manual 800 kva

Document No.: M02.0210 Document Title: USER MANUAL NHC20 / QST30G2 Issue: F Date: 01/02/2007

USER MANUAL FOR

NHC20/QST30G2 Standard & Stackable Document M02.0210


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TABLE OF CONTENTS

1.0 SAFETY 1.1. GENERAL INFORMATION.....................................................................................................1 1.2. ELECTRICAL POWER ...........................................................................................................1 1.3. MATERIALS............................................................................................................................1 1.4. OPERATIONAL PRECAUTIONS ...........................................................................................1 1.5. SAFETY LABELS ...................................................................................................................2

2.0 NOISE EMISSION 2.1. NOISE CONTROL PROHIBITED ACTS.................................................................................4 2.2. GENERATOR NOISE EMISSION CONTROL INFORMATION .............................................4

3.0 HANDLING 3.1. LIFTING / HANDLING.............................................................................................................5 3.2. STORAGE / TRANSPORT .....................................................................................................5

4.0 INSTALLATION 4.1. UNPACKING...........................................................................................................................6 4.2. LOCATION OF THE PLANT...................................................................................................6 4.3. COMMISSIONING...................................................................................................................6 4.4. PRIOR TO STARTING............................................................................................................6 4.5. ELECTRICAL CONNECTION.................................................................................................6 4.6. EARTHING..............................................................................................................................6 4.7. REMOTE FUELLING ..............................................................................................................7

5.0 GENERAL DATA 5.1. GENERAL OPERATION.........................................................................................................8 5.2. DESIGN LOAD CAPACITY ....................................................................................................8 5.3. DESIGN TEMPERATURES ....................................................................................................8 5.4. CONTAINER & BASE FRAME...............................................................................................8 5.5. DIESEL ENGINE.....................................................................................................................9 5.6. ENGINE LUBRICATION SYSTEM .........................................................................................9 5.7. ENGINE COOLING SYSTEM .................................................................................................9 5.8. ENGINE FUEL SYSTEM.........................................................................................................9 5.9. EXHAUST SYSTEM..............................................................................................................10 5.10. ENGINE CONTROL SYSTEM ..............................................................................................10 5.11. GENERATOR........................................................................................................................10 5.12. MAIN CIRCUIT BREAKER ...................................................................................................10

6.0 OPERATING INSTRUCTIONS 6.1. OPERATING CONTROLS AND INSTRUMENTS................................................................14


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6.2. PRIOR TO START ................................................................................................................23 6.3. STARTING ............................................................................................................................23 6.4. LOADING ..............................................................................................................................23 6.5. SHUT-DOWN ........................................................................................................................23 6.6. AUTO OPERATION (OPTIONAL) ........................................................................................23

7.0 MAINTENANCE 7.1. GENERAL .............................................................................................................................24 7.2. MAINTENANCE SCHEDULE ...............................................................................................25 7.3. DAILY MAINTENANCE ........................................................................................................26 7.4. WEEKLY MAINTENANCE....................................................................................................27

8.0 LUBRICATION 8.1. GENERAL INFORMATION...................................................................................................28 8.2. GENERATOR OIL CHANGE ................................................................................................28 8.3. OIL SPECIFICATION............................................................................................................28

9.0 TROUBLE SHOOTING 9.1. INTRODUCTION ...................................................................................................................29 9.2. ACTION PLAN ......................................................................................................................29 9.3. TROUBLE SHOOTING CHART ...........................................................................................30

Note Appendix Sections C and F below for non CSA Approved units. See User manual M020225 for relevant Appendix Sections C and F for 480V and 600V CSA Approved units. APPENDIX A: Material Safety Data Sheets APPENDIX B: Operating Instruction Sheet APPENDIX C: Equipment Data Sheet Document No. Rev.

G080275 SHT. 1 to 3 B APPENDIX D: Installation Outline Drawings Drawing No. Rev.

A050001 SHT. 1 of 3 B Standard A050001 SHT. 2 of 3 B Standard A050001 SHT. 3 of 3 B Standard A050210 SHT 1 of 4 A Stackable A050210 SHT 2 of 4 A Stackable A050210 SHT 3 of 4 A Stackable A050210 SHT 4 of 4 A Stackable APPENDIX E: Control Panel Layout Drawing No. Rev.

D210633 SHT. 1 of 1 A


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APPENDIX F: Electrical Schematics Drawing No. Rev. Title

D080771 SHT. 1 of 8 C Electrical Schematic for Main Circuit Diagram D080771 SHT. 2 of 8 C Electrical Schematic for Generator Bus Bar Connections D080831 SHT. 3 of 8 C Electrical Schematic for Circuit Breaker Control D080771 SHT. 4 of 8 I Electrical Schematic for Cooling Fan(s) Schematic D080771 SHT. 5 of 8 D Electrical Schematic for Change Over Panel D080846 SHT. 6 of 8 A Electrical Schematic for Synchronising-Measuring-Load Control D080846 SHT. 7 of 8 B Electrical Schematic for Engine ECM Interface D080846 SHT. 8 of 8 B Electrical Schematic for Engine Safeties Wiring Diagram APPENDIX G: Earth Leakage Option ($Option382A) APPENDIX H: Livery Layout Drawing No. Rev.

D200090 SHT. 1 of 1 A APPENDIX J: Manufacturers Component Data Document No. Rev.

M040107 SHT. 1 of 1 B APPENDIX K: Container Certificate GB-LR 60515 – 07/04 (Standard) Container Certificate BVCT 0681050/S (Stackable) APPENDIX L: DNV Spark Arrestor Certificate – M-10408 APPENDIX M Declaration of Conformity APPENDIX N: International Contact Information


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1.0 SAFETY 1.1. GENERAL INFORMATION

• Ensure that the operator reads and understands the decals and consults the manuals before maintenance or operation.

• Ensure that the Operation and Maintenance manual, and the manual holder, are not removed permanently from the machine.

• Ensure that maintenance personnel are adequately trained, competent and have read the Maintenance Manuals.

• Make sure that all protective covers are in place and that the container doors are closed during operation.

• The specification of this machine is such that the machine is not suitable for use in flammable gas

risk areas. WARNING: NO ATTEMPT SHOULD BE MADE TO OPERATE IN SUCH AREAS WITHOUT THE EXPRESS AUTHORITY FROM AGGREKO.

• Installation of this generator must be in accordance with recognised electrical codes and any local Health and Safety Codes.

1.2. ELECTRICAL POWER • Prior to installation of the generating set you should check that the electrical load to be applied is

within the rated output of the machine at the site ambient conditions.

• Before carrying out any maintenance or repairs to the Engine/Alternator assembly disconnect the starting battery and isolate the alternator from the switchboard.

• Before carrying out any maintenance repair to the AC and DC circuits, isolate these from external control panel and power supplies.

• Ensure that the generator set and the load it is connected to be properly earthed.

• The generating set should be connected to the load only by a qualified electrician and in accordance with the applicable regulations.

1.3. MATERIALS The following substances are used in the manufacture of this machine and may be hazardous to health if used incorrectly:

• Antifreeze

• Engine Lubricating Oil

• Preservative Grease

• Rust Preventative

• Diesel Fuel

• Battery Electrolyte.

AVOID INGESTION, SKIN CONTACT AND INHALATION OF FUMES.

When handling fuel, lubricating oil, cooling fluid and battery electrolyte, wear appropriate personal protection equipment.

For further information, consult Material Safety Data Sheet contained in this manual.

Avoid build-up of Engine Exhaust Fumes in confined spaces.

Avoid breathing Exhaust Fumes.

1.4. OPERATIONAL PRECAUTIONS Never operate unit without first observing all safety warnings and carefully reading the operation and maintenance manual shipped from the factory with this machine.

IF IN DOUBT CONTACT AGGREKO.


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DANGER FIRE RISK

DO NOT STAND IN FRONT OF ALTERNATOR AIR

OUTLETS WHEN UNIT IS RUNNING

Never operate the engine of this machine inside a building without adequate ventilation. Avoid breathing exhaust fumes when working on or near the machine. Do not alter or modify this machine.

A battery contains sulphuric acid and can give off gases, which are corrosive and potentially explosive. Avoid contact with skin, eyes and clothing. In case of contact, flush area immediately with water.

Exercise extreme caution when using booster battery. To jump battery, connect ends of one booster cable to the positive (+) terminal of each battery. Connect one end of other cable to the negative (-) terminal of the booster battery and other end to a ground connection away from dead battery (to avoid a spark occurring near any explosive gases that may be present). After starting unit, always disconnect cables in reverse order.

Never operate unit without first observing all safety warnings and carefully reading the operation manual.

This machine may include such materials as oil, diesel fuel, antifreeze, brake fluid, oil/air filters and batteries which may require proper disposal when performing maintenance and service tasks. Contact local authorities for proper disposal of these materials.

This machine produces loud noise with the doors open. Extended exposure to loud noise can cause hearing loss. Always wear hearing protection when doors are open.

Never inspect or service unit without first disconnecting battery cable(s) or using the battery isolator switch to prevent accidental starting.

Do not remove the pressure cap from a HOT radiator. Allow radiator to cool down before removing pressure cap.

Do not use petroleum products (solvents or fuels) under high pressure as this can penetrate the skin and result in serious illness. Wear eye protection while cleaning unit with compressed air to prevent debris from injuring eye(s).

Hot pressurized fluid can cause serious burns. Do not open radiator while hot.

Rotating fan blade can cause serious injury. Do not operate without guard in place.

Use care to avoid contacting hot surfaces (engine exhaust manifold and piping, etc.).

Never operate unit with guards, covers or screens removed. Keep hands, hair, clothing, tools, etc. well away from moving parts.

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

(Risk of electric shock)


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DISCONNECT STARTING BATTERY AND ISOLATE

LOAD BEFORE WORKING ON ENGINE /

ALTERNATOR ASSEMBLY

CAUTION Hot


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2.0 NOISE EMISSION 2.1. NOISE CONTROL PROHIBITED ACTS

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

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

Or

2) The use of the generator after such device or element of design has been removed or rendered inoperative by any person.

Among those acts included in the prohibition against tampering are these:

• Removal or rendering inoperative any of the following:

a) The engine exhaust system or parts thereof.

b) The air intake system or parts thereof.

c) Enclosure or parts thereof.

• Removal of any of the following:

a) Fan shroud

b) Vibration mounts

c) Sound absorption material

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

2.2. GENERATOR NOISE EMISSION CONTROL INFORMATION A. The removal or rendering inoperative, other than for the purpose of maintenance, repair, or

replacement of any noise control device or element of design incorporated into this generator in compliance with the noise control act;

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

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

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

OPERATING GENERATOR SET.

WARNING


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3.0 HANDLING 3.1. LIFTING / HANDLING

• The generator set is enclosed in a standard size ISO 20ft container with integrated lifting forgings on the corners.

• All lifting and handling equipment must be adequately rated for applicable weights.

• During all lifting and handling operations the following weights must be considered.

Complete Package Max. Fuel 17216 kgs (37954 lbs)

Complete Package Without Fuel 16000 kgs (35274 lbs)

• The generator set is fitted with integral stepladders on the container front cargo doors & side.

• Ensure that the correct lengths of strop / wire rope is used to ensure a level lift. Also ensure that the included angle does not exceed 90°.

CAUTION: THE GENERATOR SET SHOULD NOT BE DRAGGED.

3.2. STORAGE / TRANSPORT • Carry out the following points before transporting the generator or preparing the generator for

storage.

• Open the battery isolator switch.

• Empty the fuel tank (in case of overseas transport).

• Disconnect the battery terminals (in case of overseas transport).

• Close all fuel valves.

• Seal the remote fuel connection with a blind stop.

• Ensure that the radiator cap is fitted securely and the exhaust rain cap is closed.

• Close all doors.

All units are to be loaded flat onto transport and properly secured.


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4.0 INSTALLATION 4.1. UNPACKING

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

4.2. LOCATION OF THE PLANT The generator can be installed on any solid, flat and level surface capable of supporting the full operating load of the package. A dry, well-ventilated area where the atmosphere is as clean as possible is recommended. Ensure that the machine is positioned securely and on a stable foundation.

CAUTION: A minimum of 3 metres (9 ft) all round the generator is recommended. Hot air will exit from the roof outlet. It is important that this hot air does not re-circulate to the package inlet.

The generator must be allowed sufficient space all round and above, to enable the effective removal of the cooling air which, in turn, will reduce the risk of re–circulating the cooling air back through the generator. Adequate clearance needs to be allowed around and above the machine to permit safe access for specified maintenance tasks. Hard surfaces may reflect noise with an apparent increase in the decibel level. It is recommended that provision be made for lifting heavy components during major overhaul.

NOTE: When operating at elevated altitude please refer to engine manufacturer’s guidelines for power deration.

4.3. COMMISSIONING Upon receipt of the unit, and prior to putting it into service, it is important to adhere strictly to the instructions given below in section 4.4 PRIOR TO STARTING.

• Ensure all persons concerned are suitably competent with generator installations.

• Ensure that the operator reads and understands the decals and consults the manuals before maintenance or operation.

• Ensure that the position of the emergency stop device is known and recognised by its markings. Ensure that it is functioning correctly and that the method of operation is known.

4.4. PRIOR TO STARTING • Ensure that the unit is clean, free from debris and fluids. All connections, joints, seals must be

correctly fitted and tightened. All filters, louvers and air inlets are free and open.

• Ensure that there is a safe working procedure which has been issued by supervisory personnel, and that all persons concerned with the operation of the generator understand it.

• Ensure that the safety procedure to be applied is based on the appropriate national and local regulations.

• Ensure that the safety procedure is followed at all times.

4.5. ELECTRICAL CONNECTION • A suitably trained electrician should carry out all electrical connections.

• Ensure the generator main isolator is off and that the power cables are in good condition.

• Ensure that the phases are correct after the cables have been connected.

• Ensure all safety covers are back in place after electrical connection is complete.

4.6. EARTHING An external earthing boss is fitted onto the container at each corner of the set. This allows a dedicated earthing connection if required.


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

• One 1” Female Connector (supply)

• One ½” Female Connector (Return)

The fuel connections for external supply are located on the side of the container.


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5.0 GENERAL DATA NOTE: Each generator of this type is uniquely identified by a Plant Number and Serial Number indicated on the identification plate affixed to the outside of the control panel. This information is required when ordering spare parts. Major component serial numbers are contained within the manual.

The technical data defining the generator and the limits on its operating environment are tabulated in the Equipment Data Sheet. A copy of the Equipment Data Sheet has been included in the manual.

In order to assist in the operation and maintenance of the generator, a full set of electrical and installation drawings has been included in the manual.

5.1. GENERAL OPERATION The generator is a diesel engine driven alternator with control electronics, mounted on a bedplate with internal fuel tank. The standard package is composed of the following:

• Alternator and engine assembly

• Pressurised oil system

• Automated control system

• Instrumentation

• Safety provisions

• Engine cooler pack

• Spark arrestor / Silencer

• Internal fuel tank

The engine and alternator are integrally mounted. This assembly is isolated from the base by rubber isolation mounts.

5.2. DESIGN LOAD CAPACITY The NHC20/QST30G2 (800kVA) generator set can be run up to a maximum of 812VA at prime power rating 50Hz and 941 kVA at prime power rating 60Hz.

5.3. DESIGN TEMPERATURES The NHC20/QST30G2 (800kVA) generator set can operate through an ambient temperature range of:

• -10°C (14°F) to 50°C (122°F)

5.4. CONTAINER & BASE FRAME The overall dimensions for the generator set are 6060 X 2440 X 2600 mm.

The container is manufactured from welded steel and has access to the inside of the generator through lockable doors. Access to the roof of the container can be gained by using the integral steps on the end of the container.

The base frame has 120% capacity of the fuel tank to prevent fuel leaking out of the generator set in the event of a fuel leakage inside the generator. A level switch is fitted inside the bund for spillage indication. This will shut down the engine when activated.


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5.5. DIESEL ENGINE The generator set uses a Cummins QST30G2 diesel engine, which is capable for either 50 Hz or 60 Hz. Details of the engine are outlined below.

Type: Four Stroke, 12 Cylinder 50° V, Water Cooled, Turbo charged, C/A Aftercooler

Model: Cummins QST30G2

RPM: 1500 / 1800

Nominal Engine Output @ 1500rpm: 698kW @ Prime Power

Governor: Cummins Dominion

Starting System: 24V Battery System with Fitted Isolator

Fuel Consumption @ Continuous 1500rpm: 131 L/Hr @ 100% Prime Power

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

Sump Capacity: 133 Litres

The Lube oil specification is as per API/ASTM/SAE/CD (equivalent to series MIL-L-415993). Recommended oils are Castrol Tection T 15W-40 (previously called RX Super Plus), Shell Rimula 15W 40.

The sump can be drained using the K1 pump via a Wallminster valve.

Refer to manufacturers data for all filter information.

5.7. ENGINE COOLING SYSTEM The engine cooling consists of a pump, thermostat, heater and radiator assembly.

Cooling fluid is fed from the radiator, through the pump, which is belt driven from the engine pulley. The thermostat controls the flow to the radiator. The radiator assembly is mounted at the front of the container in a separate compartment, with the fan mounted on the container roof.

Cooling air enters the generator through the container end louvers and noise attenuation baffles. This air then passes into the container space then across the radiator assembly.

The cooling air exits through the roof of the package.

The radiator is factory filled with Shell anti-freeze and anti-corrosion coolant, in 50-50 water-coolant concentration, providing protection to –32°C. Please consult Aggreko if filling is required.

5.8. ENGINE FUEL SYSTEM The engine fuel system consists of an internal fuel tank, Racor filters (see Figure 5.2), fine fuel filter, fuel pump, injection pump and nozzles.

Fuel can be taken from either an external or the internal fuel tank. Fuel is then pumped through the Racor filters to the fine fuel filters and then passed to the injectors and then to the injection nozzles.

The internal fuel tank has a fuel capacity of 1288 Litres. A fuel level mechanical gauge is also fitted in the internal tank. The fuel tank fill point is external. There are 4 cleaning ports on the fuel tank that are all accessible through the container doors.

External fuel supply can be connected to the package using the quick release connections at the side of the container. Internal supply and return fittings/valves must be re-configured to ensure that the engine fuel is not drawn from the onboard supply.

The use of ASTM No. 2D fuel is recommended for optimum engine performance. At operating temperatures below 0°C, acceptable performance can be obtained using blends of No. 1 and No. 2D. The use of lighter fuels can reduce economy. The viscosity of fuels must be kept above 1.3 cSt to provide adequate lubrication.

Refer to manufacturers data for all filter information.


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5.9. EXHAUST SYSTEM The exhaust system consists of the exhaust ducting, exhaust silencers complete with spark arrestor and rain cap assembly. The exhaust gases exit the engine and are passed through the exhaust ducting and exhaust, out the top of the container through the rain cap assembly. Insulation and heat shields are fitted to the exhaust ducting to prevent user contact with high temperature surfaces.

Manufacturer: Universal Silencers

Spark Arrestor: DNV Certificate No M-9561

5.10. ENGINE CONTROL SYSTEM An Electronic Cummins Dominion ECM controls the engine output.

A combined DIEF/GEMPAC system is used to monitor the safety circuits and set the operation mode of the generator. See section 6.1.2 Safety Module for more detail.

5.11. GENERATOR Manufacturer: Newage Stamford

Type: HCI634H2

50Hz: 380-440 Volts Voltage Range

60Hz: 440-480 Volts

Excitation System: Rotating Field powered by Permanent Magnet Pilot Exciter

• Voltage Regulator within 1% from no load to full load MX321+PMG

5.12. MAIN CIRCUIT BREAKER Manufacturer: Schneider

Type: NW25 Withdrawable Four Pole. Electronic Overload Protection Micrologic 5.0A Motor Operated. Lockable. Off Position


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Figure 5.1 – Right Bank Side 800 kVA Generator Part Locations

SPLITTER BOX

OIL FILTERS

DCA4

FUEL WATER SEPARATOR

OIL FILL DIPSTICK

LOAD TERMINAL

BATTERY ISOLATOR

FUEL FILTER

AUXILIARY SOCKETS ACB

CONTROL


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Figure 5.2 – Left Bank Side 800 kVA Generator Part Locations

RACORS

CRANK CASE

BREATHER BOTTLE

K1 PUMP

ENGINE JB ECM

SOCKETS

ACB FACIA


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FUEL COOLER (RADIATOR COMPARTMENT)

COOLANT DRAIN VALVE (RADIATOR COMPARTMENT)

COOLANT DRAIN VALVE (RADIATOR COMPARTMENT)

COOLANT LEVEL SIGHTGLASS (RADIATOR AIR INLET)

Figure 5.3 – Additional 800 kVA Generator Part Locations


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6.0 OPERATING INSTRUCTIONS 6.1. OPERATING CONTROLS AND INSTRUMENTS

6.1.1. CONTROL PANEL The operating controls and instruments are arranged on the control panel as shown in figure 6.1. A description of each panel device is given in the key below.

Figure 6.1 – Control Panel Exterior

Gempac Display Volts Lower / Raise Pressure Meter

Remote / Off / Local Manual / Auto Hours Run

Engine Start CB Open Temperature Meter

Engine Stop CB Close

Speed Lower / Raise Alarm Reset

2 3 4

9 10

5 6

7 8

1

1

11 12 13

6

2

3

4

5

8

7

9

10

11

12

13


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Figure 6.2 – Control Panel Internals

Engine JB Socket F14

AVR Panel Aux. Socket

GEMPAC

Busbar Sensing Socket

Terminals 1-82

Dominion ECM Terminals 83-87

F12 Droop & Gain Pots.

F13

Key for figure 6.2

1

2

3

4

8

9

7

5

6

7

8

1

2

3

4

5

6

9

10

11

10

11


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6.1.2. DEIF INTERFACE Line 1 displays the mode of operation, as shown in Figure 6.3 below. If SETUP is selected, it is possible to toggle through the display options for line 1 by repeatedly pressing the VIEW button. 7 options are available:

• Generator voltage L1 L2 L3 (Vac)

• Bus voltage L1 L2 L3 (Vac)

• Generator current (A)

• Generator power factor and active power (kW)

• Generator apparent power (kVA) and reactive power (kVAr)

• Generator L1 frequency (Hz) and voltage (Vac)

• Bus L1 frequency (Hz) and voltage (Vac)

The default setting of line 2 is Generator L1 frequency and voltage, as shown above in figure 3. It is possible to change the display option for line 2 using the up/down scroll keys, while in the SETUP menu. A number of options are available, including:

F, P, Q, S, cos φ, angle between phases, V, I, frequency deviation, analogue inputs

The fourth line gives 4 options as shown in figure 3: SETUP, V1, V2, and V3. SETUP is used to enter the SETUP page; position the cursor beneath SETUP (using the left/right scroll keys) and press SEL. V1, V2 and V3 are different display options. V2 and V3 are fixed (but can be configured in the utility software). V1 is selectable from 15 views using the up/down scroll keys (each view can be separately configured using the utility software).

In addition to electrical parameters, the GEMPAC unit also displays engine parameters from the Cummins ECM via the MODBUS connection. These are displayed in views contained within V1. The following engine parameters are displayed:

- Speed

- Pressure Oil

- Temperature Coolant

- Fuel Rate

- Fuel Rack Position - Left & Right

- Temperature Intake Manifold - Left & Right

- Pressure Intake Manifold – Left & Right

- Pressure Coolant

- Temperature Oil

- Fuel Supply

- Fuel Temperature

- Droop Adjust Potentiometer

- Barometric Pressure

- Engine Running Time

- +/- 0.2V Speed Bias

Figure 6.3 – DEIF Interface


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6.1.3. ALARMS & SHUTDOWNS When a warning or a shutdown is detected, the DEIF PPU display jumps to the alarm page and the fault is displayed in clear text. This is shown in Figure 6.4. If one or more alarms have not been acknowledged, the red LED at the top left-hand corner of the display flashes. If all alarms have been acknowledged but one or more are still present, the red LED will be constantly lit. To reset alarms, the alarm reset button on the front panel should be used.

To jump to the alarm page at any time, press the alarm INFO button. To scroll through the alarms use the up/down scroll keys. It is possible to jump directly to the first or last alarm and to acknowledge an alarm by using the left/right scroll keys and the select button.

Depending upon the fault condition detected, the GEMPAC unit will carry out one of 6 fail classes, and these are listed below.

Fail Class 0 – Warning

Fail Class 1 – Engine Stop

Fail Class 2 – Emergency Stop

Fail Class 3 – Shutdown

Fail Class 4 – Emergency Shutdown

Fail Class 5 – Electrical Fault

The table below shows the function of each fail class.

Cummins ECM generated fault codes

When the ECM detects a fault, one of two messages is displayed on the GEMPAC display:

- Cummins Warning

- Cummins Shutdown

ECM warning is classed as fail class 0 and will be displayed and logged by the GEMPAC unit. ECM Shutdown is classed as fail class 2 and the generator set will shutdown. Note that this is in addition to any action that the ECM will take, e.g. reduce the maximum power available or shut the engine down. For action that the ECM will take, refer to the Cummins technical documentation on ECM fault codes. Once an ECM alarm has been detected, it is possible to display the fault code and associated text.

To display the list of fault codes within the ECM, press and hold the INFO button for a minimum of 2 seconds. Current ECM fault codes will then be displayed. Only the active (fault condition still present) will be displayed.

The GEMPAC unit can display the following ECM fault codes.

Figure 6.4 – Typical Alarm Page

FC0 FC1 FC2 FC3 FC4 FC5 Log Alarm X Display Alarm X X Log Event X X X X Deload X X Open CB X X X X X CB Feedback X X X X X Timeout Cooling Delay X Engine Stop X X X X Emergency Stop / Fuel Solenoid Close X X Close Air Flaps X Trip CB X X X


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Gempac Description Cummins ECM Message Fault Code Type

Afterc. w. inlet T exceed warn. thresh.

Aftercooler water inlet temp exceeded the warning threshold 2113 Warning

Aftercooler w inlet temp shutd. thresh.

Aftercooler water inlet temp exceeded shutdown threshold 2114 Shutdown

Aftercooler w. inlet temp sen. shorted h

Aftercooler water inlet temp sensor signal is shorted high 2111 Warning

Aftercooler w. link temp sen. shorted l

Aftercooler water link temp sensor signal is shorted low 2112 Warning

Ambient air pressure sen. shorted high

AmbientAir pressure sensor signal is shorted high 221 Warning

Ambient air pressure sen. shorted low

AmbientAir pressure sensor signal is shorted low 222 Warning

Battery is dead. Eng. can't start Battery is dead. Engine will not start 1443 Shutdown

Blowby exceeded shutdown threshold

Blowby exceeded shutdown threshold 556 Shutdown

Blowby pres. exceed. warning threshold

Blowby pressure exceeded the warning threshold 555 Warning

Blowby pressure sen. shorted high

Blowby pressure sensor signal is shorted high 719 Warning

Blowby pressure sen. shorted low

Blowby pressure sensor signal is shorted low 729 Warning

Common shutd. relay driver error

Common shutdown relay driver detected an error. 1425 Warning

Common warning relay driver error

Common warning relay driver detected an error 1426 Warning

Configuration error has been detected.

Configuration error has been detected. 1413 Shutdown

Controller pow. down error detected

Controller power down error has been detected 1417 Warning

Coolant level drop. below shutd. thresh.

Coolant level dropped below shutdown threshold 235 Shutdown

Coolant level drop. below warn. thresh.

Coolant level dropped below the warning threshold 197 Warning

Coolant pres. drop. below shutd. thresh.

Coolant pressure dropped below shutdown threshold 228 Shutdown

Coolant pres. drop. below warn. thresh.

Coolant pressure dropped below the warning threshold 233 Warning

Coolant press. sen signal low Coolant pressure sensor signal is shorted low 232 Warning

Coolant press. sen. signal high Coolant pressure sensor signal is shorted high 231 Warning

Coolant temp dropped below warn. thresh.

Coolant temp dropped below the warning threshold 152 Warning

Coolant temp. exceed shutdown threshold

Coolant temperature exceeded shutdown threshold 151 Shutdown

Coolant temperature exceeded the warning

Coolant temperature has exceeded the warning 146 Warning

Coolant temperature sensor shorted high

Coolant temperature sensor signal is shorted high 144 Warning


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Coolant temperature sensor shorted low

Coolant temperature sensor signal is shorted low 145 Warning

Droop adjust pot shorted high Droop adjust potentiometer signal is shorted high 1412 Warning

Emergency Stop (ECM) Emergency Stop (ECM) 1433 ShutdownEmergency Stop (ECM) Emergency Stop (ECM) 1434 ShutdownEng. oil burn valve solenoid shorted

Engine oil burn valve solenoid shorted low or high 223 Warning

Engine cool. l. data incorr. in l and h

Engine coolant level data incorrect both low & high at same time

422 Warning

Engine failed start No action is taken

Engine failed to start - No action is taken by theECM 359 Warning

Engine position sen. not detected

Engine position sensor signal is not detected. 236 Shutdown

Engine speed exceed. shutdown threshold

Engine speedExceeded shutdown threshold 234 Shutdown

Error det. in fuel rail act. sen. sig. Error detected in the fuel rail actuator sensor signal 468 Warning

Error det. in timing rail act. sen. sig.

Error detected in fuel timing press. or timing actuator signals 423 Warning

Error fuel timing press. /actu. sig. Error detected in the timing rail actuator sensor signal 467 Warning

Error in fuel rail pressure sen. sig.

Error detected in the fuel rail pressure sensor signal 554 Warning

Error internal ECM Error internal to the ECM 111 ShutdownE-stop path f. blown Eng. can't start

E-stop path fuse blown.Engine will not start 1437 Shutdown

Fail To shutdown Fail To shutdown 1416 Warning

Fail to start relay driver, error Fail to start relay driver detected an error 1479 Warning

fault code not known

Freq. adjust pot shorted high Frequency adjust potentiometer signal is shorted high 1411 Warning

Fuel p. deliv. pres. sen. shorted low

Fuel pump delivery pressure sensor signal is shorted low 119 Warning

Fuel p. deliv. pres.sen. shorted high

Fuel pump delivery pressure sensor signal is shorted high 118 Warning

Fuel pressure sensor shorted high

Fuel pressure sensor signal is shorted high 546 Warning

Fuel pressure sensor shorted low

Fuel pressure sensor signal is shorted low 547 Warning

Fuel pump act. not respon. to ECM comm

Fuel pump actuator is not responding to ECM commands 318 Warning

Fuel pump actuator shorted high Fuel pump actuator signal is shorted high 316 Warning

Fuel pump drv det. an error Fuel pump driver detected an error 1423 Warning

Fuel rack act. pos. sen. LB incorr, data

Fuel rack actuator position sensor left bank incorrect data 171 Warning

Fuel rack act. pos. sen. LB incorr. Data

Fuel rack actuator position sensor left bank incorrect data 174 Warning

Fuel rail actuator is responding Fuel rail actuator is responding 514 Shutdown


- 20 -

Fuel rail actuator sensor shorted high;

Fuel rail actuator sensor signal is shorted high 455 Shutdown

Fuel rail drv. det. an error Fuel rail driver detected an error 1419 Warning Fuel rail pressure sensor shorted high

Fuel rail pressure sensor signal is shorted high 451 Warning

Fuel rail pressure sensor shorted low

Fuel rail pressure sensor signal is shorted low 452 Warning

Fuel shutoff valve left bank problem

Fuel shutoff valve left bank problem 1211 Shutdown

Fuel shutoff valve no respond ECM comm

Fuel shutoff valve is not responding to ECM commands 259 Warning

Fuel shutoff valve right bank problem

Fuel shutoff valve right bank problem 1212 Shutdown

Fuel shutoff valve shorted low Fuel shutoff valve signal is shorted low. 254 Shutdown

Fuel supply pump P sen. shorted high

Fuel supply pump pressure sensor shorted high 581 Warning

Fuel supply pump P sen. shorted low

Fuel supply pump pressure sensor shorted low 582 Warning

Fuel temp exceeded shutdown threshold

Fuel temp exceeded shutdown threshold 266 Shutdown

Fuel temp. exceeded warning threshold

Fuel temperature has exceeded the warning threshold 261 Warning

Fuel temp. sensor shorted high Fuel temperature sensor signal is shorted high 263 Warning

Fuel temp. sensor shorted low Fuel temperature sensor signal is shorted low 265 Warning

Gain adjust pot sig. shorted high Gain adjust potentiometer signal is shorted high 1418 Warning

High curr. det. timing actuator 1 High current detected at fueling actuator # 1 379 Shutdown

High current det. at fueling actuator 2

High current detected at fueling actuator #2 397 Shutdown

High current det. fuel. actuator 1 High current detected at timing actuator # 1 395 Shutdown

High current det. timing actuator 2

High current detected at timing actuator #2 399 Shutdown

High fuel supply P at fuel press. sen.

High fuel supply pressure detected at the fuel press. sensor

449 Warning

High temp shutdown relay driver error

High temp shutdown relay driver detected an error 1429 Warning

High voltage det. for battery High voltage detected for battery 442 Warning Hot shutdown has occurred Hot shutdownHas occurred 611 Warning

Intake mani. air p sen. RB shorted high

Intake manifold air pressure sensor right bank signal is shorted high

128 Warning

Intake mani. air p sen. RB shorted low

Intake manifold air pressure sensor right bank signal is shorted low

129 Warning

Intake mani. air p sen. shorted high

Intake manifold air pressure sensor signal is shorted high 122 Warning

Intake mani. air p sen. shorted low

Intake manifold air pressure sensor signal is shorted low 123 Warning


- 21 -

Intake mani. air T ex. shutd. threshold

Intake manifold air temp exceeded shutdown threshold 155 Shutdown

Intake mani. air T exceed. warn. Thresh

Intake manifold air temp. exceeded the warning threshold 488 Warning

Intake mani. air T sen. RB shorted high

Intake manifold air temperature sensor right bank signal is shorted high

159 Warning

Intake mani. air T sen. RB shorted low

Intake manifold air temperature sensor right bank signal is shorted low

161 Warning

Intake mani. air T sen. shorted high

Intake manifold air temperature sensor signal is shorted high 153 Warning

Intake mani. air T sen. shorted low

Intake manifold air temperature sensor signal is shorted low 154 Warning

Internal ECM error. Internal ECM error. 343 Warning Low curr./open circ det. timing act 2

Low current or open circuit detected at fueling actuator # 2 396 Shutdown

Low curr./open circ. det. fuel. act 2

Low current or open circuit detected at timing actuator # 2 398 Shutdown

Low curr./open circ. det. fuel. act.1

Low current or open circuit detected at fueling actuator # 1 378 Shutdown

Low curr./open circ. det. timing act 1

Low current or open circuit detected at timing actuator # 1 394 Shutdown

Low engine oil level (remote) Low engine oilLevel (remote) 219 Warning

Low fuel supply pres fuel press. sen.

Low fuel supply pressure detected at the fuel press. sensor

482 Warning

Low oil pres. shutd. relay driver error

Low oil pressure shutdown relay driver detected an error 1428 Warning

Low voltage detected for battery Low voltage detected for battery 441 Warning

Mechani. misalign. betw. cam/crankshaft

Mechanical misalignment between cam-shaft and crankshaft

731 Warning

No sig. crankshaft engine pos. sensor

No signal detected from crankshaft engine position sensor

689 Warning

No signal det. main/ backup speed sen.

No signal detected from the main or backup speed sensor 121 Warning

No signal from main and backup speed sen

No signal from main & backup speed sensor 115 Shutdown

No speed signal from camshaft pos. sen .

No speed signal detected from camshaft position sensor 778 Warning

Oil level below shutdown threshold

Oil level dropped below shutdown threshold 253 Shutdown

Oil level below warning threshold Oil level dropped below the warning threshold 471 Warning

Oil level exceeded shutdown threshold

Oil level exceeded shutdown threshold 688 Shutdown

Oil level exceeded warning threshold

Oil level has exceeded the warning threshold 326 Warning

Oil level sensor error Oil level sensor error 252 Warning

Oil level sensor shorted high Oil level sensor signal is shorted high 498 Warning


- 22 -

Oil level sensor shorted low Oil level sensor signal is shorted low 499 Warning

Oil pres. below shutdown threshold

Oil pressure dropped below shutdown threshold 415 Shutdown

Oil pres. below warning thresh. Oil pressure has dropped below the warning threshold 143 Warning

Oil pres. sensor shorted high Oil pressure sensor signal is shorted high 135 Warning

Oil pres. sensor shorted low Oil pressure sensor signal is shorted low 141 Warning

Oil temp. exceeded shutdown threshold

Oil temperature exceeded shutdown threshold 214 Shutdown

Oil temp. exceeded warning threshold

Oil temperature has exceeded the warning threshold 421 Warning

Oil temp. sensor shorted high Oil temperature sensor signal is shorted high 212 Warning

Oil temp. sensor shorted low Oil temperature sensor signal is shorted low 213 Warning

Overspeed shutdown relay driver error

Overspeed shutdown relay driver detected an error 1427 Warning

Pre-high engine temp warn. relay drv err

Pre-high engine temp warning relay driver detected an error 1432 Warning

Pre-low oil p. warn. relay drv error

Pre-low oil pressure warning relay driver detected an error 1431 Warning

Rack actuator pos. sen. LB shorted high

Rack actuator position sensor left bank signal is shorted high 168 Warning

Rack actuator pos. sen. LB shorted low

Rack actuator position sensor left bank signal is shorted low 169 Warning

Rack pos. sen. right bank shorted high

Rack position sensor right bank signal is shorted high 179 Warning

Rack pos. sen. right bank shorted low

Rack position sensor right bank signal is shorted low 181 Warning

Rack position sen. right bank shorted h

Rack position sensor right bank signal is shorted high 183 Warning

Rack position sen. right bank shorted l

Rack position sensor right bank signal is shorted low 182 Warning

Rack position sensor left bank shorted h

Rack position sensor left bank signal is shorted high 166 Warning

Rack position sensor left bank shorted l

Rack position sensor left bank signal is shorted low 167 Warning

Relay high side drv detected an error

Relay high side driver detected an error 1424 Warning

The ECM watchdog has failed The ECM watchdog has failed 1473 ShutdownTiming rail act. sen sig. shorted high

Timing rail actuator sensor shorted high 116 Shutdown

Timing rail actuator not resp. ECM comm.

Timing rail actuator not responding to ECM commands 112 Shutdown

Timing rail actuator sensor shorted high

Timing rail actuator sensor signal is shorted high 113 Warning

Timing rail actuator sensor shorted low

Timing rail actuator sensor shorted low 117 Shutdown


- 23 -

Timing rail driver 1 detected an error

Timing rail driver #1 detected an error 1422 Warning

Timing rail driver 2 detected an error

Timing rail driver #2 detected an error 1421 Warning

Warn. Engine cold potent. start probl.

Warning Engine cold - potential starting problem 1435 Warning

Warning Fail to crank Warning Fail to crank 1438 Warning Warning HPI-PT fuel system drv error

Warning HPI-PT fuel system drivers detected an error 1436 Warning

6.2. PRIOR TO START Execute Daily Maintenance see section 7.1.

6.3. STARTING 1) Close the battery isolator switch.

2) Put Remote-Off-Local key switch to LOCAL.

3) Put Manual-Auto key switch in MANUAL position (Counter-clockwise).

4) Press the ENGINE START button and hold until the motor starts running.

5) Check voltmeter, Hz meter, oil pressure and coolant temperature.

6) Check the frequency and voltage on the control panel and adjust if necessary with the SPEED or VOLTS LOWER/RAISE switch.

7) Walk around the engine and check for any leakages.

6.4. LOADING 1) Allow the engine to warm-up prior to applying load.

2) Press CB CLOSE button; signal lamp should light, indicating that the main circuit breaker is closed.

6.5. SHUT-DOWN 1) Remove load from the generator.

2) Open the circuit breaker by pushing the CB OPEN button.

3) Stop the engine by pressing the ENGINE STOP button. The engine will continue to run for a cooldown period before stopping.

CAUTION: - Always open the battery isolator switch to avoid unauthorised starting during transport and maintenance.

6.6. AUTO OPERATION (OPTIONAL) 1) Close the battery isolator switch.

2) Put Remote-Off-Local key switch to LOCAL.

3) Put Manual-Auto key switch in AUTO position (Clockwise).

4) Press the ENGINE START button and hold until the motor starts running.

5) When engine runs up to speed the circuit breaker will automatically close. If voltage is detected on the bus bars, the generator will automatically synchronise to the bus voltage.

6) The generator will now regulate to the mode of operation selected.

7) A test run should be carried at least once a week.

Refer to separate manual for operation of remote option.


- 24 -

7.0 MAINTENANCE 7.1. GENERAL

In addition to periodic inspections, many of the components in these units require periodic servicing to provide maximum output and performance. Servicing may consist of pre-operation and post-operation procedures to be performed by the operating or maintenance personnel. The primary function of preventive maintenance is to prevent failure, and consequently, the need for repair. Preventive maintenance is the easiest and the least expensive type of maintenance. Maintaining your unit and keeping it clean at all times will facilitate servicing.

Ensure that maintenance personnel are adequately trained, competent and have read the Maintenance Manuals.

Prior to attempting any maintenance work, be aware of the following:

• Any unauthorized modification or failure to maintain this equipment may make it unsafe and out of factory warranty.

• Use extreme care to avoid contacting hot surfaces (engine exhaust manifold and piping, etc.).

• Never operate this machine with any guards removed.

• Imperial and Metric hardware was used in the design and assembly of this unit. Consult the parts manual for clarification of usage.

• The machine cannot be started accidentally or otherwise, by posting warning signs and/or fitting appropriate anti–start devices.

• All residual electrical power sources (mains and battery) are isolated.

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

• Anyone entering the machine is aware of the reduced level of protection and the additional hazards, including hot surfaces and intermittently moving parts.

• The machine cannot be started accidentally or otherwise, by posting warning signs and/or fitting appropriate anti–start devices.

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

• The work carried out is limited to only those tasks which require the machine to run.

• The work carried out with safety protection devices disabled or removed is limited to only those tasks which require the machine to be running with safety protection devices disabled or removed.

• All hazards present are known (e.g. pressurised components, electrically live components, removed panels, covers and guards, extreme temperatures, inflow and outflow of air, intermittently moving parts, safety valve discharge etc.).

• Appropriate personal protective equipment is worn.

• Loose clothing, jewellery, long hair etc. is made safe.

• Warning signs indicating that Maintenance Work is in Progress are posted in a position that can be clearly seen.

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

• The machine is suitably tested.

• All guards and safety protection devices are refitted.

• All panels are replaced, container and doors closed.

• Hazardous materials are effectively contained and disposed of.

To assist with ordering spare parts and other service activities, a short form list of Component Manufacturers data has been included in this manual.

Prior to engine starting, check the oil and coolant levels.

Carry out a visual check of the following:

• Leaks.


- 25 -

• Loose or damage parts.

• Worn or damaged belts, change in engine appearance.

• Refer to the Maintenance Schedule for quick reference.

Report unusual noise/vibration and/or exhaust smoke and ensure the generator set is kept clean, both inside and out.

7.2. MAINTENANCE SCHEDULE

7.2.1. INSPECTION CRITERIA

Daily Weekly Monthly 3 Months / 400 Hrs

6 Months / 800 Hrs

12 Months / 1200 hrs

Engine Oil Level C

Fuel Tank (Fill at end of day) C

Gauges / Lamps C

Air Filter C

Fuel / Water Separator Drain C

Battery Connections / Electrolyte C

Radiator Coolant Level C

Fan / Alternator Belts C

Hoses (oil, air, intake, etc.) C

Automatic Shutdown System Visual C

Fasteners / Guards C

Engine Coolant Test C

Shutdown Switch Settings Test C

C=check (adjust if necessary)

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

7.2.2. SERVICE CRITERIA

Daily Weekly Monthly 3 Months / 400 Hrs*

6 Months / 800 Hrs

12 Months / 1200 hrs

Engine Oil & Filters R

Air Filter Element R

Fuel / Water Separator Element R

Fine Fuel Element R

Engine Coolant R R=replace

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

* This figure should be in line with current service best practise.


- 26 -

7.3. DAILY MAINTENANCE

7.3.1. CHECK THE ENGINE OIL LEVEL: 1) Stop the engine and wait 5 minutes to allow the oil to drain to the oil pan.

2) Remove the dipstick and check the oil level.

3) Replenish if necessary using a recommended grade of engine oil (see section 8).

CAUTION: Never operate the engine with the oil level below the ‘L’ mark or above the ‘H’ mark. See FIG. 7.1 below.

Figure 7.1 - Engine Oil Level Check

7.3.2. CHECK THE FUEL TANK LEVEL. Check the fuel level gauge on the control panel.

Replenish as necessary using clean, good quality, diesel/Derv/Gas Oil that conforms to ISO or equivalent. Always ensure that the filler cap is replaced after replenishment.

7.3.3. CHECK THAT ALL METERS AND GAUGES FUNCTION CORRECTLY. Start the generator and inspect the following items:

• Oil pressure gauge is between 60 & 70psi.

• After 5 minutes check that the cooling water temperature gauge reads between 85 & 95°C.

• The voltage and frequency gauges are within specification.

• Fuel gauge indicates the tank is not empty.

• Engine hours display increases after 10 minutes.

• The DEIF Interface has no alarm indicators on.

7.3.4. CHECK THE AIR FILTER.

NOTE: In dusty conditions clean the primary filters regularly.

Check the air filter restriction indicator next to the air filter above the engine. If this has changed to the restricted position, then the filter will need replaced.


- 27 -

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

7.3.6. CHECK FOR LEAKS. There are several fluids used inside the generator, e.g. diesel, oil, coolant. Look for signs of leakage all around the engine.

Any source of leak should be checked and fixed. Clean up any fluid lying inside the generator and dispose of according to the appropriate local regulations.

Recurring leaks should be reported to AGGREKO.

7.4. WEEKLY MAINTENANCE

7.4.1. CHECK THE WATER/ANTIFREEZE LEVEL. Stop the engine and wait for the temperature to cool before checking the coolant level.

Remove the pressure cap slowly to relieve the pressure of the cooling system. Failure to do so could result in personal injury from heated coolant spray (See Figure 7.2).

Check the coolant level. Replenish with the correct coolant fluid as necessary (see section 8).

Figure 7.2 - Coolant Level Check

7.4.2. CARRY OUT A VISUAL CHECK OF THE DRIVE BELTS. The cooling pump, alternator and radiator fan are driven by a single belt arrangement from the engine pulley. Check the belts for signs of wear. Check the belt tension.

NOTE: Do not remove guards.


- 28 -

8.0 LUBRICATION 8.1. GENERAL INFORMATION

Lubrication is an essential part of preventive maintenance, affecting to a great extent the useful life of the unit. Different lubricants are needed and some components in the unit require more frequent lubrication than others. Therefore, it is important that the instructions regarding types of lubricants and the frequency of their application be explicitly followed. Periodic lubrication of the moving parts reduces to a minimum the possibility of mechanical failures.

The Preventive Maintenance Schedule shows those items requiring regular service and the interval in which they should be performed. A regular service program should be developed to include all items and fluids. These intervals are based on average operating conditions. In the event of extremely severe (hot, cold, dusty or wet) operating conditions, more frequent lubrication than specified may be necessary. Details concerning lubrication of the running gear are in Maintenance Section.

8.2. GENERATOR OIL CHANGE These units are normally furnished with an initial supply of oil sufficient to allow operation of the unit for approximately 3 months or 400 hours, although this should be in line with the current service best practise. The unit will however need to be topped up with oil during this period. If a unit has been completely drained of all oil, it must be refilled with new oil before it is placed in operation. Refer to specifications in Lubrication Table.

NOTICE: Some oil types are incompatible when mixed and result in the formation of varnishes, shellacs, or lacquers that may be insoluble. Such deposits can cause serious problems including clogging of the filters. Where possible, do NOT mix oils of different types and avoid mixing different brands. A type or brand change is best made at the time of a complete oil drain and refill.

If the unit has been operated for the time/ hours mentioned above, it should be completely drained of oil. If the unit has been operated under adverse conditions, or after long periods in storage, an earlier change period may be necessary as oil deteriorates with time as well as by operating conditions.

An oil change is good insurance against the accumulation of dirt, sludge, or oxidized oil products.

Completely drain the reservoir, piping, and Purafiner system. If the oil is drained immediately after the unit has been run for some time, most of the sediment will be in suspension and, therefore, will drain more readily. However, the fluid will be hot and care must be taken to avoid contact with the skin or eyes.

After the unit has been completely drained of all old fluid, close the drain valve. Add oil in the specified quantity at the filler plug. Tighten the filler plug and run the machine to circulate the oil. Check the oil level when unit is warm and not running. If not near the middle of the dipstick, stop the unit and make corrections. DO NOT OVERFILL.

8.3. OIL SPECIFICATION The oil required for this engine is:

Manufacturer: Castrol

Product Name: Tection T 15W-40 (Formerly RX Super Plus)

Relative Density @ 25°C 0.89 g/cm³

Viscosity @ 40°C 110 mm²/s

Viscosity @ 100°C 14.5 mm²/s

Viscosity Index 135

CCS –20ºC 6450 mPA.s

Total Base Number (TBN) 11.6 mgKOH/g

Flash Point (COC) 228 °C

Pour Point -36 °C

Sulphated Ash 1.5 %m


- 29 -

9.0 TROUBLE SHOOTING 9.1. INTRODUCTION

Trouble shooting for a generator set is an organized study of a particular problem or series of problems and a planned method of procedure for investigation and correction. The trouble-shooting chart that follows in Section 9.3 includes some of the problems that an operator may encounter during the operation of a generator set.

The chart does not attempt to list all of the troubles that may occur, nor does it attempt to give all of the answers for correction of the problems. The chart does give those problems that are most probable to occur. To use the trouble shooting chart:

1) Find the problem being experienced in the Symptom column on the far left.

2) Proceed to work through the possible causes in the next column, instigating the appropriate corrective action where required from the next column.

9.2. ACTION PLAN A. Think Before Acting: Study the problem thoroughly and ask yourself these questions:

1) What were the warning signals that preceded the trouble? 2) Has a similar trouble occurred before? 3) What previous maintenance work has been done? If the generator will still operate, is it safe to continue operating it to make further checks?

B. Do The Simplest Things First: Most problems are simple and easily corrected. Always check the easiest and most obvious things first, following this simple rule will save time and trouble.

Note: For trouble shooting electrical problems, refer to the Wiring Diagram Schematic found in Appendix E.

C. Double Check Before Disassembly: The source of most generator troubles can be traced not to one component alone, but to the relationship of one component with another. Too often, a generator can be partially disassembled in search of the cause of a certain trouble and all evidence is destroyed during disassembly. Check again to be sure an easy solution to the problem has not been overlooked.

D. Find And Correct Basic Cause: After a mechanical failure has been corrected, be sure to locate and correct the cause of the trouble so the same failure will not be repeated. A complaint of "premature breakdown" may be corrected by repairing any improper wiring connections, but something caused the defective wiring. The cause may be excessive vibration.


- 30 -

9.3. TROUBLE SHOOTING CHART

SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION

Battery isolator switch not closed. Close battery isolator switch.

Batteries flat or bad. Read value on battery voltage meter

(must be 24V or more). Replace or charge batteries.

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

ENGINE DOES NOT CRANK WITH 24V ELECTRIC MOTOR

Start relay at cranking motor defective.

Measure the voltage over the start relay.

Fuel tank empty. Fill up fuel tank.

Air in the fuel system. Check system for leaks. Bleed the fuel system.

Dirty fuel filters. Replace fuel filters.

Check voltage (24V) over fuel shut-off valve during crank. Call for AGGREKO support.

Optional air shutdown valve closed. Open air shutdown valve.

ENGINE CRANKS BUT DOES NOT START

Overspeed protection is activated.

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



Overspeed during acceleration. Decrease frequency setting. ENGINE STARTS UP BUT STOPS AFTERWARDS

Shutdown after 6 seconds.

Check safeties: Oil pressure – Water

temperature – Water pressure – Oil temperature (option)

Frequency too high. Adjust frequency to the correct level.

Connection between governor and fuel pump interrupted. Repair connection. ENGINE OVERSPEEDS


Engine not yet at operating temperature.

Wait until engine has reached the normal operating

temperature of 80-90ºC.

Dirty fuel filters. Replace fuel filters. ENGINE SPEED NOT

STABLE

Wear in ball eyes, linkage governor / fuel pump. Replace ball eyes.

Dirty air filters. Replace air filters.



ENGINE SHOWS EXCESS SMOKE AND / OR LACK OF

POWER

Overload. Check load.


- 31 -

SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION

Voltmeter defective. Measure voltage at outlet

terminals of alternator. If voltage measured replace voltmeter.

Voltage regulator defective. Replace voltage regulator, ALTERNATOR DOESN’T GENERATE VOLTAGE


Speed frequency too high / low.

Check frequency meter and adjust if required.

Incorrect voltage setting. Adjust voltage regulator. ALTERNATOR VOLTAGE

TOO HIGH / LOW

No identifiable cause. Consult AGGREKO.

Engine speed not stable. Check stability of engine speed. ALTERNATOR VOLTAGE

NOT STABLE Incorrect stability adjustment. Adjust stability on the voltage regulator.

Circuit breaker control switch (Figure 6.1) set remote control. Select local position.

Circuit breaker tripped. Reset circuit breaker.

Circuit breaker not charged, motor mechanism broken.

Charge motor mechanism manually, inform AGGREKO.

MAIN CIRCUIT BREAKER WILL NOT CLOSE

Lamp ‘CIRCUIT BREAKER CLOSED’ defective. Replace lamp.

MAIN CIRCUIT BREAKER CLOSES BUT TRIPS AGAIN

Switch on overload or short circuit. Remove load.


Appendix A - i

MATERIAL SAFETY DATA SHEETS

APP

END

IX A


Appendix A - ii

CASTROL TECTION T 15W-40


Appendix A - iii


Appendix A - iv


Appendix A - v


Appendix A - vi

LEAD ACID BATTERIES

HEALTH & SAFETY LEAD ACID BATTERIES ####################################

The handling and proper use of lead-acid batteries is not hazardous provided sensible precautions are observed and that Operatives having been trained in their use are adequately supervised. The purpose of this letter is threefold:- [ i] to indicate potential hazards that may arise. [ ii] to outline the precautions to be taken to minimise such hazards. [iii] to indicate action to be taken in the event of an accident. 1. SULPHURIC ACID [S.G. 1.260 - 1.300] Batteries contain sulphuric acid which may leak for a variety of reasons and may be given off as droplets and/or spray during recharging. [The Hazards] Sulphuric Acid is a poisonous and corrosive clear liquid which can burn/irritate skin and eyes and could burn clothing. [Precautions] Always handle batteries with care Always store upright Never over-fill with acid Always charge in a well ventilated area. Maximum voltage 15v per each 12v Battery. Use eye protection and protective clothing if there is any risk of acid splashing. [Emergency Action] Skin Contact: Immediately wash the affected area with copious amounts of clean water. Remove any contaminated clothing. Eye Contact Immediately irrigate eyes for at least 10 minutes with clean water. Swallowing Make the victim drink volumes of water, milk or milk of magnesia. DO NOT GIVE EMETIC In all cases seek medical attention. Speed of action is vital. [Spillages] Small spillages can be swilled away with volumes of water. [Disposal] See Section 5. 2. ELECTRICAL ENERGY [The Hazards] The accidental connection of battery terminals by conductive objects, e.g. metal tools or metal personal jewellery etc., may generate sufficient heat to cause burns, create arcing or cause molten metal to splash.


Appendix A - vii

[PAGE TWO]. [Precautions] Always ensure correct installation. The positive cable must be attached to the terminal marked [+] and the negative to the terminal marked [-]. Cables and terminals should be kept clean and securely fitted. Before using metallic tools on a battery remove metallic objects from hands and wrists. Before working on a vehicle electrical system disconnect the Battery, disconnecting the earth strap first and reconnecting last. Do not place tools on top of batteries. [Emergency Action] Burns: Apply sterile bandage. Electric Shock: Approach victim with care. Switch off or otherwise break current. If not possible, detach victim from contact by means of insulating material [wood, rubber or plastic hosepipe, folded newspaper etc] Do not touch with bare hands. In each case seek medical advice. Speed of action is vital. 3. EMISSION OF GASES A mixture of oxygen and hydrogen is emitted during charging and may be emitted if a battery is moved or shaken. [The Hazards] An explosive atmosphere exists if the concentration of hydrogen exceeds 4%. [Precautions] Always charge in a well ventilated environment. No naked flames NO SMOKING Be certain that current is switched off before making breaking connection. Always remove earth strap first and re-connect last. [Emergency Action] Explosion: Seek medical advice remembering that acid may have been sprayed. 4. WEIGHT In general terms batteries are heavy and awkward to handle. Care should be taken and correct lifting techniques employed. 5. DISPOSAL Batteries, Battery Acid, Lead and Lead compounds must be disposed of in accordance with: [a] The deposit of Poisonous Waste Act 1972 [b] The Control of Pollution Act 1974 [c] Consumer Protection Act 1987 If in doubt, consult the Environmental Department of your Local Authority. For further information refer to:- BRITISH STANDARD BS 6604; 1985 SAFE OPERATION OF STARTER BATTERIES.


Appendix A - viii

SUPERCOLDMASTER ANTIFREEZE


Appendix A - ix


Appendix A - x


Appendix B - i

OPERATING INSTRUCTION SHEET

APP

END

IX B


Appendix B - ii


Appendix C - i

EQUIPMENT DATA SHEET

APP

END

IX C


Appendix C - ii

EQUIPMENT DATA SHEET No. G080275

Rev. B Diesel Generating Set Date 01/02/2007 50Hz 800kVA

Manufacturing Birch Road Dumbarton, G82 2RF Tel: 0044 (0)1389 742214 Fax: 0044 (0)1389 742554 60Hz 800kW Page 1 of 3

1 Model Ref NHC20/QST30G2 STD & Stackable (AI)

2 Part Number Ref 602094, 602109 (Stackable)

3 Specification Ref G32.0016

4 Installation Drawing Ref A05.0001, A050210 (Stackable)

5 Maximum Ambient °C (°F) 50 (122) 50 (122)

6 Electrical Output Hz 50 60

ISO 8528-1

- Continuous Power (COP) kW (kVA) 500 (625) 604 (755)

- Prime Power (PRP) kW (kVA) 650 (812) 755 (944)

- Permissible average of PRP % 70 70

ISO3046/1

- Fuel Stop Power/Standby kW (kVA) 720 (900) 835 (1044)

Single Step load application % 56 56

7 Alternator

Class F Temp. Rise (105°C)

- Three phase kW (kVA) 664 (830) 770 (963)

- Single phase kW (kVA) - -

Ends Out 6

Make & Type Cummins Generator Technologies

HCI634H2

AVR MX321

Regulation % ±0.5

8 Circuit Breaker

Make & Type Schneider NW25

Number of poles 4

Rating Amps 2500

Trip Unit Type Micrologic 5.0

Overload Protection Range Amps 1000 – 2500 (adjustable by selector)

Short Circuit Protection Range Amps 1000 – 25000 (adjustable by selector)

Technical Department – Dumbarton Approved by


Appendix C - iii

EQUIPMENT DATA SHEET No. G080275 Rev. B Diesel Generating Set Date 01/02/2007 50Hz 800kVA


9 Load Terminals

Type Busbar M12

10 Fuel Consumption

Standby/Fuel Stop lit/hr(US gal/hr) 186 (49.2) 227 (60.0)

100% Prime Power " " 167 (44.2) 201 (53.0)

75% " " 128 (33.8) 150 (39.7)

50% " " 86 (22.7) 102 (26.9)

11 Running Hours

100% Prime Power Hours 7.7 6.4

75% " 10.0 8.6

50% " 15.0 12.6

12 Exhaust Emissions

Measurement Method TA-Luft EPA-MOH/CARB

Specific Load 100% prime ± 2% ISO8178D2

NOx – Oxides of Nitrogen 4000mg/nm³ 9.20g/kW.h

PM - Particulate Matter 130mg/hm³ 0.54g/kW.h

CO - Carbon Monoxide 650mg/hm³ 11.40g/kW.h

HC - Unburnt Hydrocarbons - 1.30g/kW.h

13 Exhaust Silencer

Make & Type Universal Silencers

Certificate No M-9561

Permissible back pressure mm (ins) Hg 13 (0.5”) 13 (0.5”)

14 Noise

Sound Power – EEC dBA (Lw) 104

Sound Pressure at 1 metre dBA 82 85

Sound Pressure at 7 metre dBA 72 76



Appendix C - iiii

EQUIPMENT DATA SHEET No. G080275 Rev. B Diesel Generating Set Date 01/02/2007 50Hz 800kVA


15 Engine

Make & Type QST30G2 NR1 CPL 2968

Cylinders & Form V12 50º

Aspiration Turbocharged & Aftercooled

Fuel Pump Bosch P7100 Direct Injection

Governor Type Electronic

Make & Model Cummins Dominion

Steady State frequency % ±0.25

Battery Voltage Volts 24

16 Overall Dimensions

- Length Metres (feet) 6.06 (20’0”)

- Width Metres (feet) 2.44 (8’0”)

- Height Metres (feet) 2.60 (8’6”)

17 Weight

- Without fuel Kg (lbs) 16000 (35274)

- With fuel Kg (lbs) 17216 (37954)

18 Capacities

- Fuel gross Litres (US gall) 1431 (378.1)

usable 1288 (340.3)

- Lub oil total 154 (40.7)

pan 133-114 (35-30)

- Coolant 383 (101.2)

19 External fuel supply

- maximum above base Metres (feet) 2.40 (7’10”)

- maximum below base Metres (feet) 1.50 (4’11”)



Appendix D - i

INSTALLATION OUTLINE DRAWING

APP

END

IX D


Appendix D - ii


Appendix D - iii


Appendix D - iv


Appendix D - v


Appendix D - vi


Appendix D - vii


Appendix D - viii


Appendix E - i

CONTROL PANEL LAYOUT

APP

END

IX E


Appendix E - ii


Appendix F - i

ELECTRICAL SCHEMATICS

APP

END

IX F


Appendix F - ii


Appendix F - iii


Appendix F - iv


Appendix F - v


Appendix F - vi


Appendix F - vii


Appendix F - viii


Appendix F - ix


Appendix G - i

EARTH LEAKAGE OPTION ($OPTION 382A)

APP

END

IX G


Appendix G - ii

Note: For units fitted with Earth Leakage Option ($Option382A) all schematics include the necessary wiring changes. Please see photographs below for location of hardware.

Earth Leakage Relay

Earth Leakage Reset Off / On Keyswitch

1

2

1

2


Appendix H- i

LIVERY LAYOUT

APP

END

IX H


Appendix H- ii


Appendix J- i

MANUFACTURERS COMPONENT DATA

APP

END

IX J


Appendix J- ii

Document No.: M040107 Date: 04/05/06 Rev: B Title: NHC20/QST30G2 Spares List & Manufacturers Data

DESCRIPTION QTY SUPPLIER / MANUFACTURER

SUPPLIER PART No.

AGGREKO PART No.

Radiator 1 Covrad CRDA0925-E1 067035SS

Radiator fan 1 Woods of Colchester

60 JEL 2/3 DFNV160LKEP 053165SS-03

Engine space fan 1 Woods of Colchester BZ531211 053196SS-01

Coupling, 3.86RB, sae18 SI470 round 1 Reynold Hitec 3580322B 051514SS

Engine Control Module 1 Cummins 4067777 Dominion N/A Battery 180Ah, 12V 4 DB Wilson 324 339002A Charging belt 2 Cummins 3094909 N/A Starter motor 1 Cummins 4081237 N/A Battery charging alternator 1 Cummins 3016627 N/A

Circuit breaker NW25, 4Pole 1 Schneider See Technical Description 293434SS

Current transformer 2000/5A 3 Celsa IRP 273039A Generator Control Module 1 Deif Multiline 2 - 010429 275158A Nicad battery 2 R.S. Components 180-358 339011A Container Air Inlet Filter 8 Baldwin PA3873 055685A Lube oil filter element 4 Cummins 3101869 N/A Baldwin BD7154 Combustion air filter element 2 Baldwin RS3982 055674A Secondary fuel filter element (eng) 1 Cummins 4010476 N/A Baldwin BF7760 Water filter element 2 Cummins 3100308 N/A Baldwin BW5075 Primary fuel filter element (eng) 1 Cummins 4095189 Baldwin BF7764 Control Panel cooling Fan 1 Eldon EF10A 317118A

Primary fuel filter element (container) 3 Racor 1000F 2020SM 100 Micron Washable

Baldwin PF7890-30 30 Micron Paper


Appendix K- i

CONTAINER CERTIFICATE

APP

END

IX K


Appendix K- ii


Appendix K- iii


Appendix L- i

DNV SPARK ARRESTOR CERTIFICATE

APP

END

IX L


Appendix L- ii


Appendix L- iii


Appendix M i

DECLARATION OF CONFORMITY

APP

END

IX M


Appendix M ii


Appendix M iii


Appendix N i

INTERNATIONAL CONTACT INFORMATION

APP

END

IX N


Appendix N ii

In case of emergencies please contact the nearest service department of AGGREKO. They can be reached 24 hours a day and are operational at any place in the world.

BELGIUM Aggreko N.V. Smallandlaan 7 2660 Hoboken Belgium Tel: (+32) 03 825 02 71 Fax: (+32) 03 825 11 81

FRANCE Aggreko S.a.r.l. 1 Chemin de l’Ancien Parc 91220 Bretigny Sur Orge France Tel: +33 (0)825 008007 Fax: +33 (0)1 69 737119

GREAT BRITAIN Aggreko Generators Ltd. Overburn Avenue DUMBARTON G82 2RL Tel: (+44) 1389 767821 Fax: (+44) 1389 761577

NETHERLANDS Aggreko International (Ned) B.V. Ketelweg 77 3356 LD Papendrecht Netherlands Tel: (+31) 078 64 41 441 Fax: (+31) 078 642 80 83

NORWAY Aggreko Norway A.S. Sorlandsveien 318 Postboks 543 EGERSUND N-4379 Norway Tel: (+47) 810 00 333 Fax: (+47) 051 46 45 90

SPAIN Aggreko Iberia S.A. Avda. Torre Mateu, 35-37 Polg. Industrial Can Salvatella 08210 Barbera del Valles BARCELONA Tel: (+34) 93 747 93 90 Fax: (+34) 93 729 02 83

EUROPE

GERMANY Frankfurt (Central Europe South East) Aggreko Deutschland GmbHDarmstadter Straße 66-68 64572 Büttelborn Germany Tel: +49 (0)61 52 93 93 0 Fax: +49 (0)61 52 93 93 99

GERMANY Mulheim (Central Europe North) Aggreko Deutschland GmbH Ruhrorter Straße 112 45478 Mülheim/Ruhr Germany Tel: +49 (0)208 58 09 70 Fax: +49 (0)208 58 09 798

ITALY Aggreko Italia srl Via Copernico, 60 20090 Trezzano sul Naviglio (Milano) Italy Tel: +39 02 4846 3024 Fax: +39 02 4451 243

NORTH AMERICA

CANADA Aggreko Inc. 300 Clarence Street Brampton, ONTARIO L6W 1T5 Tel: (+1) 905 459 3321 Fax: (+1) 905 459 3392

U.S.A. Aggreko LLC 4607 W Admiral Doyle Drive PO Box 10004 NEW IBERIA, LA 70562-0004 Tel: (+1) 337 365 5479 Fax: (+1) 337 367 0870

ASIA

REPUBLIC OF SINGAPORE Aggreko Singapore Pte Ltd 10 Pioneer Sector 1 SINGAPORE 62844 Tel: (+65) 6862 1501 Fax: (+65) 6862 0182

MIDDLE EAST

UNITED ARAB EMIRATES

Aggreko Inc. PO Box 17576 Jebel Ali DUBAI Tel: (+971) 04 834059 Fax: (+971) 04 834145

AUSTRALIA / PACIFIC

AUSTRALIA/PACIFIC Aggreko Generator Rentals Pty Ltd 101 Woodlands Drive Braeside Victoria 3195 MELBOURNE Tel: (+61) 03 586 5050 Fax: (+61) 03 586 50514

manual 800 kva

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