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5.5.3.3 DISTRIBUTION AND CONTROL CABLING

WARNING

DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS


OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A
SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET
IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT
FROM FAILURE TO OBSERVE THIS WARNING.

WARNING

HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT


DURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION
AND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN
LOAD CABLES ARE HANDLED.

WARNING

VERIFY THAT CONNECTION POINTS ARE DE-ENERGIZED BEFORE MAKING ANY


CONNECTIONS. FAILURE TO CHECK THAT CONNECTORS ARE DE-ENERGIZED
MAY RESULT IN INJURY OR DEATH.

a. Lay out and park the load cables for each phase (A, B, & C) between the PU Tie Output parking
stations and the Primary Switching Center (PSC).

b. Connect each phase cable to the appropriate phase connection on the Primary Switching Center
(PSC).

NOTE 1: For complete set-up of the Primary Switching Center (PSC), refer to Radian Inc. Commercial
Technical Manual CTM 01646.1R1260, Chapter 2.6.

NOTE 2: For Unit Isolation Procedure (any unit) - Plant with PSC, and Unit Re-Installation
Procedure – Plant with PSC, refer to Chapter 5.9, Sections 5.9.6.15 and 5.9.6.16.

c. Connect each load cables drain wire to the grounding grid.

d. Open the Tie Output connector loadbreak covers on the first PU.

e. Connect the Tie Output Cables to the appropriate phase connectors; ensure there are no cross-
phase connections.

f. Close and lock the Tie Output connector covers.

g. Repeat steps ‘a’ through ‘f’ on each remaining PU.

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

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

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

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

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

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

n. Connect third (A) (B) communication cable to “B” receptacle on third PU.

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

p. Connect the third (A) (B) communication cable to “A” receptacle on fourth PU.

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

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

5.5.3.4 SETPOINT VERIFICATION

a. Turn on PU DC control power by pushing in on the DC Control Power breaker.

b. On each of the five overcurrent relays, verify the settings:

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

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

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

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

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

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

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


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

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

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

(12) Verify the “50TN” settings.

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

(14) Verify the “50TQ” settings.

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

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

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

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

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

(20) Verify the 51N settings.

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

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

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

(1) Place ECS in the COOLDOWN/STOP position.

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

(3) Press SCROLL UP key until “OP3” is showing.

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

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

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

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

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

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

(10) Press ENTER key. “PE PASS” is showing.

(11) Press EXIT key. “OP4” is showing.

(12) Press SCROLL UP key until “OP5-0” is showing on the lower display.

(13) Press SELECT key. “POO1” followed with the value of the setpoint is showing.

(14) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing.
Use Chapter 5.1 Table 5.1.3.4-4 OP5 Settings for the parameter values to be verified.
Repeat until the desired setpoints are verified.

(15) Press EXIT key. “OP5-0” is showing on the lower display.

(16) Press SCROLL UP key until “OP5-1” is showing.

(17) Press SELECT key.

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(18) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing.
Use Chapter 5.1 Table 5.1.3.4-5 OP5-1 Settings for the parameter values to be verified.
Repeat until the desired setpoints are verified.

(19) Press EXIT key. “OP5-1” is showing.

(20) Press SCROLL UP key. “OP6” is showing.

(21) Press SELECT key.

(22) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing.
Use Chapter 5.1 Table 5.1.3.4-6 OP6 Settings for the parameter values to be verified.
Repeat until the desired setpoints are verified.

(23) Press EXIT key twice. The display returns to normal.

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

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

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

(c) Press ENTER. The correct value stops flashing on the display.

(d)Press SCROLL UP or SCROLL DOWN key to continue to verify the remaining


parameter values.
d. Return ECS1 and ECS2 to the OFF/RESET position.

NOTE: Use up or down keys to change values.

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

(1) Open the GCPG1 cabinet door.

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

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

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

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

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

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

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

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

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

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(11) When complete, press the [▼] to display parameter “01”.

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

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

(12) When complete, press the [▼] to display parameter “90”.

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

(14) Press the [▼] key to change the value to “0009”. Disables DVR parameter editing.

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

(16) Press the [▲] key to change to display parameter “01”.

(17) Close the GCPG1 cabinet door.

(18) Repeat steps ‘1 ‘through ‘16’ for Generator 2.

5.5.3.5 PRE-OPERATION CHECKS

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

5.5.3.6 PRE-OPERATION RUN

WARNING

ENSURE ALL PERSONNEL ARE CLEAR AND THE PU DOORS ARE CLOSED
PRIOR TO STARTING A GENERATOR.

WARNING

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND


ENFORCED.
NOISE LEVELS IN EXCESS OF 85 DB EXIST WITHIN AN 88-FOOT RADIUS OF AN
OPERATING DPGDS. PERSONNEL MUST WEAR SINGLE HEARING PROTECTION
WITHIN 88 FEET OF AN OPERATING DPGDS.

WARNING

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND


ENFORCED.
DURING MAINTENANCE ACTIVITIES WITH THE SIDEDOORS OPEN, NOISE
LEVELS IN EXCESS OF 113 DB EXIST WITHIN A 12-FOOT RADIUS OF AN
OPERATING DPGDS. PERSONNEL MUST WEAR DOUBLE HEARING PROTECTION
WITHIN 12 FEET OF AN OPERATING DPGDS. EXPOSURE MUST BE LIMITED TO
UNDER 2.5 HOURS.

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WARNING

BY CLOSING THE FEEDER OR TIE BREAKER, HIGH VOLTAGE WILL BE PRESENT


ON THE LOAD CABLES. ENSURE ALL PERSONNEL ARE CLEAR OF ALL LOAD
CABLES PRIOR TO CLOSING FEEDER OR TIE BREAKERS.

TABLE 5.5.3.6-1 PRE-OPERATION RUN INSTRUCTION SEQUENCE


(Perform on each PU in the power plant)
STEP -- 60HZ OPERATIONS -- -- 50HZ OPERATIONS --

1 Verify System Mode Switch (SMS) is in MANUAL

2 Verify DC Control Power is on

3 Verify Emergency Stop is pulled out

4① Verify the 60Hz light is on ① Verify the 50Hz light is on①

5 Start engine 1 by placing ECS1 in MANUAL

6 Verify the engine accelerates to 1800RPM Verify the engine accelerates to 1500RPM

7 Adjust the generator frequency to 60Hz Adjust the generator frequency to 50Hz using
using the Frequency Adjust Rheostat (FAR) the Frequency Adjust Rheostat (FAR)

8 Adjust the generator voltage to 4295VAC Adjust the generator voltage to 3915VAC
using the Voltage Adjust Rheostat (VAR) using the Voltage Adjust Rheostat (VAR)

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

10 Shutdown engine 1 by placing ECS1 in OFF/RESET

11 Start engine 2 by placing ECS2 in MANUAL

12 Verify the engine accelerates to 1800RPM Verify the engine accelerates to 1500RPM

13 Adjust the generator frequency to 60Hz Adjust the generator frequency to 50Hz using
using the Frequency Adjust Rheostat (FAR) the Frequency Adjust Rheostat (FAR)

14 Adjust the generator voltage to 4295VAC Adjust the generator voltage to 3915VAC
using the Voltage Adjust Rheostat (VAR) using the Voltage Adjust Rheostat (VAR)

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

16 Shutdown engine 2 by placing ECS2 in OFF/RESET

① If the wrong frequency light is on, open the Master Control Door and change the Frequency
Selector Switch (FSS) to the desired frequency.

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5.5.3.7 ORT SETUP

a. Remove the ORT from its case and set it up on a flat and level surface.

b. Remove the mouse from the case and plug it into the mouse (PS2) port on the back of the ORT.

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

d. Connect one end of the 150-foot patch cable to the ORT networking port on the PU.

e. Route the cable from the ORT to the PU and connect the cable to the ORT port.

f. Turn on the ORT.

g. Observe that the ORT boots to the operator’s Overview screen.

h. Select the EquipID pop-up screen and enter the necessary information for the units. This
includes the Trailer ID number, the Engine ID number, and the Generator ID number for each
PU.

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

h. Return to the Overview pop-up screen.

5.5.3.8 CONTROLS SETUP

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

NOTE: Ignore settings for Power Units not being used.

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TABLE 5.5.3.8-1 CONTROL SWITCH SETUP


PANEL SWITCH 1ST PU 2ND PU 3RD PU 4TH PU
Pushed In Pushed In Pushed In Pushed In
DC Power
(ON) (ON) (ON) (ON)
SMS OFF OFF OFF OFF
PRIME PRIME PRIME PRIME
GMS
POWER POWER POWER POWER
MASTER PRIME PRIME PRIME PRIME
CONTROL PANEL AVRS
POWER POWER POWER POWER
MCP 60Hz Light ON① ON① ON① ON①
USS A② B② C② D②
BSS NORMAL NORMAL NORMAL NORMAL
SSS OFF OFF OFF OFF
SSL All OFF All OFF All OFF All OFF
INSIDE MCP FSS 50/60 Hertz① 50/60 Hertz① 50/60 Hertz① 50/60 Hertz①
GENERATOR Emergency
Pulled-Out Pulled-Out Pulled-Out Pulled-Out
CONTROL PANEL Stop
GCPG1 ECS OFF OFF OFF OFF
GENERATOR Emergency
Pulled-Out Pulled-Out Pulled-Out Pulled-Out
CONTROL PANEL Stop
GCPG2 ECS OFF OFF OFF OFF

① With the SMS in the OFF position, the 50/60Hz lights indicate the position of the Frequency
Selector Switch (FSS). If the wrong light is on, open the door and change the switch position.
② No more than one switch can be in the same position in any multi-PU line-up. With the SMS in
OFF, none of the USI lights will be on and any previously set address on the PU is cleared.

5.5.3.9 PSC RELAY SETTING VERIFICATION

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

b. Click on Windows Start button.

c. Select Programs then Accessories then HyperTerminal.

d. Double Click on “Vista.ht”

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

NOTE: Use Com 1 communications port on the ORT.

e. Click on “Connect”.

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

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

g. Press “Enter” on the ORT.

NOTE: The overcurrent relay main menu should appear.

h. Select View Menu 1, WAY 3.

i. Select View relay settings.

j. Verify relay settings according to Table 5.5.3.9-1

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

k. Repeat steps g through I for WAY 4.

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

m. Return to the Main Menu and “Disconnect” using Windows HyperTerminal when desired
programming action is complete.

n. Disconnect the OCR end of the communication cable.

o. Repeat steps e. through l, for the right OCR (Ways 5 and 6).

p. Repeat steps e. though m. for each PSC in use.

q. Exit Windows HyperTerminal.

r. Shut-down the ORT.

TABLE 5.5.3.9-1 PSC RELAY SETTINGS


MIN. INST. TIME
PSC CABLE
FUNCTION CURVE PICKUP PICKUP DELAY
WAY SIZE
(AMPS) (KAMPS) (SEC.)
3,4, or 5 Feeder 1/0 TAP 200 1 Off
3,4, or 5 Feeder Ground 1/0 TAP 50 0 Off
3,4, or 5 Single Output 500 KCM MAIN 600 1 Off
3,4, or 5 Single Output Ground 500 KCM MAIN 100 0 Off
6 PSC Interconnect 4/0 TAP 400 0 C (64ms)
PSC Interconnect
6 4/0 TAP 80 0 C (64ms)
Ground

5.5.4 PLANT STARTUP

WARNING

ALWAYS PAD LOCK THE PSC INTERCONNECT SWITCHES. FAILURE TO DO SO


COULD RESULT IN PERSONAL INJURY. OR DAMAGE TO EQUIPMENT. IF
ATTEMPTING TO RECLOSE WAY, REFER TO SECTION 5.9.5.3.

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Starting up a Multi-PU Prime Power Plant in Manual Mode

a. At the external switchgear, close the associated connection for each PU supplying power to the
switchgear and close and pad lock the PSC interconnect switches when using more than one
primary switch.

b. At the external switchgear, close the connections between the external switchgears.

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

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

NOTE: 2: For Unit Isolation Procedure (any unit) - Plant with PSC, and Unit Re-Installation
Procedure – Plant with PSC, refer to Section 5.9, Section 5.9.6.15, and Section 5.9.6.16.

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

TABLE 5.5.4-1 SWITCH SETUP – MANUAL MODE


PANEL SWITCH 1ST PU 2ND PU 3RD PU 4TH PU
BCS-T Green Target Green Target Green Target Green Target
MASTER CONTROL SMS MANUAL MANUAL MANUAL MANUAL
PANEL MCP MSES Enable① Enable① Enable① Enable①
USI A①, ② B①, ② C① , ② D① , ②
GENERATOR BCS-G1 Green Target Green Target Green Target Green Target
CONTROL PANEL 1 BCS-F1 Green Target Green Target Green Target Green Target
GCPG1 ECS-1 OFF OFF OFF OFF
GENERATOR BCS-G2 Green Target Green Target Green Target Green Target
CONTROL PANEL 2 BCS-F2 Green Target Green Target Green Target Green Target
GCPG2 ECS-2 OFF OFF OFF OFF

① Hold the MSES in an ENABLE position until the selected USI indicator energizes. The switch
returns to the center position when released. This sets the PU networking address and enables
the control and monitoring.
② No more than one of each indicator can be on for multi-PU operations. The light on should match
USS position. The USI light will de-energize after the SMS has been in OFF for 3 seconds.

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

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

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

h. Close Generator 1 breaker by cycling BCS-G1 to the CLOSE position.

i. Observe that BCSG1 breaker closes.

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j. Place the SSS in the TIE position

k. Close the BCST by cycling BCST to the CLOSE position.

l. Return the SSS to the OFF position.

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

n. Observe the engine starts and accelerates to operating voltage and frequency.

o. At the A-unit MCP, place the Sync Source Switch (SSS) in the GEN 2 position.

p. Close BCSG2 when the two green triangular LEDs at 12 o’clock on the Synchroscope are
energized by cycling BCSG2 to the CLOSE position. For detailed instructions on manual
synchronizing refer to Chapter 5.9 Section 5.9.6.14.

q. Observe that the BCSG2 closes.

r. Return the SSS to the OFF position.

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

t. Close the BCST by cycling BCST to the CLOSE position.

u. Return the SSS to the OFF position.

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

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

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

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

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

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

bb. At the B-unit MCP, place the Sync Source Switch (SSS) in the GEN 2 position.

cc. Close BCSG2 when the two green triangular LEDs at 12 o’clock on the Synchroscope are
energized by cycling BCSG2 to the CLOSE position. For detailed instructions on manual
synchronizing refer to Chapter 5.9 Section 5.9.6.14.

dd. Return the SSS to the OFF position.

ee. At the C-unit, if installed, repeat steps ‘s’ through ‘dd’.

ff. At the D-unit, if installed, repeat steps ‘s’ through ‘dd’.

gg. At the external switchgear, close the connections of loads to the switchgear.

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hh. Ensure generators have assumed load.


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

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

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

5.5.5 PLANT OPERATIONS

Refer to Chapter 5.9 for specific operating procedures.

In this mode of operation the ORT provides no remote operation capability. It will provide monitoring of
the generator parameters.

5.5.6 POWER PLANT TEARDOWN

5.5.6.1 SHUTDOWN GENERATORS

a. Unload all generators by opening all feeder breakers. This must be done locally from the LCP or
ORT.

b. Open each BCST locally at the respective MCP.

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

d. Observe all generator breakers open.

e. Open all the switchgear generator supply disconnect switches.

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

g. Place all ECS switches in OFF/RESET.

h. Pull out the DC Control Power breaker on all PUs.

5.5.6.2 DISCONNECT CABLES

WARNING

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

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CAUTION

ALLOW ALL OPERATING ENGINES TO SHUT DOWN AND COOL DOWN


COMPLETELY.

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

b. Disconnect the ORT cable and store it in the ORT case.

c. Close and latch the ORT port on the PU.

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

5.5.6.3 DISCONNECT FUEL LINES

a. Turn all fuel system valves to the off position.

b. Disconnect the fuel hose from the PU fuel connection and the fuel supply.

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

5.5.6.4 DISCONNECT GROUNDING

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

b. Disconnect the parking stations from the ground grid.

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

5.5.6.5 PREPARE PU FOR TRANSPORTATION

a. Reinstall the four radiator splashguards (PU-810B only).

b. Verify DC Control power is off.

c. Close and lock the LCP access doors.

d. Close and lock all PU side doors.

5.5.6.6 FUEL, OIL, AND COOLANT DRAINAGE

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

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CHAPTER 5.6
OPERATING INSTRUCTIONS

SINGLE OR MULTIPLE PU, PRIME POWER, EXTERNAL SWITCH,


AUTOMATIC MODE
TABLE OF CONTENTS
SECTION TITLE PAGE
5.6 SINGLE/ MULTIPLE PU, PRIME POWER, EXTERNAL
SWITCH, AUTOMATIC MODE ................................................................................111

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

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

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

5.6.3.1 GROUNDING............................................................................................................112

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

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

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

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

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

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

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

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

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

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

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

5.6.5.2 DESCRIPTION..........................................................................................................127

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

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

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

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

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

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

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

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

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LIST OF FIGURES
FIGURE TITLE PAGE
FIGURE 5.6.3.1-1 MEP-PU-810A GROUND POINTS 112

FIGURE 5.6.3.1-2 MEP-PU-810B GROUND POINTS 113

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LIST OF TABLES
TABLE TITLE PAGE
TABLE 5.6.3.6-1 PRE-OPERATION RUN INSTRUCTION SEQUENCE 120

TABLE 5.6.3.8-1 PDC CONTROL SWITCH SETUP 122

TABLE 5.6.3.9-1 PSC RELAY SETTINGS 124

TABLE 5.6.4-1 SWITCH SETUP – AUTOMATIC MODE 125

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

5.6.1 SAFETY PROCEDURES

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

• Hot engine parts


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

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

5.6.2 POSITIONING THE PU

a. Position the PU in such a way as to allow the plant operator to have full vision of the operator
control panels on the unit.

b. Level the MEP-PU-810B front to rear with the trailer leveling hand crank.

c. Position the PU to provide a minimum of 10 feet of clearance for maintenance access on all
sides of each unit. Ensure that there are no overhead obstructions around the exhaust outlets.

WARNING

FUEL SPILLAGE CAN OCCUR IF THE POWER UNIT LEVEL IS GREATER THAN + 5
DEGREES.

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

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5.6.3 INITIAL PLANT SETUP

5.6.3.1 GROUNDING

WARNING

THERE CAN ONLY BE ONE GROUNDING POINT FOR THE PU.

a. Drive an 8-foot ground rod into the earth and should be within 6 feet of the PU and at a location
that minimizes the tripping hazard, until only 6 inches (15 cm) protrudes above the surface.

b. Repeat step “a” for each PU being used.

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

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

e. Repeat step “d” for every PU.

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

g. Remove parking stand plates from their transportation positions inside each rear, side PU door
and slide them into their respective operating positions on the sides of the PDC.

h. Connect the parking stand ground wires to either of the two chassis ground lugs on the PU.

GROUND POINT
GROUND POINT

FIGURE 5.6.3.1-1 MEP-PU-810A GROUND POINTS

NOTE: Connect only one ground point to the ground grid.

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GROUND POINT GROUND POINT

FIGURE 5.6.3.1-2 MEP-PU-810B GROUND POINTS

NOTE: Connect only one ground point to the ground grid.

5.6.3.2 FUEL MANIFOLD

WARNING

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

a. Lay out the fuel hoses between the PU, the fuel manifold, and the fuel bladders to establish the
fuel supply system. See Chapter 5.1 Figure 5.1.3.2-1 External Fuel Supply.

b. Install the external fuel hose for the PU to the Fuel Transfer Pump at the Tow end of the PU.

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

d. Connect the 3” hose, with quick-disconnect hose ends, from the fuel manifold to the fuel
bladders.

e. Connect the fuel manifold ground wire to the ground grid.

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

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5.6.3.3 DISTRIBUTION AND CONTROL CABLING

WARNING

DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS


OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A
SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET
IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT
FROM FAILURE TO OBSERVE THIS WARNING.

WARNING

HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT


DURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION
AND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN
LOAD CABLES ARE HANDLED.

WARNING

VERIFY THAT CONNECTION POINTS ARE DE-ENERGIZED BEFORE MAKING ANY


CONNECTIONS. FAILURE TO CHECK THAT CONNECTORS ARE DE-ENERGIZED
MAY RESULT IN INJURY OR DEATH.

a. Lay out and park the load cables for each phase (A, B, & C) between the PU Tie Output parking
stations and the Primary Switching Center (PSC).

b. Connect each phase cable to the appropriate phase connection on the Primary Switching Center
(PSC).

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

NOTE: 2: For Unit Isolation Procedure (any unit) - Plant with PSC, and Unit Re-Installation
Procedure – Plant with PSC, refer to Section 5.9, Section 5.9.6.15, and Section 5.9.6.16.

c. Connect each load cables drain wire to the grounding grid.

d. Open the Tie Output connector loadbreak covers on the first PU.

e. Connect the Tie Output Cables to the appropriate phase connectors; ensure there are no cross-
phase connections.

f. Close and lock the Tie Output connector covers.

g. Repeat steps ‘a’ through ‘f’ on each remaining PU.

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

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

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

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

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

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

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

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

p. Connect the third (A) (B) communication cable to “A” receptacle on fourth PU.

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

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

5.6.3.4 SETPOINT VERIFICATION

a. Turn on PU DC control power by pushing in on the DC Control Power breaker.

b. On each of the five overcurrent relays, verify the settings:

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

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

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

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

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

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

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


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

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

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

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

(12) Verify the “50TN” settings.

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

(14) Verify the “50TQ” settings.

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

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

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

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

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

(20) Verify the 51N settings.

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

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

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

(1) Place ECS in the COOLDOWN/STOP position.

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

(3) Press SCROLL UP key until “OP3” is showing.

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

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

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

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

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

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

(10) Press ENTER key. “PE PASS” is showing.

(11) Press EXIT key. “OP4” is showing.

(12) Press SCROLL UP key until “OP5-0” is showing on the lower display.

(13) Press SELECT key. “POO1” followed with the value of the setpoint is showing.

(14) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing.
Use Chapter 5.1 Table 5.1.3.4-4 OP5 Settings for the parameter values to be verified.
Repeat until the desired setpoints are verified.

(15) Press EXIT key. “OP5-0” is showing on the lower display.

(16) Press SCROLL UP key until “OP5-1” is showing.

(17) Press SELECT key.

(18) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing.
Use Chapter 5.1 Table 5.1.3.4-5 OP5-1 Settings for the parameter values to be verified.
Repeat until the desired setpoints are verified.

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(19) Press EXIT key. “OP5-1” is showing.

(20) Press SCROLL UP key. “OP6” is showing.

(21) Press SELECT key.

(22) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing.
Use Chapter 5.1 Table 5.1.3.4-6 OP6 Settings for the parameter values to be verified.
Repeat until the desired setpoints are verified.

(23) Press EXIT key twice. The display returns to normal.

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

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

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

(c) Press ENTER. The correct value stops flashing on the display.

Press SCROLL UP or SCROLL DOWN key to continue to verify the remaining


(d)
parameter values.
d. Return ECS1 and ECS2 to the OFF/RESET position.

NOTE: Use up or down keys to change values.

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

(1) Open the GCPG1 cabinet door.

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

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

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

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

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

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

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

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

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

(11) When complete, press the [▼] to display parameter “01”.

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

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

(12) When complete, press the [▼] to display parameter “90”.

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

(14) Press the [▼] key to change the value to “0009”. Disables DVR parameter editing.

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

(16) Press the [▲] key to change to display parameter “01”.

(17) Close the GCPG1 cabinet door.

(18) Repeat steps ‘1 ‘through ‘16’ for Generator 2.

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5.6.3.5 PRE-OPERATION CHECKS

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

5.6.3.6 PRE-OPERATION RUN

WARNING

ENSURE ALL PERSONNEL ARE CLEAR AND THE PU DOORS ARE CLOSED
PRIOR TO STARTING A GENERATOR.

WARNING

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND


ENFORCED.
NOISE LEVELS IN EXCESS OF 85 DB EXIST WITHIN AN 88-FOOT RADIUS OF AN
OPERATING DPGDS. PERSONNEL MUST WEAR SINGLE HEARING PROTECTION
WITHIN 88 FEET OF AN OPERATING DPGDS.

WARNING

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND


ENFORCED.
DURING MAINTENANCE ACTIVITIES WITH THE SIDEDOORS OPEN, NOISE
LEVELS IN EXCESS OF 113 DB EXIST WITHIN A 12-FOOT RADIUS OF AN
OPERATING DPGDS. PERSONNEL MUST WEAR DOUBLE HEARING PROTECTION
WITHIN 12 FEET OF AN OPERATING DPGDS. EXPOSURE MUST BE LIMITED TO
UNDER 2.5 HOURS.

WARNING

BY CLOSING THE FEEDER OR TIE BREAKER, HIGH VOLTAGE WILL BE PRESENT


ON THE LOAD CABLES. ENSURE ALL PERSONNEL ARE CLEAR OF ALL LOAD
CABLES PRIOR TO CLOSING FEEDER OR TIE BREAKERS.

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TABLE 5.6.3.6-1 PRE-OPERATION RUN INSTRUCTION SEQUENCE


(Perform on each PU in the power plant)
STEP -- 60HZ OPERATIONS -- -- 50HZ OPERATIONS --

1 Verify System Mode Switch (SMS) is in MANUAL

2 Verify DC Control Power is on

3 Verify Emergency Stop is pulled out

4① Verify the 60Hz light is on ① Verify the 50Hz light is on①

5 Start engine 1 by placing ECS1 in MANUAL

6 Verify the engine accelerates to 1800RPM Verify the engine accelerates to 1500RPM

7 Adjust the generator frequency to 60Hz Adjust the generator frequency to 50Hz using
using the Frequency Adjust Rheostat (FAR) the Frequency Adjust Rheostat (FAR)

8 Adjust the generator voltage to 4295VAC Adjust the generator voltage to 3915VAC
using the Voltage Adjust Rheostat (VAR) using the Voltage Adjust Rheostat (VAR)

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

10 Shutdown engine 1 by placing ECS1 in OFF/RESET

11 Start engine 2 by placing ECS2 in MANUAL

12 Verify the engine accelerates to 1800RPM Verify the engine accelerates to 1500RPM

13 Adjust the generator frequency to 60Hz Adjust the generator frequency to 50Hz using
using the Frequency Adjust Rheostat (FAR) the Frequency Adjust Rheostat (FAR)

14 Adjust the generator voltage to 4295VAC Adjust the generator voltage to 3915VAC
using the Voltage Adjust Rheostat (VAR) using the Voltage Adjust Rheostat (VAR)

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

16 Shutdown engine 2 by placing ECS2 in OFF/RESET

① If the wrong frequency light is on, open the Master Control Door and change the Frequency
Selector Switch (FSS) to the desired frequency.

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5.6.3.7 ORT SETUP

a. Remove the ORT from its case and set it up on a flat and level surface.

b. Remove the mouse from the case and plug it into the mouse (PS2) port on the back of the ORT.

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

d. Connect one end of the 150-foot patch cable to the ORT networking port on the PU.

e. Route the cable from the ORT to the PU and connect the cable to the ORT port.

f. Turn on the ORT.

g. Observe that the ORT boots to the operator’s Overview screen.

h. Select the EquipID pop-up screen and enter the necessary information for the units. This
includes the Trailer ID number, the Engine ID number, and the Generator ID number for each
PU.

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

h. Return to the Overview pop-up screen.

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5.6.3.8 CONTROLS SETUP

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

NOTE: Ignore settings for Power Units not being used:

TABLE 5.6.3.8-1 PDC CONTROL SWITCH SETUP


PANEL SWITCH 1ST PU 2ND PU 3RD PU 4TH PU
Pushed In Pushed In Pushed In Pushed In
DC Power
(ON) (ON) (ON) (ON)
SMS OFF OFF OFF OFF
PRIME PRIME PRIME PRIME
GMS
POWER POWER POWER POWER
MASTER CONTROL PRIME PRIME PRIME PRIME
AVRS
PANEL MCP POWER POWER POWER POWER
60Hz Light ON① ON① ON① ON①
USS A② B② C② D②
BSS NORMAL NORMAL NORMAL NORMAL
SSS OFF OFF OFF OFF
SSL All OFF All OFF All OFF All OFF
50/60 50/60 50/60 50/60
INSIDE MCP FSS
Hertz① Hertz① Hertz① Hertz①
GENERATOR Emergency
Pulled-Out Pulled-Out Pulled-Out Pulled-Out
CONTROL PANEL Stop
GCPG1 ECS OFF OFF OFF OFF
GENERATOR Emergency
Pulled-Out Pulled-Out Pulled-Out Pulled-Out
CONTROL PANEL Stop
GCPG2 ECS OFF OFF OFF OFF
① With the SMS in the OFF position, the 50/60Hz lights indicate the position of the Frequency
Selector Switch (FSS). If the wrong light is on, open the door and change the switch position.
② No more than one switch can be in the same position in any multi-PU line-up. With the SMS in
OFF, none of the USI lights will be on and any previously set address on the PU is cleared.

5.6.3.9 PSC RELAY SETTING VERIFICATION

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

b. Click on Windows Start button.

c. Select Programs then Accessories then HyperTerminal.

d. Double Click on “Vista.ht”

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

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NOTE: Use Com 1 communications port on the ORT.

e. Click on “Connect”.

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

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

g. Press “Enter” on the ORT.

NOTE: The overcurrent relay main menu should appear.

h. Select View Menu 1, WAY 3.

i. Select View relay settings.

j. Verify relay settings according to Table 5.6.3.9-1

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

k. Repeat steps g through I for WAY 4.

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

m. Return to the Main Menu and “Disconnect” using Windows HyperTerminal when desired
programming action is complete.

n. Disconnect the OCR end of the communication cable.

o. Repeat steps e. through l. for the right OCR (Ways 5 and 6).

p. Repeat steps e. though m. for each PSC in use.

q. Exit Windows HyperTerminal.

r. Shut-down the ORT.

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TABLE 5.6.3.9-1 PSC RELAY SETTINGS


MIN. INST. TIME
CABLE
PSC WAY FUNCTION CURVE PICKUP PICKUP DELAY
SIZE
(AMPS) (KAMPS) (SEC.)
3,4, or 5 Feeder 1/0 TAP 200 1 Off
Feeder
3,4, or 5 1/0 TAP 50 0 Off
Ground
Single
3,4, or 5 500 KCM MAIN 600 1 Off
Output
Single
3,4, or 5 Output 500 KCM MAIN 100 0 Off
Ground
PSC
6 4/0 TAP 400 0 C (64ms)
Interconnect
PSC
6 Interconnect 4/0 TAP 80 0 C (64ms)
Ground

5.6.4 PLANT STARTUP

WARNING

ONCE THE SYSTEM STATUS LIGHTS TURN GREEN AND THE MSES IS ENABLED,
THE PU WILL START. ENSURE PERSONNEL ARE CLEAR OF THE PU.

WARNING

ONLY ONE PU MAY BE SELECTED TO ANY ONE USS POSITION DURING MULTIPLE
PU OPERATIONS. OPERATING WITH MORE THAN ONE UNIT AT THE SAME ID
CAUSE UNSAFE AND ERRATIC OPERATIONAL CONDITIONS.

WARNING

ALWAYS PAD LOCK THE PSC INTERCONNECT SWITCHES. FAILURE TO DO SO


COULD RESULT IN PERSONAL INJURY OR DAMAGE TO EQUIPMENT

Starting up a Multi-PU Prime Power Plant in Automatic Mode

a. At the Primary Switching Center (PSC), close the associated connection for each PU supplying
power to the switchgear and close and pad lock the PSC interconnect switches when using more
than one primary switch.

b. At the PSC, close the connections between the external switchgears.

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

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

NOTE: 2: For Unit Isolation Procedure (any unit) - Plant with PSC, and Unit Re-Installation
Procedure – Plant with PSC, refer to Section 5.9, Section 5.9.6.15, and Section 5.9.6.16.

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

TABLE 5.6.4-1 SWITCH SETUP – AUTOMATIC MODE


PANEL SWITCH 1ST PU 2ND PU 3RD PU 4TH PU
BCS-T Red Target Red Target Red Target Red Target
MASTER CONTROL
PANEL MCP
SMS AUTO③ AUTO③ AUTO③ AUTO③
USS A B C D
GENERATOR BCS-G1 Red Target Red Target Red Target Red Target
CONTROL PANEL 1 BCS-F1 Red Target Red Target Red Target Red Target
GCPG1 ECS-1 AUTO AUTO AUTO AUTO
GENERATOR BCS-G2 Red Target Red Target Red Target Red Target
CONTROL PANEL 2 BCS-F2 Red Target Red Target Red Target Red Target
GCPG2 ECS-2 AUTO AUTO AUTO AUTO
MASTER CONTROL MSES Enable① Enable① Enable① Enable①
PANEL MCP USI A①, ② B①, ② C① , ② D① , ②

① Hold the MSES in an ENABLE position until the selected USI indicator energizes. The switch
returns to the center position when released. This sets the PU networking address and enables
the control and monitoring.
② No more than one of each indicator can be on for multi-PU operations. The light on should match
USS position. The USI light will de-energize after the SMS has been in OFF for 3 seconds.
③ With the SMS in AUTO any generator started, manually or automatically, will automatically
parallel to the bus. To prevent the generator from paralleling to the bus put the generator’s
breaker in the Pull-To-Lock position.
NOTE: The automatic economizing feature will shutdown one generator every 3 minutes until the
system load is at or below the 360KW/450KVA per generator threshold.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

z. Ensure generators have assumed load.


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

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

CAUTION
Improper adjustment of the VAR can cause a reverse KVAR shutdown of a generator.
5.6.5 PLANT OPERATIONS (AUTOMATIC MODE)

5.6.5.1 PRECAUTIONS AND WARNINGS

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This mode of operation places control of all generator starting, stopping, synchronizing, and load
management under the auspices of the Programmable Logic Controller (PLC) system. As long as the
SMS is in AUTO, any generator started, manually or automatically, is automatically synchronized to the
system bus. Care must be taken when starting a generator manually when the SMS is in AUTO. Either
place the associated BCS in Pull-To-Lock (prevent closing to the bus) or ensure it has the red target
visible (allow paralleling to the bus) before starting the engine. The only exception is automatic operation
of the feeder breakers. Auto Mode does not automatically close feeder breakers; it only enables remote
operation of the feeder breakers from the ORT.

5.6.5.2 DESCRIPTION

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

5.6.5.3 DEFAULT OPERATING SEQUENCE

Start-Up Sequence: The automatic controls will continuously monitor the system load. As load on the
system increases, the controls automatically start and place additional units on line in the following
sequence at 1-minute intervals:

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


b. One generator from PU “C” based on lower engine runtime.
c. One generator from PU “D” based on lower engine runtime.
d. Remaining generator from PU “A”.
e. Remaining generator from PU “B”.
f. Remaining generator from PU “C”.
g. Remaining generator from PU “D”.

Shutdown Sequence: Based on the loading experienced, the controller shuts down generator sets that
are not needed. For the purpose of explanation, we will assume that all generator sets are on line
following an initial startup. Based on load, the controls shut down generator sets in the following
sequence at 3-minute intervals:

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


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

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f. Remaining generator from PU “C”.
g. Remaining generator from PU “B”.

5.6.6 POWER PLANT TEARDOWN

5.6.6.1 SHUT DOWN GENERATORS

a. Unload all generators by opening all feeder breakers. This must be done locally from the LCP or
ORT.

b. Open each BCST locally at the respective MCP.

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

d. Observe all generator breakers open.

e. Open all the switchgear generator supply disconnect switches.

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

g. Place all ECS switches in OFF/RESET.

h. Pull out the DC Control Power breaker on all PUs.

5.6.6.2 DISCONNECT CABLES

WARNING

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

CAUTION

ALLOW ALL OPERATING ENGINES TO SHUT DOWN AND COOL DOWN COMPLETELY.

a. Disconnect the (A)(B) communication cables from between the PUs, Reinstall the
communication receptacle covers, and store inside the PUs (one per unit).

b. Disconnect the ORT cable and store it in the ORT case.

c. Close and latch the ORT port on the PU.

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

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5.6.6.3 DISCONNECT FUEL LINES

a. Turn all fuel system valves to the off position.

b. Disconnect the fuel hose from the PU fuel connection and the fuel supply.

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

5.6.6.4 DISCONNECT GROUNDING

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

b. Disconnect the parking stations from the ground grid.

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

5.6.6.5 PREPARE PU FOR TRANSPORTATION

a. Reinstall the four radiator splashguards (PU-810B only).

b. Verify DC Control power is off.

c. Close and lock the LCP access doors.

d. Close and lock all PU side doors.

5.6.6.6 FUEL, OIL, AND COOLANT DRAINAGE

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

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THIS PAGE INTENTIONALLY BLANK

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CHAPTER 5.7
OPERATING INSTRUCTIONS

MEP-PU-810 AND MEP-012 PARALLEL OPERATIONS, MANUAL AND


AUTOMATIC MODE
TABLE OF CONTENTS

SECTION TITLE PAGE


5.7 MEP-PU-810 & MEP-012 PARALLEL OPERATIONS, MANUAL AND
AUTOMATIC MODE 135

5.7.1 SAFETY PROCEDURES 135

5.7.2 MEP-PU-810 AND MEP-012 PARALLEL OPERATION DESCRIPTION 135

5.7.3 POSITIONING THE PU 136

5.7.4 INITIAL PLANT SETUP 137

5.7.4.1 GROUNDING 137

5.7.4.2 FUEL MANIFOLD 139

5.7.4.3 DISTRIBUTION AND CONTROL CABLING 140

5.7.4.4 SETPOINT VERIFICATION 142

5.7.4.5 PRE-OPERATION CHECKS 155

5.7.4.6 PRE-OPERATION RUN 157

5.7.4.7 ORT SETUP 159

5.7.4.8 CONTROLS SETUP 160

5.7.5 PLANT STARTUP 161

5.7.5.1 MANUAL MODE 161

5.7.5.1.1 STARTING UP SINGLE OR MULTIPLE PU’S IN MANUAL MODE WITH A


MEP-012 POWER PLANT 161

5.7.5.1.2 STARTING UP SINGLE OR MULTIPLE MEP-012’S WITH A MEP-PU-810


POWER PLANT IN MANUAL MODE 164

5.7.5.2 AUTOMATIC MODE 165

5.7.5.2.1 STARTING UP SINGLE OR MULTIPLE PU’S IN AUTOMATIC MODE WITH A


MEP-012 POWER PLANT 165

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5.7.5.2.2 STARTING UP SINGLE OR MULTIPLE MEP-012’S WITH A PU POWER


PLANT IN AUTOMATIC MODE 167

5.7.6 PLANT OPERATIONS 168

5.7.7 POWER PLANT TEARDOWN 168

5.7.7.1 SHUT DOWN GENERATORS 168

5.7.7.2 DISCONNECT CABLES 168

5.7.7.3 DISCONNECT FUEL LINES 169

5.7.7.4 DISCONNECT GROUNDING 169

5.7.7.5 PREPARE PU FOR TRANSPORTATION 169

5.7.7.6 FUEL, OIL, AND COOLANT DRAINAGE 169

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LIST OF FIGURES

FIGURE TITLE PAGE


FIGURE 5.7.4.1-1 MEP-PU-810A GROUND POINTS 138

FIGURE 5.7.4.1-2 MEP-PU-810B GROUND POINTS 138

FIGURE 5.7.4.2-1 EXTERNAL FUEL SUPPLY 139

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LIST OF TABLES

TABLE TITLE PAGE


TABLE 5.7.4.4-1 CT RATIO SETTINGS 142

TABLE 5.7.4.4-2 INSTANTANEOUS TRIP SETTINGS 142

TABLE 5.7.4.4-3 TIME OVERCURRENT TRIP SETTINGS 143

TABLE 5.7.4.4-4 OP5-0 SETPOINTS 145

TABLE 5.7.4.4-4 OP5-0 SETPOINTS (CONTINUED) 146

TABLE 5.7.4.4-5 OP5-1 SETPOINTS 148

TABLE 5.7.4.4-5 OP5-1 SETPOINTS (CONTINUED) 149

TABLE 5.7.4.4-5 OP5-1 SETPOINTS (CONTINUED) 150

TABLE 5.7.4.4-6 OP6 SETPOINTS 151

TABLE 5.7.4.4-6 OP6 SETPOINTS (CONTINUED) 152

TABLE 5.7.4.4-7 AVR PARAMETERS/SETPOINTS 153

TABLE 5.7.4.4-7 AVR PARAMETERS/SETPOINTS (CONTINUED) 154

TABLE 5.1.3.5-1 PRE-OPERATION CHECKLIST 155

TABLE 5.1.3.5-1 PRE-OPERATION CHECKLIST (CONTINUED) 156

TABLE 5.7.4.6-1 PRE-OPERATION RUN INSTRUCTION SEQUENCE 158

TABLE 5.7.4.8-1 CONTROL SWITCH SETUP 160

TABLE 5.7.5.1-1 SWITCH SETUP – MANUAL MODE 162

TABLE 5.7.5.1-2 GENERATOR CAPACITIES 163

TABLE 5.7.5.2.1-1 SWITCH SETUP – AUTOMATIC MODE 166

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


MODE

5.7.1 SAFETY PROCEDURES

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

• Hot engine parts


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

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

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

The MEP-PU-810 generator is an isochronous generator. It operates at 50 or 60 Hertz for its


complete load range of 0-420KW. By design, a single isochronous generator will assume the
load on the bus up to its full capacity. To allow multiple isochronous generators to work in parallel
Load Share Modules (LSM) are used. Each generator has its own LSM and these are
interconnected by load share lines. The LSMs of online generators put a voltage on the load
share lines that is sensed by all other LSMs. Each LSM then compares the load share line
voltage to its internal load voltage and develops an error signal. This error is then used to raise
or lower the KW load carried by that generator until all online generators are sharing the load
equally (no error signal). With this type of operation no adjustment to the generator frequency is
required to distribute load equally among the generators. This also allows multiple generators,
even ones of different capacity, to operate in parallel under all conditions from no-load to full-load.

The MEP-012 will be operated as a droop generator. As it is loaded from 0-750KW, its frequency
droops by a set ratio. The generator’s frequency adjust potentiometer is then raised to maintain
the desired frequency. Operating multiple droop generators together requires the operator to
adjust generator frequency potentiometers to distribute the load proportionally among generators.
Additionally, the operator must constantly adjust generator frequencies to maintain the required
frequency whenever loads are added or shed.

Both kinds of generators may be operated together; however, close attention must be paid to the
system load and the droop unit’s frequency. The isochronous generator will set system
frequency and try to assume its full capacity. This requires the operator to lower the droop unit
frequency to transfer the load to the isochronous generator. That unit carries load increases up
to the capacity of the droop unit. Additional load above the total capacity of both generators will
obviously require an additional generator. Load decreases below the full capacity rating of just
the isochronous unit will require the operator to shutdown the droop unit.

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The recommended method of operating MEP-PU-810s and MEP-012s together is to place the
MEP-PU-810 generators on the bus and allow them to carry the normal load. When the system
load approaches the rated capacity of the MEP-PU-810 generator(s), add MEP-012 generators
as required to provide the necessary capacity. As the load drops off, shutdown the MEP-012
generator(s).

CAUTION

THE MEP-PU-810 WILL TRY TO ASSUME ITS RATED LOAD WHEN PARALLELED
WITH ANOTHER GENERATOR THAT IS OPERATING IN DROOP. VOLTAGE AND
FREQUENCY ADJUSTMENTS ON THE DROOP PLANT MUST BE USED TO
CONTROL THE LOAD SHARING BETWEEN THE PLANT AND THE MEP-PU-810.

There may be situations where the recommended method of operation is not ideal. In these
situations, understanding the way isochronous and droop generators work and operational
experience are useful in achieving a line-up that is best for the application.

5.7.3 POSITIONING THE PU

a. Position the PU in such a way as to allow the plant operator to have full vision of the operator
control panels on the unit.

b. Level the MEP-PU-810B front to rear with the trailer leveling hand crank.

c. Position the PU to provide a minimum of 10 feet of clearance for maintenance access on all
sides of each unit. Ensure that there are no overhead obstructions around the exhaust outlets.

WARNING

FUEL SPILLAGE CAN OCCUR IF THE POWER UNIT LEVEL IS GREATER THAN + 5
DEGREES.

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

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5.7.4 INITIAL PLANT SETUP

5.7.4.1 GROUNDING

WARNING

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

a. Drive an 8-foot ground rod into the earth and should be within 6 feet of the PU and at a location
that minimizes the tripping hazard, until only 6 inches (15 cm) protrudes above the surface.

b. Repeat step “a” for each PU being used.

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

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

e. Repeat step “d” for every PU.

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

g. Remove parking stand plates from their transportation positions inside each rear, side PU door
and slide them into their respective operating positions on the sides of the PDC.

h. Connect the parking stand ground wires to either of the two chassis ground lugs on the PU.

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GROUND POINT GROUND POINT

FIGURE 5.7.4.1-1 MEP-PU-810A GROUND POINTS

NOTE: Connect only one ground point to the ground grid.

GROUND POINT GROUND POINT

FIGURE 5.7.4.1-2 MEP-PU-810B GROUND POINTS

NOTE: Connect only one ground point to the ground grid.

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5.7.4.2 FUEL MANIFOLD

WARNING

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

a. Lay out the fuel hoses between the PU, the fuel manifold, and the fuel bladders to establish the
fuel supply system see Figure 5.7.4.2-1.

b. Install the external fuel hose for the PU to the Fuel Transfer Pump at the Tow end of the PU.

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

d. Connect the 3” hose, with quick-disconnect hose ends, from the fuel manifold to the fuel
bladders.

e. Connect the fuel manifold ground wire to the ground grid.

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

FIGURE 5.7.4.2-1 EXTERNAL FUEL SUPPLY

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5.7.4.3 DISTRIBUTION AND CONTROL CABLING

WARNING

DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS


OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A
SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET
IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT
FROM FAILURE TO OBSERVE THIS WARNING.

WARNING

HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT


DURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION
AND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN
LOAD CABLES ARE HANDLED.

WARNING

VERIFY THAT CONNECTION POINTS ARE DE-ENERGIZED BEFORE MAKING ANY


CONNECTIONS. FAILURE TO CHECK CONNECTORS DE-ENERGIZED MAY
RESULT IN INJURY OR DEATH.

a. Lay out and park the load cables for each phase (A, B, & C) between the PU Tie Output parking
stations and the load.

b. Connect each phase cable to the appropriate phase connection on the Primary Switching Center
(PSC).

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

NOTE: 2: For Unit Isolation Procedure (any unit) - Plant with PSC, and Unit Re-Installation
Procedure – Plant with PSC, refer to Section 5.9, Section 5.9.6.15, and Section 5.9.6.16.

c. Connect each load cables drain wire to the grounding grid.

d. Open the Tie Output connector loadbreak covers on the first PU.

e. Connect the Tie Output Cables to the appropriate phase connectors; ensure there are no cross-
phase connections.

f. Close and lock the Tie Output connector covers.

g. Repeat steps ‘b’ through ‘f’ on each remaining PU.

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

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

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

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

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

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

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

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

p. Connect the third (A) (B) communication cable to “A” receptacle on fourth PU.

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

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

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5.7.4.4 SETPOINT VERIFICATION

a. Turn on the control power by pushing in the DC Control Power breaker.

b. On each of the five overcurrent relays, verify the settings:

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

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

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

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

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

(6) Verify the “P” and “N” values match the following table:

TABLE 5.7.4.4-1 CT RATIO SETTINGS


BREAKER RELAY CT RATIO “P” VALUE “N” VALUE
GENERATOR 100:5 20 20
FEEDER 200:5 40 40
TIE 200:5 40 40

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


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

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

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

TABLE 5.7.4.4-2 INSTANTANEOUS TRIP SETTINGS


PHASE NEUTRAL NEGATIVE SEQUENCE
INSTANTANEOUS INSTANTANEOUS TRIP
BREAKER RELAY
TRIP 50TP TRIP 50TN 50 TQ
PU TD PU TD PU TD
GENERATOR 0.0 0m 3.0 0m 3.0 0m
FEEDER 7.5 84m 1.25 84m 0 0m
TIE 0.0 0m 0 0m 0.0 0m

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

(12) Verify the 50TN settings in Table 5.7.4.4-2.

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

(14) Verify the “50TQ” settings

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

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

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

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

TABLE 5.7.4.4-3 TIME OVERCURRENT TRIP SETTINGS


PHASE TIME OVERCURRENT NEUTRAL TIME OVERCURRENT
BREAKER RELAY TRIP 51P TRIP 51N
PU TD C PU TD C
GENERATOR 4.50 0.5 VV2 1.25 0.5 VV2
FEEDER 2.50 1.0 VV2 1.00 1.0 VV2
TIE 5.00 2.0 VV2 1.50 2.0 VV2

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

(20) Verify the 51N settings in Table 5.7.4.4-3.

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

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

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

(1) Place ECS in the COOLDOWN/STOP position.

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

(3) Press SCROLL UP key until “OP3” is showing.

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

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

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

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

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

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

(10) Press ENTER key. “PE PASS” is showing.

(11) Press EXIT key. “OP4” is showing.

(12) Press SCROLL UP key until “OP5-0” is showing on the lower display.

(13) Press SELECT key. “POO1” followed with the value of the setpoint is showing.

(14) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing.
Use Table 5.7.4.4-4 for the parameter values to be verified. Repeat until the desired
setpoints are verified.

(15) Press EXIT key. “OP5-0” is showing on the lower display.

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(16) Press SCROLL UP key until “OP5-1” is showing.

(17) Press SELECT key.

(18) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing.
Use Table 5.7.4.4-5 for the parameter values to be verified. Repeat until the desired
setpoints are verified.

(19) Press EXIT key. “OP5-1” is showing.

(20) Press SCROLL UP key until “OP6” is showing.

(21) Press SELECT key.

(22) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing.
Use Table 5.7.4.4-6 OP6 Setpoints for the parameter values to be verified. Repeat until the
desired setpoints are verified.

(23) Press EXIT Key twice. The display returns to normal.

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

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

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

(c) Press ENTER. The correct value stops flashing on the display.

Press SCROLL UP or SCROLL DOWN key to continue to verify the remaining


(d)
parameter values.
d. At GSCG1 and GSCG2, verify the operation settings using the following table:

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TABLE 5.7.4.4-4 OP5-0 SETPOINTS
SETPOINTS OP5-0 ENGINE/GENERATOR PROGRAMMING①
FACTORY DPGDS
SETPOINT-NAME-DESCRIPTIONS RANGE OF VALUES
DEFAULT SETPOINT
P001 - Fuel Solenoid Type: type of fuel system solenoid 0- ETR fuel solenoid
0 0
used on the genset. 1- ETS fuel solenoid
P002 - Units Shown: type of measurement units shown 0-for English units (PSI, ºF)
0 0
on the GSC+ display. 1-for metric units (kPa, ºC).
P003 - Shutdown Override For Engine Fault: GSC+ 0-for engine shutdown
response to a low engine oil pressure or high coolant 1-for alarm only (shutdown override, no 0 0
temperature fault. engine shutdown).
P004 - Shutdown Override For Sensor Fault: GSC+ 0-for alarm only shutdown override, no
response to a diagnostic fault with the engine oil pressure engine shutdown). 0 0
sensor, coolant temperature sensor, oil temperature
sensor, sensor power supply or coolant loss sensor. 1-for engine shutdown.

P005 - Coolant Loss Sensor Installed: tells whether or 0-for gensets without a coolant loss sensor
not the optional engine coolant loss sensor is installed on 0 1
the genset. 1-for gensets with coolant loss sensor

0-for engine shutdown.


P006 - Shutdown Override For Coolant Loss Fault:
1-for alarm only (shutdown override, no 0 0
GSC+ response to an engine coolant loss fault.
engine shutdown).
P007 - System Voltage, 24 Or 32 Volts: system voltage
24 or 32. 24 24
(battery voltage) of the genset.
P008 - This setpoint is not currently being used by the
N/A N/A N/A
GSC+ and cannot be programmed.
P009 - Number Of Ring Gear Teeth: number of teeth on
the ring gear of the engine. Used by the GSC+ to 95 to 350 teeth in increments of one tooth. 136 teeth 136 teeth
determine engine speed.
P010 - Engine Overspeed: engine speed used by the
GSC+ to declare that an engine overspeed fault exists.
500 to 4330 rpm in increments of 10 rpm. 2120 rpm 2120 rpm
The engine overspeed setpoint (for all 60 Hz applications)
is 1.18 times the rated speed.
P011 - Crank Terminate Speed: engine speed used by
the GSC+ to disengage the starting motor during engine 100 to 1000 rpm in increments of 10 rpm. 400 rpm 400 rpm
cranking.
P012 - Oil Step Speed: engine speed used by the GSC+
for distinguishing between rated speed and idle speed 400 to 1800 rpm in increments of 10 rpm. 1350 rpm 1350 rpm
when a low oil pressure fault exists.

P013② - Low Oil Pressure Shutdown At Rated Speed:


oil pressure used by the GSC+ to declare that a low oil 30 PSI 30 PSI
pressure shutdown fault exists with engine at rated speed 5 to 61PSI (34 to 420kPa) in increments of 1
(205 kPa) (205 kPa)
(the engine speed must have exceeded the oil step speed
for nine seconds).

P014② - Low Oil Pressure Shutdown At Idle Speed:


oil pressure used by the GSC+ to declare that a low oil
10 PSI 10 PSI
pressure shutdown fault exists with the engine at idle 20 to 336kPa (3 to 49PSI) in increments of 1
speed (the engine must have been running for at least 9 (70 kPa) (70 kPa)
seconds and the engine speed must be less than oil step
speed).

P015③ - High Water Temperature Shutdown: coolant


185 to 253ºF (85 to 123ºC) in increments of 225ºF 225ºF
temperature used by the GSC+ to declare a high coolant
temperature shutdown fault exists (after a 10 second 1 (107ºC) (107ºC)
delay).
P016 - Low Water Temperature Alarm: coolant
temperature used by the GSC+ to declare that a low 70ºF 70ºF
32 to 97ºF (0 to 36ºC) in increments of 1
coolant temperature alarm fault exists (after a 2 second (21ºC) (21ºC)
delay).

5-145
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DRS RADIAN CTM 01646.1R0253/1R0254

TABLE 5.7.4.4-4 OP5-0 SETPOINTS (CONTINUED)


SETPOINTS OP5-0 ENGINE/GENERATOR PROGRAMMING①
FACTORY DPGDS
SETPOINT-NAME-DESCRIPTIONS RANGE OF VALUES
DEFAULT SETPOINT
P017 - Total Cycle Crank Time: cycle crank time used by the 5 to 120 seconds in increments of 1
90 seconds 90 seconds
GSC+ to declare that an overcrank fault exists. second.
P018 - Cycle Crank Time: amount of time the GSC+ cranks 5 to 60 seconds in increments of 1
10 seconds 10 seconds
and then rests the starting motor during a single crank cycle. second.
P019 - Cooldown Time: amount of time the GSC+ allows the 0 to 30 minutes in increments of 1
5 minutes 5 minutes
engine to run after a normal shutdown is initiated. minute.

P020④ - AC Voltage: nominal AC voltage of the generator. 700, 150, 300, 500, 600, 750, 3.0k,
The GSC+ measures the AC voltage and shows it on the 4.5k, 5.20k, 5.25k, 9.0k, 15.0k, 18.0k, 700 5.20k
display. 30.0k
P021 - AC Current Full Scale: nominal full scale AC current 75, 100, 150, 200, 300, 400, 600, 800,
of the generator. AC current full scale is equal to the ratio of 1000, 1200, 1500, 2000, 2500, 3000, 600A 100A
the external current transformers in the generator housing. and 4000A

P022⑤ - GSC+ Engine Number: informs other devices on


01 (Gen 1)
01 through 08 01
the CAT Data Link of the engine number for the GSC+. 02 (Gen 2)

SETPOINTS - OP5-0-ENGINE/GENERATOR PROGRAMMING①


RANGE OF FACTORY 60HZ 50HZ
SETPOINT-NAME-DESCRIPTIONS
VALUES DEFAULT SETPOINT SETPOINT
P023 - Engine Type: identifies the engine as a 0 - MUI diesel
mechanical unit injector (MUI) diesel, spark
1 - Gas 0 2 2
ignited (gas), or electronic unit injector (EUI)
diesel engine. 2 - EUI diesel
P024 - Crank Time Delay: amount of time the
GSC+ delays activation of the fuel control relay
(FCR) during a crank cycle. This setpoint is for 0 to 20 seconds in increments of 1
5 Seconds 5 Seconds 5 Seconds
Gas engines only. The P024 setpoint only second.
functions when the P023 setpoint is set to 1 (gas
engine).
0 - for gensets without an oil
P025 - Oil Temperature Sensor Installed: tells temperature sensor
whether or not the optional engine oil temperature 0 0 0
sensor is installed on the genset. 1 - for gensets with an oil
temperature sensor
P026 - High Oil Temperature Shutdown: oil
temperature used by the GSC+ to declare a high 185 to 253ºF (85 to 123ºC) in
225ºF (107ºC) 225ºF (107ºC) 225ºF (107ºC)
oil temperature shutdown fault exists (after a 10 increments of 1
second delay). Refer to the panel model number.
P027 - Shutdown Override For High Oil 0 - for alarm only (shutdown override,
Temperature Fault: GSC+ response to an engine no engine shutdown). 0 0 0
high oil temperature fault. 1 - for engine shutdown.
P028 - Nameplate Voltage: rated voltage of the
generator. This setpoint is used for protective 100 to 25kV in increments of 1 480V 4160V 3800V
relaying functions.
P029 - Nameplate Current: rated current output
0 to 4000 A in increments of 1 600A 80A 73A
of the generator.
P030 - Nameplate Power: rated power capability 0 through 10MW in increments of
400kW 420kW 350kW
of the generator. 1kW.
P031 - Rated Frequency: nominal frequency
50 or 60Hz 60Hz 60Hz 50Hz
rating of genset.
P032 - Connection Configuration Of Generator: 0 - wye
0 0 0
wye or delta configuration of generator. 1 - delta
P033 - Number Of Generator Poles. 0 through 254 in increments of 2. 4 4 4

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① The setpoints (stored or being programmed) must match the specified DPGDS setpoints.
② When oil pressure drops to within 5PSI (34kPa) of the P013 or P014 setpoint, a low oil pressure alarm
is issued by the GSC+.
③ When coolant temperature rises to within 11ºF (6ºC) of the P015 setpoint, a high coolant temperature
alarm is issued by the GSC+.
④ The values other than the default (700V) are for switchgear applications and require the use of external
potential transformers and the removal of the AC voltage range jumper located in the relay module.
The DPGDS unit is factory configured for the 5.20 K value. See the Caterpillar Electronic Modular
Control Panel II+ manual topic AC Voltage Range Selection in the Testing and Adjusting section.
⑤ After setpoint P022 is reprogrammed, the GSC+ must be power cycled (powered down and then
powered up)

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TABLE 5.7.4.4-5 OP5-1 SETPOINTS


SETPOINTS OP5-1 PROTECTIVE RELAYING PROGRAMMING①
FACTORY 60HZ 50HZ
SETPOINT-NAME-DESCRIPTION RANGE OF VALUES
DEFAULT SETPOINT SETPOINT
P101 - Generator Overvoltage Alarm Enable: the 0 - disabled
GSC+ enables or disables the generator 1 1 1
overvoltage alarm function. 1 - enabled
P102 - Generator Overvoltage Alarm Threshold:
100 to 125% of nameplate voltage in
voltage the GSC+ uses to issue an overvoltage 105% 105% 105%
increments of 1%.
alarm.
P103 - Generator Overvoltage Alarm Time Delay:
amount of time the GSC+ waits before issuing an 0 through 120 seconds② in increments 10 seconds 10 seconds 10 seconds
overvoltage alarm. of 1
P104 - Generator Overvoltage Shutdown Enable: 0 - disabled
the GSC+ enables or disables the generator 1 1 1
overvoltage shutdown function. 1 - enabled
P105 - Generator Overvoltage Shutdown
100 to 125% of nameplate voltage in
Threshold: voltage the GSC+ uses to issue an 110% 110% 110%
increments of 1%.
overvoltage shutdown.
P106 - Generator Overvoltage Shutdown Time
Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments 10 seconds 10 seconds 10 seconds
issuing an overvoltage shutdown. of 1
P107 - Generator Undervoltage Alarm Enable: 0 - disabled
the GSC+ enables or disables the generator 1 1 1
undervoltage alarm function. 1 - enabled
P108 - Generator Undervoltage Alarm
60 to 100% of nameplate voltage in
Threshold: voltage the GSC+ uses to issue an 90% 90% 90%
increments of 1%.
undervoltage alarm.
P109 - Generator Undervoltage Alarm Time
Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments 10 seconds 10 seconds 10 seconds
issuing an undervoltage alarm. of 1
P110 - Generator Undervoltage Shutdown 0 - disabled
Enable: the GSC+ enables or disables the 1 1 1
generator undervoltage shutdown function. 1 - enabled
P111 - Generator Undervoltage Shutdown
60 through 100% of rated voltage in
Threshold: voltage the GSC+ uses to issue an 85% 85% 85%
increments of 1%.
undervoltage shutdown.
P112 - Generator Undervoltage Shutdown Time
Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments 15 seconds 03 seconds 03 seconds
issuing an undervoltage shutdown. of 1
P113 - Generator Overfrequency Alarm Enable: 0 - disabled
the GSC+ enables or disables the generator 1 1 1
overfrequency alarm function. 1 - enabled

P114 - Generator Overfrequency Alarm 50-60Hz, for 50Hz Gen 53Hz


Threshold: frequency the GSC+ uses to issue an 60-70Hz, for 60Hz Gen 63Hz 63 Hz 53 Hz
overfrequency alarm. 400-480, for 400Hz Gen 422Hz
P115 - Generator Overfrequency Alarm Time
Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments 10 seconds 10 seconds 10 seconds
issuing an overfrequency alarm. of 1
P116 - Generator Overfrequency Shutdown 0 - disabled
Enable: the GSC+ enables or disables the 1 1 1
generator overfrequency shutdown function. 1 - enabled

P117 - Generator Overfrequency Shutdown 50-60Hz, for 50Hz Gen 55Hz


Threshold: frequency the GSC+ uses to issue an 60-70Hz, for 60Hz Gen 66Hz 66Hz 55Hz
overfrequency shutdown. 400-480, for 400Hz Gen 440Hz

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TABLE 5.7.4.4-5 OP5-1 SETPOINTS (CONTINUED)
SETPOINTS OP5-1 PROTECTIVE RELAYING PROGRAMMING①
FACTORY 60HZ 50HZ
SETPOINT-NAME-DESCRIPTION RANGE OF VALUES
DEFAULT SETPOINT SETPOINT
P118 - Generator Overfrequency Shutdown Time
Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments 10 seconds 10 seconds 10 seconds
issuing an overfrequency shutdown. of 1
P119 - Generator Underfrequency Alarm Enable: 0 - disabled
the GSC+ enables or disables the generator 1 1 1
underfrequency alarm function. 1 - enabled

P120 - Generator Underfrequency Alarm 30-50Hz, for 50Hz Gen 48Hz


Threshold: frequency the GSC+ uses to issue an 36-60Hz, for 60Hz Gen 57Hz 57Hz 48Hz
underfrequency alarm. 240-400, for 400Hz Gen 378Hz
P121 - Generator Underfrequency Alarm Time
Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments 10 seconds 10 seconds 10 seconds
issuing an underfrequency alarm. of 1
P122 - Generator Underfrequency Shutdown 0 - disabled
Enable: the GSC+ enables or disables the generator 1 1 1
underfrequency shutdown function. 1 - enabled

P123 - Generator Underfrequency Shutdown 30-50Hz, for 50Hz Gen 45Hz


Threshold: frequency the GSC+ uses to issue an 36-60Hz, for 60Hz Gen 54Hz 54Hz 45Hz
underfrequency shutdown. 240-400, for 400Hz Gen 360Hz
P124 - Generator Underfrequency Shutdown
Time Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments 15 seconds 03 seconds 03 seconds
issuing an underfrequency shutdown. of 1
P125 - Generator Reverse Power Shutdown 0 - disabled
Enable: the GSC+ enables or disables the generator 1 1 1
reverse power shutdown function. 1 - enabled
P126 - Generator Reverse Power Shutdown
0 through 20% of rated power in
Threshold: level of reverse power the GSC+ uses to 15% 4% 4%
increments of 1%.
issue a reverse power shutdown.
P127 - Generator Reverse Power Shutdown Time
Delay: amount of time the GSC+ waits before 0 through 30 seconds② in increments 10 seconds 4 seconds 4 seconds
issuing a reverse power shutdown. of 1
P128 - Generator Overcurrent Alarm Enable: the 0 - disabled
1 1 1
GSC+ enables or disables the overcurrent alarm. 1 - enabled
P129 - Generator Phase Overcurrent Alarm
100 through 160% of nameplate current
Threshold: level of current the GSC+ uses to issue a 105% 150% 150%
in increments of 5%
phase overcurrent alarm.
P130 - Generator Phase Overcurrent Alarm Time
Delay: amount of time the GSC+ waits before 0 through 250 seconds② in increments 0 seconds 0 seconds 0 seconds
issuing a phase overcurrent alarm. of 1
P131 - Generator Total Overcurrent Alarm
100 through 160% of three times
Threshold: level of current the GSC+ uses to issue a 105% 150%. 150%
nameplate current in increments of 5%
total overcurrent alarm.
P132 - Generator Total Overcurrent Alarm Time
Delay: amount of time the GSC+ waits before 0 through 250 seconds② in increments 0 seconds 0 seconds 0 seconds
issuing a total overcurrent alarm. of 1
P133 – Generator Overcurrent Shutdown Enable: 0 – disabled
the GSC+ enables or disables the overcurrent 1 1 1
shutdown. 1 – enabled
P134 – Generator Phase Overcurrent Shutdown
100 through 160% in increments of 5%
Threshold: level of current the 110% 150% 150%
GSC+ uses to issue a phase overcurrent shutdown.
P135 – Generator Phase Overcurrent Shutdown
Time Delay: amount of time the GSC+ waits before 0 through 250 seconds② in increments 0 seconds 10 seconds 10 seconds
issuing a phase overcurrent shutdown. of 1

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TABLE 5.7.4.4-5 OP5-1 SETPOINTS (CONTINUED)


SETPOINTS OP5-1 PROTECTIVE RELAYING PROGRAMMING①
FACTORY 60HZ 50HZ
SETPOINT-NAME-DESCRIPTION RANGE OF VALUES
DEFAULT SETPOINT SETPOINT
P136 - Generator Total Overcurrent Shutdown
100 through 160% of three times
Threshold: level of current the GSC+ uses to 110% 150%. 150%
nameplate current in increments of 5%
issue a total overcurrent shutdown.
P137 - Generator Total Overcurrent Shutdown
Time Delay: amount of time the GSC+ waits 0 through 250 seconds② in 0 seconds 10 seconds 10 seconds
before issuing a total overcurrent shutdown. increments of 1
P138 - KW Level Relay Enable : the GSC+ 0 - disabled
1 1 1
enables or disables the kW level relay function. 1 - enabled
P139 - KW Level Relay Threshold: level of
0 through 110% of nameplate power in
power the GSC+ uses to activate the kW level 105% 105% 105%
increments of 1%
relay function.
P140 - KW Level Relay Time Delay: amount of
time the GSC+ waits before activating the kW level 0 through 120 seconds② in 0 seconds 0 seconds 0 seconds
relay function. increments of 1
P141 - KW Level Relay Disengage Threshold:
0 through 110% of nameplate power in
level of power the GSC+ uses to deactivate the 100% 100% 100%
increments of 1%.
kW level relay function.
P142 - KW Level Relay Disengage Time Delay:
amount of time the GSC+ waits before 0 through 120 seconds② in 10 seconds 10 seconds 10 seconds
deactivating the kW level relay function. increments of 1

① The setpoints are programmed at the factory to the default value.


② When programmed to 0 seconds, the actual time is from 0.5 to 1.0 seconds.

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TABLE 5.7.4.4-6 OP6 SETPOINTS


SETPOINTS OP6 SPARE INPUT/OUTPUT PROGRAMMING
FACTORY DPGDS
SETPOINT-NAME-DESCRIPTIONS RANGE OF VALUES
DEFAULT SETPOINT
SP01 - Spare Input 1 Active State. Input state used by the 0-active low
0 0
GSC+ to declare a SP1 fault exists. 1-active high
SP02 - Spare Input 1 Response: GSC+ response to a SP1 0-shutdown
0 0
fault. 1-alarm
SP03 - Spare Input 1 Time Delay: Amount of time the GSC+
0 - 250 seconds in increments of 1 0 seconds 1 second
waits before responding to a SP1 fault.
SP04 - Spare Input 2 Active State. Input state used by the 0-active low
0 1
GSC+ to declare a SP2 fault exists. 1-active high
SP05 - Spare Input 2 Response: GSC+ response to a SP2 0-shutdown
0 0
fault. 1-alarm
SP06 - Spare Input 2 Time Delay: Amount of time the GSC+
0 - 250 seconds in increments of 1 0 seconds 0 seconds
waits before responding to a SP2 fault.
SP07 - Spare Input 3 Active State. Input state used by the 0-active low
0 0
GSC+ to declare a SP3 fault exists. 1-active high
SP08 - Spare Input 3 Response: GSC+ response to a SP3 0-shutdown
0 0
fault. 1-alarm
SP09 - Spare Input 3 Time Delay: Amount of time the GSC+
0 - 250 seconds in increments of 1 0 seconds 0 seconds
waits before responding to a SP3 fault.
SP10 - Spare Input 4 Active State. Input state used by the 0-active low
0 0
GSC+ to declare a SP4 fault exists. 1-active high
SP11 - Spare Input 4 Response: GSC+ response to a SP4 0-shutdown
0 0
fault. 1-alarm
SP12 - Spare Input 4 Time Delay: Amount of time the GSC+
0 - 250 seconds in increments of 1 0 seconds 0 seconds
waits before responding to a SP4 fault.
SP13 - Spare Output Response: GSC+ response to the spare 0-active low
0 0
output trigger condition. 1-active high
0-unused

1-active SP1 fault②

2-active SP2 fault②

3-active SP3 fault②

4-active SP4 fault②


SP14 - Spare Output Trigger Condition: The condition used
5-any combination of active SP faults②
8 8
by the GSC+ to trigger the spare output response
6-any active shutdown
7-any active alarm or shutdown
8-cooldown mode

9-coolant loss mode②

10-high oil temp fault②


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

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TABLE 5.7.4.4-6 OP6 SETPOINTS (CONTINUED)


SETPOINTS OP6 SPARE INPUT/OUTPUT PROGRAMMING
FACTORY DPGDS
SETPOINT-NAME-DESCRIPTIONS RANGE OF VALUES
DEFAULT SETPOINT
0-unused

1-active SP1 fault②

2-active SP2 fault②

3-active SP3 fault②

4-active SP4 fault②


SP16 - Spare Relay Output Trigger Condition: The condition
5-any combination of active SP faults②
8 1
used by the GSC+ to trigger the spare relay.
6-any active shutdown
7-any active alarm or shutdown
8-cooldown mode

9-coolant loss mode②

10-high oil temp fault②


11-CCM control
0-unused

1-active SP1 fault②

2-active SP2 fault②

3-active SP3 fault②


SP17 - Spare Indicator 1 Trigger Condition: The condition
4-active SP4 fault② 0 6
used by the GSC+ to trigger spare indicator①.
5-any combination of active SP1, SP2,

SP3 or SP4 faults②

6-Coolant loss fault②

7-high oil temperature fault②


SP18 - Spare Indicator 2 Trigger Condition: The condition
Battle Short mode. 0 0 Battleshort③
used by the GSC+ to trigger spare indicator②.
SP19 - Spare Indicator 3 Trigger Condition: The condition 0 In 50Hz
Not in 60 Hz mode. 0
used by the GSC+ to trigger spare indicator③. Mode③

① The setpoints are programmed at the factory to the default value.

② Either alarm or shutdown faults are valid trigger conditions

③ Battleshort and 50Hz Mode are unique features to DPGDS for spare indicators 2 and 3.

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

NOTE: Use up or down keys to change values.

f. At the AVR verify the operation settings using Table 5.7.4.4-7:

(1) Open the GCPG1 cabinet door.

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

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

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

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

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

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

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

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

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

(11) When complete, press the [▼] to display parameter “01”.

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

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

TABLE 5.7.4.4-7 AVR PARAMETERS/SETPOINTS


DPGDS
DPGDS AVR PARAMETERS
SETPOINTS
RANGE OF DEFAULT 60HZ 50HZ
PARAMETER TITLE TYPE UNITS
VALUES VALUE OPS OPS

01 Generator Output Voltage Program Volts 0080-9999 480① 4160 3800


Ratio of Output Voltage To
02 Program 001.0-100.0 001.0 17.3 17.3
Sensing Voltage
03 Generator Type Program 0000-0004 0004 4 4
04 Rated Generator Output Current Program Amps 0000-9999 0600 80 73
CT Voltage At Rated Generator
05② Current
Program Volts 01.00-05.00 05.00 4.00 3.66

06 Knee Frequency Program Hz 045.0-065.0 050.0 59.8 49.8


07 Decreasing Volts/Hz Slope I Program Volts/Hz 001.0-010.0 002.0 2.0 2.0
08 Decreasing Volts/Hz Slope 2 Program Volts/Hz 001.0-010.0 002.0 2.0 2.0
09 Minimum Voltage Program % 050.0-100.0 050.0 50.0 50.0
10 Under Frequency Point Program Hz 020.0-040.0 025.0 25.0 25.0
11 Overvoltage Trip Point Program % 0105-0140 014.0 125.0 125.0
12 Overvoltage Trip Time Program Seconds 0002-0030 0002 5 5
13 Under Voltage Trip Point Program % 0060-0095 0060 75 75
14 Under Voltage Trip Time Program Seconds 0030-0120 0030 30 30
000.0-0
15 Voltage Gain (IR Compensation) Program % 0000 0 0
10.0

16⑤ Integral Gain Program 001.0-020.0 006.0 6.0 6.0

17⑥ Proportional Gain Program 001.0-020.0 005.0 5.0 5.0


Single Phase Sensing Select
18 Program 0000,0001 0000 0000 0000
(0=three phase, 1=single phase)
19 Diode Monitor Trip Point Program Amps 001.0-010.0 002.0 2.0 2.0

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TABLE 5.7.4.4-7 AVR PARAMETERS/SETPOINTS (CONTINUED)


DPGDS
DPGDS AVR PARAMETERS
SETPOINTS
RANGE OF DEFAULT 60HZ 50HZ
PARAMETER TITLE TYPE UNITS
VALUES VALUE OPS OPS
30 Droop Percentage Program % 000.0-010.0 0000 3 3

31③ pf/Kvar Select (0=pf, 1=Kvar) Program 0000, 0001 0000 0 0

32③ Pf Reference Program 00.60-01.10 01.00 0.8 0.8

33③ KVAR Reference Program Per Unit 00.00-01.00 0000 0.10 0.10

34③ Reverse Power Trip Point Program % 000.0-020.0 010.0 15 15

35③ Reverse Power Trip Time Program Seconds 000.0-020.0 010.0 5 5


50 Generator Output Frequency View Hz
51 Generator Output Voltage View Volts
52 Generator Output Current View Amps
Generator Reactive Output
53 View Amps
Current
54 Generator Real Current View Amps
55 Exciter Field Current View Amps
Three Phase Kilowatts
56③ (KB and later)
View KW

57③ Power Factor View


Three Phase Kvar (KE and
58③, ④ later)
View

60 Hours View Hours 0000-9999


90 Password Program 0009 0009
91 Software ID View
92 Latest Fault View 0000 0000 0000
93 Previous Fault View 0000 0000 0000
94 Fault Clear View
96 Shutdown Fault Reset Switch

①- Default value for output voltage is different depending on regulator sensing voltage. If the regulator is
designed for 120 volts sensing, then the default output voltage is 4160 volts. All other sensing types
have the default output voltage set to 480 volts.
②- Digital Voltage Regulators with earlier software (KD and earlier) have 1 less digit to the right of the
decimal point.
③- Optional feature.
④- New parameter on serial number prefix KE and later Digital Voltage Regulators.
⑤- Previous range of 0001-099.9 and default value of 002.0
⑥-Previous range of 0001-099.9 and default value of 002.0

(12) When complete, press the [▼] to display parameter “90”.

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

(14) Press the [▼] key to change the value to “0009”. Disables DVR parameter editing.

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

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(16) Press the [▲] key to change to display parameter “01”.

(17) Close the GCPG1 cabinet door.

(18) Repeat steps ‘1 ‘through ‘16’ for Generator 2.

5.7.4.5 PRE-OPERATION CHECKS

Starting from the left rear of the PU and working around the PU in a clockwise direction, perform the
following checks (Gen. 1 is on the left and Gen. 2 is on the right):

TABLE 5.1.3.5-1 PRE-OPERATION CHECKLIST


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

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TABLE 5.1.3.5-1 PRE-OPERATION CHECKLIST (CONTINUED)


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

① The Battery Parallel Switch should be left in the OFF position except in extreme conditions where
the additional DC power is required to crank an engine. Once started, return the switch to the OFF
position.

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5.7.4.6 PRE-OPERATION RUN

WARNING

ENSURE ALL PERSONNEL ARE CLEAR AND THE PU DOORS ARE CLOSED
PRIOR TO STARTING A GENERATOR.

WARNING

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND


ENFORCED. NOISE LEVELS IN EXCESS OF 85 DB EXIST WITHIN AN 88-FOOT
RADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR SINGLE HEARING
PROTECTION WITHIN 88 FEET OF AN OPERATING DPGDS.

WARNING

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND


ENFORCED. DURING MAINTENANCE ACTIVITIES WITH THE SIDEDOORS OPEN,
NOISE LEVELS IN EXCESS OF 113 DB EXIST WITHIN A 12-FOOT RADIUS OF AN
OPERATING DPGDS. PERSONNEL MUST WEAR DOUBLE HEARING PROTECTION
WITHIN 12 FEET OF AN OPERATING DPGDS. EXPOSURE MUST BE LIMITED TO
UNDER 2.5 HOURS.

WARNING

BY CLOSING THE FEEDER OR TIE BREAKER, HIGH VOLTAGE WILL BE PRESENT


ON THE LOAD CABLES. ENSURE ALL PERSONNEL ARE CLEAR OF ALL LOAD
CABLES PRIOR TO CLOSING FEEDER OR TIE BREAKERS.

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TABLE 5.7.4.6-1 PRE-OPERATION RUN INSTRUCTION SEQUENCE


(Perform on each PU in the power plant)
STEP -- 60HZ OPERATIONS -- -- 50HZ OPERATIONS --

1 Verify System Mode Switch (SMS) is in MANUAL

2 Verify DC Control Power is on

3 Verify Emergency Stop is pulled out

4① Verify the 60Hz light is on ① Verify the 50Hz light is on①

5 Start engine 1 by placing ECS1 in MANUAL

6 Verify the engine accelerates to 1800RPM Verify the engine accelerates to 1500RPM

7 Adjust the generator frequency to 60Hz Adjust the generator frequency to 50Hz using
using the Frequency Adjust Rheostat (FAR) the Frequency Adjust Rheostat (FAR)

8 Adjust the generator voltage to 4295VAC Adjust the generator voltage to 3915VAC
using the Voltage Adjust Rheostat (VAR) using the Voltage Adjust Rheostat (VAR)

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

10 Shutdown engine 1 by placing ECS1 in OFF/RESET

11 Start engine 2 by placing ECS2 in MANUAL

12 Verify the engine accelerates to 1800RPM Verify the engine accelerates to 1500RPM

13 Adjust the generator frequency to 60Hz Adjust the generator frequency to 50Hz using
using the Frequency Adjust Rheostat (FAR) the Frequency Adjust Rheostat (FAR)

14 Adjust the generator voltage to 4295VAC Adjust the generator voltage to 3915VAC
using the Voltage Adjust Rheostat (VAR) using the Voltage Adjust Rheostat (VAR)

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

16 Shutdown engine 2 by placing ECS2 in OFF/RESET

① If the wrong frequency light is on, open the Master Control Door and change the Frequency
Selector Switch (FSS) to the desired frequency.

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5.7.4.7 ORT SETUP

a. Remove the ORT from its case and set it up on a flat and level surface.

b. Remove the mouse from the case and plug it into the mouse (PS2) port on the back of the ORT.

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

d. Connect one end of the 150-foot patch cable to the ORT networking port on the PU.

e. Route the cable from the ORT to the PU and connect the cable to the ORT port.

f. Turn on the ORT.

g. Observe that the ORT boots to the operator’s Overview screen.

h. Select the Equip ID pop-up screen and enter the necessary information for the units. This
includes the Trailer ID number, the Engine ID number, and the Generator ID number for each
PU.

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

h. Return to the Overview pop-up screen.

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5.7.4.8 CONTROLS SETUP

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

TABLE 5.7.4.8-1 CONTROL SWITCH SETUP


PANEL SWITCH SETUP
DC Control Breaker Pushed In (ON)
SMS OFF
GMS PRIME POWER
AVRS PRIME POWER
MASTER CONTROL PANEL 60Hz Light ON①
MCP
USS A②
BSS NORMAL
SSS OFF
SSL lights All OFF
INSIDE MCP FSS 50/60 Hertz①
GENERATOR CONTROL Emergency Stop Pulled-Out
PANEL GCPG1 ECS OFF
GENERATOR CONTROL Emergency Stop Pulled-Out
PANEL GCPG2 ECS OFF

① With the SMS in the OFF position, the 50/60Hz lights indicate the position of the Frequency
Selector Switch (FSS). If the wrong light is on, open the door and change the switch position.
② No more than one switch can be in the same position in any multi-PU line-up. With the SMS in
OFF, none of the USI lights will be on and any previously set address on the PU is cleared.

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5.7.5 PLANT STARTUP

CAUTION

ENSURE THERE IS SUFFICIENT KW LOAD FOR BOTH GENERATOR UNITS ON


THE BUS BEFORE PARALLELING A MEP-PU-810 POWER UNIT INTO AN
OPERATING MEP-012 PLANT OR MEP-012 GENERATOR INTO AN OPERATING
MEP-PU-810 PLANT.

5.7.5.1 MANUAL MODE

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


POWER PLANT

WARNING

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND


ENFORCED.
NOISE LEVELS IN EXCESS OF 85 DB EXIST WITHIN AN 88-FOOT RADIUS OF AN
OPERATING DPGDS. PERSONNEL MUST WEAR SINGLE HEARING PROTECTION
WITHIN 88 FEET OF AN OPERATING DPGDS.

WARNING

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND


ENFORCED.
DURING MAINTENANCE ACTIVITIES WITH THE SIDEDOORS OPEN, NOISE
LEVELS IN EXCESS OF 113 DB EXIST WITHIN A 12-FOOT RADIUS OF AN
OPERATING DPGDS. PERSONNEL MUST WEAR DOUBLE HEARING PROTECTION
WITHIN 12 FEET OF AN OPERATING DPGDS. EXPOSURE MUST BE LIMITED TO
UNDER 2.5 HOURS.

CAUTION

THIS PROCEDURE IS FOR OPERATION OF A MEP-PU-810 WITH AN EXISTING


POWER PLANT THAT IS OPERATING IN DROOP (PARALLELING A MEP-PU-810 TO
A MEP-012 PLANT). THE PROCEDURE ASSUMES THAT THE DROOP PLANT IS
ON-LINE CARRYING THE LOAD AND THE PU IS PROPERLY CONNECTED TO THE
EXISTING PLANT.

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

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

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TABLE 5.7.5.1-1 SWITCH SETUP – MANUAL MODE


PANEL SWITCH 1ST PU 2ND PU 3RD PU 4TH PU
BCS-T Green Target Green Target Green Target Green Target
MASTER CONTROL SMS MANUAL MANUAL MANUAL MANUAL
PANEL MCP MSES Enable① Enable① Enable① Enable①
USI A①, ② B①, ② C①, ② D① , ②
GENERATOR BCS-G1 Green Target Green Target Green Target Green Target
CONTROL PANEL 1 BCS-F1 Green Target Green Target Green Target Green Target
GCPG1 ECS-1 OFF OFF OFF OFF
GENERATOR BCS-G2 Green Target Green Target Green Target Green Target
CONTROL PANEL 2 BCS-F2 Green Target Green Target Green Target Green Target
GCPG2 ECS-2 OFF OFF OFF OFF
① Hold the MSES in an ENABLE position until the selected USI indicator energizes. The switch
returns to the center position when released. This sets the PU networking address and enables
the control and monitoring.
② No more than one of each indicator can be on for multi-PU operations. The light on should match
USS position. The USI light will de-energize after the SMS has been in OFF for 3 seconds.

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

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

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

d. Close BCSG1 by cycling BCSG1 to the CLOSE position.

e. Observe that the BCSG1 breaker closes.

f. Place the SSS in the TIE position

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

h. Observe that the BCST breaker closes.

i. Return the SSS to the OFF position.

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

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


Unit-A PU.

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

m. Observe the engine starts and accelerates to operating voltage and frequency.

n. At the A-unit MCP, place the Sync Source Switch (SSS) in the GEN 2 position.

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o. Close BCSG2 breaker when the two green triangular LEDs at 12 o’clock on the Synchroscope
are energized by cycling BCSG2 to the CLOSE position. For detailed instructions on manual
synchronizing, refer to Section 5.9.6.14.

p. Observe that the BCSG2 breaker closes.

q. Return the SSS to the OFF position.

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

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


Unit-A PU.

t. Repeat steps ‘b’ through ‘s’ for each PU (B – D) put into the plant lineup, increasing the maximum
capacity by 420KW for each PU generator added to the bus see Table 5.7.5.1-2.

u. Ensure generators have assumed load. After the MEP-PU-810 have stabilized proceed with the
following if necessary:
v. Observe the KW, PF and KVAR of each MEP-PU-810 generator at the LCP.

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

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

QUANTITY ONLINE 1 2 3 4 5 6 7 8

KW 420 840 1260 1680 2100 2520 2940 3360

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5.7.5.1.2 STARTING UP SINGLE OR MULTIPLE MEP-012’S WITH A MEP-PU-810 POWER


PLANT IN MANUAL MODE

WARNING

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND


ENFORCED.
NOISE LEVELS IN EXCESS OF 85 DB EXIST WITHIN AN 88-FOOT RADIUS OF AN
OPERATING DPGDS. PERSONNEL MUST WEAR SINGLE HEARING PROTECTION
WITHIN 88 FEET OF AN OPERATING DPGDS.

WARNING

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND


ENFORCED.
DURING MAINTENANCE ACTIVITIES WITH THE SIDEDOORS OPEN, NOISE
LEVELS IN EXCESS OF 113 DB EXIST WITHIN A 12-FOOT RADIUS OF AN
OPERATING DPGDS. PERSONNEL MUST WEAR DOUBLE HEARING PROTECTION
WITHIN 12 FEET OF AN OPERATING DPGDS. EXPOSURE MUST BE LIMITED TO
UNDER 2.5 HOURS.

This procedure is for operation of a MEP-012 with an existing MEP-PU-810 power plant that is operating
in Prime Power mode (paralleling a MEP-012 to a MEP-PU-810 plant). The procedure assumes that the
Prime Power plant is on-line carrying the load and the MEP-012 is properly connected to the existing
plant.

a. Complete the setup of each MEP-012 generator per the MEP-012 Instruction Manual.
b. At the external switchgear, close the disconnect switch (multiple PU lineup). At the PU MCP
close the Tie Breaker (single PU lineup only).
c. At the MEP-012 control panel, start the generator.
d. Match the MEP-012 voltage to the bus voltage.
e. Manually synchronize the MEP-012 into the PU plant.
f. At the MEP-012 control panel, slowly increase the generator frequency control to transfer load,
up to the maximum capacity of the MEP-012 generator.
g. Repeat steps b through f for each additional MEP-012 being paralleled into the PU plant (multiple
PU lineups only).
h. Maintain only the number of MEP-012 generators on the bus necessary to carry the system load.
Extra MEP-012 generators should be unloaded and shutdown until required.

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5.7.5.2 AUTOMATIC MODE

CAUTION

LOAD CHANGES WILL INITIALLY BE APPLIED TO THE MEP-012 UNIT(S) AND


WILL THEN AUTOMATICALLY TRANSFER TO THE MEP-PU-810 UNIT(S) AFTER A
10 TO 15 SECOND DELAY. THE MEP-012 OPERATOR MUST MAINTAIN AN
ADEQUATE RESERVE CAPACITY TO ABSORB THE APPLIED LOAD CHANGE.
EXCEEDING THE MEP-012 CAPACITY WILL CAUSE THE MEP-012 UNIT(S) TO GO
INTO OVERLOAD AND DROP OFFLINE, RESULTING IN A COMPLETE SHUTDOWN.

CAUTION

LOAD CHANGES WILL BE ABSORBED OR SHED BY THE MEP-PU-810 UNIT(S).


THE MEP-012 UNIT(S) FREQUENCY CONTROL MUST BE ADJUSTED TO ACHIEVE
THE DESIRED LOAD BALANCE AND TO PREVENT OVERLOADING.

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


POWER PLANT

WARNING

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND


ENFORCED. NOISE LEVELS IN EXCESS OF 85 DB EXIST WITHIN AN 88-FOOT
RADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR SINGLE HEARING
PROTECTION WITHIN 88 FEET OF AN OPERATING DPGDS.

WARNING

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND


ENFORCED. DURING MAINTENANCE ACTIVITIES WITH THE SIDEDOORS OPEN,
NOISE LEVELS IN EXCESS OF 113 DB EXIST WITHIN A 12-FOOT RADIUS OF AN
OPERATING DPGDS. PERSONNEL MUST WEAR DOUBLE HEARING PROTECTION
WITHIN 12 FEET OF AN OPERATING DPGDS. EXPOSURE MUST BE LIMITED TO
UNDER 2.5 HOURS.

WARNING

ONCE THE SYSTEM STATUS LIGHTS TURN GREEN AND THE MSES IS ENABLED,
THE PU WILL START. ENSURE PERSONNEL ARE CLEAR OF THE PU.

WARNING

ONLY ONE PU MAY BE SELECTED TO ANY ONE USS POSITION DURING MULTIPLE
PU OPERATIONS. OPERATING WITH MORE THAN ONE UNIT AT THE SAME ID
CAUSE UNSAFE AND ERRATIC OPERATIONAL CONDITIONS.

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This procedure is for operation of a MEP-PU-810 with an existing power plant that is operating in Droop
(paralleling a MEP-PU-810 to a MEP-012 plant). The procedure assumes that the Droop plant is on-line
carrying the load and the PU is properly connected to the existing plant.

a. Complete the plant startup following the Automatic Mode start up procedures described in
Section 5.7.5.2, then proceed as follows:

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

TABLE 5.7.5.2.1-1 SWITCH SETUP – AUTOMATIC MODE


PANEL SWITCH 1ST PU 2ND PU 3RD PU 4TH PU
BCS-T Red Target Red Target Red Target Red Target
MASTER CONTROL
PANEL MCP
SMS AUTO③ AUTO③ AUTO③ AUTO③
USS A B C D
GENERATOR BCS-G1 Red Target Red Target Red Target Red Target
CONTROL PANEL 1 BCS-F1 Red Target Red Target Red Target Red Target
GCPG1 ECS-1 OFF OFF OFF OFF
GENERATOR BCS-G2 Red Target Red Target Red Target Red Target
CONTROL PANEL 2 BCS-F2 Red Target Red Target Red Target Red Target
GCPG2 ECS-2 OFF OFF OFF OFF
MASTER CONTROL MSES Enable① Enable① Enable① Enable①
PANEL MCP USI A①, ② B①, ② C① , ② D① , ②

① Hold the MSES in an ENABLE position until the selected USI indicator energizes. The switch
returns to the center position when released. This sets the PU networking address and enables
the control and monitoring.
② No more than one of each indicator can be on for multi-PU operations. The light on should match
USS position. The USI light will de-energize after the SMS has been in OFF for 3 seconds.
③ With the SMS in AUTO any generator started, manually or automatically, will automatically
parallel to the bus. To prevent the generator from paralleling to the bus put the generator’s
breaker in the Pull-To-Lock position.

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

d. Ensure that the ECS on all other units is in the OFF position.

e. Move the Master Start Enable Switch (MSES) the ENABLE position and hold until the engine
starts to crank.

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

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

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h. Adjust the voltage and frequency on the MEP-012A to achieve and stabilize the desired load
share.

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

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

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

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

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

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


AUTOMATIC MODE

This procedure is for operation of a MEP-012 with an existing MEP-PU-810 power plant that is operating
in Prime Power mode (paralleling a MEP-012 to a MEP-PU-810 plant). The procedure assumes that the
Prime Power plant is on-line carrying the load and the MEP-012 is properly connected to the existing
plant.

a. At the MEP-PU-810 system ORT, disable the PU plant Economizing feature. This will prevent
the plant from dropping PU generators offline under light loading conditions due to the MEP-012
generator(s) being online.
b. Complete the setup of each MEP-012 generator per the MEP-012 Instruction Manual.
c. At the external switchgear, close the disconnect switch (multiple PU lineup). At the PU MCP
close the Tie Breaker (single PU lineup only).
d. At the MEP-012 control panel, start the generator.
e. Match the MEP-012 voltage to the bus voltage.
f. Manually synchronize the MEP-012 into the PU system.
g. At the MEP-012 control panel, slowly increase the generator frequency control to transfer load
up to the desired capacity of the MEP-012 generator.
h. Repeat steps c through g for each additional MEP-012 being paralleled into the PU system
(multiple PU lineups only).
j. Maintain only the number of MEP-012 generators on the bus necessary to carry the system load.
Extra MEP-012 generators should be unloaded and shutdown until required.

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

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5.7.6 PLANT OPERATIONS

Refer to Chapter 5.9 for specific procedures

In this manual mode of operation, the ORT provides no remote operation capability. It will provide
monitoring of the generator parameters.

5.7.7 POWER PLANT TEARDOWN

5.7.7.1 SHUT DOWN GENERATORS

a. Reduce the load on the MEP-PU-810 plant to zero by adjusting voltage and frequency of the
Droop Plant.

b. Open all load connections. If the PU is in Manual Mode, this must be done locally using the Local
Control Panels (LCPs). If the PU is in Automatic, this can be done remotely using the ORT or
locally using the Local Control Panels (LCPs).

c. Open both generator breakers using the respective BCS switches.

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

e. Allow all engines to complete cooldown and shut down (5 minutes).

f. Place all ECS switches in OFF/RESET.

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

5.7.7.2 DISCONNECT CABLES

WARNING

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

CAUTION

ALLOW ALL OPERATING ENGINES TO SHUT DOWN AND COOL DOWN


COMPLETELY.

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

b. Disconnect the ORT cable and store it in the ORT case.

c. Close and latch the ORT port on the PU.

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

5.7.7.3 DISCONNECT FUEL LINES

a. Turn all fuel system valves to the off position.

b. Disconnect the fuel hose from the PU fuel connection and the fuel supply.

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

5.7.7.4 DISCONNECT GROUNDING

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

b. Disconnect the parking stations from the ground grid.

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

5.7.7.5 PREPARE PU FOR TRANSPORTATION

a. Reinstall the four radiator splashguards (PU-810B only).

b. Verify DC Control power is off.

c. Close and lock the LCP access doors.

d. Close and lock all PU side doors.

5.7.7.6 FUEL, OIL, AND COOLANT DRAINAGE

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

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CHAPTER 5.8
OPERATING INSTRUCTIONS

UTILITY PARALLEL CONFIGURATION

TABLE OF CONTENTS

SECTION TITLE PAGE


5.8 UTILITY PARALLEL CONFIGURATION 175

5.8.1 SAFETY PROCEDURES 175

5.8.2 POSITIONING THE PU 175

5.8.3 INITIAL PLANT SETUP 176

5.8.3.1 GROUNDING 176

5.8.3.2 FUEL MANIFOLD 178

5.8.3.3 DISTRIBUTION AND CONTROL CABLING 178

5.8.3.4 SETPOINT VERIFICATION 179

5.8.3.5 PRE-OPERATION CHECKS 182

5.8.3.6 PRE-OPERATION RUN 183

5.8.3.7 ORT SETUP 185

5.8.3.8 CONTROLS SETUP 186

5.8.4 PLANT STARTUP 187

5.8.4.1 GENERAL 187

5.8.4.2 MANUAL MODE 187

5.8.4.3 AUTOMATIC MODE 187

5.8.5 PLANT OPERATIONS 190

5.8.6 POWER PLANT TEARDOWN 190

5.8.6.1 SHUT DOWN GENERATORS 190

5.8.6.2 DISCONNECT CABLES 190

5.8.6.3 DISCONNECT FUEL LINES 191

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TABLE OF CONTENTS

SECTION TITLE PAGE


5.8.6.4 DISCONNECT GROUNDING 191

5.8.6.5 PREPARE PU FOR TRANSPORTATION 191

5.8.6.6 FUEL, OIL, AND COOLANT DRAINAGE 191

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LIST OF FIGURES

FIGURE TITLE PAGE


FIGURE 5.8.3.1-1 MEP-PU-810A GROUND POINTS 177

FIGURE 5.8.3.1-2 MEP-PU-810B GROUND POINTS 177

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LIST OF TABLES

TABLE TITLE PAGE


TABLE 5.8.3.6-1 PRE-OPERATION RUN INSTRUCTION SEQUENCE 184

TABLE 5.8.3.8-1 PDC CONTROL SWITCHES SETUP 186

TABLE 5.8.4-1 SWITCH SETUP – AUTOMATIC MODE 188

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5.8 UTILITY PARALLEL CONFIGURATION

5.8.1 SAFETY PROCEDURES

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

• Hot engine parts


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

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

5.8.2 POSITIONING THE PU

a. Position the PU in such a way as to allow the plant operator to have full vision of the operator
control panels on the unit.

b. Level the MEP-PU-810B front to rear with the trailer leveling hand crank.

c. Position the PU to provide a minimum of 10 feet of clearance for maintenance access on all
sides of each unit. Ensure that there are no overhead obstructions around the exhaust outlets.

WARNING

FUEL SPILLAGE CAN OCCUR IF THE POWER UNIT LEVEL IS GREATER THAN + 5
DEGREES.

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

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5.8.3 INITIAL PLANT SETUP

5.8.3.1 GROUNDING

WARNING

THERE CAN ONLY BE ONE GROUNDING POINT FOR THE PU.

a. Drive an 8-foot ground rod into the earth and should be within 6 feet of the PU and at a location
that minimizes the tripping hazard, until only 6 inches (15 cm) protrudes above the surface.

b. Repeat step “a” for each PU being used.

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

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

e. Repeat step “d” for every PU.

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

g. Remove parking stand plates from their transportation positions inside each rear, side PU door
and slide them into their respective operating positions on the sides of the PDC.

h. Connect the parking stand ground wires to either of the two chassis ground lugs on the PU.

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GROUND POINT GROUND POINT

FIGURE 5.8.3.1-1 MEP-PU-810A GROUND POINTS

NOTE: Connect only one ground point to the ground grid.

GROUND POINT GROUND POINT

FIGURE 5.8.3.1-2 MEP-PU-810B GROUND POINTS

NOTE: Connect only one ground point to the ground grid.

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5.8.3.2 FUEL MANIFOLD

WARNING

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

a. Lay out the fuel hoses between the PU, the fuel manifold, and the fuel bladders to establish the
fuel supply system. See Chapter 5.1 Figure 5.1.3.2-1 External Fuel Supply.

b. Install the external fuel hose for the PU to the Fuel Transfer Pump at the Tow end of the PU.

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

d. Connect the 3” hose, with quick-disconnect hose ends, from the fuel manifold to the fuel
bladders.

e. Connect the fuel manifold ground wire to the ground grid.

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

5.8.3.3 DISTRIBUTION AND CONTROL CABLING

WARNING

VERIFY THAT CONNECTION POINTS ARE DE-ENERGIZED BEFORE MAKING ANY


CONNECTIONS. FAILURE TO CHECK CONNECTORS DE-ENERGIZED MAY
RESULT IN INJURY OR DEATH.

a. Lay out and park the load cables for each phase (A, B, & C) between the PU Tie Output parking
stations and the load.

b. Connect each load cable to the appropriate phase connection on the utility bus. Ensure there
are no cross-phase connections.

c. Connect each load cables drain wire to the grounding grid.

d. Open the Tie Output connector loadbreak covers on the first PU.

e. Connect the Tie Output Cables to the appropriate phase connectors; ensure there are no cross-
phase connections.

f. Close and lock the Tie Output connector covers.

g. Repeat steps ‘b’ through ‘f’ on each remaining PU.

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

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

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

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

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

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

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

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

p. Connect the third (A) (B) communication cable to “A” receptacle on fourth PU.

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

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

5.8.3.4 SETPOINT VERIFICATION

a. Turn on PU DC control power by pushing in on the DC Control Power breaker.

b. On each of the five overcurrent relays, verify the settings:

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

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

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

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

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

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

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


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

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

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

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

(12) Verify the 50TN settings.

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

(14) Verify the “50TQ” settings

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

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

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

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

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

(20) Verify the 51N settings.

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

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

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

(1) Place ECS in the COOLDOWN/STOP position.

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

(3) Press SCROLL UP key until “OP3” is showing.

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

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

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

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

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

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

(10) Press ENTER key. “PE PASS” is showing.

(11) Press EXIT key. “OP4” is showing.

(12) Press SCROLL UP key until “OP5-0” is showing on the lower display.

(13) Press SELECT key. “POO1” followed with the value of the setpoint is showing.

(14) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing.
Use Chapter 5.1 Table 5.1.3.4-4 OP5-0 Setpoints for the parameter values to be verified.
Repeat until all OP5-0 setpoints are verified.

(15) Press EXIT key. “OP5-0” is showing on the lower display.

(16) Press SCROLL UP key until “OP5-1” is showing.

(17) Press SELECT key.

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(18) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing.
Use Chapter 5.1 Table 5.1.3.4-5 OP5-1 Setpoints for the parameter values to be verified.
Repeat until all OP5-1 Setpoints are verified.

(19) Press EXIT key. “OP5-1” is showing.

(20) Press SCROLL UP key until “OP6” is showing.

(21) Press SELECT key.

(22) Press SCROLL UP or SCROLL DWON key. The next setpoint with its value is showing.
Using Chapter 5.1 Table 5.1.3.4-6 OP6 Setpoints for the parameter values to be verified.
Repeat until all OP6 Setpoints are verified.

(24) Press EXIT Key twice. The display returns to normal.

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

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

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

(c) Press ENTER. The correct value stops flashing on the display.

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

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

NOTE: Use up or down keys to change values.

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

(1) Open the GCPG1 cabinet door.

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

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

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

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

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

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

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

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

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

(11) When complete, press the [▼] to display parameter “01”.

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

(12) When complete, press the [▼] to display parameter “90”.

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

(14) Press the [▼] key to change the value to “0009”. Disables DVR parameter editing.

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

(16) Press the [▲] key to change to display parameter “01”.

(17) Close the GCPG1 cabinet door.

(18) Repeat steps ‘1 ‘through ‘17’ for Generator 2.

5.8.3.5 PRE-OPERATION CHECKS

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

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5.8.3.6 PRE-OPERATION RUN

WARNING

ENSURE ALL PERSONNEL ARE CLEAR AND THE PU DOORS ARE CLOSED
PRIOR TO STARTING A GENERATOR.

WARNING

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND


ENFORCED. NOISE LEVELS IN EXCESS OF 85 DB EXIST WITHIN AN 88-FOOT
RADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR SINGLE HEARING
PROTECTION WITHIN 88 FEET OF AN OPERATING DPGDS.

WARNING

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND


ENFORCED. DURING MAINTENANCE ACTIVITIES WITH THE SIDEDOORS OPEN,
NOISE LEVELS IN EXCESS OF 113 DB EXIST WITHIN A 12-FOOT RADIUS OF AN
OPERATING DPGDS. PERSONNEL MUST WEAR DOUBLE HEARING PROTECTION
WITHIN 12 FEET OF AN OPERATING DPGDS. EXPOSURE MUST BE LIMITED TO
UNDER 2.5 HOURS.

WARNING

BY CLOSING THE FEEDER OR TIE BREAKER, HIGH VOLTAGE WILL BE PRESENT


ON THE LOAD CABLES. ENSURE ALL PERSONNEL ARE CLEAR OF ALL LOAD
CABLES PRIOR TO CLOSING FEEDER OR TIE BREAKERS.

WARNING

IF PHASE ROTATION IS DIFFERENT, PRIOR TO CORRECTING PHASE ROTATION,


ENSURE THE LOAD CABLES ARE DE-ENERGIZED. ISOLATE THE LOAD CABLES
FROM THE UTILITY AND CORRECT THE PHASE ROTATION PROBLEM.

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TABLE 5.8.3.6-1 PRE-OPERATION RUN INSTRUCTION SEQUENCE


(Perform on each PU in the power plant)
STEP -- 60HZ OPERATIONS -- -- 50HZ OPERATIONS --

1 Verify System Mode Switch (SMS) is in MANUAL

2 Verify DC Control Power is on

3 Verify Emergency Stop is pulled out

4① Verify the 60Hz light is on ① Verify the 50Hz light is on①

5 Start engine 1 by placing ECS1 in MANUAL

6 Verify the engine accelerates to 1800RPM Verify the engine accelerates to 1500RPM

7 Adjust the generator frequency to 60Hz Adjust the generator frequency to 50Hz using
using the Frequency Adjust Rheostat (FAR) the Frequency Adjust Rheostat (FAR)

8 Adjust the generator voltage to 4295VAC Adjust the generator voltage to 3915VAC
using the Voltage Adjust Rheostat (VAR) using the Voltage Adjust Rheostat (VAR)

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

10 Shutdown engine 1 by placing ECS1 in OFF/RESET

11 Start engine 2 by placing ECS2 in MANUAL

12 Verify the engine accelerates to 1800RPM Verify the engine accelerates to 1500RPM

13 Adjust the generator frequency to 60Hz Adjust the generator frequency to 50Hz using
using the Frequency Adjust Rheostat (FAR) the Frequency Adjust Rheostat (FAR)

14 Adjust the generator voltage to 4295VAC Adjust the generator voltage to 3915VAC
using the Voltage Adjust Rheostat (VAR) using the Voltage Adjust Rheostat (VAR)

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

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

17 Shutdown engine 2 by placing ECS2 in OFF/RESET

① If the wrong frequency light is on, open the Master Control Door and change the Frequency
Selector Switch (FSS) to the desired frequency.

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5.8.3.7 ORT SETUP

a. Remove the ORT from its case and set it up on a flat and level surface.

b. Remove the mouse from the case and plug it into the mouse (PS2) port on the back of the ORT.

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

d. Connect one end of the 150-foot patch cable to the ORT networking port on the PU.

e. Route the cable from the ORT to the PU and connect the cable to the ORT port.

f. Turn on the ORT.

g. Observe that the ORT boots to the operator’s Overview screen.

h. Select the EquipID pop-up screen and enter the necessary information for the units. This
includes the Trailer ID number, the Engine ID number, and the Generator ID number for each
PU.

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

h. Return to the Overview pop-up screen.

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5.8.3.8 CONTROLS SETUP

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

NOTE: Ignore settings for Power Units not being used:

TABLE 5.8.3.8-1 PDC CONTROL SWITCHES SETUP


PANEL SWITCH 1ST PU 2ND PU 3RD PU 4TH PU
Pushed In Pushed In Pushed In Pushed In
DC Power
(ON) (ON) (ON) (ON)
SMS OFF OFF OFF OFF
UTILITY UTILITY UTILITY UTILITY
GMS
PARALLEL PARALLEL PARALLEL PARALLEL
UTILITY UTILITY UTILITY UTILITY
Master Control AVRS
PARALLEL PARALLEL PARALLEL PARALLEL
Panel MCP
60Hz Light ON① ON① ON① ON①
USS A② B② C② D②
BSS NORMAL NORMAL NORMAL NORMAL
SSS OFF OFF OFF OFF
SSL All OFF All OFF All OFF All OFF

Inside MCP FSS 50/60 Hertz① 50/60 Hertz① 50/60 Hertz① 50/60 Hertz①
Emergency
Generator Control Pulled-Out Pulled-Out Pulled-Out Pulled-Out
Stop
Panel GCPG1
ECS OFF OFF OFF OFF
Emergency
Generator Control Pulled-Out Pulled-Out Pulled-Out Pulled-Out
Stop
Panel GCPG2
ECS OFF OFF OFF OFF
① With the SMS in the OFF position, the 50/60Hz lights indicate the position of the Frequency
Selector Switch (FSS). If the wrong light is on, open the door and change the switch position.
② No more than one switch can be in the same position in any multi-PU line-up. With the SMS in
OFF, none of the USI lights will be on and any previously set address on the PU is cleared.

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5.8.4 PLANT STARTUP

5.8.4.1 GENERAL

CAUTION

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

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

5.8.4.2 MANUAL MODE

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

5.8.4.3 AUTOMATIC MODE

WARNING

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND


ENFORCED.
NOISE LEVELS IN EXCESS OF 85 DB EXIST WITHIN AN 88-FOOT RADIUS OF AN
OPERATING DPGDS. PERSONNEL MUST WEAR SINGLE HEARING PROTECTION
WITHIN 88 FEET OF AN OPERATING DPGDS.

WARNING

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND


ENFORCED.
DURING MAINTENANCE ACTIVITIES WITH THE SIDEDOORS OPEN, NOISE
LEVELS IN EXCESS OF 113 DB EXIST WITHIN A 12-FOOT RADIUS OF AN
OPERATING DPGDS. PERSONNEL MUST WEAR DOUBLE HEARING PROTECTION
WITHIN 12 FEET OF AN OPERATING DPGDS. EXPOSURE MUST BE LIMITED TO
UNDER 2.5 HOURS.

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WARNING

ONCE THE SYSTEM STATUS LIGHTS TURN GREEN AND THE MSES IS ENABLED,
THE PU WILL START. ENSURE PERSONNEL ARE CLEAR OF THE PU.

WARNING

ONLY ONE PU MAY BE SELECTED TO ANY ONE USS POSITION DURING MULTIPLE
PU OPERATIONS. OPERATING WITH MORE THAN ONE UNIT AT THE SAME ID
CAUSE UNSAFE AND ERRATIC OPERATIONAL CONDITIONS.

Starting up PUs in Utility Parallel in Automatic Mode

a. At the utility connection, close the associated connection for each PU supplying power to the
utility.

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

TABLE 5.8.4-1 SWITCH SETUP – AUTOMATIC MODE


PANEL SWITCH 1ST PU 2ND PU 3RD PU 4TH PU
Master Control
BCS-T Red Target Red Target Red Target Red Target
Panel MCP
Generator BCS-G1 Red Target Red Target Red Target Red Target
Control Panel 1
GCPG1 ECS-1 AUTO AUTO AUTO AUTO

Generator BCS-G2 Red Target Red Target Red Target Red Target
Control Panel 2
GCPG2 ECS-2 AUTO AUTO AUTO AUTO

SMS AUTO③ AUTO③ AUTO③ AUTO③


Master Control
Panel MCP
MSES Enable① Enable① Enable① Enable①

USI A①, ② B①, ② C① , ② D① , ②

① Hold the MSES in an ENABLE position until the selected USI indicator energizes. The switch
returns to the center position when released. This sets the PU networking address and enables
the control and monitoring.
② No more than one of each indicator can be on for multi-PU operations. The light on should match
USS position. The USI light will de-energize after the SMS has been in OFF for 3 seconds.
③ With the SMS in AUTO any generator started, manually or automatically, will automatically
parallel to the bus. To prevent the generator from paralleling to the bus put the generator’s
breaker in the Pull-To-Lock position.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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y. Ensure generators have assumed load. After the desired load has been stabilized, proceed with
the following if necessary:

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

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

CAUTION
Improper adjustment of the VAR can cause a reverse KVAR shutdown of a generator.
NOTE: The automatic economizing feature is disabled while a generator is operating in Utility
Parallel mode.

5.8.5 PLANT OPERATIONS

Refer to Chapter 5.9 for specific operating procedures.

The power plant must be in Auto Mode to be operated remotely or to adjust the load on the generators.

5.8.6 POWER PLANT TEARDOWN

5.8.6.1 SHUT DOWN GENERATORS

a. Unload all generators by opening all Tie breakers. This must be done locally from the LCP or
ORT.

b. Open both generator breakers using the respective BCS switches.

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

d. Allow all engines to complete cooldown and shut down (5 minutes).

e. Place all ECS switches in OFF/RESET.

f. Pull out the DC Control Power breaker on the PU.

5.8.6.2 DISCONNECT CABLES

WARNING

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

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CAUTION

ALLOW ALL OPERATING ENGINES TO SHUT DOWN AND COOL DOWN


COMPLETELY.

a. Disconnect the (A)(B) communication cables from between the PUs, Reinstall the
communications cable receptacle covers, and store inside the PUs (one per unit).

b. Disconnect the ORT cable and store it in the ORT case.

c. Close and latch the ORT port on the PU.

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

5.8.6.3 DISCONNECT FUEL LINES

a. Turn all fuel system valves to the off position.

b. Disconnect the fuel hose from the PU fuel connection and the fuel supply.

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

5.8.6.4 DISCONNECT GROUNDING

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

b. Disconnect the parking stations from the ground grid.

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

5.8.6.5 PREPARE PU FOR TRANSPORTATION

a. Reinstall the four radiator splashguards (PU-810B only).

b. Verify DC Control power is off.

c. Close and lock the LCP access doors.

d. Close and lock all PU side doors.

5.8.6.6 FUEL, OIL, AND COOLANT DRAINAGE

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

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THIS PAGE INTENTIONALLY BLANK

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CHAPTER 5.9
OPERATING INSTRUCTIONS

SPECIFIC OPERATING PROCEDURES


TABLE OF CONTENTS

SECTION TITLE PAGE


5.9 SPECIFIC OPERATING PROCEDURES 196

5.9.1 SAFETY PROCEDURES 196

5.9.2 CHANGE OPERATING FREQUENCY FROM 50HZ TO 60HZ 197

5.9.2.1 MASTER CONTROL PANEL 197

5.9.2.2 DIGITAL VOLTAGE REGULATOR (AVR) 197

5.9.2.3 GENERATOR SET CONTROLLER (GSC+) 199

5.9.3 CHANGE OPERATING FREQUENCY FROM 60HZ TO 50HZ 209

5.9.3.1 MASTER CONTROL PANEL 209

5.9.3.2 DIGITAL VOLTAGE REGULATOR (AVR) 209

5.9.3.3 GENERATOR SET CONTROLLER (GSC+) 210

5.9.4 RE-DESIGNATE A PU WITHOUT PLANT SHUTDOWN 211

5.9.5 FAULT RESETTING 212

5.9.5.1 OVERCURRENT RELAY TRIP AND BREAKER LOCKOUT 212

5.9.5.2 ENGINE OR GENERATOR FAULT 212

5.9.5.3 RE-CLOSING PSC INTERCONNECT AFTER A FAULT 213

5.9.6 GENERATOR PROCEDURES 214

5.9.6.1 ADD A GENERATOR TO THE BUS – MANUAL MODE 214

5.9.6.2 ADD A GENERATOR TO THE BUS - AUTO MODE 215

5.9.6.3 ADD A GENERATOR TO THE BUS – ORT 215

5.9.6.4 TAKE A GENERATOR OFFLINE – MANUAL MODE 215

5.9.6.5 TAKE A GENERATOR OFFLINE – AUTO MODE – WITHOUT ORT 216

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TABLE OF CONTENTS

SECTION TITLE PAGE


5.9.6.6 TAKE A GENERATOR OFFLINE – AUTO MODE - WITH ORT 216

5.9.6.7 ACKNOWLEDGE AN ALARM OR FAULT – MANUAL MODE 217

5.9.6.8 ACKNOWLEDGE AN ALARM OR FAULT – AUTO MODE 217

5.9.6.9 ACKNOWLEDGE AN ALARM OR FAULT – ORT 217

5.9.6.10 ADD AND REMOVE GENERATOR FROM PLANT LINE-UP WITH ORT 217

5.9.6.11 ECONOMIZING ON/OFF – ORT 218

5.9.6.12 CHANGE FROM MANUAL MODE TO AUTOMATIC MODE 218

5.9.6.13 CHANGE FROM AUTOMATIC MODE TO MANUAL MODE 219

5.9.6.14 UNIT ISOLATION PROCEDURE (ANY UNIT) – PLANT WITH PSC 219

5.9.6.15 UNIT RE-INSTALLATION PROCEDURE – PLANT WITH PSC 220

5.9.6.16 ISOLATING A PU IN A TWO PLANT, NO PSC, LINEUP 221

5.9.6.17 RE-INSTALLING THE SECOND PU INTO A TWO-PLANT-NO-PSC LINEUP 222

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LIST OF TABLES

TABLE TITLE PAGE


TABLE 5.9.2.2-1 AVR PARAMETERS/SETPOINTS 198

TABLE 5.9.2.2-1 AVR PARAMETERS/SETPOINTS 199

TABLE 5.9.2.3-1 OP5-0 SETPOINTS 201

TABLE 5.9.2.3-2 OP5-1 SETPOINTS 204

TABLE 5.9.2.3-3 OP6 SETPOINTS 207

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5.9 SPECIFIC OPERATING PROCEDURES

5.9.1 SAFETY PROCEDURES

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

• Hot engine parts


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

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

WARNING

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND


ENFORCED. NOISE LEVELS IN EXCESS OF 85 DB EXIST WITHIN AN 88-FOOT
RADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR SINGLE HEARING
PROTECTION WITHIN 88 FEET OF AN OPERATING DPGDS.

WARNING

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND


ENFORCED. DURING MAINTENANCE ACTIVITIES WITH THE SIDEDOORS OPEN,
NOISE LEVELS IN EXCESS OF 113 DB EXIST WITHIN A 12-FOOT RADIUS OF AN
OPERATING DPGDS. PERSONNEL MUST WEAR DOUBLE HEARING PROTECTION
WITHIN 12 FEET OF AN OPERATING DPGDS. EXPOSURE MUST BE LIMITED TO
UNDER 2.5 HOURS.

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5.9.2 CHANGE OPERATING FREQUENCY FROM 50HZ TO 60HZ

5.9.2.1 MASTER CONTROL PANEL

a. Push-in DC Control Power Circuit Breaker.

b. Open the MCP cabinet door.

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

d. Close the MCP cabinet door.

5.9.2.2 DIGITAL VOLTAGE REGULATOR (AVR)

a. Open GCPG1 cabinet door.

b. At the AVR verify/change the operation settings for 60 Hz using Table 5.9.2.2-1:

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

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

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

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

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

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

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

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

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

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TABLE 5.9.2.2-1 AVR PARAMETERS/SETPOINTS


DPGDS
DPGDS AVR PARAMETERS
SETPOINTS
RANGE OF DEFAULT 60HZ 50HZ
PARAMETER TITLE TYPE UNITS
VALUES VALUE OPS OPS
01 Generator Output Voltage Program Volts 0080-9999 480① 4160 3800

02 Ratio of Output Voltage To Program 001.0-100.0 001.0 17.3 17.3


Sensing Voltage
03 Generator Type Program 0000-0004 0004 4 4
04 Rated Generator Output Current Program Amps 0000-9999 0600 80 73
05② CT Voltage At Rated Generator Program Volts 01.00-05.00 05.00 4.00 3.66
Current
06 Knee Frequency Program Hz 045.0-065.0 050.0 59.8 49.8
07 Decreasing Volts/Hz Slope I Program Volts/Hz 001.0-010.0 002.0 2.0 2.0
08 Decreasing Volts/Hz Slope 2 Program Volts/Hz 001.0-010.0 002.0 2.0 2.0
09 Minimum Voltage Program % 050.0-100.0 050.0 50.0 50.0
10 Under Frequency Point Program Hz 020.0-040.0 025.0 25.0 25.0
11 Overvoltage Trip Point Program % 0105-0140 014.0 125.0 125.0
12 Overvoltage Trip Time Program Seconds 0002-0030 0002 5 5
13 Under Voltage Trip Point Program % 0060-0095 0060 75 75
14 Under Voltage Trip Time Program Seconds 0030-0120 0030 30 30
15 Voltage Gain (IR Compensation) Program % 000.0-0 0000 0 0
10.0
16⑤ Integral Gain Program 001.0-020.0 006.0 6.0 6.0

17⑥ Proportional Gain Program 001.0-020.0 005.0 5.0 5.0

18 Single Phase Sensing Select Program 0000,0001 0000 0000 0000


(0=three_phase,_1=single
phase)
19 Diode Monitor Trip Point Program Amps 001.0-010.0 002.0 2.0 2.0
30 Droop Percentage Program % 000.0-010.0 0000 3 3
31③ pf/kVAR Select (0=pf, 1=kVAR) Program 0000, 0001 0000 0 0

32③ Pf Reference Program 00.60-01.10 01.00 0.8 0.8

33③ KVAR Reference Program Per Unit 00.00-01.00 0000 .10 .10

34③ Reverse Power Trip Point Program % 000.0-020.0 010.0 15 15

35③ Reverse Power Trip Time Program Seconds 000.0-020.0 010.0 5 5

50 Generator Output Frequency View Hz


51 Generator Output Voltage View Volts
52 Generator Output Current View Amps
53 Generator Reactive Output View Amps
Current
54 Generator Real Current View Amps
55 Exciter Field Current View Amps
56③ Three Phase Kilowatts (KB and View KW
later)
57③ Power Factor View

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TABLE 5.9.2.2-1 AVR PARAMETERS/SETPOINTS


DPGDS
DPGDS AVR PARAMETERS
SETPOINTS
RANGE OF DEFAULT 60HZ 50HZ
PARAMETER TITLE TYPE UNITS
VALUES VALUE OPS OPS
58③,④ Three Phase kVAR (KE and View
later)
60 Hours View Hours 0000-9999
90 Password Program 0009 0009
91 Software ID View
92 Latest Fault View 0000 0000 0000
93 Previous Fault View 0000 0000 0000
94 Fault Clear View
96 Shutdown Fault Reset Switch

①- Default value for output voltage is different depending on regulator sensing voltage. If the regulator is
designed for 120 volts sensing, then the default output voltage is 4160 volts. All other sensing types
have the default output voltage set to 480 volts.
②- Digital Voltage Regulators with earlier software (KD and earlier) have 1 less digit to the right of the
decimal point.
③- Optional feature.
④- New parameter on serial number prefix KE and later Digital Voltage Regulators.
⑤- Previous range of 0001-099.9 and default value of 002.0
⑥-Previous range of 0001-099.9 and default value of 002.0

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

l. When complete, press the [▼] to display parameter “90”.

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

n. Press the [▼] key to change the value to “0009”. Disables parameter editing.

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

p. Press the [▲] key to change to display parameter “01”.

q. Close GCPG1 cabinet door.

r. Repeat steps ‘a ‘through ‘q’ for Generator 2.

5.9.2.3 GENERATOR SET CONTROLLER (GSC+)

At GSCG1, verify/change the operation settings for 60 Hz using Table 5.9.2.3-1 and Table 5.9.2.3-2:

a. Place ECS in the COOLDOWN/STOP position.

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

c. Press SCROLL UP key until “OP3” is showing.

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d. Press SELECT key. “PE - -“ is showing.

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

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

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

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

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

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

k. Press ENTER key. “PE PASS” is showing.

l. Press EXIT key. “OP4” is showing.

m. Press SCROLL UP key until “OP5-0” is showing on the lower display.

n. Press SELECT key, the value of the setpoint is showing.

o. Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing.

p. Press SELECT key. The value of the setpoint is flashing. Use the GSC Setpoints Table 5.9.2.3-1
for the values to verify/change in each parameter.

q. Press SCROLL UP or SCROLL DOWN key to adjust the value of the setpoint.

NOTE: To adjust the value of some setpoints, it is necessary to press and release the scroll key
several times in order for the value to change. To rapidly scroll through a large range of
values, press and hold the appropriate scroll key.

r. Press ENTER key. The value of the setpoint stops flashing.

s. Repeat steps ‘o’ through ‘r’ until all the desired setpoints are adjusted.

t. Press EXIT key. “OP5-0” is showing on the lower display.

u. Repeat steps ‘m’ through ‘s’ for “OP5-1” using Table 5.9.2.3-2.

v. Press EXIT key twice. The display returns to normal.

w. Return ECS to the OFF/RESET position.

x. Repeat steps ‘a’ through ‘w’ for GSC G2.

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TABLE 5.9.2.3-1 OP5-0 SETPOINTS


SETPOINTS OP5-0 ENGINE/GENERATOR PROGRAMMING①
FACTORY DPGDS
SETPOINT-NAME-DESCRIPTIONS RANGE OF VALUES
DEFAULT SETPOINT
P001 - Fuel Solenoid Type: type of fuel system solenoid 0- ETR fuel solenoid
0 0
used on the genset. 1- ETS fuel solenoid
P002 - Units Shown: type of measurement units shown 0-for English units (PSI, ºF)
0 0
on the GSC+ display. 1-for metric units (kPa, ºC).
P003 - Shutdown Override For Engine Fault: GSC+ 0-for engine shutdown
response to a low engine oil pressure or high coolant 1-for alarm only (shutdown override, no 0 0
temperature fault. engine shutdown).
P004 - Shutdown Override For Sensor Fault: GSC+ 0-for alarm only shutdown override, no
response to a diagnostic fault with the engine oil pressure engine shutdown). 0 0
sensor, coolant temperature sensor, oil temperature
sensor, sensor power supply or coolant loss sensor. 1-for engine shutdown.

P005 - Coolant Loss Sensor Installed: tells whether or 0-for gensets without a coolant loss sensor
not the optional engine coolant loss sensor is installed on 0 1
the genset. 1-for gensets with coolant loss sensor

0-for engine shutdown.


P006 - Shutdown Override For Coolant Loss Fault:
1-for alarm only (shutdown override, no 0 0
GSC+ response to an engine coolant loss fault.
engine shutdown).
P007 - System Voltage, 24 Or 32 Volts: system voltage
24 or 32. 24 24
(battery voltage) of the genset.
P008 - This setpoint is not currently being used by the
N/A N/A N/A
GSC+ and cannot be programmed.
P009 - Number Of Ring Gear Teeth: number of teeth on
the ring gear of the engine. Used by the GSC+ to 95 to 350 teeth in increments of one tooth. 136 teeth 136 teeth
determine engine speed.
P010 - Engine Overspeed: engine speed used by the
GSC+ to declare that an engine overspeed fault exists.
500 to 4330 rpm in increments of 10 rpm. 2120 rpm 2120 rpm
The engine overspeed setpoint (for all 60 Hz applications)
is 1.18 times the rated speed.
P011 - Crank Terminate Speed: engine speed used by
the GSC+ to disengage the starting motor during engine 100 to 1000 rpm in increments of 10 rpm. 400 rpm 400 rpm
cranking.
P012 - Oil Step Speed: engine speed used by the GSC+
for distinguishing between rated speed and idle speed 400 to 1800 rpm in increments of 10 rpm. 1350 rpm 1350 rpm
when a low oil pressure fault exists.

P013② - Low Oil Pressure Shutdown At Rated Speed:


oil pressure used by the GSC+ to declare that a low oil 30 PSI 30 PSI
pressure shutdown fault exists with engine at rated speed 5 to 61PSI (34 to 420kPa) in increments of 1
(205 kPa) (205 kPa)
(the engine speed must have exceeded the oil step speed
for nine seconds).

P014② - Low Oil Pressure Shutdown At Idle Speed:


oil pressure used by the GSC+ to declare that a low oil
10 PSI 10 PSI
pressure shutdown fault exists with the engine at idle 20 to 336kPa (3 to 49PSI) in increments of 1
speed (the engine must have been running for at least 9 (70 kPa) (70 kPa)
seconds and the engine speed must be less than oil step
speed).

P015③ - High Water Temperature Shutdown: coolant


185 to 253ºF (85 to 123ºC) in increments of 225ºF 225ºF
temperature used by the GSC+ to declare a high coolant
temperature shutdown fault exists (after a 10 second 1 (107ºC) (107ºC)
delay).
P016 - Low Water Temperature Alarm: coolant
temperature used by the GSC+ to declare that a low 70ºF 70ºF
32 to 97ºF (0 to 36ºC) in increments of 1
coolant temperature alarm fault exists (after a 2 second (21ºC) (21ºC)
delay).

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TABLE 5.9.2.3-1 OP5-0 SETPOINTS (CONTINUED)


SETPOINTS OP5-0 ENGINE/GENERATOR PROGRAMMING①
FACTORY DPGDS
SETPOINT-NAME-DESCRIPTIONS RANGE OF VALUES
DEFAULT SETPOINT
P017 - Total Cycle Crank Time: cycle crank time used by the 5 to 120 seconds in increments of 1
90 seconds 90 seconds
GSC+ to declare that an overcrank fault exists. second.
P018 - Cycle Crank Time: amount of time the GSC+ cranks 5 to 60 seconds in increments of 1
10 seconds 10 seconds
and then rests the starting motor during a single crank cycle. second.
P019 - Cooldown Time: amount of time the GSC+ allows the 0 to 30 minutes in increments of 1
5 minutes 5 minutes
engine to run after a normal shutdown is initiated. minute.

P020④ - AC Voltage: nominal AC voltage of the generator. 700, 150, 300, 500, 600, 750, 3.0k,
The GSC+ measures the AC voltage and shows it on the 4.5k, 5.20k, 5.25k, 9.0k, 15.0k, 18.0k, 700 5.20k
display. 30.0k
P021 - AC Current Full Scale: nominal full scale AC current 75, 100, 150, 200, 300, 400, 600, 800,
of the generator. AC current full scale is equal to the ratio of 1000, 1200, 1500, 2000, 2500, 3000, 600A 100A
the external current transformers in the generator housing. and 4000A

P022⑤ - GSC+ Engine Number: informs other devices on


01 (Gen 1)
01 through 08 01
the CAT Data Link of the engine number for the GSC+. 02 (Gen 2)

SETPOINTS - OP5-0-ENGINE/GENERATOR PROGRAMMING①


RANGE OF FACTORY 60HZ 50HZ
SETPOINT-NAME-DESCRIPTIONS
VALUES DEFAULT SETPOINT SETPOINT
P023 - Engine Type: identifies the engine as a 0 - MUI diesel
mechanical unit injector (MUI) diesel, spark
1 - Gas 0 2 2
ignited (gas), or electronic unit injector (EUI)
diesel engine. 2 - EUI diesel
P024 - Crank Time Delay: amount of time the
GSC+ delays activation of the fuel control relay
(FCR) during a crank cycle. This setpoint is for 0 to 20 seconds in increments of 1
5 Seconds 5 Seconds 5 Seconds
Gas engines only. The P024 setpoint only second.
functions when the P023 setpoint is set to 1 (gas
engine).
0 - for gensets without an oil
P025 - Oil Temperature Sensor Installed: tells temperature sensor
whether or not the optional engine oil temperature 0 0 0
sensor is installed on the genset. 1 - for gensets with an oil
temperature sensor
P026 - High Oil Temperature Shutdown: oil
temperature used by the GSC+ to declare a high 185 to 253ºF (85 to 123ºC) in
225ºF (107ºC) 225ºF (107ºC) 225ºF (107ºC)
oil temperature shutdown fault exists (after a 10 increments of 1
second delay). Refer to the panel model number.
P027 - Shutdown Override For High Oil 0 - for alarm only (shutdown override,
Temperature Fault: GSC+ response to an engine no engine shutdown). 0 0 0
high oil temperature fault. 1 - for engine shutdown.
P028 - Nameplate Voltage: rated voltage of the
generator. This setpoint is used for protective 100 to 25kV in increments of 1 480V 4160V 3800V
relaying functions.
P029 - Nameplate Current: rated current output
0 to 4000 A in increments of 1 600A 80A 73A
of the generator.
P030 - Nameplate Power: rated power capability 0 through 10MW in increments of
400kW 420kW 350kW
of the generator. 1kW.
P031 - Rated Frequency: nominal frequency
50 or 60Hz 60Hz 60Hz 50Hz
rating of genset.
P032 - Connection Configuration Of Generator: 0 - wye
0 0 0
wye or delta configuration of generator. 1 – delta
P033 - Number Of Generator Poles. 0 through 254 in increments of 2. 4 4 4

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① The setpoints (stored or being programmed) must match the specified DPGDS setpoints.
② When oil pressure drops to within 5PSI (34kPa) of the P013 or P014 setpoint, a low oil pressure alarm
is issued by the GSC+.
③ When coolant temperature rises to within 11ºF (6ºC) of the P015 setpoint, a high coolant temperature
alarm is issued by the GSC+.
④ The values other than the default (700V) are for switchgear applications and require the use of external
potential transformers and the removal of the AC voltage range jumper located in the relay module.
The DPGDS unit is factory configured for the 5.20 K value. See the Caterpillar Electronic Modular
Control Panel II+ manual topic AC Voltage Range Selection in the Testing and Adjusting section.
⑤ After setpoint P022 is reprogrammed, the GSC+ must be power cycled (powered down and then
powered up)

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TABLE 5.9.2.3-2 OP5-1 SETPOINTS


SETPOINTS OP5-1 PROTECTIVE RELAYING PROGRAMMING①
FACTORY 60HZ 50HZ
SETPOINT-NAME-DESCRIPTION RANGE OF VALUES
DEFAULT SETPOINT SETPOINT
P101 - Generator Overvoltage Alarm Enable: the 0 - disabled
GSC+ enables or disables the generator 1 1 1
overvoltage alarm function. 1 – enabled
P102 - Generator Overvoltage Alarm Threshold:
100 to 125% of nameplate voltage in
voltage the GSC+ uses to issue an overvoltage 105% 105% 105%
increments of 1%.
alarm.
P103 - Generator Overvoltage Alarm Time Delay:
amount of time the GSC+ waits before issuing an 0 through 120 seconds② in increments 10 seconds 10 seconds 10 seconds
overvoltage alarm. of 1
P104 - Generator Overvoltage Shutdown Enable: 0 - disabled
the GSC+ enables or disables the generator 1 1 1
overvoltage shutdown function. 1 – enabled
P105 - Generator Overvoltage Shutdown
100 to 125% of nameplate voltage in
Threshold: voltage the GSC+ uses to issue an 110% 110% 110%
increments of 1%.
overvoltage shutdown.
P106 - Generator Overvoltage Shutdown Time
Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments 10 seconds 10 seconds 10 seconds
issuing an overvoltage shutdown. of 1
P107 - Generator Undervoltage Alarm Enable: 0 - disabled
the GSC+ enables or disables the generator 1 1 1
undervoltage alarm function. 1 – enabled
P108 - Generator Undervoltage Alarm
60 to 100% of nameplate voltage in
Threshold: voltage the GSC+ uses to issue an 90% 90% 90%
increments of 1%.
undervoltage alarm.
P109 - Generator Undervoltage Alarm Time
Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments 10 seconds 10 seconds 10 seconds
issuing an undervoltage alarm. of 1
P110 - Generator Undervoltage Shutdown 0 - disabled
Enable: the GSC+ enables or disables the 1 1 1
generator undervoltage shutdown function. 1 – enabled
P111 - Generator Undervoltage Shutdown
60 through 100% of rated voltage in
Threshold: voltage the GSC+ uses to issue an 85% 85% 85%
increments of 1%.
undervoltage shutdown.
P112 - Generator Undervoltage Shutdown Time
Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments 15 seconds 03 seconds 03 seconds
issuing an undervoltage shutdown. of 1
P113 - Generator Overfrequency Alarm Enable: 0 - disabled
the GSC+ enables or disables the generator 1 1 1
overfrequency alarm function. 1 – enabled

P114 - Generator Overfrequency Alarm 50-60Hz, for 50Hz Gen 53Hz


Threshold: frequency the GSC+ uses to issue an 60-70Hz, for 60Hz Gen 63Hz 63 Hz 53 Hz
overfrequency alarm. 400-480, for 400Hz Gen 422Hz
P115 - Generator Overfrequency Alarm Time
Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments 10 seconds 10 seconds 10 seconds
issuing an overfrequency alarm. of 1
P116 - Generator Overfrequency Shutdown 0 - disabled
Enable: the GSC+ enables or disables the 1 1 1
generator overfrequency shutdown function. 1 – enabled

P117 - Generator Overfrequency Shutdown 50-60Hz, for 50Hz Gen 55Hz


Threshold: frequency the GSC+ uses to issue an 60-70Hz, for 60Hz Gen 66Hz 66Hz 55Hz
overfrequency shutdown. 400-480, for 400Hz Gen 440Hz

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TABLE 5.9.2.3-2 OP5-1 SETPOINTS (CONTINUED)


SETPOINTS OP5-1 PROTECTIVE RELAYING PROGRAMMING①
FACTORY 60HZ 50HZ
SETPOINT-NAME-DESCRIPTION RANGE OF VALUES
DEFAULT SETPOINT SETPOINT
P118 - Generator Overfrequency Shutdown Time
Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments 10 seconds 10 seconds 10 seconds
issuing an overfrequency shutdown. of 1
P119 - Generator Underfrequency Alarm Enable: 0 - disabled
the GSC+ enables or disables the generator 1 1 1
underfrequency alarm function. 1 – enabled

P120 - Generator Underfrequency Alarm 30-50Hz, for 50Hz Gen 48Hz


Threshold: frequency the GSC+ uses to issue an 36-60Hz, for 60Hz Gen 57Hz 57Hz 48Hz
underfrequency alarm. 240-400, for 400Hz Gen 378Hz
P121 - Generator Underfrequency Alarm Time
Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments 10 seconds 10 seconds 10 seconds
issuing an underfrequency alarm. of 1
P122 - Generator Underfrequency Shutdown 0 - disabled
Enable: the GSC+ enables or disables the generator 1 1 1
underfrequency shutdown function. 1 – enabled

P123 - Generator Underfrequency Shutdown 30-50Hz, for 50Hz Gen 45Hz


Threshold: frequency the GSC+ uses to issue an 36-60Hz, for 60Hz Gen 54Hz 54Hz 45Hz
underfrequency shutdown. 240-400, for 400Hz Gen 360Hz
P124 - Generator Underfrequency Shutdown
Time Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments 15 seconds 03 seconds 03 seconds
issuing an underfrequency shutdown. of 1
P125 - Generator Reverse Power Shutdown 0 - disabled
Enable: the GSC+ enables or disables the generator 1 1 1
reverse power shutdown function. 1 – enabled
P126 - Generator Reverse Power Shutdown
0 through 20% of rated power in
Threshold: level of reverse power the GSC+ uses to 15% 4% 4%
increments of 1%.
issue a reverse power shutdown.
P127 - Generator Reverse Power Shutdown Time
Delay: amount of time the GSC+ waits before 0 through 30 seconds② in increments 10 seconds 4 seconds 4 seconds
issuing a reverse power shutdown. of 1
P128 - Generator Overcurrent Alarm Enable: the 0 - disabled
1 1 1
GSC+ enables or disables the overcurrent alarm. 1 – enabled
P129 - Generator Phase Overcurrent Alarm
100 through 160% of nameplate current
Threshold: level of current the GSC+ uses to issue a 105% 150% 150%
in increments of 5%
phase overcurrent alarm.
P130 - Generator Phase Overcurrent Alarm Time
Delay: amount of time the GSC+ waits before 0 through 250 seconds② in increments 0 seconds 0 seconds 0 seconds
issuing a phase overcurrent alarm. of 1
P131 - Generator Total Overcurrent Alarm
100 through 160% of three times
Threshold: level of current the GSC+ uses to issue a 105% 150%. 150%
nameplate current in increments of 5%
total overcurrent alarm.
P132 - Generator Total Overcurrent Alarm Time
Delay: amount of time the GSC+ waits before 0 through 250 seconds② in increments 0 seconds 0 seconds 0 seconds
issuing a total overcurrent alarm. of 1
P133 – Generator Overcurrent Shutdown Enable: 0 – disabled
the GSC+ enables or disables the overcurrent 1 1 1
shutdown. 1 – enabled
P134 – Generator Phase Overcurrent Shutdown
100 through 160% in increments of 5%
Threshold: level of current the 110% 150% 150%
GSC+ uses to issue a phase overcurrent shutdown.
P135 – Generator Phase Overcurrent Shutdown
Time Delay: amount of time the GSC+ waits before 0 through 250 seconds② in increments 0 seconds 10 seconds 10 seconds
issuing a phase overcurrent shutdown. of 1

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DRS RADIAN CTM 01646.1R0253/1R0254

TABLE 5.9.2.3-2 OP5-1 SETPOINTS (CONTINUED)


SETPOINTS OP5-1 PROTECTIVE RELAYING PROGRAMMING①
FACTORY 60HZ 50HZ
SETPOINT-NAME-DESCRIPTION RANGE OF VALUES
DEFAULT SETPOINT SETPOINT
P136 - Generator Total Overcurrent
Shutdown Threshold: level of current the 100 through 160% of three times
110% 150%. 150%
GSC+ uses to issue a total overcurrent nameplate current in increments of 5%
shutdown.
P137 - Generator Total Overcurrent
Shutdown Time Delay: amount of time the 0 through 250 seconds② in increments 0 seconds 10 seconds 10 seconds
GSC+ waits before issuing a total overcurrent of 1
shutdown.
P138 - KW Level Relay Enable : the GSC+ 0 - disabled
enables or disables the kW level relay 1 1 1
function. 1 – enabled
P139 - KW Level Relay Threshold: level of
0 through 110% of nameplate power in
power the GSC+ uses to activate the kW level 105% 105% 105%
increments of 1%
relay function.
P140 - KW Level Relay Time Delay: amount
of time the GSC+ waits before activating the 0 through 120 seconds② in increments 0 seconds 0 seconds 0 seconds
kW level relay function. of 1
P141 - KW Level Relay Disengage
0 through 110% of nameplate power in
Threshold: level of power the GSC+ uses to 100% 100% 100%
increments of 1%.
deactivate the kW level relay function.
P142 - KW Level Relay Disengage Time
Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments 10 seconds 10 seconds 10 seconds
deactivating the kW level relay function. of 1

① The setpoints are programmed at the factory to the default value.


② When programmed to 0 seconds, the actual time is from 0.5 to 1.0 seconds.

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TABLE 5.9.2.3-3 OP6 SETPOINTS


SETPOINTS OP6 SPARE INPUT/OUTPUT PROGRAMMING
FACTORY DPGDS
SETPOINT-NAME-DESCRIPTIONS RANGE OF VALUES
DEFAULT SETPOINT
SP01 - Spare Input 1 Active State. Input state used by the 0-active low
0 0
GSC+ to declare a SP1 fault exists. 1-active high
SP02 - Spare Input 1 Response: GSC+ response to a SP1 0-shutdown
0 0
fault. 1-alarm
SP03 - Spare Input 1 Time Delay: Amount of time the GSC+
0 - 250 seconds in increments of 1 0 seconds 1 second
waits before responding to a SP1 fault.
SP04 - Spare Input 2 Active State. Input state used by the 0-active low
0 1
GSC+ to declare a SP2 fault exists. 1-active high
SP05 - Spare Input 2 Response: GSC+ response to a SP2 0-shutdown
0 0
fault. 1-alarm
SP06 - Spare Input 2 Time Delay: Amount of time the GSC+
0 - 250 seconds in increments of 1 0 seconds 0 seconds
waits before responding to a SP2 fault.
SP07 - Spare Input 3 Active State. Input state used by the 0-active low
0 0
GSC+ to declare a SP3 fault exists. 1-active high
SP08 - Spare Input 3 Response: GSC+ response to a SP3 0-shutdown
0 0
fault. 1-alarm
SP09 - Spare Input 3 Time Delay: Amount of time the GSC+
0 - 250 seconds in increments of 1 0 seconds 0 seconds
waits before responding to a SP3 fault.
SP10 - Spare Input 4 Active State. Input state used by the 0-active low
0 0
GSC+ to declare a SP4 fault exists. 1-active high
SP11 - Spare Input 4 Response: GSC+ response to a SP4 0-shutdown
0 0
fault. 1-alarm
SP12 - Spare Input 4 Time Delay: Amount of time the GSC+
0 - 250 seconds in increments of 1 0 seconds 0 seconds
waits before responding to a SP4 fault.
SP13 - Spare Output Response: GSC+ response to the spare 0-active low
0 0
output trigger condition. 1-active high
0-unused

1-active SP1 fault②

2-active SP2 fault②

3-active SP3 fault②

4-active SP4 fault②


SP14 - Spare Output Trigger Condition: The condition used
5-any combination of active SP faults②
8 8
by the GSC+ to trigger the spare output response
6-any active shutdown
7-any active alarm or shutdown
8-cooldown mode

9-coolant loss mode②

10-high oil temp fault②


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

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TABLE 5.9.2.3-3 OP6 SETPOINTS (CONTINUED)


SETPOINTS OP6 SPARE INPUT/OUTPUT PROGRAMMING
FACTORY DPGDS
SETPOINT-NAME-DESCRIPTIONS RANGE OF VALUES
DEFAULT SETPOINT
0-unused

1-active SP1 fault②

2-active SP2 fault②

3-active SP3 fault②

4-active SP4 fault②


SP16 - Spare Relay Output Trigger Condition: The condition
5-any combination of active SP faults②
8 1
used by the GSC+ to trigger the spare relay.
6-any active shutdown
7-any active alarm or shutdown
8-cooldown mode

9-coolant loss mode②

10-high oil temp fault②


11-CCM control
0-unused

1-active SP1 fault②

2-active SP2 fault②

3-active SP3 fault②


SP17 - Spare Indicator 1 Trigger Condition: The condition
4-active SP4 fault② 0 6
used by the GSC+ to trigger spare indicator①.
5-any combination of active SP1, SP2,

SP3 or SP4 faults②

6-Coolant loss fault②

7-high oil temperature fault②


SP18 - Spare Indicator 2 Trigger Condition: The condition
Battle Short mode. 0 0 Battleshort③
used by the GSC+ to trigger spare indicator②.
SP19 - Spare Indicator 3 Trigger Condition: The condition 0 In 50Hz
Not in 60 Hz mode. 0
used by the GSC+ to trigger spare indicator③. Mode③

① The setpoints are programmed at the factory to the default value.

② Either alarm or shutdown faults are valid trigger conditions

③ Battleshort and 50Hz Mode are unique features to DPGDS for spare indicators 2 and 3.

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5.9.3 CHANGE OPERATING FREQUENCY FROM 60HZ TO 50HZ

5.9.3.1 MASTER CONTROL PANEL

a. Turn on DC power.

b. Open the MCP cabinet door.

c. Place the Frequency Selector Switch (FSS) in the 50 Hz position.

d. Close the MCP cabinet door.

5.9.3.2 DIGITAL VOLTAGE REGULATOR (AVR)

a. Open the GCPG1 cabinet door.

b. At the AVR verify/change the operation settings for 50Hz using Table 5.9.2.2-1:

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

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

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

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

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

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

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

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

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

l. When complete, press the [▼] to display parameter “90”.

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

n. Press the [▼] key to change the value to “0009”. Disables parameter editing.

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

p. Press the [▲] key to change to display parameter “01”.

q. Close the GCPG1 cabinet door.

r. Repeat steps ‘a ‘through ‘q’ for Generator 2.

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5.9.3.3 GENERATOR SET CONTROLLER (GSC+)

At GSC G1, verify/change the operation settings for 50 Hz using Table 5.9.2.3-1 and Table 5.9.2.3-2.

a. Place ECS in the STOP/COOLDOWN position.

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

c. Press SCROLL UP key until “OP3” is showing.

d. Press SELECT key. “PE - -“ is showing.

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

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

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

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

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

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

k. Press ENTER key. “PE PASS” is showing.

l. Press EXIT key. “OP4” is showing.

m. Press SCROLL UP key until “OP5-0” is showing on the lower display.

n. Press SELECT key. The value of the setpoint is showing.

o. Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing.

p. Press SELECT key. The value of the setpoint is flashing. Use the GSC+ Setpoints Table for the
values to verify/change in each parameter.

q. Press SCROLL UP or SCROLL DOWN key to adjust the value of the setpoint.

NOTE: To adjust the value of some setpoints, it is necessary to press and release the scroll key
several times in order for the value to change. To rapidly scroll through a large range of
values, press and hold the appropriate scroll key.

r. Press ENTER key. The value of the setpoint stops flashing.

s. Repeat steps ‘o’ through ‘r’ until all the desired setpoints are adjusted.

t. Press EXIT key. “OP5-0” is showing on the lower display.

u. Repeat steps ‘m’ through ‘s’ for “OP5-1”..

v. Press EXIT key twice. The display returns to normal.

w. Return ECS to the OFF/RESET position.

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x. Repeat steps ‘a’ through ‘w’ for GSC G2.

5.9.4 RE-DESIGNATE A PU WITHOUT PLANT SHUTDOWN

In a multi-PU plant operating in the automatic mode, the PU designated as the “A” unit (PU-A) controls
the Economizing function of the plant. There must always be one, and only one, PU designated as PU-A
for the plant to operate properly. Each of the other PUs in the plant must also be uniquely designated
(PU-B, PU-C, etc.). If it becomes necessary to shutdown PU-A, another unit must be designated as PU-
A. It may be applied to any unit that is connected to the system network. However, there can be only one
(1) PU per plant configured with an individual address.

a. Turn off the economizer on the ORT.

b. Place the SMS in the MANUAL position for all units in the plant.

c. Place the ECS in the MANUAL/START position for all units in the plant.

NOTE: Wait five (5) seconds.

d. Place the SMS in the OFF position on all units in the plant—wait for the USI light to go out.

e. Place the USS in the desired position (A, B, C, or D). Note the general procedure in the Section
above.

NOTE: If necessary, reroute Communication Cables.

f. Place the SMS in the MANUAL position for all units in the plant.

g. Place the MSES in the ENABLE position and hold until the USI energizes.

h. Verify that the correct unit selector indicator is lit for each unit.

i. Place the ECS in the AUTO position on each unit in the plant.

NOTE: Wait five (5) seconds.

j. Place the SMS in the AUTO position on each unit in the plant.

NOTE: After re-designation of any PU, the system defaults to ECONOMIZER MODE.

j. Enter equipment ID for re-designated units on the ORT.

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5.9.5 FAULT RESETTING

5.9.5.1 OVERCURRENT RELAY TRIP AND BREAKER LOCKOUT

WARNING

DO NOT RESET A FAULT BEFORE DETERMINING AND CORRECTING THE CAUSE


OF A FAULT. RECORD ALL FAULTS/ALARMS BEFORE CLEARING. FAILURE TO
CORRECT A FAULT BEFORE RESETTING CAN RESULT IN DEATH, PERSONAL
INJURY, OR EQUIPMENT DAMAGE

a. At the overcurrent relay with the “TRIP” LED on:

(1) Press the UP arrow twice to get to “1.1 RECLOSER OFF” display.

(2) Press the DOWN arrow key once to get to “1.2 TARGETS YES” display.

(3) Press RIGHT arrow key twice to get to “1.3 ALARMS YES” display.

(4) Press and Hold “RESET” key to clear the trip.

(5) Observe the “TRIP” LED de-energizes.

b. At the MCP:

(1) Cycle the MSES to ENABLE to reset the control lockout.

(2) Observe the red SSL de-energizes and the generator will sync and close to the bus if the
engine is still running.

5.9.5.2 ENGINE OR GENERATOR FAULT

WARNING

DO NOT RESET A FAULT BEFORE DETERMINING AND CORRECTING THE CAUSE


OF A FAULT. RECORD ALL FAULTS/ALARMS BEFORE CLEARING. FAILURE TO
CORRECT A FAULT BEFORE RESETTING CAN RESULT IN DEATH, PERSONAL
INJURY, OR EQUIPMENT DAMAGE

a. At the respective GCP, place the ECS in OFF/RESET.

b. Observe the fault LED(s) de-energize.

c. At the MCP, cycle the MSES to reset the engine lockout.

d. Observe the red SSL de-energizes.

e. Place the ECS in COOLDOWN/STOP.

f. Observe the fault LED(s) and red SSL remain de-energized.

g. Return respective Generator to manual or automatic mode of operation as appropriate.

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5.9.5.3 RE-CLOSING PSC INTERCONNECT AFTER A FAULT

WARNING

DO NOT RESET A FAULT BEFORE DETERMINING AND CORRECTING THE CAUSE


OF A FAULT. FAILURE TO CORRECT A FAULT BEFORE RESETTING CAN
RESULT IN DEATH, PERSONAL INJURY, OR EQUIPMENT DAMAGE

WARNING

DO NOT RE-CLOSE THE PSC INTERCONNECT SWITCHES UNLESS ONE SIDE OF


THE SWITCH IS NOT ENERGIZED. FAILURE TO CORRECT A FAULT BEFORE
RESETTING CAN RESULT IN DEATH, PERSONAL INJURY, OR EQUIPMENT
DAMAGE

NOTE: This procedure assumes the PUs in the plant are operating in Automatic and that PSC1 is
chosen to power down prior to re-closing the interconnect. The procedure may also be used
for isolation of PSC2 by substituting “PSC2” for “PSC1” and “PSC1” for “PSC2”.

a. At the ORT, open the GCGG1 and GCGG2 breakers for all Power Units connected to PSC 1.

b. At PSC 1, open and reset all ways connected to loads.

c. Unlock, open and reset the interconnecting switches on PSC 1 and PSC 2.

d. Close and lock PSC 2 interconnect Switch.

e. Close and lock PSC 1 interconnect switch.

f. At the ORT, close all generator breakers on all Power Units connected to PSC 1.

g. At PSC 1, close all ways connected to loads.

NOTE: For Interconnection and Operating Procedures of the Primary Switching Center (PSC), refer
to USAF TO 35F14-1-1/USA TM9-6115-725-14&P.

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5.9.6 GENERATOR PROCEDURES

5.9.6.1 ADD A GENERATOR TO THE BUS – MANUAL MODE

WARNING

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND


ENFORCED. NOISE LEVELS IN EXCESS OF 85 DB EXIST WITHIN AN 88-FOOT
RADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR SINGLE HEARING
PROTECTION WITHIN 88 FEET OF AN OPERATING DPGDS.

WARNING

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND


ENFORCED. DURING MAINTENANCE ACTIVITIES WITH THE SIDEDOORS OPEN,
NOISE LEVELS IN EXCESS OF 113 DB EXIST WITHIN A 12-FOOT RADIUS OF AN
OPERATING DPGDS. PERSONNEL MUST WEAR DOUBLE HEARING PROTECTION
WITHIN 12 FEET OF AN OPERATING DPGDS. EXPOSURE MUST BE LIMITED TO
UNDER 2.5 HOURS.

At the GCP for the generator to be added to the bus, perform the following:

NOTE: This procedure assumes that the DC Power is on, and the Generator Pre-Operation inspection has
been performed.

a. Place the ECS in MANUAL.

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

c. Check Voltage and Frequency (3915 VAC, 50 hz or 4295 VAC, 60 hz). Adjust as necessary
using FAR and VAR.

d. Check the following engine parameters:


i Coolant Water Temperature (nominally 180°F)
i Oil Pressure (nominally 40 psi)

e. Place the Sync Source Switch in the oncoming GEN position

f. Observe that the BVFM energizes and shows the bus voltage.

g. Observe that the green rectangular LEDs at 3 and 9 on the synchroscope are on. This indicates
that the synchroscope sees both running and incoming buses as being energized.

h. Observe that the synchroscope appears to be rotating slowly in the clockwise direction. The
LEDs composing the circular pattern on the sync scope sequentially illuminate in a clockwise
rotation pattern.

i. When the triangular green LED at 12 o-clock energizes, close the BCSG breaker switch.

NOTE: You will have to wait until the triangular green LED to reach 12 0-clock.

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j. Observe that the breaker closed LED energizes and the open LED de-energizes.

k. Verify the syncscope LEDs stop rotating.

l. Place the Sync Source Switch back in the OFF position.

m. Verify that the generator takes load from the bus.

5.9.6.2 ADD A GENERATOR TO THE BUS - AUTO MODE

At the PU for the generator to be added, perform the following:

a. At the MCP, cycle the MSES switch.

b. Observe idle generator starts and automatically parallels to the bus.

5.9.6.3 ADD A GENERATOR TO THE BUS – ORT

a. Select the PU Control Screen for the generator to be added to the bus.

b. Press on the START button.

c. Observe the button now says STOP.

d. Observe the generator’s color changes to red.

e. Observe the status text says RUNNING.

f. Observe the generator breaker closes and the generator assumes load.

g. Return to the OVERVIEW screen and verify the generators are sharing load equally.

NOTE: If the added generator reduces the individual generator load below the economizing
threshold, then the control system will automatically shutdown a generator after three
minutes.

5.9.6.4 TAKE A GENERATOR OFFLINE – MANUAL MODE

CAUTION

ENSURE THERE WILL BE SUFFICIENT GENERATING CAPACITY AVAILABLE


BEFORE TAKING A GENERATOR OFF LINE.

At the GCP for the generator you want to shutdown, perform the following:

a. Open the generator’s breaker by turning the BCS to TRIP and releasing when the green indicator
light energizes.

b. Place the ECS in STOP/COOLDOWN.

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c. Observe the generator continues to run for 5 minutes then shuts down.

d. Place the ECS in OFF/RESET.

5.9.6.5 TAKE A GENERATOR OFFLINE – AUTO MODE – WITHOUT ORT

CAUTION

ENSURE THERE WILL BE SUFFICIENT GENERATING CAPACITY AVAILABLE


BEFORE TAKING A GENERATOR OFF LINE.

At the PU for the generator to be shutdown, perform the following:

a. At the MCP, place SMS in MANUAL without stopping in OFF.

b. At the GCP for the off going generator, open the generator’s breaker by turning the BCS to TRIP
and releasing when the green indicator light energizes.

c. At the GCP for the off going generator, place the ECS in STOP/COOLDOWN.

d. At the MCP, place the SMS in AUTO.

e. Observe the generator continues to run for 5 minutes then shuts down.

f. At the GCP for the off going generator, place the ECS in OFF/RESET.

5.9.6.6 TAKE A GENERATOR OFFLINE – AUTO MODE - WITH ORT

CAUTION

ENSURE THERE WILL BE SUFFICIENT GENERATING CAPACITY AVAILABLE


BEFORE TAKING A GENERATOR OFF LINE.

a. Select the PU Control Screen for the generator to be shutdown.

b. Click on the STOP button.

c. Observe the button now says START.

d. Observe the generator’s color changes to green.

e. Observe the status text says COOLDOWN.

f. Observe the generator breaker opens.

g. Return to the OVERVIEW screen and verify the remaining generators are sharing load equally.

h. Observe the generator continues to run for 5 minutes then shuts down.

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5.9.6.7 ACKNOWLEDGE AN ALARM OR FAULT – MANUAL MODE

At the PU with the active alarm or fault, perform the following:

a. Press the Silence pushbutton and hold for 1 second.

b. Repeat ‘a.’ until the horn silences.

NOTE: The repeated pressing of the Silence button is required for multiple alarms or faults. The
Silence button will silence only one alarm/fault per action.

5.9.6.8 ACKNOWLEDGE AN ALARM OR FAULT – AUTO MODE

At the PU with the active alarm or fault, perform the following:

a. Press the Silence pushbutton and hold for 1 second.

b. Repeat ‘a.’ until the horn silences.

NOTE: The repeated pressing of the BSPB is required for multiple alarms or faults. The BSPB will
silence only one alarm/fault per action.

5.9.6.9 ACKNOWLEDGE AN ALARM OR FAULT – ORT

On the Critical Alarm Screen Pop-up:

a. Select the top alarm.

b. Repeat this for each active alarm.

NOTE: This screen cannot be exited until all alarms are acknowledged. Acknowledging alarms on
the ORT also silences the buzzer(s) on the PU(s).

NOTE: All Alarms should be acknowledged individually.

5.9.6.10 ADD AND REMOVE GENERATOR FROM PLANT LINE-UP WITH ORT

a. Select the PU Control Screen for the generator to be added to the bus.

b. Click on the START button.

c. Observe the button now says STOP.

d. Observe the generator’s color changes to red.

e. Observe the status text says RUNNING.

f. Observe the generator breaker closes and the generator assumes load.

h. Select the PU Control Screen for the generator desiring to take offline.

i. Click on the STOP button.

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j. Observe the button now says START.

k. Observe the engine’s color changes to green.

l. Observe the status text says COOLDOWN.

m. Observe the generator breaker opens.

n. Return to the OVERVIEW screen and verify the generators are sharing load equally.

o. Observe the generator continues to run for 5 minutes then shuts down.

5.9.6.11 ECONOMIZING ON/OFF – ORT

From any PU Control Screen, perform the following:

a. Press the “Economize OFF” button to disable economizing.

b. Press the “Economize ON” button to enable economizing.

NOTE: Disabling economizing only stops the control system from shutting down generators during
light load conditions. To prevent overloading generators the “add” feature remains active and
cannot be disabled.

5.9.6.12 CHANGE FROM MANUAL MODE TO AUTOMATIC MODE

WARNING

ONLY ONE PU MAY BE SELECTED TO ANY ONE USS POSITION DURING


MULTIPLE PU OPERATIONS. OPERATING WITH MORE THAN ONE UNIT AT THE
SAME ID CAUSE UNSAFE AND ERRATIC OPERATIONAL CONDITIONS.

At each PU to be put in Automatic mode, perform the following:

a. At the MCP, place the SMS in AUTO without stopping in OFF.

b. At GCPG1, place ECSA in AUTO.

c. At GCPG2, place ECSB in AUTO.

d. At the MCP, place the MSES in ENABLE and release.

e. Observe that either generator, if online, remains online.

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5.9.6.13 CHANGE FROM AUTOMATIC MODE TO MANUAL MODE

WARNING

ONLY ONE PU MAY BE SELECTED TO ANY ONE USS POSITION DURING


MULTIPLE PU OPERATIONS. OPERATING WITH MORE THAN ONE UNIT AT THE
SAME ID CAUSE UNSAFE AND ERRATIC OPERATIONAL CONDITIONS.

At each PU to be put into Manual Mode, perform the following:

a. At the MCP, place the SMS in MANUAL without stopping in OFF.

b. At GCPG1, place ECSA in MANUAL.

c. At GCPG2, place ECSB in MANUAL.

d. Observe that either generator, if online, remains online.

5.9.6.14 UNIT ISOLATION PROCEDURE (ANY UNIT) – PLANT WITH PSC

a. Place the System Mode Switch (SMS) in “Manual” on all units in the plant.

OBSERVE:

• System Status Light (SSL) green LEDs on all units are not illuminated indicating that the units
are operating in Manual Mode and that there are no faults or alarms.

b. Start all off-line Engine/Generator sets on the units NOT being isolated.

c. Sync and close to the bus all off-line Engine/Generator sets.

OBSERVE:

• All Engine/Generator sets share the load equally.

d. Place the SMS to “OFF” on the unit being isolated.

e. Connect (A) (B) Communication cables as required to maintain the load share bus.

• If the unit being isolated is an end unit on the communication bus (Unit A or Unit D), no
additional (A) (B) Communication cable connections are required.

• If the unit being isolated is an inner unit on the communication bus (Unit B or Unit C),
connect an (A) (B) Communication cable between the output connector (B) on Unit D to the
input connector (A) on Unit A.

f. Disconnect the (A) (B) Communication cable(s) on the unit being isolated.

g. Ensure that there is an (A) (B) Communication cable connected to the output connector (B) on
unit that is now the right end unit on the communication bus and that the input connector end of
that (A) (B) Communication cable is capped.

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h. If the ORT cable is connected to the unit being isolated, move the cable to another unit.

OBSERVE:

• Both Engine/Generator breakers on the unit being isolated open

• Remaining on-line Engine/Generator sets in the plant share the load equally

i. Place the ECS for both Engine/Generator sets in the “Cool down” position on the unit being
isolated.

OBSERVE:

• Both Engines shut-down after 5 minutes.

j. Open the Tie breaker on the unit being isolated.

k. Turn off the DC Control Power Circuit Breaker on the unit being isolated.

l. Open the ESG input switch for the unit being isolated.

m. Place the ESG input switch for the unit being isolated in the “Grounded” position if so equipped.

n. Place the BCST on the unit being isolated in the “Pull-to-Lock” position.

o. On the external switchgear, visually confirm, through the viewing windows, that the ESG switch is
in the grounded position.

NOTE: At this point the Tie Power cables are completely de-energized. However, safe working
practice requires the use of personal protective equipment until a circuit is grounded. If the
ESG is equipped with internal circuit grounding, then step “n” can be accomplished without
the use of Hot Stick or lineman’s gloves. If the ESG is not equipped with internal circuit
grounding, then personal protective equipment should be used.

p. Using a Hot Stick and lineman’s gloves, disconnect and Park the Tie load cables.

NOTE: The unit is now electrically isolated.

q. Re-designate the MEP-PU-810s to ensure that one and only one unit is designated A, B, C or D.
There must be a unit designated as “A”.

r. Place the System Mode Switch (SMS) on all units in the plant to the “Automatic” position. DO
NOT pause in the “OFF” position when transitioning the SMS from “Manual” to “Automatic".

s. Cycle the Master Start Enable Switch (MSES) on all units in the plant to the “Enable” position
and hold for 3 seconds.

NOTE: The plant is now operating in automatic.

5.9.6.15 UNIT RE-INSTALLATION PROCEDURE – PLANT WITH PSC

a. Ensure the switch for the PSC input to be used is open (“Grounded” if so equipped)

b. Connect the load power cables between the MEP-PU-810 Tie output and the PSC input.

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c. Connect unit equipment ground.

d. Connect the (A) (B) Communication cable(s) with other units in the plant.

NOTE: If the unit being installed is an end unit, ensure a (A) (B) Communication cable is connected
to the output side connector.

NOTE: If the unit being installed is replacing center unit, disconnect the (A) (B) Communication cable
that is connecting the two end units at the input side of the left most unit.

e. Perform initial plant setup. Refer to Section 5.7.4.4.

f. Setup the unit to operate in the same mode as the unit(s) that the (A) (B) Communication
cable(s) are connected to (either Automatic / Prime Power or Automatic / Utility Parallel)

g. Enter equipment ID for replacement unit on the ORT.

OBSERVE:

• System Status Light (SSC) on all Units: both green lights are on steady indicating the
Engine/Generator sets are available in Automatic mode; the amber and red lights are off
indicating no active alarms or faults.

h. Close the PSC input switch.

OBSERVE:

• The Tie breaker closes as soon as power is received from the PSC.

• The MEP-PU-810 internal bus is energized and common with the power plant bus.

i. Designate the unit according to the plant setup, ensure one and only one unit is designated “A”,
“B”, “C”, or “D”.

j. One unit must be designated “A”

k. Cycle the MSS to the “ENABLE” position and hold until an engine cranks.

OBSERVE:

• Both Engine/Generator sets start, sync and close to the bus

NOTE: The unit is now integrated with the power plant.

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

a. At each PU, change to the Manual Mode per Section 5.9.5.13.

b. Start any idle generators on the PU that are to remain operating per Section 5.9.5.1.

c. Open both feeders breakers on the PU to be isolated.

d. Open the “B” plant Tie breaker from its MCP.

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e. Place the BCST to the Pull-To-Lock position.

f. Open the “A” plant Tie breaker from its MCP.

g. Place the BCST to the Pull-To-Lock position.

h. Verify the generators on the remaining PU are carrying the load properly.

i. Take the generators on the PU being isolated offline per Section 5.9.5.4.

j. Using a Hot Stick and lineman’s gloves, disconnect and park the Tie Load Cables on the
operating PU.

k. Verify that the isolated PU feeders are not looped to any operating feeders.

l. Using a Hot Stick and lineman’s gloves, disconnect and park the Feeder Load Cables on the
isolated PU.

m. If either of the feeders on the operating PU is unused, the disconnected feeder cables from the
isolated PU may be relocated to that feeder.

n. Disconnect the (A) (B) Communication cable (s) between PUs.

o. On the isolated PU, place its SMS in OFF.

p. Observe the isolated generators shutdown after 5 minutes of cooldown.

q. De-energize the isolated PU by pulling out on its DC Power breaker.

r. If the remaining PU is designated as “B”, follow the procedure in Section 5.9.3 for re-designating
that unit as “A”.

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

This procedure assumes that the operating PU is operating as Unit “A” in AUTOMATIC.

a. Place the operating PU in MANUAL by putting its SMS in MANUAL without stopping in OFF.

b. Observe no operating generators drop off line.

c. Position and Ground the incoming PU and perform the startup checks for the unit per Chapter
5.3.

d. Turn on the PU’s DC power by pushing in on the DC Control Power Circuit Breaker.

e. Verify the PU’s SMS is in OFF.

f. Connect the Tie Load Cables between the PUs.

g. Connect the (A) (B) Communication cable between the PUs; ‘B-plug’ on operating unit to ‘A-plug’
on incoming unit.

h. Connect the other (A) (B) Communication cable into the incoming PU’s ‘B-plug’, leaving the
loose end capped.

i. Place the USS on the incoming unit in the “B” position.

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j. Cycle the incoming tie breaker switch to display the red target.

k. Place the operating PU’s SMS in AUTOMATIC without stopping in OFF.

l. Observe the operating PU’s tie breaker automatically closes.

m. Place the incoming PU SMS in AUTOMATIC.

n. Observe incoming PU’s tie breaker automatically closes.

o. Cycle both generator and feeder breaker switches to display red targets.

p. Place both ECSA and ECSB in AUTOMATIC.

q. Observe that the generator ready lights on the SSL energize.

r. Cycle the incoming unit MSES and observe the “B” USI energizes.

s. Observe both generators start and parallel to the bus.

t. At 3-minute intervals, depending on the load, the automatic system shuts down unnecessary
generators.

u. On the ORT, enter equipment ID for the new unit installed.

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CHAPTER 5.10
OPERATING INSTRUCTIONS

PARALLELING MULTIPLE PU PLANTS, EXTERNAL SWITCH,


AUTOMATIC MODE
TABLE OF CONTENTS

SECTION TITLE PAGE


5.10 PARALLELING MULTIPLE PU PLANTS, EXTERNAL SWITCH, AUTOMATIC
MODE 229

5.10.1 PLANT 1 (PRIME POWER CONFIGURATION) 229

5.10.1.1 SAFETY PROCEDURES 229

5.10.1.2 POSITIONING THE PU 229

5.10.1.3 INITIAL PLANT SETUP 230

5.10.1.3.1 GROUNDING 230

5.10.1.3.2 FUEL MANIFOLD 232

5.10.1.3.3 DISTRIBUTION AND CONTROL CABLING 233

5.10.1.3.4 SETPOINT VERIFICATION 235

5.10.1.3.5 PRE-OPERATION CHECKS 248

5.10.1.3.6 PRE-OPERATION RUN 250

5.10.1.3.7 ORT SETUP 252

5.10.1.3.8 CONTROLS SETUP 253

5.10.1.4 PLANT STARTUP 254

5.10.1.5 PLANT OPERATIONS 257

5.10.1.5.1 PRECAUTIONS AND WARNINGS 257

5.10.1.5.2 DESCRIPTION 257

5.10.1.5.3 DEFAULT OPERATING SEQUENCE 257

5.10.2 PLANT 2 (UTILITY PARALLEL CONFIGURATION) 258

5.10.2.1 SAFETY PROCEDURES 258

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TABLE OF CONTENTS

SECTION TITLE PAGE


5.10.2.2 POSITIONING THE PU 258

5.10.2.3 INITIAL PLANT SETUP 259

5.10.2.3.1 GROUNDING 259

5.10.2.3.2 FUEL MANIFOLD 261

5.10.2.3.3 DISTRIBUTION AND CONTROL CABLING 262

5.10 2.3.4 SETPOINT VERIFICATION 263

5.10.2.3.5 PRE-OPERATION CHECKS 276

5.10.2.3.6 PRE-OPERATION RUN 278

5.10.2.3.7 ORT SETUP 280

5.10.2.3.8 CONTROLS SETUP 281

5.10.2.4 PLANT STARTUP 282

5.10.2.4.1 GENERAL 282

5.10.2.4.2 MANUAL MODE 283

5.10.2.4.3 AUTOMATIC MODE 283

5.10.2.4 PLANT OPERATIONS 285

5.10.2.5 POWER PLANT TEARDOWN (PLANT 1 & PLANT 2) 285

5.10.2.5.1 SHUT DOWN GENERATORS 285

5.10.2.5.2 DISCONNECT CABLES 286

5.10.2.5.3 DISCONNECT FUEL LINES 286

5.10.2.5.4 DISCONNECT GROUNDING 286

5.10.2.5.5 PREPARE PU FOR TRANSPORTATION 287

5.10.2.5.6 FUEL, OIL, AND COOLANT DRAINAGE 287

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LIST OF FIGURES

FIGURE TITLE PAGE


FIGURE 5.10.1.3.1-1 MEP-PU-810A GROUND POINTS 231

FIGURE 5.10.1.3.1-2 MEP-PU-810B GROUND POINTS 231

FIGURE 5.10.1.3.2-1 EXTERNAL FUEL SUPPLY 232

FIGURE 5.10.2.3.1-1 MEP-PU-810A GROUND POINTS 260

FIGURE 5.10.2.3.1-3 MEP-PU-810B GROUND POINTS 260

FIGURE 5.10.2.3.2-1 EXTERNAL FUEL SUPPLY 261

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LIST OF TABLES

TABLE TITLE PAGE


TABLE 5.10.1.3.4-1 CT RATIO SETTINGS 235
TABLE 5.10.1.3.4-2 INSTANTANEOUS TRIP SETTINGS 235
TABLE 5.10.1.3.4-3 TIME OVERCURRENT TRIP SETTINGS 236
TABLE 5.10.1.3.4-4 OP5-0 SETPOINTS 238
TABLE 5.10.1.3.4-4 OP5-0 SETPOINTS (CONTINUED) 239
TABLE 5.10.1.3.4-5 OP5-1 SETPOINTS 241
TABLE 5.10.1.3.4-5 OP5-1 SETPOINTS (CONTINUED) 242
TABLE 5.10.1.3.4-5 OP5-1 SETPOINTS (CONTINUED) 243
TABLE 5.10.1.3.4-6 OP6 SETPOINTS 244
TABLE 5.10.1.3.4-6 OP6 SETPOINTS (CONTINUED) 245
TABLE 5.10.1.3.4-7 AVR PARAMETERS/SETPOINTS 246
TABLE 5.10.1.3.4-7 AVR PARAMETERS/SETPOINTS (CONTINUED) 247
TABLE 5.10.1.3.5-1 PRE-OPERATION CHECKLIST 248
TABLE 5.10.1.3.5-1 PRE-OPERATION CHECKLIST (CONTINUED) 249
TABLE 5.10.1.3.6-1 PRE-OPERATION RUN INSTRUCTION SEQUENCE 251
TABLE 5.10.1.3.8-1 PDC CONTROL SWITCH SETUP 253
TABLE 5.10.1.4-1 SWITCH SETUP – AUTOMATIC MODE 255
TABLE 5.10.2.3.4-1 CT RATIO SETTINGS 263
TABLE 5.10.2.3.4-2 INSTANTANEOUS TRIP SETTINGS 264
TABLE 5.10.2.3.4-3 TIME OVERCURRENT TRIP SETTINGS 264
TABLE 5.10.2.3.4-4 OP5-0 SETPOINTS 266
TABLE 5.10.2.3.4-4 OP5-0 SETPOINTS (CONTINUED) 267
TABLE 5.10.2.3.4-5 OP5-1 SETPOINTS 269
TABLE 5.10.2.3.4-5 OP5-1 SETPOINTS (CONTINUED) 270
TABLE 5.10.2.3.4-5 OP5-1 SETPOINTS (CONTINUED) 271
TABLE 5.10.2.3.4-6 OP6 SETPOINTS 272
TABLE 5.10.2.3.4-6 OP6 SETPOINTS (CONTINUED) 273
TABLE 5.10.2.3.4-7 AVR PARAMETERS/SETPOINTS 274
TABLE 5.10.2.3.4-7 AVR PARAMETERS/SETPOINTS (CONTINUED) 275
TABLE 5.10.2.3.5-1 PRE-OPERATION CHECKLIST 276
TABLE 5.10.2.3.5-1 PRE-OPERATION CHECKLIST (CONTINUED) 277
TABLE 5.10.2.3.6-1 PRE-OPERATION RUN INSTRUCTION SEQUENCE 279
TABLE 5.10.2.3.8-1 PDC CONTROL SWITCH SETUP 281
TABLE 5.10.2.4.3-1 SWITCH SETUP – AUTOMATIC MODE 283

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5.10 PARALLELING MULTIPLE PU PLANTS, EXTERNAL SWITCH, AUTOMATIC MODE

This procedure is for parallel operation of two MEP-PU-810 power plants. One plant must be operated in
Prime Power Mode (Plant 1) and the second plant must be operated in Utility Parallel Mode (Plant 2).
The procedure assumes that both plants will be connected to external switchgear (PSC or US Army
CCV). Once the two plants are setup and operating in parallel, the Utility Parallel plant will produce a
fixed power that is specified by the operator and the Prime Power plant will provide power to make up the
difference between the total load requirement and the power being produced by the Utility Parallel plant.
Each plant is remotely controlled by its own ORT.

5.10.1 PLANT 1 (PRIME POWER CONFIGURATION)

5.10.1.1 SAFETY PROCEDURES

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

• Hot engine parts


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

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

5.10.1.2 POSITIONING THE PU

a. Position the PU in such a way as to allow the plant operator to have full vision of the operator
control panels on the unit.

b. Level the MEP-PU-810B front to rear with the trailer leveling hand crank.

c. Position the PU to provide a minimum of 10 feet of clearance for maintenance access on all
sides of each unit. Ensure that there are no overhead obstructions around the exhaust outlets.

WARNING

FUEL SPILLAGE CAN OCCUR IF THE POWER UNIT LEVEL IS GREATER THAN + 5
DEGREES.

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

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5.10.1.3 INITIAL PLANT SETUP

5.10.1.3.1 GROUNDING

WARNING

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

a. Drive an 8-foot ground rod into the earth and should be within 6 feet of the PU and at a location
that minimizes the tripping hazard, until only 6 inches (15 cm) protrudes above the surface.

b. Repeat step “a” for each PU being used.

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

d. Using a #2 AWG copper conductor, secure one end of a ground cable to one of the slotted
ground studs on the PU, see Figure 5.1.3.1-1 or Figure 5.1.3.1-3. Secure the other end of the
ground cable to the ground rod.

e. Repeat step “d” for every PU.

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

g. Remove parking stand plates from their transportation positions inside each rear, side PU door
and slide them into their respective operating positions on the sides of the PDC.

h. Connect the parking stand ground wires to either of the two chassis ground lugs on the PU.

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GROUND POINT GROUND POINT

FIGURE 5.10.1.3.1-1 MEP-PU-810A GROUND POINTS

NOTE: Connect only one ground point to the ground grid.

GROUND POINT GROUND POINT

FIGURE 5.10.1.3.1-2 MEP-PU-810B GROUND POINTS

NOTE: Connect only one ground point to the ground grid.

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5.10.1.3.2 FUEL MANIFOLD

WARNING

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

a. Lay out the fuel hoses between the PU, the fuel manifold, and the fuel bladders to establish the
fuel supply system see Figure 5.10.3.2-1.

b. Install the external fuel hose for the PU to the Fuel Transfer Pump at the Tow end of the PU.

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

d. Connect the 3” hose, with quick-disconnect hose ends, from the fuel manifold to the fuel
bladders.

e. Connect the fuel manifold ground wire to the ground grid.

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

FIGURE 5.10.1.3.2-1 EXTERNAL FUEL SUPPLY

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5.10.1.3.3 DISTRIBUTION AND CONTROL CABLING

WARNING

DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS


OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A
SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET
IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT
FROM FAILURE TO OBSERVE THIS WARNING.

WARNING

HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT


DURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION
AND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN
LOAD CABLES ARE HANDLED.

WARNING

VERIFY THAT CONNECTION POINTS ARE DE-ENERGIZED BEFORE MAKING ANY


CONNECTIONS. FAILURE TO CHECK THAT CONNECTORS ARE DE-ENERGIZED
MAY RESULT IN INJURY OR DEATH.

a. Lay out and park the load cables for each phase (A, B, & C) between the PU Tie Output parking
stations and the load.

b. Connect each phase cable to the appropriate phase connection on the Primary Switching Center
(PSC).

NOTE 1: For complete set-up of the Primary Switching Center (PSC), refer to Radian Inc. Commercial
Technical Manual CTM 01646.1R1260, Chapter 2.6.

NOTE 2: For Unit Isolation Procedure (any unit) - Plant with PSC, and Unit Re-Installation
Procedure – Plant with PSC, refer to Chapter 5.9, Sections 5.9.6.15 and 5.9.6.16.

c. Connect each load cables drain wire to the grounding grid.

d. Open the Tie Output connector loadbreak covers on the first PU.

e. Connect the Tie Output Cables to the appropriate phase connectors; ensure there are no cross-
phase connections.

f. Close and lock the Tie Output connector covers.

g. Repeat steps ‘b’ through ‘f’ on each remaining PU.

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

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

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

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

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

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

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

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

q. Connect the third (A) (B) communication cable to “A” receptacle on fourth PU.

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

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

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5.10.1.3.4 SETPOINT VERIFICATION

a. Turn on PU DC control power by pushing in on the DC Control Power breaker.

b. On each of the five overcurrent relays, verify the settings:

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

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

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

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

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

(6) Verify the “P” and “N” values match the following table:

TABLE 5.10.1.3.4-1 CT RATIO SETTINGS


BREAKER RELAY CT RATIO “P” VALUE “N” VALUE
GENERATOR 100:5 20 20
FEEDER 200:5 40 40
TIE 200:5 40 40

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


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

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

(10) Verify the 50TP “PU” and “TD” settings in Table 5.10.1.3.4-2. In order to edit values,
Press the “Edit” key. Select correct value, and press “Edit” again to save changes.
Ensure light is off otherwise you can accidentally change value again.

TABLE 5.10.1.3.4-2 INSTANTANEOUS TRIP SETTINGS


PHASE NEUTRAL NEGATIVE SEQUENCE
INSTANTANEOUS INSTANTANEOUS TRIP
BREAKER RELAY
TRIP 50TP TRIP 50TN 50 TQ
PU TD PU TD PU TD
GENERATOR 0.0 0m 3.0 0m 3.0 0m
FEEDER 7.5 84m 1.25 84m 0 0m
TIE 0.0 0m 0 0m 0.0 0m

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

(12) Verify the “50TN” settings.

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

(14) Verify the “50TQ” settings

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

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

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

(18) Verify the 51P “PU”, “TD”, and “C” settings in Table 5.10.1.3.4-3.

TABLE 5.10.1.3.4-3 TIME OVERCURRENT TRIP SETTINGS


PHASE TIME OVERCURRENT NEUTRAL TIME OVERCURRENT
BREAKER RELAY TRIP 51P TRIP 51N
PU TD C PU TD C
GENERATOR 4.50 0.5 VV2 1.25 0.5 VV2
FEEDER 2.50 1.0 VV2 1.00 1.0 VV2
TIE 5.00 2.0 VV2 1.50 2.0 VV2

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

(20) Verify the “51N” settings.

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

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

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

(1) Place ECS in the COOLDOWN/STOP position.

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

(3) Press SCROLL UP key until “OP3” is showing.

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

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

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

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

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

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

(10) Press ENTER key. “PE PASS” is showing.

(11) Press EXIT key. “OP4” is showing.

(12) Press SCROLL UP key until “OP5-0” is showing on the lower display.

(13) Press SELECT key. “POO1” followed with the value of the setpoint is showing.

(14) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing.
Use table 5.10.3.4-4 for the parameter values to be verified.

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(15) Repeat step “15” until the desired setpoints are verified.

(16) Press EXIT key. “OP5-0” is showing on the lower display.

(17) Press SCROLL UP key until “OP5-1” is showing.

(18) Press SELECT key.

(19) Repeat steps 15 and 16 for “OP5-1” using Table 5.10.3.4-5.

(20) Repeat steps 17, 18, and 19 for OP6.

(21) Repeat steps 15 and 16 for “OP6” using Table 5.10.3.4-6.

(22) Press EXIT Key twice. The display returns to normal.

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

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

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

(c) Press ENTER. The correct value stops flashing on the display.

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

d. At GSC G1 and GSC G2, verify the operation settings using the following table:

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TABLE 5.10.1.3.4-4 OP5-0 SETPOINTS
SETPOINTS OP5-0 ENGINE/GENERATOR PROGRAMMING①
FACTORY DPGDS
SETPOINT-NAME-DESCRIPTIONS RANGE OF VALUES
DEFAULT SETPOINT
P001 - Fuel Solenoid Type: type of fuel system solenoid 0- ETR fuel solenoid
0 0
used on the genset. 1- ETS fuel solenoid
P002 - Units Shown: type of measurement units shown 0-for English units (PSI, ºF)
0 0
on the GSC+ display. 1-for metric units (kPa, ºC).
P003 - Shutdown Override For Engine Fault: GSC+ 0-for engine shutdown
response to a low engine oil pressure or high coolant 1-for alarm only (shutdown override, no 0 0
temperature fault. engine shutdown).
P004 - Shutdown Override For Sensor Fault: GSC+ 0-for alarm only shutdown override, no
response to a diagnostic fault with the engine oil pressure engine shutdown). 0 0
sensor, coolant temperature sensor, oil temperature
sensor, sensor power supply or coolant loss sensor. 1-for engine shutdown.

P005 - Coolant Loss Sensor Installed: tells whether or 0-for gensets without a coolant loss sensor
not the optional engine coolant loss sensor is installed on 0 1
the genset. 1-for gensets with coolant loss sensor

0-for engine shutdown.


P006 - Shutdown Override For Coolant Loss Fault:
1-for alarm only (shutdown override, no 0 0
GSC+ response to an engine coolant loss fault.
engine shutdown).
P007 - System Voltage, 24 Or 32 Volts: system voltage
24 or 32. 24 24
(battery voltage) of the genset.
P008 - This setpoint is not currently being used by the
N/A N/A N/A
GSC+ and cannot be programmed.
P009 - Number Of Ring Gear Teeth: number of teeth on
the ring gear of the engine. Used by the GSC+ to 95 to 350 teeth in increments of one tooth. 136 teeth 136 teeth
determine engine speed.
P010 - Engine Overspeed: engine speed used by the
GSC+ to declare that an engine overspeed fault exists.
500 to 4330 rpm in increments of 10 rpm. 2120 rpm 2120 rpm
The engine overspeed setpoint (for all 60 Hz applications)
is 1.18 times the rated speed.
P011 - Crank Terminate Speed: engine speed used by
the GSC+ to disengage the starting motor during engine 100 to 1000 rpm in increments of 10 rpm. 400 rpm 400 rpm
cranking.
P012 - Oil Step Speed: engine speed used by the GSC+
for distinguishing between rated speed and idle speed 400 to 1800 rpm in increments of 10 rpm. 1350 rpm 1350 rpm
when a low oil pressure fault exists.

P013② - Low Oil Pressure Shutdown At Rated Speed:


oil pressure used by the GSC+ to declare that a low oil 30 PSI 30 PSI
pressure shutdown fault exists with engine at rated speed 5 to 61PSI (34 to 420kPa) in increments of 1
(205 kPa) (205 kPa)
(the engine speed must have exceeded the oil step speed
for nine seconds).

P014② - Low Oil Pressure Shutdown At Idle Speed:


oil pressure used by the GSC+ to declare that a low oil
10 PSI 10 PSI
pressure shutdown fault exists with the engine at idle 20 to 336kPa (3 to 49PSI) in increments of 1
speed (the engine must have been running for at least 9 (70 kPa) (70 kPa)
seconds and the engine speed must be less than oil step
speed).

P015③ - High Water Temperature Shutdown: coolant


185 to 253ºF (85 to 123ºC) in increments of 225ºF 225ºF
temperature used by the GSC+ to declare a high coolant
temperature shutdown fault exists (after a 10 second 1 (107ºC) (107ºC)
delay).
P016 - Low Water Temperature Alarm: coolant
temperature used by the GSC+ to declare that a low 70ºF 70ºF
32 to 97ºF (0 to 36ºC) in increments of 1
coolant temperature alarm fault exists (after a 2 second (21ºC) (21ºC)
delay).

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TABLE 5.10.1.3.4-4 OP5-0 SETPOINTS (CONTINUED)


SETPOINTS OP5-0 ENGINE/GENERATOR PROGRAMMING①
FACTORY DPGDS
SETPOINT-NAME-DESCRIPTIONS RANGE OF VALUES
DEFAULT SETPOINT
P017 - Total Cycle Crank Time: cycle crank time used by the 5 to 120 seconds in increments of 1
90 seconds 90 seconds
GSC+ to declare that an overcrank fault exists. second.
P018 - Cycle Crank Time: amount of time the GSC+ cranks 5 to 60 seconds in increments of 1
10 seconds 10 seconds
and then rests the starting motor during a single crank cycle. second.
P019 - Cooldown Time: amount of time the GSC+ allows the 0 to 30 minutes in increments of 1
5 minutes 5 minutes
engine to run after a normal shutdown is initiated. minute.

P020④ - AC Voltage: nominal AC voltage of the generator. 700, 150, 300, 500, 600, 750, 3.0k,
The GSC+ measures the AC voltage and shows it on the 4.5k, 5.20k, 5.25k, 9.0k, 15.0k, 18.0k, 700 5.20k
display. 30.0k
P021 - AC Current Full Scale: nominal full scale AC current 75, 100, 150, 200, 300, 400, 600, 800,
of the generator. AC current full scale is equal to the ratio of 1000, 1200, 1500, 2000, 2500, 3000, 600A 100A
the external current transformers in the generator housing. and 4000A

P022⑤ - GSC+ Engine Number: informs other devices on


01 (Gen 1)
01 through 08 01
the CAT Data Link of the engine number for the GSC+. 02 (Gen 2)

SETPOINTS - OP5-0-ENGINE/GENERATOR PROGRAMMING①


RANGE OF FACTORY 60HZ 50HZ
SETPOINT-NAME-DESCRIPTIONS
VALUES DEFAULT SETPOINT SETPOINT
P023 - Engine Type: identifies the engine as a 0 - MUI diesel
mechanical unit injector (MUI) diesel, spark
1 - Gas 0 2 2
ignited (gas), or electronic unit injector (EUI)
diesel engine. 2 - EUI diesel
P024 - Crank Time Delay: amount of time the
GSC+ delays activation of the fuel control relay
(FCR) during a crank cycle. This setpoint is for 0 to 20 seconds in increments of 1
5 Seconds 5 Seconds 5 Seconds
Gas engines only. The P024 setpoint only second.
functions when the P023 setpoint is set to 1 (gas
engine).
0 - for gensets without an oil
P025 - Oil Temperature Sensor Installed: tells temperature sensor
whether or not the optional engine oil temperature 0 0 0
sensor is installed on the genset. 1 - for gensets with an oil
temperature sensor
P026 - High Oil Temperature Shutdown: oil
temperature used by the GSC+ to declare a high 185 to 253ºF (85 to 123ºC) in
225ºF (107ºC) 225ºF (107ºC) 225ºF (107ºC)
oil temperature shutdown fault exists (after a 10 increments of 1
second delay). Refer to the panel model number.
P027 - Shutdown Override For High Oil 0 - for alarm only (shutdown override,
Temperature Fault: GSC+ response to an engine no engine shutdown). 0 0 0
high oil temperature fault. 1 - for engine shutdown.
P028 - Nameplate Voltage: rated voltage of the
generator. This setpoint is used for protective 100 to 25kV in increments of 1 480V 4160V 3800V
relaying functions.
P029 - Nameplate Current: rated current output
0 to 4000 A in increments of 1 600A 80A 73A
of the generator.
P030 - Nameplate Power: rated power capability 0 through 10MW in increments of
400kW 420kW 350kW
of the generator. 1kW.
P031 - Rated Frequency: nominal frequency
50 or 60Hz 60Hz 60Hz 50Hz
rating of genset.
P032 - Connection Configuration Of Generator: 0 - wye
0 0 0
wye or delta configuration of generator. 1 - delta
P033 - Number Of Generator Poles. 0 through 254 in increments of 2. 4 4 4

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① The setpoints (stored or being programmed) must match the specified DPGDS setpoints.
② When oil pressure drops to within 5PSI (34kPa) of the P013 or P014 setpoint, a low oil pressure alarm
is issued by the GSC+.
③ When coolant temperature rises to within 11ºF (6ºC) of the P015 setpoint, a high coolant temperature
alarm is issued by the GSC+.
④ The values other than the default (700V) are for switchgear applications and require the use of external
potential transformers and the removal of the AC voltage range jumper located in the relay module.
The DPGDS unit is factory configured for the 5.20 K value. See the Caterpillar Electronic Modular
Control Panel II+ manual topic AC Voltage Range Selection in the Testing and Adjusting section.
⑤ After setpoint P022 is reprogrammed, the GSC+ must be power cycled (powered down and then
powered up)

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TABLE 5.10.1.3.4-5 OP5-1 SETPOINTS


SETPOINTS OP5-1 PROTECTIVE RELAYING PROGRAMMING①
FACTORY 60HZ 50HZ
SETPOINT-NAME-DESCRIPTION RANGE OF VALUES
DEFAULT SETPOINT SETPOINT
P101 - Generator Overvoltage Alarm Enable: the 0 - disabled
GSC+ enables or disables the generator 1 1 1
overvoltage alarm function. 1 - enabled
P102 - Generator Overvoltage Alarm Threshold:
100 to 125% of nameplate voltage in
voltage the GSC+ uses to issue an overvoltage 105% 105% 105%
increments of 1%.
alarm.
P103 - Generator Overvoltage Alarm Time Delay:
amount of time the GSC+ waits before issuing an 0 through 120 seconds② in increments 10 seconds 10 seconds 10 seconds
overvoltage alarm. of 1
P104 - Generator Overvoltage Shutdown Enable: 0 - disabled
the GSC+ enables or disables the generator 1 1 1
overvoltage shutdown function. 1 - enabled
P105 - Generator Overvoltage Shutdown
100 to 125% of nameplate voltage in
Threshold: voltage the GSC+ uses to issue an 110% 110% 110%
increments of 1%.
overvoltage shutdown.
P106 - Generator Overvoltage Shutdown Time
Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments 10 seconds 10 seconds 10 seconds
issuing an overvoltage shutdown. of 1
P107 - Generator Undervoltage Alarm Enable: 0 - disabled
the GSC+ enables or disables the generator 1 1 1
undervoltage alarm function. 1 - enabled
P108 - Generator Undervoltage Alarm
60 to 100% of nameplate voltage in
Threshold: voltage the GSC+ uses to issue an 90% 90% 90%
increments of 1%.
undervoltage alarm.
P109 - Generator Undervoltage Alarm Time
Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments 10 seconds 10 seconds 10 seconds
issuing an undervoltage alarm. of 1
P110 - Generator Undervoltage Shutdown 0 - disabled
Enable: the GSC+ enables or disables the 1 1 1
generator undervoltage shutdown function. 1 - enabled
P111 - Generator Undervoltage Shutdown
60 through 100% of rated voltage in
Threshold: voltage the GSC+ uses to issue an 85% 85% 85%
increments of 1%.
undervoltage shutdown.
P112 - Generator Undervoltage Shutdown Time
Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments 15 seconds 03 seconds 03 seconds
issuing an undervoltage shutdown. of 1
P113 - Generator Overfrequency Alarm Enable: 0 - disabled
the GSC+ enables or disables the generator 1 1 1
overfrequency alarm function. 1 - enabled

P114 - Generator Overfrequency Alarm 50-60Hz, for 50Hz Gen 53Hz


Threshold: frequency the GSC+ uses to issue an 60-70Hz, for 60Hz Gen 63Hz 63 Hz 53 Hz
overfrequency alarm. 400-480, for 400Hz Gen 422Hz
P115 - Generator Overfrequency Alarm Time
Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments 10 seconds 10 seconds 10 seconds
issuing an overfrequency alarm. of 1
P116 - Generator Overfrequency Shutdown 0 - disabled
Enable: the GSC+ enables or disables the 1 1 1
generator overfrequency shutdown function. 1 - enabled

P117 - Generator Overfrequency Shutdown 50-60Hz, for 50Hz Gen 55Hz


Threshold: frequency the GSC+ uses to issue an 60-70Hz, for 60Hz Gen 66Hz 66Hz 55Hz
overfrequency shutdown. 400-480, for 400Hz Gen 440Hz

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TABLE 5.10.1.3.4-5 OP5-1 SETPOINTS (CONTINUED)
SETPOINTS OP5-1 PROTECTIVE RELAYING PROGRAMMING①
FACTORY 60HZ 50HZ
SETPOINT-NAME-DESCRIPTION RANGE OF VALUES
DEFAULT SETPOINT SETPOINT
P118 - Generator Overfrequency Shutdown Time
Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments 10 seconds 10 seconds 10 seconds
issuing an overfrequency shutdown. of 1
P119 - Generator Underfrequency Alarm Enable: 0 - disabled
the GSC+ enables or disables the generator 1 1 1
underfrequency alarm function. 1 - enabled

P120 - Generator Underfrequency Alarm 30-50Hz, for 50Hz Gen 48Hz


Threshold: frequency the GSC+ uses to issue an 36-60Hz, for 60Hz Gen 57Hz 57Hz 48Hz
underfrequency alarm. 240-400, for 400Hz Gen 378Hz
P121 - Generator Underfrequency Alarm Time
Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments 10 seconds 10 seconds 10 seconds
issuing an underfrequency alarm. of 1
P122 - Generator Underfrequency Shutdown 0 - disabled
Enable: the GSC+ enables or disables the generator 1 1 1
underfrequency shutdown function. 1 - enabled

P123 - Generator Underfrequency Shutdown 30-50Hz, for 50Hz Gen 45Hz


Threshold: frequency the GSC+ uses to issue an 36-60Hz, for 60Hz Gen 54Hz 54Hz 45Hz
underfrequency shutdown. 240-400, for 400Hz Gen 360Hz
P124 - Generator Underfrequency Shutdown
Time Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments 15 seconds 03 seconds 03 seconds
issuing an underfrequency shutdown. of 1
P125 - Generator Reverse Power Shutdown 0 - disabled
Enable: the GSC+ enables or disables the generator 1 1 1
reverse power shutdown function. 1 - enabled
P126 - Generator Reverse Power Shutdown
0 through 20% of rated power in
Threshold: level of reverse power the GSC+ uses to 15% 4% 4%
increments of 1%.
issue a reverse power shutdown.
P127 - Generator Reverse Power Shutdown Time
Delay: amount of time the GSC+ waits before 0 through 30 seconds② in increments 10 seconds 4 seconds 4 seconds
issuing a reverse power shutdown. of 1
P128 - Generator Overcurrent Alarm Enable: the 0 - disabled
1 1 1
GSC+ enables or disables the overcurrent alarm. 1 - enabled
P129 - Generator Phase Overcurrent Alarm
100 through 160% of nameplate current
Threshold: level of current the GSC+ uses to issue a 105% 150% 150%
in increments of 5%
phase overcurrent alarm.
P130 - Generator Phase Overcurrent Alarm Time
Delay: amount of time the GSC+ waits before 0 through 250 seconds② in increments 0 seconds 0 seconds 0 seconds
issuing a phase overcurrent alarm. of 1
P131 - Generator Total Overcurrent Alarm
100 through 160% of three times
Threshold: level of current the GSC+ uses to issue a 105% 150%. 150%
nameplate current in increments of 5%
total overcurrent alarm.
P132 - Generator Total Overcurrent Alarm Time
Delay: amount of time the GSC+ waits before 0 through 250 seconds② in increments 0 seconds 0 seconds 0 seconds
issuing a total overcurrent alarm. of 1
P133 – Generator Overcurrent Shutdown Enable: 0 – disabled
the GSC+ enables or disables the overcurrent 1 1 1
shutdown. 1 – enabled
P134 – Generator Phase Overcurrent Shutdown
100 through 160% in increments of 5%
Threshold: level of current the 110% 150% 150%
GSC+ uses to issue a phase overcurrent shutdown.
P135 – Generator Phase Overcurrent Shutdown
Time Delay: amount of time the GSC+ waits before 0 through 250 seconds② in increments 0 seconds 10 seconds 10 seconds
issuing a phase overcurrent shutdown. of 1

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TABLE 5.10.1.3.4-5 OP5-1 SETPOINTS (CONTINUED)


SETPOINTS OP5-1 PROTECTIVE RELAYING PROGRAMMING①
FACTORY 60HZ 50HZ
SETPOINT-NAME-DESCRIPTION RANGE OF VALUES
DEFAULT SETPOINT SETPOINT
P136 - Generator Total Overcurrent
Shutdown Threshold: level of current the 100 through 160% of three times
110% 150%. 150%
GSC+ uses to issue a total overcurrent nameplate current in increments of 5%
shutdown.
P137 - Generator Total Overcurrent
Shutdown Time Delay: amount of time the 0 through 250 seconds② in increments 0 seconds 10 seconds 10 seconds
GSC+ waits before issuing a total overcurrent of 1
shutdown.
P138 - KW Level Relay Enable : the GSC+ 0 - disabled
enables or disables the kW level relay 1 1 1
function. 1 - enabled
P139 - KW Level Relay Threshold: level of
0 through 110% of nameplate power in
power the GSC+ uses to activate the kW level 105% 105% 105%
increments of 1%
relay function.
P140 - KW Level Relay Time Delay: amount
of time the GSC+ waits before activating the 0 through 120 seconds② in increments 0 seconds 0 seconds 0 seconds
kW level relay function. of 1
P141 - KW Level Relay Disengage
0 through 110% of nameplate power in
Threshold: level of power the GSC+ uses to 100% 100% 100%
increments of 1%.
deactivate the kW level relay function.
P142 - KW Level Relay Disengage Time
Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments 10 seconds 10 seconds 10 seconds
deactivating the kW level relay function. of 1

① The setpoints are programmed at the factory to the default value.


② When programmed to 0 seconds, the actual time is from 0.5 to 1.0 seconds.

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DRS RADIAN CTM: 01646.1R0253/1R0254

TABLE 5.10.1.3.4-6 OP6 SETPOINTS


SETPOINTS OP6 SPARE INPUT/OUTPUT PROGRAMMING
FACTORY DPGDS
SETPOINT-NAME-DESCRIPTIONS RANGE OF VALUES
DEFAULT SETPOINT
SP01 - Spare Input 1 Active State. Input state used by the 0-active low
0 0
GSC+ to declare a SP1 fault exists. 1-active high
SP02 - Spare Input 1 Response: GSC+ response to a SP1 0-shutdown
0 0
fault. 1-alarm
SP03 - Spare Input 1 Time Delay: Amount of time the GSC+
0 - 250 seconds in increments of 1 0 seconds 1 second
waits before responding to a SP1 fault.
SP04 - Spare Input 2 Active State. Input state used by the 0-active low
0 1
GSC+ to declare a SP2 fault exists. 1-active high
SP05 - Spare Input 2 Response: GSC+ response to a SP2 0-shutdown
0 0
fault. 1-alarm
SP06 - Spare Input 2 Time Delay: Amount of time the GSC+
0 - 250 seconds in increments of 1 0 seconds 0 seconds
waits before responding to a SP2 fault.
SP07 - Spare Input 3 Active State. Input state used by the 0-active low
0 0
GSC+ to declare a SP3 fault exists. 1-active high
SP08 - Spare Input 3 Response: GSC+ response to a SP3 0-shutdown
0 0
fault. 1-alarm
SP09 - Spare Input 3 Time Delay: Amount of time the GSC+
0 - 250 seconds in increments of 1 0 seconds 0 seconds
waits before responding to a SP3 fault.
SP10 - Spare Input 4 Active State. Input state used by the 0-active low
0 0
GSC+ to declare a SP4 fault exists. 1-active high
SP11 - Spare Input 4 Response: GSC+ response to a SP4 0-shutdown
0 0
fault. 1-alarm
SP12 - Spare Input 4 Time Delay: Amount of time the GSC+
0 - 250 seconds in increments of 1 0 seconds 0 seconds
waits before responding to a SP4 fault.
SP13 - Spare Output Response: GSC+ response to the spare 0-active low
0 0
output trigger condition. 1-active high
0-unused

1-active SP1 fault②

2-active SP2 fault②

3-active SP3 fault②

4-active SP4 fault②


SP14 - Spare Output Trigger Condition: The condition used
5-any combination of active SP faults②
8 8
by the GSC+ to trigger the spare output response
6-any active shutdown
7-any active alarm or shutdown
8-cooldown mode

9-coolant loss mode②

10-high oil temp fault②


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

5-244
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DRS RADIAN CTM: 01646.1R0253/1R0254

TABLE 5.10.1.3.4-6 OP6 SETPOINTS (CONTINUED)


SETPOINTS OP6 SPARE INPUT/OUTPUT PROGRAMMING
FACTORY DPGDS
SETPOINT-NAME-DESCRIPTIONS RANGE OF VALUES
DEFAULT SETPOINT
0-unused

1-active SP1 fault②

2-active SP2 fault②

3-active SP3 fault②

4-active SP4 fault②


SP16 - Spare Relay Output Trigger Condition: The condition
5-any combination of active SP faults②
8 1
used by the GSC+ to trigger the spare relay.
6-any active shutdown
7-any active alarm or shutdown
8-cooldown mode

9-coolant loss mode②

10-high oil temp fault②


11-CCM control
0-unused

1-active SP1 fault②

2-active SP2 fault②

3-active SP3 fault②


SP17 - Spare Indicator 1 Trigger Condition: The condition
4-active SP4 fault② 0 6
used by the GSC+ to trigger spare indicator①.
5-any combination of active SP1, SP2,

SP3 or SP4 faults②

6-Coolant loss fault②

7-high oil temperature fault②


SP18 - Spare Indicator 2 Trigger Condition: The condition
Battle Short mode. 0 0 Battleshort③
used by the GSC+ to trigger spare indicator②.
SP19 - Spare Indicator 3 Trigger Condition: The condition 0 In 50Hz
Not in 60 Hz mode. 0
used by the GSC+ to trigger spare indicator③. Mode③

① The setpoints are programmed at the factory to the default value.

② Either alarm or shutdown faults are valid trigger conditions

③ Battleshort and 50Hz Mode are unique features to DPGDS for spare indicators 2 and 3.

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

NOTE: Use up or down keys to change values.

f. At the AVR verify the operation settings using Table 5.10.1.3.4-7:

(1) Open the GCPG1 cabinet door.

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

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DRS RADIAN CTM: 01646.1R0253/1R0254

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

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

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

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

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

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

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

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

(11) When complete, press the [▼] to display parameter “01”.

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

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

TABLE 5.10.1.3.4-7 AVR PARAMETERS/SETPOINTS


DPGDS
DPGDS AVR PARAMETERS
SETPOINTS
RANGE OF DEFAULT 60HZ 50HZ
PARAMETER TITLE TYPE UNITS
VALUES VALUE OPS OPS

01 Generator Output Voltage Program Volts 0080-9999 480① 4160 3800


Ratio of Output Voltage To
02 Program 001.0-100.0 001.0 17.3 17.3
Sensing Voltage
03 Generator Type Program 0000-0004 0004 4 4
04 Rated Generator Output Current Program Amps 0000-9999 0600 80 73
CT Voltage At Rated Generator
05② Current
Program Volts 01.00-05.00 05.00 4.00 3.66

06 Knee Frequency Program Hz 045.0-065.0 050.0 59.8 49.8


07 Decreasing Volts/Hz Slope I Program Volts/Hz 001.0-010.0 002.0 2.0 2.0
08 Decreasing Volts/Hz Slope 2 Program Volts/Hz 001.0-010.0 002.0 2.0 2.0
09 Minimum Voltage Program % 050.0-100.0 050.0 50.0 50.0
10 Under Frequency Point Program Hz 020.0-040.0 025.0 25.0 25.0
11 Overvoltage Trip Point Program % 0105-0140 014.0 125.0 125.0
12 Overvoltage Trip Time Program Seconds 0002-0030 0002 5 5
13 Under Voltage Trip Point Program % 0060-0095 0060 75 75
14 Under Voltage Trip Time Program Seconds 0030-0120 0030 30 30
000.0-0
15 Voltage Gain (IR Compensation) Program % 0000 0 0
10.0

16⑤ Integral Gain Program 001.0-020.0 006.0 6.0 6.0

17⑥ Proportional Gain Program 001.0-020.0 005.0 5.0 5.0


Single Phase Sensing Select
18 Program 0000,0001 0000 0000 0000
(0=three phase, 1=single phase)
19 Diode Monitor Trip Point Program Amps 001.0-010.0 002.0 2.0 2.0

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DRS RADIAN CTM: 01646.1R0253/1R0254

TABLE 5.10.1.3.4-7 AVR PARAMETERS/SETPOINTS (CONTINUED)


DPGDS
DPGDS AVR PARAMETERS
SETPOINTS
RANGE OF DEFAULT 60HZ 50HZ
PARAMETER TITLE TYPE UNITS
VALUES VALUE OPS OPS
30 Droop Percentage Program % 000.0-010.0 0000 3 3

31③ pf/Kvar Select (0=pf, 1=Kvar) Program 0000, 0001 0000 0 0

32③ Pf Reference Program 00.60-01.10 01.00 0.8 0.8

33③ KVAR Reference Program Per Unit 00.00-01.00 0000 0.10 0.10

34③ Reverse Power Trip Point Program % 000.0-020.0 010.0 15 15

35③ Reverse Power Trip Time Program Seconds 000.0-020.0 010.0 5 5


50 Generator Output Frequency View Hz
51 Generator Output Voltage View Volts
52 Generator Output Current View Amps
53 Generator Reactive Output Current View Amps
54 Generator Real Current View Amps
55 Exciter Field Current View Amps
Three Phase Kilowatts
56③ (KB and later)
View KW

57③ Power Factor View

58③, ④ Three Phase Kvar (KE and later) View


60 Hours View Hours 0000-9999
90 Password Program 0009 0009
91 Software ID View
92 Latest Fault View 0000 0000 0000
93 Previous Fault View 0000 0000 0000
94 Fault Clear View
96 Shutdown Fault Reset Switch

①- Default value for output voltage is different depending on regulator sensing voltage. If the regulator is
designed for 120 volts sensing, then the default output voltage is 4160 volts. All other sensing types
have the default output voltage set to 480 volts.
②- Digital Voltage Regulators with earlier software (KD and earlier) have 1 less digit to the right of the
decimal point.
③- Optional feature.
④- New parameter on serial number prefix KE and later Digital Voltage Regulators.
⑤- Previous range of 0001-099.9 and default value of 002.0
⑥-Previous range of 0001-099.9 and default value of 002.0

(12) When complete, press the [▼] to display parameter “90”.

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

(14) Press the [▼] key to change the value to “0009”. Disables DVR parameter editing.

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

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DRS RADIAN CTM: 01646.1R0253/1R0254

(16) Press the [▲] key to change to display parameter “01”.

(17) Close the GCPG1 cabinet door.

(18) Repeat steps ‘1 ‘through ‘16’ for Generator 2.

5.10.1.3.5 PRE-OPERATION CHECKS

Starting from the left rear of the PU and working around the PU in a clockwise direction, perform the
following checks (Gen. 1 is on the left and Gen. 2 is on the right):

TABLE 5.10.1.3.5-1 PRE-OPERATION CHECKLIST


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

5-248
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USA TM 9-6115-484-14
DRS RADIAN CTM: 01646.1R0253/1R0254

TABLE 5.10.1.3.5-1 PRE-OPERATION CHECKLIST (CONTINUED)


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

① The Battery Parallel Switch should be left in the OFF position except in extreme conditions where
the additional DC power is required to crank an engine. Once started, return the switch to the OFF
position.

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DRS RADIAN CTM: 01646.1R0253/1R0254

5.10.1.3.6 PRE-OPERATION RUN

WARNING

ENSURE ALL PERSONNEL ARE CLEAR AND THE PU DOORS ARE CLOSED
PRIOR TO STARTING A GENERATOR.

WARNING

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND


ENFORCED.
NOISE LEVELS IN EXCESS OF 85 DB EXIST WITHIN AN 88-FOOT RADIUS OF AN
OPERATING DPGDS. PERSONNEL MUST WEAR SINGLE HEARING PROTECTION
WITHIN 88 FEET OF AN OPERATING DPGDS.

WARNING

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND


ENFORCED.
DURING MAINTENANCE ACTIVITIES WITH THE SIDEDOORS OPEN, NOISE
LEVELS IN EXCESS OF 113 DB EXIST WITHIN A 12-FOOT RADIUS OF AN
OPERATING DPGDS. PERSONNEL MUST WEAR DOUBLE HEARING PROTECTION
WITHIN 12 FEET OF AN OPERATING DPGDS. EXPOSURE MUST BE LIMITED TO
UNDER 2.5 HOURS.

WARNING

BY CLOSING THE FEEDER OR TIE BREAKER, HIGH VOLTAGE WILL BE PRESENT


ON THE LOAD CABLES. ENSURE ALL PERSONNEL ARE CLEAR OF ALL LOAD
CABLES PRIOR TO CLOSING FEEDER OR TIE BREAKERS.

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DRS RADIAN CTM: 01646.1R0253/1R0254

TABLE 5.10.1.3.6-1 PRE-OPERATION RUN INSTRUCTION SEQUENCE


(Perform on each PU in the power plant)
STEP -- 60HZ OPERATIONS -- -- 50HZ OPERATIONS --

1 Verify System Mode Switch (SMS) is in MANUAL

2 Verify DC Control Power is on

3 Verify Emergency Stop is pulled out

4① Verify the 60Hz light is on ① Verify the 50Hz light is on①

5 Start engine 1 by placing ECS1 in MANUAL

6 Verify the engine accelerates to 1800RPM Verify the engine accelerates to 1500RPM

7 Adjust the generator frequency to 60Hz Adjust the generator frequency to 50Hz using
using the Frequency Adjust Rheostat (FAR) the Frequency Adjust Rheostat (FAR)

8 Adjust the generator voltage to 4295VAC Adjust the generator voltage to 3915VAC
using the Voltage Adjust Rheostat (VAR) using the Voltage Adjust Rheostat (VAR)

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

10 Shutdown engine 1 by placing ECS1 in OFF/RESET

11 Start engine 2 by placing ECS2 in MANUAL

12 Verify the engine accelerates to 1800RPM Verify the engine accelerates to 1500RPM

13 Adjust the generator frequency to 60Hz Adjust the generator frequency to 50Hz using
using the Frequency Adjust Rheostat (FAR) the Frequency Adjust Rheostat (FAR)

14 Adjust the generator voltage to 4295VAC Adjust the generator voltage to 3915VAC
using the Voltage Adjust Rheostat (VAR) using the Voltage Adjust Rheostat (VAR)

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

16 Shutdown engine 2 by placing ECS2 in OFF/RESET

① If the wrong frequency light is on, open the Master Control Door and change the Frequency
Selector Switch (FSS) to the desired frequency.

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DRS RADIAN CTM: 01646.1R0253/1R0254

5.10.1.3.7 ORT SETUP

a. Remove the ORT from its case and set it up on a flat and level surface.

b. Remove the mouse from the case and plug it into the mouse (PS2) port on the back of the ORT.

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

d. Connect one end of the 150-foot patch cable to the ORT networking port on the PU.

e. Route the cable from the ORT to the PU and connect the cable to the ORT port.

f. Turn on the ORT.

g. Observe that the ORT boots to the operator’s Overview screen.

h. Select the EquipID pop-up screen and enter the necessary information for the units. This
includes the Trailer ID number, the Engine ID number, and the Generator ID number for each
PU.

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

h. Return to the Overview pop-up screen.

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DRS RADIAN CTM: 01646.1R0253/1R0254

5.10.1.3.8 CONTROLS SETUP

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

NOTE: Ignore settings for Power Units not being used.

TABLE 5.10.1.3.8-1
PDC CONTROL SWITCH SETUP
PANEL SWITCH 1ST PU 2ND PU 3RD PU 4TH PU
Pushed In Pushed In Pushed In Pushed In
DC Power
(ON) (ON) (ON) (ON)
SMS OFF OFF OFF OFF
PRIME PRIME PRIME PRIME
GMS
POWER POWER POWER POWER
MASTER CONTROL PANEL PRIME PRIME PRIME PRIME
AVRS
MCP POWER POWER POWER POWER
60Hz Light ON① ON① ON① ON①
USS A② B② C② D②
BSS NORMAL NORMAL NORMAL NORMAL
SSS OFF OFF OFF OFF
SSL All OFF All OFF All OFF All OFF
50/60 50/60 50/60 50/60
INSIDE MCP FSS
Hertz① Hertz① Hertz① Hertz①
Emergency
GENERATOR CONTROL Pulled-Out Pulled-Out Pulled-Out Pulled-Out
Stop
PANEL GCPG1
ECS OFF OFF OFF OFF
Emergency
GENERATOR CONTROL Pulled-Out Pulled-Out Pulled-Out Pulled-Out
Stop
PANEL GCPG2
ECS OFF OFF OFF OFF
① With the SMS in the OFF position, the 50/60Hz lights indicate the position of the Frequency
Selector Switch (FSS). If the wrong light is on, open the door and change the switch position.
② No more than one switch can be in the same position in any multi-PU line-up. With the SMS in
OFF, none of the USI lights will be on and any previously set address on the PU is cleared.

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5.10.1.4 PLANT STARTUP

Starting up a Multi-PU Prime Power Plant in Automatic Mode

WARNING

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND


ENFORCED. NOISE LEVELS IN EXCESS OF 85 DB EXIST WITHIN AN 88-FOOT
RADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR SINGLE HEARING
PROTECTION WITHIN 88 FEET OF AN OPERATING DPGDS.

WARNING

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND


ENFORCED. DURING MAINTENANCE ACTIVITIES WITH THE SIDEDOORS OPEN,
NOISE LEVELS IN EXCESS OF 113 DB EXIST WITHIN A 12-FOOT RADIUS OF AN
OPERATING DPGDS. PERSONNEL MUST WEAR DOUBLE HEARING PROTECTION
WITHIN 12 FEET OF AN OPERATING DPGDS. EXPOSURE MUST BE LIMITED TO
UNDER 2.5 HOURS.

WARNING

ONCE THE SYSTEM STATUS LIGHTS TURN GREEN AND THE MSES IS ENABLED,
THE PU WILL START. ENSURE PERSONNEL ARE CLEAR OF THE PU.

WARNING

ONLY ONE PU MAY BE SELECTED TO ANY ONE USS POSITION DURING MULTIPLE
PU OPERATIONS. OPERATING WITH MORE THAN ONE UNIT AT THE SAME ID
CAUSE UNSAFE AND ERRATIC OPERATIONAL CONDITIONS.

a. At the external switchgear, close the associated connection for each PU supplying power to the
switchgear.

b. At the external switchgear, close the connections between the external switchgears.

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

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

NOTE: 2: For Unit Isolation Procedure (any unit) - Plant with PSC, and Unit Re-Installation
Procedure – Plant with PSC, refer to Section 5.9, Section 5.9.6.15, and Section 5.9.6.16.

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

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TABLE 5.10.1.4-1 SWITCH SETUP – AUTOMATIC MODE


PANEL SWITCH 1ST PU 2ND PU 3RD PU 4TH PU
Red Red Red Red
BCS-T
Target Target Target Target
MASTER CONTROL PANEL MCP
SMS AUTO③ AUTO③ AUTO③ AUTO③
USS A B C D
Red Red Red Red
BCS-G1
Target Target Target Target
GENERATOR CONTROL PANEL 1
Red Red Red Red
GCPG1 BCS-F1
Target Target Target Target
ECS-1 AUTO AUTO AUTO AUTO
Red Red Red Red
BCS-G2
Target Target Target Target
GENERATOR CONTROL PANEL 2
Red Red Red Red
GCPG2 BCS-F2
Target Target Target Target
ECS-2 AUTO AUTO AUTO AUTO
MSES Enable① Enable① Enable① Enable①
MASTER CONTROL PANEL MCP
USI A①, ② B①, ② C① , ② D① , ②

① Hold the MSES in an ENABLE position until the selected USI indicator energizes. The switch
returns to the center position when released. This sets the PU networking address and enables
the control and monitoring.
② No more than one of each indicator can be on for multi-PU operations. The light on should match
USS position. The USI light will de-energize after the SMS has been in OFF for 3 seconds.
③ With the SMS in AUTO any generator started, manually or automatically, will automatically
parallel to the bus. To prevent the generator from paralleling to the bus put the generator’s
breaker in the Pull-To-Lock position.
NOTE: The automatic economizing feature will shutdown one generator every 3 minutes until the
system load is at or below the 360KW/450KVA per generator threshold.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

y. At the external switchgear, close load connections to supply power to the loads.

z. Ensure generators have assumed load. After the load has stabilized, proceed with the following if
necessary:

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

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

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

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5.10.1.5 PLANT OPERATIONS

5.10.1.5.1 PRECAUTIONS AND WARNINGS

This mode of operation places control of all generator starting, stopping, synchronizing, and load
management under the auspices of the Programmable Logic Controller (PLC) system. As long as the
SMS is in AUTO, any generator started, manually or automatically, is automatically synchronized to the
system bus. Care must be taken when starting a generator manually when the SMS is in AUTO. Either
place the associated BCS in Pull-To-Lock (prevent closing to the bus) or ensure it has the red target
visible (allow paralleling to the bus) before starting the engine. The only exception is automatic operation
of the feeder breakers. Auto Mode does not automatically close feeder breakers; it only enables remote
operation of the feeder breakers from the ORT.

5.10.1.5.2 DESCRIPTION

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

5.10.1.5.3 DEFAULT OPERATING SEQUENCE

Start-Up Sequence: The automatic controls will continuously monitor the system load. As load on the
system increases, the controls automatically start and place additional units on line in the following
sequence at 1-minute intervals:

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


b. One generator from PU “C” based on lower engine runtime.
c. One generator from PU “D” based on lower engine runtime.
d. Remaining generator from PU “A”.
e. Remaining generator from PU “B”.
f. Remaining generator from PU “C”.
g. Remaining generator from PU “D”.

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Shutdown Sequence: Based on the loading experienced, the controller shuts down generator sets that
are not needed. For the purpose of explanation, we will assume that all generator sets are on line
following an initial startup. Based on load, the controls shut down generator sets in the following
sequence at 3-minute intervals:

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


b. One generator from PU “C” based on higher engine runtime.
c. One generator from PU “B” based on higher engine runtime.
d. One generator from PU “A” based on higher engine runtime.
e. Remaining generator from PU “D”.
f. Remaining generator from PU “C”.
g. Remaining generator from PU “B”.

5.10.2 PLANT 2 (UTILITY PARALLEL CONFIGURATION)

5.10.2.1 SAFETY PROCEDURES

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

• Hot engine parts


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

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

5.10.2.2 POSITIONING THE PU

a. Position the PU in such a way as to allow the plant operator to have full vision of the operator
control panels on the unit.

b. Level the MEP-PU-810B front to rear with the trailer leveling hand crank.

c. Position the PU to provide a minimum of 10 feet of clearance for maintenance access on all
sides of each unit. Ensure that there are no overhead obstructions around the exhaust outlets.

WARNING

FUEL SPILLAGE CAN OCCUR IF THE POWER UNIT LEVEL IS GREATER THAN + 5
DEGREES.

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

5.10.2.3 INITIAL PLANT SETUP

5.10.2.3.1 GROUNDING

WARNING

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

a. Drive an 8-foot ground rod into the earth and should be within 6 feet of the PU and at a location
that minimizes the tripping hazard, until only 6 inches (15 cm) protrudes above the surface.

b. Repeat step “a” for each PU being used.

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

d. Using a #2 AWG copper conductor, secure one end of a ground cable to one of the slotted
ground studs on the PU, see Figure 5.1.3.1-1 or Figure 5.1.3.1-3. Secure the other end of the
ground cable to the ground rod.

e. Repeat step “d” for every PU.

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

g. Remove parking stand plates from their transportation positions inside each rear, side PU door
and slide them into their respective operating positions on the sides of the PDC.

h. Connect the parking stand ground wires to either of the two chassis ground lugs on the PU.

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GROUND POINT GROUND POINT

FIGURE 5.10.2.3.1-1 MEP-PU-810A GROUND POINTS

NOTE: Connect only one ground point to the ground grid.

GROUND POINT

GROUND POINT

FIGURE 5.10.2.3.1-2 MEP-PU-810B GROUND POINTS

NOTE: Connect only one ground point to the ground grid.

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5.10.2.3.2 FUEL MANIFOLD

WARNING

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

a. Lay out the fuel hoses between the PU, the fuel manifold, and the fuel bladders to establish the
fuel supply system see Figure 5.10.2.3.2-1.

b. Install the external fuel hose for the PU to the Fuel Transfer Pump at the Tow end of the PU.

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

d. Connect the 3” hose, with quick-disconnect hose ends, from the fuel manifold to the fuel
bladders.

e. Connect the fuel manifold ground wire to the ground grid.

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

FIGURE 5.10.2.3.2-1 EXTERNAL FUEL SUPPLY

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5.10.2.3.3 DISTRIBUTION AND CONTROL CABLING

WARNING

DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS


OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A
SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS
CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM
FAILURE TO OBSERVE THIS WARNING.

WARNING

HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT DURING
CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION AND AVOID
CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN LOAD CABLES
ARE HANDLED.

WARNING

VERIFY THAT CONNECTION POINTS ARE DE-ENERGIZED BEFORE MAKING ANY


CONNECTIONS. FAILURE TO CHECK THAT CONNECTORS ARE DE-ENERGIZED MAY
RESULT IN INJURY OR DEATH.

a. Lay out and park the load cables for each phase (A, B, & C) between the PU Tie Output parking
stations and the load.

b. Connect each phase cable to the appropriate phase connection on the Primary Switching Center
(PSC).

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

NOTE: 2: For Unit Isolation Procedure (any unit) - Plant with PSC, and Unit Re-Installation
Procedure – Plant with PSC, refer to Section 5.9, Section 5.9.6.15, and Section 5.9.6.16.

c. Connect each load cables drain wire to the grounding grid.

d. Open the Tie Output connector loadbreak covers on the first PU.

e. Connect the Tie Output Cables to the appropriate phase connectors; ensure there are no cross-
phase connections.

f. Close and lock the Tie Output connector covers.

g. Repeat steps ‘b’ through ‘f’ on each remaining PU.

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

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

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

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

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

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

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

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

p. Connect third (A) (B) communication cable to “A” receptacle on fourth PU.

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

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

5.10 2.3.4 SETPOINT VERIFICATION

a. Turn on PU DC control power by pushing in on the DC Control Power breaker.

b. On each of the five overcurrent relays, verify the settings:

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

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

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

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

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

(6) Verify the “P” and “N” values match the following table:

TABLE 5.10.2.3.4-1 CT RATIO SETTINGS


BREAKER RELAY CT RATIO “P” VALUE “N” VALUE
GENERATOR 100:5 20 20
FEEDER 200:5 40 40
TIE 200:5 40 40

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


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

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

(10) Verify the 50TP “PU” and “TD” settings in Table 5.10.2.3.4-2. In order to edit values,
Press the “Edit” key. Select correct value, and press “Edit” again when correct. Ensure
light is off otherwise you can accidentally change value again.

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TABLE 5.10.2.3.4-2 INSTANTANEOUS TRIP SETTINGS


PHASE NEUTRAL NEGATIVE SEQUENCE
INSTANTANEOUS INSTANTANEOUS TRIP
BREAKER RELAY
TRIP 50TP TRIP 50TN 50 TQ
PU TD PU TD PU TD
GENERATOR 0.0 0m 3.0 0m 3.0 0m
FEEDER 7.5 84m 1.25 84m 0 0m
TIE 0.0 0m 0 0m 0.0 0m

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

(12) Verify the 50TN “PU” and “TD” settings in Table 5.10.2.3.4-2.

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

(14) Verify the “50TQ” settings

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

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

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

(18) Verify the 51P “PU”, “TD”, and “C” settings in Table 5.10.2.3.4-3.

TABLE 5.10.2.3.4-3 TIME OVERCURRENT TRIP SETTINGS


PHASE TIME OVERCURRENT NEUTRAL TIME OVERCURRENT
BREAKER RELAY TRIP 51P TRIP 51N
PU TD C PU TD C
GENERATOR 4.50 0.5 VV2 1.25 0.5 VV2
FEEDER 2.50 1.0 VV2 1.00 1.0 VV2
TIE 5.00 2.0 VV2 1.50 2.0 VV2

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

(20) Verify the 51N “PU”, “TD”, and “C” settings in Table 5.10.2.3.4-3.

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

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

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

(1) Place ECS in the COOLDOWN/STOP position.

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

(3) Press SCROLL UP key until “OP3” is showing.

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

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

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

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

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

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

(10) Press ENTER key. “PE PASS” is showing.

(11) Press EXIT key. “OP4” is showing.

(12) Press SCROLL UP key until “OP5-0” is showing on the lower display.

(13) Press SELECT key. “POO1” followed with the value of the setpoint is showing.

(14) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing.
Use Table 5.10.2.3.4-4 for the parameter values to be verified.

(15) Repeat step “15” until the desired setpoints are verified.

(16) Press EXIT key. “OP5-0” is showing on the lower display.

(17) Press SCROLL UP key until “OP5-1” is showing.

(18) Press SELECT key.

(19) Repeat steps 15 and 16 for “OP5-1” using Table 5.10.2.3.4-5.

(20) Repeat steps 17, 18, and 19 for OP6.

(21) Repeat steps 15 and 16 for “OP6” using Table 5.10.2.3.4-6.

(22) Press EXIT Key twice. The display returns to normal.

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

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

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

(c) Press ENTER. The correct value stops flashing on the display.

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

d. At GSC G1, verify the operation settings using the following table:

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TABLE 5.10.2.3.4-4 OP5-0 SETPOINTS
SETPOINTS OP5-0 ENGINE/GENERATOR PROGRAMMING①
FACTORY DPGDS
SETPOINT-NAME-DESCRIPTIONS RANGE OF VALUES
DEFAULT SETPOINT
P001 - Fuel Solenoid Type: type of fuel system solenoid 0- ETR fuel solenoid
0 0
used on the genset. 1- ETS fuel solenoid
P002 - Units Shown: type of measurement units shown 0-for English units (PSI, ºF)
0 0
on the GSC+ display. 1-for metric units (kPa, ºC).
P003 - Shutdown Override For Engine Fault: GSC+ 0-for engine shutdown
response to a low engine oil pressure or high coolant 1-for alarm only (shutdown override, no 0 0
temperature fault. engine shutdown).
P004 - Shutdown Override For Sensor Fault: GSC+ 0-for alarm only shutdown override, no
response to a diagnostic fault with the engine oil pressure engine shutdown). 0 0
sensor, coolant temperature sensor, oil temperature
sensor, sensor power supply or coolant loss sensor. 1-for engine shutdown.

P005 - Coolant Loss Sensor Installed: tells whether or 0-for gensets without a coolant loss sensor
not the optional engine coolant loss sensor is installed on 0 1
the genset. 1-for gensets with coolant loss sensor

0-for engine shutdown.


P006 - Shutdown Override For Coolant Loss Fault:
1-for alarm only (shutdown override, no 0 0
GSC+ response to an engine coolant loss fault.
engine shutdown).
P007 - System Voltage, 24 Or 32 Volts: system voltage
24 or 32. 24 24
(battery voltage) of the genset.
P008 - This setpoint is not currently being used by the
N/A N/A N/A
GSC+ and cannot be programmed.
P009 - Number Of Ring Gear Teeth: number of teeth on
the ring gear of the engine. Used by the GSC+ to 95 to 350 teeth in increments of one tooth. 136 teeth 136 teeth
determine engine speed.
P010 - Engine Overspeed: engine speed used by the
GSC+ to declare that an engine overspeed fault exists.
500 to 4330 rpm in increments of 10 rpm. 2120 rpm 2120 rpm
The engine overspeed setpoint (for all 60 Hz applications)
is 1.18 times the rated speed.
P011 - Crank Terminate Speed: engine speed used by
the GSC+ to disengage the starting motor during engine 100 to 1000 rpm in increments of 10 rpm. 400 rpm 400 rpm
cranking.
P012 - Oil Step Speed: engine speed used by the GSC+
for distinguishing between rated speed and idle speed 400 to 1800 rpm in increments of 10 rpm. 1350 rpm 1350 rpm
when a low oil pressure fault exists.

P013② - Low Oil Pressure Shutdown At Rated Speed:


oil pressure used by the GSC+ to declare that a low oil 30 PSI 30 PSI
pressure shutdown fault exists with engine at rated speed 5 to 61PSI (34 to 420kPa) in increments of 1
(205 kPa) (205 kPa)
(the engine speed must have exceeded the oil step speed
for nine seconds).

P014② - Low Oil Pressure Shutdown At Idle Speed:


oil pressure used by the GSC+ to declare that a low oil
10 PSI 10 PSI
pressure shutdown fault exists with the engine at idle 20 to 336kPa (3 to 49PSI) in increments of 1
speed (the engine must have been running for at least 9 (70 kPa) (70 kPa)
seconds and the engine speed must be less than oil step
speed).

P015③ - High Water Temperature Shutdown: coolant


185 to 253ºF (85 to 123ºC) in increments of 225ºF 225ºF
temperature used by the GSC+ to declare a high coolant
temperature shutdown fault exists (after a 10 second 1 (107ºC) (107ºC)
delay).
P016 - Low Water Temperature Alarm: coolant
temperature used by the GSC+ to declare that a low 70ºF 70ºF
32 to 97ºF (0 to 36ºC) in increments of 1
coolant temperature alarm fault exists (after a 2 second (21ºC) (21ºC)
delay).

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TABLE 5.10.2.3.4-4 OP5-0 SETPOINTS (CONTINUED)


SETPOINTS OP5-0 ENGINE/GENERATOR PROGRAMMING①
FACTORY DPGDS
SETPOINT-NAME-DESCRIPTIONS RANGE OF VALUES
DEFAULT SETPOINT
P017 - Total Cycle Crank Time: cycle crank time used by the 5 to 120 seconds in increments of 1
90 seconds 90 seconds
GSC+ to declare that an overcrank fault exists. second.
P018 - Cycle Crank Time: amount of time the GSC+ cranks 5 to 60 seconds in increments of 1
10 seconds 10 seconds
and then rests the starting motor during a single crank cycle. second.
P019 - Cooldown Time: amount of time the GSC+ allows the 0 to 30 minutes in increments of 1
5 minutes 5 minutes
engine to run after a normal shutdown is initiated. minute.

P020④ - AC Voltage: nominal AC voltage of the generator. 700, 150, 300, 500, 600, 750, 3.0k,
The GSC+ measures the AC voltage and shows it on the 4.5k, 5.20k, 5.25k, 9.0k, 15.0k, 18.0k, 700 5.20k
display. 30.0k
P021 - AC Current Full Scale: nominal full scale AC current 75, 100, 150, 200, 300, 400, 600, 800,
of the generator. AC current full scale is equal to the ratio of 1000, 1200, 1500, 2000, 2500, 3000, 600A 100A
the external current transformers in the generator housing. and 4000A

P022⑤ - GSC+ Engine Number: informs other devices on


01 (Gen 1)
01 through 08 01
the CAT Data Link of the engine number for the GSC+. 02 (Gen 2)

SETPOINTS - OP5-0-ENGINE/GENERATOR PROGRAMMING①


RANGE OF FACTORY 60HZ 50HZ
SETPOINT-NAME-DESCRIPTIONS
VALUES DEFAULT SETPOINT SETPOINT
P023 - Engine Type: identifies the engine as a 0 - MUI diesel
mechanical unit injector (MUI) diesel, spark
1 - Gas 0 2 2
ignited (gas), or electronic unit injector (EUI)
diesel engine. 2 - EUI diesel
P024 - Crank Time Delay: amount of time the
GSC+ delays activation of the fuel control relay
(FCR) during a crank cycle. This setpoint is for 0 to 20 seconds in increments of 1
5 Seconds 5 Seconds 5 Seconds
Gas engines only. The P024 setpoint only second.
functions when the P023 setpoint is set to 1 (gas
engine).
0 - for gensets without an oil
P025 - Oil Temperature Sensor Installed: tells temperature sensor
whether or not the optional engine oil temperature 0 0 0
sensor is installed on the genset. 1 - for gensets with an oil
temperature sensor
P026 - High Oil Temperature Shutdown: oil
temperature used by the GSC+ to declare a high 185 to 253ºF (85 to 123ºC) in
225ºF (107ºC) 225ºF (107ºC) 225ºF (107ºC)
oil temperature shutdown fault exists (after a 10 increments of 1
second delay). Refer to the panel model number.
P027 - Shutdown Override For High Oil 0 - for alarm only (shutdown override,
Temperature Fault: GSC+ response to an engine no engine shutdown). 0 0 0
high oil temperature fault. 1 - for engine shutdown.
P028 - Nameplate Voltage: rated voltage of the
generator. This setpoint is used for protective 100 to 25kV in increments of 1 480V 4160V 3800V
relaying functions.
P029 - Nameplate Current: rated current output
0 to 4000 A in increments of 1 600A 80A 73A
of the generator.
P030 - Nameplate Power: rated power capability 0 through 10MW in increments of
400kW 420kW 350kW
of the generator. 1kW.
P031 - Rated Frequency: nominal frequency
50 or 60Hz 60Hz 60Hz 50Hz
rating of genset.
P032 - Connection Configuration Of Generator: 0 - wye
0 0 0
wye or delta configuration of generator. 1 - delta
P033 - Number Of Generator Poles. 0 through 254 in increments of 2. 4 4 4

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① The setpoints (stored or being programmed) must match the specified DPGDS setpoints.
② When oil pressure drops to within 5PSI (34kPa) of the P013 or P014 setpoint, a low oil pressure alarm
is issued by the GSC+.
③ When coolant temperature rises to within 11ºF (6ºC) of the P015 setpoint, a high coolant temperature
alarm is issued by the GSC+.
④ The values other than the default (700V) are for switchgear applications and require the use of external
potential transformers and the removal of the AC voltage range jumper located in the relay module.
The DPGDS unit is factory configured for the 5.20 K value. See the Caterpillar Electronic Modular
Control Panel II+ manual topic AC Voltage Range Selection in the Testing and Adjusting section.
⑤ After setpoint P022 is reprogrammed, the GSC+ must be power cycled (powered down and then
powered up)

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TABLE 5.10.2.3.4-5 OP5-1 SETPOINTS


SETPOINTS OP5-1 PROTECTIVE RELAYING PROGRAMMING①
FACTORY 60HZ 50HZ
SETPOINT-NAME-DESCRIPTION RANGE OF VALUES
DEFAULT SETPOINT SETPOINT
P101 - Generator Overvoltage Alarm Enable: the 0 - disabled
GSC+ enables or disables the generator 1 1 1
overvoltage alarm function. 1 - enabled
P102 - Generator Overvoltage Alarm Threshold:
100 to 125% of nameplate voltage in
voltage the GSC+ uses to issue an overvoltage 105% 105% 105%
increments of 1%.
alarm.
P103 - Generator Overvoltage Alarm Time Delay:
amount of time the GSC+ waits before issuing an 0 through 120 seconds② in increments 10 seconds 10 seconds 10 seconds
overvoltage alarm. of 1
P104 - Generator Overvoltage Shutdown Enable: 0 - disabled
the GSC+ enables or disables the generator 1 1 1
overvoltage shutdown function. 1 - enabled
P105 - Generator Overvoltage Shutdown
100 to 125% of nameplate voltage in
Threshold: voltage the GSC+ uses to issue an 110% 110% 110%
increments of 1%.
overvoltage shutdown.
P106 - Generator Overvoltage Shutdown Time
Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments 10 seconds 10 seconds 10 seconds
issuing an overvoltage shutdown. of 1
P107 - Generator Undervoltage Alarm Enable: 0 - disabled
the GSC+ enables or disables the generator 1 1 1
undervoltage alarm function. 1 - enabled
P108 - Generator Undervoltage Alarm
60 to 100% of nameplate voltage in
Threshold: voltage the GSC+ uses to issue an 90% 90% 90%
increments of 1%.
undervoltage alarm.
P109 - Generator Undervoltage Alarm Time
Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments 10 seconds 10 seconds 10 seconds
issuing an undervoltage alarm. of 1
P110 - Generator Undervoltage Shutdown 0 - disabled
Enable: the GSC+ enables or disables the 1 1 1
generator undervoltage shutdown function. 1 - enabled
P111 - Generator Undervoltage Shutdown
60 through 100% of rated voltage in
Threshold: voltage the GSC+ uses to issue an 85% 85% 85%
increments of 1%.
undervoltage shutdown.
P112 - Generator Undervoltage Shutdown Time
Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments 15 seconds 03 seconds 03 seconds
issuing an undervoltage shutdown. of 1
P113 - Generator Overfrequency Alarm Enable: 0 - disabled
the GSC+ enables or disables the generator 1 1 1
overfrequency alarm function. 1 - enabled

P114 - Generator Overfrequency Alarm 50-60Hz, for 50Hz Gen 53Hz


Threshold: frequency the GSC+ uses to issue an 60-70Hz, for 60Hz Gen 63Hz 63 Hz 53 Hz
overfrequency alarm. 400-480, for 400Hz Gen 422Hz
P115 - Generator Overfrequency Alarm Time
Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments 10 seconds 10 seconds 10 seconds
issuing an overfrequency alarm. of 1
P116 - Generator Overfrequency Shutdown 0 - disabled
Enable: the GSC+ enables or disables the 1 1 1
generator overfrequency shutdown function. 1 - enabled

P117 - Generator Overfrequency Shutdown 50-60Hz, for 50Hz Gen 55Hz


Threshold: frequency the GSC+ uses to issue an 60-70Hz, for 60Hz Gen 66Hz 66Hz 55Hz
overfrequency shutdown. 400-480, for 400Hz Gen 440Hz

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TABLE 5.10.2.3.4-5 OP5-1 SETPOINTS (CONTINUED)
SETPOINTS OP5-1 PROTECTIVE RELAYING PROGRAMMING①
FACTORY 60HZ 50HZ
SETPOINT-NAME-DESCRIPTION RANGE OF VALUES
DEFAULT SETPOINT SETPOINT
P118 - Generator Overfrequency Shutdown Time
Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments 10 seconds 10 seconds 10 seconds
issuing an overfrequency shutdown. of 1
P119 - Generator Underfrequency Alarm Enable: 0 - disabled
the GSC+ enables or disables the generator 1 1 1
underfrequency alarm function. 1 - enabled

P120 - Generator Underfrequency Alarm 30-50Hz, for 50Hz Gen 48Hz


Threshold: frequency the GSC+ uses to issue an 36-60Hz, for 60Hz Gen 57Hz 57Hz 48Hz
underfrequency alarm. 240-400, for 400Hz Gen 378Hz
P121 - Generator Underfrequency Alarm Time
Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments 10 seconds 10 seconds 10 seconds
issuing an underfrequency alarm. of 1
P122 - Generator Underfrequency Shutdown 0 - disabled
Enable: the GSC+ enables or disables the generator 1 1 1
underfrequency shutdown function. 1 - enabled

P123 - Generator Underfrequency Shutdown 30-50Hz, for 50Hz Gen 45Hz


Threshold: frequency the GSC+ uses to issue an 36-60Hz, for 60Hz Gen 54Hz 54Hz 45Hz
underfrequency shutdown. 240-400, for 400Hz Gen 360Hz
P124 - Generator Underfrequency Shutdown
Time Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments 15 seconds 03 seconds 03 seconds
issuing an underfrequency shutdown. of 1
P125 - Generator Reverse Power Shutdown 0 - disabled
Enable: the GSC+ enables or disables the generator 1 1 1
reverse power shutdown function. 1 - enabled
P126 - Generator Reverse Power Shutdown
0 through 20% of rated power in
Threshold: level of reverse power the GSC+ uses to 15% 4% 4%
increments of 1%.
issue a reverse power shutdown.
P127 - Generator Reverse Power Shutdown Time
Delay: amount of time the GSC+ waits before 0 through 30 seconds② in increments 10 seconds 4 seconds 4 seconds
issuing a reverse power shutdown. of 1
P128 - Generator Overcurrent Alarm Enable: the 0 - disabled
1 1 1
GSC+ enables or disables the overcurrent alarm. 1 - enabled
P129 - Generator Phase Overcurrent Alarm
100 through 160% of nameplate current
Threshold: level of current the GSC+ uses to issue a 105% 150% 150%
in increments of 5%
phase overcurrent alarm.
P130 - Generator Phase Overcurrent Alarm Time
Delay: amount of time the GSC+ waits before 0 through 250 seconds② in increments 0 seconds 0 seconds 0 seconds
issuing a phase overcurrent alarm. of 1
P131 - Generator Total Overcurrent Alarm
100 through 160% of three times
Threshold: level of current the GSC+ uses to issue a 105% 150%. 150%
nameplate current in increments of 5%
total overcurrent alarm.
P132 - Generator Total Overcurrent Alarm Time
Delay: amount of time the GSC+ waits before 0 through 250 seconds② in increments 0 seconds 0 seconds 0 seconds
issuing a total overcurrent alarm. of 1
P133 – Generator Overcurrent Shutdown Enable: 0 – disabled
the GSC+ enables or disables the overcurrent 1 1 1
shutdown. 1 – enabled
P134 – Generator Phase Overcurrent Shutdown
100 through 160% in increments of 5%
Threshold: level of current the 110% 150% 150%
GSC+ uses to issue a phase overcurrent shutdown.
P135 – Generator Phase Overcurrent Shutdown
Time Delay: amount of time the GSC+ waits before 0 through 250 seconds② in increments 0 seconds 10 seconds 10 seconds
issuing a phase overcurrent shutdown. of 1

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TABLE 5.10.2.3.4-5 OP5-1 SETPOINTS (CONTINUED)


SETPOINTS OP5-1 PROTECTIVE RELAYING PROGRAMMING①
FACTORY 60HZ 50HZ
SETPOINT-NAME-DESCRIPTION RANGE OF VALUES
DEFAULT SETPOINT SETPOINT
P136 - Generator Total Overcurrent
Shutdown Threshold: level of current the 100 through 160% of three times
110% 150%. 150%
GSC+ uses to issue a total overcurrent nameplate current in increments of 5%
shutdown.
P137 - Generator Total Overcurrent
Shutdown Time Delay: amount of time the 0 through 250 seconds② in increments 0 seconds 10 seconds 10 seconds
GSC+ waits before issuing a total overcurrent of 1
shutdown.
P138 - KW Level Relay Enable : the GSC+ 0 - disabled
enables or disables the kW level relay 1 1 1
function. 1 - enabled
P139 - KW Level Relay Threshold: level of
0 through 110% of nameplate power in
power the GSC+ uses to activate the kW level 105% 105% 105%
increments of 1%
relay function.
P140 - KW Level Relay Time Delay: amount
of time the GSC+ waits before activating the 0 through 120 seconds② in increments 0 seconds 0 seconds 0 seconds
kW level relay function. of 1
P141 - KW Level Relay Disengage
0 through 110% of nameplate power in
Threshold: level of power the GSC+ uses to 100% 100% 100%
increments of 1%.
deactivate the kW level relay function.
P142 - KW Level Relay Disengage Time
Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments 10 seconds 10 seconds 10 seconds
deactivating the kW level relay function. of 1

① The setpoints are programmed at the factory to the default value.


② When programmed to 0 seconds, the actual time is from 0.5 to 1.0 seconds.

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TABLE 5.10.2.3.4-6 OP6 SETPOINTS


SETPOINTS OP6 SPARE INPUT/OUTPUT PROGRAMMING
FACTORY DPGDS
SETPOINT-NAME-DESCRIPTIONS RANGE OF VALUES
DEFAULT SETPOINT
SP01 - Spare Input 1 Active State. Input state used by the 0-active low
0 0
GSC+ to declare a SP1 fault exists. 1-active high
SP02 - Spare Input 1 Response: GSC+ response to a SP1 0-shutdown
0 0
fault. 1-alarm
SP03 - Spare Input 1 Time Delay: Amount of time the GSC+
0 - 250 seconds in increments of 1 0 seconds 1 second
waits before responding to a SP1 fault.
SP04 - Spare Input 2 Active State. Input state used by the 0-active low
0 1
GSC+ to declare a SP2 fault exists. 1-active high
SP05 - Spare Input 2 Response: GSC+ response to a SP2 0-shutdown
0 0
fault. 1-alarm
SP06 - Spare Input 2 Time Delay: Amount of time the GSC+
0 - 250 seconds in increments of 1 0 seconds 0 seconds
waits before responding to a SP2 fault.
SP07 - Spare Input 3 Active State. Input state used by the 0-active low
0 0
GSC+ to declare a SP3 fault exists. 1-active high
SP08 - Spare Input 3 Response: GSC+ response to a SP3 0-shutdown
0 0
fault. 1-alarm
SP09 - Spare Input 3 Time Delay: Amount of time the GSC+
0 - 250 seconds in increments of 1 0 seconds 0 seconds
waits before responding to a SP3 fault.
SP10 - Spare Input 4 Active State. Input state used by the 0-active low
0 0
GSC+ to declare a SP4 fault exists. 1-active high
SP11 - Spare Input 4 Response: GSC+ response to a SP4 0-shutdown
0 0
fault. 1-alarm
SP12 - Spare Input 4 Time Delay: Amount of time the GSC+
0 - 250 seconds in increments of 1 0 seconds 0 seconds
waits before responding to a SP4 fault.
SP13 - Spare Output Response: GSC+ response to the spare 0-active low
0 0
output trigger condition. 1-active high
0-unused

1-active SP1 fault②

2-active SP2 fault②

3-active SP3 fault②

4-active SP4 fault②


SP14 - Spare Output Trigger Condition: The condition used
5-any combination of active SP faults②
8 8
by the GSC+ to trigger the spare output response
6-any active shutdown
7-any active alarm or shutdown
8-cooldown mode

9-coolant loss mode②

10-high oil temp fault②


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

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TABLE 5.10.2.3.4-6 OP6 SETPOINTS (CONTINUED)


SETPOINTS OP6 SPARE INPUT/OUTPUT PROGRAMMING
FACTORY DPGDS
SETPOINT-NAME-DESCRIPTIONS RANGE OF VALUES
DEFAULT SETPOINT
0-unused

1-active SP1 fault②

2-active SP2 fault②

3-active SP3 fault②

4-active SP4 fault②


SP16 - Spare Relay Output Trigger Condition: The condition
5-any combination of active SP faults②
8 1
used by the GSC+ to trigger the spare relay.
6-any active shutdown
7-any active alarm or shutdown
8-cooldown mode

9-coolant loss mode②

10-high oil temp fault②


11-CCM control
0-unused

1-active SP1 fault②

2-active SP2 fault②

3-active SP3 fault②


SP17 - Spare Indicator 1 Trigger Condition: The condition
4-active SP4 fault② 0 6
used by the GSC+ to trigger spare indicator①.
5-any combination of active SP1, SP2,

SP3 or SP4 faults②

6-Coolant loss fault②

7-high oil temperature fault②


SP18 - Spare Indicator 2 Trigger Condition: The condition
Battle Short mode. 0 0 Battleshort③
used by the GSC+ to trigger spare indicator②.
SP19 - Spare Indicator 3 Trigger Condition: The condition 0 In 50Hz
Not in 60 Hz mode. 0
used by the GSC+ to trigger spare indicator③. Mode③

① The setpoints are programmed at the factory to the default value.

② Either alarm or shutdown faults are valid trigger conditions

③ Battleshort and 50Hz Mode are unique features to DPGDS for spare indicators 2 and 3.

e. Return ECS1 to the OFF/RESET position.

NOTE: Use up or down keys to change values.

f. At the AVR verify the operation settings using Table 5.10.2.3.4-7:

(1) Open the GCPG1 cabinet door.

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

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

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

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

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

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

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

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

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

(11) When complete, press the [▼] to display parameter “01”.

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

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

TABLE 5.10.2.3.4-7 AVR PARAMETERS/SETPOINTS


DPGDS
DPGDS AVR PARAMETERS
SETPOINTS
RANGE OF DEFAULT 60HZ 50HZ
PARAMETER TITLE TYPE UNITS
VALUES VALUE OPS OPS

01 Generator Output Voltage Program Volts 0080-9999 480① 4160 3800


Ratio of Output Voltage To
02 Program 001.0-100.0 001.0 17.3 17.3
Sensing Voltage
03 Generator Type Program 0000-0004 0004 4 4
04 Rated Generator Output Current Program Amps 0000-9999 0600 80 73
CT Voltage At Rated Generator
05② Current
Program Volts 01.00-05.00 05.00 4.00 3.66

06 Knee Frequency Program Hz 045.0-065.0 050.0 59.8 49.8


07 Decreasing Volts/Hz Slope I Program Volts/Hz 001.0-010.0 002.0 2.0 2.0
08 Decreasing Volts/Hz Slope 2 Program Volts/Hz 001.0-010.0 002.0 2.0 2.0
09 Minimum Voltage Program % 050.0-100.0 050.0 50.0 50.0
10 Under Frequency Point Program Hz 020.0-040.0 025.0 25.0 25.0
11 Overvoltage Trip Point Program % 0105-0140 014.0 125.0 125.0
12 Overvoltage Trip Time Program Seconds 0002-0030 0002 5 5
13 Under Voltage Trip Point Program % 0060-0095 0060 75 75
14 Under Voltage Trip Time Program Seconds 0030-0120 0030 30 30
000.0-0
15 Voltage Gain (IR Compensation) Program % 0000 0 0
10.0

16⑤ Integral Gain Program 001.0-020.0 006.0 6.0 6.0

17⑥ Proportional Gain Program 001.0-020.0 005.0 5.0 5.0


Single Phase Sensing Select
18 Program 0000,0001 0000 0000 0000
(0=three phase, 1=single phase)
19 Diode Monitor Trip Point Program Amps 001.0-010.0 002.0 2.0 2.0

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TABLE 5.10.2.3.4-7 AVR PARAMETERS/SETPOINTS (CONTINUED)


DPGDS
DPGDS AVR PARAMETERS
SETPOINTS
RANGE OF DEFAULT 60HZ 50HZ
PARAMETER TITLE TYPE UNITS
VALUES VALUE OPS OPS
30 Droop Percentage Program % 000.0-010.0 0000 3 3

31③ pf/Kvar Select (0=pf, 1=Kvar) Program 0000, 0001 0000 0 0

32③ Pf Reference Program 00.60-01.10 01.00 0.8 0.8

33③ KVAR Reference Program Per Unit 00.00-01.00 0000 0.10 0.10

34③ Reverse Power Trip Point Program % 000.0-020.0 010.0 15 15

35③ Reverse Power Trip Time Program Seconds 000.0-020.0 010.0 5 5


50 Generator Output Frequency View Hz
51 Generator Output Voltage View Volts
52 Generator Output Current View Amps
Generator Reactive Output
53 View Amps
Current
54 Generator Real Current View Amps
55 Exciter Field Current View Amps
Three Phase Kilowatts
56③ (KB and later)
View KW

57③ Power Factor View

58③, ④ Three Phase Kvar (KE and later) View


60 Hours View Hours 0000-9999
90 Password Program 0009 0009
91 Software ID View
92 Latest Fault View 0000 0000 0000
93 Previous Fault View 0000 0000 0000
94 Fault Clear View
96 Shutdown Fault Reset Switch

①- Default value for output voltage is different depending on regulator sensing voltage. If the regulator is
designed for 120 volts sensing, then the default output voltage is 4160 volts. All other sensing types
have the default output voltage set to 480 volts.
②- Digital Voltage Regulators with earlier software (KD and earlier) have 1 less digit to the right of the
decimal point.
③- Optional feature.
④- New parameter on serial number prefix KE and later Digital Voltage Regulators.
⑤- Previous range of 0001-099.9 and default value of 002.0
⑥-Previous range of 0001-099.9 and default value of 002.0

(12) When complete, press the [▼] to display parameter “90”.

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

(14) Press the [▼] key to change the value to “0009”. Disables DVR parameter editing.

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

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(16) Press the [▲] key to change to display parameter “01”.

(17) Close the GCPG1 cabinet door.

(18) Repeat steps ‘1 ‘through ‘16’ for Generator 2.

5.10.2.3.5 PRE-OPERATION CHECKS

Starting from the left rear of the PU and working around the PU in a clockwise direction, perform the
following checks (Gen. 1 is on the left and Gen. 2 is on the right):

TABLE 5.10.2.3.5-1 PRE-OPERATION CHECKLIST


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

5-276
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TABLE 5.10.2.3.5-1 PRE-OPERATION CHECKLIST (CONTINUED)


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

① The Battery Parallel Switch should be left in the OFF position except in extreme conditions where
the additional DC power is required to crank an engine. Once started, return the switch to the OFF
position.

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5.10.2.3.6 PRE-OPERATION RUN

WARNING

ENSURE ALL PERSONNEL ARE CLEAR AND THE PU DOORS ARE CLOSED
PRIOR TO STARTING A GENERATOR.

WARNING

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND


ENFORCED. NOISE LEVELS IN EXCESS OF 85 DB EXIST WITHIN AN 88-FOOT
RADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR SINGLE HEARING
PROTECTION WITHIN 88 FEET OF AN OPERATING DPGDS.

WARNING

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND


ENFORCED. DURING MAINTENANCE ACTIVITIES WITH THE SIDEDOORS OPEN,
NOISE LEVELS IN EXCESS OF 113 DB EXIST WITHIN A 12-FOOT RADIUS OF AN
OPERATING DPGDS. PERSONNEL MUST WEAR DOUBLE HEARING PROTECTION
WITHIN 12 FEET OF AN OPERATING DPGDS. EXPOSURE MUST BE LIMITED TO
UNDER 2.5 HOURS.

WARNING

BY CLOSING THE FEEDER OR TIE BREAKER, HIGH VOLTAGE WILL BE PRESENT


ON THE LOAD CABLES. ENSURE ALL PERSONNEL ARE CLEAR OF ALL LOAD
CABLES PRIOR TO CLOSING FEEDER OR TIE BREAKERS.

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TABLE 5.10.2.3.6-1 PRE-OPERATION RUN INSTRUCTION SEQUENCE


(Perform on each PU in the power plant)
STEP -- 60HZ OPERATIONS -- -- 50HZ OPERATIONS --

1 Verify System Mode Switch (SMS) is in MANUAL

2 Verify DC Control Power is on

3 Verify Emergency Stop is pulled out

4① Verify the 60Hz light is on ① Verify the 50Hz light is on①

5 Start engine 1 by placing ECS1 in MANUAL

6 Verify the engine accelerates to 1800RPM Verify the engine accelerates to 1500RPM

7 Adjust the generator frequency to 60Hz Adjust the generator frequency to 50Hz using
using the Frequency Adjust Rheostat (FAR) the Frequency Adjust Rheostat (FAR)

8 Adjust the generator voltage to 4295VAC Adjust the generator voltage to 3915VAC
using the Voltage Adjust Rheostat (VAR) using the Voltage Adjust Rheostat (VAR)

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

10 Shutdown engine 1 by placing ECS1 in OFF/RESET

11 Start engine 2 by placing ECS2 in MANUAL

12 Verify the engine accelerates to 1800RPM Verify the engine accelerates to 1500RPM

13 Adjust the generator frequency to 60Hz Adjust the generator frequency to 50Hz using
using the Frequency Adjust Rheostat (FAR) the Frequency Adjust Rheostat (FAR)

14 Adjust the generator voltage to 4295VAC Adjust the generator voltage to 3915VAC
using the Voltage Adjust Rheostat (VAR) using the Voltage Adjust Rheostat (VAR)

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

16 Shutdown engine 2 by placing ECS2 in OFF/RESET

① If the wrong frequency light is on, open the Master Control Door and change the Frequency
Selector Switch (FSS) to the desired frequency.

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5.10.2.3.7 ORT SETUP

a. Remove the ORT from its case and set it up on a flat and level surface.

b. Remove the mouse from the case and plug it into the mouse (PS2) port on the back of the ORT.

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

d. Connect one end of the 150-foot patch cable to the ORT networking port on the PU.

e. Route the cable from the ORT to the PU and connect the cable to the ORT port.

f. Turn on the ORT.

g. Observe that the ORT boots to the operator’s Overview screen.

h. Select the EquipID pop-up screen and enter the necessary information for the units. This
includes the Trailer ID number, the Engine ID number, and the Generator ID number for each
PU.

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

i. Return to the Overview pop-up screen.

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5.10.2.3.8 CONTROLS SETUP

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

NOTE: Ignore settings for PUs not being used.

TABLE 5.10.2.3.8-1
PDC CONTROL SWITCH SETUP
PANEL SWITCH 1ST PU 2ND PU 3RD PU 4TH PU
Pushed In Pushed In Pushed In Pushed In
DC Power
(ON) (ON) (ON) (ON)
SMS OFF OFF OFF OFF
UTILITY UTILITY UTILITY UTILITY
GMS
PARALLEL PARALLEL PARALLEL PARALLEL
UTILITY UTILITY UTILITY UTILITY
MASTER CONTROL PANEL AVRS
PARALLEL PARALLEL PARALLEL PARALLEL
MCP
60Hz Light ON① ON① ON① ON①
USS A② B② C② D②
BSS NORMAL NORMAL NORMAL NORMAL
SSS OFF OFF OFF OFF
SSL All OFF All OFF All OFF All OFF
50/60 50/60 50/60 50/60
INSIDE MCP FSS
Hertz① Hertz① Hertz① Hertz①
Emergency
GENERATOR CONTROL Pulled-Out Pulled-Out Pulled-Out Pulled-Out
Stop
PANEL GCPG1
ECS OFF OFF OFF OFF
Emergency
GENERATOR CONTROL Pulled-Out Pulled-Out Pulled-Out Pulled-Out
Stop
PANEL GCPG2
ECS OFF OFF OFF OFF

① With the SMS in the OFF position, the 50/60Hz lights indicate the position of the Frequency
Selector Switch (FSS). If the wrong light is on, open the door and change the switch position.
② No more than one switch can be in the same position in any multi-PU line-up. With the SMS in
OFF, none of the USI lights will be on and any previously set address on the PU is cleared.

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5.10.2.4 PLANT STARTUP

5.10.2.4.1 GENERAL

WARNING

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND


ENFORCED.
NOISE LEVELS IN EXCESS OF 85 DB EXIST WITHIN AN 88-FOOT RADIUS OF AN
OPERATING DPGDS. PERSONNEL MUST WEAR SINGLE HEARING PROTECTION
WITHIN 88 FEET OF AN OPERATING DPGDS.

WARNING

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND


ENFORCED.
DURING MAINTENANCE ACTIVITIES WITH THE SIDEDOORS OPEN, NOISE
LEVELS IN EXCESS OF 113 DB EXIST WITHIN A 12-FOOT RADIUS OF AN
OPERATING DPGDS. PERSONNEL MUST WEAR DOUBLE HEARING PROTECTION
WITHIN 12 FEET OF AN OPERATING DPGDS. EXPOSURE MUST BE LIMITED TO
UNDER 2.5 HOURS.

CAUTION

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

CAUTION

SETTING THE DESIRED LOAD ON THE ORT FOR A UTILITY PARALLEL PLANT TO
A VALUE THAT CAUSES THE PLANT OUTPUT TO REDUCE THE LOAD ON A
PARALLELED PRIME POWER PLANT BELOW ECONOMIZER SETTINGS WILL
CAUSE PRIME POWER PLANT GENERATORS TO SHUT DOWN.

Operating one PU utility parallel power plant with another PU power plant should be done with the PUs
operating in automatic mode. This provides the operator with control over the amount of load the
generators will carry. Operating PUs in manual in the Utility Parallel Mode limits the units to carrying only
25KW per generator. The PUs can be started and put online manually, but should be operated
automatically using an ORT.

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5.10.2.4.2 MANUAL MODE

Use Section 5.5.4 (Starting up a Multi-PU Prime Power Plant in Manual Mode) procedure 2.5 to start the
plant manually. Use Section 5.9.6.12 to change the units to Auto Mode to allow changing the load.

5.10.2.4.3 AUTOMATIC MODE

WARNING

ONCE THE SYSTEM STATUS LIGHTS TURN GREEN AND THE MSES IS ENABLED,
THE PU WILL START. ENSURE PERSONNEL ARE CLEAR OF THE PU.

WARNING

ONLY ONE PU MAY BE SELECTED TO ANY ONE USS POSITION DURING MULTIPLE
PU OPERATIONS. OPERATING WITH MORE THAN ONE UNIT AT THE SAME ID
CAUSE UNSAFE AND ERRATIC OPERATIONAL CONDITIONS.

Starting up a Multi-PU in Utility Parallel Plant in Automatic Mode

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

TABLE 5.10.2.4.3-1
SWITCH SETUP – AUTOMATIC MODE
PANEL SWITCH 1ST PU 2ND PU 3RD PU 4TH PU
BCS-T Red Target Red Target Red Target Red Target
MASTER CONTROL PANEL
MCP
SMS AUTO③ AUTO③ AUTO③ AUTO③
USS A B C D
GENERATOR CONTROL BCS-G1 Red Target Red Target Red Target Red Target
PANEL 1 GCPG1 ECS-1 AUTO AUTO AUTO AUTO
GENERATOR CONTROL BCS-G2 Red Target Red Target Red Target Red Target
PANEL 2 GCPG2 ECS-2 AUTO AUTO AUTO AUTO
MASTER CONTROL PANEL MSES Enable① Enable① Enable① Enable①
MCP USI A①, ② B①, ② C① , ② D① , ②

① Hold the MSES in an ENABLE position until the selected USI indicator energizes. The switch
returns to the center position when released. This sets the PU networking address and enables
the control and monitoring.
② No more than one of each indicator can be on for multi-PU operations. The light on should match
USS position. The USI light will de-energize after the SMS has been in OFF for 3 seconds.
③ With the SMS in AUTO any generator started, manually or automatically, will automatically
parallel to the bus. To prevent the generator from paralleling to the bus put the generator’s
breaker in the Pull-To-Lock position.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

u. Observe that each generator assumes 25KW when it parallels to the bus.

v. From the ORT, set the desired load for each generator to carry. The load value shown on the
ORT is on a per generator basis.

w. At the external switchgear, close load connections to supply power to the loads.

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x. Ensure generators have assumed load. After the load has stabilized, proceed with the following if
necessary:

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

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

CAUTION
Improper adjustment of the VAR can cause a reverse KVAR shutdown of a generator.
NOTE: The automatic economizing feature is disabled while a generator is operating in Utility
Parallel mode.

5.10.2.4 PLANT OPERATIONS

The power plant must be in Auto Mode to be operated remotely or adjust the load on the generators.

5.10.2.5 POWER PLANT TEARDOWN (PLANT 1 & PLANT 2)

5.10.2.5.1 SHUT DOWN GENERATORS

a. Ensure there is sufficient Plant 1 generator capacity online to carry the combined Plant 1 and
Plant 2 load.

b. Unload all Plant 2 generators using the Plant 2 ORT.

c. Open each Plant 2 generator breaker from the ORT or locally from its respective LCP.

d. Place each Plant 2 PU in manual by placing its respective SMS in MANUAL without stopping in
OFF.

e. Open each Plant 2 tie breaker locally at the respective MCP.

f. Place all Plant 2 generators in cooldown by placing all Plant 2 SMS switches in OFF.

g. Allow all Plant 2 engines to complete cooldown and shutdown (5 minutes).

h. Place all Plant 2 ECS switches in OFF/RESET.

i. Pull out the DC Control Power breaker on all Plant 2 PUs.

j. Unload all Plant 1 generators by opening all load breakers, either at the external switchgear or at
the PU if the PU feeder breakers are used.

k. Place each Plant 1 PU in manual by placing its respective SMS in MANUAL without stopping in
OFF.

l. Open each Plant 1 tie breaker locally at the respective MCP.

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m. Place all Plant 1 generators in cooldown by placing all SMS switches to OFF.

n. Observe all generator breakers open.

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

p. Place all ECS switches in OFF/RESET.

q. Pull out the DC Control Power breaker on all PUs.

r. Open all the external switchgear generator disconnect switches for Plant 1 and Plant 2.

5.10.2.5.2 DISCONNECT CABLES

WARNING

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

CAUTION

ALLOW ALL OPERATING ENGINES TO SHUT DOWN AND COOL DOWN


COMPLETELY.

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

b. Disconnect the ORT cable and store it in the ORT case.

c. Close and latch the ORT port on the PU.

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

5.10.2.5.3 DISCONNECT FUEL LINES

a. Turn all fuel system valves to the off position.

b. Disconnect the fuel hose from the PU fuel connection and the fuel supply.

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

5.10.2.5.4 DISCONNECT GROUNDING

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

b. Disconnect the parking stations from the ground grid.

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

5.10.2.5.5 PREPARE PU FOR TRANSPORTATION

a. Reinstall the four radiator splashguards (PU-810B only).

b. Verify DC Control power is off.

c. Close and lock the LCP access doors.

d. Close and lock all PU side doors.

5.10.2.5.6 FUEL, OIL, AND COOLANT DRAINAGE

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

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THIS PAGE INTENTIONALLY BLANK

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CHAPTER 5.11
OPERATING INSTRUCTIONS

TWO-PLANT, MULTIPLE PU, PRIME POWER, EXTERNAL SWITCH,


AUTOMATIC MODE
TABLE OF CONTENTS
SECTION TITLE PAGE
5.11 TWO-PLANT, MULTIPLE PU, PRIME POWER, EXTERNAL SWITCH,

AUTOMATIC MODE ..................................................................................................293

5.11.1 SAFETY PROCEDURES ...........................................................................................293

5.11.2 POSITIONING THE PU ..............................................................................................293

5.11.3 INITIAL PLANT SETUP .............................................................................................294

5.11.3.1 GROUNDING .............................................................................................................294

5.11.3.2 FUEL MANIFOLD ......................................................................................................296

5.11.3.3 DISTRIBUTION AND CONTROL CABLING .............................................................297

5.11.3.4 SETPOINT VERIFICATION .......................................................................................290

5.11.3.5 PRE-OPERATION CHECKS .....................................................................................304

5.11.3.6 PSC RELAY SETTING VERIFICATION ....................................................................306

5.11.3.7 PRE-OPERATION RUN .............................................................................................308

5.11.3.8 CONTROLS SETUP...................................................................................................310

5.11.3.8.1 PLANT ONE ...............................................................................................................310

5.11.3.8.2 PLANT TWO ..............................................................................................................310

5.11.3.9 ORT SETUP ...............................................................................................................311

5.11.3.9.1 PLANT ONE ...............................................................................................................311

5.11.3.9.2 PLANT TWO ..............................................................................................................312

5.11.4 PLANT STARTUP......................................................................................................312

5.11.5 PLANT OPERATIONS (AUTOMATIC MODE) ..........................................................315

5.11.5.1 PRECAUTIONS AND WARNINGS............................................................................315

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5.11.5.2 DESCRIPTION ...........................................................................................................315

5.11.6 POWER PLANT TEARDOWN...................................................................................315

5.11.6.1 SHUT DOWN GENERATORS ...................................................................................315

5.11.6.2 DISCONNECT CABLES ............................................................................................316

5.11.6.3 DISCONNECT FUEL LINES......................................................................................316

5.11.6.4 DISCONNECT GROUNDING ....................................................................................316

5.11.6.5 PREPARE PU FOR TRANSPORTATION .................................................................317

5.11.6.6 FUEL, OIL, AND COOLANT DRAINAGE .................................................................317

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LIST OF FIGURES
FIGURE TITLE PAGE
FIGURE 5.11.3.1-1 MEP-PU-810A GROUND POINTS 295

FIGURE 5.11.3.1-2 MEP-PU-810B GROUND POINTS 295

FIGURE 5.11.3.2-1 EXTERNAL FUEL SUPPLY, TYPICAL FOR EACH 4 PU PLANT 296

FIGURE 5.11.3.3-1 TWO-PLANT LAYOUT DIAGRAM 298

FIGURE 5.11.3.3-2 PLANT EXPANSION ADAPTER 299

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LIST OF TABLES
TABLE TITLE PAGE
TABLE 5.11.3.4-1 CT RATIO SETTINGS 290

TABLE 5.11.3.4-2 INSTANTANEOUS TRIP SETTINGS 290

TABLE 5.11.3.4-3 TIME OVERCURRENT TRIP SETTINGS 291

TABLE 5.11.3.4-4 OP5-0 SETPOINTS 293

TABLE 5.11.3.4-4 OP5-0 SETPOINTS (CONTINUED) 294

TABLE 5.11.3.4-5 OP5-1 SETPOINTS 296

TABLE 5.11.3.4-5 OP5-1 SETPOINTS (CONTINUED) 297

TABLE 5.11.3.4-5 OP5-1 SETPOINTS (CONTINUED) 298

TABLE 5.11.3.4-6 OP6 SETPOINTS 299

TABLE 5.11.3.4-6 OP6 SETPOINTS (CONTINUED) 300

TABLE 5.11.3.4-7 AVR PARAMETERS/SETPOINTS 301

TABLE 5.11.3.4-7 AVR PARAMETERS/SETPOINTS (CONTINUED) 302

TABLE 5.11.3.5-1 PRE-OPERATION CHECKLIST 304

TABLE 5.11.3.5-1 PRE-OPERATION CHECKLIST (CONTINUED) 305

TABLE 5.11.3.6-1 PSC RELAY SETTINGS 307

TABLE 5.11.3.7-1 PRE-OPERATION RUN INSTRUCTION SEQUENCE 309

TABLE 5.11.3.8-1 PDC CONTROL SWITCH SETUP 310

TABLE 5.11.3.8-2 PDC CONTROL SWITCH SETUP 311

TABLE 5.11.4-1 SWITCH SETUP (EACH PLANT) – AUTOMATIC MODE 313

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5.11 TWO-PLANT, MULTIPLE PU, PRIME POWER, EXTERNAL SWITCH,


AUTOMATIC MODE

5.11.1 SAFETY PROCEDURES

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

• Hot engine parts


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

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

5.11.2 POSITIONING THE PU

a. Position the PU in such a way as to allow the plant operator to have full vision of the operator
control panels on the unit.

b. Level the MEP-PU-810B front to rear with the trailer leveling hand crank.

c. Position the PU to provide a minimum of 10 feet of clearance for maintenance access on all
sides of each unit. Ensure that there are no overhead obstructions around the exhaust outlets.

WARNING

FUEL SPILLAGE CAN OCCUR IF THE POWER UNIT LEVEL IS GREATER THAN + 5
DEGREES.

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

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5.11.3 INITIAL PLANT SETUP

5.11.3.1 GROUNDING

a. Drive an 8-foot ground rod into the earth. It should be within 6 feet of the PU and at a location
that minimizes the tripping hazard, until only 6 inches (15 cm) protrudes above the surface.

b. Repeat step “a” for each PU being used.

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

d. Using a #2 AWG copper conductor, secure one end of a ground cable to one of the slotted
ground studs on the PU, see Figure 5.11.3.1-1 or Figure 5.11.3.1-2. Secure the other end of the
ground cable to the ground rod.

e. Repeat step “d” for every PU.

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

g. Remove parking stand plates from their transportation positions inside each rear, side PU door
and slide them into their respective operating positions on the sides of the PDC.

h. Connect the parking stand ground wires to either of the two chassis ground lugs on the PU.

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GROUND POINT GROUND POINT

FIGURE 5.11.3.1-1 MEP-PU-810A GROUND POINTS

NOTE: Connect only one ground point to the ground grid.

GROUND POINT GROUND POINT

FIGURE 5.11.3.1-2 MEP-PU-810B GROUND POINTS

NOTE: Connect only one ground point to the ground grid.

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5.11.3.2 FUEL MANIFOLD

WARNING

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

a. Lay out the fuel hoses between the PU, the fuel manifold, and the fuel bladders to establish the
fuel supply system see. Figure 5.11.3.2-1. This is a typical set-up for each 4 PU plant.

b. Install the external fuel hose for the PU to the Fuel Transfer Pump at the Tow end of the PU.

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

d. Connect the 3” hose, with quick-disconnect hose ends, from the fuel manifold to the fuel
bladders.

e. Connect the fuel manifold ground wire to the ground grid.

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

FIGURE 5.11.3.2-1 EXTERNAL FUEL SUPPLY, TYPICAL FOR EACH 4 PU PLANT

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5.11.3.3 DISTRIBUTION AND CONTROL CABLING

WARNING

DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS


OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A
SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET
IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT
FROM FAILURE TO OBSERVE THIS WARNING.

WARNING

HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT


DURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION
AND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN
LOAD CABLES ARE HANDLED.

WARNING

VERIFY THAT CONNECTION POINTS ARE DE-ENERGIZED BEFORE MAKING ANY


CONNECTIONS. FAILURE TO CHECK THAT CONNECTORS ARE DE-ENERGIZED
MAY RESULT IN INJURY OR DEATH.

a. Lay out and park the load cables for each phase (A, B, & C) on the PU Tie Output parking
stations on all PUs.

b. Connect each phase cable to the appropriate phase connection on the Primary Switching Center
(PSC). Refer to Figure 5.11.3.3-1 for Two-Plant and PSC layout diagram

c. Connect each load cables drain wire to the grounding grid.

d. Open the Tie Output connector loadbreak covers on the first PU.

e. Connect the Tie Output Cables to the appropriate phase connectors; ensure there are no cross-
phase connections.

f. Close and lock the Tie Output connector covers.

g. Repeat steps ‘b’ through ‘f’ on each remaining PU.

h. Connect communication cables to each PU

i. Install the Multi-Plant Expansion Adapter between plant 1 D unit and plant 2 A unit (See figure
5.11.3.3-2). The Adapter is stored inside the PDC of the PU behind the door rails. Ensure that D
unit on plant two has the second communication cable installed and the loose end is capped.

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FIGURE 5.11.3.3-1

ORT ORT

PLANT 1 PLANT 2
Plant Expansion
A B C D Adapter A B C D
G1 G2 G1 G2 G1 G2 G1 G2 G1 G2 G1 G2 G1 G2 G1 G2

52G1 52G2 52G1 52G2 52G1 52G2 52G1 52G2 52G1 52G2 52G1 52G2 52G1 52G2 52G1 52G2

52F1 52F1 52F1 52F1 52F1 52F1 52F1 52F1

52F2 52T 52F2 52T 52F2 52T 52F2 52T 52F2 52T 52F2 52T 52F2 52T 52F2 52T
TWO-PLANT LAYOUT DIAGRAM
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PSC 1 PSC 2
PSC 3 PSC 4

DRS RADIAN CTM 01646.1R0253/1R0254


6 5 4 3 2 1
6 5 4 3 2 1

6 5 4 3 2 6 5 4 3 2 1
1

LOAD
LOAD LOAD
LOAD

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Multi-Plant Multi-Plant Adapter


Expansion Storage Location
Adapter Installed (Behind Door)

FIGURE 5.11.3.3-2 PLANT EXPANSION ADAPTER

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5.11.3.4 SETPOINT VERIFICATION

a. Turn on PU DC control power by pushing in on the DC Control Power breaker.

b. On each of the five overcurrent relays, verify the settings:

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

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

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

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

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

(6) Verify the “P” and “N” values match the following table:

TABLE 5.11.3.4-1 CT RATIO SETTINGS


BREAKER RELAY CT RATIO “P” VALUE “N” VALUE
GENERATOR 100:5 20 20
FEEDER 200:5 40 40
TIE 200:5 40 40

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


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

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

(10) Verify the 50TP “PU” and “TD” settings in Table 5.11.3.4-2. In order to edit values, Press
the “Edit” key. Select correct value, and press “Edit” again to save changes. Ensure
light is off otherwise you can accidentally change value again.

TABLE 5.11.3.4-2 INSTANTANEOUS TRIP SETTINGS


PHASE NEUTRAL NEGATIVE SEQUENCE
INSTANTANEOUS INSTANTANEOUS TRIP
BREAKER RELAY
TRIP 50TP TRIP 50TN 50 TQ
PU TD PU TD PU TD
GENERATOR 0.0 0m 3.0 0m 3.0 0m
FEEDER 7.5 84m 1.25 84m 0 0m
TIE 0.0 0m 0 0m 0.0 0m

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

(12) Verify the “50TN” settings in Table 5.11.3.4-2.

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

(14) Verify the “50TQ” settings

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

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

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

(18) Verify the 51P “PU”, “TD”, and “C” settings in Table 5.11.3.4-3.

TABLE 5.11.3.4-3 TIME OVERCURRENT TRIP SETTINGS


PHASE TIME OVERCURRENT NEUTRAL TIME OVERCURRENT
BREAKER RELAY TRIP 51P TRIP 51N
PU TD C PU TD C
GENERATOR 4.50 0.5 VV2 1.25 0.5 VV2
FEEDER 2.50 1.0 VV2 1.00 1.0 VV2
TIE 5.00 2.0 VV2 1.50 2.0 VV2

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

(20) Verify the “51N” settings in Table 5.11.3.4-3.

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

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

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

(1) Place ECS in the COOLDOWN/STOP position.

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

(3) Press SCROLL UP key until “OP3” is showing.

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

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

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

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

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

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

(10) Press ENTER key. “PE PASS” is showing.

(11) Press EXIT key. “OP4” is showing.

(12) Press SCROLL UP key until “OP5-0” is showing on the lower display.

(13) Press SELECT key. “POO1” followed with the value of the setpoint is showing.

(14) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing.
Use Table 5.11.3.4-4 for the parameter values to be verified. Repeat until the desired
setpoints are verified.

(15) Press EXIT key. “OP5-0” is showing on the lower display.

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(16) Press SCROLL UP key until “OP5-1” is showing.

(17) Press SELECT key.

(18) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing.
Use Table 5.11.3.4-5 OP5-1 Setpoints for the parameter values to be verified. Repeat until
all the desired setpoints are verified.

(19) Press EXIT key. “OP5-1” is showing.

(20) Press SCROLL UP key until “OP6” is showing.

(21) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing.
Use “OP6” Setpoints, Table 5.11.3.4-6 for the parameter values to be verified. Repeat until
all the desired setpoints are verified.

(22) Press EXIT Key twice. The display returns to normal.

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

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

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

(c) Press ENTER. The correct value stops flashing on the display.

(d) Press SCROLL UP or SCROLL DOWN key to continue to verify the remaining
parameter values.
d. At GSC G1 and GSC G2, verify the operation settings using the following table:

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TABLE 5.11.3.4-4 OP5-0 SETPOINTS


SETPOINTS OP5-0 ENGINE/GENERATOR PROGRAMMING①
FACTORY DPGDS
SETPOINT-NAME-DESCRIPTIONS RANGE OF VALUES
DEFAULT SETPOINT
P001 - Fuel Solenoid Type: type of fuel system solenoid 0- ETR fuel solenoid
0 0
used on the genset. 1- ETS fuel solenoid
P002 - Units Shown: type of measurement units shown 0-for English units (PSI, ºF)
0 0
on the GSC+ display. 1-for metric units (kPa, ºC).
P003 - Shutdown Override For Engine Fault: GSC+ 0-for engine shutdown
response to a low engine oil pressure or high coolant 1-for alarm only (shutdown override, no 0 0
temperature fault. engine shutdown).
P004 - Shutdown Override For Sensor Fault: GSC+ 0-for alarm only shutdown override, no
response to a diagnostic fault with the engine oil pressure engine shutdown). 0 0
sensor, coolant temperature sensor, oil temperature
sensor, sensor power supply or coolant loss sensor. 1-for engine shutdown.

P005 - Coolant Loss Sensor Installed: tells whether or 0-for gensets without a coolant loss sensor
not the optional engine coolant loss sensor is installed on 0 1
the genset. 1-for gensets with coolant loss sensor

0-for engine shutdown.


P006 - Shutdown Override For Coolant Loss Fault:
1-for alarm only (shutdown override, no 0 0
GSC+ response to an engine coolant loss fault.
engine shutdown).
P007 - System Voltage, 24 Or 32 Volts: system voltage
24 or 32. 24 24
(battery voltage) of the genset.
P008 - This setpoint is not currently being used by the
N/A N/A N/A
GSC+ and cannot be programmed.
P009 - Number Of Ring Gear Teeth: number of teeth on
the ring gear of the engine. Used by the GSC+ to 95 to 350 teeth in increments of one tooth. 136 teeth 136 teeth
determine engine speed.
P010 - Engine Overspeed: engine speed used by the
GSC+ to declare that an engine overspeed fault exists.
500 to 4330 rpm in increments of 10 rpm. 2120 rpm 2120 rpm
The engine overspeed setpoint (for all 60 Hz applications)
is 1.18 times the rated speed.
P011 - Crank Terminate Speed: engine speed used by
the GSC+ to disengage the starting motor during engine 100 to 1000 rpm in increments of 10 rpm. 400 rpm 400 rpm
cranking.
P012 - Oil Step Speed: engine speed used by the GSC+
for distinguishing between rated speed and idle speed 400 to 1800 rpm in increments of 10 rpm. 1350 rpm 1350 rpm
when a low oil pressure fault exists.

P013② - Low Oil Pressure Shutdown At Rated Speed:


oil pressure used by the GSC+ to declare that a low oil 30 PSI 30 PSI
pressure shutdown fault exists with engine at rated speed 5 to 61PSI (34 to 420kPa) in increments of 1
(205 kPa) (205 kPa)
(the engine speed must have exceeded the oil step speed
for nine seconds).

P014② - Low Oil Pressure Shutdown At Idle Speed:


oil pressure used by the GSC+ to declare that a low oil
10 PSI 10 PSI
pressure shutdown fault exists with the engine at idle 20 to 336kPa (3 to 49PSI) in increments of 1
speed (the engine must have been running for at least 9 (70 kPa) (70 kPa)
seconds and the engine speed must be less than oil step
speed).

P015③ - High Water Temperature Shutdown: coolant


185 to 253ºF (85 to 123ºC) in increments of 225ºF 225ºF
temperature used by the GSC+ to declare a high coolant
temperature shutdown fault exists (after a 10 second 1 (107ºC) (107ºC)
delay).
P016 - Low Water Temperature Alarm: coolant
temperature used by the GSC+ to declare that a low 70ºF 70ºF
32 to 97ºF (0 to 36ºC) in increments of 1
coolant temperature alarm fault exists (after a 2 second (21ºC) (21ºC)
delay).

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TABLE 5.11.3.4-4 OP5-0 SETPOINTS (CONTINUED)


SETPOINTS OP5-0 ENGINE/GENERATOR PROGRAMMING①
FACTORY DPGDS
SETPOINT-NAME-DESCRIPTIONS RANGE OF VALUES
DEFAULT SETPOINT
P017 - Total Cycle Crank Time: cycle crank time used by the 5 to 120 seconds in increments of 1
90 seconds 90 seconds
GSC+ to declare that an overcrank fault exists. second.
P018 - Cycle Crank Time: amount of time the GSC+ cranks 5 to 60 seconds in increments of 1
10 seconds 10 seconds
and then rests the starting motor during a single crank cycle. second.
P019 - Cooldown Time: amount of time the GSC+ allows the 0 to 30 minutes in increments of 1
5 minutes 5 minutes
engine to run after a normal shutdown is initiated. minute.

P020④ - AC Voltage: nominal AC voltage of the generator. 700, 150, 300, 500, 600, 750, 3.0k,
The GSC+ measures the AC voltage and shows it on the 4.5k, 5.20k, 5.25k, 9.0k, 15.0k, 18.0k, 700 5.20k
display. 30.0k
P021 - AC Current Full Scale: nominal full scale AC current 75, 100, 150, 200, 300, 400, 600, 800,
of the generator. AC current full scale is equal to the ratio of 1000, 1200, 1500, 2000, 2500, 3000, 600A 100A
the external current transformers in the generator housing. and 4000A

P022⑤ - GSC+ Engine Number: informs other devices on


01 (Gen 1)
01 through 08 01
the CAT Data Link of the engine number for the GSC+. 02 (Gen 2)

SETPOINTS - OP5-0-ENGINE/GENERATOR PROGRAMMING①


RANGE OF FACTORY 60HZ 50HZ
SETPOINT-NAME-DESCRIPTIONS
VALUES DEFAULT SETPOINT SETPOINT
P023 - Engine Type: identifies the engine as a 0 - MUI diesel
mechanical unit injector (MUI) diesel, spark
1 - Gas 0 2 2
ignited (gas), or electronic unit injector (EUI)
diesel engine. 2 - EUI diesel
P024 - Crank Time Delay: amount of time the
GSC+ delays activation of the fuel control relay
(FCR) during a crank cycle. This setpoint is for 0 to 20 seconds in increments of 1
5 Seconds 5 Seconds 5 Seconds
Gas engines only. The P024 setpoint only second.
functions when the P023 setpoint is set to 1 (gas
engine).
0 - for gensets without an oil
P025 - Oil Temperature Sensor Installed: tells temperature sensor
whether or not the optional engine oil temperature 0 0 0
sensor is installed on the genset. 1 - for gensets with an oil
temperature sensor
P026 - High Oil Temperature Shutdown: oil
temperature used by the GSC+ to declare a high 185 to 253ºF (85 to 123ºC) in
225ºF (107ºC) 225ºF (107ºC) 225ºF (107ºC)
oil temperature shutdown fault exists (after a 10 increments of 1
second delay). Refer to the panel model number.
P027 - Shutdown Override For High Oil 0 - for alarm only (shutdown override,
Temperature Fault: GSC+ response to an engine no engine shutdown). 0 0 0
high oil temperature fault. 1 - for engine shutdown.
P028 - Nameplate Voltage: rated voltage of the
generator. This setpoint is used for protective 100 to 25kV in increments of 1 480V 4160V 3800V
relaying functions.
P029 - Nameplate Current: rated current output
0 to 4000 A in increments of 1 600A 80A 73A
of the generator.
P030 - Nameplate Power: rated power capability 0 through 10MW in increments of
400kW 420kW 350kW
of the generator. 1kW.
P031 - Rated Frequency: nominal frequency
50 or 60Hz 60Hz 60Hz 50Hz
rating of genset.
P032 - Connection Configuration Of Generator: 0 - wye
0 0 0
wye or delta configuration of generator. 1 - delta
P033 - Number Of Generator Poles. 0 through 254 in increments of 2. 4 4 4

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① The setpoints (stored or being programmed) must match the specified DPGDS setpoints.
② When oil pressure drops to within 5PSI (34kPa) of the P013 or P014 setpoint, a low oil pressure alarm
is issued by the GSC+.
③ When coolant temperature rises to within 11ºF (6ºC) of the P015 setpoint, a high coolant temperature
alarm is issued by the GSC+.
④ The values other than the default (700V) are for switchgear applications and require the use of external
potential transformers and the removal of the AC voltage range jumper located in the relay module.
The DPGDS unit is factory configured for the 5.20 K value. See the Caterpillar Electronic Modular
Control Panel II+ manual topic AC Voltage Range Selection in the Testing and Adjusting section.
⑤ After setpoint P022 is reprogrammed, the GSC+ must be power cycled (powered down and then
powered up)

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TABLE 5.11.3.4-5 OP5-1 SETPOINTS


SETPOINTS OP5-1 PROTECTIVE RELAYING PROGRAMMING①
FACTORY 60HZ 50HZ
SETPOINT-NAME-DESCRIPTION RANGE OF VALUES
DEFAULT SETPOINT SETPOINT
P101 - Generator Overvoltage Alarm Enable: the 0 - disabled
GSC+ enables or disables the generator 1 1 1
overvoltage alarm function. 1 - enabled
P102 - Generator Overvoltage Alarm Threshold:
100 to 125% of nameplate voltage in
voltage the GSC+ uses to issue an overvoltage 105% 105% 105%
increments of 1%.
alarm.
P103 - Generator Overvoltage Alarm Time Delay:
amount of time the GSC+ waits before issuing an 0 through 120 seconds② in increments 10 seconds 10 seconds 10 seconds
overvoltage alarm. of 1
P104 - Generator Overvoltage Shutdown Enable: 0 - disabled
the GSC+ enables or disables the generator 1 1 1
overvoltage shutdown function. 1 - enabled
P105 - Generator Overvoltage Shutdown
100 to 125% of nameplate voltage in
Threshold: voltage the GSC+ uses to issue an 110% 110% 110%
increments of 1%.
overvoltage shutdown.
P106 - Generator Overvoltage Shutdown Time
Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments 10 seconds 10 seconds 10 seconds
issuing an overvoltage shutdown. of 1
P107 - Generator Undervoltage Alarm Enable: 0 - disabled
the GSC+ enables or disables the generator 1 1 1
undervoltage alarm function. 1 - enabled
P108 - Generator Undervoltage Alarm
60 to 100% of nameplate voltage in
Threshold: voltage the GSC+ uses to issue an 90% 90% 90%
increments of 1%.
undervoltage alarm.
P109 - Generator Undervoltage Alarm Time
Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments 10 seconds 10 seconds 10 seconds
issuing an undervoltage alarm. of 1
P110 - Generator Undervoltage Shutdown 0 - disabled
Enable: the GSC+ enables or disables the 1 1 1
generator undervoltage shutdown function. 1 - enabled
P111 - Generator Undervoltage Shutdown
60 through 100% of rated voltage in
Threshold: voltage the GSC+ uses to issue an 85% 85% 85%
increments of 1%.
undervoltage shutdown.
P112 - Generator Undervoltage Shutdown Time
Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments 15 seconds 03 seconds 03 seconds
issuing an undervoltage shutdown. of 1
P113 - Generator Overfrequency Alarm Enable: 0 - disabled
the GSC+ enables or disables the generator 1 1 1
overfrequency alarm function. 1 - enabled

P114 - Generator Overfrequency Alarm 50-60Hz, for 50Hz Gen 53Hz


Threshold: frequency the GSC+ uses to issue an 60-70Hz, for 60Hz Gen 63Hz 63 Hz 53 Hz
overfrequency alarm. 400-480, for 400Hz Gen 422Hz
P115 - Generator Overfrequency Alarm Time
Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments 10 seconds 10 seconds 10 seconds
issuing an overfrequency alarm. of 1
P116 - Generator Overfrequency Shutdown 0 - disabled
Enable: the GSC+ enables or disables the 1 1 1
generator overfrequency shutdown function. 1 - enabled

P117 - Generator Overfrequency Shutdown 50-60Hz, for 50Hz Gen 55Hz


Threshold: frequency the GSC+ uses to issue an 60-70Hz, for 60Hz Gen 66Hz 66Hz 55Hz
overfrequency shutdown. 400-480, for 400Hz Gen 440Hz

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TABLE 5.11.3.4-5 OP5-1 SETPOINTS (CONTINUED)
SETPOINTS OP5-1 PROTECTIVE RELAYING PROGRAMMING①
FACTORY 60HZ 50HZ
SETPOINT-NAME-DESCRIPTION RANGE OF VALUES
DEFAULT SETPOINT SETPOINT
P118 - Generator Overfrequency Shutdown Time
Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments 10 seconds 10 seconds 10 seconds
issuing an overfrequency shutdown. of 1
P119 - Generator Underfrequency Alarm Enable: 0 - disabled
the GSC+ enables or disables the generator 1 1 1
underfrequency alarm function. 1 - enabled

P120 - Generator Underfrequency Alarm 30-50Hz, for 50Hz Gen 48Hz


Threshold: frequency the GSC+ uses to issue an 36-60Hz, for 60Hz Gen 57Hz 57Hz 48Hz
underfrequency alarm. 240-400, for 400Hz Gen 378Hz
P121 - Generator Underfrequency Alarm Time
Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments 10 seconds 10 seconds 10 seconds
issuing an underfrequency alarm. of 1
P122 - Generator Underfrequency Shutdown 0 - disabled
Enable: the GSC+ enables or disables the generator 1 1 1
underfrequency shutdown function. 1 - enabled

P123 - Generator Underfrequency Shutdown 30-50Hz, for 50Hz Gen 45Hz


Threshold: frequency the GSC+ uses to issue an 36-60Hz, for 60Hz Gen 54Hz 54Hz 45Hz
underfrequency shutdown. 240-400, for 400Hz Gen 360Hz
P124 - Generator Underfrequency Shutdown
Time Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments 15 seconds 03 seconds 03 seconds
issuing an underfrequency shutdown. of 1
P125 - Generator Reverse Power Shutdown 0 - disabled
Enable: the GSC+ enables or disables the generator 1 1 1
reverse power shutdown function. 1 - enabled
P126 - Generator Reverse Power Shutdown
0 through 20% of rated power in
Threshold: level of reverse power the GSC+ uses to 15% 4% 4%
increments of 1%.
issue a reverse power shutdown.
P127 - Generator Reverse Power Shutdown Time
Delay: amount of time the GSC+ waits before 0 through 30 seconds② in increments 10 seconds 4 seconds 4 seconds
issuing a reverse power shutdown. of 1
P128 - Generator Overcurrent Alarm Enable: the 0 - disabled
1 1 1
GSC+ enables or disables the overcurrent alarm. 1 - enabled
P129 - Generator Phase Overcurrent Alarm
100 through 160% of nameplate current
Threshold: level of current the GSC+ uses to issue a 105% 150% 150%
in increments of 5%
phase overcurrent alarm.
P130 - Generator Phase Overcurrent Alarm Time
Delay: amount of time the GSC+ waits before 0 through 250 seconds② in increments 0 seconds 0 seconds 0 seconds
issuing a phase overcurrent alarm. of 1
P131 - Generator Total Overcurrent Alarm
100 through 160% of three times
Threshold: level of current the GSC+ uses to issue a 105% 150%. 150%
nameplate current in increments of 5%
total overcurrent alarm.
P132 - Generator Total Overcurrent Alarm Time
Delay: amount of time the GSC+ waits before 0 through 250 seconds② in increments 0 seconds 0 seconds 0 seconds
issuing a total overcurrent alarm. of 1
P133 – Generator Overcurrent Shutdown Enable: 0 – disabled
the GSC+ enables or disables the overcurrent 1 1 1
shutdown. 1 – enabled
P134 – Generator Phase Overcurrent Shutdown
100 through 160% in increments of 5%
Threshold: level of current the 110% 150% 150%
GSC+ uses to issue a phase overcurrent shutdown.
P135 – Generator Phase Overcurrent Shutdown
Time Delay: amount of time the GSC+ waits before 0 through 250 seconds② in increments 0 seconds 10 seconds 10 seconds
issuing a phase overcurrent shutdown. of 1

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TABLE 5.11.3.4-5 OP5-1 SETPOINTS (CONTINUED)


SETPOINTS OP5-1 PROTECTIVE RELAYING PROGRAMMING①
FACTORY 60HZ 50HZ
SETPOINT-NAME-DESCRIPTION RANGE OF VALUES
DEFAULT SETPOINT SETPOINT
P136 - Generator Total Overcurrent
Shutdown Threshold: level of current the 100 through 160% of three times
110% 150%. 150%
GSC+ uses to issue a total overcurrent nameplate current in increments of 5%
shutdown.
P137 - Generator Total Overcurrent
Shutdown Time Delay: amount of time the 0 through 250 seconds② in increments 0 seconds 10 seconds 10 seconds
GSC+ waits before issuing a total overcurrent of 1
shutdown.
P138 - KW Level Relay Enable : the GSC+ 0 - disabled
1 1 1
enables or disables the kW level relay function. 1 - enabled
P139 - KW Level Relay Threshold: level of
0 through 110% of nameplate power in
power the GSC+ uses to activate the kW level 105% 105% 105%
increments of 1%
relay function.
P140 - KW Level Relay Time Delay: amount of
time the GSC+ waits before activating the kW 0 through 120 seconds② in increments 0 seconds 0 seconds 0 seconds
level relay function. of 1
P141 - KW Level Relay Disengage
0 through 110% of nameplate power in
Threshold: level of power the GSC+ uses to 100% 100% 100%
increments of 1%.
deactivate the kW level relay function.
P142 - KW Level Relay Disengage Time
Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments 10 seconds 10 seconds 10 seconds
deactivating the kW level relay function. of 1

① The setpoints are programmed at the factory to the default value.


② When programmed to 0 seconds, the actual time is from 0.5 to 1.0 seconds.

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TABLE 5.11.3.4-6 OP6 SETPOINTS


SETPOINTS OP6 SPARE INPUT/OUTPUT PROGRAMMING
FACTORY DPGDS
SETPOINT-NAME-DESCRIPTIONS RANGE OF VALUES
DEFAULT SETPOINT
SP01 - Spare Input 1 Active State. Input state used by the 0-active low
0 0
GSC+ to declare a SP1 fault exists. 1-active high
SP02 - Spare Input 1 Response: GSC+ response to a SP1 0-shutdown
0 0
fault. 1-alarm
SP03 - Spare Input 1 Time Delay: Amount of time the GSC+
0 - 250 seconds in increments of 1 0 seconds 1 second
waits before responding to a SP1 fault.
SP04 - Spare Input 2 Active State. Input state used by the 0-active low
0 1
GSC+ to declare a SP2 fault exists. 1-active high
SP05 - Spare Input 2 Response: GSC+ response to a SP2 0-shutdown
0 0
fault. 1-alarm
SP06 - Spare Input 2 Time Delay: Amount of time the GSC+
0 - 250 seconds in increments of 1 0 seconds 0 seconds
waits before responding to a SP2 fault.
SP07 - Spare Input 3 Active State. Input state used by the 0-active low
0 0
GSC+ to declare a SP3 fault exists. 1-active high
SP08 - Spare Input 3 Response: GSC+ response to a SP3 0-shutdown
0 0
fault. 1-alarm
SP09 - Spare Input 3 Time Delay: Amount of time the GSC+
0 - 250 seconds in increments of 1 0 seconds 0 seconds
waits before responding to a SP3 fault.
SP10 - Spare Input 4 Active State. Input state used by the 0-active low
0 0
GSC+ to declare a SP4 fault exists. 1-active high
SP11 - Spare Input 4 Response: GSC+ response to a SP4 0-shutdown
0 0
fault. 1-alarm
SP12 - Spare Input 4 Time Delay: Amount of time the GSC+
0 - 250 seconds in increments of 1 0 seconds 0 seconds
waits before responding to a SP4 fault.
SP13 - Spare Output Response: GSC+ response to the spare 0-active low
0 0
output trigger condition. 1-active high
0-unused

1-active SP1 fault②

2-active SP2 fault②

3-active SP3 fault②

4-active SP4 fault②


SP14 - Spare Output Trigger Condition: The condition used
5-any combination of active SP faults②
8 8
by the GSC+ to trigger the spare output response
6-any active shutdown
7-any active alarm or shutdown
8-cooldown mode

9-coolant loss mode②

10-high oil temp fault②


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

5-299
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DRS RADIAN CTM 01646.1R0253/1R0254

TABLE 5.11.3.4-6 OP6 SETPOINTS (CONTINUED)


SETPOINTS OP6 SPARE INPUT/OUTPUT PROGRAMMING
FACTORY DPGDS
SETPOINT-NAME-DESCRIPTIONS RANGE OF VALUES
DEFAULT SETPOINT
0-unused

1-active SP1 fault②

2-active SP2 fault②

3-active SP3 fault②

4-active SP4 fault②


SP16 - Spare Relay Output Trigger Condition: The condition
5-any combination of active SP faults②
8 1
used by the GSC+ to trigger the spare relay.
6-any active shutdown
7-any active alarm or shutdown
8-cooldown mode

9-coolant loss mode②

10-high oil temp fault②


11-CCM control
0-unused

1-active SP1 fault②

2-active SP2 fault②

3-active SP3 fault②


SP17 - Spare Indicator 1 Trigger Condition: The condition
4-active SP4 fault② 0 6
used by the GSC+ to trigger spare indicator①.
5-any combination of active SP1, SP2,

SP3 or SP4 faults②

6-Coolant loss fault②

7-high oil temperature fault②


SP18 - Spare Indicator 2 Trigger Condition: The condition
Battle Short mode. 0 0 Battleshort③
used by the GSC+ to trigger spare indicator②.
SP19 - Spare Indicator 3 Trigger Condition: The condition 0 In 50Hz
Not in 60 Hz mode. 0
used by the GSC+ to trigger spare indicator③. Mode③

① The setpoints are programmed at the factory to the default value.

② Either alarm or shutdown faults are valid trigger conditions

③ Battleshort and 50Hz Mode are unique features to DPGDS for spare indicators 2 and 3.

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

NOTE: Use up or down keys to change values.

f. At the AVR verify the operation settings using Table 5.6.3.4-7:

(1) Open the GCPG1 cabinet door.

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

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

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

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

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

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

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

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

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

(11) When complete, press the [▼] to display parameter “01”.

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

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

TABLE 5.11.3.4-7 AVR PARAMETERS/SETPOINTS


DPGDS
DPGDS AVR PARAMETERS
SETPOINTS
RANGE OF DEFAULT 60HZ 50HZ
PARAMETER TITLE TYPE UNITS
VALUES VALUE OPS OPS

01 Generator Output Voltage Program Volts 0080-9999 480① 4160 3800


Ratio of Output Voltage To Sensing
02 Program 001.0-100.0 001.0 17.3 17.3
Voltage
03 Generator Type Program 0000-0004 0004 4 4
04 Rated Generator Output Current Program Amps 0000-9999 0600 80 73
CT Voltage At Rated Generator
05② Current
Program Volts 01.00-05.00 05.00 4.00 3.66

06 Knee Frequency Program Hz 045.0-065.0 050.0 59.8 49.8


07 Decreasing Volts/Hz Slope I Program Volts/Hz 001.0-010.0 002.0 2.0 2.0
08 Decreasing Volts/Hz Slope 2 Program Volts/Hz 001.0-010.0 002.0 2.0 2.0
09 Minimum Voltage Program % 050.0-100.0 050.0 50.0 50.0
10 Under Frequency Point Program Hz 020.0-040.0 025.0 25.0 25.0
11 Overvoltage Trip Point Program % 0105-0140 014.0 125.0 125.0
12 Overvoltage Trip Time Program Seconds 0002-0030 0002 5 5
13 Under Voltage Trip Point Program % 0060-0095 0060 75 75
14 Under Voltage Trip Time Program Seconds 0030-0120 0030 30 30
15 Voltage Gain (IR Compensation) Program % 000.0-0 10.0 0000 0 0

16⑤ Integral Gain Program 001.0-020.0 006.0 6.0 6.0

17⑥ Proportional Gain Program 001.0-020.0 005.0 5.0 5.0


Single Phase Sensing Select
18 Program 0000,0001 0000 0000 0000
(0=three phase, 1=single phase)
19 Diode Monitor Trip Point Program Amps 001.0-010.0 002.0 2.0 2.0

5-301
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DRS RADIAN CTM 01646.1R0253/1R0254

TABLE 5.11.3.4-7 AVR PARAMETERS/SETPOINTS (CONTINUED)


DPGDS
DPGDS AVR PARAMETERS
SETPOINTS
RANGE OF DEFAULT 60HZ 50HZ
PARAMETER TITLE TYPE UNITS
VALUES VALUE OPS OPS
30 Droop Percentage Program % 000.0-010.0 0000 3 3

31③ pf/Kvar Select (0=pf, 1=Kvar) Program 0000, 0001 0000 0 0

32③ Pf Reference Program 00.60-01.10 01.00 0.8 0.8

33③ KVAR Reference Program Per Unit 00.00-01.00 0000 0.10 0.10

34③ Reverse Power Trip Point Program % 000.0-020.0 010.0 15 15

35③ Reverse Power Trip Time Program Seconds 000.0-020.0 010.0 5 5


50 Generator Output Frequency View Hz
51 Generator Output Voltage View Volts
52 Generator Output Current View Amps
53 Generator Reactive Output Current View Amps
54 Generator Real Current View Amps
55 Exciter Field Current View Amps
Three Phase Kilowatts
56③ (KB and later)
View KW

57③ Power Factor View

58③, ④ Three Phase Kvar (KE and later) View


60 Hours View Hours 0000-9999
90 Password Program 0009 0009
91 Software ID View
92 Latest Fault View 0000 0000 0000
93 Previous Fault View 0000 0000 0000
94 Fault Clear View
96 Shutdown Fault Reset Switch

①- Default value for output voltage is different depending on regulator sensing voltage. If the regulator is designed for 120
volts sensing, then the default output voltage is 4160 volts. All other sensing types have the default output voltage set to 480 volts.

②- Digital Voltage Regulators with earlier software (KD and earlier) have 1 less digit to the right of the decimal point.

③- Optional feature.

④- New parameter on serial number prefix KE and later Digital Voltage Regulators.

⑤- Previous range of 0001-099.9 and default value of 002.0

⑥- Previous range of 0001-099.9 and default value of 002.0

(12) When complete, press the [▼] to display parameter “90”.

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

(14) Press the [▼] key to change the value to “0009”. Disables DVR parameter editing.

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DRS RADIAN CTM 01646.1R0253/1R0254

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

(16) Press the [▲] key to change to display parameter “01”.

(17) Close the GCPG cabinet door.

(18) Repeat steps ‘1 ‘through ‘17’ for Generator 2.

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5.11.3.5 PRE-OPERATION CHECKS

Starting from the left rear of the PU and working around the PU in a clockwise direction, perform the
following checks (Gen. 1 is on the left and Gen. 2 is on the right):

TABLE 5.11.3.5-1 PRE-OPERATION CHECKLIST


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

5-304
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254

TABLE 5.11.3.5-1 PRE-OPERATION CHECKLIST (CONTINUED)


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

① The Battery Parallel Switch should be left in the OFF position except in extreme conditions where
the additional DC power is required to crank an engine. Once started, return the switch to the OFF
position. If the battery parallel switch is left in the “ON” position, it could cause one of the generators in
the PU to shut down when the other generator is tyring to start.

5-305
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254

5.11.3.6 PSC RELAY SETTING VERIFICATION

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

b. Click on Windows Start button.

c. Select Programs then “Accessories” then “Communication” then “HyperTerminal”.

d. Double Click on “Vista.ht”

NOTE: Use Com 1 communications port on the ORT.

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

f. Click on “PSC”, press “Enter” on the ORT.

NOTE: The overcurrent relay main menu should appear.

g. Select View Menu 1, WAY 3. Then press “enter”

h. Select View relay settings. Then press “enter”

i. Verify relay settings according to Table 5.11.3.6-1

NOTE: Refer to S&C Instruction Sheet 681-515 page 14, PROGRAMMING to change
settings.
The User Password “6601” must be entered to change control settings and test trip the
solenoids.

j. To change relay settings, press “enter”

k. Select “Switch to Main Menu”

l. Select Configuration Menu 1 or 2

m. Type in Password-6601

n. Select “Change relay Settings” Press “enter”

o. Set relay settings according to Table 5.11.3.6-1

p. Ensure new settings are saved by pressing “Y” then “enter”

q. Repeat steps g through p for WAY 4.

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

s. Return to the Main Menu and “Disconnect” using Windows HyperTerminal when desired
programming action is complete.

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t. Disconnect the OCR end of the communication cable.

CAUTION

WAY 5 TRIP SETTINGS ARE DIFFERENT DEPENDING ON WHETHER IT IS DESIGNATED AS A


TIE-IN POINT FOR ANOTHER PSC OR A FEEDER OUTPUT. ALWAYS ENSURE THAT THE
TRIP SETTINGS ARE PROPERLY SET FOR THE APPLICATION. FAILURE TO DO SO MAY
CAUSE WAY 5 TO TRIP OFF LINE

u. Repeat steps e. through t. for the right OCR (Ways 5 and 6).

v. Repeat steps e. though u. for each PSC in use.

x. Exit Windows HyperTerminal.

y. Shut-down the ORT.

TABLE 5.11.3.6-1 PSC RELAY SETTINGS


MIN. INST. TIME
CABLE TCC
PSC WAY FUNCTION PICKUP PICKUP DELAY
SIZE CURVE
(AMPS) (KAMPS) (SEC.)
3,4, or 5 Feeder 1/0 TAP 200 1 Off
Feeder
3,4, or 5 1/0 TAP 50 Off Off
Ground
3,4, or 5 Single Output 500 KCM MAIN 600 1 Off
Single Output
3,4, or 5 500 KCM MAIN 100 0 Off
Ground
PSC
5 or 6 4/0 TAP 400 0 C (64ms)
Interconnect
PSC
6 Interconnect 4/0 TAP 80 0 C (64ms)
Ground

5-307
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5.11.3.7 PRE-OPERATION RUN

WARNING

ENSURE ALL PERSONNEL ARE CLEAR AND THE PU DOORS ARE CLOSED
PRIOR TO STARTING A GENERATOR.

WARNING

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND


ENFORCED.
NOISE LEVELS IN EXCESS OF 85 DB EXIST WITHIN AN 88-FOOT RADIUS OF AN
OPERATING DPGDS. PERSONNEL MUST WEAR SINGLE HEARING PROTECTION
WITHIN 88 FEET OF AN OPERATING DPGDS.

WARNING

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND


ENFORCED.
DURING MAINTENANCE ACTIVITIES WITH THE SIDEDOORS OPEN, NOISE
LEVELS IN EXCESS OF 113 DB EXIST WITHIN A 12-FOOT RADIUS OF AN
OPERATING DPGDS. PERSONNEL MUST WEAR DOUBLE HEARING PROTECTION
WITHIN 12 FEET OF AN OPERATING DPGDS. EXPOSURE MUST BE LIMITED TO
UNDER 2.5 HOURS.

WARNING

BY CLOSING THE FEEDER OR TIE BREAKER, HIGH VOLTAGE WILL BE PRESENT


ON THE LOAD CABLES. ENSURE ALL PERSONNEL ARE CLEAR OF ALL LOAD
CABLES PRIOR TO CLOSING FEEDER OR TIE BREAKERS.

5-308
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DRS RADIAN CTM 01646.1R0253/1R0254

TABLE 5.11.3.7-1 PRE-OPERATION RUN INSTRUCTION SEQUENCE


(Perform on each PU in the power plant(s))
STEP -- 60HZ OPERATIONS -- -- 50HZ OPERATIONS --

1 Verify System Mode Switch (SMS) is in MANUAL

2 Verify DC Control Power is on

3 Verify Emergency Stop is pulled out

4① Verify the 60Hz light is on ① Verify the 50Hz light is on①

5 Start engine 1 by placing ECS1 in MANUAL (START)

6 Verify the engine accelerates to 1800RPM Verify the engine accelerates to 1500RPM

7 Adjust the generator frequency to 60Hz Adjust the generator frequency to 50Hz using
using the Frequency Adjust Rheostat (FAR) the Frequency Adjust Rheostat (FAR)

8 Adjust the generator voltage to 4295VAC Adjust the generator voltage to 3915VAC
using the Voltage Adjust Rheostat (VAR) using the Voltage Adjust Rheostat (VAR)

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

10 Shutdown engine 1 by placing ECS1 in OFF/RESET

11 Start engine 2 by placing ECS2 in MANUAL (START)

12 Verify the engine accelerates to 1800RPM Verify the engine accelerates to 1500RPM

13 Adjust the generator frequency to 60Hz Adjust the generator frequency to 50Hz using
using the Frequency Adjust Rheostat (FAR) the Frequency Adjust Rheostat (FAR)

14 Adjust the generator voltage to 4295VAC Adjust the generator voltage to 3915VAC
using the Voltage Adjust Rheostat (VAR) using the Voltage Adjust Rheostat (VAR)

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

16 Close all BCS-T on all PUs in the plant lineup(s)

17 At each PDC toggle the Phase Rotation Test Light switch, verify that light ABC lights②

18 Open all BCS-T to isolate the PU

19 Open BCS-G2 on the PU

20 Shutdown engine 2 by placing ECS2 in OFF/RESET

① If the wrong frequency light is on, open the Master Control Door and change the Frequency
Selector Switch (FSS) to the desired frequency with the SMS in OFF.
② If wrong phase rotation lights (CBA), shutdown plant and check for proper cable connections

5-309
USAF TO 35C2-3-518-1
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DRS RADIAN CTM 01646.1R0253/1R0254

5.11.3.8 CONTROLS SETUP

5.11.3.8.1 PLANT ONE

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

NOTE: Ignore settings for Power Units not being used:

TABLE 5.11.3.8-1 PDC CONTROL SWITCH SETUP


PANEL SWITCH 1ST PU 2ND PU 3RD PU 4TH PU
Pushed In Pushed In Pushed In Pushed In
DC Power
(ON) (ON) (ON) (ON)
SMS OFF OFF OFF OFF
PRIME PRIME PRIME PRIME
GMS
POWER POWER POWER POWER
PRIME PRIME PRIME PRIME
MASTER CONTROL AVRS
POWER POWER POWER POWER
PANEL MCP
60Hz Light ON① ON① ON① ON①
USS A② B② C② D②
BSS NORMAL NORMAL NORMAL NORMAL
SSS OFF OFF OFF OFF
SSL All OFF All OFF All OFF All OFF
50/60 50/60 50/60 50/60
INSIDE MCP FSS
Hertz① Hertz① Hertz① Hertz①
GENERATOR Emergency
Pulled-Out Pulled-Out Pulled-Out Pulled-Out
CONTROL PANEL Stop
GCPG1 ECS OFF OFF OFF OFF
GENERATOR Emergency
Pulled-Out Pulled-Out Pulled-Out Pulled-Out
CONTROL PANEL Stop
GCPG2 ECS OFF OFF OFF OFF
① With the SMS in the OFF position, the 50/60Hz lights indicate the position of the Frequency
Selector Switch (FSS). If the wrong light is on, open the door and change the switch position.
② No more than one switch can be in the same position in any multi-PU line-up Per 4 PU plant.
With the SMS in OFF, none of the USI lights will be on and any previously set address on the PU
is cleared.

5.11.3.8.2 Plant Two

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

CAUTION

ENSURE THAT THE PLANT EXPANSION ADAPTER IS INSTALLED BETWEEN PLANT 1 D UNIT
AND PLANT 2 A UNIT. DAMAGE TO THE PLANT OR IMPROPER OPERATION MAY OCCUR IF
THE DEVICE IS NOT INSTALLED

5-310
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NOTE: Ignore settings for Power Units not being used:

TABLE 5.11.3.8-2 PDC CONTROL SWITCH SETUP


PANEL SWITCH 1ST PU 2ND PU 3RD PU 4TH PU
Pushed In Pushed In Pushed In Pushed In
DC Power
(ON) (ON) (ON) (ON)
SMS OFF OFF OFF OFF
PRIME PRIME PRIME PRIME
GMS
POWER POWER POWER POWER
PRIME PRIME PRIME PRIME
MASTER CONTROL AVRS
POWER POWER POWER POWER
PANEL MCP
60Hz Light ON① ON① ON① ON①
USS A② B② C② D②
BSS NORMAL NORMAL NORMAL NORMAL
SSS OFF OFF OFF OFF
SSL All OFF All OFF All OFF All OFF
50/60 50/60 50/60 50/60
INSIDE MCP FSS
Hertz① Hertz① Hertz① Hertz①
GENERATOR Emergency
Pulled-Out Pulled-Out Pulled-Out Pulled-Out
CONTROL PANEL Stop
GCPG1 ECS OFF OFF OFF OFF
GENERATOR Emergency
Pulled-Out Pulled-Out Pulled-Out Pulled-Out
CONTROL PANEL Stop
GCPG2 ECS OFF OFF OFF OFF
① With the SMS in the OFF position, the 50/60Hz lights indicate the position of the Frequency
Selector Switch (FSS). If the wrong light is on, open the door and change the switch position.
② No more than one switch can be in the same position in any multi-PU line-up per 4 PU plant.
With the SMS in OFF, none of the USI lights will be on and any previously set address on the PU
is cleared.

5.11.3.9 ORT SETUP

5.11.3.9.1 PLANT ONE

a. Remove the ORT from its case and set it up on a flat and level surface.

b. Remove the mouse from the case and plug it into the mouse (PS2) port on the back of the ORT
(if needed).

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

d. Connect one end of the 150-foot patch cable to the ORT networking port on the back of ORT.

e. Route the cable from the ORT to the PU and connect the cable to the ORT port on the bottom of
PDC on Gen 1 side.

f. Turn on the ORT by pressing the power switch forward.

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g. Observe that the ORT boots to the Login screen.

h. Login as Operator, no password

i.. Select the EquipID pop-up screen and enter the necessary information for the units. This
includes the Trailer ID number, the Engine ID number, and the Generator ID number for each
PU.

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

NOTE: Unit must be designated (A,B,C,D light) must be on.

k. Return to the Overview pop-up screen (Home)

5.11.3.9.2 PLANT TWO

Repeat steps a. through k above.

5.11.4 PLANT STARTUP

WARNING

ONCE THE SYSTEM STATUS LIGHTS TURN GREEN AND THE MSES IS ENABLED,
THE PU WILL START. ENSURE PERSONNEL ARE CLEAR OF THE PU.

WARNING

ONLY ONE PU MAY BE SELECTED TO ANY ONE USS POSITION IN PLANT 1 OR


PLANT 2 DURING TWO PLANT OPERATIONS. OPERATING WITH MORE THAN ONE
UNIT AT THE SAME ID MAY CAUSE UNSAFE AND ERRATIC OPERATIONAL
CONDITIONS.

WARNING

ALWAYS PAD LOCK THE PSC INTERCONNECT SWITCHES. FAILURE TO DO SO


COULD RESULT IN PERSONAL INJURY OR DAMAGE TO EQUIPMENT

CAUTION

THE TIE BREAKER MUST REMAIN CLOSED AT ALL TIMES WHILE A PU IS IN AN


OPERATING PLANT LINEUP. OPENING THE TIE BREAKER WILL CAUSE LOAD
SHARING TO BE AFFECTED AND THE PLANT TO OPERATE IMPROPERLY

CAUTION

THE DC POWER MUST REMAIN ON AT ALL TIMES WHILE A PU IN AN OPERATING


LINEUP, EVEN WITH NO ENGINES OPERATING ON THAT PU. TURNING OFF DC
POWER WILL AFFECT NETWORK COMMUNICATIONS BETWEEN UNITS AND THE
ORT

5-312
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DRS RADIAN CTM 01646.1R0253/1R0254

Starting up a Multi-PU Prime Power Plant in Automatic Mode

a. At the Primary Switching Center (PSC), close the associated connection for each PU supplying
power to the switchgear and close and pad lock the PSC interconnect switches when using more
than one primary switch.

b. At the PSC, close the connections between the external switchgears.

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

d. Complete the switch arrangements according to the following Table, and verify the lamp
indicators. Set all units up before enabling the MSES at Master Control Panel.

TABLE 5.11.4-1SWITCH SETUP (EACH PLANT) – AUTOMATIC MODE


PANEL SWITCH 1ST PU 2ND PU 3RD PU 4TH PU
BCS-T Red Target Red Target Red Target Red Target
MASTER CONTROL
PANEL MCP
SMS AUTO③ AUTO③ AUTO③ AUTO③
USS A B C D
GENERATOR BCS-G1 Red Target Red Target Red Target Red Target
CONTROL PANEL 1 BCS-F1 Red Target Red Target Red Target Red Target
GCPG1 ECS-1 AUTO AUTO AUTO AUTO
GENERATOR BCS-G2 Red Target Red Target Red Target Red Target
CONTROL PANEL 2 BCS-F2 Red Target Red Target Red Target Red Target
GCPG2 ECS-2 AUTO AUTO AUTO AUTO
MASTER CONTROL Gen 1 Green Gen 1 Green Gen 1 Green Gen 1 Green
SSL
PANEL Gen 2 Green Gen 2 Green Gen 2 Green Gen 2 Green
MASTER CONTROL MSES Enable① Enable① Enable① Enable①
PANEL MCP USI A①, ② B①, ② C①, ② D①, ②
① Hold the MSES in the ENABLE position until the selected USI indicator energizes. The switch
returns to the center position when released. This sets the PU networking address and enables
the control and monitoring. NOTE: both generators will start and BCS-G1, BCS-G2, and
BCS-T close as indicated by the red breaker status lights.
② No more than one of each indicator can be on for multi-PU operations. The light on should match
USS position. The USI light will de-energize after the SMS has been in OFF for 3 seconds.
③ With the SMS in AUTO any generator started, manually or automatically, will automatically
parallel to the bus. To prevent the generator from paralleling to the bus put the generator’s
breaker in the Pull-To-Lock position.

NOTE: The automatic economizing feature will shutdown one generator every 3 minutes until the
system load is at or below the 350KW/470KVA per generator threshold.
NOTE: Enable all units MSES and observe the following:
PLANT 1
e. At A-unit, observe Generator 1 automatically starts and accelerates to operating voltage and
frequency.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Plant 2
Observe steps e through x above.

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

z. Ensure generators have assumed load. After the load has stabilized for both power
plants, proceed with the following if necessary:

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

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

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

5.11.5 PLANT OPERATIONS (AUTOMATIC MODE)

5.11.5.1 PRECAUTIONS AND WARNINGS

This mode of operation places control of all generator starting, stopping, synchronizing, and load
management under the auspices of the Programmable Logic Controller (PLC) system. As long as the
SMS is in AUTO, any generator started, manually or automatically, is automatically synchronized to the
system bus. Care must be taken when starting a generator manually when the SMS is in AUTO. Either
place the associated BCS in Pull-To-Lock (prevent closing to the bus) or ensure it has the red target
visible (allow paralleling to the bus) before starting the engine. The only exception is automatic operation
of the feeder breakers. Auto Mode does not automatically close feeder breakers; it only enables remote
operation of the feeder breakers from the ORT.

5.11.5.2 DESCRIPTION

The master controller (the designated “A” unit in each plant) will control all connected generators, in their
respective plant based on the total system KW/KVA load. The controller shuts down one of the
generators after 3 minutes should the system load drop below a level where the remaining generator load
would not exceed 85% (350kW) if a generator is shutdown. If the load of the remaining generator
exceeds 85% (350kW) for one minute, a standby generator is started and paralleled to the bus. A change
of system load is recognized by the control system and appropriate action is taken to maintain generator
load in the 85% (350 KW/470 KVA) range. The system never automatically shuts down the final generator
under normal operating conditions. The shutdown of the final generator must be done following manual
operating procedures. The default configuration is Economizing Mode on. The economizing mode can be
turned off from the ORT. Through the ORT, the AUTO shut down is disabled but the AUTO start-up
remains active to prevent overloading the online generator(s).

5.11.6 POWER PLANT TEARDOWN

5.11.6.1 SHUT DOWN GENERATORS

a. Place SMS in Manual.

b. Unload all generators by opening all feeder breakers. This must be done locally from the LCP or
ORT.

c. Open each BCST locally at the respective MCP.

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

e. Observe all generator breakers open.

f. Open all the switchgear generator supply disconnect switches.

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

h. Place all ECS switches in OFF/RESET.

i. Pull out the DC Control Power breaker on all PUs.

5.11.6.2 DISCONNECT CABLES

WARNING

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

CAUTION

ALLOW ALL OPERATING ENGINES TO SHUT DOWN AND COOL DOWN COMPLETELY.

a. Disconnect the communication cables from between the PUs and store inside the PUs (one per
unit).

b. Reinstall the communication cable receptacle covers.

c. Disconnect the ORT cable and store it in the ORT case.

d. Close and latch the ORT port on the PU.

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

5.11.6.3 DISCONNECT FUEL LINES

a. Turn all fuel system valves to the off position.

b. Disconnect the fuel hose from the PU fuel connection and the fuel supply.

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

5.11.6.4 DISCONNECT GROUNDING

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

b. Disconnect the parking stations from the ground grid.

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

5.11.6.5 PREPARE PU FOR TRANSPORTATION

a. Reinstall the four radiator splashguards (PU-810B only).

b. Verify DC Control power is off.

c. Close and lock the LCP access doors.

d. Close and lock all PU side doors.

Refer to Section 4.3 “MOVEMENT” to complete preparation for transportation.


5.11.6.6 FUEL, OIL, AND COOLANT DRAINAGE

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

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THIS PAGE INTENTIONALLY BLANK

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CHAPTER 6
SCHEDULED MAINTENANCE
TABLE OF CONTENTS

SECTION TITLE PAGE


6.0 SCHEDULED MAINTENANCE 4
6.1 SAFETY PROCEDURES 4
6.2 DAILY PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) 15
6.3 PREVENTIVE MAINTENANCE CHECKS AND SERVICES
(SCHEDULED) (PMCS) 18
6.3.2 RUNNING GEAR SCHEDULED MAINTENANCE 21
6.3.2.1 MEP-PU 810A RUNNING GEAR SCHEDULED MAINTENANCE 21
6.3.2.2 MEP-PU 810B RUNNING GEAR SCHEDULED MAINTENANCE 23
6.3.3 SR4B ALTERNATOR SCHEDULED MAINTENANCE 25
6.3.4 PRIMARY DISTRIBUTION CENTER (PDC) SCHEDULED MAINTENANCE 26
6.4 REQUIRED INSPECTIONS NOT COVERED IN OTHER CHAPTERS 28
6.4.1 INSPECT THE EXTERNAL FUEL MANIFOLD 28
6.4.2 INSPECT FRONT, MIDDLE, REAR ENGINE / ALTERNATOR SUPPORT
ASSEMBLY 29
6.4.3 INSPECT THE OIL PAN ASSEMBLY 29
6.4.4 INSPECT THE FRONT AND REAR CRANKSHAFT AND ACCESSORY DRIVE
SEALS 30
6.4.5 INSPECT THE CRANKSHAFT VIBRATION DAMPER 31
6.4.6 INSPECT THE CYLINDER HEAD GROUNDING STUD 31
6.4.7 INSPECT THE ENGINE MOUNTS 32
6.4.8 INSPECT THE SWITCHGEAR 32
6.5 SERVICE REQUIREMENTS NOT COVERED IN OTHER CHAPTERS 33
6.5.1 ENGINE CRANKCASE BREATHER SERVICE REQUIREMENTS 34
6.5.1.1 FUME COLLECTOR BOX VENT STACK 34
6.5.2 CYLINDER HEAD GROUNDING STUD SERVICE REQUIREMENTS 35
6.5.3 FUEL TANK SEDIMENT SERVICE REQUIREMENTS 37
6.5.4 REMOTE TERMINAL UNIT (RTU) 37

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LIST OF TABLES

TABLE TITLE PAGE


TABLE 6.2-1 DAILY MAINTENANCE CHECKS AND SERVICES 15
TABLE 6.2-1 DAILY MAINTENANCE CHECKS AND SERVICES (CONTINUED) 16
TABLE 6.3-1 PREVENTIVE MAINTENANCE CHECKS AND SERVICES
(SCHEDULED PMCS) 18
TABLE 6.3-1 PREVENTIVE MAINTENANCE CHECKS AND SERVICES
(SCHEDULED PMCS) (CONTINUED) 19
TABLE 6.3-1 PREVENTIVE MAINTENANCE CHECKS AND SERVICES
(SCHEDULED PMCS) (CONTINUED) 20
TABLE 6.3.2.1-1 MEP-PU-810A MAINTENANCE SCHEDULE 21
TABLE 6.3.2.1-1 MEP-PU-810A MAINTENANCE SCHEDULE (CONTINUED) 22
TABLE 6.3.2.2-1 MEP-PU-810B MAINTENANCE SCHEDULE 23
TABLE 6.3.2.2-1 MEP-PU-810B MAINTENANCE SCHEDULE (CONTINUED) 24
TABLE 6.3.3-1 SR4B ALTERNATOR SCHEDULED MAINTENANCE 25
TABLE 6.3.4-1 PRIMARY DISTRIBUTION CENTER (PDC) SCHEDULED
MAINTENANCE 26
TABLE 6.3.4-1 PRIMARY DISTRIBUTION CENTER (PDC) SCHEDULED
MAINTENANCE (CONTINUED) 27

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LIST OF FIGURES

FIGURE TITLE PAGE


6.5.2-1 CYLINDER HEAD GROUNDING STUD 36

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6.0 SCHEDULED MAINTENANCE

Scheduled Maintenance procedures covered in this section are:

• Daily Preventive Maintenance Checks And Services (PMCS)


• Preventive Maintenance Checks And Services (Scheduled)(PMCS)
• Required Inspections Not Covered In Other Chapters
• Service Requirements Not Covered In Other Chapters

6.1 SAFETY PROCEDURES

WARNING

IMPORTANT: SAFETY WARNINGS ARE APPROPRIATE FOR ALL MAINTENANCE


ACTIVITIES. READ THIS SECTION, PRIOR TO PERFORMING ANY MAINTENANCE

WARNING

THE EQUIPMENT COVERED IN THIS MANUAL MUST BE INSTALLED, OPERATED,


AND MAINTAINED BY QUALIFIED PERSONS WHO ARE KNOWLEDGEABLE IN THE
INSTALLATION, OPERATION, AND MAINTENANCE OF MEDIUM VOLTAGE
ELECTRICAL POWER GENERATION EQUIPMENT ALONG WITH ASSOCIATED
HAZARDS. A QUALIFIED PERSON IS ONE WHO IS TRAINED AND COMPETENT IN:

• THE SKILLS AND TECHNIQUES NECESSARY TO DISTINGUISH


ENERGIZED PARTS FROM NON-ENERGIZED PARTS OF ELECTRICAL
EQUIPMENT.

• THE SKILLS AND TECHNIQUES NECESSARY TO DETERMINE THE


PROPER APPROACH DISTANCES CORRESPONDING TO THE VOLTAGES
TO WHICH THE QUALIFIED PERSON WILL BE EXPOSED.

• THE PROPER USE OF SPECIAL PRECAUTIONARY TECHNIQUES,


PERSONAL PROTECTIVE EQUIPMENT, INSULATING AND SHIELDING
MATERIALS, AND INSULATED TOOLS FOR WORKING ON OR NEAR
ENERGIZED PARTS OF ELECTRICAL EQUIPMENT AND ROTATING
MACHINERY.

• THE PROPER USE OF SPECIAL PRECAUTIONARY TECHNIQUES,


PERSONAL PROTECTIVE EQUIPMENT, INSULATING AND SHIELDING
MATERIALS, AND INSULATED TOOLS FOR WORKING ON OR NEAR
EXPOSED HOT SURFACES OF ENGINE AND EXHAUST SYSTEM
COMPONENTS.

THESE INSTRUCTIONS ARE INTENDED ONLY FOR SUCH QUALIFIED PERSONS.


THEY ARE NOT A SUBSTITUTE FOR ADEQUATE TRAINING AND EXPERIENCE IN
SAFETY PROCEDURES FOR THIS TYPE OF EQUIPMENT.

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WARNING

BATTERY ELECTROLYTE CONTAINS SULFURIC ACID, WHICH CAN CAUSE


SEVERE CHEMICAL BURNS. AVOID ALL CONTACT. SKIN AND EYE PROTECTION
IS REQUIRED. IN CASE OF CONTACT, IMMEDIATELY FLUSH WITH LARGE
AMOUNTS OF CLEAN WATER AND OBTAIN MEDICAL AID.

WARNING

WHEN DISCONNECTING BATTERY CABLES, ALWAYS DISCONNECT NEGATIVE


TERMINAL FIRST. WHEN RECONNECTING, CONNECT NEGITIVE TERMINAL LAST.
FAILURE TO COMPLY MAY CAUSE SPARKING AND CONSEQUENT BATTERY
EXPLOSION.

WARNING

HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT


DURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION
AND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN
LOAD CABLES ARE HANDLED.

WARNING

DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS


OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A
SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET
IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT
FROM FAILURE TO OBSERVE THIS WARNING.

WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING.


FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.

WARNING

SIDE PANELS ARE HEAVY. USE EXTREME CAUTION WHEN UNBOLTING AND
REMOVING.

WARNING

TOP PANELS ARE HEAVY. USE EXTREME CAUTION WHEN UNBOLTING AND
REMOVING.

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WARNING

MUFFLER ASSEMBLIES ARE HEAVY. USE EXTREME CAUTION WHEN UNBOLTING


AND REMOVING.

WARNING

ENSURE THAT HEATER STRIP COVERS ARE ON WHEN GENERATOR IS


RUNNING. LOW VOLTAGE IS PRESENT AT THE HEATER STRIP TERMINALS

WARNING

THE INSULATION TESTER PRODUCES HIGH VOLTAGE. TO AVOID PERSONAL


INJURY DURING THE TEST, DO NOT TOUCH THE WINDING BEING TESTED OR
THE TEST LEADS.

WARNING

DO NOT COME IN CONTACT WITH LOAD TERMINAL DURING TEST. DEATH BY


ELECTROCUTION MAY RESULT

WARNING

FOLLOW MANUFACTURER'S TEST PROCEDURES INCLUDED WITH THE TEST


EQUIPMENT

WARNING

ALWAYS CONSIDER AN ARRESTER TO BE ENERGIZED UNTIL THE LINE AND


GROUND LEADS HAVE BEEN DISCONNECTED FROM THE CIRCUIT.

WARNING

NEVER INSTALL A DAMAGED ARRESTER. A DAMAGED ARRESTER MAY


MALFUNCTION VIOLENTLY, CAUSING SEVERE PERSONAL INJURY.

WARNING

USE OF A LIFTING DEVICE IS RECOMMENDED FOR REMOVING THE STATION


POWER TRANSFORMER. EXTREMELY HEAVY OVER 100 LBS

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WARNING

PRIOR TO TROUBLESHOOTING THE POWER UNIT (PU), ENSURE THE TIE AND
FEEDER CABLES ARE ALL INSTALLED ON PARKING STANDS, TO PREVENT THE
POSSIBILITY OF UTILITY POWER BEING FED BACK INTO GENERATOR SET.
ENSURE EQUIPMENT IS PROPERLY TAGGED AND NOT ENERGIZED. RESIDUAL
VOLTAGE IS PRESENT AT THE GENERATOR LEADS WITH THE REGULATOR
TURNED OFF, REACHING SEVERAL HUNDRED VOLTS ON THE GENERATOR SET.
PROPER INSULATION AND ISOLATION OF METERING EQUIPMENT MUST BE
OBSERVED WHEN TESTING GENERATOR. USE PROPER TEST EQUIPMENT TO
CHECK FOR VOLTAGE BEFORE PROCEEDING. FAILURE TO COMPLY MAY
RESULT IN DEATH BY ELECTROCUTION.

WARNING

BEFORE WORKING ON THE BATTERY CHARGER, ENSURE THAT AC POWER IS


OFF AND DISCONNECTED. ALSO, DISCONNECT THE NEGATIVE BATTERY LEAD

WARNING

ETHER IS HIGHLY FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY


TRACT. USE ONLY IN AN ADEQUATELY VENTILATED AREA. SKIN, EYE. AND
RESPIRATORY PROTECTION IS REQUIRED. FAILURE TO COMPLY MAY RESULT
IN SERIOUS INJURY OR ILLNESS.

WARNING

DIESEL FUEL IS FLAMMABLE AND MODERATELY TOXIC TO EYES, SKIN, AND


RESPIRATORY TRACT. SKIN AND EYE PROTECTION REQUIRED. AVOID
REPEATED OR PROLONGED CONTACT. USE IN WELL-VENTILATED AREA.
FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY OR ILLNESS.

WARNING

WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE


TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT.
MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY
OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST
EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS
USER.

WARNING

ONLY ONE PU MAY BE SELECTED TO ANY ONE USS POSITION DURING


MULTIPLE PU OPERATIONS. OPERATING WITH MORE THAN ONE UNIT AT THE
SAME ID MAY CAUSE UNSAFE AND ERRATIC OPERATIONAL CONDITIONS.

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WARNING

EXPLOSION HAZARD – WHEN IN HAZARDOUS LOCATIONS, DISCONNECT


POWER BEFORE REPLACING OR WIRING MODULES.

WARNING

ALWAYS WEAR EYE PROTECTION WHEN YOU PERFORM ANY SERVICE WORK
ON A COOLING SYSTEM

WARNING

RELEASE THE PRESSURE IN THE COOLING SYSTEM BEFORE PERFORMING ANY


SERVICE WORK. IF THE PRESSURE IN THE COOLING SYSTEM IS NOT
RELEASED OR THE TEMPERATURE OF THE SYSTEM IS NOT PERMITTED TO
COOL, STEAM OR HOT WATER MAY BE RELEASED WHEN YOU REMOVE THE
FILLER CAP. THIS MAY CAUSE PERSONAL INJURY.

WARNING

TO RELEASE THE PRESSURE IN A COOLING SYSTEM, LET THE SYSTEM COOL,


PUT A HEAVY CLOTH OVER THE CAP AND LOOSEN IT SLOWLY.

WARNING

DO NOT ALLOW UNDILUTED CORROSION INHIBITORS OR DILUTED/UNDILUTED


RADIATOR CLEANERS TO COME IN CONTACT WITH THE SKIN OR EYES.

WARNING

DO NOT USE CHROMATE CORROSION INHIBITORS IN A COOLING SYSTEM.

WARNING

ALWAYS FOLLOW THE MANUFACTURER’S INSTRUCTIONS WHEN HANDLING


CORROSION INHIBITORS, RADIATOR CLEANERS OR ANTIFREEZE. BE
ESPECIALLY SURE TO FOLLOW THE MANUFACTURER’S RECOMMENDATIONS
CONCERNING TOXICITY.

WARNING

ETHYLENE GLYCOL MAY CATCH FIRE WHEN IT IS HOT OR EXPOSED TO AN


OPEN FLAME. DO NOT WELD, CUT OR USE AN OPEN FLAME NEAR LEAKING
COOLANT THAT CONTAINS ANTIFREEZE.

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WARNING

DO NOT USE ALCOHOL IN PLACE OF ANTIFREEZE. ALCOHOL HAS A LOWER


BOILING TEMPERATURE AND FLASH POINT.

WARNING

DO NOT ATTEMPT TO TIGHTEN ANY HOSE CLAMPS WHILE THE COOLING


SYSTEM IS HOT OR UNDER PRESSURE. IF THERE IS A FAILURE OF THE HOSE
CLAMP WHEN IT IS TIGHTENED, A SUDDEN LOSS OF HOT COOLANT OR STEAM
COULD RESULT.

WARNING

DO NOT REMOVE FILLER CAP AFTER OPERATION UNTIL SYSTEM HAS COOLED
DOWN. FAILURE TO ALLOW ENGINE COOLANT TO COOL DOWN COULD RESULT
IN SECOND AND THIRD DEGREE BURNS. CAP MAY BE HALF-TURNED TO
RELIEVE PRESSURE AND THEN REMOVED TO INSPECT COOLANT LEVEL.

WARNING

PERSONAL INJURY CAN RESULT FROM HOT COOLANT, STEAM AND ALKALI.

WARNING

AT OPERATING TEMPERATURE, ENGINE COOLANT IS HOT AND UNDER


PRESSURE. THE RADIATOR AND ALL LINES TO THE ENGINE CONTAIN HOT
COOLANT OR STEAM. ANY CONTACT CAN CAUSE SEVERE BURNS.

WARNING

REMOVE FILLER CAP SLOWLY TO RELIEVE PRESSURE ONLY WHEN THE


ENGINE IS STOPPED AND THE FILLER CAP IS COOL ENOUGH TO TOUCH WITH
YOUR BARE HAND.

WARNING

COOLING SYSTEM CONDITIONER CONTAINS ALKALI. AVOID CONTACT WITH


SKIN AND EYES.

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WARNING

HOT OIL AND HOT COMPONENTS CAN CAUSE PERSONAL INJURY. DO NOT
ALLOW HOT OIL OR HOT COMPONENTS TO CONTACT THE SKIN. DO NOT DRAIN
THE OIL WHEN THE ENGINE IS COLD. AS THE OIL COOLS, SUSPENDED WASTE
PARTICLES SETTLE ON THE BOTTOM OF THE OIL PAN. THE WASTE PARTICLES
ARE NOT REMOVED WHEN DRAINING COLD OIL. DRAIN THE CRANKCASE WITH
THE ENGINE STOPPED. DRAIN THE CRANKCASE WITH THE OIL WARM. THIS
DRAINING METHOD ALLOWS THE WASTE PARTICLES THAT ARE SUSPENDED IN
THE OIL TO BE DRAINED PROPERLY.

WARNING

HYDRAULIC FLUID IS HOT AND UNDER HIGH PRESSURE. DO NOT PLACE ANY
PART OF YOUR BODY OVER ANY LEAK. SEVERE INJURY CAN OCCUR IF THIS
HAPPENS.

WARNING

DO NOT MIX PETROLEUM BASED OIL WITH BRAKE FLUID. THIS WILL CAUSE
SEAL SWELLING AND NON-FUNCTIONING BRAKES.

WARNING

THE HYDRAULIC PRESSURE HELD IN THE BREAKAWAY LEVER MAY CAUSE THE
LEVER TO SNAP QUICKLY. KEEP HANDS AND FINGERS CLEAR, AS YOU RESET
THE BREAKAWAY MECHANISM. WHEN TOWING, AVOID SHARP TURNS THAT
CAN CAUSE THE ACTUATOR TO BIND AGAINST THE TOW VEHICLE. THIS CAN
DAMAGE THE ACTUATOR AND TRAILER, CAUSING BRAKE FAILURE.

WARNING

DO NOT GET GREASE OR OIL ON BRAKE LININGS. BRAKES WILL NOT


FUNCTION PROPERLY

WARNING

DO NOT MIX LITHIUM, CALCIUM, SODIUM OR BARIUM COMPLEX GREASES DUE


TO POSSIBLE COMPATIBILITY PROBLEMS. WHEN CHANGING FROM ONE TYPE
OF GREASE TO ANOTHER, IT IS NECESSARY TO ENSURE ALL THE OLD GREASE
HAS BEEN REMOVED.

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WARNING

DO NOT DISASSEMBLE THE SPRING BRAKE. IT CONTAINS A COMPRESSED


SPRING THAT MAY CAUSE INJURY IF REMOVED. THE SPRING BRAKE MUST BE
CAGED BEFORE SERVICING AND SHOULD ONLY BE PERFORMED BY QUALIFIED
PERSONNEL.

WARNING

FAILURE TO CORRECTLY LUBRICATE BEARINGS AND MAINTAIN PROPER


LUBRICATION COULD CAUSE BEARING AND AXLE SPINDLE DAMAGE, WHICH
COULD RESULT IN THE WHEEL LOCKING UP OR COMING OFF DURING VEHICLE
OPERATION.

WARNING

APPLYING HIGH VOLTAGES ACROSS THE CONTACTS OF THE VACUUM


INTERRUPTERS MAY PRODUCE X-RAYS. THE RADIATION MAY INCREASE WITH
AN INCREASE IN THE VOLTAGE OR A DECREASE IN THE DISTANCE BETWEEN
THE OPEN CONTACTS. THE LEVELS OF RADIATION GENERATED AT THE
RECOMMENDED TEST VOLTAGES AND NORMAL BREAKER OPEN GAP SPACING
ARE EXTREMELY LOW. HOWEVER, AS A PRECAUTIONARY MEASURE IT IS
RECOMMENDED THAT ALL PERSONNEL STAND AT LEAST THREE FEET AWAY
FROM THE BREAKER WHILE TESTING.

CAUTION

SIGNIFICANT DIFFERENCES BETWEEN THE MEP-PU-810A AND MEP-PU-810B


REQUIRE SPECIFIC INSTRUCTIONS FOR EACH VERSION.

CAUTION

DO NOT ALLOW THE STARTER MOTOR TO OPERATE MORE THAN 30 SECONDS.


ALLOW IT TO COOL AT LEAST 2 MINUTES BEFORE RE-ENERGIZING THE
MOTOR. OVERHEATING WILL DAMAGE THE MOTOR.

CAUTION

ALWAYS HANDLE SURGE ARRESTERS PACKED OR UNPACKED VERY


CAREFULLY. DO NOT DROP, JAR, OR HANDLE AN ARRESTER ROUGHLY.
DROPPING, JARRING, AND/OR ROUGH HANDLING MAY DAMAGE THE
ARRESTER INTERNALLY OR EXTERNALLY. THIS COULD MAKE THE ARRESTER
INCAPABLE OF PROTECTING THE CIRCUIT AND COULD SHORTEN THE SERVICE
LIFE OF THE ARRESTER SIGNIFICANTLY.

6-11
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CAUTION

DO NOT USE A COMMERCIAL COOLANT/ANTIFREEZE THAT ONLY MEETS THE


ASTM D3306 OR D4656 SPECIFICATION. THIS TYPE OF COOLANT/ANTIFREEZE IS
MADE FOR LIGHT DUTY AUTOMOTIVE APPLICATIONS.

CAUTION

TURBOCHARGER BEARING FAILURES CAN CAUSE LARGE QUANTITIES OF OIL


TO ENTER THE AIR INLET AND EXHAUST SYSTEMS AND AIR TO AIR AFTER
COOLER. LOSS OF ENGINE LUBRICANT CAN RESULT IN SERIOUS ENGINE
DAMAGE. TURBOCHARGER COMPONENTS REQUIRE PRECISION CLEARANCES.
THE TURBOCHARGER CARTRIDGE MUST BE BALANCED DUE TO HIGH RPM.
SEVERE SERVICE APPLICATIONS CAN ACCELERATE COMPONENT WEAR.
SEVERE SERVICE APPLICATIONS REQUIRE MORE FREQUENT INSPECTIONS OF
THE CARTRIDGE.

CAUTION

WHEEL NUT OR BOLTS MUST BE APPLIED AND MAINTAINED AT THE PROPER


TORQUE LEVELS TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND
POSSIBLE DANGEROUS SEPARATION OF WHEELS FROM YOUR AXLE.

CAUTION

THE MAXIMUM TOWING SPEED IS 20 MPH FOR THE MEP-PU-810A.

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a. Safety precautions must be observed while any maintenance is being performed. Safety
precautions must be observed to ensure that the operator/technician cannot have contact with the
following:

• Hot engine parts


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

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

c. Minor Maintenance can be performed while one generator is running and the other generator
set has been shutdown. Some examples of this maintenance are:

• Lubrication System – Oil and Filter Change.


• Hydraulic System – Oil and Filter Change.
• Fuel System – Primary and Secondary Filter Change.
• Coolant System – Coolant Change.
• Minor Troubleshooting.
• Check Fluid levels and add required fluids.

(1) The generator set that has been shut down must be rendered unable to start, and cool
enough for the maintenance to be performed. Procedures to render a generator set
unable to start are:

(a) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators.


(b) Push to OPEN the Emergency Stop Switch.
(c) Place the Engine Control Switch (ECS) in the OFF position.
(d) Place a DO NOT OPERATE tag on the generator control panel.
(e) Turn the Battery Bank Parallel Switch to the OFF position.
(f) De-energize the Battery Charger.
(g) Disconnect the negative and positive cables from the Battery Bank for the engine
due maintenance.
(h) Place a DO NOT OPERATE tag on the Battery Bank.
(i) Place the generator Circuit Breaker in the LOCK OUT position.
(j) Disconnect the 7P1 and 7P2 Connectors located on the inside panel of the PDC.
(k) Close and Lock the generator set control panel.

NOTE: The fuel transfer pump electrical power is normally fed directly from the G1 generator set
battery bank. If you disconnect the G1 battery bank, the external fuel transfer pump will not
function. Place the Fuel Pump Source Switch (S2) into the (G1 or G2 position) for the
generator set not receiving maintenance.

d. Major maintenance or service requires that the PU MUST be shutdown, isolated from any
power plant electrical bus or utility connection, isolated from any power plant control
system, and rendered unable to start. This is accomplished by performing the following:

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(1) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators.


(2) Isolate the PU from any power plant or utility connection in accordance with Section
5.9.6.15, Unit Isolation Procedure with PSC. Note 1 and 2.
(3) Isolate the PU from any power plant control system in accordance with Note 3.
(4) Pull to open the PU DC Power Control Breaker.
(5) Push to open both Emergency Stop Switches.
(6) Place both Engine Control Switches (ECS) in the OFF position.
(7) Place a DO NOT OPERATE tag on both generator control panels.
(8) Turn the Battery Bank Parallel Switch to the OFF position.
(9) De-energize both Battery Chargers.
(10) Disconnect the negative and positive cables from both Battery Banks.
(11) Place a DO NOT OPERATE tag on both Battery Banks.
(12) Place all Circuit Breakers in the LOCK OUT position.
(13) Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC.
(14) Close and Lock both generator set control panels.

NOTE 1: Also the PU must be completely electrically isolated from the power distribution bus and
any other electrical source that can back feed into the PU. All medium voltage cables need to
be placed on the standoff insulators by use of hot sticks and other safety gear.

NOTE 2: Ensure cables are not energized by opening the circuit breaker of the Primary Switching
Center (PSC), then disconnect Load Cables (Using the proper safety gear) on the PU and
place them on the Parking Stands.

NOTE 3: When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control
power is turned off to the PU. This will cause the HUB to stop functioning. This causes the
network to not see the equipment shutdown and all PU’s after it. When pulling major
maintenance the Communication Cable must be routed to the next PU in order to reestablish
the communication network. In Automatic Mode of operation, if the PU being isolated is
designated as “A” unit then you must redesignate another PU as “A” in accordance with
Section 5.9.4. Re-desgnate a PU Without Plant Shutdown.

6-14
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DRS RADIAN CTM 01646.1R0253/1R0254

6.2 DAILY PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)

a. The required daily Before (B), During (D) and After (A) Preventive Maintenance Checks and
Services (PMCS) are identified in Table 6.2-1.

b. All Safety Warnings and Cautions in Section 6.1 apply to this Table.

TABLE 6.2-1 DAILY MAINTENANCE CHECKS AND SERVICES


OPERATOR DAILY TIME
ITEMS TO BE INSPECTED/INSPECTION PROCEDURES
B D A (MHrs)

GROUND TERMINALS:
X Ensure the Power Unit, Ground Grid and Load Cable Drain Lines are properly connected to 0.1
Ground.
EXHAUST:
• Check Muffler Flex Connector pipe between engine and roof for condition, leakage and
X X X security. 0.1
• During operation, be alert for development of excessively black, white, or blue exhaust
smoke.

COOLING SYSTEM:
X X X Check radiator for proper coolant level before starting. During operation, check radiator and 0.1
all cooling lines for leakage and security.

LUBE OIL SYSTEM:


• Check Dip Stick for proper oil level.
X X X • During operation, check for leakage. 0.1
• Change Oil at intervals specified in Table 6.3-1, Preventive Maintenance Checks and
Services.
BATTERY CHARGER:
X X X During operation verify voltmeter measures approximately 26 – 29 VDC and ampmeter 0.1
measures > 2 amps DC.

BATTERIES AND CABLES:


X 0.1
Service Batteries and check Battery Cables for security. See Section 9.4.1.5 for reference.

AIR FILTER DIFFERENTIAL PRESSURE GAUGE:


Check condition of Air Filter by checking the Air Filter Differential Pressure gauge located on
the Filter Monitoring Panel. If the Air Filter High Differential Pressure Alarm is activated on
X the (GCP), or the Air Filter Differential Pressure Gauge reads 25 inches of water, the Air Filter 0.1
needs to be changed. Replace the Air Filter at intervals specified in Section 16.3.1, Air Filter.
Change the Air Filter at intervals specified in Table 6.3-1, Preventive Maintenance Checks
and Services.
PRIMARY FUEL FILTER DIFFERENTIAL PRESSURE GAUGE:
Check condition of the Primary Fuel Filter by checking the Primary Fuel Filter Differential
X gauge located on the Filter Monitoring Panel. If the Primary Fuel Filter Differential Pressure 0.1
Alarm is activated on the (GCP), or the Primary Fuel Filter Differential Pressure Gauge reads
5 PSID, the Primary Fuel Filter needs to be changed. Change the Primary Fuel Filter at
intervals specified in Table 6.3-1, Preventive Maintenance Checks and Services.
SECONDARY FUEL FILTER DIFFERENTIAL PRESSURE GAUGE:
Check condition of the Secondary Fuel Filter by checking the Secondary Fuel Filter
Differential gauge located on the Filter Monitoring Panel. If the Secondary Fuel Filter
X Differential Pressure Alarm is activated on the (GCP), or the Secondary Fuel Filter Differential 0.1
Pressure Gauge reads 30 PSID, the Secondary Fuel Filter needs to be changed. Change
the Secondary Fuel Filter at intervals specified in Table 6.3-1, Preventive Maintenance
Checks and Services.

6-15
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TABLE 6.2-1 DAILY MAINTENANCE CHECKS AND SERVICES (CONTINUED)


OPERATOR
DAILY TIME
ITEMS TO BE INSPECTED/INSPECTION PROCEDURES
(MHrs)
B D A
OIL FILTER DIFFERENTIAL PRESSURE GAUGE:
Check condition of the Oil Filter by checking the Oil Filter Differential gauge located on the
X Filter Monitoring Panel. If the Oil Filter Differential Pressure Alarm is activated on the (GCP), 0.1
or the Oil Filter Differential Pressure Gauge reads 30 PSID, the Oil Filter needs to be
changed. Change the Oil Filter at intervals specified in Table 6.3-1, Preventive Maintenance
Checks and Services.
FUMES DISPOSAL COLLECTOR:
X X X Ensure that the Fumes Disposal Collector is drained and wipe down any oil residue in and 0.1
around fumes box vent pipe.

EXTERNAL FUEL SUPPLY:


X X X Check that external fuel supply is adequate for the mission and is properly connected to the 0.1
Power Unit External Fuel Transfer System.

FUEL SYSTEM:
• During operation, check all Fuel lines for leakage and security.
X X X 0.2
• Clean fuel strainer at interval specified in Table 6.3-1, Preventive Maintenance Checks
and Services.

FUEL/SEPERATOR:
X X 0.1
Drain Water from Cup.

HYDRAULIC SYSTEM:
• During operation, check all hydraulic lines for leakage and security.
X X X • Replace the 3 Micron (Absolute), Filter at intervals specified in Table 6.3-1, Preventive 0.1
Maintenance Checks and Services.
• Check fluid level. Fluid level should be approximately ¾ full on the tank mounted fluid
level gauge. Look for leaks.
CABLING:
X X • Check for Proper Mechanical Connections and Phase Color Coding. 0.1
• Check for Cable Damage and proper Medium Voltage Cable Terminations.
EXTERNAL FUEL TRANSFER PUMP CONTROLS:
• During Operation, check all fuel lines, valves and pumps for leaks and security.
X X X • Ensure that the position of the External Fuel Transfer Pump Control switches, are in the 0.1
proper position.
• Inspect Fuel Solenoid Valve for leaks, damage.

MEP-PU-810B, DC LIGHTS:
X X 0.1
Check for proper operation.

MEP-PU-810A & MEP-PU-810B, AC LIGHTS:


X X 0.1
Check for proper operation.

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THIS PAGE IS INTENTIONALLY BLANK

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6.3 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (SCHEDULED) (PMCS)

a. Table 6.3-1 identifies the scheduled preventive maintenance requirements for the MEP-PU-810. The Preventive Maintenance Checks and
Services (PMCS) are to be performed at the intervals identified. All Safety Warnings and Cautions in Section 6.1 apply to this Table.

b. Problems encountered during the MEP-PU-810 operations that do not present safety hazards or do not degrade operations must be identified for
correction during scheduled maintenance periods or at the end of operations, as appropriate.

CAUTION

PROBLEMS WHICH PRESENT SAFETY HAZARDS AND WHICH SIGNIFICANTLY DEGRADE OPERATIONS
REQUIRE THE STOPPING OF ALL OPERATIONS IMMEDIATELY. RECORD ALL DEFICIENCIES AND
SHORTCOMINGS, TOGETHER WITH THE CORRECTIVE ACTION TAKEN, ON THE APPLICABLE FORMS.

TABLE 6.3-1 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (SCHEDULED PMCS)


INTERVAL (HOURS/GALLONS/YEARS)
3,000 HOURS 6,000 HOURS
40 250 HOURS
ITEMS TO BE INSPECTED ACTION REQUIRED 30,000 (GAL), 60,000 (GAL), FOR INSTRUCTIONS REFER TO:
HOURS OR ANNUALLY
OR 3 YEARS OR 6 YEARS
See Section 13.4.5 and NOTE 1.
AFTERCOOLER CORE Inspect, Clean ●
Test annually
Evaluate for possible overhaul
ENGINE ● ● Caterpillar Dealer and NOTE 1.
needs
CYLINDER HEAD GROUNDING STUD Inspect, Service ● See Section 6.5.2 and NOTE 1.
ENGINE LUBE OIL/ FILTER Replace ● See Section 14.3 and NOTE 1.
ENGINE AIR FILTER Replace ● See Section 16.3.2 and NOTE 1.
ENGINE CRANKCASE BREATHERS Service ● See Section 6.5.1 and NOTE 1.
FUME COLLECTOR BOX VENT
● See Section 6.5.1.1
STACK
FUEL SYSTEM PRIMARY FILTER Replace ● See Section 11.3.1 and NOTE 1.
FUEL SYSTEM SECONDARY FUEL
Replace ● See Section 11.3.2 and NOTE 1.
FILTER
FUEL TANK Inspect ● See Section 6.5.3 and NOTE 1.
FUEL SYSTEM STRAINER Service ● See Section 11.3.3 and NOTE 1.

6-18
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TABLE 6.3-1 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (SCHEDULED PMCS) (CONTINUED)
INTERVAL (HOURS/GALLONS/YEARS)
INITIAL 250
3,000
(HOURS)
250 HOURS, 1,000 HOURS
(INCLUDE 8,000 16,000 6,000 HOURS
ITEMS TO BE ACTION 2,500 (GAL) HOURS OR 30,000
THE – HOURS OR HOURS OR 60,000 (GAL), COMMENTS
INSPECTED REQUIRED OR SEMI – (GAL),
STANDARD ANNUALLY 3 YEARS OR 6 YEARS
ANNUALLY ANNUALLY OR 3
250 H
YEARS
SERVICE)
See Section 15.4.5,
Section 15.4.6 and
HOSES AND CLAMPS Inspect, Replace ● Section 15.4.7 and
NOTE 1.
See Section 13.4.5
RADIATOR Inspect (Exterior) ● and NOTE 1.
ENGINE VALVE LASH See Section 15.4.8,
AND INJECTOR Inspect, Adjust ● ● and Section 15.4.9
TIMING and NOTE 1.
ENGINE SPEED
SENSOR, (FLYWHEEL Clean, Inspect, See Section 12.4.1.4
HOUSING MOUNTED - Adjust ● ● ● and NOTE 1.
MPU)
ENGINE PROTECTIVE See Section 12.4.1
DEVICES
Inspect ● and NOTE 1.
INSPECT RADIATOR See Section 13.4.3
CAP GASKET
Inspect ● and NOTE 1.
WATER
See Section 13.4.1
TEMPERATURE Replace ● and NOTE 1.
REGULATORS
CRANKSHAFT See Section 6.4.5 and
VIBRATION DAMPER
Inspect ● NOTE 1.
See Section 6.4.7 and
ENGINE MOUNTS Inspect ● NOTE 1.
ENGINE SPEED / Check, Clean, See Section 12.4.1.7
TIMING SENSORS Calibrate ● ● and NOTE 1.
See Section 15.4.2
TURBOCHARGER Inspect ● and NOTE 1.

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TABLE 6.3-1 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (SCHEDULED PMCS) (CONTINUED)
INTERVAL (HOURS/GALLONS/YEARS)
INITIAL 250
3,000
(HOURS)
250 HOURS, 1,000 HOURS
(INCLUDE 8,000 16,000 6,000 HOURS
ITEMS TO BE ACTION 2,500 (GAL) HOURS OR 30,000
THE – HOURS OR HOURS OR 60,000 (GAL), COMMENTS
INSPECTED REQUIRED OR SEMI – (GAL),
STANDARD ANNUALLY 3 YEARS OR 6 YEARS
ANNUALLY ANNUALLY OR 3
250 H
YEARS
SERVICE)
JACKET WATER See Section 13.4.2
PUMP
Inspect ● and NOTE 1.
See Section 9.4.6 and
STARTING MOTOR Inspect ● NOTE 1.
Test: ●
COOLING SYSTEM
Level 1 Test ● See Section 13.3 and
ELC NOTE 1.
Level 2 Test ●
Change
(At 6000 hours) ●
COOLING SYSTEM
Add See Section 13.3 and
ELC EXTENDER
(At 3000 hours) ● NOTE 1.
PACKAGE
HOUSING ACCESS
DOORS, RAIN CAPS
Inspect ● See Section 8.3.1

HYDRAULIC SYSTEM
STRAINER
Clean ● ● See Section 19.3.1

HYDRAULIC SYSTEM See Section 19.3.1 and


FLUID
Replace ● NOTE 2
HYDRAULIC SYSTEM
FLUID FILTER AND Replace ● ● See Section 19.3.1
O-RING
STATION POWER
TRANSFORMER
Inspect ● See Section 10.4.1.1

NOTE 1: For Additional information see SMCS Code: 1000;7500, in SEBU6959-01, or later version and SMCS Code: 1000;7500, in SEBU7163-01, or
later version.

NOTE 2: An annual fluid sample should be taken and analyzed. The fluid change schedule may be adjusted accordingly.

6-20
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6.3.2 RUNNING GEAR SCHEDULED MAINTENANCE

6.3.2.1 MEP-PU 810A RUNNING GEAR SCHEDULED MAINTENANCE

a. Table 6.3.2.1-1 identifies the MEP-PU-810A Running Gear Scheduled Maintenance. The MEP-PU-810A Running Gear Scheduled Maintenance
is to be performed at the intervals identified. All Safety Warnings and Cautions in Section 6.1 apply to this Table.

b. Problems encountered during the MEP-PU-810A operations that do not present safety hazards or do not degrade operations must be identified
for correction during scheduled maintenance periods or at the end of operations, as appropriate.

CAUTION

PROBLEMS WHICH PRESENT SAFETY HAZARDS AND WHICH SIGNIFICANTLY DEGRADE OPERATIONS
REQUIRE THE STOPPING OF ALL OPERATIONS IMMEDIATELY. RECORD ALL DEFICIENCIES AND
SHORTCOMINGS, TOGETHER WITH THE CORRECTIVE ACTION TAKEN, ON THE APPLICABLE FORMS.

TABLE 6.3.2.1-1 MEP-PU-810A MAINTENANCE SCHEDULE


ITEM FUNCTION REQUIRED WEEKLY 3 MONTHS 6 MONTHS 12 MONTHS COMMENTS

Must be serviced by a qualified mechanic familiar with


BRAKES Test that they are operational At Every Use
this type of axle. See NOTE 1.
Adjust to proper operating Must be serviced by a qualified mechanic familiar with
BRAKE ADJUSTMENT ● this type of axle. See NOTE 1.
clearance
Inspect for wear & Must be serviced by a qualified mechanic familiar with
BRAKE LININGS ● this type of axle. See NOTE 1.
contamination
Must be serviced by a qualified mechanic familiar with
BRAKE CYLINDERS Check for leaks & sticking ● this type of axle. See NOTE 1.
Must be serviced by a qualified mechanic familiar with
BRAKE LINES Inspect for cracks, leaks, kinks ● this type of axle. See NOTE 1.
Must be serviced by a qualified mechanic familiar with
BRAKE ACTUATOR Check oil level ● this type of axle. See NOTE 1.

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TABLE 6.3.2.1-1 MEP-PU-810A MAINTENANCE SCHEDULE (CONTINUED)


ITEM FUNCTION REQUIRED WEEKLY 3 MONTHS 6 MONTHS 12 MONTHS COMMENTS

Check breakaway chain and Must be serviced by a qualified mechanic familiar with
BREAKAWAY SYSTEM At Every Use this type of axle. See NOTE 1.
lever
Inspect for abnormal wear or Must be serviced by a qualified mechanic familiar with
HUB/DRUM ● this type of axle. See NOTE 1.
scoring
WHEEL BEARINGS & Inspect for corrosion or wear. Must be serviced by a qualified mechanic familiar with
● this type of axle. See NOTE 1.
CUPS Clean & repack
Inspect for leakage. Replace if Must be serviced by a qualified mechanic familiar with
SEALS ● this type of axle. See NOTE 1.
removed.
Tighten to specified torque Must be serviced by a qualified mechanic familiar with
WHEEL NUTS & BOLTS ● this type of axle. See NOTE 1.
values
Inspect for cracks, dents or Must be serviced by a qualified mechanic familiar with
WHEELS ● this type of axle. See NOTE 1.
distortion
TIRE INFLATION Inflate tires to manufacturer’s Must be serviced by a qualified mechanic familiar with
● this type of axle. See NOTE 1.
PRESSURE specification
Inspect for cuts, wear, bulging, Must be serviced by a qualified mechanic familiar with
TIRE CONDITION ● this type of axle. See NOTE 1.
etc.

NOTE 1: For Additional information refer to Section 18.3.1.

6-22
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6.3.2.2 MEP-PU 810B RUNNING GEAR SCHEDULED MAINTENANCE

a. Table 6.3.2.2-1 identifies the MEP-PU-810B Running Gear Scheduled Maintenance. The MEP-PU-810B Running Gear Scheduled Maintenance
is to be performed at the intervals identified. All Safety Warnings and Cautions in Section 6.1 apply to this Table.

b. Problems encountered during the MEP-PU-810B operations that do not present safety hazards or do not degrade operations must be identified
for correction during scheduled maintenance periods or at the end of operations, as appropriate.

CAUTION

PROBLEMS WHICH PRESENT SAFETY HAZARDS AND WHICH SIGNIFICANTLY DEGRADE OPERATIONS
REQUIRE THE STOPPING OF ALL OPERATIONS IMMEDIATELY. RECORD ALL DEFICIENCIES AND
SHORTCOMINGS, TOGETHER WITH THE CORRECTIVE ACTION TAKEN, ON THE APPLICABLE FORMS.

TABLE 6.3.2.2-1 MEP-PU-810B MAINTENANCE SCHEDULE


EVERY EVERY
EVERY
EVERY 1,000 25,000 TO 100,000
ITEM FUNCTION REQUIRED WEEKLY 12,000 COMMENTS
MILES 30,000 MILES OR
MILES
MILES ANNUALLY

BRAKES Test that they are operational At Every Use

AIR TANK Drain condensation ●


Must be serviced by a qualified
BRAKE
Adjust to proper operating clearance ● mechanic familiar with this type of
ADJUSTMENT axle. See NOTE 1.
Must be serviced by a qualified
BRAKE LININGS Inspect for wear & contamination ● mechanic familiar with this type of
axle. See NOTE 1.
Must be serviced by a qualified
BRAKE LINES Inspect for cracks, leaks, kinks ● ● ● ● mechanic familiar with this type of
axle. See NOTE 1.
Must be serviced by a qualified
HUB/DRUM Inspect for abnormal wear or scoring ● ● ● ● mechanic familiar with this type of
axle. See NOTE 1.
WHEEL Must be serviced by a qualified
Inspect for corrosion or wear. Clean &
BEARINGS & ● mechanic familiar with this type of
repack axle. See NOTE 1.
CUPS

6-23
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TABLE 6.3.2.2-1 MEP-PU-810B MAINTENANCE SCHEDULE (CONTINUED)


EVERY EVERY
EVERY
EVERY 1,000 25,000 TO 100,000
ITEM FUNCTION REQUIRED WEEKLY 12,000 COMMENTS
MILES 30,000 MILES OR
MILES
MILES ANNUALLY
Must be serviced by a qualified
Inspect for leakage. Replace if
SEALS ● ● ● ● ● mechanic familiar with this type of
removed. axle. See NOTE 1.
Must be serviced by a qualified
WHEEL NUTS &
Tighten to specified torque values At Every Use mechanic familiar with this type of
BOLTS axle. See NOTE 1.
Must be serviced by a qualified
WHEELS Inspect for cracks, dents or distortion ● ● ● ● ● mechanic familiar with this type of
axle. See NOTE 1.
Must be serviced by a qualified
TIRE INFLATION Inflate tires to manufacturer’s
● mechanic familiar with this type of
PRESSURE specification axle. See NOTE 1.
Must be serviced by a qualified
TIRE CONDITION Inspect for cuts, wear, bulging, etc. ● mechanic familiar with this type of
axle. See NOTE 1.
Must be serviced by a qualified
Check oil level in wheel hub and inspect
WHEEL HUB ● ● ● ● ● mechanic familiar with this type of
wheel for leaks. axle. See NOTE 1.
Must be serviced by a qualified
CAMSHAFT Inspect for any signs of wear ● mechanic familiar with this type of
axle. See NOTE 1.
CAMSHAFT Must be serviced by a qualified
SPIDER Inspect for any signs of wear ● mechanic familiar with this type of
axle. See NOTE 1.
BUSHING
CAMSHAFT
Must be serviced by a qualified
SUPPORT
Inspect for any signs of wear ● mechanic familiar with this type of
BRACKET axle. See NOTE 1.
BUSHING
BRAKE Must be serviced by a qualified
ACTUATING Lubricate ● mechanic familiar with this type of
axle. See NOTE 1.
COMPONENTS
Check brake air chambers and slack
Must be serviced by a qualified
BRAKE adjusters Inspect brake rollers, roller
● ● ● ● mechanic familiar with this type of
COMPONENTS shafts, anchor pins and bushings and axle. See NOTE 1.
replace it necessary.

NOTE 1: For Additional information refer to Section 18.3.2.

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6.3.3 SR4B ALTERNATOR SCHEDULED MAINTENANCE

a. Table 6.3.3-1 identifies the SR4B Alternator Scheduled Maintenance. The SR4B Alternator Scheduled Maintenance is to be performed at the
intervals identified. All Safety Warnings and Cautions in Section 6.1 apply to this Table.

b. Problems encountered during the SR4B Alternator operations that do not present safety hazards or do not degrade operations must be identified
for correction during scheduled maintenance periods or at the end of operations, as appropriate.

CAUTION

PROBLEMS WHICH PRESENT SAFETY HAZARDS AND WHICH SIGNIFICANTLY DEGRADE OPERATIONS
REQUIRE THE STOPPING OF ALL OPERATIONS IMMEDIATELY. RECORD ALL DEFICIENCIES AND
SHORTCOMINGS, TOGETHER WITH THE CORRECTIVE ACTION TAKEN, ON THE APPLICABLE FORMS.

TABLE 6.3.3-1 SR4B ALTERNATOR SCHEDULED MAINTENANCE


MAINTENANCE SCHEDULE TOPICS LIMITS / COMMENTS
Visual Inspection:
• Cleaning Check operation, moisture, dust, oils, grease, debris, bolts, exciter, flex plates, electrical
Before placing unit in operation
• Looseness connections, debris, cleanliness, looseness. See NOTE 1 and NOTE 2 for additional information.
• Walk around
• Generator - Dry
• Generator – Set - Test
• Insulation – Test
When Required See NOTE 1 and NOTE 2 for additional information.
• Rotating Rectifier – Test
• Varistor - Test
• Winding – Test
• Electrical Connections - Check
Every Week • Generator - Clean See NOTE 1 and NOTE 2 for additional information.
• Walk – Around Inspection
Use 28.3 grams (1 ounce) of grease. Inspect bearing and bracket every major engine overhaul.
Every 1000 HOURS Lubrication, Spherical Roller Bearings
See NOTE 1 and NOTE 2 for additional information.

Every 2000 Hours Lubrication, Ball Bearings Do not over grease. Use only one ounce. See NOTE 1 and NOTE 2 for additional information.
• Rotating Rectifier - Check
Minimum 1 megohm + rated V / 1000 (Typically much higher)
Every 7500 Hours or Annually • Generator – Clean
See NOTE 1 and NOTE 2 for additional information.
• Insulation Check

NOTE 1: For Additional information refer to Section 10.4.5.2.1.

NOTE 2: For Additional information see SMCS Code: 4450, in SEBU6918-02, or later version and SMCS Code: 4450, in SENR5359-01, or later
version.

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6.3.4 PRIMARY DISTRIBUTION CENTER (PDC) SCHEDULED MAINTENANCE

a. Table 6.3.4-1 identifies the Primary Distribution Center (PDC) Scheduled Maintenance. The Primary Distribution Center (PDC) Scheduled
Maintenance is to be performed at the intervals identified. All Safety Warnings and Cautions in Section 6.1 apply to this Table.

b. Problems encountered during the Primary Distribution Center (PDC) operations that do not present safety hazards or do not degrade operations
must be identified for correction during scheduled maintenance periods or at the end of operations, as appropriate.

CAUTION

PROBLEMS WHICH PRESENT SAFETY HAZARDS AND WHICH SIGNIFICANTLY DEGRADE OPERATIONS
REQUIRE THE STOPPING OF ALL OPERATIONS IMMEDIATELY. RECORD ALL DEFICIENCIES AND
SHORTCOMINGS, TOGETHER WITH THE CORRECTIVE ACTION TAKEN, ON THE APPLICABLE FORMS.

TABLE 6.3.4-1 PRIMARY DISTRIBUTION CENTER (PDC) SCHEDULED MAINTENANCE


INTERVAL
ITEMS TO BE 250 HOURS OF PRIOR TO USE AS
ACTION REQUIRED ANNUALLY COMMENTS
INSPECTED OPERATION REQUIRED
Inspect for: ● ● See NOTE 1

LOAD TERMINALS
• Damage ● ● See NOTE 1
• Cleanliness ● ● See NOTE 1
• Missing components ● ● See NOTE 1
Inspect for: ● ● See Section 6.4.8
• Damage ● ● See Section 6.4.8
SWITCHGEAR • Cleanliness ● ● See Section 6.4.8
• Missing components ● ● See Section 6.4.8
Perform: Re-torque BUS ● ● See Section 6.4.8

ELECTRICAL COMPONENT Inspect all wire terminal screws for tightness.


TERMINAL SCREWS Tighten if loose. ● ● ● All

NOTE 1: For Additional information refer to Section 10.4.7.1.

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WARNING

APPLYING HIGH VOLTAGES ACROSS THE CONTACTS OF THE VACUUM INTERRUPTERS MAY PRODUCE X-
RAYS. THE RADIATION MAY INCREASE WITH AN INCREASE IN THE VOLTAGE OR A DECREASE IN THE
DISTANCE BETWEEN THE OPEN CONTACTS. THE LEVELS OF RADIATION GENERATED AT THE
RECOMMENDED TEST VOLTAGES AND NORMAL BREAKER OPEN GAP SPACING ARE EXTREMELY LOW.
HOWEVER, AS A PRECAUTIONARY MEASURE IT IS RECOMMENDED THAT ALL PERSONNEL STAND AT LEAST
THREE FEET AWAY FROM THE BREAKER WHILE TESTING.

TABLE 6.3.4-1 PRIMARY DISTRIBUTION CENTER (PDC) SCHEDULED MAINTENANCE (CONTINUED)


INTERVAL
ITEMS TO BE
ACTION REQUIRED PRIOR TO USE AS REQUIRED ANNUALLY COMMENTS
INSPECTED
Inspect for: ● ● See Note 2
• Damage ● ● See Note 2
• Cleanliness ● ● See Note 2
CIRCUIT BREAKER • Missing components ● ● See Note 2
(MEDIUM VOLTAGE) Test: ● ● See Note 3
• Insulation Resistance ● ● See Note 3
• AC High Voltage Potential (HYPOT) ● ● See Note 3
• Digital Low Resistance Ohm (DLRO) reading ● ● See Note 3

NOTE 1: For Additional information refer to Section 10.4.7.1.

NOTE 2: For Additional information refer to Section 10.4.11.1.

NOTE 3: For Additional information refer to Section 10.4.11.2.

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6.4 REQUIRED INSPECTIONS NOT COVERED IN OTHER CHAPTERS

The following Inspections are covered in this section:

• Inspect the External Fuel Manifold


• Inspect the Front, Middle, Rear Engine / Alternator Support Assembly
• Inspect the Oil Pan Assembly
• Inspect the Front and Rear Crankshaft and Accessory Drive Seals
• Inspect the Vibration Damper
• Inspect the Cylinder Head Grounding Stud
• Inspect the Engine Mounts
• Inspect the Switch Gear

6.4.1 INSPECT THE EXTERNAL FUEL MANIFOLD

WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING.


FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.

CAUTION

CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING


PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND
REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE
CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY
COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO
LOCAL REGULATIONS AND MANDATES.

Inspect the Fuel Manifold for the following conditions:

a. Inspect the Fuel Manifold for leaks.

b. Inspect the Fuel Manifold for loose or missing hardware.

c. Inspect the Fuel Manifold for damage.

6.4.1.2. SERVICE

If leaks or damage are found at the fuel manifold requiring the fuel supply to be interrupted to the
PU the fuel transfer pump shall be shut-off prior to closing the fuel line.

a. Shutdown and Isolate PU in accordance with Section 5.1.6.1.


b. Turn off fuel transfer pumps on PU by setting fuel pump control switch to the center (OFF)
position.
c. Repair/replace fuel manifold as required.
d. Open fuel supply valve to PU.
e. Turn-on fuel transfer pump by setting pump control switch to “A” (Automatic) position.
f. Return PU to operation in accordance with Section 5 as appropriate for mode of operation.

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6.4.2 INSPECT FRONT, MIDDLE, REAR ENGINE / ALTERNATOR SUPPORT ASSEMBLY

WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING.


FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.

CAUTION

CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING


PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND
REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE
CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY
COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO
LOCAL REGULATIONS AND MANDATES.

The Front, Middle, Rear Engine / Alternator Support Assembly provides a means of attaching the
Engine/Alternator to the PU Frame Assembly.

Inspect the Front, Middle, Rear Engine / Alternator Support Assembly for the following conditions:

a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool
enough for the maintenance to be performed, and Communication Cable (A) and (B)
rerouted to the next PU. See Section 6.1.d. for procedures.

b. Inspect the Front, Middle, Rear Engine / Alternator Support Assembly for improper mounting of
the Engine/Alternator.

c. Inspect the Front, Middle, Rear Engine / Alternator Support Assembly for deterioration of the
rubber mounts. Replace defective rubber mounts as necessary.

d. Inspect the Front, Middle, Rear Engine / Alternator Support Assembly for any crack weldments
on the frame.

6.4.3 INSPECT THE OIL PAN ASSEMBLY

WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING.


FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.

CAUTION

CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING


PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND
REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE
CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY
COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO
LOCAL REGULATIONS AND MANDATES.

The oil pan assembly, being the lowest point of the engine assembly, provides a means for housing the
oil pump assembly and attachment of oil drain lines.

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Inspect the Oil Pan Assembly for the following conditions:

a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool
enough for the maintenance to be performed, and Communication Cable (A) and (B)
rerouted to the next PU. See Section 6.1.d. for procedures.

b. Inspect the Oil Pan Assembly for cracks, nicks, dents or other damage that could cause leakage.
Make repairs as necessary.

c. Inspect the Oil Pan Assembly for evidence of leakage around gasket areas. Make repairs as
necessary.

d. Inspect the Oil Pan Assembly for evidence of leakage around threaded holes. Make repairs as
necessary.

e. Inspect the Oil Pan Assembly for evidence of leakage around the drain plug. Make repairs as
necessary.

6.4.4 INSPECT THE FRONT AND REAR CRANKSHAFT AND ACCESSORY DRIVE SEALS

WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING.


FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.

CAUTION

CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING


PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND
REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE
CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY
COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO
LOCAL REGULATIONS AND MANDATES.

The front and rear crankshaft and accessory drive seals are provided to prevent engine oil from leaking
out of engine block where crankshaft and accessory drive shaft exit engine assembly.

Inspect the Front and Rear Crankshaft and Accessory Drive Seals for the following conditions:

a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool
enough for the maintenance to be performed, and Communication Cable (A) and (B)
rerouted to the next PU. See Section 6.1.d. for procedures.

b. Inspect the Front and Rear Crankshaft and Accessory Drive Seals for evidence of leakage on the
floor or below the flywheel area and on the front end of the engine (Vibration Damper).

NOTE: Slight seepage around seal area is considered normal.

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6.4.5 INSPECT THE CRANKSHAFT VIBRATION DAMPER

WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING.


FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.

CAUTION

CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING


PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND
REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE
CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY
COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO
LOCAL REGULATIONS AND MANDATES.

The Crankshaft Vibration Damper is a fluid filled case.

Inspect the Crankshaft Vibration Damper for the following conditions:

a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool
enough for the maintenance to be performed, and Communication Cable (A) and (B)
rerouted to the next PU. See Section 6.1.d. for procedures.

b. Inspect the Crankshaft Vibration Damper for evidence of dents.

c. Inspect the Crankshaft Vibration Damper for evidence of cracks.

d. Inspect the Crankshaft Vibration Damper for evidence of leaking of fluid.

e. Replace the damper if it has any of the above damage.

6.4.6 INSPECT THE CYLINDER HEAD GROUNDING STUD

WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING.


FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.

The Cylinder Head Grounding Stud must have a wire ground to the battery.

Inspect the Cylinder Head Grounding Stud for the following conditions:

a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool
enough for the maintenance to be performed, and Communication Cable (A) and (B)
rerouted to the next PU. See Section 6.1.d. for procedures.

b. Inspect the Cylinder Head Grounding Studs wiring harness for damage.

c. Inspect the Cylinder Head Grounding Stud for corrosion on the stud.

d. Correct any faults found.

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6.4.7 INSPECT THE ENGINE MOUNTS

WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING.


FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.

CAUTION

CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING


PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND
REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE
CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY
COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO
LOCAL REGULATIONS AND MANDATES.

Inspect the Engine Mounts for the following conditions:

a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool
enough for the maintenance to be performed, and Communication Cable (A) and (B)
rerouted to the next PU. See Section 6.1.d. for procedures.

b. Inspect the Engine Mounts for signs of deterioration, if deterioration is found the mount should be
replaced.

c. Inspect the Engine Mounts for proper bolt torque, 150 Ft-Lbs.

d. Engine vibration can be caused by the following conditions:

• Improper mounting of the engine.


• Deterioration of the engine mounts.

6.4.8 INSPECT THE SWITCHGEAR

WARNING

HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT


DURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION
AND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN
LOAD CABLES ARE HANDLED.

WARNING

DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF


POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS
CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM
FAILURE TO OBSERVE THIS WARNING.

6-32
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WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING.


FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.

WARNING

HIGH VOLTAGE, USE PROPER PROTECTIVE EQUIPMENT AND PROPER TEST


EQUIPMENT.

WARNING

DISCHARGE CAPACITIVE CHARGE FROM ALL EXPOSED CONDUCTORS

Inspect the Switchgear for the following:

a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant
electrical bus or utility connection, isolated from any power plant control system, and rendered
unable to start. See Section 6.1.d. for procedures.

b. Remove the PDC from the PU. See Chapter 22 for reference.

c. Inspect the Internal AC Electrical System Bus for proper mounting.

d. Inspect the Internal AC Electrical System Bus for loose connections, physical damage and heat
damage.

e. Inspect the Internal AC Electrical System Bus and associated wiring for signs of insulation
breakdown such as cracked sleeves and burned insulation.

f. Inspect the Internal AC Electrical System Bus Mounting Bolts for proper torque. The torque
should be checked using the following guidelines:

• Annually or other time period required by USAF AFJMAN 32-1082, USA TM 5-684 and
current NETA Standards to verify tightness of accessible bolted electrical connections.
• The proper torque for the Bus mounting bolts is 20 ft. lbs.

6.5 SERVICE REQUIREMENTS NOT COVERED IN OTHER CHAPTERS

The following Service Requirements are covered in this section:

• Engine Crankcase Breather Service Requirements


• Cylinder Head Grounding Stud Service Requirements
• Fuel Tank Sediment Service Requirements
• Remote Terminal Unit (RTU)

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6.5.1 ENGINE CRANKCASE BREATHER SERVICE REQUIREMENTS

WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING.


FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.

CAUTION

CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING


PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND
REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE
CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY
COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO
LOCAL REGULATIONS AND MANDATES.

If the crankcase breather is not maintained on a regular basis, the crankcase breather will become
plugged. A plugged crankcase breather will cause excessive crankcase pressure that may cause
crankcase seal leakage.

To service the Engine Crankcase Breather, proceed with the following:

a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool
enough for the maintenance to be performed, and Communication Cable (A) and (B)
rerouted to the next PU. See Section 6.1.c. for procedures.

b. To service the Engine Crankcase Breather, loosen the Engine Crankcase Breather Hose Clamp
and remove the hose from the Engine Crankcase Breather.

c. Loosen and remove the Cover Clamp and Engine Crankcase Breather Cover.

d. Wash the Engine Crankcase Breather Element, in solvent that is clean and non-flammable.
Allow the Engine Crankcase Breather Element to dry before reinstalling it.

e. Install a new seal.

f. If the Engine Crankcase Breather cannot be cleaned, install a clean and dry element.

g. Reinstall the Engine Crankcase Breather Clamp and Cover.

h. Reinstall the Engine Crankcase Breather Hose Clamp on the hose, connect the hose to the
Engine Crankcase Breather Cover and tighten the hose clamp.

NOTE: Refer to Caterpillar Manual SEBU 7163.

6.5.1.1 FUME COLLECTOR BOX VENT STACK

The Fume Collector Box Vent Stack contains a rough grade of steel wool that must be cleaned
periodically to keep the vent stack from clogging.

To service the Fume Collector Box Vent Stack, proceed with the following:

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a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool
enough for the maintenance to be performed

b. Unscrew the top of the vent stack.

c. Flush the vent stack with one gallon of hot soapy water.

d. Drain the Fume Collector Box of all soapy water.

e. Screw on the top of the vent stack

6.5.2 CYLINDER HEAD GROUNDING STUD SERVICE REQUIREMENTS

WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING.


FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.

The Cylinder Head Grounding Stud must have a wire ground to the battery.

To Service the Cylinder Head Grounding Stud, proceed with the following:

a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool
enough for the maintenance to be performed, and Communication Cable (A) and (B)
rerouted to the next PU. See Section 6.1.d. for procedures.

b. To Service the Cylinder Head Grounding Stud, re-torque the Cylinder Head Grounding Stud to
35 ± 7 ft-lbs at every oil change. Ground wires and straps should be combined at engine
grounds. All grounds should be tight and free of corrosion.

c. To Service the Cylinder Head Grounding Stud, clean the Cylinder Head Grounding Stud and the
terminals for the cylinder head ground strap with a clean cloth.

d. If the connections are corroded, clean the connections with a solution of baking soda and water.

e. Keep the cylinder head grounding stud and the strap clean and coated with MPGM grease or
petroleum jelly.

6-35
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CYLINDER HEAD
GROUNDING
STUD

FIGURE 6.5.2-1 CYLINDER HEAD GROUNDING STUD

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6.5.3 FUEL TANK SEDIMENT SERVICE REQUIREMENTS

WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING.


FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.

CAUTION

CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING


PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND
REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE
CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY
COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO
LOCAL REGULATIONS AND MANDATES.

Fuel quality is critical to the performance and to the service life of the engine. Water in the fuel tank can
cause excessive fuel system wear. Condensation occurs during the heating and cooling of fuel. The
condensation occurs as the fuel passes through the system fuel system and the fuel returns to the fuel
tank. Draining the fuel tank regularly and obtaining fuel from reliable sources can help to eliminate water
in the fuel.

To Service the Fuel Tank, proceed with the following:

a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool
enough for the maintenance to be performed, and Communication Cable rerouted to the
next PU. See Section 6.1.d. for procedures.

b. Inspect the Fuel Tank using a flashlight to view through the filler cap for sediment or water. The
fuel drain is located directly below the filler cap and any sediment or water should be visible. If
detected, Service.

c. To Service the Fuel Tank, empty the Fuel Tank with an external pump.

d. After the Fuel Tank is empty, remove the Fuel Tank Drain Plug and drain the sediment into a
suitable container.

e. Reinstall the Fuel Tank Drain Plug.

6.5.4 REMOTE TERMINAL UNIT (RTU)

To Service the RTU, proceed with the following:

CAUTION
THIS SERVICE MUST BE PERFORMED EVERY 6-MONTHS IF THE PU IS IN STORAGE. IT IS
CRITICAL THAT THE RTU BATTERY BE RECHARGED TO MAINTAIN PROGRAMMED VARIABLES
IN THE RTU MEMORY. IF THE RTU BATTERY IS ALLOWED TO DISCHARGE COMPLETELY, THE
RTU SOFTWARE WILL HAVE TO BE RELOADED BEFORE OPERATION.

a. If the PU is in storage and the batteries have been disconnected, reconnect the batteries.

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b. Connect an external 120 VAC power source to the battery chargers and ensure the chargers are
supplying current to the batteries.

c. Open the MCP flip up door.

d. Turn on the DC Power Circuit Breaker (CB1). The PDC will be powered up and the RTU battery
will recharge through internal circuitry.

e. Leave the 120 VAC power source connected to the battery chargers and the CB1 on for a
minimum of 8 hours to recharge the RTU battery.

f. After 8 hours, Turn off CB1, disconnect the 120 VAC power source to the battery chargers, and
disconnect the PU batteries for continued storage.

NOTE: This service can be performed in conjunction with other service of the PU, has long as the
DC Power remains turned on for 8 continuous hours every 6-months.

6-38
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USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254

CHAPTER 7
UNSCHEDULED MAINTENANCE/TROUBLESHOOTING
TABLE OF CONTENTS

SECTION TITLE PAGE


7.0 UNSCHEDULED MAINTENANCE / TROUBLESHOOTING PROCEDURES 5

7.1 SAFETY PROCEDURES 5

7.2 UNSCHEDULED MAINTENANCE PROCEDURES 17

7.2.1 HOUSING ASSEMBLY UNSCHEDULED MAINTENANCE PROCEDURES 17

7.2.2 DC SYSTEM COMPONENTS UNSCHEDULED MAINTENANCE


PROCEDURES 17

7.2.3 AC SYSTEM COMPONENTS UNSCHEDULED MAINTENANCE


PROCEDURES 18

7.2.4 FUEL SYSTEM COMPONENTS UNSCHEDULED MAINTENANCE


PROCEDURES 18

7.2.5 CONTROL AND INSTRUMENT COMPONENTS UNSCHEDULED


MAINTENANCE PROCEDURES 18

7.2.6 COOLING SYSTEM COMPONENTS UNSCHEDULED MAINTENANCE


PROCEDURES 19

7.2.7 LUBRICATION SYSTEM COMPONENTS UNSCHEDULED MAINTENANCE


PROCEDURES 19

7.2.8 ENGINE COMPONENTS UNSCHEDULED MAINTENANCE PROCEDURES 19

7.2.9 AIR INTAKE AND EXHAUST SYSTEM COMPONENTS UNSCHEDULED


MAINTENANCE PROCEDURES 19

7.2.10 REMOTE OPERATOR TERMINAL (ORT) UNSCHEDULED MAINTENANCE


PROCEDURES 20

7.2.11 RUNNING GEAR/TRAILER ASSEMBLY COMPONENTS UNSCHEDULED


MAINTENANCE PROCEDURES 20

7.2.12 HYDRAULIC SYSTEM COMPONENTS UNSCHEDULED MAINTENANCE


PROCEDURES 20

7.2.13 ENGINE/ALTERNATOR UNSCHEDULED MAINTENANCE PROCEDURES 20

7.2.14 PDC UNSCHEDULED MAINTENANCE PROCEDURES 20

7.3 TROUBLESHOOTING PROCEDURES 21

7-1
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TABLE OF CONTENTS

SECTION TITLE PAGE


7.3.1 BASIC ENGINE TROUBLESHOOTING PROCEEDURES 23

7.3.2 BASIC EMCP+ TROUBLESHOOTING PROCEDURES 34

7.3.3 BASIC GENERATOR OPERATIONS TROUBLESHOOTING PROCEDURES 35

7.3.4 TROUBLESHOOTING THE FUEL PRIMER PUMP 47

7.3.5 COOLING SYSTEM TROUBLE SHOOTING PROCEDURES 48

7.3.6 RUNNING GEAR/TRAILER TROUBLESHOOTING PROCEDURES 51

7.3.6.1 MEP-PU-810A RUNNING GEAR/TRAILER TROUBLESHOOTING


PROCEDURES 51

7.3.6.2 MEP-PU-810B RUNNING GEAR/TRAILER TROUBLESHOOTING


PROCEDURES 53

7.3.6.2.1 TROUBLESHOOTING THE ABS SYSTEM 53

7.3.6.2.2 MEP-PU-810A RUNNING GEAR/TRAILER TROUBLESHOOTING


PROCEDURES 58

7.3.7 HYDRAULIC SYSTEM TROUBLESHOOTING PROCEDURES 60

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LIST OF TABLES

TABLE TITLE PAGE


TABLE 7.3.1-1 BASIC ENGINE TROUBLESHOOTING PROCEDURES 23

TABLE 7.3.1-1 BASIC ENGINE TROUBLESHOOTING PROCEDURES


(CONTINUED) 24

TABLE 7.3.1-1 BASIC ENGINE TROUBLESHOOTING PROCEDURES


(CONTINUED) 25

TABLE 7.3.1-1 BASIC ENGINE TROUBLESHOOTING PROCEDURES


(CONTINUED) 26

TABLE 7.3.1-1 BASIC ENGINE TROUBLESHOOTING PROCEDURES


(CONTINUED) 27

TABLE 7.3.1-1 BASIC ENGINE TROUBLESHOOTING PROCEDURES


(CONTINUED) 28

TABLE 7.3.1-1 BASIC ENGINE TROUBLESHOOTING PROCEDURES


(CONTINUED) 29

TABLE 7.3.1-1 BASIC ENGINE TROUBLESHOOTING PROCEDURES


(CONTINUED) 30

TABLE 7.3.1-1 BASIC ENGINE TROUBLESHOOTING PROCEDURES


(CONTINUED) 31

TABLE 7.3.1-1 BASIC ENGINE TROUBLESHOOTING PROCEDURES


(CONTINUED) 32

TABLE 7.3.1-1 BASIC ENGINE TROUBLESHOOTING PROCEDURES


(CONTINUED) 33

TABLE 7.3.2-1 BASIC EMCP + TROUBLESHOOTING PROCEDURES 34

TABLE 7.3.3-1 BASIC GENERATOR OPERATIONS TROUBLESHOOTING


PROCEDURES 36

TABLE 7.3.3-1 BASIC GENERATOR OPERATIONS TROUBLESHOOTING


PROCEDURES (CONTINUED) 37

TABLE 7.3.3-1 BASIC GENERATOR OPERATIONS TROUBLESHOOTING


PROCEDURES (CONTINUED) 38

TABLE 7.3.3-1 BASIC GENERATOR OPERATIONS TROUBLESHOOTING


PROCEDURES (CONTINUED) 39

TABLE 7.3.3-1 BASIC GENERATOR OPERATIONS TROUBLESHOOTING


PROCEDURES (CONTINUED) 40

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LIST OF TABLES

TABLE TITLE PAGE


TABLE 7.3.3-1 BASIC GENERATOR OPERATIONS TROUBLESHOOTING
PROCEDURES (CONTINUED) 41

TABLE 7.3.3-1 BASIC GENERATOR OPERATIONS TROUBLESHOOTING


PROCEDURES (CONTINUED) 42

TABLE 7.3.3-1 BASIC GENERATOR OPERATIONS TROUBLESHOOTING


PROCEDURES (CONTINUED) 43

TABLE 7.3.3-1 BASIC GENERATOR OPERATIONS TROUBLESHOOTING


PROCEDURES (CONTINUED) 44

TABLE 7.3.3-1 BASIC GENERATOR OPERATIONS TROUBLESHOOTING


PROCEDURES (CONTINUED) 45

TABLE 7.3.3-1 BASIC GENERATOR OPERATIONS TROUBLESHOOTING


PROCEDURES (CONTINUED) 46

TABLE 7.3.5-1 COOLANT SYSTEM TROUBLESHOOTING PROCEDURES 48

TABLE 7.3.5-1 COOLANT SYSTEM TROUBLESHOOTING PROCEDURES


(CONTINUED) 49

TABLE 7.3.5-1 COOLANT SYSTEM TROUBLESHOOTING PROCEDURES


(CONTINUED) 50

TABLE 7.3.6.1-1 MEP-PU-810A RUNNING GEAR/TRAILER TROUBLESHOOTING


PROCEDURES 51

TABLE 7.3.6.1-1 MEP-PU-810A RUNNING GEAR/TRAILER TROUBLESHOOTING


PROCEDURES (CONTINUED) 52

TABLE 7.3.6.2.1-1 TROUBLESHOOTING THE ABS SYSTEM 54

TABLE 7.3.6.2.1-1 TROUBLESHOOTING THE ABS SYSTEM (CONTINUED) 55

TABLE 7.3.6.2.1-1 TROUBLESHOOTING THE ABS SYSTEM (CONTINUED) 56

TABLE 7.3.6.2.1-1 TROUBLESHOOTING THE ABS SYSTEM (CONTINUED) 57

TABLE 7.3.6.2.2-1 MEP-PU-810B RUNNING GEAR/TRAILER TROUBLESHOOTING


PROCEDURES 58

TABLE 7.3.6.2.2-1 MEP-PU-810B RUNNING GEAR/TRAILER TROUBLESHOOTING


PROCEDURES (CONTINUED) 59

TABLE 7.3.7-1 HYDRAULIC SYSTEM TROUBLESHOOTING PROCEDURES 60

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7.0 UNSCHEDULED MAINTENANCE / TROUBLESHOOTING PROCEDURES

Unscheduled Maintenance / Troubleshooting procedures covered in this section are:

• Unscheduled Maintenance Procedures


• For In-Depth Troubleshooting Procedures see USAF TO 35C2-3-518-21 and CTM
01646.1R0253/1R0254 TR

7.1 SAFETY PROCEDURES

WARNING

IMPORTANT: SAFETY WARNINGS ARE APPROPRIATE FOR ALL MAINTENANCE


ACTIVITIES. READ THIS SECTION, PRIOR TO PERFORMING ANY MAINTENANCE

WARNING

THE EQUIPMENT COVERED IN THIS MANUAL MUST BE INSTALLED, OPERATED,


AND MAINTAINED BY QUALIFIED PERSONS WHO ARE KNOWLEDGEABLE IN THE
INSTALLATION, OPERATION, AND MAINTENANCE OF MEDIUM VOLTAGE
ELECTRICAL POWER GENERATION EQUIPMENT ALONG WITH ASSOCIATED
HAZARDS. A QUALIFIED PERSON IS ONE WHO IS TRAINED AND COMPETENT IN:

• THE SKILLS AND TECHNIQUES NECESSARY TO DISTINGUISH


ENERGIZED PARTS FROM NON-ENERGIZED PARTS OF ELECTRICAL
EQUIPMENT.

• THE SKILLS AND TECHNIQUES NECESSARY TO DETERMINE THE


PROPER APPROACH DISTANCES CORRESPONDING TO THE VOLTAGES
TO WHICH THE QUALIFIED PERSON WILL BE EXPOSED.

• THE PROPER USE OF SPECIAL PRECAUTIONARY TECHNIQUES,


PERSONAL PROTECTIVE EQUIPMENT, INSULATING AND SHIELDING
MATERIALS, AND INSULATED TOOLS FOR WORKING ON OR NEAR
ENERGIZED PARTS OF ELECTRICAL EQUIPMENT AND ROTATING
MACHINERY.

• THE PROPER USE OF SPECIAL PRECAUTIONARY TECHNIQUES,


PERSONAL PROTECTIVE EQUIPMENT, INSULATING AND SHIELDING
MATERIALS, AND INSULATED TOOLS FOR WORKING ON OR NEAR
EXPOSED HOT SURFACES OF ENGINE AND EXHAUST SYSTEM
COMPONENTS.

THESE INSTRUCTIONS ARE INTENDED ONLY FOR SUCH QUALIFIED PERSONS.


THEY ARE NOT A SUBSTITUTE FOR ADEQUATE TRAINING AND EXPERIENCE IN
SAFETY PROCEDURES FOR THIS TYPE OF EQUIPMENT.

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WARNING

BATTERY ELECTROLYTE CONTAINS SULFURIC ACID, WHICH CAN CAUSE


SEVERE CHEMICAL BURNS. AVOID ALL CONTACT. SKIN AND EYE PROTECTION
IS REQUIRED. IN CASE OF CONTACT, IMMEDIATELY FLUSH WITH LARGE
AMOUNTS OF CLEAN WATER AND OBTAIN MEDICAL AID.

WARNING

WHEN DISCONNECTING BATTERY CABLES, ALWAYS DISCONNECT NEGATIVE


TERMINAL FIRST. WHEN RECONNECTING, CONNECT NEGITIVE TERMINAL LAST.
FAILURE TO COMPLY MAY CAUSE SPARKING AND CONSEQUENT BATTERY
EXPLOSION.

WARNING

HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT


DURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION
AND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN
LOAD CABLES ARE HANDLED.

WARNING

DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS


OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A
SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET
IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT
FROM FAILURE TO OBSERVE THIS WARNING.

WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING.


FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.

WARNING

SIDE PANELS ARE HEAVY. USE EXTREME CAUTION WHEN UNBOLTING AND
REMOVING.

WARNING

TOP PANELS ARE HEAVY. USE EXTREME CAUTION WHEN UNBOLTING AND
REMOVING.

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WARNING

MUFFLER ASSEMBLIES ARE HEAVY. USE EXTREME CAUTION WHEN


UNBOLTING AND REMOVING.

WARNING

ENSURE THAT HEATER STRIP COVERS ARE ON WHEN GENERATOR IS


RUNNING. LOW VOLTAGE IS PRESENT AT THE HEATER STRIP TERMINALS

WARNING

THE INSULATION TESTER PRODUCES HIGH VOLTAGE. TO AVOID PERSONAL


INJURY DURING THE TEST, DO NOT TOUCH THE WINDING BEING TESTED OR
THE TEST LEADS.

WARNING

DO NOT COME IN CONTACT WITH LOAD TERMINAL DURING TEST. DEATH BY


ELECTROCUTION MAY RESULT

WARNING

FOLLOW MANUFACTURER'S TEST PROCEDURES INCLUDED WITH THE TEST


EQUIPMENT

WARNING

ALWAYS CONSIDER AN ARRESTER TO BE ENERGIZED UNTIL THE LINE AND


GROUND LEADS HAVE BEEN DISCONNECTED FROM THE CIRCUIT.

WARNING

NEVER INSTALL A DAMAGED ARRESTER. A DAMAGED ARRESTER MAY


MISSOPERATE VIOLENTLY, CAUSING SEVERE PERSONAL INJURY.

WARNING

USE OF A LIFTING DEVICE IS RECOMMENDED FOR REMOVING THE STATION


POWER TRANSFORMER. EXTREMELY HEAVY OVER 100 LBS

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WARNING

PRIOR TO TROUBLESHOOTING THE POWER UNIT (PU), ENSURE THE TIE AND
FEEDER CABLES ARE ALL INSTALLED ON PARKING STANDS, TO PREVENT THE
POSSIBILITY OF UTILITY POWER BEING FED BACK INTO GENERATOR SET.
ENSURE EQUIPMENT IS PROPERLY TAGGED AND NOT ENERGIZED. RESIDUAL
VOLTAGE IS PRESENT AT THE GENERATOR LEADS WITH THE REGULATOR
TURNED OFF, REACHING SEVERAL HUNDRED VOLTS ON THE GENERATOR SET.
PROPER INSULATION AND ISOLATION OF METERING EQUIPMENT MUST BE
OBSERVED WHEN TESTING GENERATOR. USE PROPER TEST EQUIPMENT TO
CHECK FOR VOLTAGE BEFORE PROCEEDING. FAILURE TO COMPLY MAY
RESULT IN DEATH BY ELECTROCUTION.

WARNING

BEFORE WORKING ON THE BATTERY CHARGER, ENSURE THAT AC POWER IS


OFF AND DISCONNECTED. ALSO, DISCONNECT THE NEGATIVE BATTERY LEAD

WARNING

ETHER IS HIGHLY FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY


TRACT. USE ONLY IN AN ADEQUATELY VENTILATED AREA. SKIN, EYE. AND
RESPIRATORY PROTECTION ARE REQUIRED. FAILURE TO COMPLY MAY
RESULT IN SERIOUS INJURY OR ILLNESS.

WARNING

DIESEL FUEL IS FLAMMABLE AND MODERATELY TOXIC TO EYES, SKIN, AND


RESPIRATORY TRACT. SKIN AND EYE PROTECTION REQUIRED. AVOID
REPEATED OR PROLONGED CONTACT. USE IN WELL-VENTILATED AREA.
FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY OR ILLNESS.

WARNING

WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE


TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT.
MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY
OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST
EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS
USER.

WARNING

ONLY ONE PU MAY BE SELECTED TO ANY ONE USS POSITION DURING


MULTIPLE PU OPERATIONS. OPERATING WITH MORE THAN ONE UNIT AT THE
SAME ID MAY CAUSE UNSAFE AND ERRATIC OPERATIONAL CONDITIONS.

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WARNING

EXPLOSION HAZARD – WHEN IN HAZARDOUS LOCATIONS, DISCONNECT


POWER BEFORE REPLACING OR WIRING MODULES.

WARNING

ALWAYS WEAR EYE PROTECTION WHEN YOU PERFORM ANY SERVICE WORK
ON A COOLING SYSTEM

WARNING

RELEASE THE PRESSURE IN THE COOLING SYSTEM BEFORE PERFORMING ANY


SERVICE WORK. IF THE PRESSURE IN THE COOLING SYSTEM IS NOT
RELEASED OR THE TEMPERATURE OF THE SYSTEM IS NOT PERMITTED TO
COOL, STEAM OR HOT WATER MAY BE RELEASED WHEN YOU REMOVE THE
FILLER CAP. THIS MAY CAUSE PERSONAL INJURY.

WARNING

TO RELEASE THE PRESSURE IN A COOLING SYSTEM, LET THE SYSTEM COOL,


PUT A HEAVY CLOTH OVER THE CAP AND LOOSEN IT SLOWLY.

WARNING

DO NOT ALLOW UNDILUTED CORROSION INHIBITORS OR DILUTED/UNDILUTED


RADIATOR CLEANERS TO COME IN CONTACT WITH THE SKIN OR EYES.

WARNING

DO NOT USE CHROMATE CORROSION INHIBITORS IN A COOLING SYSTEM.

WARNING

ALWAYS FOLLOW THE MANUFACTURER’S INSTRUCTIONS WHEN HANDLING


CORROSION INHIBITORS, RADIATOR CLEANERS OR ANTIFREEZE BE
ESPECIALLY SURE TO FOLLOW THE MANUFACTURER’S RECOMMENDATIONS
CONCERNING TOXICITY.

WARNING

ETHYLENE GLYCOL MAY CATCH FIRE WHEN IT IS HOT OR EXPOSED TO AN


OPEN FLAME. DO NOT WELD, CUT OR USE AN OPEN FLAME NEAR LEAKING
COOLANT THAT CONTAINS ANTIFREEZE.

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WARNING

DO NOT USE ALCOHOL IN PLACE OF ANTIFREEZE. ALCOHOL HAS A LOWER


BOILING TEMPERATURE AND FLASH POINT.

WARNING

DO NOT ATTEMPT TO TIGHTEN ANY HOSE CLAMPS WHILE THE COOLING


SYSTEM IS HOT OR UNDER PRESSURE. IF THERE IS A FAILURE OF THE HOSE
CLAMP WHEN IT IS TIGHTENED, A SUDDEN LOSS OF HOT COOLANT OR STEAM
COULD RESULT.

WARNING

DO NOT REMOVE FILLER CAP AFTER OPERATION UNTIL SYSTEM HAS COOLED
DOWN. FAILURE TO ALLOW ENGINE COOLANT TO COOL DOWN COULD RESULT
IN SECOND AND THIRD DEGREE BURNS. CAP MAY BE HALF-TURNED TO
RELIEVE PRESSURE AND THEN REMOVED TO INSPECT COOLANT LEVEL.

WARNING

PERSONAL INJURY CAN RESULT FROM HOT COOLANT, STEAM AND ALKALI.

WARNING

AT OPERATING TEMPERATURE, ENGINE COOLANT IS HOT AND UNDER


PRESSURE. THE RADIATOR AND ALL LINES TO THE ENGINE CONTAIN HOT
COOLANT OR STEAM. ANY CONTACT CAN CAUSE SEVERE BURNS.

WARNING

REMOVE FILLER CAP SLOWLY TO RELIEVE PRESSURE ONLY WHEN THE


ENGINE IS STOPPED AND THE FILLER CAP IS COOL ENOUGH TO TOUCH WITH
YOUR BARE HAND.

WARNING

COOLING SYSTEM CONDITIONER CONTAINS ALKALI. AVOID CONTACT WITH


SKIN AND EYES.

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WARNING

HOT OIL AND HOT COMPONENTS CAN CAUSE PERSONAL INJURY. DO NOT
ALLOW HOT OIL OR HOT COMPONENTS TO CONTACT THE SKIN. DO NOT DRAIN
THE OIL WHEN THE ENGINE IS COLD. AS THE OIL COOLS, SUSPENDED WASTE
PARTICLES SETTLE ON THE BOTTOM OF THE OIL PAN. THE WASTE PARTICLES
ARE NOT REMOVED WHEN DRAINING COLD OIL. DRAIN THE CRANKCASE WITH
THE ENGINE STOPPED. DRAIN THE CRANKCASE WITH THE OIL WARM. THIS
DRAINING METHOD ALLOWS THE WASTE PARTICLES THAT ARE SUSPENDED IN
THE OIL TO BE DRAINED PROPERLY.

WARNING

DO NOT ALLOW GASKET MATERIAL TO FALL INSIDE ROCKER LEVER HOUSING.


FAILURE TO COMPLY MAY RESULT IN DAMAGE TO ENGINE.

WARNING

DO NOT RESET A FAULT BEFORE DETERMINING AND CORRECTING THE CAUSE OF A


FAULT. FAILURE TO CORRECT A FAULT BEFORE RESETTING CAN RESULT IN DEATH,
PERSONAL INJURY, OR EQUIPMENT DAMAGE

WARNING

HYDRAULIC FLUID IS HOT AND UNDER HIGH PRESSURE. DO NOT PLACE ANY
PART OF YOUR BODY OVER ANY LEAK. SEVERE INJURY CAN OCCUR IF THIS
HAPPENS.

WARNING

THE HYDRAULIC PRESSURE HELD IN THE SYSTEM MAY CAUSE THE LEVER TO
SNAP QUICKLY. KEEP HANDS AND FINGERS CLEAR, AS YOU RESET THE
BREAKAWAY MECHANISM. WHEN TOWING, AVOID SHARP TURNS THAT CAN
CAUSE THE ACTUATOR TO BIND AGAINST THE TOW VEHICLE. THIS CAN
DAMAGE THE ACTUATOR AND TRAILER, CAUSING BRAKE FAILURE.

WARNING

DO NOT MIX PETROLEUM BASED OIL WITH BRAKE FLUID. THIS WILL CAUSE
SEAL SWELLING AND NON-FUNCTIONING BRAKES.

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WARNING

ASBESTOS DUST HAZARD

SINCE SOME BRAKE SHOE FRICTION MATERIALS CONTAIN ASBESTOS.


CERTAIN PRECAUTIONS MUST BE TAKEN WHEN SERVICING BRAKES:

AVOID CREATING OR BREATHING DUST. AVOID MACHINING, FILING, OR


GRINDING THE BRAKE LININGS. DO NOT USE COMPRESSED AIR OR DRY
BRUSHING FOR CLEANING. DUST CAN BE REMOVED WITH A DAMP BRUSH.

WARNING

THE HYDRAULIC PRESSURE HELD IN THE SYSTEM MAY CAUSE THE LEVER TO
SNAP QUICKLY. KEEP HANDS AND FINGERS CLEAR, AS YOU RESET THE
BREAKAWAY MECHANISM. WHEN TOWING, AVOID SHARP TURNS THAT CAN
CAUSE THE ACTUATOR TO BIND AGAINST THE TOW VEHICLE. THIS CAN
DAMAGE THE ACTUATOR AND TRAILER, CAUSING BRAKE FAILURE.

WARNING

SALTWATER, GRANULAR FERTILIZERS AND OTHER CORROSIVE MATERIALS


ARE DESTRUCTIVE TO METAL. TO PROLONG THE LIFE OF A BRAKING SYSTEM
USED UNDER CORROSIVE CONDITIONS, WE RECOMMEND THAT THE
ACTUATOR BE FLUSHED AFTER USE WITH A HIGH PRESSURE WATER HOSE.
BE SURE TO RE-GREASE BEARINGS AND OIL ALL MOVING PARTS AFTER THE
UNIT HAS DRIED. AT THE END OF THE SEASON, WHEN UNIT IS TO BE STORED,
REMOVE THE BRAKE DRUMS AND CLEAN INSIDE THE BRAKES. PACK WHEEL
BEARINGS BEFORE DRUM IS INSTALLED. FAILURE TO PROPERLY AND
ADEQUATELY GREASE AND MAINTAIN THE ACTUATOR COULD WEAKEN IT
AND/OR CAUSE IT TO FAIL AND RESULT IN SERIOUS INJURY AND/OR
PROPERTY DAMAGE.

WARNING

PROPER MATCHING OF THE TIRE/WHEEL COMBINATION IS ESSENTIAL TO


PROPER FUNCTION OF YOUR TRAILER RUNNING GEAR. SOME TIRES MAY CALL
FOR A MAXIMUM INFLATION PRESSURE ABOVE THE RIM OR WHEEL CAPACITY.
DO NOT EXCEED MAXIMUM INFLATION PRESSURES FOR RIMS OR WHEELS.
CATASTROPHIC FAILURE MAY RESULT.

WARNING

DO NOT GET GREASE OR OIL ON BRAKE LININGS. BRAKES WILL NOT


FUNCTION PROPERLY

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WARNING

DO NOT MIX LITHIUM, CALCIUM, SODIUM OR BARIUM COMPLEX GREASES DUE


TO POSSIBLE COMPATIBILITY PROBLEMS. WHEN CHANGING FROM ONE TYPE
OF GREASE TO ANOTHER, IT IS NECESSARY TO ENSURE ALL THE OLD GREASE
HAS BEEN REMOVED.

WARNING

DO NOT DISASSEMBLE THE SPRING BRAKE. IT CONTAINS A COMPRESSED


SPRING THAT MAY CAUSE INJURY IF REMOVED. THE SPRING BRAKE MUST BE
CAGED BEFORE SERVICING AND SHOULD ONLY BE PERFORMED BY QUALIFIED
PERSONNEL.

WARNING

FAILURE TO CORRECTLY LUBRICATE BEARINGS AND MAINTAIN PROPER


LUBRICATION COULD CAUSE BEARING AND AXLE SPINDLE DAMAGE, WHICH
COULD RESULT IN THE WHEEL LOCKING UP OR COMING OFF DURING VEHICLE
OPERATION.

CAUTION

SIGNIFICANT DIFFERENCES BETWEEN THE MEP-PU-810A AND MEP-PU-810B


REQUIRE SPECIFIC INSTRUCTIONS FOR EACH VERSION.

CAUTION

DO NOT ALLOW THE STARTER MOTOR TO OPERATE MORE THAN 30 SECONDS.


ALLOW IT TO COOL AT LEAST 2 MINUTES BEFORE RE-ENERGIZING THE
MOTOR. OVERHEATING WILL DAMAGE THE MOTOR.

CAUTION

ALWAYS HANDLE SURGE ARRESTERS PACKED OR UNPACKED VERY


CAREFULLY. DO NOT DROP, JAR, OR HANDLE AN ARRESTER ROUGHLY.
DROPPING, JARRING, AND/OR ROUGH HANDLING MAY DAMAGE THE
ARRESTER INTERNALLY OR EXTERNALLY. THIS COULD MAKE THE ARRESTER
INCAPABLE OF PROTECTING THE CIRCUIT AND COULD SHORTEN THE SERVICE
LIFE OF THE ARRESTER SIGNIFICANTLY.

CAUTION

CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING


PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND
REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE
CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY
COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO
LOCAL REGULATIONS AND MANDATES.

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CAUTION

THE WATER TEMPERATURE REGULATORS (2 EA) ARE AN IMPORTANT PART OF


THE COOLING SYSTEM. THE WATER TEMPERATURE REGULATORS DIVIDE THE
COOLANT FLOW BETWEEN THE RADIATOR AND THE BYPASS ELBOW. THIS WILL
MAINTAIN THE CORRECT ENGINE TEMPERATURE. IF THE WATER TEMPERATURE
REGULATORS ARE NOT INSTALLED IN THE SYSTEM, THERE IS NO MECHANICAL
TEMPERATURE CONTROL. MOST OF THE COOLANT WILL GO THROUGH THE
BYPASS. THIS WILL CAUSE THE ENGINE TO OVERHEAT IN HOT WEATHER. IF A
HIGHER VOLUME OF COOLANT GOES THROUGH THE RADIATOR, THE ENGINE
WILL NOT REACH NORMAL OPERATING TEMPERATURES. THIS OCCURS DURING
COLD WEATHER.

CAUTION

DO NOT USE A COMMERCIAL COOLANT/ANTIFREEZE THAT ONLY MEETS THE


ASTM D3306 OR D4656 SPECIFICATION. THIS TYPE OF COOLANT/ANTIFREEZE IS
MADE FOR LIGHT DUTY AUTOMOTIVE APPLICATIONS.

CAUTION

IF NON ELC COOLANTS HAVE BEEN USED, IMPROPER OR INCOMPLETE


RINSING OF THE COOLING SYSTEM CAN RESULT IN DAMAGE TO COPPER AND
OTHER METAL COMPONENTS. TO AVOID DAMAGE TO THE COOLING SYSTEM,
MAKE SURE TO COMPLETELY FLUSH THE COOLING SYSTEM WITH CLEAN
WATER. CONTINUE TO FLUSH THE SYSTEM UNTIL ALL SIGNS OF THE
CLEANING AGENT ARE GONE.

CAUTION

TURBOCHARGER BEARING FAILURES CAN CAUSE LARGE QUANTITIES OF OIL


TO ENTER THE AIR INLET AND EXHAUST SYSTEMS AND AIR TO AIR AFTER
COOLER. LOSS OF ENGINE LUBRICANT CAN RESULT IN SERIOUS ENGINE
DAMAGE. TURBOCHARGER COMPONENTS REQUIRE PRECISION CLEARANCES.
THE TURBOCHARGER CARTRIDGE MUST BE BALANCED DUE TO HIGH RPM.
SEVERE SERVICE APPLICATIONS CAN ACCELERATE COMPONENT WEAR.
SEVERE SERVICE APPLICATIONS REQUIRE MORE FREQUENT INSPECTIONS OF
THE CARTRIDGE.

CAUTION

IF A TURBOCHARGER FAILURE OCCURS, REMOVE THE AIR TO AIR AFTER


COOLER CORE. FLUSH THE AIR TO AIR AFTER COOLER CORE INTERNALLY
WITH A SOLVENT THAT REMOVES OIL AND OTHER FORIEN SUBSTANCES.
SHAKE THE AFTER COOLER CORE ASSEMBLY IN ORDER TO REMOVE ANY
TRAPPED DEBRIS. WASH THE AFTER COOLER CORE ASSEMBLY WITH HOT
SOAPY WATER. THOROUGHLY RINCE THIS ASSEMBLY WITH CLEAN WATER,
AND THEN BLOW DRY THE ASSEMBLY IN THE REVERSE DIRECTION OF NORMAL
AIR FLOW. TO MAKE SURE THAT THE WHOLE SYSTEM IS CLEAN, CAREFULLY
INSPECT THE SYSTEM.

CAUTION

BE EXTREMELY CAREFUL - WEIGHT HAZARD - THE TURBOCHARGER WEIGHS


75 LBS.

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CAUTION

WHEEL NUT OR BOLTS MUST BE APPLIED AND MAINTAINED AT THE PROPER


TORQUE LEVELS TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND
POSSIBLE DANGEROUS SEPARATION OF WHEELS FROM YOUR AXLE.

CAUTION

THE MAXIMUM TOWING SPEED IS 20 MPH FOR THE MEP-PU-810A.

a. Safety precautions must be observed while any maintenance is being performed. Safety
precautions must be observed to ensure that the operator/technician cannot have contact with the
following:

• Hot engine parts


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

b. Minor troubleshooting can be performed while both engines are running as long as safety
precautions are taken.

c. Minor maintenance can be performed while one generator set is running and the other
generator set has been shutdown. Some examples of this maintenance are:

• Lubrication System – Oil and Filter Change.


• Hydraulic System – Oil and Filter Change.
• Fuel System – Primary and Secondary Filter Change.
• Coolant System – Coolant Change.
• Minor Troubleshooting.
• Check Fluid levels and add required fluids.

(1) The generator set that has been shut down must be rendered unable to start, and cool
enough for the maintenance to be performed. Procedures to render a generator set
unable to start are:

(a) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators.


(b) Push to OPEN the Emergency Stop Switch.
(c) Place the Engine Control Switch (ECS) in the OFF position.
(d) Place a DO NOT OPERATE tag on the generator control panel.
(e) Turn the Battery Bank Parallel Switch to the OFF position.
(f) De-energize the Battery Charger.
(g) Disconnect the negative and positive cables from the Battery Bank for the engine
due maintenance.
(h) Place a DO NOT OPERATE tag on the Battery Bank.
(i) Place the generator Circuit Breaker in the LOCK OUT position.

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(j) Disconnect the 7P1 and 7P2 Connectors located on the inside panel of the PDC.
(k) Close and Lock the generator set control panel.

NOTE: The fuel transfer pump electrical power is normally fed directly from the G1 generator set
battery bank. If you disconnect the G1 battery bank, the external fuel transfer pump will not
function. Place the Fuel Pump Source Switch (S2) into the (G1 or G2 position). Place the S2
in the (G1 or G2) position, for the generator set not receiving maintenance.

d. Major maintenance or service requires that the PU MUST be shutdown, isolated from any
power plant electrical bus or utility connection, isolated from any power plant control
system, and rendered unable to start. This is accomplished by performing the following:

(1) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators.


(2) Isolate the PU from any power plant or utility connection in accordance with Section
5.9.6.15, Unit Isolation Procedure with PSC. See Note 1 and 2.
(3) Isolate the PU from any power plant control system in accordance with NOTE 3.
(4) Pull to open the PU DC Power Control Breaker.
(5) Push to open both Emergency Stop Switches.
(6) Place both Engine Control Switches (ECS) in the OFF position.
(7) Place a DO NOT OPERATE tag on both generator control panels.
(8) Turn the Battery Bank Parallel Switch to the OFF position.
(9) De-energize both Battery Chargers.
(10) Disconnect the negative and positive cables from both Battery Banks.
(11) Place a DO NOT OPERATE tag on both Battery Banks.
(12) Place all Circuit Breakers in the LOCK OUT position.
(13) Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC.
(14) Close and Lock both generator set control panels.

NOTE 1: Also the PU must be completely electrically isolated from the power distribution bus and
any other electrical source that can back feed into the PU. All medium voltage cables need to
be placed on the standoff insulators by use of hot sticks and other safety gear.

NOTE 2: Ensure cables are not energized by opening the circuit breaker of the Primary Switching
Center (PSC), then disconnect Load Cables (Using the proper safety gear) on the PU and
place them on the Parking Stands.

NOTE 3: When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control
power is turned off to the PU. This will cause the HUB to stop functioning. This causes the
network to not see the equipment shutdown and all PU’s after it. When pulling major
maintenance the (A) (B) Communication Cable must be routed to the next PU in order to
reestablish the communication network.

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7.2 UNSCHEDULED MAINTENANCE PROCEDURES

All Safety Warnings and Cautions in Section 7.1 apply to this section.

7.2.1 HOUSING ASSEMBLY UNSCHEDULED MAINTENANCE PROCEDURES

The following Unscheduled Maintenance Procedures are located in Chapter 8 of this manual:

a. Remove and install Access Doors and Front Side Panels.

b. Remove and install Plenum Assembly Screens.

c. Remove and install Side Panels.

d. Remove and install Top Panel Assembly

e. Remove and install Battery Bank Tray Assembly

f. Remove and install Fuel Tank and Hydraulic Reservoir Assemblies

g. Remove and install Muffler Assembly

7.2.2 DC SYSTEM COMPONENTS UNSCHEDULED MAINTENANCE PROCEDURES

The following Unscheduled Maintenance Procedures are located in Chapter 9 of this manual:

a. Remove and install Batteries.

b. Remove and install Battery Cables.

c. Remove and install Battery Charger.

d. Remove and install Wiring Harness.

e. Remove and install Battery Bank DC Tie Switch.

f. Remove and install Starter Motor/Solenoid.

g. Remove and install DC Control Power Circuit Breaker.

h. Remove and install DC Panel Lights and Indicators.

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7.2.3 AC SYSTEM COMPONENTS UNSCHEDULED MAINTENANCE PROCEDURES

The following Unscheduled Maintenance Procedures are located in Chapter 10 of this manual:

a. Remove and install Station Power Transformer.

b. Remove and install Wiring Harness.

c. Remove and install Power Panel Board.

d. Remove and install Alternator.

e. Remove and install Varistor and Rectifier Block Assembly.

f. Remove and install High Voltage Output Terminals.

g. Remove and install Surge Arrestors.

h. Remove and install Instrument Potential Transformers.

i. Remove and install Instrument Current Transformers.

j. Remove and install Generator Feeder Breakers.

7.2.4 FUEL SYSTEM COMPONENTS UNSCHEDULED MAINTENANCE PROCEDURES

The following Unscheduled Maintenance Procedures are located in Chapter 11 of this manual:

a. Remove and install Fuel Solenoid Valve (L3).

b. Remove and install External Fuel Transfer Pump Assembly.

c. Remove and install Fuel Primer Pump.

d. Remove and install Engine Mounted Fuel Transfer Pump.

e. Remove and install Fuel Float Switch Assembly.

7.2.5 CONTROL AND INSTRUMENT COMPONENTS UNSCHEDULED MAINTENANCE


PROCEDURES

The following Unscheduled Maintenance Procedures are located in Chapter 12 of this manual:

a. Remove and install Engine Control Devices.

b. Remove and install PDC Controls and Instruments.

(1) Remove and install Generator Control Panel.

(2) Remove and install Master Control Panel.

(3) Remove and install Controls and Instruments within the interior of PDC.

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7.2.6 COOLING SYSTEM COMPONENTS UNSCHEDULED MAINTENANCE PROCEDURES

The following Unscheduled Maintenance Procedures are located in Chapter 13 of this manual:

a. Remove and install Water Temperature Regulator & Manifold.

b. Remove and install Water Pump.

c. Remove and install Filler Cap.

d. Remove and install Engine Oil Cooler.

e. Remove and install Radiator/Aftercooler Assembly.

7.2.7 LUBRICATION SYSTEM COMPONENTS UNSCHEDULED MAINTENANCE


PROCEDURES

There are no Unscheduled Maintenance Procedures for Chapter 14, Lubrication System.

7.2.8 ENGINE COMPONENTS UNSCHEDULED MAINTENANCE PROCEDURES

The following Unscheduled Maintenance Procedures are located in Chapter 15 of this manual:

a. Remove and install Valve Covers.

b. Remove and install Turbocharger.

c. Remove and install Air Intake Manifold.

d. Remove and install Exhaust Manifold.

e. Remove and install Air Transfer Tubes.

f. Remove and install Coolant Transfer Tubes.

g. Remove and install Hydraulic Fluid Transfer Hoses.

7.2.9 AIR INTAKE AND EXHAUST SYSTEM COMPONENTS UNSCHEDULED


MAINTENANCE PROCEDURES

There are no Unscheduled Maintenance Procedures for Chapter 16, Air Intake and Exhaust System.

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7.2.10 REMOTE OPERATOR TERMINAL (ORT) UNSCHEDULED MAINTENANCE


PROCEDURES

There are no Unscheduled Maintenance Procedures for Chapter 17, Remote Operator Terminal (ORT).

7.2.11 RUNNING GEAR/TRAILER ASSEMBLY COMPONENTS UNSCHEDULED


MAINTENANCE PROCEDURES

There are no Unscheduled Maintenance Procedures for Chapter 18, Running Gear/Trailer Assembly.

7.2.12 HYDRAULIC SYSTEM COMPONENTS UNSCHEDULED MAINTENANCE


PROCEDURES

The following Unscheduled Maintenance Procedures are located in Chapter 19 of this manual:

a. Remove and install Hydraulic Pump.

b. Remove and install Radiator Motor.

c. Remove and install Air-to-Air Aftercooler (ATAAC) Motor.

d. Remove and install Engine Compartment Vent Motor.

e. Remove and install Radiator Fan Assembly.

f. Remove and install Aftercooler Fan Assembly.

g. Remove and install Engine Compartment Vent Fan Assembly.

h. Remove and install Radiator Motor Fan Blades.

i. Remove and install Aftercooler Motor Fan Blades.

j. Remove and install Engine Compartment Vent Fan Motor Fan Blades.

k. Remove and install Hydraulic Tank Low Level Shutdown Switch (HTLL).

7.2.13 ENGINE/ALTERNATOR UNSCHEDULED MAINTENANCE PROCEDURES

The following Unscheduled Maintenance Procedures are located in Chapter 21 of this manual:

a. Remove and install Engine/Alternator.

7.2.14 PDC UNSCHEDULED MAINTENANCE PROCEDURES

The following Unscheduled Maintenance Procedures are located in Chapter 22 of this manual:

a. Remove and install PDC.

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7.3 TROUBLESHOOTING PROCEDURES

Troubleshooting procedures covered in this section are:

• Basic Engine Troubleshooting Procedures


• Basic EMCP + Troubleshooting Procedures
• Basic Generator Operations Troubleshooting Procedures
• Troubleshooting the Fuel Primer Pump
• Cooling System Troubleshooting Procedures
• Running Gear / Trailer Troubleshooting Procedures
• Hydraulic System Troubleshooting Procedures

All Safety Warnings and Cautions in Section 7.1 apply to this section.

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7.3.1 BASIC ENGINE TROUBLESHOOTING PROCEEDURES

Table 7.3.1-1 contains Basic Engine Troubleshooting Procedures for locating and correcting operating troubles that may develop in the generator
set. Each malfunction, for either an individual component or entire system, is followed by a series of tests or inspections that will help determine
the probable cause and corrective actions to take.

Troubleshoot in accordance with Table 7.3.1-1. All Safety Warnings and Cautions in Section 7.1 apply to this table.

This manual cannot list all malfunctions that may occur, nor all tests or inspections and corrective actions. If a malfunction cannot be corrected by
listed corrective actions, notify supervisor and or contact Radian Inc.

NOTE: Although troubleshooting can be a daunting task. Troubleshooting can be made much easier if you start by isolating the fault first.
The first task is to determine if the system or device is getting the proper inputs AC voltage, AC current, DC voltage and DC current.
Check for loose wires and blown fuses. By isolating the fault by eliminating obvious problems will make the technicians job much
easier. When Caterpillar manuals are referenced, go to the SMCS CODE found in that manual.

TABLE 7.3.1-1 BASIC ENGINE TROUBLESHOOTING PROCEDURES


MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION

1. PU Setup 1. Check PU setup. Refer to Section 5.1.3, make corrections as necessary.


PROBLEM 1:
2. DC Control Power Circuit Breaker (CBCP) 2. Place CBCP to the ON (Push-in) position.
ENGINE FAILS TO
3. Starter and Starter Solenoid 3. Test the Starter and Starter Solenoid refer to Section 9.4.6.2
CRANK
4. Engine Fault. 4. Check the GSC+ for a shutdown fault, refer to RENR2227-02 for troubleshooting procedures.

1. Open Fuel Shutoff Valve; refer to Figure 11.3.1-1 for reference.


• Prime Fuel System; refer to Section 11.3.5 for procedures.
1. Fuel • Check Fuel Filters, refer to Section 11.3 for reference.
• Check Fuel Quality (Have Fuel Sample Checked), refer to SENR1067-02 or later
PROBLEM 2: version, SMCS CODE: 1280-081 for procedures.

2. Check Engine Timing; refer to Section 15.4.8, Section 15.4.9, Section 15.4.10 and Section
ENGINE CRANKS BUT 2. Incorrect Engine Timing
15.4.11 for reference.
WILL NOT START
3. Check for obstructions in the Air Plenum Assembly, refer to Section 16.3.2 for reference.
3. Intake Air • Check Air Filter for obstructions, replace Air Filter as necessary, refer to Section 16.3.2
for reference.
4. Engine Mounted Fuel Pump 4. Check Engine Mounted Fuel Pump; refer to Section 11.4.4 for reference.

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TABLE 7.3.1-1 BASIC ENGINE TROUBLESHOOTING PROCEDURES (CONTINUED)


MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION

1. Open Fuel Shutoff Valve; refer to Figure 11.3.1-1 for reference.


• Check Fuel Level in Fuel Tank.
• Prime Fuel System; refer to Section 11.3.5 for procedures.
1. Fuel System • Check Fuel Filters, refer to Section 11.3 for reference.
• Check Fuel Quality (Have Fuel Sample Checked), refer to SENR1067-02 or later
PROBLEM 3: version, SMCS CODE: 1280-081 for procedures.
• Perform Fuel System Test and Adjusting; refer to SENR1067-02 or later version, SMCS
ENGINE SHUTS DOWN CODE: 1250-040 for procedures.
SOON AFTER 2. Check Engine Timing; refer to Section 15.4.8, Section 15.4.9, Section 15.4.10 and Section
2. Incorrect Engine Timing
STARTING. 15.4.11 for reference.
3. Check for obstructions in the Air Plenum Assembly, refer to Section 16.3.2 for reference.
3. Intake Air • Check Air Filter for obstructions, replace Air Filter as necessary, refer to Section 16.3.2
for reference.

4. Engine Mounted Fuel Pump 4. Check Engine Mounted Fuel Pump, refer to Section 11.4.4 for reference.

1. Check Turbocharger, refer to SENR1068-01 or later version, SMCS CODE: 1052-040.


1. Turbocharger
Replace if turbocharger does not spin freely or damaged.
2. Engine Fault 2. Check the GSC+ for a shutdown fault, refer to RENR2227-02 for troubleshooting procedures.
3. Check for obstructions in the Air Plenum Assembly, refer to Section 16.3.2 for reference.
3. Intake Air • Check Air Filter for obstructions, replace Air Filter as necessary, refer to Section 16.3.2
for reference.
PROBLEM 4:
4. Check Engine Timing; refer to Section 15.4.8, Section 15.4.9, Section 15.4.10 and Section
4. Incorrect Engine Timing
15.4.11 for reference.
ENGINE RUNS 5. Open Fuel Shutoff Valve; refer to Figure 11.3.1-1 for reference.
ERRATICALLY OR • Check Fuel Level in Fuel Tank.
MISFIRES.
• Prime Fuel System; refer to Section 11.3.5 for procedures.
5. Fuel System • Check Fuel Filters, refer to Section 11.3 for reference.
• Check Fuel Quality (Have Fuel Sample Checked), refer to SENR1067-02 or later
version, SMCS CODE: 1280-081 for procedures.
• Perform Fuel System Test and Adjusting; refer to SENR1067-02 or later version, SMCS
CODE: 1250-040 for procedures.

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TABLE 7.3.1-1 BASIC ENGINE TROUBLESHOOTING PROCEDURES (CONTINUED)


MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION

1. Check Turbocharger; refer to SENR1068-01 or later version, SMCS CODE: 1052-040.


1. Turbocharger
Replace if turbocharger does not spin freely or damaged.
PROBLEM 5: 2. Incorrect Engine Timing
2. Check Engine Timing; refer to Section 15.4.8, Section 15.4.9, Section 15.4.10 and Section
15.4.11 for reference.
ENGINE EXHAUST 3. Check for obstructions in the Air Plenum Assembly, refer to Section 16.3.2 for reference.
EXCESSIVELY BLACK. 3. Intake Air • Check Air Filter for obstructions, replace Air Filter as necessary, refer to Section 16.3.2
for reference.
4. Engine Overloading 4. Check for excessive engine overloading, correct as necessary.
1. Check Ether Injection System, refer to Section 11.3.4. If problem occurs after an ether start,
1. Ether Injection Assembly
check ether installation for defects resulting in applications of excessive ether to engine.
2. Check Cooling System for proper operation; refer to Section 13.4 for reference.
• Check coolant for low temperature.
2. Cooling System • Check for faulty (stuck open) thermostat.
PROBLEM 6: • Test engine coolant thermostats for proper operation. Refer to SENR1067-02, or later
version, SMCS CODE: 1355-081; 1355-081. Replace defective thermostats.
ENGINE EXHAUST 3. Check Turbocharger; refer to SENR1068-01 or later version, SMCS CODE: 1052-040.
WHITE OR BLUE. 3. Turbocharger • Replace if turbocharger does not spin freely or damaged.
• Check turbocharger seals for leakage..
4. Check for excessive oil consumption. If excessive oil consumption is noted, major rebuild
4. Lubrication System
may be necessary; refer to higher level maintenance.
5. Check Engine Timing; refer to Section 15.4.8, Section 15.4.9, Section 15.4.10 and Section
5. Engine Timing
15.4.11 for reference.
PROBLEM 7: 1. Check Engine Timing; refer to Section 15.4.8, Section 15.4.9, Section 15.4.10 and Section
1. Engine Timing
15.4.11 for reference.

GENERATOR OUTPUT 2. Check the AVR for proper operations; refer to SENR5833-02 or later version, SMCS CODE:
2. Automatic Voltage Regulator (AVR)
4467 for reference.
FREQUENCY/VOLTAGE
CANNOT BE 3. Check the GSC+ for a shutdown fault, refer to RENR2227-02 or later version, for
3. Engine Fault
MAINTAINED. troubleshooting procedures.

PROBLEM 8: 1. Engine Performance


1. Perform all tests and inspections contained in Problems 4 through 7. Make appropriate
corrections.

LOW POWER OR LOSS 2. Check for high oil level; refer to Section 14.3.1 for reference.
2. Lubrication System
OF POWER. • Drain excess oil.

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TABLE 7.3.1-1 BASIC ENGINE TROUBLESHOOTING PROCEDURES (CONTINUED)


MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION

1. Check GSC Settings, refer to Annex B.


1. EMCP • GSC+ settings may be improperly set.
• Check and correct.
2. Open Fuel Shutoff Valve; refer to Figure 11.3.1-1 for reference.
• Check Fuel Level in Fuel Tank.
PROBLEM 9: • Prime Fuel System; refer to Section 11.3.5 for procedures.
2. Fuel System • Check Fuel Filters, refer to Section 11.3 for reference.
ENGINE CANNOT • Check Fuel Quality (Have Fuel Sample Checked), refer to SENR1067-02 or later
REACH GOVERNED version, SMCS CODE: 1280-081 for procedures.
RPM. • Perform Fuel System Test and Adjusting; refer to SENR1067-02 or later version, SMCS
CODE: 1250-040 for procedures.
3. Check Engine Timing; refer to Section 15.4.8, Section 15.4.9, Section 15.4.10 and Section
3. Engine Timing
15.4.11 for reference.
4. Check Fuel Injector, refer to SENR1067-02 or later version, SMCS CODE: 1290-081 for
4. Fuel Injectors
procedures.
1. Check for obstructions in the Air Plenum Assembly, refer to Section 16.3.2 for reference.
1. Intake Air • Check Air Filter for obstructions, replace Air Filter as necessary, refer to Section 16.3.2
for reference.
2. Check Turbocharger; refer to Caterpillar Manual SENR1068-01 or later version, SMCS
CODE: 1052-040.
2. Turbocharger
• Replace if turbocharger does not spin freely or damaged.
• Check turbocharger seals.

PROBLEM 10: 3. Muffler 3. Check the Muffler, refer to Section 8.4.7.1 for reference.
4. Open Fuel Shutoff Valve; refer to Figure 11.3.1-1 for reference.
EXCESSIVE FUEL • Check Fuel Level in Fuel Tank.
CONSUMPTION. • Prime Fuel System; refer to Section 11.3.5 for procedures.
4. Fuel System • Check Fuel Filters, refer to Section 11.3 for reference.
• Check Fuel Quality (Have Fuel Sample Checked), refer to SENR1067-02 or later
version, SMCS CODE: 1280-081 for procedures.
• Perform Fuel System Test and Adjusting; refer to SENR1067-02 or later version, SMCS
CODE: 1250-040 for procedures.
5. Check Engine Timing; refer to Section 15.4.8, Section 15.4.9, Section 15.4.10 and Section
5. Engine Timing
15.4.11 for reference.

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TABLE 7.3.1-1 BASIC ENGINE TROUBLESHOOTING PROCEDURES (CONTINUED)


MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION

1. Inspect Lubrication System for proper operation; refer to Section 14.3.2 for reference.
• Tighten all oil connections.
• Check for external oil leaks.
1. Lubrication System
• Check grade of oil being used against weather conditions that unit is being operated in.
• Inspect for Excessive Oil Consumption; refer to RENRRENR1067-02 or later version,
PROBLEM 11: SMCS CODE: 1348-040 for reference.
2. Check Turbocharger; refer to Caterpillar Manual SENR1068-01 or later version, SMCS
CODE: 1052-040.
EXCESSIVE OIL • Replace if turbocharger does not spin freely or damaged.
CONSUMPTION.
2. Turbocharger • Check turbocharger seals.
• Check turbocharger crossover and exhaust casing for wetness. If wet, turbocharger is
defective.
• Replace defective turbocharger.
3. Check engine crankcase breathers for obstructions, refer to SEBU7163-01 or later version,
3. Engine Crankcase Breathers
SMCS CODE: 1317-070 for reference.
1. Open Fuel Shutoff Valve; refer to Figure 11.3.1-1 for reference.
• Check Fuel Level in Fuel Tank.
• Prime Fuel System; refer to Section 11.3.5 for procedures.
1. Fuel System • Check Fuel Filters, refer to Section 11.3 for reference.
• Check Fuel Quality (Have Fuel Sample Checked), refer to SENR1067-02 or later
version, SMCS CODE: 1280-081 for procedures.
• Perform Fuel System Test and Adjusting; refer to SENR1067-02 or later version, SMCS
CODE: 1250-040 for procedures.
2. Inspect Lubrication System for proper operation; refer to Section 14.3.2 for reference.
PROBLEM 12: • Tighten all oil connections.
• Check for external oil leaks.
CRANKCASE SLUDGE. 2. Lubrication System
• Check grade of oil being used against weather conditions that unit is being operated in.
• Check the oil filter to see if it is clogged.
• Change oil filters more often and observe for proper oil temperature.
3. Check Cooling System for proper operation; refer to Section 13.4 for reference.
• Check coolant for low temperature.
• Check for faulty (stuck open) thermostat.
3. Coolant System
• Test engine coolant thermostats for proper operation. Refer to SENR1067-02, or later
version, SMCS CODE: 1355-081; 1355-081.
• Replace defective thermostats.

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TABLE 7.3.1-1 BASIC ENGINE TROUBLESHOOTING PROCEDURES (CONTINUED)


MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION

1. Check Cooling System for proper operation; refer to Section 13.4 for reference.
• Check coolant for low temperature.
• Check for faulty (stuck open) thermostat.
1. Coolant System • Check for proper coolant level and evidence of leaks.
• Test engine coolant thermostats for proper operation. Replace defective thermostats.
Refer to Caterpillar Manual SENR1067-02, Dated November 2001 or later, SMCS
CODE: 1355-081; 1355-081.
2. Open Fuel Shutoff Valve; refer to Figure 11.3.1-1 for reference.
• Check Fuel Level in Fuel Tank.
PROBLEM 13: • Prime Fuel System; refer to Section 11.3.5 for procedures.
2. Fuel System • Check Fuel Filters, refer to Section 11.3 for reference.
OIL DILUTION • Check Fuel Quality (Have Fuel Sample Checked), refer to SENR1067-02 or later
(CRANKCASE). version, SMCS CODE: 1280-081 for procedures.
• Perform Fuel System Test and Adjusting; refer to SENR1067-02 or later version, SMCS
CODE: 1250-040 for procedures.
3. Inspect Lubrication System for proper operation; refer to Section 14.3.2 for reference.
• Tighten all oil connections.
• Check for external oil leaks.
3. Lubrication System • Check grade of oil being used against weather conditions that unit is being operated in.
• Check the oil filter to see if it is clogged.
• Change oil filters more often and observe for proper oil temperature.
• Take oil sample from crankcase to see if there is evidence of coolant or fuel in the oil.
1. Inspect Lubrication System for proper operation; refer to Section 14.3.2 for reference.
• Tighten all oil connections.
• Check for external oil leaks.
1. Lubrication System
PROBLEM 14: • Check grade of oil being used against weather conditions that unit is being operated in.
• Check the oil filter to see if it is clogged.
LOW OIL PRESSURE. • Check oil level.
2. Engine Oil Pump 2. Check the Engine Oil Pump; refer to SENR1067-02 or later version, SMCS CODE:1304-040
3. Test Oil Pressure Sensor; refer to Caterpillar Manual RENR 2227-01 or later version, Section
3. Oil Pressure Sensor
P – 520.

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TABLE 7.3.1-1 BASIC ENGINE TROUBLESHOOTING PROCEDURES (CONTINUED)


MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION

1. Check Cooling System for proper operation; refer to Section 13.4 for reference.
• Check coolant for low temperature.
PROBLEM 15: • Check for faulty (stuck open) thermostat.
1. Thermostat • Check for proper coolant level and evidence of leaks.
• Test engine coolant thermostats for proper operation. Refer to SENR1067-02, or later
COOLANT
version, SMCS CODE: 1355-081; 1355-081.
TEMPERATURE TOO
LOW. • Replace defective thermostats.
2. Refer to Section 12.4.1.1 and RENR 2227-01, Section P – 516 or later version and
2. Coolant Temperature Sensor Troubleshooting Procedures are found in RENR1067-01 or later version. Replace if
defective.
1. Cooling System Check (Overheating), refer to RENR1067-02 or later version, SMCS CODE:
PROBLEM 16: 1350-535 for reference.
1. Coolant System
• Check the Radiator Cooling fan to see if it functioning properly. Refer to Section 19.4.3
for reference.
COOLANT
2. Check the water pump to see if it functioning properly. Refer to RENR1067-02 or later
TEMPERATURE TOO 2. Water Pump
version, SMCS CODE: 1361-040; 1361-081 for reference.
HIGH. 3. Check crankcase oil level. Use proper grade for weather conditions. Refer to Annex G,
3. Oil Level and Grade
Consumable Operating and Maintenance Supplies.
1. Check crankcase oil level. Use proper grade for weather conditions. Refer to Annex G,
1. Oil Level and Grade
PROBLEM 17: Consumable Operating and Maintenance Supplies.

2. Inspect increased oil temperature. Refer to RENR1067-02 or later version, SMCS CODE:
2. Engine Oil
OIL TEMPERATURE 1348-040.
TOO HIGH.
3. Engine Load 3. Check KW load on the GSC. Make appropriate loading corrections.

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USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254

TABLE 7.3.1-1 BASIC ENGINE TROUBLESHOOTING PROCEDURES (CONTINUED)


MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION

1. Ether 1. Check for possible improper use of starting aid.


2. Check Fuel Quality (Have Fuel Sample Checked), refer to SENR1067-02 or later version,
2. Fuel
SMCS CODE: 1280-081 for procedures.
3. Check Cooling System for proper operation; refer to Section 13.4 for reference.
• Check coolant for low temperature.
PROBLEM 18: • Check for faulty (stuck open) thermostat.
3. Thermostat • Check for proper coolant level and evidence of leaks.
• Test engine coolant thermostats for proper operation. Refer to SENR1067-02, or later
KNOCKS (COMBUSTION version, SMCS CODE: 1355-081; 1355-081.
NOISE). • Replace defective thermostats.
4. Engine Load 4. Check KW load on the GSC. Make appropriate corrections.
5. Check Engine Timing; refer to Section 15.4.8, Section 15.4.9, Section 15.4.10 and Section
5. Engine Timing
15.4.11 for reference.
6. Check grade of oil being used against weather conditions that unit is being operated in.
6. Engine Oil
Refer to Annex G.
1. Check for defective oil pressure sensor. Refer to RENR 2227-02 or later version, Section P –
PROBLEM 19: 520.
1. Oil Pressure Sensor
• Replace if defective.
EXCESSIVE OIL 2. Check grade of oil being used against weather conditions that unit is being operated in.
PRESSURE. 2. Engine Oil
Refer to Annex G.
1. External Fuel Transfer Pump Switch
1. Check that the External Fuel Transfer Pump Switch is in the G1 or G2 position.
PROBLEM 20: G1/G2
2. Battery Bank 2. Inspect the battery bank, refer to Section 9.4.1.1.
FUEL TRANSFER PUMP 3. Inspect the External Fuel Transfer Pump Assembly for proper operation. Refer to Section
3. External Fuel Transfer Pump.
11.4.2.1.
NOT WORKING.
4. Fuel Float Switch Assembly 4. Inspect the Fuel Float Switch Assembly. Refer to Section 11.4.5.1
PROBLEM 21: If engine does not start refer to RENR 2227-02 or later version, Section 3: Troubleshooting
All Without a Diagnostic Code; or Section 4: Troubleshooting With a Diagnostic Code. And refer to
RENR1200-01 or later version, SMCS CODE: 4490.
ALL ENGINE FAULTS

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USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254

TABLE 7.3.1-1 BASIC ENGINE TROUBLESHOOTING PROCEDURES (CONTINUED)


MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION

1. DC Control Power Circuit Breaker (CBCP) 1. Place CBCP to the ON (Push-in) position.
2. Battery Bank 2. Inspect the battery bank, refer to Section 9.4.1.1.
3. Verify the A/B Control Cable is connected.
3. Control Cables
• Verify the ORT Cable is connected.
4. Control Switch Positions 4. Verify Switch Setup. Refer to Section 5.2.3.8.
5. Engine Faults 5. Clear all Active Engine Faults.
6. Advanced Troubleshooting Procedures: 6. Perform the following Steps:
• GSC+ • Place CBCP to the ON (Push-in) position.
• PCM • Place both ECS in AUTO
• Verify there are no GSC+ shutdowns active.
• CCM
• Place the SMS in AUTO position.
• ATB • Verify that the SSL two green lights are illuminated.
PROBLEM 22: • PT1 • Place running engine ECS to OFF/RESET.
• PT2 • Move the MSES to the ENABLE position (momentary)
• PT3 • Verify that associated ARR relay energizes. Indicator LED that is located on the relay
ENGINE WILL NOT
• CT1 module should illuminate. Refer to FO-22.
START IN AUTO • If the ARR relay does not energize, check for 24VDC between terminal “A1 and “A2” at
• CT2 the coil.
• CT3 • Check for continuity across the ARR contacts. Lack of continuity across the contacts
• CB2 indicates a failed relay module, replace the relay module. A verification check may be
• CB4 done by swapping the relay with one of the spare (SPR) modules.
• Check for 24VDC at the coil; if voltage is present continue to next step. If 24VDC is not
• ECS present; refer to Table 7.3.3-1, Problem 10 to troubleshoot RTU problems.
• ESPB • Check that the engine starts in MANUAL.
• ARR1 • If the engine starts in MANUAL check the wiring from the associated ARR contact to the
• SR GSC+ module.
• If engine does not start refer to RENR 2227-02 or later version, Section 3:
• SMMS
Troubleshooting without a Diagnostic Code; or Section 4: Troubleshooting With a
• FSPR Diagnostic Code. And refer to RENR1200-01 or later version, SMCS CODE: 4490.

7-31
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254

TABLE 7.3.1-1 BASIC ENGINE TROUBLESHOOTING PROCEDURES (CONTINUED)


MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION