Aggreko - 100kW User Manual PDF

 

 

Operation and Maintenance Manual Power GHP/QSB5-G9 TIER 4i 100kW US STD & OFFSHORE

REVISION HISTORY Rev. No.

Rev. Date

Details of Changes

Prepared By

Reviewed By

Approved By

G

11/08/2016

Updated A05/G08 and D20 added to manual.

G. Rabone

R. Maguire

W. Telfer

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  1.0 

SAFETY SAFE TY .................................. ................................................... ................................. ................................. .................................. .................................. ........................ .......5 

1.1. 

General Information ............................................................. ......................................................................................................................... ............................................................5 

1.2. 

Electrical Power ................................................................... ............................................................................................................................... ............................................................5 

1.3. 

Materials .............................................................................................................................. ........................................................................................................................................... .............5 

1.4. 

Operational Precautions .................................................................................................................. ..................................................................................................................6 

1.5. 

Safety Labels ................................................................................................................................... ...................................................................................................................................7 

2.0 

NOISE EMISSION EMISSION................................. .................................................. .................................. ................................. ................................. ........................... ..........8 

2.1. 

Noise Control Prohibited Acts .......................................................................................................... ..........................................................................................................8 

2.2. 

Generator Noise Emission Em ission Control Information ...............................................................................8 

3.0 

HANDLIN HAN DLING G ................................. .................................................. ................................. ................................. .................................. ................................. ..................... .....9 

3.1. 

Lifting / Handling .............................................................................................................................. .............................................................................................................................. 9 

3.2. 

Storage / Transport .......................................................................................................................... ..........................................................................................................................9 

4.0 

INSTALLA INSTA LLATION TION ............................... ................................................ .................................. .................................. .................................. .............................. .............10 

4.1. 

Unpacking ...................................................................................................................................... ......................................................................................................................................10 

4.2. 

Location of the Plant ................................................................................................ ...................................................................................................................... ......................10 

4.3. 

Commissioning..................................................................... Commissioning............................................................................................................................... ..........................................................10 

4.4. 

Prior to Starting .......................................................................................... .............................................................................................................................. ....................................10 

4.5. 

Electrical Connection ..................................................................................................................... .....................................................................................................................10 

4.6. 

Earthing ..................................................................... .......................................................................................................................................... .....................................................................11 

4.7. 

Remote Fuelling ............................................................................................................................. .............................................................................................................................11 

5.0 

GENERAL GENE RAL DATA................................ ................................................. .................................. .................................. .................................. ........................... ..........11 

5.1. 

General Operation ......................................................................................................................... .........................................................................................................................11 

5.2. 

Design Load Capacity ............................................... .................................................................................................................... .....................................................................11 

5.3. 

Design Temperatures .......................................................... .................................................................................................................... ..........................................................12 

5.4. 

Canopy & Base Frame ......................................................... ................................................................................................................... ..........................................................12 

5.5. 

Diesel Engine ................................................................................................................................. .................................................................................................................................12 

5.6. 

Engine Lubrication System ............................................................................................................12 

5.7. 

Engine Cooling System ........... ................................................................................. ....................................................................................................... .................................12 

5.8. 

Engine Fuel System .................................................. ....................................................................................................................... .....................................................................13 

5.9. 

Exhaust System ............................................................................................................................. .............................................................................................................................13 

5.10.  Engine Control System ..................................................................................................................13  5.11.  Generator ....................................................................................................................................... .......................................................................................................................................14  5.12.  Main Circuit Breaker ...................................................................................................................... ......................................................................................................................14  5.13.  Voltage Selector Switch ................................................................................................................. .................................................................................................................14  5.14.   Aggreko Remote Monitoring .................................................................................... .......................................................................................................... ......................17  5.15.  Operating Controls and Instruments .............................................................................................. ..............................................................................................18 

5.15.1. 

Control Contr ol Panel Panel ............................... ................................................ .................................. .................................. .................................. ................... ..18  

5.15.2. 

Control Contr ol Module Module ................................ ................................................. .................................. .................................. ................................. ................20 

5.15.3. 

Display Disp lay Pages ................................. .................................................. .................................. .................................. ................................. ................21 

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  5.16.  Operating procedure ...................................................................................................................... ......................................................................................................................22 

5.16.1. 

Manual Operation ................... .......... ................... ................... .................. ................... ................... .................. ................... ................... ........... 22 

5.16.2. 

Remote/standby operation ................................................................................. 23 

5.17.  Modes of operation ........................................................................................................................23 

5.17.1. 

Single set operation.................. ........ ................... ................... ................... .................. .................. ................... ................... .................. ......... 23 

5.17.2. 

Loadsharing with another 5510 controller ................... .......... ................... ................... .................. ................... ............ .. 23 

5.17.3. 

Baseload operation ............................................................................................ 24 

5.17.4. 

Loadsharing with a GENerator set fitted with analogue parallel lines .................. ......... ......... 25 

5.18.   Alarm functions ........................................................................................................ .............................................................................................................................. ......................25  5.19.  Changing Parameters .......................................................... .................................................................................................................... ..........................................................26 

5.19.1. 

General Gener al ................................ ................................................. .................................. .................................. .................................. ........................... ..........26 

5.19.2. 

Parameter Adjustment For Alternative Alternator Configurations .................. ......... ............... ...... 28 

6.0 

MAINTENA MAIN TENANCE NCE ................................. .................................................. .................................. .................................. .................................. ........................... ..........29 

6.1. 

General ..................................................................... .......................................................................................................................................... .....................................................................29 

6.2. 

Maintenance Schedule ...................................................................... .................................................................................................................. ............................................30 

6.2.1. 

Inspection Criteria ................... .......... ................... ................... .................. ................... ................... .................. ................... ................... ............. .... 30 

6.2.2. 

Service Serv ice Crite Criteria ria ................................. ................................................. ................................. .................................. .................................. ................... .. 31 

6.3. 

Daily Maintenance ............................................................... ......................................................................................................................... ..........................................................32 

6.3.1. 

Check The Engine Oil Level: .................................................................................. 32 

6.3.2. 

Check The Fuel Tank Tank Level .................. ......... ................... ................... .................. .................. ................... ................... .................. ......... 32 

6.3.3. 

Check That All Meters And Gauges Function Correctly......................... Correctly................ ................... ................. ....... 32 

6.3.4. 

Check The Air Air Filter ................... .......... ................... ................... .................. ................... ................... .................. ................... ................... ........... 33 

6.3.5. 

Check The Battery ................................................................................................. 33 

6.3.6. 

Check Che ck For Leaks Leaks.......................................... .......................................................... ................................. .................................. ......................... ........33 

6.4. 

Weekly Maintenance ...................................................................................................................... ......................................................................................................................33 

6.4.1. 

Check The Water/Antifreeze Water/Antifreeze Level................... .......... ................... ................... .................. .................. ................... ................. ....... 33 

6.4.2. 

Carry Out A Visual Visual Check Of The Driv Drive e Belts. ....................... .............. .................. ................... ................... ............. .... 34 

7.0 

LUBRICA LUB RICATION TION ................................. ................................................. ................................. .................................. .................................. .............................. .............35 

7.1. 

General Information ............................................................. ....................................................................................................................... ..........................................................35 

7.2. 

Generator Oil Change ............................................... .................................................................................................................... .....................................................................35 

7.3. 

Oil specification .............................................................................................................................. ..............................................................................................................................35 

Trouble Trou ble Shooting Shooting................................ ................................................. ................................. ................................. .................................. .................................. ...................... .....36  7.4. 

Introduction .............................................................. .................................................................................................................................... ......................................................................36 

7.5. 

 Action Plan ............................................................... ..................................................................................................................................... ......................................................................36 

7.6. 

Trouble Shooting Chart ............................................. .................................................................................................................. .....................................................................37 

 APPENDIX A - MATERIAL MATERIAL SAFETY DATA SHEETS SHEETS ..................... ........... ................... .................. .................. ................... ................. ....... 39   APPENDIX B – B – EQUIPM  EQUIPMENT ENT DATA SHEET .................. ........ ................... .................. ................... ................... .................. ................... .............. .... 77   August 2016

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   APPENDIX C – C – INSTALLATION  INSTALLATION OUTLINE DRAWING DRAWING ................... ......... ................... .................. .................. ................... ................. ....... 82   APPENDIX D – D – CONTR  CONTROL OL PANEL LAYOUT .................. ......... ................... ................... .................. ................... ................... .................. ............ ... 84   APPENDIX E – E – ALTERNATOR  ALTERNATOR & AVR SCHEMATIC DIAGRAM ................... ......... ................... .................. ................... ............ 86   APPENDIX F – F – MAIN  MAIN LOAD & METERING SCHEMATIC DIAGRAM .................. ......... ................... ................... ............. .... 88   APPENDIX G – G – DC  DC CONTROL SYSTEM SCHEMATIC DIAGRAM .................. ......... .................. ................... ................. ....... 90   APPENDIX H – H –  ECM 2250 INTERCONNECTIONS ................ .................................. .................................. ................................. ...................... .....92   APPENDIX I – I – TERMINAL  TERMINAL LAYOUT & ENGINE WIRING WIRING ................... .......... ................... ................... .................. ................... ............ .. 94   APPENDIX J – J – LIVER  LIVERY Y LAYOUT LAYOUT DRAWING DRAWING ......................... ............... ................... .................. ................... ................... .................. ............... ...... 96   APPENDIX K – K – MANUFACTURE  MANUFACTURERS RS COMPONENT DATA .................. ........ ................... .................. ................... ................... ........... 98   APPENDIX L – L – LIFTING  LIFTING BEAM CERTIFICATE ........................................................................ 100    APPENDIX M – M – DNV  DNV SPARK ARRESTOR CERTIFICATE ................... ......... ................... .................. ................... .................. ........ 102 

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  1.0

SAFETY 1.1.

General Information

Ensure that the operator reads and understands the decals and consults the manuals before maintenance or operation. Ensure that the Operation and Maintenance manual, and the manual holder, are not removed permanently from the machine. Ensure that maintenance personnel are adequately trained, competent and have read the Maintenance Manuals. Make sure that all protective covers are in place and that the canopy/doors are closed during operation. The specification of this machine is such that the machine is not suitable for use in flammable gas risk WARNING: NO ATTEMPT SHOULD BE MADE TO OPERATE IN SUCH AREAS WITHOUT areas. THE EXPRESS AUTHORITY FROM AGGREKO.  AGGREKO.   Installation of this generator must be in accordance with recognised electrical codes and any local Health and Safety Codes.

1.2.

Electrical Power

Prior to installation of the generating set you should check that the electrical load to be applied is within the rated output of the machine at the site ambient conditions. Before carrying out any maintenance or repairs to the Engine/Alternator assembly disconnect the starting battery and isolate the alternator from the switchboard. Before carrying out any maintenance repair to the AC and DC circuits, isolate these from external control panel and power supplies. Ensure that the generator set and the load it is connected to are properly earthed. The generating set should be connected to the load only by a qualified electrician and in accordance with the applicable regulations.

1.3.

Materials

The following substances are used in the manufacture of this machine and may be hazardous to health if used incorrectly:  Antifreeze Engine Lubricating Oil Preservative Grease Rust Preventative Diesel Fuel Battery Electrolyte.

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AVOID INGESTION, SKIN CONTACT AND INHALATION OF FUMES. When handling fuel, lubricating oil, cooling fluid and battery electrolyte, wear appropriate personal protection equipment. For further information, consult Material Safety Data Sheet contained in this manual.  Avoid build-up of Engine Exhaust Fumes in confined spaces.  Avoid breathing Exhaust Fumes.

1.4.

Operational Precautions

Never operate unit without first observing all safety warnings and carefully reading the operation and maintenance manual shipped from the factory with this machine. IF IN DOUBT CONTACT AGGREKO. Never operate the engine of this machine inside a building without adequate ventilation. Avoid breathing exhaust fumes when working on or near the machine. Do not alter or modify this machine.  A battery contains sulphuric acid and can give off gases, which are corrosive and potentially explosive.  Avoid contact with skin, eyes and clothing. In case of contact, flush area immediately with water. Exercise extreme caution when using booster battery. To jump battery, connect ends of one booster cable to the positive (+) terminal of each battery. Connect one end of other cable to the negative (-) terminal of the booster battery and other end to a ground connection away from dead battery (to avoid a spark occurring near any explosive gases that may be present). After starting unit, always disconnect cables in reverse order. Never operate unit without first observing all safety warnings and carefully reading the operation manual. This machine may include such materials as oil, diesel fuel, antifreeze, oil/air filters and batteries which may require proper disposal when performing maintenance and service tasks. Contact local authorities for proper disposal of these materials. This machine produces loud noise with the doors open. Extended exposure to loud noise can cause hearing loss. Always wear hearing protection when doors are open. Never inspect or service unit without first disconnecting battery cable(s) or using the battery isolator switch to prevent accidental starting. Do not remove the pressure cap from a HOT radiator. Allow radiator to cool down before removing pressure cap. Do not use petroleum products (solvents or fuels) under high pressure as this can penetrate the skin and result in serious illness. Wear eye protection while cleaning unit with compressed air to prevent debris from injuring eye(s). Hot pressurized fluid can cause serious burns. Do not open radiator while hot. Rotating fan blade can cause serious injury. Do not operate without guard in place. Use care to avoid contacting hot surfaces (engine exhaust manifold and piping, etc.). Never operate unit with guards, covers or screens removed. Keep hands, hair, clothing, tools, etc. well away from moving parts.

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1.5.

Safety Labels

Look for these signs on machine, which point out potential hazards to the safety of you and others. Read and understand thoroughly. Heed warnings and follow instructions.

DANGER FIRE RISK RISK OF ELECTRIC SHOCK DO NOT STAND IN FRONT OF ALTERNATOR AIR OUTLETS WHEN UNIT IS RUNNING 

CAUTION Hot

DISCONNECT STARTING BATTERY AND ISOLATE LOAD BEFORE WORKING ON ENGINE / ALTERNATOR ASSEMBLY 

(for stackable containers only)

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  2.0

NOISE EMISSION 2.1.

Noise Control Prohibited Acts

WARNING Tampering with noise control system prohibited The following acts or misuse of the unit are prohibited: 1)

The removal or rendering inoperative by any pers persons, ons, other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new generator for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use

Or 2)

The use of the gener generator ator after such dev device ice or element of design has been remov removed ed or rendered inoperativ inoperative e by any person.

 Among those acts included in the prohibition against tampering are these: Removal or rendering inoperative any of the following: a)

The engine exhaust system or parts thereof.

b)

The air intake system or parts thereof.

c)

Enclosure or parts thereof. Removal of any of the following:

 

Fan shroud

 

Vibration mounts

 

Sound absorption material







Operation of the generator with any of the enclosure doors open.

2.2.

Generator Noise Emission Control Information

 A.

The removal or rendering inoperative, other than for the purpose of maintenance, repair, or replacement of any noise control device or element of design incorporated into this generator in compliance with the noise control act;

B.

The use of this generator after such device or element of design has been removed or rendered inoperative.

THIS GENERATOR HAS BEEN SPECIFICALLY DESIGNED WITH A SOUND ATTENUATING ENCLOSURE. THE CANOPY DOORS SHOULD REMAIN LOCKED SHUT UNDER NORMAL OPERATING CONDITIONS. UNDER ANY OTHER CONDITIONS EXCESSIVE NOISE LEVELS CAN BE PRODUCED AND PROLONGED EXPOSURE IS HAZARDOUS TO HEARING.

FOR SAFETY, EAR PROTECTION SHOULD ALWAYS BE WORN WHEN WORKING IN THE VICINITY OF AN OPERATING GENERATOR SET.

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  3.0

HANDLING 3.1.

Lifting / Handling

The generator set includes 1 lifting beam and forklift pockets. There is the option for a two-point lift configuration suitable for offshore service. All All lifting  lifting and handling equipment must be adequately rated for applicable weights. During all lifting and handling operations the following weights must be considered. Complete Package Max. Fuel

6920 lbs

(3139 kgs)

Complete Package Without Fuel 5816 lbs

(2638 kgs)

Bolt on steel plate buffers are located at the front and rear of the base to protect the body of the generator. Where 2 point lifting is provided, ensure that the correct length of strop / wire rope is used on each lifting beam to ensure a level lift. Also ensure that the included angle does not exceed 90°.

CAUTION: THE GENERATOR SET SHOULD NOT BE LIFTED OR DRAGGED BY THE END BUFFERS.

3.2.

Storage / Transport

Carry out the following points before transporting the generator or preparing the generator for storage. Empty the fuel tank (in case of overseas transport). Disconnect the battery terminals (in case of overseas transport). Close all fuel valves. Seal the remote fuel connection with a blind stop. Ensure that the radiator cap is fitted securely and the exhaust rain cap is closed. Close all doors.  All units are to be loaded flat onto transport and properly secured.

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  4.0

INSTALLATION 4.1.

Unpacking

Ensure that the correct fork lift truck slots or marked lifting / tie down points are used whenever the machine is lifted or transported.

4.2.

Location of the Plant

The generator can be installed on any solid, flat and level surface capable of supporting the full operating load of the package. A dry, well-ventilated area where the atmosphere is as clean as possible is recommended. Ensure that the machine is positioned securely and on a stable foundation. CAUTION: A minimum of 1 metre (3 ft) all round the generator is recommended. Hot air will exit from the roof outlet. It is important that this hot air does not re-circulate to the package inlet. The generator must be allowed sufficient space all round and above, to enable the effective removal of the cooling air which, in turn, will reduce the risk of re –circulating the cooling air back through the generator.  Adequate clearance needs to be allowed around and above the machine to permit safe access for specified maintenance tasks. Hard surfaces may reflect noise with an apparent increase in the decibel level. It is recommended that provision be made for lifting heavy components during major overhaul. NOTE: When operating at elevated altitude please refer to engine manufacturer’s guidelines for power deration.

4.3.

Commissioning

Upon receipt of the unit, and prior to putting it into service, it is important to adhere strictly to the instructions given below in section 4.4 PRIOR TO STARTING. STARTING. Ensure all persons concerned are suitably competent with generator installations. Ensure that the operator reads and understands the decals and consults the manuals before maintenance or operation. Ensure that the position of the emergency stop device is known and recognised by its markings. Ensure that it is functioning correctly and that the method of operation is known.

4.4.

Prior to Starting

Ensure that the unit is clean, free from debris and fluids. All connections, joints, seals must be correctly fitted and tightened. All filters, louvers and air inlets are free and open. Ensure that there is a safe working procedure which has been issued by supervisory personnel, and that all persons concerned with the operation of the generator understand it. Ensure that the safety procedure to be applied is based on the appropriate national and local regulations. Ensure that the safety procedure is followed at all times.

4.5.

Electrical Connection

 A suitably trained electrician should carry out all electrical connections. Ensure the generator main isolator is off and that the power cables are in good condition. Ensure that the phases are correct after the cables have been connected. Ensure all safety covers are back in place after electrical connection is complete.

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  4.6.

Earthing

 An external earthing boss is fitted onto the base frame at the control panel end of the set. This allows a dedicated earthing connection if required.

4.7.

Remote Fuelling

External fuel tank supply can be connected to the generator set.

One ½” BSP Adaptor (Supply)   One ½” BSP Adaptor (Return)   There is an access hole in the base frame to allow access to the internal fuel connections.

5.0

GENERAL DATA

NOTE: Each generator of this type is uniquely identified by a Plant Number and Serial Number indicated NOTE: Each on the identification plate affixed to the outside of the control panel. This information is required when ordering spare parts. Major component serial numbers are contained within the manual. The technical data defining the generator and the limits on its operating environment are tabulated in the Equipment Data Sheet. A copy of the Equipment Data Sheet has been included in the manual. In order to assist in the operation and maintenance of the generator, a full set of electrical and installation drawings has been included in the manual.

5.1.

General Operation

The generator is a diesel engine driven alternator with control electronics, mounted on a bedplate with internal fuel tank. The standard package is composed of the following:  Alternator and engine assembly Pressurised oil system with cooler  Automated control system Instrumentation Safety provisions Engine cooler pack Spark arrestor / Silencer Internal fuel tank The engine and alternator are integrally mounted. This assembly is isolated from the base by rubber isolation mounts.

5.2.

Design Load Capacity

The GHP/QSB5-G9 (106kVA @ 50 Hz PRP) generator set can be run up to a maximum of 122 kVA @ 60 Hz at prime power rating. It is strongly advised that this set should not be run for extended periods of time on less than 30% load.

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  5.3.

Design Temperatures

The GHP/QSB5-G9 (100kW) generator set can operate through an ambient temperature range of: -10°C (14°F) to 45°C (100°F)

5.4.

Canopy & Base Frame

The overall dimensions for the generator set are 3430 X 1200 X 2088 mm. The canopy is manufactured from welded Galvatite and has access to the inside of the generator through lockable doors. The base frame has 120% capacity of the fuel tank to prevent fuel leaking out of the generator set in the event of a fuel leakage inside the generator. A level switch is fitted inside the bund for spillage indication. This will shut down the engine when activated.

5.5.

Diesel Engine

The generator set uses a Cummins Diesel Engine, which is capable for either 50 Hz or 60 Hz. Details of the engine are outlined below. Type:

4 cylinder inline turbo charged and charge air cooled

Model:

Cummins QSB5-G9

RPM:

1500 / 1800

Nominal Engine Output @ 1500rpm:

85kWm @ Prime Power

Governor:

CM2250 (Engine Management System)

Starting System:

12V battery system

Fuel Consumption 1500rpm:

5.6.

@

Continuous

25 L/Hr @ 100% Prime Power

Engine Lubrication System

The engine oil lubrication system includes pump, strainer and sump all fitted internally within the engine block. Oil filtration is fitted to the side of the engine block for ease of access and maintenance. Total Oil Capacity:

12.1 Ltrs

The Lube oil specification is as per API CJ4 / CES20081 The sump can be drained using the K1 pump via a Ball valve. Refer to manufacturers data for all filter information.

5.7.

Engine Cooling System

The engine cooling consists of a pump, thermostat, heater and radiator assembly. Cooling fluid is from the radiator, through the pump, which is belt driven from the engine pulley. The thermostat controls the flow to the radiator. The radiator assembly is mounted at the front of the engine, with the fan mounted on the front of the engine. Cooling air enters the generator through the canopy end louvers and noise attenuation baffles. This air then passes into the canopy space then across the radiator assembly. The cooling air exits through the roof of the package.

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  The coolant is factory filled with Valvoline HD Extended Life RTU coolant, providing protection to  –37°C. Please consult Aggreko if filling is required. There is a radiator expansion tank fitted to this unit that should be checked, prior to starting the unit.

5.8.

Engine Fuel System

CAUTION: This engine utilises a Highbefore Pressure Common fuel system Cummins engine manual must be consulted carrying out Rail maintenance onand anythe part of this system. The engine fuel system consists of an internal fuel tank, Racor filter (see Figure 5.2), fine fuel filter, fuel pump, injection pump and nozzles. Fuel can be taken from either an external or the internal fuel tank. A manual selection valve is used to select the fuel supply direction. Fuel is then pumped through the Racor filter to the fine fuel filters and then passed to the injectors and then to the injection nozzles. The internal fuel tank has a fuel capacity of 686 686 Litres.  Litres. Low warning and low shut-off sensors are fitted in the internal fuel tank. The fuel tank fill point is internal. There are 2 cleaning ports on the fuel tank that are all accessible through the canopy doors. External fuel supply can be connected to the package using the ½” BSP Adaptors. Internal supply and return fittings/valves must be re-configured to ensure that the engine fuel is not drawn from the onboard supply.  The use of ASTM No. 2D Ultra Low Sulphur Diesel (15 PPM) fuel is mandatory for optimum engine performance. At operating temperatures below 0°C, acceptable performance can be obtained using blends of No. 1 and No. 2D. The viscosity of fuels must be kept above 1.3 cSt to provide adequate lubrication. When changing the secondary (fine) fuel filter it is a Cummins recommendation to fit this filter dry and then prime via the manual priming pump, set the pump to “pump” prior to priming the filter. Ensure the priming pump is set to “run” after priming the filter. Refer to manufacturers data for all filter information.

5.9.

Exhaust System

The exhaust system consists of the exhaust ducting, exhaust silencer complete with DOC and rain cap assembly. The exhaust gases exit the engine and are passed through the exhaust ducting and exhaust, out the top of the canopy through the rain cap assembly. Insulation and heat shields are fitted to the exhaust ducting to prevent user contact with high temperature surfaces.

5.10.

Exhaust Manufacturer:

IMS

DOC Manufacturer:

Cummins

Engine Control System

 An Engine Management System (CM2250) ( CM2250) controls the engine output.  A Deep Sea Electronic 5510 control module is used to monitor the safety circuits and set the operation mode of the generator. See section 6.1.2 Control Module for more detail.

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  5.11. Generator Manufacturer:

Voltage Range

Newage Stamford

Type:

UC1274E

50Hz:

380-415 Volts

60Hz:

416-480 Volts

Voltage Regulator within 1% from no load to full load AS440

1 Phase configurable on Alternator TB & A voltage selector which is fitted

5.12.

Main Circuit Breaker Manufacturer: Type:

5.13.

Schneider NLG400-3P

Voltage Selector Switch Manufacturer: Type:

UK Solenoid. C315GBM607*01ER.

This switch allows the unit to have various alternator wiring configurations to be selected.

1. 2. 3.

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Series Star. Parallel Star Parallel Zig Zag

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Oil Pressure Gauge

Priming Pump

Fuel Selector Valve

AMOT Valve (Offshore) K1 Oil Pump

Vent Valve

Battery Switch

Fi ure 5.2 – 100 kW Generator Part Locations

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VOLTAGE SELECTOR SWITCH

Figure 5.3 5.3 - 100 kW Generator Part Locations

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  5.14.

Aggreko Remote Monitoring

The Aggreko Remote Monitoring (ARM) system is the corporate telemetry solution developed by  Aggreko Manufacturing in conjunction with Telemisis Ltd and Aggreko Technology services(ATS), based on Telemisis proprietary SiteWatch product offering.  ARM is designed to provide a fully featured remote asset management system. ARM monitors all aspects of the equipment, no matter how continually checking any signs that could lead to equipment failure alerting designated usersremote, by email or text message asfor required. The telemetry module used on this generator is the ATT1 rugged cellular module. Manufacturer:

Telemisis

Type:  ATT1 For information on system administration, general operation and installation refer to the OEM product literature. Literature available from ARM v4 help tab:

For comprehensive detail on ATT1 configuration please refer to the OEM literature.

The ATT1 is now hosted on V4 ARM server, access to this portal is available from the URL below, https://arm.aggreko.biz/  https://arm.aggreko.biz/  The website can be accessed from any internet portal (see your system administrator to obtain a system account), on successful login you will be granted access to the ARM system level in accordance to your individual user privileges and customer settings.

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  OPERATING INSTRUCTIONS

5.15.

Operating Controls and Instruments

5.15.1. Control Panel The operating controls and instruments are arranged on the control panel as shown in figures 6.1 and 6.2. A description of each panel device is given in the key below.

1

2

Figure 6.1 6.1   – – Control Panel Exterior

1

5510 controller

2

Power ON/OFF

Key for figure 6.1

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16

17

15

6

1

18 10 12

4 2

5 11

7 12 8

3 9

14 13 Figure 6.2  6.2  – – Control Panel Interior 1

 AVR

10

MCB1 (DC Control Supply)

2

400/5A CT,s

11

Diodes V1-V3

3

Schneider NLG400-3P 

12

4

MCB7 (For Diagnostics)

13

Relays R1 (Run Relay) R2 & R3 MCCB Open/Close Relays Base-load Switch & Diagnostics Plug

5

MCB6 (ECM supply)

14

Current Limiter Device Busbarin

6

MCB5 MCB 5 Water Heater Heater

15

Earth Bar

7

MCB4 (Breaker Controls)

16

Deep Sea 5510 Controller

17

Telemetry ATT1 unit

18

Telemetry 1A Fuses F1 & F2

8 9

MCB3

(Generator Sensing

Volts) MCB2 (Generator Bus Volts)

Key for figure 6.2  6.2   August 2016

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  5.15.2. Control Module The control module used on this generator set is the 5510 control module by Deep Sea. Figure 6.3 below shows the front panel layout of the 5510 control module.

12

1

2

11

3 10

9

4

6

5

7

8

Figure 6.3 6.3   – – 5510 Generator controller

1

Display scroll buttons

7

1. Auto select 2. Accept setpoint value

2

CB open button

8

Mute alarm/lamp test

3

CB indication

9

Manual start

4

Stop button/alarm accept

10

Generator indication

5

1. Manual select 2. Scroll down/reduce

11

CB close button

12

Status LEDs

available

1.  –  6

2. Scroll up/increase

1 – in normal mode 2 – in configuration mode Key for figure 6.3 The 5510 generator control module is an automatic engine control module. It has all the features of the 5310 control module but with synchronising synchronising and loadsharing/baseload capability. capability. In addition, the 5510 control module is equipped with integrated push buttons for circuit breaker control. The features of the 5510 controller include:   Text based LCD (supporting multiple languages)   Comprehensive metering of electrical parameters (voltage, current, power)   Engine parameter monitoring   Manual and remote/standby operation   Synchronising capability with displayed synchroscope   

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Loadsharing capability between two 5510 controllers via CANBUS connection (see “modes of operation” for further details)  

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Loadsharing capability between 5510 and older units with conventional parallel loadsharing lines (see “modes of operation” for further details)  

 

Baseload or parallel to mains operation (see “modes of operation” for further details)  

 

Comprehensive range of alarms

 

Compatible with different alternator configurations

 

Support of electronic engines via J1939 CANBUS interface

 

On Aggreko canopy sets, binary inputs on the 5510 controller are configured configured for remote start input, circuit breaker status and alarms, e.g. Low fuel level or fuel spillage.

 

Analogue inputs are typically configured for low oil pressure, high water temperature (either senders or discrete switches) and fuel gauge (where fitted).

 

Binary outputs are configured for circuit breaker open and close and, where fitted, for Air flap closed (on offshore sets). In addition, one output is dedicated to provide a common alarm output which provides a positive DC signal in the event of any alarm. 

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5.15.3. Display Pages The 5510 module displays the following pages on the LCD. Pressing the green Info green Info button  button will scroll between these pages. Pressing the Up or  Down arrow buttons arrow  buttons will scroll between instrumentation parameters. If no parameters are selected, selected, then autoscroll through the parameters with begin. i. Status page This shows the current status of the generator; e.g. generator at rest, manual mode, auto mode. When the generator is running, generator parameters are also show shown n (as displayed in figure 6.3). ii.

Engine instrumentation

iii.

Displays information related to the engine such as engine speed, battery voltage and run time. If connected to an electronic engine, a range of additional engine parameters are displayed which is dependent upon the engine type. These include parameters such as inlet temperature, turbo pressure and fuel consumption. Gen instrumentation Displays electrical parameters relating to the engine. These include:

iv.

- 

Generator phase voltages

- 

Generator line voltages

- 

Frequency

- 

Generator currents

- 

Generator real power and apparent power

- 

Power factor and reactive power

- 

kWh

- 

Phase sequence

- 

Synchroscope

Bus instrumentation  As the 5510 controller is capable of synchronising, bus information is displayed separately to generator information. This includes:

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v.

- 

Generator line voltages

- 

Frequency

- 

Phase sequence

Current alarm page Displays the current alarms in clear text.

Front Panel LEDs The following LEDs are provided.  

Green LED to indicate circuit breaker closed [symbol 3 in figure 6.3]

 

Green LED to indic indicate ate Gener Generator ator av available ailable (lit after st starting arting tim timers ers have ex expired) pired) [sy [symbol mbol 1 10 0 in figure 6.3]

 

Red LEDs for stop, manual and auto indication

 

Status LEDs to indicate:

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





-  Remote start input signal present. -  Alternative voltage selected. When alternativ alternative e vol voltage tage is selected, under and overvoltage protection is halved. In addition, overcurrent protection is doubled. Alternative v voltage oltage is intended for use when the generator set alternator windings are configured in parallel, as opposed to series configuration.

-  Alternative fre frequency quency se selected. lected. For US generator s sets, ets, norm normal al frequency is 60Hz and alternative frequency is 50Hz. 50Hz. For European and AI generator sets, normal normal frequency is 50Hz and alternative frequency is 60Hz. When alternative frequency is selected protection settings for over/under frequency and over/under speed are moved accordingly.

-  Common alarm indic indication. ation. This LED is lit if any alarm c condition ondition is detected.

5.16.

Operating procedure CAUTION: - Always open the battery isolator switch to avoid unauthorised starting during transport and maintenance.  maintenance.  This section describes describes the basic o operation peration of the generator set. For more details on the different modes of operation, see section 6.3 Modes of operation below.

5.16.1. Manual Operation To start generator:

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1.

Prior to starting, exercise daily maintenance. See section 7.1.

2.

Turn on DC power.

3.

Check that no alarms are pres present. ent. If a shutdown condition is present, the generator set w will ill not be allowed to start.

4.

Ensure that the baseload switch inside the panel is OFF.

5.

Press the manual select  select button. The display will read “Generator at rest” and “Waiting in Manual”.   Manual”.

6.

Press the manual start start button.  button.

7.

Once the ge generator nerator has run-up to s speed, peed, check the frequency and volt voltage. age. Voltage can be adjusted via the AVR or potentiometer. potentiometer. Frequency can only be ad adjusted justed on non-electronic engines.

8.

Walk around the engine and check for any leakages.

9.

After the start up timers have expi expired, red, close the circ circuit uit break breaker er by press pressing ing the CB clos close e push button. Once the circuit break breaker er is closed, the 5510 will regulate the voltage voltage and frequency to its

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  nominal values. These can be adjusted from the front panel display. See section 6.5 Changing parameters for details on how to adjust these parameters. To stop generator: 1.

Open circuit breaker by pressing the

CB open push button.

2.

Allow the engine to cool down for at least 5 minutes, es especially pecially when the set has been running with a high load.

3.

Press engine stop stop..

5.16.2. Remote/standby operation motorised breakers will close automatically. automatically. The 5510 CAUTION: In remote operation, motorised controller will close onto a dead bus or synchronise onto a live bus after the start-up timers have expired.

5.17.

1.

Turn on DC power

2.

Check for alarms

3.

Ensure that the bu busload sload sw switch itch inside the pane panell is OFF

4.

mode”   Press Auto select. select. The display will read “Generator at rest” and “Auto mode”

5. 6.

The generator set can be started by prov providing iding a connection between term terminals inals 2 and 3. Generator set can be stopped by removing the connection betw between een terminals 2 and 3.

7.

A test run should be carried out at least on once ce a week.

Modes of operation Please read section 6.2 Operating procedure for details on the basic operation of the 5510 controller. For 50 or 60 Hz operation (the vast majority of operating conditions) it will not be necessary to manually adjust the nominal frequency as this is automatically changed when alternative frequency is selected. For more details, se see e section 6.5 Changing param parameters. eters.

5.17.1. Single set operation When used as a standalone generator, the 5510 will regulate to its internal voltage and frequency nominal settings as soon as the breaker is closed. closed. If any adjustment to frequency or voltage is made made when the breaker is closed, the controller will regulate back to its nominal n ominal setpoints.

5.17.2. Loadsharing with another 5510 controller Loadsharing between 2 or more 5510 controllers is achieved via the Multiset Communications (MSC) CANBUS link. Communications link The connection is made using using 2 core screened cab cable. le. See diagram 6.4 below below..

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Figure 6.4 6.4   – – MSC CANBUS connection between 5510 control modules Notes: a.

The Multiset Communications link terminals are only to be connected to other Deep Sea controllers and not to any other device.

b.

Do not connect the MSC cable screen (SCR) to earth at any point. Protection from interference is provided within the module and may be compromised by earthing the MSC cable screen.

c.

The maximum total length of the MSC link is 250 m.

d.  A 120Ω resistor must be  placed on the first and last devices on the communications bus. e.

Up to 16 Deep Sea controllers can be connected via the MSC link.

The features of the MSC link include: f.

Determining which which set closes onto a dead bus, eliminating the chance that two

g.

sets close onto a dead bus at the same time. Active and reactive loadsharing loadsharing (equivalent to analogue loadsharing lines).

h.

Identifying when sets should start or stop when used in automatic start/stop on load demand mode. A digital input input requires to be configured for this mode in order to use this feature.

5.17.3. Baseload operation Baseload mode is used to export a fixed power and PF from a generator set. It is normally used when in parallel with the mains. The toggle switch located within the generator control panel is used to select baseload mode. The power and PF that the unit will operate at are set in the configuration menu, as shown in figure 6.5, and are termed “load parallel power” and “load power factor” respectively. Refer to section 6.5 Changing parameters for details on how to set parameters.

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Figure 6.5  6.5  – – Configuration menu pages which are required to be set for baseload operation When setting the power levels shown in figure 6.5 for baseload operation, take care not to set the value above the load that is is available. This can result in other generation experiencing reverse power conditions.

5.17.4. Loadsharing with a GENerator set fitted with with analogue parallel lines lines The normal loadsharing mode of operation of the 5510 controller is to loadshare with other 5510 devicesanalogue via the MSC link. However, it is possible to loadshare with sets possessing conventional parallel lines using a Deep Sea P123 interface available separately from Deep Sea. Figure 6.6 shows a photograph of this module. One P123 is required for each 5510 controller and connects between the MSC CANBUS connection and the analogue line. line. Please note that advanced CANBUS features such as 1 set closure onto a dead bus and automatic start/stop on load demand are Figure 6.6 – 6.6 – P123  P123 loadsharing interface module not available when analogue parallel lines are used.

5.18.

Alarm functions When an alarm condition has been detected, the alarm page will be displayed automatically. Depending upon the severity of the alarm, the 5510 control module will take one of the following courses of action.

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  1. -

Warning Display the alarm in clear text and sound an audible alarm

2. Shutdown Display the alarm in clear text and sound an audible alarm -

Trip the circuit breaker

-

Shutdown the generator set

3.

Controlled shutdown

-

Display the alarm in clear text and sound an audible alarm

-

Trip the circuit breaker

-

Cooldown the generator set for the cooldown period and shutdown the machine















5.19.

Figure 6.7 – Alarm page display

  The audible alarm can be muted using using the mute alarm button alarm button [symbol 8 in figure 6.3].   Warnings will be automatically removed when the relevant parameter has returned to within its normal operating range.   Shutdowns require to be acknowledged using using the stop button. If the shutdown condition is still present, the shutdown will continue to be displayed.   When a shutdown condition is still still present after the machine has shutdown, e.g. Emergency stop or Air flap closed, the module will prevent the generator set from cranking and starting until the condition has been removed and the shutdown has been acknowledged. “Generator at rest and locked out” will be displayed on the LCD.    In the event of an alarm, the Common alarm LED alarm LED will light   A common alarm output is provided, which will turn high (+12v D DC) C) when any alarm is detected. See the wiring wiring diagrams for the terminal number.   Up to the last 25 shutdown conditions conditions will be displayed in the event log.

Changing Parameters

5.19.1. General For most applications, required parameter changes can be undertaken from the front fascia. Full configuration can be undertaken using the configuration software. To access the front panel editor Press the Stop/Reset Stop/Reset and  and Info Info buttons  buttons simultaneously. Enter PIN Number With the limited access pin number, the following can be adjusted: Language

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   Alternative Frequency  – Enable/Disable  Alternative Voltage – Enable/Disable  AC System Generator Full Load Droop – Enable/Disable (electronic engines only) Droop percentage (electronic engines only) Contrast Date and Time Generator Run Priority (for automatic start/stop on load demand mode)  Auto Scroll Time Generator CT Primary Rating Generator CT Secondary Rating Generator Control Full kW Rating Generator Control Full kVAr Rating Load Ramp Rate Load Level for more sets (for automatic start/stop on load demand mode) Load Level for less sets (for automatic start/stop on load demand mode) Load Parallel Power (for baseload mode) Load Power Factor (for baseload mode) With the full access pin number, in addition to the above, the full range of alarm setpoints and timers can also be adjusted. Pressing the + and - buttons will scroll up and down through the parameters. To adjust a parameter Scroll to the desired parameter using the + and - buttons Press the tick tick button  button and the parameter will start to flash Press the + or - button to adjust the parameter to the desired value Press the tick tick button  button to save the value To select another parameter to edit, press the + or  – button To exit the front panel configuration editor at any time, press the Stop/Reset Stop/Reset button  button When adjusting the date and time, the Up and Down arrows are arrows are used to scroll between seconds, minutes, hours, day, month and year  Alternative frequency and alternative voltage When alternative frequency is selected within the configuration menu, the generator set changes from its primary frequency setting to its alternative frequency setting, i.e. from 50 to 60 Hz or vice versa. In Europe and AI, 50 Hz is the primary setting, whereas in the US, 60 Hz is the primary setting. The status LED labelled “alterative freq” will light to indicate that alternative frequency is selected.  All alarm set points for frequency and speed within the 5510 controller will be adjusted accordingly when alternative frequency is selected. In addition, the nominal frequency will also be moved. For certain electronic engines, such as the Scania DC12/16, the 5510 controller will automatically adjust the engine speed between 50 and 60 Hz. For nonelectronic engines, the speed must be adjusted separately via the governor.

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   Alternative voltage may be required when changing the alternator configuration, e.g. from series star to parallel star. When alternative voltage is selected, all alarm setpoints for voltage and the nominal voltage are halved.  

5.19.2. Parameter Adjustment For Alternative Alternator Configurations The Deep Sea 5510 module is designed to be used with different alternator configurations. When changing the alternator configuration, it may be necessary to adjust the AC System  System  and/or Alternative Voltage   within the Deep Sea module, depending upon how the alternator is being configured. The table Voltage below outlines the most common alternator configurations and the corresponding Deep Sea set up. Alternator configuration

Deep Sea set-up AC System

Alternative Voltage

Series star

3 phase, 4 wire

Disable

Parallel star

3 phase, 4 wire

Enable Enable for 120V Ph-N

Parallel zig-zag

1 phase, 2 wire or 2 phase, 3 wire depending upon output configuration

Double delta

1 phase, 2 wire or 2 phase, 3 wire depending upon output configuration

Series zig-zag

1 phase, 2 wire or 2 phase, 3 wire depending upon output configuration

Disable

3 phase, 3 wire

Disable

Disable for 220-240V Ph-N Enable for 120V Ph-N

Series Delta

Disable for 220-240V Ph-N

Table 0-1 Deep Sea controller set up for different alternator configurations By selecting alternative voltage the voltage protection is halved. The actual output voltage value is adjusted separately via the AVR. When 1 phase 2 wire or 2 phase 3 wire ac systems are selected on the Deep Sea 5510 controller, the number of phase voltage and current readings which are displayed changes to 1 or 2 respectively. When 3 phase 3 wire ac system is selec selected, ted, only line voltages are displayed. This configuration can be used with a mid-winding or floating neutral.

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  6.0

MAINTENANCE 6.1.

General

The Cummins QSB5-G9 engine is supplied with an after treatment package which is required to achieve emissions compliance. This package is part of the “certified system” which includes all components from air intake to DOC (see pg. 26 for DOC maintenance details) outlet. There are strict guidelines for the modification of any of these components by OEM or end user which need to be adhered to in order to maintain certification. If there is any doubt please refer back to Aggreko Manufacturing for advice prior to carrying out any modifications / repairs. In addition to periodic inspections, many of the components in these units require periodic servicing to provide maximum output and performance. Servicing may consist of pre-operation and post-operation procedures to be performed by the operating or maintenance personnel. The primary function of preventive maintenance is to prevent failure, and consequently, the need for repair. Preventive maintenance is the easiest and the least expensive type of maintenance. Maintaining your unit and keeping it clean at all times will facilitate servicing. Ensure that maintenance personnel are adequately trained, competent and have read the Maintenance Manuals. Prior to attempting any maintenance work, be aware of the following:  

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

 



 



Any unauthorized modification or failure to maintain this equipment may make it unsafe and out of factory warranty. Use extreme care to avoid contacting hot surfaces (engine exhaust manifold and piping, piping, etc.). Never operate this machine with any guards removed. Imperial and Metric hardware was used in the design and assembly of this unit. Consult the parts manual for clarification of usage. The machine cannot be started accidentally or otherwise, by posting warning signs and/or fitting appropriate anti  – –start devices. All residual electrical power sources sources (mains and battery) are isolated.

Prior to opening or removing panels or covers to work inside a machine, ensure that:  



 



Anyone entering the machine is aware aware of the reduced level of protection and the additional hazards, including hot surfaces and intermittently moving parts. The machine cannot be started accidentally or otherwise, by posting warning signs and/or fitting appropriate anti  – –start devices.

Prior to attempting any maintenance work on a running machine, ensure that:    

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The work carried out is limited limited to only those those tasks which require the machine to run. The work carried out with safety protection devices disabled or removed is limited to only those tasks which require the machine to be running with safety protection devices disabled or removed. All hazards present are known (e.g. pressurised components, electrically live components, removed panels, covers and guards, extreme temperatures, inflow and outflow of air, intermittently moving parts, safety valve discharge etc.). Appropriate personal protective equipment is worn. Loose clothing, jewellery, long hair etc. is made safe. Warning signs indicating that Maintenance Work is in Progress are posted in a position that can be clearly seen.

Upon completion of maintenance tasks and prior to returning the machine into service, ensure that:    





The machine is suitably tested. All guards and safety protection devices are refitted.

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



All panels are replaced, canopy and doors closed. Hazardous materials are effectively contained and disposed of.

To assist with ordering spare parts and other service activities, a short form list of Component Manufacturers data has been included in this manual. Prior to engine starting, check the oil and coolant levels. Carry out a visual check of the following:      

 



Leaks. Loose or damage parts. Worn or damaged belts, change in engine appearance.

Refer to the Maintenance Schedule for quick reference. Report unusual noise/vibration and/or exhaust smoke and ensure the generator set is kept clean, both inside and out.

6.2.

Maintenance Schedule

6.2.1.

Inspection Criteria Daily Engine Oil Level

C

Fuel Tank (Fill at end of day)

C

Gauges / Lamps

C

 Air Filter

C

Fuel / Water Separator Drain

C

Battery Connections / Electrolyte

C

Weekly

Radiator Coolant Level

C

Fan / Alternator Belts Hoses (oil, air, intake, etc.)

C

Monthly

3 Months / 500 Hrs

6 Months / 1000 Hrs

12 Months / 2000 hrs

C

 Automatic Shutdown System Visual

C

Fasteners / Guards

C

Engine Coolant Test

C

Shutdown Switch Settings Test

C

 Alternator load cable integrity (including inside alternator terminal box)

C

C=check (adjust if necessary)

Refer to manufacturers operating and maintenance instructions for additional information and all other maintenance.

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  6.2.2.

Service Criteria Daily

Weekly

Monthly

3 Months / 400 Hrs*

Engine Oil & Filters

6 Months / 1000 Hrs

5 years / 4800 hrs

R

 Air Filter Element

R

Fuel / Water Separator Element

R

Fine Fuel Element

R

Engine Coolant

R

R=replace Refer to manufacturers operating and maintenance instructions for additional information and all other maintenance. * This figure should be in line with current service best practise. DOC Operation: - If operation is at low load and low ambient then DOC has a potential to block. Too clear DOC then run at 80% 80 % for 2 hrs. Please refer to graph below for more details.

QSB5 T4i Operating Guidance

9

 August 2016

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6.3.

Daily Maintenance

6.3.1.

Check The Engine Oil Level:

 A. the engine and wait 5 minutes to allow B. Stop Remove the dipstick and check the oil level. the oil to drain to the oil pan. C. Replenish if necessary using a recommended grade of engine oil (see section 8). CAUTION: Never operate the engine with the oil level below the ‘L’ mark or above the ‘H’

mark. See FIG. 7.1 below. Figure 7.1 7.1 - Engine Oil Level Check

6.3.2.

Check The Fuel Tank Level

Check the fuel level gauge on the control panel. Replenish as necessary using clean, good quality, diesel/Derv/Gas Oil that conforms to ISO or equivalent.  Always ensure that the filler cap is replaced after replenishment. 6.3.3.

Check That All Meters And Gauges Function Correctly

Start the generator and inspect the following items: -

Oil pressure gauge is between 85 & 95psi.

-

After 5 minutes check that that the cooling water water temperature gauge reads between 45 & 55°C. The voltage and frequency gauges are within specification. Fuel gauge indicates the tank is not empty.

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  -

Engine hours display increases after 10 minutes. Safety module has no alarm indicators on. Press the “LAMP TEST” button on the control panel a nd confirm that all indicator lamps are working. 6.3.4.

Check The Air Filter

NOTE: In dusty conditions clean the primary filters regularly. Check the air filter restriction indicator next to the air filter above the engine. If this has changed to the restricted position, then the filter will need replaced. 6.3.5.

Check The Battery

Check that the battery connections are properly installed and that the electrolyte level in each cell covers the top plates. If necessary, top up with clean distilled water. 6.3.6.

Check For Leaks

There are several fluids used inside the generator, e.g. diesel, oil, coolant. Look for signs of leakage all around the engine.  Any source oftoleak should be checked and fixed. f ixed. Clean up any fluid lying inside the generator and dispose of according the appropriate local regulations. Recurring leaks should be reported to AGGREKO. AGGREKO.  

6.4.

Weekly Maintenance

6.4.1.

Check The Water/Antifreeze Level

Stop the engine and wait for the temperature to cool before checking the coolant level. Remove the pressure cap slowly to relieve the pressure of the cooling system. Failure to do so could result in personal injury from heated coolant spray (See Figure 7.2). Check the coolant level. Replenish with the correct coolant fluid as necessary (see section 8).

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  Figure 7.2 7.2 - Coolant Level Check

6.4.2.

Carry Out A Vi Visual sual Check Of The Drive Belts.

The cooling pump, alternator and radiator fan are driven by a single belt arrangement from the engine pulley. Check the belts for signs of wear. Check the belt tension. NOTE: Do not remove guards.  guards. 

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  7.0

LUBRICATION 7.1.

General Information

Lubrication is an essential part of preventive maintenance, affecting to a great extent the useful life of the unit. Different lubricants are needed and some components in the unit require more frequent lubrication than others. Therefore, it is important that the instructions regarding types of lubricants and the frequency of their application be explicitly followed. Periodic lubrication of the moving parts reduces to a minimum the possibility of mechanical failures. The Preventive Maintenance Schedule shows those items requiring regular service and the interval in which they should be performed. A regular service program should be developed to include all items and fluids. These intervals are based on average operating conditions. In the event of extremely severe (hot, cold, dusty or wet) operating conditions, more frequent lubrication than specified may be necessary. Details concerning lubrication of the running gear are in Maintenance Section.

7.2.

Generator Oil Change

These units are normally furnished with an initial supply of oil sufficient to allow operation of the unit for approximately 6 months or 400 hours, although this should be in line with the current service best practise. The unit will however need to be topped up with oil during this period. If a unit has been completely drained of all oil, it must be refilled r efilled with new oil before it is placed in operation. Refer to specifications in Lubrication Table. NOTICE: Some oil types are incompatible when mixed and result in the formation of varnishes, shellacs, or lacquers that may be insoluble. Such deposits can cause serious problems including clogging of the filters. Where possible, do NOT mix oils of different types and avoid mixing different brands. A type or brand change is best made at the time of a complete oil drain and refill. If the unit has been operated for the time/ hours mentioned above, it should be completely drained of oil. If the unit has been operated under adverse conditions, or after long periods in storage, an earlier change period may be necessary as oil deteriorates with time as well as by operating conditions.  An oil change is good insurance against the accumulation of dirt, sludge, or oxidized oil products. Completely drain the reservoir, piping. If the oil is drained immediately after the unit has been run for some time, most of the sediment will be in suspension and, therefore, will drain more readily. However, the fluid will be hot and care must be taken to avoid contact with the skin or eyes.  After the unit has been completely drained of all old fluid, close the drain valve. Add oil in the specified quantity at the filler plug. Tighten the filler plug and run the machine to circulate the oil. Check the oil level when unit is warm and not running. If not near the middle of the dipstick, stop the unit and make corrections. DO NOT OVERFILL.

7.3.

Oil specification The oil required for this engine is:

 August 2016

Manufacturer:

Fuchs

Product Name:

Titan Cargo 15W-40

Relative Density @ 15°C:

0.876 g/cm³

Viscosity @ 40°C

115.3 mm²/s

Viscosity @ 100°C

15.1 mm²/s

Viscosity Index

136

Flash Point (COC)

248 °C

Pour Point

-45 °C

Sulphated Ash:

1.0%

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  Trouble Shooting 7.4.

Introduction

Trouble shooting for a generator set is an organized study of a particular problem or series of problems and a planned method of procedure for investigation and correction. The trouble-shooting chart that follows in Section 9.3 includes some of the problems that an operator may encounter during the operation of a generator set. The chart does not attempt to list all of the troubles that may occur, nor does it attempt to give all of the answers for correction of the problems. The chart does give those problems that are most probable to occur. To use the trouble shooting chart: 1) Find the problem being being experienced in the Symptom Symptom column  column on the far left. 2) Proceed to work through the possible causes in the next column, instigating the appropriate corrective action where required from the next column.

7.5.

Action Plan

Think Before Acting: Study Acting: Study the problem thoroughly and ask yourself these questions: 1) What were the warning signals that preceded the trouble? 2) similar trouble occurred before? 3) Has Whataprevious maintenance work has been done? If the generator will still operate, is it safe to continue operating it to make further checks? Do The Simplest Things First: Most problems are simple and easily corrected. Always check the easiest and most obvious things first, following this simple rule will save time and trouble. Note: For  For trouble shooting electrical problems, refer to the Wiring Diagram Schematic found in Note:  Appendix D.  D.  Double Check Before Disassembly: The source of most generator troubles can be traced not to one component alone, but to the relationship of one component with another. Too often, a generator can be partially disassembled in search of the cause of a certain trouble and all evidence is destroyed during disassembly. Check again to be sure an easy solution to the problem has not been overlooked. Find And Correct Basic Cause: After Cause: After a mechanical failure has been corrected, be sure to locate and correct the cause of the trouble so the same failure will not be repeated. A complaint of "premature breakdown" may be corrected by repairing any improper wiring connections, but something caused the defective wiring. The cause may be excessive vibration.

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  7.6.

Trouble Shooting Chart SYMPTOM

POSSIBLE CAUSE

CORRECTIVE ACTION

Battery isolator switch not closed.

Close battery isolator switch.

Batteries flat or bad. Read ENGINE DOES NOT CRANK WITH 12V/24V ELECTRIC MOTOR

ENGINE CRANKS BUT DOES NOT START

ENGINE STARTS UP BUT STOPS AFTERWARDS

ENGINE OVERSPEEDS

value on battery voltage meter (must be 12V/24V or more).

Replace or charge batteries.

Mini circuit breaker of 10A in terminal box is open.

Reset.

Start relay at cranking motor defective.

Measure the voltage over the start relay.

Fuel tank empty.

Fill up fuel tank.

 Air in the fuel system.

Check system for leaks. Bleed the fuel system.

Dirty fuel filters.

Replace fuel filters.

Check voltage (12V/24V) over fuel shut-off valve during crank.

Call for AGGREKO AGGREKO support.  support.

Optional air shutdown valve closed.

Open air shutdown valve.

Overspeed protection is activated.

Put key back to 0 and try to start the engine again.

 Air in the fuel system.

Check system for leaks. Bleed the fuel system.

Dirty fuel filters.

Replace fuel filters.

Overspeed during acceleration.

Decrease frequency setting.

Shutdown after 6 seconds.

Check safeties: Oil pressure – pressure – Water  Water  – Water temperature – temperature  Water pressure – pressure –   Oil temperature (option)

Frequency too high.

 Adjust frequency to the correct correct level.

Connection between governor

Repair connection.

and fuel pump interrupted.

ENGINE SPEED NOT STABLE

ENGINE SHOWS EXCESS SMOKE AND / OR LACK OF POWER

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 Air in the fuel system.

Check system for leaks. Bleed the fuel system.

Engine not yet at operating temperature.

Wait until engine has reached the normal operating temperature of 80-90ºC.

Dirty fuel filters.

Replace fuel filters.

Wear in ball eyes, linkage governor / fuel pump.

Replace ball eyes.

Dirty air filters.

Replace air filters.

Dirty fuel filters.

Replace fuel filters.

 Air in the fuel system.

Check system for leaks. Bleed the fuel system.

Overload.

Check load.

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  SYMPTOM

ALTERNATOR DOESN’T GENERATE VOLTAGE

ALTERNATOR VOLTAGE TOO HIGH / LOW

ALTERNATOR VOLTAGE NOT STABLE

MAIN CIRCUIT BREAKER WILL NOT CLOSE

MAIN CIRCUIT BREAKER CLOSES BUT TRIPS AGAIN

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POSSIBLE CAUSE

CORRECTIVE ACTION

Voltmeter defective.

Measure voltage at outlet terminals of alternator. If voltage measured replace voltmeter.

Voltage regulator defective.

Replace voltage regulator,

 Air in the fuel system.

Check system leaks. Bleed the fuel for system.

Speed frequency too high / low.

Check frequency meter and adjust if required.

Incorrect voltage setting.

Adjust voltage regulator.

No identifiable cause.

Consult AGGREKO AGGREKO..

Engine speed not stable.

Check stability of engine speed.

Incorrect stability adjustment.

 Adjust stability on the voltage voltage regulator.

Circuit breaker control switch (Figure 6.1) set remote control.

Select local position.

Circuit breaker tripped.

Reset circuit breaker.

Circuit breaker not charged,

Charge motor mechanism

motor mechanism broken. Lamp ‘CIRCUIT BREAKER CLOSED’ defective.  defective. 

manually, inform AGGREKO AGGREKO..

Switch on overload or short circuit.

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Replace lamp. Remove load.

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 APPENDIX A - MATERIAL SAFETY DATA SHEETS

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 APPENDIX B  EQUIPMENT DATA SHEET  – 

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 APPENDIX C  INSTALLATION OUTLINE DRAWING  – 

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 APPENDIX D  CONTROL PANEL LAYOUT  – 

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 APPENDIX E  ALTERNATOR & AVR SCHEMATIC DIAGRAM  – 

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 APPENDIX F  MAIN LOAD & METERING SCHEMATIC DIAGRAM  – 

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 APPENDIX G  DC CONTROL SYSTEM SCHEMATIC DIAGRAM  – 

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 APPENDIX H  ECM 2250 INTERCONNECTIONS  – 

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 APPENDIX I  TERMINAL LAYOUT & ENGINE WIRING  – 

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 APPENDIX J  LIVERY LAYOUT DRAWING  – 

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 APPENDIX K  MANUFACTURERS COMPONENT DATA  – 

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 APPENDIX L  LIFTING BEAM CERTIFICATE  – 

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 APPENDIX M  DNV SPARK ARRESTOR CERTIFICATE  – 

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