277 697 400 series opman english

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GENERATING SETOPERATOR’S MANUAL


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GENERATING SETOPERATOR’S MANUAL

This manual has been designed as a guide to operators to aid in starting, stopping and otherwise operating the generating set.The Generating Set Technical Operation and Maintenance Manual, the Engine Manual and the Alternator Manuals are designedfor qualified generating set technicians for installation, maintenance and trouble shooting of the set.

Document: OL3- GBIssue Date: 08/08Part Number: 277-697


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TABLE OF CONTENTS

1. INTRODUCTION...........................................................................................................................................................................................................1

2. SAFETY.........................................................................................................................................................................................................................1 2.1 General ...................................................................................................................................................................................................................12.2 Installation, Handling and Towing ...........................................................................................................................................................................12.3 Fire and Explosion ..................................................................................................................................................................................................12.4 Mechanical ..............................................................................................................................................................................................................12.5 Chemical .................................................................................................................................................................................................................12.6 Noise .......................................................................................................................................................................................................................12.7 Electrical..................................................................................................................................................................................................................1

2.8 First Aid For Electric Shock.....................................................................................................................................................................................2

3. GENERAL DESCRIPTION............................................................................................................................................................................................3

4. CONTROL SYSTEM DESCRIPTION AND TROUBLE SHOOTING ............................................................................................................................4 4.1 Control System Description and Identification ........................................................................................................................................................44.2 Functional Description LCP1 Control Systems .......................................................................................................................................................74.3 Functional Description LCP2 Control Systems .......................................................................................................................................................74.4 Functional Description PowerWizard Control Systems...........................................................................................................................................74.5 Control System Options and Upgrades...................................................................................................................................................................84.6 Control System Fault Finding/Trouble Shooting Guide LCP1/LCP2.....................................................................................................................104.7 Control System Fault Finding/Trouble Shooting Guide PowerWizard Panels ......................................................................................................114.8 Load Transfer Panels...........................................................................................................................................................................................124.9 Engine Interface Module Description ...................................................................................................................................................................124.10 Output Circuit Breaker Description.......................................................................................................................................................................12

5. OPERATION ...............................................................................................................................................................................................................13

5.1 General .................................................................................................................................................................................................................135.2 Pre-Start Checks (applicable to all control systems).............................................................................................................................................135.3 Normal Startup/Shutdown - LCP1 Keystart Panel ................................................................................................................................................135.4 Normal Manual Startup/Shutdown - LCP2 Autostart Panels.................................................................................................................................145.5 Automatic Startup/Shutdown - LCP2 Autostart Panels .........................................................................................................................................145.6 Normal Manual Startup/Shutdown - PowerWizard Autostart Panels ....................................................................................................................145.7 Automatic Startup/Shutdown - PowerWizard Autostart Panels.............................................................................................................................15

6. MAINTENANCE ..........................................................................................................................................................................................................15 6.1 Battery Removal and Fitting...................................................................................................................................................................................15

HAZARD LABELS................................................................................................................................................................................................................16 INDEX ..............................................................................................................................................................................................................................17


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1. INTRODUCTION

This generating set is one of a family of heavy duty industrialgenerating sets designed to be ready to run when it arrives,requiring only the addition of coolant, fuel and battery acid. Yearsof diesel generating set experience has gone into the set toproduce a quality source of electrical power that is efficient andreliable.

This Operator’s Manual has been prepared to assist in operationof the generating set.

Always ensure that maintenance, adjustments and repairs aredone by personnel who are authorised to do the work and have

been properly trained.Every generating set is uniquely defined by a model number andserial number indicated on a rating plate affixed to the panelenclosure. This information is required when ordering spareparts or when service or warranty work is required.

2. SAFETY

2.1 General

The generating set is designed to be safe when used in thecorrect manner. Responsibility for safety, however, restswith the personnel who use the set. The following safetyprecautions, if followed, will minimise the possibility ofaccidents. Before performing any procedure or operatingtechnique, it is up to the user to ensure that it is safe. Thegenerating set should only be operated by personnel who

are authorised and trained.

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! Read and understand all safety precautions andwarnings before operating the generating set.

ARNING:

! Failure to follow the instructions, procedures, andsafety precautions in this manual may increase thepossibility of accidents and injuries.

! Never start the generating set unless it is safe to doso.

! Do not attempt to operate the generating set with aknown unsafe condition.

! If the generating set is unsafe, fit danger notices anddisconnect the battery negative ( - ) lead so that itcannot be started until the condition is corrected.

! Disconnect the battery negative ( - ) lead prior toattempting any repairs or cleaning inside theenclosure, if equipped.

! Install and operate this generating set only in fullcompliance with relevant National, Local, or FederalCodes, Standards or other requirements.

2.2 Installation, Handling and Towing

A qualified generating set technician should refer to theTechnical Manual for this information.

2.3 Fire and Explosi on

Fuels and fumes associated with generating sets can beflammable and potentially explosive. Proper care in handlingthese materials can dramatically limit the risk of fire orexplosion. However, safety dictates that fully charged BC

and ABC fire extinguishers are kept on hand. Personnelmust know how to operate them.

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! Ensure the generating set room is properly ventilated. ARNING:

! Keep the room, the floor and the generating set clean.When spills of fuel, oil, battery electrolyte or coolantoccur, they should be cleaned up immediately.

! Never store flammable liquids near the engine.! Store oily rags in covered metal containers.! Do not smoke or allow sparks, flames or other sources

of ignition around fuel or batteries. Fuel vapours areexplosive. Hydrogen gas generated by chargingbatteries is also explosive.

! Avoid refilling the fuel tank while the engine is running.

! Do not attempt to operate the generating set with anyknown leaks in the fuel system.

2.4 Mechanical

The generating set is designed with guards for protectionfrom moving parts. Care must still be taken to protectpersonnel and equipment from other mechanical hazardswhen working around the generating set.

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! Do not attempt to operate the generating set withsafety guards removed. While the generating set isrunning do not attempt to reach under or around theguards for any reason.

ARNING:

! Keep hands, arms, long hair, loose clothing and

jewellery away from pulleys, belts and other movingparts.

Att enti on: Some moving parts can not be seen clearlywhen the set is running.

! Keep access doors on enclosures, if equipped, closedand locked when not required to be open.

! Avoid contact with hot oil, hot coolant, hot exhaustgases, hot surfaces and sharp edges and corners.

! Wear protective clothing including gloves and hatwhen working around the generating set.

2.5 Chemical

Fuels, oils, coolants, lubricants and battery electrolyte usedin this generating set are typical of the industry. However,they can be hazardous to personnel i f not treated properly.

WARNING:! Do not swallow or have skin contact with fuel, oil,

coolant, lubricants or battery electrolyte. If swallowed,seek medical treatment immediately. Do not inducevomiting if fuel is swallowed. For skin contact, washwith soap and water.

! Do not wear clothing that has been contaminated byfuel or lube oil.

2.6 Noise

Generating sets that are not equipped with soundattenuating enclosures can produce noise levels in excess of105 dBA. Prolonged exposure to noise levels above 85 dBAis hazardous to hearing.

WARNING:

! Ear protection must be worn when operating orworking around an operating generating set.

2.7 Electrical

Safe and efficient operation of electrical equipment can beachieved only if the equipment is correctly operated andmaintained.

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! Ensure the generating set, including a mobile set, iseffectively grounded/earthed prior to operation.

ARNING:

! Do not touch electrically energised parts of thegenerating set and/or interconnecting cables orconductors with any part of the body or with any noninsulated conductive object.

! Use only Class BC or Class ABC extinguishers on

electrical fires.


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2.8 First Aid For Electric Shock

WARNING:

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! Do not touch the victim's skin with bare hands until thesource of electricity has been turned off.

Switch off power, if possible.

Otherwise pull the plug or pull the cable away from thevictim.

If this is not possible, stand on dry insulating materialand pull the victim clear of the conductor, preferablyusing insulated material such as dry wood.

If victim is breathing, turn the victim into the recoveryposition described below.

If victim is unconscious, perform resuscitation asrequired:

OPEN THE AIRWAY:

1. Tilt the victim's head back and liftthe chin upwards.

2. Remove objects from the mouth orthroat (including false teeth,tobacco, or chewing gum).

BREATHING:

1. Check that the victim is breathingby looking, listening and feeling forbreath.

CIRCULATION:1. Check for pulse in the victim's neck.

IF NO BREATHING BUT PULSE IS

PRESENT:

1. Pinch the victim's nose firmly.

2. Take a deep breath and seal yourlips around the victim’s lips.

3. Blow slowly into the mouthwatching forthe chest to rise. Let the chest fallcompletely. Give breathsat a rate of 10 per minute.

4. If the victim must be left toget help, give 10 breaths firstand then return quickly andcontinue.

5. Check for pulse after every 10breaths.

6. When breathing restarts, place the victim into therecovery position described later inthis section.

IF NO BREATHING AND NO PULSE:

1. Call or telephone for medical help.

2. Give two breaths and start chestcompression as follows:

3. Place heel of hand 2 fingersbreadth above ribcage/breastbone

junction.

4. Place other hand on top and interlockfingers.

5. Keeping arms straight, press down 4-5cm (1.5-2 inch) 15 times at arate of 80 per minute.

6. Repeat cycle (2 breaths, 15compressions) until medical helptakes over.

7. If condition improves, confirm pulseand continue with breaths. Checkfor pulse after every 10 breaths.

8. When breathing restarts, place thevictim into the recovery position.

RECOVERY POSITION:

1. Turn the victim onto the side.

2. Keep the head tilted with the jaw forward to maintain theopen airway.

3. Make sure the victim cannot rollforwards or backwards.

4. Check for breathing and pulseregularly. If either stops,proceed as above.

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! Do not give liquids until victim is conscious. ARNING:


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3. GENERAL DESCRIPTION

This generating set has been designed as a complete packageto provide superior performance and reliability.

Each generating set is provided with a Rating Label affixed tothe panel enclosure. This label contains the information neededto identify the generating set and its operating characteristics.This information includes, but is not limited to, the modelnumber, serial number, output characteristics such as voltage,phase and frequency, output rating in kVA and kW, and ratingtype (basis of the rating). The model and serial numbers uniquelyidentify the generating set.

The diesel engine powering the generating set has been chosenfor its reliability and the fact that it has been specifically designedfor powering generating sets. The engine is of the heavy dutyindustrial type with 4 stroke compression ignition and is fittedwith all accessories to provide a reliable power supply.

The engine electrical system is 12 volts DC.

The engine cooling system is either air cooled or water cooled.The air cooled system consists of a high capacity fan to pull coolair across the engine to cool it. The water cooled system iscomprised of a radiator, pusher fan and a thermostat.

The output electrical power is produced by an alternator finetuned to the output of this generating set.

The engine and alternator are coupled together and mounted on

a heavy duty steel baseframe. This baseframe includes apolyethylene fuel tank with a capacity of approximately 8 hoursoperation at full load.

The generating set is fitted with vibration isolators which aredesigned to reduce engine vibration being transmitted to thefoundation on which the generating set is mounted. Theseisolators are fitted between the engine/alternator feet and thebaseframe.

An exhaust silencer is provided loose for installation with thegenerating set. The silencer and exhaust system reduce thenoise emission from the engine and can direct exhaust gases tosafe outlets.

One of several types of control systems and panels may be fittedto control the operation and output of the set and to protect the

set from possible malfunctions. Section 4 of this manualprovides detailed information on these systems and will aid inidentification of the control system fitted on the generating set.

To protect the alternator a suitably rated circuit breaker, selectedfor the generating set model and output rating, is supplied.


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4. CONTROL SYSTEM DESCRIPTION AND TROUBLE

SHOOTING

4.1 Control System Description and Identification

4.1.1 Description: An electronic control system has beendesigned and installed to control and monitor the generatingset. Depending on the requirements of the set, one ofseveral different standard control systems may be fitted.These include the LCP1 Keystart Systems and the LCP2and PowerWizard Autostart Systems. Other morespecialised systems may be installed for specific installationsin which case separate documentation is provided. Thecontrol panels often use symbols instead of words todescribe the functions of controls and lamps. Figure 4.2gives a legend for each of the possible symbols.

These control systems consist of three major componentsworking together - a control panel, an engine interfacemodule and an alternator output circuit breaker.

The control panel provides a means of starting and stoppingthe generating set, monitoring its operation and output, andautomatically shutting down the set in the event of a criticalcondition arising such as low oil pressure or high enginetemperature. An LCP1, LCP2 or PowerWizard panel isinstalled as appropriate for the requirements of thegenerating set installation.

The Engine Interface Module is a sealed, engine mountedmodule that provides switching relays for the Starter MotorSolenoid, Glow Plug and Fuel Solenoid. Each of thesecircuits is protected with individual fuses mounted in themodule. Individual LEDs illuminate when each circuit isenergised. The Engine Interface Module is available in twomodels depending on the type of control panel being used -the EIM Basic (with safety relay) and the EIM Plus (withsafety relay and overspeed circuit). The LCP1 KeystartPanels and PowerWizard panels utilise the EIM Basic andthe LCP2 Autostart Panels utilise the EIM Plus.

The power output circuit breaker serves to protect thealternator by automatically disconnecting the load in theevent of overload or short circuit. It also provides a meansof switching the generating set output.

4.1.2 Panel Equipm ent LCP1/LCP2: Before starting orrunning the generating set, the operator should become fullyacquainted with the instruments and controls. The

instruments should be observed from time to time while thegenerating set is running so that any abnormal readings canbe detected before problems arise.

Figure 4.1 shows typical layouts of each of the controlpanels. Addition of optional equipment may add items to thepanel so the panel fitted on the generating set may beslightly different from the typical ones shown. The followingdescriptions explain the function of each standard item onthe panels:

1. AC VOLTMETER - A voltmeter that indicates the ACvoltage generated at the alternator output terminals.The reading indicated on the voltmeter will varydepending on the position of the voltmeter selectorswitch (item 2). It should not, however, vary while theset is operating. If the meter gives no reading while the

generating set is running, ensure that the AC voltmeterselector switch is not in the OFF position.

2. AC VOLTMETER SELECTOR SWITCH - A selectorswitch allowing the operator to select voltage readingbetween phases or between a phase and neutral. TheOFF position allows the voltmeter "zero" position to bechecked while the generating set is running.

3. AC AMMETER - An ammeter that indicates the ACelectrical current being delivered which is dependanton the connected load. A separate reading from eachof the phases is possible using the ammeter selectionswitch (item 4). If the meter gives no reading while thegenerating set is running, ensure that the AC ammeterselector switch is not in the OFF position.

4. AC AMMETER SELECTOR SWITCH - A selector

switch allowing the operator to select a current readingfrom each of the phases. The OFF position allows theammeter "zero" position to be checked while thegenerating set is running.

5. FREQUENCY METER - A meter that indicates theoutput frequency of the generating set. At partial loadthe frequency will be slightly higher than normal,

depending on the droop of the governor. In practice,no load frequencies of approximately 52 and 62 Hz for50 Hz and 60 Hz respectively, are considered normal.The frequencies will fall, as the set is loaded, to 50 Hzand 60 Hz at full load.

6. HOURS RUN METER - A meter that indicates the totalnumber of hours of generating set operation to aid inmaintenance.

7. DC BATTERY VOLTMETER - A voltmeter thatindicates the state of charge of the battery. When theengine is at standstill the normal battery voltage will be12 to 14 volts. During starting, the needle will drop to

about 70% of normal and oscillate as the enginecranks. Once the engine has started, the needleshould return to its normal value. If the batterycharging alternator is charging correctly, the voltagereading will always be higher with the generating setrunning than when it is stopped.

8. FAULT INDICATOR LAMPS - Fault lamps thatilluminate to indicate that the protective circuitry hassensed the indicated condition. The lamp should bered on conditions for which the system will initiate ashutdown of the set. For alarms, the lamp can be redor amber.

9. LAMP TEST PUSHBUTTON - A button to illuminatethe fault lamps for testing.

10. KEY SWITCH (LCP1) - A four position switch thatprovides a means of starting and operating thegenerating set.

Position “O” - OFF/RESETPower is turned off and protection circuitry is reset inthis position.

Position - RUNDC power is supplied to the control system and on theLCP1 panel the fault protection timer relay is initiated.

Position - THERMOSTARTDC power is supplied to the thermostart circuit (onlyrequired on turbocharged engines).

Position - CRANKDC power is supplied to the starter motor to crank theengine.

11. CONTROL SWITCH (LCP2) - A three position switchthat provides a means of controlling the generating setfunctions.

Position - RUNThe autostart function is initiated to immediately startand run the generating set.

Position “O” - OFF/RESETThe generating set is shut down if running andautomatic start is inhibited. Protection circuitry is resetin this position.

Position - AUTO The control circuitry is ready to initiate an automaticstart upon receiving a remote start signal.

12. EMERGENCY STOP PUSHBUTTON - A red lock-down pushbutton that immediately shuts down thegenerating set and will inhibit start until the pushbuttonhas been released by turning it clockwise. Pressingthis button also illuminates the OVERSPEED faultlamp even though an overspeed has not occurred.Prior to restarting the set, this fault lamp must be reset

by turning the Control Switch to Position “O” (Off).

13. THERMOSTART PREHEAT BUTTON (LCP2Turbocharged only) - A button to activate thethermostart preheat circuit.

4.1.3 Panel Equipment for PowerWizard: Before startingor running the generating set, the operator should becomefully acquainted with the control module’s display and pushbuttons. The display should be observed from time to time

while the generating set is running so that any abnormalreadings can be detected before problems arise.

Figure 4.1 (c) shows a typical layout of the PowerWizardcontrol panel. Addition of optional equipment may add itemsto the panel so the panel fitted on the generating set may beslightly different from the typical one shown. The following

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descriptions explain the function of each standard item onthe panels:

1. DISPLAY SCREEN - This screen will display all thegenerating set’s information from sensor readings toevent logs. Please see section 4.1.4 for displaypreferences.

2. AC OVERVIEW - The “AC Overview” key will navigatethe display to first screen of AC information. The “ACOverview” information contains various AC parametersthat summarize the electrical operation of thegenerating set.

3. ENGINE OVERVIEW - The “Engine Overview” key will

navigate the display to the first screen of engineinformation. The “Engine Overview” informationcontains various engine parameters that summarizethe operation of the generating set.

4. YELLOW WARNING LIGHT - A flashing yellow lightindicates that there are unacknowledged activewarnings. A solid yellow light indicates that there areacknowledged warnings active. If there are any activewarnings the yellow light will change from flashingyellow to solid yellow after the Alarm Acknowledge keyis pressed. If there are no longer any active warnings,the yellow light will turn off after the “Acknowledge” keyis pressed.

5. RED SHUTDOWN LIGHT - A flashing red lightindicates that there are unacknowledged activeshutdown events. A solid red light indicates that there

are acknowledged shutdown events active. If there areany active shutdown events the red light will changefrom flashing red to solid red after the Alarm

Acknowledge key is pressed. Any condition that hascaused a shutdown event must be manually reset. Ifthere are no longer any active shutdown events, the redlight will turn off.

6. ALARM ACKNOWLEDGMENT SILENCE - Pressingthe “Acknowledge” key will cause the horn relay outputto turn off and silence the horn. Pressing the key willalso cause any yellow or red flashing lights to turn off orto become solid depending on the active status of thealarms. The “Acknowledge” key may also be configuredto send out a “Global Alarm Silence ” on “J1939 DataLink” which will silence horns on annunciators.

7. LAMP TEST - Pressing and holding the “Lamp Test”key will cause all of the LED’s and the display screenpixels to turn on solid until the key is released.

8. RUN - Pressing the “RUN” key will cause the engine toenter the “RUN” mode.

9. AUTO - Pressing the “AUTO” key will cause the engineto enter the “AUTO” mode.

10. STOP - Pressing the “STOP” key will cause the engineto enter the “STOP” mode.

11. UP - The “Up” key is used to navigate up through thevarious menus or monitoring screens. The “Up” key isalso used during setpoint entry. During numeric dataentry the Up key is used in order to increment the digits(0-9). If the setpoint requires selection from a list, the“Up” key is used to navigate UP through the list.

12. ESCAPE - The “ESCAPE” key is used during menunavigation in order to navigate up through themenu/sub-menu structure. Each key press causes theuser to move backwards/upwards through thenavigation menus. The “Escape” key is also used tocancel out of data entry screens during setpointprogramming. If the “Escape” key is pressed duringsetpoint programming, none of the changes made onscreen will be saved to memory.

13. RIGHT - The “Right” key is used during setpointadjustment. During numeric data entry, the “Right” keyis used to choose which digit is being edited. The“Right” key is also used during certain setpointadjustments to select or deselect a check box. If a boxhas a check mark inside the box, pressing the “Right”

key will cause the check mark to disappear, disablingthe function. If the box does not have a check markinside the box, pressing the “Right” key will cause acheck mark to appear, Enabling the function.

14. ENTER - The “Enter” key is used during menunavigation to select menu items in order to navigateforward/downward in the menu/sub-menu structure.The “Enter” key is also used during setpointprogramming in order to save setpoints changes.Pressing the “Enter” key during setpoint programmingcauses setpoint changes to be saved to memory.

15. DOWN - The “Down” key is used to navigate down

through the various menus or monitoring screens. The“Down” key is also used during setpoint entry. Duringnumeric data entry the “Down” key is used in order todecrement the digits (0-9). If the setpoint requiresselection from a list, the “Down” key is used to navigateDOWN through the list.

16. LEFT - The “Left” key is used during setpointadjustment. During numeric data entry, the“ Left” key isused to choose which digit is being edited. The “Left”key is also used during certain setpoint adjustments toselect or deselect a check box. If a box has a checkmark inside the box, pressing the “Left” key will causethe check mark to disappear, disabling the function. Ifthe box does not have a check mark inside the box,pressing the “Left ” key will cause a check mark toappear, enabling the function.

17. EMERGENCY STOP PUSHBUTTON - A red lock-downpushbutton that immediately shuts down the generatingset and will inhibit start until the pushbutton has beenreleased by turning it clockwise. Prior to restarting theset, this fault must be reset by pressing the ‘stop’ buttonon the module and resetting the fault in the ‘event logmenu’.

18. MODULE DATA LINK CONNECTION - This enablesthe service tool to communicate with the module.

4.1.4 Display Preferences for PowerWizard Panels: Tochange the display preferences, from the main menu scrolldown to the 'Preferences' item (last in the menu). Press the'Enter' Key. Scroll down through the preferences menu untilthe desired display preference is highlighted. Press 'Enter' toadjust this preference.

CONTRAST: The display contrast may require adjustmentfrom the factory default depending on viewing angle andambient temperature. The contrast is adjusted between 0%and 100% by pressing the left and right keys. Pressing Enteraccepts the changes and Escape aborts the changes.

BACKLIGHT: The backlight is usually left at 100%, howeveron occasions the user may wish to reduce the backlightintensity. The backlight can be adjusted between 0 to 100%by pressing the left and right keys. Pressing Enter acceptsthe changes and Escape aborts the changes.

PRESSURE UNITS: The pressure units can be adjustedbetween kPa/psi/bar. Use the left and right keys to select thepreferred pressure units. Pressing Enter accepts the newpressure units; pressing escape aborts the change inpressure units.

TEMPERATURE UNITS: The temperature units can be

adjusted between ºC and °F. Use the left and right keys toselect the preferred temperature units. Pressing Enteraccepts the change; pressing escape aborts the change.

VOLUME: Volume is used on some optional parameters(such as fuel consumption rate). It can be selected betweenLitres, US Gallons and Imperial Gallons using the left andright keys. Pressing enter accepts the new volume units;pressing escape aborts the change to the volume units.

DISPLAY LANGUAGE: The display language can beadjusted between the customer language and 'TechnicianEnglish'. 'Technician English' is a reduced version of thedisplay strings in English to facilitate factory testing andcommissioning. As it is not a complete set of display strings,it is not suitable for customer use.


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Figure 4.1 (a): Diagram of Typical LCP1 Control Panel

Figure 4.1 (b): Diagram of Typical LCP2 Control Panel

Figure 4.1 (c): Diagram of Typical PowerWizard Control Panel

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4.2 Functional Description LCP1 Control Systems

The LCP1 Control Systems provide for manual starting andstopping of the generating set and provide protection for theengine against both high engine temperature and low oilpressure.

4.2.1 Functions (LCP1): Section 5 of this manual providesdetailed guidance and checklists for the operation of thegenerating set. This section provides a more detaileddescription of the functions of the control system duringoperation.

WARNING:

! The Key Switch must not be turned to position“ ” (Thermostart) or “ ” (Crank) whi le theengine is running.

During start, turning the Key Switch through Position “ ”

(Run) to Position “ ” (Thermostart) activates thethermostart, if fitted. This preheats the induction air andshould be held for 7 seconds. Turning the Key Switch further

to position “ ” (Crank) provides power to the starter motorwhich cranks the engine. The starter motor will be disengagedwhen the Key Switch is released so it must be held in thisposition until the engine starts and then immediately released

and allowed to return to Position “ ” (Run).

Note:

Position “ ” is only used on generating sets with

turbocharged engines.To prevent overheating of the starter motor the engine shouldnot be cranked for more than 5 to 7 seconds. An interval of 10seconds should be allowed between start attempts. If theengine has not started after 4 attempts, refer to a qualifiedgenerating set technician.

Once the generating set is running properly, the electrical loadis applied to the set by switching the alternator output circuitbreaker to "ON" (handle in the up position).

When shutting down the generating set, the load should befirst turned off by switching the alternator output circuit breakerto "OFF" (handle down). This allows the engine to cool prior tostopping it. After a few minutes the Key Switch is turned toPosition "O" (Off) which shuts the generating set down.

In case of emergency where immediate shutdown is

necessary, the Key Switch should be turned to Position "O"(Off) immediately without first disconnecting the load.

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! If at any time the generating set stops because of afault, the fault should be rectified before trying to

restart the generating set.

ARNING

4.2.2 Protective Circuit s (LCP1): When high engine

temperature is sensed, the High Engine Temperature fault lamp illuminates and the generating set is automatically shutdown. The fault lamp will remain illuminated and the enginelocked out until the fault has been acknowledged and reset byturning the Key Switch to Position "O" (Off).

When low lube oil pressure is sensed the Low Oil Pressure

fault lamp illuminates and the generating set is

automatically shut down. Reset is effected by turning the KeySwitch to Position "O" (Off).

4.3 Functional Description LCP2 Control Systems

The LCP2 Control Systems provide for automatic starting andstopping of the generating set from a remote signal as well asmanual starting and stopping. This makes it appropriate forstandby generating systems. Protection is provided by thecontrol system against high engine temperature, low oilpressure, fail to start and overspeed.

4.3.1 Function (LCP2): Section 5 of this manual providesdetailed guidance and checklists for the operation of thegenerating set. This section provides a more detaileddescription of the functions of the control system duringoperation.

When the Control Switch is turned to Position “ ” (Run) or a

remote start signal is received with the Control Switch with the

Control Switch in Position “ ” (Auto), the control system will

initiate its automatic start sequence.

If the engine fails to fire after 3 start attempts then the FAIL TOSTART lamp will illuminate. Refer to a qualified generating settechnician to determine the cause of failure to start. Start will

be inhibited until the protection circuits of the control system

are reset by turning the Control Switch to Position “O” (Off).

Manually the generating set can be stopped at any time bypressing the Emergency Stop Pushbutton or by turning theControl Switch to Position “O” (Off). The set will alsoautomatically shutdown when the remote start signal isremoved.

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! If at any time the generating set stops because of afault, the fault should be rectified before trying torestart the generator.

ARNING:

4.3.2 Protective Circ uits (LCP2): When high enginetemperature is sensed, the High Engine Temperature fault lamp illuminates and the generating set is automatically shutdown. The fault lamp will remain illuminated and the enginelocked out until the fault has been acknowledged and reset by

turning the Control Switch to Position “O” (Off).

When low oil pressure is sensed, the Low Oil Pressurefault lamp illuminates and the generating set is automaticallyshut down. Reset is effected by turning the Control Switch toPosition “O” (Off).

Engine speed is monitored by the Overspeed circuit located inthe EIM Plus. When Engine overspeed is sensed the

Overspeed fault lamp illuminates and the generating setwill shut down. The fault lamp will remain illuminated and theengine locked out until the fault has been reset by turning the

Control Switch to Position “O” (Off). The OVERSPEEDfault lamp will also illuminate when the Emergency StopPushbutton has been pressed, even though an overspeed hasnot occurred.

The additional possible Shutdown circuits (not all available onall sets) include shutdown on:

Low Coolant Level (on water cooled engines)Low Fuel Level

The additional possible Alarm circuits (not all available on allsets) include alarms for:

Low Coolant Temperature (on water cooled engines)Low Fuel Level

4.4 Functional Description PowerWizard Control Systems

The PowerWizard Control Systems provide for automatic

starting and stopping of the generating set from a remotesignal as well as manual starting and stopping. This makes itappropriate for standby generating systems. Protection isprovided by the control system against high enginetemperature, low oil pressure, fail to start and overspeed.

4.4.1 Function (PowerWizard): Section 5 of this manualprovides detailed guidance and checklists for the operation ofthe generating set. This section provides a more detaileddescription of the functions of the control system duringoperation.

When the RUN key is pressed or a remote start signal isreceived with the module in AUTO mode, the control systemwill initiate its automatic start sequence.

If the engine fails to fire after 3 start attempts then the modulewill go into the shutdown mode as it has detected a FAIL TO

START. Refer to a qualified generating set technician todetermine the cause of failure to start. Start will be inhibiteduntil the FAIL TO START shutdown event has been reset.

Manually the generating set can be stopped at any time bypressing the STOP key. A COOLDOWN time will thencommence before the set will stop. The set will alsoautomatically stop when the remote start signal is removed.

Again, a COOLDOWN time will then commence before the setwill stop. The set will immediately stop by pressing theEmergency Stop Pushbutton.

WARNING:

! If at any time the generating set stops because of afault, the fault should be rectified before trying torestart the generator.

4.4.2 Protective Circui ts (PowerWizard): When high engine

temperature is sensed, the generating set is automatically shutdown. The RED SHUTDOWN LIGHT will begin to flash untilthe ACKNOWLEGE key is pressed. The RED SHUTDOWNLIGHT will stay on until the fault has been resolved on thegenerating set and the HIGH ENGINE TEMPERATUREshutdown event has been reset.

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8

When low oil pressure is sensed, the generating set isautomatically shut down. The RED SHUTDOWN LIGHT willbegin to flash until the ACKNOWLEGE key is pressed. TheRED SHUTDOWN LIGHT will stay on until the fault has beenresolved on the generating set and the LOW OIL PRESSUREshutdown event has been reset.

Engine speed is monitored by the speed sensor in the flywheel housing of the generating set. When overspeed issensed, the generating set is automatically shut down. TheRED SHUTDOWN LIGHT will begin to flash until the

ACKNOWLEGE key is pressed. The RED SHUTDOWNLIGHT will stay on until the fault has been resolved on the

generating set and the OVERSPEED shutdown event hasbeen reset.

The additional possible Shutdown circuits (not all available onall sets) include shutdown on:

Low Coolant Level (on water cooled engines)Low Fuel Level

The additional possible Alarm circuits (not all available on allsets) include alarms for:

Low Coolant Temperature (on water cooled engines)Low Fuel Level

4.5 Control System Options and Upgrades

A variety of options may be fitted to customise the controlsystem to a specific installation. The following sections coverthe use and operation of some of these options.

4.5.1 Battery Trick le Chargers: These chargers are designedto ensure that the starter batteries maintain their charge even ifthe generating set is not operated for long periods.

Control switches for the chargers are not normally fitted toprevent inadvertent switching off of the charger. The controlsystem will automatically disconnect the charger on startup ofthe generating set. While the engine is running the batteriesare charged by the engine driven battery charging alternator.

4.5.2 Heaters : In addition to conventional space heaters thatare useful in keeping the generating set warm and dry in coldor humid environments, two types of heater may be fitted onthe generating set.

For water cooled engines, immersion type heaters (engineheaters) may be fitted in the engine coolant system to ensurethat the engine is easy to start and able to take load more

quickly.Panel anti-condensation heaters (panel heaters) may be fittedin the control panel to keep moisture levels down.


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A KEY SWITCH / CONTROL SWITCH

A1 Off A3 Run

A2 Crank A4 Auto

B FAULT LAMPS

B1 Fail to Start B4 Overspeed

B2 High Engine Temperature B5 Other Shutdown Fault

B3 Low Oil Pressure

C PANEL

C1 AC Voltmeter C4 Battery Voltmeter

C2 AC Frequency Meter C5 Lamp Test Switch

C3 AC Ammeter

Figure 4.2: Legend of LCP1 and LCP2 Control Panel Symbols

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4.6 Control System Fault Finding/Troubl e Shooting Guide

LCP1/LCP2

FAULT SYMPTOM REMEDY

Engine Failsto Start(LCP1 Only)

Engine DoesNot Crankwhen KeySwitch Turnedto Position

“ ” (Crank)

1. Check operation of KeySwitch.2. Check no fault lampsilluminated. Reset, if required,after remedying indicated fault.3. Refer to a qualifiedgenerating set technician.

Engine Fails

to Start(LCP2 Only)

Engine Does

Not Crankwhen StartSignal Given,EitherManually ViaControl Switchor

AutomaticallyVia a RemoteSignal

1. Check all Emergency Stop

Pushbuttons are released(including any remote buttons).If no remote stop is used, havethe technician ensure "RemoteStop" terminals are linked.2. Check that Control Switch isnot off.3. Check no fault lamps areilluminated. Reset, if required,after remedying indicated fault.4. Refer to a qualifiedgenerating set technician.

10


Alarm for

Low FuelLevel(Optional

Alarm -LCP2 Only)

“Low Fuel

Level” Alarm LampIlluminates

1. Check fuel level in day tank.

Fill as necessary.2. Refer to a qualifiedgenerating set technician.

Alarm forLow CoolantTemp.(Optional

Alarm -LCP2 Only)

“Low CoolantTemp” AlarmLampIlluminates

1. Check that the immersionheaters are switched on andare operating.2. Refer to a qualifiedgenerating set technician.

No VoltageProducedWhenGeneratingSet is

Running(All controlsystems)

No Voltage On AC VoltmeterOr OnSeparateMeter

1. Check voltmeter selectorswitch is not in the OFFposition.2. Refer to a qualifiedgenerating set technician.

GeneratingSet DoesNot Go OnLoad(All controlsystems)

GeneratingSet is Runningbut the Load isNot BeingPowered

1. Check circuit breaker is ON(handle up).2. Refer to a qualifiedgenerating set technician.


GeneratingSet DoesNot StopManually

(All controlsystems)

GeneratingSet ContinuesRunning AfterBeing

Switched Off

1. Check Key Switch or ControlSwitch position, as appropriate.2. Check that the generatingset stops when the Emergency

Stop Pushbutton is depressed.3. Refer to a qualifiedgenerating set technician.

GeneratingSet DoesNot StopWhen In

Auto Mode(LCP2 Only)

GeneratingSet Does NotStop AfterRemote StartSignal isRemoved

1. Check that generating setstops when the EmergencyStop Pushbutton is depressedor the Control Switch is turnedoff.2. Refer to a qualifiedgenerating set technician.


Engine FailsTo Start(All controlsystems)

EngineCranks ButDoes NotFire OrEngineStarts ButStops After20 Seconds.(Fail To

StartFault LampIlluminateson LCP2Panel.)

1. Check fuel level.2. Check that Canopy ExternalEmergency Stop Pushbuttons, iffitted, are not depressed.3. Refer to a qualifiedgenerating set technician.

EngineStops Dueto HighEngineTemp.(All controlsystems)

High Engine

TempFault LampIlluminates

1. Check engine was notoverloaded.2. Check radiator obstructions.3. Refer to a qualifiedgenerating set technician.

EngineStops Dueto Low Oil

Pressure(All controlsystems)

Low OilPressure

Fault

Lamp Illuminates

1. Refer to a qualifiedgenerating set technician.


EngineStops DuetoOverspeed(LCP2 Only)

Overspeed

FaultLampIlluminates

Note: The OVERSPEED faultlamp will also illuminate after theEmergency Stop Pushbutton hasbeen depressed even thoughthere has been no overspeedcondition. The Emergency StopPushbutton and any remote stopbuttons must be released beforethe fault can be cleared.1. Refer to a qualified generatingset technician.

EngineStops Dueto LowCoolantLevel(OptionalShutdown -LCP2 Only)

“LowCoolantLevel” FaultLampIlluminates

1. Refer to a qualified generatingset technician.

EngineStops Dueto Low FuelLevel(OptionalShutdown -LCP2 Only)

“Low FuelLevel” FaultLampIlluminates

1. Check fuel level in day tank.Fill as necessary.2. Refer to a qualified generatingset technician.


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11

4.7 Control System Fault Finding/Troubl e Shooting Guide

PowerWizard Panels


Engine Failsto Start

Engine DoesNot Crankwhen StartSignal Given,EitherManually ViaRun Key or

Automatically

Via a RemoteSignal

1. Check all Emergency StopPushbuttons are released.2. Check that the Stop Light isnot on.3. Check no Shutdown eventsare active. Reset, if required,after remedying indicated fault.4. Refer to a qualified

generating set technician.


Alarm forLow FuelLevel(optional)

“Low FuelLevel”

Alarm in eventlog. AmberLEDIlluminates

1. Check fuel level in day tank.Fill as necessary.2. Refer to a qualifiedgenerating set technician.

Alarm forLow CoolantTemp.(optional)

“Low CoolantTemp” Alarmin event log.

Amber LEDIlluminates

1. Check that the immersionheaters are switched on andare operating.2. Refer to a qualifiedgenerating set technician.

No VoltageProducedWhenGeneratingSet isRunning

No Voltage On AC Sensingdisplay screen

1. Check AC sensing fuses F1- F32. Refer to a qualifiedgenerating set technician.

GeneratingSet DoesNot Go OnLoad

GeneratingSet is Runningbut the Load isNot BeingPowered

1. Check circuit breaker is ON(handle up).2. Refer to a qualifiedgenerating set technician.


GeneratingSet DoesNot StopManually

GeneratingSet ContinuesRunning AfterBeingSwitched Off

1. Check Stop key asappropriate.2. Check that the generatingset stops when the EmergencyStop Pushbutton is depressed.3. Check the Cooldown timerhas timed out.4. Refer to a qualifiedgenerating set technician.

GeneratingSet DoesNot StopWhen In

Auto Mode

GeneratingSet Does NotStop AfterRemote StartSignal isRemoved

1. Check that generating setstops when the EmergencyStop Pushbutton is depressedor the Stop key is held downfor 5 seconds and Cooldowntime is skipped.2. Refer to a qualifiedgenerating set technician.


Engine FailsTo Start

EngineCranks ButDoes NotFire OrEngineStarts ButStops After20 Seconds.

1. Check fuel level.2. Check that Canopy ExternalEmergency Stop Pushbuttons, iffitted, are not depressed.3. Refer to a qualified generatingset technician.

Engine

Stops Dueto HighEngineTemp.

High Engine

Temp inevent log.RedShutdownLEDIlluminates

1. Check engine was not

overloaded.2. Check radiator obstructions.3. Refer to a qualified generatingset technician.

EngineStops Dueto Low OilPressure

Low OilPressure inevent log.RedShutdownLEDIlluminates

1. Refer to a qualifiedgenerating set technician.


EngineStops DuetoOverspeed

Overspeedin event log.RedShutdownLEDIlluminates


EngineStops Dueto LowCoolantLevel(optional)

“LowCoolantLevel” inevent log.RedShutdownLEDIlluminates


EngineStops Due

to Low FuelLevel(optional)

“Low FuelLevel” in

event log.RedShutdownLEDIlluminates

1. Check fuel level in day tank.Fill as necessary.



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4.8 Load Transfer Panels

When the generating set is installed to automatically providestandby power in the event of mains failure, a load transferpanel is required. This transfer panel is designed to sense whenthe mains have failed, signal the generating set to start, switchthe load from the failed mains to the generating set and thenswitch it back after the mains are re-established. SeeFigure 4.3

Figure 4.3: Function of a Load Transfer Panel

A choice of load transfer panels is offered. Please refer to theCTI manual for full details on the CTI Transfer Sytem.

4.8.1 ATI Intelligent Load Transfer Panel: The ATI IntelligentLoad Transfer Panel is designed to work with the LCP2 andPowerWizard Autostart Control Systems to form an automaticmains failure system.

Status Panel: The front of the door has the status panel and

main control switch. This status panel has four indicator LEDsas shown in Figure 4.4. Pressing the Lamp Test Button willilluminate these indicator LEDs.

Item Description

1. “Mains Available” Status LED2. “Mains on Load” Status LED3. “Generator on Load” Status LED4. “Generator Available” Status LED5. No Generator or mains on Load Status LED

Figure 4.4: ATI Series Load Transfer Panel Status Display

Controls: The test key on the front panel has three modes:-

AUTOMATIC MODE - The normal position for automaticoperation.

TEST WITHOUT LOAD - For testing the generating set withoutconnecting the load.

TEST WITH LOAD - For testing the generating set with the loadconnected.

WARNING:

! Internal maintenance should only be carried out bytrained personnel due to the high voltages presentinside the enclosure.

The ATI series Load Transfer Panel operates as follows:

On mains failure, the generating set is automatically started andthe switch transfers to connect the load to the generator.

On restoration of mains power, the load is transferred back tothe mains. After a cool down period, the generating set isautomatically shut down.

Manual Retransfer Function : If enabled, this allows theoperator to manually control the timing of the retransfer of theload from the generating set to the restored mains supply. Thecontrol is a simple push button on the ATI control module.

With the Manual Retransfer function enabled or disabled, on

mains failure the generating set will start and accept load in thenormal sequence. With the Manual Retransfer Functiondisabled, the load will be automatically retransferred back to themains when available as described above.

With the Manual Retransfer function enabled, on restoration ofthe mains, the “Mains Available” indicator will illuminate but thegenerator will continue to supply load. When it is convenient for

retransfer to take place, the operator presses the RetransferButton which causes the load to be transferred back to themains and, after a cool down period, automatically shuts downthe generator.

4.8.2 TC Compact Load Transfer Panel: The TC CompactLoad Transfer Panel is designed to work with the AutostartControl Systems (LCP2) to form an automatic mains failuresystem.

Status Panel and Controls: The status panel has twoindicator lamps. They show that the load is either connected tothe mains supply or to the generating set. The controls consistof a Mode Selector Switch with three positions:-

AUTOMATIC MODE - The normal position for automaticoperation.

TEST WITHOUT LOAD - For testing the generating set withoutconnecting the load.

TEST WITH LOAD - For testing the generating set with the loadconnected.

The TC Series Load Transfer Panel operates as follows:

On mains failure the generating set is automatically started andthe contactors closed to connect the load to the generator.

On restoration of mains power the load is transferred back tothe mains and the generating set is shutdown.

4.9 Engine Interface Module Description

The Engine Interface Module is a sealed, engine mountedmodule that provides switching relays for the Starter MotorSolenoid, Glow Plug (only on turbocharged generating sets) andFuel Solenoid. Each of these circuits is protected withindividual fuses mounted in the module. Individual LED’silluminate when each circuit is energised.

Item Description Item Description1. Glow Plug Symbol 8. Secondary Socket2. Fuel Symbol 9. Starter Solenoid Fuse3. Fuel Solenoid Fuse 10. Starter LED4. Fuel LED 11. Overspeed Set-up LED

5. Main Connector Socket 12. Overspeed Adjuster6. Glow Plug Fuse 13. Starter Symbol7. Glow Plug LED

Figure 4.5: Engine Interface Module

There are two versions of the Engine Interface Module available- EIM Basic and EIM Plus.

EIM Basic: The EIM is utilised in conjunction with the LCP1Keystart panel/PowerWizard Autostart panels. It consists ofthree relays to carry currents associated with the Fuel ControlSolenoid, Starter Motor Solenoid and the Glow Plug. Themodule is powered directly from the battery.

EIM Plus: The EIM Plus is used in conjunction with the LCP2 Autostart Panel and occasionally with the LCP1 Keystart panel.It consists of the same three relays as above plus circuitry tomonitor engine speed via a magnetic pick-up mounted on theengine flywheel housing and to set the Overspeed Trip Point.The module is powered directly from the battery. The EIM Plusmonitors the speed signal from the magnetic pick-up. If theengine speed rises above a certain pre-settable value, themodule sends a zero volt signal to the generating set controlpanel to activate the Overspeed Fault circuitry.

4.10 Output Circu it Breaker Description

The alternator output circuit breaker is a miniature case circuitbreaker (MCB) of sufficient rating for the generating set output.Electrical output is switchable through this device, with “ON”being indicated by the handle being up. The breaker will carryits rated current continuously but will trip to off-position if therating on any one phase is exceeded for a period depending onthe percentage overload and the circuit breaker characteristics.

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5. OPERATION

5.1 General

The generating set is equipped with an electronic controlsystem. This will be one of a range of systems such as thePowerwizad, LCP1 or LCP2 control system. See Section 4 ofthis manual to identify which system is fitted on the generatingset and for a functional description of each.

These control systems allow the operator to manually orautomatically control the generating set. They have protectioncircuits to detect an alarm fault or shut down the set if problemsoccur. Details of the capabilities of each system are containedin Section 4. The LCP1/LCP2 control panels use symbolsinstead of words to describe the functions of the controls andlamps. Figure 4.2 gives a legend for each of the possiblesymbols.

The following procedures detail the steps required to preparethe set for operation and start and stop it normally. A qualifiedgenerating set technician should start the set for the first timeafter installation or after the set has been out of service for atime for maintenance purposes. Section 5.2, Pre-Start Checksare applicable with all control systems. Section 5.3 coversoperation of the LCP1 Keystart Control Systems. Sections 5.4,and 5.5 cover operation of the LCP2 Series Autostart ControlSystems. Section 5.6 and 5.7 cover operation of thePowerWizard series Autostart control systems.

5.2 Pre-Start Checks (applicable to all control systems)The following checks should be performed prior to starting thegenerating set:

WARNING:

! As generating sets with autostart control panels(PowerWizard/LCP2) can be remotely started withoutwarning, always ensure the control panel is switched

off before carrying out any checks.

19. Ensure the Control Switch/Key Switch is Off on theLCP1/LCP2 Panels.

Or

The Stop Key is activated on the PowerWizard Panel.

WARNING:

! Do not remove the radiator cap on water cooledengines when the coolant is hot. Do not add large

amounts of cold coolant to a hot system as seriousdamage could result.

Note:

Diesel engines normally consume lube oil at a rate of .25%to 1% of the fuel consumption.

2. Check the engine oil and coolant levels (water cooledengines) - replenish as necessary.

WARNING:

! When fill ing the fuel tank, do not smoke or use anopen flame in the vicinity.

3. Check the fuel level - fill as necessary.

WARNING:

! Before adjusting fan and alternator belts disconnectthe battery negative (-) lead.

4. Check the condition and tension of the fan and enginealternator belts - tighten as necessary.

5. Check all hoses for loose connections or deterioration -tighten or replace as necessary.

6. Check the battery terminals for corrosion - clean asnecessary.

WARNING:

! When work ing wit h the batteries, do not smoke or usean open flame in the vicinity. Hydrogen gas from

batteries is explosive.

! Do not short the posit ive and negative terminalstogether.

7. Check the battery electrolyte level - fill with distilled wateras necessary.

8. Check the control panel and the generating set for heavyaccumulation of dust and dirt - clean as necessary.These can pose an electrical hazard or give rise to coolingproblems.

9. Check the air filter restriction indicator, if fitted - replacethe filter as necessary.

10. Clear the area around the generating set of any insecureitems that could inhibit operation or cause injury. Ensurecooling air ventilation screens are clear.

11. Visually check the entire generating set for signs of leaksfrom the fuel system, cooling system or lubrication seals.

12. Periodically drain exhaust system condensate traps, ifequipped.

13. Ensure the Alternator Output Circuit Breaker is in the"OFF" (handle down) position.

5.3 Normal Startup/Shutdown - LCP1 Keystart Panel

The following procedure should be used for normal starts on agenerating set equipped with an LCP1 Keystart Control System:

Note:

The generating set may be stopped at any time by pushingthe Emergency Stop Pushbutton or turning the Key Switchto Position "O" (Off).

1. Complete Pre-Start checks as per Section 5.2.

2. Check the battery voltage by turning the keyswitch from

Position “O” (Off) to Position “ ” (Run) and reading thebattery voltmeter. A fully charged battery will indicate 12to 14 volts. Return the keyswitch to Position “O” (Off).

Note:

The engine will not start if any fault indicators areilluminated. Reset the control system by turning the KeySwitch to Position "O" (Off). Ensure the faults have beencorrected prior to attempting to start the generating set.

WARNING:

! The Key Switch must not be turned to pos it ion “ ”(Thermostar t) or “ ” (Crank) while the engine isrunning.

3. Start: Turn the Key Switch from Position "O" (Off) through

Position “ ” (Run) to Posit ion “ ” (Thermostart) toactivate the thermostart, if fitted. Hold for 7 seconds topreheat the induction air. After this time, the Key Switch

should be further turned to Position “ ” (Crank) to crankthe engine. When the engine starts, release the Key

Switch immediately allowing it to return to Position “ ”(Run).

Note:

Position “ ” is only used on generating sets withturbocharged engines.

Do not crank the engine for more than 5 to 7 secondsshould the engine fail to start. Allow an interval of 10seconds and always turn the Key Switch fully off (Position“O”) between cranking attempts. If, after 4 crankingattempts, the engine still has not started, refer to the troubleshooting guide in Section 4 or the Engine Manual todetermine the cause of failure to start.

WHEN ENGINE HAS STARTED

4. Check for any abnormal noise or vibration.

5. Check for fluid leakage or leaks in the exhaust system.

6. Switch the Alternator Output Circuit Breaker to "ON"(handle up).

7. Shutdown: To shut the generating set down, turn off theload by switching the Alternator Output Circuit Breaker to

"OFF" (handle down). Allow the generating set to runwithout load for a few minutes to cool. Then turn the KeySwitch to Position "O" (Off). The generating set willshutdown.

In case of an emergency where immediate shutdown isnecessary, the Key Switch should be turned to Position"O" (Off) immediately without disconnecting the load.

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Note:

Turning the Key Switch to Position "O" (Off) will also resetthe protective circuits after a fault has been detected.Ensure that the fault has been rectified prior to restartingthe generating set.

5.4 Normal Manual Startup/Shutdown - LCP2 Autostart Panels

The following procedure should be used for normal manualstarts on a generating set equipped with an LCP2 AutostartControl System:

Note:

The generating set may be stopped at any time by pushingthe Emergency Stop Pushbutton or turning the ControlSwitch to Position “O” (Off).

Pressing the Emergency Stop Pushbutton also illuminates

the Overspeed “ ” fault lamp even though anoverspeed has not occurred. Prior to restarting the set,the Emergency Stop Pushbutton must be released byturning it clockwise. The fault lamp must also be reset by



Note:

The engine will not start if any fault indicators areilluminated. Reset the control system by turning the Key

Switch to Position "O" (Off). Ensure the faults have beencorrected prior to attempting to start the generating set.

2. Manual Start: Ensure the Emergency Stop Pushbutton andany remote Stop Pushbuttons are released.

For Turbocharged engines only: If the engine is cold, prior

to turning the Control Switch to Position “ ” (Run) push in

the Thermostart pushbutton labelled “ ” and hold for15 seconds.

Turn the Control Switch to Position “ ” (Run).

The engine will automatically crank up to 3 times or until theengine fires. If the engine does not fire, the control systemlocks-out on "Fail to Start" and illuminates a fault lamp on

the control panel. If this happens refer to the troubleshooting guide in Section 4.5 or a qualified generating settechnician to determine the cause of failure to start.


3. Check for any abnormal noise or vibration.

4. Check for fluid leakage or leaks in the exhaust system.

5. Check the control panel for indications of abnormaloperation, particularly abnormally high temperature orabnormally low oil pressure, when engine gauges havebeen fitted. The oil pressure should be in the normalrange within about 10 seconds of starting.


7. Shutdown: To shut the generating set down, turn off theload by switching the Alternator Output Circuit Breaker to"OFF" (handle down). Allow the generating set to runwithout load for a few minutes to cool. Then turn theControl Switch to Position “O” (Off). The generating setwill shutdown.

In case of an emergency where immediate shutdown isnecessary, the Emergency Stop Button should be pushedimmediately without disconnecting the load.

5.5 Automatic Startup/Shutdow n - LCP2 Autostart Panels

The following procedure should be used for preparing agenerating set equipped with an LCP2 Autostart Control Systemto be started from a remote location.

Note:

The generating set may be stopped at any time by pushingthe Emergency Stop Pushbutton or turning the Control

Switch to Position “O” (Off).

Pressing the Emergency Stop Pushbutton also illuminates

the Overspeed “ ” fault lamp even though anoverspeed has not occurred. Prior to restarting the set,the Emergency Stop Pushbutton must be released by

turning it clockwise. The fault lamp must also be reset by



Note:

The engine will not be able to start if any fault indicatorsare illuminated. Reset the control system by turning the

Control Switch to Position “O” (Off). Ensure the faultshave been corrected prior to attempting to start thegenerating set.

2. Automatic Start : Ensure the Emergency Stop Pushbuttonand any remote Stop Pushbuttons are released.

Turn

the Control Switch to Position “ ” (Auto).


The generating set is now ready to automatically start when itreceives a remote start signal. When the start signal isremoved it will automatically stop.

5.6 Normal Manual Startup/Shutdown - PowerWizard AutostartPanels

The following procedure should be used for normal manualstarts on a generating set equipped with an PowerWizard

Autostart Control System:

Note:

The generating set may be stopped at any time by pushingthe Emergency Stop Pushbutton or holding down the

STOP key for 5 seconds on the module and selecting the‘SKIP COOLDOWN’ option by pressing the ENTER key.

Prior to restarting the set, the EMEGENCY STOP faultmust be reset by pressing the STOP key on the moduleand resetting the fault in the ‘event log’.


Note:

The engine will not start if any shutdown fault has not beenreset in the module. The ‘event log’ is the menu to resetfaults. Ensure the faults have been corrected prior toattempting to start the generating set.

2. Manual Start: Ensure the Emergency Stop Pushbutton andany remote Stop Pushbuttons are released.

If the Engine is cold then it is recommended to activate theglow plugs before the engine is started. This will beactivated automatically for the pre-set time when the RUNkey is pressed.

After the glow plug time has exceeded the engine willautomatically crank up to 3 times or until the engine fires. Ifthe engine does not fire, the control system locks-out on“Fail to Start” and this will activate the FAIL TO STARTshutdown in the module. If this happens refer to the troubleshooting guide in section 4.7 or a qualified generating settechnician to determine the cause of failure to start.


3. Check for any abnormal noise or vibration.4. Check for fluid leakage or leaks in the exhaust system.

5. Check the control panel for indications of abnormaloperation, particularly abnormally high temperature orabnormally low oil pressure. Pressing the ENGINEOVERVIEW key will display these readings. The oilpressure should be in the normal range within 10 secondsof starting.


7. Shutdown: To shut the generating set down, turn off theload by switching the alternator Output Circuit Breaker to

“OFF” (handle down). Press the STOP key and this willactivate the COOLDOWN timer to allow the generating setto cool without load. After the COOLDOWN timer hastimed out the engine will stop. The COOLDOWN timercan be bypassed by holding the STOP key for 5 secondsthen selecting the option to SKIP COOLDOWN bypressing the ENTER key.

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In case of an emergency where immediate shutdown isnecessary, the Emergency Stop Button should be pushedimmediately without disconnecting the load.

Battery acid can burn clothing and skin and even causeblindness if it leaks, so wear protective clothing when inspectinga battery prior to its disconnection / transportation

5.7 Automatic Startup/Shutdown - PowerWizard Autostart

Panels Disconnect the battery safely before inspecting it (see below)

Before removing a battery, carry out a thorough inspection of itscondition. Use a torch if visibility is poor to check all sides of thebattery for any marks, dents or leaks

The following procedure should be used for preparing agenerating set equipped with an PowerWizard Autostart ControlSystem to be started from a remote location.

If the battery has any severe dents or leaks then contact aprofessional battery engineering service for assistance and get

it repaired or replaced, do not attempt to remove it

Note:

The generating set may be stopped at any time by pushingthe Emergency Stop Pushbutton or holding down theSTOP key for 5 seconds on the module and selecting the‘SKIP COOLDOWN’ option by pressing the ENTER key.

During transport, cover the terminals so they cannot be shortedout

Prior to restarting the set, the EMEGENCY STOP faultmust be reset by pressing the STOP key on the moduleand reseting the fault in the ‘event log’.

Keep the battery upright at all times

When removing a battery for whatever reason always ensure allload is removed before disconnecting the battery so that nosparks are created. Disconnect the negative cable first followedby the positive cable to avoid short circuit against any metalframework, then remove the hold down clamp or strap securingthe battery base. The battery can be fairly heavy so be carefulwhen lifting and carrying the battery. Seek assistance ifrequired.


Note:

The engine will not start if any shutdown fault has not beenreset in the module. The ‘event log’ is the menu to resetfaults. Ensure the faults have been corrected prior toattempting to start the generating set.

2. Automat ic Start: Ensure the Emergency Stop Pushbuttonand any remote Stop Pushbuttons are released. Press the

AUTO key on the module.

When refitting the battery, ensure the terminal posts are

correctly aligned with the cables to avoid wrong connection andplace the new battery into the hold-down tray and re-attach thehold-down clamp or strap. Attach and tighten the positivebattery cable to the positive terminal first. Then attach andtighten the negative battery cable to the negative terminal.


The generating set is now ready to automatically start when itreceives a remote start signal. When the start signal isremoved it will automatically stop after the cooldown period.

6. MAINTENANCE

A good maintenance programme is the key to long generating setlife. Maintenance and service should only be carried out byqualified technicians. Records of this work should be kept to aid indeveloping an efficient maintenance programme.

In general, the generating set should be kept clean. Do not permitliquids such as fuel or oil film to accumulate on any internal orexternal surfaces or on, under or around any acoustic material, iffitted. Wipe down surfaces using an aqueous industrial cleaner. Donot use flammable solvents for cleaning purposes.

Any acoustic material with a protective covering that has been tornor punctured should be replaced immediately to preventaccumulation of liquids or oil film within the material.

Refer to a qualified generating set technician for details of requiredpreventative maintenance.

6.1 Battery Removal and Fitti ng

Batteries, as used in generators, by law, must not be disposed of

with household waste.

Batteries contain hazardous materials and in the charged state,each cell contains electrodes of lead metal (Pb) and lead (IV)dioxide (PbO2) in an electrolyte of about 33.5% w/w (6 Molar)sulphuric acid (H2SO4). In the discharged state both electrodes turninto lead(II) sulfate (PbSO4) and the electrolyte loses its dissolved

sulphuric acid and becomes primarily water.

It can be damaging to the environment to send these to landfill,burning batteries can also cause atmospheric pollution.

Dealing with lead acid batteries can be hazardous so it is importantto follow all safety guidelines.

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HAZARD LABELS

Some or all of these hazard warning labels will appear on your generating set:

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INDEX

Ammeter ............................................................................................... 4Battery Trickle Chargers ....................................................................... 8Battery Voltmeter .................................................................................. 4Circuit Breaker...................................................................................... 8Control Switch....................................................................................... 4Control System ..................................................................................... 4

LCP1 Panel ...................................................................................... 4LCP2 Panels .................................................................................... 4PowerWizard Panels........................................................................ 4

Electric Shock....................................................................................... 2Emergency Stop............................................................................... 4, 5Engine Interface Module.....................................................................12Fault Finding................................................................................. 10, 11Fault Lamps...................................................................................... 4, 5First Aid................................................................................................. 2Frequency Meter................................................................................... 4Heaters ................................................................................................. 8Hours Run Meter .................................................................................. 4Key Switch ............................................................................................ 4Load Transfer Panels ......................................................................... 12Maintenance ....................................................................................... 15Panel Equipment .................................................................................. 4Pre-Start Checks ................................................................................ 13

Rating Label ..........................................................................................3Safety ....................................................................................................1

Chemical...........................................................................................1Electrical ...........................................................................................1Fire and Explosion ............................................................................1Handling............................................................................................1Installation.........................................................................................1Mechanical........................................................................................1Noise.................................................................................................1Towing ..............................................................................................1

ShutdownLCP1 Panel.....................................................................................13LCP2 Panel.....................................................................................14PowerWizard Panels ......................................................................14

StartupLCP1 Panel.....................................................................................13LCP2 Panel.....................................................................................14PowerWizard Panels ......................................................................14

TC Compact Load Transfer Panel.......................................................12Glow Plugs ............................................................................................3

ATI Intelligent Load Transfer Panel.....................................................12Trouble Shooting ...........................................................................10, 11Voltmeter...............................................................................................4

277 697 400 series opman english

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