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Date: Feb.

16h, 2011
Rev. 1: Feb.23rd, 2011
Distribution: Total E&P Indonesie

Technical Bulletin
Troubleshooting Procedure Turbo-Generator Fails To Rotate
Before starting up the CCVT, investigate the reason for the shut down. If the CCVT was shut
down due to failure, download the DTCU history file for information, and proceed to troubleshoot
as described in the O&M manual. If the shutdown was initiated by an operator or by remote
shutdown such as ESD, proceed to normal start up.
The startup sequence of the CCVT is as follows:
1. 7 minutes pre-purge with clean air
2. Start up the CCVT
3. The DTCU applies a holding current to the excitation coil so that the turbo-generator
does not rotate too early.
4. At a set vapor generator temperature of 65C for 4kW units or 85C for 1.2kW and 3kW
units, the burner will extinguish for a warm up period, to allow lubricant to accumulate in
the motive fluid collection tank that is located below the condenser.
5. After 20-30 minutes the burner will fire up again.
6. The turbo-generator (TG) should begin rotating when the vapor generator temperature is
in the range of 90 - 120C, depending on the CCVT model and on ambient conditions.
7. If the TG has not yet begun to rotate 75 minutes after the CCVT was started up, the
holding current will be released. This removes any resistance to TG rotation.
NOTE if the main switch is switched off or the Reset button pushed at any time during
the start up the 75 minute timer is reset.
8. After another 30 minutes, if the TG still is not rotating, Fail Code 71 fail to run will
appear in the DTCU display.
Troubleshooting Procedure:
1. During the startup, verify that the vapor generator is heating up properly.
2. Verify that the condenser is heating up properly as well. The condenser temperature
should increase by at least 3C during the warm up period and should continue to
increase in temperature during the startup period. If not there is a lack of proper vacuum.
3. Make sure that vapor generator temperature does not rise above 140C while the TG is
not yet rotating. If the temperature rises above 140C and there is still no frequency,
unplug the EVS solenoid valve to extinguish the burner.

NOTE - The DTCU does not register an unplugged solenoid as a failure.

4. The condenser temperature should remain within the normal range. Refer to the O&M
manual to check if degassing is required.
5. Allow the CCVT to run through the complete start up procedure as described above.
Refrain from switching the unit off or pushing the Reset button during this time. Monitor
the vapor generator and condenser temperatures throughout.
6. After receiving Fail Code 71, do not press Reset.
7. If the vapor generator temperature was above 140C at the time of failure, allow it to cool
down to 140C before proceeding.
NOTE - The temperature cannot be seen in the DTCU display at this time since FAIL 71
appears. Do not press reset. Connect to the DTCU with a laptop and PCView software
to read the temperature.
8. Try to release the TG by mechanical impact. Use a rubber mallet or wooden board to hit
the support rail on which the canister is mounted. Do not hit the canister itself!
9. As soon as the TG starts rotating, press the Reset button to connect the loads.
WARNING Do not attempt this with a discharged battery as that will overload the
CCVT. When the Reset button is pressed the overloading will cause a sudden
deceleration just as the frequency was in acceleration mode. This sudden shock may
affect the bearings and cause the TG to seize permanently.
10. If the TG still fails to rotate, then the bearings have seized and the canister should be
replaced. The failed canister can be returned to Ormat for repair as long as the
preservation procedure described in the Turbo-generator canister replacement manual,
Ormat doc. No. 0.505.90.508.0, is followed.