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ASCOT INTERNATIONAL srl Z.I.

Terza Strada -93012 Gela (CL) Italia


e-mail info@ascot international-italia.it
Tel. +39 0933 901192 Fax +30 0933 915448

HPU MANUAL
End fabrication book

ORC/12050
48-7-600 Ah
48-20-1550 Ah

TECHNICAL
OPERATION
AND
MAINTENANCE

POWER PLANT & GENERATOR SETS MEDIUM & LOW VOLTAGE


Address: ASCOT INTERNATIONAL srl Z.I. Terza Strada -93012 Gela (CL) Italia
e-mail info@ascot international-italia.it
Tel. +39 0933 901192 Fax +30 0933 915448
ISO 9001 :2000 Certified Company

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HPU MANUAL

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INDEX: OPERATORS MANUAL


SECTION 1.

FOREWORD ...................................................................................................................... 6

SECTION 2.

QUICK START PROCEDURE ........................................................................................... 7

2.1.

Preliminary Operations ....................................................................................................... 7

2.2.

First Start-Up With Load and External Battery Disconnected in

2.3.

AUT mode With Load Connected ....................................................................................... 8

2.3.1.

Power cable connection point (48-7-600) .......................................................................... 9

2.3.2.

Power cable connection point (48-20-1550) .................................................................... 10

2.4.

How to set the IP500 for the first Start .............................................................................. 11

SECTION 3.

manual mode .............. 8

SAFETY: PRECAUTIONS BEFORE USE ....................................................................... 15

3.1.

Introduction ....................................................................................................................... 15

3.2.

Warnings and Recommendations..................................................................................... 15

3.3.

Handling of the HPU ......................................................................................................... 16

3.3.1.

48-7-600 ........................................................................................................................... 16

3.3.2.

48-20-1550 ....................................................................................................................... 17

3.4.

Canopy/battery box disassembly ...................................................................................... 18

3.5.

Installation of HPU ............................................................................................................ 23

3.6.

Safety and Prevention rules .............................................................................................. 26

3.7.

First Starting ...................................................................................................................... 27

3.7.1.

Engine Lubricating Circuit(optional) ................................................................................. 27

3.7.2.

HPU supplied without oil cooling liquid............................................................................. 27

3.7.3.

Preliminary Checks to First Starting ................................................................................. 27

3.7.4.

Preparing engine Starting Batteries ................................................................................. 28

3.7.5.

Refuelling of Fuel Tank .................................................................................................... 28

3.7.6.

Starting ............................................................................................................................. 29

SECTION 4.

INSTALLATION, HANDLING AND STORAGE ................................................................ 30

4.1.

General ............................................................................................................................. 30

4.2.

Engine ............................................................................................................................... 38

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HPU MANUAL

4.2.1.

48-7-600 (perkins 403d-114) ............................................................................................ 38

4.2.2.

48-20-1550 (deutz f3m2011) ............................................................................................ 39

4.3.

DC generator..................................................................................................................... 40

4.4.

Hpu view ........................................................................................................................... 41

4.4.1.

48-7-600 ........................................................................................................................... 41

4.4.2.

48-20-1550 ....................................................................................................................... 42

4.5.

Hpu noise level.................................................................................................................. 43

4.5.1.

48-7-600 ........................................................................................................................... 43

4.5.2.

48-20-1550 ....................................................................................................................... 44

SECTION 5.

OPERATION..................................................................................................................... 45

5.1.

General ............................................................................................................................. 45

5.2.

Pre-Start Checks ............................................................................................................... 45

5.3.

Initial Start-up/Shutdown ................................................................................................... 46

5.4.

Normal Manual Startup/Shutdown .................................................................................... 48

5.5.

Automatic Startup.............................................................................................................. 48

SECTION 6.

electrical drawing .............................................................................................................. 50

6.1.

48-7-600 ............................................................................................................................ 50

6.2.

48-20-1550 ........................................................................................................................ 61

SECTION 7.

MAINTENANCE................................................................................................................ 72

7.1.

General ............................................................................................................................. 72

7.2.

Preventative Maintenance ................................................................................................ 72

7.3.

Removal of Engine and/or Alternator ................................................................................ 73

7.4.

Engine Battery Maintenance ............................................................................................. 75

7.5.

Filling ................................................................................................................................. 75

7.6.

Initial the current indicated below...................................................................................... 75

7.7.

Topping Up........................................................................................................................ 75

7.8.

Charging the Battery ......................................................................................................... 75

7.9.

Manual for use and maintenance for motive batteries ...................................................... 76

SECTION 8.
8.1.

COMPONENTS MANUALS ............................................................................................. 90


Engine ............................................................................................................................... 90

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8.1.1.

48-7-600 ........................................................................................................................... 90

8.1.2.

48-20-1550 ..................................................................................................................... 183

8.2.

DC GENERATOR ........................................................................................................... 223

8.3.

INSTRUCTION MANUAL HPU CONTROL PANEL ....................................................... 235

8.4.

IP500 User Manual ...................................................................................................... 281

8.5.

AIR CONDICTIONING SYSTEM .................................................................................... 291

8.5.1.

AIR-CONDICTIONER MANUAL ................................................................................... 291

8.5.2.

CENTRAL CONTROL UNIT MANUAL.......................................................................... 334

8.5.3.

BATTERY CONTROL UNIT MANUAL .......................................................................... 367

SECTION 9.

WARRANTY and spare parts ......................................................................................... 370

SECTION 1

HPU MANUAL

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SECTION 1.

F O RE WO R D

Before the operator attempts to use the HPU and before any maintenance work is to be undertaken, the
operating instructions or the maintenance manuals are to be read carefully and must be fully understood.
It is self-explanatory that only fully experienced skilled maintenance and operational staff are entitled to
work with the HPU equipment.
To ensure the best efficiency, reliability and lifetime of the equipment, only original spare parts should be
used.
It is also to be ensured that all equipment and tools for maintenance are in good condition.
The operation manual is primarily intended for use by the operating and maintenance personnel. It is
assumed that it will always be at the disposal of such personnel for the operation and for the required
maintenance.
This manual has been prepared on the assumption that operation and maintenance of the equipment
concerned will always be carried out by personnel having the special knowledge, training and qualification
needed to handle in a professional manner engines of the corresponding size, the associated auxiliary
equipment, as well as fuel and other operating media.
Therefore, general applicable rules, which may also concern such items as protection against danger, are
specified in this manual only in exceptional cases. It must be assumed that the operating and
maintenance personnel are familiar with the rules concerned.
The responsibility for correct and safe operation of the equipment and/or of human life are solely within
the operator's responsibility. More detailed instructions concerning the operation and maintenance of the
HPU components can be gathered from the instructions, leaflets and descriptions included in the different
sections of the HPU's documentation issued for this particular plant.
The maintenance and servicing works must be carried out punctually and completely in order to ensure
correct operation of the plant and to ensure not to jeopardise the warranty of the equipment.

HPU MANUAL
SECTION 2.

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Q UI CK S T AR T P RO CE D U RE

The HPU you have received has been fully tested in the Ascot international factory as per testing
certificate attached in the End Fabrication Booklet, moreover in order to check that no damage has been
received during transportation, before installation we suggest you perform the following testing operation:

2.1. PRELIMINARY OPERATIONS


1) Check that the EMERGENCY PUSH BUTTON is released.
CHECK AND IF NECESSARY RELEASE THE
EMERGENCY STOP BUTTON IF PRESSED THE HPU
WILL NEVER START

2) Set the control card in STOP mode.


3) Check carefully the Oil that MUST be at MAX level, if it is at low level, refill properly otherwise this
may create problems during the start up procedure.
4) Check the fuel oil and refill until the tank is full : for proper functioning you should have at least
20% of the total volume .
5) If the engine battery is not charged, re-charge the start-up battery for at least 12 hours.

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HPU MANUAL

2.2. FIRST START-UP WITH LOAD

AND

EXTERNAL BATTERY DISCONNECTED IN

MANUAL MODE
For the first start-up, in order to check the proper functioning of the HPU, it is advisable to start up the
HPU, without any Load connected.
1) After having performed the PRELIMINARY OPERATION
2) Set the control card in MANUAL mode.
3) Press the decrease button on the controller to let the engine start at minimum speed.
4) Push the green START Button: due to possible air in the fuel oil circuit, it may be possible that
the gen set does not start at the first attempt, in this case, repeat by means of Pushing the
START button continuously for min 3 sec and max 7 second; if a second attempt is required,
please wait at least 30 seconds between each attempt.
5) If no alarm appears on the display, keep the HPU running for at least 1 minute and then stop by
means of pushing the STOP button.
6) Set the control card in OFF mode .
7) Wait for 5 minutes and check the oil level (via the dipstick), as the HPU is oil cooled it may be
required that you add some oil as some of the oil could be in the radiator section.

2.3. AUT MODE WITH LOAD CONNECTED


Once you have performed successfully the FIRST START UP procedures, you are ready to connect the
Load in order to perform function test of the gen set.
1) Turn off the HPU.
2) Connect the power cables as the POINT 2.3.1
3) Always Connect the grounding (there is 1 connection points externally on the base frame)
4) Turn on the HPU.
5) Set the control card in AUTO mode .
6) In this mode the HPU starts only for external low battery voltage and stops when the
external battery are fully charged.

HPU MANUAL

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2.3.1. POWER CABLE CONNECTION POINT (48-7-600)


Once you have performed successfully the FIRST START UP procedures, you are ready to connect the
POWER CABLES

+ 48 GROUND
LOAD

- 48 GROUND
LOAD

AC LOAD

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HPU MANUAL

2.3.2. POWER CABLE CONNECTION POINT (48-20-1550)


Once you have performed successfully the FIRST START UP procedures, you are ready to connect the
POWER CABLES

+ 48 GROUND
LOAD

- 48 LOAD

MAINS

AC LOAD

HPU MANUAL
2.4. HOW TO SET THE IP500 FOR THE FIRST START

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SECTION 3.

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S AF E T Y : P RE CAU T I O N S B E FO RE US E

3.1. INTRODUCTION
This section provides the general instruction for the receiving, handling, installation and first starting of the
HPU.

3.2. WARNINGS AND RECOMMENDATIONS


Instructions indicated in this paper must remain together with the HPU in any movement as well as
reselling.
The user must comply with the instructions and written warnings in the present document.

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3.3. HANDLING OF THE HPU


3.3.1. 48-7-600

HPU MANUAL

HPU MANUAL
3.3.2. 48-20-1550

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HPU MANUAL

3.4. CANOPY/BATTERY BOX DISASSEMBLY


For a right disassembly of the canopy from the battery box, please follow the procedure below:
-

Turn off inverter charger and HPU control panel;

Disconnect negative pole of 12 Vdc starting battery;

Disconnect from the positive bus bar as per following picture

1. 48 Vdc BATTERY
PACK POSITIVE
POLE

ATTENTION !!!
TO DISCONNECT THE BATTERIES FIRST POSITIVE POLE, AND
AFTER THE NEGATIVE POLE.
TO RECONNECT THE BATTERIES FIRST NEGATIVE POLE, AND
AFTER THE POSITIVE POLE
OTHERWISE YOU COULD DAMAGE OPERATORS OR MATERIALS

HPU MANUAL

Dissect battery pack and inverter fuses;

Disconnect cables from the fuses

BATTERY PACK
NEGATIVE POLE

Disconnect the cable from the terminal load

NEGATIVE TERMINAL
LOAD

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INVERTER CHARGER
NEGATIVE POLE

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HPU MANUAL

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DATE 5/11/2012

Disconnect the connector indicated below and pull it down through the cable gland

CONNECTORS

CABLE GLAND
-

Disconnect the connectors and the two fuel pipes indicated below

HPU MANUAL

ATTENTION!!
BEFORE DESASSEMBLY
REMOVE ALL BOLTS FOR
LIFT BRACKET

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PAG. 21
DATE 5/11/2012

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HPU MANUAL

TO LIFT THE BATTERY BOX SEPARATELY, UNSCREW THE BOLTS AND FIX
THE BATTERY BOX BRACKETS SUPPLIED AS ACCESSORY COMPLETE WITH
RELATED BOLTS

NOTE: For a right battery box lifting, you have to use n4 belts with minimum length 1,5 m for each

CAUTION
As the user receive the HPU, he must check that it is not damaged or tampered during shipment.

DANGER
Lifting, loading and unloading procedures are very dangerous operations and must be carried out by
skilled personnel, equipped with suitable equipment and means of individual safety protection, in
compliance with current laws.

CAUTION
Once received, the HPU must be stored in a suitable place, preferably closed, dry and not dusty,
especially if a long-term storage is required before installation.

CAUTION

HPU MANUAL

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DATE 5/11/2012

All the elements of the packing (plastic bags, PVC sheets) must be collected for disposal. For these
operations, it's necessary to comply with applicable laws.

3.5. INSTALLATION OF HPU


DANGER
Regardless if the HPU is mobile or stationary, it is always necessary to perform the installation
procedures before using it. If not correctly installed, the HPU can cause serious danger to people or
animals. The sources of danger are mechanical, thermal and electrical.
So before operating, the person responsible for carrying out of the HPU, must be sure that the installation
has been executed in a workmanlike way and that all the institutional authorisations for the starting of the
HPU are available.

REMOVING WOOD TRANSPORTATION BLOCKS

Please, remove all the wood battery blocks (installed only for transportation)

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HPU MANUAL

UNSCREW THE BOLT


AND REMOVE THE
WOOD BLOCKS

REPLACE THE UNSCREWED


BOLTS WITH THE BOLTS
SUPPLIED AS ACCESSORY

HPU MANUAL

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DATE 5/11/2012

Safety Signals on the Genarating Set


Although each HPU has been manufactured in accordance with currently applicable safety rules, there
could be further risks.
Labels, placed on the HPU, mark these potential risks

Fig.1 Safety placed on the gen sets


With reference to figure 1, read carefully the following warnings and remember their meaning:
1.

Before each maintenance operation, stop the engine and read the instructions manual;

2.

Danger, do not approach, hot surfaces;

3.

Shearing danger, do not approach the engine's fan;

4.

It's mandatory to use individual means for acoustic protection;

5.

It's forbidden to remove safety devices;

6.

It's forbidden to repair, adjust or refill oil during operation;

7.

Electric shock danger even with non-operating machine,

8.

It's forbidden to perform interventions before switching off the voltage.

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HPU MANUAL

3.6. SAFETY AND PREVENTION RULES


DANGER
It's absolutely forbidden to remove the panels or any kind of protections from the HPU, especially during
operations.

CAUTION
The use of the HPU causes the overheating of some parts of the engine, of the exhaust pipeline, of the oil
pan and other components and adjacent material. So it's necessary that some checks be carried out with
non-operating machine and after the cooling of it.

DANGER
It's forbidden to start the HPU in a closed and not sufficiently ventilated room.

DANGER
It's absolutely forbidden to start the HPU before having installed the exhaust gas pipeline.

DANGER
It's forbidden to start the HPU before the complete electrical and mechanical installation of it, to be
performed in compliance with the requirements of current rules and laws.

Electrical Safety
Operating with electric and electronic devices means operating with an invisible risk that may cause
serious safety dangers.
Use only insulated tool because if at low voltage (48Vdc), can be dangerous to touch live parts with not
isolated tools because the very high currents in case of short circuit from positive to negative or from
negative to ground maybe very dangerous.
One of the more serious dangers, when operating with electric devices, is electrocution.

CAUTION
It's absolutely forbidden to perform any operations on parts that are not usually accessible and may be
under voltage.
It's absolutely mandatory, before any intervention on the HPU, to turn off all the feed, to stop the HPU and
to wait that all the moving parts are stopped.

HPU MANUAL

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PAG. 27
DATE 5/11/2012

If electric shock has struck someone, perform, as soon as possible, the procedures reported in the
General Instructions Manual or in other equivalent document.

3.7. FIRST STARTING


3.7.1. ENGINE LUBRICATING CIRCUIT(OPTIONAL)
The HPU is supplied with first refilling of lube oil. Before starting the HPU it's recommended to check if the
oil level is correct (second top notch on the rod).
For lube oil quantity requested and for the relative refuelling plug, check the engine use and maintenance
handbook.
The Hpu can not run for a long period with a load less than 25 % of its nominal power otherwise it will
cosume a lot of lube oil and its lifetime will be reduced

3.7.2. HPU SUPPLIED WITHOUT OIL COOLING LIQUID.


(Available only for oil-cooled engine in the range of 20-44 kVA)

CAUTION
Don't run the engine when the cooling circuit is empty.
After a short period of operation, check if the oil level in the sump is correct. Possible oil shortage must be
refilled.

3.7.3. PRELIMINARY CHECKS TO FIRST STARTING


Before starting the HPU it's necessary to carry out the following checks:
Check that each mechanical part and also all the ancillary elements, provided with the station, are
perfectly installed;
Check that there are no other foreign elements left in the station;
Check that all the earthing and equipotential connections have been made;
Check the efficiency of the earthing system;
Check that all cable terminals are tight;
Check the correspondence polarity between other batteries and load, before feeding the user loads;
Check the correct sense of rotation of the fuel lift pump, if provided;
Check the sealing of the fuel system.

CAUTION

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HPU MANUAL

The supply line of the auxiliary electric circuit must be fed only when it's certain that all electric
connections have been completed in a workmanlike manner.
Indeed, it's necessary to check that the engine has been correctly refilled with oil and coolant liquid and
that the cooling circuit has been correctly purged of air.

3.7.4. PREPARING ENGINE STARTING BATTERIES


The batteries are sent in condition of full charge.
The electrolyte is highly corrosive and water reactive.
Connect the battery cables in accordance with their polarity and tight the terminal bolts;
Carry out the complete battery charging using battery charger of the control panel fed by the mains (if
present). In case of commercial battery, check that the charge occurs with a current intensity equal to
1/10 of the battery capacity until its voltage has achieved the value of about or 29V.
When the charge is completed, use distilled water to level the electrolyte about 5-10 mm above the
separating sectors or the maximum level notch (if present). At the end, dry all wet surfaces from
electrolyte, place the plugs and clean carefully.
For the activation of special batteries (free maintenance, nickel cadmium, etc.) comply with specific
instructions.

WARNING
From now on, all refilling operations shall be performed using only demineralised water.

3.7.5. REFUELLING OF FUEL TANK


For safety reasons, the HPU is provided with an empty fuel tank.
This tank has a fuel refilling entry to fill manually the tank.
The fuel tank must be provided with diesel engine fuel (minimum calorific power: 10200 Kcal/Kg).
First start of the HPU must be carried out in manual mode.
In case of problems during starting or during operation of the diesel engine, it's necessary to drain the fuel
pipes by the manual pump of the engine.
Suitable drain plugs that must be progressively loosened and, after drainage, immediately tightened
perform the draining.
Another drainage point is usually placed over the head of the fuel filter.
However, each diesel engine has its own drain points and the procedure may change from one engine to
another.
For this reason it's always better to consult the use and maintenance manual of the engine.
At the end of the drain operations, stop the engine and dry the parts that have been wetted by the fuel,
taking into account that it's a dangerous liquid because it is highly flammable and highly pollutant.

HPU MANUAL

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PAG. 29
DATE 5/11/2012

When the temperature lowers under zero, the fuel can cause some problems because of solidification.
To face this phenomena, there are additives that can be added to the fuel, in accordance with supplier's
indications.
CAUTION!
If after the refilling of the fuel tank there appears an incorrect fuel value, please pull out the fuel level
sender and after cleaning, please leave it in the tank

3.7.6. STARTING
If the HPU is equipped with an automatic control panel, it's necessary to preset it in the manual mode.
During first starting operations diesel engine can show some small uncertainties that can affect
performance. It's possible that in this phase, checking devices show false anomalies (low r.p.m., errors of
voltage, over speed).
If these phenomena occurs, repeat the manual starting sequence after 30 second.
In case of uncertainty of the engine it's necessary to push the start button only after the engine is
completely stopped. This procedure avoids to the collision between the pinion of the starter engine with
the ring gear.
Once the engine is started, perform the checks if check that there are no losses of oil, coolant , fuel and
gas from the exhaust pipe.
If all checks are positive, the HPU can be considered operational.

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HPU MANUAL

PAG.30
DATE 5/11/2012

SECTION 4.

I NS T AL L AT I O N, H AN D L I N G AN D S TO R AG E

4.1. GENERAL
This section discusses factors important in the effective and safe installation of the HPU.
Installation and handling is greatly simplified when the HPU has been equipped with an enclosure.
These enclosures provide a self contained HPU system that is easily transportable and requires minimal
installation. They also automatically give protection from the elements and protection from unauthorised
access

WARNING:
Make sure all personnel are out of the canopy or container, if equipped, before closing and latching
enclosure doors.
Before closing canopy or enclosure doors, ensure all obstructions (especially hands and fingers) are clear
to prevent damage or injury.
Because the canopied HPUs are easily transportable and may be installed and operated in a temporary
location, many of the fixed installation details given in this chapter may not apply.
The following considerations must be still given when temporarily installing the HPU:
Locating the HPU where it will be protected from damage and away from exhaust fumes from other
engines or other airborne contaminants such as dust, lint, smoke, oil mist or vapours.
Locating the HPU on a firm level ground that will support the weight of the HPU and avoid movement due
to the vibration of the operating set.
Ensuring that fumes from the exhaust outlet will not be a hazard especially when wind is taken into
account.
Electrical grounding of the HPU at all times.
Providing access lo refill the fuel tank when required.
Protecting electrical cables installed between the HPU and the load. If these are laid on the ground
ensure they are boxed in or covered to prevent damage or injury to personnel.
If the enclosed HPU is installed inside a building, adequate fresh cooling air must be provided and the
engine exhaust and hot coolant air exhaust must be ducted outside the building. The ducting and exhaust
pipe work must be designed to minimise backpressure that would have a detrimental effect on HPU
performance.

HPU MANUAL

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PAG. 31
DATE 5/11/2012

MOVING THE HPU


The HPU base frame is specifically designed for ease of moving the set. Improper handling can seriously
damage components.
Using a forklift, the HPU can be lifted or carefully pushed/pulled by the base frame. If pushing, do not
push the base frame directly with fork. Always use wood between forks and the base frame to spread the
load and prevent damage. If the set will be regularly moved, it should be fitted with the optional "Oil Field
Skid" which provides forklift pockets in the base frame along with eyes for pulling.

WARNING:
Never lift the HPU by attaching to the engine or alternator lifting lugs.
Ensure the lifting rigging and supporting structure is in good condition and is suitably rated.
Keep all personnel away from the HPU when it is suspended.
Canopied cells have lifting points facility as standard.
A spreader bar is required lo prevent damaging the cell. It is positioned over the centre of gravity (nearer
the engine), not the centre of the cell, lo allow a vertical lift. Guide ropes should be used to prevent
twisting or swinging of the cell once it has been lifted clear of the ground. Do not attempt to lift in high
winds. Place the HPU down on a level surface capable of supporting its weight. This manner of lifting
should only be used for a single lift for installation.
HPUs to be air lifted by helicopter should be lifted by sling.
LOCATION
Selecting a location for the HPU can be the most important part of any installation procedure. The
following factors are important in determining the location:
Adequate ventilation.
Protection from the elements such as rain, snow, sleet, wind driven precipitation, flood water, direct
sunlight, freezing temperatures, or excessive heat.
Protection from exposure to airborne contaminants such as abrasive or conductive dust, lint, smoke, oil
mist, vapours, engine exhaust fumes or other contaminants.
Protection from impact from falling objects such as trees or poles, or from motor vehicles or trucks.
Clearance around the HPU for cooling and access for service: at least 1 metre (3.3 feet) around the set
and at least 2 metres (6.6 feet) headroom above the set.
Access to move the entire HPU into the room. Air inlet and outlet vents can often be made removable lo
provide an access point.
Limited access to unauthorised personnel.

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PAG.32
DATE 5/11/2012

HPU MANUAL

If it is necessary to locate the HPU outside of the building, the HPU should be enclosed in a weatherproof
canopy or container-type housing which is available for any sets. These enclosures are also useful in
temporary installations inside or outside the building.
Vibration Isolators.
Flexible Exhaust Coupling Flexible Air Discharge Duct.
FOUNDATIONS AND VIBRATION ISOLATION
The HPU is shipped assembled on a rigid base frame that precisely aligns the alternator and engine and
needs only to be bolted down to a suitably prepared surface
Foundation:
A reinforced concrete pad makes the best foundation for the HPU. It provides a rigid support to prevent
deflection and vibration. Typically the foundation should be 150 mm to 200 mm (6 to 8 inches) deep and
at least as wide and long as the HPU.
In any case the foundation weight should be at least three times the HPU weight. The ground or floor
below the foundation should be properly prepared and should be structurally suited to carry the weight of
the foundation pad and the generating cell. (if the HPU is to be installed above the ground floor the
building structure must be able to support the weight of the HPU, fuel storage and accessories.) Relevant
building codes should be consulted and complied with. If the floor may be wet from time to time, such as
in a boiler room, the pad should be raised above the floor. This will provide a dry footing for the HPU and
for those who connect, service or operate it. It will also minimise corrosive action on the base frame.
Vibration Isolation:
To minimise engine vibrations being transmitted to the building. The HPU is fitted with vibration isolators.
On small and medium sized sets these isolators are fitted between the engine/alternator feet and the
base frame. This allows the frame to be rigidly bolted to the foundation. On larger sets the coupled
engine-alternator is rigidly attached to the base frame and the vibration isolators are supplied loose for
fitting between the base frame and the foundation. In any cases the sets should be securely bolted to the
ground (either through the base frame or through the vibration isolators) to prevent movement.
Vibration isolation is also required between the HPU and its external connections. This is achieved by use
of flexible connections in the fuel lines, exhaust system, radiator air discharge duct, electrical conduit for
control and power cables and other externally connected support systems.
On mobile sets the HPU should be mounted using "captivation mounts". These mounts minimise vibration
and include a captivation feature that prevents the set breaking away in case of road accident.

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DATE 5/11/2012

COMBUSTION AIR INLET


Air for engine combustion must be clean and as cool as possible. Normally this air can be drawn from the
area surrounding the HPU via the engine mounted air filter.
However, in some cases due to dust, dirt, or heat, the air around the set is unsuitable. In these eases an
inlet duct should be fitted. This duct should run from the source of clean air (outside the building, another
room, etc.) to the engine mounted air filter. Do not remove the air filter and mount it at a remote location
as this can increase the possibility of dirt leaking through the ductwork and into the engine inlet.
COOLING AND VENTILATION
The engine, alternator, and exhaust piping radiate heat that can result in a high enough temperature to
adversely affect the performance of the HPU. It is therefore important that adequate ventilation is
provided to keep the engine and alternator cool. Proper air flow requires that the air comes in at the
alternator end of the set, passes over the engine, through the radiator and out of the room via a flexible
exhaust duct. Without the ducting of the hot air outside the room the fan will tend to draw that hot air
around and back through the radiator, reducing the cooling effectiveness.
The air inlet and exit openings should be large enough to ensure free flow of air into and out of the room.
As a rough guide the openings should each be at least 1.5 times the area of the radiator core.
The inlet and exit openings should have louvers for weather protection. These may be fixed but
preferably should be movable in cold climates so that while the HPU is not operating the louvers can be
closed. This will allow the room to be kept warm which will assist starting and load acceptance. For
automatic starting HPUs, if the louvers are movable they must be automatically operated. They should be
programmed to open immediately upon starting the engine. The force of radiator air should not be
depended upon to open the louvers vanes unless the system has been specifically designed for this.
When a remote radiator or heat exchanger cooling system is used, the radiated heat from the HPU must
still be removed from the room.
EXHAUST
WARNING:
Engine exhaust emissions are hazardous to personnel.
Other exhaust design criteria are as follows:

Exhaust components including turbochargers can be very hot and must be guarded where they
could be accidentally touched.

A flexible connection between the exhaust manifold and the piping system should be used lo
prevent transmission of engine vibration to the piping and the building and to allow for thermal
expansion and any slight misalignment of the piping.

Ensure that the silencer and al pipes are well supported to limit strain on the connectors which
could result in cracks or leaks.

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HPU MANUAL

Exhaust system components located within the HPU room should be insulated to reduce heat
radiation and noise levels. Pipes and the silencer, whether located inside or outside the building,
should be located well clear of any combustible material.

Any long horizontal or vertical piping should slope away from the engine and include drain traps
al their lowest points lo prevent water from reaching the engine or silencer.

On HPUs above 150 kVA the silencer installation must include a purge plug for venting of the
exhaust system in the event of difficult starting. The plug should be located adjacent to the
exhaust flange and positioned to allow access.

Where the pipe goes through a wall there should be a sleeve in the opening to absorb vibration
and isolate combustible material from the hot pipes .There may also be an expansion joint in the
pipe to compensate for lengthwise thermal expansion or contraction.

The purpose of the engine exhaust system is to direct the exhaust gases outside to a location and height
where the fumes and odours will not become an annoyance or hazard and to reduce noise. A suitable
exhaust silencer must be incorporated in to the exhaust piping to reduce the noise level from the engine.
It can be fitted either inside or outside the building. Canopied HPUs include exhaust system within the
enclosure.
Open HPUs will generally be supplied with a loose industrial class silencer, a stub pipe and a bellows.
The engine exhaust for all indoor HPUs must be piped outdoors via leak free piping in compliance with
relevant Codes, Standards and other requirements.
Ensure hot exhaust silencers, piping and turbochargers, if fitted, are clear of combustible material and are
guarded for personnel protection per safety requirements.
Ensure that fumes from the exhaust outlet will not be a hazard.
In designing an exhaust system, the primary consideration is to not exceed the allowable backpressure
permitted by the engine manufacturer. Excessive backpressure seriously affects engine output durability
and fuel consumption. To limit the backpressure the exhaust piping should be as short and straight as
possible. Any required bends should have a curve radius of at least 1.5 times the inside diameter of the
pipe.
The outer end of the exhaust pipe, if horizontal, should be cut at 60 to the horizontal or should be fitted
with a rain hood or cap, if vertical, to prevent rain or snow from entering the exhaust system.
The exhaust pipe must not be connected to exhausts from other HPUs or other equipment, such as a
furnace or boiler.

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Fire Precautions
When planning the HPU installation the following points should be considered:

The room should be designed so that there is an easy escape route for operating personnel in
the event of fire within the room.

Supply a Class BC or Class ABC fire extinguisher and/or fire extinguishing system.

Gravity operated fire valves released by temperature operated fusible links mounted above the
engine can be installed in the fuel lines.

STARTING BATTERIES
WARNING
Do not smoke or allow sparks, flames or other sources of Ignition around batteries. Hydrogen gas
generated by charging batteries is explosive.
The starting batteries should be located as close as possible to the HPU while still being accessible for
servicing. This will prevent electrical losses from long cables that could impact on the engine starting
capability of the batteries.
ELECTRICAL CONNECTION
On site electrical installation will generally consist only of connecting up the site load to the HPU output
terminals. Only fully qualified and experienced electrical technicians should carry out electrical
installation, service and repair work.

WARNING
Make electrical connections in compliance with relevant Electrical Codes, Standards or other
requirements. This includes requirements about grounding and ground/earth faults.
Cabling:
Due to movement of HPUs on their vibration mounts, the electrical connection to the set should be made
with flexible cable. This will prevent transmission of vibrations and possible damage to the alternator or
circuit breaker terminals. If flexible cabling can not be used throughout the installation then a link box
should be installed close to the set with a flexible connection to the set.
The cable should be protected by laying it in a duct or cable tray. However, the duct or tray should never
be rigidly connected to the HPU. When bending cable, reference must be made to the recommended
minimum bending radius.
The cable must be suitable for the output voltage of the HPU and the rated current of the HPU. In
determining the size, allowances should be made for ambient temperature, method of installation,
proximity of other cables, etc.
All connections should be carefully checked for integrity.

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HPU MANUAL

GROUNDING REQUIREMENTS:
Regulations vary for different locations. The frame of the HPU must be positively connected to earth.
Since the set is mounted on vibration isolators, the ground connection must be flexible to avoid possible
breakage due to vibration.
The ground connection point positions are marked with the yellow earth sign.
Ground connection cables or straps should have at least full load current carrying capacity and meet
applicable regulations.
DC GENERATOR RECONNECTION:
Most alternators can be reconnected to suit different output voltages. The reconnection procedures are
given in the alternator Manual. Ensure that all other components such as circuit breakers, current
transformers, cables and ammeters are suitable before operating at a different voltage.
INSULATION TEST:
Before starting the HPU after installation, test the insulation resistance of the windings. The Automatic
Voltage Regulator (AVR) should be disconnected and the rotating diodes either shorted out with
temporary links or disconnected. Any control wiring must also be disconnected.
A 500V Megger or similar instrument should be used. Disconnect any earthing conductor connected
between positive and earth and megger an output terminal to earth. The insulation resistance should be
in excess of 5M to earth. Should the insulation resistance be less than 5M the winding must be dried
out. See the Alternator Manual for procedures.
ACOUSTIC SILENCING
Control of HPU noise is becoming very important in most installations. There is a range of options
available to control the noise level.
WARNING
Ear protection must be worn when operating or working around an operating HPU.
Exhaust Silencers
The exhaust silencer will decrease sound levels from the engine. Varying degrees of sound attenuation
are available from different types of silencers. These levels are often described by terms such as
industrial, residential, critical or supercritical.

Enclosures
Canopy or containerized type enclosures can be designed to meet a specific sound level requirement.

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Other Sound Attenuation


For installations in buildings there are other types of equipment such as acoustic louvers, splitter vents
and fan silencers, as well as sound absorbing wall coverings that can be used to reduce the noise levels
of HPUs.
STORAGE
Long term storage can have detrimental effects on both the engine and DC generator. These effects can
be minimised by properly preparing and storing the HPU.

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4.2. ENGINE
4.2.1. 48-7-600 (PERKINS 403D-114)

HPU MANUAL
4.2.2. 48-20-1550 (DEUTZ F3M2011)

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4.3. DC GENERATOR

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HPU MANUAL
4.4. HPU VIEW
4.4.1. 48-7-600

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4.5. HPU NOISE LEVEL
4.5.1. 48-7-600

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SECTION 5.

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O P E R AT I O N

5.1. GENERAL
The HPU is equipped with a electronic control system. See Section 8 of this manual for a functional
description of it.
These control systems allow the operator to manually or automatically control the HPU. It has protection
circuits to sound an optional alarm and even shutdown the set if problems occur. Details of the
capabilities of it are contained in Section 8.
The following procedures detail the steps required to prepare the set for operation, start and stop it for the
first time after installation, and start and stop it normally.

5.2. PRE-START CHECKS


The following checks should be performed prior to starting the HPU:
WARNING!:
As HPUs with autostart control panels can be remotely started without warning, always ensure the control
panel is switched off before carrying out any checks.
1.

Ensure the Control Switch/Key Switch is Off.

WARNING!:
Do not remove the radiator cap when the coolant is hot. Do not add large amounts of cold
coolant to a hot system as serious damage could result.
2.

Check the engine oil and coolant levels - replenish as necessary.


Note:

Diesel engines normally consume lube oil at a rate of 2,5 to 1 % of the fuel
consumption.

When adding coolant to the radiator system, always pour slowly to help prevent air from
becoming trapped in the engine.

WARNING!:
When filling the fuel tank, do not smoke or use an open flame in the vicinity.
3.

Check the fuel level - fill as necessary.

WARNING!:

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Before tightening fan belts, disconnect the battery negative (-) lead to ensure the engine cannot
be accidentally started.
4.

Check the condition and tension of the fan and engine alternator belts. Tighten as necessary.

5.

Check all hoses for loose connections or deterioration. Tighten or replace as necessary.

6.

Check the battery terminals for corrosion - clean as necessary.

WARNING!:
When working with the batteries, do not smoke or use an open flame in the vicinity. Hydrogen
gas from batteries is explosive. Do not short the positive and negative terminals together.
7.

Check the battery electrolyte level. Fill with distilled water as necessary. If the battery is new and
has never been wet charged, fill with suitable premixed electrolyte and charge.

8.

Check the control panel and the HPU for heavy accumulation of dust and dirt. Clean as necessary.
These can pose an electrical hazard or give rise to cooling problems.

9.

Check the air filter restriction indicator, if fitted replace the filter as necessary.

10. Clear the area around the HPU of any insecure items that could inhibit operation or cause injury.
Ensure cooling air ventilation screens are clear.
11. Visually check the entire HPU for signs of leaks from the fuel system, cooling system or lubrication
seals.
12. Periodically drain exhaust system condensate traps, if equipped.
13. Ensure the Alternator Output Circuit Breaker (if fitted) is in the 'OFF" (handle down) position.
14. Check the GEN hinibit selector switch is to on position.

5.3.

INITIAL START-UP/SHUTDOWN

The following procedure should be used when manually starting the HPU for the first time or when it has
been out of service for a time for maintenance purposes:
Note:
The HPU may be stopped at any time by pushing the STOP push button or the Emergency Stop
Pushbutton.
1.

Complete Pre-Start checks as per Section 5.2.

2.

Connect the batteries to the engine, positive lead first then the negative lead.

3.

Prime the lube oil system by first removing one wire from the fuel solenoid or actuator. This
prevents the engine from starting. Push the manual push button. Push the Start Button: the
engine will crank and oil pressure is registered on the gauge. Now reconnect the wire to the fuel
solenoid or actuator. Should the oil pressure still not have built up after 3 cranking attempts,
investigate the reason for lack of oil pressure prior to further cranking attempts.

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WARNING!:
Excessive cranking with an unprimed fuel system may cause a build-up of unburned fuel gases in
the exhaust system which could be potentially explosive.
4.

Prime the fuel system using the hand priming pump and bleed entrapped air from the fuel filter see Engine Manual for details.

5.

Start: Ensure the Emergency Stop Pushbutton and any remote Stop Push buttons are released. "
Push the Manual push button and than push the START push button. The engine will crank until
the engine starts. If the engine does not start, refer to the Engine Manual to determine the cause
of failure to start.

WARNING!:
Unburned fuel gases can build-up in the exhaust system after multiple failed attempted starts, Unscrew
the plugs on the exhaust outlet elbows or stub pipes and allow the unburned fuel to dissipate. Once all
signs of unburned fuel (white smoke) have disappeared and any other problems causing the failure to
start have been rectified, replace the plugs and repeat the cranking procedure.
WHEN ENGINE HAS STARTED
6.

After approximately 1 minute shutdown the HPU by pressing the Stop Pushbutton. Remove the
radiator cap and wait 5 minutes for the system to settle and any trapped air to escape. Re-check
the coolant level and refill as necessary.

NOTE:
A newly filled coolant system can have air locks that must be cleared by running the engine for a
short time and the system refilled prior to extended running of the engine.
7.

Restart the engine following the procedures in step 5 above.

8.

Check for any abnormal noise or vibration.

9.

Check for fluid leakage or leaks in the exhaust system.

10. Check the control panel for indications of abnormal operation, particularly abnormally high
temperature or abnormally low oil pressure. The oil pressure should be in the normal range within
about 10 seconds of starting.
11. Check the control panel for output voltage and frequency. The voltage is factory set and should
indicate the rated voltage. Adjustments should only be carried out by a qualified technician.
Details of these connections can be found in the Alternator Manual.

WARNING!:
12. Shutdown: To shutdown the HPU press the Stop Pushbutton .
13. The load cables can now be connected to the HPU in preparation for normal operation.

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HPU MANUAL

5.4. NORMAL MANUAL STARTUP/SHUTDOWN


1.

Complete Pre-Start checks as per Section 5.2.

NOTE:
The engine will not start if any fault indicators are illuminated. Reset the control system by
pushing the RESET push button. Ensure the faults have been corrected prior to attempting
to start the HPU.
2.

Manual Start: Ensure the Emergency Stop Pushbutton and any remote Stop Pushbuttons
are released, Push the manual push button and than push the start push button and than
the engine will crank. If the engine does not start refer to the Engine Manual to determine
the cause of failure to start,

WARNING!:
Unburned fuel gases can build-up in the exhaust system after multiple failed attempted
starts. Unscrew the plugs on the exhaust outlet elbows or stub pipes and allow the
unburned fuel to dissipate. Once all signs of unburned fuel (white smoke) have
disappeared and any other problems causing the failure to start have been rectified,
replace the plugs and repeat the cranking procedure.
WHEN ENGINE HAS STARTED
3.

Check for any abnormal noise or vibration.

4.

Check for fluid leakage or leaks in the exhaust system.

5.

Check the control panel for indications of abnormal operation, particularly abnormally high
temperature or abnormally low oil pressure. The oil pressure should be in the normal range
within about 10 seconds of starting.

6.

Turn the selector GENERATOR ON LOAD in ON position.

Note:
Load can now be applied lo the HPU.
7.

Shutdown: To shut the HPU down, turn off the load by turning the HPU ON LOAD selector
switch to OFF . Allow the HPU to run without load for a few minutes to cool. Then push
the "STOP" push button. The HPU will shutdown.

8.

In case of an emergency where immediate shutdown is necessary, the Emergency Stop


Pushbutton should be pushed immediately without disconnecting the load

5.5. AUTOMATIC STARTUP


The following procedure should be used for preparing a HPU to be started from a remote
location,

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DATE 5/11/2012

Note:
The HPU may be stopped at any time by pushing the STOP push button or the Emergency
Stop Pushbutton.
1. Complete Pre-Start checks as per Section 5.2.

Note:
The engine will not be able to start if any fault indicators are illuminated, Reset the control system by
pushing the RESET push button. Ensure the faults have been corrected prior to attempting to start the
HPU.
2. Automatic Start: To make this operation please set the control card in "AUTO" mode.
3. Set the GEN hinibit selector switch to the OFF position.
4. Turn the selector GENERATOR ON LOAD in ON position.

The HPU is now ready to automatically start when it receives a remote start signal. When the start signal
is removed will automatically stop.
Various timers for warming up , cool down and many other various parameters are settable.

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SECTION 6.
6.1. 48-7-600

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E LE C T RI C AL D R AW I N G

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6.2. 48-20-1550

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SECTION 7.

M AI N TE N AN C E

7.1. GENERAL
A good maintenance programme is the key to a long HPU lifetime.
Maintenance and service should only be carried out by qualified technicians. Records of this work should
be kept to aid in developing an efficient maintenance programme.
In general, the HPU should be kept clean. Do not permit liquids such as fuel or oil film to accumulate on
any internal or external surfaces or on, under or around any acoustic material, if fitted. Wipe down
surfaces using an aqueous industrial cleaner. Do not use flammable solvents for cleaning purposes.
Any acoustic material with a protective covering that has been torn or punctured should be replaced
immediately to prevent accumulation of liquids or oil film within the material.

7.2. PREVENTATIVE MAINTENANCE


Depending on the application of the HPU, requirement for preventative maintenance will vary. The
preventative maintenance requirements associated with the engine are detailed in the Engine Manual
which should be reviewed in. conjunction with this section. Maintenance intervals for the engine may be
more frequent than those shown in this section.

Daily or at Each Start up:


(For standby sets these procedures may be performed weekly.) A walk around inspection
should be performed on a daily basis and prior to starting the engine. The pre-start checks
should be performed during this walk around. Procedures for performing the checks on the
engine can be found in the Engine Manual.

7.2.2 Every Two Weeks:


(For standby sets that have not been run.) Perform an operational check on the HPU by
starting and running the set for 5 minutes.
WARNING:
Do not run diesel engines at low loads for long periods

7.2.3 Every Month:


(For standby sets that have not been run on load.) Perform an operational and load check on
the HPU by starting and running the set on at least 50% load for 1 to 2 hours.

7.2.4 Every Six Months or 250 Hours:


Repeat the daily procedures plus the following:
1. Check all control system safety devices by electrically simulating faults.

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2. Clean all battery cap vents.


3. Tighten all exhaust connections.
4. Tighten all electrical connections.
5. Perform other engine maintenance as specified in the Engine Manual.
6. Start the engine and observe the instrument panel to ensure that all gauges and meters
are operating properly.
7. If a spark arrestor has been fitted, this should be removed and thoroughly cleaned to
remove any carbon build-up.

7.2.5 Alternator Preventative Maintenance:


There is no routine maintenance required on the alternator, however periodic inspection of the
alternator winding condition and periodic cleaning is recommended.

7.2.6 Engine Preventative Maintenance:


See the Engine Manual provided with this manual for information on regular maintenance
required to keep the engine operating efficiently.

7.3. REMOVAL OF ENGINE AND/OR ALTERNATOR


The following procedures should be used for removal of the engine and/or alternator.
1. Isolate and disconnect electrical power supply to auxiliary equipment such as a water
heater.
2. Disconnect the battery (negative lead first) and remove if necessary.
3. If the HPU is equipped with a canopy, remove the fixing bolts on each side, disconnect
the exhaust system and then remove the canopy.
4. Isolate and disconnect the control panel and remove together with stand from the HPU,
ensuring that all cables have been adequately identified to facilitate reconnection.
5. If the engine and alternator are both to be removed, they may be lifted out as one unit
using the lifting eyes provided on both the engine and alternator. First the bolts holding
the engine/alternator to the baseframe have to be removed.

7.3.1 Engine Removal Only:


1. If only the engine is to be removed, the wiring loom should first be removed from the
engine.

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2. If the alternator is fitted with only one set of feet then the front end of the alternator will
have to be firmly supported before removing the engine.
3. Remove the bolts holding the engine to the base. It may also be advantageous to loosen
the alternator mounting bolts.
4. Remove the alternator fan guards.
5. Support the rotor assembly using a sling or wooden supports taking care not to damage
the fan.
6. Remove the bolts between the flexible coupling and the engine flywheel.
7. Support the rear of the engine using an overhead crane or simi1ar device.
8. Remove the coupling housing bolts.
9. The engine is now moved forward until it is clear of the alternator and may be lifted away
from the base.

7.3.2 Dc generator Removal Only:


1. If only the alternator is to be removed, the rear of the engine must be firmly supported.
2. Remove the Dc generator wiring loom.
3. Remove the bolts holding the dc generator to the baseframe. Loosen the engine bolts as
well.
4. Remove the dc generator alternator fan covers and support the rotor and the front of the
alternator. Ensure that the rotor is positioned with a pole at the bottom centre line. This is to
avoid any damage to the bearing or exciter by limiting the rotor movement to that of the air
gap.
5. Uncouple the dc generator from the engine as per Section 9.3.1.
6. Support the dc generator using a sling or similar device and slide the complete alternator
back on the base before lifting.

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7.4. ENGINE BATTERY MAINTENANCE


WARNING!
Wear an acid resistant apron and face shield or goggles when servicing the battery. If electrolyte is spilled
on skin or clothing, flush immediately with large quantities of water.

7.5. FILLING
The battery will often be shipped dry. Pre-mixed electrolyte of the correct specific gravity will have to be
added. Remove the vent plugs and fill each cell with the electrolyte until the level is 8 mm (5/16 inch)
above the top edge of the separators. Allow the battery to stand for 15 minutes. Check and adjust the
level as necessary.

7.6. INITIAL THE CURRENT INDICATED BELOW


This will ensure that the acid is sufficiently mixed within the battery. Failure to give this charge at this time
may impair the capacity of the battery.
The above 4 hour charge period may need to be extended as follows: to 8 hours if the battery has been
stored for 3 months or more at temperatures in excess of 30C (86F) or humidity above 80%; to 12 hours
if the storage has exceeded 1 year.
At the end of the charging period, the electrolyte levels should be checked and restored if necessary by
addition of sulphuric acid electrolyte at the correct specific gravity. The vents should then be replaced.

7.7. TOPPING UP
Normal operation and charging of the battery will cause some of the water to evaporate. This will require
occasional topping up of the battery.
Clean the battery first to avoid contamination and remove the vent plugs. Add distilled water, until the
level is 8 mm (5/16 inch) above the separators. Replace vent plugs.

7.8. CHARGING THE BATTERY


WARNING!
Always ensure battery charging is carried out in a well ventilated area away from sparks and naked
flames.

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Never operate a battery charger where unprotected from rain or snow. The charger should never be used
near water.
Always switch the charger off prior to disconnecting the battery.
The engine driven alternator and or a static battery charger, if fitted, should maintain the batteries in a
charged state. However, if the battery has recently been filled or recharging is required the battery may
be disconnected from the HPU and connected to an external battery charger.

7.9. MANUAL FOR USE AND MAINTENANCE FOR MOTIVE BATTERIES

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Discharge final voltage


Capacity is always referred to a voltage value at end of discharge (voltage value per
element at end of discharge
during a 5-hour discharge period is approximately 0.3 Volt lower than open-circuit rated
voltage value- The
minimum final voltage is a function of the discharge rate (Pic.1).
Battery design and quantity of plates
Capacity depends on accumulator design: type and quantity of plates, relationship
between active substance
quantity and available electrolyte, element dimensions, etc.
Battery age
Ascot power batteries PZS generally reach their rated capacity after a few working cycles
(charging and
discharging), and subsequently maintain their performance level for a long time (approx.
1500 cycles),
depending on battery use.

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HPU MANUAL

HPU MANUAL

SECTION 7
PAG. 87
DATE 5/11/2012

SECTION 7
PAG.88
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 7
PAG. 89
DATE 5/11/2012

SECTION 8
PAG.90
DATE 05/11/2012

SECTION 8.
8.1. ENGINE
8.1.1. 48-7-600

HPU MANUAL
C O M P O NE N TS M AN U AL S

HPU MANUAL

SECTION 8
PAG. 91
DATE 5/11/2012

SECTION 8
PAG.92
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 93
DATE 5/11/2012

SECTION 8
PAG.94
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 95
DATE 5/11/2012

SECTION 8
PAG.96
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 97
DATE 5/11/2012

SECTION 8
PAG.98
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 99
DATE 5/11/2012

SECTION 8
PAG.100
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 101
DATE 5/11/2012

SECTION 8
PAG.102
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 103
DATE 5/11/2012

SECTION 8
PAG.104
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 105
DATE 5/11/2012

SECTION 8
PAG.106
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 107
DATE 5/11/2012

SECTION 8
PAG.108
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 109
DATE 5/11/2012

SECTION 8
PAG.110
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 111
DATE 5/11/2012

SECTION 8
PAG.112
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 113
DATE 5/11/2012

SECTION 8
PAG.114
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 115
DATE 5/11/2012

SECTION 8
PAG.116
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 117
DATE 5/11/2012

SECTION 8
PAG.118
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 119
DATE 5/11/2012

SECTION 8
PAG.120
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 121
DATE 5/11/2012

SECTION 8
PAG.122
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 123
DATE 5/11/2012

SECTION 8
PAG.124
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 125
DATE 5/11/2012

SECTION 8
PAG.126
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 127
DATE 5/11/2012

SECTION 8
PAG.128
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 129
DATE 5/11/2012

SECTION 8
PAG.130
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 131
DATE 5/11/2012

SECTION 8
PAG.132
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 133
DATE 5/11/2012

SECTION 8
PAG.134
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 135
DATE 5/11/2012

SECTION 8
PAG.136
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 137
DATE 5/11/2012

SECTION 8
PAG.138
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 139
DATE 5/11/2012

SECTION 8
PAG.140
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 141
DATE 5/11/2012

SECTION 8
PAG.142
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 143
DATE 5/11/2012

SECTION 8
PAG.144
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 145
DATE 5/11/2012

SECTION 8
PAG.146
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 147
DATE 5/11/2012

SECTION 8
PAG.148
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 149
DATE 5/11/2012

SECTION 8
PAG.150
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 151
DATE 5/11/2012

SECTION 8
PAG.152
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 153
DATE 5/11/2012

SECTION 8
PAG.154
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 155
DATE 5/11/2012

SECTION 8
PAG.156
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 157
DATE 5/11/2012

SECTION 8
PAG.158
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 159
DATE 5/11/2012

SECTION 8
PAG.160
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 161
DATE 5/11/2012

SECTION 8
PAG.162
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 163
DATE 5/11/2012

SECTION 8
PAG.164
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 165
DATE 5/11/2012

SECTION 8
PAG.166
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 167
DATE 5/11/2012

SECTION 8
PAG.168
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 169
DATE 5/11/2012

SECTION 8
PAG.170
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 171
DATE 5/11/2012

SECTION 8
PAG.172
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 173
DATE 5/11/2012

SECTION 8
PAG.174
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 175
DATE 5/11/2012

SECTION 8
PAG.176
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 177
DATE 5/11/2012

SECTION 8
PAG.178
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 179
DATE 5/11/2012

SECTION 8
PAG.180
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 181
DATE 5/11/2012

SECTION 8
PAG.182
DATE 05/11/2012

HPU MANUAL

HPU MANUAL
8.1.2. 48-20-1550

SECTION 8
PAG. 183
DATE 5/11/2012

SECTION 8
PAG.184
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 185
DATE 5/11/2012

SECTION 8
PAG.186
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 187
DATE 5/11/2012

SECTION 8
PAG.188
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 189
DATE 5/11/2012

SECTION 8
PAG.190
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 191
DATE 5/11/2012

SECTION 8
PAG.192
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 193
DATE 5/11/2012

SECTION 8
PAG.194
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 195
DATE 5/11/2012

SECTION 8
PAG.196
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 197
DATE 5/11/2012

SECTION 8
PAG.198
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 199
DATE 5/11/2012

SECTION 8
PAG.200
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 201
DATE 5/11/2012

SECTION 8
PAG.202
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 203
DATE 5/11/2012

SECTION 8
PAG.204
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 205
DATE 5/11/2012

SECTION 8
PAG.206
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 207
DATE 5/11/2012

SECTION 8
PAG.208
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 209
DATE 5/11/2012

SECTION 8
PAG.210
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 211
DATE 5/11/2012

SECTION 8
PAG.212
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 213
DATE 5/11/2012

SECTION 8
PAG.214
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 215
DATE 5/11/2012

SECTION 8
PAG.216
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 217
DATE 5/11/2012

SECTION 8
PAG.218
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 219
DATE 5/11/2012

SECTION 8
PAG.220
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 221
DATE 5/11/2012

SECTION 8
PAG.222
DATE 05/11/2012

HPU MANUAL

HPU MANUAL
8.2. DC GENERATOR

SECTION 8
PAG. 223
DATE 5/11/2012

SECTION 8
PAG.224
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 225
DATE 5/11/2012

SECTION 8
PAG.226
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 227
DATE 5/11/2012

SECTION 8
PAG.228
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 229
DATE 5/11/2012

SECTION 8
PAG.230
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 231
DATE 5/11/2012

SECTION 8
PAG.232
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 233
DATE 5/11/2012

SECTION 8
PAG.234
DATE 05/11/2012

HPU MANUAL

HPU MANUAL
8.3. INSTRUCTION MANUAL HPU CONTROL PANEL

SECTION 8
PAG. 235
DATE 5/11/2012

SECTION 8
PAG.236
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 237
DATE 5/11/2012

SECTION 8
PAG.238
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 239
DATE 5/11/2012

SECTION 8
PAG.240
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 241
DATE 5/11/2012

SECTION 8
PAG.242
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 243
DATE 5/11/2012

SECTION 8
PAG.244
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 245
DATE 5/11/2012

SECTION 8
PAG.246
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 247
DATE 5/11/2012

SECTION 8
PAG.248
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 249
DATE 5/11/2012

SECTION 8
PAG.250
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 251
DATE 5/11/2012

SECTION 8
PAG.252
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 253
DATE 5/11/2012

SECTION 8
PAG.254
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 255
DATE 5/11/2012

SECTION 8
PAG.256
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 257
DATE 5/11/2012

SECTION 8
PAG.258
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 259
DATE 5/11/2012

SECTION 8
PAG.260
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 261
DATE 5/11/2012

SECTION 8
PAG.262
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 263
DATE 5/11/2012

SECTION 8
PAG.264
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 265
DATE 5/11/2012

SECTION 8
PAG.266
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 267
DATE 5/11/2012

SECTION 8
PAG.268
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 269
DATE 5/11/2012

SECTION 8
PAG.270
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 271
DATE 5/11/2012

SECTION 8
PAG.272
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 273
DATE 5/11/2012

SECTION 8
PAG.274
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 275
DATE 5/11/2012

SECTION 8
PAG.276
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 277
DATE 5/11/2012

SECTION 8
PAG.278
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 279
DATE 5/11/2012

SECTION 8
PAG.280
DATE 05/11/2012

HPU MANUAL

HPU MANUAL
8.4. IP500 USER MANUAL

SECTION 8
PAG. 281
DATE 5/11/2012

SECTION 8
PAG.282
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 283
DATE 5/11/2012

SECTION 8
PAG.284
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 285
DATE 5/11/2012

SECTION 8
PAG.286
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 287
DATE 5/11/2012

SECTION 8
PAG.288
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 289
DATE 5/11/2012

SECTION 8
PAG.290
DATE 05/11/2012

HPU MANUAL

HPU MANUAL
8.5. AIR CONDICTIONING SYSTEM
8.5.1. AIR-CONDICTIONER MANUAL

SECTION 8
PAG. 291
DATE 5/11/2012

SECTION 8
PAG.292
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 293
DATE 5/11/2012

SECTION 8
PAG.294
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 295
DATE 5/11/2012

SECTION 8
PAG.296
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 297
DATE 5/11/2012

SECTION 8
PAG.298
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 299
DATE 5/11/2012

SECTION 8
PAG.300
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 301
DATE 5/11/2012

SECTION 8
PAG.302
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 303
DATE 5/11/2012

SECTION 8
PAG.304
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 305
DATE 5/11/2012

SECTION 8
PAG.306
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 307
DATE 5/11/2012

SECTION 8
PAG.308
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 309
DATE 5/11/2012

SECTION 8
PAG.310
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 311
DATE 5/11/2012

SECTION 8
PAG.312
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 313
DATE 5/11/2012

SECTION 8
PAG.314
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 315
DATE 5/11/2012

SECTION 8
PAG.316
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 317
DATE 5/11/2012

SECTION 8
PAG.318
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 319
DATE 5/11/2012

SECTION 8
PAG.320
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 321
DATE 5/11/2012

SECTION 8
PAG.322
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 323
DATE 5/11/2012

SECTION 8
PAG.324
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 325
DATE 5/11/2012

SECTION 8
PAG.326
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 327
DATE 5/11/2012

SECTION 8
PAG.328
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 329
DATE 5/11/2012

SECTION 8
PAG.330
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 331
DATE 5/11/2012

SECTION 8
PAG.332
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 333
DATE 5/11/2012

SECTION 8
PAG.334
DATE 05/11/2012

HPU MANUAL

8.5.2. CENTRAL CONTROL UNIT MANUAL

HPU MANUAL

SECTION 8
PAG. 335
DATE 5/11/2012

SECTION 8
PAG.336
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 337
DATE 5/11/2012

SECTION 8
PAG.338
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 339
DATE 5/11/2012

SECTION 8
PAG.340
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 341
DATE 5/11/2012

SECTION 8
PAG.342
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 343
DATE 5/11/2012

SECTION 8
PAG.344
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 345
DATE 5/11/2012

SECTION 8
PAG.346
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 347
DATE 5/11/2012

SECTION 8
PAG.348
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 349
DATE 5/11/2012

SECTION 8
PAG.350
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 351
DATE 5/11/2012

SECTION 8
PAG.352
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 353
DATE 5/11/2012

SECTION 8
PAG.354
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 355
DATE 5/11/2012

SECTION 8
PAG.356
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 357
DATE 5/11/2012

SECTION 8
PAG.358
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 359
DATE 5/11/2012

SECTION 8
PAG.360
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 361
DATE 5/11/2012

SECTION 8
PAG.362
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 363
DATE 5/11/2012

SECTION 8
PAG.364
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 365
DATE 5/11/2012

SECTION 8
PAG.366
DATE 05/11/2012

HPU MANUAL

HPU MANUAL
8.5.3. BATTERY CONTROL UNIT MANUAL

SECTION 8
PAG. 367
DATE 5/11/2012

SECTION 8
PAG.368
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 8
PAG. 369
DATE 5/11/2012

SECTION 9
PAG.370
DATE 05/11/2012

SECTION 9.

HPU MANUAL
W AR R AN T Y AN D S P AR E P AR T S

HPU MANUAL

SECTION 9
PAG. 371
DATE 5/11/2012

SECTION 9
PAG.372
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 9
PAG. 373
DATE 5/11/2012

SECTION 9
PAG.374
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 9
PAG. 375
DATE 5/11/2012

SECTION 9
PAG.376
DATE 05/11/2012

HPU MANUAL

HPU MANUAL

SECTION 9
PAG. 377
DATE 5/11/2012