Instruction Manual

for AC Generators

QAS38 YdS TNV

Instruction manual .................................................................................. 3

Circuit diagrams ...........................................................................................................23

Printed Matter N°
2954 9020 00
ATLAS COPCO - PORTABLE AIR DIVISION
11/2004 www.atlascopco.com

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 QAS38 YdS TNV

Warranty and Liability Limitation

Use only authorized parts.
Any damage or malfunction caused by the use of unauthorized parts is not covered by Warranty or
Product Liability.
The manufacturer does not accept any liability for any damage arising for modifications, additions
or conversions made without the manufacturer's approval in writing.

Copyright 2004, Atlas Copco Airpower n.v., Antwerp, Belgium.

Any unauthorized use or copying of the contents or any part thereof is prohibited.
This applies in particular to trademarks, model denominations, part numbers and drawings.

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 Instruction Manual

Congratulations on the purchase of your QAS38 AC generator.

It is a solid, safe and reliable machine, built according to the
latest technology. Follow the instructions in this booklet and we
guarantee you years of troublefree operation. Please read the
following instructions carefully before starting to use your ma-
chine.
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.

Contents

1. Safety precautions for portable 6. Checks and trouble shooting...........................16

generators ...................................................................4 6.1. Checking voltmeter P4........................................16
6.2. Checking frequency meter P5 ............................16
2. Leading particulars .................................................8 6.3. Checking ammeters P1, P2 en P3 ......................16
2.1. General description ..............................................8 6.4. Alternator trouble shooting ...............................17
2.2. Bodywork ..............................................................9 6.5. Engine trouble shooting.....................................17
2.3. Markings................................................................9
2.4. Drain plugs and filler caps ...................................9 7. Technical specifications ....................................19
2.5. Control and indicator panel .................................9 7.1. Readings on gauges ...........................................19
2.6. Remote start (RS)................................................11 7.2. Settings of switches............................................19
2.7. Dip-switches........................................................11 7.3. Specifications of the engine/alternator/unit .....19
2.8. Output connections ............................................11 7.4. Conversion list of SI units into British units .....22
2.9. Spillage free ........................................................12 7.5. Dataplate .............................................................22
2.10. Triple voltage (3V) ..............................................12

3. Operating instructions ........................................12

3.1. Installation...........................................................12
3.2. Connecting the generator ..................................13
3.3. Before starting ....................................................13
3.4. Starting ................................................................14
3.5. During operation.................................................14
3.6. Stopping ..............................................................14

4. Maintenance ............................................................15
4.1. Maintenance schedule .......................................15
4.2. Engine maintenance...........................................15
4.3. (*) Measuring the alternator insulation
resistance ............................................................15

5. Storage of the generator ...................................16

5.1. Storage ................................................................16
5.2. Preparing for operation after storage ...............16

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 QAS38 YdS TNV

1. Safety precautions for portable generators

To be read attentively and acted accordingly before towing, lifting, operating, performing maintenance or repairing the generator.

1.1 Introduction
The policy of Atlas Copco is to provide the users of their equipment with safe, If any statement in this manual does not comply with local legislation, the
reliable and efficient products. Factors taken into account are among others: stricter of the two shall be applied.
- the intended and predictable future use of the products, and the environ- Statements in these safety precautions should not be interpreted as suggestions,
ments in which they are expected to operate, recommendations or inducements that it should be used in violation of any
- applicable rules, codes and regulations, applicable laws or regulations.
- the expected useful product life, assuming proper service and
maintenance,
- providing the manual with up-to-date information. 1.2 General safety precautions
Before handling any product, take time to read the relevant instruction manual. 1 The owner is responsible for maintaining the unit in a safe operating
Besides giving detailed operating instructions, it also gives specific condition. Unit parts and accessories must be replaced if missing or
information about safety, preventive maintenance, etc. unsuitable for safe operation.
Keep the manual always at the unit location, easy accessible to the operating
personnel. 2 The supervisor, or the responsible person, shall at all times make sure that
all instructions regarding machinery and equipment operation and mainte-
See also the safety precautions of the engine and possible other equipment, nance are strictly followed and that the machines with all accessories and
which are separately sent along or are mentioned on the equipment or parts of safety devices, as well as the consuming devices, are in good repair, free of
the unit. abnormal wear or abuse, and are not tampered with.
These safety precautions are general and some statements will therefore not 3 Whenever there is an indication or any suspicion that an internal part of a
always apply to a particular unit. machine is overheated, the machine shall be stopped but no inspection
Only people that have the right skills should be allowed to operate, adjust, covers shall be opened before sufficient cooling time has elapsed; this to
perform maintenance or repair on Atlas Copco equipment. It is the avoid the risk of spontaneous ignition of oil vapor when air is admitted.
responsibility of management to appoint operators with the appropriate 4 Normal ratings (pressures, temperatures, speeds, etc.) shall be durably
training and skill for each category of job. marked.
Skill level 1: Operator 5 Operate the unit only for the intended purpose and within its rated limits
An operator is trained in all aspects of operating the unit with the push-buttons, (pressure, temperature, speeds, etc.).
and is trained to know the safety aspects. 6 The machinery and equipment shall be kept clean, i.e. as free as possible
Skill level 2: Mechanical technician from oil, dust or other deposits.
A mechanical technician is trained to operate the unit the same as the operator. 7 To prevent an increase in working temperature, inspect and clean heat
In addition, the mechanical technician is also trained to perform maintenance transfer surfaces (cooler fins, intercoolers, water jackets, etc.) regularly.
and repair, as described in the instruction manual, and is allowed to change See the maintenance schedule.
settings of the control and safety system. A mechanical technician does not
work on live electrical components. 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.
Skill level 3: Electrical technician
9 Pressure and temperature gauges shall be checked regularly with regard to
An electrical technician is trained and has the same qualifications as both the their accuracy. They shall be replaced whenever outside acceptable toler-
operator and the mechanical technician. In addition, the electrical technician ances.
may carry out electrical repairs within the various enclosures of the unit. This
includes work on live electrical components. 10 Safety devices shall be tested as described in the maintenance schedule of
the instruction manual to determine that they are in good operating
Skill level 4: Specialist from the manufacturer condition.
This is a skilled specialist sent by the manufacturer or its agent to perform
complex repairs or modifications to the equipment. 11 Mind the markings and information labels on the unit.

In general it is recommended that not more than two people operate the unit, 12 In the event the safety labels are damaged or destroyed, they must be
more operators could lead to unsafe operating conditions. Take necessary steps replaced to ensure operator safety.
to keep unauthorized persons away from the unit and eliminate all possible 13 Keep the work area neat. Lack of order will increase the risk of accidents.
sources of danger at the unit.
14 When working on the unit, wear safety clothing. Depending on the kind of
When handling, operating, overhauling and/or performing maintenance or activities these are: safety glasses, ear protection, safety helmet (including
repair on Atlas Copco equipment, the mechanics are expected to use safe visor), safety gloves, protective clothing, safety shoes. Do not wear the
engineering practices and to observe all relevant local safety requirements and hair long and loose (protect long hair with a hairnet), or wear loose
ordinances. The following list is a reminder of special safety directives and clothing or jewelry.
precautions mainly applicable to Atlas Copco equipment.
15 Take precautions against fire. Handle fuel, oil and anti-freeze with care
Neglecting the safety precautions may endanger people as well as environment because they are inflammable substances. Do not smoke or approach with
and machinery: naked flame when handling such substances. Keep a fire-extinguisher in
- endanger people due to electrical, mechanical or chemical influences, the vicinity.
- endanger the environment due to leakage of oil, solvents or other sub- 16a Portable generators (with earthing pin):
stances, Earth the generator as well as the load properly.
- endanger the machinery due to function failures.
16b Portable generators IT:
All responsibility for any damage or injury resulting from neglecting these
Note: This generator is built to supply a sheer alternating current IT
precautions or by non-observance of ordinary caution and due care required in
network.
handling, operating, maintenance or repair, also if not expressly mentioned in
Earth the load properly.
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.

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 Instruction Manual

1.3 Safety during transport and installa- 1.4 Safety during use and operation
tion 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.
To lift a unit, all loose or pivoting parts, e.g. doors and towbar, shall first be
securely fastened. 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
Do not attach cables, chains or ropes directly to the lifting eye; apply a crane
atmosphere by a pipe of sufficient diameter; do this in such a way that no
hook or lifting shackle meeting local safety regulations. Never allow sharp
extra back pressure is created for the engine. If necessary, install an extrac-
bends in lifting cables, chains or ropes.
tor. Observe any existing local regulations. Make sure that the unit has suf-
Helicopter lifting is not allowed. ficient air intake for operation. If necessary, install extra air intake ducts.
It is strictly forbidden to dwell or stay in the risk zone under a lifted load.
3 When operating in a dust-laden atmosphere, place the unit so that dust is
Never lift the unit over people or residential areas. Lifting acceleration and
not carried towards it by the wind. Operation in clean surroundings
retardation shall be kept within safe limits.
considerably extends the intervals for cleaning the air intake filters and the
1 Before towing the unit: cores of the coolers.
- check the towbar, the brake system and the towing eye. Also check the
4 Never remove a filler cap of the cooling water system of a hot engine. Wait
coupling of the towing vehicle,
until the engine has sufficiently cooled down.
- check the towing and brake capability of the towing vehicle,
- check that the towbar, jockey wheel or stand leg is safely locked in the 5 Never refill fuel while the unit is running, unless otherwise stated in the
raised position, Atlas Copco Instruction Book (AIB). Keep fuel away from hot parts such
- ascertain that the towing eye can swivel freely on the hook, as air outlet pipes or the engine exhaust. Do not smoke when fuelling.
- check that the wheels are secure and that the tires are in good condition When fuelling from an automatic pump, an earthing cable should be
and inflated correctly, connected to the unit to discharge static electricity. Never spill nor leave
- connect the signalisation cable, check all lights and connect the oil, fuel, coolant or cleansing agent in or around the unit.
pneumatic brake couplers, 6 All doors shall be shut during operation so as not to disturb the cooling air
- attach the safety break-away cable or safety chain to the towing vehicle, flow inside the bodywork and/or render the silencing less effective. A door
- remove wheel chocks, if applied, and disengage the parking brake. should be kept open for a short period only e.g. for inspection or
2 To tow a unit use a towing vehicle of ample capacity. Refer to the adjustment.
documentation of the towing vehicle.
7 Periodically carry out maintenance works according to the maintenance
3 If the unit is to be backed up by the towing vehicle, disengage the overrun schedule.
brake mechanism (if it is not an automatic mechanism).
8 Stationary housing guards are provided on all rotating or reciprocating
4 Never exceed the maximum towing speed of the unit (mind the local parts not otherwise protected and which may be hazardous to personnel.
regulations). Machinery shall never be put into operation, when such guards have been
5 Place the unit on level ground and apply the parking brake before removed, before the guards are securely reinstalled.
disconnecting the unit from the towing vehicle. Unclip the safety break- 9 Noise, even at reasonable levels, can cause irritation and disturbance
away cable or safety chain. If the unit has no parking brake or jockey which, over a long period of time, may cause severe injuries to the nervous
wheel, immobilize the unit by placing chocks in front of and/or behind the system of human beings.
wheels. When the towbar can be positioned vertically, the locking device When the sound pressure level, at any point where personnel normally has
must be applied and kept in good order. to attend, is:
6 To lift heavy parts, a hoist of ample capacity, tested and approved below 70 dB(A): no action needs to be taken,
according to local safety regulations, shall be used. above 70 dB(A): noise-protective devices should be provided for people
continuously being present in the room,
7 Lifting hooks, eyes, shackles, etc., shall never be bent and shall only have
below 85 dB(A): no action needs to be taken for occasional visitors
stress in line with their design load axis. The capacity of a lifting device
staying a limited time only,
diminishes when the lifting force is applied at an angle to its load axis.
above 85 dB(A): room to be classified as a noise-hazardous area and an
8 For maximum safety and efficiency of the lifting apparatus all lifting obvious warning shall be placed permanently at each
members shall be applied as near to perpendicular as possible. If required, entrance to alert people entering the room, for even
a lifting beam shall be applied between hoist and load. relatively short times, about the need to wear ear
9 Never leave a load hanging on a hoist. protectors,
above 95 dB(A): the warning(s) at the entrance(s) shall be completed
10 A hoist has to be installed in such a way that the object will be lifted with the recommendation that also occasional visitors
perpendicular. If that is not possible, the necessary precautions must be shall wear ear protectors,
taken to prevent load-swinging, e.g. by using two hoists, each at above 105 dB(A): special ear protectors that are adequate for this noise
approximately the same angle not exceeding 30° from the vertical. level and the spectral composition of the noise shall be
11 Locate the unit away from walls. Take all precautions to ensure that hot air provided and a special warning to that effect shall be
exhausted from the engine and driven machine cooling systems cannot be placed at each entrance.
recirculated. If such hot air is taken in by the engine or driven machine 10 Insulation or safety guards of parts the temperature of which can be in
cooling fan, this may cause overheating of the unit; if taken in for excess of 80 °C (175 °F) and which may be accidentally touched by
combustion, the engine power will be reduced. personnel shall not be removed before the parts have cooled to room
temperature.
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, 11 Never operate the unit in surroundings where there is a possibility of
consult Atlas Copco. taking in flammable or toxic fumes.
13 The electrical connections shall correspond to local codes. The machines 12 If the working process produces fumes, dust or vibration hazards, etc., take
shall be earthed and protected against short circuits by fuses or circuit the necessary steps to eliminate the risk of personnel injury.
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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 QAS38 YdS TNV

13 When using compressed air or inert gas to clean down equipment, do so 1.5 Safety during maintenance and repair
with caution and use the appropriate protection, at least safety glasses, for
Maintenance, overhaul and repair work shall only be carried out by adequately
the operator as well as for any bystander. Do not apply compressed air or
trained personnel; if required, under supervision of someone qualified for the
inert gas to your skin or direct an air or gas stream at people. Never use it
job.
to clean dirt from your clothes.
1 Use only the correct tools for maintenance and repair work, and only tools
14 When washing parts in or with a cleaning solvent, provide the required
which are in good condition.
ventilation and use appropriate protection such as a breathing filter, safety
glasses, rubber apron and gloves, etc. 2 Parts shall only be replaced by genuine Atlas Copco replacement parts.
15 Safety shoes should be compulsory in any workshop and if there is a risk, 3 All maintenance work, other than routine attention, shall only be
however small, of falling objects, wearing of a safety helmet should be undertaken when the unit is stopped. Steps shall be taken to prevent
included. 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.
16 If there is a risk of inhaling hazardous gases, fumes or dust, the respiratory
On engine-driven units the battery shall be disconnected and removed or
organs must be protected and depending on the nature of the hazard, so
the terminals covered by insulating caps.
must the eyes and skin.
On electrically driven units the main switch shall be locked in open
17 Remember that where there is visible dust, the finer, invisible particles will position and the fuses shall be taken out. A warning sign bearing a legend
almost certainly be present too; but the fact that no dust can be seen is not such as ”work in progress; do not supply voltage” shall be attached to the
a reliable indication that dangerous, invisible dust is not present in the air. fuse box or main switch.
18 Never operate the generator in excess of its limits as indicated in the 4 Prior to stripping an engine or other machine or undertaking major
technical specifications and avoid long no-load sequences. overhaul on it, prevent all movable parts from rolling over or moving.
19 Never operate the generator in a humid atmosphere. Excessive moisture 5 Make sure that no tools, loose parts or rags are left in or on the machine.
causes worsening of the generator insulation. Never leave rags or loose clothing near the engine air intake.
20 Do not open electrical cabinets, cubicles or other equipment while voltage 6 Never use flammable solvents for cleaning (fire-risk).
is supplied. If such cannot be avoided, e.g. for measurements, tests or
7 Take safety precautions against toxic vapors of cleaning liquids.
adjustments, have the action carried out by a qualified electrician only,
with appropriate tools, and ascertain that the required bodily protection 8 Never use machine parts as a climbing aid.
against electrical hazards is applied. 9 Observe scrupulous cleanliness during maintenance and repair. Keep away
21 Never touch the power terminals during operation of the machine. dirt, cover the parts and exposed openings with a clean cloth, paper or
tape.
22 Whenever an abnormal condition arises, e.g. excessive vibration, noise,
Adour, etc., switch the circuit breakers to OFF and stop the engine. Correct 10 Never weld on or perform any operation involving heat near the fuel or oil
the faulty condition before restarting. 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
23 Check the electric cables regularly. Damaged cables and insufficient
way modify, pressure vessels. Disconnect the alternator cables during arc
lightening of connections may cause electric shocks. Whenever damaged
welding on the unit.
wires or dangerous conditions are observed, switch the circuit breakers to
OFF and stop the engine. Replace the damaged wires or correct the 11 Support the towbar and the axle(s) securely if working underneath the unit
dangerous condition before restarting. Make sure that all electric or when removing a wheel. Do not rely on jacks.
connections are securely tightened. 12 Do not remove any of, or tamper with, the sound-damping material. Keep
24 Avoid overloading the generator. The generator is provided with circuit the material free of dirt and liquids such as fuel, oil and cleansing agents.
breakers for overload protection. When a breaker has tripped, reduce the If any sound-damping material is damaged, replace it to prevent the sound
concerned load before restarting. pressure level from increasing.
25 If the generator is used as stand-by for the mains supply, it must not be 13 Use only lubricating oils and greases recommended or approved by Atlas
operated without control system which automatically disconnects the Copco or the machine manufacturer. Ascertain that the selected lubricants
generator from the mains when the mains supply is restored. comply with all applicable safety regulations, especially with regard to
explosion or fire-risk and the possibility of decomposition or generation of
26 Never remove the cover of the output terminals during operation. Before
hazardous gases. Never mix synthetic with mineral oil.
connecting or disconnecting wires, switch off the load and the circuit
breakers, stop the machine and make sure that the machine cannot be 14 Protect the engine, alternator, air intake filter, electrical and regulating
started inadvertently or there is any residual voltage on the power circuit. components, etc., to prevent moisture ingress, e.g. when steam-cleaning.
27 Running the generator at low load for long periods will reduce the lifetime 15 When performing any operation involving heat, flames or sparks on a
of the engine. machine, the surrounding components shall first be screened with non-
flammable material.

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 Instruction Manual

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.
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.

1.6 Tool applications safety

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.

1.7 Battery safety precautions

Batteries
When servicing batteries, always wear protecting clothing and glasses.
1 The electrolyte in batteries is a sulfuric 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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 QAS38 YdS TNV

2. Leading particulars

2.1 General description

The QAS38 is an AC generator, built for continuous running at The generator can run in 3 different modes:
sites where no electricity is available or as stand-by in cases of in-
1 phase 60 Hz 240 V 37.15 hp / 27.7 kW
terruption of the mains.
3 phase - lower voltage 60 Hz 208 V 43.31 hp / 32.3 kW
The QAS38 generator is driven by a water-cooled diesel engine, 3 phase - higher voltage 60 Hz 480 V 43.31 hp / 32.3 kW
manufactured by YANMAR.
An overview of the main parts is given in the diagram below.

FCW 4
2
1

1615 6945 00

FCW F
5 DPF FCO
ET
FCF E

AF
DH C
3
8 A

6
7
8

DFW
FPF
DFO
FF
OF
OLD
G1

1 Lifting rod DH Drain and access hole (in the frame)

2 Guiding rod DPF Drain plug fuel
3 Side doors, access to engine and alternator E Engine
4 Engine exhaust ET Expansion tank engine cooling system
5 Data Plate F Fan
6 Side door, access to control and indicator panel FCF Filler cap fuel
7 Output terminal board FCO Filler cap engine oil
8 Hole for forklift FCW Filter cap cooling water
A Alternator FF Fuel filter
AF Air filter FPF Fuel pre-filter
C Coupling G1 Battery
DFO Drain flexible engine oil OF Oil filter
DFW Drain flexible cooling water OLD Engine oil level dipstick

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 Instruction Manual

2.2 Bodywork
The alternator, the engine, the cooling system, etc. are enclosed in
a sound-insulated bodywork that can be opened by means of side Indicates that the alternator should not be cleaned
doors (and service plates). with high pressurised water.
The recess in the roof has a lifting rod in the middle and a guiding
rod at both sides.
QAS 38 Yd TNV

Every 250 h 2912 6038 00 Indicates the partnumbers of the different

! Never use the guiding rods to lift the generator. Every 500 h 2912 6039 00
Yearly (max. 2000 h) 2912 6040 00
Engine oil PAROIL 15W40 PAROIL 5W30
5 l (1.3 US gal) 1615 5953 00 1604 6060 00
service packs and of the engine oil.
20 l (5 US gal) 1615 5954 00 1604 6059 00
210 l (55 US gal) 1615 5955 00 These parts can be ordered to the factory.
To be able to lift the QAS38 by means of a forklift, rectangular Engine coolant PARCOOL EGEG
PARCOOL
5 l (1.3 US gal) 1604 5308 00
20 l (5 US gal) 1604 5307 01
holes are provided in the frame. 210 l (55 US gal) 1604 5306 00

2.3 Markings 2.4 Drain plugs and filler caps

A brief description of all markings provided on the QAS38 is given The drain holes for the engine oil, the coolant and the plug for the
hereafter. 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
Indicates that an electric voltage, dangerous to
generator through the drain hole.
life, is present. Never touch the electric termi-
nals during operation. 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.
Indicates that the engine exhaust is a hot and
harmful gas, which is toxic in case of inhala- 2.5 Control and indicator panel
tion. Always make sure that the unit is operated
outside or in a well-ventilated room. The control and indicator panel is located behind a door in the side
panel. The hinged door is partly transparent and allows easy access
Indicates that these parts can become very hot
to the parts mounted behind it. Panel light H1 lights up as soon as
during operation (e.g. engine, cooler, etc.). Al-
the starter switch is turned into position or the remote start/stop
ways make sure that these parts are cooled
switch is put in position start, indicating that the fuel solenoid is en-
down before touching them.
ergized.
Indicates that the generator may be refuelled
diesel with diesel fuel only. ST P8 P1 H1 P2 P3
¡C

Indicates the drain for the engine oil. 60 80 100 120

A 60 A 60 A 60
40 40 40
L1 L1 L1
20 20 20

bar 0 0 0
60/5A I 60/5A I 60/5A I

2 3 4
M E M E M E

0 1 5

Indicates the drain for the coolant. RPM

60 65
L1L2
OFF

L1-N
V 400
55
50 L2L3
L2-N
200 L1

45 L3L1 0
1/2 LL LN
0 1/1 I
M E
I
M E

Indicates the drain plug for the engine fuel.

PAROIL
P6 F4 P9 P7 P5 S4 P4 R11
15W40
Use 15W40 oil only
H1 ......Panel light
Indicates that the guiding rods may not be used to
lift the generator. Always use the lifting rod in the
2.5.1 Engine gauges
roof of the generator to lift it.
P6 ......Hourmeter
Indicates the lifting eye of the generator. P7 ......Fuel level gauge

P8 ......Engine coolant temperature gauge

Indicates that the unit may start auto-
matically and that the instruction book P9 ......Engine oil pressure gauge
has to be consulted prior to use.

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 QAS38 YdS TNV

2.5.2 Generator gauges F4 ...... Fuse

The fuse activates when the current from the battery to the en-
P1 ...... Ammeter line L1
gine control circuit exceeds its setting. The fuse can be
Indicates the outgoing current in the first line (L1). switched on and off by pushing the button.

P2 ...... Ammeter line L2 L1 ...... Electrical system indicator

Indicates the outgoing current in the second line (L2). Lights up when the electrical system of the engine is energized.

P3 ...... Ammeter line L3 L2 ...... Engine preheating system indicator

Indicates the outgoing current in the third line (L3). Lights up when the glow plugs in the engine, used to facilitate
starting, are warming up. Extinguishes after approximately 10
P4 ...... Voltmeter seconds. Bypassing of the preheattime is allowed e.g. when
Indicates the voltage selected by means of voltage selector starting a hot engine, but the preheat system remains active.
switch S4.
L3 ...... Alternator charging indicator
P5 ...... Frequency / RPM meter Goes out after starting, indicating that the alternator is charg-
Indicates the frequency of the supply voltage and the speed of ing. A failing alternator however will not shut the engine down.
the engine.
L4 ...... AC shut down indicator
S4...... Voltmeter selector switch Lights up when no AC input (< 75 V line-to-neutral) is present.
Allows to measure the voltage between each of the phases and
between each phase and the neutral. It also allows to switch off L5 ...... Overspeed shut down indicator
the voltmeter. Lights up when the engine’s speed has exceeded 115 % of the
nominal speed.
2.5.3 Engine controls and lamps
L6 ...... Engine coolant temperature fault indicator
Lights up when the high engine coolant temperature was the
L1 cause of shut down.
L2
L3 L7 ...... Engine oil pressure fault indicator
L4 Lights up when the low engine oil pressure was the cause of
L5
shut down.
L6
ST
L7
L8 L8 ...... Spare shut down indicator
Can be used to wire an extra shut down, e.g. for low fuel level
in case a switch is incorporated in the fuel tank.

F4 R11.... Output voltage adjust potentiometer

Allows to adjust the output voltage. R11 is located on the con-
ST...... Starter switch trol and indicator panel.

The starter switch is a three-position switch.

– : used to select normal start and to disable remote start
–O: used to switch off the power supply from the battery
or to reset after a shut down due to a failure. The unit
will not be able to start up.
– : used to select remote start.

After approximately 20 seconds in position with-

! out starting, the control system will automatically
shut down (battery saving purpose) indicating a low
oil pressure failure. In this case, a reset of the control
system by putting the switch in position O is neces-
sary.

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2.6 Remote start (RS) S2 ......Emergency stop button

"Remote start" allows to switch the unit on or off without using the Push the button to stop the generator in case of an emergency.
control panel located on the unit. The start module of the control When the button is pressed, it must be unlocked, by turning it
panel provides extra connections for the remote start/stop switch anti-clockwise, before the generator can be restarted.
and the plant contactor (voltage free contact), both to be installed
Q1.1...Circuit breaker for low voltage
by the customer.
Interrupts the low voltage power supply towards X1, X2, X3
The plant contactor should be sized according to the and X4 when a short-circuit occurs at the load side, or when the
! load. The maximum current through the voltage
free contact is 3 A.
overcurrent protection (125 A) is activated. It must be reset
manually after eliminating the problem.

The remote start/stop switch Sx has to meet the fol- Q1.2...Circuit breaker for high voltage
lowing specifications: 12 V DC, 4 A.
Interrupts the high voltage power supply towards X1, X2, X3
Refer to the circuit diagram for the correct connec- and X4 when a short-circuit occurs at the load side, or when the
tion of the plant contactor and the remote start/stop overcurrent protection (50 A) is activated. It must be reset man-
switch. ually after eliminating the problem.

A shunt trip coil will switch off Q1.1 or Q1.2 Q2......Circuit breaker
(depending on the mode the unit is running in) in
Interrupts phases L1 and L2 towards X2 when a short-circuit
case of an emergency stop or an earth fault. occurs at the load side, or when the overcurrent protection
(50 A) is activated. It must be reset manually after eliminating
2.7 Dip-switches the problem.
For correct functioning of the module, the DIP switches at the back Q3......Circuit breaker
of the control module should be positioned as follows:
Interrupts line L1 and L2 towards X3 when a short-circuit oc-
curs at the load side, or when the overcurrent protection (50 A)
ON is activated. It must be reset manually after eliminating the
problem.

5H 1 2 3 4 Q4......Circuit breaker
Interrupts line L2 towards X4 when a short-circuit occurs at the
load side, or when the overcurrent protection (20 A) is activat-
2.8 Output connections ed. It must be reset manually after eliminating the problem.

The output connections are situated below the control and indicator X1 ......Main power supply - Terminal board
panel.
Terminals L1, L2, L3, N (=neutral) and PE (=grounding), hid-
Q2
den behind the control panel door and behind a small transpar-
Q1.2 Q3 ent door.
Q1.1 Q4
X2 ......Single phase outlet socket
208-240V 480V Provides lines L1, L2, and N (=neutral).

X3 ......Single phase outlet socket

L1 L2 L3 N PE
Provides lines L1, L2, and N (=neutral).
4

X25
3
2
1

X1 X4 ......Single phase outlet socket

Provides lines L2, N (=neutral) and PE (=grounding).

X25 ....Connection block

Allows easy connection for a remote start switch.

X2 S2 Refer to the circuit diagrams for the correct connec-

X4 X3 ! tion.

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2.9 Spillage free 3. Operating instructions

A Spillage free skid with forklift slots allows the customer to trans-
In your own interest, always strictly observe all rele-
port the generator easily with a forklift.
It avoids accidential spilling of engine fluids.
! vant safety instructions.

Do not operate the generator in excess of the limita-

tions mentioned in the Technical Specifications.
2.10 Triple voltage (3V)
Local rules concerning the setting up of low voltage
The generator can run in three different modes: power installations (below 1,000 V) must be
– 1 phase respected when connecting site distribution panels,
switch gear or loads to the generator.
– 3 phase, lower voltage
At each start-up and at any time a new load is con-
– 3 phase, higher voltage nected, the earthing of the generator must be veri-
Depending on which mode the generator is running in, circuit fied. Earthing must be done either by the earthing
breaker Q1.1 or Q1.2 will be operational. rod or, if available, by an existing, suitable earthing
installation. The protective system against excessive
Circuit breakers Q1.1 and Q1.2 cannot be switched on at the same
contact voltage is not effective unless a suitable
time. This is prevented by means of the auxiliary voltage selection
earthing is made.
relays K11 and K12 (refer to the circuit diagram).
The selection between the three modes is done by means of S10. The generator is wired for a TN-system to IEC 364-
3, i.e. one point in the power source directly earthed
S10.... Output voltage selector switch - in this case the neutral. The exposed conductive
parts of the electric installation must be directly con-
Allows to select a 3 phase high output voltage, a 3 phase low
nected to the functional earth.
output voltage or a 1 phase low output voltage. Selector switch
S10 is located on the alternator. If operating the generator in another power system,
e.g. an IT-system, other protective devices required
Changing the output voltage is only allowed after
! shutdown.
for these types must be installed. In any case only a
qualified electrician is authorized to remove the con-
After changing the output voltage by means of the nection between the neutral (N) and earth terminals
selection switch S10, adjust the output voltage by in the terminal box of the alternator.
means of potentiometer R11 to the required value.
3.1 Installation
1 phase
When using this selection, the generator provides a 240 V output – Place the generator on a horizontal, even and solid floor.
voltage. – Protect the generator against dust and rain if it is operated outside.

3 phase lower voltage – Check that the engine exhaust is not directed towards people. If the
generator is operated indoors, install an exhaust pipe of sufficient
When using this selection, the generator provides a 208 V output diameter to duct the engine exhaust towards the outside. Check for
voltage. sufficient ventilation so that the cooling air is not recirculated. If
necessary, consult Atlas Copco.
3 phase higher voltage
– Leave enough space for operation, inspection and maintenance (at
When using this selection, the generator provides a 480 V output least 1 meter at each side).
voltage.
– 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.

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3.2 Connecting the generator Protection

3.2.1 Precautions for non-linear and sensitive For safety reasons, it is necessary to provide an iso-
loads ! lating switch or circuit breaker in each load circuit.
Local legislation may impose the use of isolating
devices which can be locked.
Non-linear loads draw currents with high contents
! in harmonics, causing distortion in the wave form of
the voltage generated by the alternator.
– 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
The most common non-linear, 3-phase loads are thyristor/rectifier- in a safe way without forming coils.
controlled loads, such as convertors supplying voltage to variable
speed motors, uninterruptable power supplies and Telecom sup- – Open the door of the control and indicator panel and the transparent
plies. Gas-discharge lighting arranged in single-phase circuits gen- door in front of the terminal board X1.
erate high 3rd harmonics and risk for excessive neutral current. – Provide the wire ends with cable lugs suited for the cable terminals.
Loads most sensitive to voltage distortion include incandescent – Loosen the cable clamp and push the wire ends of the load cable
lamps, discharge lamps, computers, X-ray equipment, audio ampli- through the orifice and clamp.
fiers and elevators.
– Connect the wires to the proper terminals (L1, L2, L3, N and PE) of
Consult Atlas Copco for measures against the adverse influence of X1 and tighten the bolts securely.
non-linear loads.
– Tighten the cable clamp.
3.2.2 Quality, minimum section and maximum – Close the transparent door in front of X1.
length of cables
The cable connected to the terminal board of the generator must be 3.3 Before starting
selected in accordance with local legislation. The type of cable, its
rated voltage and current carrying capacity are determined by in- – With the generator standing level, check the engine oil level and top
stallation conditions, stress and ambient temperature. For flexible up if necessary. The oil level must be near to, but not exceed the
wiring, rubber-sheathed, flexible core conductors must be used. high mark on the engine oil level dipstick.
– Check the coolant level in the expansion tank of the engine cooling
3.2.3 Connecting the load system. The water level must be near to the FULL mark. Add cool-
ant if necessary.
Site distribution panel
– Drain any water and sediment from the fuel pre-filter. Check the
If outlet sockets are required, they must be mounted on a site distri- fuel level and top up if necessary. It is recommended to fill the tank
bution panel supplied from the terminal board of the generator and after the day’s operation to prevent watervapor in a nearly empty
in compliance with local regulations for power installations on tank from condensing.
building sites.
– 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.

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3.4 Starting 3.5 During operation

Following points should be carried out regularly:
To start up the unit locally, without using the re-
mote start/stop switch, proceed as follows: – Check the engine gauges and the lamps for normal readings.

– Put the starter switch in position . The unit starts a preheating cy- Avoid to let the engine run out of fuel. If it hap-
cle which takes 12 seconds. ! pened, priming will speed up the starting.
– After the preheating period, the unit will start. The starting attempt – Check for leakage of oil, fuel or cooling water.
will take maximum 12 seconds. If the unit does not start immediate-
ly, it will perform another two starting attempts. – Avoid long low-load periods (< 30 %). In this case, an output drop
and higher oil consumption of the engine could occur.
– Approximately 15 seconds after starting (stabilization time for the
generator), the timer relay closes the voltage free contact and the – Check, by means of the generator gauges, that the voltage between
plant contactor is energized (if installed). the phases is identical and that the rated current per phase is not ex-
ceeded.
– Check that the warning lamps on the control and indicator panel are
out. Refer to “Control and indicator panel” for component locations. – When single-phase loads are connected to the generator output ter-
minals, keep all loads well-balanced (in 3 phase output voltage
– Run the engine for approximately 5 minutes to warm up. mode).
– Check the engine oil pressure (P9) and the cooling water tempera- – If circuit breakers are activated during operation, switch off the load
ture (P8). and stop the generator. Check and, if necessary, decrease the load.
– Check the voltmeter P4 (with voltmeter selector switch S4 in differ-
The generator’s side doors may only remain opened
ent positions) and the frequency meter P5.
! for short periods during operation, to carry out
– Switch on circuit breaker Q1.1 or Q1.2, depending on the mode the checks for example.
generator is running in.
– Switch on the load and check the ammeters P1, P2 and P3, voltmeter 3.6 Stopping
P4 (voltmeter selector switch S4 in different positions) and the fre-
quency meter P5. To stop the unit when the starter switch is in posi-
tion , proceed as follows:
To start up the unit from a remote location using
the remote start/stop switch, proceed as follows: – Switch off the load.

– Put the starter switch in position . – Switch off circuit breakers Q1.1 or Q1.2, depending on the mode the
unit is running in.
– Switch on circuit breakers Q1.1 or Q1.2, depending on the mode the
unit is running in. – Let the engine run for about 5 minutes.

– Put the remote start/stop switch in position start. The unit starts a – Stop the engine by putting the starter switch in position O.
preheating cycle which takes 12 seconds.
To stop the unit when the starter switch is in posi-
– After the preheating period, the unit will start. The starting attempt tion , proceed as follows:
will take maximum 12 seconds.
– Switch off the load.
– Approximately 15 seconds after starting (stabilization time for the
generator), the timer relay closes the voltage free contact and the – Let the engine run for about 5 minutes.
plant contactor is energized (if installed).
– Stop the engine by putting the remote start/stop switch in position
– Check that the warning lamps on the control and indicator panel are stop or by putting the starter switch in position O.
out. Refer to “Control and indicator panel” for component locations.
Lock the side doors and the door of the indicators
– Run the engine for approximately 5 minutes to warm up.
– Check the engine oil pressure (P9) and the cooling water tempera-
! and control panel to avoid unauthorized access.

ture (P8).
– Check the voltmeter P4 (with voltmeter selector switch S4 in differ-
ent positions) and the frequency meter P5.
– Switch on the load and check the ammeters P1, P2 and P3, voltmeter
P4 (voltmeter selector switch S4 in different positions) and the fre-
quency meter P5.

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 Instruction Manual

4. Maintenance

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

4.1 Maintenance schedule Daily Initial Small Normal Yearly

50 hours 250 hours 500 hours 2000 hours
SERVICE PAK - With unit 2912 6038 00 2912 6039 00 2912 6040 00
For the most important subassemblies, Atlas Copco has developed service kits that combine all wear parts. These service kits offer you
the benefits of genuine parts, save on administration costs and are offered at reduced price, compared to the loose components. Refer to
the parts list for more information on the contents of the service kits.
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 Check/Drain Check/Drain Check/Drain Check/Drain
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
Air cleaner and dust bowl Clean Clean Clean Clean
Air filter element (1) Clean Replace Replace
Safety cartridge Replace
Valve clearance Check/adjust Check/adjust Check/adjust Check/adjust
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 Measure Measure Measure
Tightness of nuts and bolts Check Check
Door hinges and locks Grease Grease
Fixation of hoses, cables and pipes Check Check
Inspection by Atlas Copco Service technician !
(1) More frequently when operating in a dusty environment. Evacuate 4.3 (*)Measuring the alternator insulation
dust from the airfilter valve daily. resistance
(2) A Service Bulletin (ASB) dealing elaborately with batteries and A 500 V megger is required to measure the alternator insulation re-
due care is available on request. sistance.
If the N-terminal is connected to the earthing system, it must be dis-
4.2 Engine maintenance connected from the earth terminal. Disconnect the AVR. Discon-
nect the radio interference suppressor.
Refer to the engine’s operator manual for full maintenance, includ-
ing instructions for changing the oil and cooling water and replac- Connect the megger between the earth terminal and terminal L1
ing the fuel, oil and air filters. and generate a voltage of 500 V. The scale must indicate a resis-
tance of at least 5 MΩ.
Refer to the alternator operating and maintenance instructions for
more details.

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5. Storage of the generator 6. Checks and trouble shooting

5.1 Storage Never perform a test run with connected power

– Store the generator in a dry, frost-free room which is well ventilat-

! cables. Never touch an electrical connector without
a voltage check.
ed.
When a failure occurs, always report what you expe-
– Run the engine regularly, e.g. once a week, until it is warmed up. If rienced before, during and after the failure. Infor-
this is impossible, extra precautions must be taken: mation with regard to the load (type, size, power
– Consult the engine’s operator manual. factor, etc.), vibrations, exhaust gas colour, insula-
tion check, odours, output voltage, leaks and dam-
– Remove the battery. Store it in a dry, frost-free room. Keep the aged parts, ambient temperature, daily and normal
battery clean and its terminals lightly covered with petroleum maintenance and altitude might be helpful to
jelly. Recharge the battery regularly. quickly locate the problem. Also report any infor-
mation regarding the humidity and location of the
– Clean the generator and protect all electrical components against
generator (e.g. close to sea).
moisture.
– Place silicagel bags, VCI paper (Volatile Corrosion Inhibitor) or
another drying agent inside the generator and close the doors.
6.1 Checking voltmeter P4
– Stick sheets of VCI paper with adhesive tape on the bodywork to – Put a voltmeter in parallel with voltmeter P4 on the control panel.
close off all openings. – Check that the read-out of both voltmeters is the same.
– Wrap the generator, except the bottom, with a plastic bag. – Stop the generator and disconnect one terminal.
– Check that the internal resistance of the voltmeter is high.
5.2 Preparing for operation after storage
Before operating the generator again, remove the wrapping, VCI 6.2 Checking frequency meter P5
paper and silicagel bags and check the generator thoroughly (go
through the checklist “Before starting”). – Run the unit at normal speed.

– Consult the engine’s operator manual. – Put a voltmeter in parallel with frequency meter P5.

– Check that the insulation resistance of the generator exceeds 5 MΩ. – If the measured voltage is higher than 200 V, the frequency meter
has to work properly.
– Replace the fuel filter and fill the fuel tank. Vent the fuel system.
If not, remove the frequency meter, connect it with the mains
– Reinstall and connect the battery, if necessary after being recharged. (240 V) and check that it indicates 60 Hz.
– Submit the generator to a test run.
6.3 Checking ammeters P1, P2 en P3
– 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.

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6.4 Alternator trouble shooting

Symptom Possible cause Corrective action

Alternator does not excite. 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 Ω resistor in series respecting the polarities.
After being excited alterna- Connections are interrupted. Check connection cables as per attached drawings.
tor does not excite.
Low voltage at no load. Voltage potentiometer out of setting. Reset voltage.
Intervention of protection. Check rpm.
Winding failure. Check windings.
High voltage at no load. Voltage potentiometer out of setting. Reset voltage.
Failed regulator. Substitute regulator.
Lower than rated voltage at Voltage potentiometer out of setting. Reset voltage potentiometer.
load.
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.
Higher than rated voltage at Voltage potentiometer out of setting. Reset voltage potentiometer.
load.
Loose sensing wires on AVR. Check sensing wires on AVR.
Failed regulator. Substitute regulator.
Unstable voltage. Speed variation in engine. Check regularity of rotation.
Regulator out of setting. Regulate stability of regulator by acting on “STA-
BILITY” potentiometer.

6.5 Engine trouble shooting

The table below gives an overview of the possible engine problems – Cold start system used incorrectly.
and their possible causes. – Fault in cold start system.
– Restriction in fuel tank vent.
6.5.1 The starter motor turns the engine
– Wrong type or grade of fuel used.
too slowly
– Restriction in exhaust pipe.
– Battery capacity too low.
– Bad electrical connection. 6.5.3 Not enough power
– Fault in starter motor. – Restriction in a fuel pipe.
– Wrong grade of lubricating oil. – Fault in fuel lift pump.
– Dirty fuel filter element.
6.5.2 The engine does not start or is difficult
to start – Restriction in air filter/cleaner or induction system.
– Air in fuel system.
– Starter motor turns engine too slowly. – Fault in atomizers or atomizers of an incorrect type.
– Fuel tank empty.
– Restriction in fuel tank vent.
– Fault in fuel control solenoid. – Wrong type or grade of fuel used.
– Restriction in a fuel pipe. – Restricted movement of engine speed control.
– Fault in fuel lift pump.
– Restriction in exhaust pipe.
– Dirty fuel filter element. – Engine temperature is too high.
– Air in fuel system. – Engine temperature is too low.
– Fault in atomizers.

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6.5.4 Misfire 6.5.10 The engine runs erratically

– Restriction in a fuel pipe. – Fault in fuel control.
– Fault in fuel lift pump. – Restriction in a fuel pipe.
– Dirty fuel filter element. – Fault in fuel lift pump.
– Air in fuel system. – Dirty fuel filter element.
– Fault in atomizers or atomizers of an incorrect type. – Restriction in air filter/cleaner or induction system.
– Fault in cold start system. – Air in fuel system.
– Engine temperature is too high. – Fault in atomizers or atomizers of an incorrect type.
– Incorrect valve tip clearances. – Fault in cold start system.
– Restriction in fuel tank vent.
6.5.5 The pressure of the lubricating oil is – Restricted movement of engine speed control.
too low
– Engine temperature is too high.
– Wrong grade of lubricating oil. – Incorrect valve tip clearances.
– Not enough lubricating oil in sump.
– Defective gauge. 6.5.11 Vibration
– Dirty lubricating oil filter element. – Fault in atomizers or atomizers of an incorrect type.
– Restricted movement of engine speed control.
6.5.6 High fuel consumption
– Engine temperature is too high.
– Restriction in air filter/cleaner or induction system. – Fan damaged.
– Fault in atomizers or atomizers of an incorrect type. – Fault in engine mounting or flywheel housing.
– Fault in cold start system.
– Wrong type or grade of fuel used. 6.5.12 The pressure of the lubricating oil is
– Restricted movement of engine speed control. too high
– Restriction in exhaust pipe. – Wrong grade of lubricating oil.
– Engine temperature is too low. – Defective gauge.
– Incorrect valve tip clearances.
6.5.13 The engine temperature is too high
6.5.7 Black exhaust smoke – Restriction in air filter/cleaner or induction system.
– Restriction in air filter/cleaner or induction system. – Fault in atomizers or atomizers of an incorrect type.
– Fault in atomizers or atomizers of an incorrect type. – Fault in cold start system.
– Fault in cold start system. – Restriction in exhaust pipe.
– Wrong type or grade of fuel used. – Fan damaged.
– Restriction in exhaust pipe. – Too much lubricating oil in sump.
– Engine temperature is too low. – Restriction in air or water passages of radiator.
– Incorrect valve tip clearances. – Insufficient coolant in system.
– Engine overload. 6.5.14 Crankcase pressure
6.5.8 Blue or white exhaust smoke – Restriction in breather pipe.
– Wrong grade of lubricating oil. – Vacuum pipe leaks or fault in exhauster.
– Fault in cold start system. 6.5.15 Bad compression
– Engine temperature is too low.
– Restriction in air filter/cleaner or induction system.
6.5.9 The engine knocks – Incorrect valve tip clearances.
– Fault in fuel lift pump. 6.5.16 The engine starts and stops
– Fault in atomizers or atomizers of an incorrect type.
– Fault in cold start system. – Dirty fuel filter element.
– Wrong type or grade of fuel used. – Restriction in air filter/cleaner or induction system.
– Engine temperature is too high. – Air in fuel system.
– Incorrect valve tip clearances.
6.5.17 The engine shuts down after approximately
15 seconds
– Bad connection towards oil pressure switch/coolant temperature
switch.
– DIP switch on back of module wrong positioned.

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7. Technical specifications

7.1 Readings on gauges

Gauge Reading US Metric
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

7.2 Settings of switches

Switch Function Activates at Activates at
Engine oil pressure shut down 7.25 psi 0.5 bar
Engine coolant temperature shut down 221 °F 105 °C

7.3 Specifications of the engine/alternator/unit

US Metric

Reference Rated frequency 60 Hz 60 Hz

conditions 1) Rated speed (optional) 1800 rpm 1800 rpm
Generator service duty PRP PRP
Absolute inlet pressure 100 kPa 100 kPa
Relative air humidity 30 % 30 %
Air inlet temperature 77 °F 25°C

Limitations Maximum ambient temperature 104 °F 40 °C

2) Altitude capability 3281 ft 1000 m
Relative air humidity maximum 85 % 85 %
Minimum starting temperature -0.4 °F -18 °C

Performance Rated active power (PRP) 3ph 43.31 hp 32.3 kW

data 2) 3) 5) Rated active power (PRP) 1ph (optional) 37.15 hp 27.7 kW
Rated power factor (lagging) 3phase 0.8 0.8
Rated power factor (lagging) 1phase (optional) 1.0 1.0
Rated apparent power (PRP) 3ph 40 kVA 40 kVA
Rated apparent power (PRP) 1ph (optional) 27.7 kVA 27.7 kVA
Rated voltage 3ph. line to line 480 V 480 V
Rated voltage 3ph. line to line lower voltage (optional) 208 V 208 V
Rated voltage 1ph. line to line (optional) 240V 240V
Rated current 3ph. 48.1 A 48.1 A
Rated current 3ph. lower voltage (optional) 111 A 111 A
Rated current 1ph. (optional) 115.5 A 115.5 A
Performance class (acc.ISO 8528-5:1993) G2 G2
Frequency droop <5 <5
(optional) isochronous isochronous
Fuel consumption at full load/no load 17.49/3.20 lb/h 7.93/1.45 kg/h
Specific fuel consumption 0.52 lb/kWh 0.236 kg/kWh
Fuel autonomy at full load 8.8 h 8.8 h
Max. oil consumption at full load 0.70 oz/h 20 g/h
Maximum sound power level (LWA)
95 dB(A) 95 dB(A)
measured according to 2000/14/EC OND
Capacity of fuel tank 21.38 Usgal 81 l
Single step load acceptance 100 % 100 %

2954 9020 00 19

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 QAS38 YdS TNV

Application Mode of operation PRP PRP

data Site land use land use
Operation single single
Start-up and control mode (optional) manual/auto. manual/auto.
Start-up time unspecified unspecified
Mobility/ Config. acc. to ISO 8528-1:1993 transportable/D transportable/D
(optional) mobile/E mobile/E
Mounting fully resilient fully resilient
Climatic exposure open air open air
Degree of protection (cubicle) IP54 IP54
Status of neutral earthed earthed

Alternator Standard IEC34-1 IEC34-1

Make MECC ALTE MECC ALTE
Model ECO 32 3S ECO 32 3S
Rated output, class H temp. rise 48 kVA 48 kVA
Degree of protection IP 21 IP 21
Insulation stator class H H
Insulation rotor class H H
Number of wires 12 12

Engine Type YANMAR 4TNV98-GGE 4TNV98-GGE

Rated net output 48.81 hp 36.4 kW
Coolant water water
Combustion system direct injection direct injection
Aspiration natural aspirated natural aspirated
Number of cylinders 4 4
Swept volume 0.88 Usgal 3.319 l
Speed governing mechanical mechanical
Capacity of oil sump 2.64 Usgal 10 l
Capacity of cooling system 2.64 Usgal 10 l
Electrical system 12 Vdc 12 Vdc

Power Circuit-breaker, 3ph (optional)

circuit Number of poles 3 3
Thermal release It 50 A 50 A
Magnetic release Im 3..5xIn 3..5xIn
Circuit-breaker, 3ph, lower voltage (optional)
Number of poles 3 3
Thermal release It 125 A 125 A
Magnetic release Im 3..5xIn 3..5xIn
Fault current protection
Residual current release IDn
Insulation resistance (optional)

Outlet GFCI duplex (1x) GFCI duplex (1x)

sockets 2p+E 2p+E
20A 125V 20A 125V

Temp Power (2x) Temp Power (2x)

2p + N + E 2p + N + E
50 A 125/250 V 50 A 125/250 V

Unit Dimensions (LxWxH) 81.12 x 37.09 x 45.12in 2080 x 951 x 1157 mm

Weight net mass 1986.71 lb 901 kg
Weight wet mass 2242.49 lb 1017 kg

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 Instruction Manual

Notes

1) Reference conditions for engine performance to ISO 3046-1.

2) See derating diagram or consult the factory for other conditions.
3) At reference conditions unless otherwise stated.
4) Rating Definition (ISO 8528-1):
• LTP: Limited Time Power is the maximum electrical power which a generating set is capable of delivering (at variable
load), in the event of a utility power failure (for up to 500 hours per year of which a maximum of 300 hours is continuous
running). No overload is permitted on these ratings. The alternator is peak continuous rated (as defined in ISO 8528-3) at
25°C (77.00 °F).
• PRP: Prime Power is the maximum power available during a variable power sequence, which may be run for an unlim-
ited number of hours per year, between stated maintenance intervals and under the stated ambient conditions. A 10%
overload is permitted for 1 hour in 12 hours. The permissible average power output during a 24h period shall not exceed
the stated load factor of 80%.
5) Specific mass fuel used: 0.86 kg/l (1.90 lb/Usgal).

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 QAS38 YdS TNV

7.4 Conversion list of SI units into British units

1 bar = 14.504 psi 1m = 3.281 ft

1g = 0.035 oz 1 mm = 0.039 in
1 kg = 2.205 lb 1 m³/min = 35.315 cfm
1 km/h = 0.621 mile/h 1 mbar = 0.401 in wc
1 kW = 1.341 hp (UK and US) 1N = 0.225 lbf
1l = 0.264 US gal 1 Nm = 0.738 lbf.ft
1l = 0.220 lmp gal (UK) t°F = 32 + (1.8 x t°C)

1l = 0.035 cu.ft t°C = (t°F - 32)/1.8

– A temperature difference of 1°C = a temperature difference of 1.8 °F

7.5 Dataplate

1 2 3 A Maximum permitted loaden weight of the vehicle

B Maximum permitted road weight of the front axle
4 C Maximum permitted road weight of the rear axle
5
6 1 Company code
2 Product code
3 Unit serial number
4 Name of the manufacturer
5 EEC or national type approval number
7
6 Vehicle identification number
8
9 7 Model number
10 8 Frequency
11 9 Apparent power
12 10 Active power
13
11 Nominal rated voltage
14
12 Nominal rated current
13 Power factor
14 Manufacturing year
15 16 17 15 EEC mark in accordance with Machine Directive 89/392E
16 Mode of operation
17 Winding connections

22 2954 9020 00

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 Circuit diagrams

2954 9020 00 23
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 CIRCUIT DIAGRAM

9822 0888 25/07

Applicable for QAS38 YdS TNV

SINGLE FREQUENCY
see note 2 Y11
to Engine

233
Wire harness

12
12
1 n
5

234
b54

N11
(+) (-) 1
205

233
MPU
206

ACT

234
b54
1
1

237

237
R11 R11 A
B11

238

238
205
206

(0) S2b
B
1

a2 24 23
+
C
to Engine Circuit Diagram

12 14
K12 11
D
12

- a6 E

from
Remote Start module
see
Engine Circuit Diagram
Q1.1 Q1.2 P1 Wire size
X Y Z
333
331

332
330

QAS 28 80A 40A 0-100A h f g

QAS 38 125A 50A 0-100A j f h a3 a3 a0 a0
X25 X25 X25 X25
(0) : OPTIONAL EQUIPMENT
1 2 3 4
REMOTE START

Note 1:
3ph higher voltage : connect 2-3 ; 6-7 ; 10-11 ; 4-8-12(N) 13 Kx A1
Sx
3ph lower voltage : connect 1-3 ; 5-7 ; 9-11 ; 2-4-6-8-10-12(N) 14 A2
1ph lower voltage : connect 1-3 ; 5-7 ; 2-4-10-12(N) ; 6-8-9-11
Customer's installation
Sx: min. 12V dc, 4A
Note 2: Kx: to be wired between Generator
and Load
The actuator replaces the Fuel stop solenoid valve (mentioned coil: max. 240VAC
on the Engine Control Circuit diagram). 3A AC11

24 2954 9020 00
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 CIRCUIT DIAGRAM

LEGEND : Wire size: Colour code:

G3 aa = 0.5 mm2 0 = black
See note 1 a = 1 mm 2 1 = brown
1 3 b = 1.5 mm2 2 = red
12
2 4
6 c = 2.5 mm2 3 = orange
5
1 11
10 8 7 1 3 d = 4 mm2 4 = yellow
F4

110
9 5 = green

109
2 2 4
3 1 2 e = 6 mm 2
11
12 3 6 = blue
12
4 10 bx0 K13 A1 K11 A1 K12 A1 a0 f = 10 mm2 7 = purple
11 8 9 F5

106
g = 16 mm 2

105
6 6
10
7 5 5 3 4 A2 A2 A2 8 = grey
9 8
7 2 h = 25 mm2 9 = white
bx0 a0
S10 i = 35 mm2 54 = green/yellow
j = 50 mm2
N12
60Hz

k = 70 mm2
l = 95 mm2
L1 L2 L3 N
bx = 1.5 mm2 NSGAFOeU
W1
U1

N1
V1
237

238

239

x0 x0 x0 x6 Z54

141
a8 142
a8 143
a8
T1 T2 T3 P3 P2 P1
153
a8 152 A A A
a8 151
1 a8

F1
126 125
V1 U1

S4

129
1 2
a0 F2 4 a0 8 P4
3 410 15 a0
6 9
a0 a0 2 3
F3 V
127

1211 7
W1

A 5 6
a0 a0
128
124
N1

7 8 a0

110
a6 a6
124

a0
a6 P5

Hz
118
118

B a3 a3
C
12 14
K11 11
104

W1

D
U1

V1
103

Q1.1 a3 Q1.2 a3 Y0 Y0 Y0
c2 Z54 c2

>> >> >> >> >> >>

EA EA

7 c1 7 c1
12

L1

L2

L3

E a6 Y0 Y0 Y0

X2 X3 X4
2L1

2L2

3L1

3L2

f0 f0 f0 f0
Q2 Q3
>> >> >> >>
50A 50A
4L2
L1

L2

L3

Q4 c0
N1

X0 X0 X0 Z54
N1
K13

>>
N1 L2 L1 L2 L1

f54 f6 f54 f6 20A c54 c6

X1
1 3 5 7

2 4 6 8

f0
f0
f0
L1 L2 L3 N PE f0
h6

B11 Speed sensor N12 Automatic voltage regulator S2b Emergency stop
F1-5 Fuse 4A P1-3 Amperemeter S4 Voltmeter selector switch
G3 Alternator P4 Voltmeter S11 Frequency selector switch 50Hz/60Hz
Kx Plant contactor P5 Frequencymeter 45-65Hz T1-3 Current transformer 500A/5A
K11 Auxiliary relay voltage selection Q1.1 Circuit breaker 3-pole X1 Terminal board
(lower voltage) Q1.2 Circuit breaker 3-pole X2 Outlet socket
K12 Auxiliary relay voltage selection Q2-3 Circuit breaker 50A/2-pole X3 Outlet socket
(higher voltage) Q4 Circuit breaker 20A/1-pole X4 Outlet socket
K13 Contactor R11 Supply voltage adjust potentiometer X25 Terminal strip
N11 Speed controller Sx Remote start/stop switch Y11 Actuator

2954 9020 00 25
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 CIRCUIT DIAGRAM

9822 0888 28/05

Applicable for QAS38 YdS TNV

26 2954 9020 00
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 CIRCUIT DIAGRAM

B7 Fuel level sensor K1 Preheat relay S2a Emergency stop button (S2b, Power Circ.)
B8 Coolant temperature sensor K5 Starter relay S7 Low fuel level switch
B9 Oil pressure sensor M1 Starter motor S7’ Low fuel level switch, warning
E1 Preheat resistor N4 Control module S8 Coolant high temperature switch
F4 Fuse N12 Speed controller (only used when an over- S9 Engine oil low pressure switch
G1 Battery 12 V speed protection is required) X10 15-pole connector
G2 Charging alternator P6 Hourmeter X16 Module connector
H1 Panel light P7 Fuel level gauge X17 Fuel level unit connector
H7 Flash light low fuel (optional) P8 Coolant temperature gauge Y1 Fuel stop solenoid
K0 Starter solenoid P9 Oil pressure gauge

2954 9020 00 27
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 CIRCUIT DIAGRAM

9822 0888 38/02

Applicable for QAS38 YdS TNV

)
*
F4
10A
X10
1

A1 c2
124

5
a0 a6 c3 a3 a3 a3 a3 a3
X16 X16 X16
N4 13
Emerg.
1
B+
16
REMOTE
6
FUEL
X16 19 Stop START
PN ON PC
22 H1 P6 P7 P8 P9
X16 20 OFF h
PL PCC
REMOTE 21
X16
START SPARE
2 11
WL TEMP OIL PH B-
9 3 4 10 5
X16 X16 X16 X16 X16
12

12

12

12

11

12

10

12
3

5
b3 b3 b3 b3 b3 b6 a6 a6 a6 a3 a6 a3 a6 a3 c3

A3 A2 B2 B1 A4 C2 C1 B5 B4 A5

X10 X10 X10 X10 X10 X10 X10 X10 X10 X10

5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

28 2954 9020 00
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 CIRCUIT DIAGRAM

230VAC 115VAC
)
*
141

141
a8 a8
P1 P1

A A
151

151
127

a8 a8
a0
142

142
a8 a8
P5 P4 P2 P5 P4 P2

Hz V A Hz V A
b0 b0 b0 b0
129

128

129

128
152

152
a8 a8
5 9 3 5 9 3
1 7 1 7
12 11 12 11
143

143
S4 10
4 6 8
2
S4 10
4 6 8
2

a8 a8
P3 P3

A A
127

127
126

153

126

153
110
124

124
125

125

a6 a0 a0 a0 a8 a6 a0 a0 a0 a0 a8

25 26 27 28 29 30 31 25 26 27 28 29 30 31

Legend
Wire size : Colour code :
aa = 0.5mm2 0 = black
a = 1 mm 2 1 = brown
b = 1.5mm 2 2 = red
c = 2.5mm 2 3 = orange
d = 4 mm 2 4 = yellow
e = 6 mm 2 5 = green
f = 10 mm 2 6 = blue
g = 16 mm 2 7 = purple
h = 25 mm 2 8 = grey
i = 35 mm 2 9 = white
j = 50 mm 2 54= green/yellow
k = 70 mm 2
l = 95 mm 2
bx = 1.5 mm 2 NSGAFOeU
lx = 95 mm 2 STK
px = 185 mm2 STK

F4 Fuse P4 Voltmeter P8 Coolant temperature gauge

H1 Panel light P5 Frequencymeter P9 Oil pressure gauge
N4 Control module P6 Hourmeter X10 15-pole connector
P3 Amperemeter P7 Fuel level gauge X16 Module connector

2954 9020 00 29
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 CIRCUIT DIAGRAM

Automatic voltage regulator

EXCITER

ROTATING PART STATOR

+
U2 U1

V2 V1

W2 W1
–

GREEN
BLACK

BLACK

GREEN

GREEN
BLACK

SLOW FUSE 6,3A

RED
RED

6
6

5
5

4
4

3
3

2
2

1
P
1

0
B 0

B
+
+

-
-

60Hz

100 K

BLUE

YELLOW

30 2954 9020 00
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 Printed in Belgium 11/2004 - 2954 9020 00

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 Instruction Manual for AC Generators

QAS38 YdS TNV

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