TM 9-6115-484-14 MEP-PU-810A/B PART 3

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 5.5.3.3

DISTRIBUTION AND CONTROL CABLING WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT DURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION AND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN LOAD CABLES ARE HANDLED. WARNING VERIFY THAT CONNECTION POINTS ARE DE-ENERGIZED BEFORE MAKING ANY CONNECTIONS. FAILURE TO CHECK THAT CONNECTORS ARE DE-ENERGIZED MAY RESULT IN INJURY OR DEATH.

a. Lay out and park the load cables for each phase (A, B, & C) between the PU Tie Output parking stations and the Primary Switching Center (PSC). b. Connect each phase cable to the appropriate phase connection on the Primary Switching Center (PSC). NOTE 1:

For complete set-up of the Primary Switching Center (PSC), refer to Radian Inc. Commercial Technical Manual CTM 01646.1R1260, Chapter 2.6.

NOTE 2:

For Unit Isolation Procedure (any unit) - Plant with PSC, and Unit Re-Installation Procedure – Plant with PSC, refer to Chapter 5.9, Sections 5.9.6.15 and 5.9.6.16.

c.

Connect each load cables drain wire to the grounding grid.

d. Open the Tie Output connector loadbreak covers on the first PU. e. Connect the Tie Output Cables to the appropriate phase connectors; ensure there are no crossphase connections. f.

Close and lock the Tie Output connector covers.

g. Repeat steps ‘a’ through ‘f’ on each remaining PU. h. Connect the first (A) (B) communication cable to “B” receptacle on first PU. i.

Route the first (A) (B) communication cable to second PU.

j.

Connect the first (A) (B) communication cable to “A” receptacle on second PU.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 k.

Connect the second (A) (B) communication cable to “B” receptacle on second PU.

l.

Route the second (A) (B) communication cable to second PU.

m. Connect the second (A) (B) communication cable to “A” receptacle on third PU. n. Connect third (A) (B) communication cable to “B” receptacle on third PU. o. Route the third (A) (B) communication cable to fourth PU. p. Connect the third (A) (B) communication cable to “A” receptacle on fourth PU. q. Connect the fourth (A) (B) communication cable to “B” receptacle on fourth PU. r.

Leave the loose end of the fourth cable loose and capped.

5.5.3.4 SETPOINT VERIFICATION a. Turn on PU DC control power by pushing in on the DC Control Power breaker. b. On each of the five overcurrent relays, verify the settings: (1)

Press the [▲] key to get to the top-level menu “1 REPORT STATUS”.

(2)

Press the [►] key 5 times to display “6 GENERAL SETTINGS”.

(3)

Press the [▼] key to display “6.1 COM SETTINGS”.

(4)

Press the [►] key 2 times to display “6.3 POWER SYSTEM SETTINGS”.

(5)

Press the [▼] key to display “6.3.1 CT RATIO”.

(6)

Verify the “P” and “N” values match Chapter 5.1 Table 5.1.3.4-1 CT Ratio Settings.

(7)

Press the [▲] key 2 times to display “6 GENERAL SETTINGS”.

(8)

Press the [◄] key to display “5 PROTECTION LOGIC USER”.

(9)

Press the [▼] key 3 times to display “5.1.1.1 50TP”.

(10) Verify the 50TP “PU” and “TD” settings in Chapter 5.1 Table 5.1.3.4-2 Instantaneous Trip Settings. In order to edit values, Press the “Edit” key. Select correct value, and press “Edit” again to save changes. Ensure light is off otherwise you can accidentally change value again. (11) Press the [►] key to display “5.1.1.2 50TN”. (12)

Verify the “50TN” settings.

(13)

Press the [►] key to display “5.1.1.3”.

(14)

Verify the “50TQ” settings.

(15)

Press the [▲] key to display “5.1.1 50T SETTINGS”.

5-95

c.

(16)

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 Press the [►] key to display “5.1.2 51 SETTINGS”.

(17)

Press the [▼] key to display “5.1.2.1 51P”.

(18)

Verify the 51P “PU”, “TD”, and “C” settings in Chapter 5.1 Table 5.1.3.4-3 Time Overcurrent Settings.

19)

Press the [►] key to display “5.1.2.2 51N”.

(20)

Verify the 51N settings.

(21)

Press the [▲] key 3 times to display “5 PROTECTION LOGIC USER”.

Use the following procedure to verify the Generator 1 and Generator 2 GSC+ settings:

NOTE:

Refer to the “EMCPII+ Reference Chart”, located on the interior Generator Control Panel Door (Look-up) (1)

Place ECS in the COOLDOWN/STOP position.

(2)

Press SERVICE MODE key to enter service mode. OP1 is showing on the lower display.

(3)

Press SCROLL UP key until “OP3” is showing.

(4)

Press SELECT key. “PE -“ with the first dash flashing is showing.

(5)

Press SCROLL RIGHT key. “PE 1 -“ with the second dash flashing is showing.

(6)

Press SCROLL DOWN key. “PE 13 –“ with the third dash flashing is showing.

(7)

Press SCROLL UP key. “PE 132 –“ with the fourth dash flashing is showing.

(8)

Press SCROLL DOWN key. “PE 1323 –“ with the fifth dash flashing is showing.

(9)

Press SCROLL RIGHT key. “PE13231” with all digits not flashing is showing.

(10) Press ENTER key. “PE PASS” is showing. (11) Press EXIT key. “OP4” is showing. (12) Press SCROLL UP key until “OP5-0” is showing on the lower display. (13) Press SELECT key. “POO1” followed with the value of the setpoint is showing. (14) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing. Use Chapter 5.1 Table 5.1.3.4-4 OP5 Settings for the parameter values to be verified. Repeat until the desired setpoints are verified. (15) Press EXIT key. “OP5-0” is showing on the lower display. (16) Press SCROLL UP key until “OP5-1” is showing. (17) Press SELECT key.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (18) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing. Use Chapter 5.1 Table 5.1.3.4-5 OP5-1 Settings for the parameter values to be verified. Repeat until the desired setpoints are verified. (19) Press EXIT key. “OP5-1” is showing. (20) Press SCROLL UP key. “OP6” is showing. (21) Press SELECT key. (22) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing. Use Chapter 5.1 Table 5.1.3.4-6 OP6 Settings for the parameter values to be verified. Repeat until the desired setpoints are verified. (23) Press EXIT key twice. The display returns to normal. NOTE:

If an incorrect setpoint value is displayed, the value must be changed to match the DPGDS setpoint value as follows: (a)

With the setpoint with the incorrect value showing on the display, press the SELECT key. The incorrect value flashes on the display.

(b)

Press SCROLL UP or SCROLL DOWN key until the correct value appears flashing on the display.

(c)

Press ENTER. The correct value stops flashing on the display.

Press SCROLL UP or SCROLL DOWN key to continue to verify the remaining parameter values. d. Return ECS1 and ECS2 to the OFF/RESET position. (d)

NOTE:

Use up or down keys to change values.

e. At the AVR verify the operation settings using Chapter 5.1 Table 5.1.3.4-7 AVR Parameter/Setpoints: (1)

Open the GCPG1 cabinet door.

(2)

Press the [▼] key to display parameter “90”.

(3)

Press the [◄►] key to display the current value.

(4)

Press the [▲] key to change the value to “0015”. Enables parameter editing.

(5)

Press the [◄►] key to accept change and display the parameter number.

(6)

Press the [▲] key to the next parameter needed to change.

(7)

Press the [◄►] key to display the current value.

(8)

Press the [▲] or [▼] key to change the value.

(9)

Press the [◄►] key to accept change and display the parameter number.

(10) Repeat steps ‘5’ through ‘9’ for the each parameter needing to be changed.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (11) When complete, press the [▼] to display parameter “01”. NOTE:

Parameters 20, 21, 22, 36, 37, and 38 are displayed but not used.

NOTE:

Parameters 23 to 29, 39 to 49, 59 and 61 to 89 are not displayed and not used. (12) When complete, press the [▼] to display parameter “90”. (13) Press the [◄►] key to display the current value. (14) Press the [▼] key to change the value to “0009”. Disables DVR parameter editing. (15) Press the [◄►] key to accept change and display the parameter number. (16) Press the [▲] key to change to display parameter “01”. (17) Close the GCPG1 cabinet door. (18) Repeat steps ‘1 ‘through ‘16’ for Generator 2.

5.5.3.5

PRE-OPERATION CHECKS

Starting from the left rear of the PU and working around the PU in a clockwise direction, perform the checks identified in Chapter 5.1 Table 5.1.3.5-1 Pre-Operation Checklist. (Gen. 1 is on the left and Gen. 2 is on the right): 5.5.3.6

PRE-OPERATION RUN WARNING ENSURE ALL PERSONNEL ARE CLEAR AND THE PU DOORS ARE CLOSED PRIOR TO STARTING A GENERATOR. WARNING HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND ENFORCED. NOISE LEVELS IN EXCESS OF 85 DB EXIST WITHIN AN 88-FOOT RADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR SINGLE HEARING PROTECTION WITHIN 88 FEET OF AN OPERATING DPGDS. WARNING HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND ENFORCED. DURING MAINTENANCE ACTIVITIES WITH THE SIDEDOORS OPEN, NOISE LEVELS IN EXCESS OF 113 DB EXIST WITHIN A 12-FOOT RADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR DOUBLE HEARING PROTECTION WITHIN 12 FEET OF AN OPERATING DPGDS. EXPOSURE MUST BE LIMITED TO UNDER 2.5 HOURS.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 WARNING BY CLOSING THE FEEDER OR TIE BREAKER, HIGH VOLTAGE WILL BE PRESENT ON THE LOAD CABLES. ENSURE ALL PERSONNEL ARE CLEAR OF ALL LOAD CABLES PRIOR TO CLOSING FEEDER OR TIE BREAKERS. TABLE 5.5.3.6-1 PRE-OPERATION RUN INSTRUCTION SEQUENCE (Perform on each PU in the power plant) STEP

-- 60HZ OPERATIONS --

-- 50HZ OPERATIONS --

1

Verify System Mode Switch (SMS) is in MANUAL

2

Verify DC Control Power is on

3

Verify Emergency Stop is pulled out

4① 5

Verify the 60Hz light is on ①

Verify the 50Hz light is on①

Start engine 1 by placing ECS1 in MANUAL

6

Verify the engine accelerates to 1800RPM

Verify the engine accelerates to 1500RPM

7

Adjust the generator frequency to 60Hz using the Frequency Adjust Rheostat (FAR)

Adjust the generator frequency to 50Hz using the Frequency Adjust Rheostat (FAR)

8

Adjust the generator voltage to 4295VAC using the Voltage Adjust Rheostat (VAR)

Adjust the generator voltage to 3915VAC using the Voltage Adjust Rheostat (VAR)

9

Close BCS-G1, toggle the Phase Rotation Test Light switch, verify that light ABC lights, open BCSG1

10

Shutdown engine 1 by placing ECS1 in OFF/RESET

11

Start engine 2 by placing ECS2 in MANUAL

12

Verify the engine accelerates to 1800RPM

Verify the engine accelerates to 1500RPM

13

Adjust the generator frequency to 60Hz using the Frequency Adjust Rheostat (FAR)

Adjust the generator frequency to 50Hz using the Frequency Adjust Rheostat (FAR)

14

Adjust the generator voltage to 4295VAC using the Voltage Adjust Rheostat (VAR)

Adjust the generator voltage to 3915VAC using the Voltage Adjust Rheostat (VAR)

15

Close BCS-G2, toggle the Phase Rotation Test Light switch, verify that light ABC lights, open BCSG2

16

Shutdown engine 2 by placing ECS2 in OFF/RESET ①

If the wrong frequency light is on, open the Master Control Door and change the Frequency Selector Switch (FSS) to the desired frequency.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 5.5.3.7

ORT SETUP

a. Remove the ORT from its case and set it up on a flat and level surface. b. Remove the mouse from the case and plug it into the mouse (PS2) port on the back of the ORT. c.

If 120VAC power is available, connect the ORT power supply cord to the 120VAC power. The ORT can operate up to three hours on its batteries.

d. Connect one end of the 150-foot patch cable to the ORT networking port on the PU. e. Route the cable from the ORT to the PU and connect the cable to the ORT port. f.

Turn on the ORT.

g. Observe that the ORT boots to the operator’s Overview screen. h. Select the EquipID pop-up screen and enter the necessary information for the units. This includes the Trailer ID number, the Engine ID number, and the Generator ID number for each PU. i.

Select the Oneline pop-up screen and enter the descriptor for the main load connected to the feeders.

h. Return to the Overview pop-up screen. 5.5.3.8

CONTROLS SETUP

Complete the switch arrangements according to the following Table, and verify the lamp indicators: NOTE:

Ignore settings for Power Units not being used.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 TABLE 5.5.3.8-1 PANEL

MASTER CONTROL PANEL MCP

INSIDE MCP GENERATOR CONTROL PANEL GCPG1 GENERATOR CONTROL PANEL GCPG2

CONTROL SWITCH SETUP SWITCH 1ST PU Pushed In DC Power (ON) SMS OFF PRIME GMS POWER PRIME AVRS POWER 60Hz Light ON① USS BSS SSS SSL FSS Emergency Stop ECS Emergency Stop ECS

2ND PU Pushed In (ON) OFF PRIME POWER PRIME POWER

3RD PU Pushed In (ON) OFF PRIME POWER PRIME POWER

4TH PU Pushed In (ON) OFF PRIME POWER PRIME POWER

ON①

ON①

ON①

A② NORMAL OFF All OFF

B② NORMAL OFF All OFF

C② NORMAL OFF All OFF

D② NORMAL OFF All OFF

50/60 Hertz①

50/60 Hertz①

50/60 Hertz①

50/60 Hertz①

Pulled-Out

Pulled-Out

Pulled-Out

Pulled-Out

OFF

OFF

OFF

OFF

Pulled-Out

Pulled-Out

Pulled-Out

Pulled-Out

OFF

OFF

OFF

OFF

① With the SMS in the OFF position, the 50/60Hz lights indicate the position of the Frequency

Selector Switch (FSS). If the wrong light is on, open the door and change the switch position. ②

5.5.3.9

No more than one switch can be in the same position in any multi-PU line-up. With the SMS in OFF, none of the USI lights will be on and any previously set address on the PU is cleared.

PSC RELAY SETTING VERIFICATION

a. Turn on the ORT and log in as administrator using the procedures of PSC Manual (Table 3.3.2-1 DPGDS ORT ADMINISTRATOR LOG-IN PROCEDURE). b. Click on Windows Start button. c.

Select Programs then Accessories then HyperTerminal.

d. Double Click on “Vista.ht” NOTE:

if “vista.ht” does not appear on the menu, refer to the windows 98 procedure contained in APPENDIX C of S&C instruction sheet 681-515 to create it.

NOTE:

Use Com 1 communications port on the ORT.

e. Click on “Connect”. NOTE:

Do Not Connect the communication cable before completing step “e”. Otherwise Windows NT will search for a new device on the ORT COM port.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 f.

Connect the communication cable between the ORT to the left (Ways 3 and 4) Overcurrent Relay (OCR).

g. Press “Enter” on the ORT. NOTE:

The overcurrent relay main menu should appear.

h. Select View Menu 1, WAY 3. i.

Select View relay settings.

j.

Verify relay settings according to Table 5.5.3.9-1

NOTE:

Refer to S&C Instruction Sheet 681-515 page 14, PROGRAMMING to change settings.

k.

Repeat steps g through I for WAY 4.

l.

Return to the main menu and test the “Trip Function” of each interrupter using the Test Trip Menu.

m. Return to the Main Menu and “Disconnect” using Windows HyperTerminal when desired programming action is complete. n. Disconnect the OCR end of the communication cable. o. Repeat steps e. through l, for the right OCR (Ways 5 and 6). p. Repeat steps e. though m. for each PSC in use. q. Exit Windows HyperTerminal. r.

Shut-down the ORT.

TABLE 5.5.3.9-1 PSC WAY

FUNCTION

3,4, or 5 3,4, or 5 3,4, or 5 3,4, or 5 6 6

5.5.4

PSC RELAY SETTINGS

Feeder Feeder Ground Single Output Single Output Ground PSC Interconnect PSC Interconnect Ground

TAP TAP MAIN MAIN TAP

MIN. PICKUP (AMPS) 200 50 600 100 400

INST. PICKUP (KAMPS) 1 0 1 0 0

TIME DELAY (SEC.) Off Off Off Off C (64ms)

TAP

80

0

C (64ms)

CABLE SIZE

CURVE

1/0 1/0 500 KCM 500 KCM 4/0 4/0

PLANT STARTUP WARNING ALWAYS PAD LOCK THE PSC INTERCONNECT SWITCHES. FAILURE TO DO SO COULD RESULT IN PERSONAL INJURY. OR DAMAGE TO EQUIPMENT. IF ATTEMPTING TO RECLOSE WAY, REFER TO SECTION 5.9.5.3.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 Starting up a Multi-PU Prime Power Plant in Manual Mode a. At the external switchgear, close the associated connection for each PU supplying power to the switchgear and close and pad lock the PSC interconnect switches when using more than one primary switch. b. At the external switchgear, close the connections between the external switchgears. c.

At the external switchgear, open all connections of loads to the switchgear.

NOTE: 1: For complete set-up of the Primary Switching Center (PSC), refer to USAF TO 35F14-1-1 and USA TM9-6115-725-14&P. NOTE: 2: For Unit Isolation Procedure (any unit) - Plant with PSC, and Unit Re-Installation Procedure – Plant with PSC, refer to Section 5.9, Section 5.9.6.15, and Section 5.9.6.16. d. Complete the switch arrangements according to the following Table, and verify the lamp indicators: TABLE 5.5.4-1 SWITCH SETUP – MANUAL MODE PANEL SWITCH 1ST PU BCS-T Green Target SMS MANUAL MASTER CONTROL MSES PANEL MCP Enable①

2ND PU Green Target MANUAL

3RD PU Green Target MANUAL

4TH PU Green Target MANUAL

Enable①

Enable①

Enable①

A①, ② Green Target Green Target OFF Green Target Green Target OFF

B①, ② Green Target Green Target OFF Green Target Green Target OFF

C① , ② Green Target Green Target OFF Green Target Green Target OFF

D① , ② Green Target Green Target OFF Green Target Green Target OFF

GENERATOR CONTROL PANEL 1 GCPG1 GENERATOR CONTROL PANEL 2 GCPG2

USI BCS-G1 BCS-F1 ECS-1 BCS-G2 BCS-F2 ECS-2

①

Hold the MSES in an ENABLE position until the selected USI indicator energizes. The switch returns to the center position when released. This sets the PU networking address and enables the control and monitoring.

②

No more than one of each indicator can be on for multi-PU operations. The light on should match USS position. The USI light will de-energize after the SMS has been in OFF for 3 seconds.

e. At A-unit GCPG1 place the Engine Control Switch (ECS) in MANUAL. f.

Observe the generator starts and accelerates to operating voltage and frequency.

g. At the A-unit MCP, place the Sync Source Switch (SSS) in the GEN 1 position. h. Close Generator 1 breaker by cycling BCS-G1 to the CLOSE position. i.

Observe that BCSG1 breaker closes.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 j.

Place the SSS in the TIE position

k.

Close the BCST by cycling BCST to the CLOSE position.

l.

Return the SSS to the OFF position.

m. At A-unit GCPG2 place the Engine Control Switch (ECS) in MANUAL. n. Observe the engine starts and accelerates to operating voltage and frequency. o. At the A-unit MCP, place the Sync Source Switch (SSS) in the GEN 2 position. p. Close BCSG2 when the two green triangular LEDs at 12 o’clock on the Synchroscope are energized by cycling BCSG2 to the CLOSE position. For detailed instructions on manual synchronizing refer to Chapter 5.9 Section 5.9.6.14. q. Observe that the BCSG2 closes. r.

Return the SSS to the OFF position.

s.

At B-unit MCP, place the SSS in the TIE position.

t.

Close the BCST by cycling BCST to the CLOSE position.

u. Return the SSS to the OFF position. v.

At B-unit GCPG1, place the Engine Control Switch (ECS) in MANUAL.

w. Observe the generator starts and accelerates to operating voltage and frequency. x.

At the B-unit MCP, place the Sync Source Switch (SSS) in the GEN 1 position.

y.

Close BCSG1 when the two green triangular LEDs at 12 o’clock on the Synchroscope are energized by cycling BCSG1 to the CLOSE position. For detailed instructions on manual synchronizing refer to Chapter 5.9 Section 5.9.6.14.

z.

At B-unit GCPG2, place the Engine Control Switch (ECS) in MANUAL.

aa. Observe the generator starts and accelerates to operating voltage and frequency. bb. At the B-unit MCP, place the Sync Source Switch (SSS) in the GEN 2 position. cc. Close BCSG2 when the two green triangular LEDs at 12 o’clock on the Synchroscope are energized by cycling BCSG2 to the CLOSE position. For detailed instructions on manual synchronizing refer to Chapter 5.9 Section 5.9.6.14. dd. Return the SSS to the OFF position. ee. At the C-unit, if installed, repeat steps ‘s’ through ‘dd’. ff. At the D-unit, if installed, repeat steps ‘s’ through ‘dd’. gg. At the external switchgear, close the connections of loads to the switchgear.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 hh. Ensure generators have assumed load. ii.

Observe the KW, PF and KVAR of each generator at the LCP.

Note: If adjustment is needed for KVAR balance, start with the generator that is the furthest from the average KVAR (either too low or too high). Make minor adjustments of the Voltage Adjust Rheostat (VAR) until the KVAR sharing between generators are within +/– 10% of the average plant KVAR load. This adjustment will typically be required only once during initial power plant setup and is intended to compensate for meter variations among generators.

CAUTION Improper adjustment of the VAR can cause a reverse KVAR shutdown of a generator. 5.5.5

PLANT OPERATIONS

Refer to Chapter 5.9 for specific operating procedures. In this mode of operation the ORT provides no remote operation capability. It will provide monitoring of the generator parameters. 5.5.6

POWER PLANT TEARDOWN

5.5.6.1

SHUTDOWN GENERATORS

a. Unload all generators by opening all feeder breakers. This must be done locally from the LCP or ORT. b. Open each BCST locally at the respective MCP. c.

Place all generators in cooldown by placing all SMS switches in OFF.

d. Observe all generator breakers open. e. Open all the switchgear generator supply disconnect switches. f.

Allow all engines to completely cooldown and shutdown (5 minutes).

g. Place all ECS switches in OFF/RESET. h. Pull out the DC Control Power breaker on all PUs. 5.5.6.2

DISCONNECT CABLES

WARNING NEVER REMOVE POWER CABLES BY HAND, USE HOT STICK AND HIGH VOLTAGE GLOVES. NEVER TOUCH A HIGH VOLTAGE LEAD OR TERMINAL UNTIL IT HAS BEEN DISCHARGED TO GROUND. FAILURE TO OBSERVE THE WARNING MAY RESULT IN DEATH BY ELECTROCUTION.

5-105

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 CAUTION ALLOW ALL OPERATING ENGINES TO SHUT DOWN AND COOL DOWN COMPLETELY. a. Disconnect the (A)(B) communication cables from between the PUs, Reinstall the communication cable receptacle covers, and store inside the PUs (one per unit). b. Disconnect the ORT cable and store it in the ORT case. c.

Close and latch the ORT port on the PU.

d. Disconnect all load cables used in operation of the PUs. 5.5.6.3

DISCONNECT FUEL LINES

a. Turn all fuel system valves to the off position. b. Disconnect the fuel hose from the PU fuel connection and the fuel supply. c. 5.5.6.4

Drain any fuel from the hoses into an auxiliary fuel supply and store the hoses. DISCONNECT GROUNDING

a.

Remove ground connections from the PU and store with the ground rod.

b.

Disconnect the parking stations from the ground grid.

c.

Remove the parking stations from their operating positions and reinstall them in their transportation locations on the inside of the PU rear side access doors.

5.5.6.5

PREPARE PU FOR TRANSPORTATION

a. Reinstall the four radiator splashguards (PU-810B only). b. Verify DC Control power is off. c.

Close and lock the LCP access doors.

d. Close and lock all PU side doors. 5.5.6.6

FUEL, OIL, AND COOLANT DRAINAGE

The Power Unit may be safely shipped with oil, fuel, and coolant at maximum capacities or less. Draining fluids is not required unless federal, state, or local regulations prohibit shipment with fluids present. Refer to Section 14.3.1.1, Section 13.4.5.5 and Section 6.5.3 for procedures for draining the oil, coolant and fuel liquids respectively.

5-106

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254

CHAPTER 5.6 OPERATING INSTRUCTIONS SINGLE OR MULTIPLE PU, PRIME POWER, EXTERNAL SWITCH, AUTOMATIC MODE TABLE OF CONTENTS SECTION

TITLE

PAGE

5.6

SINGLE/ MULTIPLE PU, PRIME POWER, EXTERNAL SWITCH, AUTOMATIC MODE ................................................................................111

5.6.1

SAFETY PROCEDURES .........................................................................................111

5.6.2

POSITIONING THE PU ............................................................................................111

5.6.3

INITIAL PLANT SETUP ...........................................................................................112

5.6.3.1

GROUNDING............................................................................................................112

5.6.3.2

FUEL MANIFOLD.....................................................................................................113

5.6.3.3

DISTRIBUTION AND CONTROL CABLING ...........................................................114

5.6.3.4

SETPOINT VERIFICATION......................................................................................115

5.6.3.5

PRE-OPERATION CHECKS....................................................................................119

5.6.3.6

PRE-OPERATION RUN ...........................................................................................119

5.6.3.7

ORT SETUP..............................................................................................................121

5.6.3.8

CONTROLS SETUP .................................................................................................122

5.6.3.9

PSC RELAY SETTING VERIFICATION ..................................................................122

5.6.4

PLANT STARTUP ....................................................................................................124

5.6.5

PLANT OPERATIONS (AUTOMATIC MODE) ........................................................126

5.6.5.1

PRECAUTIONS AND WARNINGS ..........................................................................126

5.6.5.2

DESCRIPTION..........................................................................................................127

5.6.5.3

DEFAULT OPERATING SEQUENCE......................................................................127

5.6.6

POWER PLANT TEARDOWN .................................................................................128

5.6.6.1

SHUT DOWN GENERATORS .................................................................................128

5.6.6.2

DISCONNECT CABLES ..........................................................................................128

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5.6.6.3

DISCONNECT FUEL LINES ....................................................................................129

5.6.6.4

DISCONNECT GROUNDING...................................................................................129

5.6.6.5

PREPARE PU FOR TRANSPORTATION ...............................................................129

5.6.6.6

FUEL, OIL, AND COOLANT DRAINAGE................................................................129

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LIST OF FIGURES FIGURE

TITLE

PAGE

FIGURE 5.6.3.1-1

MEP-PU-810A GROUND POINTS

112

FIGURE 5.6.3.1-2

MEP-PU-810B GROUND POINTS

113

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LIST OF TABLES TABLE

TITLE

PAGE

TABLE 5.6.3.6-1

PRE-OPERATION RUN INSTRUCTION SEQUENCE

120

TABLE 5.6.3.8-1

PDC CONTROL SWITCH SETUP

122

TABLE 5.6.3.9-1

PSC RELAY SETTINGS

124

TABLE 5.6.4-1

SWITCH SETUP – AUTOMATIC MODE

125

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 5.6

SINGLE/ MULTIPLE PU, PRIME POWER, EXTERNAL SWITCH, AUTOMATIC MODE

5.6.1

SAFETY PROCEDURES

a. Safety precautions must be observed while operating or maintaining the PU. Safety precautions must be observed to ensure that the operator/technician cannot have contact with the following: • • • • • • •

Hot engine parts Hot engine fluids Medium Voltage AC electricity Low Voltage AC electricity Low Voltage DC electricity Rotating Parts High noise levels

b. Minor Troubleshooting can be performed while both engines are running as long as safety precautions are taken. Refer to the appropriate troubleshooting section for recommendations. 5.6.2

POSITIONING THE PU

a. Position the PU in such a way as to allow the plant operator to have full vision of the operator control panels on the unit. b. Level the MEP-PU-810B front to rear with the trailer leveling hand crank. c.

Position the PU to provide a minimum of 10 feet of clearance for maintenance access on all sides of each unit. Ensure that there are no overhead obstructions around the exhaust outlets. WARNING FUEL SPILLAGE CAN OCCUR IF THE POWER UNIT LEVEL IS GREATER THAN + 5 DEGREES.

d. Ensure that the ground is capable of supporting the weight of the PU. The site surface should be as level as possible (+ 5 degrees).

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INITIAL PLANT SETUP

5.6.3.1

GROUNDING WARNING THERE CAN ONLY BE ONE GROUNDING POINT FOR THE PU.

a. Drive an 8-foot ground rod into the earth and should be within 6 feet of the PU and at a location that minimizes the tripping hazard, until only 6 inches (15 cm) protrudes above the surface. b. Repeat step “a” for each PU being used. c.

Connect all of the grounding rods together with a #2 AWG copper conductor creating a central ground grid.

d. Using a #2 AWG copper conductor, secure one end of a ground cable to one of the slotted ground studs on the PU, see Figure 5.6.3.1-1 or Figure 5.6.3.1-3. Secure the other end of the ground cable to the ground rod. e. Repeat step “d” for every PU. f.

Test Ground Resistance using Ground Resistance Test Equipment. Resistance must be 25Ω or less. Refer to Annex H for special equipment required for this task.

g. Remove parking stand plates from their transportation positions inside each rear, side PU door and slide them into their respective operating positions on the sides of the PDC. h. Connect the parking stand ground wires to either of the two chassis ground lugs on the PU.

GROUND POINT

FIGURE 5.6.3.1-1 NOTE:

GROUND POINT

MEP-PU-810A GROUND POINTS

Connect only one ground point to the ground grid.

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GROUND POINT

FIGURE 5.6.3.1-2 NOTE: 5.6.3.2

GROUND POINT

MEP-PU-810B GROUND POINTS

Connect only one ground point to the ground grid. FUEL MANIFOLD WARNING ENSURE THAT THE FUEL LINES ARE PROTECTED FROM ALL ELECTRICAL CABLES AND ARE ROUTED TO MINIMIZE THE POTENTIAL FOR PHYSICAL DAMAGE OR CAUSING A TRIPPING HAZARD.

a. Lay out the fuel hoses between the PU, the fuel manifold, and the fuel bladders to establish the fuel supply system. See Chapter 5.1 Figure 5.1.3.2-1 External Fuel Supply. b. Install the external fuel hose for the PU to the Fuel Transfer Pump at the Tow end of the PU. c.

Connect the other end of the fuel hose to the fuel manifold outlets.

d. Connect the 3” hose, with quick-disconnect hose ends, from the fuel manifold to the fuel bladders. e. Connect the fuel manifold ground wire to the ground grid. f.

Open only the appropriate fuel manifold valves (once connected to the PU) to supply fuel to the power units and check for leaks.

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DISTRIBUTION AND CONTROL CABLING WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT DURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION AND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN LOAD CABLES ARE HANDLED. WARNING VERIFY THAT CONNECTION POINTS ARE DE-ENERGIZED BEFORE MAKING ANY CONNECTIONS. FAILURE TO CHECK THAT CONNECTORS ARE DE-ENERGIZED MAY RESULT IN INJURY OR DEATH.

a. Lay out and park the load cables for each phase (A, B, & C) between the PU Tie Output parking stations and the Primary Switching Center (PSC). b. Connect each phase cable to the appropriate phase connection on the Primary Switching Center (PSC). NOTE: 1: For complete set-up of the Primary Switching Center (PSC), refer to USAF TO 35F14-1-1 and USA TM9-6115-725-14&P. NOTE: 2: For Unit Isolation Procedure (any unit) - Plant with PSC, and Unit Re-Installation Procedure – Plant with PSC, refer to Section 5.9, Section 5.9.6.15, and Section 5.9.6.16. c.

Connect each load cables drain wire to the grounding grid.

d. Open the Tie Output connector loadbreak covers on the first PU. e. Connect the Tie Output Cables to the appropriate phase connectors; ensure there are no crossphase connections. f.

Close and lock the Tie Output connector covers.

g. Repeat steps ‘a’ through ‘f’ on each remaining PU. h. Connect the first (A) (B) communication cable to “B” receptacle on first PU. i.

Route the first (A) (B) communication cable to second PU.

j.

Connect the first (A) (B) communication cable to “A” receptacle on second PU.

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k.

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 Connect the second (A) (B) communication cable to “B” receptacle on second PU.

l.

Route the second (A) (B) communication cable to third PU.

m. Connect the second (A) (B) communication cable to “A” receptacle on third PU. n. Connect the third (A) (B) communication cable to “B” receptacle on third PU. o. Route the third (A) (B) communication cable to fourth PU. p. Connect the third (A) (B) communication cable to “A” receptacle on fourth PU. q. Connect the fourth (A) (B) communication cable to “B” receptacle on fourth PU. r.

Leave the loose end of fourth cable loose and capped.

5.6.3.4 SETPOINT VERIFICATION a. Turn on PU DC control power by pushing in on the DC Control Power breaker. b. On each of the five overcurrent relays, verify the settings: (1)

Press the [▲] key to get to the top-level menu “1 REPORT STATUS”.

(2)

Press the [►] key 5 times to display “6 GENERAL SETTINGS”.

(3)

Press the [▼] key to display “6.1 COM SETTINGS”.

(4)

Press the [►] key 2 times to display “6.3 POWER SYSTEM SETTINGS”.

(5)

Press the [▼] key to display “6.3.1 CT RATIO”.

(6)

Verify the “P” and “N” values match Chapter 5.1 Table 5.1.3.4-1 CT Ratio Settings.

(7)

Press the [▲] key 2 times to display “6 GENERAL SETTINGS”.

(8)

Press the [◄] key to display “5 PROTECTION LOGIC USER”.

(9)

Press the [▼] key 3 times to display “5.1.1.1 50TP”.

(10) Verify the 50TP “PU” and “TD” settings in Chapter 5.1 Table 5.1.3.4-2 Instantaneous Trip Settings. In order to edit values, Press the “Edit” key. Select correct value, and press “Edit” again to save changes. Ensure light is off otherwise you can accidentally change value again. (11)

Press the [►] key to display “5.1.1.2 50TN”.

(12)

Verify the “50TN” settings.

(13)

Press the [►] key to display “5.1.1.3”.

(14)

Verify the “50TQ” settings.

(15)

Press the [▲] key to display “5.1.1 50T SETTINGS”.

(16)

Press the [►] key to display “5.1.2 51 SETTINGS”.

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c.

(17)

Press the [▼] key to display “5.1.2.1 51P”.

(18)

Verify the 51P “PU”, “TD”, and “C” settings in Chapter 5.1 Table 5.1.3.4-3 Time Overcurrent Settings.

19)

Press the [►] key to display “5.1.2.2 51N”.

(20)

Verify the 51N settings.

(21)

Press the [▲] key 3 times to display “5 PROTECTION LOGIC USER”.

Use the following procedure to verify the Generator 1 and Generator 2 GSC+ settings:

NOTE:

Refer to the “EMCPII+ Reference Chart”, located on the interior Generator Control Panel Door (Look-up) (1)

Place ECS in the COOLDOWN/STOP position.

(2)

Press SERVICE MODE key to enter service mode. OP1 is showing on the lower display.

(3)

Press SCROLL UP key until “OP3” is showing.

(4)

Press SELECT key. “PE -“ with the first dash flashing is showing.

(5)

Press SCROLL RIGHT key. “PE 1 -“ with the second dash flashing is showing.

(6)

Press SCROLL DOWN key. “PE 13 –“ with the third dash flashing is showing.

(7)

Press SCROLL UP key. “PE 132 –“ with the fourth dash flashing is showing.

(8)

Press SCROLL DOWN key. “PE 1323 –“ with the fifth dash flashing is showing.

(9)

Press SCROLL RIGHT key. “PE13231” with all digits not flashing is showing.

(10) Press ENTER key. “PE PASS” is showing. (11) Press EXIT key. “OP4” is showing. (12) Press SCROLL UP key until “OP5-0” is showing on the lower display. (13) Press SELECT key. “POO1” followed with the value of the setpoint is showing. (14) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing. Use Chapter 5.1 Table 5.1.3.4-4 OP5 Settings for the parameter values to be verified. Repeat until the desired setpoints are verified. (15) Press EXIT key. “OP5-0” is showing on the lower display. (16) Press SCROLL UP key until “OP5-1” is showing. (17) Press SELECT key. (18) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing. Use Chapter 5.1 Table 5.1.3.4-5 OP5-1 Settings for the parameter values to be verified. Repeat until the desired setpoints are verified.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (19) Press EXIT key. “OP5-1” is showing. (20) Press SCROLL UP key. “OP6” is showing. (21) Press SELECT key. (22) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing. Use Chapter 5.1 Table 5.1.3.4-6 OP6 Settings for the parameter values to be verified. Repeat until the desired setpoints are verified. (23) Press EXIT key twice. The display returns to normal. NOTE:

If an incorrect setpoint value is displayed, the value must be changed to match the DPGDS setpoint value as follows: (a)

With the setpoint with the incorrect value showing on the display, press the SELECT key. The incorrect value flashes on the display.

(b)

Press SCROLL UP or SCROLL DOWN key until the correct value appears flashing on the display.

(c)

Press ENTER. The correct value stops flashing on the display.

Press SCROLL UP or SCROLL DOWN key to continue to verify the remaining parameter values. d. Return ECS1 and ECS2 to the OFF/RESET position. (d)

NOTE:

Use up or down keys to change values.

e. At the AVR verify the operation settings using Chapter 5.1 Table 5.1.3.4-7 AVR Parameter/Setpoints: (1)

Open the GCPG1 cabinet door.

(2)

Press the [▼] key to display parameter “90”.

(3)

Press the [◄►] key to display the current value.

(4)

Press the [▲] key to change the value to “0015”. Enables parameter editing.

(5)

Press the [◄►] key to accept change and display the parameter number.

(6)

Press the [▲] key to the next parameter needed to change.

(7)

Press the [◄►] key to display the current value.

(8)

Press the [▲] or [▼] key to change the value.

(9)

Press the [◄►] key to accept change and display the parameter number.

(10) Repeat steps ‘5’ through ‘9’ for the each parameter needing to be changed. (11) When complete, press the [▼] to display parameter “01”.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 Parameters 20, 21, 22, 36, 37, and 38 are displayed but not used.

NOTE:

Parameters 23 to 29, 39 to 49, 59 and 61 to 89 are not displayed and not used. (12) When complete, press the [▼] to display parameter “90”. (13) Press the [◄►] key to display the current value. (14) Press the [▼] key to change the value to “0009”. Disables DVR parameter editing. (15) Press the [◄►] key to accept change and display the parameter number. (16) Press the [▲] key to change to display parameter “01”. (17) Close the GCPG1 cabinet door. (18) Repeat steps ‘1 ‘through ‘16’ for Generator 2.

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PRE-OPERATION CHECKS

Starting from the left rear of the PU and working around the PU in a clockwise direction, perform the checks identified in Chapter 5.1 Table 5.1.3.5-1 Pre-Operation Checklist. (Gen. 1 is on the left and Gen. 2 is on the right): 5.6.3.6

PRE-OPERATION RUN WARNING ENSURE ALL PERSONNEL ARE CLEAR AND THE PU DOORS ARE CLOSED PRIOR TO STARTING A GENERATOR. WARNING HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND ENFORCED. NOISE LEVELS IN EXCESS OF 85 DB EXIST WITHIN AN 88-FOOT RADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR SINGLE HEARING PROTECTION WITHIN 88 FEET OF AN OPERATING DPGDS. WARNING HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND ENFORCED. DURING MAINTENANCE ACTIVITIES WITH THE SIDEDOORS OPEN, NOISE LEVELS IN EXCESS OF 113 DB EXIST WITHIN A 12-FOOT RADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR DOUBLE HEARING PROTECTION WITHIN 12 FEET OF AN OPERATING DPGDS. EXPOSURE MUST BE LIMITED TO UNDER 2.5 HOURS. WARNING BY CLOSING THE FEEDER OR TIE BREAKER, HIGH VOLTAGE WILL BE PRESENT ON THE LOAD CABLES. ENSURE ALL PERSONNEL ARE CLEAR OF ALL LOAD CABLES PRIOR TO CLOSING FEEDER OR TIE BREAKERS.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 TABLE 5.6.3.6-1 PRE-OPERATION RUN INSTRUCTION SEQUENCE (Perform on each PU in the power plant) STEP

-- 60HZ OPERATIONS --

-- 50HZ OPERATIONS --

1

Verify System Mode Switch (SMS) is in MANUAL

2

Verify DC Control Power is on

3

Verify Emergency Stop is pulled out

4① 5

Verify the 60Hz light is on ①

Verify the 50Hz light is on①

Start engine 1 by placing ECS1 in MANUAL

6

Verify the engine accelerates to 1800RPM

Verify the engine accelerates to 1500RPM

7

Adjust the generator frequency to 60Hz using the Frequency Adjust Rheostat (FAR)

Adjust the generator frequency to 50Hz using the Frequency Adjust Rheostat (FAR)

8

Adjust the generator voltage to 4295VAC using the Voltage Adjust Rheostat (VAR)

Adjust the generator voltage to 3915VAC using the Voltage Adjust Rheostat (VAR)

9

Close BCS-G1, toggle the Phase Rotation Test Light switch, verify that light ABC lights, open BCSG1

10

Shutdown engine 1 by placing ECS1 in OFF/RESET

11

Start engine 2 by placing ECS2 in MANUAL

12

Verify the engine accelerates to 1800RPM

Verify the engine accelerates to 1500RPM

13

Adjust the generator frequency to 60Hz using the Frequency Adjust Rheostat (FAR)

Adjust the generator frequency to 50Hz using the Frequency Adjust Rheostat (FAR)

14

Adjust the generator voltage to 4295VAC using the Voltage Adjust Rheostat (VAR)

Adjust the generator voltage to 3915VAC using the Voltage Adjust Rheostat (VAR)

15

Close BCS-G2, toggle the Phase Rotation Test Light switch, verify that light ABC lights, open BCSG2

16

Shutdown engine 2 by placing ECS2 in OFF/RESET ①

If the wrong frequency light is on, open the Master Control Door and change the Frequency Selector Switch (FSS) to the desired frequency.

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ORT SETUP

a. Remove the ORT from its case and set it up on a flat and level surface. b. Remove the mouse from the case and plug it into the mouse (PS2) port on the back of the ORT. c.

If 120VAC power is available, connect the ORT power supply cord to the 120VAC power. The ORT can operate up to three hours on its batteries.

d. Connect one end of the 150-foot patch cable to the ORT networking port on the PU. e. Route the cable from the ORT to the PU and connect the cable to the ORT port. f.

Turn on the ORT.

g. Observe that the ORT boots to the operator’s Overview screen. h. Select the EquipID pop-up screen and enter the necessary information for the units. This includes the Trailer ID number, the Engine ID number, and the Generator ID number for each PU. i.

Select the Oneline pop-up screen and enter the descriptor for the main load connected to the feeders.

h. Return to the Overview pop-up screen.

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CONTROLS SETUP

Complete the switch arrangements according to the following Table, and verify the lamp indicators: NOTE:

Ignore settings for Power Units not being used:

TABLE 5.6.3.8-1 PANEL

PDC CONTROL SWITCH SETUP SWITCH 1ST PU Pushed In DC Power (ON) SMS OFF PRIME GMS POWER PRIME MASTER CONTROL AVRS POWER PANEL MCP 60Hz Light ON①

2ND PU Pushed In (ON) OFF PRIME POWER PRIME POWER

3RD PU Pushed In (ON) OFF PRIME POWER PRIME POWER

4TH PU Pushed In (ON) OFF PRIME POWER PRIME POWER

ON①

ON①

ON①

A② NORMAL OFF All OFF 50/60

B② NORMAL OFF All OFF 50/60

C② NORMAL OFF All OFF 50/60

D② NORMAL OFF All OFF 50/60

Hertz①

Hertz①

Hertz①

Hertz①

Pulled-Out

Pulled-Out

Pulled-Out

Pulled-Out

OFF

OFF

OFF

OFF

Pulled-Out

Pulled-Out

Pulled-Out

Pulled-Out

OFF

OFF

OFF

OFF

USS BSS SSS SSL INSIDE MCP

FSS

GENERATOR CONTROL PANEL GCPG1 GENERATOR CONTROL PANEL GCPG2

Emergency Stop ECS Emergency Stop ECS

① With the SMS in the OFF position, the 50/60Hz lights indicate the position of the Frequency

Selector Switch (FSS). If the wrong light is on, open the door and change the switch position. ② No more than one switch can be in the same position in any multi-PU line-up. With the SMS in

OFF, none of the USI lights will be on and any previously set address on the PU is cleared. 5.6.3.9

PSC RELAY SETTING VERIFICATION

a. Turn on the ORT and log in as administrator using the procedures of PSC Manual (Table 3.3.2-1 DPGDS ORT ADMINISTRATOR LOG-IN PROCEDURE). b. Click on Windows Start button. c.

Select Programs then Accessories then HyperTerminal.

d. Double Click on “Vista.ht” NOTE:

If “vista.ht” does not appear on the menu, refer to the Windows 98 procedure contained in APPENDIX C of S&C instruction sheet 681-515 to create it.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 NOTE:

Use Com 1 communications port on the ORT.

e. Click on “Connect”. NOTE: f.

Do Not Connect the communication cable before completing step “e”. Otherwise Windows NT will search for a new device on the ORT COM port. Connect the communication cable between the ORT to the left (Ways 3 and 4) Overcurrent Relay (OCR).

g. Press “Enter” on the ORT. NOTE:

The overcurrent relay main menu should appear.

h. Select View Menu 1, WAY 3. i.

Select View relay settings.

j.

Verify relay settings according to Table 5.6.3.9-1

NOTE:

Refer to S&C Instruction Sheet 681-515 page 14, PROGRAMMING to change settings.

k. Repeat steps g through I for WAY 4. l. Return to the main menu and test the “Trip Function” of each interrupter using the Test Trip Menu. m. Return to the Main Menu and “Disconnect” using Windows HyperTerminal when desired programming action is complete. n. Disconnect the OCR end of the communication cable. o. Repeat steps e. through l. for the right OCR (Ways 5 and 6). p. Repeat steps e. though m. for each PSC in use. q. Exit Windows HyperTerminal. r. Shut-down the ORT.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 TABLE 5.6.3.9-1 PSC WAY 3,4, or 5 3,4, or 5 3,4, or 5 3,4, or 5 6 6

5.6.4

PSC RELAY SETTINGS

FUNCTION

CABLE SIZE

CURVE

MIN. PICKUP (AMPS)

INST. PICKUP (KAMPS)

TIME DELAY (SEC.)

1/0

TAP

200

1

Off

1/0

TAP

50

0

Off

500 KCM

MAIN

600

1

Off

500 KCM

MAIN

100

0

Off

4/0

TAP

400

0

C (64ms)

4/0

TAP

80

0

C (64ms)

Feeder Feeder Ground Single Output Single Output Ground PSC Interconnect PSC Interconnect Ground

PLANT STARTUP WARNING ONCE THE SYSTEM STATUS LIGHTS TURN GREEN AND THE MSES IS ENABLED, THE PU WILL START. ENSURE PERSONNEL ARE CLEAR OF THE PU. WARNING ONLY ONE PU MAY BE SELECTED TO ANY ONE USS POSITION DURING MULTIPLE PU OPERATIONS. OPERATING WITH MORE THAN ONE UNIT AT THE SAME ID CAUSE UNSAFE AND ERRATIC OPERATIONAL CONDITIONS.

WARNING ALWAYS PAD LOCK THE PSC INTERCONNECT SWITCHES. FAILURE TO DO SO COULD RESULT IN PERSONAL INJURY OR DAMAGE TO EQUIPMENT Starting up a Multi-PU Prime Power Plant in Automatic Mode a. At the Primary Switching Center (PSC), close the associated connection for each PU supplying power to the switchgear and close and pad lock the PSC interconnect switches when using more than one primary switch. b. At the PSC, close the connections between the external switchgears. c.

At the PSC, open all the connections of loads to the PSC.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 NOTE: 1: For complete set-up of the Primary Switching Center (PSC), refer to USAF TO 35F14-1-1 and USA TM9-6115-725-14&P. NOTE: 2: For Unit Isolation Procedure (any unit) - Plant with PSC, and Unit Re-Installation Procedure – Plant with PSC, refer to Section 5.9, Section 5.9.6.15, and Section 5.9.6.16. d. Complete the switch arrangements according to the following Table, and verify the lamp indicators: TABLE 5.6.4-1 PANEL

SWITCH SETUP – AUTOMATIC MODE SWITCH 1ST PU 2ND PU BCS-T Red Target Red Target MASTER CONTROL SMS AUTO③ AUTO③ PANEL MCP USS A B BCS-G1 Red Target Red Target GENERATOR CONTROL PANEL 1 BCS-F1 Red Target Red Target GCPG1 ECS-1 AUTO AUTO BCS-G2 Red Target Red Target GENERATOR CONTROL PANEL 2 BCS-F2 Red Target Red Target GCPG2 ECS-2 AUTO AUTO MSES Enable① Enable① MASTER CONTROL PANEL MCP USI B①, ② A①, ②

3RD PU Red Target

4TH PU Red Target

AUTO③ C Red Target Red Target AUTO Red Target Red Target AUTO

AUTO③ D Red Target Red Target AUTO Red Target Red Target AUTO

Enable①

Enable①

C① , ②

D① , ②

① Hold the MSES in an ENABLE position until the selected USI indicator energizes. The switch

returns to the center position when released. This sets the PU networking address and enables the control and monitoring. ② No more than one of each indicator can be on for multi-PU operations. The light on should match

USS position. The USI light will de-energize after the SMS has been in OFF for 3 seconds. ③ With the SMS in AUTO any generator started, manually or automatically, will automatically

parallel to the bus. To prevent the generator from paralleling to the bus put the generator’s breaker in the Pull-To-Lock position. NOTE:

The automatic economizing feature will shutdown one generator every 3 minutes until the system load is at or below the 360KW/450KVA per generator threshold.

e. At A-unit, observe Generator 1 automatically starts and accelerates to operating voltage and frequency. f.

At A-unit, observe Generator 1 automatically closes to the system bus.

g. At A-unit, observe the Tie breaker automatically closes. h. At B-unit, observe the Tie breaker automatically closes. i.

At C-unit, observe the Tie breaker automatically closes.

j.

At D-unit, observe the Tie breaker automatically closes.

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At A-unit, observe Generator 2 automatically starts and accelerates to operating voltage and frequency.

l.

At A-unit, observe Generator 2 automatically parallels to the system bus.

m. At B-unit, observe Generator 1 automatically starts and accelerates to operating voltage and frequency. n. At B-unit, observe Generator 1 automatically parallels to the system bus. o. At B-unit, observe Generator 2 automatically starts and accelerates to operating voltage and frequency. p. At B-unit, observe Generator 2 automatically parallels to the system bus. q. At C-unit, observe Generator 1 automatically starts and accelerates to operating voltage and frequency. r.

At C-unit, observe Generator 1 automatically parallels to the system bus.

s.

At C-unit, observe Generator 2 automatically starts and accelerates to operating voltage and frequency.

t.

At C-unit, observe Generator 2 automatically parallels to the system bus.

u. At D-unit, observe Generator 1 automatically starts and accelerates to operating voltage and frequency. v.

At D-unit, observe Generator 1 automatically parallels to the system bus.

w. At D-unit, observe Generator 2 automatically starts and accelerates to operating voltage and frequency. x.

At D-unit, observe Generator 2 automatically parallels to the system bus.

y.

At the external switchgear, close all switches/breakers connecting the external switchgear to the load (s).

z.

Ensure generators have assumed load.

aa. Observe the KW, PF and KVAR of each generator at the LCP. Note: If adjustment is needed for KVAR balance, start with the generator that is the furthest from the average KVAR (either too low or too high). Make minor adjustments of the Voltage Adjust Rheostat (VAR) until the KVAR sharing between generators are within +/– 10% of the average plant KVAR load. This adjustment will typically be required only once during initial power plant setup and is intended to compensate for meter variations among generators.

CAUTION Improper adjustment of the VAR can cause a reverse KVAR shutdown of a generator. 5.6.5

PLANT OPERATIONS (AUTOMATIC MODE)

5.6.5.1

PRECAUTIONS AND WARNINGS

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DESCRIPTION

The master controller (the designated “A” unit) will control all connected generators based on the total system KW/KVA load. The controller shuts down one of the generators after 3 minutes should the system load drop below a level where the remaining generator load would not exceed 85% (360kW) if a generator is shutdown. If the load of the remaining generator exceeds 85% (360kW) for one minute, a standby generator is started and paralleled to the bus. A change of system load is recognized by the control system and appropriate action is taken to maintain generator load in the 85% (360 KW/450 KVA) range. The system never automatically shuts down the final generator under normal operating conditions. The shutdown of the final generator must be done following manual operating procedures. The default configuration is Economizing Mode on. The economizing mode can be turned off from the ORT. Through the ORT, the AUTO shut down is disabled but the AUTO start-up remains active to prevent overloading the online generator(s). 5.6.5.3

DEFAULT OPERATING SEQUENCE

Start-Up Sequence: The automatic controls will continuously monitor the system load. As load on the system increases, the controls automatically start and place additional units on line in the following sequence at 1-minute intervals: a. One generator from PU “B” based on lower engine runtime. b. One generator from PU “C” based on lower engine runtime. c.

One generator from PU “D” based on lower engine runtime.

d. Remaining generator from PU “A”. e. Remaining generator from PU “B”. f.

Remaining generator from PU “C”.

g. Remaining generator from PU “D”. Shutdown Sequence: Based on the loading experienced, the controller shuts down generator sets that are not needed. For the purpose of explanation, we will assume that all generator sets are on line following an initial startup. Based on load, the controls shut down generator sets in the following sequence at 3-minute intervals: a. One generator from PU “D” based on higher engine runtime. b. One generator from PU “C” based on higher engine runtime. c.

One generator from PU “B” based on higher engine runtime.

d. One generator from PU “A” based on higher engine runtime. e. Remaining generator from PU “D”.

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Remaining generator from PU “C”.

g. Remaining generator from PU “B”. 5.6.6

POWER PLANT TEARDOWN

5.6.6.1

SHUT DOWN GENERATORS

a. Unload all generators by opening all feeder breakers. This must be done locally from the LCP or ORT. b. Open each BCST locally at the respective MCP. c.

Place all generators in cooldown by placing all SMS switches in OFF.

d. Observe all generator breakers open. e. Open all the switchgear generator supply disconnect switches. f.

Allow all engines to completely cooldown and shutdown (5 minutes).

g. Place all ECS switches in OFF/RESET. h. Pull out the DC Control Power breaker on all PUs. 5.6.6.2

DISCONNECT CABLES WARNING NEVER REMOVE POWER CABLES BY HAND, USE HOT STICK AND HIGH VOLTAGE GLOVES. NEVER TOUCH A HIGH VOLTAGE LEAD OR TERMINAL UNTIL IT HAS BEEN DISCHARGED TO GROUND. FAILURE TO OBSERVE THE WARNING MAY RESULT IN DEATH BY ELECTROCUTION. CAUTION ALLOW ALL OPERATING ENGINES TO SHUT DOWN AND COOL DOWN COMPLETELY.

a. Disconnect the (A)(B) communication cables from between the PUs, Reinstall the communication receptacle covers, and store inside the PUs (one per unit). b. Disconnect the ORT cable and store it in the ORT case. c.

Close and latch the ORT port on the PU.

d. Disconnect all load cables used in operation of the PUs.

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DISCONNECT FUEL LINES

a. Turn all fuel system valves to the off position. b. Disconnect the fuel hose from the PU fuel connection and the fuel supply. c. 5.6.6.4

Drain any fuel from the hoses into an auxiliary fuel supply and store the hoses. DISCONNECT GROUNDING

a.

Remove ground connections from the PU and store with the ground rod.

b.

Disconnect the parking stations from the ground grid.

c.

Remove the parking stations from their operating positions and reinstall them in their transportation locations on the inside of the PU rear side access doors.

5.6.6.5

PREPARE PU FOR TRANSPORTATION

a. Reinstall the four radiator splashguards (PU-810B only). b. Verify DC Control power is off. c.

Close and lock the LCP access doors.

d. Close and lock all PU side doors. 5.6.6.6

FUEL, OIL, AND COOLANT DRAINAGE

The Power Unit may be safely shipped with oil, fuel, and coolant at maximum capacities or less. Draining fluids is not required unless federal, state, or local regulations prohibit shipment with fluids present. Refer to Section 14.3.1.1, Section 13.4.5.5 and Section 6.5.3 for procedures for draining the oil, coolant and fuel liquids respectively.

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CHAPTER 5.7 OPERATING INSTRUCTIONS MEP-PU-810 AND MEP-012 PARALLEL OPERATIONS, MANUAL AND AUTOMATIC MODE TABLE OF CONTENTS SECTION

TITLE

5.7

MEP-PU-810 & MEP-012 PARALLEL OPERATIONS, MANUAL AND AUTOMATIC MODE

135

5.7.1

SAFETY PROCEDURES

135

5.7.2

MEP-PU-810 AND MEP-012 PARALLEL OPERATION DESCRIPTION

135

5.7.3

POSITIONING THE PU

136

5.7.4

INITIAL PLANT SETUP

137

5.7.4.1

GROUNDING

137

5.7.4.2

FUEL MANIFOLD

139

5.7.4.3

DISTRIBUTION AND CONTROL CABLING

140

5.7.4.4

SETPOINT VERIFICATION

142

5.7.4.5

PRE-OPERATION CHECKS

155

5.7.4.6

PRE-OPERATION RUN

157

5.7.4.7

ORT SETUP

159

5.7.4.8

CONTROLS SETUP

160

5.7.5

PLANT STARTUP

161

5.7.5.1

MANUAL MODE

161

5.7.5.1.1

STARTING UP SINGLE OR MULTIPLE PU’S IN MANUAL MODE WITH A MEP-012 POWER PLANT

161

STARTING UP SINGLE OR MULTIPLE MEP-012’S WITH A MEP-PU-810 POWER PLANT IN MANUAL MODE

164

5.7.5.2

AUTOMATIC MODE

165

5.7.5.2.1

STARTING UP SINGLE OR MULTIPLE PU’S IN AUTOMATIC MODE WITH A MEP-012 POWER PLANT 165

5.7.5.1.2

PAGE

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5.7.5.2.2

STARTING UP SINGLE OR MULTIPLE MEP-012’S WITH A PU POWER PLANT IN AUTOMATIC MODE

167

5.7.6

PLANT OPERATIONS

168

5.7.7

POWER PLANT TEARDOWN

168

5.7.7.1

SHUT DOWN GENERATORS

168

5.7.7.2

DISCONNECT CABLES

168

5.7.7.3

DISCONNECT FUEL LINES

169

5.7.7.4

DISCONNECT GROUNDING

169

5.7.7.5

PREPARE PU FOR TRANSPORTATION

169

5.7.7.6

FUEL, OIL, AND COOLANT DRAINAGE

169

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LIST OF FIGURES FIGURE

TITLE

PAGE

FIGURE 5.7.4.1-1

MEP-PU-810A GROUND POINTS

138

FIGURE 5.7.4.1-2

MEP-PU-810B GROUND POINTS

138

FIGURE 5.7.4.2-1

EXTERNAL FUEL SUPPLY

139

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LIST OF TABLES TABLE

TITLE

PAGE

TABLE 5.7.4.4-1

CT RATIO SETTINGS

142

TABLE 5.7.4.4-2

INSTANTANEOUS TRIP SETTINGS

142

TABLE 5.7.4.4-3

TIME OVERCURRENT TRIP SETTINGS

143

TABLE 5.7.4.4-4

OP5-0 SETPOINTS

145

TABLE 5.7.4.4-4

OP5-0 SETPOINTS (CONTINUED)

146

TABLE 5.7.4.4-5

OP5-1 SETPOINTS

148

TABLE 5.7.4.4-5

OP5-1 SETPOINTS (CONTINUED)

149

TABLE 5.7.4.4-5

OP5-1 SETPOINTS (CONTINUED)

150

TABLE 5.7.4.4-6

OP6 SETPOINTS

151

TABLE 5.7.4.4-6

OP6 SETPOINTS (CONTINUED)

152

TABLE 5.7.4.4-7

AVR PARAMETERS/SETPOINTS

153

TABLE 5.7.4.4-7

AVR PARAMETERS/SETPOINTS (CONTINUED)

154

TABLE 5.1.3.5-1

PRE-OPERATION CHECKLIST

155

TABLE 5.1.3.5-1

PRE-OPERATION CHECKLIST (CONTINUED)

156

TABLE 5.7.4.6-1

PRE-OPERATION RUN INSTRUCTION SEQUENCE

158

TABLE 5.7.4.8-1

CONTROL SWITCH SETUP

160

TABLE 5.7.5.1-1

SWITCH SETUP – MANUAL MODE

162

TABLE 5.7.5.1-2

GENERATOR CAPACITIES

163

TABLE 5.7.5.2.1-1

SWITCH SETUP – AUTOMATIC MODE

166

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MEP-PU-810 & MEP-012 PARALLEL OPERATIONS, MANUAL AND AUTOMATIC MODE

5.7.1

SAFETY PROCEDURES

a. Safety precautions must be observed while operating or maintaining the PU. Safety precautions must be observed to ensure that the operator/technician cannot have contact with the following: • • • • • • •

Hot engine parts Hot engine fluids Medium Voltage AC electricity Low Voltage AC electricity Low Voltage DC electricity Rotating Parts High noise levels

b. Minor Troubleshooting can be performed while both engines are running as long as safety precautions are taken. Refer to the appropriate troubleshooting section for recommendations. 5.7.2

MEP-PU-810 AND MEP-012 PARALLEL OPERATION DESCRIPTION The MEP-PU-810 generator is an isochronous generator. It operates at 50 or 60 Hertz for its complete load range of 0-420KW. By design, a single isochronous generator will assume the load on the bus up to its full capacity. To allow multiple isochronous generators to work in parallel Load Share Modules (LSM) are used. Each generator has its own LSM and these are interconnected by load share lines. The LSMs of online generators put a voltage on the load share lines that is sensed by all other LSMs. Each LSM then compares the load share line voltage to its internal load voltage and develops an error signal. This error is then used to raise or lower the KW load carried by that generator until all online generators are sharing the load equally (no error signal). With this type of operation no adjustment to the generator frequency is required to distribute load equally among the generators. This also allows multiple generators, even ones of different capacity, to operate in parallel under all conditions from no-load to full-load. The MEP-012 will be operated as a droop generator. As it is loaded from 0-750KW, its frequency droops by a set ratio. The generator’s frequency adjust potentiometer is then raised to maintain the desired frequency. Operating multiple droop generators together requires the operator to adjust generator frequency potentiometers to distribute the load proportionally among generators. Additionally, the operator must constantly adjust generator frequencies to maintain the required frequency whenever loads are added or shed. Both kinds of generators may be operated together; however, close attention must be paid to the system load and the droop unit’s frequency. The isochronous generator will set system frequency and try to assume its full capacity. This requires the operator to lower the droop unit frequency to transfer the load to the isochronous generator. That unit carries load increases up to the capacity of the droop unit. Additional load above the total capacity of both generators will obviously require an additional generator. Load decreases below the full capacity rating of just the isochronous unit will require the operator to shutdown the droop unit.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 The recommended method of operating MEP-PU-810s and MEP-012s together is to place the MEP-PU-810 generators on the bus and allow them to carry the normal load. When the system load approaches the rated capacity of the MEP-PU-810 generator(s), add MEP-012 generators as required to provide the necessary capacity. As the load drops off, shutdown the MEP-012 generator(s). CAUTION THE MEP-PU-810 WILL TRY TO ASSUME ITS RATED LOAD WHEN PARALLELED WITH ANOTHER GENERATOR THAT IS OPERATING IN DROOP. VOLTAGE AND FREQUENCY ADJUSTMENTS ON THE DROOP PLANT MUST BE USED TO CONTROL THE LOAD SHARING BETWEEN THE PLANT AND THE MEP-PU-810. There may be situations where the recommended method of operation is not ideal. In these situations, understanding the way isochronous and droop generators work and operational experience are useful in achieving a line-up that is best for the application. 5.7.3

POSITIONING THE PU

a. Position the PU in such a way as to allow the plant operator to have full vision of the operator control panels on the unit. b. Level the MEP-PU-810B front to rear with the trailer leveling hand crank. c.

Position the PU to provide a minimum of 10 feet of clearance for maintenance access on all sides of each unit. Ensure that there are no overhead obstructions around the exhaust outlets. WARNING FUEL SPILLAGE CAN OCCUR IF THE POWER UNIT LEVEL IS GREATER THAN + 5 DEGREES.

d. Ensure that the ground is capable of supporting the weight of the PU. The site surface should be as level as possible (+ 5 degrees).

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INITIAL PLANT SETUP

5.7.4.1

GROUNDING WARNING THERE CAN ONLY BE ONE GROUNDING POINT FOR THE PU. WHEN USING A NEUTRAL GROUND RESISTER (NGR), IT MUST USE THE PU GROUND ROD TO AVOID CREATING A GROUND LOOP.

a. Drive an 8-foot ground rod into the earth and should be within 6 feet of the PU and at a location that minimizes the tripping hazard, until only 6 inches (15 cm) protrudes above the surface. b. Repeat step “a” for each PU being used. c.

Connect all of the grounding rods together with a #2 AWG copper conductor creating a central ground grid.

d. Using a #2 AWG copper conductor, secure one end of a ground cable to one of the slotted ground studs on the PU, see Figure 5.7.4.1-1 or Figure 5.7.4.1-3. Secure the other end of the ground cable to the ground rod. e. Repeat step “d” for every PU. f.

Test Ground Resistance using Ground Resistance Test Equipment. Resistance must be 25Ω or less. Refer to Annex H for special equipment required for this task.

g. Remove parking stand plates from their transportation positions inside each rear, side PU door and slide them into their respective operating positions on the sides of the PDC. h. Connect the parking stand ground wires to either of the two chassis ground lugs on the PU.

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GROUND POINT

FIGURE 5.7.4.1-1 NOTE:

GROUND POINT

MEP-PU-810A GROUND POINTS

Connect only one ground point to the ground grid.

GROUND POINT

FIGURE 5.7.4.1-2 NOTE:

GROUND POINT

MEP-PU-810B GROUND POINTS

Connect only one ground point to the ground grid.

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FUEL MANIFOLD WARNING ENSURE THAT THE FUEL LINES ARE PROTECTED FROM ALL ELECTRICAL CABLES AND ARE ROUTED TO MINIMIZE THE POTENTIAL FOR PHYSICAL DAMAGE OR CAUSING A TRIPPING HAZARD.

a. Lay out the fuel hoses between the PU, the fuel manifold, and the fuel bladders to establish the fuel supply system see Figure 5.7.4.2-1. b. Install the external fuel hose for the PU to the Fuel Transfer Pump at the Tow end of the PU. c.

Connect the other end of the fuel hose to the fuel manifold outlets.

d. Connect the 3” hose, with quick-disconnect hose ends, from the fuel manifold to the fuel bladders. e. Connect the fuel manifold ground wire to the ground grid. f.

Open only the appropriate fuel manifold valves (once connected to the PU) to supply fuel to the power units and check for leaks.

FIGURE 5.7.4.2-1

EXTERNAL FUEL SUPPLY

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DISTRIBUTION AND CONTROL CABLING WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT DURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION AND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN LOAD CABLES ARE HANDLED. WARNING VERIFY THAT CONNECTION POINTS ARE DE-ENERGIZED BEFORE MAKING ANY CONNECTIONS. FAILURE TO CHECK CONNECTORS DE-ENERGIZED MAY RESULT IN INJURY OR DEATH.

a. Lay out and park the load cables for each phase (A, B, & C) between the PU Tie Output parking stations and the load. b. Connect each phase cable to the appropriate phase connection on the Primary Switching Center (PSC). NOTE: 1:

For complete set-up of the Primary Switching Center (PSC), refer to USAF TO 35F14-1-1 and USA TM9-6115-725-14&P.

NOTE: 2:

For Unit Isolation Procedure (any unit) - Plant with PSC, and Unit Re-Installation Procedure – Plant with PSC, refer to Section 5.9, Section 5.9.6.15, and Section 5.9.6.16.

c.

Connect each load cables drain wire to the grounding grid.

d. Open the Tie Output connector loadbreak covers on the first PU. e. Connect the Tie Output Cables to the appropriate phase connectors; ensure there are no crossphase connections. f.

Close and lock the Tie Output connector covers.

g. Repeat steps ‘b’ through ‘f’ on each remaining PU. h. Connect the first (A) (B) communication cable to “B” receptacle on first PU.

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Route the first (A) (B) communication cable to second PU.

j.

Connect the first (A) (B) communication cable to “A” receptacle on second PU.

k.

Connect the second (A) (B) communication cable to “B” receptacle on second PU.

l.

Route the second (A) (B) communication cable to second PU.

m. Connect the second (A) (B) communication cable to “A” receptacle on third PU. n. Connect the third (A) (B) communication cable to “B” receptacle on third PU. o. Route the third (A) (B) communication cable to fourth PU. p. Connect the third (A) (B) communication cable to “A” receptacle on fourth PU. q. Connect the fourth (A) (B) communication cable to “B” receptacle on fourth PU. r.

Leave the loose end of fourth cable loose and capped.

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SETPOINT VERIFICATION

a. Turn on the control power by pushing in the DC Control Power breaker. b. On each of the five overcurrent relays, verify the settings: (1)

Press the [▲] key to get to the top-level menu “1 REPORT STATUS”.

(2)

Press the [►] key 5 times to display “6 GENERAL SETTINGS”.

(3)

Press the [▼] key to display “6.1 COM SETTINGS”.

(4)

Press the [►] key 2 times to display “6.3 POWER SYSTEM SETTINGS”.

(5)

Press the [▼] key to display “6.3.1 CT RATIO”. Verify the “P” and “N” values match the following table:

(6)

TABLE 5.7.4.4-1 BREAKER RELAY GENERATOR FEEDER TIE

CT RATIO SETTINGS CT RATIO 100:5 200:5 200:5

“P” VALUE 20 40 40

(7)

Press the [▲] key 2 times to display “6 GENERAL SETTINGS”.

(8)

Press the [◄] key to display “5 PROTECTION LOGIC USER”.

(9)

Press the [▼] key 3 times to display “5.1.1.1 50TP”.

“N” VALUE 20 40 40

(10) Verify the 50TP “PU” and “TD” settings in Table 5.7.4.4-2. In order to edit values, Press the “Edit” key. Select correct value, and press “Edit” again to save changes. Ensure light is off otherwise you can accidentally change value again. TABLE 5.7.4.4-2 BREAKER RELAY GENERATOR FEEDER TIE

INSTANTANEOUS TRIP SETTINGS PHASE NEUTRAL INSTANTANEOUS INSTANTANEOUS TRIP 50TP TRIP 50TN PU TD PU TD 0.0 0m 3.0 0m 7.5 84m 1.25 84m 0.0 0m 0 0m

(11)

Press the [►] key to display “5.1.1.2 50TN”.

(12)

Verify the 50TN settings in Table 5.7.4.4-2.

(13)

Press the [►] key to display “5.1.1.3”.

(14)

Verify the “50TQ” settings

(15)

Press the [▲] key to display “5.1.1 50T SETTINGS”.

(16)

Press the [►] key to display “5.1.2 51 SETTINGS”.

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NEGATIVE SEQUENCE TRIP 50 TQ PU TD 3.0 0m 0 0m 0.0 0m

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (17)

Press the [▼] key to display “5.1.2.1 51P”.

(18)

Verify the 51P “PU”, “TD”, and “C” settings in Table 5.7.4.4-3.

TABLE 5.7.4.4-3 BREAKER RELAY GENERATOR FEEDER TIE

c.

TIME OVERCURRENT TRIP SETTINGS PHASE TIME OVERCURRENT TRIP 51P PU TD C 4.50 0.5 VV2 2.50 1.0 VV2 5.00 2.0 VV2

NEUTRAL TIME OVERCURRENT TRIP 51N PU TD C 1.25 0.5 VV2 1.00 1.0 VV2 1.50 2.0 VV2

(19)

Press the [►] key to display “5.1.2.2 51N”.

(20)

Verify the 51N settings in Table 5.7.4.4-3.

(21)

Press the [▲] key 3 times to display “5 PROTECTION LOGIC USER”.

Use the following procedure to verify the Generator 1 and Generator 2 GSC+ settings in step “d”:

NOTE:

Refer to the “EMCPII+ Reference Chart”, located on the interior Generator Control Panel Door (Look-up) (1)

Place ECS in the COOLDOWN/STOP position.

(2)

Press SERVICE MODE key to enter service mode. OP1 is showing on the lower display.

(3)

Press SCROLL UP key until “OP3” is showing.

(4)

Press SELECT key. “PE -“ with the first dash flashing is showing.

(5)

Press SCROLL RIGHT key. “PE 1 -“ with the second dash flashing is showing.

(6)

Press SCROLL DOWN key. “PE 13 –“ with the third dash flashing is showing.

(7)

Press SCROLL UP key. “PE 132 –“ with the fourth dash flashing is showing.

(8)

Press SCROLL DOWN key. “PE 1323 –“ with the fifth dash flashing is showing.

(9)

Press SCROLL RIGHT key. “PE13231” with all digits not flashing is showing.

(10) Press ENTER key. “PE PASS” is showing. (11) Press EXIT key. “OP4” is showing. (12) Press SCROLL UP key until “OP5-0” is showing on the lower display. (13) Press SELECT key. “POO1” followed with the value of the setpoint is showing. (14) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing. Use Table 5.7.4.4-4 for the parameter values to be verified. Repeat until the desired setpoints are verified. (15) Press EXIT key. “OP5-0” is showing on the lower display.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (16) Press SCROLL UP key until “OP5-1” is showing. (17) Press SELECT key. (18) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing. Use Table 5.7.4.4-5 for the parameter values to be verified. Repeat until the desired setpoints are verified. (19)

Press EXIT key. “OP5-1” is showing.

(20) Press SCROLL UP key until “OP6” is showing. (21) Press SELECT key. (22) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing. Use Table 5.7.4.4-6 OP6 Setpoints for the parameter values to be verified. Repeat until the desired setpoints are verified. (23) Press EXIT Key twice. The display returns to normal. NOTE:

If an incorrect setpoint value is displayed, the value must be changed to match the DPGDS setpoint value as follows: (a)

With the setpoint with the incorrect value showing on the display, press the SELECT key. The incorrect value flashes on the display.

(b)

Press SCROLL UP or SCROLL DOWN key until the correct value appears flashing on the display.

(c)

Press ENTER. The correct value stops flashing on the display.

Press SCROLL UP or SCROLL DOWN key to continue to verify the remaining parameter values. d. At GSCG1 and GSCG2, verify the operation settings using the following table: (d)

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 TABLE 5.7.4.4-4

OP5-0 SETPOINTS

SETPOINTS OP5-0 ENGINE/GENERATOR PROGRAMMING① FACTORY DPGDS SETPOINT-NAME-DESCRIPTIONS RANGE OF VALUES DEFAULT SETPOINT P001 - Fuel Solenoid Type: type of fuel system solenoid used on the genset.

0- ETR fuel solenoid 1- ETS fuel solenoid

0

0

P002 - Units Shown: type of measurement units shown on the GSC+ display.

0-for English units (PSI, ºF) 1-for metric units (kPa, ºC).

0

0

P003 - Shutdown Override For Engine Fault: GSC+ response to a low engine oil pressure or high coolant temperature fault.

0-for engine shutdown 1-for alarm only (shutdown override, no engine shutdown).

0

0

P004 - Shutdown Override For Sensor Fault: GSC+ response to a diagnostic fault with the engine oil pressure sensor, coolant temperature sensor, oil temperature sensor, sensor power supply or coolant loss sensor.

0-for alarm only shutdown override, no engine shutdown). 1-for engine shutdown.

0

0

P005 - Coolant Loss Sensor Installed: tells whether or not the optional engine coolant loss sensor is installed on the genset.

0-for gensets without a coolant loss sensor 1-for gensets with coolant loss sensor

0

1

P006 - Shutdown Override For Coolant Loss Fault: GSC+ response to an engine coolant loss fault.

0-for engine shutdown. 1-for alarm only (shutdown override, no engine shutdown).

0

0

P007 - System Voltage, 24 Or 32 Volts: system voltage (battery voltage) of the genset.

24 or 32.

24

24

P008 - This setpoint is not currently being used by the GSC+ and cannot be programmed.

N/A

N/A

N/A

P009 - Number Of Ring Gear Teeth: number of teeth on the ring gear of the engine. Used by the GSC+ to determine engine speed.

95 to 350 teeth in increments of one tooth.

136 teeth

136 teeth

P010 - Engine Overspeed: engine speed used by the GSC+ to declare that an engine overspeed fault exists. The engine overspeed setpoint (for all 60 Hz applications) is 1.18 times the rated speed.

500 to 4330 rpm in increments of 10 rpm.

2120 rpm

2120 rpm

P011 - Crank Terminate Speed: engine speed used by the GSC+ to disengage the starting motor during engine cranking.

100 to 1000 rpm in increments of 10 rpm.

400 rpm

400 rpm

P012 - Oil Step Speed: engine speed used by the GSC+ for distinguishing between rated speed and idle speed when a low oil pressure fault exists.

400 to 1800 rpm in increments of 10 rpm.

1350 rpm

1350 rpm

P013② - Low Oil Pressure Shutdown At Rated Speed: oil pressure used by the GSC+ to declare that a low oil pressure shutdown fault exists with engine at rated speed (the engine speed must have exceeded the oil step speed for nine seconds).

5 to 61PSI (34 to 420kPa) in increments of 1

30 PSI (205 kPa)

30 PSI (205 kPa)

P014② - Low Oil Pressure Shutdown At Idle Speed: oil pressure used by the GSC+ to declare that a low oil pressure shutdown fault exists with the engine at idle speed (the engine must have been running for at least 9 seconds and the engine speed must be less than oil step speed).

20 to 336kPa (3 to 49PSI) in increments of 1

10 PSI (70 kPa)

10 PSI (70 kPa)

P015③ - High Water Temperature Shutdown: coolant temperature used by the GSC+ to declare a high coolant temperature shutdown fault exists (after a 10 second delay).

185 to 253ºF (85 to 123ºC) in increments of 1

225ºF (107ºC)

225ºF (107ºC)

P016 - Low Water Temperature Alarm: coolant temperature used by the GSC+ to declare that a low coolant temperature alarm fault exists (after a 2 second delay).

32 to 97ºF (0 to 36ºC) in increments of 1

70ºF (21ºC)

70ºF (21ºC)

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 TABLE 5.7.4.4-4

OP5-0 SETPOINTS (CONTINUED)

SETPOINTS OP5-0 ENGINE/GENERATOR PROGRAMMING① FACTORY SETPOINT-NAME-DESCRIPTIONS RANGE OF VALUES DEFAULT

DPGDS SETPOINT

P017 - Total Cycle Crank Time: cycle crank time used by the 5 to 120 seconds in increments of 1 GSC+ to declare that an overcrank fault exists. second.

90 seconds

90 seconds

P018 - Cycle Crank Time: amount of time the GSC+ cranks and then rests the starting motor during a single crank cycle.

10 seconds

10 seconds

5 minutes

5 minutes

700, 150, 300, 500, 600, 750, 3.0k, 4.5k, 5.20k, 5.25k, 9.0k, 15.0k, 18.0k, 30.0k

700

5.20k

75, 100, 150, 200, 300, 400, 600, 800, 1000, 1200, 1500, 2000, 2500, 3000, and 4000A

600A

100A

01

01 (Gen 1) 02 (Gen 2)

5 to 60 seconds in increments of 1 second.

P019 - Cooldown Time: amount of time the GSC+ allows the 0 to 30 minutes in increments of 1 engine to run after a normal shutdown is initiated. minute. P020④ - AC Voltage: nominal AC voltage of the generator. The GSC+ measures the AC voltage and shows it on the display. P021 - AC Current Full Scale: nominal full scale AC current of the generator. AC current full scale is equal to the ratio of the external current transformers in the generator housing. P022⑤ - GSC+ Engine Number: informs other devices on the CAT Data Link of the engine number for the GSC+.

01 through 08

SETPOINTS - OP5-0-ENGINE/GENERATOR PROGRAMMING① RANGE OF FACTORY 60HZ 50HZ SETPOINT-NAME-DESCRIPTIONS DEFAULT SETPOINT SETPOINT VALUES P023 - Engine Type: identifies the engine as a mechanical unit injector (MUI) diesel, spark ignited (gas), or electronic unit injector (EUI) diesel engine.

0 - MUI diesel 1 - Gas 2 - EUI diesel

P024 - Crank Time Delay: amount of time the GSC+ delays activation of the fuel control relay (FCR) during a crank cycle. This setpoint is for Gas engines only. The P024 setpoint only functions when the P023 setpoint is set to 1 (gas engine).

0 to 20 seconds in increments of 1 second.

0 - for gensets without an oil P025 - Oil Temperature Sensor Installed: tells temperature sensor whether or not the optional engine oil temperature 1 - for gensets with an oil sensor is installed on the genset. temperature sensor P026 - High Oil Temperature Shutdown: oil temperature used by the GSC+ to declare a high 185 to 253ºF (85 to 123ºC) in increments of 1 oil temperature shutdown fault exists (after a 10 second delay). Refer to the panel model number. 0 - for alarm only (shutdown override, P027 - Shutdown Override For High Oil Temperature Fault: GSC+ response to an engine no engine shutdown). high oil temperature fault. 1 - for engine shutdown. P028 - Nameplate Voltage: rated voltage of the generator. This setpoint is used for protective relaying functions. P029 - Nameplate Current: rated current output of the generator.

0

2

2

5 Seconds

5 Seconds

5 Seconds

0

0

0

225ºF (107ºC)

225ºF (107ºC) 225ºF (107ºC)

0

0

0

100 to 25kV in increments of 1

480V

4160V

3800V

0 to 4000 A in increments of 1

600A

80A

73A

400kW

420kW

350kW

60Hz

60Hz

50Hz

0

0

0

4

4

4

P030 - Nameplate Power: rated power capability 0 through 10MW in increments of of the generator. 1kW. P031 - Rated Frequency: nominal frequency 50 or 60Hz rating of genset. P032 - Connection Configuration Of Generator: 0 - wye wye or delta configuration of generator. 1 - delta P033 - Number Of Generator Poles. 0 through 254 in increments of 2.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 ①

The setpoints (stored or being programmed) must match the specified DPGDS setpoints.

② When oil pressure drops to within 5PSI (34kPa) of the P013 or P014 setpoint, a low oil pressure alarm is issued by the GSC+. ③ When coolant temperature rises to within 11ºF (6ºC) of the P015 setpoint, a high coolant temperature alarm is issued by the GSC+. ④ The values other than the default (700V) are for switchgear applications and require the use of external potential transformers and the removal of the AC voltage range jumper located in the relay module. The DPGDS unit is factory configured for the 5.20 K value. See the Caterpillar Electronic Modular Control Panel II+ manual topic AC Voltage Range Selection in the Testing and Adjusting section. ⑤ After setpoint P022 is reprogrammed, the GSC+ must be power cycled (powered down and then powered up)

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 TABLE 5.7.4.4-5

OP5-1 SETPOINTS

SETPOINTS OP5-1 PROTECTIVE RELAYING PROGRAMMING① FACTORY 60HZ 50HZ SETPOINT-NAME-DESCRIPTION RANGE OF VALUES DEFAULT SETPOINT SETPOINT P101 - Generator Overvoltage Alarm Enable: the 0 - disabled GSC+ enables or disables the generator 1 - enabled overvoltage alarm function. P102 - Generator Overvoltage Alarm Threshold: voltage the GSC+ uses to issue an overvoltage alarm. P103 - Generator Overvoltage Alarm Time Delay: amount of time the GSC+ waits before issuing an overvoltage alarm.

100 to 125% of nameplate voltage in increments of 1%. 0 through 120 seconds② in increments of 1

P104 - Generator Overvoltage Shutdown Enable: 0 - disabled the GSC+ enables or disables the generator 1 - enabled overvoltage shutdown function. P105 - Generator Overvoltage Shutdown Threshold: voltage the GSC+ uses to issue an overvoltage shutdown.

100 to 125% of nameplate voltage in increments of 1%.

P106 - Generator Overvoltage Shutdown Time Delay: amount of time the GSC+ waits before issuing an overvoltage shutdown. P107 - Generator Undervoltage Alarm Enable: the GSC+ enables or disables the generator undervoltage alarm function. P108 - Generator Undervoltage Alarm Threshold: voltage the GSC+ uses to issue an undervoltage alarm.

0 through 120 seconds② in increments of 1

P109 - Generator Undervoltage Alarm Time Delay: amount of time the GSC+ waits before issuing an undervoltage alarm.

0 through 120 seconds② in increments of 1

P110 - Generator Undervoltage Shutdown Enable: the GSC+ enables or disables the generator undervoltage shutdown function.

0 - disabled 1 - enabled

P111 - Generator Undervoltage Shutdown Threshold: voltage the GSC+ uses to issue an undervoltage shutdown. P112 - Generator Undervoltage Shutdown Time Delay: amount of time the GSC+ waits before issuing an undervoltage shutdown. P113 - Generator Overfrequency Alarm Enable: the GSC+ enables or disables the generator overfrequency alarm function.

0 - disabled 1 - enabled 60 to 100% of nameplate voltage in increments of 1%.

60 through 100% of rated voltage in increments of 1%. 0 through 120 seconds② in increments of 1 0 - disabled 1 - enabled

P114 - Generator Overfrequency Alarm Threshold: frequency the GSC+ uses to issue an overfrequency alarm.

50-60Hz, for 50Hz Gen 60-70Hz, for 60Hz Gen 400-480, for 400Hz Gen

P115 - Generator Overfrequency Alarm Time Delay: amount of time the GSC+ waits before issuing an overfrequency alarm. P116 - Generator Overfrequency Shutdown Enable: the GSC+ enables or disables the generator overfrequency shutdown function.

0 through 120 seconds② in increments of 1

P117 - Generator Overfrequency Shutdown Threshold: frequency the GSC+ uses to issue an overfrequency shutdown.

50-60Hz, for 50Hz Gen 60-70Hz, for 60Hz Gen 400-480, for 400Hz Gen

0 - disabled 1 - enabled

5-148

1

1

1

105%

105%

105%

10 seconds

10 seconds

10 seconds

1

1

1

110%

110%

110%

10 seconds

10 seconds

10 seconds

1

1

1

90%

90%

90%

10 seconds

10 seconds

10 seconds

1

1

1

85%

85%

85%

15 seconds

03 seconds

03 seconds

1

1

1

53Hz 63Hz 422Hz

63 Hz

53 Hz

10 seconds

10 seconds

10 seconds

1

1

1

55Hz 66Hz 440Hz

66Hz

55Hz

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 TABLE 5.7.4.4-5

OP5-1 SETPOINTS (CONTINUED)

SETPOINTS OP5-1 PROTECTIVE RELAYING PROGRAMMING① FACTORY 60HZ SETPOINT-NAME-DESCRIPTION RANGE OF VALUES DEFAULT SETPOINT P118 - Generator Overfrequency Shutdown Time Delay: amount of time the GSC+ waits before issuing an overfrequency shutdown.

0 through 120 seconds② in increments of 1

P119 - Generator Underfrequency Alarm Enable: the GSC+ enables or disables the generator underfrequency alarm function.

0 - disabled 1 - enabled

P120 - Generator Underfrequency Alarm Threshold: frequency the GSC+ uses to issue an underfrequency alarm.

30-50Hz, for 50Hz Gen 36-60Hz, for 60Hz Gen 240-400, for 400Hz Gen

P121 - Generator Underfrequency Alarm Time Delay: amount of time the GSC+ waits before issuing an underfrequency alarm. P122 - Generator Underfrequency Shutdown Enable: the GSC+ enables or disables the generator underfrequency shutdown function.

0 through 120 seconds② in increments of 1

P123 - Generator Underfrequency Shutdown Threshold: frequency the GSC+ uses to issue an underfrequency shutdown.

30-50Hz, for 50Hz Gen 36-60Hz, for 60Hz Gen 240-400, for 400Hz Gen

P124 - Generator Underfrequency Shutdown Time Delay: amount of time the GSC+ waits before issuing an underfrequency shutdown. P125 - Generator Reverse Power Shutdown Enable: the GSC+ enables or disables the generator reverse power shutdown function. P126 - Generator Reverse Power Shutdown Threshold: level of reverse power the GSC+ uses to issue a reverse power shutdown.

0 through 120 seconds② in increments of 1

P127 - Generator Reverse Power Shutdown Time Delay: amount of time the GSC+ waits before issuing a reverse power shutdown.

0 through 30 seconds② in increments of 1

P128 - Generator Overcurrent Alarm Enable: the GSC+ enables or disables the overcurrent alarm.

0 - disabled 1 - enabled

P129 - Generator Phase Overcurrent Alarm Threshold: level of current the GSC+ uses to issue a phase overcurrent alarm. P130 - Generator Phase Overcurrent Alarm Time Delay: amount of time the GSC+ waits before issuing a phase overcurrent alarm. P131 - Generator Total Overcurrent Alarm Threshold: level of current the GSC+ uses to issue a total overcurrent alarm. P132 - Generator Total Overcurrent Alarm Time Delay: amount of time the GSC+ waits before issuing a total overcurrent alarm.

10 seconds

10 seconds

10 seconds

1

1

1

48Hz 57Hz 378Hz

57Hz

48Hz

10 seconds

10 seconds

10 seconds

1

1

1

45Hz 54Hz 360Hz

54Hz

45Hz

15 seconds

03 seconds

03 seconds

1

1

1

15%

4%

4%

10 seconds

4 seconds

4 seconds

1

1

1

100 through 160% of nameplate current in increments of 5%

105%

150%

150%

0 through 250 seconds② in increments of 1

0 seconds

0 seconds

0 seconds

100 through 160% of three times nameplate current in increments of 5%

105%

150%.

150%

0 through 250 seconds② in increments of 1

0 seconds

0 seconds

0 seconds

1

1

1

110%

150%

150%

0 seconds

10 seconds

10 seconds

0 - disabled 1 - enabled

0 - disabled 1 - enabled 0 through 20% of rated power in increments of 1%.

P133 – Generator Overcurrent Shutdown Enable: 0 – disabled the GSC+ enables or disables the overcurrent 1 – enabled shutdown. P134 – Generator Phase Overcurrent Shutdown 100 through 160% in increments of 5% Threshold: level of current the GSC+ uses to issue a phase overcurrent shutdown. P135 – Generator Phase Overcurrent Shutdown Time Delay: amount of time the GSC+ waits before issuing a phase overcurrent shutdown.

50HZ SETPOINT

0 through 250 seconds② in increments of 1

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OP5-1 SETPOINTS (CONTINUED)

SETPOINTS OP5-1 PROTECTIVE RELAYING PROGRAMMING① FACTORY 60HZ SETPOINT-NAME-DESCRIPTION RANGE OF VALUES DEFAULT SETPOINT P136 - Generator Total Overcurrent Shutdown Threshold: level of current the GSC+ uses to issue a total overcurrent shutdown.

100 through 160% of three times nameplate current in increments of 5%

P137 - Generator Total Overcurrent Shutdown Time Delay: amount of time the GSC+ waits before issuing a total overcurrent shutdown.

0 through 250 seconds② in increments of 1

P138 - KW Level Relay Enable : the GSC+ enables or disables the kW level relay function.

0 - disabled 1 - enabled

P139 - KW Level Relay Threshold: level of power the GSC+ uses to activate the kW level relay function. P140 - KW Level Relay Time Delay: amount of time the GSC+ waits before activating the kW level relay function. P141 - KW Level Relay Disengage Threshold: level of power the GSC+ uses to deactivate the kW level relay function. P142 - KW Level Relay Disengage Time Delay: amount of time the GSC+ waits before deactivating the kW level relay function.

0 through 110% of nameplate power in increments of 1% 0 through 120 seconds② in increments of 1 0 through 110% of nameplate power in increments of 1%. 0 through 120 seconds② in increments of 1

①

The setpoints are programmed at the factory to the default value.

②

When programmed to 0 seconds, the actual time is from 0.5 to 1.0 seconds.

5-150

50HZ SETPOINT

110%

150%.

150%

0 seconds

10 seconds

10 seconds

1

1

1

105%

105%

105%

0 seconds

0 seconds

0 seconds

100%

100%

100%

10 seconds

10 seconds

10 seconds

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254

TABLE 5.7.4.4-6

OP6 SETPOINTS SETPOINTS OP6 SPARE INPUT/OUTPUT PROGRAMMING

SETPOINT-NAME-DESCRIPTIONS

RANGE OF VALUES

FACTORY DPGDS DEFAULT SETPOINT

SP01 - Spare Input 1 Active State. Input state used by the GSC+ to declare a SP1 fault exists.

0-active low 1-active high

0

0

SP02 - Spare Input 1 Response: GSC+ response to a SP1 fault.

0-shutdown 1-alarm

0

0

SP03 - Spare Input 1 Time Delay: Amount of time the GSC+ waits before responding to a SP1 fault.

0 - 250 seconds in increments of 1

0 seconds

1 second

0

1

0

0

0 seconds

0 seconds

0

0

0

0

0 seconds

0 seconds

SP04 - Spare Input 2 Active State. Input state used by the GSC+ to declare a SP2 fault exists. SP05 - Spare Input 2 Response: GSC+ response to a SP2 fault. SP06 - Spare Input 2 Time Delay: Amount of time the GSC+ waits before responding to a SP2 fault. SP07 - Spare Input 3 Active State. Input state used by the GSC+ to declare a SP3 fault exists. SP08 - Spare Input 3 Response: GSC+ response to a SP3 fault.

0-active low 1-active high 0-shutdown 1-alarm 0 - 250 seconds in increments of 1 0-active low 1-active high 0-shutdown 1-alarm

SP09 - Spare Input 3 Time Delay: Amount of time the GSC+ waits before responding to a SP3 fault.

0 - 250 seconds in increments of 1

SP10 - Spare Input 4 Active State. Input state used by the GSC+ to declare a SP4 fault exists.

0-active low 1-active high

0

0

SP11 - Spare Input 4 Response: GSC+ response to a SP4 fault.

0-shutdown 1-alarm

0

0

SP12 - Spare Input 4 Time Delay: Amount of time the GSC+ waits before responding to a SP4 fault.

0 - 250 seconds in increments of 1

0 seconds

0 seconds

SP13 - Spare Output Response: GSC+ response to the spare output trigger condition.

0-active low 1-active high

0

0

8

8

1

1

0-unused 1-active SP1 fault② 2-active SP2 fault② 3-active SP3 fault② SP14 - Spare Output Trigger Condition: The condition used by the GSC+ to trigger the spare output response

4-active SP4 fault② 5-any combination of active SP faults② 6-any active shutdown 7-any active alarm or shutdown 8-cooldown mode 9-coolant loss mode②

10-high oil temp fault② 11-CCM control SP15 – Spare Relay Output Response: GSC+ response to the 0-relay inactive when triggered spare relay trigger condition. 1-relay active when triggered

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 TABLE 5.7.4.4-6

OP6 SETPOINTS (CONTINUED) SETPOINTS OP6 SPARE INPUT/OUTPUT PROGRAMMING

SETPOINT-NAME-DESCRIPTIONS

RANGE OF VALUES

FACTORY DPGDS DEFAULT SETPOINT

0-unused 1-active SP1 fault② 2-active SP2 fault② 3-active SP3 fault② SP16 - Spare Relay Output Trigger Condition: The condition used by the GSC+ to trigger the spare relay.

4-active SP4 fault② 5-any combination of active SP faults② 6-any active shutdown 7-any active alarm or shutdown 8-cooldown mode

8

1

0

6

Battle Short mode.

0

0 Battleshort③

Not in 60 Hz mode.

0

9-coolant loss mode② 10-high oil temp fault② 11-CCM control 0-unused 1-active SP1 fault② 2-active SP2 fault② 3-active SP3 fault② SP17 - Spare Indicator 1 Trigger Condition: The condition used by the GSC+ to trigger spare indicator①.

4-active SP4 fault② 5-any combination of active SP1, SP2, SP3 or SP4 faults② 6-Coolant loss fault② 7-high oil temperature fault②

SP18 - Spare Indicator 2 Trigger Condition: The condition used by the GSC+ to trigger spare indicator②. SP19 - Spare Indicator 3 Trigger Condition: The condition used by the GSC+ to trigger spare indicator③.

① The setpoints are programmed at the factory to the default value. ② Either alarm or shutdown faults are valid trigger conditions ③ Battleshort and 50Hz Mode are unique features to DPGDS for spare indicators 2 and 3.

e. Return ECS1 and ECS2 to the OFF/RESET position. NOTE: f.

Use up or down keys to change values. At the AVR verify the operation settings using Table 5.7.4.4-7: (1)

Open the GCPG1 cabinet door.

(2)

Press the [▼] key to display parameter “90”.

5-152

0 In 50Hz Mode③

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (3)

Press the [◄►] key to display the current value.

(4)

Press the [▲] key to change the value to “0015”. Enables parameter editing.

(5)

Press the [◄►] key to accept change and display the parameter number.

(6)

Press the [▲] key to the next parameter needed to change.

(7)

Press the [◄►] key to display the current value.

(8)

Press the [▲] or [▼] key to change the value.

(9)

Press the [◄►] key to accept change and display the parameter number.

(10) Repeat steps ‘5’ through ‘9’ for the each parameter needing to be changed. (11) When complete, press the [▼] to display parameter “01”. NOTE:

Parameters 20, 21, 22, 36, 37, and 38 are displayed but not used.

NOTE:

Parameters 23 to 29, 39 to 49, 59 and 61 to 89 are not displayed and not used.

TABLE 5.7.4.4-7

AVR PARAMETERS/SETPOINTS DPGDS SETPOINTS

DPGDS AVR PARAMETERS PARAMETER 01 02 03 04

TITLE Generator Output Voltage Ratio of Output Voltage To Sensing Voltage Generator Type Rated Generator Output Current

TYPE

UNITS

RANGE OF VALUES

DEFAULT VALUE

60HZ OPS

50HZ OPS

Program

Volts

0080-9999

480①

4160

3800

001.0-100.0

001.0

17.3

17.3

Program Program Program

Amps

0000-0004 0000-9999

0004 0600

4 80

4 73

Program

Volts

01.00-05.00

05.00

4.00

3.66

06 07 08

CT Voltage At Rated Generator Current Knee Frequency Decreasing Volts/Hz Slope I Decreasing Volts/Hz Slope 2

Program Program Program

Hz Volts/Hz Volts/Hz

045.0-065.0 001.0-010.0 001.0-010.0

050.0 002.0 002.0

59.8 2.0 2.0

49.8 2.0 2.0

09 10 11 12 13 14

Minimum Voltage Under Frequency Point Overvoltage Trip Point Overvoltage Trip Time Under Voltage Trip Point Under Voltage Trip Time

Program Program Program Program Program Program

% Hz % Seconds % Seconds

050.0 025.0 014.0 0002 0060 0030

50.0 25.0 125.0 5 75 30

50.0 25.0 125.0 5 75 30

15

Voltage Gain (IR Compensation)

Program

%

050.0-100.0 020.0-040.0 0105-0140 0002-0030 0060-0095 0030-0120 000.0-0 10.0

0000

0

0

Integral Gain

Program

001.0-020.0

006.0

6.0

6.0

Proportional Gain

Program

001.0-020.0

005.0

5.0

5.0

Program

0000,0001

0000

0000

0000

001.0-010.0

002.0

2.0

2.0

05②

16⑤ 17⑥ 18 19

Single Phase Sensing Select (0=three phase, 1=single phase) Diode Monitor Trip Point

Program

Amps

5-153

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 TABLE 5.7.4.4-7

AVR PARAMETERS/SETPOINTS (CONTINUED) DPGDS SETPOINTS

DPGDS AVR PARAMETERS TYPE

UNITS

RANGE OF VALUES

Droop Percentage

Program

%

000.0-010.0

0000

3

3

31③

pf/Kvar Select (0=pf, 1=Kvar)

Program

0000, 0001

0000

0

0

32③

Pf Reference

Program

00.60-01.10

01.00

0.8

0.8

33③

KVAR Reference

Program

Per Unit

00.00-01.00

0000

0.10

0.10

34③

Reverse Power Trip Point

Program

%

000.0-020.0

010.0

15

15

35③ 50 51 52

Reverse Power Trip Time

Program

Seconds

000.0-020.0

010.0

5

5

View View View

Hz Volts Amps

View

Amps

View View

Amps Amps

View

KW

0009

0009

0000 0000

0000 0000

PARAMETER 30

53 54 55

TITLE

Generator Output Frequency Generator Output Voltage Generator Output Current Generator Reactive Output Current

56③

Generator Real Current Exciter Field Current Three Phase Kilowatts (KB and later)

57③

Power Factor

View

Three Phase Kvar (KE and later)

View

58③, ④ 60 90

Hours Password

91 92 93 94 96

Software ID Latest Fault Previous Fault Fault Clear Shutdown Fault Reset

View Program

Hours

DEFAULT VALUE

60HZ OPS

50HZ OPS

0000-9999

View View View View Switch

0000 0000

①- Default value for output voltage is different depending on regulator sensing voltage. If the regulator is

designed for 120 volts sensing, then the default output voltage is 4160 volts. All other sensing types have the default output voltage set to 480 volts. ②- Digital Voltage Regulators with earlier software (KD and earlier) have 1 less digit to the right of the

decimal point. ③- Optional feature. ④- New parameter on serial number prefix KE and later Digital Voltage Regulators. ⑤- Previous range of 0001-099.9 and default value of 002.0

⑥-Previous range of 0001-099.9 and default value of 002.0 (12) When complete, press the [▼] to display parameter “90”. (13) Press the [◄►] key to display the current value. (14) Press the [▼] key to change the value to “0009”. Disables DVR parameter editing. (15) Press the [◄►] key to accept change and display the parameter number.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (16) Press the [▲] key to change to display parameter “01”. (17) Close the GCPG1 cabinet door. (18) Repeat steps ‘1 ‘through ‘16’ for Generator 2. 5.7.4.5

PRE-OPERATION CHECKS

Starting from the left rear of the PU and working around the PU in a clockwise direction, perform the following checks (Gen. 1 is on the left and Gen. 2 is on the right): TABLE 5.1.3.5-1 PRE-OPERATION CHECKLIST ITEM ACTION REQUIRED NUMBER Ensure the parking brake is set. Rotate the crank in a clockwise rotation 1 (PU-810 A) to set. Ensure that the wheels are properly chocked or the Spring Brakes are 1 (PU-810-B) set by opening the petcock on the air tank and evacuating all the air. Check the ground connection. 2 Check that the ORT communication cable is connected properly. 3 Ensure the feeder output cables, if used, are properly connected and 4 that the concentric neutrals are connected to ground. Ensure that the feeder output cover is secured. (Locked) 5 Check Parking Stands for proper mounting and connection. 6 Check the two 120-Volt auxiliary duplex receptacles and the 60 amp 3 7 phase receptacle cables are securely connected or the covers are properly installed / closed. Open the left rear PU side access door and inspect the area for cleanliness, loose electrical connections, loose hardware, and leaks 8 around the oil filter and lines. Check for signs of heat damage or other abnormalities. Check all high voltage panels for security Ensure that the battery charger voltmeter displays (24 VDC), is plugged into the battery charger receptacle, and that all circuit breakers are 9 turned on. Return to this step after a generator breaker is closed to ensure charger is supplying current to the batteries. Visually inspect the air intake duct for obstructions or foreign objects. 10 Close the left rear PU door. 11 Open the left front PU side access door and inspect the area for 12 cleanliness, loose electrical connections, loose hardware, leaks around oil and fuel lines, signs of heat damage or other abnormalities. Drain the crankcase vent reservoir (fumes box) into a proper container. 13 If necessary, open the Primary Fuel Filter Drain Valve and drain any 14 accumulated water into an appropriate container. Check oil level for Generator 1. 15 Ensure fuel shutoff valve is in the open position (valve handle is parallel 16 to the fuel hose). Close the left front PU side access door. 17 Remove the Gen. 1 splashguard (PU-810 B). 18 Check the fuel tank, hydraulic tank, and radiator fill tank for signs of 19 damage or leaks. Check fuel level with the built-in dipstick, coolant levels through the 20 coolant sightglass and hydraulic fluid levels with the sightglass.

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CHECK COMPLETED

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 TABLE 5.1.3.5-1 PRE-OPERATION CHECKLIST (CONTINUED) ITEM ACTION REQUIRED NUMBER Check the fuel transfer pump assembly for mounting security and leaks. Place the fuel transfer mode switch in “A” (automatic mode) position. 21 Place the fuel transfer pump power switch in the G1 position. Check the condition of the batteries for cleanliness and signs of damage. Check the battery electrical connections for tightness and 22 signs of corrosion. Check to ensure that the battery isolation switch is in the OFF 23 position.① Remove the Gen. 2 splashguard (PU-810B only). 24 Open the PU right side front access door and inspect the area for cleanliness, loose electrical connections, loose hardware, leaks around 25 oil and fuel lines, signs of heat damage or other abnormalities. Check oil level for Generator 2. 26 Drain the crankcase vent reservoir (fumes box) into a proper container. 27 If necessary open the Primary Fuel Filter Drain Valve and drain any 28 water accumulated into an appropriate container Ensure manual fuel cutoff valve is in the open position; valve handle is 29 parallel to the fuel hose. Close the right front PU side access door. 30 Open the right rear PU side access door and inspect the area for cleanliness, loose electrical connections, loose hardware, leaks, around 31 the oil filter, and for signs of heat damage or other abnormalities. Check all high voltage access panels for security. Visually inspect the air intake for obstructions or foreign objects. 32 Ensure that the battery charger voltmeter displays (24 VDC), is plugged into the battery charger receptacle, and that all circuit breakers are 33 turned on. Return to this step after a generator breaker is closed to ensure charger is supplying current to the batteries. Check Parking Stands for proper mounting and connection. 34 Check with a flashlight between generator sets G1 and G2 for leaks, 35 loose hardware, and any other potential problem. Close the right rear PU side access door. 36 Ensure the tie output cables are properly connected and that the 37 concentric neutrals are connected to ground. Ensure that the tie-output cover is secured. (Locked) 38 Check PU equipment grounds for proper connection. 39 Check that the PU interconnect control cable is properly connected to 40 the “B” connector. Inspect the exterior fuel system for proper connection, leaks, and 41 availability of fuel. Open all three PDC doors. Check for damage, loose connections, and 42 foreign objects. Position the 50/60 Hz selector switch in the proper mode. 43 Close all PDC doors. 44 ①

CHECK COMPLETED

The Battery Parallel Switch should be left in the OFF position except in extreme conditions where the additional DC power is required to crank an engine. Once started, return the switch to the OFF position.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 5.7.4.6

PRE-OPERATION RUN WARNING ENSURE ALL PERSONNEL ARE CLEAR AND THE PU DOORS ARE CLOSED PRIOR TO STARTING A GENERATOR. WARNING HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND ENFORCED. NOISE LEVELS IN EXCESS OF 85 DB EXIST WITHIN AN 88-FOOT RADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR SINGLE HEARING PROTECTION WITHIN 88 FEET OF AN OPERATING DPGDS. WARNING HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND ENFORCED. DURING MAINTENANCE ACTIVITIES WITH THE SIDEDOORS OPEN, NOISE LEVELS IN EXCESS OF 113 DB EXIST WITHIN A 12-FOOT RADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR DOUBLE HEARING PROTECTION WITHIN 12 FEET OF AN OPERATING DPGDS. EXPOSURE MUST BE LIMITED TO UNDER 2.5 HOURS. WARNING BY CLOSING THE FEEDER OR TIE BREAKER, HIGH VOLTAGE WILL BE PRESENT ON THE LOAD CABLES. ENSURE ALL PERSONNEL ARE CLEAR OF ALL LOAD CABLES PRIOR TO CLOSING FEEDER OR TIE BREAKERS.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 TABLE 5.7.4.6-1 PRE-OPERATION RUN INSTRUCTION SEQUENCE (Perform on each PU in the power plant) STEP

-- 60HZ OPERATIONS --

-- 50HZ OPERATIONS --

1

Verify System Mode Switch (SMS) is in MANUAL

2

Verify DC Control Power is on

3

Verify Emergency Stop is pulled out

4① 5

Verify the 60Hz light is on ①

Verify the 50Hz light is on①

Start engine 1 by placing ECS1 in MANUAL

6

Verify the engine accelerates to 1800RPM

Verify the engine accelerates to 1500RPM

7

Adjust the generator frequency to 60Hz using the Frequency Adjust Rheostat (FAR)

Adjust the generator frequency to 50Hz using the Frequency Adjust Rheostat (FAR)

8

Adjust the generator voltage to 4295VAC using the Voltage Adjust Rheostat (VAR)

Adjust the generator voltage to 3915VAC using the Voltage Adjust Rheostat (VAR)

9

Close BCS-G1, toggle the Phase Rotation Test Light switch, verify that light ABC lights, open BCSG1

10

Shutdown engine 1 by placing ECS1 in OFF/RESET

11

Start engine 2 by placing ECS2 in MANUAL

12

Verify the engine accelerates to 1800RPM

Verify the engine accelerates to 1500RPM

13

Adjust the generator frequency to 60Hz using the Frequency Adjust Rheostat (FAR)

Adjust the generator frequency to 50Hz using the Frequency Adjust Rheostat (FAR)

14

Adjust the generator voltage to 4295VAC using the Voltage Adjust Rheostat (VAR)

Adjust the generator voltage to 3915VAC using the Voltage Adjust Rheostat (VAR)

15

Close BCS-G2, toggle the Phase Rotation Test Light switch, verify that light ABC lights, open BCSG2

16

Shutdown engine 2 by placing ECS2 in OFF/RESET ①

If the wrong frequency light is on, open the Master Control Door and change the Frequency Selector Switch (FSS) to the desired frequency.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 5.7.4.7

ORT SETUP

a. Remove the ORT from its case and set it up on a flat and level surface. b. Remove the mouse from the case and plug it into the mouse (PS2) port on the back of the ORT. c.

If 120VAC power is available, connect the ORT power supply cord to the 120 VAC power. The ORT can operate up to three hours on its batteries.

d. Connect one end of the 150-foot patch cable to the ORT networking port on the PU. e. Route the cable from the ORT to the PU and connect the cable to the ORT port. f.

Turn on the ORT.

g. Observe that the ORT boots to the operator’s Overview screen. h. Select the Equip ID pop-up screen and enter the necessary information for the units. This includes the Trailer ID number, the Engine ID number, and the Generator ID number for each PU. i.

Select the Oneline pop-up screen and enter the descriptor for the main load connected to the feeders.

h. Return to the Overview pop-up screen.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 5.7.4.8

CONTROLS SETUP

Complete the switch arrangements according to the following Table, and verify the lamp indicators: TABLE 5.7.4.8-1 CONTROL SWITCH SETUP PANEL SWITCH DC Control Breaker SMS GMS AVRS MASTER CONTROL PANEL 60Hz Light MCP USS BSS SSS SSL lights FSS INSIDE MCP Emergency Stop GENERATOR CONTROL PANEL GCPG1 ECS Emergency Stop GENERATOR CONTROL PANEL GCPG2 ECS

SETUP Pushed In (ON) OFF PRIME POWER PRIME POWER ON① A② NORMAL OFF All OFF 50/60 Hertz① Pulled-Out OFF Pulled-Out OFF

① With the SMS in the OFF position, the 50/60Hz lights indicate the position of the Frequency

Selector Switch (FSS). If the wrong light is on, open the door and change the switch position. ②

No more than one switch can be in the same position in any multi-PU line-up. With the SMS in OFF, none of the USI lights will be on and any previously set address on the PU is cleared.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 5.7.5

PLANT STARTUP CAUTION ENSURE THERE IS SUFFICIENT KW LOAD FOR BOTH GENERATOR UNITS ON THE BUS BEFORE PARALLELING A MEP-PU-810 POWER UNIT INTO AN OPERATING MEP-012 PLANT OR MEP-012 GENERATOR INTO AN OPERATING MEP-PU-810 PLANT.

5.7.5.1

MANUAL MODE

5.7.5.1.1

STARTING UP SINGLE OR MULTIPLE PU’S IN MANUAL MODE WITH A MEP-012 POWER PLANT WARNING

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND ENFORCED. NOISE LEVELS IN EXCESS OF 85 DB EXIST WITHIN AN 88-FOOT RADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR SINGLE HEARING PROTECTION WITHIN 88 FEET OF AN OPERATING DPGDS. WARNING HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND ENFORCED. DURING MAINTENANCE ACTIVITIES WITH THE SIDEDOORS OPEN, NOISE LEVELS IN EXCESS OF 113 DB EXIST WITHIN A 12-FOOT RADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR DOUBLE HEARING PROTECTION WITHIN 12 FEET OF AN OPERATING DPGDS. EXPOSURE MUST BE LIMITED TO UNDER 2.5 HOURS. CAUTION THIS PROCEDURE IS FOR OPERATION OF A MEP-PU-810 WITH AN EXISTING POWER PLANT THAT IS OPERATING IN DROOP (PARALLELING A MEP-PU-810 TO A MEP-012 PLANT). THE PROCEDURE ASSUMES THAT THE DROOP PLANT IS ON-LINE CARRYING THE LOAD AND THE PU IS PROPERLY CONNECTED TO THE EXISTING PLANT. NOTE:

The MEP-PU-810 must be connected to the MEP-012A common bus (PDC or PSC).

a. Complete the switch arrangements according to the following Table, and verify the lamp indicators:

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 TABLE 5.7.5.1-1 SWITCH SETUP – MANUAL MODE PANEL SWITCH 1ST PU BCS-T Green Target SMS MANUAL MASTER CONTROL MSES PANEL MCP Enable① GENERATOR CONTROL PANEL 1 GCPG1 GENERATOR CONTROL PANEL 2 GCPG2

USI BCS-G1 BCS-F1 ECS-1 BCS-G2 BCS-F2 ECS-2

①, ②

A Green Target Green Target OFF Green Target Green Target OFF

2ND PU Green Target MANUAL

3RD PU Green Target MANUAL

4TH PU Green Target MANUAL

Enable①

Enable①

Enable①

①, ②

B Green Target Green Target OFF Green Target Green Target OFF

①, ②

C Green Target Green Target OFF Green Target Green Target OFF

D① , ② Green Target Green Target OFF Green Target Green Target OFF

① Hold the MSES in an ENABLE position until the selected USI indicator energizes. The switch

returns to the center position when released. This sets the PU networking address and enables the control and monitoring. ② No more than one of each indicator can be on for multi-PU operations. The light on should match

USS position. The USI light will de-energize after the SMS has been in OFF for 3 seconds. a. At A-unit GCPG1, place the Engine Control Switch (ECS) in MANUAL. b. Observe the generator starts and accelerates to operating voltage and frequency. c.

At the A-unit MCP, place the Sync Source Switch (SSS) in the GEN 1 position.

d. Close BCSG1 by cycling BCSG1 to the CLOSE position. e. Observe that the BCSG1 breaker closes. f.

Place the SSS in the TIE position

g. Close BCST breaker when the two green triangular LEDs at 12 o’clock on the Synchroscope are energized by cycling BCST to the CLOSE position. For detailed instructions on manual synchronizing, refer to Section 5.9.6.14. h. Observe that the BCST breaker closes. i.

Return the SSS to the OFF position.

j.

At the MEP-012 control panel, slowly reduce the generator frequency to transfer up to a maximum of 420KW to the Unit-A Generator 1.

k.

Shutdown a MEP-012 generator if necessary to maintain load up to a maximum of 420KW on Unit-A PU.

l.

At A-unit GCPG2 place the Engine Control Switch (ECS) in MANUAL.

m. Observe the engine starts and accelerates to operating voltage and frequency. n. At the A-unit MCP, place the Sync Source Switch (SSS) in the GEN 2 position.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 o. Close BCSG2 breaker when the two green triangular LEDs at 12 o’clock on the Synchroscope are energized by cycling BCSG2 to the CLOSE position. For detailed instructions on manual synchronizing, refer to Section 5.9.6.14. p. Observe that the BCSG2 breaker closes. q. Return the SSS to the OFF position. r.

At the MEP-012 control panel, slowly reduce the generator frequency to transfer an additional load up to a maximum of 420KW to the Unit-A Generator 2.

s.

Shutdown a MEP-012 generator if necessary to maintain load up to a maximum of 840KW on Unit-A PU.

t.

Repeat steps ‘b’ through ‘s’ for each PU (B – D) put into the plant lineup, increasing the maximum capacity by 420KW for each PU generator added to the bus see Table 5.7.5.1-2.

u. Ensure generators have assumed load. After the MEP-PU-810 have stabilized proceed with the following if necessary: v.

Observe the KW, PF and KVAR of each MEP-PU-810 generator at the LCP.

Note: If adjustment is needed for KVAR balance, start with the generator that is the furthest from the average KVAR (either too low or too high). Make minor adjustments of the Voltage Adjust Rheostat (VAR) until the KVAR sharing between generators are within +/– 10% of the average plant KVAR load. This adjustment will typically be required only once during initial power plant setup and is intended to compensate for meter variations among generators.

CAUTION Improper adjustment of the VAR can cause a reverse KVAR shutdown of a generator. TABLE 5.7.5.1-2

GENERATOR CAPACITIES

QUANTITY ONLINE

1

2

3

4

5

6

7

8

KW

420

840

1260

1680

2100

2520

2940

3360

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 5.7.5.1.2

STARTING UP SINGLE OR MULTIPLE MEP-012’S WITH A MEP-PU-810 POWER PLANT IN MANUAL MODE WARNING

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND ENFORCED. NOISE LEVELS IN EXCESS OF 85 DB EXIST WITHIN AN 88-FOOT RADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR SINGLE HEARING PROTECTION WITHIN 88 FEET OF AN OPERATING DPGDS. WARNING HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND ENFORCED. DURING MAINTENANCE ACTIVITIES WITH THE SIDEDOORS OPEN, NOISE LEVELS IN EXCESS OF 113 DB EXIST WITHIN A 12-FOOT RADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR DOUBLE HEARING PROTECTION WITHIN 12 FEET OF AN OPERATING DPGDS. EXPOSURE MUST BE LIMITED TO UNDER 2.5 HOURS. This procedure is for operation of a MEP-012 with an existing MEP-PU-810 power plant that is operating in Prime Power mode (paralleling a MEP-012 to a MEP-PU-810 plant). The procedure assumes that the Prime Power plant is on-line carrying the load and the MEP-012 is properly connected to the existing plant. a. Complete the setup of each MEP-012 generator per the MEP-012 Instruction Manual. b. At the external switchgear, close the disconnect switch (multiple PU lineup). At the PU MCP close the Tie Breaker (single PU lineup only). c.

At the MEP-012 control panel, start the generator.

d. Match the MEP-012 voltage to the bus voltage. e. Manually synchronize the MEP-012 into the PU plant. f.

At the MEP-012 control panel, slowly increase the generator frequency control to transfer load, up to the maximum capacity of the MEP-012 generator.

g. Repeat steps b through f for each additional MEP-012 being paralleled into the PU plant (multiple PU lineups only). h. Maintain only the number of MEP-012 generators on the bus necessary to carry the system load. Extra MEP-012 generators should be unloaded and shutdown until required.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 5.7.5.2

AUTOMATIC MODE CAUTION LOAD CHANGES WILL INITIALLY BE APPLIED TO THE MEP-012 UNIT(S) AND WILL THEN AUTOMATICALLY TRANSFER TO THE MEP-PU-810 UNIT(S) AFTER A 10 TO 15 SECOND DELAY. THE MEP-012 OPERATOR MUST MAINTAIN AN ADEQUATE RESERVE CAPACITY TO ABSORB THE APPLIED LOAD CHANGE. EXCEEDING THE MEP-012 CAPACITY WILL CAUSE THE MEP-012 UNIT(S) TO GO INTO OVERLOAD AND DROP OFFLINE, RESULTING IN A COMPLETE SHUTDOWN. CAUTION LOAD CHANGES WILL BE ABSORBED OR SHED BY THE MEP-PU-810 UNIT(S). THE MEP-012 UNIT(S) FREQUENCY CONTROL MUST BE ADJUSTED TO ACHIEVE THE DESIRED LOAD BALANCE AND TO PREVENT OVERLOADING.

5.7.5.2.1

STARTING UP SINGLE OR MULTIPLE PU’S IN AUTOMATIC MODE WITH A MEP-012 POWER PLANT WARNING

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND ENFORCED. NOISE LEVELS IN EXCESS OF 85 DB EXIST WITHIN AN 88-FOOT RADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR SINGLE HEARING PROTECTION WITHIN 88 FEET OF AN OPERATING DPGDS. WARNING HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND ENFORCED. DURING MAINTENANCE ACTIVITIES WITH THE SIDEDOORS OPEN, NOISE LEVELS IN EXCESS OF 113 DB EXIST WITHIN A 12-FOOT RADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR DOUBLE HEARING PROTECTION WITHIN 12 FEET OF AN OPERATING DPGDS. EXPOSURE MUST BE LIMITED TO UNDER 2.5 HOURS. WARNING ONCE THE SYSTEM STATUS LIGHTS TURN GREEN AND THE MSES IS ENABLED, THE PU WILL START. ENSURE PERSONNEL ARE CLEAR OF THE PU. WARNING ONLY ONE PU MAY BE SELECTED TO ANY ONE USS POSITION DURING MULTIPLE PU OPERATIONS. OPERATING WITH MORE THAN ONE UNIT AT THE SAME ID CAUSE UNSAFE AND ERRATIC OPERATIONAL CONDITIONS.

5-165

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 This procedure is for operation of a MEP-PU-810 with an existing power plant that is operating in Droop (paralleling a MEP-PU-810 to a MEP-012 plant). The procedure assumes that the Droop plant is on-line carrying the load and the PU is properly connected to the existing plant. a. Complete the plant startup following the Automatic Mode start up procedures described in Section 5.7.5.2, then proceed as follows: b. Complete the switch arrangements according to the following Table, and verify the lamp indicators: TABLE 5.7.5.2.1-1 SWITCH SETUP – AUTOMATIC MODE PANEL MASTER CONTROL PANEL MCP GENERATOR CONTROL PANEL 1 GCPG1 GENERATOR CONTROL PANEL 2 GCPG2 MASTER CONTROL PANEL MCP

SWITCH

1ST PU

2ND PU

3RD PU

4TH PU

BCS-T SMS USS BCS-G1 BCS-F1 ECS-1 BCS-G2 BCS-F2 ECS-2 MSES

Red Target

Red Target

Red Target

Red Target

AUTO③ A Red Target Red Target OFF Red Target Red Target OFF

AUTO③ B Red Target Red Target OFF Red Target Red Target OFF

AUTO③ C Red Target Red Target OFF Red Target Red Target OFF

AUTO③ D Red Target Red Target OFF Red Target Red Target OFF

Enable①

Enable①

Enable①

Enable①

USI

A①, ②

B①, ②

C① , ②

D① , ②

① Hold the MSES in an ENABLE position until the selected USI indicator energizes. The switch

returns to the center position when released. This sets the PU networking address and enables the control and monitoring. ② No more than one of each indicator can be on for multi-PU operations. The light on should match

USS position. The USI light will de-energize after the SMS has been in OFF for 3 seconds. ③ With the SMS in AUTO any generator started, manually or automatically, will automatically

parallel to the bus. To prevent the generator from paralleling to the bus put the generator’s breaker in the Pull-To-Lock position. c.

At A-unit GCPG1, place the Engine Control Switch (ECS) to the AUTO position.

d. Ensure that the ECS on all other units is in the OFF position. e. Move the Master Start Enable Switch (MSES) the ENABLE position and hold until the engine starts to crank. f.

Observe that the Tie Breaker closes, Engine/Generator 1 starts, synchronizes and closes to the bus.

g. At the PU system ORT, disable the PU plant Economizing feature. This will prevent the plant from dropping PU generators offline during light loading conditions.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 h. Adjust the voltage and frequency on the MEP-012A to achieve and stabilize the desired load share. i.

Repeat steps c. through h. for each MEP-PU-810 Engine/Generator to be brought on-line.

j.

Ensure generators have assumed load. After the load has stabilized on the MEP-PU-810, proceed with the following if necessary:

k.

Observe the KW, PF and KVAR of each generator at the LCP of each MEP-PU-810.

Note: If adjustment is needed for KVAR balance, start with the generator that is the furthest from the average KVAR (either too low or too high). Make minor adjustments of the Voltage Adjust Rheostat (VAR) until the KVAR sharing between generators are within +/– 10% of the average plant KVAR load. This adjustment will typically be required only once during initial power plant setup and is intended to compensate for meter variations among generators.

CAUTION Improper adjustment of the VAR can cause a reverse KVAR shutdown of a generator.

5.7.5.2.2

STARTING UP SINGLE OR MULTIPLE MEP-012’S WITH A PU POWER PLANT IN AUTOMATIC MODE

This procedure is for operation of a MEP-012 with an existing MEP-PU-810 power plant that is operating in Prime Power mode (paralleling a MEP-012 to a MEP-PU-810 plant). The procedure assumes that the Prime Power plant is on-line carrying the load and the MEP-012 is properly connected to the existing plant. a. At the MEP-PU-810 system ORT, disable the PU plant Economizing feature. This will prevent the plant from dropping PU generators offline under light loading conditions due to the MEP-012 generator(s) being online. b. Complete the setup of each MEP-012 generator per the MEP-012 Instruction Manual. c.

At the external switchgear, close the disconnect switch (multiple PU lineup). At the PU MCP close the Tie Breaker (single PU lineup only).

d. At the MEP-012 control panel, start the generator. e. Match the MEP-012 voltage to the bus voltage. f.

Manually synchronize the MEP-012 into the PU system.

g. At the MEP-012 control panel, slowly increase the generator frequency control to transfer load up to the desired capacity of the MEP-012 generator. h. Repeat steps c through g for each additional MEP-012 being paralleled into the PU system (multiple PU lineups only). j.

NOTE:

Maintain only the number of MEP-012 generators on the bus necessary to carry the system load. Extra MEP-012 generators should be unloaded and shutdown until required. If the PUs exceed their nominal 85% loading setpoint, an idle PU generator will start and parallel to the bus. This oncoming generator will affect the load on all online generators including the MEP-012(s). Manual load correction by the operator will be required. This feature is embedded in the automatic operation of the MEP-PU-810 and cannot be disabled.

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PLANT OPERATIONS

Refer to Chapter 5.9 for specific procedures In this manual mode of operation, the ORT provides no remote operation capability. It will provide monitoring of the generator parameters. 5.7.7

POWER PLANT TEARDOWN

5.7.7.1

SHUT DOWN GENERATORS

a. Reduce the load on the MEP-PU-810 plant to zero by adjusting voltage and frequency of the Droop Plant. b. Open all load connections. If the PU is in Manual Mode, this must be done locally using the Local Control Panels (LCPs). If the PU is in Automatic, this can be done remotely using the ORT or locally using the Local Control Panels (LCPs). c.

Open both generator breakers using the respective BCS switches.

d. Place both generators in cooldown by placing both ECS switches in STOP/COOLDOWN. e. Allow all engines to complete cooldown and shut down (5 minutes). f.

Place all ECS switches in OFF/RESET.

g. Pull out the DC Control Power breaker on the PU. 5.7.7.2

DISCONNECT CABLES WARNING NEVER REMOVE POWER CABLES BY HAND, USE HOT STICK AND HIGH VOLTAGE GLOVES. NEVER TOUCH A HIGH VOLTAGE LEAD OR TERMINAL UNTIL IT HAS BEEN DISCHARGED TO GROUND. FAILURE TO OBSERVE THE WARNING MAY RESULT IN DEATH BY ELECTROCUTION. CAUTION ALLOW ALL OPERATING ENGINES TO SHUT DOWN AND COOL DOWN COMPLETELY.

a. Disconnect the (A)(B) communication cables from between the PUs, Reinstall the communincation cable receptacle covers, and store inside the PUs (one per unit). b. Disconnect the ORT cable and store it in the ORT case. c.

Close and latch the ORT port on the PU.

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DISCONNECT FUEL LINES

a. Turn all fuel system valves to the off position. b. Disconnect the fuel hose from the PU fuel connection and the fuel supply. c. 5.7.7.4

Drain any fuel from the hoses into an auxiliary fuel supply and store the hoses. DISCONNECT GROUNDING

a.

Remove ground connections from the PU and store with the ground rod.

b.

Disconnect the parking stations from the ground grid.

c.

Remove the parking stations from their operating positions and reinstall them in their transportation locations on the inside of the PU rear side access doors.

5.7.7.5

PREPARE PU FOR TRANSPORTATION

a. Reinstall the four radiator splashguards (PU-810B only). b. Verify DC Control power is off. c.

Close and lock the LCP access doors.

d. Close and lock all PU side doors. 5.7.7.6

FUEL, OIL, AND COOLANT DRAINAGE

The Power Unit may be safely shipped with oil, fuel, and coolant at maximum capacities or less. Draining fluids is not required unless federal, state, or local regulations prohibit shipment with fluids present. Refer to Section 14.3.1.1, Section 13.4.5.5 and Section 6.5.3 for procedures for draining the oil, coolant and fuel liquids respectively.

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THIS PAGE INTENTIONALLY BLANK

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CHAPTER 5.8 OPERATING INSTRUCTIONS UTILITY PARALLEL CONFIGURATION TABLE OF CONTENTS SECTION

TITLE

PAGE

5.8

UTILITY PARALLEL CONFIGURATION

175

5.8.1

SAFETY PROCEDURES

175

5.8.2

POSITIONING THE PU

175

5.8.3

INITIAL PLANT SETUP

176

5.8.3.1

GROUNDING

176

5.8.3.2

FUEL MANIFOLD

178

5.8.3.3

DISTRIBUTION AND CONTROL CABLING

178

5.8.3.4

SETPOINT VERIFICATION

179

5.8.3.5

PRE-OPERATION CHECKS

182

5.8.3.6

PRE-OPERATION RUN

183

5.8.3.7

ORT SETUP

185

5.8.3.8

CONTROLS SETUP

186

5.8.4

PLANT STARTUP

187

5.8.4.1

GENERAL

187

5.8.4.2

MANUAL MODE

187

5.8.4.3

AUTOMATIC MODE

187

5.8.5

PLANT OPERATIONS

190

5.8.6

POWER PLANT TEARDOWN

190

5.8.6.1

SHUT DOWN GENERATORS

190

5.8.6.2

DISCONNECT CABLES

190

5.8.6.3

DISCONNECT FUEL LINES

191

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TABLE OF CONTENTS SECTION

TITLE

PAGE

5.8.6.4

DISCONNECT GROUNDING

191

5.8.6.5

PREPARE PU FOR TRANSPORTATION

191

5.8.6.6

FUEL, OIL, AND COOLANT DRAINAGE

191

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LIST OF FIGURES FIGURE

TITLE

PAGE

FIGURE 5.8.3.1-1

MEP-PU-810A GROUND POINTS

177

FIGURE 5.8.3.1-2

MEP-PU-810B GROUND POINTS

177

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LIST OF TABLES TABLE

TITLE

PAGE

TABLE 5.8.3.6-1

PRE-OPERATION RUN INSTRUCTION SEQUENCE

184

TABLE 5.8.3.8-1

PDC CONTROL SWITCHES SETUP

186

SWITCH SETUP – AUTOMATIC MODE

188

TABLE 5.8.4-1

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UTILITY PARALLEL CONFIGURATION

5.8.1

SAFETY PROCEDURES

a. Safety precautions must be observed while operating or maintaining the PU. Safety precautions must be observed to ensure that the operator/technician cannot have contact with the following: • • • • • • •

Hot engine parts Hot engine fluids Medium Voltage AC electricity Low Voltage AC electricity Low Voltage DC electricity Rotating Parts High noise levels

b. Minor Troubleshooting can be performed while both engines are running as long as safety precautions are taken. Refer to the appropriate troubleshooting section for recommendations. 5.8.2

POSITIONING THE PU

a. Position the PU in such a way as to allow the plant operator to have full vision of the operator control panels on the unit. b. Level the MEP-PU-810B front to rear with the trailer leveling hand crank. c.

Position the PU to provide a minimum of 10 feet of clearance for maintenance access on all sides of each unit. Ensure that there are no overhead obstructions around the exhaust outlets. WARNING FUEL SPILLAGE CAN OCCUR IF THE POWER UNIT LEVEL IS GREATER THAN + 5 DEGREES.

d. Ensure that the ground is capable of supporting the weight of the PU. The site surface should be as level as possible (+ 5 degrees).

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INITIAL PLANT SETUP

5.8.3.1

GROUNDING WARNING THERE CAN ONLY BE ONE GROUNDING POINT FOR THE PU.

a. Drive an 8-foot ground rod into the earth and should be within 6 feet of the PU and at a location that minimizes the tripping hazard, until only 6 inches (15 cm) protrudes above the surface. b. Repeat step “a” for each PU being used. c.

Connect all of the grounding rods together with a #2 AWG copper conductor creating a central ground grid.

d. Using a #2 AWG copper conductor, secure one end of a ground cable to one of the slotted ground studs on the PU, see Figure 5.8.3.1-1 or Figure 5.8.3.1-3. Secure the other end of the ground cable to the ground rod. e. Repeat step “d” for every PU. f.

Test Ground Resistance using Ground Resistance Test Equipment. Resistance must be 25Ω or less. Refer to Annex H for special equipment required for this task.

g. Remove parking stand plates from their transportation positions inside each rear, side PU door and slide them into their respective operating positions on the sides of the PDC. h. Connect the parking stand ground wires to either of the two chassis ground lugs on the PU.

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GROUND POINT

FIGURE 5.8.3.1-1 NOTE:

GROUND POINT

MEP-PU-810A GROUND POINTS

Connect only one ground point to the ground grid.

GROUND POINT

FIGURE 5.8.3.1-2 NOTE:

GROUND POINT

MEP-PU-810B GROUND POINTS

Connect only one ground point to the ground grid.

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FUEL MANIFOLD WARNING ENSURE THAT THE FUEL LINES ARE PROTECTED FROM ALL ELECTRICAL CABLES AND ARE ROUTED TO MINIMIZE THE POTENTIAL FOR PHYSICAL DAMAGE OR CAUSING A TRIPPING HAZARD.

a. Lay out the fuel hoses between the PU, the fuel manifold, and the fuel bladders to establish the fuel supply system. See Chapter 5.1 Figure 5.1.3.2-1 External Fuel Supply. b. Install the external fuel hose for the PU to the Fuel Transfer Pump at the Tow end of the PU. c.

Connect the other end of the fuel hose to the fuel manifold outlets.

d. Connect the 3” hose, with quick-disconnect hose ends, from the fuel manifold to the fuel bladders. e. Connect the fuel manifold ground wire to the ground grid. f.

5.8.3.3

Open only the appropriate fuel manifold valves (once connected to the PU) to supply fuel to the power units and check for leaks. DISTRIBUTION AND CONTROL CABLING WARNING VERIFY THAT CONNECTION POINTS ARE DE-ENERGIZED BEFORE MAKING ANY CONNECTIONS. FAILURE TO CHECK CONNECTORS DE-ENERGIZED MAY RESULT IN INJURY OR DEATH.

a. Lay out and park the load cables for each phase (A, B, & C) between the PU Tie Output parking stations and the load. b. Connect each load cable to the appropriate phase connection on the utility bus. Ensure there are no cross-phase connections. c.

Connect each load cables drain wire to the grounding grid.

d. Open the Tie Output connector loadbreak covers on the first PU. e. Connect the Tie Output Cables to the appropriate phase connectors; ensure there are no crossphase connections. f.

Close and lock the Tie Output connector covers.

g. Repeat steps ‘b’ through ‘f’ on each remaining PU. h. Connect the first (A) (B) communication cable to “B” receptacle on first PU. i.

Route the first (A) (B) communication cable to second PU.

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Connect the first (A) (B) communication cable to “A” receptacle on second PU.

k.

Connect the second (A) (B) communication cable to “B” receptacle on second PU.

l.

Route the second (A) (B) communication cable to second PU.

m. Connect the second (A) (B) communication cable to “A” receptacle on third PU. n. Connect the third (A) (B) communication cable to “B” receptacle on third PU. o. Route the third (A) (B) communication cable to fourth PU. p. Connect the third (A) (B) communication cable to “A” receptacle on fourth PU. q. Connect the fourth (A) (B) communication cable to “B” receptacle on fourth PU. r.

Leave the loose end of the fourth cable loose and capped.

5.8.3.4

SETPOINT VERIFICATION

a. Turn on PU DC control power by pushing in on the DC Control Power breaker. b. On each of the five overcurrent relays, verify the settings: (1)

Press the [▲] key to get to the top-level menu “1 REPORT STATUS”.

(2)

Press the [►] key 5 times to display “6 GENERAL SETTINGS”.

(3)

Press the [▼] key to display “6.1 COM SETTINGS”.

(4)

Press the [►] key 2 times to display “6.3 POWER SYSTEM SETTINGS”.

(5)

Press the [▼] key to display “6.3.1 CT RATIO”.

(6)

Verify the “P” and “N” values match Chapter 5.1 Table 5.1.3.4-1, CT Ratio Settings.

(7)

Press the [▲] key 2 times to display “6 GENERAL SETTINGS”.

(8)

Press the [◄] key to display “5 PROTECTION LOGIC USER”.

(9)

Press the [▼] key 3 times to display “5.1.1.1 50TP”.

(10) Verify the 50TP “PU” and “TD” settings match Chapter 5.1 Table 5.1.3.4-2, Instantaneous Trip Settings. In order to edit values, Press the “Edit” key. Select correct value, and press “Edit” again to save changes. Ensure light is off otherwise you can accidentally change value again. (11) Press the [►] key to display “5.1.1.2 50TN”. (12) Verify the 50TN settings. (13) Press the [►] key to display “5.1.1.3”. (14) Verify the “50TQ” settings

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (15) Press the [▲] key to display “5.1.1 50T SETTINGS”. (16) Press the [►] key to display “5.1.2 51 SETTINGS”. (17) Press the [▼] key to display “5.1.2.1 51P”. (18) Verify the 51P “PU”, “TD”, and “C” settings in Chapter 5.1 Table 5.1.3.4-3 Time Overcurrent Settings. (19) Press the [►] key to display “5.1.2.2 51N”. (20) Verify the 51N settings. (21) Press the [▲] key 3 times to display “5 PROTECTION LOGIC USER”. c.

Use the following procedure to verify the Generator 1 and Generator 2 GSC+ settings:

NOTE:

Refer to the “EMCPII+ Reference Chart”, located on the interior Generator Control Panel Door (Look-up) (1)

Place ECS in the COOLDOWN/STOP position.

(2)

Press SERVICE MODE key to enter service mode. OP1 is showing on the lower display.

(3)

Press SCROLL UP key until “OP3” is showing.

(4)

Press SELECT key. “PE -“ with the first dash flashing is showing.

(5)

Press SCROLL RIGHT key. “PE 1 -“ with the second dash flashing is showing.

(6)

Press SCROLL DOWN key. “PE 13 –“ with the third dash flashing is showing.

(7)

Press SCROLL UP key. “PE 132 –“ with the fourth dash flashing is showing.

(8)

Press SCROLL DOWN key. “PE 1323 –“ with the fifth dash flashing is showing.

(9)

Press SCROLL RIGHT key. “PE13231” with all digits not flashing is showing.

(10) Press ENTER key. “PE PASS” is showing. (11) Press EXIT key. “OP4” is showing. (12) Press SCROLL UP key until “OP5-0” is showing on the lower display. (13) Press SELECT key. “POO1” followed with the value of the setpoint is showing. (14) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing. Use Chapter 5.1 Table 5.1.3.4-4 OP5-0 Setpoints for the parameter values to be verified. Repeat until all OP5-0 setpoints are verified. (15) Press EXIT key. “OP5-0” is showing on the lower display. (16) Press SCROLL UP key until “OP5-1” is showing. (17) Press SELECT key.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (18) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing. Use Chapter 5.1 Table 5.1.3.4-5 OP5-1 Setpoints for the parameter values to be verified. Repeat until all OP5-1 Setpoints are verified. (19) Press EXIT key. “OP5-1” is showing. (20) Press SCROLL UP key until “OP6” is showing. (21) Press SELECT key. (22) Press SCROLL UP or SCROLL DWON key. The next setpoint with its value is showing. Using Chapter 5.1 Table 5.1.3.4-6 OP6 Setpoints for the parameter values to be verified. Repeat until all OP6 Setpoints are verified. (24) Press EXIT Key twice. The display returns to normal. NOTE:

If an incorrect setpoint value is displayed, the value must be changed to match the DPGDS setpoint value as follows: (a)

With the setpoint with the incorrect value showing on the display, press the SELECT key. The incorrect value flashes on the display.

(b)

Press SCROLL UP or SCROLL DOWN key until the correct value appears flashing on the display.

(c)

Press ENTER. The correct value stops flashing on the display.

(d)

Press SCROLL UP or SCROLL DOWN key to continue to verify the remaining parameter values.

d. Return ECS1 and ECS2 to the OFF/RESET position. NOTE:

Use up or down keys to change values.

e. At the AVR verify the operation settings using Chapter 5.1 Table 5.1.3.4-7 AVR Parameter/Sepoints: (1)

Open the GCPG1 cabinet door.

(2)

Press the [▼] key to display parameter “90”.

(3)

Press the [◄►] key to display the current value.

(4)

Press the [▲] key to change the value to “0015”. Enables parameter editing.

(5)

Press the [◄►] key to accept change and display the parameter number.

(6)

Press the [▲] key to the next parameter needed to change.

(7)

Press the [◄►] key to display the current value.

(8)

Press the [▲] or [▼] key to change the value.

(9)

Press the [◄►] key to accept change and display the parameter number.

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Parameters 20, 21, 22, 36, 37, and 38 are displayed but not used. (12) When complete, press the [▼] to display parameter “90”. (13) Press the [◄►] key to display the current value. (14) Press the [▼] key to change the value to “0009”. Disables DVR parameter editing. (15) Press the [◄►] key to accept change and display the parameter number. (16) Press the [▲] key to change to display parameter “01”. (17) Close the GCPG1 cabinet door. (18) Repeat steps ‘1 ‘through ‘17’ for Generator 2.

5.8.3.5

PRE-OPERATION CHECKS

Starting from the left rear of the PU and working around the PU in a clockwise direction, perform the checks indentified in Chapter 5.1 Table 5.1.3.5-1 Pre-Operation Checklist. (Gen. 1 is on the left and Gen. 2 is on the right):

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PRE-OPERATION RUN

WARNING ENSURE ALL PERSONNEL ARE CLEAR AND THE PU DOORS ARE CLOSED PRIOR TO STARTING A GENERATOR. WARNING HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND ENFORCED. NOISE LEVELS IN EXCESS OF 85 DB EXIST WITHIN AN 88-FOOT RADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR SINGLE HEARING PROTECTION WITHIN 88 FEET OF AN OPERATING DPGDS. WARNING HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND ENFORCED. DURING MAINTENANCE ACTIVITIES WITH THE SIDEDOORS OPEN, NOISE LEVELS IN EXCESS OF 113 DB EXIST WITHIN A 12-FOOT RADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR DOUBLE HEARING PROTECTION WITHIN 12 FEET OF AN OPERATING DPGDS. EXPOSURE MUST BE LIMITED TO UNDER 2.5 HOURS. WARNING BY CLOSING THE FEEDER OR TIE BREAKER, HIGH VOLTAGE WILL BE PRESENT ON THE LOAD CABLES. ENSURE ALL PERSONNEL ARE CLEAR OF ALL LOAD CABLES PRIOR TO CLOSING FEEDER OR TIE BREAKERS. WARNING IF PHASE ROTATION IS DIFFERENT, PRIOR TO CORRECTING PHASE ROTATION, ENSURE THE LOAD CABLES ARE DE-ENERGIZED. ISOLATE THE LOAD CABLES FROM THE UTILITY AND CORRECT THE PHASE ROTATION PROBLEM.

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-- 60HZ OPERATIONS --

-- 50HZ OPERATIONS --

1

Verify System Mode Switch (SMS) is in MANUAL

2

Verify DC Control Power is on

3

Verify Emergency Stop is pulled out

4① 5

Verify the 60Hz light is on ①

Verify the 50Hz light is on①

Start engine 1 by placing ECS1 in MANUAL

6

Verify the engine accelerates to 1800RPM

Verify the engine accelerates to 1500RPM

7

Adjust the generator frequency to 60Hz using the Frequency Adjust Rheostat (FAR)

Adjust the generator frequency to 50Hz using the Frequency Adjust Rheostat (FAR)

8

Adjust the generator voltage to 4295VAC using the Voltage Adjust Rheostat (VAR)

Adjust the generator voltage to 3915VAC using the Voltage Adjust Rheostat (VAR)

9

Close BCSG1, toggle the Phase Rotation Test Light switch, verify that light ABC lights, open BCSG1

10

Shutdown engine 1 by placing ECS1 in OFF/RESET

11

Start engine 2 by placing ECS2 in MANUAL

12

Verify the engine accelerates to 1800RPM

Verify the engine accelerates to 1500RPM

13

Adjust the generator frequency to 60Hz using the Frequency Adjust Rheostat (FAR)

Adjust the generator frequency to 50Hz using the Frequency Adjust Rheostat (FAR)

14

Adjust the generator voltage to 4295VAC using the Voltage Adjust Rheostat (VAR)

Adjust the generator voltage to 3915VAC using the Voltage Adjust Rheostat (VAR)

15

Close BCST, toggle the Phase Rotation Test Light switch, verify that light ABC lights, open BCST

16

Close BCSG2, toggle the Phase Rotation Test Switch, verify that light ABC lights, open BCSG2

17

Shutdown engine 2 by placing ECS2 in OFF/RESET ①

If the wrong frequency light is on, open the Master Control Door and change the Frequency Selector Switch (FSS) to the desired frequency.

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ORT SETUP

a. Remove the ORT from its case and set it up on a flat and level surface. b. Remove the mouse from the case and plug it into the mouse (PS2) port on the back of the ORT. c.

If 120VAC power is available, connect the ORT power supply cord to the 120VAC power. The ORT can operate up to three hours on its batteries.

d. Connect one end of the 150-foot patch cable to the ORT networking port on the PU. e. Route the cable from the ORT to the PU and connect the cable to the ORT port. f.

Turn on the ORT.

g. Observe that the ORT boots to the operator’s Overview screen. h. Select the EquipID pop-up screen and enter the necessary information for the units. This includes the Trailer ID number, the Engine ID number, and the Generator ID number for each PU. i.

Select the Oneline pop-up screen and enter the descriptor for the main load connected to the feeders.

h. Return to the Overview pop-up screen.

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CONTROLS SETUP

Complete the switch arrangements according to the following Table, and verify the lamp indicators: NOTE:

Ignore settings for Power Units not being used:

TABLE 5.8.3.8-1 PANEL

PDC CONTROL SWITCHES SETUP 1ST PU

2ND PU

3RD PU

4TH PU

Pushed In (ON) OFF UTILITY PARALLEL UTILITY PARALLEL

Pushed In (ON) OFF UTILITY PARALLEL UTILITY PARALLEL

Pushed In (ON) OFF UTILITY PARALLEL UTILITY PARALLEL

Pushed In (ON) OFF UTILITY PARALLEL UTILITY PARALLEL

60Hz Light

ON①

ON①

ON①

ON①

USS BSS SSS

A② NORMAL OFF

B② NORMAL OFF

C② NORMAL OFF

D② NORMAL OFF

SSL

All OFF

All OFF

All OFF

All OFF

FSS

50/60 Hertz①

50/60 Hertz①

50/60 Hertz①

50/60 Hertz①

Pulled-Out

Pulled-Out

Pulled-Out

Pulled-Out

OFF

OFF

OFF

OFF

Pulled-Out

Pulled-Out

Pulled-Out

Pulled-Out

OFF

OFF

OFF

OFF

SWITCH DC Power SMS GMS

Master Control Panel MCP

Inside MCP Generator Control Panel GCPG1 Generator Control Panel GCPG2

AVRS

Emergency Stop ECS Emergency Stop ECS

① With the SMS in the OFF position, the 50/60Hz lights indicate the position of the Frequency

Selector Switch (FSS). If the wrong light is on, open the door and change the switch position. ②

No more than one switch can be in the same position in any multi-PU line-up. With the SMS in OFF, none of the USI lights will be on and any previously set address on the PU is cleared.

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PLANT STARTUP

5.8.4.1

GENERAL CAUTION DO NOT SET THE DESIRED LOAD ON THE ORT SLIDEBAR FOR A UTILITY PARALLEL PU OR PLANT TO A VALUE THAT EXCEEDS THE TOTAL AVAILABLE LOAD. PARALLELED PRIME POWER GENERATORS MAY BE REVERSE POWERED AND TRIP OFFLINE. PLANT OPERATORS MUST MONITOR THE TOTAL PLANT LOAD TO PREVENT THE UTILITY PARALLEL PU OR PLANT FROM OVERPOWERING THE SYSTEM. SET THE DESIRED LOAD ON THE ORT SLIDEBAR FOR A UTILITY PARALLEL PU OR PLANT TO A VALUE THAT PREVENTS OVERLOAD OF THE PRIME POWER GENERATORS. FAILURE TO FOLLOW THIS CAUTION MAY RESULT IN POWER FAILURE .

Operating PUs in parallel with a utility source should be done with the PUs operating in Automatic mode. This provides the operator with control over the amount of load the generators will carry. Operating PUs in Manual mode with a utility source limits the units to carrying only 25KW per generator. The PUs can be started and put online manually, but should be operated automatically using an ORT. 5.8.4.2

MANUAL MODE

Use Section 5.5.4 (Multi-PU Prime Power Manual Startup) to start a plant manually. Use Section 5.9.6.12 to change the units to Auto mode to allow changing the load. 5.8.4.3

AUTOMATIC MODE WARNING HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND ENFORCED. NOISE LEVELS IN EXCESS OF 85 DB EXIST WITHIN AN 88-FOOT RADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR SINGLE HEARING PROTECTION WITHIN 88 FEET OF AN OPERATING DPGDS. WARNING HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND ENFORCED. DURING MAINTENANCE ACTIVITIES WITH THE SIDEDOORS OPEN, NOISE LEVELS IN EXCESS OF 113 DB EXIST WITHIN A 12-FOOT RADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR DOUBLE HEARING PROTECTION WITHIN 12 FEET OF AN OPERATING DPGDS. EXPOSURE MUST BE LIMITED TO UNDER 2.5 HOURS.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 WARNING ONCE THE SYSTEM STATUS LIGHTS TURN GREEN AND THE MSES IS ENABLED, THE PU WILL START. ENSURE PERSONNEL ARE CLEAR OF THE PU. WARNING ONLY ONE PU MAY BE SELECTED TO ANY ONE USS POSITION DURING MULTIPLE PU OPERATIONS. OPERATING WITH MORE THAN ONE UNIT AT THE SAME ID CAUSE UNSAFE AND ERRATIC OPERATIONAL CONDITIONS. Starting up PUs in Utility Parallel in Automatic Mode a. At the utility connection, close the associated connection for each PU supplying power to the utility. b. Complete the switch arrangements according to the following Table, and verify the lamp indicators: TABLE 5.8.4-1 SWITCH SETUP – AUTOMATIC MODE PANEL

SWITCH

1ST PU

2ND PU

3RD PU

4TH PU

Master Control Panel MCP

BCS-T

Red Target

Red Target

Red Target

Red Target

Generator Control Panel 1 GCPG1

BCS-G1

Red Target

Red Target

Red Target

Red Target

ECS-1

AUTO

AUTO

AUTO

AUTO

Generator Control Panel 2 GCPG2

BCS-G2

Red Target

Red Target

Red Target

Red Target

ECS-2

AUTO

AUTO

AUTO

AUTO

SMS

AUTO③

AUTO③

AUTO③

AUTO③

MSES

Enable①

Enable①

Enable①

Enable①

USI

A①, ②

B①, ②

C① , ②

D① , ②

Master Control Panel MCP

①

Hold the MSES in an ENABLE position until the selected USI indicator energizes. The switch returns to the center position when released. This sets the PU networking address and enables the control and monitoring.

②

No more than one of each indicator can be on for multi-PU operations. The light on should match USS position. The USI light will de-energize after the SMS has been in OFF for 3 seconds.

③ With the SMS in AUTO any generator started, manually or automatically, will automatically

parallel to the bus. To prevent the generator from paralleling to the bus put the generator’s breaker in the Pull-To-Lock position.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 c.

At A-unit, observe the Tie breaker automatically closes.

d. At A-unit, observe Generator 1 automatically starts and accelerates to operating voltage and frequency. e. At A-unit, observe Generator 2 automatically starts and accelerates to operating voltage and frequency. f.

At B-unit, observe the Tie breaker automatically closes.

g. At B-unit, observe Generator 1 automatically starts and accelerates to operating voltage and frequency. h. At B-unit, observe Generator 2 automatically starts and accelerates to operating voltage and frequency. i.

At C-unit, observe the Tie breaker automatically closes.

j.

At C-unit, observe Generator 1 automatically starts and accelerates to operating voltage and frequency.

k.

At C-unit, observe Generator 2 automatically starts and accelerates to operating voltage and frequency.

l.

At D-unit, observe the Tie breaker automatically closes.

m. At D-unit, observe Generator 1 automatically starts and accelerates to operating voltage and frequency. n. At D-unit, observe Generator 2 automatically starts and accelerates to operating voltage and frequency. o. At A-unit, observe Generator 1 automatically parallels to the system bus. p. At A-unit, observe Generator 2 automatically parallels to the system bus. q. At B-unit, observe Generator 1 automatically parallels to the system bus. r.

At B-unit, observe Generator 2 automatically parallels to the system bus.

s.

At C-unit, observe Generator 1 automatically parallels to the system bus.

t.

At C-unit, observe Generator 2 automatically parallels to the system bus.

u. At D-unit, observe Generator 1 automatically parallels to the system bus. v.

At D-unit, observe Generator 2 automatically parallels to the system bus.

w. Observe that each generator assumes 25KW when it parallels to the system bus. x.

From the ORT, set the desired load for all generators running. The load is set on a per generator basis.

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y. z.

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 Ensure generators have assumed load. After the desired load has been stabilized, proceed with the following if necessary: Observe the KW, PF and KVAR of each generator at the LCP.

Note: If adjustment is needed for KVAR balance, start with the generator that is the furthest from the average KVAR (either too low or too high). Make minor adjustments of the Voltage Adjust Rheostat (VAR) until the KVAR sharing between generators are within +/– 10% of the average plant KVAR load. This adjustment will typically be required only once during initial power plant setup and is intended to compensate for meter variations among generators.

CAUTION Improper adjustment of the VAR can cause a reverse KVAR shutdown of a generator. NOTE:

5.8.5

The automatic economizing feature is disabled while a generator is operating in Utility Parallel mode. PLANT OPERATIONS

Refer to Chapter 5.9 for specific operating procedures. The power plant must be in Auto Mode to be operated remotely or to adjust the load on the generators. 5.8.6

POWER PLANT TEARDOWN

5.8.6.1

SHUT DOWN GENERATORS

a. Unload all generators by opening all Tie breakers. This must be done locally from the LCP or ORT. b. Open both generator breakers using the respective BCS switches. c.

Place both generators in cooldown by placing both ECS switches in STOP/COOLDOWN.

d. Allow all engines to complete cooldown and shut down (5 minutes). e. Place all ECS switches in OFF/RESET. f. 5.8.6.2

Pull out the DC Control Power breaker on the PU. DISCONNECT CABLES WARNING NEVER REMOVE POWER CABLES BY HAND, USE HOT STICK AND HIGH VOLTAGE GLOVES. NEVER TOUCH A HIGH VOLTAGE LEAD OR TERMINAL UNTIL IT HAS BEEN DISCHARGED TO GROUND. FAILURE TO OBSERVE THE WARNING MAY RESULT IN DEATH BY ELECTROCUTION.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 CAUTION ALLOW ALL OPERATING ENGINES TO SHUT DOWN AND COOL DOWN COMPLETELY. a. Disconnect the (A)(B) communication cables from between the PUs, Reinstall the communications cable receptacle covers, and store inside the PUs (one per unit). b. Disconnect the ORT cable and store it in the ORT case. c.

Close and latch the ORT port on the PU.

d. Disconnect all load cables used in operation of the PUs. 5.8.6.3

DISCONNECT FUEL LINES

a. Turn all fuel system valves to the off position. b. Disconnect the fuel hose from the PU fuel connection and the fuel supply. c. 5.8.6.4

Drain any fuel from the hoses into an auxiliary fuel supply and store the hoses. DISCONNECT GROUNDING

a.

Remove ground connections from the PU and store with the ground rod.

b.

Disconnect the parking stations from the ground grid.

c.

Remove the parking stations from their operating positions and reinstall them in their transportation locations on the inside of the PU rear side access doors.

5.8.6.5

PREPARE PU FOR TRANSPORTATION

a. Reinstall the four radiator splashguards (PU-810B only). b. Verify DC Control power is off. c.

Close and lock the LCP access doors.

d. Close and lock all PU side doors. 5.8.6.6

FUEL, OIL, AND COOLANT DRAINAGE

The Power Unit may be safely shipped with oil, fuel, and coolant at maximum capacities or less. Draining fluids is not required unless federal, state, or local regulations prohibit shipment with fluids present. Refer to Section 14.3.1.1, Section 13.4.5.5 and Section 6.5.3 for procedures for draining the oil, coolant and fuel liquids respectively.

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THIS PAGE INTENTIONALLY BLANK

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CHAPTER 5.9 OPERATING INSTRUCTIONS SPECIFIC OPERATING PROCEDURES TABLE OF CONTENTS SECTION

TITLE

PAGE

5.9

SPECIFIC OPERATING PROCEDURES

196

5.9.1

SAFETY PROCEDURES

196

5.9.2

CHANGE OPERATING FREQUENCY FROM 50HZ TO 60HZ

197

5.9.2.1

MASTER CONTROL PANEL

197

5.9.2.2

DIGITAL VOLTAGE REGULATOR (AVR)

197

5.9.2.3

GENERATOR SET CONTROLLER (GSC+)

199

5.9.3

CHANGE OPERATING FREQUENCY FROM 60HZ TO 50HZ

209

5.9.3.1

MASTER CONTROL PANEL

209

5.9.3.2

DIGITAL VOLTAGE REGULATOR (AVR)

209

5.9.3.3

GENERATOR SET CONTROLLER (GSC+)

210

5.9.4

RE-DESIGNATE A PU WITHOUT PLANT SHUTDOWN

211

5.9.5

FAULT RESETTING

212

5.9.5.1

OVERCURRENT RELAY TRIP AND BREAKER LOCKOUT

212

5.9.5.2

ENGINE OR GENERATOR FAULT

212

5.9.5.3

RE-CLOSING PSC INTERCONNECT AFTER A FAULT

213

5.9.6

GENERATOR PROCEDURES

214

5.9.6.1

ADD A GENERATOR TO THE BUS – MANUAL MODE

214

5.9.6.2

ADD A GENERATOR TO THE BUS - AUTO MODE

215

5.9.6.3

ADD A GENERATOR TO THE BUS – ORT

215

5.9.6.4

TAKE A GENERATOR OFFLINE – MANUAL MODE

215

5.9.6.5

TAKE A GENERATOR OFFLINE – AUTO MODE – WITHOUT ORT

216

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TABLE OF CONTENTS SECTION

TITLE

PAGE

5.9.6.6

TAKE A GENERATOR OFFLINE – AUTO MODE - WITH ORT

216

5.9.6.7

ACKNOWLEDGE AN ALARM OR FAULT – MANUAL MODE

217

5.9.6.8

ACKNOWLEDGE AN ALARM OR FAULT – AUTO MODE

217

5.9.6.9

ACKNOWLEDGE AN ALARM OR FAULT – ORT

217

5.9.6.10

ADD AND REMOVE GENERATOR FROM PLANT LINE-UP WITH ORT

217

5.9.6.11

ECONOMIZING ON/OFF – ORT

218

5.9.6.12

CHANGE FROM MANUAL MODE TO AUTOMATIC MODE

218

5.9.6.13

CHANGE FROM AUTOMATIC MODE TO MANUAL MODE

219

5.9.6.14

UNIT ISOLATION PROCEDURE (ANY UNIT) – PLANT WITH PSC

219

5.9.6.15

UNIT RE-INSTALLATION PROCEDURE – PLANT WITH PSC

220

5.9.6.16

ISOLATING A PU IN A TWO PLANT, NO PSC, LINEUP

221

5.9.6.17

RE-INSTALLING THE SECOND PU INTO A TWO-PLANT-NO-PSC LINEUP

222

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LIST OF TABLES TABLE

TITLE

PAGE

TABLE 5.9.2.2-1

AVR PARAMETERS/SETPOINTS

198

TABLE 5.9.2.2-1

AVR PARAMETERS/SETPOINTS

199

TABLE 5.9.2.3-1

OP5-0 SETPOINTS

201

TABLE 5.9.2.3-2

OP5-1 SETPOINTS

204

TABLE 5.9.2.3-3

OP6 SETPOINTS

207

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SPECIFIC OPERATING PROCEDURES

5.9.1

SAFETY PROCEDURES

a. Safety precautions must be observed while operating and or maintaining the power unit. Refer to the appropriate troubleshooting section for recommendations Safety precautions must be observed to ensure that the operator/technician cannot have contact with the following:

•

• Hot engine parts • Hot engine fluids • Medium Voltage AC electricity • Low Voltage AC electricity • Low Voltage DC electricity • Rotating Parts High noise levels

b. Minor Troubleshooting can be performed while both engines are running as long as safety precautions are taken. Refer to the appropriate troubleshooting section for recommendations. WARNING HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND ENFORCED. NOISE LEVELS IN EXCESS OF 85 DB EXIST WITHIN AN 88-FOOT RADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR SINGLE HEARING PROTECTION WITHIN 88 FEET OF AN OPERATING DPGDS. WARNING HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND ENFORCED. DURING MAINTENANCE ACTIVITIES WITH THE SIDEDOORS OPEN, NOISE LEVELS IN EXCESS OF 113 DB EXIST WITHIN A 12-FOOT RADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR DOUBLE HEARING PROTECTION WITHIN 12 FEET OF AN OPERATING DPGDS. EXPOSURE MUST BE LIMITED TO UNDER 2.5 HOURS.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 5.9.2

CHANGE OPERATING FREQUENCY FROM 50HZ TO 60HZ

5.9.2.1

MASTER CONTROL PANEL

a. Push-in DC Control Power Circuit Breaker. b. Open the MCP cabinet door. c.

Place the Frequency Selector Switch (FSS) in the 60 Hz position.

d. Close the MCP cabinet door. 5.9.2.2

DIGITAL VOLTAGE REGULATOR (AVR)

a. Open GCPG1 cabinet door. b. At the AVR verify/change the operation settings for 60 Hz using Table 5.9.2.2-1: c.

Press the [▼] key to display parameter “90”.

d. Press the [◄►] key to display the current value. e. Press the [▲] key to change the value to “0015”. Enables parameter editing. f.

Press the [◄►] key to accept change and display the parameter number.

g. Press the [▲] key to the next parameter needed to change. h. Press the [◄►] key to display the current value. i.

Press the [▲] or [▼] key to change the value.

j.

Press the [◄►] key to accept change and display the parameter number.

k.

Repeat steps ‘g’ through ‘j’ for each parameter needing to be changed.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 TABLE 5.9.2.2-1

AVR PARAMETERS/SETPOINTS DPGDS SETPOINTS

DPGDS AVR PARAMETERS PARAMETER

TITLE

TYPE

UNITS

RANGE OF VALUES

DEFAULT VALUE

60HZ OPS

50HZ OPS

01

Generator Output Voltage

Program

Volts

0080-9999

480①

4160

3800

02

Ratio of Output Voltage To Sensing Voltage Generator Type

Program

001.0-100.0

001.0

17.3

17.3

0000-0004

0004

4

4

Program Program

Amps Volts

0000-9999 01.00-05.00

0600 05.00

80 4.00

73 3.66

06 07

Rated Generator Output Current CT Voltage At Rated Generator Current Knee Frequency Decreasing Volts/Hz Slope I

Program Program

Hz Volts/Hz

045.0-065.0 001.0-010.0

050.0 002.0

59.8 2.0

49.8 2.0

08 09 10 11 12 13 14

Decreasing Volts/Hz Slope 2 Minimum Voltage Under Frequency Point Overvoltage Trip Point Overvoltage Trip Time Under Voltage Trip Point Under Voltage Trip Time

Program Program Program Program Program Program Program

Volts/Hz % Hz % Seconds % Seconds

001.0-010.0 050.0-100.0 020.0-040.0 0105-0140 0002-0030 0060-0095 0030-0120

002.0 050.0 025.0 014.0 0002 0060 0030

2.0 50.0 25.0 125.0 5 75 30

2.0 50.0 25.0 125.0 5 75 30

15

Voltage Gain (IR Compensation)

Program

%

0000

0

0

16⑤

Integral Gain

Program

000.0-0 10.0 001.0-020.0

006.0

6.0

6.0

17⑥

Proportional Gain

Program

001.0-020.0

005.0

5.0

5.0

18

Program

0000,0001

0000

0000

0000

31③

Single Phase Sensing Select (0=three_phase,_1=single phase) Diode Monitor Trip Point Droop Percentage pf/kVAR Select (0=pf, 1=kVAR)

Program Program Program

001.0-010.0 000.0-010.0 0000, 0001

002.0 0000 0000

2.0 3 0

2.0 3 0

32③

Pf Reference

Program

00.60-01.10

01.00

0.8

0.8

33③

KVAR Reference

Program

Per Unit

00.00-01.00

0000

.10

.10

34③

Reverse Power Trip Point

Program

%

000.0-020.0

010.0

15

15

35③

Reverse Power Trip Time

Program

Seconds

000.0-020.0

010.0

5

5

50 51 52 53

Generator Output Frequency Generator Output Voltage Generator Output Current Generator Reactive Output Current

View View View View

Hz Volts Amps Amps

54 55

Generator Real Current Exciter Field Current Three Phase Kilowatts (KB and later)

View View View

Amps Amps KW

Power Factor

View

03 04 05②

19 30

56③ 57③

Program

Amps %

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AVR PARAMETERS/SETPOINTS DPGDS SETPOINTS

DPGDS AVR PARAMETERS PARAMETER

TITLE

TYPE

58③,④

Three Phase kVAR (KE and later)

View

60

Hours

View

90 91 92 93 94 96

Password Software ID Latest Fault Previous Fault Fault Clear Shutdown Fault Reset

Program View View View View Switch

UNITS

RANGE OF VALUES

Hours

0000-9999

DEFAULT VALUE

0000 0000

60HZ OPS

50HZ OPS

0009

0009

0000 0000

0000 0000

①- Default value for output voltage is different depending on regulator sensing voltage. If the regulator is

designed for 120 volts sensing, then the default output voltage is 4160 volts. All other sensing types have the default output voltage set to 480 volts. ②- Digital Voltage Regulators with earlier software (KD and earlier) have 1 less digit to the right of the

decimal point. ③- Optional feature. ④- New parameter on serial number prefix KE and later Digital Voltage Regulators. ⑤- Previous range of 0001-099.9 and default value of 002.0

⑥-Previous range of 0001-099.9 and default value of 002.0 NOTE: l.

Parameters 20, 21, 22, 36, 37, and 38 are displayed but not used. When complete, press the [▼] to display parameter “90”.

m. Press the [◄►] key to display the current value. n. Press the [▼] key to change the value to “0009”. Disables parameter editing. o. Press the [◄►] key to accept change and display the parameter number. p. Press the [▲] key to change to display parameter “01”. q. Close GCPG1 cabinet door. r. 5.9.2.3

Repeat steps ‘a ‘through ‘q’ for Generator 2. GENERATOR SET CONTROLLER (GSC+)

At GSCG1, verify/change the operation settings for 60 Hz using Table 5.9.2.3-1 and Table 5.9.2.3-2: a. Place ECS in the COOLDOWN/STOP position. b. Press SERVICE MODE key to enter service mode. “OP1” is showing on the lower display. c.

Press SCROLL UP key until “OP3” is showing.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 d. Press SELECT key. “PE - -“ is showing. e. Press SELECT key. “PE -“ with the first dash flashing is showing. f.

Press SCROLL RIGHT key. “PE 1 -“ with the second dash flashing is showing.

g. Press SCROLL DOWN key. “PE 13 –“ with the third dash flashing is showing. h. Press SCROLL UP key. “PE 132 –“ with the fourth dash flashing is showing. i.

Press SCROLL DOWN key. “PE 1323 –“ with the fifth dash flashing is showing.

j.

Press SCROLL RIGHT key. “PE13231” with all digits not flashing is showing.

k.

Press ENTER key. “PE PASS” is showing.

l.

Press EXIT key. “OP4” is showing.

m. Press SCROLL UP key until “OP5-0” is showing on the lower display. n. Press SELECT key, the value of the setpoint is showing. o. Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing. p. Press SELECT key. The value of the setpoint is flashing. Use the GSC Setpoints Table 5.9.2.3-1 for the values to verify/change in each parameter. q. Press SCROLL UP or SCROLL DOWN key to adjust the value of the setpoint. NOTE:

To adjust the value of some setpoints, it is necessary to press and release the scroll key several times in order for the value to change. To rapidly scroll through a large range of values, press and hold the appropriate scroll key.

r.

Press ENTER key. The value of the setpoint stops flashing.

s.

Repeat steps ‘o’ through ‘r’ until all the desired setpoints are adjusted.

t.

Press EXIT key. “OP5-0” is showing on the lower display.

u. Repeat steps ‘m’ through ‘s’ for “OP5-1” using Table 5.9.2.3-2. v.

Press EXIT key twice. The display returns to normal.

w. Return ECS to the OFF/RESET position. x.

Repeat steps ‘a’ through ‘w’ for GSC G2.

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OP5-0 SETPOINTS

SETPOINTS OP5-0 ENGINE/GENERATOR PROGRAMMING① FACTORY DPGDS SETPOINT-NAME-DESCRIPTIONS RANGE OF VALUES DEFAULT SETPOINT P001 - Fuel Solenoid Type: type of fuel system solenoid used on the genset.

0- ETR fuel solenoid 1- ETS fuel solenoid

0

0

P002 - Units Shown: type of measurement units shown on the GSC+ display.

0-for English units (PSI, ºF) 1-for metric units (kPa, ºC).

0

0

P003 - Shutdown Override For Engine Fault: GSC+ response to a low engine oil pressure or high coolant temperature fault.

0-for engine shutdown 1-for alarm only (shutdown override, no engine shutdown).

0

0

P004 - Shutdown Override For Sensor Fault: GSC+ response to a diagnostic fault with the engine oil pressure sensor, coolant temperature sensor, oil temperature sensor, sensor power supply or coolant loss sensor.

0-for alarm only shutdown override, no engine shutdown). 1-for engine shutdown.

0

0

P005 - Coolant Loss Sensor Installed: tells whether or not the optional engine coolant loss sensor is installed on the genset.

0-for gensets without a coolant loss sensor 1-for gensets with coolant loss sensor

0

1

P006 - Shutdown Override For Coolant Loss Fault: GSC+ response to an engine coolant loss fault.

0-for engine shutdown. 1-for alarm only (shutdown override, no engine shutdown).

0

0

P007 - System Voltage, 24 Or 32 Volts: system voltage (battery voltage) of the genset.

24 or 32.

24

24

P008 - This setpoint is not currently being used by the GSC+ and cannot be programmed.

N/A

N/A

N/A

P009 - Number Of Ring Gear Teeth: number of teeth on the ring gear of the engine. Used by the GSC+ to determine engine speed.

95 to 350 teeth in increments of one tooth.

136 teeth

136 teeth

P010 - Engine Overspeed: engine speed used by the GSC+ to declare that an engine overspeed fault exists. The engine overspeed setpoint (for all 60 Hz applications) is 1.18 times the rated speed.

500 to 4330 rpm in increments of 10 rpm.

2120 rpm

2120 rpm

P011 - Crank Terminate Speed: engine speed used by the GSC+ to disengage the starting motor during engine cranking.

100 to 1000 rpm in increments of 10 rpm.

400 rpm

400 rpm

P012 - Oil Step Speed: engine speed used by the GSC+ for distinguishing between rated speed and idle speed when a low oil pressure fault exists.

400 to 1800 rpm in increments of 10 rpm.

1350 rpm

1350 rpm

P013② - Low Oil Pressure Shutdown At Rated Speed: oil pressure used by the GSC+ to declare that a low oil pressure shutdown fault exists with engine at rated speed (the engine speed must have exceeded the oil step speed for nine seconds).

5 to 61PSI (34 to 420kPa) in increments of 1

30 PSI (205 kPa)

30 PSI (205 kPa)

P014② - Low Oil Pressure Shutdown At Idle Speed: oil pressure used by the GSC+ to declare that a low oil pressure shutdown fault exists with the engine at idle speed (the engine must have been running for at least 9 seconds and the engine speed must be less than oil step speed).

20 to 336kPa (3 to 49PSI) in increments of 1

10 PSI (70 kPa)

10 PSI (70 kPa)

P015③ - High Water Temperature Shutdown: coolant temperature used by the GSC+ to declare a high coolant temperature shutdown fault exists (after a 10 second delay).

185 to 253ºF (85 to 123ºC) in increments of 1

225ºF (107ºC)

225ºF (107ºC)

P016 - Low Water Temperature Alarm: coolant temperature used by the GSC+ to declare that a low coolant temperature alarm fault exists (after a 2 second delay).

32 to 97ºF (0 to 36ºC) in increments of 1

70ºF (21ºC)

70ºF (21ºC)

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OP5-0 SETPOINTS (CONTINUED)

SETPOINTS OP5-0 ENGINE/GENERATOR PROGRAMMING① FACTORY SETPOINT-NAME-DESCRIPTIONS RANGE OF VALUES DEFAULT

DPGDS SETPOINT

P017 - Total Cycle Crank Time: cycle crank time used by the 5 to 120 seconds in increments of 1 GSC+ to declare that an overcrank fault exists. second.

90 seconds

90 seconds

P018 - Cycle Crank Time: amount of time the GSC+ cranks and then rests the starting motor during a single crank cycle.

10 seconds

10 seconds

5 minutes

5 minutes

700, 150, 300, 500, 600, 750, 3.0k, 4.5k, 5.20k, 5.25k, 9.0k, 15.0k, 18.0k, 30.0k

700

5.20k

75, 100, 150, 200, 300, 400, 600, 800, 1000, 1200, 1500, 2000, 2500, 3000, and 4000A

600A

100A

01

01 (Gen 1) 02 (Gen 2)

5 to 60 seconds in increments of 1 second.

P019 - Cooldown Time: amount of time the GSC+ allows the 0 to 30 minutes in increments of 1 engine to run after a normal shutdown is initiated. minute. P020④ - AC Voltage: nominal AC voltage of the generator. The GSC+ measures the AC voltage and shows it on the display. P021 - AC Current Full Scale: nominal full scale AC current of the generator. AC current full scale is equal to the ratio of the external current transformers in the generator housing. P022⑤ - GSC+ Engine Number: informs other devices on the CAT Data Link of the engine number for the GSC+.

01 through 08

SETPOINTS - OP5-0-ENGINE/GENERATOR PROGRAMMING① RANGE OF FACTORY 60HZ 50HZ SETPOINT-NAME-DESCRIPTIONS DEFAULT SETPOINT SETPOINT VALUES P023 - Engine Type: identifies the engine as a mechanical unit injector (MUI) diesel, spark ignited (gas), or electronic unit injector (EUI) diesel engine.

0 - MUI diesel 1 - Gas 2 - EUI diesel

P024 - Crank Time Delay: amount of time the GSC+ delays activation of the fuel control relay (FCR) during a crank cycle. This setpoint is for Gas engines only. The P024 setpoint only functions when the P023 setpoint is set to 1 (gas engine).

0 to 20 seconds in increments of 1 second.

0 - for gensets without an oil P025 - Oil Temperature Sensor Installed: tells temperature sensor whether or not the optional engine oil temperature 1 - for gensets with an oil sensor is installed on the genset. temperature sensor P026 - High Oil Temperature Shutdown: oil temperature used by the GSC+ to declare a high 185 to 253ºF (85 to 123ºC) in increments of 1 oil temperature shutdown fault exists (after a 10 second delay). Refer to the panel model number. 0 - for alarm only (shutdown override, P027 - Shutdown Override For High Oil Temperature Fault: GSC+ response to an engine no engine shutdown). high oil temperature fault. 1 - for engine shutdown. P028 - Nameplate Voltage: rated voltage of the generator. This setpoint is used for protective relaying functions. P029 - Nameplate Current: rated current output of the generator.

0

2

2

5 Seconds

5 Seconds

5 Seconds

0

0

0

225ºF (107ºC)

225ºF (107ºC) 225ºF (107ºC)

0

0

0

100 to 25kV in increments of 1

480V

4160V

3800V

0 to 4000 A in increments of 1

600A

80A

73A

400kW

420kW

350kW

60Hz

60Hz

50Hz

0

0

0

4

4

4

P030 - Nameplate Power: rated power capability 0 through 10MW in increments of of the generator. 1kW. P031 - Rated Frequency: nominal frequency 50 or 60Hz rating of genset. P032 - Connection Configuration Of Generator: 0 - wye wye or delta configuration of generator. 1 – delta P033 - Number Of Generator Poles. 0 through 254 in increments of 2.

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The setpoints (stored or being programmed) must match the specified DPGDS setpoints.

② When oil pressure drops to within 5PSI (34kPa) of the P013 or P014 setpoint, a low oil pressure alarm is issued by the GSC+. ③ When coolant temperature rises to within 11ºF (6ºC) of the P015 setpoint, a high coolant temperature alarm is issued by the GSC+. ④ The values other than the default (700V) are for switchgear applications and require the use of external potential transformers and the removal of the AC voltage range jumper located in the relay module. The DPGDS unit is factory configured for the 5.20 K value. See the Caterpillar Electronic Modular Control Panel II+ manual topic AC Voltage Range Selection in the Testing and Adjusting section. ⑤ After setpoint P022 is reprogrammed, the GSC+ must be power cycled (powered down and then powered up)

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TABLE 5.9.2.3-2

OP5-1 SETPOINTS

SETPOINTS OP5-1 PROTECTIVE RELAYING PROGRAMMING① FACTORY 60HZ 50HZ SETPOINT-NAME-DESCRIPTION RANGE OF VALUES DEFAULT SETPOINT SETPOINT P101 - Generator Overvoltage Alarm Enable: the 0 - disabled GSC+ enables or disables the generator 1 – enabled overvoltage alarm function. P102 - Generator Overvoltage Alarm Threshold: voltage the GSC+ uses to issue an overvoltage alarm.

100 to 125% of nameplate voltage in increments of 1%.

P103 - Generator Overvoltage Alarm Time Delay: amount of time the GSC+ waits before issuing an overvoltage alarm. P104 - Generator Overvoltage Shutdown Enable: the GSC+ enables or disables the generator overvoltage shutdown function. P105 - Generator Overvoltage Shutdown Threshold: voltage the GSC+ uses to issue an overvoltage shutdown. P106 - Generator Overvoltage Shutdown Time Delay: amount of time the GSC+ waits before issuing an overvoltage shutdown.

0 through 120 seconds② in increments of 1

P107 - Generator Undervoltage Alarm Enable: the GSC+ enables or disables the generator undervoltage alarm function.

0 - disabled 1 – enabled

P108 - Generator Undervoltage Alarm Threshold: voltage the GSC+ uses to issue an undervoltage alarm. P109 - Generator Undervoltage Alarm Time Delay: amount of time the GSC+ waits before issuing an undervoltage alarm. P110 - Generator Undervoltage Shutdown Enable: the GSC+ enables or disables the generator undervoltage shutdown function. P111 - Generator Undervoltage Shutdown Threshold: voltage the GSC+ uses to issue an undervoltage shutdown.

0 - disabled 1 – enabled 100 to 125% of nameplate voltage in increments of 1%. 0 through 120 seconds② in increments of 1

60 to 100% of nameplate voltage in increments of 1%. 0 through 120 seconds② in increments of 1 0 - disabled 1 – enabled 60 through 100% of rated voltage in increments of 1%.

P112 - Generator Undervoltage Shutdown Time Delay: amount of time the GSC+ waits before issuing an undervoltage shutdown.

0 through 120 seconds② in increments of 1

P113 - Generator Overfrequency Alarm Enable: the GSC+ enables or disables the generator overfrequency alarm function.

0 - disabled 1 – enabled

P114 - Generator Overfrequency Alarm Threshold: frequency the GSC+ uses to issue an overfrequency alarm.

50-60Hz, for 50Hz Gen 60-70Hz, for 60Hz Gen 400-480, for 400Hz Gen

P115 - Generator Overfrequency Alarm Time Delay: amount of time the GSC+ waits before issuing an overfrequency alarm.

0 through 120 seconds② in increments of 1

P116 - Generator Overfrequency Shutdown Enable: the GSC+ enables or disables the generator overfrequency shutdown function.

0 - disabled 1 – enabled

P117 - Generator Overfrequency Shutdown Threshold: frequency the GSC+ uses to issue an overfrequency shutdown.

50-60Hz, for 50Hz Gen 60-70Hz, for 60Hz Gen 400-480, for 400Hz Gen

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1

1

1

105%

105%

105%

10 seconds

10 seconds

10 seconds

1

1

1

110%

110%

110%

10 seconds

10 seconds

10 seconds

1

1

1

90%

90%

90%

10 seconds

10 seconds

10 seconds

1

1

1

85%

85%

85%

15 seconds

03 seconds

03 seconds

1

1

1

53Hz 63Hz 422Hz

63 Hz

53 Hz

10 seconds

10 seconds

10 seconds

1

1

1

55Hz 66Hz 440Hz

66Hz

55Hz

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OP5-1 SETPOINTS (CONTINUED)

SETPOINTS OP5-1 PROTECTIVE RELAYING PROGRAMMING① FACTORY 60HZ SETPOINT-NAME-DESCRIPTION RANGE OF VALUES DEFAULT SETPOINT P118 - Generator Overfrequency Shutdown Time Delay: amount of time the GSC+ waits before issuing an overfrequency shutdown.

0 through 120 seconds② in increments of 1

P119 - Generator Underfrequency Alarm Enable: the GSC+ enables or disables the generator underfrequency alarm function.

0 - disabled 1 – enabled

P120 - Generator Underfrequency Alarm Threshold: frequency the GSC+ uses to issue an underfrequency alarm.

30-50Hz, for 50Hz Gen 36-60Hz, for 60Hz Gen 240-400, for 400Hz Gen

P121 - Generator Underfrequency Alarm Time Delay: amount of time the GSC+ waits before issuing an underfrequency alarm. P122 - Generator Underfrequency Shutdown Enable: the GSC+ enables or disables the generator underfrequency shutdown function.

0 through 120 seconds② in increments of 1

P123 - Generator Underfrequency Shutdown Threshold: frequency the GSC+ uses to issue an underfrequency shutdown.

30-50Hz, for 50Hz Gen 36-60Hz, for 60Hz Gen 240-400, for 400Hz Gen

P124 - Generator Underfrequency Shutdown Time Delay: amount of time the GSC+ waits before issuing an underfrequency shutdown. P125 - Generator Reverse Power Shutdown Enable: the GSC+ enables or disables the generator reverse power shutdown function. P126 - Generator Reverse Power Shutdown Threshold: level of reverse power the GSC+ uses to issue a reverse power shutdown.

0 through 120 seconds② in increments of 1

P127 - Generator Reverse Power Shutdown Time Delay: amount of time the GSC+ waits before issuing a reverse power shutdown.

0 through 30 seconds② in increments of 1

P128 - Generator Overcurrent Alarm Enable: the GSC+ enables or disables the overcurrent alarm.

0 - disabled 1 – enabled

P129 - Generator Phase Overcurrent Alarm Threshold: level of current the GSC+ uses to issue a phase overcurrent alarm. P130 - Generator Phase Overcurrent Alarm Time Delay: amount of time the GSC+ waits before issuing a phase overcurrent alarm. P131 - Generator Total Overcurrent Alarm Threshold: level of current the GSC+ uses to issue a total overcurrent alarm. P132 - Generator Total Overcurrent Alarm Time Delay: amount of time the GSC+ waits before issuing a total overcurrent alarm.

10 seconds

10 seconds

10 seconds

1

1

1

48Hz 57Hz 378Hz

57Hz

48Hz

10 seconds

10 seconds

10 seconds

1

1

1

45Hz 54Hz 360Hz

54Hz

45Hz

15 seconds

03 seconds

03 seconds

1

1

1

15%

4%

4%

10 seconds

4 seconds

4 seconds

1

1

1

100 through 160% of nameplate current in increments of 5%

105%

150%

150%

0 through 250 seconds② in increments of 1

0 seconds

0 seconds

0 seconds

100 through 160% of three times nameplate current in increments of 5%

105%

150%.

150%

0 through 250 seconds② in increments of 1

0 seconds

0 seconds

0 seconds

1

1

1

110%

150%

150%

0 seconds

10 seconds

10 seconds

0 - disabled 1 – enabled

0 - disabled 1 – enabled 0 through 20% of rated power in increments of 1%.

P133 – Generator Overcurrent Shutdown Enable: 0 – disabled the GSC+ enables or disables the overcurrent 1 – enabled shutdown. P134 – Generator Phase Overcurrent Shutdown 100 through 160% in increments of 5% Threshold: level of current the GSC+ uses to issue a phase overcurrent shutdown. P135 – Generator Phase Overcurrent Shutdown Time Delay: amount of time the GSC+ waits before issuing a phase overcurrent shutdown.

50HZ SETPOINT

0 through 250 seconds② in increments of 1

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OP5-1 SETPOINTS (CONTINUED)

SETPOINTS OP5-1 PROTECTIVE RELAYING PROGRAMMING① SETPOINT-NAME-DESCRIPTION P136 - Generator Total Overcurrent Shutdown Threshold: level of current the GSC+ uses to issue a total overcurrent shutdown. P137 - Generator Total Overcurrent Shutdown Time Delay: amount of time the GSC+ waits before issuing a total overcurrent shutdown. P138 - KW Level Relay Enable : the GSC+ enables or disables the kW level relay function. P139 - KW Level Relay Threshold: level of power the GSC+ uses to activate the kW level relay function. P140 - KW Level Relay Time Delay: amount of time the GSC+ waits before activating the kW level relay function. P141 - KW Level Relay Disengage Threshold: level of power the GSC+ uses to deactivate the kW level relay function. P142 - KW Level Relay Disengage Time Delay: amount of time the GSC+ waits before deactivating the kW level relay function.

FACTORY DEFAULT

60HZ SETPOINT

50HZ SETPOINT

100 through 160% of three times nameplate current in increments of 5%

110%

150%.

150%

0 through 250 seconds② in increments of 1

0 seconds

10 seconds

10 seconds

1

1

1

0 through 110% of nameplate power in increments of 1%

105%

105%

105%

0 through 120 seconds② in increments of 1

0 seconds

0 seconds

0 seconds

0 through 110% of nameplate power in increments of 1%.

100%

100%

100%

0 through 120 seconds② in increments of 1

10 seconds

10 seconds

10 seconds

RANGE OF VALUES

0 - disabled 1 – enabled

① The setpoints are programmed at the factory to the default value. ② When programmed to 0 seconds, the actual time is from 0.5 to 1.0 seconds.

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TABLE 5.9.2.3-3

OP6 SETPOINTS SETPOINTS OP6 SPARE INPUT/OUTPUT PROGRAMMING

SETPOINT-NAME-DESCRIPTIONS

RANGE OF VALUES

FACTORY DPGDS DEFAULT SETPOINT

SP01 - Spare Input 1 Active State. Input state used by the GSC+ to declare a SP1 fault exists.

0-active low 1-active high

0

0

SP02 - Spare Input 1 Response: GSC+ response to a SP1 fault.

0-shutdown 1-alarm

0

0

SP03 - Spare Input 1 Time Delay: Amount of time the GSC+ waits before responding to a SP1 fault.

0 - 250 seconds in increments of 1

0 seconds

1 second

0

1

0

0

0 seconds

0 seconds

0

0

0

0

0 seconds

0 seconds

SP04 - Spare Input 2 Active State. Input state used by the GSC+ to declare a SP2 fault exists. SP05 - Spare Input 2 Response: GSC+ response to a SP2 fault. SP06 - Spare Input 2 Time Delay: Amount of time the GSC+ waits before responding to a SP2 fault. SP07 - Spare Input 3 Active State. Input state used by the GSC+ to declare a SP3 fault exists. SP08 - Spare Input 3 Response: GSC+ response to a SP3 fault.

0-active low 1-active high 0-shutdown 1-alarm 0 - 250 seconds in increments of 1 0-active low 1-active high 0-shutdown 1-alarm

SP09 - Spare Input 3 Time Delay: Amount of time the GSC+ waits before responding to a SP3 fault.

0 - 250 seconds in increments of 1

SP10 - Spare Input 4 Active State. Input state used by the GSC+ to declare a SP4 fault exists.

0-active low 1-active high

0

0

SP11 - Spare Input 4 Response: GSC+ response to a SP4 fault.

0-shutdown 1-alarm

0

0

SP12 - Spare Input 4 Time Delay: Amount of time the GSC+ waits before responding to a SP4 fault.

0 - 250 seconds in increments of 1

0 seconds

0 seconds

SP13 - Spare Output Response: GSC+ response to the spare output trigger condition.

0-active low 1-active high

0

0

8

8

1

1

0-unused 1-active SP1 fault② 2-active SP2 fault② 3-active SP3 fault② SP14 - Spare Output Trigger Condition: The condition used by the GSC+ to trigger the spare output response

4-active SP4 fault② 5-any combination of active SP faults② 6-any active shutdown 7-any active alarm or shutdown 8-cooldown mode 9-coolant loss mode②

10-high oil temp fault② 11-CCM control SP15 – Spare Relay Output Response: GSC+ response to the 0-relay inactive when triggered spare relay trigger condition. 1-relay active when triggered

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OP6 SETPOINTS (CONTINUED) SETPOINTS OP6 SPARE INPUT/OUTPUT PROGRAMMING

SETPOINT-NAME-DESCRIPTIONS

RANGE OF VALUES

FACTORY DPGDS DEFAULT SETPOINT

0-unused 1-active SP1 fault② 2-active SP2 fault② 3-active SP3 fault② SP16 - Spare Relay Output Trigger Condition: The condition used by the GSC+ to trigger the spare relay.

4-active SP4 fault② 5-any combination of active SP faults② 6-any active shutdown 7-any active alarm or shutdown 8-cooldown mode

8

1

0

6

Battle Short mode.

0

0 Battleshort③

Not in 60 Hz mode.

0

9-coolant loss mode② 10-high oil temp fault② 11-CCM control 0-unused 1-active SP1 fault② 2-active SP2 fault② 3-active SP3 fault② SP17 - Spare Indicator 1 Trigger Condition: The condition used by the GSC+ to trigger spare indicator①.

4-active SP4 fault② 5-any combination of active SP1, SP2, SP3 or SP4 faults② 6-Coolant loss fault② 7-high oil temperature fault②

SP18 - Spare Indicator 2 Trigger Condition: The condition used by the GSC+ to trigger spare indicator②. SP19 - Spare Indicator 3 Trigger Condition: The condition used by the GSC+ to trigger spare indicator③.

① The setpoints are programmed at the factory to the default value. ② Either alarm or shutdown faults are valid trigger conditions ③ Battleshort and 50Hz Mode are unique features to DPGDS for spare indicators 2 and 3.

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0 In 50Hz Mode③

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CHANGE OPERATING FREQUENCY FROM 60HZ TO 50HZ

5.9.3.1

MASTER CONTROL PANEL

a. Turn on DC power. b. Open the MCP cabinet door. c.

Place the Frequency Selector Switch (FSS) in the 50 Hz position.

d. Close the MCP cabinet door. 5.9.3.2

DIGITAL VOLTAGE REGULATOR (AVR)

a. Open the GCPG1 cabinet door. b. At the AVR verify/change the operation settings for 50Hz using Table 5.9.2.2-1: c.

Press the [▼] key to display parameter “90”.

d. Press the [◄►] key to display the current value. e. Press the [▲] key to change the value to “0015”. Enables parameter editing. f.

Press the [◄►] key to accept change and display the parameter number.

g. Press the [▲] key to the next parameter needed to change. h. Press the [◄►] key to display the current value. i.

Press the [▲] or [▼] key to change the value.

j.

Press the [◄►] key to accept change and display the parameter number.

k.

Repeat steps ‘g’ through ‘j’ for the each parameter needing to be changed.

l.

When complete, press the [▼] to display parameter “90”.

m. Press the [◄►] key to display the current value. n. Press the [▼] key to change the value to “0009”. Disables parameter editing. o. Press the [◄►] key to accept change and display the parameter number. p. Press the [▲] key to change to display parameter “01”. q. Close the GCPG1 cabinet door. r.

Repeat steps ‘a ‘through ‘q’ for Generator 2.

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GENERATOR SET CONTROLLER (GSC+)

At GSC G1, verify/change the operation settings for 50 Hz using Table 5.9.2.3-1 and Table 5.9.2.3-2. a. Place ECS in the STOP/COOLDOWN position. b. Press SERVICE MODE key to enter service mode. “OP1” is showing on the lower display. c.

Press SCROLL UP key until “OP3” is showing.

d. Press SELECT key. “PE - -“ is showing. e. Press SELECT key. “PE -“ with the first dash flashing is showing. f.

Press SCROLL RIGHT key. “PE 1 -“ with the second dash flashing is showing.

g. Press SCROLL DOWN key. “PE 13 –“ with the third dash flashing is showing. h. Press SCROLL UP key. “PE 132 –“ with the fourth dash flashing is showing. i.

Press SCROLL DOWN key. “PE 1323 –“ with the fifth dash flashing is showing.

j.

Press SCROLL RIGHT key. “PE13231” with all digits not flashing is showing.

k.

Press ENTER key. “PE PASS” is showing.

l.

Press EXIT key. “OP4” is showing.

m. Press SCROLL UP key until “OP5-0” is showing on the lower display. n. Press SELECT key. The value of the setpoint is showing. o. Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing. p. Press SELECT key. The value of the setpoint is flashing. Use the GSC+ Setpoints Table for the values to verify/change in each parameter. q. Press SCROLL UP or SCROLL DOWN key to adjust the value of the setpoint. NOTE:

To adjust the value of some setpoints, it is necessary to press and release the scroll key several times in order for the value to change. To rapidly scroll through a large range of values, press and hold the appropriate scroll key.

r.

Press ENTER key. The value of the setpoint stops flashing.

s.

Repeat steps ‘o’ through ‘r’ until all the desired setpoints are adjusted.

t.

Press EXIT key. “OP5-0” is showing on the lower display.

u. Repeat steps ‘m’ through ‘s’ for “OP5-1”.. v.

Press EXIT key twice. The display returns to normal.

w. Return ECS to the OFF/RESET position.

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Repeat steps ‘a’ through ‘w’ for GSC G2. RE-DESIGNATE A PU WITHOUT PLANT SHUTDOWN

In a multi-PU plant operating in the automatic mode, the PU designated as the “A” unit (PU-A) controls the Economizing function of the plant. There must always be one, and only one, PU designated as PU-A for the plant to operate properly. Each of the other PUs in the plant must also be uniquely designated (PU-B, PU-C, etc.). If it becomes necessary to shutdown PU-A, another unit must be designated as PUA. It may be applied to any unit that is connected to the system network. However, there can be only one (1) PU per plant configured with an individual address. a. Turn off the economizer on the ORT. b. Place the SMS in the MANUAL position for all units in the plant. c. NOTE:

Place the ECS in the MANUAL/START position for all units in the plant. Wait five (5) seconds.

d. Place the SMS in the OFF position on all units in the plant—wait for the USI light to go out. e. Place the USS in the desired position (A, B, C, or D). Note the general procedure in the Section above. NOTE: f.

If necessary, reroute Communication Cables. Place the SMS in the MANUAL position for all units in the plant.

g. Place the MSES in the ENABLE position and hold until the USI energizes. h. Verify that the correct unit selector indicator is lit for each unit. i. NOTE: j. NOTE: j.

Place the ECS in the AUTO position on each unit in the plant. Wait five (5) seconds. Place the SMS in the AUTO position on each unit in the plant. After re-designation of any PU, the system defaults to ECONOMIZER MODE. Enter equipment ID for re-designated units on the ORT.

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FAULT RESETTING

5.9.5.1

OVERCURRENT RELAY TRIP AND BREAKER LOCKOUT WARNING DO NOT RESET A FAULT BEFORE DETERMINING AND CORRECTING THE CAUSE OF A FAULT. RECORD ALL FAULTS/ALARMS BEFORE CLEARING. FAILURE TO CORRECT A FAULT BEFORE RESETTING CAN RESULT IN DEATH, PERSONAL INJURY, OR EQUIPMENT DAMAGE

a. At the overcurrent relay with the “TRIP” LED on: (1) Press the UP arrow twice to get to “1.1 RECLOSER OFF” display. (2) Press the DOWN arrow key once to get to “1.2 TARGETS YES” display. (3) Press RIGHT arrow key twice to get to “1.3 ALARMS YES” display. (4) Press and Hold “RESET” key to clear the trip. (5) Observe the “TRIP” LED de-energizes. b. At the MCP: (1) Cycle the MSES to ENABLE to reset the control lockout. (2) Observe the red SSL de-energizes and the generator will sync and close to the bus if the engine is still running. 5.9.5.2

ENGINE OR GENERATOR FAULT WARNING DO NOT RESET A FAULT BEFORE DETERMINING AND CORRECTING THE CAUSE OF A FAULT. RECORD ALL FAULTS/ALARMS BEFORE CLEARING. FAILURE TO CORRECT A FAULT BEFORE RESETTING CAN RESULT IN DEATH, PERSONAL INJURY, OR EQUIPMENT DAMAGE

a. At the respective GCP, place the ECS in OFF/RESET. b. Observe the fault LED(s) de-energize. c.

At the MCP, cycle the MSES to reset the engine lockout.

d. Observe the red SSL de-energizes. e. Place the ECS in COOLDOWN/STOP. f.

Observe the fault LED(s) and red SSL remain de-energized.

g. Return respective Generator to manual or automatic mode of operation as appropriate.

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RE-CLOSING PSC INTERCONNECT AFTER A FAULT WARNING DO NOT RESET A FAULT BEFORE DETERMINING AND CORRECTING THE CAUSE OF A FAULT. FAILURE TO CORRECT A FAULT BEFORE RESETTING CAN RESULT IN DEATH, PERSONAL INJURY, OR EQUIPMENT DAMAGE WARNING DO NOT RE-CLOSE THE PSC INTERCONNECT SWITCHES UNLESS ONE SIDE OF THE SWITCH IS NOT ENERGIZED. FAILURE TO CORRECT A FAULT BEFORE RESETTING CAN RESULT IN DEATH, PERSONAL INJURY, OR EQUIPMENT DAMAGE

NOTE:

This procedure assumes the PUs in the plant are operating in Automatic and that PSC1 is chosen to power down prior to re-closing the interconnect. The procedure may also be used for isolation of PSC2 by substituting “PSC2” for “PSC1” and “PSC1” for “PSC2”.

a. At the ORT, open the GCGG1 and GCGG2 breakers for all Power Units connected to PSC 1. b. At PSC 1, open and reset all ways connected to loads. c.

Unlock, open and reset the interconnecting switches on PSC 1 and PSC 2.

d. Close and lock PSC 2 interconnect Switch. e. Close and lock PSC 1 interconnect switch. f.

At the ORT, close all generator breakers on all Power Units connected to PSC 1.

g. At PSC 1, close all ways connected to loads. NOTE:

For Interconnection and Operating Procedures of the Primary Switching Center (PSC), refer to USAF TO 35F14-1-1/USA TM9-6115-725-14&P.

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GENERATOR PROCEDURES

5.9.6.1

ADD A GENERATOR TO THE BUS – MANUAL MODE WARNING HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND ENFORCED. NOISE LEVELS IN EXCESS OF 85 DB EXIST WITHIN AN 88-FOOT RADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR SINGLE HEARING PROTECTION WITHIN 88 FEET OF AN OPERATING DPGDS. WARNING HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND ENFORCED. DURING MAINTENANCE ACTIVITIES WITH THE SIDEDOORS OPEN, NOISE LEVELS IN EXCESS OF 113 DB EXIST WITHIN A 12-FOOT RADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR DOUBLE HEARING PROTECTION WITHIN 12 FEET OF AN OPERATING DPGDS. EXPOSURE MUST BE LIMITED TO UNDER 2.5 HOURS.

At the GCP for the generator to be added to the bus, perform the following: NOTE: This procedure assumes that the DC Power is on, and the Generator Pre-Operation inspection has been performed. a. Place the ECS in MANUAL. b. Observe the idle generator starts and accelerates to operating voltage and frequency. c.

Check Voltage and Frequency (3915 VAC, 50 hz or 4295 VAC, 60 hz). Adjust as necessary using FAR and VAR.

d. Check the following engine parameters: i Coolant Water Temperature (nominally 180°F) i Oil Pressure (nominally 40 psi) e. Place the Sync Source Switch in the oncoming GEN position f.

Observe that the BVFM energizes and shows the bus voltage.

g. Observe that the green rectangular LEDs at 3 and 9 on the synchroscope are on. This indicates that the synchroscope sees both running and incoming buses as being energized. h. Observe that the synchroscope appears to be rotating slowly in the clockwise direction. The LEDs composing the circular pattern on the sync scope sequentially illuminate in a clockwise rotation pattern. i. NOTE:

When the triangular green LED at 12 o-clock energizes, close the BCSG breaker switch. You will have to wait until the triangular green LED to reach 12 0-clock.

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Observe that the breaker closed LED energizes and the open LED de-energizes.

k.

Verify the syncscope LEDs stop rotating.

l.

Place the Sync Source Switch back in the OFF position.

m. Verify that the generator takes load from the bus. 5.9.6.2

ADD A GENERATOR TO THE BUS - AUTO MODE

At the PU for the generator to be added, perform the following: a. At the MCP, cycle the MSES switch. b. Observe idle generator starts and automatically parallels to the bus. 5.9.6.3

ADD A GENERATOR TO THE BUS – ORT

a. Select the PU Control Screen for the generator to be added to the bus. b. Press on the START button. c.

Observe the button now says STOP.

d. Observe the generator’s color changes to red. e. Observe the status text says RUNNING. f.

Observe the generator breaker closes and the generator assumes load.

g. Return to the OVERVIEW screen and verify the generators are sharing load equally. NOTE:

5.9.6.4

If the added generator reduces the individual generator load below the economizing threshold, then the control system will automatically shutdown a generator after three minutes. TAKE A GENERATOR OFFLINE – MANUAL MODE CAUTION ENSURE THERE WILL BE SUFFICIENT GENERATING CAPACITY AVAILABLE BEFORE TAKING A GENERATOR OFF LINE.

At the GCP for the generator you want to shutdown, perform the following: a. Open the generator’s breaker by turning the BCS to TRIP and releasing when the green indicator light energizes. b. Place the ECS in STOP/COOLDOWN.

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Observe the generator continues to run for 5 minutes then shuts down.

d. Place the ECS in OFF/RESET. 5.9.6.5

TAKE A GENERATOR OFFLINE – AUTO MODE – WITHOUT ORT CAUTION ENSURE THERE WILL BE SUFFICIENT GENERATING CAPACITY AVAILABLE BEFORE TAKING A GENERATOR OFF LINE.

At the PU for the generator to be shutdown, perform the following: a. At the MCP, place SMS in MANUAL without stopping in OFF. b. At the GCP for the off going generator, open the generator’s breaker by turning the BCS to TRIP and releasing when the green indicator light energizes. c.

At the GCP for the off going generator, place the ECS in STOP/COOLDOWN.

d. At the MCP, place the SMS in AUTO. e. Observe the generator continues to run for 5 minutes then shuts down. f. 5.9.6.6

At the GCP for the off going generator, place the ECS in OFF/RESET. TAKE A GENERATOR OFFLINE – AUTO MODE - WITH ORT CAUTION ENSURE THERE WILL BE SUFFICIENT GENERATING CAPACITY AVAILABLE BEFORE TAKING A GENERATOR OFF LINE.

a. Select the PU Control Screen for the generator to be shutdown. b. Click on the STOP button. c.

Observe the button now says START.

d. Observe the generator’s color changes to green. e. Observe the status text says COOLDOWN. f.

Observe the generator breaker opens.

g. Return to the OVERVIEW screen and verify the remaining generators are sharing load equally. h. Observe the generator continues to run for 5 minutes then shuts down.

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ACKNOWLEDGE AN ALARM OR FAULT – MANUAL MODE

At the PU with the active alarm or fault, perform the following: a. Press the Silence pushbutton and hold for 1 second. b. Repeat ‘a.’ until the horn silences. NOTE:

The repeated pressing of the Silence button is required for multiple alarms or faults. The Silence button will silence only one alarm/fault per action.

5.9.6.8

ACKNOWLEDGE AN ALARM OR FAULT – AUTO MODE

At the PU with the active alarm or fault, perform the following: a. Press the Silence pushbutton and hold for 1 second. b. Repeat ‘a.’ until the horn silences. NOTE:

The repeated pressing of the BSPB is required for multiple alarms or faults. The BSPB will silence only one alarm/fault per action.

5.9.6.9

ACKNOWLEDGE AN ALARM OR FAULT – ORT

On the Critical Alarm Screen Pop-up: a. Select the top alarm. b. Repeat this for each active alarm. NOTE:

This screen cannot be exited until all alarms are acknowledged. Acknowledging alarms on the ORT also silences the buzzer(s) on the PU(s).

NOTE:

All Alarms should be acknowledged individually.

5.9.6.10

ADD AND REMOVE GENERATOR FROM PLANT LINE-UP WITH ORT

a. Select the PU Control Screen for the generator to be added to the bus. b. Click on the START button. c.

Observe the button now says STOP.

d. Observe the generator’s color changes to red. e. Observe the status text says RUNNING. f.

Observe the generator breaker closes and the generator assumes load.

h. Select the PU Control Screen for the generator desiring to take offline. i.

Click on the STOP button.

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Observe the button now says START.

k.

Observe the engine’s color changes to green.

l.

Observe the status text says COOLDOWN.

m. Observe the generator breaker opens. n. Return to the OVERVIEW screen and verify the generators are sharing load equally. o. Observe the generator continues to run for 5 minutes then shuts down. 5.9.6.11

ECONOMIZING ON/OFF – ORT

From any PU Control Screen, perform the following: a. Press the “Economize OFF” button to disable economizing. b. Press the “Economize ON” button to enable economizing. NOTE:

Disabling economizing only stops the control system from shutting down generators during light load conditions. To prevent overloading generators the “add” feature remains active and cannot be disabled.

5.9.6.12

CHANGE FROM MANUAL MODE TO AUTOMATIC MODE WARNING

ONLY ONE PU MAY BE SELECTED TO ANY ONE USS POSITION DURING MULTIPLE PU OPERATIONS. OPERATING WITH MORE THAN ONE UNIT AT THE SAME ID CAUSE UNSAFE AND ERRATIC OPERATIONAL CONDITIONS. At each PU to be put in Automatic mode, perform the following: a. At the MCP, place the SMS in AUTO without stopping in OFF. b. At GCPG1, place ECSA in AUTO. c.

At GCPG2, place ECSB in AUTO.

d. At the MCP, place the MSES in ENABLE and release. e. Observe that either generator, if online, remains online.

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CHANGE FROM AUTOMATIC MODE TO MANUAL MODE WARNING

ONLY ONE PU MAY BE SELECTED TO ANY ONE USS POSITION DURING MULTIPLE PU OPERATIONS. OPERATING WITH MORE THAN ONE UNIT AT THE SAME ID CAUSE UNSAFE AND ERRATIC OPERATIONAL CONDITIONS. At each PU to be put into Manual Mode, perform the following: a. At the MCP, place the SMS in MANUAL without stopping in OFF. b. At GCPG1, place ECSA in MANUAL. c.

At GCPG2, place ECSB in MANUAL.

d. Observe that either generator, if online, remains online.

5.9.6.14

UNIT ISOLATION PROCEDURE (ANY UNIT) – PLANT WITH PSC

a. Place the System Mode Switch (SMS) in “Manual” on all units in the plant. OBSERVE: •

System Status Light (SSL) green LEDs on all units are not illuminated indicating that the units are operating in Manual Mode and that there are no faults or alarms.

b. Start all off-line Engine/Generator sets on the units NOT being isolated. c.

Sync and close to the bus all off-line Engine/Generator sets. OBSERVE: •

All Engine/Generator sets share the load equally.

d. Place the SMS to “OFF” on the unit being isolated. e. Connect (A) (B) Communication cables as required to maintain the load share bus.

f.

•

If the unit being isolated is an end unit on the communication bus (Unit A or Unit D), no additional (A) (B) Communication cable connections are required.

•

If the unit being isolated is an inner unit on the communication bus (Unit B or Unit C), connect an (A) (B) Communication cable between the output connector (B) on Unit D to the input connector (A) on Unit A.

Disconnect the (A) (B) Communication cable(s) on the unit being isolated.

g. Ensure that there is an (A) (B) Communication cable connected to the output connector (B) on unit that is now the right end unit on the communication bus and that the input connector end of that (A) (B) Communication cable is capped.

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i.

•

Both Engine/Generator breakers on the unit being isolated open

•

Remaining on-line Engine/Generator sets in the plant share the load equally

Place the ECS for both Engine/Generator sets in the “Cool down” position on the unit being isolated. OBSERVE: •

Both Engines shut-down after 5 minutes.

j.

Open the Tie breaker on the unit being isolated.

k.

Turn off the DC Control Power Circuit Breaker on the unit being isolated.

l.

Open the ESG input switch for the unit being isolated.

m. Place the ESG input switch for the unit being isolated in the “Grounded” position if so equipped. n. Place the BCST on the unit being isolated in the “Pull-to-Lock” position. o. On the external switchgear, visually confirm, through the viewing windows, that the ESG switch is in the grounded position. NOTE:

At this point the Tie Power cables are completely de-energized. However, safe working practice requires the use of personal protective equipment until a circuit is grounded. If the ESG is equipped with internal circuit grounding, then step “n” can be accomplished without the use of Hot Stick or lineman’s gloves. If the ESG is not equipped with internal circuit grounding, then personal protective equipment should be used.

p. Using a Hot Stick and lineman’s gloves, disconnect and Park the Tie load cables. NOTE:

The unit is now electrically isolated.

q. Re-designate the MEP-PU-810s to ensure that one and only one unit is designated A, B, C or D. There must be a unit designated as “A”. r.

Place the System Mode Switch (SMS) on all units in the plant to the “Automatic” position. DO NOT pause in the “OFF” position when transitioning the SMS from “Manual” to “Automatic".

s.

Cycle the Master Start Enable Switch (MSES) on all units in the plant to the “Enable” position and hold for 3 seconds.

NOTE: 5.9.6.15

The plant is now operating in automatic. UNIT RE-INSTALLATION PROCEDURE – PLANT WITH PSC

a. Ensure the switch for the PSC input to be used is open (“Grounded” if so equipped) b. Connect the load power cables between the MEP-PU-810 Tie output and the PSC input.

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Connect unit equipment ground.

d. Connect the (A) (B) Communication cable(s) with other units in the plant. NOTE:

If the unit being installed is an end unit, ensure a (A) (B) Communication cable is connected to the output side connector.

NOTE:

If the unit being installed is replacing center unit, disconnect the (A) (B) Communication cable that is connecting the two end units at the input side of the left most unit.

e. Perform initial plant setup. Refer to Section 5.7.4.4. f.

Setup the unit to operate in the same mode as the unit(s) that the (A) (B) Communication cable(s) are connected to (either Automatic / Prime Power or Automatic / Utility Parallel)

g. Enter equipment ID for replacement unit on the ORT. OBSERVE: •

System Status Light (SSC) on all Units: both green lights are on steady indicating the Engine/Generator sets are available in Automatic mode; the amber and red lights are off indicating no active alarms or faults.

h. Close the PSC input switch. OBSERVE: •

The Tie breaker closes as soon as power is received from the PSC.

•

The MEP-PU-810 internal bus is energized and common with the power plant bus.

i.

Designate the unit according to the plant setup, ensure one and only one unit is designated “A”, “B”, “C”, or “D”.

j.

One unit must be designated “A”

k.

Cycle the MSS to the “ENABLE” position and hold until an engine cranks. OBSERVE: •

NOTE:

Both Engine/Generator sets start, sync and close to the bus The unit is now integrated with the power plant.

5.9.6.16

ISOLATING A PU IN A TWO PLANT, NO PSC, LINEUP

a. At each PU, change to the Manual Mode per Section 5.9.5.13. b. Start any idle generators on the PU that are to remain operating per Section 5.9.5.1. c.

Open both feeders breakers on the PU to be isolated.

d. Open the “B” plant Tie breaker from its MCP.

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Open the “A” plant Tie breaker from its MCP.

g. Place the BCST to the Pull-To-Lock position. h. Verify the generators on the remaining PU are carrying the load properly. i.

Take the generators on the PU being isolated offline per Section 5.9.5.4.

j.

Using a Hot Stick and lineman’s gloves, disconnect and park the Tie Load Cables on the operating PU.

k.

Verify that the isolated PU feeders are not looped to any operating feeders.

l.

Using a Hot Stick and lineman’s gloves, disconnect and park the Feeder Load Cables on the isolated PU.

m. If either of the feeders on the operating PU is unused, the disconnected feeder cables from the isolated PU may be relocated to that feeder. n. Disconnect the (A) (B) Communication cable (s) between PUs. o. On the isolated PU, place its SMS in OFF. p. Observe the isolated generators shutdown after 5 minutes of cooldown. q. De-energize the isolated PU by pulling out on its DC Power breaker. r.

If the remaining PU is designated as “B”, follow the procedure in Section 5.9.3 for re-designating that unit as “A”.

5.9.6.17

RE-INSTALLING THE SECOND PU INTO A TWO-PLANT-NO-PSC LINEUP

This procedure assumes that the operating PU is operating as Unit “A” in AUTOMATIC. a. Place the operating PU in MANUAL by putting its SMS in MANUAL without stopping in OFF. b. Observe no operating generators drop off line. c.

Position and Ground the incoming PU and perform the startup checks for the unit per Chapter 5.3.

d. Turn on the PU’s DC power by pushing in on the DC Control Power Circuit Breaker. e. Verify the PU’s SMS is in OFF. f.

Connect the Tie Load Cables between the PUs.

g. Connect the (A) (B) Communication cable between the PUs; ‘B-plug’ on operating unit to ‘A-plug’ on incoming unit. h. Connect the other (A) (B) Communication cable into the incoming PU’s ‘B-plug’, leaving the loose end capped. i.

Place the USS on the incoming unit in the “B” position.

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Cycle the incoming tie breaker switch to display the red target.

k.

Place the operating PU’s SMS in AUTOMATIC without stopping in OFF.

l.

Observe the operating PU’s tie breaker automatically closes.

m. Place the incoming PU SMS in AUTOMATIC. n. Observe incoming PU’s tie breaker automatically closes. o. Cycle both generator and feeder breaker switches to display red targets. p. Place both ECSA and ECSB in AUTOMATIC. q. Observe that the generator ready lights on the SSL energize. r.

Cycle the incoming unit MSES and observe the “B” USI energizes.

s.

Observe both generators start and parallel to the bus.

t.

At 3-minute intervals, depending on the load, the automatic system shuts down unnecessary generators.

u. On the ORT, enter equipment ID for the new unit installed.

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THIS PAGE INTENTIONALLY BLANK

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CHAPTER 5.10 OPERATING INSTRUCTIONS PARALLELING MULTIPLE PU PLANTS, EXTERNAL SWITCH, AUTOMATIC MODE TABLE OF CONTENTS SECTION

TITLE

PAGE

5.10

PARALLELING MULTIPLE PU PLANTS, EXTERNAL SWITCH, AUTOMATIC MODE

229

5.10.1

PLANT 1 (PRIME POWER CONFIGURATION)

229

5.10.1.1

SAFETY PROCEDURES

229

5.10.1.2

POSITIONING THE PU

229

5.10.1.3

INITIAL PLANT SETUP

230

5.10.1.3.1

GROUNDING

230

5.10.1.3.2

FUEL MANIFOLD

232

5.10.1.3.3

DISTRIBUTION AND CONTROL CABLING

233

5.10.1.3.4

SETPOINT VERIFICATION

235

5.10.1.3.5

PRE-OPERATION CHECKS

248

5.10.1.3.6

PRE-OPERATION RUN

250

5.10.1.3.7

ORT SETUP

252

5.10.1.3.8

CONTROLS SETUP

253

5.10.1.4

PLANT STARTUP

254

5.10.1.5

PLANT OPERATIONS

257

5.10.1.5.1

PRECAUTIONS AND WARNINGS

257

5.10.1.5.2

DESCRIPTION

257

5.10.1.5.3

DEFAULT OPERATING SEQUENCE

257

5.10.2

PLANT 2 (UTILITY PARALLEL CONFIGURATION)

258

5.10.2.1

SAFETY PROCEDURES

258

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TABLE OF CONTENTS SECTION

TITLE

PAGE

5.10.2.2

POSITIONING THE PU

258

5.10.2.3

INITIAL PLANT SETUP

259

5.10.2.3.1

GROUNDING

259

5.10.2.3.2

FUEL MANIFOLD

261

5.10.2.3.3

DISTRIBUTION AND CONTROL CABLING

262

5.10 2.3.4

SETPOINT VERIFICATION

263

5.10.2.3.5

PRE-OPERATION CHECKS

276

5.10.2.3.6

PRE-OPERATION RUN

278

5.10.2.3.7

ORT SETUP

280

5.10.2.3.8

CONTROLS SETUP

281

5.10.2.4

PLANT STARTUP

282

5.10.2.4.1

GENERAL

282

5.10.2.4.2

MANUAL MODE

283

5.10.2.4.3

AUTOMATIC MODE

283

5.10.2.4

PLANT OPERATIONS

285

5.10.2.5

POWER PLANT TEARDOWN (PLANT 1 & PLANT 2)

285

5.10.2.5.1

SHUT DOWN GENERATORS

285

5.10.2.5.2

DISCONNECT CABLES

286

5.10.2.5.3

DISCONNECT FUEL LINES

286

5.10.2.5.4

DISCONNECT GROUNDING

286

5.10.2.5.5

PREPARE PU FOR TRANSPORTATION

287

5.10.2.5.6

FUEL, OIL, AND COOLANT DRAINAGE

287

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LIST OF FIGURES FIGURE

TITLE

PAGE

FIGURE 5.10.1.3.1-1

MEP-PU-810A GROUND POINTS

231

FIGURE 5.10.1.3.1-2

MEP-PU-810B GROUND POINTS

231

FIGURE 5.10.1.3.2-1

EXTERNAL FUEL SUPPLY

232

FIGURE 5.10.2.3.1-1

MEP-PU-810A GROUND POINTS

260

FIGURE 5.10.2.3.1-3

MEP-PU-810B GROUND POINTS

260

FIGURE 5.10.2.3.2-1

EXTERNAL FUEL SUPPLY

261

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LIST OF TABLES TABLE

TITLE

TABLE 5.10.1.3.4-1

CT RATIO SETTINGS

PAGE 235

TABLE 5.10.1.3.4-2

INSTANTANEOUS TRIP SETTINGS

235

TABLE 5.10.1.3.4-3

TIME OVERCURRENT TRIP SETTINGS

236

TABLE 5.10.1.3.4-4

OP5-0 SETPOINTS

238

TABLE 5.10.1.3.4-4

OP5-0 SETPOINTS (CONTINUED)

239

TABLE 5.10.1.3.4-5

OP5-1 SETPOINTS

241

TABLE 5.10.1.3.4-5

OP5-1 SETPOINTS (CONTINUED)

242

TABLE 5.10.1.3.4-5

OP5-1 SETPOINTS (CONTINUED)

243

TABLE 5.10.1.3.4-6

OP6 SETPOINTS

244

TABLE 5.10.1.3.4-6

OP6 SETPOINTS (CONTINUED)

245

TABLE 5.10.1.3.4-7

AVR PARAMETERS/SETPOINTS

246

TABLE 5.10.1.3.4-7

AVR PARAMETERS/SETPOINTS (CONTINUED)

247

TABLE 5.10.1.3.5-1

PRE-OPERATION CHECKLIST

248

TABLE 5.10.1.3.5-1

PRE-OPERATION CHECKLIST (CONTINUED)

249

TABLE 5.10.1.3.6-1

PRE-OPERATION RUN INSTRUCTION SEQUENCE

251

TABLE 5.10.1.3.8-1

PDC CONTROL SWITCH SETUP

253

TABLE 5.10.1.4-1

SWITCH SETUP – AUTOMATIC MODE

255

TABLE 5.10.2.3.4-1

CT RATIO SETTINGS

263

TABLE 5.10.2.3.4-2

INSTANTANEOUS TRIP SETTINGS

264

TABLE 5.10.2.3.4-3

TIME OVERCURRENT TRIP SETTINGS

264

TABLE 5.10.2.3.4-4

OP5-0 SETPOINTS

266

TABLE 5.10.2.3.4-4

OP5-0 SETPOINTS (CONTINUED)

267

TABLE 5.10.2.3.4-5

OP5-1 SETPOINTS

269

TABLE 5.10.2.3.4-5

OP5-1 SETPOINTS (CONTINUED)

270

TABLE 5.10.2.3.4-5

OP5-1 SETPOINTS (CONTINUED)

271

TABLE 5.10.2.3.4-6

OP6 SETPOINTS

272

TABLE 5.10.2.3.4-6

OP6 SETPOINTS (CONTINUED)

273

TABLE 5.10.2.3.4-7

AVR PARAMETERS/SETPOINTS

274

TABLE 5.10.2.3.4-7

AVR PARAMETERS/SETPOINTS (CONTINUED)

275

TABLE 5.10.2.3.5-1

PRE-OPERATION CHECKLIST

276

TABLE 5.10.2.3.5-1

PRE-OPERATION CHECKLIST (CONTINUED)

277

TABLE 5.10.2.3.6-1

PRE-OPERATION RUN INSTRUCTION SEQUENCE

279

TABLE 5.10.2.3.8-1

PDC CONTROL SWITCH SETUP

281

TABLE 5.10.2.4.3-1

SWITCH SETUP – AUTOMATIC MODE

283

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5.10

PARALLELING MULTIPLE PU PLANTS, EXTERNAL SWITCH, AUTOMATIC MODE

This procedure is for parallel operation of two MEP-PU-810 power plants. One plant must be operated in Prime Power Mode (Plant 1) and the second plant must be operated in Utility Parallel Mode (Plant 2). The procedure assumes that both plants will be connected to external switchgear (PSC or US Army CCV). Once the two plants are setup and operating in parallel, the Utility Parallel plant will produce a fixed power that is specified by the operator and the Prime Power plant will provide power to make up the difference between the total load requirement and the power being produced by the Utility Parallel plant. Each plant is remotely controlled by its own ORT. 5.10.1

PLANT 1 (PRIME POWER CONFIGURATION)

5.10.1.1

SAFETY PROCEDURES

a. Safety precautions must be observed while operating or maintaining the PU. Safety precautions must be observed to ensure that the operator/technician cannot have contact with the following: • • • • • • •

Hot engine parts Hot engine fluids Medium Voltage AC electricity Low Voltage AC electricity Low Voltage DC electricity Rotating Parts High noise levels

b. Minor Troubleshooting can be performed while both engines are running as long as safety precautions are taken. Refer to the appropriate troubleshooting section for recommendations. 5.10.1.2

POSITIONING THE PU

a. Position the PU in such a way as to allow the plant operator to have full vision of the operator control panels on the unit. b. Level the MEP-PU-810B front to rear with the trailer leveling hand crank. c.

Position the PU to provide a minimum of 10 feet of clearance for maintenance access on all sides of each unit. Ensure that there are no overhead obstructions around the exhaust outlets. WARNING FUEL SPILLAGE CAN OCCUR IF THE POWER UNIT LEVEL IS GREATER THAN + 5 DEGREES.

d. Ensure that the ground is capable of supporting the weight of the PU. The site surface should be as level as possible (+ 5 degrees).

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INITIAL PLANT SETUP

5.10.1.3.1

GROUNDING WARNING

THERE CAN ONLY BE ONE GROUNDING POINT FOR THE PU. WHEN USING A NEUTRAL GROUND RESISTER (NGR), IT MUST USE THE PU GROUND ROD TO AVOID CREATING A GROUND LOOP. a. Drive an 8-foot ground rod into the earth and should be within 6 feet of the PU and at a location that minimizes the tripping hazard, until only 6 inches (15 cm) protrudes above the surface. b. Repeat step “a” for each PU being used. c.

Connect all of the grounding rods together with a #2 AWG copper conductor creating a central ground grid.

d. Using a #2 AWG copper conductor, secure one end of a ground cable to one of the slotted ground studs on the PU, see Figure 5.1.3.1-1 or Figure 5.1.3.1-3. Secure the other end of the ground cable to the ground rod. e. Repeat step “d” for every PU. f.

Test Ground Resistance using Ground Resistance Test Equipment. Resistance must be 25Ω or less. Refer to Annex H for special equipment required for this task.

g. Remove parking stand plates from their transportation positions inside each rear, side PU door and slide them into their respective operating positions on the sides of the PDC. h. Connect the parking stand ground wires to either of the two chassis ground lugs on the PU.

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GROUND POINT

FIGURE 5.10.1.3.1-1 NOTE:

GROUND POINT

MEP-PU-810A GROUND POINTS

Connect only one ground point to the ground grid.

GROUND POINT

FIGURE 5.10.1.3.1-2 NOTE:

GROUND POINT

MEP-PU-810B GROUND POINTS

Connect only one ground point to the ground grid.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1R0254 5.10.1.3.2 FUEL MANIFOLD WARNING ENSURE THAT THE FUEL LINES ARE PROTECTED FROM ALL ELECTRICAL CABLES AND ARE ROUTED TO MINIMIZE THE POTENTIAL FOR PHYSICAL DAMAGE OR CAUSING A TRIPPING HAZARD. a. Lay out the fuel hoses between the PU, the fuel manifold, and the fuel bladders to establish the fuel supply system see Figure 5.10.3.2-1. b. Install the external fuel hose for the PU to the Fuel Transfer Pump at the Tow end of the PU. c.

Connect the other end of the fuel hose to the fuel manifold outlets.

d. Connect the 3” hose, with quick-disconnect hose ends, from the fuel manifold to the fuel bladders. e. Connect the fuel manifold ground wire to the ground grid. f.

Open only the appropriate fuel manifold valves (once connected to the PU) to supply fuel to the power units and check for leaks.

FIGURE 5.10.1.3.2-1

EXTERNAL FUEL SUPPLY

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DISTRIBUTION AND CONTROL CABLING WARNING

DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT DURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION AND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN LOAD CABLES ARE HANDLED. WARNING VERIFY THAT CONNECTION POINTS ARE DE-ENERGIZED BEFORE MAKING ANY CONNECTIONS. FAILURE TO CHECK THAT CONNECTORS ARE DE-ENERGIZED MAY RESULT IN INJURY OR DEATH. a. Lay out and park the load cables for each phase (A, B, & C) between the PU Tie Output parking stations and the load. b. Connect each phase cable to the appropriate phase connection on the Primary Switching Center (PSC). NOTE 1:

For complete set-up of the Primary Switching Center (PSC), refer to Radian Inc. Commercial Technical Manual CTM 01646.1R1260, Chapter 2.6.

NOTE 2:

For Unit Isolation Procedure (any unit) - Plant with PSC, and Unit Re-Installation Procedure – Plant with PSC, refer to Chapter 5.9, Sections 5.9.6.15 and 5.9.6.16.

c.

Connect each load cables drain wire to the grounding grid.

d. Open the Tie Output connector loadbreak covers on the first PU. e. Connect the Tie Output Cables to the appropriate phase connectors; ensure there are no crossphase connections. f.

Close and lock the Tie Output connector covers.

g. Repeat steps ‘b’ through ‘f’ on each remaining PU. h. Connect “B” end of the first (A) (B) communication cable to “B” receptacle on first PU. i.

Route the first (A) (B) communication cable to second PU.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1R0254 j.

Connect the first (A) (B) communication cable to “A” receptacle on second PU.

k.

Connect the second (A) (B) communication cable to “B” receptacle on second PU.

m. Route the second (A) (B) communication cable to second PU. n. Connect the second (A) (B) communication cable to “A” receptacle on third PU. o. Connect the third (A) (B) communication cable to “B” receptacle on third PU. p. Route the third (A) (B) communication cable to fourth PU. q. Connect the third (A) (B) communication cable to “A” receptacle on fourth PU. r.

Connect the fourth (A) (B) communication cable to “B” receptacle on fourth PU.

s.

Leave the loose end of fourth cable loose and capped.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1R0254 5.10.1.3.4

SETPOINT VERIFICATION

a. Turn on PU DC control power by pushing in on the DC Control Power breaker. b. On each of the five overcurrent relays, verify the settings: (1)

Press the [▲] key to get to the top-level menu “1 REPORT STATUS”.

(2)

Press the [►] key 5 times to display “6 GENERAL SETTINGS”.

(3)

Press the [▼] key to display “6.1 COM SETTINGS”.

(4)

Press the [►] key 2 times to display “6.3 POWER SYSTEM SETTINGS”.

(5)

Press the [▼] key to display “6.3.1 CT RATIO”.

(6)

Verify the “P” and “N” values match the following table:

TABLE 5.10.1.3.4-1 BREAKER RELAY GENERATOR FEEDER TIE

CT RATIO SETTINGS CT RATIO 100:5 200:5 200:5

“P” VALUE 20 40 40

(7)

Press the [▲] key 2 times to display “6 GENERAL SETTINGS”.

(8)

Press the [◄] key to display “5 PROTECTION LOGIC USER”.

(9)

Press the [▼] key 3 times to display “5.1.1.1 50TP”.

“N” VALUE 20 40 40

(10) Verify the 50TP “PU” and “TD” settings in Table 5.10.1.3.4-2. In order to edit values, Press the “Edit” key. Select correct value, and press “Edit” again to save changes. Ensure light is off otherwise you can accidentally change value again. TABLE 5.10.1.3.4-2 BREAKER RELAY GENERATOR FEEDER TIE

INSTANTANEOUS TRIP SETTINGS PHASE NEUTRAL INSTANTANEOUS INSTANTANEOUS TRIP 50TP TRIP 50TN PU TD PU TD 0.0 0m 3.0 0m 7.5 84m 1.25 84m 0.0 0m 0 0m

(11)

Press the [►] key to display “5.1.1.2 50TN”.

(12)

Verify the “50TN” settings.

(13)

Press the [►] key to display “5.1.1.3”.

(14)

Verify the “50TQ” settings

(15)

Press the [▲] key to display “5.1.1 50T SETTINGS”.

(16)

Press the [►] key to display “5.1.2 51 SETTINGS”.

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NEGATIVE SEQUENCE TRIP 50 TQ PU TD 3.0 0m 0 0m 0.0 0m

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1R0254 (17)

Press the [▼] key to display “5.1.2.1 51P”.

(18)

Verify the 51P “PU”, “TD”, and “C” settings in Table 5.10.1.3.4-3.

TABLE 5.10.1.3.4-3 BREAKER RELAY GENERATOR FEEDER TIE

c.

TIME OVERCURRENT TRIP SETTINGS PHASE TIME OVERCURRENT TRIP 51P PU TD C 4.50 0.5 VV2 2.50 1.0 VV2 5.00 2.0 VV2

NEUTRAL TIME OVERCURRENT TRIP 51N PU TD C 1.25 0.5 VV2 1.00 1.0 VV2 1.50 2.0 VV2

(19)

Press the [►] key to display “5.1.2.2 51N”.

(20)

Verify the “51N” settings.

(21)

Press the [▲] key 3 times to display “5 PROTECTION LOGIC USER”.

Use the following procedure to verify the Generator 1 and Generator 2 GSC+ settings:

NOTE:

Refer to the “EMCPII+ Reference Chart”, located on the interior Generator Control Panel Door (Look-up) (1)

Place ECS in the COOLDOWN/STOP position.

(2)

Press SERVICE MODE key to enter service mode. OP1 is showing on the lower display.

(3)

Press SCROLL UP key until “OP3” is showing.

(4)

Press SELECT key. “PE -“ with the first dash flashing is showing.

(5)

Press SCROLL RIGHT key. “PE 1 -“ with the second dash flashing is showing.

(6)

Press SCROLL DOWN key. “PE 13 –“ with the third dash flashing is showing.

(7)

Press SCROLL UP key. “PE 132 –“ with the fourth dash flashing is showing.

(8)

Press SCROLL DOWN key. “PE 1323 –“ with the fifth dash flashing is showing.

(9)

Press SCROLL RIGHT key. “PE13231” with all digits not flashing is showing.

(10) Press ENTER key. “PE PASS” is showing. (11) Press EXIT key. “OP4” is showing. (12) Press SCROLL UP key until “OP5-0” is showing on the lower display. (13) Press SELECT key. “POO1” followed with the value of the setpoint is showing. (14) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing. Use table 5.10.3.4-4 for the parameter values to be verified.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1R0254 (15) Repeat step “15” until the desired setpoints are verified. (16) Press EXIT key. “OP5-0” is showing on the lower display. (17) Press SCROLL UP key until “OP5-1” is showing. (18) Press SELECT key. (19) Repeat steps 15 and 16 for “OP5-1” using Table 5.10.3.4-5. (20) Repeat steps 17, 18, and 19 for OP6. (21) Repeat steps 15 and 16 for “OP6” using Table 5.10.3.4-6. (22) Press EXIT Key twice. The display returns to normal. NOTE:

If an incorrect setpoint value is displayed, the value must be changed to match the DPGDS setpoint value as follows: (a)

With the setpoint with the incorrect value showing on the display, press the SELECT key. The incorrect value flashes on the display.

(b)

Press SCROLL UP or SCROLL DOWN key until the correct value appears flashing on the display.

(c)

Press ENTER. The correct value stops flashing on the display.

(d)

Press SCROLL UP or SCROLL DOWN key to continue to verify the remaining parameter values.

d. At GSC G1 and GSC G2, verify the operation settings using the following table:

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OP5-0 SETPOINTS

SETPOINTS OP5-0 ENGINE/GENERATOR PROGRAMMING① FACTORY DPGDS SETPOINT-NAME-DESCRIPTIONS RANGE OF VALUES DEFAULT SETPOINT P001 - Fuel Solenoid Type: type of fuel system solenoid used on the genset.

0- ETR fuel solenoid 1- ETS fuel solenoid

0

0

P002 - Units Shown: type of measurement units shown on the GSC+ display.

0-for English units (PSI, ºF) 1-for metric units (kPa, ºC).

0

0

P003 - Shutdown Override For Engine Fault: GSC+ response to a low engine oil pressure or high coolant temperature fault.

0-for engine shutdown 1-for alarm only (shutdown override, no engine shutdown).

0

0

P004 - Shutdown Override For Sensor Fault: GSC+ response to a diagnostic fault with the engine oil pressure sensor, coolant temperature sensor, oil temperature sensor, sensor power supply or coolant loss sensor.

0-for alarm only shutdown override, no engine shutdown). 1-for engine shutdown.

0

0

P005 - Coolant Loss Sensor Installed: tells whether or not the optional engine coolant loss sensor is installed on the genset.

0-for gensets without a coolant loss sensor 1-for gensets with coolant loss sensor

0

1

P006 - Shutdown Override For Coolant Loss Fault: GSC+ response to an engine coolant loss fault.

0-for engine shutdown. 1-for alarm only (shutdown override, no engine shutdown).

0

0

P007 - System Voltage, 24 Or 32 Volts: system voltage (battery voltage) of the genset.

24 or 32.

24

24

P008 - This setpoint is not currently being used by the GSC+ and cannot be programmed.

N/A

N/A

N/A

P009 - Number Of Ring Gear Teeth: number of teeth on the ring gear of the engine. Used by the GSC+ to determine engine speed.

95 to 350 teeth in increments of one tooth.

136 teeth

136 teeth

P010 - Engine Overspeed: engine speed used by the GSC+ to declare that an engine overspeed fault exists. The engine overspeed setpoint (for all 60 Hz applications) is 1.18 times the rated speed.

500 to 4330 rpm in increments of 10 rpm.

2120 rpm

2120 rpm

P011 - Crank Terminate Speed: engine speed used by the GSC+ to disengage the starting motor during engine cranking.

100 to 1000 rpm in increments of 10 rpm.

400 rpm

400 rpm

P012 - Oil Step Speed: engine speed used by the GSC+ for distinguishing between rated speed and idle speed when a low oil pressure fault exists.

400 to 1800 rpm in increments of 10 rpm.

1350 rpm

1350 rpm

P013② - Low Oil Pressure Shutdown At Rated Speed: oil pressure used by the GSC+ to declare that a low oil pressure shutdown fault exists with engine at rated speed (the engine speed must have exceeded the oil step speed for nine seconds).

5 to 61PSI (34 to 420kPa) in increments of 1

30 PSI (205 kPa)

30 PSI (205 kPa)

P014② - Low Oil Pressure Shutdown At Idle Speed: oil pressure used by the GSC+ to declare that a low oil pressure shutdown fault exists with the engine at idle speed (the engine must have been running for at least 9 seconds and the engine speed must be less than oil step speed).

20 to 336kPa (3 to 49PSI) in increments of 1

10 PSI (70 kPa)

10 PSI (70 kPa)

P015③ - High Water Temperature Shutdown: coolant temperature used by the GSC+ to declare a high coolant temperature shutdown fault exists (after a 10 second delay).

185 to 253ºF (85 to 123ºC) in increments of 1

225ºF (107ºC)

225ºF (107ºC)

P016 - Low Water Temperature Alarm: coolant temperature used by the GSC+ to declare that a low coolant temperature alarm fault exists (after a 2 second delay).

32 to 97ºF (0 to 36ºC) in increments of 1

70ºF (21ºC)

70ºF (21ºC)

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OP5-0 SETPOINTS (CONTINUED)

SETPOINTS OP5-0 ENGINE/GENERATOR PROGRAMMING① FACTORY SETPOINT-NAME-DESCRIPTIONS RANGE OF VALUES DEFAULT

DPGDS SETPOINT

P017 - Total Cycle Crank Time: cycle crank time used by the 5 to 120 seconds in increments of 1 GSC+ to declare that an overcrank fault exists. second.

90 seconds

90 seconds

P018 - Cycle Crank Time: amount of time the GSC+ cranks and then rests the starting motor during a single crank cycle.

10 seconds

10 seconds

5 minutes

5 minutes

700, 150, 300, 500, 600, 750, 3.0k, 4.5k, 5.20k, 5.25k, 9.0k, 15.0k, 18.0k, 30.0k

700

5.20k

75, 100, 150, 200, 300, 400, 600, 800, 1000, 1200, 1500, 2000, 2500, 3000, and 4000A

600A

100A

01

01 (Gen 1) 02 (Gen 2)

5 to 60 seconds in increments of 1 second.

P019 - Cooldown Time: amount of time the GSC+ allows the 0 to 30 minutes in increments of 1 engine to run after a normal shutdown is initiated. minute. P020④ - AC Voltage: nominal AC voltage of the generator. The GSC+ measures the AC voltage and shows it on the display. P021 - AC Current Full Scale: nominal full scale AC current of the generator. AC current full scale is equal to the ratio of the external current transformers in the generator housing. P022⑤ - GSC+ Engine Number: informs other devices on the CAT Data Link of the engine number for the GSC+.

01 through 08

SETPOINTS - OP5-0-ENGINE/GENERATOR PROGRAMMING① RANGE OF FACTORY 60HZ 50HZ SETPOINT-NAME-DESCRIPTIONS DEFAULT SETPOINT SETPOINT VALUES P023 - Engine Type: identifies the engine as a mechanical unit injector (MUI) diesel, spark ignited (gas), or electronic unit injector (EUI) diesel engine.

0 - MUI diesel 1 - Gas 2 - EUI diesel

P024 - Crank Time Delay: amount of time the GSC+ delays activation of the fuel control relay (FCR) during a crank cycle. This setpoint is for Gas engines only. The P024 setpoint only functions when the P023 setpoint is set to 1 (gas engine).

0 to 20 seconds in increments of 1 second.

0 - for gensets without an oil P025 - Oil Temperature Sensor Installed: tells temperature sensor whether or not the optional engine oil temperature 1 - for gensets with an oil sensor is installed on the genset. temperature sensor P026 - High Oil Temperature Shutdown: oil temperature used by the GSC+ to declare a high 185 to 253ºF (85 to 123ºC) in increments of 1 oil temperature shutdown fault exists (after a 10 second delay). Refer to the panel model number. 0 - for alarm only (shutdown override, P027 - Shutdown Override For High Oil Temperature Fault: GSC+ response to an engine no engine shutdown). high oil temperature fault. 1 - for engine shutdown. P028 - Nameplate Voltage: rated voltage of the generator. This setpoint is used for protective relaying functions. P029 - Nameplate Current: rated current output of the generator.

0

2

2

5 Seconds

5 Seconds

5 Seconds

0

0

0

225ºF (107ºC)

225ºF (107ºC) 225ºF (107ºC)

0

0

0

100 to 25kV in increments of 1

480V

4160V

3800V

0 to 4000 A in increments of 1

600A

80A

73A

400kW

420kW

350kW

60Hz

60Hz

50Hz

0

0

0

4

4

4

P030 - Nameplate Power: rated power capability 0 through 10MW in increments of of the generator. 1kW. P031 - Rated Frequency: nominal frequency 50 or 60Hz rating of genset. P032 - Connection Configuration Of Generator: 0 - wye wye or delta configuration of generator. 1 - delta P033 - Number Of Generator Poles. 0 through 254 in increments of 2.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1R0254 ①

The setpoints (stored or being programmed) must match the specified DPGDS setpoints.

② When oil pressure drops to within 5PSI (34kPa) of the P013 or P014 setpoint, a low oil pressure alarm is issued by the GSC+. ③ When coolant temperature rises to within 11ºF (6ºC) of the P015 setpoint, a high coolant temperature alarm is issued by the GSC+. ④ The values other than the default (700V) are for switchgear applications and require the use of external potential transformers and the removal of the AC voltage range jumper located in the relay module. The DPGDS unit is factory configured for the 5.20 K value. See the Caterpillar Electronic Modular Control Panel II+ manual topic AC Voltage Range Selection in the Testing and Adjusting section. ⑤ After setpoint P022 is reprogrammed, the GSC+ must be power cycled (powered down and then powered up)

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TABLE 5.10.1.3.4-5 OP5-1 SETPOINTS SETPOINTS OP5-1 PROTECTIVE RELAYING PROGRAMMING① FACTORY 60HZ 50HZ SETPOINT-NAME-DESCRIPTION RANGE OF VALUES DEFAULT SETPOINT SETPOINT P101 - Generator Overvoltage Alarm Enable: the 0 - disabled GSC+ enables or disables the generator 1 - enabled overvoltage alarm function. P102 - Generator Overvoltage Alarm Threshold: voltage the GSC+ uses to issue an overvoltage alarm.

100 to 125% of nameplate voltage in increments of 1%.

P103 - Generator Overvoltage Alarm Time Delay: amount of time the GSC+ waits before issuing an overvoltage alarm. P104 - Generator Overvoltage Shutdown Enable: the GSC+ enables or disables the generator overvoltage shutdown function. P105 - Generator Overvoltage Shutdown Threshold: voltage the GSC+ uses to issue an overvoltage shutdown. P106 - Generator Overvoltage Shutdown Time Delay: amount of time the GSC+ waits before issuing an overvoltage shutdown.

0 through 120 seconds② in increments of 1

P107 - Generator Undervoltage Alarm Enable: the GSC+ enables or disables the generator undervoltage alarm function.

0 - disabled 1 - enabled

P108 - Generator Undervoltage Alarm Threshold: voltage the GSC+ uses to issue an undervoltage alarm. P109 - Generator Undervoltage Alarm Time Delay: amount of time the GSC+ waits before issuing an undervoltage alarm. P110 - Generator Undervoltage Shutdown Enable: the GSC+ enables or disables the generator undervoltage shutdown function. P111 - Generator Undervoltage Shutdown Threshold: voltage the GSC+ uses to issue an undervoltage shutdown.

0 - disabled 1 - enabled 100 to 125% of nameplate voltage in increments of 1%. 0 through 120 seconds② in increments of 1

60 to 100% of nameplate voltage in increments of 1%. 0 through 120 seconds② in increments of 1 0 - disabled 1 - enabled 60 through 100% of rated voltage in increments of 1%.

P112 - Generator Undervoltage Shutdown Time Delay: amount of time the GSC+ waits before issuing an undervoltage shutdown.

0 through 120 seconds② in increments of 1

P113 - Generator Overfrequency Alarm Enable: the GSC+ enables or disables the generator overfrequency alarm function.

0 - disabled 1 - enabled

P114 - Generator Overfrequency Alarm Threshold: frequency the GSC+ uses to issue an overfrequency alarm.

50-60Hz, for 50Hz Gen 60-70Hz, for 60Hz Gen 400-480, for 400Hz Gen

P115 - Generator Overfrequency Alarm Time Delay: amount of time the GSC+ waits before issuing an overfrequency alarm.

0 through 120 seconds② in increments of 1

P116 - Generator Overfrequency Shutdown Enable: the GSC+ enables or disables the generator overfrequency shutdown function.

0 - disabled 1 - enabled

P117 - Generator Overfrequency Shutdown Threshold: frequency the GSC+ uses to issue an overfrequency shutdown.

50-60Hz, for 50Hz Gen 60-70Hz, for 60Hz Gen 400-480, for 400Hz Gen

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1

1

1

105%

105%

105%

10 seconds

10 seconds

10 seconds

1

1

1

110%

110%

110%

10 seconds

10 seconds

10 seconds

1

1

1

90%

90%

90%

10 seconds

10 seconds

10 seconds

1

1

1

85%

85%

85%

15 seconds

03 seconds

03 seconds

1

1

1

53Hz 63Hz 422Hz

63 Hz

53 Hz

10 seconds

10 seconds

10 seconds

1

1

1

55Hz 66Hz 440Hz

66Hz

55Hz

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1R0254 TABLE 5.10.1.3.4-5 OP5-1 SETPOINTS (CONTINUED) SETPOINTS OP5-1 PROTECTIVE RELAYING PROGRAMMING① FACTORY 60HZ SETPOINT-NAME-DESCRIPTION RANGE OF VALUES DEFAULT SETPOINT P118 - Generator Overfrequency Shutdown Time Delay: amount of time the GSC+ waits before issuing an overfrequency shutdown.

0 through 120 seconds② in increments of 1

P119 - Generator Underfrequency Alarm Enable: the GSC+ enables or disables the generator underfrequency alarm function.

0 - disabled 1 - enabled

P120 - Generator Underfrequency Alarm Threshold: frequency the GSC+ uses to issue an underfrequency alarm.

30-50Hz, for 50Hz Gen 36-60Hz, for 60Hz Gen 240-400, for 400Hz Gen

P121 - Generator Underfrequency Alarm Time Delay: amount of time the GSC+ waits before issuing an underfrequency alarm. P122 - Generator Underfrequency Shutdown Enable: the GSC+ enables or disables the generator underfrequency shutdown function.

0 through 120 seconds② in increments of 1

P123 - Generator Underfrequency Shutdown Threshold: frequency the GSC+ uses to issue an underfrequency shutdown.

30-50Hz, for 50Hz Gen 36-60Hz, for 60Hz Gen 240-400, for 400Hz Gen

P124 - Generator Underfrequency Shutdown Time Delay: amount of time the GSC+ waits before issuing an underfrequency shutdown. P125 - Generator Reverse Power Shutdown Enable: the GSC+ enables or disables the generator reverse power shutdown function. P126 - Generator Reverse Power Shutdown Threshold: level of reverse power the GSC+ uses to issue a reverse power shutdown.

0 through 120 seconds② in increments of 1

P127 - Generator Reverse Power Shutdown Time Delay: amount of time the GSC+ waits before issuing a reverse power shutdown.

0 through 30 seconds② in increments of 1

P128 - Generator Overcurrent Alarm Enable: the GSC+ enables or disables the overcurrent alarm.

0 - disabled 1 - enabled

P129 - Generator Phase Overcurrent Alarm Threshold: level of current the GSC+ uses to issue a phase overcurrent alarm. P130 - Generator Phase Overcurrent Alarm Time Delay: amount of time the GSC+ waits before issuing a phase overcurrent alarm. P131 - Generator Total Overcurrent Alarm Threshold: level of current the GSC+ uses to issue a total overcurrent alarm. P132 - Generator Total Overcurrent Alarm Time Delay: amount of time the GSC+ waits before issuing a total overcurrent alarm.

10 seconds

10 seconds

10 seconds

1

1

1

48Hz 57Hz 378Hz

57Hz

48Hz

10 seconds

10 seconds

10 seconds

1

1

1

45Hz 54Hz 360Hz

54Hz

45Hz

15 seconds

03 seconds

03 seconds

1

1

1

15%

4%

4%

10 seconds

4 seconds

4 seconds

1

1

1

100 through 160% of nameplate current in increments of 5%

105%

150%

150%

0 through 250 seconds② in increments of 1

0 seconds

0 seconds

0 seconds

100 through 160% of three times nameplate current in increments of 5%

105%

150%.

150%

0 through 250 seconds② in increments of 1

0 seconds

0 seconds

0 seconds

1

1

1

110%

150%

150%

0 seconds

10 seconds

10 seconds

0 - disabled 1 - enabled

0 - disabled 1 - enabled 0 through 20% of rated power in increments of 1%.

P133 – Generator Overcurrent Shutdown Enable: 0 – disabled the GSC+ enables or disables the overcurrent 1 – enabled shutdown. P134 – Generator Phase Overcurrent Shutdown 100 through 160% in increments of 5% Threshold: level of current the GSC+ uses to issue a phase overcurrent shutdown. P135 – Generator Phase Overcurrent Shutdown Time Delay: amount of time the GSC+ waits before issuing a phase overcurrent shutdown.

50HZ SETPOINT

0 through 250 seconds② in increments of 1

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SETPOINTS OP5-1 PROTECTIVE RELAYING PROGRAMMING① SETPOINT-NAME-DESCRIPTION P136 - Generator Total Overcurrent Shutdown Threshold: level of current the GSC+ uses to issue a total overcurrent shutdown. P137 - Generator Total Overcurrent Shutdown Time Delay: amount of time the GSC+ waits before issuing a total overcurrent shutdown. P138 - KW Level Relay Enable : the GSC+ enables or disables the kW level relay function. P139 - KW Level Relay Threshold: level of power the GSC+ uses to activate the kW level relay function. P140 - KW Level Relay Time Delay: amount of time the GSC+ waits before activating the kW level relay function. P141 - KW Level Relay Disengage Threshold: level of power the GSC+ uses to deactivate the kW level relay function. P142 - KW Level Relay Disengage Time Delay: amount of time the GSC+ waits before deactivating the kW level relay function.

FACTORY DEFAULT

60HZ SETPOINT

50HZ SETPOINT

100 through 160% of three times nameplate current in increments of 5%

110%

150%.

150%

0 through 250 seconds② in increments of 1

0 seconds

10 seconds

10 seconds

1

1

1

0 through 110% of nameplate power in increments of 1%

105%

105%

105%

0 through 120 seconds② in increments of 1

0 seconds

0 seconds

0 seconds

0 through 110% of nameplate power in increments of 1%.

100%

100%

100%

0 through 120 seconds② in increments of 1

10 seconds

10 seconds

10 seconds

RANGE OF VALUES

0 - disabled 1 - enabled

① The setpoints are programmed at the factory to the default value. ② When programmed to 0 seconds, the actual time is from 0.5 to 1.0 seconds.

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TABLE 5.10.1.3.4-6 OP6 SETPOINTS SETPOINTS OP6 SPARE INPUT/OUTPUT PROGRAMMING SETPOINT-NAME-DESCRIPTIONS

RANGE OF VALUES

FACTORY DPGDS DEFAULT SETPOINT

SP01 - Spare Input 1 Active State. Input state used by the GSC+ to declare a SP1 fault exists.

0-active low 1-active high

0

0

SP02 - Spare Input 1 Response: GSC+ response to a SP1 fault.

0-shutdown 1-alarm

0

0

SP03 - Spare Input 1 Time Delay: Amount of time the GSC+ waits before responding to a SP1 fault.

0 - 250 seconds in increments of 1

0 seconds

1 second

0

1

0

0

0 seconds

0 seconds

0

0

0

0

0 seconds

0 seconds

SP04 - Spare Input 2 Active State. Input state used by the GSC+ to declare a SP2 fault exists. SP05 - Spare Input 2 Response: GSC+ response to a SP2 fault. SP06 - Spare Input 2 Time Delay: Amount of time the GSC+ waits before responding to a SP2 fault. SP07 - Spare Input 3 Active State. Input state used by the GSC+ to declare a SP3 fault exists. SP08 - Spare Input 3 Response: GSC+ response to a SP3 fault.

0-active low 1-active high 0-shutdown 1-alarm 0 - 250 seconds in increments of 1 0-active low 1-active high 0-shutdown 1-alarm

SP09 - Spare Input 3 Time Delay: Amount of time the GSC+ waits before responding to a SP3 fault.

0 - 250 seconds in increments of 1

SP10 - Spare Input 4 Active State. Input state used by the GSC+ to declare a SP4 fault exists.

0-active low 1-active high

0

0

SP11 - Spare Input 4 Response: GSC+ response to a SP4 fault.

0-shutdown 1-alarm

0

0

SP12 - Spare Input 4 Time Delay: Amount of time the GSC+ waits before responding to a SP4 fault.

0 - 250 seconds in increments of 1

0 seconds

0 seconds

SP13 - Spare Output Response: GSC+ response to the spare output trigger condition.

0-active low 1-active high

0

0

8

8

1

1

0-unused 1-active SP1 fault② 2-active SP2 fault② 3-active SP3 fault② SP14 - Spare Output Trigger Condition: The condition used by the GSC+ to trigger the spare output response

4-active SP4 fault② 5-any combination of active SP faults② 6-any active shutdown 7-any active alarm or shutdown 8-cooldown mode 9-coolant loss mode②

10-high oil temp fault② 11-CCM control SP15 – Spare Relay Output Response: GSC+ response to the 0-relay inactive when triggered spare relay trigger condition. 1-relay active when triggered

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1R0254 TABLE 5.10.1.3.4-6 OP6 SETPOINTS (CONTINUED) SETPOINTS OP6 SPARE INPUT/OUTPUT PROGRAMMING SETPOINT-NAME-DESCRIPTIONS

RANGE OF VALUES

FACTORY DPGDS DEFAULT SETPOINT

0-unused 1-active SP1 fault② 2-active SP2 fault② 3-active SP3 fault② SP16 - Spare Relay Output Trigger Condition: The condition used by the GSC+ to trigger the spare relay.

4-active SP4 fault② 5-any combination of active SP faults② 6-any active shutdown 7-any active alarm or shutdown 8-cooldown mode

8

1

0

6

Battle Short mode.

0

0 Battleshort③

Not in 60 Hz mode.

0

9-coolant loss mode② 10-high oil temp fault② 11-CCM control 0-unused 1-active SP1 fault② 2-active SP2 fault② 3-active SP3 fault② SP17 - Spare Indicator 1 Trigger Condition: The condition used by the GSC+ to trigger spare indicator①.

4-active SP4 fault② 5-any combination of active SP1, SP2, SP3 or SP4 faults② 6-Coolant loss fault② 7-high oil temperature fault②

SP18 - Spare Indicator 2 Trigger Condition: The condition used by the GSC+ to trigger spare indicator②. SP19 - Spare Indicator 3 Trigger Condition: The condition used by the GSC+ to trigger spare indicator③.

① The setpoints are programmed at the factory to the default value. ② Either alarm or shutdown faults are valid trigger conditions ③ Battleshort and 50Hz Mode are unique features to DPGDS for spare indicators 2 and 3.

e. Return ECS1 and ECS2 to the OFF/RESET position. NOTE: f.

Use up or down keys to change values. At the AVR verify the operation settings using Table 5.10.1.3.4-7: (1)

Open the GCPG1 cabinet door.

(2)

Press the [▼] key to display parameter “90”.

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0 In 50Hz Mode③

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1R0254 (3)

Press the [◄►] key to display the current value.

(4)

Press the [▲] key to change the value to “0015”. Enables parameter editing.

(5)

Press the [◄►] key to accept change and display the parameter number.

(6)

Press the [▲] key to the next parameter needed to change.

(7)

Press the [◄►] key to display the current value.

(8)

Press the [▲] or [▼] key to change the value.

(9)

Press the [◄►] key to accept change and display the parameter number.

(10) Repeat steps ‘5’ through ‘9’ for the each parameter needing to be changed. (11) When complete, press the [▼] to display parameter “01”. NOTE:

Parameters 20, 21, 22, 36, 37, and 38 are displayed but not used.

NOTE:

Parameters 23 to 29, 39 to 49, 59 and 61 to 89 are not displayed and not used.

TABLE 5.10.1.3.4-7

AVR PARAMETERS/SETPOINTS DPGDS SETPOINTS

DPGDS AVR PARAMETERS PARAMETER 01 02 03 04

TITLE Generator Output Voltage Ratio of Output Voltage To Sensing Voltage Generator Type Rated Generator Output Current

TYPE

UNITS

RANGE OF VALUES

DEFAULT VALUE

60HZ OPS

50HZ OPS

Program

Volts

0080-9999

480①

4160

3800

001.0-100.0

001.0

17.3

17.3

Program Program Program

Amps

0000-0004 0000-9999

0004 0600

4 80

4 73

Program

Volts

01.00-05.00

05.00

4.00

3.66

06 07 08

CT Voltage At Rated Generator Current Knee Frequency Decreasing Volts/Hz Slope I Decreasing Volts/Hz Slope 2

Program Program Program

Hz Volts/Hz Volts/Hz

045.0-065.0 001.0-010.0 001.0-010.0

050.0 002.0 002.0

59.8 2.0 2.0

49.8 2.0 2.0

09 10 11 12 13 14

Minimum Voltage Under Frequency Point Overvoltage Trip Point Overvoltage Trip Time Under Voltage Trip Point Under Voltage Trip Time

Program Program Program Program Program Program

% Hz % Seconds % Seconds

050.0 025.0 014.0 0002 0060 0030

50.0 25.0 125.0 5 75 30

50.0 25.0 125.0 5 75 30

15

Voltage Gain (IR Compensation)

Program

%

050.0-100.0 020.0-040.0 0105-0140 0002-0030 0060-0095 0030-0120 000.0-0 10.0

0000

0

0

Integral Gain

Program

001.0-020.0

006.0

6.0

6.0

Proportional Gain

Program

001.0-020.0

005.0

5.0

5.0

Program

0000,0001

0000

0000

0000

001.0-010.0

002.0

2.0

2.0

05②

16⑤ 17⑥ 18 19

Single Phase Sensing Select (0=three phase, 1=single phase) Diode Monitor Trip Point

Program

Amps

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1R0254 TABLE 5.10.1.3.4-7

AVR PARAMETERS/SETPOINTS (CONTINUED) DPGDS SETPOINTS

DPGDS AVR PARAMETERS TYPE

UNITS

RANGE OF VALUES

Droop Percentage

Program

%

000.0-010.0

0000

3

3

31③

pf/Kvar Select (0=pf, 1=Kvar)

Program

0000, 0001

0000

0

0

32③

Pf Reference

Program

00.60-01.10

01.00

0.8

0.8

33③

KVAR Reference

Program

Per Unit

00.00-01.00

0000

0.10

0.10

34③

Reverse Power Trip Point

Program

%

000.0-020.0

010.0

15

15

35③ 50 51 52 53

Reverse Power Trip Time

Program

Seconds

000.0-020.0

010.0

5

5

Generator Output Frequency Generator Output Voltage Generator Output Current Generator Reactive Output Current

View View View View

Hz Volts Amps Amps

View View

Amps Amps

56③

Generator Real Current Exciter Field Current Three Phase Kilowatts (KB and later)

View

KW

57③

Power Factor

View

Three Phase Kvar (KE and later)

View 0009

0009

0000 0000

0000 0000

PARAMETER 30

54 55

58③, ④ 60 90 91 92 93 94 96

TITLE

Hours Password Software ID Latest Fault Previous Fault Fault Clear Shutdown Fault Reset

View Program View

Hours

DEFAULT VALUE

60HZ OPS

50HZ OPS

0000-9999

View View View Switch

0000 0000

①- Default value for output voltage is different depending on regulator sensing voltage. If the regulator is

designed for 120 volts sensing, then the default output voltage is 4160 volts. All other sensing types have the default output voltage set to 480 volts. ②- Digital Voltage Regulators with earlier software (KD and earlier) have 1 less digit to the right of the

decimal point. ③- Optional feature. ④- New parameter on serial number prefix KE and later Digital Voltage Regulators. ⑤- Previous range of 0001-099.9 and default value of 002.0

⑥-Previous range of 0001-099.9 and default value of 002.0 (12) When complete, press the [▼] to display parameter “90”. (13) Press the [◄►] key to display the current value. (14) Press the [▼] key to change the value to “0009”. Disables DVR parameter editing. (15) Press the [◄►] key to accept change and display the parameter number.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1R0254 (16) Press the [▲] key to change to display parameter “01”. (17) Close the GCPG1 cabinet door. (18) Repeat steps ‘1 ‘through ‘16’ for Generator 2. 5.10.1.3.5

PRE-OPERATION CHECKS

Starting from the left rear of the PU and working around the PU in a clockwise direction, perform the following checks (Gen. 1 is on the left and Gen. 2 is on the right): TABLE 5.10.1.3.5-1 PRE-OPERATION CHECKLIST ITEM ACTION REQUIRED NUMBER Ensure the parking brake is set. Rotate the crank in a clockwise rotation 1 (PU-810 A) to set. Ensure that the wheels are properly chocked or the Spring Brakes are 1 (PU-810-B) set by opening the petcock on the air tank and evacuating all the air. Check the ground connection. 2 Check that the ORT communication cable is connected properly. 3 Ensure the feeder output cables, if used, are properly connected and 4 that the concentric neutrals are connected to ground. Ensure that the feeder output cover is secured. (Locked) 5 Check Parking Stands for proper mounting and connection. 6 Check the two 120-Volt auxiliary duplex receptacles and the 60 amp 3 7 phase receptacle cables are securely connected or the covers are properly installed / closed. Open the left rear PU side access door and inspect the area for cleanliness, loose electrical connections, loose hardware, and leaks 8 around the oil filter and lines. Check for signs of heat damage or other abnormalities. Check all high voltage panels for security Ensure that the battery charger voltmeter displays (24 VDC), is plugged into the battery charger receptacle, and that all circuit breakers are 9 turned on. Return to this step after a generator breaker is closed to ensure charger is supplying current to the batteries. Visually inspect the air intake duct for obstructions or foreign objects. 10 Close the left rear PU door. 11 Open the left front PU side access door and inspect the area for 12 cleanliness, loose electrical connections, loose hardware, leaks around oil and fuel lines, signs of heat damage or other abnormalities. Drain the crankcase vent reservoir (fumes box) into a proper container. 13 If necessary, open the Primary Fuel Filter Drain Valve and drain any 14 accumulated water into an appropriate container. Check oil level for Generator 1. 15 Ensure fuel shutoff valve is in the open position (valve handle is parallel 16 to the fuel hose). Close the left front PU side access door. 17 Remove the Gen. 1 splashguard (PU-810 B). 18 Check the fuel tank, hydraulic tank, and radiator fill tank for signs of 19 damage or leaks. Check fuel level with the built-in dipstick, coolant levels through the 20 coolant sightglass and hydraulic fluid levels with the sightglass.

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CHECK COMPLETED

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1R0254 TABLE 5.10.1.3.5-1 PRE-OPERATION CHECKLIST (CONTINUED) ITEM ACTION REQUIRED NUMBER Check the fuel transfer pump assembly for mounting security and leaks. Place the fuel transfer mode switch in “A” (automatic mode) position. 21 Place the fuel transfer pump power switch in the G1 position. Check the condition of the batteries for cleanliness and signs of damage. Check the battery electrical connections for tightness and 22 signs of corrosion. Check to ensure that the battery isolation switch is in the OFF 23 position.① Remove the Gen. 2 splashguard (PU-810B only). 24 Open the PU right side front access door and inspect the area for cleanliness, loose electrical connections, loose hardware, leaks around 25 oil and fuel lines, signs of heat damage or other abnormalities. Check oil level for Generator 2. 26 Drain the crankcase vent reservoir (fumes box) into a proper container. 27 If necessary open the Primary Fuel Filter Drain Valve and drain any 28 water accumulated into an appropriate container Ensure manual fuel cutoff valve is in the open position; valve handle is 29 parallel to the fuel hose. Close the right front PU side access door. 30 Open the right rear PU side access door and inspect the area for cleanliness, loose electrical connections, loose hardware, leaks, around 31 the oil filter, and for signs of heat damage or other abnormalities. Check all high voltage access panels for security. Visually inspect the air intake for obstructions or foreign objects. 32 Ensure that the battery charger voltmeter displays (24 VDC), is plugged into the battery charger receptacle, and that all circuit breakers are 33 turned on. Return to this step after a generator breaker is closed to ensure charger is supplying current to the batteries. Check Parking Stands for proper mounting and connection. 34 Check with a flashlight between generator sets G1 and G2 for leaks, 35 loose hardware, and any other potential problem. Close the right rear PU side access door. 36 Ensure the tie output cables are properly connected and that the 37 concentric neutrals are connected to ground. Ensure that the tie-output cover is secured. (Locked) 38 Check PU equipment grounds for proper connection. 39 Check that the PU interconnect control cable is properly connected to 40 the “B” connector. Inspect the exterior fuel system for proper connection, leaks, and 41 availability of fuel. Open all three PDC doors. Check for damage, loose connections, and 42 foreign objects. Position the 50/60 Hz selector switch in the proper mode. 43 Close all PDC doors. 44 ①

CHECK COMPLETED

The Battery Parallel Switch should be left in the OFF position except in extreme conditions where the additional DC power is required to crank an engine. Once started, return the switch to the OFF position.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1R0254 5.10.1.3.6

PRE-OPERATION RUN WARNING

ENSURE ALL PERSONNEL ARE CLEAR AND THE PU DOORS ARE CLOSED PRIOR TO STARTING A GENERATOR. WARNING HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND ENFORCED. NOISE LEVELS IN EXCESS OF 85 DB EXIST WITHIN AN 88-FOOT RADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR SINGLE HEARING PROTECTION WITHIN 88 FEET OF AN OPERATING DPGDS. WARNING HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND ENFORCED. DURING MAINTENANCE ACTIVITIES WITH THE SIDEDOORS OPEN, NOISE LEVELS IN EXCESS OF 113 DB EXIST WITHIN A 12-FOOT RADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR DOUBLE HEARING PROTECTION WITHIN 12 FEET OF AN OPERATING DPGDS. EXPOSURE MUST BE LIMITED TO UNDER 2.5 HOURS. WARNING BY CLOSING THE FEEDER OR TIE BREAKER, HIGH VOLTAGE WILL BE PRESENT ON THE LOAD CABLES. ENSURE ALL PERSONNEL ARE CLEAR OF ALL LOAD CABLES PRIOR TO CLOSING FEEDER OR TIE BREAKERS.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1R0254 TABLE 5.10.1.3.6-1 PRE-OPERATION RUN INSTRUCTION SEQUENCE (Perform on each PU in the power plant) STEP

-- 60HZ OPERATIONS --

-- 50HZ OPERATIONS --

1

Verify System Mode Switch (SMS) is in MANUAL

2

Verify DC Control Power is on

3

Verify Emergency Stop is pulled out

4① 5

Verify the 60Hz light is on ①

Verify the 50Hz light is on①

Start engine 1 by placing ECS1 in MANUAL

6

Verify the engine accelerates to 1800RPM

Verify the engine accelerates to 1500RPM

7

Adjust the generator frequency to 60Hz using the Frequency Adjust Rheostat (FAR)

Adjust the generator frequency to 50Hz using the Frequency Adjust Rheostat (FAR)

8

Adjust the generator voltage to 4295VAC using the Voltage Adjust Rheostat (VAR)

Adjust the generator voltage to 3915VAC using the Voltage Adjust Rheostat (VAR)

9

Close BCS-G1, toggle the Phase Rotation Test Light switch, verify that light ABC lights, open BCSG1

10

Shutdown engine 1 by placing ECS1 in OFF/RESET

11

Start engine 2 by placing ECS2 in MANUAL

12

Verify the engine accelerates to 1800RPM

Verify the engine accelerates to 1500RPM

13

Adjust the generator frequency to 60Hz using the Frequency Adjust Rheostat (FAR)

Adjust the generator frequency to 50Hz using the Frequency Adjust Rheostat (FAR)

14

Adjust the generator voltage to 4295VAC using the Voltage Adjust Rheostat (VAR)

Adjust the generator voltage to 3915VAC using the Voltage Adjust Rheostat (VAR)

15

Close BCS-G2, toggle the Phase Rotation Test Light switch, verify that light ABC lights, open BCSG2

16

Shutdown engine 2 by placing ECS2 in OFF/RESET

①

If the wrong frequency light is on, open the Master Control Door and change the Frequency Selector Switch (FSS) to the desired frequency.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1R0254 5.10.1.3.7

ORT SETUP

a. Remove the ORT from its case and set it up on a flat and level surface. b. Remove the mouse from the case and plug it into the mouse (PS2) port on the back of the ORT. c.

If 120VAC power is available, connect the ORT power supply cord to the 120VAC power. The ORT can operate up to three hours on its batteries.

d. Connect one end of the 150-foot patch cable to the ORT networking port on the PU. e. Route the cable from the ORT to the PU and connect the cable to the ORT port. f.

Turn on the ORT.

g. Observe that the ORT boots to the operator’s Overview screen. h. Select the EquipID pop-up screen and enter the necessary information for the units. This includes the Trailer ID number, the Engine ID number, and the Generator ID number for each PU. i.

Select the Oneline pop-up screen and enter the descriptor for the main load connected to the feeders.

h. Return to the Overview pop-up screen.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1R0254 5.10.1.3.8

CONTROLS SETUP

Complete the switch arrangements according to the following Table, and verify the lamp indicators: NOTE:

Ignore settings for Power Units not being used.

TABLE 5.10.1.3.8-1 PANEL

PDC CONTROL SWITCH SETUP SWITCH 1ST PU Pushed In DC Power (ON) SMS OFF PRIME GMS POWER PRIME MASTER CONTROL PANEL AVRS POWER MCP 60Hz Light ON①

2ND PU Pushed In (ON) OFF PRIME POWER PRIME POWER

3RD PU Pushed In (ON) OFF PRIME POWER PRIME POWER

4TH PU Pushed In (ON) OFF PRIME POWER PRIME POWER

ON①

ON①

ON①

A② NORMAL OFF All OFF 50/60

B② NORMAL OFF All OFF 50/60

C② NORMAL OFF All OFF 50/60

D② NORMAL OFF All OFF 50/60

Hertz①

Hertz①

Hertz①

Hertz①

Pulled-Out

Pulled-Out

Pulled-Out

Pulled-Out

OFF

OFF

OFF

OFF

Pulled-Out

Pulled-Out

Pulled-Out

Pulled-Out

OFF

OFF

OFF

OFF

USS BSS SSS SSL INSIDE MCP GENERATOR CONTROL PANEL GCPG1 GENERATOR CONTROL PANEL GCPG2

FSS Emergency Stop ECS Emergency Stop ECS

① With the SMS in the OFF position, the 50/60Hz lights indicate the position of the Frequency

Selector Switch (FSS). If the wrong light is on, open the door and change the switch position. ② No more than one switch can be in the same position in any multi-PU line-up. With the SMS in

OFF, none of the USI lights will be on and any previously set address on the PU is cleared.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1R0254 5.10.1.4

PLANT STARTUP

Starting up a Multi-PU Prime Power Plant in Automatic Mode WARNING HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND ENFORCED. NOISE LEVELS IN EXCESS OF 85 DB EXIST WITHIN AN 88-FOOT RADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR SINGLE HEARING PROTECTION WITHIN 88 FEET OF AN OPERATING DPGDS. WARNING HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND ENFORCED. DURING MAINTENANCE ACTIVITIES WITH THE SIDEDOORS OPEN, NOISE LEVELS IN EXCESS OF 113 DB EXIST WITHIN A 12-FOOT RADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR DOUBLE HEARING PROTECTION WITHIN 12 FEET OF AN OPERATING DPGDS. EXPOSURE MUST BE LIMITED TO UNDER 2.5 HOURS. WARNING ONCE THE SYSTEM STATUS LIGHTS TURN GREEN AND THE MSES IS ENABLED, THE PU WILL START. ENSURE PERSONNEL ARE CLEAR OF THE PU. WARNING ONLY ONE PU MAY BE SELECTED TO ANY ONE USS POSITION DURING MULTIPLE PU OPERATIONS. OPERATING WITH MORE THAN ONE UNIT AT THE SAME ID CAUSE UNSAFE AND ERRATIC OPERATIONAL CONDITIONS. a. At the external switchgear, close the associated connection for each PU supplying power to the switchgear. b. At the external switchgear, close the connections between the external switchgears. c.

At the external switchgear, open all the connections of loads to the external switchgear.

NOTE: 1:

For complete set-up of the Primary Switching Center (PSC), refer to USAF TO 35F14-1-1 /USA TM9-6115-725-14&P.

NOTE: 2:

For Unit Isolation Procedure (any unit) - Plant with PSC, and Unit Re-Installation Procedure – Plant with PSC, refer to Section 5.9, Section 5.9.6.15, and Section 5.9.6.16.

d. Complete the switch arrangements according to the following Table, and verify the lamp indicators:

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1R0254 TABLE 5.10.1.4-1 SWITCH SETUP – AUTOMATIC MODE PANEL SWITCH 1ST PU Red BCS-T Target MASTER CONTROL PANEL MCP SMS AUTO③ USS A Red BCS-G1 Target GENERATOR CONTROL PANEL 1 Red GCPG1 BCS-F1 Target ECS-1 AUTO Red BCS-G2 Target GENERATOR CONTROL PANEL 2 Red GCPG2 BCS-F2 Target ECS-2 AUTO MSES Enable① MASTER CONTROL PANEL MCP USI A①, ②

2ND PU Red Target

3RD PU Red Target

4TH PU Red Target

AUTO③ B Red Target Red Target AUTO Red Target Red Target AUTO

AUTO③ C Red Target Red Target AUTO Red Target Red Target AUTO

AUTO③ D Red Target Red Target AUTO Red Target Red Target AUTO

Enable①

Enable①

Enable①

B①, ②

C① , ②

D① , ②

① Hold the MSES in an ENABLE position until the selected USI indicator energizes. The switch

returns to the center position when released. This sets the PU networking address and enables the control and monitoring. ② No more than one of each indicator can be on for multi-PU operations. The light on should match

USS position. The USI light will de-energize after the SMS has been in OFF for 3 seconds. ③ With the SMS in AUTO any generator started, manually or automatically, will automatically

parallel to the bus. To prevent the generator from paralleling to the bus put the generator’s breaker in the Pull-To-Lock position. NOTE:

The automatic economizing feature will shutdown one generator every 3 minutes until the system load is at or below the 360KW/450KVA per generator threshold.

e. At A-unit, observe Generator 1 automatically starts and accelerates to operating voltage and frequency. f.

At A-unit, observe Generator 1 automatically closes to the system bus.

g. At A-unit, observe the Tie breaker automatically closes. h. At B-unit, observe the Tie breaker automatically closes. i.

At C-unit, observe the Tie breaker automatically closes.

j.

At D-unit, observe the Tie breaker automatically closes.

k.

At A-unit, observe Generator 2 automatically starts and accelerates to operating voltage and frequency.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1R0254 l.

At A-unit, observe Generator 2 automatically parallels to the system bus.

m. At B-unit, observe Generator 1 automatically starts and accelerates to operating voltage and frequency. n. At B-unit, observe Generator 1 automatically parallels to the system bus. o. At B-unit, observe Generator 2 automatically starts and accelerates to operating voltage and frequency. p. At B-unit, observe Generator 2 automatically parallels to the system bus. q. At C-unit, observe Generator 1 automatically starts and accelerates to operating voltage and frequency. r.

At C-unit, observe Generator 1 automatically parallels to the system bus.

s.

At C-unit, observe Generator 2 automatically starts and accelerates to operating voltage and frequency.

t.

At C-unit, observe Generator 2 automatically parallels to the system bus.

u. At D-unit, observe Generator 1 automatically starts and accelerates to operating voltage and frequency. v.

At D-unit, observe Generator 1 automatically parallels to the system bus.

w. At D-unit, observe Generator 2 automatically starts and accelerates to operating voltage and frequency. x.

At D-unit, observe Generator 2 automatically parallels to the system bus.

y.

At the external switchgear, close load connections to supply power to the loads.

z.

Ensure generators have assumed load. After the load has stabilized, proceed with the following if necessary:

aa. Observe the KW, PF and KVAR of each generator at the LCP. Note: If adjustment is needed for KVAR balance, start with the generator that is the furthest from the average KVAR (either too low or too high). Make minor adjustments of the Voltage Adjust Rheostat (VAR) until the KVAR sharing between generators are within +/– 10% of the average plant KVAR load. This adjustment will typically be required only once during initial power plant setup and is intended to compensate for meter variations among generators.

CAUTION Improper adjustment of the VAR can cause a reverse KVAR shutdown of a generator.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1R0254 5.10.1.5

PLANT OPERATIONS

5.10.1.5.1

PRECAUTIONS AND WARNINGS

This mode of operation places control of all generator starting, stopping, synchronizing, and load management under the auspices of the Programmable Logic Controller (PLC) system. As long as the SMS is in AUTO, any generator started, manually or automatically, is automatically synchronized to the system bus. Care must be taken when starting a generator manually when the SMS is in AUTO. Either place the associated BCS in Pull-To-Lock (prevent closing to the bus) or ensure it has the red target visible (allow paralleling to the bus) before starting the engine. The only exception is automatic operation of the feeder breakers. Auto Mode does not automatically close feeder breakers; it only enables remote operation of the feeder breakers from the ORT. 5.10.1.5.2

DESCRIPTION

The master controller (the designated “A” unit) will control all connected generators based on the total system KW/KVA load. The controller shuts down one of the generators after 3 minutes should the system load drop below a level where the remaining generator load would not exceed 85% (360kW) if a generator is shutdown. If the load of the remaining generator exceeds 85% (360kW) for one minute, a standby generator is started and paralleled to the bus. A change of system load is recognized by the control system and appropriate action is taken to maintain generator load in the 85% (360 KW/450 KVA) range. The system never automatically shuts down the final generator under normal operating conditions. The shutdown of the final generator must be done following manual operating procedures. The default configuration is Economizing Mode on. The economizing mode can be turned off from the ORT. Through the ORT, the AUTO shut down is disabled but the AUTO start-up remains active to prevent overloading the online generator(s). 5.10.1.5.3

DEFAULT OPERATING SEQUENCE

Start-Up Sequence: The automatic controls will continuously monitor the system load. As load on the system increases, the controls automatically start and place additional units on line in the following sequence at 1-minute intervals: a. One generator from PU “B” based on lower engine runtime. b. One generator from PU “C” based on lower engine runtime. c.

One generator from PU “D” based on lower engine runtime.

d. Remaining generator from PU “A”. e. Remaining generator from PU “B”. f.

Remaining generator from PU “C”.

g. Remaining generator from PU “D”.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1R0254 Shutdown Sequence: Based on the loading experienced, the controller shuts down generator sets that are not needed. For the purpose of explanation, we will assume that all generator sets are on line following an initial startup. Based on load, the controls shut down generator sets in the following sequence at 3-minute intervals: a. One generator from PU “D” based on higher engine runtime. b. One generator from PU “C” based on higher engine runtime. c.

One generator from PU “B” based on higher engine runtime.

d. One generator from PU “A” based on higher engine runtime. e. Remaining generator from PU “D”. f.

Remaining generator from PU “C”.

g. Remaining generator from PU “B”.

5.10.2

PLANT 2 (UTILITY PARALLEL CONFIGURATION)

5.10.2.1

SAFETY PROCEDURES

a. Safety precautions must be observed while operating or maintaining the PU. Safety precautions must be observed to ensure that the operator/technician cannot have contact with the following: • • • • • • •

Hot engine parts Hot engine fluids Medium Voltage AC electricity Low Voltage AC electricity Low Voltage DC electricity Rotating Parts High noise levels

b. Minor troubleshooting can be performed while both engines are running as long as safety precautions are taken. Refer to the appropriate troubleshooting section for Recommendations. 5.10.2.2

POSITIONING THE PU

a. Position the PU in such a way as to allow the plant operator to have full vision of the operator control panels on the unit. b. Level the MEP-PU-810B front to rear with the trailer leveling hand crank. c.

Position the PU to provide a minimum of 10 feet of clearance for maintenance access on all sides of each unit. Ensure that there are no overhead obstructions around the exhaust outlets. WARNING FUEL SPILLAGE CAN OCCUR IF THE POWER UNIT LEVEL IS GREATER THAN + 5 DEGREES.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1R0254 d. Ensure that the ground is capable of supporting the weight of the PU. The site surface should be as level as possible (+ 5 degrees). 5.10.2.3

INITIAL PLANT SETUP

5.10.2.3.1

GROUNDING WARNING

THERE CAN ONLY BE ONE GROUNDING POINT FOR THE PU. WHEN USING A NEUTRAL GROUND RESISTER (NGR), IT MUST USE THE PU GROUND ROD TO AVOID CREATING A GROUND LOOP. a. Drive an 8-foot ground rod into the earth and should be within 6 feet of the PU and at a location that minimizes the tripping hazard, until only 6 inches (15 cm) protrudes above the surface. b. Repeat step “a” for each PU being used. c.

Connect all of the grounding rods together with a #2 AWG copper conductor creating a central ground grid.

d. Using a #2 AWG copper conductor, secure one end of a ground cable to one of the slotted ground studs on the PU, see Figure 5.1.3.1-1 or Figure 5.1.3.1-3. Secure the other end of the ground cable to the ground rod. e. Repeat step “d” for every PU. f.

Test Ground Resistance using Ground Resistance Test Equipment. Resistance must be 25Ω or less. Refer to Annex H for special equipment required for this task.

g. Remove parking stand plates from their transportation positions inside each rear, side PU door and slide them into their respective operating positions on the sides of the PDC. h. Connect the parking stand ground wires to either of the two chassis ground lugs on the PU.

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GROUND POINT

FIGURE 5.10.2.3.1-1 NOTE:

GROUND POINT

MEP-PU-810A GROUND POINTS

Connect only one ground point to the ground grid.

GROUND POINT GROUND POINT

FIGURE 5.10.2.3.1-2 NOTE:

MEP-PU-810B GROUND POINTS

Connect only one ground point to the ground grid.

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FUEL MANIFOLD WARNING

ENSURE THAT THE FUEL LINES ARE PROTECTED FROM ALL ELECTRICAL CABLES AND ARE ROUTED TO MINIMIZE THE POTENTIAL FOR PHYSICAL DAMAGE OR CAUSING A TRIPPING HAZARD. a. Lay out the fuel hoses between the PU, the fuel manifold, and the fuel bladders to establish the fuel supply system see Figure 5.10.2.3.2-1. b. Install the external fuel hose for the PU to the Fuel Transfer Pump at the Tow end of the PU. c.

Connect the other end of the fuel hose to the fuel manifold outlets.

d. Connect the 3” hose, with quick-disconnect hose ends, from the fuel manifold to the fuel bladders. e. Connect the fuel manifold ground wire to the ground grid. f.

Open only the appropriate fuel manifold valves (once connected to the PU) to supply fuel to the power units and check for leaks.

FIGURE 5.10.2.3.2-1

EXTERNAL FUEL SUPPLY

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DISTRIBUTION AND CONTROL CABLING WARNING

DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT DURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION AND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN LOAD CABLES ARE HANDLED. WARNING VERIFY THAT CONNECTION POINTS ARE DE-ENERGIZED BEFORE MAKING ANY CONNECTIONS. FAILURE TO CHECK THAT CONNECTORS ARE DE-ENERGIZED MAY RESULT IN INJURY OR DEATH. a. Lay out and park the load cables for each phase (A, B, & C) between the PU Tie Output parking stations and the load. b. Connect each phase cable to the appropriate phase connection on the Primary Switching Center (PSC). NOTE: 1:

For complete set-up of the Primary Switching Center (PSC), refer to USAF TO 35F14-1-1 and USA TM9-6115-725-14&P.

NOTE: 2:

For Unit Isolation Procedure (any unit) - Plant with PSC, and Unit Re-Installation Procedure – Plant with PSC, refer to Section 5.9, Section 5.9.6.15, and Section 5.9.6.16.

c.

Connect each load cables drain wire to the grounding grid.

d. Open the Tie Output connector loadbreak covers on the first PU. e. Connect the Tie Output Cables to the appropriate phase connectors; ensure there are no crossphase connections. f.

Close and lock the Tie Output connector covers.

g. Repeat steps ‘b’ through ‘f’ on each remaining PU. h. Connect the first (A) (B) communication cable to “B” receptacle on first PU.

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Route the first (A) (B) communication cable to second PU.

j.

Connect the first (A) (B) communication cable to “A” receptacle on second PU.

k.

Connect the second (A) (B) communication cable to “B” receptacle on second PU.

l.

Route the second (A) (B) communication cable to second PU.

m. Connect the second (A) (B) communication cable to “A” receptacle on third PU. n. Connect the third (A) (B) communication cable to “B” receptacle on third PU. o. Route the third (A) (B) communication cable to fourth PU. p. Connect third (A) (B) communication cable to “A” receptacle on fourth PU. q. Connect the fourth (A) (B) communication cable to “B” receptacle on fourth PU. r.

Leave the loose end of the fourth cable loose and capped.

5.10 2.3.4

SETPOINT VERIFICATION

a. Turn on PU DC control power by pushing in on the DC Control Power breaker. b. On each of the five overcurrent relays, verify the settings: (1)

Press the [▲] key to get to the top-level menu “1 REPORT STATUS”.

(2)

Press the [►] key 5 times to display “6 GENERAL SETTINGS”.

(3)

Press the [▼] key to display “6.1 COM SETTINGS”.

(4)

Press the [►] key 2 times to display “6.3 POWER SYSTEM SETTINGS”.

(5)

Press the [▼] key to display “6.3.1 CT RATIO”.

(6)

Verify the “P” and “N” values match the following table:

TABLE 5.10.2.3.4-1 BREAKER RELAY GENERATOR FEEDER TIE

CT RATIO SETTINGS CT RATIO 100:5 200:5 200:5

“P” VALUE 20 40 40

(7)

Press the [▲] key 2 times to display “6 GENERAL SETTINGS”.

(8)

Press the [◄] key to display “5 PROTECTION LOGIC USER”.

(9)

Press the [▼] key 3 times to display “5.1.1.1 50TP”.

“N” VALUE 20 40 40

(10) Verify the 50TP “PU” and “TD” settings in Table 5.10.2.3.4-2. In order to edit values, Press the “Edit” key. Select correct value, and press “Edit” again when correct. Ensure light is off otherwise you can accidentally change value again.

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NEGATIVE SEQUENCE TRIP 50 TQ PU TD 3.0 0m 0 0m 0.0 0m

(11)

Press the [►] key to display “5.1.1.2 50TN”.

(12)

Verify the 50TN “PU” and “TD” settings in Table 5.10.2.3.4-2.

(13)

Press the [►] key to display “5.1.1.3”.

(14)

Verify the “50TQ” settings

(15)

Press the [▲] key to display “5.1.1 50T SETTINGS”.

(16)

Press the [►] key to display “5.1.2 51 SETTINGS”.

(17)

Press the [▼] key to display “5.1.2.1 51P”.

(18)

Verify the 51P “PU”, “TD”, and “C” settings in Table 5.10.2.3.4-3.

TABLE 5.10.2.3.4-3 BREAKER RELAY GENERATOR FEEDER TIE

c.

INSTANTANEOUS TRIP SETTINGS PHASE NEUTRAL INSTANTANEOUS INSTANTANEOUS TRIP 50TP TRIP 50TN PU TD PU TD 0.0 0m 3.0 0m 7.5 84m 1.25 84m 0.0 0m 0 0m

TIME OVERCURRENT TRIP SETTINGS PHASE TIME OVERCURRENT TRIP 51P PU TD C 4.50 0.5 VV2 2.50 1.0 VV2 5.00 2.0 VV2

NEUTRAL TIME OVERCURRENT TRIP 51N PU TD C 1.25 0.5 VV2 1.00 1.0 VV2 1.50 2.0 VV2

(19)

Press the [►] key to display “5.1.2.2 51N”.

(20)

Verify the 51N “PU”, “TD”, and “C” settings in Table 5.10.2.3.4-3.

(21)

Press the [▲] key 3 times to display “5 PROTECTION LOGIC USER”.

Use the following procedure to verify the Generator 1 GSC+ settings in step “d”:

NOTE:

Refer to the “EMCPII+ Reference Chart”, located on the interior Generator Control Panel Door (Look-up) (1)

Place ECS in the COOLDOWN/STOP position.

(2)

Press SERVICE MODE key to enter service mode. OP1 is showing on the lower display.

(3)

Press SCROLL UP key until “OP3” is showing.

(4)

Press SELECT key. “PE -“ with the first dash flashing is showing.

(5)

Press SCROLL RIGHT key. “PE 1 -“ with the second dash flashing is showing.

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Press SCROLL DOWN key. “PE 13 –“ with the third dash flashing is showing.

(7)

Press SCROLL UP key. “PE 132 –“ with the fourth dash flashing is showing.

(8)

Press SCROLL DOWN key. “PE 1323 –“ with the fifth dash flashing is showing.

(9)

Press SCROLL RIGHT key. “PE13231” with all digits not flashing is showing.

(10) Press ENTER key. “PE PASS” is showing. (11) Press EXIT key. “OP4” is showing. (12) Press SCROLL UP key until “OP5-0” is showing on the lower display. (13) Press SELECT key. “POO1” followed with the value of the setpoint is showing. (14) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing. Use Table 5.10.2.3.4-4 for the parameter values to be verified. (15) Repeat step “15” until the desired setpoints are verified. (16) Press EXIT key. “OP5-0” is showing on the lower display. (17) Press SCROLL UP key until “OP5-1” is showing. (18) Press SELECT key. (19) Repeat steps 15 and 16 for “OP5-1” using Table 5.10.2.3.4-5. (20) Repeat steps 17, 18, and 19 for OP6. (21) Repeat steps 15 and 16 for “OP6” using Table 5.10.2.3.4-6. (22) Press EXIT Key twice. The display returns to normal. NOTE:

If an incorrect setpoint value is displayed, the value must be changed to match the DPGDS setpoint value as follows: (a)

With the setpoint with the incorrect value showing on the display, press the SELECT key. The incorrect value flashes on the display.

(b)

Press SCROLL UP or SCROLL DOWN key until the correct value appears flashing on the display.

(c)

Press ENTER. The correct value stops flashing on the display.

(d)

Press SCROLL UP or SCROLL DOWN key to continue to verify the remaining parameter values.

d. At GSC G1, verify the operation settings using the following table:

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OP5-0 SETPOINTS

SETPOINTS OP5-0 ENGINE/GENERATOR PROGRAMMING① FACTORY DPGDS SETPOINT-NAME-DESCRIPTIONS RANGE OF VALUES DEFAULT SETPOINT P001 - Fuel Solenoid Type: type of fuel system solenoid used on the genset.

0- ETR fuel solenoid 1- ETS fuel solenoid

0

0

P002 - Units Shown: type of measurement units shown on the GSC+ display.

0-for English units (PSI, ºF) 1-for metric units (kPa, ºC).

0

0

P003 - Shutdown Override For Engine Fault: GSC+ response to a low engine oil pressure or high coolant temperature fault.

0-for engine shutdown 1-for alarm only (shutdown override, no engine shutdown).

0

0

P004 - Shutdown Override For Sensor Fault: GSC+ response to a diagnostic fault with the engine oil pressure sensor, coolant temperature sensor, oil temperature sensor, sensor power supply or coolant loss sensor.

0-for alarm only shutdown override, no engine shutdown). 1-for engine shutdown.

0

0

P005 - Coolant Loss Sensor Installed: tells whether or not the optional engine coolant loss sensor is installed on the genset.

0-for gensets without a coolant loss sensor 1-for gensets with coolant loss sensor

0

1

P006 - Shutdown Override For Coolant Loss Fault: GSC+ response to an engine coolant loss fault.

0-for engine shutdown. 1-for alarm only (shutdown override, no engine shutdown).

0

0

P007 - System Voltage, 24 Or 32 Volts: system voltage (battery voltage) of the genset.

24 or 32.

24

24

P008 - This setpoint is not currently being used by the GSC+ and cannot be programmed.

N/A

N/A

N/A

P009 - Number Of Ring Gear Teeth: number of teeth on the ring gear of the engine. Used by the GSC+ to determine engine speed.

95 to 350 teeth in increments of one tooth.

136 teeth

136 teeth

P010 - Engine Overspeed: engine speed used by the GSC+ to declare that an engine overspeed fault exists. The engine overspeed setpoint (for all 60 Hz applications) is 1.18 times the rated speed.

500 to 4330 rpm in increments of 10 rpm.

2120 rpm

2120 rpm

P011 - Crank Terminate Speed: engine speed used by the GSC+ to disengage the starting motor during engine cranking.

100 to 1000 rpm in increments of 10 rpm.

400 rpm

400 rpm

P012 - Oil Step Speed: engine speed used by the GSC+ for distinguishing between rated speed and idle speed when a low oil pressure fault exists.

400 to 1800 rpm in increments of 10 rpm.

1350 rpm

1350 rpm

P013② - Low Oil Pressure Shutdown At Rated Speed: oil pressure used by the GSC+ to declare that a low oil pressure shutdown fault exists with engine at rated speed (the engine speed must have exceeded the oil step speed for nine seconds).

5 to 61PSI (34 to 420kPa) in increments of 1

30 PSI (205 kPa)

30 PSI (205 kPa)

P014② - Low Oil Pressure Shutdown At Idle Speed: oil pressure used by the GSC+ to declare that a low oil pressure shutdown fault exists with the engine at idle speed (the engine must have been running for at least 9 seconds and the engine speed must be less than oil step speed).

20 to 336kPa (3 to 49PSI) in increments of 1

10 PSI (70 kPa)

10 PSI (70 kPa)

P015③ - High Water Temperature Shutdown: coolant temperature used by the GSC+ to declare a high coolant temperature shutdown fault exists (after a 10 second delay).

185 to 253ºF (85 to 123ºC) in increments of 1

225ºF (107ºC)

225ºF (107ºC)

P016 - Low Water Temperature Alarm: coolant temperature used by the GSC+ to declare that a low coolant temperature alarm fault exists (after a 2 second delay).

32 to 97ºF (0 to 36ºC) in increments of 1

70ºF (21ºC)

70ºF (21ºC)

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OP5-0 SETPOINTS (CONTINUED)

SETPOINTS OP5-0 ENGINE/GENERATOR PROGRAMMING① FACTORY SETPOINT-NAME-DESCRIPTIONS RANGE OF VALUES DEFAULT

DPGDS SETPOINT

P017 - Total Cycle Crank Time: cycle crank time used by the 5 to 120 seconds in increments of 1 GSC+ to declare that an overcrank fault exists. second.

90 seconds

90 seconds

P018 - Cycle Crank Time: amount of time the GSC+ cranks and then rests the starting motor during a single crank cycle.

10 seconds

10 seconds

5 minutes

5 minutes

700, 150, 300, 500, 600, 750, 3.0k, 4.5k, 5.20k, 5.25k, 9.0k, 15.0k, 18.0k, 30.0k

700

5.20k

75, 100, 150, 200, 300, 400, 600, 800, 1000, 1200, 1500, 2000, 2500, 3000, and 4000A

600A

100A

01

01 (Gen 1) 02 (Gen 2)

5 to 60 seconds in increments of 1 second.

P019 - Cooldown Time: amount of time the GSC+ allows the 0 to 30 minutes in increments of 1 engine to run after a normal shutdown is initiated. minute. P020④ - AC Voltage: nominal AC voltage of the generator. The GSC+ measures the AC voltage and shows it on the display. P021 - AC Current Full Scale: nominal full scale AC current of the generator. AC current full scale is equal to the ratio of the external current transformers in the generator housing. P022⑤ - GSC+ Engine Number: informs other devices on the CAT Data Link of the engine number for the GSC+.

01 through 08

SETPOINTS - OP5-0-ENGINE/GENERATOR PROGRAMMING① RANGE OF FACTORY 60HZ 50HZ SETPOINT-NAME-DESCRIPTIONS DEFAULT SETPOINT SETPOINT VALUES P023 - Engine Type: identifies the engine as a mechanical unit injector (MUI) diesel, spark ignited (gas), or electronic unit injector (EUI) diesel engine.

0 - MUI diesel 1 - Gas 2 - EUI diesel

P024 - Crank Time Delay: amount of time the GSC+ delays activation of the fuel control relay (FCR) during a crank cycle. This setpoint is for Gas engines only. The P024 setpoint only functions when the P023 setpoint is set to 1 (gas engine).

0 to 20 seconds in increments of 1 second.

0 - for gensets without an oil P025 - Oil Temperature Sensor Installed: tells temperature sensor whether or not the optional engine oil temperature 1 - for gensets with an oil sensor is installed on the genset. temperature sensor P026 - High Oil Temperature Shutdown: oil temperature used by the GSC+ to declare a high 185 to 253ºF (85 to 123ºC) in increments of 1 oil temperature shutdown fault exists (after a 10 second delay). Refer to the panel model number. 0 - for alarm only (shutdown override, P027 - Shutdown Override For High Oil Temperature Fault: GSC+ response to an engine no engine shutdown). high oil temperature fault. 1 - for engine shutdown. P028 - Nameplate Voltage: rated voltage of the generator. This setpoint is used for protective relaying functions. P029 - Nameplate Current: rated current output of the generator.

0

2

2

5 Seconds

5 Seconds

5 Seconds

0

0

0

225ºF (107ºC)

225ºF (107ºC) 225ºF (107ºC)

0

0

0

100 to 25kV in increments of 1

480V

4160V

3800V

0 to 4000 A in increments of 1

600A

80A

73A

400kW

420kW

350kW

60Hz

60Hz

50Hz

0

0

0

4

4

4

P030 - Nameplate Power: rated power capability 0 through 10MW in increments of of the generator. 1kW. P031 - Rated Frequency: nominal frequency 50 or 60Hz rating of genset. P032 - Connection Configuration Of Generator: 0 - wye wye or delta configuration of generator. 1 - delta P033 - Number Of Generator Poles. 0 through 254 in increments of 2.

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The setpoints (stored or being programmed) must match the specified DPGDS setpoints.

② When oil pressure drops to within 5PSI (34kPa) of the P013 or P014 setpoint, a low oil pressure alarm is issued by the GSC+. ③ When coolant temperature rises to within 11ºF (6ºC) of the P015 setpoint, a high coolant temperature alarm is issued by the GSC+. ④ The values other than the default (700V) are for switchgear applications and require the use of external potential transformers and the removal of the AC voltage range jumper located in the relay module. The DPGDS unit is factory configured for the 5.20 K value. See the Caterpillar Electronic Modular Control Panel II+ manual topic AC Voltage Range Selection in the Testing and Adjusting section. ⑤ After setpoint P022 is reprogrammed, the GSC+ must be power cycled (powered down and then powered up)

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TABLE 5.10.2.3.4-5 OP5-1 SETPOINTS SETPOINTS OP5-1 PROTECTIVE RELAYING PROGRAMMING① FACTORY 60HZ 50HZ SETPOINT-NAME-DESCRIPTION RANGE OF VALUES DEFAULT SETPOINT SETPOINT P101 - Generator Overvoltage Alarm Enable: the 0 - disabled GSC+ enables or disables the generator 1 - enabled overvoltage alarm function. P102 - Generator Overvoltage Alarm Threshold: voltage the GSC+ uses to issue an overvoltage alarm.

100 to 125% of nameplate voltage in increments of 1%.

P103 - Generator Overvoltage Alarm Time Delay: amount of time the GSC+ waits before issuing an overvoltage alarm. P104 - Generator Overvoltage Shutdown Enable: the GSC+ enables or disables the generator overvoltage shutdown function. P105 - Generator Overvoltage Shutdown Threshold: voltage the GSC+ uses to issue an overvoltage shutdown. P106 - Generator Overvoltage Shutdown Time Delay: amount of time the GSC+ waits before issuing an overvoltage shutdown.

0 through 120 seconds② in increments of 1

P107 - Generator Undervoltage Alarm Enable: the GSC+ enables or disables the generator undervoltage alarm function.

0 - disabled 1 - enabled

P108 - Generator Undervoltage Alarm Threshold: voltage the GSC+ uses to issue an undervoltage alarm. P109 - Generator Undervoltage Alarm Time Delay: amount of time the GSC+ waits before issuing an undervoltage alarm. P110 - Generator Undervoltage Shutdown Enable: the GSC+ enables or disables the generator undervoltage shutdown function. P111 - Generator Undervoltage Shutdown Threshold: voltage the GSC+ uses to issue an undervoltage shutdown.

0 - disabled 1 - enabled 100 to 125% of nameplate voltage in increments of 1%. 0 through 120 seconds② in increments of 1

60 to 100% of nameplate voltage in increments of 1%. 0 through 120 seconds② in increments of 1 0 - disabled 1 - enabled 60 through 100% of rated voltage in increments of 1%.

P112 - Generator Undervoltage Shutdown Time Delay: amount of time the GSC+ waits before issuing an undervoltage shutdown.

0 through 120 seconds② in increments of 1

P113 - Generator Overfrequency Alarm Enable: the GSC+ enables or disables the generator overfrequency alarm function.

0 - disabled 1 - enabled

P114 - Generator Overfrequency Alarm Threshold: frequency the GSC+ uses to issue an overfrequency alarm.

50-60Hz, for 50Hz Gen 60-70Hz, for 60Hz Gen 400-480, for 400Hz Gen

P115 - Generator Overfrequency Alarm Time Delay: amount of time the GSC+ waits before issuing an overfrequency alarm.

0 through 120 seconds② in increments of 1

P116 - Generator Overfrequency Shutdown Enable: the GSC+ enables or disables the generator overfrequency shutdown function.

0 - disabled 1 - enabled

P117 - Generator Overfrequency Shutdown Threshold: frequency the GSC+ uses to issue an overfrequency shutdown.

50-60Hz, for 50Hz Gen 60-70Hz, for 60Hz Gen 400-480, for 400Hz Gen

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1

1

1

105%

105%

105%

10 seconds

10 seconds

10 seconds

1

1

1

110%

110%

110%

10 seconds

10 seconds

10 seconds

1

1

1

90%

90%

90%

10 seconds

10 seconds

10 seconds

1

1

1

85%

85%

85%

15 seconds

03 seconds

03 seconds

1

1

1

53Hz 63Hz 422Hz

63 Hz

53 Hz

10 seconds

10 seconds

10 seconds

1

1

1

55Hz 66Hz 440Hz

66Hz

55Hz

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1R0254 TABLE 5.10.2.3.4-5 OP5-1 SETPOINTS (CONTINUED) SETPOINTS OP5-1 PROTECTIVE RELAYING PROGRAMMING① FACTORY 60HZ SETPOINT-NAME-DESCRIPTION RANGE OF VALUES DEFAULT SETPOINT P118 - Generator Overfrequency Shutdown Time Delay: amount of time the GSC+ waits before issuing an overfrequency shutdown.

0 through 120 seconds② in increments of 1

P119 - Generator Underfrequency Alarm Enable: the GSC+ enables or disables the generator underfrequency alarm function.

0 - disabled 1 - enabled

P120 - Generator Underfrequency Alarm Threshold: frequency the GSC+ uses to issue an underfrequency alarm.

30-50Hz, for 50Hz Gen 36-60Hz, for 60Hz Gen 240-400, for 400Hz Gen

P121 - Generator Underfrequency Alarm Time Delay: amount of time the GSC+ waits before issuing an underfrequency alarm. P122 - Generator Underfrequency Shutdown Enable: the GSC+ enables or disables the generator underfrequency shutdown function.

0 through 120 seconds② in increments of 1

P123 - Generator Underfrequency Shutdown Threshold: frequency the GSC+ uses to issue an underfrequency shutdown.

30-50Hz, for 50Hz Gen 36-60Hz, for 60Hz Gen 240-400, for 400Hz Gen

P124 - Generator Underfrequency Shutdown Time Delay: amount of time the GSC+ waits before issuing an underfrequency shutdown. P125 - Generator Reverse Power Shutdown Enable: the GSC+ enables or disables the generator reverse power shutdown function. P126 - Generator Reverse Power Shutdown Threshold: level of reverse power the GSC+ uses to issue a reverse power shutdown.

0 through 120 seconds② in increments of 1

P127 - Generator Reverse Power Shutdown Time Delay: amount of time the GSC+ waits before issuing a reverse power shutdown.

0 through 30 seconds② in increments of 1

P128 - Generator Overcurrent Alarm Enable: the GSC+ enables or disables the overcurrent alarm.

0 - disabled 1 - enabled

P129 - Generator Phase Overcurrent Alarm Threshold: level of current the GSC+ uses to issue a phase overcurrent alarm. P130 - Generator Phase Overcurrent Alarm Time Delay: amount of time the GSC+ waits before issuing a phase overcurrent alarm. P131 - Generator Total Overcurrent Alarm Threshold: level of current the GSC+ uses to issue a total overcurrent alarm. P132 - Generator Total Overcurrent Alarm Time Delay: amount of time the GSC+ waits before issuing a total overcurrent alarm.

10 seconds

10 seconds

10 seconds

1

1

1

48Hz 57Hz 378Hz

57Hz

48Hz

10 seconds

10 seconds

10 seconds

1

1

1

45Hz 54Hz 360Hz

54Hz

45Hz

15 seconds

03 seconds

03 seconds

1

1

1

15%

4%

4%

10 seconds

4 seconds

4 seconds

1

1

1

100 through 160% of nameplate current in increments of 5%

105%

150%

150%

0 through 250 seconds② in increments of 1

0 seconds

0 seconds

0 seconds

100 through 160% of three times nameplate current in increments of 5%

105%

150%.

150%

0 through 250 seconds② in increments of 1

0 seconds

0 seconds

0 seconds

1

1

1

110%

150%

150%

0 seconds

10 seconds

10 seconds

0 - disabled 1 - enabled

0 - disabled 1 - enabled 0 through 20% of rated power in increments of 1%.

P133 – Generator Overcurrent Shutdown Enable: 0 – disabled the GSC+ enables or disables the overcurrent 1 – enabled shutdown. P134 – Generator Phase Overcurrent Shutdown 100 through 160% in increments of 5% Threshold: level of current the GSC+ uses to issue a phase overcurrent shutdown. P135 – Generator Phase Overcurrent Shutdown Time Delay: amount of time the GSC+ waits before issuing a phase overcurrent shutdown.

50HZ SETPOINT

0 through 250 seconds② in increments of 1

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1R0254 TABLE 5.10.2.3.4-5 OP5-1 SETPOINTS (CONTINUED)

SETPOINTS OP5-1 PROTECTIVE RELAYING PROGRAMMING① SETPOINT-NAME-DESCRIPTION P136 - Generator Total Overcurrent Shutdown Threshold: level of current the GSC+ uses to issue a total overcurrent shutdown. P137 - Generator Total Overcurrent Shutdown Time Delay: amount of time the GSC+ waits before issuing a total overcurrent shutdown. P138 - KW Level Relay Enable : the GSC+ enables or disables the kW level relay function. P139 - KW Level Relay Threshold: level of power the GSC+ uses to activate the kW level relay function. P140 - KW Level Relay Time Delay: amount of time the GSC+ waits before activating the kW level relay function. P141 - KW Level Relay Disengage Threshold: level of power the GSC+ uses to deactivate the kW level relay function. P142 - KW Level Relay Disengage Time Delay: amount of time the GSC+ waits before deactivating the kW level relay function.

FACTORY DEFAULT

60HZ SETPOINT

50HZ SETPOINT

100 through 160% of three times nameplate current in increments of 5%

110%

150%.

150%

0 through 250 seconds② in increments of 1

0 seconds

10 seconds

10 seconds

1

1

1

0 through 110% of nameplate power in increments of 1%

105%

105%

105%

0 through 120 seconds② in increments of 1

0 seconds

0 seconds

0 seconds

0 through 110% of nameplate power in increments of 1%.

100%

100%

100%

0 through 120 seconds② in increments of 1

10 seconds

10 seconds

10 seconds

RANGE OF VALUES

0 - disabled 1 - enabled

① The setpoints are programmed at the factory to the default value. ② When programmed to 0 seconds, the actual time is from 0.5 to 1.0 seconds.

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TABLE 5.10.2.3.4-6 OP6 SETPOINTS SETPOINTS OP6 SPARE INPUT/OUTPUT PROGRAMMING SETPOINT-NAME-DESCRIPTIONS

RANGE OF VALUES

FACTORY DPGDS DEFAULT SETPOINT

SP01 - Spare Input 1 Active State. Input state used by the GSC+ to declare a SP1 fault exists.

0-active low 1-active high

0

0

SP02 - Spare Input 1 Response: GSC+ response to a SP1 fault.

0-shutdown 1-alarm

0

0

SP03 - Spare Input 1 Time Delay: Amount of time the GSC+ waits before responding to a SP1 fault.

0 - 250 seconds in increments of 1

0 seconds

1 second

0

1

0

0

0 seconds

0 seconds

0

0

0

0

0 seconds

0 seconds

SP04 - Spare Input 2 Active State. Input state used by the GSC+ to declare a SP2 fault exists. SP05 - Spare Input 2 Response: GSC+ response to a SP2 fault. SP06 - Spare Input 2 Time Delay: Amount of time the GSC+ waits before responding to a SP2 fault. SP07 - Spare Input 3 Active State. Input state used by the GSC+ to declare a SP3 fault exists. SP08 - Spare Input 3 Response: GSC+ response to a SP3 fault.

0-active low 1-active high 0-shutdown 1-alarm 0 - 250 seconds in increments of 1 0-active low 1-active high 0-shutdown 1-alarm

SP09 - Spare Input 3 Time Delay: Amount of time the GSC+ waits before responding to a SP3 fault.

0 - 250 seconds in increments of 1

SP10 - Spare Input 4 Active State. Input state used by the GSC+ to declare a SP4 fault exists.

0-active low 1-active high

0

0

SP11 - Spare Input 4 Response: GSC+ response to a SP4 fault.

0-shutdown 1-alarm

0

0

SP12 - Spare Input 4 Time Delay: Amount of time the GSC+ waits before responding to a SP4 fault.

0 - 250 seconds in increments of 1

0 seconds

0 seconds

SP13 - Spare Output Response: GSC+ response to the spare output trigger condition.

0-active low 1-active high

0

0

8

8

1

1

0-unused 1-active SP1 fault② 2-active SP2 fault② 3-active SP3 fault② SP14 - Spare Output Trigger Condition: The condition used by the GSC+ to trigger the spare output response

4-active SP4 fault② 5-any combination of active SP faults② 6-any active shutdown 7-any active alarm or shutdown 8-cooldown mode 9-coolant loss mode②

10-high oil temp fault② 11-CCM control SP15 – Spare Relay Output Response: GSC+ response to the 0-relay inactive when triggered spare relay trigger condition. 1-relay active when triggered

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1R0254 TABLE 5.10.2.3.4-6 OP6 SETPOINTS (CONTINUED) SETPOINTS OP6 SPARE INPUT/OUTPUT PROGRAMMING SETPOINT-NAME-DESCRIPTIONS

RANGE OF VALUES

FACTORY DPGDS DEFAULT SETPOINT

0-unused 1-active SP1 fault② 2-active SP2 fault② 3-active SP3 fault② SP16 - Spare Relay Output Trigger Condition: The condition used by the GSC+ to trigger the spare relay.

4-active SP4 fault② 5-any combination of active SP faults② 6-any active shutdown 7-any active alarm or shutdown 8-cooldown mode

8

1

0

6

Battle Short mode.

0

0 Battleshort③

Not in 60 Hz mode.

0

9-coolant loss mode② 10-high oil temp fault② 11-CCM control 0-unused 1-active SP1 fault② 2-active SP2 fault② 3-active SP3 fault② SP17 - Spare Indicator 1 Trigger Condition: The condition used by the GSC+ to trigger spare indicator①.

4-active SP4 fault② 5-any combination of active SP1, SP2, SP3 or SP4 faults② 6-Coolant loss fault② 7-high oil temperature fault②

SP18 - Spare Indicator 2 Trigger Condition: The condition used by the GSC+ to trigger spare indicator②. SP19 - Spare Indicator 3 Trigger Condition: The condition used by the GSC+ to trigger spare indicator③.

① The setpoints are programmed at the factory to the default value. ② Either alarm or shutdown faults are valid trigger conditions ③ Battleshort and 50Hz Mode are unique features to DPGDS for spare indicators 2 and 3.

e. Return ECS1 to the OFF/RESET position. NOTE: f.

Use up or down keys to change values. At the AVR verify the operation settings using Table 5.10.2.3.4-7: (1)

Open the GCPG1 cabinet door.

(2)

Press the [▼] key to display parameter “90”.

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0 In 50Hz Mode③

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1R0254 (3)

Press the [◄►] key to display the current value.

(4)

Press the [▲] key to change the value to “0015”. Enables parameter editing.

(5)

Press the [◄►] key to accept change and display the parameter number.

(6)

Press the [▲] key to the next parameter needed to change.

(7)

Press the [◄►] key to display the current value.

(8)

Press the [▲] or [▼] key to change the value.

(9)

Press the [◄►] key to accept change and display the parameter number.

(10) Repeat steps ‘5’ through ‘9’ for the each parameter needing to be changed. (11) When complete, press the [▼] to display parameter “01”. NOTE:

Parameters 20, 21, 22, 36, 37, and 38 are displayed but not used.

NOTE:

Parameters 23 to 29, 39 to 49, 59 and 61 to 89 are not displayed and not used.

TABLE 5.10.2.3.4-7

AVR PARAMETERS/SETPOINTS DPGDS SETPOINTS

DPGDS AVR PARAMETERS PARAMETER 01 02 03 04

TITLE Generator Output Voltage Ratio of Output Voltage To Sensing Voltage Generator Type Rated Generator Output Current

TYPE

UNITS

RANGE OF VALUES

DEFAULT VALUE

60HZ OPS

50HZ OPS

Program

Volts

0080-9999

480①

4160

3800

001.0-100.0

001.0

17.3

17.3

Program Program Program

Amps

0000-0004 0000-9999

0004 0600

4 80

4 73

Program

Volts

01.00-05.00

05.00

4.00

3.66

06 07 08

CT Voltage At Rated Generator Current Knee Frequency Decreasing Volts/Hz Slope I Decreasing Volts/Hz Slope 2

Program Program Program

Hz Volts/Hz Volts/Hz

045.0-065.0 001.0-010.0 001.0-010.0

050.0 002.0 002.0

59.8 2.0 2.0

49.8 2.0 2.0

09 10 11 12 13 14

Minimum Voltage Under Frequency Point Overvoltage Trip Point Overvoltage Trip Time Under Voltage Trip Point Under Voltage Trip Time

Program Program Program Program Program Program

% Hz % Seconds % Seconds

050.0 025.0 014.0 0002 0060 0030

50.0 25.0 125.0 5 75 30

50.0 25.0 125.0 5 75 30

15

Voltage Gain (IR Compensation)

Program

%

050.0-100.0 020.0-040.0 0105-0140 0002-0030 0060-0095 0030-0120 000.0-0 10.0

0000

0

0

Integral Gain

Program

001.0-020.0

006.0

6.0

6.0

Proportional Gain

Program

001.0-020.0

005.0

5.0

5.0

Program

0000,0001

0000

0000

0000

001.0-010.0

002.0

2.0

2.0

05②

16⑤ 17⑥ 18 19

Single Phase Sensing Select (0=three phase, 1=single phase) Diode Monitor Trip Point

Program

Amps

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AVR PARAMETERS/SETPOINTS (CONTINUED) DPGDS SETPOINTS

DPGDS AVR PARAMETERS TYPE

UNITS

RANGE OF VALUES

Droop Percentage

Program

%

000.0-010.0

0000

3

3

31③

pf/Kvar Select (0=pf, 1=Kvar)

Program

0000, 0001

0000

0

0

32③

Pf Reference

Program

00.60-01.10

01.00

0.8

0.8

33③

KVAR Reference

Program

Per Unit

00.00-01.00

0000

0.10

0.10

34③

Reverse Power Trip Point

Program

%

000.0-020.0

010.0

15

15

35③ 50 51 52

Reverse Power Trip Time

Program

Seconds

000.0-020.0

010.0

5

5

View View View

Hz Volts Amps

View

Amps

View View

Amps Amps

View

KW

0009

0009

0000 0000

0000 0000

PARAMETER 30

53 54 55

TITLE

Generator Output Frequency Generator Output Voltage Generator Output Current Generator Reactive Output Current

56③

Generator Real Current Exciter Field Current Three Phase Kilowatts (KB and later)

57③

Power Factor

View

Three Phase Kvar (KE and later)

View

58③, ④ 60 90 91 92 93 94 96

Hours Password Software ID Latest Fault Previous Fault Fault Clear Shutdown Fault Reset

View

Hours

DEFAULT VALUE

60HZ OPS

50HZ OPS

0000-9999

Program View View View View Switch

0000 0000

①- Default value for output voltage is different depending on regulator sensing voltage. If the regulator is

designed for 120 volts sensing, then the default output voltage is 4160 volts. All other sensing types have the default output voltage set to 480 volts. ②- Digital Voltage Regulators with earlier software (KD and earlier) have 1 less digit to the right of the

decimal point. ③- Optional feature. ④- New parameter on serial number prefix KE and later Digital Voltage Regulators. ⑤- Previous range of 0001-099.9 and default value of 002.0

⑥-Previous range of 0001-099.9 and default value of 002.0 (12) When complete, press the [▼] to display parameter “90”. (13) Press the [◄►] key to display the current value. (14) Press the [▼] key to change the value to “0009”. Disables DVR parameter editing. (15) Press the [◄►] key to accept change and display the parameter number.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1R0254 (16) Press the [▲] key to change to display parameter “01”. (17) Close the GCPG1 cabinet door. (18) Repeat steps ‘1 ‘through ‘16’ for Generator 2. 5.10.2.3.5

PRE-OPERATION CHECKS

Starting from the left rear of the PU and working around the PU in a clockwise direction, perform the following checks (Gen. 1 is on the left and Gen. 2 is on the right): TABLE 5.10.2.3.5-1 PRE-OPERATION CHECKLIST ITEM ACTION REQUIRED NUMBER Ensure the parking brake is set. Rotate the crank in a clockwise rotation 1 (PU-810 A) to set. Ensure that the wheels are properly chocked or the Spring Brakes are 1 (PU-810-B) set by opening the petcock on the air tank and evacuating all the air. Check the ground connection. 2 Check that the ORT communication cable is connected properly. 3 Ensure the feeder output cables, if used, are properly connected and 4 that the concentric neutrals are connected to ground. Ensure that the feeder output cover is secured. (Locked) 5 Check Parking Stands for proper mounting and connection. 6 Check the two 120-Volt auxiliary duplex receptacles and the 60 amp 3 7 phase receptacle cables are securely connected or the covers are properly installed / closed. Open the left rear PU side access door and inspect the area for cleanliness, loose electrical connections, loose hardware, and leaks 8 around the oil filter and lines. Check for signs of heat damage or other abnormalities. Check all high voltage panels for security Ensure that the battery charger voltmeter displays (24 VDC), is plugged into the battery charger receptacle, and that all circuit breakers are 9 turned on. Return to this step after a generator breaker is closed to ensure charger is supplying current to the batteries. Visually inspect the air intake duct for obstructions or foreign objects. 10 Close the left rear PU door. 11 Open the left front PU side access door and inspect the area for 12 cleanliness, loose electrical connections, loose hardware, leaks around oil and fuel lines, signs of heat damage or other abnormalities. Drain the crankcase vent reservoir (fumes box) into a proper container. 13 If necessary, open the Primary Fuel Filter Drain Valve and drain any 14 accumulated water into an appropriate container. Check oil level for Generator 1. 15 Ensure fuel shutoff valve is in the open position (valve handle is parallel 16 to the fuel hose). Close the left front PU side access door. 17 Remove the Gen. 1 splashguard (PU-810 B). 18 Check the fuel tank, hydraulic tank, and radiator fill tank for signs of 19 damage or leaks. Check fuel level with the built-in dipstick, coolant levels through the 20 coolant sightglass and hydraulic fluid levels with the sightglass.

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CHECK COMPLETED

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1R0254 TABLE 5.10.2.3.5-1 PRE-OPERATION CHECKLIST (CONTINUED) ITEM ACTION REQUIRED NUMBER Check the fuel transfer pump assembly for mounting security and leaks. Place the fuel transfer mode switch in “A” (automatic mode) position. 21 Place the fuel transfer pump power switch in the G1 position. Check the condition of the batteries for cleanliness and signs of damage. Check the battery electrical connections for tightness and 22 signs of corrosion. Check to ensure that the battery isolation switch is in the OFF 23 position.① Remove the Gen. 2 splashguard (PU-810B only). 24 Open the PU right side front access door and inspect the area for cleanliness, loose electrical connections, loose hardware, leaks around 25 oil and fuel lines, signs of heat damage or other abnormalities. Check oil level for Generator 2. 26 Drain the crankcase vent reservoir (fumes box) into a proper container. 27 If necessary open the Primary Fuel Filter Drain Valve and drain any 28 water accumulated into an appropriate container Ensure manual fuel cutoff valve is in the open position; valve handle is 29 parallel to the fuel hose. Close the right front PU side access door. 30 Open the right rear PU side access door and inspect the area for cleanliness, loose electrical connections, loose hardware, leaks, around 31 the oil filter, and for signs of heat damage or other abnormalities. Check all high voltage access panels for security. Visually inspect the air intake for obstructions or foreign objects. 32 Ensure that the battery charger voltmeter displays (24 VDC), is plugged into the battery charger receptacle, and that all circuit breakers are 33 turned on. Return to this step after a generator breaker is closed to ensure charger is supplying current to the batteries. Check Parking Stands for proper mounting and connection. 34 Check with a flashlight between generator sets G1 and G2 for leaks, 35 loose hardware, and any other potential problem. Close the right rear PU side access door. 36 Ensure the tie output cables are properly connected and that the 37 concentric neutrals are connected to ground. Ensure that the tie-output cover is secured. (Locked) 38 Check PU equipment grounds for proper connection. 39 Check that the PU interconnect control cable is properly connected to 40 the “B” connector. Inspect the exterior fuel system for proper connection, leaks, and 41 availability of fuel. Open all three PDC doors. Check for damage, loose connections, and 42 foreign objects. Position the 50/60 Hz selector switch in the proper mode. 43 Close all PDC doors. 44 ①

CHECK COMPLETED

The Battery Parallel Switch should be left in the OFF position except in extreme conditions where the additional DC power is required to crank an engine. Once started, return the switch to the OFF position.

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PRE-OPERATION RUN WARNING

ENSURE ALL PERSONNEL ARE CLEAR AND THE PU DOORS ARE CLOSED PRIOR TO STARTING A GENERATOR. WARNING HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND ENFORCED. NOISE LEVELS IN EXCESS OF 85 DB EXIST WITHIN AN 88-FOOT RADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR SINGLE HEARING PROTECTION WITHIN 88 FEET OF AN OPERATING DPGDS. WARNING HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND ENFORCED. DURING MAINTENANCE ACTIVITIES WITH THE SIDEDOORS OPEN, NOISE LEVELS IN EXCESS OF 113 DB EXIST WITHIN A 12-FOOT RADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR DOUBLE HEARING PROTECTION WITHIN 12 FEET OF AN OPERATING DPGDS. EXPOSURE MUST BE LIMITED TO UNDER 2.5 HOURS. WARNING BY CLOSING THE FEEDER OR TIE BREAKER, HIGH VOLTAGE WILL BE PRESENT ON THE LOAD CABLES. ENSURE ALL PERSONNEL ARE CLEAR OF ALL LOAD CABLES PRIOR TO CLOSING FEEDER OR TIE BREAKERS.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1R0254 TABLE 5.10.2.3.6-1 PRE-OPERATION RUN INSTRUCTION SEQUENCE (Perform on each PU in the power plant) STEP

-- 60HZ OPERATIONS --

-- 50HZ OPERATIONS --

1

Verify System Mode Switch (SMS) is in MANUAL

2

Verify DC Control Power is on

3

Verify Emergency Stop is pulled out

4① 5

Verify the 60Hz light is on ①

Verify the 50Hz light is on①

Start engine 1 by placing ECS1 in MANUAL

6

Verify the engine accelerates to 1800RPM

Verify the engine accelerates to 1500RPM

7

Adjust the generator frequency to 60Hz using the Frequency Adjust Rheostat (FAR)

Adjust the generator frequency to 50Hz using the Frequency Adjust Rheostat (FAR)

8

Adjust the generator voltage to 4295VAC using the Voltage Adjust Rheostat (VAR)

Adjust the generator voltage to 3915VAC using the Voltage Adjust Rheostat (VAR)

9

Close BCS-G1, toggle the Phase Rotation Test Light switch, verify that light ABC lights, open BCSG1

10

Shutdown engine 1 by placing ECS1 in OFF/RESET

11

Start engine 2 by placing ECS2 in MANUAL

12

Verify the engine accelerates to 1800RPM

Verify the engine accelerates to 1500RPM

13

Adjust the generator frequency to 60Hz using the Frequency Adjust Rheostat (FAR)

Adjust the generator frequency to 50Hz using the Frequency Adjust Rheostat (FAR)

14

Adjust the generator voltage to 4295VAC using the Voltage Adjust Rheostat (VAR)

Adjust the generator voltage to 3915VAC using the Voltage Adjust Rheostat (VAR)

15

Close BCS-G2, toggle the Phase Rotation Test Light switch, verify that light ABC lights, open BCSG2

16

Shutdown engine 2 by placing ECS2 in OFF/RESET

①

If the wrong frequency light is on, open the Master Control Door and change the Frequency Selector Switch (FSS) to the desired frequency.

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ORT SETUP

a. Remove the ORT from its case and set it up on a flat and level surface. b. Remove the mouse from the case and plug it into the mouse (PS2) port on the back of the ORT. c.

If 120VAC power is available, connect the ORT power supply cord to the 120VAC power. The ORT can operate up to three hours on its batteries.

d. Connect one end of the 150-foot patch cable to the ORT networking port on the PU. e. Route the cable from the ORT to the PU and connect the cable to the ORT port. f.

Turn on the ORT.

g. Observe that the ORT boots to the operator’s Overview screen. h. Select the EquipID pop-up screen and enter the necessary information for the units. This includes the Trailer ID number, the Engine ID number, and the Generator ID number for each PU. i.

Select the Oneline pop-up screen and enter the descriptor for the main load connected to the feeders.

i.

Return to the Overview pop-up screen.

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CONTROLS SETUP

Complete the switch arrangements according to the following Table, and verify the lamp indicators: NOTE:

Ignore settings for PUs not being used.

TABLE 5.10.2.3.8-1 PANEL

PDC CONTROL SWITCH SETUP SWITCH 1ST PU Pushed In DC Power (ON) SMS OFF UTILITY GMS PARALLEL UTILITY MASTER CONTROL PANEL AVRS PARALLEL MCP 60Hz Light ON① USS BSS SSS SSL INSIDE MCP GENERATOR CONTROL PANEL GCPG1 GENERATOR CONTROL PANEL GCPG2

FSS Emergency Stop ECS Emergency Stop ECS

2ND PU Pushed In (ON) OFF UTILITY PARALLEL UTILITY PARALLEL

3RD PU Pushed In (ON) OFF UTILITY PARALLEL UTILITY PARALLEL

4TH PU Pushed In (ON) OFF UTILITY PARALLEL UTILITY PARALLEL

ON①

ON①

ON①

A② NORMAL OFF All OFF 50/60

B② NORMAL OFF All OFF 50/60

C② NORMAL OFF All OFF 50/60

D② NORMAL OFF All OFF 50/60

Hertz①

Hertz①

Hertz①

Hertz①

Pulled-Out

Pulled-Out

Pulled-Out

Pulled-Out

OFF

OFF

OFF

OFF

Pulled-Out

Pulled-Out

Pulled-Out

Pulled-Out

OFF

OFF

OFF

OFF

① With the SMS in the OFF position, the 50/60Hz lights indicate the position of the Frequency

Selector Switch (FSS). If the wrong light is on, open the door and change the switch position. ②

No more than one switch can be in the same position in any multi-PU line-up. With the SMS in OFF, none of the USI lights will be on and any previously set address on the PU is cleared.

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PLANT STARTUP

5.10.2.4.1

GENERAL WARNING

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND ENFORCED. NOISE LEVELS IN EXCESS OF 85 DB EXIST WITHIN AN 88-FOOT RADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR SINGLE HEARING PROTECTION WITHIN 88 FEET OF AN OPERATING DPGDS. WARNING HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND ENFORCED. DURING MAINTENANCE ACTIVITIES WITH THE SIDEDOORS OPEN, NOISE LEVELS IN EXCESS OF 113 DB EXIST WITHIN A 12-FOOT RADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR DOUBLE HEARING PROTECTION WITHIN 12 FEET OF AN OPERATING DPGDS. EXPOSURE MUST BE LIMITED TO UNDER 2.5 HOURS. CAUTION DO NOT SET THE DESIRED LOAD ON THE ORT SLIDEBAR FOR A UTILITY PARALLEL PU OR PLANT TO A VALUE THAT EXCEEDS THE TOTAL AVAILABLE LOAD. PARALLELED PRIME POWER GENERATORS MAY BE REVERSE POWERED AND TRIP OFFLINE. PLANT OPERATORS MUST MONITOR THE TOTAL PLANT LOAD TO PREVENT THE UTILITY PARALLEL PU OR PLANT FROM OVERPOWERING THE SYSTEM. SET THE DESIRED LOAD ON THE ORT SLIDEBAR FOR A UTILITY PARALLEL PU OR PLANT TO A VALUE THAT PREVENTS OVERLOAD OF THE PRIME POWER GENERATORS. FAILURE TO FOLLOW THIS CAUTION MAY RESULT IN DESTRUCTION OF CONNECTED EQUIPMENT. CAUTION SETTING THE DESIRED LOAD ON THE ORT FOR A UTILITY PARALLEL PLANT TO A VALUE THAT CAUSES THE PLANT OUTPUT TO REDUCE THE LOAD ON A PARALLELED PRIME POWER PLANT BELOW ECONOMIZER SETTINGS WILL CAUSE PRIME POWER PLANT GENERATORS TO SHUT DOWN. Operating one PU utility parallel power plant with another PU power plant should be done with the PUs operating in automatic mode. This provides the operator with control over the amount of load the generators will carry. Operating PUs in manual in the Utility Parallel Mode limits the units to carrying only 25KW per generator. The PUs can be started and put online manually, but should be operated automatically using an ORT.

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MANUAL MODE

Use Section 5.5.4 (Starting up a Multi-PU Prime Power Plant in Manual Mode) procedure 2.5 to start the plant manually. Use Section 5.9.6.12 to change the units to Auto Mode to allow changing the load. 5.10.2.4.3

AUTOMATIC MODE WARNING

ONCE THE SYSTEM STATUS LIGHTS TURN GREEN AND THE MSES IS ENABLED, THE PU WILL START. ENSURE PERSONNEL ARE CLEAR OF THE PU. WARNING ONLY ONE PU MAY BE SELECTED TO ANY ONE USS POSITION DURING MULTIPLE PU OPERATIONS. OPERATING WITH MORE THAN ONE UNIT AT THE SAME ID CAUSE UNSAFE AND ERRATIC OPERATIONAL CONDITIONS. Starting up a Multi-PU in Utility Parallel Plant in Automatic Mode Complete the switch arrangements according to the following Table, and verify the lamp indicators: TABLE 5.10.2.4.3-1 PANEL

SWITCH SETUP – AUTOMATIC MODE SWITCH 1ST PU 2ND PU BCS-T Red Target Red Target MASTER CONTROL PANEL SMS AUTO③ AUTO③ MCP USS A B BCS-G1 Red Target Red Target GENERATOR CONTROL PANEL 1 GCPG1 ECS-1 AUTO AUTO GENERATOR CONTROL PANEL 2 GCPG2 MASTER CONTROL PANEL MCP

3RD PU Red Target

4TH PU Red Target

AUTO③ C Red Target AUTO

AUTO③ D Red Target AUTO

BCS-G2

Red Target

Red Target

Red Target

Red Target

ECS-2 MSES

AUTO

AUTO

AUTO

AUTO

Enable①

Enable①

Enable①

Enable①

USI

A①, ②

B①, ②

C① , ②

D① , ②

①

Hold the MSES in an ENABLE position until the selected USI indicator energizes. The switch returns to the center position when released. This sets the PU networking address and enables the control and monitoring.

②

No more than one of each indicator can be on for multi-PU operations. The light on should match USS position. The USI light will de-energize after the SMS has been in OFF for 3 seconds.

③ With the SMS in AUTO any generator started, manually or automatically, will automatically

parallel to the bus. To prevent the generator from paralleling to the bus put the generator’s breaker in the Pull-To-Lock position.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1R0254 a. At A-unit, observe Generator 1 automatically starts and accelerates to operating voltage and frequency. b. At A-unit, observe Generator 1 automatically closes to the system bus. c.

At A-unit, observe the Tie breaker automatically closes.

d. At B-unit, observe the Tie breaker automatically closes. e. At C-unit, observe the Tie breaker automatically closes. f.

At D-unit, observe the Tie breaker automatically closes.

g. At A-unit, observe Generator 2 automatically starts and accelerates to operating voltage and frequency. h. At A-unit, observe Generator 2 automatically parallels to the system bus. i.

At B-unit, observe Generator 1 automatically starts and accelerates to operating voltage and frequency.

j.

At B-unit, observe Generator 1 automatically parallels to the system bus.

k.

At B-unit, observe Generator 2 automatically starts and accelerates to operating voltage and frequency.

l.

At B-unit, observe Generator 2 automatically parallels to the system bus.

m. At C-unit, observe Generator 1 automatically starts and accelerates to operating voltage and frequency. n. At C-unit, observe Generator 1 automatically parallels to the system bus. o. At C-unit, observe Generator 2 automatically starts and accelerates to operating voltage and frequency. p. At C-unit, observe Generator 2 automatically parallels to the system bus. q. At D-unit, observe Generator 1 automatically starts and accelerates to operating voltage and frequency. r.

At D-unit, observe Generator 1 automatically parallels to the system bus.

s.

At D-unit, observe Generator 2 automatically starts and accelerates to operating voltage and frequency.

t.

At D-unit, observe Generator 2 automatically parallels to the system bus.

u. Observe that each generator assumes 25KW when it parallels to the bus. v.

From the ORT, set the desired load for each generator to carry. The load value shown on the ORT is on a per generator basis.

w. At the external switchgear, close load connections to supply power to the loads.

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x. y.

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1R0254 Ensure generators have assumed load. After the load has stabilized, proceed with the following if necessary: Observe the KW, PF and KVAR of each generator at the LCP.

Note: If adjustment is needed for KVAR balance, start with the generator that is the furthest from the average KVAR (either too low or too high). Make minor adjustments of the Voltage Adjust Rheostat (VAR) until the KVAR sharing between generators are within +/– 10% of the average plant KVAR load. This adjustment will typically be required only once during initial power plant setup and is intended to compensate for meter variations among generators.

CAUTION Improper adjustment of the VAR can cause a reverse KVAR shutdown of a generator. NOTE:

The automatic economizing feature is disabled while a generator is operating in Utility Parallel mode.

5.10.2.4

PLANT OPERATIONS

The power plant must be in Auto Mode to be operated remotely or adjust the load on the generators. 5.10.2.5

POWER PLANT TEARDOWN (PLANT 1 & PLANT 2)

5.10.2.5.1

SHUT DOWN GENERATORS

a. Ensure there is sufficient Plant 1 generator capacity online to carry the combined Plant 1 and Plant 2 load. b. Unload all Plant 2 generators using the Plant 2 ORT. c.

Open each Plant 2 generator breaker from the ORT or locally from its respective LCP.

d. Place each Plant 2 PU in manual by placing its respective SMS in MANUAL without stopping in OFF. e. Open each Plant 2 tie breaker locally at the respective MCP. f.

Place all Plant 2 generators in cooldown by placing all Plant 2 SMS switches in OFF.

g. Allow all Plant 2 engines to complete cooldown and shutdown (5 minutes). h. Place all Plant 2 ECS switches in OFF/RESET. i.

Pull out the DC Control Power breaker on all Plant 2 PUs.

j.

Unload all Plant 1 generators by opening all load breakers, either at the external switchgear or at the PU if the PU feeder breakers are used.

k.

Place each Plant 1 PU in manual by placing its respective SMS in MANUAL without stopping in OFF.

l.

Open each Plant 1 tie breaker locally at the respective MCP.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1R0254 m. Place all Plant 1 generators in cooldown by placing all SMS switches to OFF. n. Observe all generator breakers open. o. Allow all engines to complete cooldown and shutdown (5 minutes). p. Place all ECS switches in OFF/RESET. q. Pull out the DC Control Power breaker on all PUs. r.

Open all the external switchgear generator disconnect switches for Plant 1 and Plant 2.

5.10.2.5.2

DISCONNECT CABLES WARNING

NEVER REMOVE POWER CABLES BY HAND, USE HOT STICK AND HIGH VOLTAGE GLOVES. NEVER TOUCH A HIGH VOLTAGE LEAD OR TERMINAL UNTIL IT HAS BEEN DISCHARGED TO GROUND. FAILURE TO OBSERVE THE WARNING MAY RESULT IN DEATH BY ELECTROCUTION. CAUTION ALLOW ALL OPERATING ENGINES TO SHUT DOWN AND COOL DOWN COMPLETELY. a. Disconnect the (A)(B) communication cables from between the PUs, Reinstall the communication cable receptacle covers, and store inside the PUs (one per unit). b. Disconnect the ORT cable and store it in the ORT case. c.

Close and latch the ORT port on the PU.

d. Disconnect all load cables used in operation of the PUs. 5.10.2.5.3

DISCONNECT FUEL LINES

a. Turn all fuel system valves to the off position. b. Disconnect the fuel hose from the PU fuel connection and the fuel supply. c.

Drain any fuel from the hoses into an auxiliary fuel supply and store the hoses.

5.10.2.5.4

DISCONNECT GROUNDING

a.

Remove ground connections from the PU and store with the ground rod.

b.

Disconnect the parking stations from the ground grid.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1R0254 c.

Remove the parking stations from their operating positions and reinstall them in their transportation locations on the inside of the PU rear side access doors.

5.10.2.5.5

PREPARE PU FOR TRANSPORTATION

a. Reinstall the four radiator splashguards (PU-810B only). b. Verify DC Control power is off. c.

Close and lock the LCP access doors.

d. Close and lock all PU side doors. 5.10.2.5.6

FUEL, OIL, AND COOLANT DRAINAGE

The Power Unit may be safely shipped with oil, fuel, and coolant at maximum capacities or less. Draining fluids is not required unless federal, state, or local regulations prohibit shipment with fluids present. Refer to Section 14.3.1.1, Section 13.4.5.5 and Section 6.5.3 for procedures for draining the oil, coolant and fuel liquids respectively

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THIS PAGE INTENTIONALLY BLANK

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CHAPTER 5.11 OPERATING INSTRUCTIONS TWO-PLANT, MULTIPLE PU, PRIME POWER, EXTERNAL SWITCH, AUTOMATIC MODE TABLE OF CONTENTS SECTION 5.11

TITLE

PAGE

TWO-PLANT, MULTIPLE PU, PRIME POWER, EXTERNAL SWITCH, AUTOMATIC MODE ..................................................................................................293

5.11.1

SAFETY PROCEDURES ...........................................................................................293

5.11.2

POSITIONING THE PU ..............................................................................................293

5.11.3

INITIAL PLANT SETUP .............................................................................................294

5.11.3.1

GROUNDING .............................................................................................................294

5.11.3.2

FUEL MANIFOLD ......................................................................................................296

5.11.3.3

DISTRIBUTION AND CONTROL CABLING .............................................................297

5.11.3.4

SETPOINT VERIFICATION .......................................................................................290

5.11.3.5

PRE-OPERATION CHECKS .....................................................................................304

5.11.3.6

PSC RELAY SETTING VERIFICATION ....................................................................306

5.11.3.7

PRE-OPERATION RUN .............................................................................................308

5.11.3.8

CONTROLS SETUP...................................................................................................310

5.11.3.8.1

PLANT ONE ...............................................................................................................310

5.11.3.8.2

PLANT TWO ..............................................................................................................310

5.11.3.9

ORT SETUP ...............................................................................................................311

5.11.3.9.1

PLANT ONE ...............................................................................................................311

5.11.3.9.2

PLANT TWO ..............................................................................................................312

5.11.4

PLANT STARTUP......................................................................................................312

5.11.5

PLANT OPERATIONS (AUTOMATIC MODE) ..........................................................315

5.11.5.1

PRECAUTIONS AND WARNINGS............................................................................315

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5.11.5.2

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 DESCRIPTION ...........................................................................................................315

5.11.6

POWER PLANT TEARDOWN...................................................................................315

5.11.6.1

SHUT DOWN GENERATORS ...................................................................................315

5.11.6.2

DISCONNECT CABLES ............................................................................................316

5.11.6.3

DISCONNECT FUEL LINES......................................................................................316

5.11.6.4

DISCONNECT GROUNDING ....................................................................................316

5.11.6.5

PREPARE PU FOR TRANSPORTATION .................................................................317

5.11.6.6

FUEL, OIL, AND COOLANT DRAINAGE .................................................................317

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LIST OF FIGURES FIGURE

TITLE

PAGE

FIGURE 5.11.3.1-1

MEP-PU-810A GROUND POINTS

295

FIGURE 5.11.3.1-2

MEP-PU-810B GROUND POINTS

295

FIGURE 5.11.3.2-1

EXTERNAL FUEL SUPPLY, TYPICAL FOR EACH 4 PU PLANT

296

FIGURE 5.11.3.3-1

TWO-PLANT LAYOUT DIAGRAM

298

FIGURE 5.11.3.3-2

PLANT EXPANSION ADAPTER

299

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LIST OF TABLES TABLE

TITLE

PAGE

TABLE 5.11.3.4-1

CT RATIO SETTINGS

290

TABLE 5.11.3.4-2

INSTANTANEOUS TRIP SETTINGS

290

TABLE 5.11.3.4-3

TIME OVERCURRENT TRIP SETTINGS

291

TABLE 5.11.3.4-4

OP5-0 SETPOINTS

293

TABLE 5.11.3.4-4

OP5-0 SETPOINTS (CONTINUED)

294

TABLE 5.11.3.4-5

OP5-1 SETPOINTS

296

TABLE 5.11.3.4-5

OP5-1 SETPOINTS (CONTINUED)

297

TABLE 5.11.3.4-5

OP5-1 SETPOINTS (CONTINUED)

298

TABLE 5.11.3.4-6

OP6 SETPOINTS

299

TABLE 5.11.3.4-6

OP6 SETPOINTS (CONTINUED)

300

TABLE 5.11.3.4-7

AVR PARAMETERS/SETPOINTS

301

TABLE 5.11.3.4-7

AVR PARAMETERS/SETPOINTS (CONTINUED)

302

TABLE 5.11.3.5-1

PRE-OPERATION CHECKLIST

304

TABLE 5.11.3.5-1

PRE-OPERATION CHECKLIST (CONTINUED)

305

TABLE 5.11.3.6-1

PSC RELAY SETTINGS

307

TABLE 5.11.3.7-1

PRE-OPERATION RUN INSTRUCTION SEQUENCE

309

TABLE 5.11.3.8-1

PDC CONTROL SWITCH SETUP

310

TABLE 5.11.3.8-2

PDC CONTROL SWITCH SETUP

311

TABLE 5.11.4-1

SWITCH SETUP (EACH PLANT) – AUTOMATIC MODE

313

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 5.11

TWO-PLANT, MULTIPLE PU, PRIME POWER, EXTERNAL SWITCH, AUTOMATIC MODE

5.11.1

SAFETY PROCEDURES

a. Safety precautions must be observed while operating or maintaining the PU. Safety precautions must be observed to ensure that the operator/technician cannot have contact with the following: • • • • • • •

Hot engine parts Hot engine fluids Medium Voltage AC electricity Low Voltage AC electricity Low Voltage DC electricity Rotating Parts High noise levels

b. Minor Troubleshooting can be performed while both engines are running as long as

safety precautions are taken. Refer to the appropriate troubleshooting section for recommendations. 5.11.2

POSITIONING THE PU

a. Position the PU in such a way as to allow the plant operator to have full vision of the operator control panels on the unit. b. Level the MEP-PU-810B front to rear with the trailer leveling hand crank. c.

Position the PU to provide a minimum of 10 feet of clearance for maintenance access on all sides of each unit. Ensure that there are no overhead obstructions around the exhaust outlets.

WARNING FUEL SPILLAGE CAN OCCUR IF THE POWER UNIT LEVEL IS GREATER THAN + 5 DEGREES. d. Ensure that the ground is capable of supporting the weight of the PU. The site surface should be as level as possible (+ 5 degrees).

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INITIAL PLANT SETUP

5.11.3.1

GROUNDING

a. Drive an 8-foot ground rod into the earth. It should be within 6 feet of the PU and at a location that minimizes the tripping hazard, until only 6 inches (15 cm) protrudes above the surface. b. Repeat step “a” for each PU being used. c.

Connect all of the grounding rods together with a #2 AWG copper conductor creating a central ground grid.

d. Using a #2 AWG copper conductor, secure one end of a ground cable to one of the slotted ground studs on the PU, see Figure 5.11.3.1-1 or Figure 5.11.3.1-2. Secure the other end of the ground cable to the ground rod. e. Repeat step “d” for every PU. f.

Test Ground Resistance using Ground Resistance Test Equipment. Resistance must be 25Ω or less. Refer to Annex H for special equipment required for this task.

g. Remove parking stand plates from their transportation positions inside each rear, side PU door and slide them into their respective operating positions on the sides of the PDC. h. Connect the parking stand ground wires to either of the two chassis ground lugs on the PU.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254

GROUND POINT

FIGURE 5.11.3.1-1 NOTE:

GROUND POINT

MEP-PU-810A GROUND POINTS

Connect only one ground point to the ground grid.

GROUND POINT

FIGURE 5.11.3.1-2 NOTE:

GROUND POINT

MEP-PU-810B GROUND POINTS

Connect only one ground point to the ground grid.

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FUEL MANIFOLD WARNING

ENSURE THAT THE FUEL LINES ARE PROTECTED FROM ALL ELECTRICAL CABLES AND ARE ROUTED TO MINIMIZE THE POTENTIAL FOR PHYSICAL DAMAGE OR CAUSING A TRIPPING HAZARD. a. Lay out the fuel hoses between the PU, the fuel manifold, and the fuel bladders to establish the fuel supply system see. Figure 5.11.3.2-1. This is a typical set-up for each 4 PU plant. b. Install the external fuel hose for the PU to the Fuel Transfer Pump at the Tow end of the PU. c.

Connect the other end of the fuel hose to the fuel manifold outlets.

d. Connect the 3” hose, with quick-disconnect hose ends, from the fuel manifold to the fuel bladders. e. Connect the fuel manifold ground wire to the ground grid. f.

Open only the appropriate fuel manifold valves (once connected to the PU) to supply fuel to the power units and check for leaks.

FIGURE 5.11.3.2-1

EXTERNAL FUEL SUPPLY, TYPICAL FOR EACH 4 PU PLANT

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DISTRIBUTION AND CONTROL CABLING WARNING

DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT DURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION AND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN LOAD CABLES ARE HANDLED. WARNING VERIFY THAT CONNECTION POINTS ARE DE-ENERGIZED BEFORE MAKING ANY CONNECTIONS. FAILURE TO CHECK THAT CONNECTORS ARE DE-ENERGIZED MAY RESULT IN INJURY OR DEATH.

a. Lay out and park the load cables for each phase (A, B, & C) on the PU Tie Output parking stations on all PUs. b. Connect each phase cable to the appropriate phase connection on the Primary Switching Center (PSC). Refer to Figure 5.11.3.3-1 for Two-Plant and PSC layout diagram c.

Connect each load cables drain wire to the grounding grid.

d. Open the Tie Output connector loadbreak covers on the first PU. e. Connect the Tie Output Cables to the appropriate phase connectors; ensure there are no crossphase connections. f.

Close and lock the Tie Output connector covers.

g. Repeat steps ‘b’ through ‘f’ on each remaining PU. h. Connect communication cables to each PU i.

Install the Multi-Plant Expansion Adapter between plant 1 D unit and plant 2 A unit (See figure 5.11.3.3-2). The Adapter is stored inside the PDC of the PU behind the door rails. Ensure that D unit on plant two has the second communication cable installed and the loose end is capped.

5-297

FIGURE 5.11.3.3-1

ORT

ORT

PLANT 1 A G1 52G1

B G2

G1

52G2

52G1

52T

52F2

52F1

5-298

C G2 52G2

52F1

G1 52G1

D G2

G1

52G2

52G1

52F1 52T

52F2

G2 52G2

52F1 52T

52F2

PSC 1

A G1 52G1

B G2

G1

52G2

52G1

52F1 52T

52F2

C G2 52G2

52F1 52T

52F2

G1 52G1

D G2

G1

52G2

52G1

52F1 52T

52F2

5

4

3

2

52T

52F2

PSC 2

1

6

5

4

3

2

5

4

3

2

1

6

5

4

3

2

LOAD LOAD LOAD

52T

PSC 4

1 6

52G2

52F1

PSC 3 6

G2

LOAD

1

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254

TWO-PLANT LAYOUT DIAGRAM

52F2

PLANT 2 Plant Expansion Adapter

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254

Multi-Plant Adapter Storage Location (Behind Door)

Multi-Plant Expansion Adapter Installed

FIGURE 5.11.3.3-2

PLANT EXPANSION ADAPTER

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SETPOINT VERIFICATION

a. Turn on PU DC control power by pushing in on the DC Control Power breaker. b. On each of the five overcurrent relays, verify the settings: (1)

Press the [▲] key to get to the top-level menu “1 REPORT STATUS”.

(2)

Press the [►] key 5 times to display “6 GENERAL SETTINGS”.

(3)

Press the [▼] key to display “6.1 COM SETTINGS”.

(4)

Press the [►] key 2 times to display “6.3 POWER SYSTEM SETTINGS”.

(5)

Press the [▼] key to display “6.3.1 CT RATIO”.

(6)

Verify the “P” and “N” values match the following table:

TABLE 5.11.3.4-1 BREAKER RELAY GENERATOR FEEDER TIE

CT RATIO SETTINGS CT RATIO 100:5 200:5 200:5

“P” VALUE 20 40 40

(7)

Press the [▲] key 2 times to display “6 GENERAL SETTINGS”.

(8)

Press the [◄] key to display “5 PROTECTION LOGIC USER”.

(9)

Press the [▼] key 3 times to display “5.1.1.1 50TP”.

“N” VALUE 20 40 40

(10) Verify the 50TP “PU” and “TD” settings in Table 5.11.3.4-2. In order to edit values, Press the “Edit” key. Select correct value, and press “Edit” again to save changes. Ensure light is off otherwise you can accidentally change value again. TABLE 5.11.3.4-2 BREAKER RELAY GENERATOR FEEDER TIE

INSTANTANEOUS TRIP SETTINGS PHASE NEUTRAL INSTANTANEOUS INSTANTANEOUS TRIP 50TP TRIP 50TN PU TD PU TD 0.0 0m 3.0 0m 7.5 84m 1.25 84m 0.0 0m 0 0m

(11)

Press the [►] key to display “5.1.1.2 50TN”.

(12)

Verify the “50TN” settings in Table 5.11.3.4-2.

(13)

Press the [►] key to display “5.1.1.3”.

(14)

Verify the “50TQ” settings

(15)

Press the [▲] key to display “5.1.1 50T SETTINGS”.

(16)

Press the [►] key to display “5.1.2 51 SETTINGS”.

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NEGATIVE SEQUENCE TRIP 50 TQ PU TD 3.0 0m 0 0m 0.0 0m

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (17)

Press the [▼] key to display “5.1.2.1 51P”.

(18)

Verify the 51P “PU”, “TD”, and “C” settings in Table 5.11.3.4-3.

TABLE 5.11.3.4-3 BREAKER RELAY GENERATOR FEEDER TIE

c.

TIME OVERCURRENT TRIP SETTINGS PHASE TIME OVERCURRENT TRIP 51P PU TD C 4.50 0.5 VV2 2.50 1.0 VV2 5.00 2.0 VV2

NEUTRAL TIME OVERCURRENT TRIP 51N PU TD C 1.25 0.5 VV2 1.00 1.0 VV2 1.50 2.0 VV2

(19)

Press the [►] key to display “5.1.2.2 51N”.

(20)

Verify the “51N” settings in Table 5.11.3.4-3.

(21)

Press the [▲] key 3 times to display “5 PROTECTION LOGIC USER”.

Use the following procedure to verify the Generator 1 and Generator 2 GSC+ settings in step “d”:

NOTE:

Refer to the “EMCPII+ Reference Chart”, located on the interior Generator Control Panel Door (Look-up) (1)

Place ECS in the COOLDOWN/STOP position.

(2)

Press SERVICE MODE key to enter service mode. OP1 is showing on the lower display.

(3)

Press SCROLL UP key until “OP3” is showing.

(4)

Press SELECT key. “PE -“ with the first dash flashing is showing.

(5)

Press SCROLL RIGHT key. “PE 1 -“ with the second dash flashing is showing.

(6)

Press SCROLL DOWN key. “PE 13 –“ with the third dash flashing is showing.

(7)

Press SCROLL UP key. “PE 132 –“ with the fourth dash flashing is showing.

(8)

Press SCROLL DOWN key. “PE 1323 –“ with the fifth dash flashing is showing.

(9)

Press SCROLL RIGHT key. “PE13231” with all digits not flashing is showing.

(10) Press ENTER key. “PE PASS” is showing. (11) Press EXIT key. “OP4” is showing. (12) Press SCROLL UP key until “OP5-0” is showing on the lower display. (13) Press SELECT key. “POO1” followed with the value of the setpoint is showing. (14) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing. Use Table 5.11.3.4-4 for the parameter values to be verified. Repeat until the desired setpoints are verified. (15) Press EXIT key. “OP5-0” is showing on the lower display.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (16) Press SCROLL UP key until “OP5-1” is showing. (17) Press SELECT key. (18) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing. Use Table 5.11.3.4-5 OP5-1 Setpoints for the parameter values to be verified. Repeat until all the desired setpoints are verified. (19) Press EXIT key. “OP5-1” is showing. (20) Press SCROLL UP key until “OP6” is showing.

(21) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing. Use “OP6” Setpoints, Table 5.11.3.4-6 for the parameter values to be verified. Repeat until all the desired setpoints are verified.

(22) Press EXIT Key twice. The display returns to normal. NOTE:

If an incorrect setpoint value is displayed, the value must be changed to match the DPGDS setpoint value as follows: (a)

With the setpoint with the incorrect value showing on the display, press the SELECT key. The incorrect value flashes on the display.

(b)

Press SCROLL UP or SCROLL DOWN key until the correct value appears flashing on the display.

(c)

Press ENTER. The correct value stops flashing on the display.

(d)

Press SCROLL UP or SCROLL DOWN key to continue to verify the remaining parameter values. d. At GSC G1 and GSC G2, verify the operation settings using the following table:

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OP5-0 SETPOINTS

SETPOINTS OP5-0 ENGINE/GENERATOR PROGRAMMING① FACTORY DPGDS SETPOINT-NAME-DESCRIPTIONS RANGE OF VALUES DEFAULT SETPOINT P001 - Fuel Solenoid Type: type of fuel system solenoid used on the genset.

0- ETR fuel solenoid 1- ETS fuel solenoid

0

0

P002 - Units Shown: type of measurement units shown on the GSC+ display.

0-for English units (PSI, ºF) 1-for metric units (kPa, ºC).

0

0

P003 - Shutdown Override For Engine Fault: GSC+ response to a low engine oil pressure or high coolant temperature fault.

0-for engine shutdown 1-for alarm only (shutdown override, no engine shutdown).

0

0

P004 - Shutdown Override For Sensor Fault: GSC+ response to a diagnostic fault with the engine oil pressure sensor, coolant temperature sensor, oil temperature sensor, sensor power supply or coolant loss sensor.

0-for alarm only shutdown override, no engine shutdown). 1-for engine shutdown.

0

0

P005 - Coolant Loss Sensor Installed: tells whether or not the optional engine coolant loss sensor is installed on the genset.

0-for gensets without a coolant loss sensor 1-for gensets with coolant loss sensor

0

1

P006 - Shutdown Override For Coolant Loss Fault: GSC+ response to an engine coolant loss fault.

0-for engine shutdown. 1-for alarm only (shutdown override, no engine shutdown).

0

0

P007 - System Voltage, 24 Or 32 Volts: system voltage (battery voltage) of the genset.

24 or 32.

24

24

P008 - This setpoint is not currently being used by the GSC+ and cannot be programmed.

N/A

N/A

N/A

P009 - Number Of Ring Gear Teeth: number of teeth on the ring gear of the engine. Used by the GSC+ to determine engine speed.

95 to 350 teeth in increments of one tooth.

136 teeth

136 teeth

500 to 4330 rpm in increments of 10 rpm.

2120 rpm

2120 rpm

100 to 1000 rpm in increments of 10 rpm.

400 rpm

400 rpm

400 to 1800 rpm in increments of 10 rpm.

1350 rpm

1350 rpm

P013② - Low Oil Pressure Shutdown At Rated Speed: oil pressure used by the GSC+ to declare that a low oil pressure shutdown fault exists with engine at rated speed (the engine speed must have exceeded the oil step speed for nine seconds).

5 to 61PSI (34 to 420kPa) in increments of 1

30 PSI (205 kPa)

30 PSI (205 kPa)

P014② - Low Oil Pressure Shutdown At Idle Speed: oil pressure used by the GSC+ to declare that a low oil pressure shutdown fault exists with the engine at idle speed (the engine must have been running for at least 9 seconds and the engine speed must be less than oil step speed).

20 to 336kPa (3 to 49PSI) in increments of 1

10 PSI (70 kPa)

10 PSI (70 kPa)

P015③ - High Water Temperature Shutdown: coolant temperature used by the GSC+ to declare a high coolant temperature shutdown fault exists (after a 10 second delay).

185 to 253ºF (85 to 123ºC) in increments of 1

225ºF (107ºC)

225ºF (107ºC)

P016 - Low Water Temperature Alarm: coolant temperature used by the GSC+ to declare that a low coolant temperature alarm fault exists (after a 2 second delay).

32 to 97ºF (0 to 36ºC) in increments of 1

70ºF (21ºC)

70ºF (21ºC)

P010 - Engine Overspeed: engine speed used by the GSC+ to declare that an engine overspeed fault exists. The engine overspeed setpoint (for all 60 Hz applications) is 1.18 times the rated speed. P011 - Crank Terminate Speed: engine speed used by the GSC+ to disengage the starting motor during engine cranking. P012 - Oil Step Speed: engine speed used by the GSC+ for distinguishing between rated speed and idle speed when a low oil pressure fault exists.

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OP5-0 SETPOINTS (CONTINUED)

SETPOINTS OP5-0 ENGINE/GENERATOR PROGRAMMING① FACTORY SETPOINT-NAME-DESCRIPTIONS RANGE OF VALUES DEFAULT

DPGDS SETPOINT

P017 - Total Cycle Crank Time: cycle crank time used by the 5 to 120 seconds in increments of 1 GSC+ to declare that an overcrank fault exists. second.

90 seconds

90 seconds

P018 - Cycle Crank Time: amount of time the GSC+ cranks and then rests the starting motor during a single crank cycle.

10 seconds

10 seconds

5 minutes

5 minutes

5 to 60 seconds in increments of 1 second.

P019 - Cooldown Time: amount of time the GSC+ allows the 0 to 30 minutes in increments of 1 engine to run after a normal shutdown is initiated. minute. P020④ - AC Voltage: nominal AC voltage of the generator. The GSC+ measures the AC voltage and shows it on the display.

700, 150, 300, 500, 600, 750, 3.0k, 4.5k, 5.20k, 5.25k, 9.0k, 15.0k, 18.0k, 30.0k

700

5.20k

P021 - AC Current Full Scale: nominal full scale AC current of the generator. AC current full scale is equal to the ratio of the external current transformers in the generator housing.

75, 100, 150, 200, 300, 400, 600, 800, 1000, 1200, 1500, 2000, 2500, 3000, and 4000A

600A

100A

P022⑤ - GSC+ Engine Number: informs other devices on the CAT Data Link of the engine number for the GSC+.

01 through 08

01

01 (Gen 1) 02 (Gen 2)

SETPOINTS - OP5-0-ENGINE/GENERATOR PROGRAMMING① RANGE OF FACTORY 60HZ 50HZ SETPOINT-NAME-DESCRIPTIONS DEFAULT SETPOINT SETPOINT VALUES P023 - Engine Type: identifies the engine as a mechanical unit injector (MUI) diesel, spark ignited (gas), or electronic unit injector (EUI) diesel engine.

0 - MUI diesel 1 - Gas 2 - EUI diesel

P024 - Crank Time Delay: amount of time the GSC+ delays activation of the fuel control relay (FCR) during a crank cycle. This setpoint is for Gas engines only. The P024 setpoint only functions when the P023 setpoint is set to 1 (gas engine).

0 to 20 seconds in increments of 1 second.

0

2

2

5 Seconds

5 Seconds

5 Seconds

0 - for gensets without an oil P025 - Oil Temperature Sensor Installed: tells temperature sensor whether or not the optional engine oil temperature 1 - for gensets with an oil sensor is installed on the genset. temperature sensor

0

0

0

P026 - High Oil Temperature Shutdown: oil temperature used by the GSC+ to declare a high 185 to 253ºF (85 to 123ºC) in increments of 1 oil temperature shutdown fault exists (after a 10 second delay). Refer to the panel model number.

225ºF (107ºC)

0 - for alarm only (shutdown override, P027 - Shutdown Override For High Oil Temperature Fault: GSC+ response to an engine no engine shutdown). high oil temperature fault. 1 - for engine shutdown. P028 - Nameplate Voltage: rated voltage of the 100 to 25kV in increments of 1 generator. This setpoint is used for protective relaying functions. P029 - Nameplate Current: rated current output 0 to 4000 A in increments of 1 of the generator. P030 - Nameplate Power: rated power capability 0 through 10MW in increments of of the generator. 1kW. P031 - Rated Frequency: nominal frequency rating of genset.

50 or 60Hz

P032 - Connection Configuration Of Generator: 0 - wye wye or delta configuration of generator. 1 - delta P033 - Number Of Generator Poles. 0 through 254 in increments of 2.

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225ºF (107ºC) 225ºF (107ºC)

0

0

0

480V

4160V

3800V

600A

80A

73A

400kW

420kW

350kW

60Hz

60Hz

50Hz

0

0

0

4

4

4

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 ①

The setpoints (stored or being programmed) must match the specified DPGDS setpoints.

② When oil pressure drops to within 5PSI (34kPa) of the P013 or P014 setpoint, a low oil pressure alarm is issued by the GSC+. ③ When coolant temperature rises to within 11ºF (6ºC) of the P015 setpoint, a high coolant temperature alarm is issued by the GSC+. ④ The values other than the default (700V) are for switchgear applications and require the use of external potential transformers and the removal of the AC voltage range jumper located in the relay module. The DPGDS unit is factory configured for the 5.20 K value. See the Caterpillar Electronic Modular Control Panel II+ manual topic AC Voltage Range Selection in the Testing and Adjusting section. ⑤ After setpoint P022 is reprogrammed, the GSC+ must be power cycled (powered down and then powered up)

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TABLE 5.11.3.4-5

OP5-1 SETPOINTS

SETPOINTS OP5-1 PROTECTIVE RELAYING PROGRAMMING① FACTORY 60HZ 50HZ SETPOINT-NAME-DESCRIPTION RANGE OF VALUES DEFAULT SETPOINT SETPOINT P101 - Generator Overvoltage Alarm Enable: the 0 - disabled GSC+ enables or disables the generator 1 - enabled overvoltage alarm function. P102 - Generator Overvoltage Alarm Threshold: voltage the GSC+ uses to issue an overvoltage alarm.

100 to 125% of nameplate voltage in increments of 1%.

P103 - Generator Overvoltage Alarm Time Delay: amount of time the GSC+ waits before issuing an overvoltage alarm. P104 - Generator Overvoltage Shutdown Enable: the GSC+ enables or disables the generator overvoltage shutdown function. P105 - Generator Overvoltage Shutdown Threshold: voltage the GSC+ uses to issue an overvoltage shutdown. P106 - Generator Overvoltage Shutdown Time Delay: amount of time the GSC+ waits before issuing an overvoltage shutdown.

0 through 120 seconds② in increments of 1

P107 - Generator Undervoltage Alarm Enable: the GSC+ enables or disables the generator undervoltage alarm function.

0 - disabled 1 - enabled

P108 - Generator Undervoltage Alarm Threshold: voltage the GSC+ uses to issue an undervoltage alarm. P109 - Generator Undervoltage Alarm Time Delay: amount of time the GSC+ waits before issuing an undervoltage alarm. P110 - Generator Undervoltage Shutdown Enable: the GSC+ enables or disables the generator undervoltage shutdown function. P111 - Generator Undervoltage Shutdown Threshold: voltage the GSC+ uses to issue an undervoltage shutdown.

0 - disabled 1 - enabled 100 to 125% of nameplate voltage in increments of 1%. 0 through 120 seconds② in increments of 1

60 to 100% of nameplate voltage in increments of 1%. 0 through 120 seconds② in increments of 1 0 - disabled 1 - enabled 60 through 100% of rated voltage in increments of 1%.

P112 - Generator Undervoltage Shutdown Time Delay: amount of time the GSC+ waits before issuing an undervoltage shutdown.

0 through 120 seconds② in increments of 1

P113 - Generator Overfrequency Alarm Enable: the GSC+ enables or disables the generator overfrequency alarm function.

0 - disabled 1 - enabled

P114 - Generator Overfrequency Alarm Threshold: frequency the GSC+ uses to issue an overfrequency alarm.

50-60Hz, for 50Hz Gen 60-70Hz, for 60Hz Gen 400-480, for 400Hz Gen

P115 - Generator Overfrequency Alarm Time Delay: amount of time the GSC+ waits before issuing an overfrequency alarm.

0 through 120 seconds② in increments of 1

P116 - Generator Overfrequency Shutdown Enable: the GSC+ enables or disables the generator overfrequency shutdown function.

0 - disabled 1 - enabled

P117 - Generator Overfrequency Shutdown Threshold: frequency the GSC+ uses to issue an overfrequency shutdown.

50-60Hz, for 50Hz Gen 60-70Hz, for 60Hz Gen 400-480, for 400Hz Gen

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1

1

1

105%

105%

105%

10 seconds

10 seconds

10 seconds

1

1

1

110%

110%

110%

10 seconds

10 seconds

10 seconds

1

1

1

90%

90%

90%

10 seconds

10 seconds

10 seconds

1

1

1

85%

85%

85%

15 seconds

03 seconds

03 seconds

1

1

1

53Hz 63Hz 422Hz

63 Hz

53 Hz

10 seconds

10 seconds

10 seconds

1

1

1

55Hz 66Hz 440Hz

66Hz

55Hz

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 TABLE 5.11.3.4-5

OP5-1 SETPOINTS (CONTINUED)

SETPOINTS OP5-1 PROTECTIVE RELAYING PROGRAMMING① FACTORY 60HZ SETPOINT-NAME-DESCRIPTION RANGE OF VALUES DEFAULT SETPOINT P118 - Generator Overfrequency Shutdown Time Delay: amount of time the GSC+ waits before issuing an overfrequency shutdown.

0 through 120 seconds② in increments of 1

P119 - Generator Underfrequency Alarm Enable: the GSC+ enables or disables the generator underfrequency alarm function.

0 - disabled 1 - enabled

P120 - Generator Underfrequency Alarm Threshold: frequency the GSC+ uses to issue an underfrequency alarm.

30-50Hz, for 50Hz Gen 36-60Hz, for 60Hz Gen 240-400, for 400Hz Gen

P121 - Generator Underfrequency Alarm Time Delay: amount of time the GSC+ waits before issuing an underfrequency alarm. P122 - Generator Underfrequency Shutdown Enable: the GSC+ enables or disables the generator underfrequency shutdown function.

0 through 120 seconds② in increments of 1

P123 - Generator Underfrequency Shutdown Threshold: frequency the GSC+ uses to issue an underfrequency shutdown.

30-50Hz, for 50Hz Gen 36-60Hz, for 60Hz Gen 240-400, for 400Hz Gen

P124 - Generator Underfrequency Shutdown Time Delay: amount of time the GSC+ waits before issuing an underfrequency shutdown. P125 - Generator Reverse Power Shutdown Enable: the GSC+ enables or disables the generator reverse power shutdown function. P126 - Generator Reverse Power Shutdown Threshold: level of reverse power the GSC+ uses to issue a reverse power shutdown.

0 through 120 seconds② in increments of 1

P127 - Generator Reverse Power Shutdown Time Delay: amount of time the GSC+ waits before issuing a reverse power shutdown.

0 through 30 seconds② in increments of 1

P128 - Generator Overcurrent Alarm Enable: the GSC+ enables or disables the overcurrent alarm.

0 - disabled 1 - enabled

P129 - Generator Phase Overcurrent Alarm Threshold: level of current the GSC+ uses to issue a phase overcurrent alarm. P130 - Generator Phase Overcurrent Alarm Time Delay: amount of time the GSC+ waits before issuing a phase overcurrent alarm. P131 - Generator Total Overcurrent Alarm Threshold: level of current the GSC+ uses to issue a total overcurrent alarm. P132 - Generator Total Overcurrent Alarm Time Delay: amount of time the GSC+ waits before issuing a total overcurrent alarm.

10 seconds

10 seconds

10 seconds

1

1

1

48Hz 57Hz 378Hz

57Hz

48Hz

10 seconds

10 seconds

10 seconds

1

1

1

45Hz 54Hz 360Hz

54Hz

45Hz

15 seconds

03 seconds

03 seconds

1

1

1

15%

4%

4%

10 seconds

4 seconds

4 seconds

1

1

1

100 through 160% of nameplate current in increments of 5%

105%

150%

150%

0 through 250 seconds② in increments of 1

0 seconds

0 seconds

0 seconds

100 through 160% of three times nameplate current in increments of 5%

105%

150%.

150%

0 through 250 seconds② in increments of 1

0 seconds

0 seconds

0 seconds

1

1

1

110%

150%

150%

0 seconds

10 seconds

10 seconds

0 - disabled 1 - enabled

0 - disabled 1 - enabled 0 through 20% of rated power in increments of 1%.

P133 – Generator Overcurrent Shutdown Enable: 0 – disabled the GSC+ enables or disables the overcurrent 1 – enabled shutdown. P134 – Generator Phase Overcurrent Shutdown 100 through 160% in increments of 5% Threshold: level of current the GSC+ uses to issue a phase overcurrent shutdown. P135 – Generator Phase Overcurrent Shutdown Time Delay: amount of time the GSC+ waits before issuing a phase overcurrent shutdown.

50HZ SETPOINT

0 through 250 seconds② in increments of 1

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OP5-1 SETPOINTS (CONTINUED)

SETPOINTS OP5-1 PROTECTIVE RELAYING PROGRAMMING① FACTORY 60HZ SETPOINT-NAME-DESCRIPTION RANGE OF VALUES DEFAULT SETPOINT

50HZ SETPOINT

P136 - Generator Total Overcurrent Shutdown Threshold: level of current the GSC+ uses to issue a total overcurrent shutdown.

100 through 160% of three times nameplate current in increments of 5%

110%

150%.

150%

P137 - Generator Total Overcurrent Shutdown Time Delay: amount of time the GSC+ waits before issuing a total overcurrent shutdown.

0 through 250 seconds② in increments of 1

0 seconds

10 seconds

10 seconds

P138 - KW Level Relay Enable : the GSC+ enables or disables the kW level relay function.

0 - disabled 1 - enabled

1

1

1

0 through 110% of nameplate power in increments of 1%

105%

105%

105%

0 through 120 seconds② in increments of 1

0 seconds

0 seconds

0 seconds

0 through 110% of nameplate power in increments of 1%.

100%

100%

100%

0 through 120 seconds② in increments of 1

10 seconds

10 seconds

10 seconds

P139 - KW Level Relay Threshold: level of power the GSC+ uses to activate the kW level relay function. P140 - KW Level Relay Time Delay: amount of time the GSC+ waits before activating the kW level relay function. P141 - KW Level Relay Disengage Threshold: level of power the GSC+ uses to deactivate the kW level relay function. P142 - KW Level Relay Disengage Time Delay: amount of time the GSC+ waits before deactivating the kW level relay function.

①

The setpoints are programmed at the factory to the default value.

②

When programmed to 0 seconds, the actual time is from 0.5 to 1.0 seconds.

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TABLE 5.11.3.4-6

OP6 SETPOINTS SETPOINTS OP6 SPARE INPUT/OUTPUT PROGRAMMING

SETPOINT-NAME-DESCRIPTIONS

RANGE OF VALUES

FACTORY DPGDS DEFAULT SETPOINT

SP01 - Spare Input 1 Active State. Input state used by the GSC+ to declare a SP1 fault exists.

0-active low 1-active high

0

0

SP02 - Spare Input 1 Response: GSC+ response to a SP1 fault.

0-shutdown 1-alarm

0

0

SP03 - Spare Input 1 Time Delay: Amount of time the GSC+ waits before responding to a SP1 fault.

0 - 250 seconds in increments of 1

0 seconds

1 second

0

1

0

0

0 seconds

0 seconds

0

0

0

0

0 seconds

0 seconds

SP04 - Spare Input 2 Active State. Input state used by the GSC+ to declare a SP2 fault exists. SP05 - Spare Input 2 Response: GSC+ response to a SP2 fault. SP06 - Spare Input 2 Time Delay: Amount of time the GSC+ waits before responding to a SP2 fault. SP07 - Spare Input 3 Active State. Input state used by the GSC+ to declare a SP3 fault exists. SP08 - Spare Input 3 Response: GSC+ response to a SP3 fault.

0-active low 1-active high 0-shutdown 1-alarm 0 - 250 seconds in increments of 1 0-active low 1-active high 0-shutdown 1-alarm

SP09 - Spare Input 3 Time Delay: Amount of time the GSC+ waits before responding to a SP3 fault.

0 - 250 seconds in increments of 1

SP10 - Spare Input 4 Active State. Input state used by the GSC+ to declare a SP4 fault exists.

0-active low 1-active high

0

0

SP11 - Spare Input 4 Response: GSC+ response to a SP4 fault.

0-shutdown 1-alarm

0

0

SP12 - Spare Input 4 Time Delay: Amount of time the GSC+ waits before responding to a SP4 fault.

0 - 250 seconds in increments of 1

0 seconds

0 seconds

SP13 - Spare Output Response: GSC+ response to the spare output trigger condition.

0-active low 1-active high

0

0

8

8

1

1

0-unused 1-active SP1 fault② 2-active SP2 fault② 3-active SP3 fault② SP14 - Spare Output Trigger Condition: The condition used by the GSC+ to trigger the spare output response

4-active SP4 fault② 5-any combination of active SP faults② 6-any active shutdown 7-any active alarm or shutdown 8-cooldown mode 9-coolant loss mode②

10-high oil temp fault② 11-CCM control SP15 – Spare Relay Output Response: GSC+ response to the 0-relay inactive when triggered spare relay trigger condition. 1-relay active when triggered

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OP6 SETPOINTS (CONTINUED) SETPOINTS OP6 SPARE INPUT/OUTPUT PROGRAMMING

SETPOINT-NAME-DESCRIPTIONS

RANGE OF VALUES

FACTORY DPGDS DEFAULT SETPOINT

0-unused 1-active SP1 fault② 2-active SP2 fault② 3-active SP3 fault② SP16 - Spare Relay Output Trigger Condition: The condition used by the GSC+ to trigger the spare relay.

4-active SP4 fault② 5-any combination of active SP faults② 6-any active shutdown 7-any active alarm or shutdown 8-cooldown mode

8

1

0

6

Battle Short mode.

0

0 Battleshort③

Not in 60 Hz mode.

0

9-coolant loss mode② 10-high oil temp fault② 11-CCM control 0-unused 1-active SP1 fault② 2-active SP2 fault② 3-active SP3 fault② SP17 - Spare Indicator 1 Trigger Condition: The condition used by the GSC+ to trigger spare indicator①.

4-active SP4 fault② 5-any combination of active SP1, SP2, SP3 or SP4 faults② 6-Coolant loss fault② 7-high oil temperature fault②

SP18 - Spare Indicator 2 Trigger Condition: The condition used by the GSC+ to trigger spare indicator②. SP19 - Spare Indicator 3 Trigger Condition: The condition used by the GSC+ to trigger spare indicator③.

① The setpoints are programmed at the factory to the default value. ② Either alarm or shutdown faults are valid trigger conditions ③ Battleshort and 50Hz Mode are unique features to DPGDS for spare indicators 2 and 3.

e. Return ECS1 and ECS2 to the OFF/RESET position. NOTE: f.

Use up or down keys to change values. At the AVR verify the operation settings using Table 5.6.3.4-7: (1)

Open the GCPG1 cabinet door.

(2)

Press the [▼] key to display parameter “90”.

5-300

0 In 50Hz Mode③

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (3)

Press the [◄►] key to display the current value.

(4)

Press the [▲] key to change the value to “0015”. Enables parameter editing.

(5)

Press the [◄►] key to accept change and display the parameter number.

(6)

Press the [▲] key to the next parameter needed to change.

(7)

Press the [◄►] key to display the current value.

(8)

Press the [▲] or [▼] key to change the value.

(9)

Press the [◄►] key to accept change and display the parameter number.

(10) Repeat steps ‘5’ through ‘9’ for the each parameter needing to be changed. (11) When complete, press the [▼] to display parameter “01”. NOTE:

Parameters 20, 21, 22, 36, 37, and 38 are displayed but not used.

NOTE:

Parameters 23 to 29, 39 to 49, 59 and 61 to 89 are not displayed and not used.

TABLE 5.11.3.4-7

AVR PARAMETERS/SETPOINTS

DPGDS SETPOINTS

DPGDS AVR PARAMETERS PARAMETER

TITLE

TYPE

UNITS

RANGE OF VALUES

DEFAULT VALUE

60HZ OPS

50HZ OPS

Volts

0080-9999

480①

4160

3800

001.0-100.0

001.0

17.3

17.3

01

Generator Output Voltage

Program

02

Ratio of Output Voltage To Sensing Voltage

Program Program Program

Amps

0000-0004 0000-9999

0004 0600

4 80

4 73

Program

Volts

01.00-05.00

05.00

4.00

3.66

06 07

Generator Type Rated Generator Output Current CT Voltage At Rated Generator Current Knee Frequency Decreasing Volts/Hz Slope I

Program Program

Hz Volts/Hz

045.0-065.0 001.0-010.0

050.0 002.0

59.8 2.0

49.8 2.0

08 09 10 11 12 13

Decreasing Volts/Hz Slope 2 Minimum Voltage Under Frequency Point Overvoltage Trip Point Overvoltage Trip Time Under Voltage Trip Point

Program Program Program Program Program Program

Volts/Hz % Hz % Seconds %

001.0-010.0 050.0-100.0 020.0-040.0 0105-0140 0002-0030 0060-0095

002.0 050.0 025.0 014.0 0002 0060

2.0 50.0 25.0 125.0 5 75

2.0 50.0 25.0 125.0 5 75

14 15

Under Voltage Trip Time Voltage Gain (IR Compensation)

Program Program

Seconds %

0030-0120 000.0-0 10.0

0030 0000

30 0

30 0

16⑤

Integral Gain

Program

001.0-020.0

006.0

6.0

6.0

17⑥

Proportional Gain

Program

001.0-020.0

005.0

5.0

5.0

18

Single Phase Sensing Select (0=three phase, 1=single phase)

Program

0000,0001

0000

0000

0000

19

Diode Monitor Trip Point

Program

001.0-010.0

002.0

2.0

2.0

03 04 05②

5-301

Amps

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 TABLE 5.11.3.4-7

AVR PARAMETERS/SETPOINTS (CONTINUED)

DPGDS SETPOINTS

DPGDS AVR PARAMETERS TYPE

UNITS

RANGE OF VALUES

DEFAULT VALUE

60HZ OPS

50HZ OPS

Droop Percentage

Program

%

000.0-010.0

0000

3

3

31③

pf/Kvar Select (0=pf, 1=Kvar)

Program

0000, 0001

0000

0

0

32③

Pf Reference

Program

00.60-01.10

01.00

0.8

0.8

33③

KVAR Reference

Program

Per Unit

00.00-01.00

0000

0.10

0.10

34③

Reverse Power Trip Point

Program

%

000.0-020.0

010.0

15

15

35③ 50 51 52 53

Reverse Power Trip Time

Program

Seconds

000.0-020.0

010.0

5

5

Generator Output Frequency Generator Output Voltage Generator Output Current Generator Reactive Output Current

View View View View

Hz Volts Amps Amps

View View

Amps Amps

56③

Generator Real Current Exciter Field Current Three Phase Kilowatts (KB and later)

View

KW

57③

Power Factor

View

0009

0009

0000 0000

0000 0000

PARAMETER 30

54 55

58③, ④

TITLE

Three Phase Kvar (KE and later)

60 90 91

Hours Password Software ID

92 93 94 96

Latest Fault Previous Fault Fault Clear Shutdown Fault Reset

View View Program View

Hours

0000-9999

View View View Switch

0000 0000

①Default value for output voltage is different depending on regulator sensing voltage. If the regulator is designed for 120 volts sensing, then the default output voltage is 4160 volts. All other sensing types have the default output voltage set to 480 volts. ②-

Digital Voltage Regulators with earlier software (KD and earlier) have 1 less digit to the right of the decimal point.

③-

Optional feature.

④-

New parameter on serial number prefix KE and later Digital Voltage Regulators.

⑤-

Previous range of 0001-099.9 and default value of 002.0

⑥-

Previous range of 0001-099.9 and default value of 002.0

(12) When complete, press the [▼] to display parameter “90”. (13) Press the [◄►] key to display the current value. (14) Press the [▼] key to change the value to “0009”. Disables DVR parameter editing.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (15) Press the [◄►] key to accept change and display the parameter number. (16) Press the [▲] key to change to display parameter “01”. (17) Close the GCPG cabinet door. (18) Repeat steps ‘1 ‘through ‘17’ for Generator 2.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 5.11.3.5

PRE-OPERATION CHECKS

Starting from the left rear of the PU and working around the PU in a clockwise direction, perform the following checks (Gen. 1 is on the left and Gen. 2 is on the right): TABLE 5.11.3.5-1 PRE-OPERATION CHECKLIST ITEM ACTION REQUIRED NUMBER Ensure the parking brake is set. Rotate the crank in a clockwise rotation 1 (PU-810 A) to set. Ensure that the wheels are properly chocked or the Spring Brakes are 1 (PU-810-B) set by opening the petcock on the air tank and evacuating all the air. Check the ground connection. 2 Check that the ORT communication cable is connected properly. 3 Ensure the feeder output cables, if used, are properly connected and 4 that the concentric neutrals are connected to ground. Ensure that the feeder output cover is secured. (Locked) 5 Check Parking Stands for proper mounting and connection. 6 Check the two 120-Volt auxiliary duplex receptacles and the 60 amp 3 phase receptacle cables are securely connected or the covers are 7 properly installed / closed. Open the left rear PU side access door and inspect the area for cleanliness, loose electrical connections, loose hardware, and leaks 8 around the oil filter and lines. Check for signs of heat damage or other abnormalities. Check all high voltage panels for security Ensure that the battery charger voltmeter displays (24 VDC), is plugged into the battery charger receptacle, and that all circuit breakers are 9 turned on. Return to this step after a generator breaker is closed to ensure charger is supplying current to the batteries. Visually inspect the air intake duct for obstructions or foreign objects. 10 Close the left rear PU door. 11 Open the left front PU side access door and inspect the area for cleanliness, loose electrical connections, loose hardware, leaks around 12 oil and fuel lines, signs of heat damage or other abnormalities. Drain the crankcase vent reservoir (fumes box) into a proper container. 13 If necessary, open the Primary Fuel Filter Drain Valve and drain any 14 accumulated water into an appropriate container. Check oil level for Generator 1. 15 Ensure fuel shutoff valve is in the open position (valve handle is parallel 16 to the fuel hose). Close the left front PU side access door. 17 Remove the Gen. 1 splashguard (PU-810 B). 18 Check the fuel tank, hydraulic tank, and radiator fill tank for signs of 19 damage or leaks. Check fuel level with the built-in dipstick, coolant levels through the 20 coolant sightglass and hydraulic fluid levels with the sightglass.

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CHECK COMPLETED

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 TABLE 5.11.3.5-1 PRE-OPERATION CHECKLIST (CONTINUED) ITEM ACTION REQUIRED NUMBER Check the fuel transfer pump assembly for mounting security and leaks. 21 Place the fuel transfer mode switch in “A” (automatic mode) position. Place the fuel transfer pump power switch in the G1 position. Check the condition of the batteries for cleanliness and signs of 22 damage. Check the battery electrical connections for tightness and signs of corrosion. Check to ensure that the battery isolation switch is in the OFF 23 position.① Remove the Gen. 2 splashguard (PU-810B only). 24 Open the PU right side front access door and inspect the area for 25 cleanliness, loose electrical connections, loose hardware, leaks around oil and fuel lines, signs of heat damage or other abnormalities. Check oil level for Generator 2. 26 Drain the crankcase vent reservoir (fumes box) into a proper container. 27 If necessary open the Primary Fuel Filter Drain Valve and drain any 28 water accumulated into an appropriate container Ensure manual fuel cutoff valve is in the open position; valve handle is 29 parallel to the fuel hose. Close the right front PU side access door. 30 Open the right rear PU side access door and inspect the area for cleanliness, loose electrical connections, loose hardware, leaks, around 31 the oil filter, and for signs of heat damage or other abnormalities. Check all high voltage access panels for security. Visually inspect the air intake for obstructions or foreign objects. 32 Ensure that the battery charger voltmeter displays (24 VDC), is plugged into the battery charger receptacle, and that all circuit breakers are 33 turned on. Return to this step after a generator breaker is closed to ensure charger is supplying current to the batteries. Check Parking Stands for proper mounting and connection. 34 Check with a flashlight between generator sets G1 and G2 for leaks, 35 loose hardware, and any other potential problem. Close the right rear PU side access door. 36 Ensure the tie output cables are properly connected and that the 37 concentric neutrals are connected to ground. Ensure that the tie-output cover is secured. (Locked) 38 Check PU equipment grounds for proper connection. 39 Check that the PU interconnect control cable is properly connected to 40 the “B” connector. Inspect the exterior fuel system for proper connection, leaks, and 41 availability of fuel. Open all three PDC doors. Check for damage, loose connections, and 42 foreign objects. Position the 50/60 Hz selector switch in the proper mode. 43 Close all PDC doors. 44

CHECK COMPLETED

① The Battery Parallel Switch should be left in the OFF position except in extreme conditions where the additional DC power is required to crank an engine. Once started, return the switch to the OFF position. If the battery parallel switch is left in the “ON” position, it could cause one of the generators in the PU to shut down when the other generator is tyring to start.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 5.11.3.6

PSC RELAY SETTING VERIFICATION

a. Turn on the ORT and log in as administrator using the procedures of PSC Manual (Table 3.3.2-1 DPGDS ORT ADMINISTRATOR LOG-IN PROCEDURE). b. Click on Windows Start button. c.

Select Programs then “Accessories” then “Communication” then “HyperTerminal”.

d. Double Click on “Vista.ht” NOTE:

Use Com 1 communications port on the ORT.

e. Connect the communication cable between the ORT to the left (Ways 3 and 4) Overcurrent Relay (OCR). f.

Click on “PSC”, press “Enter” on the ORT. NOTE:

The overcurrent relay main menu should appear.

g. Select View Menu 1, WAY 3. Then press “enter” h. Select View relay settings. Then press “enter” i.

Verify relay settings according to Table 5.11.3.6-1 NOTE: Refer to S&C Instruction Sheet 681-515 page 14, PROGRAMMING to change settings. The User Password “6601” must be entered to change control settings and test trip the solenoids.

j.

To change relay settings, press “enter”

k.

Select “Switch to Main Menu”

l.

Select Configuration Menu 1 or 2

m. Type in Password-6601 n. Select “Change relay Settings” Press “enter” o. Set relay settings according to Table 5.11.3.6-1 p. Ensure new settings are saved by pressing “Y” then “enter” q. Repeat steps g through p for WAY 4. r. Return to the main menu and test the “Trip Function” of each interrupter using the Test Trip Menu. s.

Return to the Main Menu and “Disconnect” using Windows HyperTerminal when desired programming action is complete.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 Disconnect the OCR end of the communication cable.

t.

CAUTION WAY 5 TRIP SETTINGS ARE DIFFERENT DEPENDING ON WHETHER IT IS DESIGNATED AS A TIE-IN POINT FOR ANOTHER PSC OR A FEEDER OUTPUT. ALWAYS ENSURE THAT THE TRIP SETTINGS ARE PROPERLY SET FOR THE APPLICATION. FAILURE TO DO SO MAY CAUSE WAY 5 TO TRIP OFF LINE u. Repeat steps e. through t. for the right OCR (Ways 5 and 6). v.

Repeat steps e. though u. for each PSC in use.

x.

Exit Windows HyperTerminal.

y.

Shut-down the ORT.

TABLE 5.11.3.6-1 PSC RELAY SETTINGS PSC WAY 3,4, or 5 3,4, or 5 3,4, or 5 3,4, or 5 5 or 6 6

FUNCTION Feeder Feeder Ground Single Output Single Output Ground PSC Interconnect PSC Interconnect Ground

CABLE SIZE

TCC CURVE

MIN. PICKUP (AMPS)

INST. PICKUP (KAMPS)

TIME DELAY (SEC.)

1/0

TAP

200

1

Off

1/0

TAP

50

Off

Off

500 KCM

MAIN

600

1

Off

500 KCM

MAIN

100

0

Off

4/0

TAP

400

0

C (64ms)

4/0

TAP

80

0

C (64ms)

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 5.11.3.7

PRE-OPERATION RUN WARNING ENSURE ALL PERSONNEL ARE CLEAR AND THE PU DOORS ARE CLOSED PRIOR TO STARTING A GENERATOR. WARNING

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND ENFORCED. NOISE LEVELS IN EXCESS OF 85 DB EXIST WITHIN AN 88-FOOT RADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR SINGLE HEARING PROTECTION WITHIN 88 FEET OF AN OPERATING DPGDS. WARNING HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND ENFORCED. DURING MAINTENANCE ACTIVITIES WITH THE SIDEDOORS OPEN, NOISE LEVELS IN EXCESS OF 113 DB EXIST WITHIN A 12-FOOT RADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR DOUBLE HEARING PROTECTION WITHIN 12 FEET OF AN OPERATING DPGDS. EXPOSURE MUST BE LIMITED TO UNDER 2.5 HOURS. WARNING BY CLOSING THE FEEDER OR TIE BREAKER, HIGH VOLTAGE WILL BE PRESENT ON THE LOAD CABLES. ENSURE ALL PERSONNEL ARE CLEAR OF ALL LOAD CABLES PRIOR TO CLOSING FEEDER OR TIE BREAKERS.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 TABLE 5.11.3.7-1 PRE-OPERATION RUN INSTRUCTION SEQUENCE (Perform on each PU in the power plant(s)) STEP

-- 60HZ OPERATIONS --

-- 50HZ OPERATIONS --

1

Verify System Mode Switch (SMS) is in MANUAL

2

Verify DC Control Power is on

3

Verify Emergency Stop is pulled out

4① 5

Verify the 60Hz light is on ①

Verify the 50Hz light is on①

Start engine 1 by placing ECS1 in MANUAL (START)

6

Verify the engine accelerates to 1800RPM

Verify the engine accelerates to 1500RPM

7

Adjust the generator frequency to 60Hz using the Frequency Adjust Rheostat (FAR)

Adjust the generator frequency to 50Hz using the Frequency Adjust Rheostat (FAR)

8

Adjust the generator voltage to 4295VAC using the Voltage Adjust Rheostat (VAR)

Adjust the generator voltage to 3915VAC using the Voltage Adjust Rheostat (VAR)

9

Close BCS-G1, toggle the Phase Rotation Test Light switch, verify that light ABC lights, open BCS-G1

10

Shutdown engine 1 by placing ECS1 in OFF/RESET

11

Start engine 2 by placing ECS2 in MANUAL (START)

12

Verify the engine accelerates to 1800RPM

Verify the engine accelerates to 1500RPM

13

Adjust the generator frequency to 60Hz using the Frequency Adjust Rheostat (FAR)

Adjust the generator frequency to 50Hz using the Frequency Adjust Rheostat (FAR)

14

Adjust the generator voltage to 4295VAC using the Voltage Adjust Rheostat (VAR)

Adjust the generator voltage to 3915VAC using the Voltage Adjust Rheostat (VAR)

15

Close BCS-G2, toggle the Phase Rotation Test Light switch, verify that light ABC lights

16

Close all BCS-T on all PUs in the plant lineup(s)

17

At each PDC toggle the Phase Rotation Test Light switch, verify that light ABC lights②

18

Open all BCS-T to isolate the PU

19

Open BCS-G2 on the PU

20

Shutdown engine 2 by placing ECS2 in OFF/RESET ① If the wrong frequency light is on, open the Master Control Door and change the Frequency Selector Switch (FSS) to the desired frequency with the SMS in OFF. ② If wrong phase rotation lights (CBA), shutdown plant and check for proper cable connections

5-309

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 5.11.3.8

CONTROLS SETUP

5.11.3.8.1

PLANT ONE

Complete the switch arrangements according to the following Table, and verify the lamp indicators: NOTE:

Ignore settings for Power Units not being used:

TABLE 5.11.3.8-1 PDC CONTROL SWITCH SETUP PANEL SWITCH 1ST PU Pushed In DC Power (ON) SMS OFF PRIME GMS POWER PRIME AVRS MASTER CONTROL POWER PANEL MCP 60Hz Light ON①

2ND PU Pushed In (ON) OFF PRIME POWER PRIME POWER

3RD PU Pushed In (ON) OFF PRIME POWER PRIME POWER

4TH PU Pushed In (ON) OFF PRIME POWER PRIME POWER

ON①

ON①

ON①

A② NORMAL OFF All OFF 50/60 Hertz①

B② NORMAL OFF All OFF 50/60 Hertz①

C② NORMAL OFF All OFF 50/60 Hertz①

D② NORMAL OFF All OFF 50/60 Hertz①

Pulled-Out

Pulled-Out

Pulled-Out

Pulled-Out

OFF

OFF

OFF

OFF

Pulled-Out

Pulled-Out

Pulled-Out

Pulled-Out

OFF

OFF

OFF

OFF

USS BSS SSS SSL INSIDE MCP

FSS

GENERATOR CONTROL PANEL GCPG1 GENERATOR CONTROL PANEL GCPG2

Emergency Stop ECS Emergency Stop ECS

① With the SMS in the OFF position, the 50/60Hz lights indicate the position of the Frequency

Selector Switch (FSS). If the wrong light is on, open the door and change the switch position. ② No more than one switch can be in the same position in any multi-PU line-up Per 4 PU plant.

With the SMS in OFF, none of the USI lights will be on and any previously set address on the PU is cleared.

5.11.3.8.2

Plant Two

Complete the switch arrangements according to the following Table, and verify the lamp indicators: CAUTION ENSURE THAT THE PLANT EXPANSION ADAPTER IS INSTALLED BETWEEN PLANT 1 D UNIT AND PLANT 2 A UNIT. DAMAGE TO THE PLANT OR IMPROPER OPERATION MAY OCCUR IF THE DEVICE IS NOT INSTALLED

5-310

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 NOTE:

Ignore settings for Power Units not being used:

TABLE 5.11.3.8-2 PDC CONTROL SWITCH SETUP PANEL SWITCH 1ST PU Pushed In DC Power (ON) SMS OFF PRIME GMS POWER PRIME AVRS MASTER CONTROL POWER PANEL MCP 60Hz Light ON①

2ND PU Pushed In (ON) OFF PRIME POWER PRIME POWER

3RD PU Pushed In (ON) OFF PRIME POWER PRIME POWER

4TH PU Pushed In (ON) OFF PRIME POWER PRIME POWER

ON①

ON①

ON①

A② NORMAL OFF All OFF 50/60 Hertz①

B② NORMAL OFF All OFF 50/60 Hertz①

C② NORMAL OFF All OFF 50/60 Hertz①

D② NORMAL OFF All OFF 50/60 Hertz①

Pulled-Out

Pulled-Out

Pulled-Out

Pulled-Out

OFF

OFF

OFF

OFF

Pulled-Out

Pulled-Out

Pulled-Out

Pulled-Out

OFF

OFF

OFF

OFF

USS BSS SSS SSL INSIDE MCP

FSS

GENERATOR CONTROL PANEL GCPG1 GENERATOR CONTROL PANEL GCPG2

Emergency Stop ECS Emergency Stop ECS

① With the SMS in the OFF position, the 50/60Hz lights indicate the position of the Frequency

Selector Switch (FSS). If the wrong light is on, open the door and change the switch position. ② No more than one switch can be in the same position in any multi-PU line-up per 4 PU plant.

With the SMS in OFF, none of the USI lights will be on and any previously set address on the PU is cleared. 5.11.3.9

ORT SETUP

5.11.3.9.1

PLANT ONE

a. Remove the ORT from its case and set it up on a flat and level surface. b. Remove the mouse from the case and plug it into the mouse (PS2) port on the back of the ORT (if needed). c.

If 120VAC power is available, connect the ORT power supply cord to the 120VAC power. The ORT can operate up to three hours on its batteries.

d. Connect one end of the 150-foot patch cable to the ORT networking port on the back of ORT. e. Route the cable from the ORT to the PU and connect the cable to the ORT port on the bottom of PDC on Gen 1 side. f.

Turn on the ORT by pressing the power switch forward.

5-311

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 g. Observe that the ORT boots to the Login screen. h. Login as Operator, no password i..

Select the EquipID pop-up screen and enter the necessary information for the units. This includes the Trailer ID number, the Engine ID number, and the Generator ID number for each PU.

j.

Select the Oneline pop-up screen and enter the descriptor for the main load connected to the feeders.

NOTE: Unit must be designated (A,B,C,D light) must be on. k.

Return to the Overview pop-up screen (Home)

5.11.3.9.2

PLANT TWO

Repeat steps a. through k above. 5.11.4

PLANT STARTUP WARNING ONCE THE SYSTEM STATUS LIGHTS TURN GREEN AND THE MSES IS ENABLED, THE PU WILL START. ENSURE PERSONNEL ARE CLEAR OF THE PU. WARNING ONLY ONE PU MAY BE SELECTED TO ANY ONE USS POSITION IN PLANT 1 OR PLANT 2 DURING TWO PLANT OPERATIONS. OPERATING WITH MORE THAN ONE UNIT AT THE SAME ID MAY CAUSE UNSAFE AND ERRATIC OPERATIONAL CONDITIONS. WARNING ALWAYS PAD LOCK THE PSC INTERCONNECT SWITCHES. FAILURE TO DO SO COULD RESULT IN PERSONAL INJURY OR DAMAGE TO EQUIPMENT CAUTION THE TIE BREAKER MUST REMAIN CLOSED AT ALL TIMES WHILE A PU IS IN AN OPERATING PLANT LINEUP. OPENING THE TIE BREAKER WILL CAUSE LOAD SHARING TO BE AFFECTED AND THE PLANT TO OPERATE IMPROPERLY CAUTION THE DC POWER MUST REMAIN ON AT ALL TIMES WHILE A PU IN AN OPERATING LINEUP, EVEN WITH NO ENGINES OPERATING ON THAT PU. TURNING OFF DC POWER WILL AFFECT NETWORK COMMUNICATIONS BETWEEN UNITS AND THE ORT

5-312

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 Starting up a Multi-PU Prime Power Plant in Automatic Mode a. At the Primary Switching Center (PSC), close the associated connection for each PU supplying power to the switchgear and close and pad lock the PSC interconnect switches when using more than one primary switch. b. At the PSC, close the connections between the external switchgears. c.

At the PSC, open all the connections of loads to the PSC.

d. Complete the switch arrangements according to the following Table, and verify the lamp indicators. Set all units up before enabling the MSES at Master Control Panel. TABLE 5.11.4-1 PANEL

SWITCH SETUP (EACH PLANT) – AUTOMATIC MODE SWITCH 1ST PU 2ND PU 3RD PU BCS-T Red Target Red Target Red Target MASTER CONTROL SMS AUTO③ AUTO③ AUTO③ PANEL MCP USS A B C BCS-G1 Red Target Red Target Red Target GENERATOR CONTROL PANEL 1 BCS-F1 Red Target Red Target Red Target GCPG1 ECS-1 AUTO AUTO AUTO BCS-G2 Red Target Red Target Red Target GENERATOR CONTROL PANEL 2 BCS-F2 Red Target Red Target Red Target GCPG2 ECS-2 AUTO AUTO AUTO Gen 1 Green Gen 1 Green Gen 1 Green MASTER CONTROL SSL Gen 2 Green Gen 2 Green Gen 2 Green PANEL MASTER CONTROL PANEL MCP

4TH PU Red Target AUTO③ D Red Target Red Target AUTO Red Target Red Target AUTO Gen 1 Green Gen 2 Green

MSES

Enable①

Enable①

Enable①

Enable①

USI

A①, ②

B①, ②

C①, ②

D①, ②

① Hold the MSES in the ENABLE position until the selected USI indicator energizes. The switch

returns to the center position when released. This sets the PU networking address and enables the control and monitoring. NOTE: both generators will start and BCS-G1, BCS-G2, and BCS-T close as indicated by the red breaker status lights. ② No more than one of each indicator can be on for multi-PU operations. The light on should match

USS position. The USI light will de-energize after the SMS has been in OFF for 3 seconds. ③ With the SMS in AUTO any generator started, manually or automatically, will automatically

parallel to the bus. To prevent the generator from paralleling to the bus put the generator’s breaker in the Pull-To-Lock position. NOTE:

The automatic economizing feature will shutdown one generator every 3 minutes until the system load is at or below the 350KW/470KVA per generator threshold.

NOTE:

Enable all units MSES and observe the following:

PLANT 1 e. At A-unit, observe Generator 1 automatically starts and accelerates to operating voltage and frequency. f.

At A-unit, observe Generator 1 automatically closes to the system bus.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 g. At A-unit, observe the Tie breaker automatically closes. h. At B-unit, observe the Tie breaker automatically closes. i.

At C-unit, observe the Tie breaker automatically closes.

j.

At D-unit, observe the Tie breaker automatically closes.

k.

At A-unit, observe Generator 2 automatically starts and accelerates to operating voltage and frequency.

l.

At A-unit, observe Generator 2 automatically parallels to the system bus.

m. At B-unit, observe Generator 1 automatically starts and accelerates to operating voltage and frequency. n. At B-unit, observe Generator 1 automatically parallels to the system bus. o. At B-unit, observe Generator 2 automatically starts and accelerates to operating voltage and frequency. p. At B-unit, observe Generator 2 automatically parallels to the system bus. q. At C-unit, observe Generator 1 automatically starts and accelerates to operating voltage and frequency. r.

At C-unit, observe Generator 1 automatically parallels to the system bus.

s.

At C-unit, observe Generator 2 automatically starts and accelerates to operating voltage and frequency.

t.

At C-unit, observe Generator 2 automatically parallels to the system bus.

u. At D-unit, observe Generator 1 automatically starts and accelerates to operating voltage and frequency. v.

At D-unit, observe Generator 1 automatically parallels to the system bus.

w. At D-unit, observe Generator 2 automatically starts and accelerates to operating voltage and frequency. x.

At D-unit, observe Generator 2 automatically parallels to the system bus.

Plant 2 Observe steps e through x above. y.

At the external switchgear, close all switches/breakers connecting the external switchgear to the load (s).

z. Ensure generators have assumed load. After the load has stabilized for both power plants, proceed with the following if necessary: aa. Observe the KW, PF and KVAR of each generator at the LCP.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254

Note: If adjustment is needed for KVAR balance, start with the generator that is the furthest from the average KVAR (either too low or too high). Make minor adjustments of the Voltage Adjust Rheostat (VAR) until the KVAR sharing between generators are within +/– 10% of the average plant KVAR load. This adjustment will typically be required only once during initial power plant setup and is intended to compensate for meter variations among generators.

CAUTION Improper adjustment of the VAR can cause a reverse KVAR shutdown of a generator. 5.11.5

PLANT OPERATIONS (AUTOMATIC MODE)

5.11.5.1

PRECAUTIONS AND WARNINGS

This mode of operation places control of all generator starting, stopping, synchronizing, and load management under the auspices of the Programmable Logic Controller (PLC) system. As long as the SMS is in AUTO, any generator started, manually or automatically, is automatically synchronized to the system bus. Care must be taken when starting a generator manually when the SMS is in AUTO. Either place the associated BCS in Pull-To-Lock (prevent closing to the bus) or ensure it has the red target visible (allow paralleling to the bus) before starting the engine. The only exception is automatic operation of the feeder breakers. Auto Mode does not automatically close feeder breakers; it only enables remote operation of the feeder breakers from the ORT. 5.11.5.2

DESCRIPTION

The master controller (the designated “A” unit in each plant) will control all connected generators, in their respective plant based on the total system KW/KVA load. The controller shuts down one of the generators after 3 minutes should the system load drop below a level where the remaining generator load would not exceed 85% (350kW) if a generator is shutdown. If the load of the remaining generator exceeds 85% (350kW) for one minute, a standby generator is started and paralleled to the bus. A change of system load is recognized by the control system and appropriate action is taken to maintain generator load in the 85% (350 KW/470 KVA) range. The system never automatically shuts down the final generator under normal operating conditions. The shutdown of the final generator must be done following manual operating procedures. The default configuration is Economizing Mode on. The economizing mode can be turned off from the ORT. Through the ORT, the AUTO shut down is disabled but the AUTO start-up remains active to prevent overloading the online generator(s). 5.11.6

POWER PLANT TEARDOWN

5.11.6.1

SHUT DOWN GENERATORS

a. Place SMS in Manual. b. Unload all generators by opening all feeder breakers. This must be done locally from the LCP or ORT. c.

Open each BCST locally at the respective MCP.

5-315

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 d. Place all generators in cooldown by placing all SMS switches in OFF. e. Observe all generator breakers open. f.

Open all the switchgear generator supply disconnect switches.

g. Allow all engines to completely cooldown and shutdown (5 minutes). h. Place all ECS switches in OFF/RESET. i.

Pull out the DC Control Power breaker on all PUs.

5.11.6.2

DISCONNECT CABLES WARNING

NEVER REMOVE POWER CABLES BY HAND, USE HOT STICK AND HIGH VOLTAGE GLOVES. NEVER TOUCH A HIGH VOLTAGE LEAD OR TERMINAL UNTIL IT HAS BEEN DISCHARGED TO GROUND. FAILURE TO OBSERVE THE WARNING MAY RESULT IN DEATH BY ELECTROCUTION. CAUTION ALLOW ALL OPERATING ENGINES TO SHUT DOWN AND COOL DOWN COMPLETELY. a. Disconnect the communication cables from between the PUs and store inside the PUs (one per unit). b. Reinstall the communication cable receptacle covers. c.

Disconnect the ORT cable and store it in the ORT case.

d. Close and latch the ORT port on the PU. e. Disconnect all load cables used in operation of the PUs.

5.11.6.3

DISCONNECT FUEL LINES

a. Turn all fuel system valves to the off position. b. Disconnect the fuel hose from the PU fuel connection and the fuel supply. c.

Drain any fuel from the hoses into an auxiliary fuel supply and store the hoses.

5.11.6.4

DISCONNECT GROUNDING

a. Remove ground connections from the PU and store with the ground rod. b. Disconnect the parking stations from the ground grid.

5-316

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 c.

Remove the parking stations from their operating positions and reinstall them in their transportation locations on the inside of the PU rear side access doors.

5.11.6.5

PREPARE PU FOR TRANSPORTATION

a. Reinstall the four radiator splashguards (PU-810B only). b. Verify DC Control power is off. c.

Close and lock the LCP access doors.

d. Close and lock all PU side doors. Refer to Section 4.3 “MOVEMENT” to complete preparation for transportation. 5.11.6.6 FUEL, OIL, AND COOLANT DRAINAGE The Power Unit may be safely shipped with oil, fuel, and coolant at maximum capacities or less. Draining fluids is not required unless federal, state, or local regulations prohibit shipment with fluids present. Refer to Section 14.3.1.1, Section 13.4.5.5 and Section 6.5.3 for procedures for draining the oil, coolant and fuel liquids respectively.

5-317

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254

THIS PAGE INTENTIONALLY BLANK

5-318

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254

CHAPTER 6 SCHEDULED MAINTENANCE TABLE OF CONTENTS SECTION

TITLE

PAGE

6.0

SCHEDULED MAINTENANCE

4

6.1

SAFETY PROCEDURES

4

6.2

DAILY PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)

15

6.3

PREVENTIVE MAINTENANCE CHECKS AND SERVICES (SCHEDULED) (PMCS)

18

6.3.2

RUNNING GEAR SCHEDULED MAINTENANCE

21

6.3.2.1

MEP-PU 810A RUNNING GEAR SCHEDULED MAINTENANCE

21

6.3.2.2

MEP-PU 810B RUNNING GEAR SCHEDULED MAINTENANCE

23

6.3.3

SR4B ALTERNATOR SCHEDULED MAINTENANCE

25

6.3.4

PRIMARY DISTRIBUTION CENTER (PDC) SCHEDULED MAINTENANCE

26

6.4

REQUIRED INSPECTIONS NOT COVERED IN OTHER CHAPTERS

28

6.4.1

INSPECT THE EXTERNAL FUEL MANIFOLD

28

6.4.2

INSPECT FRONT, MIDDLE, REAR ENGINE / ALTERNATOR SUPPORT ASSEMBLY

29

6.4.3

INSPECT THE OIL PAN ASSEMBLY

29

6.4.4

INSPECT THE FRONT AND REAR CRANKSHAFT AND ACCESSORY DRIVE SEALS 30

6.4.5

INSPECT THE CRANKSHAFT VIBRATION DAMPER

31

6.4.6

INSPECT THE CYLINDER HEAD GROUNDING STUD

31

6.4.7

INSPECT THE ENGINE MOUNTS

32

6.4.8

INSPECT THE SWITCHGEAR

32

6.5

SERVICE REQUIREMENTS NOT COVERED IN OTHER CHAPTERS

33

6.5.1

ENGINE CRANKCASE BREATHER SERVICE REQUIREMENTS

34

6.5.1.1

FUME COLLECTOR BOX VENT STACK

34

6.5.2

CYLINDER HEAD GROUNDING STUD SERVICE REQUIREMENTS

35

6.5.3

FUEL TANK SEDIMENT SERVICE REQUIREMENTS

37

6.5.4

REMOTE TERMINAL UNIT (RTU)

37

6-1

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254

LIST OF TABLES TABLE

TITLE

TABLE 6.2-1

DAILY MAINTENANCE CHECKS AND SERVICES

15

TABLE 6.2-1

DAILY MAINTENANCE CHECKS AND SERVICES (CONTINUED)

16

TABLE 6.3-1

PREVENTIVE MAINTENANCE CHECKS AND SERVICES (SCHEDULED PMCS)

18

PREVENTIVE MAINTENANCE CHECKS AND SERVICES (SCHEDULED PMCS) (CONTINUED)

19

PREVENTIVE MAINTENANCE CHECKS AND SERVICES (SCHEDULED PMCS) (CONTINUED)

20

TABLE 6.3.2.1-1

MEP-PU-810A MAINTENANCE SCHEDULE

21

TABLE 6.3.2.1-1

MEP-PU-810A MAINTENANCE SCHEDULE (CONTINUED)

22

TABLE 6.3.2.2-1

MEP-PU-810B MAINTENANCE SCHEDULE

23

TABLE 6.3.2.2-1

MEP-PU-810B MAINTENANCE SCHEDULE (CONTINUED)

24

TABLE 6.3.3-1

SR4B ALTERNATOR SCHEDULED MAINTENANCE

25

TABLE 6.3.4-1

PRIMARY DISTRIBUTION CENTER (PDC) SCHEDULED MAINTENANCE

26

PRIMARY DISTRIBUTION CENTER (PDC) SCHEDULED MAINTENANCE (CONTINUED)

27

TABLE 6.3-1 TABLE 6.3-1

TABLE 6.3.4-1

PAGE

6-2

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254

LIST OF FIGURES FIGURE 6.5.2-1

TITLE

PAGE

CYLINDER HEAD GROUNDING STUD

6-3

36

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254

6.0

SCHEDULED MAINTENANCE

Scheduled Maintenance procedures covered in this section are: •

Daily Preventive Maintenance Checks And Services (PMCS)

•

Preventive Maintenance Checks And Services (Scheduled)(PMCS)

•

Required Inspections Not Covered In Other Chapters

•

Service Requirements Not Covered In Other Chapters

6.1

SAFETY PROCEDURES WARNING IMPORTANT: SAFETY WARNINGS ARE APPROPRIATE FOR ALL MAINTENANCE ACTIVITIES. READ THIS SECTION, PRIOR TO PERFORMING ANY MAINTENANCE WARNING THE EQUIPMENT COVERED IN THIS MANUAL MUST BE INSTALLED, OPERATED, AND MAINTAINED BY QUALIFIED PERSONS WHO ARE KNOWLEDGEABLE IN THE INSTALLATION, OPERATION, AND MAINTENANCE OF MEDIUM VOLTAGE ELECTRICAL POWER GENERATION EQUIPMENT ALONG WITH ASSOCIATED HAZARDS. A QUALIFIED PERSON IS ONE WHO IS TRAINED AND COMPETENT IN: •

THE SKILLS AND TECHNIQUES NECESSARY TO DISTINGUISH ENERGIZED PARTS FROM NON-ENERGIZED PARTS OF ELECTRICAL EQUIPMENT.

•

THE SKILLS AND TECHNIQUES NECESSARY TO DETERMINE THE PROPER APPROACH DISTANCES CORRESPONDING TO THE VOLTAGES TO WHICH THE QUALIFIED PERSON WILL BE EXPOSED.

•

THE PROPER USE OF SPECIAL PRECAUTIONARY TECHNIQUES, PERSONAL PROTECTIVE EQUIPMENT, INSULATING AND SHIELDING MATERIALS, AND INSULATED TOOLS FOR WORKING ON OR NEAR ENERGIZED PARTS OF ELECTRICAL EQUIPMENT AND ROTATING MACHINERY.

•

THE PROPER USE OF SPECIAL PRECAUTIONARY TECHNIQUES, PERSONAL PROTECTIVE EQUIPMENT, INSULATING AND SHIELDING MATERIALS, AND INSULATED TOOLS FOR WORKING ON OR NEAR EXPOSED HOT SURFACES OF ENGINE AND EXHAUST SYSTEM COMPONENTS.

THESE INSTRUCTIONS ARE INTENDED ONLY FOR SUCH QUALIFIED PERSONS. THEY ARE NOT A SUBSTITUTE FOR ADEQUATE TRAINING AND EXPERIENCE IN SAFETY PROCEDURES FOR THIS TYPE OF EQUIPMENT.

6-4

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 WARNING BATTERY ELECTROLYTE CONTAINS SULFURIC ACID, WHICH CAN CAUSE SEVERE CHEMICAL BURNS. AVOID ALL CONTACT. SKIN AND EYE PROTECTION IS REQUIRED. IN CASE OF CONTACT, IMMEDIATELY FLUSH WITH LARGE AMOUNTS OF CLEAN WATER AND OBTAIN MEDICAL AID. WARNING WHEN DISCONNECTING BATTERY CABLES, ALWAYS DISCONNECT NEGATIVE TERMINAL FIRST. WHEN RECONNECTING, CONNECT NEGITIVE TERMINAL LAST. FAILURE TO COMPLY MAY CAUSE SPARKING AND CONSEQUENT BATTERY EXPLOSION. WARNING HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT DURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION AND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN LOAD CABLES ARE HANDLED. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING SIDE PANELS ARE HEAVY. USE EXTREME CAUTION WHEN UNBOLTING AND REMOVING. WARNING TOP PANELS ARE HEAVY. USE EXTREME CAUTION WHEN UNBOLTING AND REMOVING.

6-5

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 WARNING MUFFLER ASSEMBLIES ARE HEAVY. USE EXTREME CAUTION WHEN UNBOLTING AND REMOVING. WARNING ENSURE THAT HEATER STRIP COVERS ARE ON WHEN GENERATOR IS RUNNING. LOW VOLTAGE IS PRESENT AT THE HEATER STRIP TERMINALS WARNING THE INSULATION TESTER PRODUCES HIGH VOLTAGE. TO AVOID PERSONAL INJURY DURING THE TEST, DO NOT TOUCH THE WINDING BEING TESTED OR THE TEST LEADS. WARNING DO NOT COME IN CONTACT WITH LOAD TERMINAL DURING TEST. DEATH BY ELECTROCUTION MAY RESULT WARNING FOLLOW MANUFACTURER'S TEST PROCEDURES INCLUDED WITH THE TEST EQUIPMENT WARNING ALWAYS CONSIDER AN ARRESTER TO BE ENERGIZED UNTIL THE LINE AND GROUND LEADS HAVE BEEN DISCONNECTED FROM THE CIRCUIT. WARNING NEVER INSTALL A DAMAGED ARRESTER. A DAMAGED ARRESTER MAY MALFUNCTION VIOLENTLY, CAUSING SEVERE PERSONAL INJURY.

WARNING USE OF A LIFTING DEVICE IS RECOMMENDED FOR REMOVING THE STATION POWER TRANSFORMER. EXTREMELY HEAVY OVER 100 LBS

6-6

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 WARNING PRIOR TO TROUBLESHOOTING THE POWER UNIT (PU), ENSURE THE TIE AND FEEDER CABLES ARE ALL INSTALLED ON PARKING STANDS, TO PREVENT THE POSSIBILITY OF UTILITY POWER BEING FED BACK INTO GENERATOR SET. ENSURE EQUIPMENT IS PROPERLY TAGGED AND NOT ENERGIZED. RESIDUAL VOLTAGE IS PRESENT AT THE GENERATOR LEADS WITH THE REGULATOR TURNED OFF, REACHING SEVERAL HUNDRED VOLTS ON THE GENERATOR SET. PROPER INSULATION AND ISOLATION OF METERING EQUIPMENT MUST BE OBSERVED WHEN TESTING GENERATOR. USE PROPER TEST EQUIPMENT TO CHECK FOR VOLTAGE BEFORE PROCEEDING. FAILURE TO COMPLY MAY RESULT IN DEATH BY ELECTROCUTION. WARNING BEFORE WORKING ON THE BATTERY CHARGER, ENSURE THAT AC POWER IS OFF AND DISCONNECTED. ALSO, DISCONNECT THE NEGATIVE BATTERY LEAD WARNING ETHER IS HIGHLY FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. USE ONLY IN AN ADEQUATELY VENTILATED AREA. SKIN, EYE. AND RESPIRATORY PROTECTION IS REQUIRED. FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY OR ILLNESS.

WARNING DIESEL FUEL IS FLAMMABLE AND MODERATELY TOXIC TO EYES, SKIN, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN WELL-VENTILATED AREA. FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY OR ILLNESS. WARNING WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT. MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS USER. WARNING ONLY ONE PU MAY BE SELECTED TO ANY ONE USS POSITION DURING MULTIPLE PU OPERATIONS. OPERATING WITH MORE THAN ONE UNIT AT THE SAME ID MAY CAUSE UNSAFE AND ERRATIC OPERATIONAL CONDITIONS.

6-7

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 WARNING EXPLOSION HAZARD – WHEN IN HAZARDOUS LOCATIONS, DISCONNECT POWER BEFORE REPLACING OR WIRING MODULES.

WARNING ALWAYS WEAR EYE PROTECTION WHEN YOU PERFORM ANY SERVICE WORK ON A COOLING SYSTEM WARNING RELEASE THE PRESSURE IN THE COOLING SYSTEM BEFORE PERFORMING ANY SERVICE WORK. IF THE PRESSURE IN THE COOLING SYSTEM IS NOT RELEASED OR THE TEMPERATURE OF THE SYSTEM IS NOT PERMITTED TO COOL, STEAM OR HOT WATER MAY BE RELEASED WHEN YOU REMOVE THE FILLER CAP. THIS MAY CAUSE PERSONAL INJURY. WARNING TO RELEASE THE PRESSURE IN A COOLING SYSTEM, LET THE SYSTEM COOL, PUT A HEAVY CLOTH OVER THE CAP AND LOOSEN IT SLOWLY. WARNING DO NOT ALLOW UNDILUTED CORROSION INHIBITORS OR DILUTED/UNDILUTED RADIATOR CLEANERS TO COME IN CONTACT WITH THE SKIN OR EYES. WARNING DO NOT USE CHROMATE CORROSION INHIBITORS IN A COOLING SYSTEM. WARNING ALWAYS FOLLOW THE MANUFACTURER’S INSTRUCTIONS WHEN HANDLING CORROSION INHIBITORS, RADIATOR CLEANERS OR ANTIFREEZE. BE ESPECIALLY SURE TO FOLLOW THE MANUFACTURER’S RECOMMENDATIONS CONCERNING TOXICITY. WARNING ETHYLENE GLYCOL MAY CATCH FIRE WHEN IT IS HOT OR EXPOSED TO AN OPEN FLAME. DO NOT WELD, CUT OR USE AN OPEN FLAME NEAR LEAKING COOLANT THAT CONTAINS ANTIFREEZE.

6-8

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 WARNING DO NOT USE ALCOHOL IN PLACE OF ANTIFREEZE. ALCOHOL HAS A LOWER BOILING TEMPERATURE AND FLASH POINT. WARNING DO NOT ATTEMPT TO TIGHTEN ANY HOSE CLAMPS WHILE THE COOLING SYSTEM IS HOT OR UNDER PRESSURE. IF THERE IS A FAILURE OF THE HOSE CLAMP WHEN IT IS TIGHTENED, A SUDDEN LOSS OF HOT COOLANT OR STEAM COULD RESULT. WARNING DO NOT REMOVE FILLER CAP AFTER OPERATION UNTIL SYSTEM HAS COOLED DOWN. FAILURE TO ALLOW ENGINE COOLANT TO COOL DOWN COULD RESULT IN SECOND AND THIRD DEGREE BURNS. CAP MAY BE HALF-TURNED TO RELIEVE PRESSURE AND THEN REMOVED TO INSPECT COOLANT LEVEL. WARNING PERSONAL INJURY CAN RESULT FROM HOT COOLANT, STEAM AND ALKALI. WARNING AT OPERATING TEMPERATURE, ENGINE COOLANT IS HOT AND UNDER PRESSURE. THE RADIATOR AND ALL LINES TO THE ENGINE CONTAIN HOT COOLANT OR STEAM. ANY CONTACT CAN CAUSE SEVERE BURNS. WARNING REMOVE FILLER CAP SLOWLY TO RELIEVE PRESSURE ONLY WHEN THE ENGINE IS STOPPED AND THE FILLER CAP IS COOL ENOUGH TO TOUCH WITH YOUR BARE HAND. WARNING COOLING SYSTEM CONDITIONER CONTAINS ALKALI. SKIN AND EYES.

6-9

AVOID CONTACT WITH

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 WARNING HOT OIL AND HOT COMPONENTS CAN CAUSE PERSONAL INJURY. DO NOT ALLOW HOT OIL OR HOT COMPONENTS TO CONTACT THE SKIN. DO NOT DRAIN THE OIL WHEN THE ENGINE IS COLD. AS THE OIL COOLS, SUSPENDED WASTE PARTICLES SETTLE ON THE BOTTOM OF THE OIL PAN. THE WASTE PARTICLES ARE NOT REMOVED WHEN DRAINING COLD OIL. DRAIN THE CRANKCASE WITH THE ENGINE STOPPED. DRAIN THE CRANKCASE WITH THE OIL WARM. THIS DRAINING METHOD ALLOWS THE WASTE PARTICLES THAT ARE SUSPENDED IN THE OIL TO BE DRAINED PROPERLY.

WARNING HYDRAULIC FLUID IS HOT AND UNDER HIGH PRESSURE. DO NOT PLACE ANY PART OF YOUR BODY OVER ANY LEAK. SEVERE INJURY CAN OCCUR IF THIS HAPPENS. WARNING DO NOT MIX PETROLEUM BASED OIL WITH BRAKE FLUID. THIS WILL CAUSE SEAL SWELLING AND NON-FUNCTIONING BRAKES.

WARNING THE HYDRAULIC PRESSURE HELD IN THE BREAKAWAY LEVER MAY CAUSE THE LEVER TO SNAP QUICKLY. KEEP HANDS AND FINGERS CLEAR, AS YOU RESET THE BREAKAWAY MECHANISM. WHEN TOWING, AVOID SHARP TURNS THAT CAN CAUSE THE ACTUATOR TO BIND AGAINST THE TOW VEHICLE. THIS CAN DAMAGE THE ACTUATOR AND TRAILER, CAUSING BRAKE FAILURE. WARNING DO NOT GET GREASE OR OIL ON BRAKE LININGS. FUNCTION PROPERLY

BRAKES WILL NOT

WARNING DO NOT MIX LITHIUM, CALCIUM, SODIUM OR BARIUM COMPLEX GREASES DUE TO POSSIBLE COMPATIBILITY PROBLEMS. WHEN CHANGING FROM ONE TYPE OF GREASE TO ANOTHER, IT IS NECESSARY TO ENSURE ALL THE OLD GREASE HAS BEEN REMOVED.

6-10

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 WARNING DO NOT DISASSEMBLE THE SPRING BRAKE. IT CONTAINS A COMPRESSED SPRING THAT MAY CAUSE INJURY IF REMOVED. THE SPRING BRAKE MUST BE CAGED BEFORE SERVICING AND SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL. WARNING FAILURE TO CORRECTLY LUBRICATE BEARINGS AND MAINTAIN PROPER LUBRICATION COULD CAUSE BEARING AND AXLE SPINDLE DAMAGE, WHICH COULD RESULT IN THE WHEEL LOCKING UP OR COMING OFF DURING VEHICLE OPERATION. WARNING APPLYING HIGH VOLTAGES ACROSS THE CONTACTS OF THE VACUUM INTERRUPTERS MAY PRODUCE X-RAYS. THE RADIATION MAY INCREASE WITH AN INCREASE IN THE VOLTAGE OR A DECREASE IN THE DISTANCE BETWEEN THE OPEN CONTACTS. THE LEVELS OF RADIATION GENERATED AT THE RECOMMENDED TEST VOLTAGES AND NORMAL BREAKER OPEN GAP SPACING ARE EXTREMELY LOW. HOWEVER, AS A PRECAUTIONARY MEASURE IT IS RECOMMENDED THAT ALL PERSONNEL STAND AT LEAST THREE FEET AWAY FROM THE BREAKER WHILE TESTING. CAUTION SIGNIFICANT DIFFERENCES BETWEEN THE MEP-PU-810A AND MEP-PU-810B REQUIRE SPECIFIC INSTRUCTIONS FOR EACH VERSION. CAUTION DO NOT ALLOW THE STARTER MOTOR TO OPERATE MORE THAN 30 SECONDS. ALLOW IT TO COOL AT LEAST 2 MINUTES BEFORE RE-ENERGIZING THE MOTOR. OVERHEATING WILL DAMAGE THE MOTOR. CAUTION ALWAYS HANDLE SURGE ARRESTERS PACKED OR UNPACKED VERY CAREFULLY. DO NOT DROP, JAR, OR HANDLE AN ARRESTER ROUGHLY. DROPPING, JARRING, AND/OR ROUGH HANDLING MAY DAMAGE THE ARRESTER INTERNALLY OR EXTERNALLY. THIS COULD MAKE THE ARRESTER INCAPABLE OF PROTECTING THE CIRCUIT AND COULD SHORTEN THE SERVICE LIFE OF THE ARRESTER SIGNIFICANTLY.

6-11

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 CAUTION DO NOT USE A COMMERCIAL COOLANT/ANTIFREEZE THAT ONLY MEETS THE ASTM D3306 OR D4656 SPECIFICATION. THIS TYPE OF COOLANT/ANTIFREEZE IS MADE FOR LIGHT DUTY AUTOMOTIVE APPLICATIONS. CAUTION TURBOCHARGER BEARING FAILURES CAN CAUSE LARGE QUANTITIES OF OIL TO ENTER THE AIR INLET AND EXHAUST SYSTEMS AND AIR TO AIR AFTER COOLER. LOSS OF ENGINE LUBRICANT CAN RESULT IN SERIOUS ENGINE DAMAGE. TURBOCHARGER COMPONENTS REQUIRE PRECISION CLEARANCES. THE TURBOCHARGER CARTRIDGE MUST BE BALANCED DUE TO HIGH RPM. SEVERE SERVICE APPLICATIONS CAN ACCELERATE COMPONENT WEAR. SEVERE SERVICE APPLICATIONS REQUIRE MORE FREQUENT INSPECTIONS OF THE CARTRIDGE. CAUTION WHEEL NUT OR BOLTS MUST BE APPLIED AND MAINTAINED AT THE PROPER TORQUE LEVELS TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSIBLE DANGEROUS SEPARATION OF WHEELS FROM YOUR AXLE. CAUTION THE MAXIMUM TOWING SPEED IS 20 MPH FOR THE MEP-PU-810A.

6-12

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 a. Safety precautions must be observed while any maintenance is being performed. Safety precautions must be observed to ensure that the operator/technician cannot have contact with the following: • • • • • • •

Hot engine parts Hot engine fluids Medium Voltage AC electricity Low Voltage AC electricity Low Voltage DC electricity Rotating Parts High noise levels

b. Minor Troubleshooting can be performed while both engines are running as long as safety precautions are taken. Refer to the appropriate troubleshooting section for recommendations. c.

Minor Maintenance can be performed while one generator is running and the other generator set has been shutdown. Some examples of this maintenance are: • • • • • •

Lubrication System – Oil and Filter Change. Hydraulic System – Oil and Filter Change. Fuel System – Primary and Secondary Filter Change. Coolant System – Coolant Change. Minor Troubleshooting. Check Fluid levels and add required fluids.

(1) The generator set that has been shut down must be rendered unable to start, and cool enough for the maintenance to be performed. Procedures to render a generator set unable to start are: (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) NOTE:

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Push to OPEN the Emergency Stop Switch. Place the Engine Control Switch (ECS) in the OFF position. Place a DO NOT OPERATE tag on the generator control panel. Turn the Battery Bank Parallel Switch to the OFF position. De-energize the Battery Charger. Disconnect the negative and positive cables from the Battery Bank for the engine due maintenance. Place a DO NOT OPERATE tag on the Battery Bank. Place the generator Circuit Breaker in the LOCK OUT position. Disconnect the 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock the generator set control panel.

The fuel transfer pump electrical power is normally fed directly from the G1 generator set battery bank. If you disconnect the G1 battery bank, the external fuel transfer pump will not function. Place the Fuel Pump Source Switch (S2) into the (G1 or G2 position) for the generator set not receiving maintenance.

d. Major maintenance or service requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. This is accomplished by performing the following:

6-13

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14)

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant or utility connection in accordance with Section 5.9.6.15, Unit Isolation Procedure with PSC. Note 1 and 2. Isolate the PU from any power plant control system in accordance with Note 3. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels.

NOTE 1:

Also the PU must be completely electrically isolated from the power distribution bus and any other electrical source that can back feed into the PU. All medium voltage cables need to be placed on the standoff insulators by use of hot sticks and other safety gear.

NOTE 2:

Ensure cables are not energized by opening the circuit breaker of the Primary Switching Center (PSC), then disconnect Load Cables (Using the proper safety gear) on the PU and place them on the Parking Stands.

NOTE 3:

When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the Communication Cable must be routed to the next PU in order to reestablish the communication network. In Automatic Mode of operation, if the PU being isolated is designated as “A” unit then you must redesignate another PU as “A” in accordance with Section 5.9.4. Re-desgnate a PU Without Plant Shutdown.

6-14

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 6.2

DAILY PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) a. The required daily Before (B), During (D) and After (A) Preventive Maintenance Checks and Services (PMCS) are identified in Table 6.2-1. b. All Safety Warnings and Cautions in Section 6.1 apply to this Table.

TABLE 6.2-1

DAILY MAINTENANCE CHECKS AND SERVICES

OPERATOR DAILY B D A

ITEMS TO BE INSPECTED/INSPECTION PROCEDURES

TIME (MHrs)

X

GROUND TERMINALS: Ensure the Power Unit, Ground Grid and Load Cable Drain Lines are properly connected to Ground.

0.1

X

X

X

EXHAUST: • Check Muffler Flex Connector pipe between engine and roof for condition, leakage and security. • During operation, be alert for development of excessively black, white, or blue exhaust smoke.

0.1

X

X

X

COOLING SYSTEM: Check radiator for proper coolant level before starting. During operation, check radiator and all cooling lines for leakage and security.

0.1

0.1

X

X

X

LUBE OIL SYSTEM: • Check Dip Stick for proper oil level. • During operation, check for leakage. • Change Oil at intervals specified in Table 6.3-1, Preventive Maintenance Checks and Services.

X

X

X

BATTERY CHARGER: During operation verify voltmeter measures approximately 26 – 29 VDC and ampmeter measures > 2 amps DC.

0.1

BATTERIES AND CABLES: Service Batteries and check Battery Cables for security. See Section 9.4.1.5 for reference.

0.1

X

AIR FILTER DIFFERENTIAL PRESSURE GAUGE: Check condition of Air Filter by checking the Air Filter Differential Pressure gauge located on the Filter Monitoring Panel. If the Air Filter High Differential Pressure Alarm is activated on the (GCP), or the Air Filter Differential Pressure Gauge reads 25 inches of water, the Air Filter needs to be changed. Replace the Air Filter at intervals specified in Section 16.3.1, Air Filter. Change the Air Filter at intervals specified in Table 6.3-1, Preventive Maintenance Checks and Services.

0.1

X

PRIMARY FUEL FILTER DIFFERENTIAL PRESSURE GAUGE: Check condition of the Primary Fuel Filter by checking the Primary Fuel Filter Differential gauge located on the Filter Monitoring Panel. If the Primary Fuel Filter Differential Pressure Alarm is activated on the (GCP), or the Primary Fuel Filter Differential Pressure Gauge reads 5 PSID, the Primary Fuel Filter needs to be changed. Change the Primary Fuel Filter at intervals specified in Table 6.3-1, Preventive Maintenance Checks and Services.

0.1

X

SECONDARY FUEL FILTER DIFFERENTIAL PRESSURE GAUGE: Check condition of the Secondary Fuel Filter by checking the Secondary Fuel Filter Differential gauge located on the Filter Monitoring Panel. If the Secondary Fuel Filter Differential Pressure Alarm is activated on the (GCP), or the Secondary Fuel Filter Differential Pressure Gauge reads 30 PSID, the Secondary Fuel Filter needs to be changed. Change the Secondary Fuel Filter at intervals specified in Table 6.3-1, Preventive Maintenance Checks and Services.

0.1

X

6-15

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 TABLE 6.2-1

DAILY MAINTENANCE CHECKS AND SERVICES (CONTINUED)

OPERATOR DAILY B D A

ITEMS TO BE INSPECTED/INSPECTION PROCEDURES

TIME (MHrs)

X

OIL FILTER DIFFERENTIAL PRESSURE GAUGE: Check condition of the Oil Filter by checking the Oil Filter Differential gauge located on the Filter Monitoring Panel. If the Oil Filter Differential Pressure Alarm is activated on the (GCP), or the Oil Filter Differential Pressure Gauge reads 30 PSID, the Oil Filter needs to be changed. Change the Oil Filter at intervals specified in Table 6.3-1, Preventive Maintenance Checks and Services.

0.1

X

X

X

FUMES DISPOSAL COLLECTOR: Ensure that the Fumes Disposal Collector is drained and wipe down any oil residue in and around fumes box vent pipe.

0.1

X

X

X

EXTERNAL FUEL SUPPLY: Check that external fuel supply is adequate for the mission and is properly connected to the Power Unit External Fuel Transfer System.

0.1

X

FUEL SYSTEM: • During operation, check all Fuel lines for leakage and security. • Clean fuel strainer at interval specified in Table 6.3-1, Preventive Maintenance Checks and Services.

0.2

X

FUEL/SEPERATOR: Drain Water from Cup.

0.1

X

HYDRAULIC SYSTEM: • During operation, check all hydraulic lines for leakage and security. • Replace the 3 Micron (Absolute), Filter at intervals specified in Table 6.3-1, Preventive Maintenance Checks and Services. • Check fluid level. Fluid level should be approximately ¾ full on the tank mounted fluid level gauge. Look for leaks.

0.1

X

CABLING: • Check for Proper Mechanical Connections and Phase Color Coding. • Check for Cable Damage and proper Medium Voltage Cable Terminations.

0.1

X

EXTERNAL FUEL TRANSFER PUMP CONTROLS: • During Operation, check all fuel lines, valves and pumps for leaks and security. • Ensure that the position of the External Fuel Transfer Pump Control switches, are in the proper position. • Inspect Fuel Solenoid Valve for leaks, damage.

0.1

X

X

MEP-PU-810B, DC LIGHTS: Check for proper operation.

0.1

X

X

MEP-PU-810A & MEP-PU-810B, AC LIGHTS: Check for proper operation.

0.1

X

X

X

X

X

X

X

X

6-16

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THIS PAGE IS INTENTIONALLY BLANK

6-17

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 6.3

PREVENTIVE MAINTENANCE CHECKS AND SERVICES (SCHEDULED) (PMCS) a. Table 6.3-1 identifies the scheduled preventive maintenance requirements for the MEP-PU-810. The Preventive Maintenance Checks and Services (PMCS) are to be performed at the intervals identified. All Safety Warnings and Cautions in Section 6.1 apply to this Table. b. Problems encountered during the MEP-PU-810 operations that do not present safety hazards or do not degrade operations must be identified for correction during scheduled maintenance periods or at the end of operations, as appropriate. CAUTION PROBLEMS WHICH PRESENT SAFETY HAZARDS AND WHICH SIGNIFICANTLY DEGRADE OPERATIONS REQUIRE THE STOPPING OF ALL OPERATIONS IMMEDIATELY. RECORD ALL DEFICIENCIES AND SHORTCOMINGS, TOGETHER WITH THE CORRECTIVE ACTION TAKEN, ON THE APPLICABLE FORMS.

TABLE 6.3-1

PREVENTIVE MAINTENANCE CHECKS AND SERVICES (SCHEDULED PMCS) INTERVAL (HOURS/GALLONS/YEARS)

ITEMS TO BE INSPECTED AFTERCOOLER CORE ENGINE CYLINDER HEAD GROUNDING STUD ENGINE LUBE OIL/ FILTER ENGINE AIR FILTER ENGINE CRANKCASE BREATHERS FUME COLLECTOR BOX VENT STACK FUEL SYSTEM PRIMARY FILTER FUEL SYSTEM SECONDARY FUEL FILTER FUEL TANK FUEL SYSTEM STRAINER

ACTION REQUIRED

40 HOURS

250 HOURS OR ANNUALLY

Inspect, Clean

3,000 HOURS 30,000 (GAL), OR 3 YEARS

6,000 HOURS 60,000 (GAL), OR 6 YEARS

See Section 13.4.5 and NOTE 1. Test annually

●

Evaluate for possible overhaul needs Inspect, Service Replace Replace Service

FOR INSTRUCTIONS REFER TO:

●

●

Caterpillar Dealer and NOTE 1. See Section 6.5.2 and NOTE 1. See Section 14.3 and NOTE 1. See Section 16.3.2 and NOTE 1. See Section 6.5.1 and NOTE 1.

● ● ● ● ●

See Section 6.5.1.1

Replace

●

See Section 11.3.1 and NOTE 1.

Replace

●

See Section 11.3.2 and NOTE 1.

Inspect Service

● ●

See Section 6.5.3 and NOTE 1. See Section 11.3.3 and NOTE 1.

6-18

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 TABLE 6.3-1

PREVENTIVE MAINTENANCE CHECKS AND SERVICES (SCHEDULED PMCS) (CONTINUED) INTERVAL (HOURS/GALLONS/YEARS)

ITEMS TO BE INSPECTED

ACTION REQUIRED

INITIAL 250 (HOURS) (INCLUDE THE – STANDARD 250 H SERVICE)

250 HOURS, 2,500 (GAL) OR ANNUALLY

HOSES AND CLAMPS

Inspect, Replace

●

RADIATOR

Inspect (Exterior)

●

ENGINE VALVE LASH AND INJECTOR TIMING ENGINE SPEED SENSOR, (FLYWHEEL HOUSING MOUNTED MPU) ENGINE PROTECTIVE DEVICES INSPECT RADIATOR CAP GASKET WATER TEMPERATURE REGULATORS CRANKSHAFT VIBRATION DAMPER

Inspect, Adjust

●

Clean, Inspect, Adjust

●

3,000 HOURS 30,000 (GAL), OR 3 YEARS

● ●

●

8,000 HOURS OR ANNUALLY

16,000 HOURS OR 3 YEARS

6,000 HOURS 60,000 (GAL), OR 6 YEARS

COMMENTS

See Section 15.4.5, Section 15.4.6 and Section 15.4.7 and NOTE 1. See Section 13.4.5 and NOTE 1. See Section 15.4.8, and Section 15.4.9 and NOTE 1. See Section 12.4.1.4 and NOTE 1. See Section 12.4.1 and NOTE 1. See Section 13.4.3 and NOTE 1.

●

Inspect Inspect

1,000 HOURS OR SEMI – ANNUALLY

●

Replace

●

See Section 13.4.1 and NOTE 1.

Inspect

●

ENGINE MOUNTS

Inspect

●

ENGINE SPEED / TIMING SENSORS

Check, Clean, Calibrate

TURBOCHARGER

Inspect

See Section 6.4.5 and NOTE 1. See Section 6.4.7 and NOTE 1. See Section 12.4.1.7 and NOTE 1. See Section 15.4.2 and NOTE 1.

●

● ●

6-19

TABLE 6.3-1

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (SCHEDULED PMCS) (CONTINUED) INTERVAL (HOURS/GALLONS/YEARS)

ITEMS TO BE INSPECTED

ACTION REQUIRED

INITIAL 250 (HOURS) (INCLUDE THE – STANDARD 250 H SERVICE)

250 HOURS, 2,500 (GAL) OR ANNUALLY

1,000 HOURS OR SEMI – ANNUALLY

3,000 HOURS 30,000 (GAL), OR 3 YEARS

JACKET WATER PUMP

Inspect

●

STARTING MOTOR

Inspect

●

Level 1 Test

16,000 HOURS OR 3 YEARS

6,000 HOURS 60,000 (GAL), OR 6 YEARS

See Section 13.4.2 and NOTE 1. See Section 9.4.6 and NOTE 1.

●

See Section 13.3 and NOTE 1.

●

Level 2 Test Change (At 6000 hours)

COOLING SYSTEM ELC EXTENDER PACKAGE HOUSING ACCESS DOORS, RAIN CAPS HYDRAULIC SYSTEM STRAINER HYDRAULIC SYSTEM FLUID HYDRAULIC SYSTEM FLUID FILTER AND O-RING STATION POWER TRANSFORMER

●

Add (At 3000 hours) Inspect

COMMENTS

●

Test: COOLING SYSTEM ELC

8,000 HOURS OR ANNUALLY

See Section 13.3 and NOTE 1.

● ●

See Section 8.3.1

●

Clean Replace Replace

●

Inspect

●

●

See Section 19.3.1

●

See Section 19.3.1 and NOTE 2

●

See Section 19.3.1 See Section 10.4.1.1

NOTE 1:

For Additional information see SMCS Code: 1000;7500, in SEBU6959-01, or later version and SMCS Code: 1000;7500, in SEBU7163-01, or later version.

NOTE 2:

An annual fluid sample should be taken and analyzed. The fluid change schedule may be adjusted accordingly.

6-20

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 6.3.2

RUNNING GEAR SCHEDULED MAINTENANCE

6.3.2.1

MEP-PU 810A RUNNING GEAR SCHEDULED MAINTENANCE

a. Table 6.3.2.1-1 identifies the MEP-PU-810A Running Gear Scheduled Maintenance. The MEP-PU-810A Running Gear Scheduled Maintenance is to be performed at the intervals identified. All Safety Warnings and Cautions in Section 6.1 apply to this Table. b. Problems encountered during the MEP-PU-810A operations that do not present safety hazards or do not degrade operations must be identified for correction during scheduled maintenance periods or at the end of operations, as appropriate. CAUTION PROBLEMS WHICH PRESENT SAFETY HAZARDS AND WHICH SIGNIFICANTLY DEGRADE OPERATIONS REQUIRE THE STOPPING OF ALL OPERATIONS IMMEDIATELY. RECORD ALL DEFICIENCIES AND SHORTCOMINGS, TOGETHER WITH THE CORRECTIVE ACTION TAKEN, ON THE APPLICABLE FORMS. TABLE 6.3.2.1-1 ITEM BRAKES BRAKE ADJUSTMENT BRAKE LININGS

MEP-PU-810A MAINTENANCE SCHEDULE FUNCTION REQUIRED Test that they are operational Adjust to proper operating clearance

WEEKLY

3 MONTHS

6 MONTHS

12 MONTHS

COMMENTS Must be serviced by a qualified mechanic familiar with

At Every Use

this type of axle. See NOTE 1. Must be serviced by a qualified mechanic familiar with this type of axle. See NOTE 1.

●

Inspect for wear & contamination

●

Must be serviced by a qualified mechanic familiar with this type of axle. See NOTE 1. Must be serviced by a qualified mechanic familiar with this type of axle. See NOTE 1. Must be serviced by a qualified mechanic familiar with this type of axle. See NOTE 1. Must be serviced by a qualified mechanic familiar with this type of axle. See NOTE 1.

BRAKE CYLINDERS

Check for leaks & sticking

●

BRAKE LINES

Inspect for cracks, leaks, kinks

●

BRAKE ACTUATOR

Check oil level

●

6-21

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 TABLE 6.3.2.1-1

MEP-PU-810A MAINTENANCE SCHEDULE (CONTINUED)

ITEM BREAKAWAY SYSTEM

FUNCTION REQUIRED Check breakaway chain and lever

3 MONTHS

6 MONTHS

Inspect for corrosion or wear.

CUPS

Clean & repack Inspect for leakage. Replace if

SEALS

removed.

WHEEL NUTS & BOLTS

Tighten to specified torque Inspect for cracks, dents or

WHEELS

●

distortion

TIRE INFLATION

Inflate tires to manufacturer’s

PRESSURE

specification

TIRE CONDITION

etc.

Must be serviced by a qualified mechanic familiar with this type of axle. See NOTE 1.

●

Must be serviced by a qualified mechanic familiar with this type of axle. See NOTE 1.

●

Must be serviced by a qualified mechanic familiar with this type of axle. See NOTE 1.

Must be serviced by a qualified mechanic familiar with this type of axle. See NOTE 1. Must be serviced by a qualified mechanic familiar with this type of axle. See NOTE 1.

●

Inspect for cuts, wear, bulging,

●

Must be serviced by a qualified mechanic familiar with this type of axle. See NOTE 1.

●

values

COMMENTS Must be serviced by a qualified mechanic familiar with this type of axle. See NOTE 1.

scoring

WHEEL BEARINGS &

12 MONTHS

At Every Use

Inspect for abnormal wear or

HUB/DRUM

NOTE 1:

WEEKLY

Must be serviced by a qualified mechanic familiar with this type of axle. See NOTE 1.

●

For Additional information refer to Section 18.3.1.

6-22

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 6.3.2.2

MEP-PU 810B RUNNING GEAR SCHEDULED MAINTENANCE

a. Table 6.3.2.2-1 identifies the MEP-PU-810B Running Gear Scheduled Maintenance. The MEP-PU-810B Running Gear Scheduled Maintenance is to be performed at the intervals identified. All Safety Warnings and Cautions in Section 6.1 apply to this Table. b. Problems encountered during the MEP-PU-810B operations that do not present safety hazards or do not degrade operations must be identified for correction during scheduled maintenance periods or at the end of operations, as appropriate. CAUTION PROBLEMS WHICH PRESENT SAFETY HAZARDS AND WHICH SIGNIFICANTLY DEGRADE OPERATIONS REQUIRE THE STOPPING OF ALL OPERATIONS IMMEDIATELY. RECORD ALL DEFICIENCIES AND SHORTCOMINGS, TOGETHER WITH THE CORRECTIVE ACTION TAKEN, ON THE APPLICABLE FORMS. TABLE 6.3.2.2-1

MEP-PU-810B MAINTENANCE SCHEDULE

ITEM

FUNCTION REQUIRED

BRAKES

Test that they are operational

AIR TANK

Drain condensation

BRAKE ADJUSTMENT

Inspect for wear & contamination

BRAKE LINES

Inspect for cracks, leaks, kinks

HUB/DRUM

Inspect for abnormal wear or scoring

BEARINGS & CUPS

MILES

EVERY 12,000 MILES

EVERY

EVERY

25,000 TO

100,000

30,000

MILES OR

MILES

ANNUALLY

COMMENTS

At Every Use

● ●

Adjust to proper operating clearance

BRAKE LININGS

WHEEL

WEEKLY

EVERY 1,000

● ●

●

●

●

●

●

●

Inspect for corrosion or wear. Clean &

●

repack

6-23

●

Must be serviced by a qualified mechanic familiar with this type of axle. See NOTE 1. Must be serviced by a qualified mechanic familiar with this type of axle. See NOTE 1. Must be serviced by a qualified mechanic familiar with this type of axle. See NOTE 1. Must be serviced by a qualified mechanic familiar with this type of axle. See NOTE 1. Must be serviced by a qualified mechanic familiar with this type of axle. See NOTE 1.

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 TABLE 6.3.2.2-1 ITEM

MEP-PU-810B MAINTENANCE SCHEDULE (CONTINUED) FUNCTION REQUIRED

Inspect for leakage. Replace if

SEALS

removed.

WHEEL NUTS & BOLTS

Tighten to specified torque values

WEEKLY

●

Inspect for cracks, dents or distortion

●

TIRE INFLATION

Inflate tires to manufacturer’s

PRESSURE

specification

●

TIRE CONDITION

Inspect for cuts, wear, bulging, etc.

●

Check oil level in wheel hub and inspect

●

wheel for leaks.

CAMSHAFT

MILES

EVERY 12,000 MILES

EVERY 100,000

30,000

MILES OR

MILES

ANNUALLY

●

●

●

●

●

●

●

●

●

●

●

●

Inspect for any signs of wear

●

Must be serviced by a qualified mechanic familiar with this type of axle. See NOTE 1.

Inspect for any signs of wear

●

Must be serviced by a qualified mechanic familiar with this type of axle. See NOTE 1.

Lubricate

●

Must be serviced by a qualified mechanic familiar with this type of axle. See NOTE 1.

CAMSHAFT BRACKET

Must be serviced by a qualified mechanic familiar with this type of axle. See NOTE 1. Must be serviced by a qualified mechanic familiar with this type of axle. See NOTE 1. Must be serviced by a qualified mechanic familiar with this type of axle. See NOTE 1. Must be serviced by a qualified mechanic familiar with this type of axle. See NOTE 1. Must be serviced by a qualified mechanic familiar with this type of axle. See NOTE 1. Must be serviced by a qualified mechanic familiar with this type of axle. See NOTE 1. Must be serviced by a qualified mechanic familiar with this type of axle. See NOTE 1.

●

BUSHING SUPPORT

COMMENTS

Inspect for any signs of wear

CAMSHAFT SPIDER

EVERY 25,000 TO

At Every Use

WHEELS

WHEEL HUB

EVERY 1,000

BUSHING BRAKE ACTUATING COMPONENTS Check brake air chambers and slack BRAKE

adjusters Inspect brake rollers, roller

COMPONENTS

shafts, anchor pins and bushings and

●

●

replace it necessary.

NOTE 1:

For Additional information refer to Section 18.3.2.

6-24

●

●

Must be serviced by a qualified mechanic familiar with this type of axle. See NOTE 1.

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 6.3.3

SR4B ALTERNATOR SCHEDULED MAINTENANCE

a. Table 6.3.3-1 identifies the SR4B Alternator Scheduled Maintenance. The SR4B Alternator Scheduled Maintenance is to be performed at the intervals identified. All Safety Warnings and Cautions in Section 6.1 apply to this Table. b. Problems encountered during the SR4B Alternator operations that do not present safety hazards or do not degrade operations must be identified for correction during scheduled maintenance periods or at the end of operations, as appropriate. CAUTION PROBLEMS WHICH PRESENT SAFETY HAZARDS AND WHICH SIGNIFICANTLY DEGRADE OPERATIONS REQUIRE THE STOPPING OF ALL OPERATIONS IMMEDIATELY. RECORD ALL DEFICIENCIES AND SHORTCOMINGS, TOGETHER WITH THE CORRECTIVE ACTION TAKEN, ON THE APPLICABLE FORMS. TABLE 6.3.3-1

SR4B ALTERNATOR SCHEDULED MAINTENANCE

MAINTENANCE SCHEDULE

Before placing unit in operation

When Required

Every Week

TOPICS Visual Inspection: • Cleaning • Looseness • Walk around • Generator - Dry • Generator – Set - Test • Insulation – Test • Rotating Rectifier – Test • Varistor - Test • Winding – Test • Electrical Connections - Check • Generator - Clean • Walk – Around Inspection

LIMITS / COMMENTS Check operation, moisture, dust, oils, grease, debris, bolts, exciter, flex plates, electrical connections, debris, cleanliness, looseness. See NOTE 1 and NOTE 2 for additional information.

See NOTE 1 and NOTE 2 for additional information.

See NOTE 1 and NOTE 2 for additional information.

Every 1000 HOURS

Lubrication, Spherical Roller Bearings

Use 28.3 grams (1 ounce) of grease. Inspect bearing and bracket every major engine overhaul. See NOTE 1 and NOTE 2 for additional information.

Every 2000 Hours

Lubrication, Ball Bearings

Do not over grease. Use only one ounce. See NOTE 1 and NOTE 2 for additional information.

Every 7500 Hours or Annually

• • •

Rotating Rectifier - Check Generator – Clean Insulation Check

Minimum 1 megohm + rated V / 1000 (Typically much higher) See NOTE 1 and NOTE 2 for additional information.

NOTE 1:

For Additional information refer to Section 10.4.5.2.1.

NOTE 2:

For Additional information see SMCS Code: 4450, in SEBU6918-02, or later version and SMCS Code: 4450, in SENR5359-01, or later version.

6-25

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 6.3.4

PRIMARY DISTRIBUTION CENTER (PDC) SCHEDULED MAINTENANCE

a. Table 6.3.4-1 identifies the Primary Distribution Center (PDC) Scheduled Maintenance. The Primary Distribution Center (PDC) Scheduled Maintenance is to be performed at the intervals identified. All Safety Warnings and Cautions in Section 6.1 apply to this Table. b. Problems encountered during the Primary Distribution Center (PDC) operations that do not present safety hazards or do not degrade operations must be identified for correction during scheduled maintenance periods or at the end of operations, as appropriate. CAUTION PROBLEMS WHICH PRESENT SAFETY HAZARDS AND WHICH SIGNIFICANTLY DEGRADE OPERATIONS REQUIRE THE STOPPING OF ALL OPERATIONS IMMEDIATELY. RECORD ALL DEFICIENCIES AND SHORTCOMINGS, TOGETHER WITH THE CORRECTIVE ACTION TAKEN, ON THE APPLICABLE FORMS. TABLE 6.3.4-1 PRIMARY DISTRIBUTION CENTER (PDC) SCHEDULED MAINTENANCE INTERVAL ITEMS TO BE INSPECTED

ACTION REQUIRED

250 HOURS OF OPERATION

Inspect for: LOAD TERMINALS

•

Damage

•

Cleanliness

•

Missing components

Inspect for: SWITCHGEAR

•

Damage

•

Cleanliness

•

Missing components

Perform: Re-torque BUS ELECTRICAL COMPONENT TERMINAL SCREWS

NOTE 1:

Inspect all wire terminal screws for tightness. Tighten if loose.

●

For Additional information refer to Section 10.4.7.1.

6-26

PRIOR TO USE AS REQUIRED

ANNUALLY

● ● ● ● ● ● ● ● ●

● ● ● ● ● ● ● ● ●

See NOTE 1

●

●

All

COMMENTS

See NOTE 1 See NOTE 1 See NOTE 1 See Section 6.4.8 See Section 6.4.8 See Section 6.4.8 See Section 6.4.8 See Section 6.4.8

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254

WARNING APPLYING HIGH VOLTAGES ACROSS THE CONTACTS OF THE VACUUM INTERRUPTERS MAY PRODUCE XRAYS. THE RADIATION MAY INCREASE WITH AN INCREASE IN THE VOLTAGE OR A DECREASE IN THE DISTANCE BETWEEN THE OPEN CONTACTS. THE LEVELS OF RADIATION GENERATED AT THE RECOMMENDED TEST VOLTAGES AND NORMAL BREAKER OPEN GAP SPACING ARE EXTREMELY LOW. HOWEVER, AS A PRECAUTIONARY MEASURE IT IS RECOMMENDED THAT ALL PERSONNEL STAND AT LEAST THREE FEET AWAY FROM THE BREAKER WHILE TESTING. TABLE 6.3.4-1 PRIMARY DISTRIBUTION CENTER (PDC) SCHEDULED MAINTENANCE (CONTINUED) INTERVAL ITEMS TO BE INSPECTED

ACTION REQUIRED

PRIOR TO USE AS REQUIRED

ANNUALLY

COMMENTS

● ● ● ● ● ● ● ●

● ● ● ● ● ● ● ●

See Note 2

Inspect for:

CIRCUIT BREAKER (MEDIUM VOLTAGE)

•

Damage

•

Cleanliness

•

Missing components

Test: •

Insulation Resistance

•

AC High Voltage Potential (HYPOT)

•

Digital Low Resistance Ohm (DLRO) reading

NOTE 1:

For Additional information refer to Section 10.4.7.1.

NOTE 2:

For Additional information refer to Section 10.4.11.1.

NOTE 3:

For Additional information refer to Section 10.4.11.2.

6-27

See Note 2 See Note 2 See Note 2 See Note 3 See Note 3 See Note 3 See Note 3

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 6.4

REQUIRED INSPECTIONS NOT COVERED IN OTHER CHAPTERS

The following Inspections are covered in this section: • • • • • • • • 6.4.1

Inspect the External Fuel Manifold Inspect the Front, Middle, Rear Engine / Alternator Support Assembly Inspect the Oil Pan Assembly Inspect the Front and Rear Crankshaft and Accessory Drive Seals Inspect the Vibration Damper Inspect the Cylinder Head Grounding Stud Inspect the Engine Mounts Inspect the Switch Gear INSPECT THE EXTERNAL FUEL MANIFOLD WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. CAUTION CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO LOCAL REGULATIONS AND MANDATES.

Inspect the Fuel Manifold for the following conditions: a. Inspect the Fuel Manifold for leaks. b. Inspect the Fuel Manifold for loose or missing hardware. c.

Inspect the Fuel Manifold for damage.

6.4.1.2. SERVICE If leaks or damage are found at the fuel manifold requiring the fuel supply to be interrupted to the PU the fuel transfer pump shall be shut-off prior to closing the fuel line. a. Shutdown and Isolate PU in accordance with Section 5.1.6.1. b. Turn off fuel transfer pumps on PU by setting fuel pump control switch to the center (OFF) position. c. Repair/replace fuel manifold as required. d. Open fuel supply valve to PU. e. Turn-on fuel transfer pump by setting pump control switch to “A” (Automatic) position. f. Return PU to operation in accordance with Section 5 as appropriate for mode of operation.

6-28

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 6.4.2

INSPECT FRONT, MIDDLE, REAR ENGINE / ALTERNATOR SUPPORT ASSEMBLY WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. CAUTION CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO LOCAL REGULATIONS AND MANDATES.

The Front, Middle, Rear Engine / Alternator Support Assembly provides a means of attaching the Engine/Alternator to the PU Frame Assembly. Inspect the Front, Middle, Rear Engine / Alternator Support Assembly for the following conditions: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See Section 6.1.d. for procedures. b. Inspect the Front, Middle, Rear Engine / Alternator Support Assembly for improper mounting of the Engine/Alternator. c.

Inspect the Front, Middle, Rear Engine / Alternator Support Assembly for deterioration of the rubber mounts. Replace defective rubber mounts as necessary.

d. Inspect the Front, Middle, Rear Engine / Alternator Support Assembly for any crack weldments on the frame. 6.4.3

INSPECT THE OIL PAN ASSEMBLY WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. CAUTION CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO LOCAL REGULATIONS AND MANDATES.

The oil pan assembly, being the lowest point of the engine assembly, provides a means for housing the oil pump assembly and attachment of oil drain lines.

6-29

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 Inspect the Oil Pan Assembly for the following conditions: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See Section 6.1.d. for procedures. b. Inspect the Oil Pan Assembly for cracks, nicks, dents or other damage that could cause leakage. Make repairs as necessary. c.

Inspect the Oil Pan Assembly for evidence of leakage around gasket areas. Make repairs as necessary.

d. Inspect the Oil Pan Assembly for evidence of leakage around threaded holes. Make repairs as necessary. e. Inspect the Oil Pan Assembly for evidence of leakage around the drain plug. Make repairs as necessary. 6.4.4

INSPECT THE FRONT AND REAR CRANKSHAFT AND ACCESSORY DRIVE SEALS WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. CAUTION CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO LOCAL REGULATIONS AND MANDATES.

The front and rear crankshaft and accessory drive seals are provided to prevent engine oil from leaking out of engine block where crankshaft and accessory drive shaft exit engine assembly. Inspect the Front and Rear Crankshaft and Accessory Drive Seals for the following conditions: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See Section 6.1.d. for procedures. b. Inspect the Front and Rear Crankshaft and Accessory Drive Seals for evidence of leakage on the floor or below the flywheel area and on the front end of the engine (Vibration Damper). NOTE:

Slight seepage around seal area is considered normal.

6-30

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 6.4.5

INSPECT THE CRANKSHAFT VIBRATION DAMPER WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. CAUTION CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO LOCAL REGULATIONS AND MANDATES.

The Crankshaft Vibration Damper is a fluid filled case. Inspect the Crankshaft Vibration Damper for the following conditions: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See Section 6.1.d. for procedures. b. Inspect the Crankshaft Vibration Damper for evidence of dents. c.

Inspect the Crankshaft Vibration Damper for evidence of cracks.

d. Inspect the Crankshaft Vibration Damper for evidence of leaking of fluid. e. Replace the damper if it has any of the above damage. 6.4.6

INSPECT THE CYLINDER HEAD GROUNDING STUD WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.

The Cylinder Head Grounding Stud must have a wire ground to the battery. Inspect the Cylinder Head Grounding Stud for the following conditions: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See Section 6.1.d. for procedures. b. Inspect the Cylinder Head Grounding Studs wiring harness for damage. c.

Inspect the Cylinder Head Grounding Stud for corrosion on the stud.

d. Correct any faults found.

6-31

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 6.4.7

INSPECT THE ENGINE MOUNTS WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. CAUTION CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO LOCAL REGULATIONS AND MANDATES.

Inspect the Engine Mounts for the following conditions: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See Section 6.1.d. for procedures. b. Inspect the Engine Mounts for signs of deterioration, if deterioration is found the mount should be replaced. c.

Inspect the Engine Mounts for proper bolt torque, 150 Ft-Lbs.

d. Engine vibration can be caused by the following conditions:

6.4.8

•

Improper mounting of the engine.

•

Deterioration of the engine mounts.

INSPECT THE SWITCHGEAR WARNING HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT DURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION AND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN LOAD CABLES ARE HANDLED. WARNING DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING.

6-32

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING HIGH VOLTAGE, USE PROPER PROTECTIVE EQUIPMENT AND PROPER TEST EQUIPMENT. WARNING DISCHARGE CAPACITIVE CHARGE FROM ALL EXPOSED CONDUCTORS Inspect the Switchgear for the following: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See Section 6.1.d. for procedures. b. Remove the PDC from the PU. See Chapter 22 for reference. c.

Inspect the Internal AC Electrical System Bus for proper mounting.

d. Inspect the Internal AC Electrical System Bus for loose connections, physical damage and heat damage. e. Inspect the Internal AC Electrical System Bus and associated wiring for signs of insulation breakdown such as cracked sleeves and burned insulation. f.

Inspect the Internal AC Electrical System Bus Mounting Bolts for proper torque. The torque should be checked using the following guidelines: • •

6.5

Annually or other time period required by USAF AFJMAN 32-1082, USA TM 5-684 and current NETA Standards to verify tightness of accessible bolted electrical connections. The proper torque for the Bus mounting bolts is 20 ft. lbs. SERVICE REQUIREMENTS NOT COVERED IN OTHER CHAPTERS

The following Service Requirements are covered in this section: • • • •

Engine Crankcase Breather Service Requirements Cylinder Head Grounding Stud Service Requirements Fuel Tank Sediment Service Requirements Remote Terminal Unit (RTU)

6-33

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 6.5.1

ENGINE CRANKCASE BREATHER SERVICE REQUIREMENTS WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. CAUTION CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO LOCAL REGULATIONS AND MANDATES.

If the crankcase breather is not maintained on a regular basis, the crankcase breather will become plugged. A plugged crankcase breather will cause excessive crankcase pressure that may cause crankcase seal leakage. To service the Engine Crankcase Breather, proceed with the following: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See Section 6.1.c. for procedures. b. To service the Engine Crankcase Breather, loosen the Engine Crankcase Breather Hose Clamp and remove the hose from the Engine Crankcase Breather. c.

Loosen and remove the Cover Clamp and Engine Crankcase Breather Cover.

d. Wash the Engine Crankcase Breather Element, in solvent that is clean and non-flammable. Allow the Engine Crankcase Breather Element to dry before reinstalling it. e. Install a new seal. f.

If the Engine Crankcase Breather cannot be cleaned, install a clean and dry element.

g. Reinstall the Engine Crankcase Breather Clamp and Cover. h. Reinstall the Engine Crankcase Breather Hose Clamp on the hose, connect the hose to the Engine Crankcase Breather Cover and tighten the hose clamp. NOTE: 6.5.1.1

Refer to Caterpillar Manual SEBU 7163. FUME COLLECTOR BOX VENT STACK

The Fume Collector Box Vent Stack contains a rough grade of steel wool that must be cleaned periodically to keep the vent stack from clogging. To service the Fume Collector Box Vent Stack, proceed with the following:

6-34

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed b. Unscrew the top of the vent stack. c.

Flush the vent stack with one gallon of hot soapy water.

d. Drain the Fume Collector Box of all soapy water. e. Screw on the top of the vent stack 6.5.2

CYLINDER HEAD GROUNDING STUD SERVICE REQUIREMENTS

WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. The Cylinder Head Grounding Stud must have a wire ground to the battery. To Service the Cylinder Head Grounding Stud, proceed with the following: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See Section 6.1.d. for procedures. b. To Service the Cylinder Head Grounding Stud, re-torque the Cylinder Head Grounding Stud to 35 ± 7 ft-lbs at every oil change. Ground wires and straps should be combined at engine grounds. All grounds should be tight and free of corrosion. c.

To Service the Cylinder Head Grounding Stud, clean the Cylinder Head Grounding Stud and the terminals for the cylinder head ground strap with a clean cloth.

d. If the connections are corroded, clean the connections with a solution of baking soda and water. e. Keep the cylinder head grounding stud and the strap clean and coated with MPGM grease or petroleum jelly.

6-35

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254

CYLINDER HEAD GROUNDING STUD

FIGURE 6.5.2-1 CYLINDER HEAD GROUNDING STUD

6-36

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 6.5.3

FUEL TANK SEDIMENT SERVICE REQUIREMENTS WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. CAUTION CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO LOCAL REGULATIONS AND MANDATES.

Fuel quality is critical to the performance and to the service life of the engine. Water in the fuel tank can cause excessive fuel system wear. Condensation occurs during the heating and cooling of fuel. The condensation occurs as the fuel passes through the system fuel system and the fuel returns to the fuel tank. Draining the fuel tank regularly and obtaining fuel from reliable sources can help to eliminate water in the fuel. To Service the Fuel Tank, proceed with the following: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable rerouted to the next PU. See Section 6.1.d. for procedures. b. Inspect the Fuel Tank using a flashlight to view through the filler cap for sediment or water. The fuel drain is located directly below the filler cap and any sediment or water should be visible. If detected, Service. c.

To Service the Fuel Tank, empty the Fuel Tank with an external pump.

d. After the Fuel Tank is empty, remove the Fuel Tank Drain Plug and drain the sediment into a suitable container. e. Reinstall the Fuel Tank Drain Plug. 6.5.4

REMOTE TERMINAL UNIT (RTU)

To Service the RTU, proceed with the following:

CAUTION THIS SERVICE MUST BE PERFORMED EVERY 6-MONTHS IF THE PU IS IN STORAGE. IT IS CRITICAL THAT THE RTU BATTERY BE RECHARGED TO MAINTAIN PROGRAMMED VARIABLES IN THE RTU MEMORY. IF THE RTU BATTERY IS ALLOWED TO DISCHARGE COMPLETELY, THE RTU SOFTWARE WILL HAVE TO BE RELOADED BEFORE OPERATION. a.

If the PU is in storage and the batteries have been disconnected, reconnect the batteries.

6-37

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 b. Connect an external 120 VAC power source to the battery chargers and ensure the chargers are supplying current to the batteries. c.

Open the MCP flip up door.

d. Turn on the DC Power Circuit Breaker (CB1). The PDC will be powered up and the RTU battery will recharge through internal circuitry. e. Leave the 120 VAC power source connected to the battery chargers and the CB1 on for a minimum of 8 hours to recharge the RTU battery. f. After 8 hours, Turn off CB1, disconnect the 120 VAC power source to the battery chargers, and disconnect the PU batteries for continued storage. NOTE: This service can be performed in conjunction with other service of the PU, has long as the DC Power remains turned on for 8 continuous hours every 6-months.

6-38

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254

CHAPTER 7 UNSCHEDULED MAINTENANCE/TROUBLESHOOTING TABLE OF CONTENTS SECTION

TITLE

7.0

UNSCHEDULED MAINTENANCE / TROUBLESHOOTING PROCEDURES

5

7.1

SAFETY PROCEDURES

5

7.2

UNSCHEDULED MAINTENANCE PROCEDURES

17

7.2.1

HOUSING ASSEMBLY UNSCHEDULED MAINTENANCE PROCEDURES

17

7.2.2

DC SYSTEM COMPONENTS UNSCHEDULED MAINTENANCE PROCEDURES

17

AC SYSTEM COMPONENTS UNSCHEDULED MAINTENANCE PROCEDURES

18

FUEL SYSTEM COMPONENTS UNSCHEDULED MAINTENANCE PROCEDURES

18

CONTROL AND INSTRUMENT COMPONENTS UNSCHEDULED MAINTENANCE PROCEDURES

18

COOLING SYSTEM COMPONENTS UNSCHEDULED MAINTENANCE PROCEDURES

19

LUBRICATION SYSTEM COMPONENTS UNSCHEDULED MAINTENANCE PROCEDURES

19

7.2.8

ENGINE COMPONENTS UNSCHEDULED MAINTENANCE PROCEDURES

19

7.2.9

AIR INTAKE AND EXHAUST SYSTEM COMPONENTS UNSCHEDULED MAINTENANCE PROCEDURES

19

REMOTE OPERATOR TERMINAL (ORT) UNSCHEDULED MAINTENANCE PROCEDURES

20

RUNNING GEAR/TRAILER ASSEMBLY COMPONENTS UNSCHEDULED MAINTENANCE PROCEDURES

20

HYDRAULIC SYSTEM COMPONENTS UNSCHEDULED MAINTENANCE PROCEDURES

20

7.2.13

ENGINE/ALTERNATOR UNSCHEDULED MAINTENANCE PROCEDURES

20

7.2.14

PDC UNSCHEDULED MAINTENANCE PROCEDURES

20

7.3

TROUBLESHOOTING PROCEDURES

21

7.2.3 7.2.4 7.2.5 7.2.6 7.2.7

7.2.10 7.2.11 7.2.12

PAGE

7-1

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254

TABLE OF CONTENTS SECTION

TITLE

7.3.1

BASIC ENGINE TROUBLESHOOTING PROCEEDURES

23

7.3.2

BASIC EMCP+ TROUBLESHOOTING PROCEDURES

34

7.3.3

BASIC GENERATOR OPERATIONS TROUBLESHOOTING PROCEDURES

35

7.3.4

TROUBLESHOOTING THE FUEL PRIMER PUMP

47

7.3.5

COOLING SYSTEM TROUBLE SHOOTING PROCEDURES

48

7.3.6

RUNNING GEAR/TRAILER TROUBLESHOOTING PROCEDURES

51

7.3.6.1

MEP-PU-810A RUNNING GEAR/TRAILER TROUBLESHOOTING PROCEDURES

51

MEP-PU-810B RUNNING GEAR/TRAILER TROUBLESHOOTING PROCEDURES

53

7.3.6.2.1

TROUBLESHOOTING THE ABS SYSTEM

53

7.3.6.2.2

MEP-PU-810A RUNNING GEAR/TRAILER TROUBLESHOOTING PROCEDURES

58

HYDRAULIC SYSTEM TROUBLESHOOTING PROCEDURES

60

7.3.6.2

7.3.7

PAGE

7-2

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254

LIST OF TABLES TABLE

TITLE

TABLE 7.3.1-1

BASIC ENGINE TROUBLESHOOTING PROCEDURES

23

TABLE 7.3.1-1

BASIC ENGINE TROUBLESHOOTING PROCEDURES (CONTINUED)

24

BASIC ENGINE TROUBLESHOOTING PROCEDURES (CONTINUED)

25

BASIC ENGINE TROUBLESHOOTING PROCEDURES (CONTINUED)

26

BASIC ENGINE TROUBLESHOOTING PROCEDURES (CONTINUED)

27

BASIC ENGINE TROUBLESHOOTING PROCEDURES (CONTINUED)

28

BASIC ENGINE TROUBLESHOOTING PROCEDURES (CONTINUED)

29

BASIC ENGINE TROUBLESHOOTING PROCEDURES (CONTINUED)

30

BASIC ENGINE TROUBLESHOOTING PROCEDURES (CONTINUED)

31

BASIC ENGINE TROUBLESHOOTING PROCEDURES (CONTINUED)

32

BASIC ENGINE TROUBLESHOOTING PROCEDURES (CONTINUED)

33

TABLE 7.3.2-1

BASIC EMCP + TROUBLESHOOTING PROCEDURES

34

TABLE 7.3.3-1

BASIC GENERATOR OPERATIONS TROUBLESHOOTING PROCEDURES

36

BASIC GENERATOR OPERATIONS TROUBLESHOOTING PROCEDURES (CONTINUED)

37

BASIC GENERATOR OPERATIONS TROUBLESHOOTING PROCEDURES (CONTINUED)

38

BASIC GENERATOR OPERATIONS TROUBLESHOOTING PROCEDURES (CONTINUED)

39

BASIC GENERATOR OPERATIONS TROUBLESHOOTING PROCEDURES (CONTINUED)

40

TABLE 7.3.1-1 TABLE 7.3.1-1 TABLE 7.3.1-1 TABLE 7.3.1-1 TABLE 7.3.1-1 TABLE 7.3.1-1 TABLE 7.3.1-1 TABLE 7.3.1-1 TABLE 7.3.1-1

TABLE 7.3.3-1 TABLE 7.3.3-1 TABLE 7.3.3-1 TABLE 7.3.3-1

PAGE

7-3

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254

LIST OF TABLES TABLE

TITLE

TABLE 7.3.3-1

BASIC GENERATOR OPERATIONS TROUBLESHOOTING PROCEDURES (CONTINUED)

41

BASIC GENERATOR OPERATIONS TROUBLESHOOTING PROCEDURES (CONTINUED)

42

BASIC GENERATOR OPERATIONS TROUBLESHOOTING PROCEDURES (CONTINUED)

43

BASIC GENERATOR OPERATIONS TROUBLESHOOTING PROCEDURES (CONTINUED)

44

BASIC GENERATOR OPERATIONS TROUBLESHOOTING PROCEDURES (CONTINUED)

45

BASIC GENERATOR OPERATIONS TROUBLESHOOTING PROCEDURES (CONTINUED)

46

TABLE 7.3.5-1

COOLANT SYSTEM TROUBLESHOOTING PROCEDURES

48

TABLE 7.3.5-1

COOLANT SYSTEM TROUBLESHOOTING PROCEDURES (CONTINUED)

49

COOLANT SYSTEM TROUBLESHOOTING PROCEDURES (CONTINUED)

50

MEP-PU-810A RUNNING GEAR/TRAILER TROUBLESHOOTING PROCEDURES

51

MEP-PU-810A RUNNING GEAR/TRAILER TROUBLESHOOTING PROCEDURES (CONTINUED)

52

TABLE 7.3.6.2.1-1

TROUBLESHOOTING THE ABS SYSTEM

54

TABLE 7.3.6.2.1-1

TROUBLESHOOTING THE ABS SYSTEM (CONTINUED)

55

TABLE 7.3.6.2.1-1

TROUBLESHOOTING THE ABS SYSTEM (CONTINUED)

56

TABLE 7.3.6.2.1-1

TROUBLESHOOTING THE ABS SYSTEM (CONTINUED)

57

TABLE 7.3.6.2.2-1

MEP-PU-810B RUNNING GEAR/TRAILER TROUBLESHOOTING PROCEDURES

58

MEP-PU-810B RUNNING GEAR/TRAILER TROUBLESHOOTING PROCEDURES (CONTINUED)

59

HYDRAULIC SYSTEM TROUBLESHOOTING PROCEDURES

60

TABLE 7.3.3-1 TABLE 7.3.3-1 TABLE 7.3.3-1 TABLE 7.3.3-1 TABLE 7.3.3-1

TABLE 7.3.5-1 TABLE 7.3.6.1-1 TABLE 7.3.6.1-1

TABLE 7.3.6.2.2-1 TABLE 7.3.7-1

PAGE

7-4

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 7.0

UNSCHEDULED MAINTENANCE / TROUBLESHOOTING PROCEDURES

Unscheduled Maintenance / Troubleshooting procedures covered in this section are: •

Unscheduled Maintenance Procedures

•

For In-Depth Troubleshooting Procedures see USAF TO 35C2-3-518-21 and CTM 01646.1R0253/1R0254 TR

7.1

SAFETY PROCEDURES WARNING IMPORTANT: SAFETY WARNINGS ARE APPROPRIATE FOR ALL MAINTENANCE ACTIVITIES. READ THIS SECTION, PRIOR TO PERFORMING ANY MAINTENANCE WARNING THE EQUIPMENT COVERED IN THIS MANUAL MUST BE INSTALLED, OPERATED, AND MAINTAINED BY QUALIFIED PERSONS WHO ARE KNOWLEDGEABLE IN THE INSTALLATION, OPERATION, AND MAINTENANCE OF MEDIUM VOLTAGE ELECTRICAL POWER GENERATION EQUIPMENT ALONG WITH ASSOCIATED HAZARDS. A QUALIFIED PERSON IS ONE WHO IS TRAINED AND COMPETENT IN: •

THE SKILLS AND TECHNIQUES NECESSARY TO DISTINGUISH ENERGIZED PARTS FROM NON-ENERGIZED PARTS OF ELECTRICAL EQUIPMENT.

•

THE SKILLS AND TECHNIQUES NECESSARY TO DETERMINE THE PROPER APPROACH DISTANCES CORRESPONDING TO THE VOLTAGES TO WHICH THE QUALIFIED PERSON WILL BE EXPOSED.

•

THE PROPER USE OF SPECIAL PRECAUTIONARY TECHNIQUES, PERSONAL PROTECTIVE EQUIPMENT, INSULATING AND SHIELDING MATERIALS, AND INSULATED TOOLS FOR WORKING ON OR NEAR ENERGIZED PARTS OF ELECTRICAL EQUIPMENT AND ROTATING MACHINERY.

•

THE PROPER USE OF SPECIAL PRECAUTIONARY TECHNIQUES, PERSONAL PROTECTIVE EQUIPMENT, INSULATING AND SHIELDING MATERIALS, AND INSULATED TOOLS FOR WORKING ON OR NEAR EXPOSED HOT SURFACES OF ENGINE AND EXHAUST SYSTEM COMPONENTS.

THESE INSTRUCTIONS ARE INTENDED ONLY FOR SUCH QUALIFIED PERSONS. THEY ARE NOT A SUBSTITUTE FOR ADEQUATE TRAINING AND EXPERIENCE IN SAFETY PROCEDURES FOR THIS TYPE OF EQUIPMENT.

7-5

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 WARNING BATTERY ELECTROLYTE CONTAINS SULFURIC ACID, WHICH CAN CAUSE SEVERE CHEMICAL BURNS. AVOID ALL CONTACT. SKIN AND EYE PROTECTION IS REQUIRED. IN CASE OF CONTACT, IMMEDIATELY FLUSH WITH LARGE AMOUNTS OF CLEAN WATER AND OBTAIN MEDICAL AID. WARNING WHEN DISCONNECTING BATTERY CABLES, ALWAYS DISCONNECT NEGATIVE TERMINAL FIRST. WHEN RECONNECTING, CONNECT NEGITIVE TERMINAL LAST. FAILURE TO COMPLY MAY CAUSE SPARKING AND CONSEQUENT BATTERY EXPLOSION. WARNING HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT DURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION AND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN LOAD CABLES ARE HANDLED. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING SIDE PANELS ARE HEAVY. USE EXTREME CAUTION WHEN UNBOLTING AND REMOVING. WARNING TOP PANELS ARE HEAVY. USE EXTREME CAUTION WHEN UNBOLTING AND REMOVING.

7-6

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 WARNING MUFFLER ASSEMBLIES ARE UNBOLTING AND REMOVING.

HEAVY.

USE

EXTREME

CAUTION

WHEN

WARNING ENSURE THAT HEATER STRIP COVERS ARE ON WHEN GENERATOR IS RUNNING. LOW VOLTAGE IS PRESENT AT THE HEATER STRIP TERMINALS WARNING THE INSULATION TESTER PRODUCES HIGH VOLTAGE. TO AVOID PERSONAL INJURY DURING THE TEST, DO NOT TOUCH THE WINDING BEING TESTED OR THE TEST LEADS. WARNING DO NOT COME IN CONTACT WITH LOAD TERMINAL DURING TEST. DEATH BY ELECTROCUTION MAY RESULT WARNING FOLLOW MANUFACTURER'S TEST PROCEDURES INCLUDED WITH THE TEST EQUIPMENT WARNING ALWAYS CONSIDER AN ARRESTER TO BE ENERGIZED UNTIL THE LINE AND GROUND LEADS HAVE BEEN DISCONNECTED FROM THE CIRCUIT. WARNING NEVER INSTALL A DAMAGED ARRESTER. A DAMAGED ARRESTER MAY MISSOPERATE VIOLENTLY, CAUSING SEVERE PERSONAL INJURY.

WARNING USE OF A LIFTING DEVICE IS RECOMMENDED FOR REMOVING THE STATION POWER TRANSFORMER. EXTREMELY HEAVY OVER 100 LBS

7-7

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 WARNING PRIOR TO TROUBLESHOOTING THE POWER UNIT (PU), ENSURE THE TIE AND FEEDER CABLES ARE ALL INSTALLED ON PARKING STANDS, TO PREVENT THE POSSIBILITY OF UTILITY POWER BEING FED BACK INTO GENERATOR SET. ENSURE EQUIPMENT IS PROPERLY TAGGED AND NOT ENERGIZED. RESIDUAL VOLTAGE IS PRESENT AT THE GENERATOR LEADS WITH THE REGULATOR TURNED OFF, REACHING SEVERAL HUNDRED VOLTS ON THE GENERATOR SET. PROPER INSULATION AND ISOLATION OF METERING EQUIPMENT MUST BE OBSERVED WHEN TESTING GENERATOR. USE PROPER TEST EQUIPMENT TO CHECK FOR VOLTAGE BEFORE PROCEEDING. FAILURE TO COMPLY MAY RESULT IN DEATH BY ELECTROCUTION. WARNING BEFORE WORKING ON THE BATTERY CHARGER, ENSURE THAT AC POWER IS OFF AND DISCONNECTED. ALSO, DISCONNECT THE NEGATIVE BATTERY LEAD WARNING ETHER IS HIGHLY FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. USE ONLY IN AN ADEQUATELY VENTILATED AREA. SKIN, EYE. AND RESPIRATORY PROTECTION ARE REQUIRED. FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY OR ILLNESS.

WARNING DIESEL FUEL IS FLAMMABLE AND MODERATELY TOXIC TO EYES, SKIN, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN WELL-VENTILATED AREA. FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY OR ILLNESS. WARNING WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT. MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS USER. WARNING ONLY ONE PU MAY BE SELECTED TO ANY ONE USS POSITION DURING MULTIPLE PU OPERATIONS. OPERATING WITH MORE THAN ONE UNIT AT THE SAME ID MAY CAUSE UNSAFE AND ERRATIC OPERATIONAL CONDITIONS.

7-8

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 WARNING EXPLOSION HAZARD – WHEN IN HAZARDOUS LOCATIONS, DISCONNECT POWER BEFORE REPLACING OR WIRING MODULES.

WARNING ALWAYS WEAR EYE PROTECTION WHEN YOU PERFORM ANY SERVICE WORK ON A COOLING SYSTEM WARNING RELEASE THE PRESSURE IN THE COOLING SYSTEM BEFORE PERFORMING ANY SERVICE WORK. IF THE PRESSURE IN THE COOLING SYSTEM IS NOT RELEASED OR THE TEMPERATURE OF THE SYSTEM IS NOT PERMITTED TO COOL, STEAM OR HOT WATER MAY BE RELEASED WHEN YOU REMOVE THE FILLER CAP. THIS MAY CAUSE PERSONAL INJURY. WARNING TO RELEASE THE PRESSURE IN A COOLING SYSTEM, LET THE SYSTEM COOL, PUT A HEAVY CLOTH OVER THE CAP AND LOOSEN IT SLOWLY. WARNING DO NOT ALLOW UNDILUTED CORROSION INHIBITORS OR DILUTED/UNDILUTED RADIATOR CLEANERS TO COME IN CONTACT WITH THE SKIN OR EYES. WARNING DO NOT USE CHROMATE CORROSION INHIBITORS IN A COOLING SYSTEM. WARNING ALWAYS FOLLOW THE MANUFACTURER’S INSTRUCTIONS WHEN HANDLING CORROSION INHIBITORS, RADIATOR CLEANERS OR ANTIFREEZE BE ESPECIALLY SURE TO FOLLOW THE MANUFACTURER’S RECOMMENDATIONS CONCERNING TOXICITY. WARNING ETHYLENE GLYCOL MAY CATCH FIRE WHEN IT IS HOT OR EXPOSED TO AN OPEN FLAME. DO NOT WELD, CUT OR USE AN OPEN FLAME NEAR LEAKING COOLANT THAT CONTAINS ANTIFREEZE.

7-9

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 WARNING DO NOT USE ALCOHOL IN PLACE OF ANTIFREEZE. ALCOHOL HAS A LOWER BOILING TEMPERATURE AND FLASH POINT. WARNING DO NOT ATTEMPT TO TIGHTEN ANY HOSE CLAMPS WHILE THE COOLING SYSTEM IS HOT OR UNDER PRESSURE. IF THERE IS A FAILURE OF THE HOSE CLAMP WHEN IT IS TIGHTENED, A SUDDEN LOSS OF HOT COOLANT OR STEAM COULD RESULT. WARNING DO NOT REMOVE FILLER CAP AFTER OPERATION UNTIL SYSTEM HAS COOLED DOWN. FAILURE TO ALLOW ENGINE COOLANT TO COOL DOWN COULD RESULT IN SECOND AND THIRD DEGREE BURNS. CAP MAY BE HALF-TURNED TO RELIEVE PRESSURE AND THEN REMOVED TO INSPECT COOLANT LEVEL. WARNING PERSONAL INJURY CAN RESULT FROM HOT COOLANT, STEAM AND ALKALI. WARNING AT OPERATING TEMPERATURE, ENGINE COOLANT IS HOT AND UNDER PRESSURE. THE RADIATOR AND ALL LINES TO THE ENGINE CONTAIN HOT COOLANT OR STEAM. ANY CONTACT CAN CAUSE SEVERE BURNS. WARNING REMOVE FILLER CAP SLOWLY TO RELIEVE PRESSURE ONLY WHEN THE ENGINE IS STOPPED AND THE FILLER CAP IS COOL ENOUGH TO TOUCH WITH YOUR BARE HAND. WARNING COOLING SYSTEM CONDITIONER CONTAINS ALKALI. SKIN AND EYES.

7-10

AVOID CONTACT WITH

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 WARNING HOT OIL AND HOT COMPONENTS CAN CAUSE PERSONAL INJURY. DO NOT ALLOW HOT OIL OR HOT COMPONENTS TO CONTACT THE SKIN. DO NOT DRAIN THE OIL WHEN THE ENGINE IS COLD. AS THE OIL COOLS, SUSPENDED WASTE PARTICLES SETTLE ON THE BOTTOM OF THE OIL PAN. THE WASTE PARTICLES ARE NOT REMOVED WHEN DRAINING COLD OIL. DRAIN THE CRANKCASE WITH THE ENGINE STOPPED. DRAIN THE CRANKCASE WITH THE OIL WARM. THIS DRAINING METHOD ALLOWS THE WASTE PARTICLES THAT ARE SUSPENDED IN THE OIL TO BE DRAINED PROPERLY.

WARNING DO NOT ALLOW GASKET MATERIAL TO FALL INSIDE ROCKER LEVER HOUSING. FAILURE TO COMPLY MAY RESULT IN DAMAGE TO ENGINE. WARNING DO NOT RESET A FAULT BEFORE DETERMINING AND CORRECTING THE CAUSE OF A FAULT. FAILURE TO CORRECT A FAULT BEFORE RESETTING CAN RESULT IN DEATH, PERSONAL INJURY, OR EQUIPMENT DAMAGE WARNING HYDRAULIC FLUID IS HOT AND UNDER HIGH PRESSURE. DO NOT PLACE ANY PART OF YOUR BODY OVER ANY LEAK. SEVERE INJURY CAN OCCUR IF THIS HAPPENS. WARNING THE HYDRAULIC PRESSURE HELD IN THE SYSTEM MAY CAUSE THE LEVER TO SNAP QUICKLY. KEEP HANDS AND FINGERS CLEAR, AS YOU RESET THE BREAKAWAY MECHANISM. WHEN TOWING, AVOID SHARP TURNS THAT CAN CAUSE THE ACTUATOR TO BIND AGAINST THE TOW VEHICLE. THIS CAN DAMAGE THE ACTUATOR AND TRAILER, CAUSING BRAKE FAILURE. WARNING DO NOT MIX PETROLEUM BASED OIL WITH BRAKE FLUID. THIS WILL CAUSE SEAL SWELLING AND NON-FUNCTIONING BRAKES.

7-11

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 WARNING ASBESTOS DUST HAZARD SINCE SOME BRAKE SHOE FRICTION MATERIALS CONTAIN ASBESTOS. CERTAIN PRECAUTIONS MUST BE TAKEN WHEN SERVICING BRAKES: AVOID CREATING OR BREATHING DUST. AVOID MACHINING, FILING, OR GRINDING THE BRAKE LININGS. DO NOT USE COMPRESSED AIR OR DRY BRUSHING FOR CLEANING. DUST CAN BE REMOVED WITH A DAMP BRUSH. WARNING THE HYDRAULIC PRESSURE HELD IN THE SYSTEM MAY CAUSE THE LEVER TO SNAP QUICKLY. KEEP HANDS AND FINGERS CLEAR, AS YOU RESET THE BREAKAWAY MECHANISM. WHEN TOWING, AVOID SHARP TURNS THAT CAN CAUSE THE ACTUATOR TO BIND AGAINST THE TOW VEHICLE. THIS CAN DAMAGE THE ACTUATOR AND TRAILER, CAUSING BRAKE FAILURE. WARNING SALTWATER, GRANULAR FERTILIZERS AND OTHER CORROSIVE MATERIALS ARE DESTRUCTIVE TO METAL. TO PROLONG THE LIFE OF A BRAKING SYSTEM USED UNDER CORROSIVE CONDITIONS, WE RECOMMEND THAT THE ACTUATOR BE FLUSHED AFTER USE WITH A HIGH PRESSURE WATER HOSE. BE SURE TO RE-GREASE BEARINGS AND OIL ALL MOVING PARTS AFTER THE UNIT HAS DRIED. AT THE END OF THE SEASON, WHEN UNIT IS TO BE STORED, REMOVE THE BRAKE DRUMS AND CLEAN INSIDE THE BRAKES. PACK WHEEL BEARINGS BEFORE DRUM IS INSTALLED. FAILURE TO PROPERLY AND ADEQUATELY GREASE AND MAINTAIN THE ACTUATOR COULD WEAKEN IT AND/OR CAUSE IT TO FAIL AND RESULT IN SERIOUS INJURY AND/OR PROPERTY DAMAGE. WARNING PROPER MATCHING OF THE TIRE/WHEEL COMBINATION IS ESSENTIAL TO PROPER FUNCTION OF YOUR TRAILER RUNNING GEAR. SOME TIRES MAY CALL FOR A MAXIMUM INFLATION PRESSURE ABOVE THE RIM OR WHEEL CAPACITY. DO NOT EXCEED MAXIMUM INFLATION PRESSURES FOR RIMS OR WHEELS. CATASTROPHIC FAILURE MAY RESULT. WARNING DO NOT GET GREASE OR OIL ON BRAKE LININGS. FUNCTION PROPERLY

7-12

BRAKES WILL NOT

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 WARNING DO NOT MIX LITHIUM, CALCIUM, SODIUM OR BARIUM COMPLEX GREASES DUE TO POSSIBLE COMPATIBILITY PROBLEMS. WHEN CHANGING FROM ONE TYPE OF GREASE TO ANOTHER, IT IS NECESSARY TO ENSURE ALL THE OLD GREASE HAS BEEN REMOVED. WARNING DO NOT DISASSEMBLE THE SPRING BRAKE. IT CONTAINS A COMPRESSED SPRING THAT MAY CAUSE INJURY IF REMOVED. THE SPRING BRAKE MUST BE CAGED BEFORE SERVICING AND SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL. WARNING FAILURE TO CORRECTLY LUBRICATE BEARINGS AND MAINTAIN PROPER LUBRICATION COULD CAUSE BEARING AND AXLE SPINDLE DAMAGE, WHICH COULD RESULT IN THE WHEEL LOCKING UP OR COMING OFF DURING VEHICLE OPERATION. CAUTION SIGNIFICANT DIFFERENCES BETWEEN THE MEP-PU-810A AND MEP-PU-810B REQUIRE SPECIFIC INSTRUCTIONS FOR EACH VERSION. CAUTION DO NOT ALLOW THE STARTER MOTOR TO OPERATE MORE THAN 30 SECONDS. ALLOW IT TO COOL AT LEAST 2 MINUTES BEFORE RE-ENERGIZING THE MOTOR. OVERHEATING WILL DAMAGE THE MOTOR. CAUTION ALWAYS HANDLE SURGE ARRESTERS PACKED OR UNPACKED VERY CAREFULLY. DO NOT DROP, JAR, OR HANDLE AN ARRESTER ROUGHLY. DROPPING, JARRING, AND/OR ROUGH HANDLING MAY DAMAGE THE ARRESTER INTERNALLY OR EXTERNALLY. THIS COULD MAKE THE ARRESTER INCAPABLE OF PROTECTING THE CIRCUIT AND COULD SHORTEN THE SERVICE LIFE OF THE ARRESTER SIGNIFICANTLY. CAUTION CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO LOCAL REGULATIONS AND MANDATES.

7-13

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 CAUTION THE WATER TEMPERATURE REGULATORS (2 EA) ARE AN IMPORTANT PART OF THE COOLING SYSTEM. THE WATER TEMPERATURE REGULATORS DIVIDE THE COOLANT FLOW BETWEEN THE RADIATOR AND THE BYPASS ELBOW. THIS WILL MAINTAIN THE CORRECT ENGINE TEMPERATURE. IF THE WATER TEMPERATURE REGULATORS ARE NOT INSTALLED IN THE SYSTEM, THERE IS NO MECHANICAL TEMPERATURE CONTROL. MOST OF THE COOLANT WILL GO THROUGH THE BYPASS. THIS WILL CAUSE THE ENGINE TO OVERHEAT IN HOT WEATHER. IF A HIGHER VOLUME OF COOLANT GOES THROUGH THE RADIATOR, THE ENGINE WILL NOT REACH NORMAL OPERATING TEMPERATURES. THIS OCCURS DURING COLD WEATHER. CAUTION DO NOT USE A COMMERCIAL COOLANT/ANTIFREEZE THAT ONLY MEETS THE ASTM D3306 OR D4656 SPECIFICATION. THIS TYPE OF COOLANT/ANTIFREEZE IS MADE FOR LIGHT DUTY AUTOMOTIVE APPLICATIONS. CAUTION IF NON ELC COOLANTS HAVE BEEN USED, IMPROPER OR INCOMPLETE RINSING OF THE COOLING SYSTEM CAN RESULT IN DAMAGE TO COPPER AND OTHER METAL COMPONENTS. TO AVOID DAMAGE TO THE COOLING SYSTEM, MAKE SURE TO COMPLETELY FLUSH THE COOLING SYSTEM WITH CLEAN WATER. CONTINUE TO FLUSH THE SYSTEM UNTIL ALL SIGNS OF THE CLEANING AGENT ARE GONE. CAUTION TURBOCHARGER BEARING FAILURES CAN CAUSE LARGE QUANTITIES OF OIL TO ENTER THE AIR INLET AND EXHAUST SYSTEMS AND AIR TO AIR AFTER COOLER. LOSS OF ENGINE LUBRICANT CAN RESULT IN SERIOUS ENGINE DAMAGE. TURBOCHARGER COMPONENTS REQUIRE PRECISION CLEARANCES. THE TURBOCHARGER CARTRIDGE MUST BE BALANCED DUE TO HIGH RPM. SEVERE SERVICE APPLICATIONS CAN ACCELERATE COMPONENT WEAR. SEVERE SERVICE APPLICATIONS REQUIRE MORE FREQUENT INSPECTIONS OF THE CARTRIDGE. CAUTION IF A TURBOCHARGER FAILURE OCCURS, REMOVE THE AIR TO AIR AFTER COOLER CORE. FLUSH THE AIR TO AIR AFTER COOLER CORE INTERNALLY WITH A SOLVENT THAT REMOVES OIL AND OTHER FORIEN SUBSTANCES. SHAKE THE AFTER COOLER CORE ASSEMBLY IN ORDER TO REMOVE ANY TRAPPED DEBRIS. WASH THE AFTER COOLER CORE ASSEMBLY WITH HOT SOAPY WATER. THOROUGHLY RINCE THIS ASSEMBLY WITH CLEAN WATER, AND THEN BLOW DRY THE ASSEMBLY IN THE REVERSE DIRECTION OF NORMAL AIR FLOW. TO MAKE SURE THAT THE WHOLE SYSTEM IS CLEAN, CAREFULLY INSPECT THE SYSTEM. CAUTION BE EXTREMELY CAREFUL - WEIGHT HAZARD - THE TURBOCHARGER WEIGHS 75 LBS.

7-14

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 CAUTION WHEEL NUT OR BOLTS MUST BE APPLIED AND MAINTAINED AT THE PROPER TORQUE LEVELS TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSIBLE DANGEROUS SEPARATION OF WHEELS FROM YOUR AXLE. CAUTION THE MAXIMUM TOWING SPEED IS 20 MPH FOR THE MEP-PU-810A. a. Safety precautions must be observed while any maintenance is being performed. Safety precautions must be observed to ensure that the operator/technician cannot have contact with the following: • • • • • • •

Hot engine parts Hot engine fluids Medium Voltage AC electricity Low Voltage AC electricity Low Voltage DC electricity Rotating Parts High noise levels

b. Minor troubleshooting can be performed while both engines are running as long as safety precautions are taken. c.

Minor maintenance can be performed while one generator set is running and the other generator set has been shutdown. Some examples of this maintenance are: Lubrication System – Oil and Filter Change. Hydraulic System – Oil and Filter Change. Fuel System – Primary and Secondary Filter Change. Coolant System – Coolant Change. Minor Troubleshooting. Check Fluid levels and add required fluids.

• • • • • •

(1) The generator set that has been shut down must be rendered unable to start, and cool enough for the maintenance to be performed. Procedures to render a generator set unable to start are: (a) (b) (c) (d) (e) (f) (g) (h) (i)

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Push to OPEN the Emergency Stop Switch. Place the Engine Control Switch (ECS) in the OFF position. Place a DO NOT OPERATE tag on the generator control panel. Turn the Battery Bank Parallel Switch to the OFF position. De-energize the Battery Charger. Disconnect the negative and positive cables from the Battery Bank for the engine due maintenance. Place a DO NOT OPERATE tag on the Battery Bank. Place the generator Circuit Breaker in the LOCK OUT position.

7-15

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (j) (k)

Disconnect the 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock the generator set control panel.

The fuel transfer pump electrical power is normally fed directly from the G1 generator set battery bank. If you disconnect the G1 battery bank, the external fuel transfer pump will not function. Place the Fuel Pump Source Switch (S2) into the (G1 or G2 position). Place the S2 in the (G1 or G2) position, for the generator set not receiving maintenance.

NOTE:

d. Major maintenance or service requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14)

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant or utility connection in accordance with Section 5.9.6.15, Unit Isolation Procedure with PSC. See Note 1 and 2. Isolate the PU from any power plant control system in accordance with NOTE 3. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels.

NOTE 1:

Also the PU must be completely electrically isolated from the power distribution bus and any other electrical source that can back feed into the PU. All medium voltage cables need to be placed on the standoff insulators by use of hot sticks and other safety gear.

NOTE 2:

Ensure cables are not energized by opening the circuit breaker of the Primary Switching Center (PSC), then disconnect Load Cables (Using the proper safety gear) on the PU and place them on the Parking Stands.

NOTE 3:

When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

7-16

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 7.2

UNSCHEDULED MAINTENANCE PROCEDURES

All Safety Warnings and Cautions in Section 7.1 apply to this section. 7.2.1

HOUSING ASSEMBLY UNSCHEDULED MAINTENANCE PROCEDURES

The following Unscheduled Maintenance Procedures are located in Chapter 8 of this manual: a. Remove and install Access Doors and Front Side Panels. b. Remove and install Plenum Assembly Screens. c.

Remove and install Side Panels.

d. Remove and install Top Panel Assembly e. Remove and install Battery Bank Tray Assembly f.

Remove and install Fuel Tank and Hydraulic Reservoir Assemblies

g. Remove and install Muffler Assembly 7.2.2

DC SYSTEM COMPONENTS UNSCHEDULED MAINTENANCE PROCEDURES

The following Unscheduled Maintenance Procedures are located in Chapter 9 of this manual: a. Remove and install Batteries. b. Remove and install Battery Cables. c.

Remove and install Battery Charger.

d. Remove and install Wiring Harness. e. Remove and install Battery Bank DC Tie Switch. f.

Remove and install Starter Motor/Solenoid.

g. Remove and install DC Control Power Circuit Breaker. h. Remove and install DC Panel Lights and Indicators.

7-17

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 7.2.3

AC SYSTEM COMPONENTS UNSCHEDULED MAINTENANCE PROCEDURES

The following Unscheduled Maintenance Procedures are located in Chapter 10 of this manual: a. Remove and install Station Power Transformer. b. Remove and install Wiring Harness. c.

Remove and install Power Panel Board.

d. Remove and install Alternator. e. Remove and install Varistor and Rectifier Block Assembly. f.

Remove and install High Voltage Output Terminals.

g. Remove and install Surge Arrestors. h. Remove and install Instrument Potential Transformers. i.

Remove and install Instrument Current Transformers.

j.

Remove and install Generator Feeder Breakers.

7.2.4

FUEL SYSTEM COMPONENTS UNSCHEDULED MAINTENANCE PROCEDURES

The following Unscheduled Maintenance Procedures are located in Chapter 11 of this manual: a. Remove and install Fuel Solenoid Valve (L3). b. Remove and install External Fuel Transfer Pump Assembly. c.

Remove and install Fuel Primer Pump.

d. Remove and install Engine Mounted Fuel Transfer Pump. e. Remove and install Fuel Float Switch Assembly. 7.2.5

CONTROL AND INSTRUMENT COMPONENTS UNSCHEDULED MAINTENANCE PROCEDURES

The following Unscheduled Maintenance Procedures are located in Chapter 12 of this manual: a. Remove and install Engine Control Devices. b. Remove and install PDC Controls and Instruments. (1)

Remove and install Generator Control Panel.

(2)

Remove and install Master Control Panel.

(3)

Remove and install Controls and Instruments within the interior of PDC.

7-18

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 7.2.6

COOLING SYSTEM COMPONENTS UNSCHEDULED MAINTENANCE PROCEDURES

The following Unscheduled Maintenance Procedures are located in Chapter 13 of this manual: a. Remove and install Water Temperature Regulator & Manifold. b. Remove and install Water Pump. c.

Remove and install Filler Cap.

d. Remove and install Engine Oil Cooler. e. Remove and install Radiator/Aftercooler Assembly. 7.2.7

LUBRICATION SYSTEM COMPONENTS UNSCHEDULED MAINTENANCE PROCEDURES

There are no Unscheduled Maintenance Procedures for Chapter 14, Lubrication System. 7.2.8

ENGINE COMPONENTS UNSCHEDULED MAINTENANCE PROCEDURES

The following Unscheduled Maintenance Procedures are located in Chapter 15 of this manual: a. Remove and install Valve Covers. b. Remove and install Turbocharger. c.

Remove and install Air Intake Manifold.

d. Remove and install Exhaust Manifold. e. Remove and install Air Transfer Tubes. f.

Remove and install Coolant Transfer Tubes.

g. Remove and install Hydraulic Fluid Transfer Hoses. 7.2.9

AIR INTAKE AND EXHAUST SYSTEM COMPONENTS UNSCHEDULED MAINTENANCE PROCEDURES

There are no Unscheduled Maintenance Procedures for Chapter 16, Air Intake and Exhaust System.

7-19

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 7.2.10

REMOTE OPERATOR TERMINAL (ORT) UNSCHEDULED MAINTENANCE PROCEDURES

There are no Unscheduled Maintenance Procedures for Chapter 17, Remote Operator Terminal (ORT). 7.2.11

RUNNING GEAR/TRAILER ASSEMBLY COMPONENTS UNSCHEDULED MAINTENANCE PROCEDURES

There are no Unscheduled Maintenance Procedures for Chapter 18, Running Gear/Trailer Assembly. 7.2.12

HYDRAULIC SYSTEM COMPONENTS UNSCHEDULED MAINTENANCE PROCEDURES

The following Unscheduled Maintenance Procedures are located in Chapter 19 of this manual: a. Remove and install Hydraulic Pump. b. Remove and install Radiator Motor. c.

Remove and install Air-to-Air Aftercooler (ATAAC) Motor.

d. Remove and install Engine Compartment Vent Motor. e. Remove and install Radiator Fan Assembly. f.

Remove and install Aftercooler Fan Assembly.

g. Remove and install Engine Compartment Vent Fan Assembly. h. Remove and install Radiator Motor Fan Blades. i.

Remove and install Aftercooler Motor Fan Blades.

j.

Remove and install Engine Compartment Vent Fan Motor Fan Blades.

k.

Remove and install Hydraulic Tank Low Level Shutdown Switch (HTLL).

7.2.13

ENGINE/ALTERNATOR UNSCHEDULED MAINTENANCE PROCEDURES

The following Unscheduled Maintenance Procedures are located in Chapter 21 of this manual: a. Remove and install Engine/Alternator. 7.2.14

PDC UNSCHEDULED MAINTENANCE PROCEDURES

The following Unscheduled Maintenance Procedures are located in Chapter 22 of this manual: a. Remove and install PDC.

7-20

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 7.3

TROUBLESHOOTING PROCEDURES

Troubleshooting procedures covered in this section are: •

Basic Engine Troubleshooting Procedures

•

Basic EMCP + Troubleshooting Procedures

•

Basic Generator Operations Troubleshooting Procedures

•

Troubleshooting the Fuel Primer Pump

•

Cooling System Troubleshooting Procedures

•

Running Gear / Trailer Troubleshooting Procedures

•

Hydraulic System Troubleshooting Procedures

All Safety Warnings and Cautions in Section 7.1 apply to this section.

7-21

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254

THIS PAGE INTENTIONALLY BLANK

7-22

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 7.3.1

BASIC ENGINE TROUBLESHOOTING PROCEEDURES

Table 7.3.1-1 contains Basic Engine Troubleshooting Procedures for locating and correcting operating troubles that may develop in the generator set. Each malfunction, for either an individual component or entire system, is followed by a series of tests or inspections that will help determine the probable cause and corrective actions to take. Troubleshoot in accordance with Table 7.3.1-1. All Safety Warnings and Cautions in Section 7.1 apply to this table. This manual cannot list all malfunctions that may occur, nor all tests or inspections and corrective actions. If a malfunction cannot be corrected by listed corrective actions, notify supervisor and or contact Radian Inc. NOTE:

Although troubleshooting can be a daunting task. Troubleshooting can be made much easier if you start by isolating the fault first. The first task is to determine if the system or device is getting the proper inputs AC voltage, AC current, DC voltage and DC current. Check for loose wires and blown fuses. By isolating the fault by eliminating obvious problems will make the technicians job much easier. When Caterpillar manuals are referenced, go to the SMCS CODE found in that manual.

TABLE 7.3.1-1

BASIC ENGINE TROUBLESHOOTING PROCEDURES

MALFUNCTION

PROBLEM 1: ENGINE FAILS TO CRANK

PROBABLE CAUSE

CORRECTIVE ACTION

1.

PU Setup

1.

Check PU setup. Refer to Section 5.1.3, make corrections as necessary.

2.

DC Control Power Circuit Breaker (CBCP)

2.

Place CBCP to the ON (Push-in) position.

3.

Starter and Starter Solenoid

3.

Test the Starter and Starter Solenoid refer to Section 9.4.6.2

4.

Engine Fault.

4.

Check the GSC+ for a shutdown fault, refer to RENR2227-02 for troubleshooting procedures.

1.

Open Fuel Shutoff Valve; refer to Figure 11.3.1-1 for reference. • Prime Fuel System; refer to Section 11.3.5 for procedures. • Check Fuel Filters, refer to Section 11.3 for reference. • Check Fuel Quality (Have Fuel Sample Checked), refer to SENR1067-02 or later version, SMCS CODE: 1280-081 for procedures.

2.

Check Engine Timing; refer to Section 15.4.8, Section 15.4.9, Section 15.4.10 and Section 15.4.11 for reference.

3.

Check for obstructions in the Air Plenum Assembly, refer to Section 16.3.2 for reference. • Check Air Filter for obstructions, replace Air Filter as necessary, refer to Section 16.3.2 for reference. Check Engine Mounted Fuel Pump; refer to Section 11.4.4 for reference.

1.

Fuel

2.

Incorrect Engine Timing

3.

Intake Air

4.

Engine Mounted Fuel Pump

PROBLEM 2: ENGINE CRANKS BUT WILL NOT START

4.

7-23

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BASIC ENGINE TROUBLESHOOTING PROCEDURES (CONTINUED)

MALFUNCTION

PROBABLE CAUSE

CORRECTIVE ACTION 1.

1.

Fuel System

2.

Incorrect Engine Timing

3.

Intake Air

4.

Engine Mounted Fuel Pump

1.

Turbocharger

2.

Engine Fault

3.

Intake Air

4.

Incorrect Engine Timing

PROBLEM 3: ENGINE SHUTS DOWN SOON AFTER STARTING.

PROBLEM 4: ENGINE RUNS ERRATICALLY OR MISFIRES.

2. 3.

4.

Check Engine Mounted Fuel Pump, refer to Section 11.4.4 for reference.

1.

Check Turbocharger, refer to SENR1068-01 or later version, SMCS CODE: 1052-040. Replace if turbocharger does not spin freely or damaged. Check the GSC+ for a shutdown fault, refer to RENR2227-02 for troubleshooting procedures. Check for obstructions in the Air Plenum Assembly, refer to Section 16.3.2 for reference. • Check Air Filter for obstructions, replace Air Filter as necessary, refer to Section 16.3.2 for reference. Check Engine Timing; refer to Section 15.4.8, Section 15.4.9, Section 15.4.10 and Section 15.4.11 for reference. Open Fuel Shutoff Valve; refer to Figure 11.3.1-1 for reference. • Check Fuel Level in Fuel Tank. • Prime Fuel System; refer to Section 11.3.5 for procedures. • Check Fuel Filters, refer to Section 11.3 for reference. • Check Fuel Quality (Have Fuel Sample Checked), refer to SENR1067-02 or later version, SMCS CODE: 1280-081 for procedures. • Perform Fuel System Test and Adjusting; refer to SENR1067-02 or later version, SMCS CODE: 1250-040 for procedures.

2. 3.

4. 5.

5.

Fuel System

Open Fuel Shutoff Valve; refer to Figure 11.3.1-1 for reference. • Check Fuel Level in Fuel Tank. • Prime Fuel System; refer to Section 11.3.5 for procedures. • Check Fuel Filters, refer to Section 11.3 for reference. • Check Fuel Quality (Have Fuel Sample Checked), refer to SENR1067-02 or later version, SMCS CODE: 1280-081 for procedures. • Perform Fuel System Test and Adjusting; refer to SENR1067-02 or later version, SMCS CODE: 1250-040 for procedures. Check Engine Timing; refer to Section 15.4.8, Section 15.4.9, Section 15.4.10 and Section 15.4.11 for reference. Check for obstructions in the Air Plenum Assembly, refer to Section 16.3.2 for reference. • Check Air Filter for obstructions, replace Air Filter as necessary, refer to Section 16.3.2 for reference.

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BASIC ENGINE TROUBLESHOOTING PROCEDURES (CONTINUED)

MALFUNCTION

PROBLEM 5: ENGINE EXHAUST EXCESSIVELY BLACK.

PROBABLE CAUSE 1.

Turbocharger

2.

Incorrect Engine Timing

3.

Intake Air

4.

Engine Overloading

1.

Ether Injection Assembly

CORRECTIVE ACTION 1. 2. 3.

4.

Check for excessive engine overloading, correct as necessary.

1.

Check Ether Injection System, refer to Section 11.3.4. If problem occurs after an ether start, check ether installation for defects resulting in applications of excessive ether to engine. Check Cooling System for proper operation; refer to Section 13.4 for reference. • Check coolant for low temperature. • Check for faulty (stuck open) thermostat. • Test engine coolant thermostats for proper operation. Refer to SENR1067-02, or later version, SMCS CODE: 1355-081; 1355-081. Replace defective thermostats. Check Turbocharger; refer to SENR1068-01 or later version, SMCS CODE: 1052-040. • Replace if turbocharger does not spin freely or damaged. • Check turbocharger seals for leakage.. Check for excessive oil consumption. If excessive oil consumption is noted, major rebuild may be necessary; refer to higher level maintenance. Check Engine Timing; refer to Section 15.4.8, Section 15.4.9, Section 15.4.10 and Section 15.4.11 for reference.

2.

PROBLEM 6: ENGINE EXHAUST WHITE OR BLUE.

PROBLEM 7: GENERATOR OUTPUT FREQUENCY/VOLTAGE CANNOT BE MAINTAINED.

PROBLEM 8: LOW POWER OR LOSS OF POWER.

2.

Cooling System

3.

Turbocharger

4.

Lubrication System

5.

Engine Timing

1.

Engine Timing

2.

Automatic Voltage Regulator (AVR)

3.

Engine Fault

1.

Engine Performance

2.

Lubrication System

Check Turbocharger; refer to SENR1068-01 or later version, SMCS CODE: 1052-040. Replace if turbocharger does not spin freely or damaged. Check Engine Timing; refer to Section 15.4.8, Section 15.4.9, Section 15.4.10 and Section 15.4.11 for reference. Check for obstructions in the Air Plenum Assembly, refer to Section 16.3.2 for reference. • Check Air Filter for obstructions, replace Air Filter as necessary, refer to Section 16.3.2 for reference.

3.

4. 5. 1.

Check Engine Timing; refer to Section 15.4.8, Section 15.4.9, Section 15.4.10 and Section 15.4.11 for reference.

2.

Check the AVR for proper operations; refer to SENR5833-02 or later version, SMCS CODE: 4467 for reference.

3.

Check the GSC+ for a shutdown fault, refer to RENR2227-02 or later version, for troubleshooting procedures.

1.

Perform all tests and inspections contained in Problems 4 through 7. Make appropriate corrections.

2.

Check for high oil level; refer to Section 14.3.1 for reference. • Drain excess oil.

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BASIC ENGINE TROUBLESHOOTING PROCEDURES (CONTINUED)

MALFUNCTION

PROBABLE CAUSE

CORRECTIVE ACTION 1.

1.

EMCP 2.

PROBLEM 9: ENGINE CANNOT REACH GOVERNED RPM.

PROBLEM 10:

2.

Fuel System

3.

Engine Timing

4.

Fuel Injectors

1.

Intake Air

2.

Turbocharger

3.

Muffler

3. 4. 1.

Check for obstructions in the Air Plenum Assembly, refer to Section 16.3.2 for reference. • Check Air Filter for obstructions, replace Air Filter as necessary, refer to Section 16.3.2 for reference.

2.

Check Turbocharger; refer to Caterpillar Manual SENR1068-01 or later version, SMCS CODE: 1052-040. • Replace if turbocharger does not spin freely or damaged. • Check turbocharger seals.

3.

Check the Muffler, refer to Section 8.4.7.1 for reference.

4.

Open Fuel Shutoff Valve; refer to Figure 11.3.1-1 for reference. • Check Fuel Level in Fuel Tank. • Prime Fuel System; refer to Section 11.3.5 for procedures. • Check Fuel Filters, refer to Section 11.3 for reference. • Check Fuel Quality (Have Fuel Sample Checked), refer to SENR1067-02 or later version, SMCS CODE: 1280-081 for procedures. • Perform Fuel System Test and Adjusting; refer to SENR1067-02 or later version, SMCS CODE: 1250-040 for procedures.

5.

Check Engine Timing; refer to Section 15.4.8, Section 15.4.9, Section 15.4.10 and Section 15.4.11 for reference.

EXCESSIVE FUEL CONSUMPTION. 4.

Fuel System

5.

Engine Timing

Check GSC Settings, refer to Annex B. • GSC+ settings may be improperly set. • Check and correct. Open Fuel Shutoff Valve; refer to Figure 11.3.1-1 for reference. • Check Fuel Level in Fuel Tank. • Prime Fuel System; refer to Section 11.3.5 for procedures. • Check Fuel Filters, refer to Section 11.3 for reference. • Check Fuel Quality (Have Fuel Sample Checked), refer to SENR1067-02 or later version, SMCS CODE: 1280-081 for procedures. • Perform Fuel System Test and Adjusting; refer to SENR1067-02 or later version, SMCS CODE: 1250-040 for procedures. Check Engine Timing; refer to Section 15.4.8, Section 15.4.9, Section 15.4.10 and Section 15.4.11 for reference. Check Fuel Injector, refer to SENR1067-02 or later version, SMCS CODE: 1290-081 for procedures.

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BASIC ENGINE TROUBLESHOOTING PROCEDURES (CONTINUED)

MALFUNCTION

PROBABLE CAUSE

CORRECTIVE ACTION 1.

1.

Lubrication System

PROBLEM 11: EXCESSIVE OIL CONSUMPTION.

2.

2.

Turbocharger

3.

Engine Crankcase Breathers

3. 1.

1.

Fuel System

2.

PROBLEM 12: CRANKCASE SLUDGE.

2.

Lubrication System

3. 3.

Coolant System

Inspect Lubrication System for proper operation; refer to Section 14.3.2 for reference. • Tighten all oil connections. • Check for external oil leaks. • Check grade of oil being used against weather conditions that unit is being operated in. • Inspect for Excessive Oil Consumption; refer to RENRRENR1067-02 or later version, SMCS CODE: 1348-040 for reference. Check Turbocharger; refer to Caterpillar Manual SENR1068-01 or later version, SMCS CODE: 1052-040. • Replace if turbocharger does not spin freely or damaged. • Check turbocharger seals. • Check turbocharger crossover and exhaust casing for wetness. If wet, turbocharger is defective. • Replace defective turbocharger. Check engine crankcase breathers for obstructions, refer to SEBU7163-01 or later version, SMCS CODE: 1317-070 for reference. Open Fuel Shutoff Valve; refer to Figure 11.3.1-1 for reference. • Check Fuel Level in Fuel Tank. • Prime Fuel System; refer to Section 11.3.5 for procedures. • Check Fuel Filters, refer to Section 11.3 for reference. • Check Fuel Quality (Have Fuel Sample Checked), refer to SENR1067-02 or later version, SMCS CODE: 1280-081 for procedures. • Perform Fuel System Test and Adjusting; refer to SENR1067-02 or later version, SMCS CODE: 1250-040 for procedures. Inspect Lubrication System for proper operation; refer to Section 14.3.2 for reference. • Tighten all oil connections. • Check for external oil leaks. • Check grade of oil being used against weather conditions that unit is being operated in. • Check the oil filter to see if it is clogged. • Change oil filters more often and observe for proper oil temperature. Check Cooling System for proper operation; refer to Section 13.4 for reference. • Check coolant for low temperature. • Check for faulty (stuck open) thermostat. • Test engine coolant thermostats for proper operation. Refer to SENR1067-02, or later version, SMCS CODE: 1355-081; 1355-081. • Replace defective thermostats.

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BASIC ENGINE TROUBLESHOOTING PROCEDURES (CONTINUED)

MALFUNCTION

PROBABLE CAUSE

CORRECTIVE ACTION 1.

1.

Coolant System

2.

PROBLEM 13: OIL DILUTION (CRANKCASE).

2.

Fuel System

3.

3.

Lubrication System

1.

PROBLEM 14:

1.

Lubrication System

2.

Engine Oil Pump

3.

Oil Pressure Sensor

LOW OIL PRESSURE. 2. 3.

Check Cooling System for proper operation; refer to Section 13.4 for reference. • Check coolant for low temperature. • Check for faulty (stuck open) thermostat. • Check for proper coolant level and evidence of leaks. • Test engine coolant thermostats for proper operation. Replace defective thermostats. Refer to Caterpillar Manual SENR1067-02, Dated November 2001 or later, SMCS CODE: 1355-081; 1355-081. Open Fuel Shutoff Valve; refer to Figure 11.3.1-1 for reference. • Check Fuel Level in Fuel Tank. • Prime Fuel System; refer to Section 11.3.5 for procedures. • Check Fuel Filters, refer to Section 11.3 for reference. • Check Fuel Quality (Have Fuel Sample Checked), refer to SENR1067-02 or later version, SMCS CODE: 1280-081 for procedures. • Perform Fuel System Test and Adjusting; refer to SENR1067-02 or later version, SMCS CODE: 1250-040 for procedures. Inspect Lubrication System for proper operation; refer to Section 14.3.2 for reference. • Tighten all oil connections. • Check for external oil leaks. • Check grade of oil being used against weather conditions that unit is being operated in. • Check the oil filter to see if it is clogged. • Change oil filters more often and observe for proper oil temperature. • Take oil sample from crankcase to see if there is evidence of coolant or fuel in the oil. Inspect Lubrication System for proper operation; refer to Section 14.3.2 for reference. • Tighten all oil connections. • Check for external oil leaks. • Check grade of oil being used against weather conditions that unit is being operated in. • Check the oil filter to see if it is clogged. • Check oil level. Check the Engine Oil Pump; refer to SENR1067-02 or later version, SMCS CODE:1304-040 Test Oil Pressure Sensor; refer to Caterpillar Manual RENR 2227-01 or later version, Section P – 520.

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BASIC ENGINE TROUBLESHOOTING PROCEDURES (CONTINUED)

MALFUNCTION

PROBABLE CAUSE

CORRECTIVE ACTION 1.

PROBLEM 15:

1.

Thermostat

2.

Coolant Temperature Sensor

PROBLEM 16:

1.

Coolant System

COOLANT TEMPERATURE TOO HIGH.

2.

Water Pump

3.

Oil Level and Grade

1.

Oil Level and Grade

2.

Engine Oil

3.

Engine Load

COOLANT TEMPERATURE TOO LOW.

PROBLEM 17: OIL TEMPERATURE TOO HIGH.

2.

Check Cooling System for proper operation; refer to Section 13.4 for reference. • Check coolant for low temperature. • Check for faulty (stuck open) thermostat. • Check for proper coolant level and evidence of leaks. • Test engine coolant thermostats for proper operation. Refer to SENR1067-02, or later version, SMCS CODE: 1355-081; 1355-081. • Replace defective thermostats. Refer to Section 12.4.1.1 and RENR 2227-01, Section P – 516 or later version and Troubleshooting Procedures are found in RENR1067-01 or later version. Replace if defective.

1.

Cooling System Check (Overheating), refer to RENR1067-02 or later version, SMCS CODE: 1350-535 for reference. • Check the Radiator Cooling fan to see if it functioning properly. Refer to Section 19.4.3 for reference.

2.

Check the water pump to see if it functioning properly. Refer to RENR1067-02 or later version, SMCS CODE: 1361-040; 1361-081 for reference. Check crankcase oil level. Use proper grade for weather conditions. Refer to Annex G, Consumable Operating and Maintenance Supplies.

3. 1.

Check crankcase oil level. Use proper grade for weather conditions. Refer to Annex G, Consumable Operating and Maintenance Supplies.

2.

Inspect increased oil temperature. Refer to RENR1067-02 or later version, SMCS CODE: 1348-040.

3.

Check KW load on the GSC. Make appropriate loading corrections.

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BASIC ENGINE TROUBLESHOOTING PROCEDURES (CONTINUED)

MALFUNCTION

PROBABLE CAUSE 1.

Ether

2.

Fuel

CORRECTIVE ACTION 1. 2. 3.

PROBLEM 18:

3.

Thermostat

4.

Engine Load

5.

Engine Timing

6.

Engine Oil

1.

Oil Pressure Sensor

2.

Engine Oil

1. 2.

External Fuel Transfer Pump Switch G1/G2 Battery Bank

3.

External Fuel Transfer Pump.

4.

Fuel Float Switch Assembly

KNOCKS (COMBUSTION NOISE).

PROBLEM 19: EXCESSIVE OIL PRESSURE.

PROBLEM 20: FUEL TRANSFER PUMP NOT WORKING.

PROBLEM 21: All

ALL ENGINE FAULTS

4.

Check for possible improper use of starting aid. Check Fuel Quality (Have Fuel Sample Checked), refer to SENR1067-02 or later version, SMCS CODE: 1280-081 for procedures. Check Cooling System for proper operation; refer to Section 13.4 for reference. • Check coolant for low temperature. • Check for faulty (stuck open) thermostat. • Check for proper coolant level and evidence of leaks. • Test engine coolant thermostats for proper operation. Refer to SENR1067-02, or later version, SMCS CODE: 1355-081; 1355-081. • Replace defective thermostats. Check KW load on the GSC. Make appropriate corrections.

5.

Check Engine Timing; refer to Section 15.4.8, Section 15.4.9, Section 15.4.10 and Section 15.4.11 for reference.

6.

Check grade of oil being used against weather conditions that unit is being operated in. Refer to Annex G.

1.

Check for defective oil pressure sensor. Refer to RENR 2227-02 or later version, Section P – 520. • Replace if defective.

2.

Check grade of oil being used against weather conditions that unit is being operated in. Refer to Annex G.

1.

Check that the External Fuel Transfer Pump Switch is in the G1 or G2 position.

2. 3.

Inspect the battery bank, refer to Section 9.4.1.1. Inspect the External Fuel Transfer Pump Assembly for proper operation. Refer to Section 11.4.2.1.

4.

Inspect the Fuel Float Switch Assembly. Refer to Section 11.4.5.1

If engine does not start refer to RENR 2227-02 or later version, Section 3: Troubleshooting Without a Diagnostic Code; or Section 4: Troubleshooting With a Diagnostic Code. And refer to RENR1200-01 or later version, SMCS CODE: 4490.

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BASIC ENGINE TROUBLESHOOTING PROCEDURES (CONTINUED)

MALFUNCTION

PROBLEM 22: ENGINE WILL NOT START IN AUTO

PROBABLE CAUSE 1. 2.

DC Control Power Circuit Breaker (CBCP) Battery Bank

3.

Control Cables

4. 5. 6.

Control Switch Positions Engine Faults Advanced Troubleshooting Procedures: • GSC+ • PCM • CCM • ATB • PT1 • PT2 • PT3 • CT1 • CT2 • CT3 • CB2 • CB4 • ECS • ESPB • ARR1 • SR • SMMS • FSPR

CORRECTIVE ACTION 1. 2. 3. 4. 5. 6.

Place CBCP to the ON (Push-in) position. Inspect the battery bank, refer to Section 9.4.1.1. Verify the A/B Control Cable is connected. • Verify the ORT Cable is connected. Verify Switch Setup. Refer to Section 5.2.3.8. Clear all Active Engine Faults. Perform the following Steps: • Place CBCP to the ON (Push-in) position. • Place both ECS in AUTO • Verify there are no GSC+ shutdowns active. • Place the SMS in AUTO position. • Verify that the SSL two green lights are illuminated. • Place running engine ECS to OFF/RESET. • Move the MSES to the ENABLE position (momentary) • Verify that associated ARR relay energizes. Indicator LED that is located on the relay module should illuminate. Refer to FO-22. • If the ARR relay does not energize, check for 24VDC between terminal “A1 and “A2” at the coil. • Check for continuity across the ARR contacts. Lack of continuity across the contacts indicates a failed relay module, replace the relay module. A verification check may be done by swapping the relay with one of the spare (SPR) modules. • Check for 24VDC at the coil; if voltage is present continue to next step. If 24VDC is not present; refer to Table 7.3.3-1, Problem 10 to troubleshoot RTU problems. • Check that the engine starts in MANUAL. • If the engine starts in MANUAL check the wiring from the associated ARR contact to the GSC+ module. • If engine does not start refer to RENR 2227-02 or later version, Section 3: Troubleshooting without a Diagnostic Code; or Section 4: Troubleshooting With a Diagnostic Code. And refer to RENR1200-01 or later version, SMCS CODE: 4490.

7-31

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BASIC ENGINE TROUBLESHOOTING PROCEDURES (CONTINUED)

MALFUNCTION

PROBLEM 23: ENGINE WILL NOT START IN MANUAL

PROBABLE CAUSE 1. 2.

DC Control Power Circuit Breaker (CBCP) Battery Bank

3.

Control Cables

4. 5. 6.

Control Switch Positions Engine Faults Advanced Troubleshooting Procedures: • GSC+ • PCM • CCM • ATB • PT1 • PT2 • PT3 • CT1 • CT2 • CT3 • CB2 • CB4 • ECS • ESPB • ARR1 • SR • SMMS • FSPR

CORRECTIVE ACTION 1. 2. 3. 4. 5. 6.

Place CBCP to the ON (Push-in) position. Inspect the battery bank, refer to Section 9.4.1.1. Verify the A/B Control Cable is connected. • Verify the ORT Cable is connected. Verify Switch Setup. Refer to Section 5.2.3.8. Clear all Active Engine Faults. Perform the following Steps: • Place CBCP to the ON (Push-in) position. • Place both ECS in AUTO • Verify there are no GSC+ shutdowns active. • Place the SMS in AUTO position. • Verify that the SSL two green lights are illuminated. • Place running engine ECS to OFF/RESET. • Move the MSES to the ENABLE position (momentary) • Verify that associated ARR relay energizes. Indicator LED that is located on the relay module should illuminate. Refer to FO-22. • If the ARR relay does not energize, check for 24VDC between terminal “A1 and “A2” at the coil. • Check for continuity across the ARR contacts. Lack of continuity across the contacts indicates a failed relay module, replace the relay module. A verification check may be done by swapping the relay with one of the spare (SPR) modules. • Check for 24VDC at the coil; if voltage is present continue to next step. If 24VDC is not present; refer to Table 7.3.3-1, Problem 10 to troubleshoot RTU problems. • Check that the engine starts in MANUAL. • If the engine starts in MANUAL check the wiring from the associated ARR contact to the GSC+ module. • If engine does not start refer to RENR 2227-02 or later version, Section 3: Troubleshooting Without a Diagnostic Code; or Section 4: Troubleshooting With a Diagnostic Code. And refer to RENR1200-01 or later version, SMCS CODE: 4490.

7-32

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BASIC ENGINE TROUBLESHOOTING PROCEDURES (CONTINUED)

MALFUNCTION

PROBLEM 24: ENGINE DOES NOT STAY RUNNING ONCE STARTED

PROBABLE CAUSE 1. 2.

DC Control Power Circuit Breaker (CBCP) Battery Bank

3.

Control Cables

4. 5.

CORRECTIVE ACTION 1. 2. 3.

Place CBCP to the ON (Push-in) position. Inspect the battery bank, refer to Section 9.4.1.1. Verify the A/B Control Cable is connected. • Verify the ORT Cable is connected.

Control Switch Positions

4.

Verify Switch Setup. Refer to Section 5.2.3.8.

Engine Faults

5.

Clear all Active Engine Faults.

6.

Open Fuel Shutoff Valve; refer to Figure 11.3.1-1 for reference. • Check Fuel Level in Fuel Tank. • Prime Fuel System; refer to Section 11.3.5 for procedures. • Check Fuel Filters, refer to Section 11.3 for reference. • Check Fuel Quality (Have Fuel Sample Checked), refer to SENR1067-02 or later version, SMCS CODE: 1280-081 for procedures. • Perform Fuel System Test and Adjusting; refer to SENR1067-02 or later version, SMCS CODE: 1250-040 for procedures. Perform the following Steps: • Place CBCP to the ON (Push-in) position. • Place both ECS in AUTO • Verify there are no GSC+ shutdowns active. • Place the SMS in AUTO position. • Verify that the SSL two green lights are illuminated. • Place running engine ECS to OFF/RESET. • Move the MSES to the ENABLE position (momentary) • Verify that associated ARR relay energizes. Indicator LED that is located on the relay module should illuminate. Refer to FO-22. • If the ARR relay does not energize, check for 24VDC between terminal “A1 and “A2” at the coil. • Check for continuity across the ARR contacts. Lack of continuity across the contacts indicates a failed relay module, replace the relay module. A verification check may be done by swapping the relay with one of the spare (SPR) modules. • Check for 24VDC at the coil; if voltage is present continue to next step. If 24VDC is not present; refer to Table 7.3.3-1, Problem 10 to troubleshoot RTU problems. • Check that the engine starts in MANUAL. • If the engine starts in MANUAL check the wiring from the associated ARR contact to the GSC+ module. • If engine does not start refer to RENR 2227-02 or later version, Section 3: Troubleshooting Without a Diagnostic Code; or Section 4: Troubleshooting With a Diagnostic

6.

Fuel System

7.

Advanced Troubleshooting Procedures: • GSC+ • PCM • CCM • ATB • PT1 • PT2 • PT3 • CT1 • CT2 • CT3 • CB2 • CB4 • ECS • ESPB • ARR1 • SR • SMMS • FSPR

7.

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BASIC EMCP+ TROUBLESHOOTING PROCEDURES

Table 7.3.2-1 contains Basic EMCP+ Troubleshooting Procedures for locating and correcting operating troubles that may develop in the generator set. Each malfunction, for either an individual component or entire system, is followed by a series of tests or inspections that will help determine the probable cause and corrective actions to take. Troubleshoot in accordance with Table 7.3.2-1. All Safety Warnings and Cautions in Section 7.1 apply to this table. This manual cannot list all malfunctions that may occur, nor all tests or inspections and corrective actions. If a malfunction cannot be corrected by listed corrective actions, notify supervisor and or contact Radian Inc. NOTE:

Although troubleshooting can be a daunting task. Troubleshooting can be made much easier if you start by isolating the fault first. The first task is to determine if the system or device is getting the proper inputs AC voltage, AC current, DC voltage and DC current. Check for loose wires and blown fuses. By isolating the fault by eliminating obvious problems will make the technicians job much easier.

TABLE 7.3.2-1

BASIC EMCP + TROUBLESHOOTING PROCEDURES

MALFUNCTION

PROBLEM

PROBABLE CAUSE

CORRECTIVE ACTION

1.

DC Control Power Circuit Breaker (CBCP)

1.

Place CBCP to the ON (Push-in) position.

2.

Battery Bank

2.

Inspect the battery bank, refer to Section 9.4.1.1.

3.

Check for 24VDC on the GSC+ between Terminals “RM B+” and “RM28”, refer to FO-12A or 12B. If GSC still doesn’t function refer problem to Caterpillar.

EMCP+ NOT FUNCTIONING PROPERLY

3.

EMCP+ not functioning properly

•

Refer to 3456 DPGDS Generator Set Engine – Supplement, Dated November 1998.

•

RENR1200-01 or later version.

•

SEBU6918-02 or later version.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 7.3.3

BASIC GENERATOR OPERATIONS TROUBLESHOOTING PROCEDURES

Table 7.3.3-1 contains Basic Generator Operations Troubleshooting Procedures information for locating and correcting operating troubles that may develop in the generator set. Each malfunction, for either an individual component or entire system, is followed by a series of tests or inspections that will help determine the probable cause and corrective actions to take. Troubleshoot in accordance with Table 7.3.3-1. All Safety Warnings and Cautions in Section 7.1 apply to this table. This manual cannot list all malfunctions that may occur, nor all tests or inspections and corrective actions. If a malfunction cannot be corrected by listed corrective actions, notify supervisor and or contact Radian Inc. NOTE:

Although troubleshooting can be a daunting task. Troubleshooting can be made much easier if you start by isolating the fault first. The first task is to determine if the system or device is getting the proper inputs AC voltage, AC current, DC voltage and DC current. Check for loose wires and blown fuses. By isolating the fault by eliminating obvious problems will make the technicians job much easier.

NOTE:

This section of the troubleshooting procedures is needed for component isolation purposes. These procedures make it possible to rapidly determine what component may be out of adjustment or defective.

NOTE:

While troubleshooting within this section, keep in mind that you cannot check continuity across the HUB. You must check continuity up to and then past the HUB.

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SYMPTOM

• •

PROBLEM 1: LOAD SHARING BETWEEN

• • •

GENERATORS DURING PRIME

•

POWER OPERATION •

Engine Not Sharing Load Engine Will Not Operate In Parallel Undesirable Speed Decrease With Load Increase Erratic Load Sharing Module Operation Load Signal Voltage Low – LOAD GAIN Adjustment Will Not Raise Load Signal Voltage High – LOAD GAIN Adjustment Will Not Lower Engine Does Not Properly Share Load With Other Units

COMPONENTS AFFECTED

TEST PROCEDURES/ CORRECTIVE ACTION 1. 2. 3. 4. 5. 6.

• • • • • • • • • • • •

LSM PT4 PT5 CT1 CT2 CT3 GDR1 GDR2 52CL1 52CL2 52CL3 BLR

Place CBCP to the ON (Push-in) position. Verify the A/B Control Cable is connected. Verify the ORT Cable is connected. Verify that the load cables are connected properly to the load. Check that the Air Tubes rubber connectors have not become disconnected. Test the load-share wiring between both LSMs and external connectors: • Place CBCP to the OFF (Pulled-out) position. • Disconnect LS-Net cable(s) from the PDC at 23PA & 23PB. • Steps a, and b need to be performed with DC control power on. (a) Pull out on the blue test lever on relay 52CL3. This will manually operate the relay’s contacts. (b) Test the continuity from 23PA-C to 23PB-C and the continuity from 23PA-M to 23PBM. This tests the load share signal lines through the PDC. Lack of continuity indicates a bad 52CL3 relay or bad wiring. • Pull out 52CL1-test lever and push in 52CL3-test lever. • Test the continuity from LSMA-10 to 23PA-M and from LSMA-11 to 23PA-C. This tests the load share signal lines from generator A LSM to external connection 23PA. Lack of continuity indicates a bad 52CL1 relay or bad wiring. • Pull out 52CL2-test lever and push in 52CL1-test lever. Pull out 52CL3-test lever. • Test the continuity from LSMB-10 to 23PB-M and from LSMB-11 to 23PB-C. This tests the load share signal lines from generator B LSM to external connection 23PB. Lack of continuity indicates a bad 52CL2 relay or bad wiring. • Push in all control relay test levers, which are pulled out. • Refer toSENR6565-02 or later version. This manual combines two separate manuals. Refer to RENR2471-01 or later version, SMCS CODE: 4490-035.

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SYMPTOM

COMPONENTS AFFECTED

TEST PROCEDURES Place CBCP to the ON (Push-in) position. Verify the A/B Control Cable is connected. Verify the ORT Cable is connected. Verify that the load cables are connected properly to the load. Test the output of XD to be between 0-3VDC based on the ORT input of 0- 420KW: (a) Connect an ORT to the PDC and start the PPCAMP software

1. 2. 3. 4. 5.

Ensure there is an "A" unit connected, or the ORT will not allow adjustment of the base load level.

NOTE:

PROBLEM 2: LOAD SHARING BETWEEN GENERATORS DURING UTILITY PARALLEL

•

Engine Does Not Carry Set Baseload

• • • • • • • • • •

(b) (c) (d). (e) (f) (g)

LSM PT4 PT5 CT1 CT2 CT3 XD 52CL1 52CL2 BLR

(h) (i) (j) (k)

Place ECS(s) in OFF/RESET Place GMS in UTILITY PARALLEL Place SMS in MANUAL Disconnect the output of XD, terminal plug 8 & 9. Toggle MSES. Adjust the Baseload level and, using a Multimeter set on the VCD scale, measure the VDC output of XD changing proportionally. If the signal is good then the Baseload control is functioning between the RTU and XD. Reconnect XD terminal plug. If the XD is not functioning properly refer to Table 7.3.3-1. Push-in all control relay test levers that are pulled out. If proper voltage was detected at the LSM's refer to SENR6565-02 or later version SMCS CODE: 4490-035.

6. Test the Paralleling Input of LSM to be between 0-3VDC: (a) (b) (c) (d) (e) (f)

Check that the relay energized LED is lit on BLR. This indicates the PDC is in Baseload Mode. Pull-out 52CL1(2)-test lever. This will manually operate the relay’s contacts. Check voltage at LSM terminals 10 & 11 matches the voltage out of XD. If the voltage was not present check the wiring between XD terminals 7 & 8 and LSM terminals 10 & 11. See FO-21 for reference. Check the contact continuity of relays in the circuit. Replace any relay that is non-functional. Relay BLR should be on, 52CL1(2) can be forced closed using the test lever. Push-in all control relays test levers that are pulled out.

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SYMPTOM

COMPONENTS AFFECTED

TEST PROCEDURES 1.

1.

‘B’, ‘C’, or ‘D’ Unit is not responding to commands from ‘A’ unit.

(a) (b) (c)

2.

PROBLEM 3: COMMUNICATIONS BETWEEN PDC'S IS NOT WORKING

2.

ORT only recognizes unit to which it is connected.

Test the DC power to the Hub:

• • • • •

RTU HUB PS5 IMA IMB

Place CBCP to the ON (Push-in) position. Visually observe that the power LEDs on the Hub and the RTU come on. If the power LED does not energize on the Hub, check VDC power to the Hub at “PWR+ and PWR –“, there should be 24VDC present.

Test the communications between an ORT and the RTU: (a) (b) (c) (d) (e) (f) (g) (h) (i) (j)

Connect an ORT to the PDC. Start the ORT to the PPCAMP software. Place SMS in MANUAL. Toggle MSES. Visually observe the Hub LED for port 2. This LED should be flashing. This indicates that the ORT is communicating with the Hub. If the LED is not flashing check the RJ45 connections to make sure it is properly seated on both sides of the Ethernet connector. Check the connection to Hub port 2 is properly seated. Visually observe port 3 LED on the Hub is flashing rapidly. Flashing indicates that the RTU is communicating with the Hub. Visually observe the LNK and ACT indicators on the RTU. Flashing LEDs indicate that the RTU is communicating out its Ethernet port. If the LEDs are not flashing check the RJ45 connection to make sure it is properly seated on the RTU. Check the connection to Hub port 3 is properly seated. If the Ethernet LEDs on the RTU are flashing and no communications are visible through the Hub, replace the Hub.

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SYMPTOM

COMPONENTS AFFECTED

TEST PROCEDURES 1. Generator will not auto-synchronize:

1.

Generator does not auto synchronize to the bus.

PROBLEM 4: GENERATOR WILL NOT SYNCHRONIZE

2.

Generator cannot be manually synchronized to the bus.

(a) (b) (c) (d) (e) (f) (g) • • • • • • • • • • • • • • •

SPMA (15/25) SC/25M BVFM PT6 PT7 PT8 SSS SMS SBR1 SBR2 SBR3 ASR1 ASR2 25M1 25M2

(h) (i) (j) (k)

2.

Place CBCP to the ON (Push-in) position. Place affected generator ECS in AUTO. Verify there are no GSC+ shutdowns active. Place SMS in AUTO. Place functioning engine ECS to OFF/RESET. Toggle MSES and hold for 6 seconds. This allows the system to reset itself. Verify that associated ASR relay momentarily energizes. Indicator LED that is located on the relay module should illuminate momentarily. If the ASR relay does not energize, check for 24VDC at the coil terminals “A1 and A2”. Refer to FO-23. If there isn’t 24VDC at the coil, go to Table 7.3.3-1, Problem 10. Check for continuity across the ASR contacts. Lack of continuity across the contacts indicates a failed relay module, replace the relay module. A verification check may be done swapping the relay with one of the spare (SPR) modules. Check that the SYNC ENABLE LED on the SPMA is blinking. If the SPMA is enabled but the breaker will not close, go to Woodward Manual 82384R, Chapter 4, Calibration and Check procedure.

Generator cannot be manually synchronized: (a) (b) (c) (d) (e) (f) (g) (h) (i) (j)

Place CBCP to the ON (Push-in) position. Place affected engine ECS in STOP/COOLDOWN. Verify that there a HOT bus for these tests. Verify there are no GSC+ shutdowns active. Place affected engine ECS in MANUAL. Select the associated generator on SSS. Check that the three LEDs on the Sync scope rotate clockwise around the meter. If the LEDs do not, replace the Syncscope meter. This is a diagnostic the meter goes through upon energizing. Check operation of the Sync-check relay by confirming that the associated 25M relay energizes when the Syncscope is at 12o’clock. The LED on the relay module will energize when the sync-check contact closes. If the relay does not energize check the wiring from the Syncroscope relay contacts to the 25M relay. If the wiring is found to be good and the other generator can be manually synchronized replace the affected 25M relay.

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SYMPTOM

COMPONENTS AFFECTED

TEST PROCEDURES 1. Generator breaker does not operate:

PROBLEM 5: GENERATOR OUTPUT BREAKER WILL NOT OPERATE

Generator breaker does not close.

• • • • • • • • • • • • • • • • • • • • •

52G1 52G2 15/25A 15/25B 50/51G1 50/512 PT6 BCSG1 BCSG2 SSS SBR2 BRG1 BRG2 OCR1 OCR2 52T1 52T2 52C1 52C2 25M1 25M2

NOTE: Troubleshooting procedure written for generator #1; substitute 2 or B for troubleshooting generator #2. (a) (b) (c) (d) (e) (f) (g) (h)

Place CBCP to the ON (Push-in) position. Check the overcurrent relay for proper operation and active faults; clear any active faults. Refer to Section 12.4.2.1.2. Place affected engine ECS in STOP/COOLDOWN. Verify there are no GSC+ shutdowns active. Place affected engine ECS in MANUAL. Select the associated generator on SSS. Verify that relay G1BR has energized by inspecting its indicator. If G1BR is not picked up, use a multimeter on the VAC scale, check for 120VAC at terminals 300A & CP20A. WARNING

HIGH VOLTAGE, USE PROPER PROTECTIVE EQUIPMENT AND PROPER TEST EQUIPMENT. (i) (j) (k) (l)

If 120VAC is not present at these terminals check transformer PT6 and its fuses. Check that 52T1 is not energized. If 52T1 is energized go to Table 7.3.3-1, Problem 10. Place CBCP to the OFF (Pull-out) position. Check continuity between terminal 300A and terminal 332 with BCSG1 in the CLOSE position. This will indicate whether the door switches’ contacts are operating. (m) Check continuity between terminals 332 and 334. This tests the manual sync and dead-bus close circuit. (n) Pull-out BRG1 test lever and test for continuity to 52G1 terminal 2. Continuity indicates the circuit to the breaker close coil is good. (o) Reset BRG1 test lever. (p) Test 52G1 circuits on the breaker itself, including the fuse, bridge rectifier, and the coil itself.

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SYMPTOM

COMPONENTS AFFECTED

TEST PROCEDURES WARNING

PROBLEM 6: FEEDER BREAKER WILL

Feeder breaker does not close.

NOT OPERATE

• • • • • • • • • • • • •

52F1 52F2 50/51F1 50/51F2 PT6 BCSF1 BCSF2 OCR4 OCR5 52T4 52T5 52C4 52C5

HIGH VOLTAGE, USE PROPER PROTECTIVE EQUIPMENT AND PROPER TEST EQUIPMENT. Generator breaker does not operate: NOTE: Procedure written for feeder #1. With power applied to the system bus, check that relay SBR is energized. Indicated by the indicator being lit. (a) (b)

1.

PROBLEM 7: TIE BREAKER WILL NOT OPERATE

Breaker does not close manually with System Bus energized.

• • • • • • • • • •

52T 50/51T PT7 PT8 TBCS SMS SBR2 TBR 52T3 52C3

Place CBCP to the ON (Push-in) position. Check the overcurrent relay for proper operation and active faults; clear any active faults. Refer to Section 12.4.2.1.2. (c) If the relay is off, use a multimeter on the VAC scale and check for 120VAC between terminals SB31 and SBP20. If there is no voltage, check transformer PT7 and its fusing. (d) Place CBCP to the OFF (Pull-out) position. (e) Check continuity between terminal SB31 and terminal 324(328) with BCSF1 and BCSF2 in the CLOSE position. This will indicate whether the door switch contacts are operating. (f) Check continuity between terminals 324(328) and 52F1(52F2) terminal 2. (g) Continuity indicates the circuit to the breaker close coil is good. (h) Test 52F1 circuits on the breaker itself, including the fuse, bridge rectifier, and the coil itself. Breaker does not close manually with System Bus energized: (a) (b) (c) (d) (e) (f) (g) (h) (i) (j)

Place CBCP to the ON (Push-in) position. Check the overcurrent relay for proper operation and active faults; clear any active faults. Refer to Section 12.4.2.2.2. Check SBR relay is energized and TBR relay is de-energized. Check for 120VAC at terminals SB31 and SBP20. If there is no voltage, check the medium voltage fuse on PT7, refer to FO-25, B-2. Place SMS in MANUAL. Hold BCST in the CLOSE position and check for 120VAC between terminals 313 and SBP20, refer to FO-25, B-2. Place CBCP to the OFF (Pull-out) position. De-energize AC power to PDC. Test wiring continuity between terminal SBP20 and 52T terminal “Neutral” refer to FO-25, B2. Pull-out SBR2 test lever. Test wiring continuity between terminal 313 and 52T terminal 2, refer to FO-25, B-2.

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SYMPTOM

COMPONENTS AFFECTED

TEST PROCEDURES 2.

Breaker does not close automatically with System Bus energized:

NOTE: The tie breaker will only automatically close if there is another MEP-PU-810 connected to the LS-Net connector on the ‘B’ side of the PDC. (a) (b) (c) (d)

2. Breaker does not close automatically with System Bus energized. • • • • • • • • • •

PROBLEM 7:

TIE BREAKER WILL NOT OPERATE (CONTINUED)

3. Breaker does not close manually with Tie Bus energized.

52T 50/51T PT7 PT8 TBCS SMS SBR2 TBR 52T3 52C3

3.

Place CBCP to the ON (Push-in) position. Check SBR relay is energized and TBR relay is de-energized. Check for 120VAC at terminals SB31 and SBP20; refer to FO-25, B-2. Check for 120VAC at terminals SB31 and SBP20. If there is no voltage, check the medium voltage fuse on PT7, refer to FO-25, B-2. (e) Place SMS in AUTO. (f) Toggle MSES. (g) Check that 52C3 energizes and that 52T3 is not energized. If 52C3 LED is not visible check for 120VAC between terminal 313 and SBP20. (h) If there is no voltage at terminal 313, go to Table 7.3.3-1, Problem 10. (i) Place CBCP to the OFF (Pull-out) position. (j) De-energize AC power to PDC. (k) Test wiring continuity between terminal SBP20 and 52T terminal “Neutral”, refer to FO-25, B-2. (l) Pull-out SBR2 test lever. Test wiring continuity between terminal 313 and 52T terminal 2, refer to FO-25, B-2. Breaker does not close manually with Tie Bus energized: (a) (b) (c) (d) (e) (f) (g) (h) (i) (j)

Place CBCP to the ON (Push-in) position. Check TBR relay is energized and SBR relay is de-energized. Check for 120VAC at terminals B31 and BP20. Check for 120VAC at terminals SB31 and SBP20. If there is no voltage, check the medium voltage fuse on PT8, refer to FO-25, B-2. Place SMS in MANUAL. Hold BCST in the CLOSE position and check for 120VAC between terminals 313 and BP20, refer to FO-25, B-2. Place CBCP to the OFF (Pull-out) position. De-energize AC power to PDC. Test wiring continuity between terminal BP20 and 52T terminal “Neutral”, refer to FO-25, B2. Pull-out TBR test lever. Test wiring continuity between terminal 313 and 52T terminal 2, refer to FO-25, B-2.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 TABLE 7.3.3-1 BASIC GENERATOR OPERATIONS TROUBLESHOOTING PROCEDURES (CONTINUED) MALFUNCTION

SYMPTOM

COMPONENTS AFFECTED

TEST PROCEDURES 4.

Breaker does not close automatically with Tie Bus energized:

NOTE: The tie breaker will only automatically close if there is another MEP-PU-810 connected to the LS-Net connector on the ‘A’ side of the PDC. (a) (b) (c) (d)

Place CBCP to the ON (Push-in) position. Check TBR relay is energized and SBR relay is de-energized. Check for 120VAC at terminals B31 and BP20; refer to FO-25, B-2. Check for 120VAC at terminals SB31 and SBP20. If there is no voltage, check the medium voltage fuse on PT8, refer to FO-25, B-2. (e) Place SMS in AUTO. (f) Toggle MSES. (g) Check that 52C3 energizes and that 52T3 is not energized; refer to FO-25, B-2. (h) If 52C3 LED is not visible check for 120VAC between terminal 313 and BP20, refer to FO25, B-2. (i) If there is no voltage at terminal 313 go to Table 7.3.3-1, Problem 10. (j) Place CBCP to the OFF (Pull-out) position. (k) De-energize AC power to PDC. (l) Test wiring continuity between terminal BP20 and 52T terminal “Neutral”, refer to FO-25, B2. (m) Pull-out TBR test lever. Test wiring continuity between terminal 313 and 52T terminal 2, refer to FO-25, B-2.

4. Breaker does not close automatically with System Bus energized. • • • • • • • • • •

PROBLEM 7:

TIE BREAKER WILL NOT OPERATE (CONTINUED)

5. Breaker does not open manually.

52T 50/51T PT7 PT8 TBCS SMS SBR2 TBR 52T3 52C3

5.

Breaker does not open manually: (a) (b) (c) (d) (e) (f) (g) (h) (i) (j)

Place CBCP to the ON (Push-in) position. Check SBR relay is energized. Check for 120VAC at terminals SB31 and SBP20. If there is no voltage transformer PT7 and its fusing need checking. Place SMS in MANUAL. Hold BCST in the CLOSE position and check for 120VAC between terminals 320 and SBP20. Place CBCP to the OFF (Pull-out) position. De-energize AC power to PDC. Pull-out SBR2 test lever. Test wiring continuity between terminal 320 and 52T terminal 6. Test wiring continuity between terminal SBP20 and 52T terminals 1 & 7. Test 52T circuits on the breaker itself, including the fuse, bridge rectifier, and the coil itself.

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SYMPTOM

PROBLEM 7:

TIE BREAKER WILL NOT

6. Breaker does not open automatically.

OPERATE (CONTINUED))

PROBLEM 8:

1.

Fault Code: 705 - Generator reverse power shutdown.

2.

Fault Code: 802 - Generator no voltage.

3.

Fault Code: 701 - Generator low voltage.

4.

Fault Code: 702 - Generator high voltage.

5.

Generator unstable voltage.

GENERATOR VOLTAGE CONTROL

6.

KVAR/PF control during Utility Parallel Ops.

COMPONENTS AFFECTED • • • • • • • • • •

52T 50/51T PT7 PT8 TBCS SMS SBR2 TBR 52T3 52C3

TEST PROCEDURES 6.

(a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) 1.

2. • • • • • • • • • • •

AVRA AVRB VAR PT1 PT2 PT3 CT4 AVRSA AVRSB PSR1 PSR2

Breaker does not open automatically:

3. 4.

5.

6.

Place CBCP to the ON (Push-in) position. Check SBR relay is energized. Check for 120VAC at terminals SB31 and SBP20. If there is no voltage transformer PT7 and its fusing need checking. Check that 52T3 relay is energized. If 52T3 is not energized check, go to Table 7.3.3-1, Problem 10. Check for 120VAC between terminals 320 and SBP20. Place CBCP to the OFF (Pull-out) position. De-energize AC power to PDC. Pull-out SBR2 test lever. Test wiring continuity between terminal 320 and 52T terminal 6. Test wiring continuity between terminal SBP20 and 52T terminals 1 & 7. Test 52T circuits on the breaker itself, including the fuse, bridge rectifier, and the coil itself.

Generator reverse power shutdown: • Follow troubleshooting procedures as described in Caterpillar’s Digital Voltage Regulator Manual SENR5833-02 or later version, SMCS CODE: 4467. Generator no voltage: • Follow troubleshooting procedures as described in Caterpillar’s Digital Voltage Regulator Manual SENR5833-02 or later version, SMCS CODE: 4467. Generator low voltage: • Follow troubleshooting procedures as described in Caterpillar’s Digital Voltage Regulator Manual SENR5833-02 or later version, SMCS CODE: 4467. Generator high voltage: • Follow troubleshooting procedures as described in Caterpillar’s Digital Voltage Regulator Manual SENR5833-02 or later version, SMCS CODE: 4467. Generator unstable voltage: • Follow troubleshooting procedures as described in Caterpillar’s Digital Voltage Regulator Manual SENR5833-02 or later version, SMCS CODE: 4467. KVAR/PF control during Utility Parallel Operations: • Check status LED of PSR. During parallel operations with the utility the relay should be on. If the relay is off, go to Table 7.3.3-1, Problem 10. • Test the energized relay, using a multimeter on the VDC scale, check voltage differential between AVR terminals 41 & 50. • No differential indicates that the voltage regulator is in KVAR/PF mode. Go to Caterpillar’s Digital Voltage Regulator Manual SENR5833-02 or later version, SMCS CODE: 4467.

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SYMPTOM

COMPONENTS AFFECTED

TEST PROCEDURES 1. No DC control power: See NOTE 1 (a) (b)

1. No DC control power.

PROBLEM 9:

• • • • •

DC CONTROL POWER

D2A D2B D3 D4 CBCP

Check Batteries. Refer to Section 9.4.1.1. Check D2A and D2B between terminals 1 & 2. A nominal voltage of 24VDC needs to be present. Refer to FO-7, D-8, D-6 for reference. See NOTE 1. (c) Check DC voltage D3 and D4 between terminals 1 & TBC 30. A nominal voltage of 24VDC needs to be present. See NOTE 1 and Refer to FO-7 for reference. (d) Check voltage between terminal 100 & 2AB. Refer to FO-7 for reference. (e) If there is not 24VDC on terminal 100, check connection to CBCP. Refer to FO-7 for reference. (f) Check the voltage at both terminals on CBCP. With the breaker closed 24VDC should be present on terminal to ground. Refer to FO-7 for reference. (g) Replace CB if not closing. If CB is tripping open, a ground in the DC circuit exists and must be located. (h) Place CBCP to the OFF (Pull-out) position. (i) Check condition of the diodes D2A, D2B, D3, & D4. Replace any diode that has failed. 2. Operating generator shuts down when second unit on PU starts: (a)

2. Operating generator shuts down when second unit on PU starts.

(b) (c) (d) (e)

NOTE 1:

Check the status of the Battery Tie Switch (located at front of PU). If closed, open the switch to isolate engine battery circuits. Check DC voltage between terminals 1A & 2AB. A nominal voltage of 24VDC needs to be present. Lack of DC voltage indicates Engine 1 batteries are not supplying 24VDC to the PDC. Check DC voltage between terminals 1A & 30AB. A nominal voltage of 24VDC needs to be present. Lack of DC voltage indicates Engine 2 batteries are not supplying 24VDC to the PDC.

Diode Test Procedure: The “Diode Check Function” on a Digital Multimeter should be used because the normal “Ohms Function” on a digital multimeter does not produce enough voltage to properly test a diode. 1. Reverse Bias – Diode blocks – meter will read (Open Circuit). 2. Forward bias – Diode conducts – meter will read 0.05VDC – 0.8VDC. 3. Incorrect readings: If the diode reads 0 in both directions, it is shorted. If the diode reads (Open Circuit) in both directions. Replace the defective diode.

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SYMPTOM

1. No automatic engine start/stop.

2. No automatic generator synchronizing.

PROBLEM 10: PROGRAMMABLE LOGIC CONTROL SYSTEM (RTU)

3. Breakers cannot be manually closed.

4. Generator operates in speed droop instead of isochronous.

COMPONENTS AFFECTED

• • • • • • • • • • • • • • • •

RTU DIM1 DIM2 DIM3 DOM1 DOM2 PCM CCM P15 SMS MSES BSS GMS FSS AVRS USS

TEST PROCEDURES 1. No automatic engine start/stop: See FO-11 for reference. (a) Check engine 1, check DOM1, Out-2 status LED. (b) If the status LED is on, check for 24VDC at ARR1 terminal A1. (c) If there is no voltage at ARR1-A1, check for 24VDC at DOM1-17. (d) If 24VDC is absent, check the wiring to the terminal. (e) If 24VDC is present, go to Sixnet, VersaTRAK Manual, Section 10 and Sixnet, SIXTRAK manual, Section 9 for reference. 2. No automatic generator synchronizing: See FO-11 for reference. (a) Check SPMA-A, check the DOM1 Out - 3 status LED. (b) If the status LED is on, check for 24VDC at ASR1 terminal A1. (c) If there is no voltage at ASR1-A1, check for 24VDC at DOM1 - 17. (d) If 24VDC is absent, check the wiring to the terminal. (e) If 24VDC is present, go to Sixnet, VersaTRAK Manual, Section 10 and Sixnet, SIXTRAK manual, Section 9 for reference. 3. Breakers cannot be manually closed: See FO-23 for reference. (a) Check the “Uplink Port” LEDs on the RTU. Both should be flashing. This indicates the RTU is communicating with the PCM. (b) Check the display on the CCM for “E00” and for 3 small intermittently blinking LEDs. This indicates that the PCM is communicating with the CCM and the CCM is communicating with the GSC+ modules. (c) Check SPR5 status LED and DOM1-16 LED is on. This indicates that power is being sent to the PCM. (d) Check for 24VDC at P15 “INPUT + - “ terminals and for 15VDC at “OUTPUT + - “ terminals. This indicates that power is available for the PCM. See FO-22 for reference. (e) Check status of 52T1. See FO-22 for reference. (f) There will only be a light when synchronizing on to the bus. If the status LED is on, check DOM1-6 status LED. See FO-22 for reference. (g) If both above are on go to Sixnet, VersaTRAK Manual, Section 10 and Sixnet, SIXTRAK manual, Section 9 for reference. 4. Generator operates in speed droop instead of isochronous: (a) Check GDR1 status LED and DOM1-12 LED are off, this indicates that the control system is not in speed droop. See FO-22 for reference. (b) If the status LED is on, check position of GMS not in UTILITY PARALLEL. (c) With the generator breaker closed, check continuity between LSM terminals 13 & 14. An open connection indicates that the generator is operating in speed droop. (d) Check circuit wiring for improper connections. (e) Check operation of relay 52CL1.

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TROUBLESHOOTING THE FUEL PRIMER PUMP

All Safety Warnings and Cautions in Section 7.1 apply to this section. To troubleshoot the Fuel Primer Pump, perform the following: a. Attempt to prime the fuel system according to Section 11.4.4. b. If the procedure does not work, replace the Fuel Primer Pump.

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COOLING SYSTEM TROUBLE SHOOTING PROCEDURES

All Safety Warnings and Cautions in Section 7.1 apply to this table. a. There are three basic problems typical of cooling systems: •

Overheating

•

Loss of coolant

•

Overcooling

b. A problem in the cooling system should first be diagnosed by visual inspection. If the problem cannot be diagnosed, tools must be used to find the cause of the problem. TABLE 7.3.5-1 COOLANT SYSTEM TROUBLESHOOTING PROCEDURES PROBLEM

POSSIBLE CAUSES •

Internal leaks caused by cracked cylinder head, cracked cylinder block, loose cylinder heads, damaged radiator

PROBLEM 1:

core, and damaged gaskets.

LOW COOLANT LEVEL

PROBLEM 2: REDUCED AIR FLOW THROUGH RADIATOR

NOTE 1: NOTE 2:

External leaks caused by loose connections, expansion tank cap or cooling system relief valve with defects.

•

See Note 1 and Note 2.

•

Plugged radiator core.

•

Damaged or bent radiator fins.

•

Fan is damaged or installed backwards.

•

Damaged fan shroud, wrong diameter fan or incorrect number of fan blades.

•

Incorrect fan blade position (Fan projection out of the shroud must be approximately 50%).

•

See Note 1 and Note 2.

Refer to Section 13.3.4 for additional information. Refer to SENR1067-02 or later version, SMCS CODE: 1350-040 for additional reference.

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POSSIBLE CAUSES

PROBLEM 3:

•

Defective expansion tank cap.

INSUFFICIENT COOLING SYSTEM

•

Detective radiator top tank neck or stud.

PRESSURE

•

See Note 1 and Note 2.

•

Air in cooling system because of incorrect cooling system fill.

•

Combustion gases in cooling system from loose cylinder head, cracked cylinder head, loose or defective precombustion chamber, defective cylinder head gasket, worn cylinder liner counter bore.

PROBLEM 4: •

Low coolant level.

•

Steam in cooling system because of engine or low coolant level.

•

See Note 1 and Note 2.

•

Stuck water temperature regulator(s).

•

Absence of water temperature regulator(s).

•

Lose water pump impeller.

•

Internal radiator plugged.

•

See Note 1 and Note 2.

•

High ambient air temperature.

•

Plugged openings in screens for engine compartment with a blower fan.

PROBLEM 6:

•

Disconnected inlet air pipe in engine room.

HIGH INLET AIR TEMPERATURE OR

•

Dirty after-cooler core.

RESTRICTION

•

Plugged air cleaner.

•

Damaged or carbon packed turbocharger.

•

See Note 1 and Note 2.

COOLANT OVERFLOW

PROBLEM 5: INSUFFICIENT COOLANT FLOW

NOTE 1: NOTE 2:

Refer to Section 13.3.4 for additional information. Refer to SENR1067-02 or later version, SMCS CODE: 1350-040 for additional reference.

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PROBLEM 8: EXHAUST RESTRICTION

NOTE 1: NOTE 2:

POSSIBLE CAUSES •

Insufficient flow through coolant radiator.

•

Scale on cylinder liners or cylinder head.

•

See Note 1 and Note 2.

•

Damaged turbocharger.

•

Restriction in exhaust pipes.

•

Water in muffler.

•

Loose baffle in muffler.

•

See Note 1 and Note 2.

Refer to Section 13.3.4 for additional information. Refer to SENR1067-02 or later version, SMCS CODE: 1350-040 for additional reference.

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RUNNING GEAR/TRAILER TROUBLESHOOTING PROCEDURES

7.3.6.1

MEP-PU-810A RUNNING GEAR/TRAILER TROUBLESHOOTING PROCEDURES

All Safety Warnings and Cautions in Section 7.1 apply to this table. TABLE 7.3.6.1-1

MEP-PU-810A RUNNING GEAR/TRAILER TROUBLESHOOTING PROCEDURES

SYMPTOM PROBLEM 1: NO BRAKES

PROBLEM 2: WEAK BRAKES

CAUSE

REMEDIES

1.

Broken or Kinked Brake Lines

•

Repair or Replace

2.

Severe Under-adjustment

•

Adjust Brakes

3.

Malfunctioning Actuation System

•

Troubleshoot System

1.

Brake Adjustment Not Correct

•

Manual - Adjust Brakes; Automatic - Make Several Reverse Stops

2.

Excessively Worn Brake Linings

•

Replace Shoe & Lining

3.

Incorrect Lining

•

Install Correct Shoe & Lining

4.

Grease or Fluid Soaked Lining

•

Repair Grease Seal or Wheel Cylinder. Install New Shoe and Lining

5.

Frozen Master Cylinder or Wheel Cylinder Pistons

•

Recondition or Replace All Cylinders, Brake Fluid

6.

Glazed Lining

•

Refurbish or Replace

7.

Excessive Drum Wear

•

Replace

8.

Trapped Air in Lines

•

Bleed System

9.

Malfunctioning Actuating System

•

Troubleshoot System

PROBLEM 3:

1.

Brake Adjustment Not Correct

•

Manual - Adjust Brakes; Automatic - Make Several Reverse Stops

HARSH BRAKES

2.

Grease or Fluid on Linings

•

Replace Shoe & Lining

NOTE: Refer to Section 18.3.1 for reference.

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MEP-PU-810A RUNNING GEAR/TRAILER TROUBLESHOOTING PROCEDURES (CONTINUED)

SYMPTOM

CAUSE

REMEDIES

PROBLEM 4:

1.

Grease or Oil on Linings

•

Clean or Replace

SURGING BRAKES

2.

Out of Round Drums or Cracked Drums

•

Machine or Replace

1.

Under-adjustment

•

Adjust

PROBLEM 5:

2.

Lack of Lubrication

•

Lubricate

NOISY BRAKES

3.

Broken Brake Components

•

Replace Components

4.

Incorrect Brake Components

•

Correct

1.

Loose, Bent or Broken Brake Components

•

Replace Components

2.

Under-adjustment

•

Adjust

3.

Out of Round Drums

•

Machine or Replace

1.

Incorrect Tire Pressure

•

Inflate Evenly on Both Sides to Req. Pressures

2.

Unmatched Tires on Same Axle

•

Match Tires on Axles

PROBLEM 7:

3.

Restricted Brake Lines or Hoses

•

Repair or Replace

PULLS TO ONE SIDE

4.

Malfunctioning Cylinder Assembly

•

Check for Stuck or Sluggish Pistons

5.

Defective or Damaged Shoe and Lining

•

Install New Shoe and Lining-Complete Axle

6.

One Side Out-of-Adjustment

•

Adjust

1.

Improper Fluid

•

Replace Rubber Parts, Fill with DOT4 Fluid

PROBLEM 6: LOCKING BRAKES

PROBLEM 8:

2.

Blocked Master Cylinder

•

Open with Compressed Air or Replace Cylinder

DRAGGING

3.

Parking Brake Set or Frozen

•

Free Brake and Lubricate

4.

Improper Lining Thickness or Location

•

Install New Shoes and Linings

NOTE: Refer to Section 18.3.1 for reference.

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MEP-PU-810B RUNNING GEAR/TRAILER TROUBLESHOOTING PROCEDURES

All Safety Warnings and Cautions in Section 7.1 apply to this section. 7.3.6.2.1

TROUBLESHOOTING THE ABS SYSTEM

In-Service ABS Dynamic Check:

(DO NOT use a battery charger)

To check the operation of the entire ABS system, hook a tractor to the trailer and charge the trailers air tank. Ensure that the petcock is closed (Figure 18.3.2.2-1). Turn on the ignition key and ensure that the warning light (Figure 18.2.1.2.5-3) comes on briefly, and then goes out. Pull the trailer at a speed above 6 mph and make a brake application until the tractor-trailer has come to a complete stop. Verify that the ABS light has remained OFF. If the light remains OFF, the system is functioning properly. If the ABS system detected an error during the stop, the warning light will be ON. If the light never comes on, then refer to the Troubleshooting Information – “No ABS Warning Light illumination”. If the light stays ON with the ignition key ON, refer to the Troubleshooting Information – “ABS light stays ON when there is Power to the ABS System”. NOTE 1:

Disconnect power from the ABS system before testing continuity for opens or shorts, or making any repairs.

NOTE 2:

Most ABS problems are related to: • Cut, corroded, or abraded wires. • Corroded connectors and terminals, • Connector terminals not latched or seated correctly to mating assemblies. • Excessive sensor air gap, sensor clip retention, or bearing endplay.

NOTE 3:

Refer to Foldout FO-55 and FO-56 for a complete wiring diagram of the ABS system

Before Getting Started: This guide lists the most typical problems only. Consult Radian Inc for anything not addressed here. •

Power is required at Stop light circuit, pin 4, and air is needed to both the supply and service glad hands.

•

Do NOT use a battery charger- to power the ABS.

•

A Volt/Ohm Meter is needed for some of the troubleshooting procedures.

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•

Before disconnecting anything, remove electrical power and air pressure from the system.

•

The numbers in parentheses ( ) refer to the callouts in the wiring layout shown in Figure 18.2.1.2.5-1.

Start Here: All Safety Warnings and Cautions in Section 7.1 apply to this table. Don't overlook the obvious. Check to make sure that you have power and that everything is connected properly. TABLE 7.3.6.2.1-1

TROUBLESHOOTING THE ABS SYSTEM REMEDY

SYMPTOM a. b.

PROBLEM 1: NO ABS WARNING LIGHT ILLUMINATION

c. d. e. f. g.

Check the bulb to verify that it is functional. If not functional, replace it. Verify that there is power to the ECU. Disconnect the main wire harness 19 pin connector and check for B+ (positive power) at either pin #3 or pin #1. The voltage drop between the SAE. J560-7 way and the ECU should not exceed 2 volts. If no power exists at either pin, then check continuity between these pins and the SAE J560-7 way connector red and blue circuits. Make necessary repairs and retest. If the problem is still present, remove the main wire harness 19 pin connector at the ECU and verify continuity between pin #10 and the light. The remaining light wire must be grounded to the trailer chassis or connected to the SAE J560-7 way connector ground wire. Check for continuity between the light wire and ground. Repair as necessary and retest. Listen for 2 clicks when reconnecting the main wire harness to the ECU and secure the connection with the attached metal latch. ABS brakes only work when connected to a 12VDC system.

NOTE: Refer to Section 18.2.1.2.5 and 18.3.2 for additional information.

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TROUBLESHOOTING THE ABS SYSTEM (CONTINUED) REMEDY

SYMPTOM

PROBLEM 2: ABS LIGHT COMES ON AND GOES OFF

a. b. c. d. e.

While the trailer is sitting still only, there is also a valve blow down (air exhausts from ABS relay valve). This is normal and indicates that the ABS system is Ok. The ABS light will come on and go off. The valve blow down is an audio check of the solenoids (located on the top of the ABS relay valve). If the ABS is powered up when traveling above 6 mph, the ABS light will stay off unless there is a fault.

a.

This troubleshooting procedure requires that electrical power be connected, Refer to FO-51, for the following steps: • Older tractors power ABS through the stop light circuit and the ABS light will come on when the brakes are applied. Verity that there is adequate power at the trailer 7-way, pin 4 (1). • There should be 12-14VDC for test purposes. • If there is no power then the tractor wiring or coiled power cable needs repaired. • If there is power at the 7-way, check for 10-14VDC at the power cord connector (2). • If no power exists, then the trailer ABS power cord needs repair. • Most trailers have Integral ABS power in the main trailer wiring. • Check the bulb to verity that it is functional. If not functional, replace it. • Disconnect the ABS wire harness at the power Cord (2). Check for continuity through the light wiring (3). The resistance should be 3-6 Ohms. If this is not the case, then the light wiring needs to be repaired. • Check connections for excessive pin spread and/or corrosion. If the problem remains, disconnect the ABS ECU connector (4). • Check for bent pins, repair and test. • Test for continuity between pins in the valve connector and ABS ECU connector a multimeter. • See FO-51 for pin assignments. • Replace harness if bad, and ECU if problem continues to exist (5).

PROBLEM 3: ABS LIGHT NEVER COMES ON OR IS VERY DIM b.

NOTE: Refer to Section 18.2.1.2.5 and 18.3.2 for additional information.

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TROUBLESHOOTING THE ABS SYSTEM (CONTINUED) REMEDY

SYMPTOM a.

This troubleshooting procedure requires that power be applied to the trailer for 30 seconds/off to verity. The ABS is powered through the auxiliary circuit whenever the key is in the “on" position and the stop light circuit with the brakes applied.

NOTE: b. c.

PROBLEM 4: ABS LIGHT STAYS ON WHEN THERE IS POWER TO THE ABS SYSTEM

d. e. f. g.

NOTE:

For some sensor faults the trailer must be driven above 6 mph for the light to go off.

Verify the voltage at the 7-way (pin #4) is 12-14 volts and that a valve blow down occurs when powering the ABS. If there is no blow down, then verify that air pressure was applied to the service brakes. If there is air pressure to the service bakes, then disconnect the solenoid connector (6) and check the resistance at the solenoid pins: • Readings across the two bottom pins should be 7-9 Ohms. • Readings between either the bottom pin and the top pin should be 3.5-4.5 Ohms. • If resistance is okay, then check the female pins in the connector for excessive pin spread and/or corrosion. • Repair and test. If there is a valve blow down, then a sensor is the most likely issue. The sensor gap could be too large. Try pushing the sensors in until they touch the exciter (7). If the problem remains, disconnect the sensor connectors from the sensors and measure the resistance between the two pins in the sensor connector housing (8). The reading for each sensor should be between 980 and 2350 Ohms. Check for pin spread and/or corrosion also. The sensor should be replaced, if an issue is found. Measure the AC voltage at each sensor while rotating the wheel at a rate of 1 revolution every two seconds. The reading should average greater than .200 Volts. If this is not the case, replace the sensor. If the problem persists, disconnect the ECU connector (4). • Check for bent pins. • Repair and retest. • Test for continuity between pins in the valve connector and ABS ECU connector a multimeter. • See FO-51 for pin assignments. • Replace harness if bad, and ECU if problem continues to exist (5).

Refer to Section 18.2.1.2.5 and 18.3.2 for additional information.

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TROUBLESHOOTING THE ABS SYSTEM (CONTINUED) REMEDY

SYMPTOM a. b. c.

PROBLEM 5: ABS WARNING LIGHT ONLY COMES ON SOMETIMES

d. e.

a.

PROBLEM 6: ABS WARNING LIGHT COMES ON WHEN POWERED UP, GOES OFF

b.

ABOVE 6 MPH, BUT WHEELS LOCK UP c.

NOTE:

Intermittent problems are the most difficult to diagnose. The best place to start is at the speed sensors: • Sensor gap could be too large. • Try pushing in the sensors until they touch the exciter. Next, check for loose sensor and excess wheel endplay: • The sensor should fit tight in its mounting. • If the sensor feels loose, replace the sensor clip. • If wheel-bearing endplay is excessive, or if the wheel bearing is worn, the sensor can produce an intermittent signal and cause a fault. • Repair as needed and retest. Another possible cause is a damaged exciter ring. • Inspect the exciter ring teeth closely. • If any damage is found, replace the exciter. If no problem is found, then the rest of the electrical system needs to be inspected. • The most common cause of ABS faults involves wires and connectors. • This can include connectors not latched properly, bad splices, abrasions, spread or bent pins, pin corrosion, and wire strand breaks. • Check for these conditions at each connection. • Inspect all splices for tightness and damage. • Repair or replace as required. A dragging service or parking break, a pinched or kinked delivery hose can all cause wheel lock. A perfectly functioning ABS system may not be able to overcome these problems. • Examine hoses and breaks for these conditions. • Replace, repair, or adjust any defective hardware and retest. If both sensors have excessive gap or if both exciters are missing, the ABS system will always assume that the vehicle is sitting still. There will be no indication of a fault. In this case, the ABS system cannot respond to a locked wheel condition. • Reseat the sensors until they touch the exciter. • Inspect for missing exciters. If the problem still exists, contact Radian Inc.

Refer to Section 18.2.1.2.5 and 18.3.2 for additional information.

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MEP-PU-810A RUNNING GEAR/TRAILER TROUBLESHOOTING PROCEDURES

All Safety Warnings and Cautions in Section 7.1 apply to this table. TABLE 7.3.6.2.2-1

MEP-PU-810B RUNNING GEAR/TRAILER TROUBLESHOOTING PROCEDURES

SYMPTOM PROBLEM 1: NO BRAKES

PROBLEM 2: WEAK BRAKES

PROBLEM 3: HARSH BRAKES

NOTE:

CAUSE

REMEDIES

1. Broken or Kinked Brake Lines 2. Severe Under-adjustment 3. Malfunctioning Actuation System

• • •

Repair or Replace Adjust Brakes Troubleshoot System

1. 2. 3. 4. 5. 6. 7. 8. 9.

• • • • • • • • •

Manually - Adjust Brakes; Automatic - Make Several Reverse Stops Replace Shoe & Lining Install Correct Shoe & Lining Repair Grease Seal or Wheel Cylinder. Install New Shoe and Lining Recondition or Replace All Cylinders, Brake Fluid Refurbish or Replace Replace Bleed System Troubleshoot System

• •

Manually - Adjust Brakes; Automatic - Make Several Reverse Stops Replace Shoe & Lining

Brake Adjustment Not Correct Excessively Worn Brake Linings Incorrect Lining Grease or Fluid Soaked Lining Frozen Master Cylinder or Wheel Cylinder Pistons Glazed Lining Excessive Drum Wear Trapped Air in Lines Malfunctioning Actuating System

1. Brake Adjustment Not Correct 2. Grease or Fluid on Linings

Refer to Section 18.2.1.2.5 and 18.3.2 for additional information.

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MEP-PU-810B RUNNING GEAR/TRAILER TROUBLESHOOTING PROCEDURES (CONTINUED)

SYMPTOM PROBLEM 4: SURGING BRAKES

PROBLEM 5: NOISY BRAKES

PROBLEM 6: LOCKING BRAKES

PROBLEM 7: PULLS TO ONE SIDE

PROBLEM 8: DRAGGING

NOTE:

CAUSE

REMEDIES

1. Grease or Oil on Linings 2. Out of Round Drums or Cracked Drums

• •

Clean or Replace Machine or Replace

1. 2. 3. 4.

Under-adjustment Lack of Lubrication Broken Brake Components Incorrect Brake Components

• • • •

Adjust Lubricate Replace Components Correct

1. 2. 3. 4.

Loose, Bent or Broken Brake Components Under-adjustment Out of Round Drums Insufficient Air Pressure to release brakes

• • • • •

Replace Components Adjust Machine or replace Check air lines for leaks Check towing vehicle for proper air pressure

1. 2. 3. 4. 5. 6.

Incorrect Tire Pressure Unmatched Tires on Same Axle Restricted Brake Lines or Air Hoses Malfunctioning Cylinder Assembly Defective or Damaged Shoe and Lining One Side Out-of-Adjustment

• • • • • •

Inflate tires to proper pressure Match tires on axles Repair or replace Check for stuck or sluggish pistons Install new shoes and linings for the axle Adjust

1. 2. 3. 4.

Improper Fluid Blocked Master Cylinder Parking Brake Set or Frozen Improper Lining Thickness or Location

• • • •

Replace rubber parts, fill with DOT4 Fluid Open with compressed air or replace cylinder Free brake and lubricate Install new shoes and linings

Refer to Section 18.2.1.2.5 and 18.3.2 for additional information.

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HYDRAULIC SYSTEM TROUBLESHOOTING PROCEDURES

All Safety Warnings and Cautions in Section 7.1 apply to this table. TABLE 7.3.7-1

HYDRAULIC SYSTEM TROUBLESHOOTING PROCEDURES REMEDY

SYMPTOM a.

Ensure hydraulic fluid level is correct and that the pump is not cavitating. Refer to Section 19.3 for additional information.

b.

If all fan motors are turning slowly, you should ensure that the engine is turning at the correct RPM. The pumps and motors are all the same displacement, therefore, motor speed is directly proportional the engine speed: • At 60 Hz, the fan RPM should be 1750 RPM or greater. • At 50 Hz, the fan RPM should be 1650 RPM or greater.

c.

Next, check the Pressure Relief Valves. They are preset at the factory and cannot be changed. Refer to Section 19.4.1 for reference.

d.

If the problem still persists, then the pump should be tested for volumetric efficiency and repaired or replaced as necessary. Refer to Section 19.4.2.1 for additional information.

e.

If problem still persists, then the motor or motor(s) should be repaired or replaced. Refer to Section 19.4.2.1 for additional information.

f.

Check hydraulic fluid temperature, ensure the hydraulic fluid being used is within the proper temperature range for the location.

SLOW FAN SPEED

NOTE:

NOTE:

If fans do not spin at all, then the suction line shutoff valves may be closed or oil level may be too low.

Refer to Section 19.2 and 18.3.2 for additional information.

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CHAPTER 8 HOUSING ASSEMBLY REPAIR TABLE OF CONTENTS SECTION

TITLE

PAGE

8.0

REPAIR OF HOUSING ASSEMBLY

5

8.1

SAFETY PROCEDURES

5

8.2

BRIEF DESCRIPTION

7

8.3

SERVICE REQUIREMENTS

7

8.3.1

INSPECT POWER UNIT HOUSING

7

8.3.2

CLEAN POWER UNIT HOUSING

8

8.4

COMPONENT REPAIR PROCEDURES

8

8.4.1

ACCESS DOORS AND FRONT SIDE PANELS

8

8.4.1.1

INSPECT THE ACCESS DOORS AND FRONT SIDE PANELS

10

8.4.1.2

REMOVE THE ACCESS DOORS AND FRONT SIDE PANELS

10

8.4.1.3

INSTALL THE ACCESS DOORS AND FRONT SIDE PANELS

11

8.4.1.4

SERVICE THE ACCESS DOORS AND FRONT SIDE PANELS

11

8.4.1.5

REPAIR THE ACCESS DOORS AND FRONT SIDE PANELS

11

8.4.2

PLENUM ASSEMBLY SCREENS

12

8.4.2.1

INSPECT THE PLENUM ASSEMBLY SCREENS

13

8.4.2.2

REMOVE THE PLENUM ASSEMBLY SCREENS

14

8.4.2.3

INSTALL THE PLENUM ASSEMBLY SCREENS

14

8.4.2.4

SERVICE THE PLENUM ASSEMBLY SCREENS

15

8.4.2.5

REPAIR THE PLENUM ASSEMBLY SCREENS

15

8.4.3

SIDE PANELS

16

8.4.3.1

INSPECT THE SIDE PANELS

17

8.4.3.2

REMOVE THE SIDE PANELS

17

8.4.3.3

INSTALL THE SIDE PANELS

17

8-1

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8.4.3.4

SERVICE THE SIDE PANELS

18

8.4.3.5

REPAIR THE SIDE PANELS

18

8.4.4

“A” AND “B” MODEL TOP PANEL ASSEMBLY

19

8.4.4.1

INSPECT THE “A” AND “B” MODEL TOP PANEL ASSEMBLY

20

8.4.4.2

REMOVE THE “A” AND “B” MODEL TOP PANEL ASSEMBLY

20

8.4.4.2.1

REMOVE THE REAR ROOF PANEL SECTION

20

8.4.4.2.2

REMOVE THE FRONT ROOF PANEL SECTION

21

8.4.4.3

INSTALL THE “A” AND “B” MODEL TOP PANEL ASSEMBLY

21

8.4.4.3.1

INSTALL THE REAR ROOF PANEL SECTION

21

8.4.4.3.2

INSTALL THE FRONT ROOF PANEL SECTION

22

8.4.4.4

SERVICE THE TOP PANEL ASSEMBLY

23

8.4.4.5

REPAIR THE TOP PANEL ASSEMBLY

23

8.4.5

BATTERY BOX ASSEMBLY

24

8.4.5.1

INSPECT THE BATTERY BOX ASSEMBLY

26

8.4.5.2

REMOVE THE BATTERY BOX ASSEMBLY

26

8.4.5.3

INSTALL THE BATTERY BOX ASSEMBLY

27

8.4.5.4

SERVICE THE BATTERY BOX ASSEMBLY

28

8.4.5.5

REPAIR THE BATTERY BOX ASSEMBLY

28

8.4.6

FUEL TANK AND HYDRAULIC RESERVOIR ASSEMBLIES

29

8.4.6.1

INSPECT THE FUEL TANK AND HYDRAULIC RESERVOIR ASSEMBLIES

29

8.4.6.2

REMOVE THE FUEL TANK AND HYDRAULIC RESERVOIR ASSEMBLIES

30

8.4.6.2.1

REMOVE THE FUEL TANK

32

8.4.6.2.2

REMOVE THE HYDRAULIC RESERVOIR

34

8.4.6.3

INSTALL THE FUEL TANK AND HYDRAULIC RESERVOIR ASSEMBLIES

36

8.4.6.3.1

INSTALL THE FUEL TANK

36

8.4.6.3.2

INSTALL THE HYDRAULIC RESERVOIR

37

8.4.6.3

SERVICE THE FUEL TANK AND HYDRAULIC RESERVOIR ASSEMBLIES

39

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8.4.6.4

REPAIR THE FUEL TANK AND HYDRAULIC RESERVOIR ASSEMBLIES

39

8.4.7

MUFFLER ASSEMBLY

40

8.4.7.1

INSPECT THE MUFFLER ASSEMBLY

40

8.4.7.2

REMOVE THE MUFFLER ASSEMBLY

41

8.4.7.3

INSTALL THE MUFFLER ASSEMBLY

41

8.4.7.4

SERVICE THE MUFFLER ASSEMBLY

42

8.4.7.5

REPAIR THE MUFFLER ASSEMBLY

42

8-3

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254

LIST OF FIGURES FIGURE

TITLE

PAGE

FIGURE 8.4.1-1

MEP-PU-810, ACCESS DOORS AND FRONT SIDE PANELS

9

FIGURE 8.4.2-1

MEP-PU-810 A & B, TOP PLENUM SCREENS

12

FIGURE 8.4.2.1-1

MEP-PU-810 A & B, BOTTOM PLENUM SCREENS

13

FIGURE 8.4.3-1

MEP-PU-810 SIDE PANELS

16

FIGURE 8.4.4-1

“A” MODEL TOP PANEL ASSEMBLY

19

FIGURE 8.4.5-1

BATTERY BOX ASSEMBLY

24

FIGURE 8.4.5-2

BATTERY BOX ASSEMBLY (SIDE VIEW)

25

FIGURE 8.4.5-3

BATTERY BOX ASSEMBLY (TOP VIEW)

25

FIGURE 8.4.6-1

REMOVABLE TANK ASSEMBLIES

29

FIGURE 8.4.6.2-1

EXTERNAL FUEL DISTRIBUTION MANIFOLD, SHUTOFF VALVE

30

FIGURE 8.4.6.2-2

FUEL TANK SUPPLY, SHUTOFF VALVE

30

FIGURE 8.4.6.2-3

EXTERIOR FUEL PUMP ASSEMBLY (NEW AND OLD)

31

FIGURE 8.4.6.2.2-1

HYDRAULIC RESERVOIR SUPPLY, SHUTOFF VALVE

34

FIGURE 8.4.7-1

MUFFLER ASSEMBLY

40

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REPAIR OF HOUSING ASSEMBLY

The following areas are covered in this Chapter: •

Safety

•

Brief Description

•

Service Requirements

•

Component Repair Procedures

8.1

SAFETY PROCEDURES a. Safety precautions must be observed while any maintenance is being performed. Safety precautions must be observed to ensure that the operator/technician cannot have contact with the following: • • • • • • •

Hot engine parts Hot engine fluids Medium Voltage AC electricity Low Voltage AC electricity Low Voltage DC electricity Rotating Parts High noise levels

b. Minor troubleshooting can be performed while both engines are running as long as safety precautions are taken. c.

Minor maintenance can be performed while one generator set is running and the other generator set has been shutdown. Some examples of this maintenance are: Lubrication System – Oil and Filter Change. Hydraulic System – Oil and Filter Change. Fuel System – Primary and Secondary Filter Change. Coolant System – Coolant Change. Minor Troubleshooting. Check Fluid levels and add required fluids.

• • • • • •

(1) The generator set that has been shut down must be rendered unable to start, and cool enough for the maintenance to be performed. Procedures to render a generator set unable to start are: (a) (b) (c) (d) (e) (f) (g) (h) (i)

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Push to OPEN the Emergency Stop Switch. Place the Engine Control Switch (ECS) in the OFF position. Place a DO NOT OPERATE tag on the generator control panel. Turn the Battery Bank Parallel Switch to the OFF position. De-energize the Battery Charger. Disconnect the negative and positive cables from the Battery Bank for the engine due maintenance. Place a DO NOT OPERATE tag on the Battery Bank. Place the generator Circuit Breaker in the LOCK OUT position.

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Disconnect the 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock the generator set control panel.

The fuel transfer pump electrical power is normally fed directly from the G1 generator set battery bank. If you disconnect the G1 battery bank, the external fuel transfer pump will not function. Place the Fuel Pump Source Switch (FPSS) into the (G1 or G2 position). Place the FPSS in the (G1 or G2) position, for the generator set not receiving maintenance.

NOTE:

d. Major maintenance or service requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14)

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant or utility connection in accordance with Section 5.9.6.15, Unit Isolation Procedure with PSC. (Note 1 and 2.) Isolate the PU from any power plant control system in accordance with Note 3. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels.

NOTE 1:

Also the PU must be completely electrically isolated from the power distribution bus and any other electrical source that can back feed into the PU. All medium voltage cables need to be placed on the standoff insulators by use of hot sticks and other safety gear.

NOTE 2:

A Qualified Electrician needs to ensure load cables are not energized by opening the circuit breaker of the Primary Switching Center (PSC), then disconnect Load Cables (Using the proper safety gear) on the PU and place them on the Parking Stands.

NOTE 3:

When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

8-6

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 8.2

BRIEF DESCRIPTION

The Power Unit Housing is a weather tight enclosure that provides easily removable access panels, doors, and screens for major maintenance, overhaul, and replacement of all major mechanical and electrical components. This includes easy access and removal of the Primary Distribution Center (PDC) and both engine/generator sets. The housing provides ISO container features. Air intake and exhaust openings allow operation with all doors closed. A three-step ladder is provided to assist personnel access to the interior of the MEP-PU 810B model. 8.3

SERVICE REQUIREMENTS

8.3.1

INSPECT POWER UNIT HOUSING WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING ACCESS DOORS AND PANELS ARE HEAVY. USE EXTREME CAUTION WHEN UNBOLTING AND REMOVING. THIS TASK IS A TWO PERSON LIFT. WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.

Inspect the interior and exterior of the Power Unit Housing for the following: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures in paragraph 8.1.d. b. Inspect the interior and exterior of the Power Unit Housing for weather-stripping for cracks, deterioration and signs of water leaks. c.

Inspect the interior and exterior of the Power Unit Housing for housing frame for cracks, dents, corrosion, rust, and deterioration.

d. Inspect the interior and exterior of the Power Unit Housing for hardware for damage, missing components, corrosion and broken locking mechanisms. e. Inspect the Power Unit Housing air cleaner plenum assembly screens and upper and lower plenum screens for debris, mounting and missing hardware.

8-7

f.

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 Inspect the interior and exterior of the Power Unit Housing mounting hardware for corrosion and missing components.

8.3.2

CLEAN POWER UNIT HOUSING WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING ACCESS DOORS AND PANELS ARE HEAVY. USE EXTREME CAUTION WHEN UNBOLTING AND REMOVING. THIS TASK IS A TWO PERSON LIFT. WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.

Clean the interior and exterior of the Power Unit Housing as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures in paragraph 8.1.d. b. Clean the interior and exterior of the Power Unit Housing using stiff brushes, clean cloths, and cleaning detergent. c.

Repaint as necessary.

8.4

COMPONENT REPAIR PROCEDURES

•

Access Doors and Front Side Panels

•

Plenum Assembly Screens

•

Side Panels

•

“A” and “B” Model Top Panels Assembly

•

Battery Box Assembly

•

Fuel Tank and Hydraulic Reservoir Assemblies

•

Muffler Assembly

8.4.1

ACCESS DOORS AND FRONT SIDE PANELS

The following maintenance procedures are provided for the access doors and front side panels.

8-8

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 Inspect Remove Install Service Repair

FIGURE 8.4.1-1

MEP-PU-810, ACCESS DOORS AND FRONT SIDE PANELS

8-9

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 8.4.1.1

INSPECT THE ACCESS DOORS AND FRONT SIDE PANELS

Inspect the Access Doors and Front Side Panels for the following: a. Inspect the Access Doors and Front Side Panels hinges for rust, bends, and ease of operation. b. Inspect the Access Doors and Front Side Panels frames for corrosion, rust, dents, and binding. c.

Inspect the Access Doors and Front Side Panels latches for condition and proper operation.

d. Inspect the Access Doors and Front Side Panels interior door panels for mounting, sharp edges and missing components. e. Inspect the Access Doors and Front Side Panels mounting hardware for missing or damaged components. 8.4.1.2

REMOVE THE ACCESS DOORS AND FRONT SIDE PANELS WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING ACCESS DOORS AND PANELS ARE HEAVY. USE EXTREME CAUTION WHEN UNBOLTING AND REMOVING. THIS TASK IS A TWO PERSON LIFT. WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.

To remove the Access Doors and Front Side Panels, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures in paragraph 8.1.d. b. Remove and retain the mounting hardware that secures the Access Doors and Front Side Panels to the Power Unit. Open the door latch use Figure 8.4.1-1 as reference. c.

Carefully remove the Access Doors and Front Side Panels. Use two people for removal of the Access Doors and Front Side Panels.

d. Store removed items in an area where they will not be damaged.

8-10

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INSTALL THE ACCESS DOORS AND FRONT SIDE PANELS WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING ACCESS DOORS AND PANELS ARE HEAVY. USE EXTREME CAUTION WHEN UNBOLTING AND REMOVING. THIS TASK IS A TWO PERSON LIFT. WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.

To install the Access Doors and Front Side Panels, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures in paragraph 8.1.d. b. Carefully place door or front side panel in place. Use two people for installation of the Access Doors and Front Side Panels. c. 8.4.1.4

Reinstall retained mounting hardware. SERVICE THE ACCESS DOORS AND FRONT SIDE PANELS

Service the removed Access Doors and Front Side Panels by cleaning using stiff brushes, clean cloths, and cleaning detergent. 8.4.1.5

REPAIR THE ACCESS DOORS AND FRONT SIDE PANELS

To repair the removed the Access Doors and Front Side Panels, proceed as follows: a. Straighten bent doors and frames. b. Repaint as required in accordance with MIL-T-7O4.

8-11

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 c.

If locking door latch is damaged, remove latch by removing mounting hardware that secures the latch to the access door. Replace the latch.

d. If sharp areas or burrs are found, use a file to smooth the area and repaint the area. 8.4.2

PLENUM ASSEMBLY SCREENS

The following maintenance procedures are provided for the plenum assembly screens. Inspect Remove Install Service Repair

FIGURE 8.4.2-1

MEP-PU-810 A & B, TOP PLENUM SCREENS

8-12

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 8.4.2.1

INSPECT THE PLENUM ASSEMBLY SCREENS

Inspect the Plenum Assembly Screens for the following: a. Inspect the Plenum Assembly Screens for rust. b. Inspect the Plenum Assembly Screens for bends or distortion. c.

Inspect the Plenum Assembly Screens for missing mounting hardware.

FIGURE 8.4.2.1-1

MEP-PU-810 A & B, BOTTOM PLENUM SCREENS

8-13

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 8.4.2.2

REMOVE THE PLENUM ASSEMBLY SCREENS WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.

To remove the Plenum Assembly Screens, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures in paragraph 8.1.d. b. Remove and retain the mounting hardware that secures the Plenum Assembly Screens to the Power Unit use Figure 8.4.2-1 and Figure 8.4.2.1-1 as reference. c.

8.4.2.3

Carefully lift screens (From on top of Power Unit) or drop plenum screens (From beneath the Power Unit). This task requires two people to lift the Plenum Assembly Screens. INSTALL THE PLENUM ASSEMBLY SCREENS WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.

To install the Plenum Assembly Screens, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures in paragraph 8.1.d.

8-14

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 Use two people for b. Carefully place the Plenum Assembly Screens back into position. installation of the Plenum Assembly Screens; use Figure 8.4.2-1 and Figure 8.4.2.1-1, as references. c. 8.4.2.4

Replace the retained mounting hardware that secures the Plenum Assembly Screens to the PU. SERVICE THE PLENUM ASSEMBLY SCREENS

Service the removed Plenum Assembly Screens by cleaning using stiff brushes, clean cloths, and cleaning detergent. 8.4.2.5

REPAIR THE PLENUM ASSEMBLY SCREENS

To repair the removed Plenum Assembly Screens, proceed as follows: a. Straighten bent or distorted plenum screens. b. Repaint as required .

8-15

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 8.4.3

SIDE PANELS

The following maintenance procedures are provided for the side panels. Inspect Remove Install Service Repair

FIGURE 8.4.3-1

MEP-PU-810 SIDE PANELS

8-16

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 8.4.3.1

INSPECT THE SIDE PANELS

Inspect the Side Panels for the following: a. Inspect the Side Panels for bent or distorted side panels, and ease of fit. b. Inspect the Side Panels for corrosion, rust, dents, and binding. 8.4.3.2

REMOVE THE SIDE PANELS WARNING HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT DURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION AND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN LOAD CABLES ARE HANDLED. WARNING SIDE PANELS ARE HEAVY. USE EXTREME CAUTION WHEN UNBOLTING AND REMOVING. WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.

To remove the side panels, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures in paragraph 8.1.d. b. Remove and retain the mounting hardware that secures the Side Panels to the MEP-PU-810 use Figure 8.4.3-1 for reference. c.

Carefully remove the Side Panel. Use two people for removing the Side Panels.

d. Check gaskets for cracks and deterioration and replace, if necessary, before re-installing the Side Panels. 8.4.3.3

INSTALL THE SIDE PANELS WARNING HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT DURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION AND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN LOAD CABLES ARE HANDLED.

8-17

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 WARNING SIDE PANELS ARE HEAVY. USE EXTREME CAUTION WHEN UNBOLTING AND REMOVING. WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. To install the Side Panels, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures in paragraph 8.1.d. b. Check gaskets for cracks and deterioration and replace, if necessary, before re-installing the Side Panels use Figure 8.4.3-1 for reference. c.

Carefully place the Side Panels back into position. Use two people for installation of the Side Panels.

d. Install the retained mounting hardware that secures the Side Panels to the MEP-PU-810. 8.4.3.4

SERVICE THE SIDE PANELS

Service the Side Panels by cleaning using stiff brushes, clean cloths, and cleaning detergent. 8.4.3.5

REPAIR THE SIDE PANELS

To repair the Side Panels, proceed as follows: a. Straighten bent or distorted Side Panels. b. Repaint as required .

8-18

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 8.4.4 NOTE:

“A” AND “B” MODEL TOP PANEL ASSEMBLY The rear roof section on the “B” model is permanent and cannot be removed.

The following maintenance procedures are provided for the top panel assembly. Inspect Repair Install Service Repair

FIGURE 8.4.4-1

“A” MODEL TOP PANEL ASSEMBLY

8-19

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 8.4.4.1

INSPECT THE “A” AND “B” MODEL TOP PANEL ASSEMBLY

Inspect the Top Panel Assembly for the following: a. Inspect the Top Panel Assembly for bent or damaged top panels, and leakage. b. Inspect the Top Panel Assembly for corrosion, rust, and tightness of mounting hardware. 8.4.4.2

REMOVE THE “A” AND “B” MODEL TOP PANEL ASSEMBLY

8.4.4.2.1

REMOVE THE REAR ROOF PANEL SECTION

NOTE:

The Rear Roof Panel Section on the “B” model is permanently mounted and cannot be removed. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING TOP PANELS ARE HEAVY. USE EXTREME CAUTION WHEN HANDLING. WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.

To remove the Rear Roof Panel Section, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures in paragraph 8.1.d. b. Remove and retain the mounting hardware securing the Muffler to the Rear Roof Panel Section use Figure 8.4.4-1 for reference. c.

Remove and retain the mounting hardware securing the Rear Roof Panel Section to the Power Unit frame from inside the unit.

d. Remove the Muffler Assembly use Section 8.4.7, Muffler Assembly for reference. e. Using a forklift or crane, carefully lift and remove the Rear Roof Panel Section. f.

Clean off sealing compound from Rear Roof Panel Section and Muffler.

8-20

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 8.4.4.2.2

REMOVE THE FRONT ROOF PANEL SECTION WARNING

DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING TOP PANELS ARE HEAVY. USE EXTREME CAUTION WHEN HANDLING. WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. To remove the Front Roof Panel Section, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures in paragraph 8.1.d. b. Remove and retain the mounting hardware securing the Muffler and the Front Roof Panel Section. c.

Remove and retain the mounting hardware securing the Front Top Panel Section to the Power Unit frame from inside the unit.

d. Remove the Muffler Assembly use Section 8.4.7, Muffler Assembly for reference. e. Using a forklift or crane, carefully lift and remove the Front Top Panel Section. f.

Clean off sealing compound from the Front Top Panel Section and Muffler.

8.4.4.3

INSTALL THE “A” AND “B” MODEL TOP PANEL ASSEMBLY

8.4.4.3.1

INSTALL THE REAR ROOF PANEL SECTION WARNING

DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING.

8-21

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 WARNING TOP PANELS ARE HEAVY. USE EXTREME CAUTION WHEN HANDLING. WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. To install the Rear Roof Panel Section, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures in paragraph 8.1.d.. b. Using a forklift or crane, carefully lift and place the top rear panel on the unit. c.

Install the mounting hardware securing the Rear Roof Panel Section to the frame.

d. Install the Muffler Assembly use Section 8.4.7, Muffler Assembly for reference. 8.4.4.3.2

INSTALL THE FRONT ROOF PANEL SECTION WARNING

DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING TOP PANELS ARE HEAVY. USE EXTREME CAUTION WHEN HANDLING. WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. To install the Front Roof Panel Section, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures in paragraph 8.1.d. b. Using a forklift or crane, carefully lift and place the top front panel on the unit. c.

Install retained the mounting hardware securing the Front Roof Panel Section to the frame.

8-22

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 d. Install the Muffler Assembly use Section 8.4.7, Muffler Assembly for reference. 8.4.4.4

SERVICE THE TOP PANEL ASSEMBLY

Service the removed Front Roof Panel Section by cleaning using stiff brushes, clean cloths, and cleaning detergent. 8.4.4.5

REPAIR THE TOP PANEL ASSEMBLY

To repair the removed Front Roof Panel Section, proceed as follows: a. Straighten top panels. b. Repaint as required.

8-23

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 8.4.5

BATTERY BOX ASSEMBLY

The following maintenance procedures are provided for the battery box assembly: Inspect Remove Install Service Repair

FIGURE 8.4.5-1

BATTERY BOX ASSEMBLY

8-24

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254

FIGURE 8.4.5-2

BATTERY BOX ASSEMBLY (SIDE VIEW)

FIGURE 8.4.5-3

BATTERY BOX ASSEMBLY (TOP VIEW)

8-25

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 8.4.5.1

INSPECT THE BATTERY BOX ASSEMBLY

Inspect the Battery Box Assembly for the following: a. Inspect the Battery Box Assembly for corrosion or damage. b. Inspect the Battery Box Assembly for security of attachment. c. 8.4.5.2

Inspect the Battery Box Assembly for missing components or hardware. REMOVE THE BATTERY BOX ASSEMBLY WARNING BATTERY ELECTROLYTE CONTAINS SULFURIC ACID, WHICH CAN CAUSE SEVERE CHEMICAL BURNS. AVOID ALL CONTACT. SKIN AND EYE PROTECTION IS REQUIRED. IN CASE OF CONTACT, IMMEDIATELY FLUSH WITH LARGE AMOUNTS OF CLEAN WATER AND OBTAIN MEDICAL AID. WARNING WHEN DISCONNECTING BATTERY CABLES, ALWAYS DISCONNECT NEGATIVE TERMINAL FIRST. WHEN RECONNECTING. CONNECT POSITIVE TERMINAL FIRST. FAILURE TO COMPLY MAY CAUSE SPARKING AND CONSEQUENT BATTERY EXPLOSION. WARNING HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT DURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION AND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN LOAD CABLES ARE HANDLED. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.

8-26

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 To remove the Battery Box Assembly, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures in paragraph 8.1.d. b. Remove Items 3, 4, 5, and 6, use Figure 8.4.5-1, Figure 8.4.5-2 and Figure 8.4.5-3 for reference. c.

Remove the batteries use Chapter 9.4.1.3. for removal procedures.

d. Remove Items 1, 2, and 7. 8.4.5.3

INSTALL THE BATTERY BOX ASSEMBLY WARNING BATTERY ELECTROLYTE CONTAINS SULFURIC ACID, WHICH CAN CAUSE SEVERE CHEMICAL BURNS. AVOID ALL CONTACT. SKIN AND EYE PROTECTION IS REQUIRED. IN CASE OF CONTACT, IMMEDIATELY FLUSH WITH LARGE AMOUNTS OF CLEAN WATER AND OBTAIN MEDICAL AID. WARNING WHEN DISCONNECTING BATTERY CABLES, ALWAYS DISCONNECT NEGATIVE TERMINAL FIRST. WHEN RECONNECTING. CONNECT POSITIVE TERMINAL FIRST. FAILURE TO COMPLY MAY CAUSE SPARKING AND CONSEQUENT BATTERY EXPLOSION. WARNING HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT DURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION AND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN LOAD CABLES ARE HANDLED. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.

8-27

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 To install the Battery Box Assembly, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures in paragraph 8.1.d. b. Clean mounting points, repainting as necessary, prior to assembly. c.

Reinstall Items 1, 2, and 7, use Figure 8.4.5-1, Figure 8.4.5-2 and Figure 8.4.5-3 for reference.

d. Reinstall the batteries. Use Section 9.4.1.4, for install procedures. e. Reinstall Items 3, 4, 5, and 6. 8.4.5.4

SERVICE THE BATTERY BOX ASSEMBLY

Service the Battery Box Assembly by cleaning using stiff brushes, clean cloths, and cleaning detergent. 8.4.5.5

REPAIR THE BATTERY BOX ASSEMBLY

To repair the Battery Box Assembly, proceed as follows: a. Repair or replace damaged or missing components and hardware. b. Repaint as required.

8-28

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 8.4.6

FUEL TANK AND HYDRAULIC RESERVOIR ASSEMBLIES

The following maintenance procedures are provided for the Fuel Tank and Hydraulic Reservoir Assemblies: Inspect Remove Install Service Repair

FIGURE 8.4.6-1 8.4.6.1

REMOVABLE TANK ASSEMBLIES

INSPECT THE FUEL TANK AND HYDRAULIC RESERVOIR ASSEMBLIES

Inspect the Fuel Tank and Hydraulic Reservoir Assemblies for the following: a. Inspect the Fuel Tank and Hydraulic Reservoir Assemblies for damage and leaks. b. Inspect the Fuel Tank and Hydraulic Reservoir Assemblies for security of attachment. c.

Inspect the Fuel Tank and Hydraulic Reservoir Assemblies for damaged, loose or missing hardware.

8-29

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 8.4.6.2

REMOVE THE FUEL TANK AND HYDRAULIC RESERVOIR ASSEMBLIES

FUEL SHUTOFF VALVE

FIGURE 8.4.6.2-1

EXTERNAL FUEL DISTRIBUTION MANIFOLD, SHUTOFF VALVE

FIGURE 8.4.6.2-2

FUEL TANK SUPPLY, SHUTOFF VALVE

8-30

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254

FIGURE 8.4.6.2-3

EXTERIOR FUEL PUMP ASSEMBLY (NEW AND OLD)

8-31

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 8.4.6.2.1

REMOVE THE FUEL TANK WARNING

BATTERY ELECTROLYTE CONTAINS SULFURIC ACID, WHICH CAN CAUSE SEVERE CHEMICAL BURNS. AVOID ALL CONTACT. SKIN AND EYE PROTECTION IS REQUIRED. IN CASE OF CONTACT, IMMEDIATELY FLUSH WITH LARGE AMOUNTS OF CLEAN WATER AND OBTAIN MEDICAL AID. WARNING WHEN DISCONNECTING BATTERY CABLES, ALWAYS DISCONNECT NEGATIVE TERMINAL FIRST. WHEN RECONNECTING, CONNECT NEGATIVE TERMINAL LAST. FAILURE TO COMPLY MAY CAUSE SPARKING AND CONSEQUENT BATTERY EXPLOSION. WARNING HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT DURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION AND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN LOAD CABLES ARE HANDLED. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. CAUTION CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO LOCAL REGULATIONS AND MANDATES. To remove the Fuel Tank, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures in paragraph 8.1.d.

8-32

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 b. Shut off respective Fuel Shutoff Valve on External Fuel Distribution Manifold use Figure 8.4.6.2-1 for reference. c.

Shut off the Fuel Tank Supply Shutoff Valve use Figure 8.4.6.2-2 for reference.

d. Drain the Fuel Tank into an approved container with a capacity of at least 120 gallons. Loosen and Remove the plug on either side of the bottom of the fuel tank to drain fuel. e. Place drain pan under the External Fuel Manifold Hose connection at the Power Unit. f.

Disconnect the External Fuel Manifold Supply Hose at the Fuel Solenoid Valve Strainer fitting and cap hose, use Figure 8.4.6.2-3 for reference.

g. Place a Cap fitting on Fuel Solenoid Valve Strainer fitting, to prevent contamination. h. Remove the Batteries, use Chapter 9.4.1.3. for removal procedures. i.

Remove the Battery Box Assembly use, Section 8.4.5.2 for reference.

j.

Tag and disconnect the Fuel Transfer Pump wires inside Float Control Box Assembly. Use FO43A, FO-43B, FO-44A, FO-44B and FO-43C for reference.

k.

Tag and disconnect fuel solenoid valve wires inside Float Control Box Assembly.

l.

Tag and disconnect the 6 Deutsch connectors for Fuel Control Box Wiring.

m. Remove and retain conduit nuts and remove conduit fittings from Float Control Box assembly. n

Remove and retain bolts securing Fuel Pump Bracket Assembly to the Fuel Tank and remove the assembly.

o. Remove and retain both Top Plenum Screens per Section 8.4.2. p. Protect and cover both radiator cores to prevent damage. q. Remove and retain bolts, washers and nuts securing both Front Center Covers. r.

Disconnect two Fuel Supply hoses from rear of the fuel tank.

s.

Disconnect two fuel return hoses from rear of the fuel tank.

t.

Support the fuel tank with forklift or crane.

u. Remove and retain the bolts and washers securing the Fuel Tank and remove the Fuel Tank.

8-33

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 8.4.6.2.2

REMOVE THE HYDRAULIC RESERVOIR

FIGURE 8.4.6.2.2-1

HYDRAULIC RESERVOIR SUPPLY, SHUTOFF VALVE

WARNING BATTERY ELECTROLYTE CONTAINS SULFURIC ACID, WHICH CAN CAUSE SEVERE CHEMICAL BURNS. AVOID ALL CONTACT. SKIN AND EYE PROTECTION IS REQUIRED. IN CASE OF CONTACT, IMMEDIATELY FLUSH WITH LARGE AMOUNTS OF CLEAN WATER AND OBTAIN MEDICAL AID. WARNING WHEN DISCONNECTING BATTERY CABLES, ALWAYS DISCONNECT NEGATIVE TERMINAL FIRST. WHEN RECONNECTING, CONNECT NEGATIVE TERMINAL LAST. FAILURE TO COMPLY MAY CAUSE SPARKING AND CONSEQUENT BATTERY EXPLOSION.

8-34

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254

WARNING HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT DURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION AND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN LOAD CABLES ARE HANDLED. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. CAUTION CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO LOCAL REGULATIONS AND MANDATES. To remove the Hydraulic Fluid Reservoir, proceed as follows: NOTE:

The following procedures are for either hydraulic reservoir. Repeat steps for second reservoir if second reservoir removal is required.

a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures in paragraph 8.1.d. b. Remove and retain Top Plenum Screens per Section 8.4.2. c.

Cut the Tie Strap on the Hydraulic Reservoir Supply Shutoff Valve. degrees to close the valve. Use Figure 8.4.6.2.2-1 for reference.

Rotate the handle 90

d. Drain the Hydraulic Fluid Reservoir into approved container(s). Replace plug using threadsealing compound. Dispose of fluid per local facility procedures. Use Figure 8.4.6-1 as a reference. e. Remove and retain the hose clamp securing the Return Hose to access cover. f.

Disconnect the Return Hose at “T” fitting. Cap/plug both ends to prevent dirt from entering.

8-35

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 g. Disconnect the float level wire harness from the rear of tank. h. Disconnect supply hose. Cap/plug both ends to prevent dirt from entering. i.

Disconnect Case Return Hose. Cap/plug both ends to prevent dirt from entering.

j.

Support tank with forklift or crane.

k.

Remove and retain mounting bolts, nuts and washers and remove hydraulic reservoir.

8.4.6.3

INSTALL THE FUEL TANK AND HYDRAULIC RESERVOIR ASSEMBLIES

8.4.6.3.1

INSTALL THE FUEL TANK WARNING

BATTERY ELECTROLYTE CONTAINS SULFURIC ACID, WHICH CAN CAUSE SEVERE CHEMICAL BURNS. AVOID ALL CONTACT. SKIN AND EYE PROTECTION IS REQUIRED. IN CASE OF CONTACT, IMMEDIATELY FLUSH WITH LARGE AMOUNTS OF CLEAN WATER AND OBTAIN MEDICAL AID. WARNING WHEN DISCONNECTING BATTERY CABLES, ALWAYS DISCONNECT NEGATIVE TERMINAL FIRST. WHEN RECONNECTING, CONNECT NEGATIVE TERMINAL LAST. FAILURE TO COMPLY MAY CAUSE SPARKING AND CONSEQUENT BATTERY EXPLOSION. WARNING HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT DURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION AND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN LOAD CABLES ARE HANDLED. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.

8-36

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 To install the fuel tank, proceed as follows: (Use Figure 8.4.6-1 as a reference) a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures in paragraph 8.1.d. b. Using a forklift or crane, carefully raise the fuel tank into place. reference. c.

Use Figure 8.4.6-1 as a

Reinstall with retained bolts, washers, and nuts securing fuel tank.

d. Reinstall two fuel supply hoses from rear of the fuel tank using thread-sealing compound. e. Reinstall two fuel return hoses from rear of the fuel tank using thread-sealing compound. f.

Reinstall Front Center Covers with retained bolts, washers and nuts.

g. Reinstall both Top Plenum Assembly Screens per Section 8.4.2. h. Reinstall Fuel Pump Bracket Assembly to the Fuel Tank with retained bolts and washers. i.

Reinstall the Fuel Transfer Pump and Solenoid Valve conduit and attach to the Float Control Box assembly with conduit nuts. Use FO-43A, FO-43B, FO-44A, FO-44B and FO-43C for reference.

j.

Reinstall Fuel Transfer Pump wires inside the Float Control Box Assembly box and remove tags.

k.

Reinstall the Solenoid Valve wires inside the Float Control Box Assembly box and remove tags.

l.

Reinstall the batteries and Battery Box Assembly per 8.4.5.

m. Remove cap covering the fitting on Fuel Solenoid Valve Strainer fitting. n. Reinstall Fuel Manifold Hose to the Fuel Solenoid Valve Strainer fitting. o. Open respective hand valve on Fuel Distribution Manifold. 8.4.6.3.2

INSTALL THE HYDRAULIC RESERVOIR WARNING

BATTERY ELECTROLYTE CONTAINS SULFURIC ACID, WHICH CAN CAUSE SEVERE CHEMICAL BURNS. AVOID ALL CONTACT. SKIN AND EYE PROTECTION IS REQUIRED. IN CASE OF CONTACT, IMMEDIATELY FLUSH WITH LARGE AMOUNTS OF CLEAN WATER AND OBTAIN MEDICAL AID. WARNING WHEN DISCONNECTING BATTERY CABLES, ALWAYS DISCONNECT NEGATIVE TERMINAL FIRST. WHEN RECONNECTING, CONNECT NEGATIVE TERMINAL LAST. FAILURE TO COMPLY MAY CAUSE SPARKING AND CONSEQUENT BATTERY EXPLOSION.

8-37

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 WARNING HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT DURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION AND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN LOAD CABLES ARE HANDLED. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. To install the Hydraulic Fluid Reservoir, proceed as follow: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures in paragraph 8.1.d. b. Using a forklift or crane, lift hydraulic reservoir into place. Use Figure 8.4.6-1 as a reference. c.

Reinstall the Hydraulic Fluid Reservoir to the Power Unit using retained bolts, nuts and washers.

d. Remove cap/plug and Reinstall Return Hose at “T” fitting. e. Remove cap/plug and Reinstall Case Return Hose. f.

Remove cap/plug and Reinstall Supply Hose.

g. Open hand valve 90 degrees and tie strap open. h. Reinstall the fluid level switch harness. i.

Reinstall the hose at access cover plate.

j.

Refill reservoir with applicable hydraulic fluid.

k.

Reinstall the Top Plenum Assembly Screens per Section 8.4.2.

l.

Operate unit and check for leaks.

8-38

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 8.4.6.3

SERVICE THE FUEL TANK AND HYDRAULIC RESERVOIR ASSEMBLIES

Service the exterior of the Removable Tank Assemblies by cleaning using stiff brushes, clean cloths, and cleaning detergent. 8.4.6.4

REPAIR THE FUEL TANK AND HYDRAULIC RESERVOIR ASSEMBLIES

To repair the Removable Tank Assemblies, proceed as follows: a. Remove large dents as necessary. b. Holes or cracks must be welded and pressure tested. NOTE:

Welding must be done by a certified welder, applying all safety requirements necessary for fuel tank welding.

NOTE:

The interior of the hydraulic reservoir must be maintained in an absolutely clean condition or professionally cleaned to be absolutely clean of contamination.

c.

Repaint the exterior surfaces as required.

8-39

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 8.4.7

MUFFLER ASSEMBLY

The following maintenance procedures are provided for the muffler assembly: Inspect Remove Install Service Repair

FIGURE 8.4.7-1 8.4.7.1

MUFFLER ASSEMBLY

INSPECT THE MUFFLER ASSEMBLY

Inspect the Muffler Assembly for the following conditions: a. Inspect the Muffler Assembly, Rain-caps to ensure they open and close freely. b. Inspect the Muffler Assembly to ensure the Exhaust Wrap is secure and not damaged. c.

Inspect the Muffler Assembly for Exhaust leaks.

d. Inspect the Muffler Assembly for loose and missing hardware.

8-40

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 8.4.7.2

REMOVE THE MUFFLER ASSEMBLY WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING MUFFLER ASSEMBLIES ARE UNBOLTING AND REMOVING.

HEAVY.

USE

EXTREME

CAUTION

WHEN

WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. To remove the Muffler Assembly, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures in paragraph 8.1.d. b. Remove and retain the mounting hardware between the Flex Connector and Muffler. Figure 8.4.7-1 as a reference. c.

Use

Remove the Muffler mounting hardware.

d. Clean all mating surfaces. e. Connect lifting straps to the Muffler and lift the muffler from the PU with a minimum of 1 ton capacity lifting device. f. 8.4.7.3

Remove all old or excess caulk and mastic from the PU. INSTALL THE MUFFLER ASSEMBLY WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING.

8-41

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 WARNING MUFFLER ASSEMBLIES ARE UNBOLTING AND REMOVING.

HEAVY.

USE

EXTREME

CAUTION

WHEN

WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. To install the Muffler Assembly, proceed as follows: a.

This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures in paragraph 8.1.d.

b. Connect lifting straps to the Muffler and lift the Muffler with a minimum of 1-ton capacity lifting device and place the Muffler into position on the Power Unit (Use Figure 8.4.7-1 as a reference). c.

Reinstall the Muffler using Mastic Sealant (CMCO Part# 633270).

d. Reinstall the Muffler mounting hardware. e. Reinstall the gasket and retained mounting hardware between flex connector and muffler. 8.4.7.4

SERVICE THE MUFFLER ASSEMBLY

To service the Muffler Assembly, proceed as follows: Service the exterior of the Muffler Assembly by cleaning using stiff brushes, clean cloths, and detergent. 8.4.7.5

REPAIR THE MUFFLER ASSEMBLY

To repair the Muffler Assembly, proceed as follows: a. Replace missing or damaged hardware. b. Replace missing or damaged rain caps. c.

Holes or cracks must be welded and pressure tested.

d. Repaint muffler exterior as required.

8-42

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254

CHAPTER 9 DIRECT CURRENT (DC) SYSTEM REPAIR TABLE OF CONTENTS SECTION

TITLE

PAGE

9.0

DIRECT CURRENT (DC) SYSTEM REPAIR

6

9.1

SAFETY PROCEDURES

6

9.2

DIRECT CURRENT (DC) SYSTEM DESCRIPTION

8

9.3

SERVICE REQUIREMENTS

8

9.4

COMPONENT REPAIR PROCEDURES

9

9.4.1

BATTERIES

9

9.4.1.1

INSPECT BATTERIES

9

9.4.1.2

TEST BATTERIES

10

9.4.1.3

REMOVE BATTERIES

10

9.4.1.4

INSTALL BATTERIES

11

9.4.1.5

SERVICE BATTERIES

12

9.4.2

BATTERY CABLES

12

9.4.2.1

INSPECT BATTERY CABLES

12

9.4.2.2

TEST BATTERY CABLES

12

9.4.2.3

REMOVE BATTERY CABLES

13

9.4.2.4

INSTALL BATTERY CABLES

13

9.4.2.5

SERVICE BATTERY CABLES

13

9.4.3

BATTERY CHARGER

14

9.4.3.1

INSPECT BATTERY CHARGER

15

9.4.3.2

TEST BATTERY CHARGER

15

9.4.3.3

REMOVE BATTERY CHARGER

16

9.4.3.4

INSTALL BATTERY CHARGER

17

9.4.3.5

SERVICE BATTERY CHARGER

18

9-1

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TABLE OF CONTENTS SECTION

TITLE

PAGE

9.4.4

WIRING HARNESS

18

9.4.4.1

INSPECT WIRING HARNESS

18

9.4.4.2

TEST WIRING HARNESS

19

9.4.4.3

REMOVE WIRING HARNESSES

20

9.4.4.4

INSTALL WIRING HARNESS

20

9.4.4.5

WIRING HARNESSES REPAIR

20

9.4.5

BATTERY BANK DC TIE SWITCH

21

9.4.5.1

INSPECT BATTERY BANK DC TIE SWITCH

22

9.4.5.2

TEST BATTERY BANK DC TIE SWITCH

22

9.4.5.3

REMOVE BATTERY BANK DC TIE SWITCH

24

9.4.5.4

INSTALL BATTERY BANK DC TIE SWITCH

24

9.4.6

STARTER MOTOR AND STARTER SOLENOID

25

9.4.6.1

INSPECT STARTER MOTOR AND STARTER SOLENOID

25

9.4.6.2

TEST STARTER MOTOR AND STARTER SOLENOID

27

9.4.6.3

REMOVE STARTER MOTOR AND STARTER SOLENOID

29

9.4.6.4

INSTALL STARTER MOTOR AND STARTER SOLENOID

31

9.4.6.5

ADJUST STARTER PINION CLEARANCE

34

9.4.7

DC CONTROL POWER CIRCUIT BREAKER (CBCP)

36

9.4.7.1

INSPECT DC CONTROL POWER CIRCUIT BREAKER (CBCP)

36

9.4.7.2

TEST DC CONTROL POWER CIRCUIT BREAKER (CBCP)

37

9.4.7.3

REMOVE DC CONTROL POWER CIRCUIT BREAKER (CBCP)

38

9.4.7.4

INSTALL DC CONTROL POWER CIRCUIT BREAKER (CBCP)

38

9.4.8

DC PANEL LIGHTS AND FAULT INDICATOR LIGHTS

39

9.4.8.1

INSPECT DC PANEL LIGHTS AND FAULT INDICATOR LIGHTS

39

9.4.8.2

TEST DC PANEL LIGHTS AND FAULT INDICATOR LIGHTS

40

9-2

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TABLE OF CONTENTS SECTION

TITLE

PAGE

9.4.8.3

REMOVE DC PANEL LIGHT BULBS AND FAULT INDICATOR LIGHTS

40

9.4.8.4

INSTALL DC PANEL LIGHT BULBS AND FAULT INDICATOR LIGHTS

40

9-3

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LIST OF FIGURES FIGURE

TITLE

PAGE

FIGURE 9.2-1

BATTERY INTERCONNECT DIAGRAM

8

FIGURE 9.4.1-1

BATTERY BOX ASSEMBLY

9

FIGURE 9.4.3-1

BATTERY CHARGER

14

FIGURE 9.4.5-1

SCHEMATIC OF BATTERY BANK DC TIE SWITCH

21

FIGURE 9.4.5-2

BATTERY BANK DC TIE SWITCH

21

FIGURE 9.4.6-1

STARTER MOTOR

25

FIGURE 9.4.6.2-1

STARTER MOTOR

28

FIGURE 9.4.6.4-1

STARTER MOTOR SIDE VIEW

31

FIGURE 9.4.6.4-2

STARTER MOTOR FRONT VIEW

32

FIGURE 9.4.6.4-3

STARTER MOTOR FRONT VIEW

32

FIGURE 9.4.6.5-1

PINION CLEARANCE

34

FIGURE 9.4.6.5-2

PINION ADJUSTMENT

34

FIGURE 9.4.7-1

DC CONTROL POWER CIRCUIT BREAKER (CBCP)

36

FIGURE 9.4.8-1

DC PANEL LIGHTS AND FAULT INDICATOR LIGHTS

39

9-4

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LIST OF TABLES TABLE

TITLE

PAGE

TABLE 9.4.6.4-1

STARTER TORQUE SPECIFICATIONS

9-5

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DIRECT CURRENT (DC) SYSTEM REPAIR

The DC electrical system consists of relays, solenoids, motors, indicators and other components that combine to start, stop control, and monitor the MEP-PU-810. This section contains maintenance procedures for the DC electrical system. Test, adjust, replace and repair components of the DC system in accordance with the following procedures. Maintenance procedures are provided for the following Direct Current (DC) System Components: •

Batteries

•

Battery Cables

•

Battery Charger

•

Wiring Harnesses

•

Battery Bank DC Tie Switch

•

Starter Motor and Starter Solenoid

•

Fuel Transfer Pump

•

DC Control Breaker

•

DC Panel Light Bulbs and Fault Indicator Lights

9.1

SAFETY PROCEDURES a. Safety precautions must be observed while any maintenance is being performed. Safety precautions must be observed to ensure that the operator/technician cannot have contact with the following: • • • • • • •

Hot engine parts Hot engine fluids Medium Voltage AC electricity Low Voltage AC electricity Low Voltage DC electricity Rotating Parts High noise levels

b. Minor troubleshooting can be performed while both engines are running as long as safety precautions are taken. c.

Minor maintenance can be performed while one generator set is running and the other generator set has been shutdown. Some examples of this maintenance are: • • • • • •

Lubrication System – Oil and Filter Change. Hydraulic System – Oil and Filter Change. Fuel System – Primary and Secondary Filter Change. Coolant System – Coolant Change. Minor Troubleshooting. Check Fluid levels and add required fluids.

9-6

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (1) The generator set that has been shut down must be rendered unable to start, and cool enough for the maintenance to be performed. Procedures to render a generator set unable to start are: (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k)

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Push to OPEN the Emergency Stop Switch. Place the Engine Control Switch (ECS) in the OFF position. Place a DO NOT OPERATE tag on the generator control panel. Turn the Battery Bank Parallel Switch to the OFF position. De-energize the Battery Charger. Disconnect the negative and positive cables from the Battery Bank for the engine due maintenance. Place a DO NOT OPERATE tag on the Battery Bank. Place the generator Circuit Breaker in the LOCK OUT position. Disconnect the 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock the generator set control panel.

The fuel transfer pump electrical power is normally fed directly from the G1 generator set battery bank. If you disconnect the G1 battery bank, the external fuel transfer pump will not function. Place the Fuel Pump Source Switch (S2) into the (G1 or G2 position). Place the S2 in the (G1 or G2) position, for the generator set not receiving maintenance.

NOTE:

d. Major maintenance or service requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14)

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant or utility connection in accordance with Section 5.9.6.15, Unit Isolation Procedure with PSC. Note 1 and 2. Isolate the PU from any power plant control system in accordance with Note 3. Pull to open the PU DC Power Control Breaker. Push to OPEN both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels.

NOTE 1:

Also the PU must be completely electrically isolated from the power distribution bus and any other electrical source that can back feed into the PU. All medium voltage cables need to be placed on the standoff insulators by use of hot sticks and other safety gear.

NOTE 2:

Ensure cables are not energized by opening the circuit breaker of the Primary Switching Center (PSC), then disconnect Load Cables (Using the proper safety gear) on the PU and place them on the Parking Stands.

NOTE 3:

When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

9-7

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 9.2

DIRECT CURRENT (DC) SYSTEM DESCRIPTION

CHASSIS GROUND

INTERCONNECT SWITCH

G2A+

20A BATTERY CHARGER DC OUTPUT

20A BATTERY CHARGER DC OUTPUT

G1A+

G1B+ NATO PLUG

CHASSIS GROUND

G2B+

G2-

*

FUEL TRANSFER G1- CONTROL

BATTERIES (2) 8D

+ -

G1-

G2-

-

+

+

-

-

BATTERIES (2) 8D +

*

WHEN MAINTENANCE WILL BE PERFORMED ON GEN-SET REQUIRING BATTERIES TO BE DISCONNECTED, PLACE BATTERY SOURCE SWITCH ON FUEL TRANSFER CONTROL BOX TO POSITION OF OPERATIONAL GEN-SET (G1 OR G2) EACH BATTERY IS 12 VOLT MAINTENANCE FREE 1260 CRANKING AMPS @ 32°F

FIGURE 9.2-1

BATTERY INTERCONNECT DIAGRAM

The DC system has two functions, Starting and Control. Foldouts FO - 7 to FO – 12B are the DC Electrical Schematics for Primary Distribution Center (PDC) control and Engine control systems. 9.3

SERVICE REQUIREMENTS

Service requirements for the DC system: There are no general DC System service requirements. However, each component that requires specific services is listed in the Component Repair Procedures, Section 9.4.

9-8

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 9.4

COMPONENT REPAIR PROCEDURES

9.4.1

BATTERIES

The following maintenance procedures are provided for the batteries: Inspect Test Remove Install Service

FIGURE 9.4.1-1 9.4.1.1

BATTERY BOX ASSEMBLY

INSPECT BATTERIES

Inspect the Batteries for the following: a. Inspect the Batteries for cracks, leaks, or damaged cover. b. Inspect the Batteries to ensure they are Maintenance Free Batteries. c.

Inspect the Battery Cables for corrosion, cracks, or breaks.

d. Inspect the Battery Terminals for corrosion and proper connection of cables. e. Inspect the Battery Box hardware for damage, corrosion, and loose or missing components.

9-9

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 9.4.1.2

TEST BATTERIES

To test the Batteries, proceed as follows: a. The batteries supplied with the PU are maintenance free. Water or electrolyte is not added to the batteries. b. Use the Caterpillar Battery Load Tester, 4C-4911, or equivalent, to test the battery condition. Use the test equipment manufacturers instructions for testing batteries. Refer to Caterpillar manual SEHS9249 for operation of the Caterpillar Operation Manual for the 4C-4911, Battery Load Tester. 9.4.1.3

REMOVE BATTERIES WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING BATTERY ELECTROLYTE CONTAINS SULFURIC ACID, WHICH CAN CAUSE SEVERE CHEMICAL BURNS. AVOID ALL CONTACT. SKIN AND EYE PROTECTION IS REQUIRED. IN CASE OF CONTACT, IMMEDIATELY FLUSH WITH LARGE AMOUNTS OF CLEAN WATER. OBTAIN MEDICAL AID WHEN EYES ARE AFFECTED. WARNING WHEN DISCONNECTING BATTERY CABLES, ALWAYS DISCONNECT NEGATIVE TERMINAL FIRST. WHEN RECONNECTING, CONNECT NEGATIVE TERMINAL LAST. FAILURE TO COMPLY MAY CAUSE SPARKING AND CONSEQUENT BATTERY EXPLOSION. WARNING HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT DURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION AND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN LOAD CABLES ARE HANDLED. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING.

9-10

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 To remove the Batteries, proceed as follows using Figure 9.2-1 as a reference: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. (2) Isolate the PU from any power plant control system in accordance with Note 1. (3) Pull to open the PU DC Power Control Breaker. (4) Push to open both Emergency Stop Switches. (5) Place both Engine Control Switches (ECS) in the OFF position. (6) Place a DO NOT OPERATE tag on both generator control panels. (7) Turn the Battery Bank Parallel Switch to the OFF position. (8) De-energize both Battery Chargers. (9) Disconnect the negative and positive cables from both Battery Banks. (10)Place a DO NOT OPERATE tag on both Battery Banks. (11)Place all Circuit Breakers in the LOCK OUT position. (12)Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. (13)Close and Lock both generator set control panels. NOTE: The fuel transfer pump electrical power is normally fed directly from the G1 generator set battery bank. If you disconnect the G1 battery bank, the external fuel transfer pump will not function. Place the Fuel Pump Source Switch (S2) into the (G1 or G2 position). Place the S2 in the (G1 or G2) position, for the generator set not receiving maintenance. b. Ensure the Battery Bank DC Tie Switch is in the “OFF” position. c.

Disconnect both negative battery cables from the batteries.

d. Remove the jumper cables from both sets of batteries. e. Disconnect both positive battery cables from the batteries. f.

Remove both battery hold down brackets and bolts.

g. Remove batteries carefully using proper lifting technique and/or appropriate material handling equipment. 9.4.1.4

INSTALL BATTERIES

To install Batteries, proceed as follows using FO-37, as a reference: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 9.4.1.3. b. Ensure the Battery Bank DC Tie Switch is in the “OFF” position. c.

Reinstall battery on battery tray carefully using proper lifting technique and/or appropriate material handling equipment.

d. Reinstall battery hold down brackets and bolts. e. Connect both positive battery cables to the batteries.

9-11

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 f.

Reinstall the jumper cables onto both sets of batteries.

g. Connect both negative battery cables to the batteries. 9.4.1.5

SERVICE BATTERIES

Service the Batteries as follows: a. Replace damaged clamps, nuts, lock washers, and hold-down channels. b. If battery terminal corrosion is present, disconnect both negative battery cables, disconnect the cable from corroded terminal, clean terminal with a solution of baking soda and water; then flush with clean water, reconnect to cleaned terminal, reconnect both battery cables. c. 9.4.2

Repaint areas where required. BATTERY CABLES

The following maintenance procedures are provided for the battery cables: Inspect Test Remove Install Service 9.4.2.1

INSPECT BATTERY CABLES

Inspect the Battery Cables as follows (Using FO – 37A and FO – 37B as a reference): a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 9.1.4.3. b. Check the cables for corrosion, insulation breaks, deterioration, or other damage. c. 9.4.2.2

Check the cable connectors for corrosion and security of attachment. TEST BATTERY CABLES

To test the Battery Cables, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 9.1.4.3. b. Ensure the Battery Bank DC Tie Switch is in the “OFF” position. c.

Disconnect both negative battery cables from the batteries.

d. Remove the jumper cables from both sets of batteries.

9-12

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 e. Disconnect both positive battery cables from the batteries. f.

Using a multimeter, set to OHMS (Ω) Rx1 scale, test continuity of each cable.

g. Replace the cable if the reading is above zero ohms. 9.4.2.3 REMOVE BATTERY CABLES To remove the Battery Cables, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 9.1.4.3. b. Ensure the Battery Bank DC Tie Switch is in the “OFF” position. c.

Disconnect both negative battery cables from the batteries.

d. Remove the jumper cables from both sets of batteries. e. Disconnect both positive battery cables from the batteries. f. 9.4.2.4

Remove damaged battery cable. INSTALL BATTERY CABLES

To install the Battery Cables, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 9.1.4.3. b. Ensure the Battery Bank DC Tie Switch is in the “OFF” position. c.

Connect both positive battery cables to the batteries.

d. Reinstall the jumper cables onto both sets of batteries. e. Connect both negative battery cables to the batteries. 9.4.2.5

SERVICE BATTERY CABLES

To service the Battery Cables, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 9.1.4.3. b. If battery cable terminal corrosion is present, disconnect both negative battery cables; disconnect corroded battery cable terminal, clean battery cable terminal with a solution of baking soda and water; flush with clean water. c.

Using a stiff bristle brush, clean battery cable connector.

d. Reconnect cleaned terminal, reconnect negative battery cables.

9-13

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 9.4.3

BATTERY CHARGER

The following maintenance procedures are provided for the Battery Charger: Inspect Test Remove Install Service

DC CIRCUIT BREAKER (CB2)

AC CIRCUIT BREAKER (CB1)

FIGURE 9.4.3-1

BATTERY CHARGER

The MBC6 Battery Charger will switch modes (float or equalize) depending on the state of charge in the battery and upon external loads. The mode switching decision is based on the charger output current at the “+”’ and “-“ terminals. When the battery and/or other loads require much over 50% of rated current, the charger switches to equalize mode and remains there until the battery is charged (and/or loads are reduced) and the output current drops below 50% of rated current. At that point the charger will switch to the float mode, with a corresponding reduction in output current, and remain in ‘float’ until the next demand occurs. For complete charger details, refer to the Master Control System Battery Charger Instruction Manual, MBC6X-24V-20A-LA.

9-14

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 9.4.3.1

INSPECT BATTERY CHARGER

Inspect the Battery Charger as follows, using Figure 9.4.3-1 as a reference. a. Inspect input and output cables for deterioration or physical damage. b. Inspect charger mounting for security of attachment. c.

Inspect gauges for deterioration or physical damage.

d. Inspect input AC Power Circuit Breaker (CB1) for proper mechanical function. e. Inspect output DC Power Circuit Breaker (CB2) for proper mechanical function. 9.4.3.2

TEST BATTERY CHARGER

To test the Battery Charger, proceed as follows using Figure 9.4.3-1 as a reference: a. Ensure that the Battery Charger input power cable is connected to an active source of 120VAC electrical power. b. Ensure that the battery bank is properly connected and the Battery Charger is properly connected to the battery bank. c.

Push CB1 to close the AC input power circuit breaker.

d. Push CB2 to close the DC output circuit breaker. e. Observe that the DC Ammeter indicates a low rate of charging current flow. f.

Observe that the DC Voltmeter indicates 26 VDC, + 3 volts.

g. Recheck AC supply and/or DC output if there is no DC output. h. Replace the Battery Charger if it does not function properly.

9-15

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 9.4.3.3

REMOVE BATTERY CHARGER WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT DURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION AND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN LOAD CABLES ARE HANDLED. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING.

To remove the Battery Charger, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14)

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant or utility connection in accordance with Section 5.9.6.15, Unit Isolation Procedure with PSC. Isolate the PU from any power plant control system in accordance with Note 3. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels.

NOTE 1:

Also the PU must be completely electrically isolated from the power distribution bus and any other electrical source that can back feed into the PU. All medium voltage cables need to be placed on the standoff insulators by use of hot sticks and other safety gear.

NOTE 2:

Ensure cables are not energized by opening the circuit breaker of the Primary Switching Center (PSC), then disconnect Load Cables (Using the proper safety gear) on the PU and place them on the Parking Stands.

9-16

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 NOTE 3:

When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Disconnect the 120 VAC battery charger power plug from the receptacle underneath the panel board box. c.

Place a tag on the battery charger power plug noting that the battery charger has been removed.

d. Open the front cover to gain access to the inside of the charger. e

Tag and disconnect the Neutral, Hot and Ground wires at the AC terminal board and tape leads to prevent shorting should the power plug get reconnected accidentally.

f.

Unscrew conduit clamp nut holding AC wires to the charger and pull wire harness out of charger.

g. Tag and disconnect the + and – wires at DC terminal board and tape leads to prevent shorting should the batteries get reconnected accidentally. h. Unscrew conduit clamp nut holding DC wires to charger and pull wire harness out of charger. i.

Remove the 4 nuts securing the battery charger to station transformer. The charger is now free to be lifted off the vibration mounts.

j.

Reinstall the securing hardware and vibration mounts to prevent loss. Inspect hardware and vibration mounts for damage, Replace if necessary.

9.4.3.4

INSTALL BATTERY CHARGER

To install the Battery Charger, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures and warnings in paragraph 9.4.3.3. b. Install and Secure the Battery Charger on the 4 vibration mounts using existing hardware. c.

Open the front-cover to obtain access to the AC and DC terminals.

d. Insert the DC power harness into the Battery Charger and secure with conduit clamp nut. e. Remove tape and attach the wires to the DC terminal board. Remove tag. f.

Install the AC power harness into the charger and secure with conduit clamp nut.

g. Remove the marking tape and attach the wires to the AC terminal board. h. Close the Battery Charger cover and reinstall the mounting screws. i.

Reconnect the positive and then the negative battery cables to the batteries. Remove marking tag.

9-17

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 l.

Plug in the 120VAC plug. Remove marking tag.

m. Check operation as described in 9.4.3.2 above. 9.4.3.5

SERVICE BATTERY CHARGER

To service the battery charger, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 9.4.3.3. b. Clean the exterior by wiping the surface with a rag and with water based degreaser. c.

Open the front cover by loosening the securing hardware.

d. Clean the interior of dust with low pressure compressed air or vacuum cleaner. e. Close the front cover and replace the securing hardware. 9.4.4

WIRING HARNESS

The following maintenance procedures are provided for the Wiring Harnesses: Inspect Test Remove Install Repair 9.4.4.1

INSPECT WIRING HARNESS WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT DURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION AND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN LOAD CABLES ARE HANDLED. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING.

9-18

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 To inspect the Wiring Harness, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14)

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant or utility connection in accordance with Section 5.9.6.15, Unit Isolation Procedure with PSC. See Notes 1 and 2. Isolate the PU from any power plant control system in accordance with Note 3. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels.

NOTE 1:

Also the PU must be completely electrically isolated from the power distribution bus and any other electrical source that can back feed into the PU. All medium voltage cables need to be placed on the standoff insulators by use of hot sticks and other safety gear.

NOTE 2:

Ensure cables are not energized by opening the circuit breaker of the Primary Switching Center (PSC), then disconnect Load Cables (Using the proper safety gear) on the PU and place them on the Parking Stands.

NOTE 3:

When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Check Wiring Harness for cracking insulation or frayed areas. c.

Check that all terminal lugs are securely attached to wire ends.

d. Ensure that the Wiring Harness are bundled and tied together securely. e. Check security of all hangers, clamps, and hardware that secure the Wiring Harness to the generator set or other support. f. 9.4.4.2

Check that no wire is in contact with any sharp edge or any heat producing surface of the engine or exhaust system or other support. TEST WIRING HARNESS

To test the Wiring Harness, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures and warnings in paragraph 9.4.4.1.

9-19

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 b. Test the suspect wiring harness wires for continuity and internal shorts using a multimeter set to check OHMS (Ω) Rx1 scale. Use FO-1 to FO-44C for reference. 9.4.4.3

REMOVE WIRING HARNESSES

To remove the Wiring Harness, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures and warnings in paragraph 9.4.4.1. b. Tag both ends of all wires to be removed. c.

Disconnect all wire harness wire terminations.

b. Unfasten all wire harness attachments. e. Remove wire harness from PU. 9.4.4.4

INSTALL WIRING HARNESS

To install the Wiring Harness, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures and warnings in paragraph 9.4.4.1. b. Install the wire harness into the PU in the same physical place that the old harness was removed. c.

Fasten all wire harness attachments to the harness.

d. Reconnect all wire harness connections. e. Secure loose or excess wire with wire ties. f. 9.4.4.5

Remove all tags. WIRING HARNESSES REPAIR

To repair the Wiring Harness, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures and warnings in paragraph 9.4.4.1. b

Repair wiring harnesses by splicing, and replacing damaged terminal lugs and connections, and soldering damaged components.

c.

Repair wiring harnesses in accordance with AFTO 1-1A-14.

9-20

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 9.4.5

BATTERY BANK DC TIE SWITCH

The following maintenance procedures are provided for the Battery Bank DC Tie Switch: Inspect Test Remove Install

FIGURE 9.4.5-1

SCHEMATIC OF BATTERY BANK DC TIE SWITCH

FIGURE 9.4.5-2

BATTERY BANK DC TIE SWITCH

9-21

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 a. The Battery Bank DC Tie Switch is located at the front of the PU, above and centered between the two hydraulic tanks, next to the NATO slave receptacle. Use Figure 9.4.5-1 for reference. b. It is a two-position switch that is normally open. The operator can close the switch, which then parallels the two battery banks together when additional cranking power is needed for starting either generator set. c.

9.4.5.1

When the NATO slave receptacle is used for starting or charging, the Battery Bank DC Tie Switch must be closed to start the roadside generator or charge its batteries. INSPECT BATTERY BANK DC TIE SWITCH WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.

To inspect the Battery Bank DC Tie Switch, proceed as follows: a. Check the Battery Bank DC Tie Switch for physical damage, deterioration, or missing parts. b. Check the wires for cracking insulation or frayed areas. c.

Check that all terminal lugs are securely attached to terminals and to wire ends.

d. Check security of all hangers, clamps, and mounting hardware. e. Check that no wire is in contact with any sharp surface. 9.4.5.2

TEST BATTERY BANK DC TIE SWITCH WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING WHEN DISCONNECTING BATTERY CABLES, ALWAYS DISCONNECT NEGATIVE TERMINAL FIRST. WHEN RECONNECTING, CONNECT NEGATIVE TERMINAL LAST. FAILURE TO COMPLY MAY CAUSE SPARKING AND CONSEQUENT BATTERY EXPLOSION. WARNING HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT DURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION AND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN LOAD CABLES ARE HANDLED.

9-22

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. To test the Battery Bank DC Tie Switch, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) NOTE 1:

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels. When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Tag and disconnect cables from the Battery Bank DC Tie Switch. c.

Using a multimeter set on OHMS (Ω) Rx1 scale: (1)

Place the Battery Bank DC Tie Switch in the “ON” position, the meter should read 1 OHM or less.

(2)

Place the Battery Bank DC Tie Switch in the “OFF” position, the meter should read infinite Ohms.

d. Replace the Battery Bank DC Tie Switch if it fails any of the above tests.

9-23

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 9.4.5.3

REMOVE BATTERY BANK DC TIE SWITCH

To remove the Battery Bank DC Tie Switch, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 9.4.5.2. b. Tag and disconnect cables from the Battery Bank DC Tie Switch. c.

Remove the handle set screw and remove handle. See Figure 9.4.5-2.

d. Remove the Battery Bank DC Tie Switch mounting nut and washer. See Figure 9.4.5-2. e. Remove the Battery Bank DC Tie Switch. 9.4.5.4

INSTALL BATTERY BANK DC TIE SWITCH

To install the Battery Bank DC Tie Switch, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 9.4.5.2. b. Place the Battery Bank DC Tie Switch into position. See Figure 9.4.5-1. c.

Reinstall the Battery Bank DC Tie Switch mounting nut and washer. See Figure 9.4.5-2

d. Reinstall the handle and Reinstall handle set screw. See Figure 9.4.5-2. e. Remove tags and connect the Battery Cables to the Battery Bank DC Tie Switch.

9-24

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 9.4.6

STARTER MOTOR AND STARTER SOLENOID

The following maintenance procedures are provided for the Starter Motor and Starter Solenoid: Inspect Test Remove Install Adjust

STARTER MOUNTING BOLT

FIGURE 9.4.6-1 9.4.6.1

STARTER MOTOR

INSPECT STARTER MOTOR AND STARTER SOLENOID

To inspect the Starter Motor and Starter Solenoid, proceed as follows: WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT DURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION AND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN LOAD CABLES ARE HANDLED.

9-25

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) NOTE 1:

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels. When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Corrosion on solenoid terminals. Disconnect battery cable and clean terminals as required. c.

Damage and security of mounting.

d. Discoloration and other signs of overheating.

9-26

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 9.4.6.2

TEST STARTER MOTOR AND STARTER SOLENOID WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT DURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION AND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN LOAD CABLES ARE HANDLED. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. CAUTION DO NOT ALLOW THE STARTER MOTOR TO OPERATE MORE THAN 30 SECONDS. ALLOW IT TO COOL AT LEAST 2 MINUTES BEFORE RE-ENERGIZING THE MOTOR. OVERHEATING WILL DAMAGE THE MOTOR. CAUTION

TWO PEOPLE ARE REQUIRED TO PERFORM THIS TASK THE STARTER WEIGHS 70 LBS. To test the Starter Motor and Starter Solenoid, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, and cool enough for the test to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) NOTE 1:

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. Place all Circuit Breakers in the LOCK OUT position. When the DC Control Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

9-27

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254

FIGURE 9.4.6.2-1

STARTER MOTOR

b. Test of the starter motor and electrical solenoid assembly consists of a test of the complete unit followed by a pinion clearance check and adjustment. Refer to Figure 9.4.6.2-1 for the following steps: c.

Use a multimeter in the DC voltage range to find starting system components that do not function.

d. Move the Engine Control Switch (ECS) to the Manual Start position in order to activate the starting solenoid. The starting solenoid’s operation can he heard as the pinion of the starting motor is engaged with the ring gear on the engine flywheel. e. If a solenoid for a starting motor will not operate, it is possible that the current from the battery did not reach the solenoid. Fasten one lead of the multimeter to the connection (1) for the battery cable on the solenoid. Put the other lead to a good ground. A zero reading indicates that there is a broken circuit from the battery. More testing is necessary when there is a voltage reading on the multimeter. Turn ECS to “OFF/RESET”. f.

The solenoid operation also closes the electric circuit to the motor. Connect one lead of the multimeter to the solenoid connection (2) that is fastened to the motor. Put the other lead to a good ground. Move the Engine Control Switch (ECS) to the Manual Start position to activate the starting solenoid and look at the multimeter. A reading of 24VDC shows that the problem is in the motor. The motor must be removed for further testing. A reading of 0VDC, on the multimeter shows that the solenoid contacts do not close. This is an indication of the need for repair to the solenoid or an adjustment to be made to the starting motor pinion clearance. Turn ECS to “OFF/RESET”.

9-28

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 g. To test, fasten one multimeter lead to the connection (3) for the small wire at the solenoid and fasten the other lead to the ground. Move the Engine Control Switch (ECS) to the Manual Start position to activate the starting solenoid and look at the multimeter. A voltage reading shows that the problem is in the solenoid. A 0VDC reading indicates that the problem is in the ECS or the wires to the ECS. Turn ECS to “OFF/RESET”. h. Refer to FO-15, D6, for this task. Fasten one multimeter lead to the ECS at the terminal ECSA (1) for the wire from the battery. Fasten the other lead to a good ground. A 0VDC reading indicates a broken circuit from the battery. Make a check of the circuit breaker and associated wiring. If there is a voltage reading, the problem is in the ECS or in the wires for the ECS. i.

Starting motors that operate too slowly can have an overload because of too much friction in the engine that is being started. Slow operation of the starting motors can also be caused by a short circuit, loose connections and/or dirt in the motor.

9.4.6.3

REMOVE STARTER MOTOR AND STARTER SOLENOID WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT DURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION AND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN LOAD CABLES ARE HANDLED. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. CAUTION

TWO PEOPLE ARE REQUIRED TO PERFORM THIS TASK THE STARTER WEIGHS 70 LBS. To remove the Starter Motor and Starter Solenoid, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2) (3)

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker.

9-29

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) NOTE 1:

Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels. When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Remove the PU side panel see Section 8.4.1 for reference. c.

Remove the Fumes Disposal Collector mounting bolts and set Fumes Disposal Collector aside.

d. Tag and disconnect wiring from the Starter Motor and Starter Solenoid. e

Using Figure 9.4.6-1 as a reference, fasten a hoist to the starting motor. Remove the three Starter mounting bolts that hold the starting motor to flywheel housing.

f.

Remove Starter Motor and Starter Solenoid from the flywheel housing. The weight of the Starter Motor and Starter Solenoid is 32 kg (70 lb).

9-30

9.4.6.4

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 INSTALL STARTER MOTOR AND STARTER SOLENOID CAUTION

TWO PEOPLE ARE REQUIRED TO PERFORM THIS TASK THE STARTER WEIGHS 70 LBS. To install the Starter Motor and Starter Solenoid, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 9.4.6.3. b. Using a hoist, position the Starter Motor and Starter Solenoid into the flywheel housing. The weight of the Starter Motor and Starter Solenoid is 32 kg (70 lb). c.

Reinstall the mounting bolts, washers, and lock washers. Torque all mounting bolts and electrical connections according to Table 9.4.6.4-1 using Figure 9.4.6.4-1, Figure 9.4.6.4-2 and Figure 9.4.6.4-3.

d. Remove Tags and connect wiring. e. Reinstall the Fumes Disposal Collector. f.

Reinstall the PU Side Panel see Section 8.4.1 for reference.

FIGURE 9.4.6.4-1

STARTER MOTOR SIDE VIEW

9-31

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254

FIGURE 9.4.6.4-2

STARTER MOTOR FRONT VIEW

FIGURE 9.4.6.4-3

STARTER MOTOR FRONT VIEW

9-32

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 TABLE 9.4.6.4-1

STARTER TORQUE SPECIFICATIONS STARTER TORQUE SPECIFICATIONS

ITEM NUMBER

ACTION REQUIRED

TORQUE REQUIREMENTS

1

Tighten the nut on the battery terminal to the following torque

22 ± 3 Ft-Lbs (30.5 ± 3.5 Nm)

9.4.6.4-1

2

Tighten the nut to the following torque.

22 ± 3 Ft-Lbs (30.5 ± 3.5 Nm)

9.4.6.4-1 & 9.4.6.4-2

3

Tighten the nut on the ground terminal to the following torque.

22 ± 3 Ft-Lbs (30.5 ± 3.5 Nm)

9.4.6.4-2

4

Tighten the nut on the switch terminal to the following torque.

20 ± 2 In-Lbs (2.25 ± 0.25 Nm)

9.4.6.4-2 & 9.4.6.4-3

5

Tighten the nut on the motor terminal to the following torque.

22 ± 3 Ft-Lbs (30.5 ± 3.5 Nm)

9.4.6.4-2 & 9.4.6.4-3

6

Tighten the nut on the motor frame terminal to the following torque.

13 ± 2 Ft-Lbs (17.5 ± 2.5 Nm)

9.4.6.4-2 & 9.4.6.4-3

7

Tighten the Starter Mounting Bolts to the following torque.

160 + 30 Ft-Lbs (215 + 40 Nm)

9.4.6.4-3

9-33

REFERENCE FIGURE

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 9.4.6.5

ADJUST STARTER PINION CLEARANCE

FIGURE 9.4.6.5-1

PINION CLEARANCE

FIGURE 9.4.6.5-2

PINION ADJUSTMENT

To adjust the Starter Pinion Clearance, proceed as follows: a. This procedure is conducted with the starter motor removed from the PU. b. Use a screwdriver to turn the pinion on the exposed drive assembly in the drive housing. Tight bearings, bent armature shaft, or a loose pole shoe screw will cause armature binding. If armature does not turn freely, replace the starter. If armature rotates freely, conduct the testing as follows: •

Reinstall the solenoid without connector (1) from the MOTOR connections (terminal) on the solenoid to the motor. Use Figure 9.4.6.5-1 for reference.

9-34

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 •

Connect a 24VDC Power Source, to the solenoid, to the "SW” terminal (2). Use Figure 9.4.6.5-1 for reference.

•

Connect the other side of the 24VDC Power Source to connector (3). Use Figure 9.4.6.5-1 for reference.

•

For a moment, connect a wire from the solenoid connection (terminal), which is marked “MOTOR”, to the ground connection (terminal). The pinion will shift to the crank position and the pinion will stay there until the battery is disconnected.

•

Push the pinion toward the end with the commutator in order to remove free movement.

•

Pinion clearance (6) must be 9.1 mm (0.358 inch). Use Figure 9.4.6.5-2 for reference.

•

In order to adjust the pinion clearance, remove the plug and turn the shaft nut (4). Use Figure 9.4.6.5-2 for reference.

•

After the adjustment is completed, reinstall the plug over the nut (4) and reinstall the connector (1) between the MOTOR terminal on the solenoid and the starter motor.

9-35

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 9.4.7

DC CONTROL POWER CIRCUIT BREAKER (CBCP)

The following maintenance procedures are provided for the DC Control Power Circuit Breaker (CBCP): Inspect Test Remove Install

RETAINING NUT

FIGURE 9.4.7-1

DC CONTROL POWER CIRCUIT BREAKER (CBCP)

See Figure 9.4.7-1 for reference. The DC Control Power Circuit Breaker (CBCP) provides G1 and G2 an automatic safety disconnect of battery power from its circuits in case of short circuit or circuit overload. 9.4.7.1

INSPECT DC CONTROL POWER CIRCUIT BREAKER (CBCP)

To inspect the DC Control Power Circuit Breaker (CBCP), proceed as follows: a. Check for discoloration and signs of overheating. b. Check for cracks, breaks, evidence of damage, and corrosion. c.

Check for freedom of movement.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 9.4.7.2

TEST DC CONTROL POWER CIRCUIT BREAKER (CBCP) WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT DURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION AND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN LOAD CABLES ARE HANDLED. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING.

To test the DC Control Power Circuit Breaker (CBCP), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) NOTE 1:

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels. When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Tag and disconnect wires from the DC Control Breaker.

9-37

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 c.

Test the DC Control Breaker using a Multi-Amp MS-2 Circuit Breaker Tester or equivalent according to the test equipment and breaker manufacturer instructions.

d. Ensure that the Circuit Breaker will continuously carry rated current. Must trip at 135% rated current within one hour. e. Replace the DC Control Breaker if it fails testing. 9.4.7.3

REMOVE DC CONTROL POWER CIRCUIT BREAKER (CBCP)

To remove the DC Control Power Circuit Breaker (CBCP), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 9.4.7.2. b. Open the Master Control Panel (MCP) door. c.

Tag and disconnect the wiring to DC Control Breaker.

d. Remove retaining nut and remove the DC Control Breaker. 9.4.7.4

INSTALL DC CONTROL POWER CIRCUIT BREAKER (CBCP)

To install the DC Control Power Circuit Breaker (CBCP), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 9.4.7.2. b. Position the DC Control Power Circuit Breaker into the MCP and secure it with its retaining nut. c.

Connect the wiring as tagged and discard tags.

d. Close the MCP door and tighten captive screws.

9-38

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 9.4.8

DC PANEL LIGHTS AND FAULT INDICATOR LIGHTS

The following maintenance procedures are provided for the DC Panel Lights and Fault Indicator Lights: Inspect Test Remove Install

PANEL LIGHTS

PANEL LIGHTS

FAULT INDICATOR LIGHTS

CONTACTOR INDICATOR LIGHTS

CONTACTOR INDICATOR LIGHTS

FIGURE 9.4.8-1 9.4.8.1

DC PANEL LIGHTS AND FAULT INDICATOR LIGHTS

INSPECT DC PANEL LIGHTS AND FAULT INDICATOR LIGHTS

Inspect the DC Panel Lights and Fault Indicator Lights every 250 hours for the following conditions: a. Check for loose wires and terminal screws. b. Check for burnt out bulbs or indicator lamps. c.

Check for loose Mounting hardware.

d. Check for security of attachment and signs of overheating.

9-39

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 9.4.8.2

TEST DC PANEL LIGHTS AND FAULT INDICATOR LIGHTS

To test the DC Panel Lights and Fault Indicator Lights, proceed as follows: a. Close the DC Control Power Circuit Breaker (Push-in). Push the “Press to Test” ring on each of the fault indicator lamps that have that feature. The light should illuminate. If the light does not illuminate or on lights that do-not have the press to test feature, remove the bulb and test it. Use an ohmmeter to check continuity. b. Test DC Panel Lights by placing the PANEL LIGHTS toggle switch to the ON position. The DC Panel Lights should illuminate. If not, remove the bulb and test it using an ohmmeter to check continuity. c. 9.4.8.3

Replace bulbs that fail test. REMOVE DC PANEL LIGHT BULBS AND FAULT INDICATOR LIGHTS

To remove the DC light bulbs and indicators, proceed as follows: a. Pull-out the DC Control Circuit Breaker. b. Remove defective light bulb. 9.4.8.4

INSTALL DC PANEL LIGHT BULBS AND FAULT INDICATOR LIGHTS

To install the DC light bulbs and indicators, proceed as follows: a. Install new serviceable light bulb. b. Push-in the DC Control Circuit Breaker.

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CHAPTER 10 ALTERNATING CURRENT (AC) SYSTEM REPAIR TABLE OF CONTENTS SECTION

TITLE

PAGE

10.0

ALTERNATING CURRENT (AC) SYSTEM REPAIR

7

10.1

SAFETY INSTRUCTIONS

7

10.2

BRIEF SYSTEM DESCRIPTION

9

10.3

SERVICE REQUIREMENTS

12

10.4

COMPONENT REPAIR PROCEDURES

12

10.4.1

STATION POWER TRANSFORMER

12

10.4.1.1

INSPECT STATION POWER TRANSFORMER

13

10.4.1.2

TEST STATION POWER TRANSFORMER

14

10.4.1.2.1

INSULATION RESISTANCE TEST

15

10.4.1.2.2

TURNS RATIO TEST

16

10.4.1.2.3

INSULATION RESISTANCE TEST

16

10.4.1.3

REMOVE STATION POWER TRANSFORMER

17

10.4.1.4

INSTALL STATION POWER TRANSFORMER

18

10.4.2

208/120VAC RECEPTACLES

19

10.4.2.1

INSPECT 208/120VAC RECEPTACLES

20

10.4.2.2

TEST 208/120VAC RECEPTACLES

21

10.4.2.2.1

TEST 208/120VAC RECEPTACLES (INTERNAL AND EXTERNAL)

21

10.4.2.2.2

TEST 120-VAC (GFCI) DUPLEX RECEPTACLES

21

10.4.2.2.3

REMOVE 120/208 VAC RECEPTACLES (EXTERNAL)

21

10.4.2.2.4

INSTALLL 120/208 VAC RECEPTACLES (EXTERNAL)

21

10.4.3

WIRING HARNESSES

24

10.4.3.1

INSPECT WIRING HARNESS

24

10.4.3.2

TEST WIRING HARNESS

25

10-1

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254

TABLE OF CONTENTS SECTION

TITLE

PAGE

10.4.3.3

REMOVE WIRING HARNESS

26

10.4.3.4

INSTALL WIRING HARNESS

26

10.4.3.5

REPAIR WIRING HARNESS

26

10.4.4

POWER PANEL BOARD

27

10.4.4.1

INSPECT PANEL BOARD

27

10.4.4.2

TEST PANEL BOARD AND BREAKERS

28

10.4.4.3

REMOVE PANEL BOARD

29

10.4.4.4

INSTALL PANEL BOARD

30

10.4.5

ALTERNATOR

31

10.4.5.1

INSPECT ALTERNATOR

31

10.4.5.2

TEST ALTERNATOR

32

10.4.5.2.1

RECOMMENDED PERIODIC INSULATION CHECKS

33

10.4.5.2.2

INSULATION RESISTANCE TEST

33

10.4.5.2.2.1

TEST PROCEDURES

34

10.4.5.2.2.1.1

MAIN ARMATURE (STATOR-L4) TEST

35

10.4.5.2.2.1.2

EXCITER FIELD (STATOR-L1) TEST

36

10.4.5.2.2.1.3

EXCITER ARMATURE (ROTOR-L2) TEST

37

10.4.5.2.2.1.4

PILOT EXCITER ARMATURE (L5) TEST

38

10.4.5.2.2.1.5

MAIN ROTOR (L3) TEST

36

10.4.5.3

REMOVE ALTERNATOR

41

10.4.5.4

INSTALL ALTERNATOR

41

10.4.5.5

GENERATOR STARTUP CHECKLIST

42

10.4.6

VARISTOR AND RECTIFIER BLOCK ASSEMBLY

44

10.4.6.1

INSPECT VARISTOR AND RECTIFIER BLOCK ASSEMBLY

46

10.4.6.2

TEST RECTIFER BLOCK AND VARISTOR (CR7) ASSEMBLY

46

10.4.6.3

TEST RECTIFER BLOCK ASSEMBLY

49

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TABLE OF CONTENTS SECTION

TITLE

PAGE

10.4.6.4

REMOVE VARISTOR AND RECTIFIER BLOCK ASSEMBLY

49

10.4.6.5

INSTALL RECTIFIER BLOCK ASSEMBLY

50

10.4.7

MEDIUM VOLTAGE OUTPUT TERMINALS

51

10.4.7.1

INSPECT MEDIUM VOLTAGE OUTPUT TERMINAL

52

10.4.7.2

TEST MEDIUM VOLTAGE OUTPUT TERMINAL

54

10.4.7.3

REMOVE MEDIUM VOLTAGE OUTPUT TERMINAL

56

10.4.7.4

INSTALL MEDIUM VOLTAGE OUTPUT TERMINAL

58

10.4.8

SURGE ARRESTERS (SA1, SA2, SA3)

59

10.4.8.1

INSPECT SURGE ARRESTER (SA1, SA2, SA3)

60

10.4.8.2

TEST SURGE ARRESTER (SA1, SA2, SA3)

61

10.4.8.3

REMOVE SURGE ARRESTER (SA1, SA2, SA3)

62

10.4.8.4

INSTALL SURGE ARRESTER (SA1, SA2, SA3)

63

10.4.9

INSTRUMENT POTENTIAL TRANSFORMERS (PT)

64

10.4.9.1

INSPECT INSTRUMENT POTENTIAL TRANSFORMERS (PT)

65

10.4.9.2

TEST INSTRUMENT POTENTIAL TRANSFORMERS (PT)

65

10.4.9.2.1

INSULATION RESISTANCE TEST

67

10.4.9.2.2

TURN RATIO TEST

68

10.4.9.3

REMOVAL INSTRUMENT POTENTIAL TRANSFORMERS (PT)

68

10.4.9.4

INSTALL INSTRUMENT POTENTIAL TRANSFORMERS (PT)

69

10.4.10

INSTRUMENT CURRENT TRANSFORMER (CT)

70

10.4.10.1

INSPECT INSTRUMENT CURRENT TRANSFORMER (CT)

71

10.4.10.2

TEST INSTRUMENT CURRENT TRANSFORMER (CT)

72

10.4.10.3

REMOVAL INSTRUMENT CURRENT TRANSFORMER (CT)

72

10.4.10.4

INSTALL INSTRUMENT CURRENT TRANSFORMER (CT)

72

10.4.11

GENERATOR, FEEDER AND TIE BREAKERS

73

10.4.11.1

INSPECT GENERATOR, FEEDER AND TIE BREAKERS

74

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TABLE OF CONTENTS SECTION

TITLE

PAGE

10.4.11.2

TEST GENERATOR, FEEDER AND TIE BREAKERS

75

10.4.11.3

REMOVE GENERATOR, FEEDER AND TIE BREAKERS

76

10.4.11.4

INSTALL GENERATOR, FEEDER AND TIE BREAKERS

77

10-4

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LIST OF FIGURES FIGURE

TITLE

PAGE

FIGURE 10.4.1-1

STATION POWER TRANSFORMER

12

FIGURE 10.4.2-1

208VAC AND 120VAC EXTERNAL RECEPTACLES

19

FIGURE 10.4.2-2

120VAC INTERNAL RECEPTACLES

20

FIGURE 10.4.4-1

POWER PANEL BOARD

27

FIGURE 10.4.5-1

ALTERNATOR

31

FIGURE 10.4.5-2

TEMPERATURE CORRECTION CHART

40

FIGURE 10.4.6-1

ROTATING FIELD ASSEMBLY

44

FIGURE 10.4.6-2

RECTIFIER BLOCK ASSEMBLY LABELED

45

FIGURE 10.4.6-3

DIODE RECTIFIER BLOCK

45

FIGURE 10.4.6-4

VARISTOR CR8

46

FIGURE 10.4.7-1

TIE OUTPUT TERMINALS

51

FIGURE 10.4.7-2

FEEDER OUTPUT TERMINALS

52

FIGURE 10.4.7.3-1

TYPICAL LOAD TERMINAL BREAKOUT

56

FIGURE 10.4.7.3-2

LOWER FRONT COVER

57

FIGURE 10.4.8-1

SURGE ARRESTERS (SA1, SA2, SA3)

59

FIGURE 10.4.8-2

LEFT REAR OF PDC

62

FIGURE 10.4.9-1

POTENTIAL TRANSFORMERS LEFT OR RIGHT SECTION

64

FIGURE 10.4.9-2

POTENTIAL TRANSFORMERS CENTER SECTION

65

FIGURE 10.4.10-1

INSTRUMENT CURRENT TRANSFORMERS

70

FIGURE 10.4.11-1

GENERATOR, FEEDER & TIE BREAKER

73

FIGURE 10.4.11.3-1 TIE BREAKER MECHANICAL LATCH STIFFNER PLATE

77

FIGURE 10.4.11.4-1 CONTACTOR CONTROL BOARD

78

FIGURE 10.4.11.4-2 CONTROL BOARD DIPSWITCH

79

10-5

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LIST OF TABLES TABLE

TITLE

PAGE

TABLE 10.2-1 FOLDOUT DESCRIPTIONS TABLE 10.4.5-1

10

GENERATOR INSULATION RESISTANCE TEST MAINTENANCE RECORD (EXAMPLE FORM) 40

TABLE 10.4.5.5-1

GENERATOR START-UP CHECKLIST (1 OF 2) (EXAMPLE FORM)

42

TABLE 10.4.5.5-1

GENERATOR START-UP CHECKLIST (2 OF 2) (EXAMPLE FORM)

43

10-6

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10.0

ALTERNATING CURRENT (AC) SYSTEM REPAIR

Maintenance procedures are provided for the following AC System Components: •

Station Power Transformer

•

208/120VAC Receptacles

•

Wiring Harnesses

•

Power Panel Board

•

Alternator

•

Varistor and Rectifier Block Assembly

•

Medium Voltage Output Terminals

•

Surge Arrestors

•

Instrument Potential Transformer (PT)

•

Instrument Current Transformer (CT)

•

Generator, Feeder, and Tie Breakers

10.1

SAFETY INSTRUCTIONS

a. Safety precautions must be observed while any maintenance is being performed. Safety precautions must be observed to ensure that the operator/technician cannot have contact with the following: • • • • • • •

Hot engine parts Hot engine fluids Medium Voltage AC electricity Low Voltage AC electricity Low Voltage DC electricity Rotating Parts High noise levels

b. Minor troubleshooting can be performed while both engines are running as long as safety precautions are taken. c.

Minor maintenance can be performed while one generator set is running and the other generator set has been shutdown. Some examples of this maintenance are: • • • • • •

Lubrication System – Oil and Filter Change. Hydraulic System – Oil and Filter Change. Fuel System – Primary and Secondary Filter Change. Coolant System – Coolant Change. Minor Troubleshooting. Check Fluid levels and add required fluids.

10-7

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (1) The generator set that has been shut down must be rendered unable to start, and cool enough for the maintenance to be performed. Procedures to render a generator set unable to start are: (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k)

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Push to OPEN the Emergency Stop Switch. Place the Engine Control Switch (ECS) in the OFF position. Place a DO NOT OPERATE tag on the generator control panel. Turn the Battery Bank Parallel Switch to the OFF position. De-energize the Battery Charger. Disconnect the negative and positive cables from the Battery Bank for the engine due maintenance. Place a DO NOT OPERATE tag on the Battery Bank. Place the generator Circuit Breaker in the LOCK OUT position. Disconnect the 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock the generator set control panel.

The fuel transfer pump electrical power is normally fed directly from the G1 generator set battery bank. If you disconnect the G1 battery bank, the external fuel transfer pump will not function. Place the Fuel Pump Source Switch (S2) into the (G1 or G2 position). Place the S2 in the (G1 or G2) position, for the generator set not receiving maintenance.

NOTE:

d. Major maintenance or service requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. This is accomplished by performing the following: (1) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. (2) Isolate the PU from any power plant or utility connection in accordance with Section 5.9.6.15, Unit Isolation Procedure with PSC. See Note 1 and 2. (3) Isolate the PU from any power plant control system in accordance with Note 3. (4) Pull to open the PU DC Power Control Breaker. (5) Push to OPEN both Emergency Stop Switches. (6) Place both Engine Control Switches (ECS) in the OFF position. (7) Place a DO NOT OPERATE tag on both generator control panels. (8) Turn the Battery Bank Parallel Switch to the OFF position. (9) De-energize both Battery Chargers. (10)Disconnect the negative and positive cables from both Battery Banks. (11)Place a DO NOT OPERATE tag on both Battery Banks. (12)Place all Circuit Breakers in the LOCK OUT position. (13)Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. (14)Close and Lock both generator set control panels. NOTE 1:

Also the PU must be completely electrically isolated from the power distribution bus and any other electrical source that can back feed into the PU. All medium voltage cables need to be placed on the standoff insulators by use of hot sticks and other safety gear.

NOTE 2:

Ensure cables are not energized by opening the circuit breaker of the Primary Switching Center (PSC), then disconnect Load Cables (Using the proper safety gear) on the PU and place them on the Parking Stands.

NOTE 3:

When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

10-8

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254

WARNING APPLYING HIGH VOLTAGES ACROSS THE CONTACTS OF THE VACUUM INTERRUPTERS MAY PRODUCE X-RAYS. THE RADIATION MAY INCREASE WITH AN INCREASE IN THE VOLTAGE OR A DECREASE IN THE DISTANCE BETWEEN THE OPEN CONTACTS. THE LEVELS OF RADIATION GENERATED AT THE RECOMMENDED TEST VOLTAGES AND NORMAL BREAKER OPEN GAP SPACING ARE EXTREMELY LOW. HOWEVER, AS A PRECAUTIONARY MEASURE IT IS RECOMMENDED THAT ALL PERSONNEL STAND AT LEAST THREE FEET AWAY FROM THE BREAKER WHILE TESTING. 10.2

BRIEF SYSTEM DESCRIPTION

•

Alternator

•

Distribution System

•

AC Prints

a. The SR4B is a three phase, alternating current and brushless type generator. It is a four pole design. The stationary main armature bolts to the engine flywheel housing. A flexible plate type coupling connects the rotor shaft to the engine flywheel. The rotating main field is keyed directly to the rotor shaft. The generator is self-ventilated with air entry through screened openings at the rear of the generator and air discharge through screened openings at the drive-coupling end. The fan attaches to rotor shaft. A bearing supports the exciter end of the rotor shaft. b. The PU is configured for 840Kw at 60Hz at a .8 power factor, 4160/2400 VAC at 1800 rpm. c.

The PU is configured for 700Kw at 50Hz at a .8 power factor, 3800/2200 VAC at 1500 rpm.

d. Internally connected in a “Y” configuration. e. Voltage is regulated by the Caterpillar Automatic Voltage Regulator (AVR). f.

Parking Stands are supplied for Medium Voltage Cables when disconnected from the PU.

g. Each Feeder Breaker is set to operate with a 100-amp load. h. The Tie Breaker is designed to operate at 200 amps. • Contactors use 120VAC as control voltage for opening and closing. All contactors require a constant 120VAC signal to stay closed except for the Tie Breaker, which has a mechanical interlock to keep it closed. The AC & DC prints called Foldouts are structured as follows:

• i.

10-9

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 TABLE 10.2-1

FOLDOUT DESCRIPTIONS POWER UNIT LIST OF FOLDOUTS DESCRIPTION

DPGDS ABBREVIATIONS DPGDS ABBREVIATIONS, DEVICES AND NOTES PU - ONE-LINE ELECTRICAL DIAGRAM, (WITH PROTECTIVE DEVICES) DPGDS AC SCHEMATIC, SHEET 1 OF 4 DPGDS AC SCHEMATIC, SHEET 2 OF 4 DPGDS AC SCHEMATIC, SHEET 3 OF 4 DPGDS AC SCHEMATIC, SHEET 4 OF 4 DPGDS DC SCHEMATIC, PDC DC CONTROL SCHEMATIC, SHEET 1 OF 7 DPGDS DC SCHEMATIC, PDC DC RTU AND I/O SCHEMATIC, SHEET 2 OF 7 DPGDS DC SCHEMATIC, PDC DC DISCRETE INPUT SCHEMATIC, SHEET 3 OF 7 DPGDS DC SCHEMATIC, PDC DC DISCRETE INPUT SCHEMATIC, SHEET 4 OF 7 DPGDS DC SCHEMATIC, PDC DC DISCRETE OUTPUT SCHEMATIC, SHEET 5 OF 7 DPGDS DC SCHEMATIC, PDC DC PANEL SCHEMATIC, SHEET 6 OF 7 DPGDS DC SCHEMATIC, PDC DC PANEL SCHEMATIC, SHEET 7 OF 7 WIRING DIAGRAMS POWER SUPPLIES FOR PCM AND HUB, SHEET 1 OF 30 WIRING DIAGRAMS GENERATOR 1/FEEDER 1 DOOR SUBPAN, SHEET 2 OF 30 WIRING DIAGRAMS GENERATOR 1/FEEDER 1 DOOR, SHEET 3 OF 30 WIRING DIAGRAMS GENERATOR 1/FEEDER 1 DOOR, SHEET 4 OF 30 WIRING DIAGRAMS GENERATOR 1/CONTACTOR & POTENTIAL TRANSFORMER, SHEET 5 OF 30 WIRING DIAGRAMS GENERATOR 1 TERMINAL BOARD, SHEET 6 OF 30 WIRING DIAGRAMS LOAD TIE DOOR, SHEET 7 OF 30 WIRING DIAGRAM MASTER CONTROL PANEL DOOR CONTACTOR AND POTENTIAL TRANSFORMER, SHEET 8 OF 30

FOLDOUT NUMBER FOLDOUT 1 FOLDOUT 2 FOLDOUT 3 FOLDOUT 4A FOLDOUT 4B FOLDOUT 5 FOLDOUT 6 FOLDOUT 7 FOLDOUT 8 FOLDOUT 9 FOLDOUT 10 FOLDOUT 11 FOLDOUT 12A FOLDOUT 12B FOLDOUT 13 FOLDOUT 14 FOLDOUT 15 FOLDOUT 16 FOLDOUT 17 FOLDOUT 18 FOLDOUT 19 FOLDOUT 20

WIRING DIAGRAM MASTER CONTROL PANEL “SWING DOOR”, SHEET 9 OF 30

FOLDOUT 21

WIRING DIAGRAM MASTER CONTROL PANEL “SWING DOOR”, SHEET 10 OF 30 WIRING DIAGRAM MASTER CONTROL PANEL “SWING DOOR”, SHEET 11 OF 30 WIRING DIAGRAM MASTER CONTROL PANEL TERMINAL BOARD, SHEET 12 OF 30 WIRING DIAGRAM MASTER CONTROL PANEL TERMINAL BOARD, SHEET 13 OF 30 WIRING DIAGRAM GENERATOR 2/FEEDER 2 DOOR, SHEET 14 OF 30 WIRING DIAGRAM GENERATOR 2/FEEDER 2 DOOR, SHEET 15 OF 30 WIRING DIAGRAM GENERATOR 2/FEEDER 2 DOOR, SHEET 16 OF 30 WIRING DIAGRAM GENERATOR 2/FEEDER 2 CONTACTOR – POTENTIAL TRANSFORMERS, SHEET 17 OF 30

FOLDOUT 22 FOLDOUT 23

10-10

FOLDOUT 24 FOLDOUT 25 FOLDOUT 26 FOLDOUT 27 FOLDOUT 28 FOLDOUT 29

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 TABLE 10.2-1 FOLDOUT DESCRIPTIONS (CONTINUED) POWER UNIT LIST OF FOLDOUTS DESCRIPTION WIRING DIAGRAM GENERATOR 2 TERMINAL BOARD, SHEET 18 OF 30 WIRING DIAGRAM PDC ENGINE/GENERATOR CONTROL PLUGS, SHEET 19 OF 30 WIRING DIAGRAM A-B COMMUNICATION CABLE, SHEET 20 OF 30 WIRING DIAGRAM ENGINE FLUID LEVEL SWITCHES, SHEET 21 OF 30 WIRING DIAGRAM POWER UNIT HARNESS, SHEET 22 OF 30 WIRING DIAGRAM POWER UNIT HARNESS - GENERATOR TO BUS, SHEET 23 OF 30 WIRING DIAGRAM POWER UNIT HARNESS - GENERATOR TO BUS, SHEET 24 OF 30 WIRING DIAGRAM SYSTEM POWER DISTRIBUTION TO LOAD BREAK ELBOWS, SHEET 25 OF 30 WIRING DIAGRAM POWER DISTRIBUTION 4160/2400 VAC 3 TO 208/120 VAC 3 PHASE, SHEET 26 OF 30 WIRING DIAGRAM POWER DISTRIBUTION 4160/2400 VAC 3 TO 208/120 VAC 3 PHASE, SHEET 27 OF 30 WIRING DIAGRAM POWER DISTRIBUTION 4160/2400 VAC 3 TO 208/120 VAC 3 PHASE, SHEET 28 OF 30 WIRING DIAGRAM, POWER DISTRIBUTION DEVICES, SHEET 29 OF 30 WIRING DIAGRAM BATTERY LEAD INSTALLATION AND INTERCONNECT, SHEET 30 OF 30 ENGINE WIRING DIAGRAM, SHEET 1 OF 5 ENGINE WIRING DIAGRAM, SHEET 2 OF 5 ENGINE WIRING DIAGRAM, SHEET 3 OF 5 ENGINE WIRING DIAGRAM, SHEET 4 OF 5 ENGINE WIRING DIAGRAM, SHEET 5 OF 5 SCHEMATIC, FUEL TRANSFER CONTROL BOX ASSEMBLY, SHEET 1 OF 5 WIRING DIAGRAM, FUEL TRANSFER CONTROL BOX ASSEMBLY, SHEET 2 OF 5 WIRING DIAGRAM, FUEL TRANSFER CONTROL BOX ASSEMBLY, SHEET 3 OF 5 WIRING DIAGRAM, FUEL TRANSFER CONTROL BOX ASSEMBLY, SHEET 4 OF 5 WIRING DIAGRAM, FUEL TRANSFER CONTROL BOX ASSEMBLY, SHEET 5 OF 5 SCHEMATIC DIAGRAM INTERNAL FUEL SYSTEM, SHEET 1 OF 2 SCHEMATIC DIAGRAM EXTERNAL FUEL SYSTEM, SHEET 2 OF 2 SCHEMATIC DIAGRAM, B MODEL, 7-PIN CONNECTOR, SHEET 1 OF 4 SCHEMATIC DIAGRAM, B MODEL, 7-PIN CONNECTOR, SHEET 2 OF 4 SCHEMATIC DIAGRAM, B MODEL, 7-PIN CONNECTOR, SHEET 3 OF 4 SCHEMATIC DIAGRAM, B MODEL, 7-PIN CONNECTOR, SHEET 4 OF 4 SCHEMATIC DIAGRAM, B MODEL, 12-PIN CONNECTOR, SHEET 1 OF 2 SCHEMATIC DIAGRAM, B MODEL, 12-PIN CONNECTOR, SHEET 2 OF 2 SCHEMATIC DIAGRAM, B MODEL, ABS BRAKE SYSTEM, SHEET 1 OF1 NOTE:

FOLDOUT NUMBER FOLDOUT 30 FOLDOUT 31 FOLDOUT 32 FOLDOUT 33 FOLDOUT 34 FOLDOUT 35A FOLDOUT 35B FOLDOUT 35 C FOLDOUT 36A FOLDOUT 36B FOLDOUT 36C FOLDOUT 36D FOLDOUT 37 FOLDOUT 38 FOLDOUT 39 FOLDOUT 40 FOLDOUT 41 FOLDOUT 42 FOLDOUT 43A FOLDOUT 43B FOLDOUT 44A FOLDOUT 44B FOLDOUT 44C FOLDOUT 48 FOLDOUT 49 FOLDOUT 50 FOLDOUT 51 FOLDOUT 52A FOLDOUT 52B FOLDOUT 53 FOLDOUT 54 FOLDOUT 55

The MEP-PU-810A and MEP-PU-810B use medium voltage vacuum breakers for the distribution.

10-11

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 10.3

SERVICE REQUIREMENTS

The AC “System” does require service. Each subcomponent that requires a service will be addressed in that section. 10.4

COMPONENT REPAIR PROCEDURES

10.4.1

STATION POWER TRANSFORMER

The following maintenance procedures are provided for the Station Power Transformer: Inspect Test: •

Test Fuses

•

Insulation Resistance Test

•

Turns Ratio Test

Remove Install

STATION POWER TRANSFORMER

FIGURE 10.4.1-1

STATION POWER TRANSFORMER

10-12

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 10.4.1.1

INSPECT STATION POWER TRANSFORMER WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING PRIOR TO TROUBLESHOOTING THE POWER UNIT (PU), ENSURE THE TIE AND FEEDER CABLES ARE ALL INSTALLED ON PARKING STANDS, TO PREVENT THE POSSIBILITY OF UTILITY POWER BEING FED BACK INTO GENERATOR SET. ENSURE EQUIPMENT IS PROPERLY TAGGED AND NOT ENERGIZED. RESIDUAL VOLTAGE IS PRESENT AT THE GENERATOR LEADS WITH THE REGULATOR TURNED OFF, REACHING SEVERAL HUNDRED VOLTS ON THE GENERATOR SET. PROPER INSULATION AND ISOLATION OF METERING EQUIPMENT MUST BE OBSERVED WHEN TESTING GENERATOR. USE PROPER TEST EQUIPMENT TO CHECK FOR VOLTAGE BEFORE PROCEEDING. FAILURE TO COMPLY MAY RESULT IN DEATH BY ELECTROCUTION. WARNING DISCHARGE CAPACITIVE CHARGE FROM ALL EXPOSED CONDUCTORS Inspect the station power transformer for the following conditions: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. This is accomplished by performing the following: (1) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. (2) Isolate the PU from any power plant or utility connection in accordance with Section 5.9.6.15, Unit Isolation Procedure with PSC. See Note 1 and 2. (3) Isolate the PU from any power plant control system in accordance with Note 3. (4) Pull to open the PU DC Power Control Breaker. (5) Push to open both Emergency Stop Switches. (6) Place both Engine Control Switches (ECS) in the OFF position. (7) Place a DO NOT OPERATE tag on both generator control panels. (8) Turn the Battery Bank Parallel Switch to the OFF position. (9) De-energize both Battery Chargers. (10)Disconnect the negative and positive cables from both Battery Banks. (11)Place a DO NOT OPERATE tag on both Battery Banks. (12)Place all Circuit Breakers in the LOCK OUT position. (13)Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. (14)Close and Lock both generator set control panels. NOTE 1:

Also the PU must be completely electrically isolated from the power distribution bus and any other electrical source that can back feed into the PU. All medium voltage cables need to be placed on the standoff insulators by use of hot sticks and other safety gear.

10-13

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 NOTE 2:

Ensure cables are not energized by opening the circuit breaker of the Primary Switching Center (PSC), then disconnect Load Cables (Using the proper safety gear) on the PU and place them on the Parking Stands.

NOTE 3:

When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Remove the four screws from the Tie Panel and swing it outward exposing the transformer fuse block and Tie Breaker. c.

Discharge capacitive charge from exposed conductors.

d. Visually inspect Fuse 12, Fuse 13 and Fuse 14 and fuse block for looseness, burning, corrosion, and physical damage. Ensure fuses are properly rated (5A-4800 VAC). e. Remove both Battery Chargers. See Section 9.4.3.3 for reference. f.

Remove transformer access panels.

g. Discharge capacitive charge from all exposed conductors. h. Visually inspect the transformer for the following: •

Corrosion

•

Physical damage

•

Loose connections

•

Shorted, frayed, or broken wires

•

Loose mountings

•

Damage and signs of overheating

i. j.

Install all access panels and secure with mounting hardware. Install both Battery Chargers.

10.4.1.2

TEST STATION POWER TRANSFORMER

To test the Station Power Transformer, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures and warnings in paragraph 10.4.1.1. b. Remove the four screws from the Tie Panel and swing it outward exposing the transformer fuse block and load Tie Breaker. c.

Discharge capacitive charge from exposed conductors.

10-14

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 Test Fuses: d. Visually inspect Fuse 12, Fuse 13 and Fuse 14 and fuse block for looseness, burning, corrosion, and physical damage. Ensure fuses are properly rated (5A-4800 VAC). e. Remove fuses from the fuse block using the proper fuse puller and high voltage gloves. f.

Test fuses for continuity. Replace if defective.

g. Perform appropriate tests if neccessary. (See Section 10.4.1.2.1 and/or Section 10.4.1.2.2) h. Reinstall fuses using the proper fuse puller and high voltage gloves. i.

Reinstall all access panels and secure with mounting hardware.

10.4.1.2.1

INSULATION RESISTANCE TEST

To test the transformer proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures and warnings in paragraph 10.4.1.1. b. Remove the four screws from the Tie Panel and swing it outward exposing the transformer fuse block and Tie Breaker. c.

Discharge capacitive charge from exposed conductors.

d. Remove fuses prior to this test. e. Remove both Battery Chargers. See Section 9.4.3.3 for reference. f.

Remove transformer access panels.

g. Disconnect high voltage and low voltage leads from the transformer. h. Using a multimeter set to OHMS (Ω) Rx1 scale, perform individual continuity checks on transformer primary and secondary windings. i.

Connect a 500V Megger to either primary lead and to ground. Short the secondary terminals to ground before connecting the Megger leads to primary terminals. Operate the Megger for 60 seconds and observe resistance. Reading on each transformer should be not less than 20 megohm. Short the primary lead to ground before disconnecting.

j.

Short high voltage terminals to ground before connecting the Megger. Connect the Megger to either secondary lead and to ground. Operate the Megger for 60 seconds and observe resistance. Reading should be not less than 1 megohm. Short the secondary lead to ground before disconnecting.

k.

Connect Megger leads between primary and secondary windings. Operate the Megger for 60 seconds and observe resistance. Reading should not be less than 20 megohm. Short both windings to ground before disconnecting.

10-15

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 10.4.1.2.2

TURNS RATIO TEST

Turns ratio testing of transformers provides a direct means to detect loose or open connections, shorted or open turns in the transformer windings, incorrect polarity connections, and to verify precisely the noload voltage ratio of the transformer, at all tap positions. The turns ratio of a transformer is defined as the number of turns in one winding in relation to the number of turns in the other winding of the same phase, which is also equal to the no-load voltage ratio. To test the transformer proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures and warnings in paragraph 10.4.1.1. b. Remove the four screws from the Load Tie Panel and swing it outward exposing the transformer fuse block and Tie Breaker. c.

Discharge capacitive charge from exposed conductors.

d. Remove fuses prior to this test. e. Remove both Battery Chargers. See Section 9.4.3.3 for reference. f.

Remove transformer access panels.

g. Tag and disconnect wiring leads from the transformer to include the panel board wiring. h. Perform a TTR test using the test equipment’s manufactures procedures. The turns ratio is required to be within ±1/2 percent or (.005), of the indicated nameplate voltage ratio.

i.

•

If the transformer fails any of the above requirements, remove and forward to next higher level of maintenance.

•

If the transformers meet above requirements, connect wiring leads and discard tags.

Reinstall access panel and both Battery Chargers with securing hardware.

10.4.1.2.3

INSULATION RESISTANCE TEST

a. Using a multimeter set to OHMS (Ω) Rx1 scale, perform individual continuity checks on transformer primary and secondary windings. b. Connect a 500V Megger to either primary lead and to ground. Short the secondary terminals to ground before connecting Megger leads to primary terminals. Operate Megger for 60 seconds and observe resistance. Reading on each transformer should be not less than 20 meg-ohms. Short the primary lead to ground before disconnecting. c.

Short the high voltage terminals to ground before connecting Megger. Connect Megger to either secondary lead and to ground. Operate the Megger for 60 seconds and observe resistance. Reading should be not less than 1 meg-ohm. Short the secondary lead to ground before disconnecting.

10-16

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 d. Connect Megger between primary and secondary windings. Operate the Megger for 60 seconds and observe resistance. Reading should not be less than 20 meg-ohms. Short both windings to ground before disconnecting. 10.4.1.3

REMOVE STATION POWER TRANSFORMER WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING PRIOR TO TROUBLESHOOTING THE POWER UNIT (PU), ENSURE THE TIE AND FEEDER CABLES ARE ALL INSTALLED ON PARKING STANDS, TO PREVENT THE POSSIBILITY OF UTILITY POWER BEING FED BACK INTO GENERATOR SET. ENSURE EQUIPMENT IS PROPERLY TAGGED AND NOT ENERGIZED. RESIDUAL VOLTAGE IS PRESENT AT THE GENERATOR LEADS WITH THE REGULATOR TURNED OFF, REACHING SEVERAL HUNDRED VOLTS ON THE GENERATOR SET. PROPER INSULATION AND ISOLATION OF METERING EQUIPMENT MUST BE OBSERVED WHEN TESTING GENERATOR. USE PROPER TEST EQUIPMENT TO CHECK FOR VOLTAGE BEFORE PROCEEDING. FAILURE TO COMPLY MAY RESULT IN DEATH BY ELECTROCUTION. WARNING DISCHARGE CAPACITIVE CHARGE FROM ALL EXPOSED CONDUCTORS WARNING USE OF A LIFTING DEVICE IS RECOMMENDED FOR REMOVING THE STATION POWER TRANSFORMER. EXTREMELY HEAVY OVER 100 LBS To remove the station power transformer, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures in paragraph 10.4.1.1. b. Remove the four screws from the Load Tie Panel and swing it outward exposing the transformer fuse block and Tie Breaker. c.

Discharge capacitive charge from exposed conductors.

d. Remove the three transformer fuses. e. Remove both Battery Chargers. See Section 9.4.3.3 for reference. f.

Remove transformer access panels.

g. Tag and disconnect wiring leads from the transformer.

10-17

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 h. Remove conduit and wires from the PDC and panel board.

i.

Place a strap around the transformer and connect it to a lift. Remove mounting hardware and carefully, remove the transformer from the PU. Extra care must be taken due to the transformer’s weight and size of work area.

10.4.1.4

INSTALL STATION POWER TRANSFORMER WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING PRIOR TO TROUBLESHOOTING THE POWER UNIT (PU), ENSURE THE TIE AND FEEDER CABLES ARE ALL INSTALLED ON PARKING STANDS, TO PREVENT THE POSSIBILITY OF UTILITY POWER BEING FED BACK INTO GENERATOR SET. ENSURE EQUIPMENT IS PROPERLY TAGGED AND NOT ENERGIZED. RESIDUAL VOLTAGE IS PRESENT AT THE GENERATOR LEADS WITH THE REGULATOR TURNED OFF, REACHING SEVERAL HUNDRED VOLTS ON THE GENERATOR SET. PROPER INSULATION AND ISOLATION OF METERING EQUIPMENT MUST BE OBSERVED WHEN TESTING GENERATOR. USE PROPER TEST EQUIPMENT TO CHECK FOR VOLTAGE BEFORE PROCEEDING. FAILURE TO COMPLY MAY RESULT IN DEATH BY ELECTROCUTION. WARNING DISCHARGE CAPACITIVE CHARGE FROM ALL EXPOSED CONDUCTORS WARNING USE OF A LIFTING DEVICE IS RECOMMENDED FOR REMOVING THE STATION POWER TRANSFORMER. EXTREMELY HEAVY OVER 100 LBS To install the Station Power Transformer, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures in paragraph 10.4.1.1. b. Reinstall the transformer from either side of the PU, and secure with the mounting hardware. c.

Reinstall the conduit from the PDC and Panel Board.

d. Connect wiring to the transformer and discard tags. e. Reinstall and secure access cover panels with mounting hardware.

10-18

f. f.

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 Reinstall both Battery Chargers. See Section 9.4.3.4 for reference. Reinstall the transformer fuses. Close the Tie Panel by swinging it inward and secure the door with the four (4) mounting screws.

10.4.2

208/120VAC RECEPTACLES

The following maintenance procedures are provided for the 208/120VAC Receptacles: Inspect Test Remove Install

FIGURE 10.4.2-1

208VAC AND 120VAC EXTERNAL RECEPTACLES

10-19

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254

FIGURE 10.4.2-2

120VAC INTERNAL RECEPTACLES

There are two 120 VAC, 20-amp, single-phase, GFCI duplex receptacles and one 208 VAC, three-phase, 60 amp receptacle located under the trailer housing on the roadside of the unit. (See Figure 10.4.2-1). There are also two 120VAC internal receptacles, located under the panel board, near the rear of the alternator (See Figure 10.4.2-2). 10.4.2.1

INSPECT 208/120VAC RECEPTACLES

Inspect the 208/120VAC receptacles for the following conditions: a. Loose connections and shorted, frayed, or broken wires. b. Security of attachment. c.

Signs of burning or overheating.

d. Cover for proper operation.

10-20

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 10.4.2.2

TEST 208/120VAC RECEPTACLES

10.4.2.2.1

TEST 208/120VAC RECEPTACLES (INTERNAL AND EXTERNAL)

To test the 208/120VAC receptacle, proceed as follows: WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. a.

Ensure receptacles are free of foreign matter.

b.

Using a multimeter set to AC scale, • • •

10.4.2.2.2

Check presence of 120VAC in receptacles phase to neutral. Check 208VAC, phase to phase, and 120VAC phase to neutral in the three phase receptacle. Using a phase rotation meter, Check for proper phase rotation (A, B, C) at the 208 VAC receptacle TEST 120-VAC (GFCI) DUPLEX RECEPTACLES

To test the GFCI Receptacles, proceed as follows: a.

With the system energized, press the (TEST) button on the receptacle.

b. Press the (RESET) button. The receptacle should reset. c.

Test receptacle with multimeter in “AC” mode. Ensure the receptacle is energized with the RESET in and de-energized with the reset out (TRIPPED).

10.4.2.2.3

REMOVE 120/208 VAC RECEPTACLES AND (EXTERNAL) WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING PRIOR TO TROUBLESHOOTING THE POWER UNIT (PU), ENSURE THE TIE AND FEEDER CABLES ARE ALL INSTALLED ON PARKING STANDS, TO PREVENT THE POSSIBILITY OF UTILITY POWER BEING FED BACK INTO GENERATOR SET. ENSURE EQUIPMENT IS PROPERLY TAGGED AND NOT ENERGIZED. RESIDUAL VOLTAGE IS PRESENT AT THE GENERATOR LEADS WITH THE REGULATOR TURNED OFF, REACHING SEVERAL HUNDRED VOLTS ON THE GENERATOR SET. PROPER INSULATION AND ISOLATION OF METERING EQUIPMENT MUST BE OBSERVED WHEN TESTING GENERATOR. USE PROPER TEST EQUIPMENT TO CHECK FOR VOLTAGE BEFORE PROCEEDING. FAILURE TO COMPLY MAY RESULT IN DEATH BY ELECTROCUTION.

10-21

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 To Remove the 120/208 VAC Receptacles (External): a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. This is accomplished by performing the following: (1) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. (2) Isolate the PU from any power plant or utility connection in accordance with Section 5.9.6.15, Unit Isolation Procedure with PSC. See Note 1 and 2. (3) Isolate the PU from any power plant control system in accordance with Note 3. (4) Pull to open the PU DC Power Control Breaker. (5) Push to open both Emergency Stop Switches. (6) Place both Engine Control Switches (ECS) in the OFF position. (7) Place a DO NOT OPERATE tag on both generator control panels. (8) Turn the Battery Bank Parallel Switch to the OFF position. (9) De-energize both Battery Chargers. (10)Disconnect the negative and positive cables from both Battery Banks. (11)Place a DO NOT OPERATE tag on both Battery Banks. (12)Place all Circuit Breakers in the LOCK OUT position. (13)Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. (14)Close and Lock both generator set control panels. NOTE 1:

Also the PU must be completely electrically isolated from the power distribution bus and any other electrical source that can back feed into the PU. All medium voltage cables need to be placed on the standoff insulators by use of hot sticks and other safety gear.

NOTE 2:

Ensure cables are not energized by opening the circuit breaker of the Primary Switching Center (PSC), then disconnect Load Cables (Using the proper safety gear) on the PU and place them on the Parking Stands.

NOTE 3:

When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Place the correct circuit brekaer located in PU Distribution Center to the OFF position. CB2 is the 120/208 VAC 3-phase 60 amp receptacle. CB3 is the 120 VAC GFI receptacles c.

Ensure power is removed from the receptacles by checking for AC voltage with a multimeter.

d. Remove screws from receptacle cover plate. e. Remove screw from receptacle and remove. f.

Tag and Disconnect wires from receptacle.

10-22

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 10.4.2.2.4

INSTALL 120/208 VAC RECEPTACLES AND (EXTERNAL)

To Install the 120/208 VAC Receptacles (External) a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures and warnings in paragraph 10.4.2.2.3. b. Reconnect the wires to the receptacles. c.

Attach receptacle to the box.

d. Replace gasket and cover plate and secure with screws. e. Turn Circuit Breaker ON.

10-23

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 10.4.3

WIRING HARNESSES

The following maintenance procedures are provided for the Wiring Harnesses: Inspect Test Remove Install Repair Harnesses interconnect elements of the AC electrical power generation and control system. Refer to the drawing Fold-outs (FO) FO - 1 and FO – 44C to provide representations of components and circuit interconnection within the generator set. For the following tasks, isolate the PU from the high voltage source. 10.4.3.1

INSPECT WIRING HARNESS WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING PRIOR TO TROUBLESHOOTING THE POWER UNIT (PU), ENSURE THE TIE AND FEEDER CABLES ARE ALL INSTALLED ON PARKING STANDS, TO PREVENT THE POSSIBILITY OF UTILITY POWER BEING FED BACK INTO GENERATOR SET. ENSURE EQUIPMENT IS PROPERLY TAGGED AND NOT ENERGIZED. RESIDUAL VOLTAGE IS PRESENT AT THE GENERATOR LEADS WITH THE REGULATOR TURNED OFF, REACHING SEVERAL HUNDRED VOLTS ON THE GENERATOR SET. PROPER INSULATION AND ISOLATION OF METERING EQUIPMENT MUST BE OBSERVED WHEN TESTING GENERATOR. USE PROPER TEST EQUIPMENT TO CHECK FOR VOLTAGE BEFORE PROCEEDING. FAILURE TO COMPLY MAY RESULT IN DEATH BY ELECTROCUTION. WARNING DISCHARGE CAPACITIVE CHARGE FROM ALL EXPOSED CONDUCTORS To inspect the wiring harnesses, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. This is accomplished by performing the following: (1) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. (2) Isolate the PU from any power plant or utility connection in accordance with Section 5.9.6.15, Unit Isolation Procedure with PSC. See Note 1 and 2.

10-24

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (3) Isolate the PU from any power plant control system in accordance with Note 3. (4) Pull to open the PU DC Power Control Breaker. (5) Push to open both Emergency Stop Switches. (6) Place both Engine Control Switches (ECS) in the OFF position. (7) Place a DO NOT OPERATE tag on both generator control panels. (8) Turn the Battery Bank Parallel Switch to the OFF position. (9) De-energize both Battery Chargers. (10)Disconnect the negative and positive cables from both Battery Banks. (11)Place a DO NOT OPERATE tag on both Battery Banks. (12)Place all Circuit Breakers in the LOCK OUT position. (13)Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. (14)Close and Lock both generator set control panels. NOTE 1:

Also the PU must be completely electrically isolated from the power distribution bus and any other electrical source that can back feed into the PU. All medium voltage cables need to be placed on the standoff insulators by use of hot sticks and other safety gear.

NOTE 2:

Ensure cables are not energized by opening the circuit breaker of the Primary Switching Center (PSC), then disconnect Load Cables (Using the proper safety gear) on the PU and place them on the Parking Stands.

NOTE 3:

When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Check wires for cracking insulation or frayed areas. c.

Check that all terminal lugs and screws are securely attached to wire ends.

d. Ensure that wires are tied together as tightly as possible to avoid rubbing. e. Check security of all hangers, clamps, and hardware that secure wiring harnesses to generator set. 10.4.3.2

TEST WIRING HARNESS

To test the wiring and harnesses using the following steps: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures and warnings in paragraph 10.4.3.1. b. Check all suspect wires for continuity to ground. Refer to applicable wiring diagram FO - 1 through FO – 44C. c.

Test wires relating to malfunctioning circuit for continuity and internal shorts, where there is an indication that a given harness is causing a malfunction.

10-25

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 10.4.3.3

REMOVE WIRING HARNESS

To remove the wiring and harnesses, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures and warnings in paragraph 10.4.3.1. b. Remove all hangers, clamps, and ties attaching harness being removed from generator set. c.

Tag and disconnect all wires terminating in lugs from their mountings by removing nuts and washers attached to their lugs.

d. Where wires are soldered to a connector, the connector is considered part of the harness and is reinstalled with the harness. Remove screws, nuts, and washers, as necessary, to remove multiple connectors. e. Remove harness from generator set by withdrawing wires past any obstruction until wires are free of generator set. 10.4.3.4

INSTALL WIRING HARNESS

To install wiring and harnesses, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures and warnings in paragraph 10.4.3.1. b. Refer to the appropriate wiring diagram FO - 1 through FO – 44C for the routing of harness being reinstalled. c.

Carefully feed replacement wires in the harness past any obstruction into position as follows: • • •

Ensure there is no strain on any wire when it is in place and its connectors and mounting lugs are attached to the generator set. Ensure no wire is bent over any sharp surface that might wear through wire insulation in normal service. Ensure no wire is in contact with any heat producing part of the engine or exhaust system.

d. Attach multiple connectors using screws, nuts, and washers removed previously. e. Attach all wires terminating in lugs to the correct stud or terminal by replacing mounting hardware removed in the prior section. 10.4.3.5

REPAIR WIRING HARNESS

To repair the wiring and harnesses, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures and warnings in paragraph 10.4.3.1. b. Repair wiring and harnesses in accordance with Technical Order TO 1-1A-14.

10-26

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 10.4.4

POWER PANEL BOARD

The following maintenance procedures are provided for the Power Panel Board: Inspect Test Remove Install

FIGURE 10.4.4-1 10.4.4.1

POWER PANEL BOARD

INSPECT PANEL BOARD

To inspect the panel board, proceed as follows: a. Inspect the Panel Board for damage. b. Inspect for looseness of hardware. c.

Inspect for missing hardware.

10-27

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 10.4.4.2

TEST PANEL BOARD AND BREAKERS WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING THE INSULATION TESTER PRODUCES HIGH VOLTAGE. TO AVOID PERSONAL INJURY DURING THE TEST, DO NOT TOUCH THE WINDING BEING TESTED OR THE TEST LEADS. WARNING FOLLOW MANUFACTURER'S TEST PROCEDURES INCLUDED WITH THE TEST EQUIPMENT WARNING PRIOR TO TROUBLESHOOTING THE POWER UNIT (PU), ENSURE THE TIE AND FEEDER CABLES ARE ALL INSTALLED ON PARKING STANDS, TO PREVENT THE POSSIBILITY OF UTILITY POWER BEING FED BACK INTO GENERATOR SET. ENSURE EQUIPMENT IS PROPERLY TAGGED AND NOT ENERGIZED. RESIDUAL VOLTAGE IS PRESENT AT THE GENERATOR LEADS WITH THE REGULATOR TURNED OFF, REACHING SEVERAL HUNDRED VOLTS ON THE GENERATOR SET. PROPER INSULATION AND ISOLATION OF METERING EQUIPMENT MUST BE OBSERVED WHEN TESTING GENERATOR. USE PROPER TEST EQUIPMENT TO CHECK FOR VOLTAGE BEFORE PROCEEDING. FAILURE TO COMPLY MAY RESULT IN DEATH BY ELECTROCUTION. To test the power panel board, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. This is accomplished by performing the following: (1) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. (2) Isolate the PU from any power plant or utility connection in accordance with Section 5.9.6.15, Unit Isolation Procedure with PSC. See Note 1 and 2. (3) Isolate the PU from any power plant control system in accordance with Note 3. (4) Pull to open the PU DC Power Control Breaker. (5) Push to open both Emergency Stop Switches. (6) Place both Engine Control Switches (ECS) in the OFF position. (7) Place a DO NOT OPERATE tag on both generator control panels. (8) Turn the Battery Bank Parallel Switch to the OFF position. (9) De-energize both Battery Chargers.

10-28

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (10)Disconnect the negative and positive cables from both Battery Banks. (11)Place a DO NOT OPERATE tag on both Battery Banks. (12)Place all Circuit Breakers in the LOCK OUT position. (13)Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. (14)Close and Lock both generator set control panels. NOTE 1:

Also the PU must be completely electrically isolated from the power distribution bus and any other electrical source that can back feed into the PU. All medium voltage cables need to be placed on the standoff insulators by use of hot sticks and other safety gear.

NOTE 2:

Ensure cables are not energized by opening the circuit breaker of the Primary Switching Center (PSC), then disconnect Load Cables (Using the proper safety gear) on the PU and place them on the Parking Stands.

NOTE 3:

When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. The MS-2 Circuit Breaker Tester or equivalent is required to test the circuit breakers. c.

Connect the test cables according to the test equipment manufactures recommendations.

d. Test each breaker according to the test equipment manufactures recommendations. e. No testing for the panel enclosure is required. 10.4.4.3

REMOVE PANEL BOARD

To remove the power panel board, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures and warnings in paragraph 10.4.3.1. b. Remove the 6 front cover-mounting screws and remove the front cover. c.

Remove the 5 interior cover-mounting screws and remove the interior cover.

d. Tag and disconnect the wiring from each circuit breaker and remove all conduit mounting hardware and remove all conduit from the panel. e. Disconnect wires, conduit hardware and box for switch, for interior lighting. f.

Remove the power distribution panel mounting bolts and remove the panel.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 10.4.4.4

INSTALL PANEL BOARD

To install the panel board, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures and warnings in paragraph 10.4.3.1. b. Reinstall the power distribution panel and secure with mounting hardware. c.

Reinstall all conduits with mounting hardware. Reconnect all wiring and remove wire tags.

d. Reinstall wires, conduit hardware and box for switch, for interior lighting. e. Reinstall the interior cover with the 5 mounting screws. f.

Reinstall the front cover with the 6 mounting screws.

10-30

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 10.4.5

ALTERNATOR

The following maintenance procedures are provided for the Alternator: Inspect Test Remove Install Generator Startup Checklist

FIGURE 10.4.5-1 10.4.5.1

ALTERNATOR

INSPECT ALTERNATOR

To inspect generator assembly, proceed as follows: a. Check that no wire is in contact with any sharp surface or any heat producing surface of the engine or exhaust system. b. Check for obstructions to air intakes and air outlets. c.

Check for signs of burning or overheating.

d. Before initial start-up or after storage of a generator, use a Megger to check insulation resistance for moisture and/or foreign material. See Section 10.4.5.2 for the procedure. A resistance reading of one megohm or less is an indication that the winding has absorbed too much moisture. Refer to SENR5359-01 or later version, SMCS CODE 4450 for additional reference.

10-31

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 If an oven is used for drying, use a forced air rather than a radiant oven because radiant ovens can cause localized overheating. If there is a possibility that insulation resistance has lowered to a dangerous level, contact your local Caterpillar Dealer.

NOTE:

e. The Strip Heater is not connected for DPGDS, there are no thermostats installed. The strip heater heats the windings to remove moisture and should be connected at all times in high humidity conditions. Use the strip heater only when the unit is not operating. To power the space heaters, connect an outside 115-volt or 220-volt cable to the space heater terminal block, located on top of the alternator housing. Stop the drying procedure every hour and check the insulation resistance. Remember, the only way to turn off the strip heaters is to unplug it from the power source. Continue the drying process until the insulation resistance is acceptable. f.

Alternative drying methods are explained in the Caterpillar manual SENR5359-01 or SEHS912401 or later versions.

10.4.5.2

TEST ALTERNATOR WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE HANGING CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE BURNS, LOSS OF LIMB AND OR DEATH. WARNING PRIOR TO TROUBLESHOOTING THE POWER UNIT (PU), ENSURE THE TIE AND FEEDER CABLES ARE ALL INSTALLED ON PARKING STANDS, TO PREVENT THE POSSIBILITY OF UTILITY POWER BEING FED BACK INTO GENERATOR SET. ENSURE EQUIPMENT IS PROPERLY TAGGED AND NOT ENERGIZED. RESIDUAL VOLTAGE IS PRESENT AT THE GENERATOR LEADS WITH THE REGULATOR TURNED OFF, REACHING SEVERAL HUNDRED VOLTS ON THE GENERATOR SET. PROPER INSULATION AND ISOLATION OF METERING EQUIPMENT MUST BE OBSERVED WHEN TESTING GENERATOR. USE PROPER TEST EQUIPMENT TO CHECK FOR VOLTAGE BEFORE PROCEEDING. FAILURE TO COMPLY MAY RESULT IN DEATH BY ELECTROCUTION. WARNING DISCHARGE CAPACITIVE CHARGE FROM ALL EXPOSED CONDUCTORS WARNING ENSURE THAT HEATER STRIP COVERS ARE ON WHEN GENERATOR IS RUNNING. LOW VOLTAGE IS PRESENT AT THE HEATER STRIP TERMINALS

10-32

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 WARNING THE INSULATION TESTER PRODUCES HIGH VOLTAGE. TO AVOID PERSONAL INJURY DURING THE TEST, DO NOT TOUCH THE WINDING BEING TESTED OR THE TEST LEADS. 10.4.5.2.1

RECOMMENDED PERIODIC INSULATION CHECKS

a. Periodically use a Megger to check generator main stator winding insulation resistance. The frequency of the insulation resistance test is determined by the generator’s environment and by previous Megger test indicators. b. Test the main stator windings with a Megger in the following situations: (1) Before initial startup of generator set. (2) After generator storage. (3) Every three months if generator is operating in a humid environment or is not protected from the elements by an enclosed area. (4) Every six months if the generator is installed in an enclosed area with relatively low humidity and minimal temperature variations. (5) If generator has not been run under load for three months or more. (6) Test every week and use space heaters if the generator is exposed to a seawater environment or if the surrounding conditions are very humid (relative humidity above 75%) or if a recent test reading was less than three megohm. In applications where salt and high humidity are present, space heaters must be operated whenever the generator is not operating under load. This is the only way to maintain Megger test readings above one megohm. c.

The insulation resistance check is described in Caterpillar Special Instruction Manual SEHS 9124-01. A reading of one megohm or less indicates that the winding has absorbed too much moisture.

NOTE:

10.4.5.2.2

This is a guideline only. It may be necessary to Megger more frequently if the environment is extremely humid, salty or if the last Megger test was close to one megohm. INSULATION RESISTANCE TEST

a. The presence of moisture, dust, grease and other foreign matter within the generator, causes the insulation on the coils of wire (windings) to deteriorate. This deterioration reduces the resistance of the insulation. b. The insulation resistance (Megger) test measures the resistance of the insulation on the windings. The insulation tester (Megger) produces a high potential voltage between the test leads. During the test, a small current flows which the tester converts to a resistance reading. This test is performed as part of periodic maintenance to detect the deterioration of the winding insulation. A rapid decrease of insulation resistance over a short period of time indicates the need for generator cleanup.

10-33

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 c.

The Megger test should also be performed to detect the presence of moisture on any generators that have not been used for a period of time. If moisture is present, the windings must be dried prior to testing. If the measured insulation resistance is less than specified and the clean up or drying procedure does not correct the discrepancy, the winding needs to be reconditioned or replaced.

d. The specified insulation resistance is an approximate value. It is possible to operate the generator with less than the specified value. However, a generator with low winding insulation resistance is far more likely to have a failure than a generator with acceptable insulation resistance. The test gives accurate results only when the generator windings are dry and at room temperature. e. The minimum recommended insulation resistance of each winding must be one meg-ohm (1,000,000 ohms) or greater. 10.4.5.2.2.1

TEST PROCEDURES

Refer to SENR5359-01 or later version, SMCS CODE 4450 for test procedures. The following test procedures are to be used as a guide only. WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE HANGING CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE BURNS, LOSS OF LIMB AND OR DEATH. WARNING PRIOR TO TROUBLESHOOTING THE POWER UNIT (PU), ENSURE THE TIE AND FEEDER CABLES ARE ALL INSTALLED ON PARKING STANDS, TO PREVENT THE POSSIBILITY OF UTILITY POWER BEING FED BACK INTO GENERATOR SET. ENSURE EQUIPMENT IS PROPERLY TAGGED AND NOT ENERGIZED. RESIDUAL VOLTAGE IS PRESENT AT THE GENERATOR LEADS WITH THE REGULATOR TURNED OFF, REACHING SEVERAL HUNDRED VOLTS ON THE GENERATOR SET. PROPER INSULATION AND ISOLATION OF METERING EQUIPMENT MUST BE OBSERVED WHEN TESTING GENERATOR. USE PROPER TEST EQUIPMENT TO CHECK FOR VOLTAGE BEFORE PROCEEDING. FAILURE TO COMPLY MAY RESULT IN DEATH BY ELECTROCUTION. WARNING DISCHARGE CAPACITIVE CHARGE FROM ALL EXPOSED CONDUCTORS WARNING ENSURE THAT HEATER STRIP COVERS ARE ON WHEN GENERATOR IS RUNNING. LOW VOLTAGE IS PRESENT AT THE HEATER STRIP TERMINALS

10-34

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 WARNING THE INSULATION TESTER PRODUCES HIGH VOLTAGE. TO AVOID PERSONAL INJURY DURING THE TEST, DO NOT TOUCH THE WINDING BEING TESTED OR THE TEST LEADS. WARNING FOLLOW MANUFACTURER'S TEST PROCEDURES INCLUDED WITH THE TEST EQUIPMENT 10.4.5.2.2.1.1

MAIN ARMATURE (STATOR-L4) TEST

To test the Main Armature (Stator L4), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. This is accomplished by performing the following: (1) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. (2) Isolate the PU from any power plant or utility connection in accordance with Section 5.9.6.15, Unit Isolation Procedure with PSC. See Note 1 and 2. (3) Isolate the PU from any power plant control system in accordance with Note 3. (4) Pull to open the PU DC Power Control Breaker. (5) Push to open both Emergency Stop Switches. (6) Place both Engine Control Switches (ECS) in the OFF position. (7) Place a DO NOT OPERATE tag on both generator control panels. (8) Turn the Battery Bank Parallel Switch to the OFF position. (9) De-energize both Battery Chargers. (10)Disconnect the negative and positive cables from both Battery Banks. (11)Place a DO NOT OPERATE tag on both Battery Banks. (12)Place all Circuit Breakers in the LOCK OUT position. (13)Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. (14)Close and Lock both generator set control panels. NOTE 1:

Also the PU must be completely electrically isolated from the power distribution bus and any other electrical source that can back feed into the PU. All medium voltage cables need to be placed on the standoff insulators by use of hot sticks and other safety gear.

NOTE 2:

Ensure cables are not energized by opening the circuit breaker of the Primary Switching Center (PSC), then disconnect Load Cables (Using the proper safety gear) on the PU and place them on the Parking Stands.

NOTE 3:

When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Remove the upper most access panel from the PDC (generator side).

10-35

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 c.

Discharge capacitive charges (with grounding stick) from all bus work and conductors.

d. Disconnect load cables T1, T2, T3, and T0 from PDC bus work. e. Isolate Isolate the main armature (L4) from the voltage regulator by disconnecting J11 and generator lead (T0) from the enclosure ground. Connector J11 is the deutsch connector on top of the alternator housing. f.

Remove the protective shroud from the rear of the generator.

g. Inspect all wiring, cables, and connectors for moisture, dirt and grime, etc. If moisture is present, DO NOT TEST. Dry unit first in accordance with Special Instructions SEHS 9124-01, Cleaning and Drying of Electrical Set Generators. h. Connect one test lead of the insulation tester (Megger) to the generator enclosure (ground). i.

Connect the other test lead of the Megger to generator lead T1.

j.

Apply 1,000 volts DC.

k.

The insulation resistance must be one megohm or greater.

l.

Repeat steps h – k for generator leads T2, T3, and T0.

m. Reconnect load cables T1, T2, T3, and T0 to the PDC bus work. n. Reconnect J11 connector and generator lead (T0) to the enclosure ground. o. Record the results on Table 10.4.5-1, using Figure 10.4.5-2 for temperature correction. p. Reinstall the PDC access panel q. Reinstall the generator protective shroud. 10.4.5.2.2.1.2

EXCITER FIELD (STATOR-L1) TEST

To test the Exciter Field (Stator L1), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures and warnings in paragraph 10.4.5.2.2.1. b. Remove the upper most access panel from the PDC (generator side). c.

Discharge capacitive charges (with grounding stick) from all bus work and conductors.

d. Disconnect load cables T1, T2, T3, and T0 from bus work. e. Isolate the exciter field (L1) from the voltage regulator by disconnecting J11 connector. f.

Remove the protective shroud from the rear of the generator.

g. Connect one test lead of the Megger to the generator enclosure (ground).

10-36

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 h. Connect the other test lead of the Megger to generator exciter field lead F1 or F2 (pin 6 or 7 of J11 connector). i.

Apply 1,000 volts DC.

j.

Measure the resistance of the exciter field winding insulation to ground. The resistance must be 0.25 megohm (250,000 ohms) or greater.

k.

Reconnect the J11 connector.

l.

Reconnect the load cables T1, T2, T3 and T0 to the PDC bus work.

m. Reinstall the PDC access panel. n. Reinstall the generator protective shroud. 10.4.5.2.2.1.3

EXCITER ARMATURE (ROTOR-L2) TEST

To test the Exciter Armature (Rotor L2), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures and warnings in paragraph 10.4.5.2.2.1. b. Remove the upper most access panel from the PDC (generator side). c.

Discharge capacitive charges (with a grounding stick) from all bus work and conductors.

d. Disconnect load cables T1, T2, T3, and T0 from the PDC bus work. e. Remove the protective shroud from the rear of the generator. f.

Isolate the exciter armature (L2) from the rectifier circuit. Disconnect AC1, AC2, and AC3 from the rectifier block. Refer to figure 10.4.6-2, pg. 10-58. Prevent these wires from touching one another or contacting ground.

g. Connect one Megger test lead to the rotor shaft. h. Connect the other test lead of the Megger to one of the exciter leads. i.

Apply 1,000 volts DC.

j.

Repeat steps g, h, and i for the remaining two leads.

k.

The insulation resistance must be 0.25 megohm (250,000 ohms) or greater.

l.

Reconnect the exciter armature (L2) AC1, AC2 and AC3 to the rectifier block. Torque screws to 20 – 25 in-lbs.

m. Reconnect the load cables T1, T2, T3 and T0 to the PDC bus work. n. Reinstall the PDC access panel. o. Reinstall the generator protective shroud.

10-37

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254

10.4.5.2.2.1.4

PILOT EXCITER ARMATURE (L5) TEST

To test the Pilot Exciter Armature (L5), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures and warnings in paragraph 10.4.5.2.2.1. b. Remove the upper most access panel from the PDC (generator side). c.

Discharge capacitive charges (with a grounding stick) from all bus work and conductors.

d. Disconnect load cables T1, T2, T3, and T0 from the PDC bus work. e. Remove the protective shroud from the rear of the generator. f.

Isolate the pilot exciter armature (L5) from the PDC AVR (Voltage Regulator) by disconnecting PMG 11, 12, and 13 from termination points J11-1, J11-2, and J11-3 (Refer to FO 35A).

g. Connect one test lead of the Megger to the generator enclosure (ground). h. Connect the other lead of the Megger to one lead of the pilot exciter armature (J11-1, 2 or 3). i.

Apply 1,000 volts DC.

j.

Repeat steps g, h and i for the other two leads.

k.

The insulation resistance must be 0.25 megohm (250,000 ohms) or greater.

l.

Record the results on Table 10.4.5-1, using Figure 10.4.5-2 for temperature correction.

m. Reinstall the shroud. n. Reconnect J11 connector. o. Reconnect load cables T1, T2, T3, and T0 to bus work. p. Reinstall PDC access panel. 10.4.5.2.2.1.5

MAIN ROTOR (L3) TEST

To test the Main Rotor (L3), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures and warnings in paragraph 10.4.5.2.2.1. b. Remove the upper most access panel from the PDC (generator side). c.

Discharge capacitive charges (with a grounding stick) from all bus work and conductors.

d. Disconnect load cables T1, T2, T3, and T0 from bus work.

10-38

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 e. Isolate the PDC AVR (Voltage Regulator) by disconnecting the J11 connector. f.

Remove the protective shroud from the rear of the generator.

g. Isolate the main rotor field (L3) from the rectifier circuit (diode block containing CR1 – CR6, Fig 10.4.6-2) by Disconnecting the positive and negative output wire from the diode block. h. Connect one test lead of the Megger to one of the main field wires (either positive or negative). i.

Connect the other lead of the Megger to any part of the main rotor shaft. The bolts which hold the rectifier block assembly onto the end of the main rotor is acceptable.

j.

Apply 1,000 volts DC.

k.

The insulation resistance must be 0.25 megohm (250,000 ohms) or greater.

l.

Record the results on Table 10.4.5-1, using Figure 10.4.5-2 for temperature correction.

m. Reinstall the positive and negative leads to the rectifer block. Torque to 20 to 25 in-lbs. n. Reinstall the shroud. o. Reconnect load cables T1, T2, T3, and T0 to bus work. p. Reinstall the J11 connector. q. Reinstall PDC access panel.

10-39

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 TABLE 10.4.5-1 GENERATOR INSULATION RESISTANCE TEST MAINTENANCE RECORD (EXAMPLE FORM) Engine S/N ________________________________________________________________________ Generator S/N ______________________________________________________________________ Date

30 Sec Read

60 Sec Read

Ambient Temperature

Correction factor

30 Sec. Corrected

60 Sec. Corrected

T1-GND T2-GND T3-GND T0-GND T1-T2 T2-T3 T1-T3

Comments: _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _________________________________________________________________________________

FIGURE 10.4.5-2

TEMPERATURE CORRECTION CHART

10-40

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 10.4.5.3

REMOVE ALTERNATOR

Refer to Caterpillar SR4B Service Manual SENR5359-01, dated September 1999, or later. Separating the generator from the engine and reattaching it are normally dealer level task. If this must be done in the field, follow the instructions in the Caterpillar manual SENR 5359-01. 10.4.5.4

INSTALL ALTERNATOR

Refer to Caterpillar SR4B Service Manual SENR5359-01, dated September 1999, or later. Separating the generator from the engine and reattaching it are normally dealer level task. If this must be done in the field, follow the instructions in the Caterpillar manual SENR 5359-01.

10-41

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 10.4.5.5

GENERATOR STARTUP CHECKLIST

TABLE 10.4.5.5-1 GENERATOR START-UP CHECKLIST (1 OF 2) (EXAMPLE FORM)

GENERATOR START-UP CHECKLIST RATING INFORMATION Engine Serial Number______________________ Arrangement Number______________________ Generator Serial Number___________________ Arrangement Number______________________ GENERATOR NAME PLATE INFORMATION Voltage__________________________________ Package______________ PRIME_____________ Amperage________________________________ Storage Location__________________________________________________________ Main stator Megger reading: Before Storage__________________ After Storage________________ Generator dried 24 hours prior to startup? (Y/N)______ Drying Method________________________ 30 Sec 60 Sec Megger Test 30 Sec 60 Sec Ambient Comments Reading Reading Reading Reading Temperature (SEHS 9124) Corrected Corrected Main Stator Main Rotor Beginning Exciter of storage Stator Exciter Rotor PMG Stator Main Stator Main Rotor Exciter Start-up Stator Exciter Rotor PMG Stator REGULATOR Voltage Amps Comments F1 to F2 DC 20 to 22 AC 20 to 24 AC No Load 22 to 24 AC 26 to 28 AC 26 to 30 AC 28 to 30 AC

10-42

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 TABLE 10.4.5.5-1 GENERATOR START-UP CHECKLIST (2 OF 2) (EXAMPLE FORM)

Generator Start-up Checklist (Continued) Generator Excitation name plate information F1 to F2 20 to 22 Full Load 20 to 24 22 to 24 26 to 28 26 to 30 28 to 30 ELECTRICAL Unit properly grounded: Check diodes Over current protection Over voltage protection Check for loose wiring Adjust voltage Adjust frequency MECHANICAL Bearing temperature Stator temperature Air gap on main stator Air gap on exciter stator Air gap of PMG Ambient air generator at Full Load Supply air opening to generator

DC AC AC AC AC AC AC AC Yes

Front A∅ Top Top Top

Compare to F1 to F2

No

Data Rear B∅ C∅ Bottom Bottom Bottom Temperature Size of Opening

Comments

Comments

(See Table 10.4.5.5-1) This form is optional and may be used at your organization. The form is used to create baseline information. It should be used whenever major maintenance is accomplished, such as an overhaul or alternator replacement. The form should be kept on file and referred to during the life of the equipment.

10-43

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 10.4.6

VARISTOR AND RECTIFIER BLOCK ASSEMBLY

The following maintenance procedures are provided for the Varistor (CR8) and Rectifier Block Assembly Inspect Test Remove Install

RECTIFIER BLOCK W/VARISTOR CR7

FIGURE 10.4.6-1

ROTATING FIELD ASSEMBLY

10-44

CR8 VARISTOR

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254

FIGURE 10.4.6-2

RECTIFIER BLOCK ASSEMBLY LABELED

FIGURE 10.4.6-3

DIODE RECTIFIER BLOCK

10-45

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254

FIGURE 10.4.6-4 10.4.6.1

VARISTOR CR8

INSPECT VARISTOR AND RECTIFIER BLOCK ASSEMBLY

To inspect the Rectifier Block assembly, perform the following: a. Check for signs of burning or overheating. b. Check for loose or missing hardware. 10.4.6.2

TEST RECTIFER BLOCK AND VARISTOR (CR7) ASSEMBLY

Refer to Caterpillar Manual SENR5359-01 or later for reference. are to be used as a guide only.

The following test procedures

WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE HANGING CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE BURNS, LOSS OF LIMB AND OR DEATH.

10-46

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 WARNING PRIOR TO TROUBLESHOOTING THE POWER UNIT (PU), ENSURE THE TIE AND FEEDER CABLES ARE ALL INSTALLED ON PARKING STANDS, TO PREVENT THE POSSIBILITY OF UTILITY POWER BEING FED BACK INTO GENERATOR SET. ENSURE EQUIPMENT IS PROPERLY TAGGED AND NOT ENERGIZED. RESIDUAL VOLTAGE IS PRESENT AT THE GENERATOR LEADS WITH THE REGULATOR TURNED OFF, REACHING SEVERAL HUNDRED VOLTS ON THE GENERATOR SET. PROPER INSULATION AND ISOLATION OF METERING EQUIPMENT MUST BE OBSERVED WHEN TESTING GENERATOR. USE PROPER TEST EQUIPMENT TO CHECK FOR VOLTAGE BEFORE PROCEEDING. FAILURE TO COMPLY MAY RESULT IN DEATH BY ELECTROCUTION. WARNING DISCHARGE CAPACITIVE CHARGE FROM ALL EXPOSED CONDUCTORS WARNING ENSURE THAT HEATER STRIP COVERS ARE ON WHEN GENERATOR IS RUNNING. LOW VOLTAGE IS PRESENT AT THE HEATER STRIP TERMINALS WARNING THE INSULATION TESTER PRODUCES HIGH VOLTAGE. TO AVOID PERSONAL INJURY DURING THE TEST, DO NOT TOUCH THE WINDING BEING TESTED OR THE TEST LEADS. WARNING FOLLOW MANUFACTURER'S TEST PROCEDURES INCLUDED WITH THE TEST EQUIPMENT To test the Rectifier Block and varistor (CR7) assembly, perform the following: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. This is accomplished by performing the following: (1) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. (2) Isolate the PU from any power plant or utility connection in accordance with Section 5.9.6.15, Unit Isolation Procedure with PSC. See Note 1 and 2. (3) Isolate the PU from any power plant control system in accordance with Note 3. (4) Pull to open the PU DC Power Control Breaker. (5) Push to open both Emergency Stop Switches. (6) Place both Engine Control Switches (ECS) in the OFF position. (7) Place a DO NOT OPERATE tag on both generator control panels. (8) Turn the Battery Bank Parallel Switch to the OFF position. (9) De-energize both Battery Chargers. (10)Disconnect the negative and positive cables from both Battery Banks.

10-47

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (11)Place a DO NOT OPERATE tag on both Battery Banks. (12)Place all Circuit Breakers in the LOCK OUT position. (13)Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. (14)Close and Lock both generator set control panels. NOTE 1:

Also the PU must be completely electrically isolated from the power distribution bus and any other electrical source that can back feed into the PU. All medium voltage cables need to be placed on the standoff insulators by use of hot sticks and other safety gear.

NOTE 2:

Ensure cables are not energized by opening the circuit breaker of the Primary Switching Center (PSC), then disconnect Load Cables (Using the proper safety gear) on the PU and place them on the Parking Stands.

NOTE 3:

When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. The following procedure tests all six diodes within the block. Replace the rectifier block if any meter reading differs from the one given. Refer to Figure 10.4.6-3 for referance. c.

Remove grounds from the alternator.

d. Remove the protective shroud from the rear of the generator. e. Set the digital multimeter on the diode range. f.

Tag all leads then remove all leads from the rectifier block.

g. Place the black lead on the positive (+) rectifier terminal. Place the red test lead on the following rectifier terminals: AC1, then AC2, and then AC3. All readings on the meter should be between 0.4 and 1.0. Refer to Figure 10.4.6-3 for referance. h. Place the red lead on the negative (-) rectifier terminal. Place the black test lead on the following rectifier terminals: AC1, then AC2, and then AC3. All readings on the meter should be between 0.4 and 1.0. i.

Place the red test lead on the positive (+) rectifier terminal. Place the black test lead on rectifier terminals: AC1, then AC2, and then AC3. In all cases, the meter should be OL (overload).

j.

Place the black test lead on the negative (-) rectifier terminal. Place the red test lead on rectifier terminals: AC1, then AC2, and then AC3. In all cases, the meter should be OL (overload).

NOTE:

A shorted diode can cause damage to the exciter rotor. If a diode is shorted, check the exciter rotor. Refer to the Caterpillar manual SENR5359-01, Testing and Adjusting Section, "Winding-Test".

NOTE:

This rectifier block also contains Varistor "CR7". "CR7" can be checked by measuring the resistance between the positive (+) rectifier terminal and the negative (-) rectifier terminal. The resistance should be a minimum of 15,000 ohms.

10-48

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 10.4.6.3

TEST RECTIFER BLOCK ASSEMBLY

Refer to Caterpillar Manual SENR5359-01 or later for reference. are to be used as a guide only.

The following test procedures

To test the varistor assembly (CR8), perform the following: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures and warnings in paragraph 10.4.6.2. b. To check the varistor (CR8), first disconnect the two leads from the (+) and (-) terminals of the varistor, then measure the resistance between the positive (+) rectifier terminal and the negative (-) rectifier terminal. The resistance reading should be 15,000 ohms or greater. Refer to Figure 10.4.6-4. 10.4.6.4

REMOVE VARISTOR AND RECTIFIER BLOCK ASSEMBLY

To remove the varistor and rectifier block assembly, perform the following: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures and warnings in paragraph 10.4.6.2 b. Remove the alternator protective cover. c. Tag and Remove all wires on the rectifier block and varistor. NOTE:

The wires are not marked at the factory. The wires must be marked prior to removal.

d. Loosen the four bolts and Remove entire Heat Sink Assembly with rectifier block and varistor still attached. e. Remove as required the rectifier or varistor. f. NOTE: sink.

Clean the heat sink assembly of old thermal compound. A thermal heat sink compound must be used between the rectifier components and the heat

g. Place Thermal Compound (CAT part number 5P-8937) on new rectifier block as required following manufacturer’s instructions. NOTE: Thermal Compound not required on Varistor. h. Replace rectifier block or varistor on heat sink assembly using existing hardware. i.

Paint Stripe the nut and threads of the rectifier block or varistor mounting hardware to prevent from loosening.

10-49

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 INSTALL VARISTOR AND RECTIFIER BLOCK ASSEMBLY

10.4.6.5

To install the varistor and rectifier block assembly, perform the following: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures and warnings in paragraph 10.4.6.2. b. Place Thread Lock Compound on Heat Sink bolt threads following the manufacturer’s instructions. c.

Remount the entire heat sink assembly with rectifier block and varistor attached using the four mounting bolts. Torque to 26 lbs/ft ± 3. Use Figure 10.4.6-1 and Figure 10.4.6-2 for reference.

d. Reconnect all wires to the rectifier block or varistor as required using new hardware provided and Remove tags. Torque nuts and screws as follows: ƒ ƒ

Rectifier Block (22 lb/in ± 2) Varistor (18 lb/in ± 2)

e. Secure wires with wire ties as needed. f.

Reinstall the alternator protective cover.

g. Prepare the unit for operation. h. Start the PU according to the Operation Section Chapter 5. produced on all three phases. Shut down unit.

10-50

Ensure that voltage is being

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 10.4.7

MEDIUM VOLTAGE OUTPUT TERMINALS

The following maintenance procedures are provided for the Medium Voltage Output Terminals: Inspect Test Remove Install The Feeder Output Terminals (F1 and F2) are located on the lower street-side of the PDC. The Tie Output Terminals are located on the lower curb-side of the PDC. The Feeder Output Terminals are used to connect the PU to Secondary Distribution Center (SDC). In addition, the Tie Output Terminals are used connect the PU to another PU, PSC or utility. See Figure 10.4.7-1 and Figure 10.4.7-2 for reference.

FIGURE 10.4.7-1

TIE OUTPUT TERMINALS

10-51

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254

FIGURE 10.4.7-2 10.4.7.1

FEEDER OUTPUT TERMINALS

INSPECT MEDIUM VOLTAGE OUTPUT TERMINAL WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE HANGING CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE BURNS, LOSS OF LIMB AND OR DEATH. WARNING PRIOR TO TROUBLESHOOTING THE POWER UNIT (PU), ENSURE THE TIE AND FEEDER CABLES ARE ALL INSTALLED ON PARKING STANDS, TO PREVENT THE POSSIBILITY OF UTILITY POWER BEING FED BACK INTO GENERATOR SET. ENSURE EQUIPMENT IS PROPERLY TAGGED AND NOT ENERGIZED. RESIDUAL VOLTAGE IS PRESENT AT THE GENERATOR LEADS WITH THE REGULATOR TURNED OFF, REACHING SEVERAL HUNDRED VOLTS ON THE GENERATOR SET. PROPER INSULATION AND ISOLATION OF METERING EQUIPMENT MUST BE OBSERVED WHEN TESTING GENERATOR. USE PROPER TEST EQUIPMENT TO CHECK FOR VOLTAGE BEFORE PROCEEDING. FAILURE TO COMPLY MAY RESULT IN DEATH BY ELECTROCUTION.

10-52

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 WARNING DISCHARGE CAPACITIVE CHARGE FROM ALL EXPOSED CONDUCTORS To inspect Medium Voltage Output Terminals, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. This is accomplished by performing the following: (1) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. (2) Isolate the PU from any power plant or utility connection in accordance with Section 5.9.6.15, Unit Isolation Procedure with PSC. See Note 1 and 2. (3) Isolate the PU from any power plant control system in accordance with Note 3. (4) Pull to open the PU DC Power Control Breaker. (5) Push to open both Emergency Stop Switches. (6) Place both Engine Control Switches (ECS) in the OFF position. (7) Place a DO NOT OPERATE tag on both generator control panels. (8) Turn the Battery Bank Parallel Switch to the OFF position. (9) De-energize both Battery Chargers. (10)Disconnect the negative and positive cables from both Battery Banks. (11)Place a DO NOT OPERATE tag on both Battery Banks. (12)Place all Circuit Breakers in the LOCK OUT position. (13)Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. (14)Close and Lock both generator set control panels. NOTE 1:

Also the PU must be completely electrically isolated from the power distribution bus and any other electrical source that can back feed into the PU. All medium voltage cables need to be placed on the standoff insulators by use of hot sticks and other safety gear.

NOTE 2:

Ensure cables are not energized by opening the circuit breaker of the Primary Switching Center (PSC), then disconnect Load Cables (Using the proper safety gear) on the PU and place them on the Parking Stands.

NOTE 3:

When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Remove access panels. Refer to Figure 10.4.7-1 and 10.4.7-2. c.

Visually inspect all load terminal bushings for cracks, signs of overheating, and other damage.

d. Check terminal lug connections for secure mounting. Check wiring for signs of insulation breakdown such as cracked sleeves and burned insulation. e. Inspect all cable terminal bushings for cleanliness, cracks, signs of overheating, and secure mounting. Check that the conductor terminal inside each bushing is clean and free from any obstruction. f.

Apply a light coat of silicon lubricant to the exterior of the bushing well.

10-53

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 10.4.7.2

TEST MEDIUM VOLTAGE OUTPUT TERMINAL

Refer to Caterpillar Manual SENR5359-01 or later for reference. are to be used as a guide only.

The following test procedures

WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE HANGING CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE BURNS, LOSS OF LIMB AND OR DEATH. WARNING PRIOR TO TROUBLESHOOTING THE POWER UNIT (PU), ENSURE THE TIE AND FEEDER CABLES ARE ALL INSTALLED ON PARKING STANDS, TO PREVENT THE POSSIBILITY OF UTILITY POWER BEING FED BACK INTO GENERATOR SET. ENSURE EQUIPMENT IS PROPERLY TAGGED AND NOT ENERGIZED. RESIDUAL VOLTAGE IS PRESENT AT THE GENERATOR LEADS WITH THE REGULATOR TURNED OFF, REACHING SEVERAL HUNDRED VOLTS ON THE GENERATOR SET. PROPER INSULATION AND ISOLATION OF METERING EQUIPMENT MUST BE OBSERVED WHEN TESTING GENERATOR. USE PROPER TEST EQUIPMENT TO CHECK FOR VOLTAGE BEFORE PROCEEDING. FAILURE TO COMPLY MAY RESULT IN DEATH BY ELECTROCUTION. WARNING DISCHARGE CAPACITIVE CHARGE FROM ALL EXPOSED CONDUCTORS WARNING THE INSULATION TESTER PRODUCES HIGH VOLTAGE. TO AVOID PERSONAL INJURY DURING THE TEST, DO NOT TOUCH THE WINDING BEING TESTED OR THE TEST LEADS. WARNING DO NOT COME IN CONTACT WITH LOAD TERMINAL DURING TEST. DEATH BY ELECTROCUTION MAY RESULT WARNING FOLLOW MANUFACTURER'S TEST PROCEDURES INCLUDED WITH THE TEST EQUIPMENT To test Medium Voltage Output Terminals, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. This is accomplished by performing the following:

10-54

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (1) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. (2) Isolate the PU from any power plant or utility connection in accordance with Section 5.9.6.15, Unit Isolation Procedure with PSC. See Note 1 and 2. (3) Isolate the PU from any power plant control system in accordance with Note 3. (4) Pull to open the PU DC Power Control Breaker. (5) Push to open both Emergency Stop Switches. (6) Place both Engine Control Switches (ECS) in the OFF position. (7) Place a DO NOT OPERATE tag on both generator control panels. (8) Turn the Battery Bank Parallel Switch to the OFF position. (9) De-energize both Battery Chargers. (10)Disconnect the negative and positive cables from both Battery Banks. (11)Place a DO NOT OPERATE tag on both Battery Banks. (12)Place all Circuit Breakers in the LOCK OUT position. (13)Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. (14)Close and Lock both generator set control panels. NOTE 1:

Also the PU must be completely electrically isolated from the power distribution bus and any other electrical source that can back feed into the PU. All medium voltage cables need to be placed on the standoff insulators by use of hot sticks and other safety gear.

NOTE 2:

Ensure cables are not energized by opening the circuit breaker of the Primary Switching Center (PSC), then disconnect Load Cables (Using the proper safety gear) on the PU and place them on the Parking Stands.

NOTE 3:

When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Isolate the bushing by disconnecting the load cable from the rear of the bushing. c.

Turn off test equipment before connecting a 30 kV DC hi-pot tester to the load terminal.

d. Connect the positive lead of the 30 kV DC hi-pot tester to the center conductor of the load terminal. e. Connect negative lead of tester to outer shield of parallel or feeder cable terminal. f.

Set all controls on tester to zero and turn tester on.

10-55

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 g. Slowly increase output voltage of tester to 5 kV and maintain for 1 minute. Record current meter reading. h. Slowly increase tester output to 10 kV for one minute and record current meter reading. i.

Slowly increase tester output to 15 kV and maintain for 15 minutes. Record readings at one minute intervals.

j.

After 15 minutes, slowly decrease tester output to zero volts and turn tester off.

k.

Use ground discharging stick to discharge any residual voltage.

l.

Ensure tester is turned off. Leakage current is dependent on insulation condition as well as atmospheric conditions (humidity). Leakage current normally should not exceed 50 microamperes.

NOTE:

m. Disconnect leads from load terminal. Compare all meter readings taken during test. Any sharp increase in readings during waiting periods indicates insulation breakdown of load terminal and terminal should be replaced. 10.4.7.3

REMOVE MEDIUM VOLTAGE OUTPUT TERMINAL

7

1

2 3

4

6

5

(1) Load Terminal Insert (2) Load Terminal Bushing (3) Mounting Plate (4) Protective Cover (5) Securing Cable (6) Load Terminal (7) Load Terminal Mounting Bolt FIGURE 10.4.7.3-1

TYPICAL LOAD TERMINAL BREAKOUT

10-56

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 To remove the Medium Voltage Output Terminals, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures and warnings in paragraph 10.4.7.2.

FIGURE 10.4.7.3-2

LOWER FRONT COVER

b. Remove lower front cover of the PDC. Refer to Figure 10.4.7.3-2. c.

Remove protective cover (4), and load terminal insert (1), of the output terminal you wish to remove.

d. Remove the mounting plate (3)and securing cable (5) mounting hardware for the entire bank of output terminals. e

Remove the (3M) Heat Shrink Tubing from the terminal connection.

f.

Remove the Load terminal mounting bolt (7) and load terminal (6).

10-57

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 10.4.7.4

INSTALL MEDIUM VOLTAGE OUTPUT TERMINAL

To install the Medium Voltage Output Terminals, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures and warnings in paragraph 10.4.7.2. b. Reinstall the Load Terminal bushing (2). Reinstall load terminal mounting bolt (7), load terminal (6) and (3M, BBI-3A Heat Shrinkable Tubing) or equivalant. (For torque requirements manufactures reinstallation literature). Refer to Figure 10.4.7.3-1. c.

Reinstall the mounting plate (3)and securing cable (5) mounting hardware for the entire bank of output terminals.

d. Reinstall the load terminal insert (1) and torque to manufactures specifications. (Special tool may be required). e. Reinstall the load output terminal protective covers (4). f.

Reinstall lower front cover of the PDC.

10-58

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 10.4.8

SURGE ARRESTERS (SA1, SA2, SA3)

The following maintenance procedures are provided for the Surge Arresters: Inspect Test Remove Install

FIGURE 10.4.8-1

SURGE ARRESTERS (SA1, SA2, SA3)

Surge Arresters are connected to the system bus bars, internal to the PDC. They are UltraSil heavy-duty type UHS (MOV) Metal Oxide Varistors, rated at 3 kV, and 2.55 kV Maximum Continuous Overvoltage (MCOV). The MOVs are contained in a silicone rubber housing. There is one arrester for each phase of the bus, for a total of three.

10-59

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 10.4.8.1

INSPECT SURGE ARRESTER (SA1, SA2, SA3) WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE HANGING CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE BURNS, LOSS OF LIMB AND OR DEATH. WARNING PRIOR TO TROUBLESHOOTING THE POWER UNIT (PU), ENSURE THE TIE AND FEEDER CABLES ARE ALL INSTALLED ON PARKING STANDS, TO PREVENT THE POSSIBILITY OF UTILITY POWER BEING FED BACK INTO GENERATOR SET. ENSURE EQUIPMENT IS PROPERLY TAGGED AND NOT ENERGIZED. RESIDUAL VOLTAGE IS PRESENT AT THE GENERATOR LEADS WITH THE REGULATOR TURNED OFF, REACHING SEVERAL HUNDRED VOLTS ON THE GENERATOR SET. PROPER INSULATION AND ISOLATION OF METERING EQUIPMENT MUST BE OBSERVED WHEN TESTING GENERATOR. USE PROPER TEST EQUIPMENT TO CHECK FOR VOLTAGE BEFORE PROCEEDING. FAILURE TO COMPLY MAY RESULT IN DEATH BY ELECTROCUTION. WARNING DISCHARGE CAPACITIVE CHARGE FROM ALL EXPOSED CONDUCTORS WARNING ALWAYS CONSIDER AN ARRESTER TO BE ENERGIZED UNTIL THE LINE AND GROUND LEADS HAVE BEEN DISCONNECTED FROM THE CIRCUIT. NEVER INSTALL A DAMAGED ARRESTER. A DAMAGED ARRESTER MAY MISSOPERATE VIOLENTLY, CAUSING SEVERE PERSONAL INJURY. CAUTION ALWAYS HANDLE SURGE ARRESTERS PACKED OR UNPACKED-VERY CAREFULLY. DO NOT DROP, JAR, OR HANDLE AN ARRESTER ROUGHLY. DROPPING, JARRING, AND/OR ROUGH HANDLING MAY DAMAGE THE ARRESTER INTERNALLY OR EXTERNALLY. THIS COULD MAKE THE ARRESTER INCAPABLE OF PROTECTING THE CIRCUIT AND COULD SHORTEN THE SERVICE LIFE OF THE ARRESTER SIGNIFICANTLY. To inspect the Surge Arrestor, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. This is accomplished by performing the following: (1) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. (2) Isolate the PU from any power plant or utility connection in accordance with Section 5.9.6.15, Unit Isolation Procedure with PSC. See Note 1 and 2.

10-60

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (3) Isolate the PU from any power plant control system in accordance with Note 3. (4) Pull to open the PU DC Power Control Breaker. (5) Push to open both Emergency Stop Switches. (6) Place both Engine Control Switches (ECS) in the OFF position. (7) Place a DO NOT OPERATE tag on both generator control panels. (8) Turn the Battery Bank Parallel Switch to the OFF position. (9) De-energize both Battery Chargers. (10)Disconnect the negative and positive cables from both Battery Banks. (11)Place a DO NOT OPERATE tag on both Battery Banks. (12)Place all Circuit Breakers in the LOCK OUT position. (13)Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. (14)Close and Lock both generator set control panels. NOTE 1:

Also the PU must be completely electrically isolated from the power distribution bus and any other electrical source that can back feed into the PU. All medium voltage cables need to be placed on the standoff insulators by use of hot sticks and other safety gear.

NOTE 2:

Ensure cables are not energized by opening the circuit breaker of the Primary Switching Center (PSC), then disconnect Load Cables (Using the proper safety gear) on the PU and place them on the Parking Stands.

NOTE 3:

When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Remove left rear access panels. c.

Visually inspect Surge Arrestors for cracks, signs of overheating, and other damage.

d. Check Surge Arrestor electrical connections for tightness. Check wiring for signs of insulation breakdown such as cracked sleeves and burned insulation. 10.4.8.2

TEST SURGE ARRESTER (SA1, SA2, SA3)

All UltraSil arresters have passed a complete series of production tests prior to shipment; therefore, no field-testing is required.

10-61

10.4.8.3

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 REMOVE SURGE ARRESTER (SA1, SA2, SA3)

To remove the surge arrester, perform the following:

FIGURE 10.4.8-2

LEFT REAR OF PDC

a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures and warnings in paragraph 10.4.8.1. b. Remove the lower left rear PDC panel. Refer to Figure 10.4.8-2 for reference. c.

Discharge the arrester by shorting the line terminal temporarily to ground.

d. Remove the line and ground leads from the arrester. e. Remove the hex nut, lock washer, and flat washer from the mounting bracket. f.

Remove the arrester.

10-62

10.4.8.4

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 INSTALL SURGE ARRESTER (SA1, SA2, SA3)

To install the surge arrestor, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures and warnings in paragraph 10.4.8.1. b. Install the arrester on the hanger bracket with the bolt washer and nut. Refer to Figure 10.4.8-2 for reference. c.

Torque the arrester hanger bracket nut between 20 and 25 ft-lbs.

d. Reinstall the line and ground wires to each arrester. e. Torque the nuts on the line and ground wires to 20 ft-lbs.

10-63

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INSTRUMENT POTENTIAL TRANSFORMERS (PT)

The following maintenance procedures are provided for the Instrument Potential Transformers (PT) Inspect Test Remove Install PT 6A

PT 1A

PT 2A

PT 3A

FIGURE 10.4.9-1

POTENTIAL TRANSFORMERS LEFT OR RIGHT SECTION

See Figures 10.4.9-1 and 10.4.9-2 for reference. These transformers are used to step the 3800/4160VAC down to 110/120VAC for use by control system. The transformers are located behind the cover plates on the PDC. Potential Transformers PT1, PT2 PT3, PT4 and PT5 are 5 Volt Amps (VA), 50/60 Hertz (HZ), with a 34.56:1 Ratio. PT6, PT7 and PT8 are dual primary fuse, 50 HZ with a 35:1 ratio. The Potential Transformers are step-down transformers, which furnish voltage input for the various generator control, metering, and fault protection circuits.

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PT 7

FIGURE 10.4.9-2 10.4.9.1

PT 8

POTENTIAL TRANSFORMERS CENTER SECTION

INSPECT INSTRUMENT POTENTIAL TRANSFORMERS (PT)

To inspect the Instrument Potential Transformer, proceed as follows: a. Inspect for proper mounting. b. Check for loose connections, physical damage and heat damage. c.

Check wiring for signs of insulation breakdown such as cracked sleeves and burned insulation.

10.4.9.2

TEST INSTRUMENT POTENTIAL TRANSFORMERS (PT) WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE HANGING CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE BURNS, LOSS OF LIMB AND OR DEATH. WARNING PRIOR TO TROUBLESHOOTING THE POWER UNIT (PU), ENSURE THE TIE AND FEEDER CABLES ARE ALL INSTALLED ON PARKING STANDS, TO PREVENT THE POSSIBILITY OF UTILITY POWER BEING FED BACK INTO GENERATOR SET. ENSURE EQUIPMENT IS PROPERLY TAGGED AND NOT ENERGIZED. RESIDUAL VOLTAGE IS PRESENT AT THE GENERATOR LEADS WITH THE REGULATOR TURNED OFF, REACHING SEVERAL HUNDRED VOLTS ON THE GENERATOR SET. PROPER INSULATION AND ISOLATION OF METERING EQUIPMENT MUST BE OBSERVED WHEN TESTING GENERATOR. USE PROPER TEST EQUIPMENT TO CHECK FOR VOLTAGE BEFORE PROCEEDING. FAILURE TO COMPLY MAY RESULT IN DEATH BY ELECTROCUTION.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 WARNING DISCHARGE CAPACITIVE CHARGE FROM ALL EXPOSED CONDUCTORS TO PT WARNING THE INSULATION TESTER PRODUCES HIGH VOLTAGE. TO AVOID PERSONAL INJURY DURING THE TEST, DO NOT TOUCH THE WINDING BEING TESTED OR THE TEST LEADS. WARNING FOLLOW MANUFACTURER'S TEST PROCEDURES INCLUDED WITH THE TEST EQUIPMENT To test an Instrument Potential Transformer, proceed as follows: There are two recommended tests for the station transformer. They are the Insulation Resistance Test and the Turns Ratio Test. Both tests are to be performed during maintenance. To test the transformer perform the following: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. This is accomplished by performing the following: (1) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. (2) Isolate the PU from any power plant or utility connection in accordance with Section 5.9.6.15, Unit Isolation Procedure with PSC. See Note 1 and 2. (3) Isolate the PU from any power plant control system in accordance with Note 3. (4) Pull to open the PU DC Power Control Breaker. (5) Push to open both Emergency Stop Switches. (6) Place both Engine Control Switches (ECS) in the OFF position. (7) Place a DO NOT OPERATE tag on both generator control panels. (8) Turn the Battery Bank Parallel Switch to the OFF position. (9) De-energize both Battery Chargers. (10)Disconnect the negative and positive cables from both Battery Banks. (11)Place a DO NOT OPERATE tag on both Battery Banks. (12)Place all Circuit Breakers in the LOCK OUT position. (13)Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. (14)Close and Lock both generator set control panels. NOTE 1:

Also the PU must be completely electrically isolated from the power distribution bus and any other electrical source that can back feed into the PU. All medium voltage cables need to be placed on the standoff insulators by use of hot sticks and other safety gear.

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Ensure cables are not energized by opening the circuit breaker of the Primary Switching Center (PSC), then disconnect Load Cables (Using the proper safety gear) on the PU and place them on the Parking Stands.

NOTE 3:

When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Remove retaining screws and take off access panel. c.

Test fuses first. If fuses are good or bad, continue the test procedure.

d. Tag and disconnect wiring leads from the suspect transformer. e. Perform the following tests: 10.4.9.2.1

INSULATION RESISTANCE TEST

a. Using a multimeter set to OHMS (Ω) Rx1 scale, perform individual continuity checks on transformer primary and secondary windings. b. Connect a 500V Megger to either primary lead and to ground. Short the secondary terminals to ground before connecting Megger leads to primary terminals. Operate Megger for 60 seconds and observe resistance. Reading on each transformer should be not less than 20 meg-ohms. Short the primary lead to ground before disconnecting. c.

Short the high voltage terminals to ground before connecting Megger. Connect Megger to either secondary lead and to ground. Operate the Megger for 60 seconds and observe resistance. Reading should be not less than 1 meg-ohm. Short the secondary lead to ground before disconnecting.

d. Connect Megger between primary and secondary windings. Operate the Megger for 60 seconds and observe resistance. Reading should not be less than 20 meg-ohms. Short both windings to ground before disconnecting.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 10.4.9.2.2

TURN RATIO TEST

a. Tag and disconnect wiring leads from the suspect transformer. b. Turns ratio testing of transformers provides a direct means to detect loose or open connections, shorted or open turns in the transformer windings, incorrect polarity connections and to verify precisely the no-load voltage ratio of the transformer at all tap positions. c.

Perform a TTR test using the test equipments manufactures procedures. The turns ratio is required to be within ±1/2 percent or (.005), of the indicated nameplate voltage ratio.

Ep Es

=

Np = TR Ns

Ep =voltage primary Es =voltage secondary Np =number of turns primary Ns =number of turns secondary TR =turns ratio (primary to secondary d. If the transformer fails any of the above requirements, remove and forward to next higher level of maintenance. e. If the transformers meet above requirements, connect wiring leads and discard tags. 10.4.9.3

REMOVE INSTRUMENT POTENTIAL TRANSFORMERS (PT)

To remove an Instrument Potential Transformer, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures and warnings in paragraph 10.4.9.2. b. Open Generator and Tie Breaker Control panel doors. c.

Remove access covers retaining screws and set access covers aside. WARNING DISCHARGE CAPACITIVE CHARGE FROM ALL EXPOSED CONDUCTORS TO PT

d. Tag and disconnect all wires leading to and from the transformer. e. Remove mounting hardware for fuses if necessary and hardware from PT and remove PT from the switchgear panel in the PDC.

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INSTALL INSTRUMENT POTENTIAL TRANSFORMERS (PT)

To install an Instrument Potential Transformer, proceed as follows a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures and warnings in paragraph 10.4.9.2. b. Reinstall the transformer from front of the switchgear panels, and secure with the mounting hardware. c.

Reinstall fuses and hardware as necessary.

d. Connect wiring to the transformer and discard tags. e. Reinstall and secure access cover panels with mounting hardware. f.

Close Generator and Tie Breaker Control panel doors.

g. Ensure no equipment is energized prior to reconnecting cables. h. Reconnect Parallel and Load cables to load terminals. i.

Place the CBCP to ON.

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INSTRUMENT CURRENT TRANSFORMER (CT)

The following maintenance procedures are provided for the Instrument Current Transformers (CT): Inspect Test Remove Install

GENERATOR BREAKER CT

GENERATOR BREAKER CT

LOAD TIE CT

FEEDER CT FEEDER CT

FIGURE 10.4.10-1 INSTRUMENT CURRENT TRANSFORMERS See Figure 10.4.10-1 for reference. These transformers are used to step the various current level primaries down to a 5-amp secondary for use by control system. The transformers are located between the rear of the circuit breakers and the rear wall of the PDC. Some of the Generator CTs are partially accessible through a bolted on panel on the rear wall of the PDC.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 10.4.10.1

INSPECT INSTRUMENT CURRENT TRANSFORMER (CT) WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE HANGING CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE BURNS, LOSS OF LIMB AND OR DEATH. WARNING PRIOR TO TROUBLESHOOTING THE POWER UNIT (PU), ENSURE THE TIE AND FEEDER CABLES ARE ALL INSTALLED ON PARKING STANDS, TO PREVENT THE POSSIBILITY OF UTILITY POWER BEING FED BACK INTO GENERATOR SET. ENSURE EQUIPMENT IS PROPERLY TAGGED AND NOT ENERGIZED. RESIDUAL VOLTAGE IS PRESENT AT THE GENERATOR LEADS WITH THE REGULATOR TURNED OFF, REACHING SEVERAL HUNDRED VOLTS ON THE GENERATOR SET. PROPER INSULATION AND ISOLATION OF METERING EQUIPMENT MUST BE OBSERVED WHEN TESTING GENERATOR. USE PROPER TEST EQUIPMENT TO CHECK FOR VOLTAGE BEFORE PROCEEDING. FAILURE TO COMPLY MAY RESULT IN DEATH BY ELECTROCUTION. WARNING DISCHARGE CAPACITIVE CHARGE FROM ALL EXPOSED CONDUCTORS TO CT Inspect the Instrument Current Transformers, for the following: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. This is accomplished by performing the following: (1) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. (2) Isolate the PU from any power plant or utility connection in accordance with Section 5.9.6.15, Unit Isolation Procedure with PSC. See Note 1 and 2. (3) Isolate the PU from any power plant control system in accordance with Note 3. (4) Pull to open the PU DC Power Control Breaker. (5) Push to open both Emergency Stop Switches. (6) Place both Engine Control Switches (ECS) in the OFF position. (7) Place a DO NOT OPERATE tag on both generator control panels. (8) Turn the Battery Bank Parallel Switch to the OFF position. (9) De-energize both Battery Chargers. (10)Disconnect the negative and positive cables from both Battery Banks. (11)Place a DO NOT OPERATE tag on both Battery Banks. (12)Place all Circuit Breakers in the LOCK OUT position. (13)Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. (14)Close and Lock both generator set control panels.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 NOTE 1:

Also the PU must be completely electrically isolated from the power distribution bus and any other electrical source that can back feed into the PU. All medium voltage cables need to be placed on the standoff insulators by use of hot sticks and other safety gear.

NOTE 2:

Ensure cables are not energized by opening the circuit breaker of the Primary Switching Center (PSC), then disconnect Load Cables (Using the proper safety gear) on the PU and place them on the Parking Stands.

NOTE 3:

When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Remove the PDC from the PU. See Chapter 22 for reference. c.

Inspect for proper mounting.

d. Check for loose connections, physical damage and heat damage. e. Check wiring for signs of insulation breakdown such as cracked sleeves and burned insulation. 10.4.10.2

TEST INSTRUMENT CURRENT TRANSFORMER (CT)

This Task is above this Echelon of Maintenance. (The PDC must be removed from the PU to perform this task). 10.4.10.3

REMOVAL INSTRUMENT CURRENT TRANSFORMER (CT)

This Task is above this Echelon of Maintenance. this task). 10.4.10.4

(The PDC must be removed from the PU to perform

INSTALL INSTRUMENT CURRENT TRANSFORMER (CT)

This Task is above this Echelon of Maintenance. perform this task).

The (The PDC must be removed from the PU to

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GENERATOR, FEEDER AND TIE BREAKERS

The following maintenance procedures are provided for the Generator, Feeder and Tie Breakers: Inspect Test Remove Install

Generator Breaker

Feeder Breaker

Tie Breaker

FIGURE 10.4.11-1

GENERATOR, FEEDER & TIE BREAKER

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 See Figure 10.4.11-1 for reference. The breakers installed within the PDC are actually vacuum contactors; however, for consistency through the manual they are referred to as breakers. These components use 120VAC as control voltage for opening and closing. All breakers require a constant 120VAC signal to stay closed except for the Tie Breaker. The Tie Breaker has a mechanical latch to keep it closed even when the PU is off. This circuit also requires a 120VAC to open the breaker, which is available from either side of the Tie Breaker. The breakers are located behind the cover plates on the PDC. 10.4.11.1

INSPECT GENERATOR, FEEDER AND TIE BREAKERS WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE HANGING CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE BURNS, LOSS OF LIMB AND OR DEATH. WARNING PRIOR TO TROUBLESHOOTING THE POWER UNIT (PU), ENSURE THE TIE AND FEEDER CABLES ARE ALL INSTALLED ON PARKING STANDS, TO PREVENT THE POSSIBILITY OF UTILITY POWER BEING FED BACK INTO GENERATOR SET. ENSURE EQUIPMENT IS PROPERLY TAGGED AND NOT ENERGIZED. RESIDUAL VOLTAGE IS PRESENT AT THE GENERATOR LEADS WITH THE REGULATOR TURNED OFF, REACHING SEVERAL HUNDRED VOLTS ON THE GENERATOR SET. PROPER INSULATION AND ISOLATION OF METERING EQUIPMENT MUST BE OBSERVED WHEN TESTING GENERATOR. USE PROPER TEST EQUIPMENT TO CHECK FOR VOLTAGE BEFORE PROCEEDING. FAILURE TO COMPLY MAY RESULT IN DEATH BY ELECTROCUTION. WARNING DISCHARGE CAPACITIVE CHARGE FROM ALL EXPOSED CONDUCTORS TO BREAKERS Inspect the Generator, Feeder and Tie Breakers, for the following: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. This is accomplished by performing the following: (1) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. (2) Isolate the PU from any power plant or utility connection in accordance with Section 5.9.6.15, Unit Isolation Procedure with PSC. See Note 1 and 2. (3) Isolate the PU from any power plant control system in accordance with Note 3.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (4) Pull to open the PU DC Power Control Breaker. (5) Push to open both Emergency Stop Switches. (6) Place both Engine Control Switches (ECS) in the OFF position. (7) Place a DO NOT OPERATE tag on both generator control panels. (8) Turn the Battery Bank Parallel Switch to the OFF position. (9) De-energize both Battery Chargers. (10)Disconnect the negative and positive cables from both Battery Banks. (11)Place a DO NOT OPERATE tag on both Battery Banks. (12)Place all Circuit Breakers in the LOCK OUT position. (13)Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. (14)Close and Lock both generator set control panels. NOTE 1:

Also the PU must be completely electrically isolated from the power distribution bus and any other electrical source that can back feed into the PU. All medium voltage cables need to be placed on the standoff insulators by use of hot sticks and other safety gear.

NOTE 2:

Ensure cables are not energized by opening the circuit breaker of the Primary Switching Center (PSC), then disconnect Load Cables (Using the proper safety gear) on the PU and place them on the Parking Stands.

NOTE 3:

When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Inspect for proper mounting. c.

Check for loose connections, physical damage and heat damage.

d. Check for proper operation e. Check for missing damaged or missing hardware. 10.4.11.2

TEST GENERATOR, FEEDER AND TIE BREAKERS WARNING

APPLYING HIGH VOLTAGES ACROSS THE CONTACTS OF THE VACUUM INTERRUPTERS MAY PRODUCE X-RAYS. THE RADIATION MAY INCREASE WITH AN INCREASE IN THE VOLTAGE OR A DECREASE IN THE DISTANCE BETWEEN THE OPEN CONTACTS. THE LEVELS OF RADIATION GENERATED AT THE RECOMMENDED TEST VOLTAGES AND NORMAL BREAKER OPEN GAP SPACING ARE EXTREMELY LOW. HOWEVER, AS A PRECAUTIONARY MEASURE IT IS RECOMMENDED THAT ALL PERSONNEL STAND AT LEAST THREE FEET AWAY FROM THE BREAKER WHILE TESTING. This Task is above this Echelon of Maintenance. For additional reference see Cutler-Hammer Manual I.B. 48018N

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 10.4.11.3

REMOVE GENERATOR, FEEDER AND TIE BREAKERS WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE HANGING CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE BURNS, LOSS OF LIMB AND OR DEATH. WARNING PRIOR TO TROUBLESHOOTING THE POWER UNIT (PU), ENSURE THE TIE AND FEEDER CABLES ARE ALL INSTALLED ON PARKING STANDS, TO PREVENT THE POSSIBILITY OF UTILITY POWER BEING FED BACK INTO GENERATOR SET. ENSURE EQUIPMENT IS PROPERLY TAGGED AND NOT ENERGIZED. RESIDUAL VOLTAGE IS PRESENT AT THE GENERATOR LEADS WITH THE REGULATOR TURNED OFF, REACHING SEVERAL HUNDRED VOLTS ON THE GENERATOR SET. PROPER INSULATION AND ISOLATION OF METERING EQUIPMENT MUST BE OBSERVED WHEN TESTING GENERATOR. USE PROPER TEST EQUIPMENT TO CHECK FOR VOLTAGE BEFORE PROCEEDING. FAILURE TO COMPLY MAY RESULT IN DEATH BY ELECTROCUTION. WARNING DISCHARGE CAPACITIVE CHARGE FROM ALL EXPOSED CONDUCTORS TO BREAKERS To remove the Generator, Feeder and Tie Breakers, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. This is accomplished by performing the following: (1) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. (2) Isolate the PU from any power plant or utility connection in accordance with Section 5.9.6.15, Unit Isolation Procedure with PSC. See Note 1 and 2. (3) Isolate the PU from any power plant control system in accordance with Note 3. (4) Pull to open the PU DC Power Control Breaker. (5) Push to open both Emergency Stop Switches. (6) Place both Engine Control Switches (ECS) in the OFF position. (7) Place a DO NOT OPERATE tag on both generator control panels. (8) Turn the Battery Bank Parallel Switch to the OFF position. (9) De-energize both Battery Chargers. (10)Disconnect the negative and positive cables from both Battery Banks. (11)Place a DO NOT OPERATE tag on both Battery Banks. (12)Place all Circuit Breakers in the LOCK OUT position. (13)Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. (14)Close and Lock both generator set control panels. NOTE 1:

Also the PU must be completely electrically isolated from the power distribution bus and any other electrical source that can back feed into the PU. All medium voltage cables need to be placed on the standoff insulators by use of hot sticks and other safety gear.

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Ensure cables are not energized by opening the circuit breaker of the Primary Switching Center (PSC), then disconnect Load Cables (Using the proper safety gear) on the PU and place them on the Parking Stands.

NOTE 3:

When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Remove the PDC from the PU. c.

Open Generator and Tie Breaker Control panel doors.

d. Remove the retaining screws to the access covers to the breaker needing to be removed. If necessary remove the front, rear and adjacent panels to allow access to the breaker mounting retaining screws and set access covers aside. e. Remove the heat-shrink protection from the cables to the breaker. f.

Tag and remove the wiring harness and power cables.

j.

Remove the four breaker mounting bolts and remove the breaker from the front of the PDC.

NOTE: The Tie Breaker has a plate installed on the front visible portion of the mechanical latch. Ensure the Breaker is tripped open before attempting removal of the plate. This plate must be removed by loosening of the two bolts attaching it and saved for use on the new Tie Breaker Mechanical Latch Assembly.

FIGURE 10.4.11.3-1 TIE BREAKER MECHANICAL LATCH STIFFNER PLATE

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10.4.11.4

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 INSTALL GENERATOR, FEEDER AND TIE BREAKERS

To install the Generator, Feeder and Tie Breakers, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. See procedures and warnings in paragraph 10.4.11.3. b. Reinstall the breaker and the four breaker mounting bolts. Torque to 27 Ft-Lbs. c.

Reinstall the wiring harness and power cables. Ensure that the insulating material is reinstalled on the power cables. Torque all power distribution bus bolts to 20 Ft-Lbs. Torque the power cable to breaker connection to 20 Ft-Lbs.

d. Reinstall the Bakelite mounting bolts from the rear of the breaker section divider, torque to 20 in. lbs. e. Reinstall rear panels of the PDC and reinstall the retaining screws. NOTE: The Contactor Dip Switch Settings must be verified prior to operation. Generator and Feeder Contactors Dip Switch Settings Set the contactor for 120VAC, 60Hz, 130ms by setting dipswitches 2,3, and 7 in “ON” position. This setting is applicable to both generator and feeder contactors. This setting has been determined to function best in the DPGDS application, regardless of bus voltage or frequency. See figure 10.4.11.4-2. Tie Contactor Dip Switch Settings Set the contactor for 110 VAC, 50Hz, 130ms by setting dipswitches 1,2, and 7 in “ON” position. This setting has been determined to function best in the DPGDS application, regardless of bus voltage or frequency. See figure 10.4.11.4-2.

CONTROL BOARD

FIGURE 10.4.11.4-1 CONTACTOR CONTROL BOARD

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FIGURE 10.4.11.4-2 CONTROL BOARD DIPSWITCH f.

To verify/change Dipswitch settings the Control Board must be removed. - Tag and Disconnect wires on the Control Board. See Figure 10.4.11.4-1. - Tag and Disconnect wires for auxiliary switch. - Remove Control Board mounting screws and pull Control Board out. - Verify/Change Dip Switch settings. See Figure 10.4.11.4-2. - Reinstall Control Board, secure with screws and attach wires to Control Board and Auxiliary Switch.

g. Reinstall all of the front access covers removed with the retaining screws. h. Close Generator and Tie Breaker Control panel doors. i.

Reinstall the PDC.

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