 T3 T2 T1 a0 U1 a0 V1 a0 W1 a6 N1 a0 127 a6 124 X0 U1 X0 V1 X0 W1 Y6 N1 Z54 F3 5 6 7 8 F2 3 4 F1 1 2 9822 0993 31 01 Applicable f...

Page 107: ...13 13 24 23 X0 L1 X0 L2 X0 L3 Y6 N Z54 PE L1 L2 L3 N OFF 0 1 10 4 0 90xIo QAS500 Q1 2 720A 1 00xIn OFF 0 1 10 4 1 00xIo QAS500 Q1 1 1250A 1 00xIn OFF 0 1 10 4 1 00xIo QAS325 Q1 1 800A 1 00xIn Breaker...

Page 108: ...oil Relay Stop Coil Relay Starter Relay Starter Relay NO Preheat Relay Input Input Input Input Input Input W L Input D Start Enable Remote Start Stop Configurable Configurable Fuel Level VDO C B A Coo...

Page 109: ...z54 PE z54 5 X9 12 X9 a6 12 a2 17 b6 12 a2 17 b3 14 b2 17 S2b a2 17 b3 14 K6 V6 a0 118 a6 12 b2 13 a0 118 b6 12 a0 118 a3 5 S13 S2a E B OFF RESET ON A P1 C P2 F M M3 12 11 14 d1 d2 Q1 UVT a0 443 a0 44...

Page 110: ...5 mm EPR CSP BS6195 4C nx 150mm EPR CSP BS6195 4C bx 1 5 mm NSGAFOeU Notes Note 1 The PE N connection has to be made at the alternator side of Circuit Breaker Q1 Breaker Set Characteristic dial Q1 Ir...

Page 111: ...7 Free wheeling diode Y7 O K12 Aux relay close MCB V11 V12 Free wheeling diode K11 K12 M1 Starter motor X1 Terminal board M3 Motor drive for Q1 X2 Socket outlet 16A 1phase N12 Automatic voltage regula...

Page 112: ......

Page 113: ......

Page 114: ...Printed in Belgium 05 2009 2954 3870 00 www atlascopco com...