TM 9-6115-484-14 MEP-PU-810A/B PART 6
Short Description
Download TM 9-6115-484-14 MEP-PU-810A/B PART 6...
Description
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254
FIGURE 18.3.2.6.1-2
SUPPORT AND SPIDER BUSHING LUBRICATION POINTS
Lubricate the Support and Spider Bushings (both sides) with NLGI Grade 2 grease through the Zerk fittings using Figure 18.3.2.6.1-2 as reference. For camshaft roller journals and anchor pins: Lubricate with high temperature anti-seize grease
18-35
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 18.3.2.6.2
HUB LUBRICATION
a. Check oil level in the Wheel Hub Site Glass. Ensure oil level is at the full mark. Add oil if required by removing the rubber oil cap and filling through the opening in the site glass. Refer to Annex G for type of oil. b. Recommended Lubrication: See Annex G for Specifications. 18.3.2.6.3
SERVICE BEARINGS 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. The following schedule is appropriate: a. Replace grease annually. b. Prior to repacking bearings, all old grease should be removed from the wheel hub cavity and bearings. c.
Bearings should be packed by machine if possible.
d. If a machine is unavailable, packing by hand method is acceptable, using the following method: (1) Place a quantity of grease onto the palm of your hand. (2) Press a section of the widest end of bearing into the outer edge of the grease pile closest to the thumb forcing grease into the interior of the bearing between two adjacent rollers. (3) Repeat this while rotating the bearing from roller to roller. (4) Continue this process until you have the entire bearing completely filled with grease. (5) Before reinstalling, apply a light coat of grease onto the bearing cup mating surface.
18-36
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 18.3.2.6.4
LANDING GEAR ASSEMBLY LUBRICATION
FIGURE 18.3.2.6.4-1
ZERK FITTINGS (GREASE POINTS)
a. Two lubrication points are located on each landing leg. They must be lubricated every 90 days. Zerk fittings are installed to facilitate lubrication use Figure 18.3.2.6.4-1 as reference. b. The retractable landing legs require a medium coating of general-purpose grease, apply as necessary. c.
Recommended Grease: See Appendix G for Specifications.
18-37
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254
THIS PAGE INTENTIONALLY BLANK
18-38
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254
CHAPTER 19 HYDRAULIC SYSTEM REPAIR TABLE OF CONTENTS SECTION
TITLE
PAGE
19.0
HYDRAULIC SYSTEM REPAIR
6
19.1
SAFETY INSTRUCTIONS
6
19.2
HYDRAULIC SYSTEM DESCRIPTION
9
19.2.1
HYDRAULIC FLUID RESERVOIR
9
19.2.2
HYDRAULIC SYSTEM PUMP
13
19.2.3
PRESSURE RELIEF/CONTROL BLOCK AND PRESSURE GAUGES
14
19.2.4
HYDRAULIC SYSTEM FAN MOTORS
16
19.2.5
HYDRAULIC SYSTEM COOLER
17
19.3
SERVICE REQUIREMENTS FOR HYDRAULIC SYSTEM
18
19.3.1
SERVICE THE RETURN-LINE FILTER, STRAINER, AND HYDRAULIC FLUID
18
19.3.1.1
REPLACING THE FILTER ELEMENT
20
19.3.1.2
CHANGING HYDRAULIC FLUID, VENT CAP, CLEANING THE STRAINERS
23
19.4
COMPONENT REPAIR PROCEDURES
26
19.4.1
PRESSURE RELIEF/CONTROL BLOCK
26
19.4.1.1
INSPECTING PRESSURE RELIEF/CONTROL BLOCK
27
19.4.1.2
REMOVE PRESSURE RELIEF/CONTROL BLOCK
28
19.4.1.3
INSTALL PRESSURE RELIEF/CONTROL BLOCK
29
19.4.2
HYDRAULIC PUMP
30
19.4.2.1
INSPECT HYDRAULIC PUMP
30
19.4.2.2
REMOVE HYDRAULIC PUMP
31
19.4.2.3
INSTALL HYDRAULIC PUMP
32
19.4.3
RADIATOR HYDRAULIC MOTOR
34
19.4.3.1
INSPECT RADIATOR HYDRAULIC MOTOR
34
19.4.3.2
REMOVE RADIATOR HYDRAULIC MOTOR
35
19.4.3.3
INSTALL RADIATOR-HYDRAULIC MOTOR
36
19.4.4
AIR TO AIR AFTER COOLER (ATAAC) HYDRAULIC MOTOR
38
19.4.4.1
INSPECT AIR TO AIR AFTER COOLER (ATAAC) MOTOR
38
19.4.4.2
REMOVE AIR TO AIR AFTER COOLER (ATAAC) HYDRAULIC MOTOR
39
19.4.4.3
INSTALL AIR TO AIR AFTER COOLER (ATAAC) MOTOR
40
19.4.5
ENGINE COMPARTMENT VENT-HYDRAULIC MOTOR
41
19-1
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.5.1
INSPECT ENGINE COMPARTMENT VENT-HYDRAULIC MOTOR
41
19.4.5.2
REMOVE ENGINE COMPARTMENT VENT-HYDRAULIC MOTOR
42
19.4.5.3
INSTALL ENGINE COMPARTMENT VENT-HYDRAULIC MOTOR
43
19.4.6
RADIATOR-MOTOR FAN ASSEMBLY
44
19.4.6.1
INSPECT RADIATOR-MOTOR FAN ASSEMBLY
45
19.4.6.2
REMOVE RADIATOR-MOTOR FAN ASSEMBLY
45
19.4.6.3
INSTALL RADIATOR-MOTOR FAN ASSEMBLY
46
19.4.7
AFTER COOLER-MOTOR FAN ASSEMBLY
47
19.4.7.1
INSPECT AFTER COOLER-MOTOR FAN ASSEMBLY
47
19.4.7.2
REMOVE AFTER COOLER-MOTOR FAN ASSEMBLY
48
19.4.7.3
INSTALL AFTER COOLER-MOTOR FAN ASSEMBLY
49
19.4.8
ENGINE COMPARTMENT VENT-MOTOR FAN ASSEMBLY
50
19.4.8.1
INSPECT ENGINE COMPARTMENT VENT-MOTOR FAN ASSEMBLY
51
19.4.8.2
REMOVE ENGINE COMPARTMENT VENT-MOTOR FAN ASSEMBLY
51
19.4.8.3
INSTALL ENGINE COMPARTMENT VENT-MOTOR FAN ASSEMBLY
52
19.4.9
RADIATOR-MOTOR FAN BLADES
53
19.4.9.1
REMOVE RADIATOR-MOTOR FAN BLADES
54
19.4.9.2
INSTALL RADIATOR-MOTOR FAN BLADES
56
19.4.10
AFTER COOLER-MOTOR FAN BLADES
58
19.4.10.1
REMOVE AND INSTALL AFTER COOLER-MOTOR FAN BLADES
59
19.4.11
ENGINE COMPARTMENT VENT-MOTOR FAN BLADES
60
19.4.11.1
REMOVE AND INSTALL ENGINE COMPARTMENT VENT-MOTOR FAN BLADES
60
19.4.12
HYDRAULIC TANK LOW LEVEL SHUTDOWN SWITCH (HTLL)
61
19.4.12.1
TEST HYDRAULIC TANK LOW LEVEL SHUTDOWN SWITCH (HTLL)
61
19.4.12.2
REMOVE HYDRAULIC TANK LOW LEVEL SHUTDOWN SWITCH (HTLL)
63
19.4.12.3
INSTALL HYDRAULIC TANK LOW LEVEL SHUTDOWN SWITCH (HTLL)
66
19-2
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 19.2-1 HYDRAULIC SYSTEM SCHEMATIC
9
FIGURE 19.2.1-1
HYDRAULIC FLUID RESERVOIR
10
FIGURE 19.2.1-2
HYDRAULIC TANK
11
FIGURE 19.2.1-3
FLUID LEVEL/TEMPERATURE SIGHT GAUGE
11
FIGURE 19.2.1-4
HYDRAULIC TANK SHUTOFF VALVE
12
FIGURE 19.2.2-1
HYDRAULIC SYSTEM PUMP
13
FIGURE 19.2.3-1
PRESSURE RELIEF/CONTROL BLOCK DIAGRAM
14
FIGURE 19.2.3-2
PRESSURE RELIEF/CONTROL BLOCK
15
FIGURE 19.2.3-3
HYDRAULIC SYSTEM PRESSURE GAUGES
15
FIGURE 19.2.4-1
HYDRAULIC SYSTEM FAN MOTORS
16
FIGURE 19.2.5-1
HYDRAULIC SYSTEM COOLER
17
FIGURE 19.3.1.1-1
FILTER CAP, FILL HOLE, AND JIC FILL PORT
20
FIGURE 19.3.1.1-2
FILTER CAP AND BYPASS ASSEMBLY
21
FIGURE 19.3.1.1-3
FILTER CAP ASSEMBLY WITH O-RING AND BYPASS
21
FIGURE 19.3.1.1-4
3-MICRON ABSOLUTE HYDRAULIC FILTER
22
FIGURE 19.3.1.1-5
HYDRAULIC FILTER GASKET
22
FIGURE 19.3.1.2-1
TANK ACCESS COVER AND VENT CAP
24
FIGURE 19.3.1.2-2
TANK ACCESS COVER O-RING
24
FIGURE 19.3.1.2-3
100-MESH STRAINER (141 MICRON)
25
FIGURE 19.3.1.2-4
JIC FILL PORT
25
FIGURE 19.4.1-1
PRESSURE RELIEF/CONTROL BLOCK
26
FIGURE 19.4.2-1
HYDRAULIC PUMP
30
FIGURE 19.4.2-2
HYDRAULIC PUMP, O-RING, FLANGE, AND GASKET
32
FIGURE 19.4.3-1
RADIATOR HYDRAULIC MOTOR
34
FIGURE 19.4.3.2-1
RADIATOR / AIR TO AIR AFTER COOLER (ATAAC) COMPARTMENT
36
FIGURE 19.4.4-1
AFTER COOLER HYDRAULIC MOTOR
38
FIGURE 19.4.5-1
ENGINE COMPARTMENT VENT-HYDRAULIC MOTOR
41
FIGURE 19.4.6-1
MOUNTING AND UN-MOUNTING HOLES
44
FIGURE 19.4.6-2
SHAFT MOUNTING HUB
44
FIGURE 19.4.7-1
MOUNTING AND UN-MOUNTING HOLES
47
FIGURE 19.4.8-1
MOUNTING AND UN-MOUNTING HOLES
50
FIGURE 19.4.8-2
SHAFT MOUNTING HUB
50
FIGURE 19.4.9-1
RADIATOR FAN HUB DISASSEMBLY
53
19-3
FIGURE 19.4.9.1-1
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 RADIATOR FAN ASSEMBLY (TOP HALF REMOVED) 54
FIGURE 19.4.9.1-2
RADIATOR FAN ASSEMBLY (BOTTOM HALF WITH KEEPER INSTALLED) 54
FIGURE 19.4.9.2-1
FAN BLADE WITH FAN PITCH
56
FIGURE 19.4.9.2-2
RADIATOR FAN ASSEMBLY (TOP HALF MATED WITH BOTTOM HALF)
56
FIGURE 19.4.10-1
AFTERCOOLER FAN HUB DISASSEMBLY
58
FIGURE 19.4.10.1-1 AFTERCOOLER FAN ASSEMBLY (TOP HALF REMOVED)
59
FIGURE 19.4.10.1-2 AFTERCOOLER FAN ASSEMBLY (BOTTOM HALF W/ KEEPER INSTALLED)59 FIGURE 19.4.11-1
VENT FAN HUB DISASSEMBLY
60
FIGURE 19.4.11.1–1 VENT FAN ASSEMBLY (BOTTOM HALF WITH KEEPER INSTALLED)
60
FIGURE 19.4.11.1-2 FAN BLADE WITH FAN PITCH
61
FIGURE 19.4.12.2-1 TANK ACCESS COVER
63
FIGURE 19.4.12.2-2 TANK ACCESS COVER O-RING
63
FIGURE 19.4.12.2-3 HTLL SWITCH DEUTSCH CONNECTOR
64
19-4
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254
LIST OF TABLES TABLE
TITLE
PAGE
TABLE 19.4.12.1-1
HTLL SWITCH CONTACT POSITIONS
19-5
62
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.0
HYDRAULIC SYSTEM REPAIR
Maintenance procedures are provided for the following Hydraulic System Components: •
Filter
•
Strainer
•
Fluid
•
Control Block
•
Hydraulic Pump
•
Hydraulic Motors
•
Fan Hub Assemblies
•
Fan Blade Assemblies
•
Hydraulic Tank Low Level Shutdown Switch (HTLL)
19.1
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.
• • • • • •
(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)
Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Push to OPEN the Emergency Stop Switch.
19-6
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (c) (d) (e) (f) (g) (h) (i) (j) (k)
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.
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.
NOTE 4:
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.
19-7
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 e. Material safety information: Composition and Information on Ingredients: This information is not formulated to contain ingredients, which have exposure limits established by U.S. agencies. It is not hazardous to health as defined by the European Union Dangerous Substance/Preparation Directives. Hazards Identification: (1) US OSHA HAZARDS COMMUNICATION STANDARDS: Product assessed in accordance with OSHA 29 CFR 1910.1200 and determined not to be hazardous. (2) EFFECT OF OVEREXPOSURE: No significant effect expected. (3) EMERGENCY RESPONSE DATA: Amber liquid. DOT REG No.-NA. f.
First aid measures: (1) EYE CONTACT: Flush thoroughly with cool water. If irritation occurs, call a physician. (2) SKIN CONTACT: Wash contact areas with soap and water. High-pressure accidental injection through the skin requires immediate attention for incision and/or debridgment. (3) INHALATION: Not expected to be a problem. (4) INGESTION: Not expected to be a problem. However, if greater than ½ liter (pint) is ingested, immediately give 1 to 2 glasses of water and call a physician, hospital emergency room or poison control center for assistance. Do not induce vomiting or give anything by mouth to an unconscious person. (5) EXPOSURE LIMITS: This product does not contain any components that have recognized exposure limits. However, an exposure limit of 5.00 mg/m3 is suggested for oil mist.
g. Fire fighting measures: (1) EXTINGUISHING MEDIA: Carbon dioxide, foam, dry chemical, and water fog. (2) SPECIAL FIRE FIGHTING PROCEDURES: Water or foam may cause frothing. Use water to keep fire exposed containers cool. Water spray may be used to flush spills away from exposure. Prevent runoff from fire control or dilution from entering streams, sewers, or drinking water supply. (3) UNUSUAL FIRE AND EXPLOSION HAZARDS: None. Flash point 176ºC, 349ºF. (4) ASTM D-92: Flammable limits-LEL-NA. UEL-NA. (5) NFPA HAZARD ID: Health-0. Flammability-1. Reactivity-0. (6) HAZARDOUS DECOMPOSITION PRODUCTS: Carbon Monoxide. h. Disposal considerations: (1) WASTE DISPOSAL: The product is suitable for burning in an enclosed, controlled burner for fuel value or disposal by supervised incineration. Such burning may be limited to the Recovery Conservation and Recovery Act (RCRA). In addition, the product is suitable for processing by an approved recycling facility or can be disposed of at an appropriate government waste disposal facility. Use of these methods is subject to user compliance with applicable laws and regulations and consideration of product characteristics at time of disposal. (2) RCRA INFORMATION: The unused product, in our opinion, is not specifically listed by the EPA as a hazard waste (40CFR, Part261D), nor is it formulated to contain materials which are listed hazardous waste. It does not exhibit the hazardous characteristics of ignitability, corrosivity, or reactivity and is not formulated with contaminants as determined by the Toxicity Characteristic Leaching Procedures (TCLP). However used product may be regulated.
19-8
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.2
HYDRAULIC SYSTEM DESCRIPTION
Figure 19.2-1 illustrates the Hydraulic System Schematic. The hydraulic system used in Power Unit provides the required power to cool the Power Unit. An engine mounted hydraulic gear pump takes lowpressure hydraulic fluid from the reservoir, through one 100-mesh strainer (141 Micron) with a 3 PSI bypass mounted inside the tank, and provides high-pressure fluid to the hydraulic fan motors that drive the system. The high-pressure fluid from the hydraulic pumps is then forced through a Pressure Relief/Control Block, which contains a 3,200 + 100-PSI pressure relief valve. From the control block the high-pressure fluid is transferred through the hydraulic motors, which drive the cooling fans. After the fluid passes through the hydraulic motors, the low-pressure fluid is then carried through a hydraulic fluid heat exchanger. The cycle is completed when the fluid returns to the reservoir, through the tank top 3micron absolute filter. The case drain on the After Cooler Motor allows hydraulic fluid, from the seal cavity in the motor, to drain back to the reservoir at atmospheric pressure.
FIGURE 19.2-1 19.2.1
HYDRAULIC SYSTEM SCHEMATIC
HYDRAULIC FLUID RESERVOIR
a. Figure 19.2.1-1 and Figure 19.2.1-2 illustrate the Hydraulic Fluid Reservoir. The 18-gallon reservoir has an internal strainer; a top mounted 3- micron absolute hydraulic filter, and vent cap. The reservoir also has two top mounted fill ports, a 25 PSI bypass setting and Filter Differential Gauge.
19-9
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 NOTE:
The reservoir is not pressurized. It is very important that the reservoir is filled through the top of the Filter or through the 1” JIC Fill-Port, see Figure 19.2.1-2 for reference.
b. Adding Hydraulic Fluid from the top of the filter assembly or JIC Fill-Port will ensure that contaminants are not introduced into the system. Keep the fluid level between the red and black lines on the sight gauge (See Figure 19.2.1-3) and do not overfill. This will ensure that the Air Vent Cap is kept open and the reservoir does not overflow. The reservoir also includes a Hydraulic Tank Low Level (HTLL) shutdown switch installed in the back of the reservoir, which is activated at 33% fluid remaining. This switch is wired to the GSC+ and the Hydraulic Tank Low Level Light (HTLLL) (Red LED) on the Generator Control Panel. When activated, it will automatically shut down the generator set and illuminate the HTLLL. Refer to fold out FO-12A and FO-12B for the schematic wiring of the switch and light. The reservoir also has a fluid shutoff valve, located in the rear of the Hydraulic Reservoir, where the fluid line is connected (See Figure 19.2.1-4). These valves are held open during normal operation. NOTE: c.
Prior to disconnecting any hose from a component of the system, the valves must be closed to prevent draining the reservoir. For hose connections, refer to Hose Connection Drawings FO-45, FO-46 and FO-47.
FIGURE 19.2.1-1
HYDRAULIC FLUID RESERVOIR
19-10
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 FILTER FILL PORT
JIC FILL PORT DIFFERENTIAL GAUGE
TANK BREATHER
SIGHT GLASS
FIGURE 19.2.1-2
HYDRAULIC TANK
FULL LEVEL
FIGURE 19.2.1-3
FLUID LEVEL/TEMPERATURE SIGHT GAUGE
19-11
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 NOTE:
Fluid Level should be centered within the sight gauge inspection window. Under normal operating conditions, the hydraulic fluid (being measured by this site gauge) temperature should not exceed 150 ºF. The temperature gauge is important to determine the ambient temperature (prior to plant start up) in order to ensure that the correct type of hydraulic fluid is being used. Refer to Annex G for the required hydraulic fluid in regards to seasonal ambient temperature.
FIGURE 19.2.1-4
HYDRAULIC TANK SHUTOFF VALVE
19-12
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.2.2
HYDRAULIC SYSTEM PUMP
Figure 19.2.2-1 illustrates the Hydraulic System Pump. The hydraulic pump is a positive displacement pump. This means that the pump delivers a constant flow rate at a constant RPM. The engine’s front accessory drive gears drive the pump. The pump rotates at 2,160 RPM, when the engine speed is 1,800 RPM. At this speed, the pump will deliver approximately 17.05 gallons per minute optimum flow. The pump delivers high-pressure fluid, through the control block, to the radiator cooling fan motor, to the engine air after-cooler fan motor, and the area ventilation motor. See Figure 19.2-1 for additional information.
HYDRAULIC PUMP
FIGURE 19.2.2-1
HYDRAULIC SYSTEM PUMP
19-13
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.2.3
PRESSURE RELIEF/CONTROL BLOCK AND PRESSURE GAUGES
Figure 19.2.3-1 illustrates the Pressure Relief/Control Block Diagram. Figure 19.2.3-2 illustrates the actual Pressure Relief/Control Block. The Pressure Relief/Control Block includes one high-pressure input (P1), two high-pressure outputs for the fan circuits (A1, A2), one low pressure return line (T), one relief valve (RV), that is factory set to relieve the system pressure at 3,200 ± 100 PSI to ensure that the positive displacement pump is not damaged, if there is a blockage in the system, and a low flow unloading valve (UV) that bypasses the fan circuits when the pump flow rate is less than 4 GPM. This provides a soft pump start feature before the engine reaches rated RPM during start up. The Pressure Relief/Control Block also has two pressure gauge connections (G1, G2). G1 measures the pressure on the Air-Vent Circuit and G2 measures the pressure on the Radiator Circuit. Figure 19.2.3-3 illustrates the Hydraulic System Pressure Gauges. The pressure gauges are mounted on the Engine Filter Differential Gauge Panel. The Radiator Circuit pressure gauge reads between 2,100 and 3,100 PSI, during normal operations. The Air-Vent pressure gauge reads between 2,300 and 3,100 PSI, during normal steady-state operations. The hydraulic gauges are 0 – 5000 PSI rated liquid filled gauges for anti-vibration and long life.
FIGURE 19.2.3-1
PRESSURE RELIEF/CONTROL BLOCK DIAGRAM
19-14
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 A2 A1 G2 UV RV P1 G1 T
FIGURE 19.2.3-2
FIGURE 19.2.3-3
PRESSURE RELIEF/CONTROL BLOCK
HYDRAULIC SYSTEM PRESSURE GAUGES
19-15
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.2.4
HYDRAULIC SYSTEM FAN MOTORS
Figure 19.2.4-1 illustrates the Hydraulic System Fan Motors. The hydraulic gear motors are also fixed displacement. This means that the motors will operate at a constant RPM under a constant flow rate. The high-pressure fluid delivered by the pumps drives the motors. There are three motors per cooling system: Radiator Coolant, After Cooler, and Ventilation Fan Motors. These motors are part of two separate circuits. One circuit is for the Radiator Cooling Motor only. The other includes both the After Cooler and Ventilation Fan Motors in series. All cooling motors operate between 1,750 and 2,400 RPM.
ENGINE COMPARTMENT VENT MOTOR
RADIATOR HYDRAULIC MOTOR
ATAAC HYDRAULIC MOTOR
FIGURE 19.2.4-1
HYDRAULIC SYSTEM FAN MOTORS
19-16
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.2.5
HYDRAULIC SYSTEM COOLER
Figure 19.2.5-1 illustrates the Hydraulic System Cooler. The Hydraulic System is equipped with a hydraulic-oil heat exchanger, which cools the fluid prior to the fluid returning to the reservoir. It is located in the engine coolant side of the radiator assembly. The air inlet side of the Air to Air After Cooler (ATAAC) should be blown out at the same time the air filter is changed. Under particularly dusty conditions, daily cleaning may be necessary.
HYDRAULIC SYSTEM COOLER
FIGURE 19.2.5-1
HYDRAULIC SYSTEM COOLER
19-17
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.3
SERVICE REQUIREMENTS FOR HYDRAULIC SYSTEM
19.3.1
SERVICE THE RETURN-LINE FILTER, STRAINER, AND HYDRAULIC FLUID WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING HYDRAULIC FLUID PRESSURES CAN REACH 3,000 PSI WHILE THE PU IS OPERATING. DO NOT TOUCH ANY SUSPECTED LEAKS OF THE HYDRAULIC SYSTEM. SERIOUS INJURIES COULD OCCUR TO UNPROTECTED SKIN OR EYES. CAUTION DO NOT OVERFILL THE HYDRAULIC SUMP. KEEP THE FLUID LEVEL BETWEEN THE RED AND BLACK LINES ON THE SIGHT GAUGE. IF THE TANK IS TOO FULL, IT COULD CAUSE AN OVER FLOW SITUATION. 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. CAUTION HYDRAULIC FLUIDS MAY BE HOT
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)
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.
19-18
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (13) (14)
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. The Hydraulic System: incorporates an In-tank fluid strainer, (Figure 19.3.1.2-3), and an In-tank return line filter (Figure 19.3.1.1-4). The In-tank Return Line Filter is located inside the hydraulic filter assembly at the top of the reservoir. The In-tank Return Line Filter has a color-coded pressure differential gauge, (Figure 19.2.1-2), on the side. This Differential Pressure Gauge is used to determine In-tank Return Line Filter replacement time. The Return-Line Filter also has a bypass built into the housing (Figure 19.3.1.1-3). This bypass is set to 25 PSI and will open when the pressure drop across the element exceeds 25 PSI. The Return-Line Filter is designed to have a very low pressure drop when new and at operating temperatures. As contaminants collect on the element’s surface, the pressure drop across it increases. c.
When to Service: You should replace the filter when the indicating gauge reads 20 PSI (top of green area) and the pressure should be checked at normal operating pressure. Checking the filter during cold start up will result in substantially higher readings than at normal operating temperatures. The reason for changing the filter at 20 PSI rather than 25 PSI (bypass setting) is to make sure the filter does not go into bypass, allowing fluid to return unfiltered. •
Replace: the Return-Line Filter and O-ring after every 8,000 hours of use, during any complete fluid change or every 12 months. This must be done even if the indicator gauge is in the green (below 20 PSI).
•
Inspect: the new Return-Line Filter element for any damage; prior to installation see Figure 19.3.1.1-4. The 100-mesh strainer (141 Micron) must be removed and cleaned annually. Inspect the strainer for any damage, prior to installation. The reason for having a 100-mesh (141 Micron) strainer and a 3-micron filter in the hydraulic system is to take out microscopic contaminants. The size particles this filter element removes are smaller than the human eye can see. Caution must be taken during the cleaning and replacement process not to introduce any contaminates into the system. The strainer must be removed and cleaned every time the hydraulic fluid is changed and the hydraulic fluid should be changed every 16,000 hours, or 3 years. Yearly hydraulic fluid samples should be taken and analyzed to determine fluid contamination levels. Complete fluid change may increase based on analysis findings.
19-19
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.3.1.1
REPLACING THE FILTER ELEMENT
Replace Filter every 8,000 hours of use or annually. a. Clean the area around the In-tank Return Line Filter Assembly of contaminants that could fall into the tank, during change out. You should also have a clean work area for components and elements. b. Unscrew the four mounting bolts holding the filter cap, rotate filter cap counter clockwise and remove the cap (see Figures 19.3.1.1-1 and 19.3.1.1-2 for reference). c.
Inspect the filter cap for nicks or signs of damage. Reuse if acceptable, replace if necessary (see Figure 19.3.1.1-3).
d. Discard the old O-ring and replace with new e. Remove the In-tank Return Line Filter from the housing (see Figure 19.3.1.1-4 for reference). NOTE: The solid basket remains in the filter housing. f.
Lubricate the rubber gasket on each end of the new filter with hydraulic fluid and place the filter into the basket and housing (see Figure 19.3.1.1-5).
g. Reinstall the filter cap and tighten the four bolts in an alternating fashion. Tighten each bolt in a 3-step progression. First hand tighten. Then torque each bolt to 11 ± 2 Ft-Lbs. Then torque each bolt to 22 ± 2 Ft-Lbs.
FIGURE 19.3.1.1-1
FILTER CAP, FILL HOLE, AND JIC FILL PORT
19-20
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254
FIGURE 19.3.1.1-2
FILTER CAP AND BYPASS ASSEMBLY
O-RING BYPASS
FIGURE 19.3.1.1-3
FILTER CAP ASSEMBLY WITH O-RING AND BYPASS
19-21
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254
FIGURE 19.3.1.1-4
3-MICRON ABSOLUTE HYDRAULIC FILTER
FIGURE 19.3.1.1-5
HYDRAULIC FILTER GASKET
19-22
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.3.1.2
CHANGING HYDRAULIC FLUID, VENT CAP, CLEANING THE STRAINERS
Replace the Hydraulic Fluid and clean the internal strainers every 16,000 hours or three years, sooner if yearly sampling indicates fluid contamination. a. Start engine until the hydraulic fluid reaches normal operating temperature, then shutdown the generator set. Do not allow fluid to cool. b. Remove the Drain Plug in the bottom of the Hydraulic Reservoir; see Figure 19.2.1-1 for reference. c.
Drain fluid into an appropriate container (20 gal).
d. Clean and reinstall the Hydraulic Reservoir Drain Plug. e. Remove the eight ¼-20 bolts from the Hydraulic Reservoir Access Cover, attached to the vent cap. See Figure 19.4.12.2-1 for reference. Remove the cover and O-ring f.
Unscrew the 100-mesh (141 Micron) strainer from inside the tank. Take care not to damage the strainer during removal, see Figure 19.3.1.2-3 for reference.
g. Clean the strainer thoroughly and reinstall it the Hydraulic Reservoir. Hand tighten only, do not use a wrench. h. Discard the old O-ring and reinstall a new one. See Figure 19.3.1.2-2 i.
Reinstall the Hydraulic Reservoir Access Cover and torque the eight 1/4" bolts to 10 ± 2 lb ft, see Figure 19.4.12.2-1 for reference.
j.
Unscrew the Vent Cap and install a new Vent Cap every time the hydraulic filter is changed, see Figure 19.3.1.2-1 for reference.
k.
Gravity-fill clean, filtered hydraulic fluid (approx. 18 gallons) into the reservoir through the In-tank Return Line Filter Assembly Fill Port or through the 1” JIC Fill Port, see Figure 19.2.1-2 for reference.
19-23
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254
FIGURE 19.3.1.2-1
FIGURE 19.3.1.2-2
TANK ACCESS COVER AND VENT CAP
TANK ACCESS COVER O-RING
19-24
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254
100-MESH STRAINER
FIGURE 19.3.1.2-3
100-MESH STRAINER (141 MICRON)
JIC FILL PORT
FIGURE 19.3.1.2-4
19-25
JIC FILL PORT
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4
COMPONENT REPAIR PROCEDURES
19.4.1
PRESSURE RELIEF/CONTROL BLOCK
The following maintenance procedures are provided for the Pressure Relief/Control Block: Inspect Remove Install
FIGURE 19.4.1-1
PRESSURE RELIEF/CONTROL BLOCK
19-26
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.1.1
INSPECTING PRESSURE RELIEF/CONTROL BLOCK
To inspect the Pressure Relief/Control Block using Figure 19.4.1-1, proceed as follows: a. This maintenance can be performed while the generator set not requiring maintenance is running and the generator set requiring maintenance has been shutdown. b. The generator set that requires the maintenance (G1 or G2) has been shut down, and must be rendered unable to start, and be cool enough for the maintenance to be performed. Procedures to render a generator set unable to start are: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) NOTE:
c.
Shutdown the generator set (G1 or G2) 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.
Prior to starting the Power Unit, inspect the engine compartment for any hydraulic fluid leaks. Correct any leaks as necessary.
d. Check the Hydraulic Fluid level and add fluid as necessary. e. Start the Power Unit according to Chapter 5. Allow the Power Unit to reach operating temperature and shutdown the Power Unit according to Chapter 5. f.
Check under the Power Unit for any hydraulic fluid leaks. Correct any leaks as necessary.
g. Check the Pressure Relief/Control Block for leaks, missing or loose hardware.
19-27
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.1.2
REMOVE PRESSURE RELIEF/CONTROL BLOCK
To remove the Pressure Relief/Control Block using Figure 19.4.1-1, 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 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.
b. Close the Hydraulic Fluid Shutoff Valve. See Figure 19.2.1-4 for reference. c.
Tag the 6 input and output hoses for proper reinstallation.
d. Disconnect the 6 input and output hoses. See Figure 19.4.1-1 for reference. NOTE:
Use proper procedures to collect any hydraulic fluid left in the hoses to prevent spills.
e. Remove the Pressure Relief/Control Block mounting bolts and lift the Pressure Relief/Control Block from the engine.
19-28
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.1.3
INSTALL PRESSURE RELIEF/CONTROL BLOCK
To install the Pressure Relief/Control Block 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 in paragraph 19.4.1.2. b. Reinstall the Pressure Relief/Control Block and reinstall the Pressure Relief/Control Block mounting bolts. Torque the mounting bolts to 30 + 5 Ft-Lbs. c.
Reinstall and torque the hydraulic hoses according to specifications found in Caterpillar Manual SENR3130-6 or later version.
d. Remove hydraulic hose tags. e. Refill the hydraulic system according to procedures found in Section 19.3.1.2. NOTE: f.
Use proper procedures to collect any hydraulic fluid left in the hoses to prevent spills. Open the Hydraulic Fluid Shut Off Valve. Secure the valve handle in the open position.
g. Prepare the PU to be started. All lockout and tag-out, tags must be removed. h. Inspect the Hydraulic System starting at Section 19.4.1 and ending at Section 19.4.12. i.
Start the Power Unit and allow it to reach operating temperature.
j.
Shut-down the Power Unit and inspect the hydraulic system starting at Section 19.4.1 and ending at Section 19.4.12.
k.
The unit is now ready to operate.
19-29
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.2
HYDRAULIC PUMP
The following maintenance procedures are provided for the Hydraulic Pump: Inspect Remove Install
HYDRAULIC PUMP
FIGURE 19.4.2-1 19.4.2.1
HYDRAULIC PUMP
INSPECT HYDRAULIC PUMP
To inspect the Hydraulic Pump use Figure 19.4.2-1 as reference, proceed as follows: a. Prior to starting the Power Unit, inspect the engine compartment for any hydraulic fluid leaks. Correct any leaks as necessary.
19-30
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 b. Check the hydraulic fluid level and add fluid as necessary. c.
Start the Power Unit according to Chapter 5. Allow the Power Unit to reach operating temperature and shutdown the Power Unit according to Chapter 5.
d. Check under the PU for any hydraulic fluid leaks. Correct any leaks as necessary. e. Check the Hydraulic Pump for leaks, missing or loose hardware. Note: See Figure 19.4.2-2. The hydraulic pump internal cavity between the adapter plate and pump mounting surface gets hot and must breathe (vent to the outside). As a result, small bubbles can form on the outer surface of the adapter plate or pump mounting surface. This is normal and is not an oil seep or leak. 19.4.2.2
REMOVE HYDRAULIC PUMP
To remove the Hydraulic Pumps, 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) (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.
b. Close the Hydraulic Fluid Shutoff Valve. See Figure 19.2.1-4 for reference.
19-31
c.
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 Tag the two input and output hoses for proper replacement.
d. Disconnect the two input and output hoses. See Figure 19.4.2-1 for reference. Use proper procedures to collect any hydraulic fluid left in the hoses to prevent spills.
NOTE:
e. Remove the two pump mounting bolts and lift the pump from the engine. The procedure is the same for either an inboard or outboard hydraulic pump.
NOTE: f.
Remove and discard old gasket material from the pump and engine surfaces.
g. Remove flange and O-ring, Inspect O-ring for damage and replace as necessary.
GASKET
FLANGE
HYDRAULIC PUMP
ENGINE HOUSING
FIGURE 19.4.2-2 19.4.2.3
O-RING
HYDRAULIC PUMP, O-RING, FLANGE, AND GASKET
INSTALL HYDRAULIC PUMP
To install the Hydraulic Pump 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 in paragraph 19.4.2.2. b. Install a new gasket for the pump. NOTE: c.
Do Not use the old gasket use a new gasket. Coat both contact surfaces of the new gasket with appropriate Gasket Sealant following manufacturer’s instructions. Install flange and O-ring, Apply clean engine oil to the new O-ring and ensure seal is not damaged or pinched during installation. See Figure 19.4.2-2 for reference.
NOTE: The adapter has a beveled edge. The beveled edge of the adapter must face towards the pump.
19-32
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 d. Reinstall the pump assembly and reinstall the two, pump mounting bolts. Torque the pump mounting bolts mounting bolts to 75 + 5 Ft-Lbs. e. Reinstall and torque the hydraulic hoses according to specifications found in Table 7, Torques for flared and O-Ring fittings, Caterpillar Manual SENR3130. f.
Tighten the spring clamps to 16 ± 2 in. lbs
g. Remove the hose tags. NOTE:
Use proper procedures to collect any hydraulic fluid left in the hoses to prevent spills.
h. Refill the hydraulic system according to procedures found in Section 19.3.1.2. i.
Open the Hydraulic Fluid Shut Off Valve. Secure the valve handle in the open position.
j.
Prepare the PU to be started. All lockout and tag-out, tags must be removed.
k.
Inspect the Hydraulic System starting at Section 19.4.1 and ending at Section 19.4.12.
l.
Start the Power Unit and allow it to reach operating temperature.
m. Shut-down the Power Unit and inspect the hydraulic system starting at Section 19.4.1 and ending at Section 19.4.12. n. The unit is now ready to operate.
19-33
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.3
RADIATOR HYDRAULIC MOTOR
The following maintenance procedures are provided for the Radiator Hydraulic Motor: Inspect Remove Install
FIGURE 19.4.3-1 19.4.3.1
RADIATOR HYDRAULIC MOTOR
INSPECT RADIATOR HYDRAULIC MOTOR
To inspect the Radiator Hydraulic Motor see Figure 19.4.3-1 as reference, proceed as follows: a. Prior to starting the Power Unit, inspect the engine compartment for any hydraulic fluid leaks. Correct any leaks as necessary. b. Check the hydraulic fluid level and add fluid as necessary. c.
Start the Power Unit according to Chapter 5. Allow the Power Unit to reach operating temperature and shutdown the Power Unit according to Chapter 5.
d. Check under the Power Unit for any hydraulic fluid leaks. Correct any leaks as necessary. e. Check the Radiator Hydraulic Motor for leaks, missing or loose hardware.
19-34
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.3.2
REMOVE RADIATOR HYDRAULIC MOTOR
To remove the Radiator-Hydraulic Motor, 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) (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.
b. Remove the Front Side Panel from the PU. See Figure 19.4.3.2-1 for reference.
19-35
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254
FIGURE 19.4.3.2-1
RADIATOR / AIR TO AIR AFTER COOLER (ATAAC) COMPARTMENT
c.
Remove the Radiator Fan Motor Access panel.
c.
Close the Hydraulic Fluid Shutoff Valves. See Figure 19.2.1-4 for reference.
d. Tag the input and output hoses for proper replacement. See Figure 19.4.3-1 for reference. e. Disconnect the input and output hoses. Use proper procedures to collect any hydraulic fluid left in the hoses to prevent spills.
NOTE: f.
Remove the Radiator-Hydraulic Motor Fan Assembly. See Section 19.4.6.2 for reference.
g. Remove the two motor mounting bolts and lift the motor off of its mounting bracket. 19.4.3.3
INSTALL RADIATOR-HYDRAULIC MOTOR
To install the Radiator-Hydraulic Motor, 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 in paragraph 19.4.3.2. b. Place the motor back on the mounting bracket and reinstall the mounting bolts. Torque the 3/8” bolts to 35 + 7 Ft-Lbs per Caterpillar SENR3130, Torque Specifications. c.
Reinstall the Radiator-Hydraulic Motor Fan Assembly see Section 19.4.6.3 for reference.
19-36
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 d. Reinstall the input and output hoses and torque the hydraulic fittings according to specifications found in Table 7, (Torques for flared and O-Ring fittings), Caterpillar Manual SENR3130. Torque the 3/4” input hose fitting to 37 + 5 ft. lbs, and 5/8” output fitting to 26 + 4 Ft-Lbs. e. Reinstall the Radiator and ATAAC access covers. See Figure 19.4.3.2-1 for reference. f.
Reinstall the Front Side Panel from the Power Unit. See Figure 19.4.3.2-1 for reference.
g. Refill the Hydraulic System. See Section 19.3.1.2 for procedures. h. Prepare the Power Unit to be started. All lockout and tag-out tags must be removed, the battery bank reconnected. i.
Inspect the Hydraulic System starting at Section 19.4.1 and ending at Section 19.4.12.
j.
Open the Hydraulic Fluid Shut Off Valves. Secure the valve handles in the open position.
k.
Start the Power Unit and allow it to reach operating temperature.
l.
Shut-down the Power Unit and inspect the hydraulic system starting at Section 19.4.1 and ending at Section 19.4.12.
m. The unit is now ready to operate.
19-37
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.4
AIR TO AIR AFTER COOLER (ATAAC) HYDRAULIC MOTOR
The following maintenance procedures are provided for the ATAAC Hydraulic Motor: Inspect Remove Install
FIGURE 19.4.4-1 19.4.4.1
AFTER COOLER HYDRAULIC MOTOR
INSPECT AIR TO AIR AFTER COOLER (ATAAC) MOTOR
To inspect the Air to Air After Cooler-Hydraulic Motor, proceed as follows: a. Prior to starting the PU, check the engine compartment for any hydraulic fluid leaks. Correct any leaks as necessary. b. Check the hydraulic fluid level and add fluid as necessary. c.
Start the Power Unit according to Chapter 5. Allow the Power Unit to reach operating temperature and shutdown the Power Unit according to Chapter 5.
d. Check under the Power Unit for any hydraulic fluid leaks. Correct any leaks as necessary. e. Check the Air to Air After Cooler-Hydraulic Motor for leaks, missing or loose hardware.
19-38
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.4.2
REMOVE AIR TO AIR AFTER COOLER (ATAAC) HYDRAULIC MOTOR
To remove the Air to Air After Cooler-Hydraulic Motor, 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) (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.
b. Remove the Front Side Panel from the PU. See Figure 19.4.3.2-1 for reference. c.
Remove the Radiator and ATAAC Access Covers. See Figure 19.4.3.2-1 for reference.
d. Close the Hydraulic Fluid Shutoff Valves. See Figure 19.2.1-4 for reference. CAUTION THE HYDRAULIC MOTORS FOR G1 AND G2 ATAAC ARE INSTALLED DIFFERENTLY TO ENSURE THAT THE FAN ROTATES IN THE CORRECT DIRECTION. NOTE WHICH WAY THE RELIEF PORT ON TOP OF THE MOTOR IS FACING, (FRONT OR REAR OF MOTOR AS INSTALLED). ENSURE THE NEW HYDRAULIC MOTOR IS INSTALLED IN THE SAME DIRECTION AS REMOVED. FAILURE TO OBSERVE THIS CAUTION MAY CAUSE THE FAN TO ROTATE IN THE WRONG DIRECTION.
19-39
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 e. Tag the input/output and case drain hoses for proper replacement. See Figure 19.4.4-1 for reference. f.
Disconnect the input/output and case drain hoses. See Figure 19.4.4-1 for reference. Use proper procedures to collect any hydraulic fluid left in the hoses to prevent spills.
NOTE:
g. Remove the Air to Air After Cooler-Hydraulic Motor Fan Assembly. See Section 19.4.7.2 for reference. h. Remove the two Air to Air After Cooler-Hydraulic Motor Fan Assembly mounting bolts and lift the motor off of its mounting bracket. 19.4.4.3
INSTALL AIR TO AIR AFTER COOLER (ATAAC) MOTOR
To install the Air to Air After Cooler-Hydraulic Motor, 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 in paragraph 19.4.4.2. CAUTION IF THE ATAAC HYDRAULIC FAN MOTOR IS INSTALLED INCORRECTLY THE FAN WILL ROTATE IN THE WRONG DIRECTION. ENSURE THE FAN MOTOR IS INSTALLED IN THE SAME DIRECTION AS THE ONE REMOVED (RELIEF PORT ORIENTATION). b. Reinstall the motor back on the mounting bracket and reinstall mounting bolts. Torque the 3/8” bolts to 35 + 7 Ft-Lbs per Caterpillar SENR3130, Torque Specifications. c.
Reinstall and torque the hydraulic hoses according to specifications found in Table 7, Torques for flared and O-Ring fittings, Caterpillar Manual SENR3130. Torque the 5/8” fittings to 26 + 4 Ft-Lbs Torque the 3/8” fitting to 8 + 1 Ft-Lbs. Remove hose tags.
d. Reinstall the After Cooler- Motor Fan Assembly. See Section 19.4.7.3 for reference. e. Reinstall the Radiator and ATAAC Access Covers. See Figure 19.4.3.2-1 for reference. f.
Reinstall the Front Side Panel from the Power Unit. See Figure 19.4.3.2-1 for reference.
g. Open the Hydraulic Fluid Shut Off Valves. Secure the valve handles in the open position. h. Prepare the Power Unit to be started. All lockout and tag-out, tags must be removed, and the battery bank reconnected. i.
Inspect the Hydraulic System starting at Section 19.4.1 and ending at Section 19.4.12.
j.
Start the Power Unit and allow it to reach operating temperature.
k.
Ensure the fan blades are rotating correctly (
l.
Shut-down the Power Unit and inspect the hydraulic system starting at Section 19.4.1 and ending at Section 19.4.12.
19-40
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 m. The unit is now ready to operate. 19.4.5
ENGINE COMPARTMENT VENT-HYDRAULIC MOTOR
The following maintenance procedures are provided for the Engine Compartment Vent-Hydraulic Motor: Inspect Remove Install
FIGURE 19.4.5-1 19.4.5.1
ENGINE COMPARTMENT VENT-HYDRAULIC MOTOR
INSPECT ENGINE COMPARTMENT VENT-HYDRAULIC MOTOR
To inspect the Engine Compartment Vent-Hydraulic Motor, proceed as follows: a. Prior to starting the Power Unit, check the engine compartment for any hydraulic fluid leaks. Correct any leaks as necessary. b. Check the hydraulic fluid level and add fluid as necessary. c.
Start the Power Unit according to Chapter 5. Allow the Power Unit to reach operating temperature and shutdown the Power Unit according to Chapter 5.
d. Check under the Power Unit for any hydraulic fluid leaks. Correct any leaks as necessary. e. Check the Engine Compartment Vent-Hydraulic Motor for leaks, missing or loose hardware.
19-41
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.5.2
REMOVE ENGINE COMPARTMENT VENT-HYDRAULIC MOTOR
To remove the Engine Compartment Vent-Hydraulic Motor, 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 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.
b. Remove the bolts and keeper washers from the Top Plenum Screen on the top of the Power Unit. Remove the Top Plenum Screen and Front Side Panel. See Section 8.4.1.2 and Section 8.4.2.2 for reference. c.
Close the Hydraulic Fluid Shutoff Valves. See Figure 19.2.1-4 for reference.
d. Remove the Fan Guard and Air Deflector assembly from around the motor and fan. e. Tag and Disconnect the two input and output hoses for proper replacement. See Figure 19.4.51 for reference. NOTE:
Use proper procedures to collect any hydraulic fluid left in the hoses to prevent spills.
g. Remove the Engine Compartment Vent-Motor Fan Assembly. reference.
See Section 19.4.8.2 for
h. Remove the two motor mounting bolts and then lift the motor off of its mounting bracket.
19-42
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.5.3
INSTALL ENGINE COMPARTMENT VENT-HYDRAULIC MOTOR
To install the Engine Compartment Vent-Hydraulic Motor, 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 19.4.5.2. b. Reinstall the motor back on the mounting bracket and reinstall mounting bolts. Torque the 3/8” bolts to 35 + 7 Ft-Lbs per Caterpillar SENR3130, Torque Specifications. c.
Reinstall the input and output hoses and torque the fittings according to specifications found in Table 7, Torques for flared and O-Ring fittings, Caterpillar Manual SENR3130. Torque the 1” fittings to 75 + 7 Ft-Lbs Torque the 5/8” fitting to 26 + 4 Ft-Lbs. Remove hose tags.
d. Reinstall the Engine Compartment Vent-Hydraulic Motor Fan Assembly. See Section 19.4.8.3 for reference. e. Reinstall the Fan Guard and Air Deflector assembly from around the motor and fan. f.
Reinstall the Front Side Panel from the Power Unit. See Figure 19.4.3.2-1 for reference.
g. Open the hydraulic fluid shut off valves. Secure the valve handles in the open position. h. Reinstall the PU Top Plenum Screen. i.
Prepare the Power Unit to be started. All lockout and tag-out, tags must be removed, the battery bank reconnected.
j.
Inspect the Hydraulic System starting at Section 19.4.1 and ending at Section 19.4.12.
k.
Start the Power Unit and allow it to reach operating temperature.
l.
Shut-down the Power Unit and inspect the hydraulic system starting at Section 19.4.1 and ending at Section 19.4.12.
m. The unit is now ready to operate.
19-43
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.6
RADIATOR-MOTOR FAN ASSEMBLY
The following maintenance procedures are provided for the Radiator-Motor Fan Assembly: Inspect Remove Install
FIGURE 19.4.6-1
MOUNTING AND UN-MOUNTING HOLES
FIGURE 19.4.6-2
SHAFT MOUNTING HUB
19-44
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.6.1
INSPECT RADIATOR-MOTOR FAN ASSEMBLY
To inspect the Radiator-Motor Fan Assembly, proceed as follows: a. Prior to starting the Power Unit, check the engine compartment for any hydraulic fluid leaks. Correct any leaks as necessary. b. Check the hydraulic fluid level and add fluid as necessary. c.
Start the Power Unit according to Chapter 5. Allow the Power Unit to reach operating temperature and shutdown the Power Unit according to Chapter 5.
d. Check under the Power Unit for any hydraulic fluid leaks. Correct any leaks as necessary. e. Check the Radiator-Motor Fan Assembly for leaks, missing or loose hardware. f.
Check the Radiator-Motor Fan Blades for broken fan blades, missing or loose hardware.
19.4.6.2
REMOVE RADIATOR-MOTOR FAN ASSEMBLY
To remove the Radiator-Motor Fan 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. 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.
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
19-45
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network. b. Remove the bolts and keeper washers from the Bottom Plenum Screen on the bottom of the Power Unit. Remove the Bottom Plenum Screen and Front Side Panel. See Section 8.4.1.2 and Section 8.4.2.2 for reference. c.
Close the Hydraulic Fluid Shutoff Valves. See Figure 19.2.1-4 for reference.
d. Remove the three pull-up bolts and screw them into the tapped holes in and insert them into the three un-mounting holes and tighten each screw one 360º degree turn and then move to the next screw and tighten 360º degree turn, continue until the fan assembly falls free from the shaft mounting hub. See Figure 19.4.6-1 and Figure 19.4.6-2 for reference. 19.4.6.3
INSTALL RADIATOR-MOTOR FAN ASSEMBLY
To install the Radiator-Motor Fan 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 19.4.6.2. b. Reinstall the fan assembly onto the shaft-mounting hub with the flat side of the fan blade assembly facing down. c.
Reinstall the three mounting bolts into the unthreaded mounting holes in the fan blade hub, and insert them into the threaded holes on the shaft-mounting hub. See Figure 19.4.6-1 for reference and torque to 108 inch lbs.
d. Reinstall the Bottom Plenum Screen. e. Prepare the Power Unit to be started. All lockout and tag-out, tags must be removed, the battery bank reconnected. f.
Inspect the Hydraulic System starting at Section 19.4.1 and ending at Section 19.4.12.
g. Start the Power Unit and allow it to reach operating temperature. h. Shut-down the Power Unit and inspect the hydraulic system starting at Section 19.4.1 and ending at Section 19.4.12. i.
The unit is now ready to operate.
19-46
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.7
AFTER COOLER-MOTOR FAN ASSEMBLY
The following maintenance procedures are provided for the After Cooler Fan Assembly: Inspect Remove Install
FIGURE 19.4.7-1 19.4.7.1
MOUNTING AND UN-MOUNTING HOLES
INSPECT AFTER COOLER-MOTOR FAN ASSEMBLY
To inspect the After Cooler-Motor Fan Assembly, proceed as follows: a. Prior to starting the Power Unit, inspect the engine compartment for any hydraulic fluid leaks. Correct any leaks as necessary b. Check the hydraulic fluid level and add fluid as necessary. c.
Start the Power Unit according to Chapter 5. Allow the Power Unit to reach operating temperature and shutdown the Power Unit according to Chapter 5.
d. Check under the Power Unit for any hydraulic fluid leaks. Correct any leaks as necessary. e. Check the After Cooler-Motor Fan Assembly for leaks, missing or loose hardware. f.
Check the After Cooler-Motor Fan Blades for broken fan blades, missing or loose hardware.
19-47
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.7.2
REMOVE AFTER COOLER-MOTOR FAN ASSEMBLY
To remove the After Cooler-Motor Fan 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. 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.
b. Remove the bolts and keeper washers from the Bottom Plenum Screen on the bottom of the Power Unit. Remove the Bottom Plenum Screen and Front Side Panel. See Section 8.4.1.2 and Section 8.4.2.2 for reference. c.
Remove the PU Top Plenum Screen.
d. Close the Hydraulic Fluid Shutoff Valves. See Figure 19.2.1-4 for reference. e. Remove the three pull-up bolts and screw them into the tapped holes in and insert them into the three un-mounting holes and tighten each screw one 360º degree turn and then move to the next screw and tighten 360º degree turn, continue until the fan assembly falls free from the shaft mounting hub. See Figure 19.4.7-1 for reference.
19-48
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.7.3
INSTALL AFTER COOLER-MOTOR FAN ASSEMBLY
To install the After Cooler-Motor Fan 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 19.4.7.2. b. Reinstall the fan assembly onto the shaft-mounting hub with the flat side of the fan blade assembly facing down. c.
Reinstall the three mounting bolts into the unthreaded mounting holes in the fan blade hub, and insert them into the threaded holes on the shaft-mounting hub. See Figure 19.4.6-1 for reference and torque to 108 inch lbs.
d. Reinstall the Bottom Plenum Screen. e. Open the hydraulic fluid shut-off valves and Secure handles. f.
Reinstall the PU Top Plenum Screen.
g. Prepare the Power Unit to be started. All lockout and tag-out, tags must be removed, the battery bank reconnected. h. Inspect the Hydraulic System starting at Section 19.4.1 and ending at Section 19.4.12. i.
Start the Power Unit and allow it to reach operating temperature.
j.
Shut-down the Power Unit and inspect the hydraulic system starting at Section 19.4.1 and ending at Section 19.4.12.
k.
The unit is now ready to operate.
19-49
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.8
ENGINE COMPARTMENT VENT-MOTOR FAN ASSEMBLY
The following maintenance procedures are provided for the Engine Compartment Vent-Motor Fan Assembly: Inspect Remove Install
MOUNTING UNTHREADED HOLE
UN-MOUNTING THREADED HOLE
FIGURE 19.4.8-1
MOUNTING AND UN-MOUNTING HOLES
FIGURE 19.4.8-2
SHAFT MOUNTING HUB
19-50
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.8.1
INSPECT ENGINE COMPARTMENT VENT-MOTOR FAN ASSEMBLY
To inspect the Engine Compartment Vent-Motor Fan Assembly, proceed as follows: a. Prior to starting the Power Unit, check the engine compartment for any hydraulic fluid leaks. Correct any leaks as necessary. b. Check the hydraulic fluid level and add fluid as necessary. c.
Start the Power Unit according to Chapter 5. Allow the Power Unit to reach operating temperature and shutdown the Power Unit according to Chapter 5.
d. Check under the Power Unit for any hydraulic fluid leaks. Correct any leaks as necessary. e. Check the Engine Compartment Vent-Motor Fan Assembly for leaks, missing or loose hardware. f.
Check the Engine Compartment Vent-Motor Fan blades for broken fan blades, missing or loose hardware.
19.4.8.2
REMOVE ENGINE COMPARTMENT VENT-MOTOR FAN ASSEMBLY
To remove the Engine Compartment Vent-Motor Fan 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. 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
19-51
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network. b. Remove the bolts and keeper washers from the Top Plenum Screen on the Top of the Power Unit. Remove the Top Plenum Screen and Front Side Panel. See Section 8.4.1.2 and Section 8.4.2.2 for reference. c.
Remove the Air Deflector Assembly.
d. Remove the three mounting allen-head machine screws and insert them into the three unmounting holes and tighten each screw one 360º turn and then move to the next screw and tighten 360º turn, continue until the fan assembly pulls free from the shaft mounting hub. See Figure 19.4.8.2-1 and Figure 19.4.8.2-2 for reference. 19.4.8.3
INSTALL ENGINE COMPARTMENT VENT-MOTOR FAN ASSEMBLY
To install the Engine Compartment Vent-Motor Fan 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 19.4.8.2. b. Reinstall the fan assembly onto the shaft-mounting hub with the flat side of the fan assembly facing the Radiator Assembly. c.
Reinstall the three mounting bolts into the unthreaded mounting holes in the fan blade hub, and insert them into the threaded holes on the shaft-mounting hub. See Figure 19.4.8-1 for reference and torque to 60 inch lbs.
d. Reinstall the Air Deflector Assembly. e. Prepare the Power Unit to be started. All lockout and tag-out, tags must be removed, the battery bank reconnected. f.
Inspect the Hydraulic System starting at Section 19.4.1 and ending at Section 19.4.12.
g. Start the Power Unit and allow it to reach operating temperature. h. Shut-down the Power Unit and inspect the hydraulic system starting at Section 19.4.1 and ending at Section 19.4.12. i.
The unit is now ready to operate.
19-52
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.9
RADIATOR-MOTOR FAN BLADES
The following maintenance procedures are provided for the Radiator-Motor Fan Blades: Remove Install
FIGURE 19.4.9-1
RADIATOR FAN HUB DISASSEMBLY
19-53
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.9.1 NOTE:
REMOVE RADIATOR-MOTOR FAN BLADES Care must be taken to keep track of the location of the flat washers removed during this process and during assembly the washers must be returned to the same place. The washers are used to balance the Fan Hub assembly.
FIGURE 19.4.9.1-1
RADIATOR FAN ASSEMBLY (TOP HALF REMOVED)
PLASTIC KEEPER
FIGURE 19.4.9.1-2
RADIATOR FAN ASSEMBLY (BOTTOM HALF WITH KEEPER INSTALLED)
To remove the Radiator-Motor Fan Blades, 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 19.4.8.2. b. Remove the Radiator-Motor Fan Assembly. See Section 19.4.6.2 for reference.
19-54
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 c.
Place the fan hub assembly on a flat surface.
d. Remove the 9 hub assembly bolts. See Figure 19.4.9-1 for reference. e. Remove the top half of fan hub assembly. See Figure 19.4.9.1-1 for reference. f.
Remove the broken or damaged fan blade.
g. Ensure plastic keeper is still in place. See Figure 19.4.9.1-2 for reference.
19-55
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.9.2 NOTE:
INSTALL RADIATOR-MOTOR FAN BLADES Care must be taken to keep track of the location of the flat washers removed during this process and during assembly the washers must be returned to the same place. The washers are used to balance the Fan Hub assembly.
FIGURE 19.4.9.2-1
FIGURE 19.4.9.2-2
FAN BLADE WITH FAN PITCH
RADIATOR FAN ASSEMBLY (TOP HALF MATED WITH BOTTOM HALF)
To install the Radiator-Motor Fan Blades, 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 19.4.8.2. b. Ensure that the keeper is in the correct slot. See Figure 19.4.9.1-2 for reference. c.
Install the new blade at a 40° angle. This is accomplished by placing the blade so that the keeper and the 40° angle indentation on the blade are mated together. See Figure 19.4.9.2-1 and Figure 19.4.9.2-2 for reference.
19-56
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 d. Place the top half of the hub assembly on to the bottom half of the hub assembly. See Figure 19.4.9.2-2 for reference. e. Ensure that the fan hub assembly fits together and all blades have the same pitch. f.
Reinstall all 9 of the fan hub assembly bolts. Torque to 108 inch lbs. See Figure 19.4.9-1 for reference.
g. Reinstall the Radiator-Motor Fan Assembly. See Section 19.4.6.3 for reference.
19-57
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.10
AFTER COOLER-MOTOR FAN BLADES
The following maintenance procedures are provided for the After Cooler-Motor Fan Blades: Remove Install
FIGURE 19.4.10-1
AFTERCOOLER FAN HUB DISASSEMBLY
19-58
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.10.1 NOTE:
REMOVE AND INSTALL AFTER COOLER-MOTOR FAN BLADES Care must be taken to keep track of the location of the flat washers removed during this process and during assembly the washers must be returned to the same place. The washers are used to balance the Fan Hub assembly.
FIGURE 19.4.10.1-1
AFTERCOOLER FAN ASSEMBLY (TOP HALF REMOVED)
PLASTIC KEEPER
FIGURE 19.4.10.1-2
AFTERCOOLER FAN ASSEMBLY (BOTTOM HALF W/ KEEPER INSTALLED)
To remove the Aftercooler-Motor Fan Blades, 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 19.4.8.2.
19-59
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 b. After the Aftercooler-Motor Fan Assembly has been removed, Disassembly and Reassembly procedures are the same as the Radiator Fan Motor. See Section 19.4.9.1 and 19.4.9.2 for reference. 19.4.11
ENGINE COMPARTMENT VENT-MOTOR FAN BLADES
The following maintenance procedures are provided for the Engine Compartment Vent Motor Fan Blades: Remove Install
FIGURE 19.4.11-1 19.4.11.1 NOTE:
VENT FAN HUB DISASSEMBLY
REMOVE AND INSTALL ENGINE COMPARTMENT VENT-MOTOR FAN BLADES Carefully observe the location of the flat washers removed during this process and during assembly. The washers must be returned to the same place to balance the Fan Hub assembly.
P L A S T IC K E E P E R
FIGURE 19.4.11.1–1
VENT FAN ASSEMBLY (BOTTOM HALF WITH KEEPER INSTALLED)
19-60
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254
FIGURE 19.4.11.1-2
FAN BLADE WITH FAN PITCH
To remove the Engine Compartment Vent-Motor Fan Blades, 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 19.4.8.2. b. After the Engine Compartment Vent-Motor Fan Assembly has been removed, Disassembly and Reassembly procedures are the same as the Radiator Fan Motor. See Section 19.4.9.1 and 19.4.9.2 for reference. 19.4.12
HYDRAULIC TANK LOW LEVEL SHUTDOWN SWITCH (HTLL)
The following maintenance procedures are provided for the Hydraulic Tank Low Level Shutdown Switch (HTLL): Test Remove Install There is one low fluid level shutdown switch mounted inside of each of the 18-gallon hydraulic tanks. The “float type” switch is mounted on the back of the hydraulic tank. See Figure 19.2.1-1 and refer to Section 19.2.1 for an explanation on the operation of the switch. 19.4.12.1
TEST HYDRAULIC TANK LOW LEVEL SHUTDOWN SWITCH (HTLL)
To test the Hydraulic Tank Low Level Shutdown Switch (HTLL) Switch, proceed as follows: a. Using a multimeter, set to OHMS (Ω) Rx1 scale. Test the HTLL switch wires for contact continuity in the switch positions specified in Table 19.4.12.1-1. The multimeter should indicate zero ohms when the hydraulic tank is empty. The switch is normally open.
19-61
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 b. The multimeter should indicate infinite ohms when the hydraulic tank is full. c.
Replace the switch if it fails any of the above requirements.
TABLE 19.4.12.1-1
HTLL SWITCH CONTACT POSITIONS
HYDRAULIC TANK LOW LEVEL SHUTDOWN SWITCH (HTLL) SWITCH SWITCH POSITION
SWITCH CONTACTS
HYDRAULIC TANK FULL
Infinite OHMS
HYDRAULIC TANK BELOW 33%
Ø OHMS
19-62
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.12.2
REMOVE HYDRAULIC TANK LOW LEVEL SHUTDOWN SWITCH (HTLL)
FIGURE 19.4.12.2-1
FIGURE 19.4.12.2-2
TANK ACCESS COVER
TANK ACCESS COVER O-RING
19-63
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254
HTLL DEUTSCH CONNECTION
FIGURE 19.4.12.2-3
HTLL SWITCH DEUTSCH CONNECTOR
19-64
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 To remove the Hydraulic Tank Low Level Shutdown Switch (HTLL) Switch, 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.
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 9 mounting bolts from the Top Plenum Screen Assembly and remove the screen. The screen can be slid over to the adjoining radiator screen. See Section 8.4.2 for reference. c.
Close the Hydraulic Fluid Shutoff Valve see Figure 19.2.1-4 for reference.
d. Drain the hydraulic tank of all fluid, into an appropriate container. Refer to Section 19.3.1.2 for draining the reservoir. e. Clean the area around the tank access cover of contaminants that could fall into the tank, during change out. You should also have a clean work area for components and elements. f.
Remove the eight mounting bolts from the tank access cover, attached to the breather cap. Discard the old O-ring and replace with new. See Figure 19.4.12.2-1 and 19.4.12.2-2 for reference.
19-65
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 g. Disconnect the switch from the wiring harness, at the DEUTSCH connector. 19.4.12.2-3 for details.
Se Figure
h. Unscrew the lock nut on the backside of the switch and unscrew the switch from the unit. 19.4.12.3
INSTALL HYDRAULIC TANK LOW LEVEL SHUTDOWN SWITCH (HTLL)
To install the Hydraulic Tank Low Level Shutdown Switch (HTLL) Switch, 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 19.4.12.2. b. Screw the switch into the mounting hole while insuring the switch does not bind on the bottom of the tank. The switch’s moveable plastic float should be pointed at the top of the tank. Check the switch for binding. c.
Connect the switch to the Power Unit wiring harness.
d. Reinstall the eight mounting bolts from the tank access cover, attached to the breather cap. See previous instructions for access cover installation. See Figure 19.4.12.2-1 for reference. e. Open the hydraulic fluid shutoff valve. f.
Fill the hydraulic tank with the appropriate fluid as listed in Annex G.
g. Check for leaks. h. Reinstall the Top Plenum Screen Assembly and 9 mounting bolts. i.
Inspect the hydraulic system starting at Section 19.4.1 and ending at Section 19.4.12.
j.
Start the engine and check for proper operation of fans and for fluid leaks.
k.
Shut-down the Power Unit and Inspect the hydraulic system starting at Section 19.4.1 and ending at Section 19.4.12.
l.
Place the DC Control Power Circuit Breaker (CBCP) to ON.
19-66
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254
CHAPTER 20 PU STORAGE PROCEDURES TABLE OF CONTENTS SECTION
TITLE
PAGE
20.0
PU STORAGE PROCEDURES
3
20.1
SAFETY PROCEDURES
3
20.2
PRESERVATION/STORAGE PROCEDURES FOR THE PU
5
20.2.1
PU AND TRAILER ASSEMBLY
6
20.2.2
GENERAL REQUIREMENTS: 3456 EPG ENGINE
6
20.2.2.1
COOLING SYSTEMS
6
20.2.2.1.1
CATERPILLAR COOLANT AND ANTIFREEZE
7
20.2.2.1.2
SUPPLEMENTAL COOLANT ADDITIVE
7
20.2.2.1.3
COOLING SYSTEM CLEANER
7
20.2.2.2
NECESSARY EQUIPMENT AND CONSUMABLES
7
20.3
LONG TERM STORAGE
10
20.3.1
ENGINE STORAGE - UP TO ONE YEAR
10
20.3.2
ALTERNATOR STORAGE - UP TO ONE YEAR
12
20.3.2.1
REMOVAL FROM STORAGE
12
20.3.2.2
INSULATION RESISTANCE CHECKS: (MEGGER)
12
20.3.2.3
INITIAL OPERATION AFTER STORAGE
12
20-1
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254
LIST OF TABLES TABLE
TITLE
PAGE
TABLE 20.2-1
STORAGE PROCEDURES FOR 3456 ENGINE AND SR-4B GENERATORS
20-2
5
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 20.0
PU STORAGE PROCEDURES
20.1
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) (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). Place the S2 in the (G1 or G2) position, for the generator set not receiving maintenance.
20-3
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 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.
20-4
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 20.2
PRESERVATION/STORAGE PROCEDURES FOR THE PU
TABLE 20.2-1 STORAGE PROCEDURES FOR 3456 ENGINE AND SR-4B GENERATORS PRE-STORAGE ACTIVITIES
SUBSYSTEM
▪
Clean exterior of engine of any dirt, rust, grease, and oil.
▪ ▪ ▪
Paint areas that contain paint damage with good quality paint. Remove any dirt from the air cleaners.
POSTSTORAGE ACTIVITIES Remove protective covers.
Sprayer, Paint Filters
Apply lubricant to all points identified in this manual.
Drain and replace the crankcase oil, add VCI at the rate of 34% by volume, and replace the oil filters.
3456 Engine EPG
EQUIPMENT NEEDED
▪ ▪
Remove the air filter element.
▪ ▪
Reinstall serviceable air filter
▪ ▪ ▪ ▪ ▪ ▪
Seal the exhaust pipe including any drain holes in the muffler.
▪
Apply a small amount of oil to the threads on the fuel tank filler.
▪
Seal all openings to the tank to prevent evaporation of the fuel and preservative.
▪
Remove the fuel nozzles and apply a mixture of VCI oil mixture in each cylinder. Turn the engine over slowly to put the oil on each cylinder.
▪
Spray a thin amount of VCI oil mixture on the flywheel, ring gear teeth, and start pinion. Install the covers to keep in the VCI vapors.
Turn the engine at cranking speed with the fuel off and spray a 50% VCI oil/50% engine oil mixture into the air inlet. Spray the same 50% VCI oil/50% engine oil mixture into the exhaust openings.
VCI Oil filters
Change oil and filters
VCI Air filters
VCI
Clean the primary fuel filter. Fill with calibration fluid or kerosene. Install the primary fuel filter and operate the priming pump. Drain any water or dirt from inside the fuel tank. Apply a spray inside the tank to prevent rust and add a commercial biocide to the fuel.
▪
Install all covers and ensure that tape has been installed over all openings.
▪
Apply a small amount of multipurpose grease to all moving parts.
VCI Biocide
VCI Oil
Test the cooling system.
Diesel Fuel Biocide
Prime the engine with diesel fuel.
VCI
▪
If the stored engine will be subjected to below-freezing temperatures, completely drain the system by removing the drain plugs from the engine block, oil cooler, and radiator. Clean the system and refill with a mixture of ELC antifreeze and distilled water. See Section. 4.5.3
SR-4B Generator
Test the cooling system
Sealing Tape/plastic wrap
▪
Seal all openings with tape.
▪
Perform a resistance check of the windings and record the measurement. Ensure resistance is one megohm or greater.
▪
Dry generator windings if necessary.
20-5
Megohmmeter
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 20.2.1
PU AND TRAILER ASSEMBLY
a. Prior to starting any preservation and or storage procedures for the Power Unit obtain and fill out a Preservation Form. b. Follow all Caterpillar instructions dealing with engine and alternator storage procedures. See Section 20.2.2 for reference. c.
Cover all exterior vents and screens with tarps or plastic.
d. Disconnect and remove the batteries from the PU if, the PU will be stored for longer than three months. 20.2.2
GENERAL REQUIREMENTS: 3456 EPG ENGINE
(See Caterpillar Manual SEHS9031-03, Storage Procedures For Caterpillar Products, Dated 4/97 or later).
WARNING TO AVOID PERSONAL INJURY, READ AND UNDERSTAND ALL DIRECTIONS AND HAZARDS DESCRIBED ON THE LABELS OF ANY PRODUCT USED TO PRESERVE YOUR EQUIPMENT. The following procedures are required to prepare the MEP-PU-810 for storage and/or transport. Included are instructions for preserving and packaging the engine fuel system, cooling system, lubrication system, and housing as follows: Caterpillar recommends the use of volatile corrosion inhibitors (VCI oil) in order to prevent internal engine damage due to moisture during storage. These inhibitors act by evaporating inside the engine, then condensing over the inside surfaces. This evaporation and condensing process offers full protection to surfaces that cannot be reached with preservatives that require direct application. This process also makes it easier to clean from the engine when removing the engine from storage. The volatile vapors are removed by simply running the engine to operating temperature. A mineral oil base is left behind after the volatile vapors are removed. The oil should then be drained and new oil and filters installed. 20.2.2.1
COOLING SYSTEMS
Cooling systems should be preserved with Caterpillar coolant or equivalent. Caterpillar coolant contains the necessary inhibitors to prevent corrosion and pitting. When used in the proper mixture, the coolant will prevent damage due to rust and freezing. It is common in warm climates to store the engine with water in the cooling system. In such cases, distilled or de-ionized water is recommended for use in engine cooling systems. DO NOT use hard tap water or salt softened tap water in engine cooling systems. If distilled or de-ionized water is not available, use water that meets the minimum acceptable requirements listed in Annex G.
20-6
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254
NOTE: The Caterpillar engines are equipped with air-to-air after-cooling (ATAAC), and require a minimum of 30 percent glycol (60% maximum) to prevent water pump cavitation. When approved water (distilled, de-ionized, or water that meets minimum acceptable Caterpillar requirements) is used, the water MUST be treated with six to eight percent by volume Caterpillar Supplemental Coolant Additive (SCA), also called Caterpillar Cooling System Conditioner, or equivalent. Under NO circumstances should the engine be stored without the addition of the Caterpillar Supplemental Coolant Additive or equivalent. Always fill the radiator completely full to prevent rusting of the top tank. Do not leave any exposed air space within the radiator. All exposed surface areas will rust. 20.2.2.1.1
CATERPILLAR COOLANT AND ANTIFREEZE
Caterpillar Extended Life Coolant (ELC) is the preferred coolant to use in cooling systems. Caterpillar ELC provides the best coolant service life, corrosion protection, water pump seal service life, and radiator service life. 20.2.2.1.2
SUPPLEMENTAL COOLANT ADDITIVE
Use a six to eight percent concentration of Caterpillar Cooling System Conditioner on engines that will be stored with only water in the cooling system. If the engine is stored with Caterpillar Antifreeze (ELC), there is no need to add conditioner before storage. For Caterpillar Cooling System Conditioner part numbers (See Annex G). 20.2.2.1.3
COOLING SYSTEM CLEANER
Caterpillar Cooling System Cleaner is designed to clean the cooling system of harmful scale and corrosion. It is available in 1 gal (5 gal U.S.) containers. Directions for its use are included on the container. For Caterpillar Cooling System Cleaner (Annex G) 20.2.2.2
NECESSARY EQUIPMENT AND CONSUMABLES
Use all the necessary personal protective equipment needed to perform any of the following jobs: a. Sprayer: A 1P-0540 Flow Checking Tool Group or an air compressor with a sprayer attachment can be used to prepare the engine for storage. It should be possible to change the nozzle adjustment to provide either a spray or a fog pattern. The fog adjustment pattern is better if access to components is difficult. The spray pattern is better for parts on the outside of the engine. b. Paint: Outside parts of the engine can best be protected by thorough use of good quality paint. Paint provides good protection for a storage period up to two years. Before painting, thoroughly clean the engine.
20-7
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254
c.
Plastic Bags: Use black or dark plastic bags. periods of time.
Clear plastic bags will deteriorate over long
d. Sealing Tape: Use a sealing tape with good adhesive properties. DO NOT use duct tape because it will loosen over a short period of time. Two- inch wide rolls of sealing tape are recommended. e. Coolant Conditioner Test Kit: Use the 8T-5296 Conditioner Test Kit to check the concentration of conditioner in the cooling system. Maintain the cooling system with a three to six percent concentration of conditioner. Instructions are included with the kit. f.
Coolant And Battery Tester: The tester is used for checking coolant freezing point and battery fluid condition. Instructions are provided with the tester. The 5P-0957 Coolant And Battery Tester Group is available with the temperature scale in degrees Fahrenheit. The 5P-3514 Coolant And Battery Tester Group is available with the temperature scale in degrees Celsius.
g. VCI Oil: (1) Volatile Corrosion Inhibitor (VCI) oil can be used in all tanks, engine, fuel tank, hydraulic tank, power steering tank, transmission, differential, etc. It is an oil stabilizer and rust preventative. It can be used in combination with any petrochemical. Apply by using a spraying or fogging pattern. Caterpillar recommends the use of VCI oil in order to prevent internal engine damage due to moisture during storage. These inhibitors act by evaporating inside the engine then condensing over the inside surfaces. This evaporation and condensing process offers full protection to surfaces that cannot be reached with preservatives that require direct application. This process also makes it easier to clean from the engine when removing the engine from storage. The volatile vapors are removed by running the engine to operating temperature. A mineral oil base is left behind after the volatile vapors are removed. The oil should then be drained and new oil and filters installed. VCI oil should not be used full strength on non-ferrous metals where it will have direct, prolonged contact. (2) To be successful when treating an engine with VCI oil, the engine must be completely sealed when stored. VCI oil is so volatile that any opening left unsealed will allow the vapors to escape, causing the engine to lose its protection. Volatile corrosion inhibitor (VCI), NOXRUST VCI #10 oil or equivalent oil, provides both liquid and vapor protection to ferrous metal surfaces against corrosion caused by moisture. In a closed compartment, protection is either by direct contact with VCI oil or by contact with VCI vapors. Refer to Annex G for quantities required. The VCI oil and regular oil are a 50/50 mix. h. Diesel Fuel: Diesel fuel left in fuel tanks and fuel injection systems will sometimes cause problems due to the growth of small organisms. This may result in plugged fuel filters, corrosion, sticking fuel pumps, or malfunctioning fuel injection valves. Draining the fuel injection pump and refilling it with Caterpillar Calibration Fluid can minimize this problem. NOTE:
Refer to Annex G for quantities available.
20-8
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254
i.
Caterpillar Calibration Fluid: Is the preferred choice as a preservation fluid because it contains Rust and Oxidation (R&O) inhibitors. If Caterpillar Calibration Fluid is not available, kerosene is a second consideration. However, kerosene does not contain Rust and Oxidation inhibitors and, as the result, is far from the best choice. Kerosene is preferred over diesel fuel (another alternative) because kerosene is not as prone to oxidation as diesel fuel. Kerosene also will not thicken as much as diesel fuel during long storage periods.
j.
Fuel tanks should be protected internally with VCI oil and then sealed. The fuel tank must be drained completely. All vents must sealed airtight. Spray VCI oil/regular oil at a 50/50 mix into the fuel tank filler hole, then seal with the fuel tank filler cap.
k.
Diesel Fuel Biocide: To prevent the growth of small organisms in the diesel fuel, use diesel fuel biocide such as Biobor JF or equivalent.
20-9
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 20.3
LONG TERM STORAGE
20.3.1
ENGINE STORAGE - UP TO ONE YEAR
NOTE:
If long-term storage for a period of time exceeding one year is necessary, contact your local Caterpillar Dealer for the preferred procedure to use in your specific case.
NOTE:
Upon completion of preservation, attach tag near engine start controls stating: “ENGINE PRESERVED. DO NOT CRANK UNTIL ISSUED TO USER”. Affix a red warning tag stating:
NOTE:
“DEPROCESS THIS ENGINE IN ACCORDANCE WITH INSTRUCTIONS CONTAINED ON DA FORM 2258 OR AFTO FORM 20 (ATTACHED TO THIS EQUIPMENT). IN ADDITION, AIR CLEANERS, FILL CAPS, EXHAUST STACKS, BREATHER TUBES, DIPSTICK TUBES, AND ACCESSORIES HAVE BEEN SEALED. REMOVE ALL SEALS PRIOR TO CRANKING ENGINE”. Attach tag near engine start controls.
NOTE:
a. Clean the engine of any dirt, rust, grease, and oil. Inspect the exterior. Paint areas that contain paint damage with good quality paint. b. Remove any dirt from the air cleaner(s). Check all seals, gaskets, and the filter element for damage. c.
Apply lubricant to all points shown in the chart “Lubrication & Maintenance” within the Operation & Maintenance Manual for your equipment.
d. Drain and replace the crankcase oil and change the oil filter(s). For the proper procedure (See Section 14.3.1) e. Add VCI oil to the crankcase at the rate of three to four percent by volume. If the engine crankcase is full, drain enough engine oil so the mixture can be added.
NOTE: f.
NOTE:
Remove the air filter element(s). Turn the engine at cranking speed with the P91/J91 Electronic Unit Injector Engine Harness Deutsch Connector disconnected at the engine valve cover base. •
Disconnecting the P91/J91 will keep the engine from starting during cranking. Reference: P91/J91 connector, Radian Engine Schematic, drawing number FO-37)
•
Reconnect the P91/J91 after this procedure. Use a sprayer to add a mixture of 50 percent VCI oil and 50 percent engine oil into the air inlet or turbocharger inlet. VCI oil mixture can also be added to the inlet by removing the plug for checking turbocharger boost pressure. The minimum application rate is 5.5 mL per L (3 oz per 1000 cu in) of engine displacement. The minimum application rate is critical to prevent loss of protective vapors.
g. Install the air filter element(s) and completely enclose the element(s) with dark, plastic bags. Seal them with tape. Replace the air filter covers. Place tape over all openings to seal VCI vapors in the engine.
20-10
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254
h. Use a sprayer to apply a 50 percent VCI oil and 50 percent engine oil mixture into the exhaust openings. The minimum application rate is 5.5 mL per L (3 oz per 1000 cu in) of engine displacement. Seal the exhaust pipe, including any drain holes in the muffler. i.
Remove the fuel from the secondary fuel filter housing or empty and reinstall the spin-on fuel filter element to remove any dirt and water. Drain the fuel injection pump (sleeve metering only). Clean the primary fuel filter. Fill with calibration fluid or kerosene. Install the primary fuel filter and operate the priming pump. This will send clean oil to the secondary filter and engine. Open the fuel tank drain valve and allow any water or dirt to drain from inside the fuel tank. Apply a spray of 30 mL per 30 L (1 oz per 7.50 gal U.S.) of fuel tank capacity to prevent rust in the fuel tank. Add 0.15 mL per L (.02 oz per 1 gal U.S.) of commercial biocide (such as Biobor UF or equivalent) to the fuel. Apply a small amount of oil to the threads on the fuel tank filler neck and install the cap. Seal all openings to the tank to prevent evaporation of the fuel and preservative.
j.
Remove the Electronic Unit Injectors and apply 30 mL (1 oz) of VCI oil mixture (50 percent VCI oil and 50 percent engine oil) in each cylinder. Use a Caterpillar 9S9082 Engine Turning Tool to turn the engine over slowly to put the oil on the cylinder walls. Re-install all Electronic Unit Injectors with new O-ring seals. Using the correct procedure, tighten the EUI hold down clamp with the correct torque. After re-installation of the rocker shaft assemblies, check/adjust the valve lash and the injector timing using the correct procedures.
k.
Spray a thin amount of VCI oil mixture (50 percent VCI oil and 50 percent engine oil) on the flywheel, ring gear teeth, and starter pinion. Install the covers to keep in the VCI vapors.
l.
Apply a heavy amount of multipurpose grease (MPGM) to all outside parts that move, such as rod threads, ball joints, linkage, etc.
NOTE:
Install all covers and ensure that tape has been installed over all openings, air inlet, exhaust openings, flywheel housing, crankcase breather(s), dipstick tubes, etc.
m. Ensure that all covers are air tight and weatherproof. Use a waterproof, weather resistant type tape (such as Kendall No. 231 or equivalent). Do not use duct tape. Duct tape will only seal for a short period of time. n. Under most conditions it is best to remove the batteries and use them in another application. As an alternative, place them in storage where they can be periodically checked and electrically charged again when needed. If the batteries are not removed, wash the tops of the batteries until clean. Apply an electrical charge to the batteries to obtain a specific gravity of 1.225. Disconnect the battery terminals. Place a plastic cover over the batteries. o. Place a waterproof cover over the engine. Ensure the engine cover is secure, but loose enough to allow air to circulate around the engine to prevent damage from condensation. p. Attach a tag to the engine with a notation of the date that the unit was preserved. q. Remove the waterproof cover every two or three months and check the engine for corrosion. If the engine has signs of corrosion at the check period, repeat the protection procedure.
20-11
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254
20.3.2
ALTERNATOR STORAGE - UP TO ONE YEAR
When a generator is in storage, moisture condenses in the windings. To minimize condensation, always place the generator in a dry storage area. Seal all openings with tape. Perform a resistance check of the windings. Record this reading. The purpose of this check is to provide a base line to determine if moisture or winding deterioration occurs during storage. (See Table 20.2-1) If long-term storage for a period of time exceeding one year is necessary, contact your local Caterpillar Dealer for the preferred procedure to use in your specific case.
NOTE:
20.3.2.1
REMOVAL FROM STORAGE
a. Remove all protective covers. b. Before start-up of a generator, use a megohmmeter to check insulation resistance for moisture and/or foreign material. Refer to (Section 10.4.5) for the procedure. A resistance reading of one megohm or less is an indication that the winding has absorbed too much moisture. 20.3.2.2
INSULATION RESISTANCE CHECKS: (MEGGER)
a. Test the main stator windings with a megohmmeter in the following situations: (1) Before initial startup of the generator set. (2) Every three months if the generator is operating in a humid environment. (3) If the generator has not been run under load for three months or more. This is a guideline only. It may be necessary to megger test more frequently if the environment is extremely humid, salty, or if the last megger test was close to one megohm.
NOTE:
20.3.2.3
INITIAL OPERATION AFTER STORAGE
a. The quality of oil control components used in Caterpillar engines is such that, following engine storage, only an operational check at initial start is necessary before operation. The purpose of this operational check is to ensure that the correct pressures and temperatures are kept in the lubrication, cooling, and fuel systems, and any leaks are corrected. To ensure a safe uniform check at initial start, use the following procedure: (1) Operate the engine for 30 minutes at rated speed. (2) Check frequently for leaks such as oil, coolant, and fuel during the first few hours of operation. Repair any leaks as soon as detected.
20-12
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254
CHAPTER 21 ENGINE/ALTERNATOR REMOVAL AND INSTALLATION PROCEDURES TABLE OF CONTENTS SECTION
TITLE
PAGE
21.0
ENGINE/ALTERNATOR REMOVAL AND INSTALLATION PROCEDURES
3
21.1
SAFETY PROCEDURES
3
21.2
ENGINE/ALTERNATOR REMOVAL PROCEDURES
4
21.3
ENGINE/ALTERNATOR INSTALLATION
7
21-1
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254
LIST OF TABLES TABLE
TITLE
TABLE 21.2-1
MEP-PU-810A/B ENGINE/GENERATOR REMOVAL PROCEDURE
5
TABLE 21.2-1
MEP-PU-810A/B ENGINE/GENERATOR REMOVAL PROCEDURE (CONTINUED)
6
MEP-PU-810A/B ENGINE/GENERATOR INSTALLATION PROCEDURE TABLE
8
MEP-PU-810A/B ENGINE/GENERATOR INSTALLATION PROCEDURE TABLE (CONTINUED)
9
TABLE 21.3-1 TABLE 21.3-1
PAGE
21-2
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 21.0
ENGINE/ALTERNATOR REMOVAL AND INSTALLATION PROCEDURES
21.1
SAFETY PROCEDURES
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 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.
21-3
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 21.2
ENGINE/ALTERNATOR REMOVAL PROCEDURES 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 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. CAUTION SIGNIFICANT DIFFERENCES BETWEEN THE MEP-PU-810A AND MEP-PU-810B REQUIRE SPECIFIC INSTRUCTIONS FOR EACH VERSION. 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.
21-4
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 TABLE 21.2-1
MEP-PU-810A/B ENGINE/GENERATOR REMOVAL PROCEDURE
STEP
PROCEDURE
1
Lock-out and tag-out the PU per Section 21.1.
2
Remove the PU housing side panel ("H" panel).
3
Remove the air inlet duct assembly.
4
Tag the hydraulic pressure gauge lines and fittings at the hydraulic control block.
5
Disconnect the hydraulic pressure gauge lines from the hydraulic control block.
6
Leaving the hoses connected, unbolt the hydraulic control block from the engine and secure it to the PU housing in a location, which permits engine/generator removal.
7
Leaving the hoses connected, unbolt the hydraulic pump assembly from the engine and position in a location, which permits engine/generator removal.
8
Leaving the lines connected, unbolt the engine gauge assembly from the PU housing and secure the assembly and lines to the engine.
9
Disconnect the fuel return line from the engine and secure the free end to the top of the engine compartment cooling fan guard.
10
Close the fuel inlet supply valve.
11
Disconnect the fuel inlet line at the Primary Fuel Filter and drain.
12
Open and remove the radiator cap.
13
Open the engine coolant drain valve and drain the coolant from the engine.
14
Remove the engine coolant drain hose from the engine.
15
Remove the coupling from the engine coolant supply line.
16
Remove the coupling from the engine coolant return line.
17
Remove the coupling from the charge-air hot line at the turbocharger.
18
Remove the coupling from the charge-air cold line at the intake manifold.
19
Disconnect and remove the exhaust pipe completely from the PU.
20
Tag the electrical wires and connections at the starter motor.
21
Disconnect the electrical wires at the starter motor.
22
Ensure that the crankcase oil drain valve is closed.
23
Disconnect, drain, and remove the crankcase oil drain hose.
24
Open the PDC generator connection access panel.
25
Tag the four generator high voltage output wires and the bus connections inside the PDC..
26
Disconnect the four generator high voltage output wires from the buses inside the PDC.
27
Tag the ground wire and ground bus connection inside the PDC.
28
Disconnect the ground wire from the ground bus inside the PDC.
29
Disconnect the generator wire conduit from the PDC, feed the generator and ground wires through the conduit hole, and secure the free ends to the generator.
21-5
TABLE 21.2-1 STEP
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 MEP-PU-810A/B ENGINE/GENERATOR REMOVAL PROCEDURE (CONTINUED) PROCEDURE
30
Disconnect the 40P, 7P1 and 7P2 harnesses from the PDC and secure the free end to the generator.
31
Disconnect the PU chassis ground wire from the generator mounting foot.
32
Remove the engine/generator skid from the PU chassis mounting hardware.
33
Carefully position the forks of a 10,000 lb minimum capacity forklift under the marked provisions on the engine/generator skid.
34
Using the forklift, lift the engine/generator slightly until it is just clear of the PU mounts.
35
Remove the engine/generator from the PU by carefully backing the forklift away from the PU. Be sure the engine/generator does not snag any PU components during the process.
36
Set the engine/generator down on blocks on the ground in a protected location.
21-6
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 21.3
ENGINE/ALTERNATOR INSTALLATION 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 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. CAUTION SIGNIFICANT DIFFERENCES BETWEEN THE MEP-PU-810A AND MEP-PU-810B REQUIRE SPECIFIC INSTRUCTIONS FOR EACH VERSION. 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.
21-7
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 TABLE 21.3-1
MEP-PU-810A/B ENGINE/GENERATOR INSTALLATION PROCEDURE TABLE
STEP
PROCEDURE
1
Carefully position the forks of a 10,000 lb minimum capacity forklift under the marked provisions on the engine/generator skid.
2
Using the forklift, lift the engine/generator until it is just clear of the PU mounts.
3
Insert the engine/generator into the PU by carefully moving the forklift toward the PU. Be sure the engine/generator does not snag any PU components during the process.
4
Position the engine/generator on the PU chassis mounting provisions, set in place, and remove the forklift.
5
Reinstall the engine/generator skid to PU chassis mounting hardware.
6
Reinstall the PU chassis ground wire to the generator mounting foot.
7
Reinstall the 40P, 7P1 and 7P2 harnesses from the engine/generator to the PDC.
8
Reinstall the generator and ground wires through the conduit hole in the PDC and reinstall the conduit end into the PDC.
9
Reinstall the ground wire to the ground bus inside the PDC.
10
Reinstall the four generator high voltage output wires to the buses inside the PDC.
11
Reinstall the PDC generator connection access cover.
12
Reinstall the crankcase oil drain hose.
13
Reinstall the electrical wires at the starter motor.
14
Reinstall the exhaust pipe to the muffler and the turbocharger.
15
Reinstall the coupling to the charge-air cold line at the intake manifold.
16
Reinstall the coupling to the charge air hot line at the turbocharger.
17
Reinstall the coupling to the engine coolant return line.
18
Reinstall the coupling to the engine coolant supply line.
19
Reinstall the engine coolant drain hose.
20
Close the engine coolant drain valve.
21
Refill the engine cooling system with coolant. Open the engine cooling system vent valve as necessary to release entrapped air from the engine block.
22
Reinstall the radiator cap.
23
Reinstall the fuel inlet line to the Primary fuel filter.
24
Reinstall the fuel return line.
25
Open the fuel inlet supply valve.
26
Using the fuel system hand-priming pump, prime the engine fuel system.
27
Reinstall the engine gauge assembly onto the PU housing.
28
Reinstall the hydraulic pump assembly onto the engine.
29
Reinstall the hydraulic control block onto the engine.
21-8
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 TABLE 21.3-1 (CONTINUED)
MEP-PU-810A/B ENGINE/GENERATOR INSTALLATION PROCEDURE TABLE
STEP
PROCEDURE
30
Reinstall the hydraulic pressure gauge lines to the hydraulic control block.
31
Reinstall the air inlet duct assembly.
32
Reinstall the PU housing side panel ("H" panel).
33
Reinstall both negative and positive cables on both Battery Banks and untag.
34
Un tag and reinstall both Battery Charger input power cables.
35
Check both Battery Chargers for proper operation.
21-9
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254
THIS PAGE INTENTIONALLY BLANK
21-10
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254
CHAPTER 22 PDC REMOVAL AND INSTALLATION PROCEDURES TABLE OF CONTENTS SECTION
TITLE
PAGE
22.0
PDC REMOVAL AND INSTALLATION PROCEDURES
4
22.1
SAFETY PROCEDURES
4
22.2
PRIMARY DISTRIBUTION PANEL (PDC) REMOVAL
5
22.3
PRIMARY DISTRIBUTION PANEL (PDC) INSTALLATION
8
22-1
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 22.2-1
PDC REMOVAL PROCEDURES
22-2
6
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254
LIST OF TABLES TABLE
TITLE
PAGE
TABLE 22.2-1
MEP-PU-810A PDC REMOVAL PROCEDURE
6
TABLE 22.2-1
MEP-PU-810A PDC REMOVAL PROCEDURE (CONTINUED)
7
TABLE 22.2-2
MEP-PU-810B PDC REMOVAL PROCEDURE
7
TABLE 22.3-1
MEP-PU-810A PDC INSTALLATION PROCEDURE
9
TABLE 22.3-2
MEP-PU-810B PDC INSTALLATION PROCEDURE
9
22-3
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 22.0 NOTE:
PDC REMOVAL AND INSTALLATION PROCEDURES This is a DEALER Level Task. It is included in this manual for EMERGENCY USE ONLY.
22.1
SAFETY PROCEDURES
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 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.
22-4
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 22.2
PRIMARY DISTRIBUTION PANEL (PDC) REMOVAL 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 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 DAMAGE TO PDC WILL OCCUR IF 7P1 AND 7P2 ARE TRANSPOSED. CAUTION SIGNIFICANT DIFFERENCES BETWEEN THE MEP-PU-810A AND MEP-PU-810B REQUIRE SPECIFIC INSTRUCTIONS FOR EACH VERSION. 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.
NOTE:
This is a DEALER Level Task. It is included in this manual for EMERGENCY USE ONLY.
22-5
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254
FIGURE 22.2-1
PDC REMOVAL PROCEDURES
PDC removal and installation procedures are presented in Table 22.2-1, Table 22.2-2, Table 22.3-1, and Table 22.3-2. Figure 22.2-1 illustrates the removable parts on the PDC. TABLE 22.2-1
MEP-PU-810A PDC REMOVAL PROCEDURE
STEP
PROCEDURE
1
De-energize and disconnect feeder output cables, tie output cables, and the ground cables.
2
Disconnect the battery cables from the batteries.
3
Remove Pin Plug 40P, with an Allen wrench, from the PDC, for both GEN 1 and GEN 2 units.
4
Remove Pin Plugs 7P1 and 7P2. Twist the plugs and pull out, for both GEN 1 and GEN 2 units.
5
Remove the access cover on the back of the control panel for GEN 1 and GEN 2. Tag and Disconnect generator leads T1, T2, T3, neutral and ground from the bus bars.
6
Remove the curbside cover from the transformer. Tag and Disconnect H1, H2, H3, and ground and disconnect the Seal - Tight connector.
7
Remove feeder protective covers.
8
Remove the Mounting Hardware from the PDC flashing on the right, left and top, and remove the flashing see Figure 22.2-1 for reference.
22-6
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254
TABLE 22.2-1
MEP-PU-810A PDC REMOVAL PROCEDURE (CONTINUED)
STEP
PROCEDURE
9
Remove (2) 3/8” x 1” inch bolts from the front bottom of the PDC, from under the trailer frame see Figure 22.2-1 for reference.
10
Remove (4) 3/8” x 2” inch bolts from the rear of the PDC, under the trailer frame.
11
With a 4000 lb forklift lift the PDC to clear the PU trailer frame, and remove the Korfund Pads (Packing between the PDC and Frame). Lower the panel slightly and remove the PDC.
TABLE 22.2-2
MEP-PU-810B PDC REMOVAL PROCEDURE
STEP
PROCEDURE
1
Disconnect battery cables from batteries.
2
Remove Pin Plug 40P, with an Allen wrench, from the PDC, for both units.
3
Remove Pin Plugs 7P1 and 7P2. Twist the plugs and pull out, for both units.
4
Remove access cover and filter on back of the control panel for GEN 1 and GEN 2. Disconnect generator leads T1, T2, T3, neutral and ground from the bus bars.
5
Remove cover from the transformer. Disconnect H1, H2, H3, and ground and disconnect the Seal-Tight connector.
6
Remove the Mounting Hardware from the flashing on the right, left and top of the control panel and remove the flashing.
7
Remove (2) 3/8” x 1” inch bolts from the front bottom of the PDC, from under the trailer frame.
8
Remove (2) 3/8” x 2” inch bolts from the rear of the PDC, under the trailer frame.
9
Remove the tail light assemblies.
10
With a 4000lb forklift lift the PDC to clear the PU trailer frame, and remove the Korfund Pads (Packing between the PDC and Frame). Lower the panel slightly and remove the PDC.
NOTE:
To remove or install the PDC a minimum of a 4000 lb forklift is required.
22-7
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 22.3
PRIMARY DISTRIBUTION PANEL (PDC) INSTALLATION 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 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. CAUTION SIGNIFICANT DIFFERENCES BETWEEN THE MEP-PU-810A AND MEP-PU-810B REQUIRE SPECIFIC INSTRUCTIONS FOR EACH VERSION. 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.
22-8
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 TABLE 22.3-1
MEP-PU-810A PDC INSTALLATION PROCEDURE
STEP
PROCEDURE
1
With a 4000lb forklift lift the PDC into the PU trailer slightly above the frame and reinstall the Korfund Pads (Packing between the PDC and Frame). Lower the panel and reinstall the panel.
2
Reinstall (4) 3/8” x 2” inch bolts from the rear of the PDC, under the trailer frame.
3
Reinstall (2) 3/8” x 1” inch bolts from the front bottom of the PDC, from under the trailer frame.
4
Reinstall the flashing on the right, left and top of the control panel using Mounting Hardware. Reinstall gasket as required.
5
Reinstall generator leads T1, T2, T3, neutral and ground to the bus bars. Reinstall the access cover on back of the control panel for GEN 1 and GEN 2.
6
Reinstall Pin Plugs 7P1 and 7P2. Twist the plugs and push in, for both units.
7
Reinstall H1, H2, H3 and ground in the transformer and Reinstall the Seal-Tight connector and Reinstall the transformer cover.
8
Reinstall feeder protective covers.
9
Reinstall Pin Plug 40P, to the PDC with an Allen wrench, for both units.
10
Reinstall battery cables to the batteries. See Foldout (FO 35)
TABLE 22.3-2
MEP-PU-810B PDC INSTALLATION PROCEDURE
STEP
PROCEDURE
1
With a 4000lb forklift lift the PDC slightly above the frame and reinstall the Korfund Pads (Packing between the PDC and Frame). Lower the panel and install the panel.
2
Reinstall (2) 3/8” x 2” inch bolts from the rear of the PDC, under the trailer frame.
3
Reinstall (2) 3/8” x 1” inch bolts from the front bottom of the PDC, from under the trailer frame.
4
Reinstall the flashing on the right, left and top of the control panel using Mounting Hardware.
5
Reinstall generator leads T1, T2, T3, neutral and ground to the bus bars. Reinstall the access cover and filter on back of the control panel for GEN 1 and GEN 2.
6
Reinstall Pin Plugs 7P1 and 7P2. Twist the plugs and push in, for both units.
7
Reinstall H1, H2, H3 and ground in the transformer and reinstall the Seal-Tight connector and reinstall the transformer cover.
8
Reinstall Pin Plug 40P, to the PDC with an Allen wrench, for both units.
9
Reinstall the tail light assemblies.
10
Reinstall battery cables to the batteries. See Foldout (FO 35)
22-9
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254
THIS PAGE INTENTIONALLY BLANK
22-10
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254
COMMERCIAL TECHNICAL MANUAL BOOK 2 OF 2 GENERATOR – 840 KW MEP-PU-810A/B Radian Part Numbers: 1R0253-3/1R0254-3
OPERATION AND MAINTENANCE ANNEXES A THROUGH J
© 2007 DRS RADIAN ALL RIGHTS RESERVED 5845 RICHMOND HWY. SUITE 725 ALEXANDRIA, VIRGINIA 22303-1865 FEBRUARY 23, 2007 (REVISION 5) * DISTRIBUTION STATEMENT: Approved for public release; distribution is unlimited. Questions pertaining to technical content shall be referred to 542 SEVSG/GBZFM, Robins AFB, GA 31098. Other requests for this document shall be referred to 542 MSUG/GBMUDE, Robins AFB, GA 31098. *This manual supersedes USAF TO 35C2-3-518-1/ USA TM 9-6115-484-14, JUNE 9, 2006, including all changes
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254
THIS PAGE INTENTIONALLY BLANK
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254
ANNEX A OTHER MANUAL REFERENCES FOR THE POWER UNIT The following is a list of vender reference manuals and additional DRS Radian manuals for the Power Unit: CATERPILLAR NUMBER NOVEMBER 1998, or later NOVEMBER 1998, or later REHS 0148-01, or later RENR 1200-01, or later RENR 2227-02, or later SEBP 3201-01, or later SEBU 6874-04, or later SEBU 6918-03, or later SEBU 6959-02, or later SEBU 7163-01, or later SENR 1067-02, or later SENR 1068-01, or later SENR 2995-04, or later SENR 3130-06, or later SENR 5359-01, or later SENR 5833-02, or later SENR 6565-02, or later SEHS 9615-02, or later SEHS 9124-01, or later SEHS 9031-03, or later
TITLE TROUBLESHOOTING (3456 DPGDS GENERATOR SET ENGINESUPPLEMENT) SERVICE MANUAL 3456 DPGDS GENERATOR SET ENGINESUPPLEMENT (EMCP II+ FOR EUI ENGINES) SPECIAL INSTRUCTION (PARTS LISTING OF THE DEUTSCH CONNECTORS AND COMPONENTS) SYSTEMS OPERATION TESTING AND ADJUSTING (EMCP II+ FOR EUI ENGINES) TROUBLESHOOTING (3406E GENERATOR SET ENGINES) PARTS MANUAL – 3456 DPGDS GENERATOR SET – MILITARY OPERATION AND MAINTENANCE MANUAL (CUSTOMER COMMUNICATION MODULE FOR DIESEL ENGINES) OPERATION AND MAINTENANCE MANUAL (SR4B GENERATORS AND CONTROL PANELS) CAT O&M 3406E, 3456 INDUSTRIAL ENGINE OPERATION AND MAINTENANCE MANUAL ELECTRIC SET GENERATORS SYSTEMS OPERATION TESTING AND ADJUSTING (3406E AND 3456 INDUSTRIAL ENGINES) DISASSEMBLY AND ASSEMBLY (3406E & 3456 INDUSTRIAL ENGINE) PRODUCT SAFETY SPECIFICATIONS (TORQUE SPECIFICATIONS) SERVICE MANUAL-(SR4B GENERATOR) SPECIFICATIONS SYSTEM OPERATION, TESTING AND ADJUSTING (DIGITAL VOLTAGE REGULATOR) SYSTEM OPERATION, TESTING, AND ADJUSTING (GENERATOR SET LOAD SENSOR AND LOAD SHARING MODULE) TOOL OPERATING MANUAL (SERVICING DEUTSCH HD & DT STYLE CONNECTORS) SPECIAL INSTRUCTION-CLEANING AND DRYING OF GENERATORS AND CONTROL PANELS SPECIAL INSTRUCTION (STORAGE PROCEDURE FOR CATERPILLAR PRODUCTS)
A-1
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 OTHER VENDOR MANUALS VENDOR
MANUAL NUMBER 82384R
WOODWARD
02036 CUTLER-HAMMER
I.B. 48018N 9 2899 00 990 REV: D
BASLER Z-WORLD
REVISION E
SIXNET MASTER CONTROL SYSTEMS
TITLE SPM-A SYNCHRONIZER (INSTALLATION, OPERATION, AND CALIBRATION MANUAL) LOAD SHARING MODULE (INSTALLATION, OPERATION, AND CALIBRATION MANUAL) INSTRUCTION MANUAL, FOR THE INSTALLATION, OPERATION, AND MAINTENANCE OF TRITON, SL 160/200/360/400, MEDIUM VOLTAGE VACUUM CONTACTORS BE1 – 851 OVER CURRENT RELAY INSTRUCTION MANUAL BL1600 C-PROGRAMMABLE CONTROLLER, USERS MANUAL VERSATRAK AND MINI-VERSATRAK USER MANUAL (REMOTE TERMINAL UNITS INSTALLATION AND MAINTENANCE) SIXNET USER MANUAL (MODULAR DIN RAIL I/O, INSTALLATION AND MAINTENANCE) INSTRUCTION MANUAL, BATTERY CHARGER, MODEL MBC6X-24V-20A-LA
DRS RADIAN SUPPLEMENTAL MANUALS NUMBER CTM 01646.1R0253/1R0254 TR JULY 6, 2006 CTM 01646.1R0253P/1R0254P R1 AUGUST 9, 2006, (Revision 1)
TITLE TROUBLESHOOTING PROCEDURES FOR POWER UNIT-840KW MEP-PU-810A/B POWER UNIT, 840 KW, MEP-PU-810A/B PARTS MANUAL
A-2
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254
ANNEX B DPGDS GSC+ PROGRAMMABLE SETPOINTS OP5-0 SETPOINTS
SETPOINTS OP5-0 ENGINE/GENERATOR PROGRAMMING① SETPOINT-NAME-DESCRIPTIONS
RANGE OF VALUES
FACTORY DPGDS 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
0-for engine shutdown P003 - Shutdown Override For Engine Fault: GSC+ response 1-for alarm only (shutdown override, no engine to a low engine oil pressure or high coolant temperature fault. shutdown).
0
0
P004 - Shutdown Override For Sensor Fault: GSC+ response 0-for alarm only shutdown override, no engine to a diagnostic fault with the engine oil pressure sensor, coolant shutdown). temperature sensor, oil temperature sensor, sensor power supply 1-for engine shutdown. or coolant loss sensor.
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
24
24
N/A
N/A
P007 - System Voltage, 24 Or 32 Volts: system voltage (battery 24 or 32. voltage) of the genset. P008 - This setpoint is not currently being used by the GSC+ and cannot be programmed.
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)
B-1
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 OP5-0 SETPOINTS (CONTINUED)
SETPOINTS OP5-0 ENGINE/GENERATOR PROGRAMMING① SETPOINT-NAME-DESCRIPTIONS
RANGE OF VALUES
FACTORY DEFAULT
DPGDS SETPOINT
90 seconds
90 seconds
10 seconds
10 seconds
5 minutes
5 minutes
P017 - Total Cycle Crank Time: cycle crank time used by the GSC+ to declare that an overcrank fault exists.
5 to 120 seconds in increments of 1 second.
P018 - Cycle Crank Time: amount of time the GSC+ cranks and then rests the starting motor during a single crank cycle. P019 - Cooldown Time: amount of time the GSC+ allows the engine to run after a normal shutdown is initiated.
5 to 60 seconds in increments of 1 second.
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.
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)
P022⑤ - GSC+ Engine Number: informs other devices on the CAT Data Link of the engine number for the GSC+.
0 to 30 minutes in increments of 1 minute.
01 through 08
SETPOINTS - OP5-0-ENGINE/GENERATOR PROGRAMMING① SETPOINT-NAME-DESCRIPTIONS P023 - Engine Type: identifies the engine as a mechanical unit injector (MUI) diesel, spark ignited (gas), or electronic unit injector (EUI) diesel engine.
RANGE OF VALUES 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 0 to 20 seconds in increments of 1 a crank cycle. This setpoint is for Gas engines only. second. The P024 setpoint only functions when the P023 setpoint is set to 1 (gas engine).
FACTORY DEFAULT
60HZ 50HZ SETPOINT SETPOINT
0
2
2
5 Seconds
5 Seconds
5 Seconds
P025 - Oil Temperature Sensor Installed: tells whether or not the optional engine oil temperature sensor is installed on the genset.
0 - for gensets without an oil temperature sensor 1 - for gensets with an oil temperature sensor
0
0
0
P026 - High Oil Temperature Shutdown: oil temperature used by the GSC+ to declare a high oil temperature shutdown fault exists (after a 10 second delay). Refer to the panel model number.
185 to 253ºF (85 to 123ºC) in increments of 1
225ºF (107ºC)
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
0 - for alarm only (shutdown override, no P027 - Shutdown Override For High Oil Temperature Fault: GSC+ response to an engine high engine shutdown). oil temperature fault. 1 - for engine shutdown. P028 - Nameplate Voltage: rated voltage of the generator. This setpoint is used for protective relaying 100 to 25kV in increments of 1 functions. P029 - Nameplate Current: rated current output of the 0 to 4000 A in increments of 1 generator. P030 - Nameplate Power: rated power capability of 0 through 10MW in increments of 1kW. the generator. P031 - Rated Frequency: nominal frequency rating of 50 or 60Hz genset. P032 - Connection Configuration Of Generator: wye or delta configuration of generator. P033 - Number Of Generator Poles.
0 - wye 1 - delta 0 through 254 in increments of 2.
B-2
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
⑤
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. After setpoint P022 is reprogrammed, the GSC+ must be power cycled (powered down and then powered up)
B-3
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 OP5-1 SETPOINTS
SETPOINTS OP5-1 PROTECTIVE RELAYING PROGRAMMING① SETPOINT-NAME-DESCRIPTION
RANGE OF VALUES
P101 - Generator Overvoltage Alarm Enable: the GSC+ enables or disables the generator overvoltage alarm function.
0 - disabled 1 - enabled
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.
0 through 120 seconds② in increments of 1
P104 - Generator Overvoltage Shutdown Enable: the GSC+ enables or disables the generator overvoltage shutdown function.
0 - disabled 1 - enabled
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.
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.
60 to 100% of nameplate voltage 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.
60 through 100% of rated voltage in increments of 1%.
P112 - Generator Undervoltage Shutdown Time Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments of 1 issuing an undervoltage shutdown. P113 - Generator Overfrequency Alarm Enable: 0 - disabled the GSC+ enables or disables the generator 1 - enabled overfrequency alarm function. 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
B-4
FACTORY DEFAULT
60HZ SETPOINT
50HZ SETPOINT
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 OP5-1 SETPOINTS (CONTINUED)
SETPOINTS OP5-1 PROTECTIVE RELAYING PROGRAMMING① RANGE OF VALUES
FACTORY DEFAULT
60HZ SETPOINT
50HZ 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
10 seconds
10 seconds
10 seconds
P119 - Generator Underfrequency Alarm Enable: the GSC+ enables or disables the generator underfrequency alarm function.
0 - disabled 1 - enabled
1
1
1
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
48Hz 57Hz 378Hz
57Hz
48Hz
P121 - Generator Underfrequency Alarm Time Delay: amount of time the GSC+ waits before issuing an underfrequency alarm.
0 through 120 seconds② in increments of 1
10 seconds
10 seconds
10 seconds
P122 - Generator Underfrequency Shutdown Enable: the GSC+ enables or disables the generator underfrequency shutdown function.
0 - disabled 1 - enabled
1
1
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
45Hz 54Hz 360Hz
54Hz
45Hz
P124 - Generator Underfrequency Shutdown Time Delay: amount of time the GSC+ waits before issuing an underfrequency shutdown.
0 through 120 seconds② in increments of 1
15 seconds
03 seconds
03 seconds
P125 - Generator Reverse Power Shutdown Enable: the GSC+ enables or disables the generator reverse power shutdown function.
0 - disabled 1 - enabled
1
1
1
P126 - Generator Reverse Power Shutdown Threshold: level of reverse power the GSC+ uses to issue a reverse power shutdown.
0 through 20% of rated power in increments of 1%.
15%
4%
4%
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
10 seconds
4 seconds
4 seconds
P128 - Generator Overcurrent Alarm Enable: the GSC+ enables or disables the overcurrent alarm.
0 - disabled 1 - enabled
1
1
1
105%
150%
150%
0 seconds
0 seconds
0 seconds
105%
150%.
150%
0 seconds
0 seconds
0 seconds
1
1
1
110%
150%
150%
0 seconds
10 seconds
10 seconds
SETPOINT-NAME-DESCRIPTION
P129 - Generator Phase Overcurrent Alarm 100 through 160% of nameplate current in Threshold: level of current the GSC+ uses to issue increments of 5% a phase overcurrent alarm. P130 - Generator Phase Overcurrent Alarm Time Delay: amount of time the GSC+ waits before issuing a phase overcurrent alarm.
0 through 250 seconds② in increments of 1
P131 - Generator Total Overcurrent Alarm 100 through 160% of three times nameplate Threshold: level of current the GSC+ uses to issue current in increments of 5% a total overcurrent alarm. P132 - Generator Total Overcurrent Alarm Time Delay: amount of time the GSC+ waits before issuing a total overcurrent alarm.
0 through 250 seconds② in increments of 1
P133 – Generator Overcurrent Shutdown Enable: the GSC+ enables or disables the overcurrent shutdown.
0 – disabled 1 – enabled
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 0 through 250 seconds② in increments of 1 before issuing a phase overcurrent shutdown.
B-5
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 OP5-1 SETPOINTS (CONTINUED)
SETPOINTS OP5-1 PROTECTIVE RELAYING PROGRAMMING① SETPOINT-NAMEFACTORY 60HZ RANGE OF VALUES SETPOINT DESCRIPTION DEFAULT P136 - Generator Total Overcurrent Shutdown 100 through 160% of three times nameplate Threshold: level of current the GSC+ uses to issue current in increments of 5% a total overcurrent shutdown. 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 0 through 110% of nameplate power in power the GSC+ uses to activate the kW level relay increments of 1% function. P140 - KW Level Relay Time Delay: amount of time the GSC+ waits before activating the kW level 0 through 120 seconds② in increments of 1 relay function. P141 - KW Level Relay Disengage Threshold: 0 through 110% of nameplate power in level of power the GSC+ uses to deactivate the kW increments of 1%. level relay function. P142 - KW Level Relay Disengage Time Delay: amount of time the GSC+ waits before deactivating 0 through 120 seconds② in increments of 1 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.
B-6
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 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
0
0
0
0
0 seconds
0 seconds
0
0
8
8
1
1
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. SP09 - Spare Input 3 Time Delay: Amount of time the GSC+ waits before responding to a SP3 fault. SP10 - Spare Input 4 Active State. Input state used by the GSC+ to declare a SP4 fault exists. SP11 - Spare Input 4 Response: GSC+ response to a SP4 fault. SP12 - Spare Input 4 Time Delay: Amount of time the GSC+ waits before responding to a SP4 fault. SP13 - Spare Output Response: GSC+ response to the spare output trigger condition.
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 0 - 250 seconds in increments of 1 0-active low 1-active high 0-shutdown 1-alarm 0 - 250 seconds in increments of 1 0-active low 1-active high 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
SP15 – Spare Relay Output Response: GSC+ response to the spare relay trigger condition.
10-high oil temp fault② 11-CCM control 0-relay inactive when triggered 1-relay active when triggered
B-7
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 OP6 SETPOINTS (CONTINUED)
SETPOINTS OP6 SPARE INPUT/OUTPUT PROGRAMMING SETPOINT-NAME-DESCRIPTIONS
RANGE OF VALUES
FACTORY DPGDS SETPOINT DEFAULT
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.
B-8
0 In 50Hz Mode③
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254
ANNEX C ENGINE/GENERATOR ALARM AND SHUTDOWN POINTS
ENGINE – GSC CONDITION
ALARM POINT
SHUTDOWN POINT
Low Oil Pressure: 1
•
At Rated Speed
N/A
30 psi
•
At Idle Speed
N/A
10 psi
2
Engine Overspeed
N/A
2120 rpm
3
High Coolant Temperature
N/A
225°F
4
Low Coolant Temperature
N/A
70°F
5
High Oil Temperature
N/A
225°F
C-1
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254
GENERATOR - GSC CONDITION Over Voltage: 6
10 Seconds at -
- 105%
3990 Volts
- 110%
4180 Volts
•
60Hz
- 105%
4368 Volts
- 110%
4576 Volts
10 Seconds at -
15 Seconds at -
•
50Hz
- 90%
3420 Volts
- 85%
3230 Volts
•
60Hz
- 90%
3744 Volts
- 85%
3536 Volts
10 Seconds at -
10 Seconds at -
•
50Hz
- 53Hz
- 55Hz
•
60Hz
- 63Hz
- 66Hz
Under Frequency: 9
10 Seconds at -
50Hz
Over Frequency: 8
SHUTDOWN POINT
•
Under Voltage: 7
ALARM POINT
10 Seconds at –
15 Seconds at –
•
50Hz
- 48 Hz
- 45 Hz
•
60Hz
- 57 Hz
- 54Hz
10
Reverse Power
10 Seconds at 10%
11
Phase Overcurrent
0 Seconds at 150%
10 Seconds at 150%
12
Total Overcurrent
0 Seconds at 150%
10 Seconds at 150%
C-2
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1R0254
ANNEX D BASLER OVERCURRENT RELAY SETPOINTS, ALARM AND SHUTDOWN POINTS CT RATIO SETTINGS BREAKER RELAY GENERATOR FEEDER TIE
CT RATIO 100:5 200:5 200:5
INSTANTANEOUS TRIP SETTINGS PHASE INSTANTANEOUS BREAKER RELAY TRIP 50TP PU TD 0.0 0m GENERATOR 7.5 84m FEEDER 0.0 0m TIE
“P” VALUE 20 40 40
“N” VALUE 20 40 40
NEUTRAL INSTANTANEOUS TRIP 50TN PU TD 3.0 0m 1.25 84m 0 0m
NEGATIVE SEQUENCE TRIP 50 TQ PU TD 3.0 0m 0 0m 0.0 0m
TIME OVERCURRENT TRIP SETTINGS PHASE TIME OVERCURRENT BREAKER RELAY TRIP 51P PU TD C 4.50 0.5 VV2 GENERATOR 2.50 1.0 VV2 FEEDER 5.00 2.0 VV2 TIE
D-1
NEUTRAL TIME OVERCURRENT TRIP 51N PU TD C 1.25 0.5 VV2 1.00 1.0 VV2 1.50 2.0 VV2
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1R0254
THIS PAGE INTENTIONALLY BLANK
D-2
USAF TO 35C2-3-518-1 TM 9-6115-484-14 DRS RADIAN CTM. 01646.1R0253/1RO254
ANNEX E AUTOMATIC VOLTAGE REGULATOR (AVR) SETPOINTS Step 1: Go to parameter 90 and set "DPGDS Setpoints" to 01. Setpoints can only be changed when parameter 90 is any number besides 0009. 0009 locks changes out. After all changes have been made to setpoints, return to parameter 90 and change back to 0009.
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 Rated Generator Output Current CT Voltage At Rated Generator Current
Program
001.0-100.0
001.0
17.3
17.3
03 04 05②
Program Program Program
Amps Volts
0000-0004 0000-9999 01.00-05.00
0004 0600 05.00
4 80 4.00
4 73 3.66
06 07 08 09 10
Knee Frequency Decreasing Volts/Hz Slope I Decreasing Volts/Hz Slope 2 Minimum Voltage Under Frequency Point
Program Program Program Program Program
Hz Volts/Hz Volts/Hz % Hz
045.0-065.0 001.0-010.0 001.0-010.0 050.0-100.0 020.0-040.0
050.0 002.0 002.0 050.0 025.0
59.8 2.0 2.0 50.0 25.0
49.8 2.0 2.0 50.0 25.0
11 12 13 14 15
Program Program Program Program Program Program
% Seconds % Seconds %
16⑤
Overvoltage Trip Point Overvoltage Trip Time Under Voltage Trip Point Under Voltage Trip Time Voltage Gain (IR Compensation) Integral Gain
0105-0140 0002-0030 0060-0095 0030-0120 000.0-0 10.0 001.0-020.0
014.0 0002 0060 0030 0000 006.0
125.0 5 75 30 0 6.0
125.0 5 75 30 0 6.0
17⑥
Proportional Gain
Program
001.0-020.0
005.0
5.0
5.0
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)
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) Power Factor
View View View
Amps Amps KW
18 19 30
56③ 57③
Program Program Program
Amps %
View
E-1
USAF TO 35C2-3-518-1 TM 9-6115-484-14 DRS RADIAN CTM. 01646.1R0253/1RO254
DPGDS SETPOINTS
DPGDS AVR PARAMETERS PARAMETER
TITLE
TYPE
58③,④
Three Phase kVAR (KE and later)
View
60 90 91 92
Hours Password Software ID Latest Fault
View Program View View
93 94 96
Previous Fault Fault Clear Shutdown Fault Reset
View View Switch
UNITS
RANGE OF VALUES
Hours
0000-9999
DEFAULT VALUE
60HZ OPS
50HZ OPS
0009
0009
0000
0000
0000
0000
0000
0000
① Default value for output voltage is different depending on regulator sensing voltage. If the regulator is designed for l20 volts sensing, then the default output voltage is 4l60 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 I 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:
Parameters 20, 21, 22, 36, 37, and 38 are displayed but not used.
E-2
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1RO254
ANNEX F 3456 EPG ADEM SETPOINTS
CAT ELECTRONIC TECHNICIAN ET3.0 (OCT99) ECM Summary 01/12/2000 2:36 PM 3456 EPG Engine (9BZ00002) Parameter
Value
Equipment ID Engine Serial Number use data plate value ECM Serial Number Personality Module Part Number Personality Module Release Date Personality Module Description
F-1
9BZ00002 08390151CG 1730820-00 May99 EPG 3456
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1RO254
CAT ELECTRONIC TECHNICIAN ET3.0 (OCT99) Configuration 3456 EPG Engine (9BZ00002) Parameter
Value
Description
Value
Selected Engine Rating Rating Number Rated Power Rated Peak Torque Top Engine Speed Range Test Spec ECM Identification Parameters Equipment ID Engine Serial Number use data plate value ECM Serial Number Personality Module Part Number Personality Module Release Date Personality Module Description Security Access Parameters Total Tattletale Engine/Gear Parameters Rated Engine Speed Acceleration Delay Time Engine Accel. Rate Low Idle Speed Cooldown Speed Engine Cooldown Duration Crank Duration Maximum No of Crank Cycles Configuration Continued Crank Terminate Speed I/O Configuration Parameters Ether Control Configuration ContinuedParameter Description Fuel Pressure Sensor
TT
2 669 HP at 1800 RPM 2655 lb-ft at 1200 RPM 1500 - 1945 RPM 0K1501 0 0
9BZ00002 08390151CG 1730820-00 May99 EPG 3456 1 1800 0 250 1200 1800 0 0 0
RPM Sec RPM/s RPM RPM min Sec
400
RPM
Enabled
0 0 0 0 0 0 0 0 0
Value Value Not Installed
F-2
Unit
Unit
TT 0
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1RO254
CAT ELECTRONIC TECHNICIAN ET3.0 (OCT99) (CONTINUED) Exhaust Temperature Sensor Installation Status Engine Oil Temperature Sensor Installation Status User Defined Switch Installation Status User Defined Switch Active State Configuration System Parameters FLS use data plate value FTS use data plate value System Gain
F-3
Not Installed Not Installed Not Installed Low
0 0 0 0
-28 22 0
0 0 0
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1RO254 CAT ELECTRONIC TECHNICIAN ET3.0 (OCT99) Monitoring System Tool 01/12/2000 2:43 PM 3456 EPG Engine (9BZ00002) Parameter
Value
Description
State
Trip Point
Delay Time
Low System Voltage Warn Operator
On
20 Volts
5 Sec
Low Engine Oil Pressure Warn Operator Engine Shutdown
On Off
None None
5 Sec 10 Sec
High Engine Coolant Temperature Warn Operator Engine Derate Engine Shutdown
On On Off
217 Deg F 221 Deg F 223 Deg F
5 Sec 5 Sec 20 Sec
Low Engine Coolant Temperature Warn Operator
On
167 Deg F
5 Sec
On Off
2200 RPM 2300 RPM
0 Sec 0 Sec
On
12.8 PSI
0 Sec
Warn Operator
On
172.4 Deg F
30 Sec
High Fuel Temperature Warn Operator
On
176 Deg F
30 Sec
Monitoring System Tool Continued Engine Overspeed Warn Operator Engine Shutdown Monitoring System Tool ContinuedAltitude (atmospheric pressure) Engine Derate High Engine Inlet Air Temperature
F-4
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1RO254
CAT ELECTRONIC TECHNICIAN ET3.0 (OCT99) Current Totals 01/12/2000 2:44 PM 3456 EPG Engine (9BZ00002) Parameter
Value
Description
Value
Unit
Total Time Total Fuel Ether Usage
2 31 0
hours Gal Gal
CAT ELECTRONIC TECHNICIAN ET3.0 (OCT99) Injector Codes Calibration 01/12/2000 2:43 PM 3456 EPG Engine (9BZ00002) Parameter
Value
Injector use data from each individual engine and the injector Injector 1 engine specific value Injector 2 engine specific value Injector 3 engine specific value Injector 4 engine specific value Injector 5 engine specific value Injector 6 engine specific value
F-5
Code 8837 8922 4657 7827 5622 5867
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1RO254
CAT ELECTRONIC TECHNICIAN ET3.0 (OCT99) Active Code 01/12/2000 2:42 PM 3456 EPG Engine (9BZ00002) Parameter
Value
Code
Description
No Active Codes
CAT ELECTRONIC TECHNICIAN ET3.0 (OCT99) Logged Diagnostic Codes 01/12/2000 2:42 PM 3456 EPG Engine (9BZ00002) Parameter
Value
Code
Description
Occur
First
Last
11
0
0
3456 EPG Engine (9BZ00002) Diagnostic Clock = 2 hours 91- 8
Throttle Position signal abnormal
F-6
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1RO254
Cat Electronic Technician ET3.0 (OCT99) Event Code 01/12/2000 2:42 PM 3456 EPG Engine (9BZ00002) Parameter
Value
Code
Description
Occur
First
Last
1
2
2
2
0
0
3456 EPG Engine (9BZ00002) Diagnostic Clock = 2 hours E027 E043
High Inlet Air Temperature Warning Low System Voltage Warning
CAT ELECTRONIC TECHNICIAN ET3.0 (OCT99) Status Group 1 01/12/2000 2:39 PM 3456 EPG Engine (9BZ00002) Parameter
Value
Description
Value
Unit
0 400 0 74 0 50 30 0
RPM RPM PSI %
3456 EPG Engine (9BZ00002) : 3456 EPG Engine Group 1 Engine Speed Desired Engine Speed Boost Pressure Throttle Position Fuel Position Rated Fuel Limit FRC Fuel Limit Engine Speed Droop
F-7
%
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1RO254
CAT ELECTRONIC TECHNICIAN ET3.0 (OCT99) Status Group 2 01/12/2000 2:40 PM 3456 EPG Engine (9BZ00002) Parameter
Value
Description
Value
Unit
66 66 66 0 14 14.5 15 Unavailable Parameter Unavailable Parameter
Deg F Deg F Deg F PSI PSI PSI PSI PSI PSI
3456 EPG Engine (9BZ00002) : 3456 EPG Engine Group 2 Engine Coolant Temperature Inlet Air Temperature Fuel Temperature Engine Oil Pressure Engine Oil Pressure (abs) Atmospheric Pressure Turbo Outlet Pressure (abs) Fuel Pressure Fuel Pressure (abs)
F-8
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1RO254
CAT ELECTRONIC TECHNICIAN ET3.0 (OCT99) Status Group 3 01/12/2000 2:41 PM 3456 EPG Engine (9BZ00002) Parameter
Value
Description
Value
Unit
Unavailable Parameter Unavailable Parameter Unavailable Parameter Abnormal Signal
PSI PSI Deg F Deg F
3456 EPG Engine (9BZ00002) : 3456 EPG Engine Group 3 Fuel Pressure Fuel Pressure (abs) Engine Oil Temperature Exhaust Temperature
F-9
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1RO254 CAT ELECTRONIC TECHNICIAN ET3.0 (OCT99) Status Group 4 01/12/2000 2:41 PM 3456 EPG Engine (9BZ00002) Parameter
Value
Description
Value
3456 EPG Engine (9BZ00002) : 3456 EPG Engine Group 4 Engine Control Switch Remote E-Stop Switch Startup Mode Overspeed Test Switch Ether Injection Remote Start
Unit
Stop Off Off Off Off Unavailable Parameter
CAT ELECTRONIC TECHNICIAN ET3.0 (OCT99) Status Group 5 01/12/2000 2:41 PM 3456 EPG Engine (9BZ00002) Parameter
Value
Description
Value
Unit
0 0 25 0 Off 0
GPH % Volts Sec
3456 EPG Engine (9BZ00002) : 3456 EPG Engine Group 5 Fuel Rate Engine Load Factor Battery Voltage Remaining Cooldown Time Shutdown Notify Status Engine Power Derate
F-10
%
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1RO254 CAT ELECTRONIC TECHNICIAN ET3.0 (OCT99) Monitoring System Tool 01/12/2000 2:43 PM 3456 EPG Engine (9BZ00002) Parameter
Value
Description
State
Trip Point
Delay Time
Low System Voltage Warn Operator
On
20 Volts
5 Sec
Low Engine Oil Pressure Warn Operator Engine Shutdown
On Off
None None
5 Sec 10 Sec
High Engine Coolant Temperature Warn Operator Engine Derate Engine Shutdown
On On Off
217 Deg F 221 Deg F 223 Deg F
5 Sec 5 Sec 20 Sec
Low Engine Coolant Temperature Warn Operator
On
167 Deg F
5 Sec
On Off
2200 RPM 2300 RPM
0 Sec 0 Sec
Altitude (atmospheric pressure) Engine Derate
On
12.8 PSI
0 Sec
High Engine Inlet Air Temperature Warn Operator
On
172.4 Deg F 30 Sec
High Fuel Temperature Warn Operator
On
176 Deg F
Monitoring System Tool Continued Engine Overspeed Warn Operator Engine Shutdown Monitoring System Tool Continued-
F-11
30 Sec
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1RO254
THIS PAGE INTENTIONALLY BLANK
F-12
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1R0254
ANNEX G CONSUMABLE OPERATING AND MAINTENANCE SUPPLIES Table G-1 lists the consumable materials needed to operate, maintain, and store/preserve the MEP-PU810 A/B. The items are identified by Military Specification, National Stock Number (NSN) or Vendor Part Number. MEP-PU-810 CONSUMABLE MATERIALS MEP-PU-810 MAJOR COMPONENT
SUBSYSTEM
ITEM
NSN/ PART NUMBER
DESCRIPTION
Fuel Type 1
Fuel System
Fuel JP-8
Fuel Type 2 9140-00-286-5294 Primary Fuel Filter Secondary Fuel Filter
Regular Grade, DF2 VV-F-800 (+20 to+125°F; -6.6 to +51.6°C)
QUANTITY REQUIRED FOR INITIAL START-UP 120 gallons (454 liters) 120 gallons (454 liters)
129-0372
2
1R-0749
2 Diesel Engine Oil (SAE 30) -32 °F to 104 °F
3456 ENGINE
Diesel Engine Oil (SAE 10W-30) -4 °F to 104 °F
Oil Lubrication
36 Gallons
Diesel Engine Oil (SAE 15W-40) +5 °F to 122 °F See Note 1 Lube Oil Filter
1R-0716
2
NOTE 1: Oil used in the Caterpillar 3456 engine must meet SAE viscosity ratings. (SAE = Society of Automotive Engineers) Also Oil used in the Caterpillar 3456 EPG engine must meet the following API standards. (API = American Petroleum Institute) ♦
CF-4, API GRADE OIL (Minimum requirement for 3456 EPG)
♦
CH-4, API GRADE OIL (Recommended lube for 3456 EPG)
G-1
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1R0254 MEP-PU-810 CONSUMABLE MATERIALS (CONTINUED) MEP-PU-810 MAJOR COMPONENT
SUBSYSTEM
ITEM
NSN/ PART NUMBER
DESCRIPTION
QUANTITY REQUIRED FOR INITIAL START-UP
Extended Life Coolant(ELC) 101-2844
1 Gallon, pre-diluted 50/50, -34 ºF
101-2845
55 Gallon, pre-diluted 50/50, -34 ºF
Coolant
32 Gallons Commercial Antifreeze meeting ASTM D5345 Commercial Antifreeze meeting ASTM D4985
COOLING
119-5152
1 Quart, ELC Extender, (Quantity needed is listed on bottle)
119-5150
1 Gallon, ELC Extender, (Used for adjusting lower freeze protection requirements or for mixing with correct water by customer)
Ether
2910-00-2094997
Tank, Primer, Starting (Ether)
Air Filter
4N-0015
ELC Extender
3456 ENGINE
Ether Starting System Air Intake System
2 2
Mobil AERO HF (-65˚F to 45˚F
Hydraulic System
Mobile DTE 18M (48˚F to 125˚F)
Hydraulic Fluid M9150 01 461 1142 Hydraulic Filter
RE-409-10
G-2
36 Gallons
Mobil DTE 11M (-25˚F to 75˚F) 2
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1R0254 MEP-PU-810 CONSUMABLE MATERIALS (CONTINUED) QUANTITY MEP-PU-810 REQUIRED NSN/ PART MAJOR SUBSYSTEM ITEM DESCRIPTION NUMBER FOR INITIAL COMPONENT START-UP SR-4B GENERATOR
Bearings
2S-3230 Mobil grease HP. Ronex MP. Kendall L427. Grease:
Valvoline Val-plex EP Grease. Pennzoil Premium Wheel Bearing Grease 707L. Union MP Gear Lube – LS.
Wheel Bearings/ Slack Adjusters/ Spider and Support Bushings
1.8 to 2.0 oz Every 2000 Hours Thickener Type: Lithium complex Dropping Point: 446°F minimum Consistency: 2
NLGI No.
Additives: EP, Corrosion & Oxidation Inhibitors Base Oil: Solvent Refined Petroleum Oil
Exxon Gear Oil GX80W-90.
TRAILER
Oil
Mobilube SHC 75W-90. Pennzoil Multipurpose Gear Lubricant 4092 and 4096.
Surge Brake (MEP-PU810A only) Towing assembly Landing Leg assembly (MEP-PU810B only) 3456 ENGINE
Storage/ Preservation
Brake Fluid
Grease
DOT-3 or DOT-4
1 Pint
General purpose axle grease GAA
Preserving Fluids
4C-6794
VCI Oil
5 Gallons
6V-6068
Calibration Fluid
5 Gallons
G-3
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1R0254
THIS PAGE INTENTIONALLY BLANK
G-4
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1R0254
ANNEX H SPECIAL TOOLS AND EQUIPMENT The tools and equipment required for Organizational Level Maintenance of the MEP-PU-810 are listed in the following Table: SPECIAL TOOLS AND TEST EQUIPMENT CATERPILLAR TOOLS ITEMS Battery Load Tester Ammeter Coolant and Battery Tester Strap Wrench Assembly Oil Filter Cutter Pressure Gauge Pressurizing Pump Flow Checking Tool Group Engine Turning Tool Injector Height Setting Engine Pressure Group Thermistor Indicator Group Crimping tool Diagnostic Cables Diagnostic Cables Diagnostic Cables Diagnostic Cables Wire Removal Tools Wire Removal Tools 4mm Hex tool Deutsch DT Connecter Service Kit Dial Indicator Group
NSN/ REFERENCE NUMBER 4C-4911 8T0900 5P-3514
USE Test Battery Condition Test Battery Condition Tests Coolant Freezing Point and Battery Fluid Condition
2P-8250
Remove Oil Filter
4C-5084 9S-8138 9S-8140 9S-9082
Inspect used Oil Filters for Debris To perform the Water Pump Pressure Check Inspect/Trouble-Shoot Coolant System Troubleshooting Fuel system and Preserving Engine For turning engine for maintenance
9U-7227
Setting Injector Height
1U-5470
Fuel Pressure
8T-470 8S-2328 1U-5804 7x-1710 7x-6370 7x-1715 7x-1160 151-6320 1U-5805 125-2584
Cooling System Temperature Troubleshooting Reinstall generator to engine Repair of Deutsch connectors Test/Repair of Deutsch connectors Test/Repair of Deutsch connectors Test/Repair of Deutsch connectors Test/Repair of Deutsch connectors Test/Repair of Deutsch connectors Test/Repair of Deutsch connectors Test/Repair of Deutsch connectors
9U-7250
Repair of wiring harness
8T-5096
Used to check endplay clearance of the turbocharger Used to check endplay clearance of the turbocharger Used to check endplay clearance of the turbocharger Used to check endplay clearance of the turbocharger
1P-0540
Holding Rod
7H-1945
Holding Rod
7H-1645
Universal Attachment
7H-1940
Communication Adapter II Group (ET Tool)
171-4400
Engine Diagnostics
H-1
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1R0254 SPECIAL TOOLS AND TEST EQUIPMENT (CONTINUED) SPECIAL TOOLS OTHER THAN CATERPILLAR ITEMS HIPOTRONICS DC Hipot Tester BIDDLE Digital – Low - Resistance - Ohmmeter ELASTIMOLD Bushing Installer MULTI-AMP MS-2 Circuit Breaker Tester FLUKE 1520 Meg-Ohm-Meter FLUKE 87 III Digital Multimeter AC/DC Ammeter CRAFTSMAN 12 ton jack; 9 7/8 in. to 18 5/8 in. range JOHN DOW INDUSTRIES 12 ton jack stands HIPOTRONICS Vacuum Interrupter Tester SNAP-ON Torque Wrench ¼ Inch Drive; 0 to 30 inch pound range SNAP-ON Torque Wrench 3/8 Inch Drive; 0 to 50 foot-pound range SNAP-ON Torque Wrench 1/2 Inch Drive; 0 to 250 foot-pound range SNAP-ON Torque Wrench 3/4 Inch Drive; 0 to 600 foot-pound range AEMC (Optimum Energy Products)
4 Point Ground Tester
NSN/ REFERENCE NUMBER
USE
880PL
Checking Load Break Bushings, Load Break Elbows, Load Cables
247002
Checking Contact Resistance on Contactors
200AT
For installing the 200 Amp High Voltage Bushings
MS-2-115
Tests Circuit Breaker
1520 Or Equivalent 87 III Or Equivalent 8T-0900/ 6625-00-892-1497 00950284000
Testing Alternator Insulation Resistance Trouble-Shoot/test electrical continuity, voltage, and current less than 10 Amps Trouble-Shoot/test current over 10 Amps WHEEL AND BRAKE WORK
JS - 12
Wheel and brake work
7BT60A
Checking Vacuum Bottles
GTE3A
General Maintenance
GTE50FA
General Maintenance
GTE250
General Maintenance
GTE602
General Maintenance
4630
Testing grounds during plant setup
H-2
USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254
ANNEX I POWER UNIT LOGIC FLOWCHART
I-1
Terminator
Decision
Predefined subprocess
Logic process
Data
Extract
Merge
Off-page connector
Connector
I-2
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Start - Power ON
Entry point when system is powered up
Is this the initial scan after power on?
Virtual
Initialize Variables (Page I-6)
Subroutine
PPU configuration (Page I-7)
Subroutine
Main Logic
Sets station ID & IP address for network (Page I-10)
Subroutine
Station ID
Unpacks data from Caterpillar components into RTU usable variables for each engine (Page I-15)
Subroutine
Calculates the baseload (Page I-19)
Subroutine
Controls engine (1 & 2) emergency stop button (Page I-20)
Subroutine
Controls Genset 86 lockouts (Page I-21)
Subroutine
INIT_SCN
False
True
Initialize Variables
Unpack Data
1 to 2
Calculate Baseload
Engine ESTOP Control
Lockout
Page I-4
Subprogram continues…
Note: Program runs as a continuous loop from power on until power off.
I-3
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-3
Frequency
PDC Status Unpack
LS Check Enabled
True
False
Load Share
GenSet Load Share Control
Controls 50/60Hz mode (Page I-23)
Subroutine
Unpacks PDC data into usable variables (Page I-25)
Subroutine
Is automated load sharing enabled?
Virtual
Automated load sharing control (Page I-27)
Subroutine
Unpacks Caterpillar GSC+ data into variables (Page I-29)
Subroutine
Alarm and fault summary (Page I-30)
Subroutine
Calculates total KW load, and number of generators needed for load (Page I-38)
Subroutine
Determines which genset to turn on/off if needed. (Page I-43)
Subroutine
1 to 2
Alarms
Genarator Count
Economy
Page I-5
I-4
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-4
Unit A
False
True
Operate PPU A
Operate PPU
Is PPU unit A?
DIM1-IN15
Logic Specific for operating unit A (Page I-61)
Subroutine
Logic Specific for operating units B, C & D (Page I-66)
Subroutine
Controls PDC status LEDs (Page I-70)
Subroutine
Logic to control DBC (Page I-73)
Subroutine
Controls engines, first iteration for engine 1, second for engine 2. (Page I-76)
Subroutine
Controls tie & feeder breakers (Page I-95)
Subroutine
Controls PPU buzzer. (Page I-102)
Subroutine
1 to 3
Status
DBC Control
Engine Control
1 to 2
Tie / Feeder Control
Announce
Page I-3
I-5
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Start - Initialize Variables
Entry point for initialize variables routine
IP Address
Sets the Versatrak IP address
Virtual
Set each genset condition to "Off"
Virtual
Engine Start
Set each engine start command to "Off"
Virtual
Breaker Control
Set each generator remote open/close toggle relay to "Off"
Virtual
Set each generator remote start/stop relay to "Off"
Virtual
Set engine economizing blocking to "Off"
Virtual
Set default baseload setpoint to 500
Virtual
Genset Condition
Remote Start/Stop
1 to 2
Engine Econ. Blocking
Baseload Setpoint
Return
End of subprogram.
I-6
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Start - Main Logic
SMS Not Auto
Entry point for main logic subprogram
True
SMS Not Manual
False
False
True
Time Delay 3 seconds
No SMS Change
RTU-IN1
System Mode Switch (SMS) not set to Manual
RTU-IN2
The 3 second delay allows the SMS to transition through OFF to MAN and AUTO positions without start.
Function
SMS is set to OFF and three second time delay has expired.
True
False
PDC Off
INIT_SCN
MSPB_TOG =F
System Mode Switch (SMS) not set to Auto
True
Set PDC state variable to "Off"
Virtual
Reset initial scan variable to "True". This restores the system to power-up state.
Virtual
Is Master System Enable Toggle bit set to "False"?
Virtual
Set genset initial startup lockout to "False".
Virtual
Check Gen. 1 & 2 Ready variables to see if both or only 1 are ready for Auto operation.
Virtual
Set Dual variable to "True" if both ready for Auto operation, otherwise "False".
Virtual
Set Single variable to "False" if both ready for Auto operation, otherwise "True".
Virtual
False Genset Initial Startup Lockout Reset
Genset Ready
True
False Dual Genset
Dual Genset
Single Genset
Single Genset
Page I-8
I-7
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-7
Are neither generator 1 nor generator 2 breakers closed?
DIM1-IN3 & DIM2-IN3
Set QTY_GEN_ON internal variable to 0.
Virtual
Is generator 1 breaker open and gen. 2 closed, or is gen. 1 breaker closed and gen. 2 open?
DIM1-IN3 & DIM2-IN3
Set QTY_GEN_ON internal variable to 1.
Virtual
Are both generator 1 and generator 2 breakers closed?
DIM1-IN3 & DIM2-IN3
Set QTY_GEN_ON internal variable to 2.
Virtual
Is the Generator Mode Switch in Prime Power position?
RTU-IN5
Is load sharing routine disabled?
Virtual
Is total system KW load for ORT > 50?
Virtual
Enable the load sharing routine.
Virtual
Sets the auxillary relay for generator breaker status to breaker open/close current status.
Virtual
Set auxillary tie breaker
Sets the auxillary relay for tie breaker status to current tie breaker status.
Virtual
Set auxillary system bus
Sets the auxillary relay for system bus status to current system bus status.
Virtual
Breakers not closed
True
Qty Generators On = 0
False
1 breaker closed
True
Qty Generators On = 1
False
2 breakers closed
True
Qty Generators On = 2
False
GMS Prime Power False
True
LS Check disabled False
True
Total KW > 50 False
True Enable LS Check
Set auxillary generator relays
1 to 2
Page I-9
I-8
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-8
Fuel transfer pump
Startup timer expired
True
DOM1-OUT11
Did 2500 ms pass since power on?
Virtual
Turn on the PCM (or keep it on).
DOM1-OUT16
Is the B designated unit online (connected to the ethernet network)?
Virtual
Set network value used by "A" unit to check for overcurrent on "B" unit to 0.
Virtual
Is the C designated unit online (connected to the ethernet network)?
Virtual
Set network value used by "A" unit to check for overcurrent on "C" unit to 0.
Virtual
Is the D designated unit online (connected to the ethernet network)?
Virtual
Set network value used by "A" unit to check for overcurrent on "D" unit to 0.
Virtual
PCM on
False
B RTU online
Enable / disable the fuel transfer pump if Fuel_Permissive relay is on / off.
True
False B_Status_Word =0
C RTU online
True
False C_Status_Word =0
D RTU online
True
False D_Status_Word =0
Return
End of subprogram.
I-9
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Start - Station ID
MSPB
Start of Station ID subprogram.
True
False System mode Off False
True
USS A
True
Station # =1
False
IP address =ip1
USS B
True
Station # =2
False
IP address =ip2
USS C
True
Station # =3
False
IP address =ip3
USS D False
True
Station # =4
IP address =ip4
Is the Master Start Enable Switch in either ENABLE position?
RTU-IN3
Is the System Mode Switch not in the OFF position (MAN or AUTO)?
Virtual
Unit Select Switch is in the A position.
DIM1-IN15
Set station # variable to 1.
Virtual
Set IP address to constant ip1.
Virtual
Unit Select Switch is in the B position.
DIM1-IN16
Set station # variable to 2.
Virtual
Set IP address to constant ip2.
Virtual
Unit Select Switch is in the C position.
DIM2-IN15
Set station # variable to 3.
Virtual
Set IP address to constant ip3.
Virtual
Unit Select Switch is in the D position.
DIM2-IN16
Set station # variable to 4.
Virtual
Set IP address to constant ip4.
Virtual
Page I-11
I-10
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-10
MSPB_TOG =F
True
SMS =Off
False
True
False
RTU_EN =T
RTU_ON =T
RTU_ON =T
True
False
RTU_EN =F
True
Is Master System Enable Toggle bit set to "False"?
Virtual
Is the PPU System Mode Switch in the 'Off' position?
Virtual
Local PPU configured and ready for operation, True or False.
Virtual
PPU station ID set and ready for operation, True or False.
Virtual
Is the local PPU configured and ready for operation?
Virtual
Is the PPU station ID not set and ready for operation?
Virtual
Is the local PPU not configured and ready for operation?
Virtual
Is the PPU station ID set and ready for operation?
Virtual
Set IP selection fault to T or F. This block of code is legacy code, and only used to flag a mismatch between these variables.
Virtual
Is the PPU station ID set and ready for operation?
Virtual
Is Master System Enable Toggle bit set to "False"?
Virtual
False
RTU_ON =F
True
False
RTU_EN =T
True
False
Select Fault = F
RTU_EN =F False
Select Fault = T
True
MSPB_TOG =F
True
False
Page I-12 A
Page I-12 B
I-11
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-11 A
Page I-11 B
Is there no IP selection fault?
Virtual
Set the Master System Enable Toggle bit to T.
Virtual
Is the PPU System Mode Switch in the 'OFF' position?
Virtual
Set the Master System Enable Toggle bit to F.
Virtual
RTU_ON =F
PPU station ID set and ready for operation, reset to False.
Virtual
RTU_EN =F
Local PPU configured and ready for operation, reset to False.
Virtual
Is local PPU configured and ready for operation, variable changing from T to F?
Virtual
If the input is changing from T to F and the timer has been reset, a 1 second timer will start. If the input changes from F to T while the timer is running, the timer will cancel and reset.
Virtual
Did the timer expire?
Virtual
Set the station number to 6. Having a station number of 6 means the PPU is locked out of automated load sharing.
Virtual
Set the IP address to the constant ip6.
Virtual
Set variable flagging if the station's IP address was reset, T or F.
Virtual
Select Flt =F False
SMS = Off
MSPB_TOG =T
True MSPB_TOG =F
False
RTU_EN to F
True
True
False Start or Maintain Off Timer
Timer expired False
Reset timer
True
Station # =6
Set IP Addr. to ip6
ip_reset = F
ip_reset = T
ip_reset = F
Page I-13
I-12
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-12
SMS = Off True
False
IP 1 was set
Is the PPU System Mode Switch in the 'OFF' position?
Internal
Was IP set as station 1?
Internal
Is the Unit Select Switch in the "A" position?
RTU-OUT1
PPU is configured as unit "A", T or F.
RTU-OUT1
Was IP set as station 2?
Internal
Is the Unit Select Switch in the "B" position?
RTU-OUT2
PPU is configured as unit "B", T or F.
RTU-OUT2
Was IP set as station 3?
Internal
Is the Unit Select Switch in the "C" position?
RTU-OUT3
PPU is configured as unit "C", T or F.
RTU-OUT3
True
False
USS =A
True
False USS A =F
USS A =F
IP 2 was set
USS A =T
True
False
USS =B
True
False USS B =F
USS B =F
IP 3 was set
USS B =T
True
False
USS =C
True
False USS C =F
USS C =F
Page I-14 A
Page I-14 B
USS C =T
I-13
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-14 A
Page I-14 B
IP 4 was set
Was IP set as station 4?
Internal
Is the Unit Select Switch in the "D" position?
RTU-OUT4
PPU is configured as unit "D", T or F.
RTU-OUT4
True
False
USS =D
True
False USS D =F
USS D =F
USS D =T
Return
End of subprogram.
I-14
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Start - Unpack Data
Entry point for unpack data routine
Gen. True breaker closed
Is the generator x breaker closed?
DIM1-IN3 or DIM2-IN3
Is the Engine Control Switch in the MAN position?
Virtual
Takes 16-bit analog from GSC and unpacks into 16 1-bit booleans.
Function
High coolant temperature alarm variable is false or the value from the Cat GSC.
Virtual
Low coolant temperature alarm variable is false or the value from the Cat GSC.
Virtual
Low oil pressure alarm variable is false or the value from the Cat GSC.
Virtual
Engine control switch alarm variable is false or the value from the Cat GSC.
Virtual
High oil temperature alarm variable is false or the value from the Cat GSC.
Virtual
ADEM unit control alarm variable is false or the value from the Cat GSC.
Virtual
Is the Engine Control Switch in the OFF RESET position?
Virtual
Set ESC_OFF boolean to T or F.
Virtual
False
ECS Manual
True
False
Unpack GSC Alarm Data
HCT Alarm =F
HCT Alarm =GSC T/F
LCT Alarm =F
LCT Alarm =GSC T/F
LOP Alarm =F
LOP Alarm =GSC T/F
ECS Alarm =F
ECS Alarm =GSC T/F
HOT Alarm =F
HOT Alarm =GSC T/F
Control Alarm =F
Control Alarm =GSC T/F
ECS Position =1
True
False ESC_OFF =F
ESC_OFF =T
Page I-16
I-15
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-15
ECS Position =2
True
Is the Engine Control Switch in the OFF RESET position?
Virtual
Set ESC_MAN boolean to T or F.
Virtual
Is the Engine Control Switch in the COOLDOWN position?
Virtual
Set ESC_STOP boolean to T or F.
Virtual
Is the Engine Control Switch in the AUTO position?
Virtual
Set ESC_AUTO boolean to T or F.
Virtual
Takes 16-bit analog from GSC and unpacks into 16 1-bit booleans.
Function
ADEM fault shutdown from Cat GSC, T or F.
Virtual
Emergency stop shutdown from Cat GSC, T or F.
Virtual
ORT immediate stop shutdown from Cat GSC, T or F.
Virtual
High coolant temperature shutdown from Cat GSC, T or F.
Virtual
False ESC_MAN =F
ECS Position =3
ESC_MAN =T
True
False ESC_STOP =F
ECS Position =4
ESC_STOP =T
True
False ESC_AUTO =F
ESC_AUTO =T
Unpack GSC Shutdown Data
CL Shdn =GSC T/F
EStop Shdn =GSC T/F
SF Shdn =GSC T/F
HCT Shdn =GSC T/F
Page I-17
I-16
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-16
Low oil pressure shutdown from Cat GSC, T or F. Virtual LOP Shdn =GSC T/F
Overcrank shutdown from Cat GSC, T or F.
Virtual
Overspeed shutdown from Cat GSC, T or F.
Virtual
Is the generator x breaker closed?
DIM1-IN3 or DIM2-IN3
Is the generator in cooldown status?
Virtual
Takes 16-bit analog from GSC and unpacks into 16 1-bit booleans.
Function
Generator underfrequency alarm variable is false or the value from the Cat GSC.
Virtual
Generator overfrequency alarm variable is false or the value from the Cat GSC.
Virtual
Generator undervoltage alarm variable is false or the value from the Cat GSC.
Virtual
Generator overvoltage alarm variable is false or the value from the Cat GSC.
Virtual
Generator frequency sensing alarm variable is false or the value from the Cat GSC.
Virtual
Generator reverse power alarm variable is false or the value from the Cat GSC.
Virtual
OC Shdn =GSC T/F
OSS Shdn =GSC T/F
Gen. True breaker closed
False Gen. In Cooldown False
True
Unpack Generator Alarms
Gen UnFreq =F
Gen UnFreq =GSC T/F
Gen OvFreq =F
Gen OvFreq =GSC T/F
Gen UnVolt =F
Gen UnVolt =GSC T/F
Gen OvVolt =F
Gen OvVolt =GSC T/F
Gen FreqSense =F
Gen FreqSense =GSC T/F
Gen RevPow =F
Gen RevPow =GSC T/F
Page I-18
I-17
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-17
Unpack Gen. Shutdown Data
Gen UnFreq =GSC T/F
Gen OvFreq =GSC T/F
Gen UnVolt =GSC T/F
Gen OvVolt =GSC T/F
Gen FreqSense =GSC T/F
Gen RevPow =GSC T/F
Gen. Run = Eng. Run
Return
Takes 16-bit analog from GSC and unpacks into 16 1-bit booleans.
Function
Generator underfrequency shutdown variable is set to the value from the Cat GSC.
Virtual
Generator overfrequency shutdown variable is set to the value from the Cat GSC.
Virtual
Generator undervoltage shutdown variable is set to the value from the Cat GSC.
Virtual
Generator overvoltage shutdown variable is set to the value from the Cat GSC.
Virtual
Generator frequency sensing shutdown variable is set to the value from the Cat GSC.
Virtual
Generator reverse power shutdown variable is set to the value from the Cat GSC.
Virtual
Generator running status variable = engine running status variable.
Virtual
End of subprogram.
I-18
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Start - Calculate Baseload
GMS Baseload
False
True
RTU Enabled
True
False Calculate BL_REF
Return
Is the Generator Mode Switch in the BASELOAD position?
RTU-IN5
Is the local PPU configured and ready for operation?
Virtual
Calculate Baseload Reference: take baseload setpoint (500 default), convert to KW, and limit between 500 and 9830.
Function, virtual
End of subprogram.
I-19
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Start - Engine Emg. Stops
ECS 1 to OFF
Did Engine Control Switch for engine 1 change positions to OFF RESET?
Virtual
Reset engine 1's remote emergency stop toggle to false.
Virtual
True
Is the emergency stop toggle true for engine 1?
Virtual
True
Is there a Neutral Ground Resister fault on gererator 1?
DIM1-IN7
Set Spare Immediate Shutdown to True or False for generator 1.
DOM2-OUT15
Did Engine Control Switch for engine 2 change positions to OFF RESET?
Virtual
Reset engine 2's remote emergency stop toggle to false.
Virtual
True
Is the emergency stop toggle true for engine 2?
Virtual
True
Is there a Neutral Ground Resister fault on gererator 2?
DIM2-IN7
Set Spare Immediate Shutdown to True or False for generator 2.
DOM2-OUT16
True
Reset Engine 1 Emerg. Stop
False
Eng. 1 Emerg. Stop
False NGR 1 Fault
False Spare Immediate Shutdown = F
ECS 2 to OFF
Spare Immediate Shutdown = T
True
Reset Engine 2 Emerg. Stop
False
Eng. 2 Emerg. Stop
False NGR 2 Fault
False Spare Immediate Shutdown = F
Spare Immediate Shutdown = T
Return
End of subprogram.
I-20
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Start - Lockout
Run for each genset (1 and 2) in local PPU.
Gen. OC Trip
True
Is there an overcurrent relay trip signal on generator x?
DIM1-IN5 or DIM2-IN5
True
Is there a Neutral Ground Resister fault on gererator x?
DIM1-IN7 or DIM2-IN7
True
Is engine x flagged to shutdown?
Virtual
True
Is generator x flagged to shutdown?
Virtual
True
Is the Master Start Enable Switch not in either ENABLE position?
RTU-IN3
Is generator x lockout control set to True?
Virtual
Set generator x lockout control to True or False.
Virtual
False
NGR Fault False
Eng. Shutdown False
Gen. Shutdown False
MSES Not enable False
Gen. Lockout
True
False
Gen. Lockout =F
Gen. Lockout =T
1 to 2
Page I-22
I-21
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-21
Tie OC Trip
True
Is there a tie overcurrent relay trip?
DIM1-IN13
True
Is the Master Start Enable Switch not in either ENABLE position?
RTU-IN3
Is tie lockout set to T?
Virtual
Set tie lockout to T or F.
Virtual
Is there a low fuel level in the PPU daytank?
DIM2-IN13
Is there a low fuel fault?
Virtual
Set flag to shutdown engine for low fuel.
Virtual
Is there NOT a low fuel level in the PPU daytank?
DIM2-IN13
Are the PPU engines flagged to shutdown due to low fuel?
Virtual
Reset flag to shutdown engine for low fuel.
Virtual
Pack OCR1, OCR2 and OCR3 into virtual word "stat_word".
DIM1-IN5, DIM2-IN5, & DIM1-IN13
False
MSES Not enable False
Tie lockout
True
False
Tie lockout =F
Low fuel in PPU day tank
Tie lockout =T
True
False Low fuel Fault
True
False
Not low fuel PPU day tank
Set low fuel engine shutdown =T
True
False Low fuel shutdown False
True
Set low fuel engine shutdown =F
Pack overcurrent signals into 16-bit word "stat_word"
Return
End of subroutine.
I-22
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Start - Frequency
FSS 50 Hz
Switch set for 50 Hz operation.
RTU-IN6
System mode switch is in the OFF position and parameters have been cleared.
Virtual
PLC output shows 60 Hz.
DOM1-OUT10
Set PLC output to 50 Hz.
DOM1-OUT10
Switch set for 60 Hz operation.
RTU-IN6
System mode switch is in the OFF position and parameters have been cleared.
Virtual
PLC output shows 50 Hz.
DOM1-OUT10 (ON)
Set PLC output to 60 Hz.
DOM1-OUT10 (OFF)
Is the Master system enable toggle set to True?
Virtual
Does PLC output show 60 Hz?
DOM1-OUT10 (OFF)
KVA Setpoint =489
Set KVA setpoint for loadsharing at 489.
Virtual
KW Setpoint =391
Set KW setpoint for loadsharing at 391
Virtual
Rating 60Hz =T
Current rating of 60Hz variable is T or F.
Virtual
True
False
SMS Off
True
False
PLC 60 Hz
True
False
FSS 60 Hz
True
False
SMS Off
True
False
PLC 50 Hz False
MSPB =T False
True
PLC 60 Hz
True
PLC 60 Hz False
Rating 60Hz =F
PLC 50 Hz
True
Page I-24
I-23
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-23
MSPB =T False
True
PLC 50 Hz False
Rating 50Hz =F
Is the Master system enable toggle set to True?
Virtual
Does PLC output show 50 Hz?
DOM1-OUT10 (ON)
KVA Setpoint =418
Set KVA setpoint for loadsharing at 418.
Virtual
KW Setpoint =334
Set KW setpoint for loadsharing at 334.
Virtual
Rating 50Hz =T
Current rating of 50Hz variable is T or F.
Virtual
True
Return
End of subprogram.
I-24
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Start - PDC Status
PPU A is on False
Page I-26 A
True
Is the PPU configured as A on?
RTU-OUT1
Break B Status from 16-bit word into 16 1-bit booleans. B status is the network value used by A PPU to check for overcurrents on B PPU.
Function
B PPU Gen. 1 overcurr. = T/F
Set overcurrent flag on B PPU generator 1 to T or F, as reported by B PPU.
Virtual
B PPU Gen. 2 overcurr. = T/F
Set overcurrent flag on B PPU generator 2 to T or F, as reported by B PPU.
Virtual
B PPU Tie overcurr. = T/F
Set overcurrent flag on B PPU tie connector to T or F, as reported by B PPU.
Virtual
Break C Status from 16-bit word into 16 1-bit booleans. C status is the network value used by A PPU to check for overcurrents on C PPU.
Function
Unpack C Status Data
C PPU Gen. 1 overcurr. = T/F
Set overcurrent flag on C PPU generator 1 to T or F, as reported by C PPU.
Virtual
C PPU Gen. 2 overcurr. = T/F
Set overcurrent flag on C PPU generator 2 to T or F, as reported by C PPU.
Virtual
C PPU Tie overcurr. = T/F
Set overcurrent flag on C PPU tie connector to T or F, as reported by C PPU.
Virtual
Break D Status from 16-bit word into 16 1-bit booleans. D status is the network value used by A PPU to check for overcurrents on D PPU.
Function
Unpack D Status Data
D PPU Gen. 1 overcurr. = T/F
Set overcurrent flag on D PPU generator 1 to T or F, as reported by D PPU.
Virtual
D PPU Gen. 2 overcurr. = T/F
Set overcurrent flag on D PPU generator 2 to T or F, as reported by D PPU.
Virtual
D PPU Tie overcurr. = T/F
Set overcurrent flag on D PPU tie connector to T or F, as reported by D PPU.
Virtual
Unpack B Status Data
Page I-26 B
I-25
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-25 A
Page I-25 B
Is the overcurrent flag set to T for the A PPU generator 1?
Virtual
True
Is the overcurrent flag set to T for the A PPU generator 2?
Virtual
True
Is the overcurrent flag set to T for the B PPU generator 1?
Virtual
True
Is the overcurrent flag set to T for the B PPU generator 2?
Virtual
True
Is the overcurrent flag set to T for the C PPU generator 1?
Virtual
True
Is the overcurrent flag set to T for the C PPU generator 2?
Virtual
True
Is the overcurrent flag set to T for the D PPU generator 1?
Virtual
True
True
Is the overcurrent flag set to T for the D PPU generator 2?
Virtual
D Gen. 2 Overcurr.
Genset lockout
True
Is the summary genset lockout boolean flag set to T?
Virtual
Is the Master Start Enable Switch not set to one of the ENABLE positions?
RTU-IN3
Set summary genset lockout boolean flag to T or F.
Virtual
A Gen. 1 Overcurr. False
A Gen. 2 Overcurr. False
B Gen. 1 Overcurr. False
B Gen. 2 Overcurr. False
C Gen. 1 Overcurr. False
C Gen. 2 Overcurr. False
D Gen. 1 Overcurr. False
False
Genset lockout =F
MSES =F False
True
Genset lockout =T
Return
End of subprogram.
I-26
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Start - Load Share
Load Share Enabled False
True
Set load per online generator
Gen. online=0
True
Is automated load sharing enabled?
Virtual
Calculate load per online generator, = total KW load ÷ the number of online generators. This value is then converted into a Real number.
Virtual
Does the number of online generators = 0?
Virtual
Set load sharing error control #1 to T or F.
Virtual
Calculate the maximum load per online generator, = load per online generator + 50.
Virtual
Set load sharing error control #2 to T or F.
Virtual
Calculate the minimum load per online generator, = load per online generator - 50.
Virtual
Set load sharing error control #3 to T or F.
Virtual
False per_gen_1 =F
per_gen_1 =T
Set maximum load per generator
per_gen_2 =F
per_gen_2 =T
Set minimum load per generator
per_gen_3 =F
per_gen_3 =T
Page I-28
Return
End of subprogram.
I-27
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-27
Total KW < 50
True
Is total load < 50 KW?
Virtual
True
Is the tie breaker open?
DIM1-IN12
True
Is the breaker for local PPU generator 1 open?
DIM1-IN3
Is the breaker for local PPU generator 2 open?
DIM2-IN3
Set load sharing error alarm control = F.
Virtual
Disable automated load sharing.
Virtual
False Tie not closed
False
Gen. 1 breaker not closed False
Gen. 2 breaker not closed
True
False Load sharing error alarm=F
Load sharing enable = F
Return
End of subprogram.
I-28
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Start - GenSet Load Share
Gen. breaker closed
This program runs twice on each PPU: once for generator 1 and once for generator 2.
True
Is the breaker closed for generator x (1 or 2, depending on which generator this subroutine is run for)?
DIM1-IN3 or DIM2-IN3
True
Is automated loadsharing enabled?
Virtual
True
Is the KW load on generator x (1 or 2) outside the limits Min and Max previously set for load sharing, including a 10 KW hysteresis?
Virtual
Is the value changing from F to T?
Function
Start timer to delay for 45 seconds.
Function
False
Load share enabled False
Gen. KW out of LS range False
Changing F to T False
Delay for 45 seconds
Load sharing error alarm = F
Load sharing error alarm = T
Set load sharing alarm variable to T or F.
Virtual
Gen. X load share delay = F
Gen. X load share delay = T
Set current value of load share time delay for generator x to T or F.
Virtual
Return
End of subroutine.
I-29
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Start - Alarms
High coolant temp
Is there a high coolant temperature alarm on generator 1 from the GSC?
GSC
Is there a low coolant temperature alarm on generator 1 from the GSC?
GSC
Is there a low oil ressure alarm on generator 1 from the GSC?
GSC
Is there a high oil ressure alarm on generator 1 from the GSC?
GSC
True
Is there a ADEM unit control alarm?
GSC
True
Is the battery low (3
True
False
Requires 2 gen.
True
False
Gen. online >2
True
False
Requires 1 gen. False
True
Gen. online >1
True
False
Page I-46A
Page I-46B
Page I-46C
I-45
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-45A
Page I-45C
Page I-45B
No load mgt. block
True
Is automated load management enabled?
Virtual
Set the Sub_Gen flag to T or F (flags logic to turn off a genset).
Virtual
Is flag set to turn off one genset?
Virtual
True
Does the A unit recognize the D unit?
Virtual
True
Does the D PPU have two gensets available?
Virtual
Does the A PPU have exactly one genset available?
Virtual
Does the A PPU have no gensets available?
Virtual
Does the B PPU have exactly one genset available?
Virtual
Does the B PPU have no gensets available?
Virtual
False
Sub_Gen =F
Sub-Gen
False
Sub_Gen =T
True
A unit sees D False
D unit dual on False
A unit single
True
False
A unit none
True
False
B unit single
True
False
B unit none
True
False
Page I-47A
Page I-47B
Page I-47C
I-46
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-47A
Page I-47B
C unit single
True
Does the C PPU have exactly one genset available?
Virtual
Does the C PPU have no gensets available?
Virtual
Is the logical value changing from F to T?
Function
Start or reset a 3 minute timer.
Function
Has the timer expired?
Function
Flag D PPU to shut off a genset, T or F.
Virtual
Is flag set to turn off one genset?
Virtual
True
Does the A unit recognize the C unit?
Virtual
True
Does the D PPU have two gensets available?
Virtual
True
Does the D PPU have exactly one genset available?
Virtual
True
Does the D PPU have no gensets available?
Virtual
D unit single
False
C unit none
Page I-47C
True
True
False
changing T to F
True
False
changing F to T
True
False
Reset timer
timer expired
3 minute timer
True
False
Subtract D Gen. =F
Sub-Gen
False
Subtract D Gen. =T
True
A unit sees C False
C unit dual on False
D unit single False
D unit none False
Page I-48A
Page I-48B
Page I-48C
I-47
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-47A
A unit single
Page I-47B
Page I-47C
True
Does the A PPU have exactly one genset available?
Virtual
Does the A PPU have no gensets available?
Virtual
Does the B PPU have exactly one genset available?
Virtual
Does the B PPU have no gensets available?
Virtual
Does the C PPU have exactly one genset available?
Virtual
True
Does the D PPU have no gensets available?
Virtual
True
Is the logical value changing from F to T?
Function
Start or reset a 3 minute timer.
Function
Has the timer expired?
Function
Flag C PPU to shut off a genset, T or F.
Virtual
Is flag set to turn off one genset?
Virtual
False A unit none
True
False
B unit single
True
False B unit none
True
False
C unit single False
True
D unit none False
changing T to F
True
False
changing F to T Reset timer
False
timer expired
Start 3 minute timer
True
False
Subtract C Gen. =F
Sub-Gen
Subtract C Gen. =T
True
False Page I-49A
Page I-49B
I-48
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-48A
Page I-48B
A unit sees B
True Does the A unit recognize the B unit?
Virtual
Does the B PPU have two gensets available?
Virtual
True
Does the C PPU have exactly one genset available?
Virtual
True
Does the C PPU have no gensets available?
Virtual
Does the D PPU have exactly one genset available?
Virtual
Does the D PPU have no gensets available?
Virtual
True
Does the A PPU have exactly one genset available?
Virtual
True
Does the A PPU have no gensets available?
Virtual
Does the B PPU have exactly one genset available?
Virtual
True
Does the C PPU have no gensets available?
Virtual
True
Does the D PPU have no gensets available?
Virtual
False
B unit dual on
True
False
C unit single False C unit none False
D unit single
True
False D unit none
True
False
A unit single False A unit none False
B unit single False
True
C unit none False
D unit none False
Page I-50A
Page I-50B
I-49
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-49A
changing T to F
Page I-49B
True
False
changing F to T False
Reset timer
timer expired
True
Start 3 minute timer
True
Is the logical value changing from F to T?
Function
Start or reset a 3 minute timer.
Function
Has the timer expired?
Function
Flag B PPU to shut off a genset, T or F.
Virtual
Is flag set to turn off one genset?
Virtual
Does the A PPU have both gensets available?
Virtual
Does the B PPU have exactly one genset available?
Virtual
Does the B PPU have no gensets available?
Virtual
Does the C PPU have exactly one genset available?
Virtual
Does the C PPU have no gensets available?
Virtual
False
Subtract B Gen. =F
Sub-Gen False
Subtract B Gen. =T
True
A unit dual
True
False
B unit single
True
False B unit none
True
False
C unit single
True
False C unit none
True
False
Page I-51A
Page I-51B
I-50
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-50A
Page I-50B
D unit single
True
Does the D PPU have exactly one genset available?
Virtual
Does the D PPU have no gensets available?
Virtual
Is the logical value changing from F to T?
Function
Start or reset a 3 minute timer.
Function
Has the timer expired?
Function
Flag A PPU to shut off a genset, T or F.
Virtual
Is flag set to turn on one genset?
Virtual
Is the local PPU the A unit, and it is configured and online?
Virtual
Does the local PPU have exactly one genset available?
Virtual
Does the local PPU have no gensets available?
Virtual
Does the local PPU not have both gensets online?
Virtual
False D unit none
True
False
changing T to F
True
False
changing F to T
True
False
Reset timer
timer expired
Start 3 minute timer
True
False
Subtract A Gen. =F
Add-Gen False
Subtract A Gen. =T
True
A PPU local False
True
local unit single
True
False local unit none
True
False
local unit not dual
True
False
Page I-52A
Page I-52B
Page I-52C
I-51
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-51A
Page I-51B
Page I-51C
local unit not single
True
Does the local PPU not have either genset online?
Virtual
Does the local PPU have exactly one genset online?
Virtual
Does the B PPU have exactly one genset available?
Virtual
Does the B PPU have both gensets available?
Virtual
Does the A unit not recognize the B unit?
Virtual
Does the C PPU have exactly one genset available?
Virtual
True
Does the C PPU have both gensets available?
Virtual
True
Does the A unit not recognize the C unit?
Virtual
Does the D PPU have exactly one genset available?
Virtual
True
Does the D PPU have both gensets available?
Virtual
True
Does the A unit not recognize the D unit?
Virtual
False
local unit single False
True
B unit single
True
False B unit dual
True
False A unit not see B False
True
C unit single
True
False C unit dual False A unit not see C False
D unit single
True
False D unit dual False A unit not see D False
Page I-53A
Page I-53B
I-52
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-52A
changing T to F
Page I-52B
True
False
changing F to T
True
False
Reset timer
timer expired
Start 1 minute timer
True
Is the logical value changing from F to T?
Function
Start or reset a 1 minute timer.
Function
Has the timer expired?
Function
Flag A PPU to start a genset, T or F.
Virtual
Is flag set to turn on one genset?
Virtual
Does the A unit recognize the B unit?
Virtual
Does the B PPU have exactly one genset available?
Virtual
Does the B PPU have both gensets available?
Virtual
Is the B PPU running neither genset?
Virtual
Does the local PPU have exactly one genset available?
Virtual
Does the A unit have neither genset online?
Virtual
False
Add A Gen. =F
Add-Gen False
Add A Gen. =T
True
A unit sees B False
True
B unit single
True
False B unit dual
True
False
B unit none
True
False
local unit single
True
False A unit none
True
False
Page I-54A
Page I-54B
Page I-54C
Page I-54D
I-53
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-53A
Page I-53B
Page I-53C
local unit not dual
Page I-53D
True
Does the local PPU not have both gensets available?
Virtual
Does the local PPU not have exactly one genset available?
Virtual
Does the local PPU have both gensets available?
Virtual
Does the local PPU have exactly one genset available?
Virtual
Does the B PPU have exactly one genset available?
Virtual
Does the B PPU have no gensets available?
Virtual
Does the C PPU have exactly one genset available?
Virtual
True
Does the C PPU have no gensets available?
Virtual
True
Does the A unit not recognize the C unit?
Virtual
Does the C PPU have exactly one genset available?
Virtual
True
Does the C PPU have no gensets available?
Virtual
True
Does the A unit not recognize the C unit?
Virtual
False
local unit not single
True
False
local unit dual
True
False local unit single False
True
B unit single
True
False B unit none False
True
C unit single
True
False C unit none False A unit not see C False
D unit single
True
False D unit none False A unit not see D False
Page I-54A
Page I-54B
I-54
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-54A
changing T to F
Page I-54B
True
False
changing F to T
True
False
Reset timer
timer expired
Start 1 minute timer
True
Is the logical value changing from F to T?
Function
Start or reset a 1 minute timer.
Function
Has the timer expired?
Function
Flag B PPU to start a genset, T or F.
Virtual
Is flag set to turn on one genset?
Virtual
Does the A unit recognize the C unit?
Virtual
Does the C PPU have exactly one genset available?
Virtual
Does the C PPU have both gensets available?
Virtual
Is the C PPU running neither genset?
Virtual
Does the local PPU have exactly one genset available?
Virtual
Does the local PPU have both gensets available?
Virtual
False
Add B Gen. =F
Add-Gen False
Add B Gen. =T
True
A unit sees C False
True
C unit single
True
False C unit dual
True
False
C unit none
True
False
local unit single
True
False local unit dual
True
False
Page I-56A
Page I-56B
Page I-56C
I-55
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-55A
Page I-55B
Page I-55C
B unit single
True
Does the B PPU have exactly one genset available?
Virtual
Does the B PPU have both gensets available?
Virtual
Does the local PPU have exactly one genset available?
Virtual
Does the local PPU have both gensets available?
Virtual
Does the B PPU have exactly one genset available?
Virtual
Does the B PPU have both gensets available?
Virtual
Does the C PPU have exactly one genset available?
Virtual
Does the C PPU have neither genset available?
Virtual
Does the D PPU have exactly one genset available?
Virtual
Does the D PPU have both gensets available?
Virtual
Does the A unit not recognize the D unit?
Virtual
False B unit dual
True
False
local unit single
True
False local unit dual False
True
B unit single
True
False B unit dual False
True
C unit single
True
False C unit none
True
False
D unit single
True
False D unit dual
True
False A unit not see D
True
False
Page I-57A
Page I-57B
I-56
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-56A
changing T to F
Page I-56B
True
False
changing F to T
True
False
Reset timer
timer expired
Start 1 minute timer
True
Is the logical value changing from F to T?
Function
Start or reset a 1 minute timer.
Function
Has the timer expired?
Function
Flag C PPU to start a genset, T or F.
Virtual
Is flag set to turn on one genset?
Virtual
Does the A unit recognize the D unit?
Virtual
Does the D PPU have exactly one genset available?
Virtual
Does the D PPU have both gensets available?
Virtual
Is the D PPU running neither genset?
Virtual
Does the local PPU have exactly one genset available?
Virtual
Does the local PPU have both gensets available?
Virtual
False
Add C Gen. =F
Add-Gen False
Add C Gen. =T
True
A unit sees D False
True
D unit single
True
False D unit dual
True
False
D unit none
True
False
local unit single
True
False local unit dual
True
False
Page I-58A
Page I-58B
Page I-58C
I-57
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-57A
Page I-57B
Page I-57C
B unit single
True
Does the B PPU have exactly one genset available?
Virtual
Does the B PPU have both gensets available?
Virtual
Does the C PPU have exactly one genset available?
Virtual
Does the B PPU have both gensets available?
Virtual
Does the local PPU have exactly one genset available?
Virtual
Does the local PPU have both gensets available?
Virtual
Does the B PPU have exactly one genset available?
Virtual
Does the B PPU have both gensets available?
Virtual
Does the C PPU have exactly one genset available?
Virtual
Does the C PPU have both gensets available?
Virtual
Does the D PPU have exactly one genset available?
Virtual
False B unit dual
True
False
C unit single
True
False C unit dual
True
False
local unit single
True
False local unit dual False
True
B unit single
True
False B unit dual False
True
C unit single
True
False C unit dual
True
False
D unit single
True
False
Page I-59A
Page I-59B
I-58
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-58A
changing T to F
Page I-58B
True
False
changing F to T
True
False
Reset timer
timer expired
Start 1 minute timer
True
Is the logical value changing from F to T?
Function
Start or reset a 1 minute timer.
Function
Has the timer expired?
Function
Flag D PPU to start a genset, T or F.
Virtual
Does the local PPU not have exactly one genset available?
Virtual
Does the local PPU not have both gensets available?
Virtual
A unit has no gensets available, T or F.
Virtual
Does the B PPU not have exactly one genset available?
Virtual
Does the B PPU not have both gensets available?
Virtual
Does the A unit recognize the B unit?
Virtual
B unit has no gensets available, T or F.
Virtual
False
Add D Gen. =F
local unit not single
Add D Gen. =T
True
False
local unit not dual
True
False
A_No_Gen =F
B unit not single
A_No_Gen =T
True
False
A unit not see B
B unit not dual False
True
A unit sees B
False
B_No_Gen =F
True
True
False
B_No_Gen =T
B_No_Gen =F
B_No_Gen =T
Page I-58A
I-59
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-58A
C unit not single
True
False
A unit not see C
C unit not dual
True
False
True
A unit sees C
False
C_No_Gen =T
C_No_Gen =F
D unit not dual
True
False
True
A unit sees D
False
D_No_Gen =F
C_No_Gen =T
True
False
A unit not see D
Virtual
Does the C PPU not have both gensets available?
Virtual
Does the A unit recognize the C unit?
Virtual
C unit has no gensets available, T or F.
Virtual
Does the D PPU not have exactly one genset available?
Virtual
Does the D PPU not have both gensets available?
Virtual
Does the A unit recognize the D unit?
Virtual
D unit has no gensets available, T or F.
Virtual
False
C_No_Gen =F
D unit not single
True
Does the C PPU not have exactly one genset available?
True
False
D_No_Gen =T
D_No_Gen =F
D_No_Gen =T
Return
End of subroutine.
I-60
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Start - Operate PPU A
Not A PPU
Start of subroutine of logic specific to PPU A.
True
False Not A PPU B PPU
True
True
False
Is the Unit Select Switch not in the "A" position?
DIM1-IN15
Is the PPU not configured as "A" for network?
Virtual
Is the PPU configured as "B" for network?
Virtual
Is the PPU configured as "C" for network?
Virtual
Is the PPU configured as "D" for network?
Virtual
False
C PPU
True
False
D PPU
True
False Return
local PPU enabled
Return
True
Exit Subroutine.
Is the local PPU configured and ready for operation?
Virtual
Set A PPU enabled variable, T or F.
Virtual
Is the local PPU station ID set and ready for operation?
Virtual
Set A PPU station ID set variable, T or F.
Virtual
Does the B PPU not have exactly one genset online?
Virtual
Does the B PPU not have both gensets online?
Virtual
False A_RTU_EN =F
station ready
A_RTU_EN =T
True
False A_RTU_ON =F
B unit not single
A_RTU_ON =T
True
False B unit not dual
True
False
Page I-62A
Page I-62B
I-61
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-61A
Page I-61B
B_Qty_On =0
B_0_Generators =T
B unit single
Set B PPU generator quantity online to 0.
Virtual
Set B 0 generators online variable, T or F.
Local
Does the B PPU have exactly one genset online?
Virtual
B_Qty_On =1
Set B PPU generator quantity online to 1.
Virtual
B_1_Generator =T
Set B 1 generator online variable, T or F.
Local
Does the B PPU have both genset online?
Virtual
B_Qty_On =2
Set B PPU generator quantity online to 2.
Virtual
B_2_Generators =T
Set B 2 generator online variable, T or F.
Local
Does the C PPU not have exactly one genset online?
Virtual
Does the C PPU not have both gensets online?
Virtual
B_0_Generators =F
True
False
B_1_Generator =F
B unit dual
True
False
B_2_Generators =F
C unit not single False
True
C unit not dual
True
False
Page I-63A
Page I-63B
I-62
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-62A
Page I-62B
C_Qty_On =0
C_0_Generators =T
C unit single
Set C PPU generator quantity online to 0.
Virtual
Set C 0 generators online variable, T or F.
Local
Does the C PPU have exactly one genset online?
Virtual
C_Qty_On =1
Set C PPU generator quantity online to 1.
Virtual
C_1_Generator =T
Set C 1 generator online variable, T or F.
Local
Does the C PPU have both genset online?
Virtual
C_Qty_On =2
Set C PPU generator quantity online to 2.
Virtual
C_2_Generators =T
Set C 2 generator online variable, T or F.
Local
Does the D PPU not have exactly one genset online?
Virtual
Does the D PPU not have both gensets online?
Virtual
C_0_Generators =F
True
False
C_1_Generator =F
C unit dual
True
False
C_2_Generators =F
D unit not single False
True
D unit not dual
True
False
Page I-64A
Page I-64B
I-63
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-63A
Page I-63B
D_Qty_On =0
D_0_Generators =T
D unit single
Set D PPU generator quantity online to 0.
Virtual
Set D 0 generators online variable, T or F.
Local
Does the D PPU have exactly one genset online?
Virtual
D_Qty_On =1
Set D PPU generator quantity online to 1.
Virtual
D_1_Generator =T
Set D 1 generator online variable, T or F.
Local
Does the C PPU have both genset online?
Virtual
D_Qty_On =2
Set D PPU generator quantity online to 2.
Virtual
D_2_Generators =T
Set D 2 generator online variable, T or F.
Local
Divide generator 1 total KW by 1000.
Function
Set generator 1 KW to calculated value.
Virtual
Divide generator 2 total KW by 1000.
Function
Set generator 2 KW to calculated value.
Virtual
D_0_Generators =F
True
False
D_1_Generator =F
D unit dual
True
False
D_2_Generators =F
Gen. 1 Total KW / 1000
Gen. 1 KW = Value
Gen. 2 Total KW / 1000
Gen. 2 KW = Value
Page I-65
I-64
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-64
Gen. 1 Total KVA / 1000
Divide generator 1 total KVA by 1000.
Function
Set generator 1 KVA to calculated value.
Virtual
Divide generator 2 total KVA by 1000.
Function
Gen. 2 KVA = Value
Set generator 2 KVA to calculated value.
Virtual
Gen. 1 Total KVAR / 1000
Divide generator 1 total KVAR by 1000.
Function
Set generator 1 KVAR to calculated value.
Virtual
Divide generator 2 total KVAR by 1000.
Function
Set generator 2 KVAR to calculated value.
Virtual
Gen. 1 KVA = Value
Gen. 2 Total KVA / 1000
Gen. 1 KVAR = Value
Gen. 2 Total KVAR / 1000
Gen. 2 KVAR = Value
Return
End of subprogram.
I-65
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Start - Operate PPU
USS not X
Start of subroutine of logic to operate PPU B, C, and D. This subroutine runs three times; once for each.
True
Is the Unit Select Switch not in the X position (B, C or D, depending on iteration)?
DIM1-IN16, o DIM2-IN15, o DIM2-IN16
Is the PPU not configured as X?
Virtual
True
Is the PPU configured as "A"?
Virtual
True
Is the PPU configured as Y (C if first iteration, B otherwise)?
Virtual
True
Is the PPU configured as Y (C if third iteration, D otherwise)?
Virtual
False
Unit not X
True
False
Unit is A False
Unit is Y False
Unit is Z False
Local PPU ready
Return True
False
SMS AUTO False
Exit subroutine.
PPU =X
True
Unit X DBC
True
False
Gen. 1 DBC
True
Is the local PPU configured and ready for operation?
Virtual
Set PPU variable to X (B if first iteration, C if second, D if third).
Virtual
Is the System Mode Switch in the AUTO position?
RTU-IN1
Is the network not telling PPU X that it has control of the dead bus permissive?
Virtual
Is generator 1 dead bus close permissive set?
Virtual
Is generator 1 auto sync run enabled?
Virtual
False
Gen. 1 auto sync.
True
False
Page I-67A
Page I-67B
I-66
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-66A
Page I-66B
Gen. 1 RB open
True
Is generator 1 remote breaker open?
Virtual
Close generator 1's breaker for PPU X.
Virtual
True
Is generator 1 remote breaker closed?
Virtual
True
Is generator 1 breaker open enabled?
DOM1-OUT6
True
Is engine 1 autorun enabled?
Virtual
Is the system mode switch in the AUTO position?
RTU-IN1
Is generator 1's breaker for PPU X closed?
Virtual
Open generator 1's breaker for PPU X.
Virtual
Is the System Mode Switch in the AUTO position?
RTU-IN1
Is the network not telling PPU X that it has control of the dead bus permissive?
Virtual
Is generator 2 dead bus close permissive set?
Virtual
Is generator 2 auto sync run enabled?
Virtual
Is generator 2 remote breaker open?
Virtual
Close generator 2's breaker for PPU X.
Virtual
False
Gen. 1 RB closed
Gen. 1 breaker = close
False
Gen. 1 B enabled False E1 Autorun enabled False
SMS AUTO
True
False
Gen. 1 B closed
True
False
SMS AUTO False
Gen. 1 breaker = open
True
Unit X DBC
True
False
Gen. 2 DBC
True
False
Gen. 2 auto sync. False
True
Gen. 2 RB open False
True Gen. 2 breaker = close
Page I-68
I-67
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-67
Gen. 2 RB closed
True
Is generator 2 remote breaker closed?
Virtual
True
Is generator 2 breaker open enabled?
DOM2-OUT6
True
Is engine 1 autorun enabled?
Virtual
Is the system mode switch in the AUTO position?
RTU-IN1
Is generator 2's breaker for PPU X closed?
Virtual
Open generator 2's breaker for PPU X.
Virtual
Divide generator 1 total KW by 1000.
Function
Set generator 1 KW to calculated value.
Virtual
Divide generator 2 total KW by 1000.
Function
Set generator 2 KW to calculated value.
Virtual
Divide generator 1 total KVA by 1000.
Function
Set generator 1 KVA to calculated value.
Virtual
False
Gen. 2 B enabled False
E2 Autorun enabled False
SMS AUTO False
True
Gen. 2 B closed False
True
Gen. 2 breaker = open
Gen. 1 Total KW / 1000
Gen. 1 KW = Value
Gen. 2 Total KW / 1000
Gen. 2 KW = Value
Gen. 1 Total KVA / 1000
Gen. 1 KVA = Value
Page I-69
I-68
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-68
Gen. 2 Total KVA / 1000
Divide generator 2 total KVA by 1000.
Function
Gen. 2 KVA = Value
Set generator 2 KVA to calculated value.
Virtual
Gen. 1 Total KVAR / 1000
Divide generator 1 total KVAR by 1000.
Function
Set generator 1 KVAR to calculated value.
Virtual
Divide generator 2 total KVAR by 1000.
Function
Gen. 2 KVAR = Value
Set generator 2 KVAR to calculated value.
Virtual
PPU X status word = 1
Set status word for PPU X to 1.
Virtual
Gen. 1 KVAR = Value
Gen. 2 Total KVAR / 1000
Return
End of subprogram.
I-69
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Start - Status
Eng. 1 alarm
Start of subroutine to control status LEDs.
True
Is there an alarm on engine 1?
Virtual
True
Is there an alarm on generator 1?
Virtual
True
Is there an alarm on engine 2?
Virtual
True
Is there an alarm on generator 2?
Virtual
Is the alarm buzzer energized
DOM1-OUT15
Blink output on/off, 1 second per state.
Function
Turn the amber system status light on/off.
DOM2-OUT14
True
Is generator 1 lockout set?
Virtual
True
Is generator 2 lockout set?
Virtual
True
Is tie contactor lockout set?
Virtual
False
Gen. 1 alarm False
Eng. 2 alarm False
Gen. 2 alarm False
Buzzer energized
True
False Blink
Amber SSL = Off
Gen. 1 lockout
Amber SSL = On
Amber SSL = On/Off
False Gen. 2 lockout False Tie lockout False
Page I-71A
Page I-71B
I-70
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-70A
Page I-70B
Buzzer energized
True
Is the alarm buzzer energized?
DOM1-OUT15
Blink
Blink output on/off, 1 second per state.
Function
Red SSL = On/Off
Turn the red system status light on/off.
DOM1-OUT14
Is generator 1 ready for automatic operation?
Virtual
Is the generator 1 breaker switch not in the Pull-to-Lock position?
Virtual
Is there no engine 1 alarm?
Virtual
Is there no generator 1 alarm?
Virtual
Is generator 1 lockout not set?
Virtual
True
Is there an engine 1 alarm?
Virtual
True
Is there a generator 1 alarm?
Virtual
True
Is generator 1 lockout set?
Virtual
False
Red SSL = Off
Gen. 1 ready
Red SSL = On
True
False
Gen. 1 Br. not PTL
True
False
No eng. 1 alarm False
True
No gen. 1 alarm
True
False
No gen. 1 lockout
True
False
Eng. 1 alarm False Gen. 1 alarm False Gen. 1 lockout False
Page I-72A
Page I-72B
Page I-72C
I-71
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-72A
Page I-72B
Page I-72C
Blink
Gen. 1 SSL = Off
Gen. 2 ready
Gen. 1 SSL = On/Off
Gen. 1 SSL = On
True
Blink output on/off, 500 millisecond per state.
Function
Turn the generator 1 status light on/off.
DOM1-OUT13
Is generator 2 ready for automatic operation? Virtual
False
Gen. 2 Br. not PTL
True
False
Is the generator 2 breaker switch not in the Pull-to-Lock position?
No eng. 2 alarm False
True
Virtual
Is there no engine 2 alarm? Virtual
No gen. 2 alarm
True
Is there no generator 2 alarm? Virtual
False
No gen. 2 lockout
True
Is generator 2 lockout not set? Virtual
False
Eng. 2 alarm
True
Is there an engine 2 alarm? Virtual
False
Gen. 2 alarm
True
Is there a generator 2 alarm? Virtual
False
Gen. 2 lockout False
Gen. 1 SSL = Off
True
Is generator 2 lockout set? Virtual
Blink
Gen. 1 SSL = On/Off
Gen. 1 SSL = On
Return
Blink output on/off, 500 millisecond per state.
Function
Turn the generator 2 status light on/off.
DOM2-OUT13
End of subprogram.
I-72
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Start - DBC Control
PPU not A
Subroutine to control DBC.
True
Is the PPU not configured as "A"?
False
Tie output not energ.
Return
Exit subroutine.
True
False B bus not energ.
True
False C bus not energ.
RTU-OUT1
True
False D bus not energ.
True
Is the tie output bus not energized?
DIM2-IN11
Is the B PPU system bus not energized?
Virtual
Is the C PPU system bus not energized?
Virtual
Is the D PPU system bus not energized?
Virtual
Blink output on/off, 2.5 seconds per state.
Function
Pulse On/Off to transfer dead bus close permissive between generators.
Virtual
Is the dead bus close permissive transfer pulse changing from Off to On?
Virtual
Increment a counter.
Function
Has the counter reached 4 (4 DBP pulses)?
Function
Reset the counter to 0.
Function
Set dbc current value variable to the counter.
Virtual
False
Blink
Counter of DBP = Off
DBP pulse Off to On
Counter of DBP = On/Off
True
False Increment counter
Counter =4
True
False Reset counter
DBC current value = counter
Page I-74
I-73
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-73
Tie output energ.
True
False B bus energ.
True
False C bus energ.
True
False D bus energ.
True
Is the tie output bus energized?
DIM2-IN11
Is the B PPU system bus energized?
Virtual
Is the C PPU system bus energized?
Virtual
Is the D PPU system bus energized?
Virtual
Reset the dbc counter to 0.
Function
Does the dbc current value = 0?
Virtual
Dead bus permissive set to "A" PPU, T or F.
Virtual
Does the dbc current value = 1?
Virtual
Dead bus permissive set to "B" PPU, T or F.
Virtual
Does the dbc current value = 2?
Virtual
Dead bus permissive set to "C" PPU, T or F.
Virtual
False
Reset counter
DBC curr. val. = 0
True
False A DBC =F
DBC curr. val. = 1
A DBC =T
True
False B DBC =F
DBC curr. val. = 2
B DBC =T
True
False C DBC =F
C DBC =T
Page I-75
I-74
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-74
DBC curr. val. = 3
True
Does the dbc current value = 3?
Virtual
Dead bus permissive set to "D" PPU, T or F.
Virtual
Set current DBC value to 0.
Virtual
False D DBC =F
D DBC =T
Current DBC value = 0
Return
End of subprogram.
I-75
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Start - Engine Control
MSPB_TOG =T
Subroutine to control engines. This subroutine runs twice, once for each engine (X = 1, 2).
True
False
Gen. X not ready
Is the master system enable toggle = T?
Virtual
True
Is generator X not available for auto operation?
Virtual
True
Is the system mode switch not in the AUTO position?
RTU-IN1
True
Is engine X flagged to start for initial power plant startup?
Virtual
Block engine X from starting on initial power plant startup.
Virtual
Is generator X not available for auto operation?
Virtual
Is engine X blocked from starting on initial power plant startup?
Virtual
False
SMS not AUTO False
Eng. X initial start False
Gen. X ready False
Eng. X block from start = T
True
Eng. X block not start False
True
X= genset 1
True
Does X = 1 (first iteration of this program)?
False
Eng. 1 running
True
Is engine 1 running?
Virtual
True
Is generator 1 not configured and ready for operation?
Virtual
False
Gen. 1 not ready False
X= genset 2
True
Does X = 2 (second iteration of this program)?
False
Gen. X start =F
Gen. X start =T
Flag generator X to start on initial power plant startup, T or F.
Virtual
Page I-77
I-76
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-76
Eng. X ECS AUTO
True
Is the engine control switch for engine X in the AUTO position?
Virtual
Is the system mode switch in the AUTO position?
RTU-IN1
Is there not a summary failuer on generator X?
Virtual
Is there not an overcurrent alarm on generator X?
Virtual
Is the generator X lockout control set to F?
Virtual
Does the generator X breaker have the red target visible (not green)?
DIM1-IN1 or DIM2-IN1
Is the summary genset lockout set to F?
Virtual
Generator X is available for auto operation, T or F.
Virtual
True
Is the system mode switch in the MAN position?
RTU-IN2
True
Is the engine control switch for engine X in the manual position?
Virtual
Is engine X running?
Virtual
False SMS AUTO
True
False No gen. X sum. fail.
True
False No gen. X overcurrent
True
False
Gen. X lockout = F
True
False Gen. X breaker red
True
False Genset lockout = F
True
False
Gen. X ready =F
SMS MAN
Gen. X ready =T
False
Eng. X MAN False
Eng. X running
True
False Changing F to T
True
Is the output changing from F to T?
False
Page I-78A
Page I-78B
Page I-78C
I-77
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-77A
Page I-77B
Page I-77C
Start 2 second Timer
Changing T to F
Start a 2 second timer.
True
Is the output changing from T to F?
False Reset Timer
Timer expire
Reset the timer.
True
Did the timer expire?
False
Gen. X SMS transfer = F
Eng. X ECS auto
Gen. X SMS transfer = T
True
False Gen. X breaker cl.
True
False USS A
True
False A sub. gen. F to T
True
System mode switch transfer between MAN and AUTO on generator X without affecting operation, T or F.
Virtual
Is the engine control switch for engine X in the auto position?
Virtual
Is the breaker closed on generator X (on = closed)?
DIM1-IN3 or DIM2-IN3
Is the unit select switch in the A position?
RTU-OUT1
Is the A PPU flag to shut down one genset changing from F to T?
Virtual
Is the unit select switch in the B position?
RTU-OUT2
Is the B PPU flag to shut down one genset changing from F to T?
Virtual
False
USS B
True
False B sub. gen. F to T
True
False
Page I-79A
Page I-79B
Page I-79C
I-78
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-78A
Page I-78B
USS C
Page I-78C
True
False C sub. gen. F to T
True
Is the unit select switch in the C position?
RTU-OUT3
Is the C PPU flag to shut down one genset changing from F to T?
Virtual
Is the unit select switch in the D position?
RTU-OUT4
Is the D PPU flag to shut down one genset changing from F to T?
Virtual
Is the breaker for generator X closed?
DIM1-IN3 or DIM2-IN3
False
USS D
True
False D sub. gen. F to T
True
False
Gen. X br. closed
True
False X=1
True
Is this the first iteration (run for genset 1)?
False En. 1 hm > eng. 2 hm
True
Is the hourmeter for engine 1 > hourmeter for engine 2?
Virtual
Is the hourmeter for engine 2 > hourmeter for engine 1?
Virtual
Set generator X auxillary stop 1 to T or F.
Virtual
True
Is the engine control switch for engine X in the OFF / RESET position?
Virtual
True
Is the system mode switch in the OFF position and parameters have cleared?
Virtual
En. 2 hm > eng. 1 hm
True
False
False
Gen. X Aux. stop 1 = F
Eng. X ECS OFF
Gen. X Aux. stop 1 = T
False
PDC OFF False Page I-80A
Page I-80B
I-79
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-79A
Gen. X lockout
Page I-79B
True
Is lockout set for generator X?
Virtual
True
Does the generator X breaker not have the red target visible (is green)?
DIM1-IN1 or DIM2-IN1
True
Is the summary genset lockout flag set to T?
Virtual
Set auxillary stop relay #2 for generator X to T or F.
Virtual
Is start/stop permissive for generator X = F?
Virtual
True
Is auxillary stop relay #1 for generator X from F to T?
Virtual
True
Is auxillary stop relay #1 for generator X from F to T?
Virtual
True
Is the engine control switch for engine X in the AUTO position?
Virtual
Is the remote start/stop for generator X changing from T to F?
Virtual
Gen. X SS Permissive = T
Set start/stop permissive for generator X to T.
Virtual
Gen. X RSS =F
Reset remote start/stop for generator X to F.
Virtual
False
Gen. X breaker grn. False
Genset lockout False
Gen. X Aux. Stop 2 = F
Gen. X start/stop
Gen. X Aux. Stop 2 = T
True
False Gen. X aux. stop 1 False
Gen. X aux. stop 2 False
Eng. X ECS AUTO False
Gen. X RSS
True
False
Page I-81
I-80
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-80
Eng. X ECS AUTO False
True
Is the engine control switch for engine X in the AUTO position?
Virtual
Is the master system enable toggle = T?
Virtual
True
Is engine X not running?
Virtual
True
Is generator X in cooldown?
Virtual
Is the summary failure set to F for generator X?
Virtual
Is the summary failure set to F for generator Y (the generator this iteration is not running for)?
Virtual
Is the master start eneable switch is changing to either of the two enable positions?
RTU-IN3
Is engine X running?
Virtual
Is the system mode switch transfering between AUTO and MAN?
Virtual
Is generator X flagged to run on initial power planr startup?
Virtual
Set auxillary stop relay #2 for generator X to T or F.
Virtual
MSPB_TOG True =T False Eng. X not running False
Gen. X cooldown False
Gen. X no failure
True
False
Gen. Y no failure
True
False MSES F to T
True
False
Eng. X running
True
False SMS trans. =T
True
False
Gen. X init. run
True
False
Gen. X Aux. Start 2 = F
Gen. X Aux. Start 2 = T
Page I-82
I-81
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-81
Eng. X ECS AUTO
True
False Gen. X brk. not closed
Is the engine control switch for engine X in the AUTO position?
Virtual
Is the breaker not closed for generator X?
DIM1-IN3 or DIM2-IN3
True
Is the breaker not closed for generator Y (the generator this iteration is not run for)?
DIM2-IN3 or DIM1-IN3
True
Is this the first iteration (run for genset 1)?
True
False Gen. Y brk. not closed False
X=1 False
En. 1 hm < eng. 2 hm
True
Is the hourmeter for engine 1 >= hourmeter for engine 2?
Virtual
Is the hourmeter for engine 2 < hourmeter for engine 1?
Virtual
Is generator Y not available for auto operation?
Virtual
Is generator X available for auto operation?
Virtual
True
Is the breaker for generator Y closed (the generator this iteration is not run for)?
DIM2-IN3 or DIM1-IN3
True
Is the PPU configured as "A"?
RTU-OUT1
Is the flag for the A PPU to add a genset changing from F to T?
Virtual
En. 2 hm < eng. 1 hm
True
False
False
Gen. Y not ready
True
False Gen. X ready
True
False
Gen. Y brk. Closed False
PPU A False
A add gen. F to T
True
False
Page I-83A
Page I-83B
Page I-83C
I-82
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-82A
Page I-82B
PPU B
Page I-82C
True
Is the PPU configured as "B"?
RTU-OUT2
Is the flag for the B PPU to add a genset changing from F to T?
Virtual
Is the PPU configured as "C"?
RTU-OUT2
Is the flag for the C PPU to add a genset changing from F to T?
Virtual
Is the PPU configured as "D"?
RTU-OUT2
Is the flag for the D PPU to add a genset changing from F to T?
Virtual
Set auxillary stop relay #1 for generator X to T or F.
Virtual
Is start/stop permissive for generator X = F?
Virtual
True
Is the auxillary stop relay #1 for generator X = T?
Virtual
True
Is the auxillary stop relay #2 for generator X changing from F to T?
Virtual
False B add gen. F to T
True
False
PPU C
True
False C add gen. F to T
True
False
PPU D
True
False D add gen. F to T
True
False
Gen. X Aux. Start 1 = F
Gen. X start/stop
Gen. X Aux. Start 1 = T
True
False Gen. X aux. start 1 = T False
Gen. X aux. start 2 F/T False
Page I-84A
Page I-84B
Page I-84C
I-83
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-83A
Page I-83B
Eng. X ECS AUTO
Page I-83C
True
Is the engine control switch for engine X in the AUTO position?
Virtual
Is the remote start/stop flag for generator X changing from F to T?
Virtual
Gen. X start/stop = F
Set start/stop permissive for generator X to F.
Virtual
Gen. X RSS =T
Set remote start/stop flag for generator X to T.
Virtual
Is the master system enable toggle = T?
Virtual
Is generator X available for auto operation?
Virtual
Is the start/stop permissive for generator X =F?
Virtual
True
Is the system mode switch transfering between AUTO and MAN?
Virtual
True
Is the system mode switch not in the OFF position and parameters cleared?
Virtual
False Gen. X RSS F to T
True
False
MSPB_TOG True =T False Gen. X ready =T
True
False Gen. X SS =F
True
False
SMS trans. =T False
PDC not OFF False
Changing F to T
True
Is the input changing from F to T?
False Start 250ms timer
Page I-85A
Start a 250 ms timer.
Function
Page I-85B
I-84
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-84A
Page I-84B
Changing T to F
True
False
Timer expired
Is the input changing from T to F?
Reset timer
Reset the timer.
True
Function
Has the 250 ms timer expired?
False
Eng. X autorun =F
Autostart gen. X
Eng. X autorun =T
Set engine X autorun, T or F.
Virtual
True
Is generator X flagged to autostart?
DOM1-OUT2 or DOM2-OUT2
True
Is the engine control switch for engine X in the MAN position?
Virtual
Is engine X running?
Virtual
Is the PPU set for 50 Hz?
Virtual
True
Is the average VRMS for generator X greater than 3610?
Virtual
True
Is the average VRMS for generator X less than 3990?
Virtual
False
Eng. X ECS MAN False
Eng. X running False
True
50 Hz mode False
True
VRMS avg. > 3610 False
VRMS avg. < 3990 False
Page I-86A
Page I-86B
Page I-86C
I-85
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-85A
Page I-85B
60 Hz mode
Page I-85C
True
False
VRMS avg. > 3952
True
Is the PPU set for 60 Hz?
Virtual
Is the average VRMS for generator X greater than 3952?
Virtual
Is the average VRMS for generator X less than 4368?
Virtual
False
VRMS avg. True < 4368 False
Changing F to T
True
False
Changing T to F
Start 3 second timer
True
False
Timer expired
Is the input changing from T to F?
Start a 3 second timer.
Function
Is the input changing from T to F?
Reset timer
True
Reset the timer.
Function
Has the 3 second timer expired?
False
Gen. X ready for load = F
Gen. X ready for load = T
Generator X is running and ready for load, T or F.
Virtual
Page I-87
I-86
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-86
Gen. X ready
True
False SMS AUTO
True
False Gen. X br. not PTL
True
False Tie output not energ.
True
Is generator X running and ready for load?
Virtual
Is the system mode switch in the AUTO position?
RTU-IN1
Is the breaker switch for generator X not in the Pull-To-Lock position?
DIM3-IN1 or DIM3-IN2
Is the tie output bus not energized?
DIM2-IN11
False
X=2
True
Does X = 2 (is this the second iteration of this program, run for genset 2)?
False Gen. 1 no DBC
True
Is the dead bus close permissive relay for generator 1 set to F?
Virtual
False Blink at 2.5 second cycle
Input is on
Function
True
Is the blink input on (in the on/off cycle)?
False PPU A
True
False A DBC =T
True
Is the PPU configured as "A"?
RTU-OUT1
Is the A PPU dead bus permissive close relay set to T?
Virtual
Is the PPU configured as "B"?
RTU-OUT2
Is the B PPU dead bus permissive close relay set to T?
Virtual
False
PPU B
True
False B DBC =T
True
False
Page I-88A
Page I-88B
Page I-88C
I-87
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-87A
Page I-87B
PPU C
Page I-87C
True
Is the PPU configured as "C"?
RTU-OUT3
Is the C PPU dead bus permissive close relay set to T?
Virtual
Is the PPU configured as "D"?
RTU-OUT3
Is the D PPU dead bus permissive close relay set to T?
Virtual
Generator X dead bus close permissive = T or F.
Virtual
Is engine X available for autorun?
Virtual
True
Is the PLC output to autostart genset Y set to F?
DOM1-OUT2 or DOM1-OUT2 or
True
Is the PLC output to autostart genset X set to T?
DOM1-OUT2 or DOM1-OUT2 or
True
Is generator X in cooldown?
Virtual
True
Is engine Y running?
Virtual
Is engine X not running?
Virtual
False
C DBC =T
True
False
PPU D
True
False
D DBC =T
True
False
Gen. X DBC =F
Eng. X autorun False
Gen. X DBC =T
True
Eng. Y no autostart False
Eng. X autostart False
Gen. X cooldown False Eng. Y running False
Eng. X not running
True
False
Page I-89A
Page I-89B
I-88
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-88A
Page I-88B
Autostart gen. X =F
Autostart gen. X =T
Gen. X RTL
True
False
SMS AUTO
True
False
Gen. X br. not PTL
True
False
Tie output energized
True
Autostart generator X, T or F.
DOM1-OUT2 or DOM2-OUT2
Is generator X running and ready for load?
Virtual
Is the system mode switch in the AUTO position?
RTU-IN1
Is the breaker switch for generator X not in the Pull-To-Lock position?
DIM3-IN1 or DIM3-IN2
Is the tie output bus energized?
DIM2-IN11
Is the breaker for generator X not closed?
DIM1-IN3 or DIM2-IN3
Autosync for generator X = T or F.
Virtual
Is generator X set to autosync?
Virtual
Is the rempte breaker control for generator X open?
Virtual
Is generator X available for auto operation?
Virtual
PLC output to enable autosync for generator X is T or F.
DOM1-OUT3 or DOM2-OUT3
False
Gen. X br. not closed
True
False
Gen. X autosync =F
Gen. X autosync False
Gen. X autosync =T
True
Gen. X rem. br. open False
True
Gen. X ready
True
False
Gen. X autosync output = F
Gen. X autosync output = T
Page I-90
I-89
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-89
Gen. X rem. br. open
True
Is the rempte breaker control for generator X open?
Virtual
Is generator X not set to autstart?
DOM1-OUT2 or DOM2-OUT2
Is the breaker open for generator X?
DIM1-IN3 or DIM2-IN3
Reset the generator X remote breaker control to F (breaker open).
Virtual
Is the rempte breaker control for generator X open?
Virtual
Is the local PPU configured and ready for operation?
Virtual
Is the engine control switch for generator X in the OFF position?
Virtual
Is the system mode switch in the AUTO position?
RTU-IN1
True
Is the engine control switch for generator X in the STOP position?
Virtual
True
Is generator X lockout set to T?
Virtual
True
Is the generator X breaker switch in the Pull-To-Lock position?
DIM3-IN1 or DIM3-IN2
True
Is engine X autorun not enabled?
Virtual
False
Gen. X no autostart
True
False
Gen. X br. open
True
False
Gen. X rem. br. open
Reset gen. X remote br. to F
True
False
Local PPU ready
True
False
Gen. X ECS OFF
True
False
SMS AUTO
True
False
Gen. X ECS STOP False
Gen. X lockout False
Gen. X br. PTL False Eng. X no autorun False
Page I-91A
Page I-91B
Page I-91C
I-90
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-90A
Page I-90B
Gen. X ECS AUTO
Page I-90C
True
Is the engine control switch for generator X in the AUTO position?
Virtual
Enable generator X's breaker to open, T or F.
DOM1-OUT6 or DOM2-OUT6
Is the rempte breaker control for generator X closed?
Virtual
True
Is the PLC output to enable autosync for generator X turned on?
DOM1-OUT3 or DOM2-OUT3
True
Is generator X dead bus close permissive set to T?
Virtual
Is the PLC output to enable generator X's breaker to open set to F?
DOM1-OUT6 or DOM2-OUT6
Does the generator X breaker have the red target visible (not green)?
DIM1-IN1 or DIM2-IN1
Is generator X's breaker closed?
DIM1-IN3 or DIM2-IN3
Enable generator X's breaker to close, T or F.
DOM1-OUT5 or DOM2-OUT5
Is the engine control switch for generator X in the AUTO position?
Virtual
False
Enable gen. X br. to open = F
Gen. X rem. br. closed
Enable gen. X br. to open = T
True
False
Gen. X autosync False
Gen. X DBC False
Gen. X br. open = F
True
False
Gen. X breaker red
True
False
Gen. X brkr open
True
False
Enable gen. X br. to close = F
Gen. X ECS AUTO
Enable gen. X br. to close = T
True
False
Page I-92A
Page I-92B
I-91
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-91A
Page I-91B
Gen. X no autostart
True
False
Eng. X running
True
Is the PLC output to autostart generator X set to F?
DOM1-OUT2 or DOM2-OUT2
Is engine X running?
Virtual
Is the engine control switch for engine X in the STOP position?
Virtual
Generator X is in cooldown, T or F.
Virtual
Is the automatic voltage regulator switch in the utility parallel position?
RTU-IN7
Is generator X's breaker closed?
DIM1-IN3 DIM2-IN3
Generator X utilty parallel mode = T or F.
DOM1-OUT9 or DOM2-OUT9
Is the master system enable toggle = T?
Virtual
Is engine X's rpm >= 800?
Virtual
Engine X is running, T or F.
Virtual
False
Eng. X ECS STOP
True
False
Gen. X cooldown =F
AVRS UP
Gen. X cooldown =T
True
False
Gen. X br. closed
True
False
Utility parallel =F
Utility parallel =T
MSPB_TOG True =T False
Eng. X rpm >=800
True
False
Eng. X running =F
Eng. X running =T
Page I-93
I-92
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-92
Eng. X autorun
True
False
Eng. X not running
True
False
Changing F to T
True
False
Changing T to F
Is engine X not running?
Virtual
Is the input changing from F to T?
Start 2 minute timer
Start a 2 minute timer.
Stop and reset timer
Stop and reset the 2 minute timer.
True
False
Gen. X autosync
Virtual
True
False
Timer expired
Is engine X available for autorun?
Has the 2 minute timer expired?
Page I-94C
True
Is the PLC output to autosyn generator X set to T?
DOM1-OUT3 or DOM2-OUT3
True
Is generator X dead bus close permissive set to T?
Virtual
Is the breaker for generator X not closed?
DIM1-IN3 or DIM2-IN3
False
Gen. X DBC False
Gen. X br. not closed False
True
Changing F to T False
Page I-94A
True
Start 1 minute timer
Start a 2 minute timer.
Page I-94B
I-93
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-93A
Page I-93B
Changing T to F
Page I-93C
True
False
Timer expired
Stop and reset timer
True
Stop and reset the 1 minute timer.
Has the 1 minute timer expired?
False
Gen. X fail
True
Is the summary failure for generator X set to T?
Virtual
True
Is the lockout for generator X set to T?
Virtual
Is the master start enable switch in either enable position?
RTU-IN3
Set the summary failure flag for generator X, T or F.
Virtual
False
Gen. X lockout False
MSES ENABLE
True
False
Gen. X summary failure = F
Gen. X summary failure = T
Return
End of subprogram.
I-94
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Start - Tie / Feeder Control
SMS AUTO
Controls tie & feeder breakers.
True
False Not last PPU
Is the system mode switch in the AUTO position?
RTU-IN1
Is the LS-NET casble plugged into the "B" connector?
RTU-IN8
True
Is the remote tie open/close toggle set for open?
Virtual
True
Is the tie output bus energized?
DIM2-IN11
Is the main system bus not energized?
DIM2-IN12
Is the tie output bus not energized?
DIM2-IN11
Is the main system bus energized?
DIM2-IN12
Is there no tie breaker overcurrent relay alarm?
DIM1-IN4
Is there no tie breaker overcurrent trip?
DIM1-IN13
Is the battleshort switch not in the NORMAL position?
RTU-IN4
Enable tie breaker to close, T or F.
Virtual
True
False Remote tie open False
Tie bus energized False
Main bus not ener.
True
False
Tie bus not ener.
True
False Main bus energized
True
False
No tie OC relay alm. False
True
No tie OC trip
True
False
Battleshort not normal
True
False
Enable tie close =F
Enable tie close =T
Page I-96
I-95
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-95
Tie close enable
True
False
Tie not closed
True
False
No tie open en.
True
False
Tie not PTL
True
Is the tie breaker enabled to close?
Virtual
Is the tie breaker not closed?
DIM1-IN12
Is the PLC output to enable the tie breaker to open set to F?
DOM2-OUT11
Is the tie breaker switch not in the Pull-To-Lock position?
DIM3-IN3
Is the tie breaker lockout set to F?
Virtual
Enable tie breaker to close, T or F.
DOM2-OUT10
Is the LS-NET cable not plugged into the "B" connector?
RTU-IN8
Is the generator mode switch not in the utility parallel position (is in the prime power position)?
RTU-IN5
Is the tie breaker remote open/close toggle set to close?
Virtual
Is the system mode switch in the AUTO position?
RTU-IN1
Is the tie breaker tripped due to overcurrent?
DIM1-IN13
Is the battleshort switch in the NORMAL position?
RTU-IN4
False
No tie lockout
True
False
Enable tie close =F
Last PPU
Enable tie close =T
True
False
GMS prime pow.
True
False
Tie remote closed
True
False
SMS AUTO
True
False
Tie OC trip False
True
Battleshort NORMAL
True
False
Page I-97A
Page I-97B
I-96
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-96A
Tie lockout
Page I-96B
True
Is the tie breaker lockout set to T?
Virtual
True
Is the tie breaker switch in the Pull-To-Lock position?
DIM3-IN3
Enable tie breaker to open, T or F.
DOM2-OUT11
Is the tie breaker remote open/close toggle set to close?
Virtual
Is the system mode switch changing from the AUTO position to a different position?
RTU-IN1
Reset tie breaker remote open/close to F (open).
Virtual
Is the system mode switch in the AUTO position?
RTU-IN1
Is the tie output bus energized?
DIM2-IN11
Is the feeder 1 breaker remote open/close toggle set to T (closed)?
Virtual
Is the local PPU configured and ready for operation?
Vitual
Is there not an overcurrent alarm on feeder 1?
DIM1-IN10
Is there no overcurrent trip on feeder 1?
DIM1-IN9
False
Tie PTL False
Enable tie open =F
Tie remote closed
Enable tie open =T
True
False
SMS AUTO T to F
True
False
SMS AUTO False
Tie remote close =F
True
Tie bus energized
True
False
Feeder 1 rem. close
True
False
PPU ready
True
False
No feeder 1 OC alarm False
True
No feeder 1 OC trip
True
False
Page I-98A
Page I-98B
Page I-98C
I-97
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-97A
Page I-97B
Battleshort not NORM.
Page I-97C
True
Is the battleshort switch not in the NORMAL position?
RTU-IN4
Enable feeder 1 breaker to close, T or F.
Virtual
True
Is the tie output bus not energized?
DIM2-IN11
True
Is the PLC output to enable feeder 1 breaker to open set to T?
DOM1-OUT8
True
Is the PLC output to enable feeder 1 breaker to close set to T?
Virtual
Is feeder 1 not closed (open)?
DIM1-IN8
False
Enable feeder 1 close = F
Tie bus not energ.
Enable feeder 1 close = T
False
Feeder 1 open en. False
Feeder 1 close en. False
Feeder 1 open False
True
Changing F to T
True
False
Changing T to F
Start 1 second timer
Start a 1 second timer.
Stop and reset timer
Stop and reset the 1 second timer.
True
False
Timer expired
Is the input changing from F to T?
True
Has the 1 second timer expired?
False
Page I-99A
Page I-99B
I-98
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-98A
Page I-98B
Feeder 1 rem. close
True
Is the remote open/close toggle for feeder 1 set to close?
Virtual
Set feeder 1 remote open/close toggle to F (open).
Virtual
Is the PLC output to enable feeder 1 breaker to close set to T?
Virtual
Does the feeder 1 breaker switch have the red target visible?
DIM3-IN6
Is feeder 1 not closed?
DIM1-IN8
Is the PLC output to enable feeder 1 breaker to open set to F?
DOM1-OUT8
PLC output to enable feeder 1 to close = T or F.
DOM1-OUT7
Is feeder 1 tripped because of overcurrent?
DIM1-IN9
Is the battleshort switch in the NORMAL position?
RTU-IN4
True
Is the toggle for remote open/close of feeder 1 changing from T to F?
Virtual
True
Is the breaker switch for feeder 1 in the Pull-ToLock position?
DIM3-IN4
PLC output to enable feeder 1 to open = T or F.
DOM1-OUT8
False
Feeder 1 close en.
Feeder 1 remote open/close = F
True
False
Feeder 1 br. red
True
False
Feeder 1 not closed False
True
Feeder 1 not True open en. False
Feeder 1 close enable = F
Feeder 1 OC trip
Feeder 1 close enable = T
True
False
Battleshort NORMAL
True
False
Feeder 1 rem. close False
Feeder 1 PTL False Feeder 1 open enable = F
Feeder 1 open enable = T
Page I-99
I-99
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-99
SMS AUTO
True
Is the system mode switch in the AUTO position?
RTU-IN1
Is the tie output bus energized?
DIM2-IN11
Is the feeder 2 breaker remote open/close toggle set to T (closed)?
Virtual
Is the local PPU configured and ready for operation?
Vitual
Is there not an overcurrent alarm on feeder 2?
DIM2-IN10
Is there no overcurrent trip on feeder 2?
DIM2-IN9
Is the battleshort switch not in the NORMAL position?
RTU-IN4
Enable feeder 2 breaker to close, T or F.
Virtual
True
Is the tie output bus not energized?
DIM2-IN11
True
Is the PLC output to enable feeder 2 breaker to open set to T?
DOM2-OUT8
False
Tie bus energized
True
False
Feeder 2 rem. close
True
False
PPU ready
True
False
No feeder 2 OC alarm
True
False
No feeder 2 OC trip
True
False
Battleshort not NORM.
True
False
Enable feeder 2 close = F
Tie bus not energ.
Enable feeder 2 close = T
False
Feeder 2 open en. False
Page I-100A
Page I-100B
I-100
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-99A
Feeder 2 close en.
Page I-99B
True
False Feeder 2 open
True
False Changing F to T
True
Is the PLC output to enable feeder 2 breaker to close set to T?
Virtual
Is feeder 2 not closed (open)?
DIM2-IN8
Is the input changing from F to T?
False
Changing T to F
Start 1 second timer
Start a 1 second timer.
Stop and reset timer
Stop and reset the 1 second timer.
True
False
Timer expired
True
Has the 1 second timer expired?
True
Is the remote open/close toggle for feeder 2 set to close?
Virtual
Set feeder 2 remote open/close toggle to F (open).
Virtual
Is the PLC output to enable feeder 2 breaker to close set to T?
Virtual
Does the feeder 2 breaker switch have the red target visible?
DIM3-IN7
Is feeder 2 not closed?
DIM2-IN8
False
Feeder 2 rem. close False
Feeder 2 remote open/close = F
Feeder 2 close en.
True
False Feeder 2 br. red
True
False Feeder 2 not closed
True
False
Page I-101A
Page I-101B
I-101
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-100A
Page I-100B
Feeder 2 not True open en.
Is the PLC output to enable feeder 2 breaker to open set to F?
DOM2-OUT8
False
Feeder 2 close enable = F
Feeder 2 OC trip
Feeder 2 close enable = T
True
PLC output to enable feeder 2 to close = T or F. DOM2-OUT7
Is feeder 2 tripped because of overcurrent?
DIM1-IN9
Is the battleshort switch in the NORMAL position?
RTU-IN4
True
Is the toggle for remote open/close of feeder 2 changing from T to F?
Virtual
True
Is the breaker switch for feeder 2 in the Pull-ToLock position?
DIM3-IN5
PLC output to enable feeder 1 to open = T or F.
DOM2-OUT8
False
Battleshort NORMAL
True
False
Feeder 2 rem. close False
Feeder 2 PTL False
Feeder 2 open enable = F
Feeder 2 open enable = T
Return
End of subprogram.
I-102
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Start - Announce
Eng. 1 running
Controls the PPU buzzer.
True
Is engine 1 running?
Virtual
True
Is the high coolant temperature alarm for engine 1 changing from F to T?
GSC
True
Is the low coolant temperature alarm for engine 1 changing from F to T?
GSC
True
Is the low oil pressure alarm for engine 1 changing from F to T?
GSC
True
Is the high oil temperature alarm for engine 1 changing from F to T?
GSC
Eng. 1 ADEM True F to T
Is the ADEM unit alarm for engine 1 changing from F to T?
GSC
Is the generator 1 underfrequency alarm changing from F to T?
GSC
Add 1 to the Alarm_Count variable.
Virtual
Set alarm1a variable to T.
Virtual
Is engine 1 running?
Virtual
True
Is the generator 1 overfrequency alarm changing from F to T?
GSC
True
Is the generator 1 undervoltage alarm changing from F to T?
GSC
False Eng. 1 HCT F to T False
Eng. 1 LCT F to T False
Eng. 1 LOP F to T False
Eng. 1 HOT F to T False
False
Gen. 1 UF F to T
True
False Add 1 to Alarm_Count
Alarm1a =T
Eng. 1 running
True
False Gen. 1 OF F to T False
Gen. 1 UV F to T False
Page I-103A
Page I-103B
Page I-103C
I-103
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page I-102A
Page I-102B
Page I-102C
True
Is the generator 1 overvoltage alarm changing from F to T?
GSC
True
Is the generator 1 reverse power alarm changing from F to T?
GSC
True
Is the generator 1 frequency sensing alarm changing from F to T?
GSC
Is the engine control switch for engine 1 not in the OFF position?
Virtual
Is the engine 1 battery low (
View more...
Comments
