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Generating set R350C2 (CE) - User manual - SDMO

1. 2 SPN CID SID PID PPID 2 x Description Comment 5 28 Throttle 3 Position 3 Throttle Voltage high short to V Short to V 4 Throttle Voltage low short to V Short to V 29 Throttle 2 Position 3 Throttle Voltage high short to V Short to V 4 Throttle Voltage low short to V Short to V 14 Throttle voltage out of range 84 Vehicle speed Vehicle invalid or missing Not possible with Genset Vehicle speed mismatch application 91 91 91 132 Accelerator pedal position forall Throttle Voltage high short to V Throttle Voltage low short to V Throttle calibration invalid Risk posho mii genset PWM throttle abnormal pulse width application codes declared Throttle invalid CAN value by the CAN 1587 for Throttle voltage out of range low bees Throttle calibration aborted Throttle voltage out of range 94 94 Fuel rail pressure sensor Fuel supply pressure extremely low Fuel rail pressure input voltage high Short to V Fuel rail pressure input voltage low Short to V Fuel rail pressure sensor open circuit Fuel rail pressure lost detected Fuel rail pressure higher than expected Fuel supply pressure moderately high Fuel rail pressure not developed Fuel supply pressure moder
2. LEROY SOMER Installation and maintenance 3856 en 2011 01 h ALTERNATORS Connection codes Voltage L L Factory connection FF Winding 50 Hz 60 Hz 6 220 240 220 240 ye po P KO 3 T2 T6 T12 7 240 254 Tu 16 o T5 En 8 220 240 156 1 L 1 T4 T T10 L R 250 voltage detection Pa T Q L1 U M A 0 gt T4 110 V gt T1 D O R 450 voltage detection M L2 V Voltage LM 1 2 voltage LL 0 gt T10 220 V gt T1 NDE Winding 50Hz 60Hz x 6 220 240 220 240 L3 W 1 phase 7 240 254 E 3 phase LA V 8 220 240 o L1 U R 250 voltage detection L3 W L2 V A 0 gt T8 110 V gt T11 L L R 450 voltage detection NDE M Vtage LM Ug volage LL 0 gt T3 220 V gt T2 Operating phases L2 V L3 W single phase amp Winding 50 Hz 60 Hz x T3 IPH 6 220 240 220 240 2 1g Lam M 7 250 260 L2 V 3j T4 8 200 220 240 T9 TS 250 voltage detection L 0 gt T8 110 gt T11 A 6 T n i RA50 voltage detection 5 T 0 gt T3 220 V gt T2 Voltage LM 1 2 voltage LL NDE In case of reconnection ensure that AVR voltage detection is correct The
3. llapakaAoUue ONMELWOTE OTL ioy e yia 12 LIVES tnv Mer 6a eivat ua VOLVO 77455269 9 Uma S Ap a i x iD e N 12 VOLVO 198 276 N 9 2 Appendix B Alternator user and maintenance manual 199 276 200 276 User guide and maintenance manual LEROY SOMER Alternator LSA46 2 L6 L9 LSA46 2 M3 M5 LSA46 2 VL12 46 2 SHUNT AREP amp PMG 3856 h 01 01 2011 33522061001 6 1 202 276 LEROY SOMER 3856 en 2011 01 h LSA 46 2 4 POLES ALTERNATORS Installation and maintenance 203 276 LEROY SOMER Installation and maintenance 3856 en 2011 0
4. c SPN CID SID PID PPID x Description Comment gt 9 1077 Fuel injection pump controller status 7 Attempting to fuel without command 11 Pump supply voltage out of range 12 Pump self test error 19 Pump detected communication error 31 Pump initiated engine protection 1078 ECU Pump timing status 7 ECU Pump timing moderately out of synchronisation 11 ECU Pump timing speed out of synchronisation 31 ECU Pump timing extremely out of synchronisation 1079 232 Sensor supply voltage 5 Volt Analog throttle reference 3 Sensor supply voltage high gt 5 5 Volt 4 E Sensor supply voltage low 4 44 Volt 1080 211 Sensor supply voltage Oil pressure Coolant temp fuel pressure 5V sensor supply 2 3 Sensor supply voltage high 5 5 Volt 4 E Sensor supply voltage low lt 4 40 Volt 1109 Engine ECU status 31 a Engine shutdown warning 1110 Engine status 31 a Engine shutdown 1111 268 Check parameters 2 Programmed parameter fault 1136 55 ECU Temperature 0 ECU temperature extremely high 16 ECU temperature moderately high 1172 Input temperature of the TGV compressor 3 d voltage of the temperature sensor Short to V 4 Y voltage of the temperature sensor Short to V 1180 Input temperature of the TGV turbine 0 Turbine temperature extremely high Short to V 16 E Turbine temperature moderately high Short to V 1184 173 Exhaust gas temperature sensor 1239 9
5. page 43 Every 800 hours at least every 12 months Charge air pipe leakage check 27 Primary fuel filter check not shown Every 1000 hours at least every 6 months e Coolant filter changing 9 page 37 Not at same time as coolant change Every 2000 hours O Turbocharger check not shown O Valve clearance inspection adjustment not shown Every 4000 hours O Double rocker arm iEGR inspection adjustment 2 not shown Every 12 months O EMS 2 system Inspection with diagnostic tool VODIA please refer to the VODIA User s Guide O Engine general inspection ssnm n page 27 Engine cleaning painting nnn not shown Inspection tank ventilation change not shown e Inspection air compressor change not shown Air filter inserts check change ssseeeeeenm nee page 29 Every 36 months or every 8000 hours Drive belts change nnne nnn nnns page 28 29 Every 48 months or every 10000 hours O Cooling system inspection cleaning sseseeenen page 35 EF Coolant changing iei We page
6. Noter que l offre est valable 12 mois a partir de la date de livraison du moteur puis seulement dans la mesure des stocks disponibles 195 276 Franquear o enviar fax a Document amp Distribution Cen ter Order Department ARU2 Dept 64620 SE 405 08 G teborg Suecia Fax 46 31 545 772 El pedido puede hacerse tam bi n por internet http www volvopenta com manual coupon Spedire il tagliando per posta o per fax a Document amp Distribution Center Order Department ARU2 Dept 64620 SE 405 08 G teborg Svezia Fax 46 31 545 772 L ordinazione pu essere fatta anche su Internet http www volvopenta com manual coupon ue Posta eller faxa kupongen till Dokument amp Distribution center Ordermottagningen ARU2 Avd 64620 SE 405 08 G teborg Sverige Fax 46 31 545 772 Best llningen kan aven g ras via internet http www volvopenta com manual coupon Si gracias deseo recibir gratuitamente un libro de instrucciones en espanol Numero de publicaci n 7745263 Nombre 5 o S Direc e ir iD ci n iD el x iD A Pa s Observe que la oferta es valida durante 12 meses a partir de la fecha de entre ga del motor A partir de la fecha de finalizaci n de la oferta la m
7. 49 Operation 50 Fault codes ied ee aede fine 51 Technical data 64 Generali ud sh cai shade eed o aca 64 Lubrication 66 Fuel aeey 67 Cooling system sssseseeeee 68 Electrical system 68 Safety information Read this chapter very carefully It has to do with your safety This describes how safety information is presented in the instruction book and on the product It also gives you an introduction to the basic safety rules for using and looking after the engine Check that you have received the correct instruction book before you read on If not please contact your Volvo Penta dealer Incorrect operation can lead to personal injury and damage to products or property So read the instruction book through very carefully before you start the engine or do any maintenance or servicework If there is still something which is unclear or if you feel unsure about it please con tact your Volvo Penta dealer for assistance This symbol is used in the instruction book and the product to call your attention to the fact that this is safety information Always read such information very carefully Safety texts in the instruction book have the following order of priority
8. eene ne 54 6 3 1 Presentation of the KERYS het eedem SIA ba epe EO repete arca e nce ase 54 6 3 151 Oper ting conditions be e eap Si ih ette i a a etl tte nete eq ti P E p ERE 54 6 3 1 2 Conformity to legal and regulatory requirements 55 6 3 2 Description of the KERYS lg a bem RH eodeni ep dede bs 56 6 3 2 1 Identification of the hardware components eese ener enne trenne tente enen tenete 56 6 3 2 2 Identification of the software components essent nenne tnen nein nr enne trennt tnsn ne 59 6 3 3 Description of the Man Machine Interface IH M MM1 cescceseceseceseccecececseeeseeeeceseceseeeseeeeeeeeeeseecaecnaecnaecaeesaeesaeenneees 60 6 3 3 1 The Man Machine Interf ce aiebat ape Saini ettet a o Det ee elaine sabes 60 6 3 3 2 Navigation in the Screens t rette B tee ET ee Bex dr eeu 63 6 3 4 Configurations n eie eut un Rr ate ed e aede e rope date rr e rite evades aea 68 634 1 Operating principle sis ei Beet de acte ed n a n sete Pero c ida 68 63 42 Legends cis isch odo no agentes e ote n ete eoi auae dee itte 69 6 3 4 3 Configuration in solo generating Set siun ie eE eani ei Sea E ebai Dent teen teet tnter nenne 69 6 3 4 4 Powe
9. genset grounds e d CIRCUIT BREAKER Current 7T7 77 O O transformer O 177777 O O O Ground N R S T O ej ej Ground rod 80 276 Earthing system TNS Interconnection bar between genset grounds Ground Earthing system TT Active differential circuit breaker Interconnection bar between genset grounds 7 7 77 TTTT7 Ground Type of earthing system Active differential circuit breaker Interconnection bar between genset grounds VITIT 7 7177 Ground La Oeogooooooeo N Neutral connected to grounds CIRCUIT Current O BREAKER transformer O O N R S Ground rod Neutral FS SED 27 CIRCUIT Current BREAKER transformer Oeoooooooe Ground rod EDF application On rental generating set only Neutral f a N N 2 ii CIRCUIT Current BREAKER transformer O O R S e Ground rod 81 276 EN Power plant Connection of the generating sets to the box Genset x r Neutral link GS1 current transformer link GSX current transformer 1 current transformer per GS Earth junction Ground rod box
10. 2 SPN CID SID PID PPID 2 9 Description Comment gt 9 158 158 Battery voltage sensor 1 Voltage above normal 17 ECU power down error 160 Wheel speed sensor 2 au Wheel speed input noise 164 164 Injection pressure control 168 168 Electrical system voltage 2 Electrical system voltage low Inlet air temperature 172 172 172 Ambient air temperature sensor sensor for PERKINS 3 Ambient air temperature sensor input Inlet air temperature sensor voltage high input voltage high 4 Ambient air temperature sensor input Inlet air temperature sensor voltage low input voltage low 5 Ambient air temperature sensor open circuit 15 High Inlet air temperature alarm warning 16 High Inlet air temperature alarm action alert 174 174 Fuel temperature sensor 0 Fuel temperature high most severe 3 Fuel temperature sensor input voltage high 4 Fuel temperature sensor input voltage low Fuel temperature high 16 Fuel temperature moderately high 31 Fuel temperature sensor faulty 175 175 Oil temperature sensor 0 Oil temperature extremely high 3 Oil temperature sensor input voltage high 4 Oil temperature sensor input voltage low 5 Oil temperature sensor open circuit 177 Transmission oil temperature sensor Lus A Am Not possible with Genset 9 Transmission oil temperature invalid application 189 Rated engine speed 0 Engine speed de rated 31 Engine speed de rated 190 190 190 Engine speed sensor 0 Overspeed extreme 2 Engine
11. Check that the direction of rotation of the phases between the generating set and the application is the same Important Type of cables Use H074NF type cables according to the standards in force in the country of use of the generating set In France refer to the standard C15 100 6 3 5 7 Client terminal block Refer to the wiring diagrams according to the configuration selected and the requirements 86 276 EN 6 3 6 Operation and setting menus 6 3 6 1 Layout of the menus The diagram below shows the layout of the main menus 0 Home 1 2 E eS Operation 1 1 Operation 12 Function keys 13 Synchro Column 14 Power plant measurements synthesis L5 Measurements 1 6 Alarms amp faults 1 7 User settings Archiving i Maintenance amp Metering Fault finding 2 1 3 1 Digital Events Variables archives 4 1 Provider me ees BEN Analog variables Emails archives 2 3 3 3 4 3 amp Mechanical Service variables archives intervals EA gaa Events Curves Consumables metering 2 5 3 5 Electrical Mechanical faults metering 45 3 6 Electrical metering 2 7 Regulation mode display Progress reports Configurations 6 1 Regional parameters 25 Equipment Spe Application identification Se Applications 20255 Software versions iso Regulation
12. 5 2 4 Characteristics s cR E tec de in d Si tea 5 2 2 U F fonction and LAM ccccccccccccessessseeeeeeeecececaeessssseececceeceeceuauesseeceeeeseeessaaaeaaeeeeeess 5 2 9 R250 AVIRODIIOR cid aree eie reo rete eset delice ees 5 2 4 vade ea TUE eee 6 2 5 Typical effects of the LAM esiosan ct tere rer e tiia trie efi echa en e en 7 INSTALLATION 8 3 1 Electrical checks on the AVR ainoana a e a nnn nnne nnns 8 9 2 SCUINGS st 8 R e a E aN te cbe Aen 8 3 3 9 A SPARE PARTS wevivsctsscccwcssecdecesccccuvacvunacsduuatnccucatsstecosssceacscevaicddchtinactsstaddvensnucuzdacuendensinseaics 10 41 5 Designation ineft DURO Hee ER 10 4 2 Technical support service eeeseeseesseseese esent nnne 10 Any maintenance or breakdown operations on the A V R are to be done by personnel trained on commisioning servicing and maintenance for the electrical and mechanical elements The R250 is an IP00 product It must be installed inside a unit so that this unit s cover can provide IP20 minimum total protection it must only be installed on LS alternators in the appropriate location so that when viewed externally it has a higher degree of protection than IP20 Copyright 2005 MOTEURS LEROY SOMER This document is the property of MOTEURS LEROY SO
13. AVRs CONTENTS 1 GENERAL INFORMATION eere nnn nnne nennen nenne nnns nnne nnne nnne 4 1 1 Be E H 4 122 4 2 POWER SUPPLY gmm B 5 2 1 AREP excitation System itre ia aeaaeae ane sec eaer raat sea i pea RR Ae 5 2 2 PMG excitation SySterti ecciesie odi i doen Hoe Ce a Ei EORR ENEN EARN 6 2 3 SHUNT or separate excitation system sse 7 3 TECHNICAL CHARACTERISTICS esee eene enne nennen nnn nnne nnn nnn 8 3 1 Electrical chafacteristiCs Tes fete dee ecce e etus 8 seront eee 8 3 9 and LAM functions pue e Deua ca aeree reos 12 3 4 Typical effects of the LAM with a diesel engine with or without a LAM U F only 12 SR iun P e 13 4 INSTALLATION COMMISSIONING esee eene nennen nnne nnns 14 4 1 Electrical checks on the AVR sssssseeeeene enne eene nnnm nnne 14 4 2 SUING UP PE LET DIDI 14 4 3 Electfcal faults enis nete 17 5 SPARE PARTS 18 9 12 DESIGMANON 18 5 2 Technicalisupport Service 5e E
14. LEROY SOMER Installation and maintenance 4531 en 2010 10 c R 450 AVRs 2 2 PMG excitation system The AVR monitors the alternator output With PMG excitation a permanent magnet voltage by adjusting the excitation current generator PMG added to the alternator The rotating switch should be in the PMG supplies the AVR with voltage which is position see 3 2 3 independent of the main alternator winding This system provides the machine with a short circuit current capacity of 3 IN for 10 s STATOR 6 wires T1 to T6 STATOR 12 bent T1 to T12 MAIN FIELD PMGSYSTEM e e e T1 ll T3 T9 Armature Field Q Q T6 T12 Varistor lt _ Iz A d 16 INED A 60 Hz SETTING lt S El gt m gt lt 2 5011 gm NE e ELLE ESL IET CE nn n I m according to voltage 16 14 EROY 6 9 244 276 LEROY SOMER Installation and maintenance 4531 en 2010 10 c R 450 AVRs 2 3 SHUNT or separate excitation system With SHUNT excitation the AVR is powered by the main winding 100V to 140V 50 60 Hz by using X1 X2 on the AVR The rotating switch should be the SHUNT AREP position see 3 2 3 STATOR 6 wires T1 to T6 MAIN FIELD STATOR 12 wires T1 to T12 SHUNT SYSTEM e oe
15. S4 Observe the local regulations in force for generating sets pump units or lighting towers as well as local regulations for use of fuel petrol diesel fuel and gas before using your generating set pump unit or lighting tower Fuel filling should be carried out when the engine is off except for generating sets with an automatic filling system Engine exhaust gases are toxic do not run the generating set pump unit or lighting column in unventilated premises If installed in a ventilated room additional requirements for fire and explosion protection must be observed A leaking burnt gas exhaust may increase the sound level of the generating set pump unit or lighting column To check on its efficiency regularly examine the burnt gas exhaust Pipes must be replaced as soon as their condition demands it 1 3 3 Risks related to toxic products Glycol is a toxic product and dangerous if absorbed Avoid all contact with the skin and eyes Read the instructions on the packaging The corrosion inhibitor contains alkali Do not swallow it This substance should not come into contact with the eyes In the event of contact with the eyes rinse immediately with plenty of water for at least 15 minutes Avoid prolonged or repeated contact with the skin In the event of contact with the skin wash thoroughly with water and soap CONSULT A DOCTOR IMMEDIATELY KEEP THE PRODUCT OUT OF THE REACH OF CHILDREN Warning The anti
16. Crank position input noise Permanent loss of signal High impedance of the position sensor or open circuit Sensor short to ground N oO aa Crank position Cam position out of synchronisation Crank position input missing Not informed by VOLVO Crank position sensor input pattern error 639 247 231 Communication status Bus Off error Passive bus error 11 Data registers read back failure 12 13 Loss of message error Bus CAN error 640 Engine shutdown vehicle status 11 Engine shutdown vehicle request invalid 31 Engine shutdown vehicle request 641 Status of the Turbo with variable geometry Supply voltage of the Turbo actuator low 12 Error in communication between the ECU and the TGV actuator 13 Error in position of the TGV 16 651 651 Temperature of the actuator moderately high Cylinder 1 injector status Injector outside specifications Recalibration of the injectors required Injector outside specifications Recalibration of the injectors required Short circuit high side to B4 Short circuit high side to low side or low side to B N N Short circuit high or low side to ground Cylinder 1 circuit open Cylinder 1 circuit shorted
17. Cylinder 1 balancing error mechanical failure Cylinder 1 unknown error mechanical failure 267 276 N SPN CID SID PID PPID FMI John Deere Volvo Perkins Description Comment 652 652 Cylinder 2 injector status Injector outside the specifications Recalibration of the injectors required Injector outside the specifications Recalibration of the injectors required Short circuit high side to B Short circuit high side to low side or low side to B Short circuit high or low side to ground Cylinder 2 circuit open Cylinder 2 circuit shorted Cylinder 2 balancing error mechanical failure Cylinder 2 unknown error mechanical failure 653 653 Cylinder 3 injector status Injector outside the specifications Recalibration of the injectors required Injector outside the specifications Recalibration of the injectors required Short circuit high side to B Short circuit high side to low side or low side to B Short circuit high or low side to ground Cylinder 3 circuit open Cylinder 3 circuit shorted 654 654 Cylinder 3 balancing error mechanical failure Cylinder 3 unknown error mechanical failure Cylinder 4 injector status Injector outside the specifications Recalibration of the inje
18. T2 T8 T9 EXCITER BEEN e m 0 Armature N T4 Tio 5 T11 T6 12 Power supply Detection STATOR 6 or 12 wire marking T1 to T 12 AREP SYSTEM e e T1 T7 T2 T8 T3 T9 EXCITER m o 5 E e E mmm Armature T4 Tio 5 T11 6 12 Field Voltage reference MAIN FIELD STATOR 6 or 12 wire marking T1 to T12 PMG SYSTEM e o o T1 T7 T2 T8 T3 T9 EXCITER zo 5 mA e E Armature T4 Tio 5 t11 Te T12 lel R 450 Voltage reference LEROY 5 207 276 LEROY SOMER Installation and maintenance 3856 2011 01 h LSA 46 2 4 POLES ALTERNATORS 3 INSTALLATION Personnel undertaking the various operations indicated in this section must wear personal protective equipment appropriate for mechanical and electri cal hazards 3 1 Assembly All mechanical handling operations must be undertaken using suitable equipment and the machine must be horizontal Check how much the machine weighs see 4 8 3 before choosing the lifting tool 3 1 1 Handling The generously sized lifting rings are for handling the alternator alone They must not be used to lift the genset The choice of liftinghooksorhandlesshouldbe determined by the shape of these rings Choose a lifting system which respects the integrity and the environment of the alternator
19. This mode of operation is the responsibility of the operator Temporary coupling to the grid A651 This configuration is designed to provide Y Emergency electricity supply to an installation following a grid loss Return to the grid is achieved by a temporary coupling with transfer of the generating set load to the grid Y FORCED OPERATION with a generating set Y Temporary coupling for Effacement Jour de Pointe EJP mode or other rates Information transmitted by dry contacts Optional manual or motorised circuit breaker Application load the EJP Peak Day Load Shedding system is specific to the French power grid 70 276 N Automatic operation Kerys in AUTO mode temporary grid return coupling Loss of grid voltage Adjustable grid loss acquisition delay controlled by the Kerys or by a mains detection module Generating set start request The speed and voltage of the generating set increase Power unit switched on grid side Generating set power unit switched off after voltage and frequency stabilisation Return of grid voltage Adjustable grid return acquisition delay controlled by the Kerys or by a mains detection module Synchronisation of the generating set to the grid After synchronisation the grid power unit is switched off Transfer of the active and reactive power of the generating set to the grid according to a predetermined ramp The ramp does
20. sec onds for background illumination in the display The light is then switched off if the panel is not used Set backlight brightness adjustment of illumi nation strength in the display Information Information P Engine hardware Id shows the data for the engine and DCU Engine software Id Engine Datasetlld Engine hardware ID part number of the engine control module Engine software ID part number of the software in the engine control module Engine dataset ID part number of engine data set 1 Engine dataset2 ID part number of engine data set 2 e Vehicle ID chassis number DCU hardware ID part number of the DCU DCU software ID part number of the software in the DCU DCU dataset ID part number of DCU data set 1 DCU dataset2 ID part number of DCU data set 2 17 143 276 Starting the engine Make it a habit to give the engine and engine bay a visual check before starting This will help you to discover quickly if anything abnormal has happened or is about to happen Also check that instruments and warning dis plays show normal values after you have started the engine AN WARNING Never use start spray or similar products as a starting aid Explosion risk 144 276 Before starting Check that the oil level is between the MAX and MIN marks Please refer to the Maintenance lu brication system chapter Open the fuel taps Check th
21. This manual concerns the alternator AVR which you have just purchased We wish to draw your attention to the contents of this maintenance manual By following certain important points during installation use and servicing of your AVR you can look forward to many years of trouble free operation SAFETY MEASURES Before using your machine for the first time it is important to read the whole of this installation and maintenance manual All necessary operations and interventions on this machine must be performed by a qualified technician Ourtechnical support service will be pleased to provide any additional information you may require The various interventions described in this manual accompanied by recommendations or symbols to alert the user to potential risks of accidents It is vital that you understand and take notice of the various warning symbols used Warning symbol for an operation capable of damaging or destroying the machine or surrounding equipment Warning symbol for general danger to personnel Warning symbol for electrical danger to personnel Note LEROY SOMER reserves the right to modify the characteristics of its products at any time in order to incorporate the latest technological developments The information contained in this document may therefore be changed without notice LEROY SOMER 240 276 LEROY SOMER Installation and maintenance 4531 en 2010 10 c R 450
22. When the excitation current exceeds this value a counter is activated at the speed of one record per second for 90 s When this time is elapsed the current is reduced to the value of the rated excitation current If in the meantime the excitation current drops below the threshold value the counter counts down at the same speed LEROY 8 SOMER 246 276 LEROY SOMER Installation and maintenance 4531 en 2010 10 c R 450 AVRs The limitation threshold must be adjustable between 1 and 5 5 A The genset breaker must be open during the short circuit If the genset is restarted in short circuit there is a excitation build up during 10s again at the maximum value Operation between 3 and 6 In when short circuited The excitation current ceiling during a short circuit equals 2 9 times the fixed threshold when setting the permitted excitation ceiling in continuous operation When the threshold is exceeded for a period 10 s the current is reduced to a value between 0 5 and 0 7 A shutdown In all operating conditions the maximum exc A Maximum current exc 2 9x threshold 9 5 max 9 5 A U threshold 1 5 5A Shutdown 0 5 0 7 Activation of 90 s tempo P Decrease eae Activation v i 90s tempd 90 s tempo excitation current must be limited to 9A 0 5A Overrun indications One green LED Lights up when the excitation curren
23. 233 276 LEROY SOMER Installation and maintenance 4067 en 2009 05 b R250 A V R INSTALLATION COMMISSIONING 3 1 Electrical checks on the AVR Check that all connections have been made properly as shown in the attached wiring diagram Check that the position of the jumper corresponds to the operating frequency Check whether the ST4 jumper or the remote adjustment potentiometer have been connected 3 2 Settings The different settings made during the trialaretobedoneby qualified personnel Respecting the load speed specified on the nameplate is vital in order to start a settings procedure After operational testing replace all access panels or covers The only possible settings on the machine are to be done with the A V R 3 2 1 R250 settings SHUNT system Initial potentiometer positions voltage setting potentiometer P1 for the A V R full left remote voltage setting potentiometer in the middle Operate the alternator at its rated speed if the voltage does not rise it is necessary to re magnatise the magnetic circuit slowly adjust the voltage potentiometer of theA V R P1untiltheoutputvoltage reaches its rated value Stability setting with P2 3 2 2 Special type of use Excitation circuit E E must not be left open when the machine is running A V R damage will occur 3 2 2 1 R250 field weakening SHUNT The exciter is switche
24. 50 hours 12 month ACEA E7 E5 E4 API Cl 4 CH 4 CG 4 f sulfur content is gt 1 0 by weight use oil with TBN gt 15 Lubrication oil must comply with both requirements Note API CG 4 or CH 4 can be approved in markets outside Europe instead of ACEA A3 9 Use oil with TBN 14 20 NOTE Mineral based oil either fully or semi synthetic can be used on condition that it complies with the quality requirements above VDS Volvo Drain Specification ACEA Association des Constructeurs Europ enne Automobiles API American Petroleum Institute TBN Total Base Number Viscosity Select the viscosity from the adjacent table for the appropriate continuous ambient air temperature Refers to synthetic or semi synthetic oils C SAESW D _ wool SAE 201730 soc SAE 30 i 10C SAE SU Oil change volume Please refer to the Technical Data chapter 4 pa 30 156 276 Maintenance Oil level checking and filling The oil level must be inside the marked area on the dipstick and must be checked daily before the first start Top up with oil via the filler opening on the left side of the engine Check that the correct level has been achieved Wait for a few minutes to allow the oil to run down into the sump IMPORTANT Do not fill up above the maximum oillevel Only use a recommended grade of oil please refer to previous page NOTE The oil level sensor o
25. U F and LAM function 3 3 1 Frequency variation compared with voltage without LAM Voltage Bend 57 5 Hz 48Hz lt 100 U UN 50 Hz 60 Hz Frequency 60 Hz Hz 3 3 2 LAM Load Acceptance Module characteristics 3 3 2 1 Voltage drop The LAM system is integrated in the AVR As standard it is active Role of the LAM On application of a load the genset rotation speed decreases When it falls below the preset frequency threshold the LAM causes the voltage to drop proportionately to the frequency LAM1 or to the active power LAM2 depending the the rotating switch position This reduces the active load scale applied until the speed returns to its rated value Hence the LAM can be used either to reduce the speed variation frequency and its duration for a given applied load or to increase the applied load possible for one speed variation turbo charged engine To avoid voltage oscillations the trip threshold for the LAM function should be set approximately 2 Hz below the rated frequency Voltage Rs Voltage U f 0 85 UN gt x i 1 1 i 1 48 or 58 Hz 50jor 60 Hz fc fN ST3 3 3 2 2 Soft voltage recovery function During load impacts the function helps the genset to return to its rated speed faster with a gradual increase in voltage according to the principle If the speed drops between 46 and 5
26. WARNING Never use start spray or similar prod ucts as a starting aid They may cause an explo sion in the inlet manifold Personalinjury could also be caused Starting with auxiliary batteries WARNING Batteries especially auxiliary batter ies contain hydrogen which is highly explosive in contact with air A spark which can be formed if the auxiliary batteries are wrongly connected is enough to make a battery explode and cause damage 1 Check that the auxiliary batteries are connected series or parallel so that the rated voltage corre sponds to the engine system voltage 2 First connect the red jumper cable to the auxil iary battery then to the flat battery Then connect the black jumper cable to the auxiliary battery and lastly to a place which is some distance away from the flat batteries e g at the main switch on the negative cable or the negative cable terminal on the starter motor 3 Start the engine WARNING Do not move the connections when you attempt to start the engine risk of arcing and do not stand and lean over one of the batter ies 4 Remove the jumper cables in the reverse order from installation WARNING The ordinary cables to the standard batteries must not be loosened on any condition 148 276 Operation Correct operation technique is very important for both fuel economy and engine life Always let the engine warm up to normal operating temperature before ope
27. fied by Volvo Penta please refer to Water qual ity IMPORTANT It is extremely important that the correct concentration of coolant is put in the sys tem Mix in a separate clean vessel before filling the cooling system Make sure that the liquids mix Water quality ASTM D4985 Total solid particles 340 ppm Total 9 5 dH Chloride neret 40 ppm Sulfate lt 100 ppm inene rea iie e 5 5 9 Silica acc to ASTM D859 20 mg 510 Iron acc to ASTM D1068 0 10 ppm Manganese acc to ASTM D858 lt 0 05 ppm Conductivity acc to ASTM D1125 lt 500 uS cm Organic content COD acc to 1808467 15 mgKMn0O I 160 276 161 276 Maintenance Coolant inspection WARNING Do not open the filler cap 1 when the engine is warm except in emergencies Steam or hot fluid could spray out NOTE Only open filler cap 1 Do not open filler cap 2 The coolant level must be higher than the MIN mark ing Check the coolant level daily before starting Top up with coolant as necessary please refer to Coolant filling Cooling system filling WARNING Do notopenthe filler cap 1 when the engineis warm except in emergencies Steam or hot fluid could spray out NOTE Do not open filler cap
28. touch panel 8 columns x 8 rows VVVV WV 60 276 The generating set operational keys 1 Manual mode selection The illuminated led indicates that the mode is active 2 Selecting stop mode The illuminated led indicates that the mode is active 3 Automatic mode selection The illuminated led indicates that the mode is active 4 Testin progress LED 5 n auto mode test sequence control off load test load test In manual mode engine start up and stop 6 Generating set circuit breaker opening control 7 Led indicating that generating set circuit breaker is open 8 Grid circuit breaker opening control 9 Led indicating that grid circuit breaker is open 10 Grid circuit breaker closing control 11 Led indicating that grid circuit breaker is closed 12 Led indicating the presence of grid voltage 13 Led indicating that grid circuit breaker is closed 14 Closing control for generating set circuit breaker 15 Led indicating the presence of generating set voltage The test request brings up a screen which offers a choice between load test and off load test The signalling control keys The The 4 key stops the buzzer The key clears the faults es key commands testing of the LED s on the front of the MMI 61 276 N The navigation keys It is also possible to navigate through the menus using the keypad Return to upper level or escape for the dialogue boxes E Move up Move to the left Move
29. 3 p U31 Alternator composite Voltage Indicator Alternator Frequency Indicator 42 276 Screen Pictograms Data displayed no C E 3 V1 Alternator single Voltage Indicator 2 c 3 3 y V2 Alternator single Voltage Indicator P5 J C 3 3 V3 Alternator single Voltage Indicator 5 Ge Alternator Frequency Indicator e 4 t U12 Alternator composite Voltage Indicator be 2 i c V2 Alternator single Voltage Indicator P6 E i c V1 Alternator single Voltage Indicator fe Alternator Frequency Indicator P7 0 J t V1 Alternator single Voltage Indicator A Single phase Alternator current indicator 5 00 Hz Alternator Frequency Indicator P8 Single phase Alternator current indicator 2 Al Two phase Alternator current indicator 1 n Three phase Alternator current indicator H Neutral Alternator current indicator k Lf Total Active Power Indicator k Total Reactive Power Indicator P9 09 Total Effective Power Indicator Total Power Factor Indicator lagging or leading 43 276 EN Screen Pictograms Data displayed 00 gt AX Me y cA P10 Fuel Level Indicator Indication of Battery Voltage Indication of Battery Amps Screen order of appearance according to network type with the generating set on Type of network Order of appearance 3P N 3P 2P N 1P N 1 P3 P3 2 P4 P4 P6 P
30. 9 4 0 G V E Emission control 135 276 Introduction EMS 2 EMS 2 Engine Management System is an electronic system with CAN communication Controller Area Network for diesel engine control The system has been developed by Volvo Penta and includes fuel control and diagnostic function Summary The system includes sensors control unit and unit in jectors The sensors send input signals to the control unit which controls the unit injectors in its turn Input signals The control unit receives input signals about engine operating conditions etc from the following compo nents coolant temperature sensor charge pressure charge temperature sensor crankcase pressure sensor position sensor camshaft speed sensor flywheel coolant level sensor oil level and temperature sensor oil pressure sensor fuel pressure sensor water in fuel indicator Output signals The control module uses the input signals to control the following components unit injectors starter motor main relay pre heating relay Information from the sensors provides exact informa tion about current operation conditions and allows the processor in the control unit to calculate the correct fuel injection volume and timing check engine status etc Fuel control The engine fuel requirement is analyzed up to 100 times per second The amount of fuel injected into the engine
31. APPLICATION A612 2 PRODUCTION POWER PLANIT WITHOUT GRID COUPLING APPLICATION A632 A6 3 NOT APPLICABLE 96 276 N After changeover the screen below appears 15 07 09 19 10 00 GS 1 Rental application Faults A651 Temporary power grid single Genset coupling Validation Grid CT ratio 5 To enter the value of the grid current transformer ratio press the GRID CT RATIO button on the touch screen Y Using the alphanumeric keys of the MICS KERYS enter the value of the CT ratio in tenths Example CT 100A 5A calculation 100 5 220 20x10 200 value to be entered 200 232767 Esc 6 Then press VALID 97 276 N 15 07 09 19 10 00 GS 1 Rental application Faults A651 Temporary power grid single Genset coupling Validation 15 07 09 19 10 00 Grid CT ratio 8 The KERYS saves your new configuration 98 276 N 9 After return to the KERYS home screen Y Turn on the battery isolator switch v Wait 5 seconds Y Turn off the battery isolator switch The configuration will only be taken into account if the following operations are carried out Important Power plant Without common part and without inverter A632 A633 Turn off the battery isolator switch 2 Check that the emergency stop buttons are activated 3 Press the STOP button on the KERYS B Turn the changeover switch to positio 1 SOLO G
32. High barometric pressure ECM option sensor not connected Coolant temperature sensor Coolant temperature extremely high Coolant temperature sensor input voltage high Coolant temperature sensor input voltage low Coolant temperature sensor open circuit Coolant temperature high least severe Coolant temperature moderately high Water temperature very low Coolant temperature high 111 111 Coolant level sensor Ajo o Engine coolant level low Engine coolant level low Coolant level sensor input voltage high Coolant level sensor input voltage low 153 153 Crankcase pressure sensor Value above normal Crankcase pressure sensor input voltage high Crankcase pressure sensor open circuit 157 Fuel pressure sensor in the common rail Fuel pressure too low Input voltage of the pressure sensor high Short to V Input voltage of the pressure sensor low Short to V 10 Loss of fuel pressure detected 16 Fuel pressure moderately high 17 Fuel ramp pressure not reached 18 Oil pressure moderately low 263 276 N
33. Its flow is then closed The second GS thus coupled initiates its power on ramp adjustable delay and the distribution of power among the two generating sets takes place Each generating set will then take 5096 of the required power i e 225 kW When the power required for the application reaches 7596 of the power of the two generating sets in operation GSs at priority 01 and 02 i e 900 kW the third GS at priority 03 is then started and is synchronised with GS1 and GS2 Its flow is then closed The third GS thus coupled initiates its power on ramp adjustable delay and the distribution of power among the three generating sets takes place Each generating set will then take 33 33 of the required power i e 300 kW corresponding to 50 of its rated output 600 kW When the power required for the application reaches 75 of the power of the three GSs in operation GSs at priority 01 02 and 03 i e 1350 kW the fourth GS at priority 04 is then started and synchronised with GS1 GS2 and GS3 Its flow is then closed The fourth GS thus coupled initiates its power on ramp adjustable delay and the distribution of power among the four generating sets takes place Each generating set will then take 2596 of the power required i e 337 5 kW corresponding to 56 2596 of its rated output 600 kW The power required for the application may continue to increase up to the upper plant limit 9596 of 2400 kW i e 2280 kW the setting can be changed
34. Mis paralleling S Possible consequences Abnormal Wir doles n Broken or damaged coupling noise ERR y 8 Broken or bent shaft extension Shifting and short circuit of revolving field winding Fan fractured or coming loose on shaft Irreparable damage to rotating diodes AVR surge suppressor 4 5 Electrical faults Fault Action Effect Check Cause The alternator voltage is still correct when builds up and its Lack of residual magnetism the battery is removed Connect a new battery No voltage of 4 to 12 volts to The alternator builds up but its voltage Check the connection of the voltage reference to the AVR at no load on terminals E and E does not reach the rated value when Faulty diodes start up respecting the polarity the battery is removed Armature short circuit for 2o 3 seconds The alternator builds up but its Faulty AVR voltage disappears when the battery Field windings open circuit check winding is removed Revolving field coil open circuit check the resistance Check the AVR connections AVR may be faulty Field windings short circuited Correct speed Rotating diodes burnt out tage Check the drive speed Revolving field coil short circuited Ow Check the resistance Increase the drive speed do not touch the AVR voltage pot P2 Speed too low before running at the correct speed Vo tage too AdjustAVR volta
35. PENTA SN MNT HET MVC RC TREO DC NES ee 5 Sim obrigado a Gostaria de receber gratuitamente um manual de instru es em portugu s Numero de publica o 7745267 2 8 e Endereco Q 8 i T 5 d 9 N amp Pa s Notar que a oferta valida por um periodo de 12 meses a partir da data de ent rega do motor Depois desse per odo a oferta v lida consoante a disponibili VOLVO dade PENTA A eS Sa i re 197 276 Tayxu pouriore AUTO KOUTIOVL Steubuvon rj TO HE Mag otov rtapak ro Document amp Distribution Center Order Department ARU2 Dept 64620 SE 405 08 G teborg Sweden Fax 46 31 545 772 Mnopeite ritona va TNV rrapayygA a cac p ow Tou Inter net otn SteuBuvon http www volvopenta com manual coupon Ha UMA Document amp Distribution Center Order Department ARU2 Dept 64620 SE 405 08 G teborg Sweden Fax 446 31 545 772 http www volvopenta com manual coupon Oa needa va avr turmo rou eyxstpi ou xprjonc ayyAlKh YAwWooa xwpic xp oon Api8p q k6oo0nc 7745268 Ovopa Ateu6uvon 42200 615001 155099900192
36. Shut the engine off check the oil level and top up the engine oil as necessary Check sealing round the oil filters Maintenance Cooling system The cooling system ensures that the engine works at the right temperature It is a closed system and must there fore always be filled with a mixture of at least 40 concentrated coolant and 60 water to offer protection from interior corrosion cavitation and frost bursting We recommend that you use Volvo Penta Coolant Ready Mixed or Volvo Penta Coolant concentrated mixed with pure water acc to the specification please refer to Coolant Mixing This grade of coolant is the only one that is developed for and approved by Volvo Penta The coolant should contain a good grade of ethylene glycol and a suitable chemical formula for full engine protec tion The use of only an anti corrosion preparation is not permissible for use in Volvo Penta engines Never use water by itself as the coolant IMPORTANT Coolant fluid should be used all year round This also applies in areas where there never is any risk of frost to give the engine full corrosion protection Future warranty claims related to engine and accessories may be refused if an unsuitable coolant has been used or if the recommendation for coolant mixture has not been observed NOTE The corrosion protection additives become less effective as time passes which means that the coolant must be changed Please ref
37. Wattmetric control This wattmetric control will be activated after a global operation delay This global operation enables the application to be resumed after power is restored to the different outputs and ensures stability of the load before the wattmetric control is started Depending on the power for the application the number of generating sets in production may vary in order to optimise the production for consumption The procedure is as follows e End of the global operation delay e Start of analysis of the active power consumed Y Example A generating set must be stopped according to the set thresholds e Power cut at the non priority generating set transfer of the power to the generating set s remaining in production e Uncoupling of the non priority generating set at zero power by switching on the generating set power unit e Cooling delay e Generating set stopped and set to standby Y Example of increase in power e Generating set start request e The speed of the generating set increases e Alternator excitation the generating set establishes its voltage e Request for synchronisation of the generating set to the busbar i e the other coupled generating sets e Generating set power unit switched off Return of grid voltage e Grid return acquisition delay controlled by the mains detection module e Generating set power units switched on e Cooling delay e Generating sets stopped and set to standby The Kerys PLCs re
38. at idle 2 270 KPa 89 psi Oil rade neues Please refer to the specification under Maintenance MISGOSILy Please refer to the specification under Maintenance Cil filter Full flow filter esses 2 Turbo filter By pass filter 1 Lube oil pump tei etiatn edet Gear driven 64 190 276 Technical data Fuel system Feed pump Supply pressure at 600 rpm min 100 kPa 14 5 psi Supply pressure at 1200 rpm min 300 kPa 43 5 psi Supply pressure at full load min 300 kPa 43 5 psi By pass valve Opening pressure 400 550 kPa 58 79 7 psi Fuel specification The fuel must comply with national and international standards for commercially supplied fuels such as EN 590 with nationally adapted environmental and cold requirements ASTM D 975 No1 Dand2 D JIS KK 2204 Sulfur content Complying with legal requirements in each country Low density fuel urban diesel in Sweden and city diesel in Finland can cause a loss of up to 5 of power and an increase in fuel consumption of about 2 3 65 191 276 Technical data Cooling system Pressure cap max opening pressure Volume Volume engine radiator and hoses Thermostat Quantily Opening temperature Electrical system Sy
39. do 3 CEISEEEEBREIBELTE LEROY SOMER 242 276 LEROY SOMER Installation and maintenance 4531 en 2010 10 c R 450 AVRs 2 POWER SUPPLY characteristic the second one has a Both the SHUNT AREP amp PMG excitation voltage proportional to the stator current systems are controlled by the AVR compound characteristic Booster effect The power supply voltage is rectified and filtered before being used by the AVR monitoring transistor This system provides the machine with a 2 1 AREP excitation system With AREP excitation the electronic AVR is powered by two auxiliary windings which are independent of the voltage sensing short circuit current capacity of 3 IN for 10 s circuit The rotating switch should be in the AREP The first winding has a voltage proportional position see 3 2 3 to the alternator main voltage Shunt STATOR 6 wires T1 to T6 STATOR 12 tk 1 to T12 MAIN FIELD AREP SYSTEM 9e 9 9 Aux windings T2 T8 T9 T4 T10 T6 T12 Y e e D Field Varistor Armature 10 Yellow 11 Red 12 Black 9 Green kh 50 Hz EXTFREQ E 60 Hz SETTING das INDHS OA 5021 F4 E i B E 5 5 bi jas 10 Yellow 11 Red 12 Black 9 Green EROY SSB 5 243 276
40. stabilise the green LED underneath the symbol for the generating set flashes ED e RE le H a OLI The installation is then controlled via the programmable controller in accordance with the configuration of the application gt normal emergency source switchover gt grid coupling etc The Normal Emergency switchover with grid coupling is only possible by carrying out a load test The purpose of the off load test is to start a single GS or to couple a power plant x generating sets to the emergency busbar Important At any time the generating set may be stopped by pressing Stop or by pressing 0 on the test keypad Important Pressing Stop may interrupt the power supply depending on its status when the key is pressed e g isolated grid operation The generating set will stop after a cooling delay 180 seconds by default The green LED underneath the generating set symbol goes out to indicate that the generating set has stopped 115 276 EN Switching off The generating set may be stopped at any time by pressing 0 on the test keypad A Pressing Stop may cause an interruption in the power supply depending on its status when the button is pressed e g isolated grid operation The generating set will stop after the cooling delay 180 seconds by default Important The green LED underneath the generating set symbol
41. 06 year of manufacture year 2006 49 week of manufacture week 49 Analogue inputs and outputs module Analogue inpu nd outputs module ESANA P N 31613391301 D343000 B1 Module item reference D343000 Manufacturer product reference B1 module hardware upgrade index S N 0200 0200 serial number not related with a batch number 0200 the 200 module manufactured since the start BATCH No 06 49 06 year of manufacture year 2006 49 week of manufacture week 49 Temperature inputs module Temperature inpu module ETEMP P N 31613391401 D344000 B1 Module item reference D344000 manufacturer product reference B1 module hardware upgrade index S N 0150 0150 serial number not related with a batch number 0150 the 150 module manufactured since the start BATCH No 06 49 06 year of manufacture year 2006 49 week of manufacture week 49 58 276 N 6 3 2 2 Identification of the software components Only the components base module MMI module regulation module and protection module have embedded software Software version is referred to in order to identify a program implemented in one of the components V as software version V1 05c1 1 05 is the revision which is a combination of 3 digits c main revision index 1 secondary revis
42. 1 Control panel presentation 6 2 1 1 View of the front panel Lud 2 Fig 6 1 View of the front panel Emergency stop button AU for switching off the generating set in the event of a fault which could endanger personnel or damage equipment Key switch for switching the module on off Electronic board protection fuse Scrolling and selection wheel for scrolling through the menus and screens and selecting items simply by pressing the wheel STOP button press to switch off the generating set START button press to switch on the generating set Power ON LEDs and alarm fault warning LEDs Location of USB ports Mounting bolt LCD for displaying alarms and faults operating statuses electrical and mechanical quantities ESC button for returning to the previous selection and for default RESET function MENU button for accessing the menus Lighting for the emergency stop button 37 276 o Q Fig 6 2 Description of the LEDs A lit LED indicates 1 Alarm activated flashing yellow 2 Fault found flashing red 3 Module on green on continuously Fig 6 3 Close up of USB ports 1 USB key connection HOST file transfer between USB key and TELYS and vice versa 2 Connection for microcomputer DEVICE file transfer between PC and TELYS and vice versa main module power supply 3 Protective cover 38 276 N 6 2 1 2 Description of
43. 2 Filling a completely empty system 1 Open filler cap 1 2 Checkthat all drain points are closed NOTE Only use the coolant recommended by Volvo Penta 3 Mixthe correct amount of coolant in advance to ensure that the cooling system is completely filled 4 Fill up with coolant so that the level ends up be tween the MIN and MAX markings Do not start the engine until the system is vented and com pletely filled Filling should be done with the engine stationary Fill up slowly to allow the air to flow out 5 Start the engine when the cooling system has been completely filled and vented Open any vent ing taps some while after starting to allow shut in air to escape If a heating unit is connected to the engine cooling system the heat control valve should be opened and the installation vented during filling 6 Stopthe engine after about an hour and check the coolant level Top up as necessary 35 Maintenance 36 Coolant Draining The engine must be stopped before draining and the filler cap unscrewed WARNING Do not open the filler cap 1 when the engine is warm except in emergencies Steam or hot fluid could spray out NOTE Do not open filler cap 2 On engines which are to be laid up or put in storage the engine cooling system should not be drained The coolant contains corrosion inhibiting additives 1 2 162 276 Remove the filler 1 Open all drain po
44. 21 Never use start 22 Starting with auxiliary batteries 22 eir e eerte gie ended 23 Checking instruments 23 23 Operation at low load 23 Stopping the engine 24 Before stopping sean eaire e 24 SLO PO RET 24 After Stopping resia ierit 24 Pet te te 24 127 276 Maintenance schedule 25 Maintenance eere eet 27 Engine general 27 Lubrication 30 Cooling system ssssseeeee 33 F uelSyStem c ilie eot et nre ERER 39 Electrical system 42 Component location 45 Laying Up 46 Conservation 46 Removing conservation preparations 47 Fault tracing 48 Symptoms and possible causes 48 Diagnostic function 49 Fault messages 49 Effect on
45. 4 drain cp EQ 29 4 2 Check before TOWN Tinssen ptatem ee RO EU rr De EEUU Robe etri pt R 29 4 3 Opera oMr seta rrr a ppt x ORARE CREARE ERE bist atl atria OD PLE LAS LU eR EE E 30 4 4 Unhitching the tr iler i eee nale m tote n ERU e LO DRE CRM QE COATED ERR RC DOR RTRERRE 30 4 5 Implementation for installation 2 2 ra ER eL ATE Le E E A Gaston 31 4 6 Break transmission adjustment 3 2 2 5 ette op PRO er LOT DEDERE nin ehhh aad EE E E 31 4 7 Faults and repatrs aetas epe LOUP TEE eR E el Dg e OR pe to t tbe ie idee 33 4 8 Blectrical connection diagram B estote nmn e EO DEBERE De AERE err e ebbe E 34 4 9 Complete wheels technical information E Rak RERUM E CR Re 34 5 Pr paration sagen e Rer EEE E EE E TE 35 5 1 Installation checks m 35 5 2 Checks aftersstarung the generating Set aito ER eb EA REP Pre bes suse ou 35 6 BESTIA TII IPIE EE 35 6 1 Pre Start Inspection 2 see deep oie aet ete hoteles iit e RR ie e eSI Dee tess 35 6 2 Generator set with TELYS control panel cnt tne e is metere e deese ce aep dre iae eap doe 37 6 2 1 Control panel presentation vss des ce HER EH ai
46. 9 2 Appendix B Alternator user and maintenance manual eese 199 9 3 Appendix C Comimon spare parts nene edente Deo eges iden aed uode sor eb aer adeo ora Due ded decade 259 9 4 Appendix D List of John Deere Volvo and Perkins fault codes esses eene enne 261 2 276 EN 1 Preface 1 1 General recommendations Thank you for choosing an electrical generating set from our company This manual has been designed to help you operate and maintain your electrical generating set correctly The information contained in this manual is taken from technical data available at the time of print In line with our policy of continually improving the quality of our products this information may be amended without warning Read the safety instructions attentively in order to prevent any accidents faults or damage These instructions must always be followed You are likely to encounter several warning symbols in this manual A This symbol indicates an immediate danger to human health and life in case of exposure Failure to follow the corresponding advice entails serious consequences for human health and life in case of exposure Danger A This symbol draws attention to the potential risks to human health and life in case of exposure Failure to follow the corresponding advice entails serious consequences for human health and life in case of exposure Warning T
47. AREP PMG lt 10 V Check the speed or U F knee point set too high Voltage between F and F AREP PMG gt 15V Faulty rotating diodes Short circuit in the revolving field coil Check the resistance Faulty exciter armature Caution For single phase operation check that the sensing wires com the operating terminals ing from the AVR are correctly connected to Voltage disappears during operation Check the AVR the surge suppressor the rotating diodes and replace any defective components The voltage does not return to the rated value Exciter winding open circuit Faulty exciter armature Faulty AVR Revolving field coil open circuit or short circuited Overload see LED Caution Internal protection may be activated overload open circuit short circuit Caution After operational testing or troubleshooting replace all access panels or covers LEROY SOMER 17 255 276 LEROY SOMER Installation and maintenance 4531 en 2010 10 c R 450 AVRs 5 SPARE PARTS 5 1 Designation Description Type Code Voltage regulator 450 AEM 110 RE 031 AVR 5 2 Technical support service Our technical support service will be pleased to provide any additional information you may require When ordering spare parts you should indicate the AVR type and code number Address your enquiry to your usual contact Our ext
48. According to I E C 60034 1 c us LEROY SOMER 206 276 LEROY SOMER Installation and maintenance 3856 en 2011 01 h LSA 46 2 4 POLES ALTERNATORS 2 TECHNICAL CHARACTERISTICS 1 1 Electrical characteristics The LSA 46 2 alternator is a machine without sliprings or revolving armature brushes wound as 2 3 pitch 6 or 12 wire with class H insulation and a field excitation system available in either SHUNT AREP or PMG version see 2 2 Mechanical characteristics Steel frame Cast iron end shields Protected ball bearings greased for life Mounting arrangements IM 1201 MD 35 foot and flange mounted single bearing with SAE coupling disc IM 1001 B 34 double bearing with SAE diagrams and AVR manuals flange and standard cylindrical shaft extension 2 14 Electrical options Drip proof machine self cooled Stator temperature detection sensors Degree of protection IP 23 Bearing sensors PTC PT100 etc Space heater 2 1 1 Mechanical options Interference suppression conforms to Air inlet filter standard EN 55011 group 1 class B Regreasable ball bearings Europe IP 44 protection STATOR 12 wire marking T1 to T 12 SHUNT SYSTEM e e e T1
49. Ae One ground rod for one generating set power plant Important 82 276 Earthing system IT N Isolated neutral Ground Earthing system TNS Current transformer eoooooooeo CIRCUIT BREAKER R Oeoooooooeo Ground rod Neutral connected to grounds d O LOJ O CIRCUIT O BREAKER O O 177777 O O O O Ground S N R S T Ground rod Earthing system TT Neutral d f o CIRCUIT Current BREAKER 177777 transformer 177777 O O Ground N R S T e e If equipped Ground rod Junction box 83 276 EN Connection of generating sets to client terminal boards 28 30132 34 36 38 40 42 44146 48 Xcbc3 28 30132 34 36 38 40 42 44 46 48 Xcbc3 29 31 33 35 37 39 41 43 45 7 29 31 133 35 37 39 41 43 45 B Junction box Remove the shunts at terminals 45 48 and 46 47 A Reinsert the shunts of terminals 45 and 46 after having
50. Check adjust 5 Check with the Carry out a general Engine e inspection Air filter lining Check replace Engine Clean and repaint e Driven unit belts Replace Cooling system Check clean Coolant 4 Replace This procedure should only be carried out by one of our agents 4 Do not replace the filter when draining the coolant 5 Adjust the valve clearance after 250 hours of operation following a complete reconditioning of the engine 7 3 Alternator After 20 hours in operation check the tightness of all the mounting bolts the general condition of the machine and the various electrical connections of the installation The bearings fitted on the machine are greased for life to around the service life of the grease depending on use 20 000 hours or 3 years 118 276 EN 8 Battery Fit the battery so that it is properly ventilated Maintenance should only be carried out by qualified personnel If replacing the batteries use the same type of batteries Do not throw the old battery in the fire Only use insulated tools the operator should not be wearing a watch chain or any metal object Never use sulphuric acid or acid water to top up the electrolyte level Use an approved battery fluid Batteries release oxygen and hydrogen gas which are flammable Never bring flames or sparks near the battery risk of explosion Discharge any static electri
51. FOR SAE ASSIGNMENT FMl 31 CONDITION EXISTS Used to indicate that the condition that is identified by the SPN exists when no more applicable FMI exists or in cases when the reported SPN name spells out the component and a non standard failure mode This type of fault may or may be directly associated with the value of general broadcast information This FMI will mean not available when the associated SPN is also not available as when the remainder of the packet is filled with binary ones after all data has been transmitted 276 276
52. For the operation of a generating set in the smallest possible architecture at least the following elements will be found e aman machine interface module e abase module e aregulation module 6 3 1 1 Operating conditions Y Operating temperatures 20 C 70 C Y Storage temperatures 20 C o 70 C Y Relative humidity during operation 10 to 95 without condensation according to IEC 1131 2 and equivalent UL CSA Y Relative humidity during storage 5 96 to 9595 without condensation according to IEC 1131 2 and equivalent UL CSA Y Height 2 000 m during operation Transfer 3 000 m Y Degree of protection Outside cabinet IP54 front of MMI modules Inside cabinet IP20 BASE ESTOR ESANA ETEMP back of the MMI Y Mechanical strength Free falls with packing 5 random falls of 1 mif p lt 10 kg 0 5 m from 10 to 40 kg 0 25 m gt 40 kg 54 276 EN 6 3 1 2 Conformity to legal and regulatory requirements The various components of the system comply with the following standards Y Requirements specific to programmable controllers Functional characteristics immunity robustness safety etc gt EN 61131 1 2 3 IEC 1131 2 IEC 664 EN61326 c CSA 22 2 c UL508 Y Compliance with European directives low voltage electromagnetic compatibility machinery CE marking in application of the safety requirements of standard EN 61131 2 Programmable controllers Part 2 Equipment requirements and tes
53. Hz Max High range 320V lt Un lt 530 V Low range 80 V lt Un lt 320 V The allowed adjustment range is 5 when the setting exceeds these limits please check that it is conform with the power table 3 2 1 2 Quadrature droop Quadrature droop adjustment via potentiometer P4 within a range from 0 to 8 with a PF 0 8 for 400V applications From 0 to 14 with a PF 0 8 for 240V applications From 0 to 8 for 110V applications with a step up transformer ratio of 4 placed on the voltage reference The potentiometer P4 has a non linear response Then when a 1A secondary CT is connected the effective range starts from the the second 1 3 of P4 range and in the case of a 5A secondary CT the effective range starts from the first 1 3 When a 5ACT is used the adjustment range is higher so P4 must be set to the first 1 4 anti clockwise and then progressively increase it The CT must be connected 3 2 1 3 Stability Stability adjustment via potentiometer P2 Selection of rotating switch according to the machine type and the response time as indicated in paragraph 3 2 3 3 2 1 4 Excitation limitation Excitation limitation adjustment potentiometer P3 as described below The excitation current limitation threshold in steady state is set by a potentiometer at 110 of the rated value The adjustment is made by the operator during the on load test at rated power by tuning the potentiometer
54. LEROY SOMER 208 276 LEROY SOMER Installation and maintenance 3856 en 2011 01 h LSA 46 2 4 POLES ALTERNATORS There are 2 possible methods for restoring the above minimum values a Dry out the machine for 24 hours in a drying oven at a temperature of 110 C without the regulator b Blow hot air into the air intake having made sure that the machine is rotating with the exciter field disconnected Note Prolonged standstill In order to avoid these problems we recommend the use of space heaters as well as turning over the machine from time to time Space heaters are only really effective if they are working continuously while the machine is stopped WARNING Ensure that the alternator has the degree of protection matching the defined environmental conditions 3 2 2 Mechanical checks Before starting the machine for the first time check that all fixing bolts and screws are tight the cooling air is drawn in freely the protective grilles and housing are cor rectly in place the standard direction of rotation is clock wise as seen from the shaft end phase rotation in order 1 2 3 For anti clockwise rotation swap 2 and 3 the winding connection corresponds to the site operating voltage see section 3 3 3 3 Terminal connection diagrams To modify the connection change the position ofthe stator cables onthe terminals The winding code is specified on th
55. PID SPN 158 Battery voltage CIU Cause e Short circuit to negative Faulty alternator Faulty battery battery cables Reaction Problems in engine starting Remedy e Check the supply voltage from the control unit e Check the battery e Check the alternator e Check the 8 pin contact 57 Fault codes Code 7 1 SID 1 SPN 651 Injector cylinder 1 Cause Electrical fault Faulty compression or injector Reaction Engine runs on 5 cylinders Abnormal sound e Reduced performance Remedy e Checkthatthe injector cables are not damaged e Check that the injector connections are not dam aged e Check fuel supply pressure e Check the valve clearance Do a compression test and check cylinder 1 Code 7 2 SID 2 SPN 652 Injector cylinder 2 Cause Electrical fault Faulty compression or injector Reaction Engine runs on 5 cylinders Abnormal sound Reduced performance Remedy e Check that the injector cables are not damaged e Check that the injector connections are not dam aged e Check fuel supply pressure e Check the valve clearance Do a compression test and check cylinder 2 58 Code 7 3 SID 3 SPN 653 Injector cylinder 3 Cause Electrical fault Faulty compression or injector Reaction Engine runs on 5 cylinders Abnormal sound Reduced performance Remedy e Check that the injector cables are not dama
56. Please refer to the Setup menu TEWE os ae Engue Jar n2 Rre Tae 2 Cir 2p mod n zrr pea Li az n2rIxn 1 2 3 4 5 6 1 LED display 6 ON OFF Starts and stops the system 2 START Starts the engine 7 Scroll downwards in menus 3 SPEED Reduces engine speed 8 SEL Selects in menus 4 SPEED Increases engine speed 9 Scroll upwards in menus 5 STOP Stops the engine 10 ESC Return to previous menu selection Start When the DCU panel is started up the Engine Data menu is displayed Press ESC to come to the main menu 138 276 Introduction Menus There are several sub menus under each main menu There is not space for all the menu choices on the display To scroll through the menus use the 7 and 9 buttons on the display Press the SEL button no 8 to make a selection Please refer to the illustration on the previous page NOTE The Setup menu can be used to select the language that you want to use on the display Engine data Trip Reset Main menu Preheat Setup informatia Engine data relevant engine data Diagnostics Preheat manual activation of pre heating W Governor mode activation of droop Diagnostics shows fault codes in plain language W Trip reset resets trip data Setup parameter setting W Information shows the data for the applicable hardware software data set and engine identifica tion of the engine and D
57. TA T7 T2 T8 973419 Armature Field lel 5 Q Q T4 T10 T5 T1 T6 4 T12 EIE SETTING Varistor LOA 5031 LEROY SOMER 245 276 LEROY SOMER Installation and maintenance 4531 en 2010 10 c R 450 AVRs 3 TECHNICAL CHARACTERISTICS 3 1 Electrical characteristics maximum power supply 150V 50 60 Hz Rated overload current 10A 10 s Electronic protection In the case of a short circuit the excitation current is reduced to a value less than 1A after 10 s In the event of loss of voltage reference the excitation current is reduced to a value less than 1A after 1s for AREP SHUNT 10s for PMG Inthe event of overexcitation the current is reduced as indicated in the next diagram see 3 2 1 4 Fuses F1 on X1 and F2 Z2 10A 250V Voltage sensing 0 110 V terminals 95 to 140 V 0 220 V terminals 170 to 260 V 0 380 V terminals 340 to 528 V For other voltages a transformer should be used Voltage regulation 0 5 Current sensing parallel operation input S1 S2 intended for 1 C T lt 2 5 VA cl secondary 1 Aor 5A 3 2 Configurations 3 2 1 Settings 3 2 1 1 Voltage Voltage adjustment via potentiometer P1 in the ranges described in the table below For 50 and 60
58. and a lot of water If you get battery acid in your eyes flush at once with a lot of water and get medical assistance at once Connection and disconnection When you connect batteries first connect the cable red to the pole on the battery Then connect the cable black to the pole on the battery When you disconnect batteries connect the cable black first then the cable red Cleaning Keep the batteries dry and clean Contamination and oxide on the batteries and battery poles can cause stray currents voltage drop and discharge especially in wet weather Remove oxidation from the battery poles and terminals using a brass brush Tighten the terminals securely and grease them with terminal grease or Vaseline Filling The electrolyte level should be 5 10mm 0 2 0 4 above the cell plates in the battery Fill up with dis tilled water if necessary After filling the battery should be charged for at least 30 minutes by running the engine at fast idle NOTE Some maintenance free batteries have special instructions which must be observed 43 169 276 Maintenance 44 Batteries charging WARNING Explosion risk Hydrogen is given off when batteries are charged This forms an explo sive mixture with air A short circuit open flame or spark could cause a violent explosion Ventilate well WARNING Battery electrolyte is highly corrosive Protect your eyes skin and clothes
59. are also dangerous to breathe Ensure good venti lation Use a protective mask for spraying IMPORTANT Remember the following when washing with a high pressure washer Never aim the water jet at seals rubber hoses or electrical components Conservation For up to 8 months stoppage Change the oil and oil filter on the engine then warm it up afterwards More than 8 months stoppage Conserve the lubrication and fuel systems with conservation oil Please refer to the instruction on the next page e Check that the coolant offers sufficient frost pro tection Top up as necessary Alternatively you can drain the coolant also drain the coolant filter Drain any water and contamination from the fuel filters and fuel tank Fill the fuel tank completely to avoid condensation Disconnect the battery cables clean and charge the batteries Trickle charge the batteries while the equipment is laid up A poorly charged bat tery can freeze and burst Clean the outside of the engine Do not use a high pressure washer for engine cleaning Touch up paint damage with Volvo Penta original paint Spray the components of the electrical system with water repellent spray e Check and rust proof any control cables Puta note on the engine with the date type of conservation and the conservation oil used e Cover over the air filter exhaust pipe and engine ifnecessary 46 172 276 Removing conservat
60. area where exhaust emissions are regu lated by law it is important to be aware of the fol lowing Certification means that an engine type has been checked and approved by the relevant authority The engine manufacturer guarantees that all engines made of the same type are equivalent to the certified en gine This makes special demands on the care and maintenance you give your engine as follows e Maintenance and service intervals recommended by Volvo Penta must be complied with e Only Volvo Penta original spares may be used e Service to injection pumps pump settings and in jectors must always be done by an authorized Volvo Penta workshop e The engine must not be converted or modified ex cept for the accessories and service kits which Volvo Penta has developed for the engine Warranty Introduction e installation changes to the exhaust pipe and engine air inlet ducts may be done e seals on the engine may be broken by unau thorized persons The general advice in the instruction book about oper ation care and maintenance applies AN IMPORTANT Neglected or poor care service and use of non original spareparts means that AB Volvo Penta can no longer be responsible for guaranteeing that the engine complies with the certified version Damage injury and or costs which arise from this will not be compensated by Volvo Penta Your new Volvo Penta industrial engine is covered by a limited warranty
61. artificial respiration at once in the same place the accident took place unless the victim or operator s life could be endangered by this In the event of cardiac arrest carry out cardiac massage 1 3 7 Risks related to moving the set To unload the generating sets pump units or lighting columns from their transport support brackets under optimum safety and efficiency conditions you must ensure that the following points are observed The lifting machinery equipment is suited to the work required good condition and with sufficient lifting capacity The slings are positioned in the rings provided for this operation the forklift arms are resting fully underneath all of the base frame cross beams or the lifting bars are inserted in the apertures provided for this purpose in the base to lift the entire generating set according to models For completely safe working conditions and to prevent damage to the components fitted on the upper edge of the set pump unit or lighting column the generating set pump unit or lighting column must be lifted up with an adjustable boom All the chains and cables must be parallel with each other and as perpendicular as possible with the upper edge of the generating set pump unit or lighting column If other equipment fitted on the generating set pump unit or lighting column alters its centre of gravity special lifting devices may be necessary to maintain correct balance and completely safe wor
62. covers LEROY SOMER 235 276 LEROY SOMER Installation and maintenance 4067 en 2009 05 b R250 A V R 4 SPARE PARTS 4 1 Designation Description Code A V R AEM 110 RE 019 4 2 Technical support service Ourtechnical support service will be pleased to help you with any information needed For replacement part orders it is necessary to indicate the type and the code number of the A V R Please contact your usual correspondant An extensive network of service centres is available to rapidly supply any necessary parts In order to ensure the correct operation and safety of our machines we strongly recommend that original manufacturer s spare parts are used Failure to do so will discharge the manufacturer from liabilty in the case of damage LEROY 10 SOMER 236 276 LEROY SOMER Installation and maintenance 4067 en 2009 05 b R250 A V R LEROY SOMER 237 276 11 LEROY SOMER MOTEURS LEROY SOMER 16015 ANGOULEME CEDEX FRANCE 338 567 258 RCS ANGOULEME S A au capital de 62 779 000 www leroy somer com 238 276 LEROY SOMER 4531 en 2010 10 c lt Ss gt w m E zi is This the en EF sasnsissaisns 3 SOI R 450 AVRs Installation and maintenance 239 276 LEROY SOMER Installation and maintenance 4531 en 2010 10 c R 450 AVRs
63. densities LONG LASTING PROTECTION High alkaline reserve stability and longevity of corrosion inhibitors Maintains its technical properties during prolonged use at high temperatures neutralisation of acids Ensures maximum heat transfer without the build up of deposits in the cooling system e GenCOOL PC 26 ensures optimum protection against overheating and corrosion in extreme conditions of vehicle use 21 276 N PACKAGING STORAGE e GenCOOL PC 26 is supplied in 210 metallic barrels with smooth interior linings e be stored for 2 years in its original container and packaging e Avoid zinc coated containers RECOMMENDATIONS FOR USE Compatible with the original fluid e tis recommended that the cooling system is completely drained when replacing the fluid Boiling point 105 2 R 15 602 4 Density at 20 C age 105943 R 15 602 1 Alkalinity reserve Freezing point Glassware corrosion test with antifreeze mg test piece R 15 602 7 Copper Weld Brass Steel Cast iron Cast aluminium Corrosion on warm plate test with antifreeze mg cm week 0 17 R 15 602 8 22 276 3 Installation 3 1 Unloading 3 1 1 Safety during unloading To unload electrical generating sets from their transport supports under optimum safety and efficiency conditions you need to ensure that the following points are observed Lifting machinery or equipment appropriate to the w
64. disconnected the current transformer from the junction box Important 6 3 5 4 Facility power outlet The facility power outlet if fitted provides the emergency supply to the generating set from an external electrical source It enables the different units preheating desk etc to be powered without using their batteries 84 276 N 6 3 5 5 Connecting cable between the generating sets power plant Generating set 1 Generating set 2 019x04 2 generating sets 4 i d i f Om 3 or more generating sets Generating set 2 Generating set 3 Generating set x 019x04 019x12 019x04 019x12 019x04 Connecting cable The power cables and the generating set connecting cable may intersect Power cable Important Connecting cable Rental application 1 metre MIN The generating set power cables and connecting cable cannot be placed in parallel less than 1 metre apart Power cable Important The generating set power cables the generating set connecting cable and the connections must be in perfect condition Replace them if necessary Important 85 276 EN 6 3 5 6 Power 1 Pass the power cables through the access hatch to the power box of the generating set AIPR or console depending on the generating set 2 Connect the power cables to the busbars 3 Connect the power cables to the application GENERATING SET APPLICATION
65. e oe gei eite tue 94 6 37 1 a Choice of application scienne terere e aree eet ene HR pP 94 6 3 8 USE ire tote ac E e nS beet ese beret Hte fecero oe b eere Erit ERE 103 6 3 8 1 Choice of priority generating set in power plant if equipped sess enne nre 103 6 3 3 2 Starting tests and erat anie rea i a ER oes 109 6 3 8 3 R entaloptlons asi ait ath DRE ESRB c ec ier saa ERE RO Pte hats 116 7 eite tem HER E E RD Ri LENS EN E EUR ETE DO A ER REOR ARES 118 7 1 Reminder of use orit aio e a CO REED eO Ute hen omnia ev Analysen 118 7 2 I EAN ai EL EEP E E 118 7 3 Alternator iue so orto EROR P OREL ete OU Sook a o e rH tester dort e RUP eei EEEE 118 8 Battery eesti hace aote nera eani tet LO e OE E ero e vp ete i pO ORO UE RE 119 8 1 Storage and transport 4 one eit o REO EU REEL O P CERE EO RE Dit eti riri OR re pc Rb 119 8 2 Battery Setting into SeEVICe aloe dn aU n ERU EO A ep FO Dele PELO natin 120 8 32 T E 120 8 4 Load precomzation nitate e e RO E hr a e ebbe i e De rt OA OE RIO nmi 121 8 5 Faults and remedies ueber einer Se UTR Ee epis ler poteet da oe antennae 122 9 Appendix iiss steered EE 123 9 1 Appendix Engine user and maintenance manual eese nennen nennen trennen teen enen nein 123
66. enm om Low Lo D Tish m o iwl IPS ow Tw TN TE sees o 22 28 22 fass 22 20 22 2s 22 22 16 15 5 Ex Figure 1 5 Examples of alternator identification plates Designation ARMOIRE DE 400KVA A0217010 Cde AVP31650 01C Reference SOREEL 371562 03 No OF 02280753 Figure 1 6 Example of control box identification plate 13 276 2 General description 2 1 Description Overview N e U lbt 1 Control unit 4 Protective grilles 2 External emergency stop 5 Chassis 3 Expansion bottle 6 Circuit breakers Figure 2 1 General description of the generating set 14 276 7 y 9 8 10 9 7 Battery charge alternator 9 Main circuit breaker 8 Starter batteries 10 Connection termination box Figure 2 1 continued General description of the generating set 11 15 12 16 11 Coolant filter 14 External fuel supply combined tap optional 12 Filling with fuel 15 Circuit breaker 13 Oil filters 16 Interchangeable fuel pre filters Figure 2 1 continued General description of the generating set 15 276 Fittings Socket control panels and terminals by cover type AIPR 1 LOC 400 630A ALTERNATOR 1 MAX CONNECTION CABLE CROSS SECTION 185MM 2 M10 BOLT M10 NU
67. entailing a strong risk of personal injury and machinery damage AN Carbon monoxide poisoning Only start the engine in a well ventilated area When operated in a confined space exhaust fumes and crankcase gases must be ventilated AN Operation The engine must not be operated in environments which contain explosive media since none of the elec trical and mechanical components are explosion proof Going close to a running engine is a safety risk Hair fingers loose clothes or dropped tools can catch on rotating components and cause severe injury When engines are supplied without touch guards all rotating components and hot surfaces must be pro tected after installation in their application if neces sary for personal safety 129 276 AN Ignition lock If the instrument panel does not have a key switch the engine room must be lockable to prevent unau thorized persons from starting the engine Alternative ly a lockable main switch can be used Care and maintenance Knowledge The instruction book contains instructions for doing the most common service and maintenance tasks in a safe and correct manner Read them carefully before starting work Literature for more major tasks is available from your Volvo Penta dealer Never do a job if you are not entirely sure about how to do it Please contact your Volvo Penta dealer and ask for assistance instead Stop the engine Stop the engine before opening or
68. faults Oil pressure Water temperature Start failure Overspeed Alternator min max Battery voltage min max Emergency stop Engine parameters Timer Oil pressure Water temperature Fuel level Engine speed Battery voltage KERYS Coupling pre programmed coupling mode selector Electrical measurements Voltmeter Ammeter Frequency meter Alarms and faults Oil pressure Water temperature Start failure Overspeed Alternator min max Battery voltage min max Emergency stop Engine parameters Timer Oil pressure Water temperature Fuel level Engine speed Battery voltage Additional specifications Coupling Website Troubleshooting Assistance and maintenance plotting and logging load impact 8 configurations available Compliance with international standards 19 276 EN 2 3 Fuel and consumables All specifications product features are given in the motor and alternator maintenance manuals attached to this manual In addition we recommend the consumables to be used in the specifications section 2 3 1 Specifications 2 3 1 1 Oil grades Engine Oil Make Type Make Type John Deere All John Deere John Deere PLUS 50 GenPARTS GENLUB TDX 15W40 MITSUBISHI All GenPARTS GENLUB TDX 15W40 Volvo All GenPARTS GENLUB TDX 15W40 GENLUB TDX 15W 40 Top of the range lubricant recommended for diesel engines for generating sets used under severe conditions USES
69. for training personnel in implementation and maintenance include the start up and shutdown procedures for the engines As the generating sets are fitted with control units that are specific to the generating sets only the information that appears in the documentation for the generating sets control units should be taken into consideration Important In addition according to the manufacturing criteria of the generating sets some engines may be fitted with specific electrical wiring different to that described in the engine documentation Some user and maintenance manuals for the engines fitted to generating sets cover control units and 3 276 N 1 2 Pictograms and their meanings Safety notices are clearly mounted on the equipment to draw the operator s or maintenance technician s attention to the potential dangers and explain the action to be taken in the interest of safety These notices are reproduced in this publication for ease of identification by the operator Replace any notice that is missing or illegible Caution danger Publications delivered with the generating set must be referred to Caution risk of explosion Caution risk of electric shock Protective clothing must be worn Naked flames and unprotected lights prohibited No smoking Caution toxic materials Eyes and ears must be protected Entry prohibited to non authorised persons Caution pressuris
70. in crease the speed of emptying 6 Flush the system at once very carefully with pure hot water to stop dirt from settling on the in ner surfaces again Flush until the water that runs out is completely clean Make sure that any heater controls are set to full heating during emp tying 7 If contamination should still be left after a long pe riod of flushing you can do a clean out with Volvo Penta radiator cleaner followed by finishing off with Volvo Penta neutralizer Carefully follow the instructions on the package Otherwise continue as in item 8 below 8 When the cooling system is completely free from contamination close the drain taps and plugs 9 Fill up with Volvo Penta recommended coolant following the instructions in the chapters entitled Coolant mixing and Coolant filling IMPORTANT It is extremely important that the correct concentration and volume of coolant is put in the system Mix in a separate clean ves sel before filling the cooling system Make sure that the liquids mix 164 276 Maintenance Fuel system Only use the grades of fuel recommended in the fuel specification below Always observe the greatest cleanliness during re fueling and work on the fuel system All work on the injection system of the engine must be done by an authorized workshop WARNING Fire hazard Work on the fuel system must be done with the engine cold Fuel spills on hot sur faces or electrical com
71. kVA and kW according to the ISO 13 Rated current A 8528 1 standard 14 Weight kg PRP main power 15 CE marking ESP emergency power 16 Non CE standard marking 7 Rated power factor e g GOSSTANDART 8 Maximum altitude of the site above sea level m 17 Sound pressure for the rated power 18 Sound power Figure 1 3 Example of generating set identification plate 12 276 Dieselmotor J O H N D z R MTU Motoren und Turbinen Union Friedrichshafen GmbH A FRIEDRICHSHAFEN Dieselmotor SERIAL NO 3099000000007 Leistung 1330 kW TEn wc Bs ode XXX XXX with fan kW hp XXX XXX Drehzal 1500 l min SPEED AT RATED POWER rpm MTU Motoren und Turbinen Union Friedrichshafen GmbH PRELIFT mm IN J TIMING o MADE IN SWEDEN 3826077 o Figure 1 4 Examples of engine identification plates ECO28 1L 4 SO erus ts A Gives ite 7770 T CREAIZO VICENDA TALA fox Q9 datos MERE SEY OX aurenwarsuns 2111 a rennarORS PUISSANCE I RATING wi metr om ml P T A da 2 TS CET Phase phases cose PF WECOZS 1L44 cose 08 Connex Connec 5 s 151 55 77 50 5o eo 5o 5o so 60 o eo Tenscn Voltage 350 440 400 aso 415 220 208270 230 240 ma 23 p pep e e o n espe Emm ww e ves e pae ahh e 0200 eese e papszpuspesperajerzenspoapo3nsju tus
72. more shortcut keys 10 Return to the navigator menu the functions associated with the active screen Return to the last active operating screen A 202 58 Function keys Synchro column Measurements The registration dialogue box The registration dialogue boxes To facilitate the entry of the information parameters texts there are special screens called dialogue boxes which appear when the need arises Confirmation of an entry in a menu After the modification of a value in a menu the following dialogue box appears Validation of data entered The confirmation key Valid saves the modification the escape key Esc cancels the modification 65 276 N Entry of a text Name of the modified function Text to be modified or created Inserts a space to the left of the cursor DE AERO Delete title Delete a character EN Deletes the letter shown by the cursor Deletes the entire text Closes the menu without saving the changes Saves the changes and closes the dialogue box You move within the text using the right or left arrows on the keypad The characters are entered by means of the alphanumeric keys on the keypad Entering numerical values The heading of the box provides information on the type of value entered its unit and the variable concerned These indications are linked to the type of modified parameter If it exists indicates the lowest possible value If i
73. of the machine Its standard power is 250W with 220V or 250W with 110V on request Warning the power supply is present when the machine has stopped 5 3 2 Temperature sensors with thermistors PTC These are thermistor triplets with a positive temperature coefficient installed in the stator winding 1 per phase There can be maximum of 2 triplets in the winding at 2 levels warning and trip and 1 or 2 thermistors in the shields These sensors must be linked to adapted sensing relays supplied optionally Cold resistance of cold thermistor sensors 100 to 250 per sensor 5 3 3 Connection accessories 6 wire machines coupling F 12 wire machines coupling A F F F After operational testing itis essential to replace all access panels or covers LEROY 18 Wek 220 276 LEROY SOMER Installation and maintenance 3856 en 2011 01 h LSA 46 2 4 POLES ALTERNATORS 5 4 Exploded view parts list and tightening torque 5 4 1 LSA 46 2 single bearing EBOR SOMER 221 276 LEROY SOMER Installation and maintenance 3856 2011 01 h LSA 46 2 4 POLES ALTERNATORS 5 4 2 LSA 46 2 double bearing 20 222 276 LEROY SOMER Installation and maintenance 3856 en 2011 01 h ALTERNATORS xl S
74. page 29 e Oil level checking and filling page 31 Coolant checking level Etre ett o e page 35 Change the air filter every 24 months Every 50 hours at least every 12 months Primary fuel filter Drain water contamination page 41 After the first 150 hours e Engine oil changing sssssssssssssseseeeeeeneen eere page 31 NOTE An oil change is recommended change the oil to a grade recommended by Volvo Penta After the first 1000 hours O Double rocker arm iEGR inspection adjustment not shown Then every 4000 hours Only TAD950VE TAD951VE and TAD952VE Every 50 600 hours at least every 12 months e RR Fee eed 31 e Oil filter By pass filter change page 32 Primary tuel filter change cci ioco Pokora tees page 40 Fuelilter changlng oii ie ied egeo A do page 40 Oil change intervals vary depending on oil grade and sulfur content of the fuel Please refer to page 30 Change the filters during each oil change 25 151 276 Maintenance schedule 26 Every 400 hours at least every 12 months e Fuel tank sludge trap drain eese nnns not shown Drive belts inspection enne nnns page 28 29 Batteries checking the electrolyte
75. please refer to Fuel System Venting NOTE If a water trap is installed change the filter in it at the same time as the fuel filter and clean the wa ter trap in the plastic bowl under the filter with a soft rag Primary fuel filter change 1 Undo the cable from the water trap sensor 2 Remove the water trap filter from the filter bracket Collect any spilled fuel in a collection vessel 3 Remove the lower part of the water trap from the filter 4 Clean the lower part of the water trap with a soft rag Check that the drain hole in the lower part is not blocked 5 Install a new seal on the lower part and lubricate the seal with diesel fuel Re install the lower part of the filter 6 Lubricate the seal with diesel fuel Screw the filter onto the filter bracket by hand until the rubber seal just touches the mating surface Then tighten a further half turn no more 7 Connectthe cable to the water trap sensor If necessary vent the fuel system please refer to Fuel System Venting 166 276 Maintenance Draining condensate fuel system With mechanical drain nipple 1 Open the drain nipple 1 in the base of the pri mary fuel filter NOTE Put a collection vessel under the fuel filter collect the condensate and fuel 3 Press the electric feed pump switch until water free fuel starts to run out Please refer to Compo nent positions 2 Tighten the drain nipple 1 With electric dra
76. removing the en gine hatch hood Care and maintenance work should be done with the engine stopped unless otherwise specified Prevent the engine from being started by pulling out the starter key and cutting the current with the battery isolator Lock them in the Off position Fix a notice by the operator s seat to say that work is in progress Working with or going close to a running engine is a safety risk Hair fingers loose clothes or dropped tools can catch on rotating components and cause se vere injury Volvo Penta recommends that all service work which requires the engine to be running should be done by an authorized Volvo Penta workshop Safety information Safety rules for operation and maintenance contd Lifting the engine The existing lugs on the engine should be used for lift ing Always check that the lifting devices are in good condition and that they have the correct capacity for the lift engine weight together with auxiliaries if fit ted For safety at work the engine should be lifted with an adjustable lifting boom All chains or cables should be parallel to each other and should be as square as possible to the top of the engine Please note that auxiliary equipment installed on the engine could change its center of gravity Special lifting de vices may then be needed to obtain the correct bal ance and safe handling Never carry out work on an engine that is only suspended in a lifting device Befo
77. set GS si Modification Saving in flash le 298 General parameters Thresholds E Modification Priority Return to the previous SEL priorities Display 1 2 General parameters Thresholds Press Generating set priority on the touch screen to return to the home screen A Important The configuration will only be considered valid if the following operations are carried out Y Open the battery cutout v Wait 5 seconds Y Close the battery cutout 108 276 6 3 8 2 Starting tests and stop In manual mode Starting Check there are no faults grey no fault red fault present grey no alarm orange alarm present O 90 If faults are present the fault management screen can be accessed by pressing Reset Refer to the section Alarms and Faults in the Operating menus to eliminate the faults If no faults are present manual mode can be activated by pressing Manu 109 276 The manual start up phase will begin once key 1 in the test keypad is pressed S e e me The start up request is maintained until the generating set starts it is not necessary to y Q L keep key 1 pressed This method may not under any circumstances be used to turn the engine over manually During the start up phase and until the alternator voltage and speed of the generating set stabilise the green LED under th
78. signal range for frequency or duty cycle outside Region b or the signal definition Also if the signal is an ECM output any signal whose frequency or duty cycle is not consistent with the signal which is emitted Broadcast of data value is substituted with the error indicator value FMIZ9 ABNORMAL UPDATE RATE Any failure that is detected when receipt of data via the data link or as input from a smart actuator or smart sensor is not at the update rate expected or required by the ECM outside Hegion c of the signal range definition Also any error that causes the ECM not to send information at the rate required by the system This type of fault may or may be directly associated with the value of general broadcast information FMIZ10 ABNORMAL RATE OF CHANGE Any data exclusive of the abnormalities covered by FMI 2 that is considered valid but whose data is changing at a rate that is outside the predefined limits that bound the rate of change for a properly functioning system outside Region c of the signal range definition Broadcast of data values is continued as normal 274 276 FMl 11 ROOT CAUSE NOT KNOWN It has been detected that a failure has occurred in a particular subsystem but the exact nature of the fault is not known Broadcast of data value is substituted with the error indicator value FMl 12 BAD INTELLIGENT DEVICE OR COMPONENT Internal diagnostic procedures have determined that the failure is one which re
79. start and stop the generating sets one by one via the MMI keypad The generating set power unit is switched off manually with synchronisation of each generating set to the busbar using the MMI keys F F V and V The distribution of power among the generating sets remains automatic The safety devices of the generating sets remain active in this mode of operation This mode of operation is the responsibility of the operator 78 276 6 3 5 Connections of the generating sets 6 3 5 1 Recommendations before the connections N Warning Disconnect the battery cables before carrying out any work on the generating set To disconnect the battery disconnect the negative cable first 6 3 5 2 Connections according to the configurations Power plant without common part without inverter A632 Power plant without common part and without inverter A633 Ground connection X Solo generating set without inverter A612 X Solo generating set CRF coupling A651 Ground connection box X X Facility power outlet O O O Connecting cables between the generating sets CAN BUS X Connecting cables between the generating sets Parallel line X Power cables X X X X Customer terminal Remote operation e e e e External emergency stop e e e e EJP Switch grid detection 7 e e o Grid detection by regulation card e X
80. supplied by the grid Manual generating set operation This mode of operation is selected with the MANU key The operator is able to start and stop the generating set via the MMI keypad The power unit is switched off manually with the manual synchronisation of the generating set to the grid using the keys wy F F V V the load transfer remains automatic The safety devices of the generating set remain active in this mode of operation This mode of operation is the responsibility of the operator 71 276 6 3 4 4 EN Power plant configuration Several generating sets in parallel Without common part and without Normal Emergency inverter A632 This configuration is designed to provide v v Emergency electricity supply to an installation following a grid loss The grid loss is not controlled by Kerys Return to the grid will be achieved by Normal Emergency switchover by means of a self driven inverter not controlled by Kerys FORCED OPERATION with a generating set Operation in Effacement Jour de Pointe EJP mode or other rates Information transmitted by dry contacts An active power regulation speed of the generating sets by parallel lines connected between all the regulation modules Regulation Regulation module PF module Base Base module module e ea Genset x the EJP Peak Day Load Shedding system is specific to
81. support Serice isai aee i aa aed aaa 18 5 3 ACCOSSOMES E A EAE AE E E 18 5 4 Exploded views parts list and tightening 19 EC declaration of incorporation 22 Eg 205 276 LEROY SOMER Installation and maintenance 3856 en 2011 01 h LSA 46 2 4 POLES ALTERNATORS 1 RECEIPT e C excitation system C AREP J SHUNT or PMG E 1 1 Standards and safety COMPOUND measures Our alternators comply with most international standards See the EC Declaration of Incorporation on the last page 1 2 Inspection On receipt of your alternator check that it has not suffered any damage in transit If there are obvious signs of knocks contact the transporter you may be able to claim on their insurance and after a visual check turn the machine by hand to detect any malfunction 1 3 Identification The alternator is identified by means of a nameplate fixed on the machine see drawing Make sure that the nameplate on the machine conforms to your order The machine name is defined according to various criteria for example LSA 46 2 M5 C6 4 LSA name used in the PARTNER range M Marine C Cogeneration T Telecommunications 46 2 machine type M5 model 6 4 winding number number of poles 1 3 1 Nameplate So that you can identify your machine quickly and accurately we
82. ter before you start work NOTE Reading the fault codes below such as Code 2 1 PID 97 means that 2 1 is the flashing code indicated by the diagnostic lamp on the instrument box PID 97 is read with the VODIA diagnostic tool Please refer to Reading fault codes NOTE Please refer to Wiring schedule CIU and DCU for references to the sleeves in the electrical connectors on the engine control unit Code 1 1 There are no active faults Nofaults Code 2 1 PID SPN 97 Water in fuel Cause e Water in fuel Reaction None Remedy Empty the primary fuel filter Code 2 2 PID SPN 111 Coolant level Cause Low coolant level Reaction Warning indication Engine control module reduces engine power un less the protection has been shut off with the VODIA diagnostic tool Remedy e Check the coolant level Check coolant level monitor function 178 276 Code 2 3 PID SPN 111 Coolant level sensor Cause e Short circuit to positive Fault in sensor Reaction None Remedy e Check that the coolant level sensor cable is not damaged e Check coolant level sensor function Code 2 4 SID21 SPN 637 Flywheel speed sensor Cause No signal Abnormal frequency Intermittent signal from the sensor Fault in sensor Reaction Engine is very difficult to start and runs roughly when it starts Remedy e Checkthat the sensor connector is correctly
83. that the radiator matrix is not damaged Re install the components AN IMPORTANT Do not use a high pressure power washer 37 163 276 Maintenance 38 Cooling system cleaning Cooling performance is reduced by deposits in the radi ator and cooling galleries The cooling system should be cleaned out when the coolant is changed IMPORTANT Cleaning must not be done if there is any risk of the cooling system freezing since the cleaning solution does not have any frost prevention ability 1 Empty the cooling system Please refer to Cool ing system draining 2 Putahose into the filling hole in the expansion tank and flush with pure water which complies with Volvo Penta specifications please refer to the Water Quality chapter until the water which runs out is completely clear 3 If there should still be some contamination left af ter flushing for a long time cleaning can be done with coolant Otherwise continue as in item 8 be low 4 Fill the cooling system with 15 20 mixture of concentrated coolant Only use Volvo Penta rec ommended concentrated coolant mixed with pure water 5 Drain the coolant after 1 2 days of operation NOTE To prevent suspended material from settling back in the system emptying should be done rapidly within the space of 10 minutes when the engine has not been standing still for a long time Remove the fill er cap and possibly the lower radiator hose to
84. the three generating sets takes place Each generating set will then take 33 33 of the required power i e 300 kW corresponding to 50 of its rated output 600 kW When the power required for the application reaches 75 of the power of the three GSs in operation GSs at priority 01 02 and 03 i e 1350 kW the fourth GS at priority 04 is then started and synchronised with GS1 GS2 and GS3 Its flow is then closed The fourth GS thus coupled initiates its power on ramp adjustable delay and the distribution of power among the four generating sets takes place Each generating set will then take 25 of the power required i e 337 5 kW corresponding to 56 25 of its rated output 600 kW The power required for the application may continue to increase up to the upper plant limit 95 of 2400 kW i e 2280 kW the setting can be changed This corresponds of course to the upper generating set limit i e 570 kW 95 of 600 kW Automatic operation All Kerys PLCs in AUTO mode coupling when stopped Loss of grid voltage e Grid loss acquisition delay controlled by the mains detection module Generating set power units switched off Generating set start request The generating sets speed increases Speed stabilisation delay Order of excitation for each generating set at nominal speed the voltage is then quickly established on the busbar Start of distribution of active power Resumption of use at the rated power and frequency
85. to the right Confirm function of selected key It is possible gain direct access to a menu by pressing the numerical key corresponding to its The alphanumeric keys They allow alphanumeric input by successive pressing of the keys The characters entered appear in the order they were typed on the keypad 62 276 EN 6 3 3 2 Navigation in the screens There are three types gt home screen gt the navigation screens gt the operation and configuration screens Home screen This screen is the entry point to the system It enables the main functions of the navigation to be accessed 151003 19 10 00 tome Mame EYSDMO Global Power Solution aa Fault finding Z5 Configuration Seo Maintenance 3 Archiving Metering Navigation screens These screens enable the various sub menus to be accessed Upper level Title of the active Lower levels E 07 09 19 10 00 Operation om Function keys 7 5 User adjustments 23 Synchro column 6 Alarms amp Faults M4 PS Central measurements 5 Measurements 63 276 EN When a key is selected the lower level sub menu appears if available or the allocated operation screen A sub menu can also be accessed by pressing the corresponding key E g by pressing key 1 on
86. using the generating set 1 3 5 Risks related to electrical networks Y The electrical equipment supplied with the generating set complies with standard NF C15 100 France or with the standards of the countries in question Y The earth connection must be installed in accordance with the standards in force in each country in question and with the neutral System sold Y Read the manufacturer s identification plate carefully The values for voltage power current and frequency are shown Check that these values match the supply use Y Never accidentally touch stripped cables or loose connections Y Never handle a generating set with wet hands or feet Y Maintain electrical wires and connections in good condition Using equipment in poor condition can lead to electrocution and damage to equipment Y Always disconnect the power to the equipment or facility generating set voltage battery voltage and network voltage before any operation Y The electrical connections must be made in accordance with current standards and regulations in the country of use Y Do not use faulty poorly insulated or provisionally connected wires Y Never reverse the positive and negative terminals on batteries when connecting them This could cause severe damage to the electrical equipment Follow the wiring diagram supplied by the manufacturer Y The generating set should not be connected to any other power sources such as the mains supply network In specific case
87. 0 Hz in 50Hz operation the rated voltage is recovered by following a fast gradient If the speed drops below 46 Hz since the engine needs more help the voltage follows a slow gradient as it returns to the reference value R Drop N 46 Hz Time Drop N gt 46 Hz 3 4 Typical effects of the LAM with a diesel engine with or without a LAM U F only 3 4 1 Voltage U 12 LEROY SOMER 250 276 LEROY SOMER Installation and maintenance 4531 en 2010 10 c R 450 AVRs 3 4 3 Power R729 module same as R726 with additional functions Detection of a diode fault 4 20 mA input Possibility of KVAR regulation Load on the shaft kW Voltage control with isolated D C current source applied to the terminals used for the external potentiometer Internal impedance 1 5 kQ A variation of 0 5 V corresponds to a 3 5 AVR options voltage adjustment of 10 Current transformer for parallel opera tion of 1 A or 5 A according to the po tentiometer P4 position Voltage transformer adaptation Remote voltage adjustment potentio meter 1 k O 0 5 W min adjustment range 5 range limited by internal voltage potentiometer P1 A 470 Q potentiometer can also be used to extend the adjustment range The potentiometer input must be isolated Do not connect it to the ground R 731 module 3 phase voltag
88. 1 2 on the touch screen 104 276 4 5 15 07 09 19 10 00 Faults Power return Without No load test time delay 600 Confirmation request sec Power 1 Power loss time delay sec Power return time delay sec Inversion in non coupl Whithout 7 In emergency mode Inversion in non coupl wnithout In normal mode z1 p Set point Wattmetric COntrol rating set priority Press Generating set priority on the touch screen 15 07 09 GS select Priority K select Return to the previous priorities Display 29 General parameters Thresholds Press the selection arrows on the touch screen to select the generating set 105 276 6 7 15 07 09 GS select Display le 298 General parameters Thresholds t Modification Priority Return to the previous priorities Display Valid 1 2 General parameters Thresholds Press Valid on the touch screen 106 276 8 9 Modification Priority Y select Return to the previous sa priorities Display GS select General parameters Thresholds E Press Save on the touch screen Generating set Modification GS select 01 vy idi A EI Save in flash id Esc le s 2 Soos General ees E Press Valid on the touch screen 107 276 11 EN Generating
89. 1 h LSA 46 2 4 POLES ALTERNATORS This manual concerns the alternator which you have just purchased We wish to draw your attention to the contents of this maintenance manual SAFETY MEASURES Before using your machine for the first time it is important to read the whole of this installation and maintenance manual All necessary operations and interventions on this machine must be performed by a qualified technician Ourtechnical support service will be pleased to provide any additional information you may require The various operations described in this manual are accompanied by recommenda tions or symbols to alert the user to the potential risk of accidents It is vital that you understand and take notice of the different warning symbols used WARNING Warning symbol for an operation capable of damaging or destroying the machine or surrounding equipment Warning symbol for general danger to personnel Warning symbol for electrical danger to personnel WARNING SYMBOLS We wish to draw your attention to the following 2 safety measures which must be complied with a During operation do not allow anyone to stand in front of the air outlet guards in case anything is ejected from them b Do not allow children younger than 14 to go near the air outlet guards Asetof self adhesive stickers depicting the various warning symbols is included with this maintenance manual They should be position
90. 15 December 2004 as intrinsic levels of emissions and immunity are concerned WARNING The here above mentioned generators should not be commissioned until the corresponding Gen Sets have been declared in compliance with the Directives Nr 2006 42 CE et 2004 108 CE as well as with the other relevant Directives Leroy Somer undertakes to transmit in response to a reasoned request by the national authorities relevant information on the generator Technical Managers P Betge J Begu gt AY hj 4152 2010 11 d LEROY 22 Wek 224 276 LEROY SOMER Installation and maintenance 3856 en 2011 01 h LSA 46 2 4 POLES ALTERNATORS SQ SOMER 225 276 23 LEROY SOMER LEROY SOMER 16015 ANGOULEME CEDEX FRANCE 338 567 258 RCS ANGOULEME www leroy somer com 226 276 LEROY SOMER 4067 en 2009 05 b CE oV EE E U pe iven to F1 Slow fuse 10 250V 8A ual cer This manne end U P1 Voltage 8 ey ST4 Option External potentiometrer for voltage adjusting poe eec R250 A V R Installation and maintenance 227 276 LEROY SOMER Installation and maintenance 4067 en 2009 05 b R250 A V R This manual concerns the alternator A V R which you have just purchased We wish to draw your attention to the contents of this maintenance manual By following certain important poin
91. 23 276 LEROY SOMER Installation and maintenance 3856 en 2011 01 h LSA 46 2 4 POLES ALTERNATORS Electric Power Generation Division Declaration of CE compliance and incorporation This Declaration applies to the generators designed to be incorporated into machines complying with the Machinery Directive Nr 2006 42 CE dated 17 May 2006 MOTEURS LEROY SOMER MLS HOLICE STLO SRO MOTEURS LEROY SOMER Boulevard Marcellin Leroy SLADKOVSKEHO 43 1 rue de la Burelle 16015 ANGOULEME 772 04 OLOMOUC Boite Postale 1517 France Czech Republic 45800 St Jean de Braye France Declares hereby that the electric generators of the types LSA 36 37 40 42 2 43 2 44 2 46 2 47 2 49 1 50 2 51 2 as well as their derivatives manufactured by Leroy Somer or on Leroy Somer s behalf comply with the following International Standards and Directive EN and IEC 60034 1 and 60034 5 ISO 8528 3 Reciprocating internal combustion engine driven alternating current generating sets Part 3 Alternating current generators for generating sets Low Voltage Directive Nr 2006 95 CE dated 12 December 2006 Furthermore these generators designed in compliance with the Machine Directive Nr 2006 42 are therefore able to be incorporated into Electrical Gen Sets complying with the following International Directives Machinery Directive Nr 2006 42 CE dated 17 May 2006 EMC Directive Nr 2004 108 CE dated
92. 35 36 Newly renovated engine After the first 250 hours O Valve clearance not shown 152 276 Maintenance This chapter describes how the specified maintenance points should be done Read them carefully before starting work The times when maintenance points need to be attended to are given in the previous chapter Maintenance schedule WARNING Read through the safety advice for care and maintenance work in the Safety information chap ter before starting work AN WARNING Care and maintenance work should be done with the engine stopped unless otherwise specified Make it impossible to start the engine by removing the ignition key and cutting the system voltage with the main switch Working with or going close to a running engine is a safety risk Watch out for rotating compo nents and hot surfaces Engine general 153 276 General inspection Make it a habit to give the engine and engine bay a vi sual check before the engine is started and after operation when the engine has been stopped This will help you to discover quickly if anything ab normal has happened or is about to happen Look especially carefully at oil fuel and coolant leak age loose screws worn or poorly tensioned drive belts loose connections damaged hoses and electri cal cables This inspection only takes a few minutes and can prevent serious malfun
93. 48 or the AVR access door 466 4 6 5 Replacing the NDE bearing Remove the box lid 48 and the NDE panel 365 and remove the 2 screws from the part 122 Disconnect the stator outputs T1 to T12 Disconnect the auxiliary winding wires AREP 1 2 21 22 Disconnect the exciter wires 5 6 Remove the air inlet louvre 51 If using a single bearing or double bearing machine with the regreasable bearing option Remove the bearing 78 thrust screws 72 Remove all 4 screws 37 Remove the shield 36 Take out the antifriction bearing 70 using a puller with a central screw see drawing below Fit the new antifriction bearing onto the shaft after heating it by induction to approximately 80 C Mount the new preloading wavy washer 79 the new O ring seal 349 in the shield 36 and coat the bearing seat with adhesive paste see After Sales Service If using a single bearing or double bearing machine with the regreasable bearing option Screw a threaded rod into the thrust bearing 78 Refit the end shield on the machine using a dowel and nut in the shaft extension see drawing 14 LEROY SOMER 216 276 LEROY SOMER Installation and maintenance 3856 en 2011 01 h LSA 46 2 4 POLES ALTERNATORS Slide the threaded rod into the shield hole to make it easier to assemble see basic diagram Threaded rod Do
94. 5 Warning output open circuit 412 Temperature sensor in the EGR valve 0 Temperature in the EGR extremely high 3 e voltage of the temperature sensor Short to Vx 4 ue voltage of the temperature sensor Short to V 15 Temperature in the EGR high 16 Temperature in the EGR moderately high 443 443 ENGINE RUN output status 3 Engine run output open short to B 4 Engine run output short to 523 Gear selection Gear selection invalid Not possible with Genset application 265 276 N SPN CID SID PID PPID FMI John Deere Volvo Perkins Description Comment 608 250 Data link faulty J1587 Start Stop redundancy J1939 communication bus 608 132 Redundancy of the accelerator 608 98 Redundancy of the Stop start information 611 Injector wiring status Injector wiring shorted to power source 620 262 232 Injector wiring shorted to ground 5 Volt sensor power supply FMI not informed by VOLVO Sensor power supply open short to B 626 45 Sensor power supply short to ground Start enable device intake heater and ether Start enable device output short to B Start enable device output short to ground Start enable device output open circuit Not used the control panel is in charge of managing the start enable device 627 Power supply Injecto
95. 6 lE pressure system of the 1347 Pump control valve status Paes 3 Pump control valve current high 5 Pump control valve error mismatch Fuel rail pressure control error 10 Pump control valve fuel flow not detected 271 276 N c SPN CID SID PID PPID x Description Comment 507 9 1348 Pump control valve 2 status Only for 6081HF070 5 Pump control valve 2 error mismatch 10 Pump control valve 2 fuel flow not detected 1485 1485 5 Pump power relay status EMG pe relay CF VOEVO 2 Pump power relay fault 3 a main relay short circuit igh 1568 Torque curve selection 2 Torque curve selection invalid 4 Torque curve input voltage high 9 Torque curve selection missing 1569 Fuel supply status 31 Fuel de rate 1639 Fan speed sensor 1 Fan speed signal missing 2 Fan speed signal erratic Not possible with Genset 16 Fan speed higher than expected application 18 Fan speed lower than expected 2000 ECU status 6 Vehicle ID missing 13 Security violation 2630 Air temperature at the air cooler outlet 0 Air temperature extremely high 3 Sensor input voltage high Short to V 4 Sensor input voltage low Short to V 15 Air temperature high 16 Air temperature moderately hi
96. 7 3 P5 P8 P8 P9 4 P8 P9 P9 P2 5 P9 P2 P2 P10 6 P2 P10 P10 7 10 Change screens by using the scrolling and selection wheel When the wheel is rotated clockwise the screens scroll upwards and vice versa The screens scroll in a loop E g On three phase neutral network then screen 7 then screen 1 and vice versa 6 2 1 6 Display of messages in zone 4 The display zone 4 among other things displays messages relating to the operation of the generating set The messages are as follows Initialisation of TELYS Screen no Screen Data displayed G1 Initialisation of TELYS when the power is switched on and or when loading a configuration SERIAL No 08030010000 SOFTWARE 6 1 0 NOMINAL VOLTAGE 400V G2 FREQUENCY 50Hz NOMINAL KW 320kW EARTH SYSTEM TNS Generating set serial no Software version of TELYS Alternator Nominal Voltage Alternator Nominal Frequency Nominal Active Output Neutral Point Bar graph indicating the display delay of the screen 44 276 Generating set stopped EN Screen H6 Screen Data displayed OPERATION MANUAL Press START Operating mode generating set in Manual Mode G3 to start ready to start Date and time depending on settings 24 08 2005 OPERATION AUTO WARNING Operating mode generating set in Auto Mode G4 ready to start START UP POSSIBLE IMMEDIATELY Date and tim
97. 898 CAN throttle status 9 au Speed value invalid or missing Auxiliary engine shutdown switch 979 a status EMS Auxiliary engine shutdown switch signal invalid Not used 31 Auxiliary engine shutdown switch active 971 External engine de rate switch status 31 External engine de rate switch active Not used 1069 Tire size status Tire size error Not possible with Genset Tire size invalid o application 31 Tire size error 1075 Feed pump of the fuel circuit High impedance at the terminals of the pump or open circuit 6 Pump coil short to ground 12 Pump defective 1076 Fuel Injection pump status Pump control valve closure too long Injection DE10 Pump control valve closure too short Injection DE10 Pump detected defect Injection VP44 Pump solenoid current high Injection DE10 Pump solenoid circuit open Injection DE10 Pump solenoid circuit severely shorted Injection DE10 Pump control valve closure not detected Injection DE10 Pump solenoid circuit moderately shorted Injection DE10 Pump current decay time invalid Injection DE10 270 276 N
98. AN WARNING Warns for the risk of personal injury major damage to product or property or serious malfunctions if the instruction is ignored AN IMPORTANT Is used to call attention to things which could cause damage or malfunctions to product or property NOTE Is used to call attention to important information to facilitate work operations or handling LLI This symbol is used on our products in some cases and refers to important information in the instruction book Make sure that warning and information symbols on the engine are clearly visible and legible Replace symbols which have been damaged or painted over 128 276 Safety information Safety rules for operation and maintenance A Daily checks Make it a habit to always give the engine and engine bay a visual check before operation before the en gine is started and after driving when the engine has been stopped This helps you to quickly discov er whether any leakage of fuel coolant oil or any oth er abnormal event has happened or is about to hap pen AN Fuel filling There is always a risk of fire and explosion during fuel filling Smoking is not permissible and the engine should be stopped Never over fill the tank Shut the tank cap securely Only use the fuel recommended in the instruction book The wrong grade of fuel can cause malfunctions or stop the engine In a diesel engine it can also cause the injection pump to bind and the engine will over rev
99. Always use protective goggles and gloves If acid comes into contact with your skin wash at once with soap and a lot of water If you get battery acid in your eyes flush at once with a lot of cold water and get medi cal assistance at once Charge batteries if they have become discharged If the engine is not used for a longer period of time the batter ies should be fully charged then possibly trickle charged please refer to the battery manufacturer s rec ommendations Batteries are damaged by being left dis charged and can also freeze and burst easier in cold weather IMPORTANT Observe the instruction manual for the battery charger carefully To avoid the risk of electrochemical corrosion when an external charger is connected the battery cables should be re moved from the batteries before the charger is con nected During charging unscrew the cell plugs but leave them in the plug holes Ventilate well especially if the batter ies are charged in an enclosed space WARNING Always cut the charge current before the battery charger clamps are undone Never con fuse the positive and negative poles on the batteries This can cause serious arcing and can cause an explosion For so called quick charging there are special rules Quick charging can shorten battery life and should therefore be avoided 170 276 Component location oa F ON Coolant level sensor Crankcase pressure sensor Elec
100. C 240V BA GND A44Z2 E A44Z2 manufacturer product reference wc ane E main module hardware upgrade index 43 week of manufacture week 43 Tension groupe ou r seau jeu de barres b Module de protection Protection mpdule A4422 gt 31613391601 07 year of manufacture year 2007 i A secondary module hardware upgrade index be 035 serial number related with a batch number Me eee Chae omens oat 035 the 35 module manufactured in week 04 of i the year 2008 a maximum of 999 modules that can be related with a batch number 1 Secondaire transfo de courant 82 Secondary current transformer 12 1 Secondaire transfo de courant 12 82 Secondary current transformer 13 51 Secondaire transfo de courant 480 Volts maxi cUL 240 Volts maxi Secondary current transformer 5 5 In S1 Transfo courant homopolaire Zoro sequence 20 C 70 C 57 276 N Logical inputs and outputs module and outputs module ESTOR Binary inputs and outputs D341000 B1 Module item reference D341000 manufacturer product reference B1 module hardware upgrade index S N 0250 0250 serial number not related with a batch number 0250 le 250 module manufactured since the start Batch No 06 49
101. CU f gt Eng speed rpm Boost prs Engine data 11 ped Mh pope shows relevant engine data Eng hours h Batt Volt Engine speed can be controlled with the SPEED and SPEED buttons rpm e Charge pressure kPa Coolant temperature C e Charge air temperature C Oil pressure kPa e Oil temperature C Engine hours h Battery voltage V Fuel consumption l h Instantaneous fuel consumption trip fuel 1 13 139 276 Introduction Preheat Press SEL to request preheat Governor mode Droop mode Diagnostics 7 9 20 0h Engine oil pressure signal failure Inactive Trip Data Reset Press SEL to reset trip data Preheat manual activation of pre heating When it is activated the EMS system senses when started if pre heating is needed For automatic pre heating please refer to the Setup Pre heat on ignition menu The pre heating time is adjusted to suit the engine temperature and can last for up to 50 seconds both before and after starting Also refer to Starting proce dure EMS 2 e Press SEL the text Preheat requested is dis played display automatically returns to the Engine Data menu Governor mode activates shuts off droop To set the droop level please refer to the Setup Governor gradient or Governor droop menus Select Isochronous mode or Droop mo
102. Check that the cable harness to oil pressure and charge air pressure sensor has not been dam aged e Check oil pressure and charge air pressure sen sors Code 9 8 SID 253 SPN 630 Data set memory EEPROM CIU Cause Internal fault in control module e Programming faulty Reaction Engine does not start Remedy Re program the control module If the fault re mains change the control module 60 Code 9 8 PPID 254 SPN 629 Fault in control unit CIU Cause e Faulty EEPROM CIU Faulty flash memory CIU e Fault in control module CIU Reaction ClU returns to factory setting Engine goes to idle Engine can not be started Remedy Re program the unit Code 9 9 SID 240 SPN 639 Memory fault Cause Memory fault in engine management system Reaction Engine might not start Remedy Re program the unit e Change engine control unit EMS Code 9 9 SID 253 SPN 630 Data set memory EEPROM EMS Cause Internal fault in control module Programming faulty Reaction Engine does not start Remedy e Re program the control module If the fault re mains change the control module 186 276 Fault codes Code 9 9 SID 254 SPN 629 Control module EMS Cause Internal fault in control module Reaction Engine misfires Engine does not start Remedy e Change engine control unit 187 276 PPID 19 SPN 2791 Internal EGR Cause Fault i
103. Check the intercooler cleanliness e Check if there is air in the cooling system e Check the pressure cap on the expansion tank e Check coolant temperature sensor function e Check thermostat function 182 276 Code 6 2 PID SPN 105 Charge air temperature Cause e Charge air temperature is too high Reaction Engine control module reduces engine power un less the protection has been shut off with the VODIA diagnostic tool Remedy e Check the coolant level e Checkthe intercooler cleanliness e Check charge air temperature sensor function e Check the function of the thermostat Code 6 3 PPID SID 39 SPN 677 Start output EMS SID 39 SPN Start motor relay Cause e Shorted to plus or minus e Activated for too long Reaction The engine cannot be started The engine starts immediately when ignition is tur ned on Remedy e Check that connections to the ignition key have not been damaged e Check that the cable harness to the ignition key has not been damaged Code 6 4 PPID 231 SPN 639 Data link CAN CIU Cause Faulty data link CAN CIU Reaction Instruments and warning lamps stop working Remedy e Check that the 8 pin connector is not damaged e Check that the cables between the CIU and the engine management unit are not damaged Code 6 5 PPID 231 SPN 639 Data link CAN EMS 2 Cause Internal fault in control module Reaction En
104. ENERATING SET WITHOUT GRID COUPLING 1 APPLICATION A612 2 PRODUCTION POWER PLANT WITHOUT GRID COUPLING APPLICATION A632 A633 4 3 NOT APPLICABLE 4 SOLO GENERATING SET WITH GRID COUPLING APPLICATION A651 3 If the switch is already set to 2 turn the switch and return to position 2 After changeover the screen below appears 632 Power plant without shared switching unit without Normal Emergency parallel line 633 Power plant without shared switching unit without Normal Emergency Digital Bus 5 Select the configuration A632 Power plant without shared switching unit without Normal Emergency parallel line by directly clicking on the touch screen Select the configuration A633 Power plant without shared switching unit without Normal Emergency Digital Bus by clicking directly on the touch screen N B selecting detection depends on the connection made according to Section 5 Connections of the generating sets Important 99 276 EN Back up to perform GS 1 Rental application Faults A633 Power plant without shared switching unit without Normal Emergency Digital Bus Number of gen sets in power plant Genset number Validation 6 Press the generating set number on the touch screen Back up to perform GS 1 Rental application A633 Power plant without shared switching unit without Normal Emergency Digital Bus Number of gen sets i
105. Emergency Stop 06 10 06 10 30 06 10 06 15 30 OK HELP Esc RESET OK HELP Press OK on the scrolling and selection wheel to access the help message if it is available example below Check the level fuel Esc EXIT If the alarm is no longer active it is reset automatically cause disappears Press Esc to reset a fault reset acknowledged if the cause of the fault has been removed reset not performed if the cause of the fault is still present 50 276 6 2 4 3 Activation of an alarm and a fault The appearance of an alarm and a fault causes gt yellow and red LEDs to flash gt the related screen to be displayed example below FAULTS 1 2 Emergency Stop 25 12 05 15 30 Esc RESET OK LIST EN If several faults are present the number of faults is displayed at the top of the screen The faults list can be accessed by pressing OK of the scrolling and selection wheel examples below FAULTS FAULT 25 12 05 15 30 Emergency Stop ALARM 25 12 05 15 30 Low Fuel Level OK HELP Check Emerg Stop Pos Connector s Esc Esc Press Esc to return to the previous screen Press OK to go to the HELP screen help on the highlighted fault Use the scrolling and selection wheel to scroll through the list of faults If the alarm is no longer active it is reset automatically cause disappears Press Esc to reset a fault reset acknowledged if the cause of the fault has be
106. ICE VOLTAGE SELECTOR To be operated only by qualified personnel 31811170401 Equipment damage may occur Properly adjust output voltage before connecting load 31811170501 VOLTAGE SELECTOR SWITCH MUST HOT BE TURHED WHILE THE GENSET IS RUNNING 31211170701 WARNING DANGER A poor earth connection can lead to serious injuries or death Always connect the earth terminal of the generating set to an external earth terminal WARNING Voltage selector This function should be used by qualified persons only WARNING Adjust the output voltage correctly before connecting a load WARNING The voltage selector must not be used when the generating set is operating Figure 1 2 continued Pictograms and their meanings 7 276 N 1 3 Instructions and safety regulations THESE SAFETY GUIDELINES ARE IMPORTANT If you do not understand or have any questions about any point in this manual contact your dealer who will explain it to you or give you a demonstration A list of risks and precautionary measures to take follows You should also refer to any local and national regulations that apply in accordance with your own jurisdiction KEEP THIS MANUAL This manual contains important instructions which must be followed when installing or carrying out maintenance on a generating set or batteries 1 3 1 General advice Use Y The operating and safety instructions must be made known to operating personnel They will
107. ING RANGE LEAST SEVERE LEVEL The signal communicating information is within a defined acceptable and valid range but the real world condition is below what would be considered normal as determined by the predefined least severe level limits for that particular measure of the real world condition Region h of the signal range definition Broadcast of data values is continued as normal 275 276 FMI 18 DATA VALID BUT BELOW NORMAL OPERATING RANGE MODERATELY SEVERE LEVEL The signal communicating information is within a defined acceptable and valid range but the real world condition is below what would be considered normal as determined by the predefined moderately severe level limits for that particular measure of the real world condition Region j of the signal range definition Broadcast of data values is continued as normal FMIz19 RECEIVED NETWORK DATA IN ERROR Any failure that is detected when the data received via the network is found substituted with the error indicator value i e FE16 see J1939 71 This type of failure is associated with received network data The component used to measure the real world signal is wired directly to the module sourcing the data to the network and not to the module receiving the data via the network The FMI is applicable to Region f and g of the signal range definition This type of fault may or may be directly associated with the value of general broadcast information FMI 20 30 RESERVED
108. MER It may not be reproduced in any form without prior authorization All brands and models have been registered and patents applied for LEROY SOMER 3 229 276 LEROY SOMER Installation and maintenance 4067 en 2009 05 b R250 A V R 1 SUPPLY The regulator controls the excitation current 2 ati according to the alternator s output voltage T T SHUNT excitation system With a very simple conception the SHUNT The SHUNT excitation alternator is auto excitation alternator does not have a short excited with a R 250 voltage regulator circuit capacity MAIN FIELD STATOR 12 wires marking T1 to T12 SHUNT SYSTEM e e I7 T2r 4T8 re 5 eM _ 5 Induced c T4 5 11 Te T12 Field e 6 e BOR R 250 4 x holes 5 8 x 50 x 115 mm 140 mm Slow fuse F1 250V 8A P1 6 Voltage Frequency selector 50 Hz 60 Hz for U F fonction and LAM adjustement P2 G Stability D ST4 Option External potentiometrer for voltage adjusting LEROY 2 SOMER 230 276 LEROY SOMER Installation and maintenance 4067 en 2009 05 b R250 A V R 2 R250 A V R 2 1 Characteristics Storage 55 C 85 C Operation 40 C 70 C Voltage regulation a
109. NU mode Fixed TELYS in automatic mode AUTO AUTO Flashing For 5 seconds when switching from AUTO Mode MANU mode to AUTO mode Flashing Generating set in start up phase Fixed Generating set started Fixed Generating set stabilised voltage and frequency Flashing appearance of constant movement from left to right The generating set is powering the installation Fixed The installation is supplied of Not used Not used 40 276 6 2 1 4 Alarm and fault pictograms in zone 2 N Description of the pictograms in zone 2 All the pictograms in this zone are activated when TELYS is initialised Data displayed Fuel level indicator Alarm Fault Alarm Fault lt low fuel level high fuel level lt Coolant level temperature indicator Alarm High 4 fat lt No preheating Low level level fault temperature fault 4 fault alarm f alarm ault Battery Min battery Battery charge Max battery mur voltage A voltage flashing indicator flashing LAAN s NN ashing bars Oil pressure temperature indicator Oil pressure E I lt ordow oll ly temperature Alarm Faut J gt Alarm q Fault 4 Alarm Fault 8 Emergency stop Emergency stop fault Overload or short circuit Tripping of circuit breaker following an overload or short circuit gt Engine speed Underspeed fault O
110. Rental configurations 6 3 7 1 Choice of application configuration Solo generating set Without inverter A612 1 Turn off the battery isolator switch 2 Check that the emergency stop buttons are activated 3 Press the STOP button on the KERYS 4 Turn the changeover switch to position 1 SOLO GENERATING SET WITHOUT GRID COUPLING APPLICATION A612 2 PRODUCTION POWER PLANT WITHOUT GRID COUPLING APPLICATION A632 A633 3 NOT APPLICABLE 4 SOLO GENERATING SET WITH GRID COUPLING APPLICATION A651 3 If the switch is already set to 1 turn the switch and return to position 1 After changeover the screen below appears 15 07 09 19 10 00 Rental application Faults A612 Single Genset without N E Mains supply detection using the adjustment card Validation 94 276 N 5 Select the configuration of the mains detection of the generating set by clicking directly on the touch screen Y For a mains detection by means of the regulation card you must select the configuration Mains supply detection using the adjustment card and connect the voltage reference to the terminals Xcbc1 1 2 3 Y For mains detection by an external switch you must select the configuration Mains supply detection using an external contact and connect the external switch to the terminals Xcbc3 34 35 Y For starting by means of an external switch you must select the configuration Mains supply d
111. SHI Al GenPARTS GENCOOL PC 26 C Volvo All GenPARTS GENCOOL PC 26 C GenCOOL PC 26 High protection coolant approved by manufacturers GenCOOL PC 26 is a ready to use highly protective coolant which is produced from an antifreeze recommended by the majority of European manufacturers e Itis made from antifreeze and G 48 inhibitors e It protects up to 26 C e Itis free from nitrates amines and phosphates e Itis aclear fluorescent orange liquid REFERENCES APPROVALS for the antifreeze HEAVY GOODS VEHICLE Approved by MTU MERCEDES BENZ MAN KHD GENERAL MOTORS LIGHTER VEHICLES Approved by BMW VOLKSWAGEN MERCEDES PORSCHE Conforms with VOLVO OPEL SEAT and SKODA Conforms with VOLVO IVECO VAN HOOL and STAYR specifications TRUCK specifications Conforms with the NF R 15 601 standard REINFORCED ANTI CORROSION FEATURES Protects against high temperature corrosion by oxidisation of ethylene cylinder head protection Protects against high temperature cavitation top of cylinder and coolant pump protection Non corrosive for seals and hoses Improves the efficiency and longevity of the cooling system e GenCOOL PC 26 is especially recommended for engines fitted with aluminium or light alloy radiators HIGH TEMPERATURE SUITABILITY Provides good conditions for thermal exchange Perfect stability at high temperatures e GenCOOL PC 26 is specially adapted for engines with high power
112. Short circuit high or low side to ground Cylinder 6 circuit open Cylinder 6 circuit shorted 676 39 Cylinder 6 balancing error mechanical failure Cylinder 6 unknown error mechanical failure Glow plug relay status Glow plug relay voltage high Glow plug relay voltage low 677 39 Start relay status Start relay control short circuit to high Start relay control short circuit low Start relay control open circuit 678 41 8 Volt power supply ACM 8 Volt DC supply open short to B ACM 8 Volt DC supply open short to ground 269 276 N SPN CID SID PID PPID FMI Description Comment Volvo Perkins a c 9 679 42 Regulation sensor of the injection pressure control 728 342 Secondary speed sensor Secondary engine speed sensor data intermittent Secondary engine speed sensor loss of 11 signal 12 Loss of signal sensor failure Inlet air heater signal Preheat 729 70 detection 810 Vehicle speed Not possible with Genset application 3 Inlet air heater signal high 5 Inlet air heater signal low Calculated vehicle speed input noise 861 861 Diagnostic output status 3 Diagnostic output open short to B Diagnostic output short to ground
113. Stop delay cooling OR G10 Gradual Stop delay Coolant temperature OR COOLING DOWN 1 min 30 sec 24 08 2005 Overload Gradual Stop delay OR OFF load test delay Date and time depending on settings 46 276 Generating setstop EN Screen Screen Data displayed no G11 OFF Generating set stop in progress IN PROGRESS 24 08 2005 Date and time depending on settings Operating mode changeover switching from Manual Mode to Auto Mode following auto start demand Screen Screen Data displayed no Start Demand AUTO Do you wish to change T to Auto Mode Operating mode operation in Manual Mode WARNING Immediate start OK Esc AUTOMATIC start demand Generating set stop request due to fault or by pressing STOP in Auto Mode cd Screen Data displayed Manual Mode activated Operating mode operation in Auto Mode Do you wish to change generating set in operation G13 Warning message for switching to Manual Mode to AUTO mode OK Esc after the STOP button has been pressed or a fault has appeared 47 276 EN 6 2 2 Starting A Check that the generating set circuit breaker has triggered Danger Connect the generating set battery Turn the key switch to the ON position without forcing it to the ON position the ON lamp will light up if the lamp does not light up check and replace the fuse if n
114. T 16 276 N AIPR 1 LOC 400 630A TT EDF ALTERNATOR MAX CONNECTION CABLE CROSS SECTION 185MM M10 BOLT M10 NUT 17 276 2 2 Technical specifications EN Range Generating set type RENTAL POWER R350C2 Weights and Dimensions Dimensions with standard tank Dimensions x w xh 4475mm x 1410mm x 2690mm Weight 3830kg dry weight 4300kg in operating configuration Hood M228C Noise level 67dB 7m 97 Lwa Dimensions x w xh 4527mm x 1410mm x 2780mm Weight 4520kg dry weight 5888kg in operating configuration Hood M228C DW Noise level 67dB 7m 97 Lwa Output Voltage Hz Phase Load factor Max current A Emergency Prime Prime power a kW kVA Emergency power kW kVA 400 230 50 3 0 8 505 455 280 350 252 315 1 ESP Stand by output available for emergency use under variable charge up to 200hrs per year as per ISO 8528 1 no overload available under these service conditions 2 PRP Main output available continuously under variable load for an unlimited time period per year as per ISO 8528 1 an overload of 10 one hour every 12 hours is available as per ISO3046 1 Engine data Manufacturer model VOLVO TAD941GE Type 4 cycle Turbo Air Air Cylinder confi
115. This corresponds of course to the upper generating set limit i e 570 kW 95 of 600 kW Automatic operation All Kerys PLCs in AUTO mode coupling when stopped Loss of grid voltage e Grid loss acquisition delay controlled by the mains detection module Generating set power units switched off Generating set start request The generating sets increase in speed Speed stabilisation delay Order of excitation for each generating set at nominal speed the voltage is then quickly established on the busbar Start of active power distribution Resumption of application at rated voltage and frequency 77 276 EN Wattmetric control This wattmetric control will be activated after a global operation delay This global operation enables the application to be resumed after power is restored to the different outputs and ensures stability of the load before the wattmetric control is started Depending on the power for the application the number of generating sets in production may vary in order to optimise the production to consumption The procedure is as follows e End of the global operation delay e Start of analysis of the active power consumed Y Example A generating set must be stopped according to the set thresholds e Power cut at the non priority generating set transfer of the power to the generating set s remaining in production e Uncoupling of the non priority generating set at zero power by switching on the generating set p
116. User and maintenance manual for generating sets IIIIIIIIII R350C2 33501782801NE_3 1 Bur Aide ee Be hited AA A ee iG Mee a bly Bie at ei nny Aided Ae a ele Meas 3 1 1 General recommendations 3 tede aes fas bet tie P Hcet loce hee ur Dre eren 3 1 2 Pictograms and their meanings eene nennen nnne 4 1 3 Instructions and safety regulations s i sees iiiar iirinn eene trennen rA EREN E Eea ESEK EE E E E enne nennen trennen ene 8 E3 il Generalkadvice E as S E E E aiia essere 8 1 3 2 Risks related to exhaust gases and fuels 0 eeceescseseeseceseeecsecseesecsevsccsaeccsaecasesecsevsccnaeecesaecatesecseesecnaeeeesaecatuaecseeseenassneegs 9 1 3 3 Risks related to toxic Products 4 isa cede deseada ee reped tapete PEE cet rte bred 9 1 3 4 Risk of fire burns and explosion ipd eee Doe ct dell 10 1 3 5 Risks related to electrical networks a nere d tec eec Rie Iter trees ror ge 10 1 3 6 Dangers presented by electric currents first aid eene nnne 11 1 3 7 Risks related to moving the set neo eR t eo t a de i eite ar ete ciet ar rite o 11 1 4 Identifying ar cit hae citra uet creta aO d teen e DIEA E ree Be ee dette 12 2 General description wa unn a tecto em et ae eU aA o adem ite a d ie Been ete va m erc 14 2 1 DeSCEptlO
117. Y Particularly suited to more modern engines with or without turbochargers intercoolers or sophisticated injection systems e g HEUI injector pumps Y All types of use can cope with the most demanding applications Y Depolluted engines complies with EURO 2 and EURO 3 technology and can be used with all types of diesel fuel especially ecological diesel with low sulphur content PERFORMANCE ACEA API CH 4 Y Meets level of the specifications defined by European manufacturers in the ACEA standards 98 edition ADVANTAGES Y Less frequent oil services this product has been put to the test during thousands of hours of use on worksites under varying conditions demonstrating its high quality Y Conformity with new environmental legislation adherence to new anti pollution standards required for new EURO 2 and EURO 3 engines SPECIFICATIONS SAE Grade 15W 40 Density at 15 C 0 883 Cinematic viscosity at 40 C 105 mm2 s cSt E Cinematic viscosity at 100 C 14 1 mmo 2 s cSt Viscosity index 140 3 Dynamic viscosity at 15 C 3000 mPa s cP Pour point 30 C n i Flash point 220 C 2599 Sulphated ash content 1 4 weight lt Values given as examples only 0 20 276 N 2 3 1 2 Specifications of coolants Engine Coolants Make Type Make Type John Deere All GenPARTS GENCOOL PC 26 C Mitsubishi LLC MITSUBI
118. accordance with the schedule AN WARNING Working with or going close to a run XH ae E ning engine is a safety risk Watch out for rotat ing components and hot surfaces Extra stop The extra stop AUX STOP is on the left of the en gine above the control module Please refer to Main tenance Component location WARNING Working with or going close to a run ning engine is a safety risk Watch out for rotat ing components and hot surfaces 24 150 276 Maintenance schedule General Your Volvo Penta engine and its equipment are designed for high reliability and long life It is built so as to have min imal environmental impact If given preventive maintenance according to the maintenance schedule and if Volvo Penta original spares are used these properties are retained and unnecessary malfunctions can be avoided MAINTENANCE SCHEDULE WARNING Before you start to do any maintenance work read the Maintenance chapter carefully This contains instructions for doing work in a safe and correct man ner IMPORTANT When both operation and calendar time are specified do the mainte nance job at the interval which is reached first Maintenance points marked must be done by an authorized Volvo Penta workshop Daily before first start Engine and engine bay general inspection page 27 e Air filter indicator inspection ens
119. age frequency and phase difference to this busbar see sketch Busbar U Example for 3 GSs e 0171 Circuit breaker 1 is closed the voltage is present on the busbar e Kerys 2 analyses the differences between U2 and U of the busbar before coupling e Kerys analyses the differences between and U of the busbar before coupling Each Kerys independently of its neighbour will close its discharge on the central busbar 76 276 EN Wattmetric control The wattmetric control is used when two generating sets are coupled It provides optimum management of the number of generating sets operating by constantly analysing the power required by the user Let us take the example of a power plant of 4 x 600 kW generating sets The threshold setting screen 1 7 3 3 supplies the following data Threshold 1 GS gt 2 GS 75 450 kW Threshold 2 GS gt 1 GS 30 360 kW Threshold 2 GS gt 3 GS 75 900 kW Threshold 3 GS gt 2 GS 30 540 kW Threshold 3 GS gt 4 GS 75 1350 kW Threshold 4 GS gt 3 GS 30 720 kW The maximum available power is 600 x 4 2400 kW Assuming that a single generating set is operating we will have the following sequence in the case of linear progression of the load When the power required by the application reaches 75 of the power of the generating set in operation GS at priority 01 i e 450 kW the second GS at priority 02 is started and is synchronised with GS 1
120. and the injection advance are fully electronical ly controlled via fuel valves and the unit injectors This means that the engine always receives the cor rect volume of fuel in all operating conditions which offers lower fuel consumption minimal exhaust emis sions etc Diagnostic function The task of the diagnostic function is to discover and localize any malfunctions in the EMS 2 system to protect the engine and to ensure operation in the event of serious malfunction If a malfunction is discovered this is announced by warning lamps a flashing diagnostic lamp or in plain language on the instrument panel depending on the equipment used If a fault code is obtained as a flash ing code or in plain language this is used for guidance in any fault tracing Fault codes can also be read by Volvo s VODIA tool at authorized Volvo Penta work shops If there is a serious malfunction the engine will be shut down altogether or the control unit will reduce the power delivered depending on application Once again a fault code is set for guidance in any fault tracing 136 276 Instrument EMS 2 NOTE All instruments are accessories VOLVO PENTA A 0200020020 Jj 137 276 Introduction CIU Control Interface Unit The CIU is the translator between the EMS 2 control unit and the customer s own control panel The CIU has two serial communication links a fast one and a slow one The fast one is a
121. ark appr 1 cm above the edge of the plates yes Wait 5 to 20 mins Voltage check v 12 5 V Charge for 10 minutes Fit on the generating 8 3 Check Acid density Charge status Voltage when idle 1 27 100 Above 12 60 V 1 25 80 12 54 V 1 20 60 12 36 V From 50 96 recharge 1 19 4096 12 18 V Risk of sulphation 1 13 20 Under 11 88 V Unusable 120 276 N 8 4 Load preconization Y Highly discharged or sulphated batteries formation of whitish lead sulphate deposit on the plates which becomes hard and insoluble to acid this deposit reduce the active surface of the plates and increases their internal resistance can no longer regenerate or be charged in a generating set A discharged battery should be recharged immediately or else it will suffer irreparable damage Important Battery charge cn When several batteries are connected together the following points should be checked Are the batteries connected in series Has the correct voltage been chosen 1 battery x 12 V 3 x 36V batteries Adjust the charge current to the lowest battery The power difference between the batteries must be as low as possible 4444 Example of charge 12V 60 Ah battery charging current 6 A Charge status 50 acid density 1 21 voltage when idle 12 30V The battery is short 30 Ah and this must be recharge
122. at no leakage of oil fuel or coolant occurs Check the air filter pressure drop indicator Please refer to the Maintenance Engine general chap ter Check the coolant level and that the radiator is not blocked externally Please refer to the Mainte nance cooling system chapter AN WARNING Do not open the filler cap 1 when the engine is hot Steam or hot fluid could spray out NOTE Only open filler cap 1 Do not open filler cap 2 Turn the main switch es on IMPORTANT Never disconnect the current with the main switch es when the engine is running This can damage the alternator Move the engine speed control to idle and release the opening clutch gearbox if installed Starting the engine Starting method EMS 2 The pre heating time is adjusted to suit the engine temperature and can last for up to 50 seconds both before and after starting The starter motor connection time is maximized to 30 seconds After that the starter motor circuit is cut for 80 seconds to protect the starter motor against over heating NOTE Preheating must be activated at temperattures below 0 FE M E b H n2 Salo ap rede n znr peas Li aznorIkn With pre heating 1 Depress the ON OFF button 6 2 Press the SEL button 7 to come to the main menu 3 Scroll down to Preheat with button 9 Press the SEL button 7 4 Inthe pre h
123. ately low 97 97 Water in fuel sensor Water in fuel continuously detected Water in fuel input voltage high Short to V Water in fuel input voltage low Short to V Water in fuel detected Water in fuel detected 98 98 Oil level sensor Oil level value below normal Oil level sensor input voltage high Short to V Oil level sensor input voltage low Short to V Oil level sensor open circuit 261 276 N SPN CID SID PID PPID FMI John Deere Volvo Perkins Description Comment 100 100 100 Engine oil pressure extremely low Oil pressure sensor input voltage high Short to V Oil pressure sensor input voltage low Short to V Oil pressure sensor open circuit Engine oil pressure low 18 Engine oil pressure moderately low 31 Oil pressure detected motor stopped 102 273 102 Manifold air pressure sensor Manifold air pressure above normal Manifold air pressure below normal Incoherent measurement of the oil pressure Manifold air pressure sensor input voltage high Short to V Manifold air pressure sensor input voltage low Short to V Manifold air pressure moderately low Manifold air pressure low 103 Turbo speed sensor Turbo speed too high Turbo speed sensor circuit ope
124. ation OK HELP For JOHN DEERE JD PERKINS PE and VOLVO VO engines the codes displayed are SPN and FMI codes 6 2 4 5 Horn reset Depending on the settings made menu 363 HORN the activation of an alarm and or a fault leads to the horn sounding and the following screen appearing HORN STOP PRESS OK This screen will display first any messages relating to the alarms and faults that appear as soon as OK is pressed 25 12 2005 15 30 53 276 EN 6 3 Generator set with KERYS control panel 6 3 1 Presentation of the KERYS The MICS Kerys system consists of a set of electronic modules in which each module performs a specific function These modules are interconnected according to a very precise architecture and exchange data to allow the following the command control regulation and protection of one or more generating sets according to multiple configurations The configurations range from the so called solo generating set with or without source inverter to generating sets coupled to each other enabling electrical power plants to be created that can be coupled to one or more distribution grids in low voltage LV and medium voltage MV The MICS Kerys system consists of the following modules e man machine interface module also called MMI module base module heart of the system regulation module protection module logic input output module analogue input output module temperature input module
125. be regularly updated Y Read and understand the manuals provided with the generating set pump unit or lighting column properly The manufacturer s instructions must remain at the disposal of technicians if possible in situ Y The facility must be operated under the direct or indirect supervision of a person appointed by the operator who is familiar with the operation of the facility and the dangers and drawbacks of the products used or stored in the facility Y Do not wear loose clothing or get close to machines in operation Note that the fans are not clearly visible when the engine is running Y Warn personnel present to keep their distance during operation Y notrun the generating set pump unit or lighting column without refitting the protective covers and closing all the access doors Y Never let a child touch the generating set pump unit or lighting column even when shut down Y Avoid operating the generating set pump unit or lighting tower in the presence of animals disturbance scares etc Y Engage the parking brake when the generating set or lighting tower on its trailer is installed on the operating site When chocking the trailer on a slope ensure that there is nobody in the path of the trailer Y Never start the engine without an air filter or exhaust Y Engine with turbocharger never start the engine without fitting the air filter The compressor wheel rotating inside the turbocharger may cause serious bodily injur
126. borg Ruotsi Fax 46 31 545 772 Tilauksen voi tehda my s Internetissa http www volvopenta com manual coupon Envie o tal o pelo correio ou um fax para Document amp Distribution Center Order Department ARU2 Dept 64620 SE 405 08 G teborg Su cia Fax 446 31 545 772 A encomenda tamb m pode ser feita atrav s da Internet http www volvopenta com manual coupon Ja graag Ik wil kosteloos een instructieboek in het Nederlands ontvangen Publicatienummer 7745266 e e o 9 Adres o 17 wo e e i e e N Land Ei Denk eraan dat de aanbieding geldt tot 12 maanden na levering van de motor daarna nog slechts indien beschikbaar VOLWVO PENTA nuc mg un MENSCHEN EP NEC c i E E 5 Kyll kiitos haluan suomenkielisen ohjekirjan veloituksetta Julkaisunumero 7745264 a Nimi 2 o o g Osoite D 8 T D 9 Maa Ota huomioon ett tarjous on voimassa 1 vuoden ajan moottorin luovutusp iv m r st sen j lkeen vain VOLVO tuotteen saatavuuden perusteella
127. c or intermittent data includes all measurements that change at a rate that is not considered possible in the real world condition and must be caused by improper operation of the measuring device or its connection to the module Broadcast of data value is substituted with the error indicator value Incorrect data includes any data not received and any data that is exclusive of the situations covered by FMls 3 4 5 and 6 Data may also be considered incorrect if it is inconsistent with other information collected or known about the system FMIZ3 VOLTAGE ABOVE NORMAL OR SHORTED TO HIGH SOURCE a A voltage signal data or otherwise is above the predefined limits that bound the range Region e of the signal range definition Broadcast of data value is substituted with the error indicator value b Any signal external to an electronic control module whose voltage remains at a high level when the ECM commands it to low Broadcast of data value is substituted with the error indicator value FMIZ4 VOLTAGE BELOW NORMAL OR SHORTED TO LOW SOURCE a A voltage signal data or otherwise is below the predefined limits that bound the range Region e of the signal range definition Broadcast of data value is substituted with the error indicator value b Any signal external to an electronic control module whose voltage remains at a low level when the ECM commands it to high Broadcast of data value is substituted with the error indi
128. can be started but not stopped Remedy e Check that the starter switch connections are not damaged e Check that the ignition switch cable is not damaged Code 5 4 PID 45 SPN 626 Preheating relay Cause Short circuit to positive or earth ground e Open circuit Reaction Preheating can not be activated Preheating is constantly connected Remedy e Check that the relay input cable is not damaged e Check relay function Code 5 7 PID SPN 98 Oil level Cause e Oil level is too low Reaction Warning indication Remedy e Check the oil level 55 Code 5 8 PID SPN 175 Oil temperature Cause Oil temperature is too high Reaction e Warning indication The engine control module limits engine output unless protection has been turned off with the diagnosis tool VODIA Remedy e Check the oil level e Check the oil temperature e Check the oil temperature sensor function Code 5 9 PID SPN 98 Oil level sensor Cause e Shorted to plus or minus Break Reaction None Remedy e Check that the cable harness to the oil level sen sor has not been damaged e Check the oil level sensor function Code 6 1 PID SPN 110 Coolant temperature Cause e Coolant temperature is too high Reaction Engine control module reduces engine power un less the protection has been shut off with the VODIA diagnostic tool Remedy e Check the coolant level e
129. cator value FMIZ5 CURRENT BELOW NORMAL OR OPEN CIRCUIT a A current signal data or otherwise is below the predefined limits that bound the range Region e of the signal range definition Broadcast of data value is substituted with the error indicator value b Any signal external to an electronic control module whose current remains off when the ECM commands it on Broadcast of data value is substituted with the error indicator value FMIZ6 CURRENT ABOVE NORMAL OR GROUNDED CIRCUIT a A current signal data or otherwise is above the predefined limits that bound the range Region e of the signal range definition Broadcast of data value is substituted with the error indicator value b Any signal external to an electronic control module whose current remains on when the ECM commands it off Broadcast of data value is substituted with the error indicator value FMI 7 MECHANICAL SYSTEM NOT RESPONDING OR OUT OF ADJUSTMENT Any fault that is detected as the result of an improper mechanical adjustment or an improper response or action of a mechanical system that with a reasonable confidence level is not caused by an electronic or electrical system failure This type of fault may or may be directly associated with the value of general broadcast information FMIZ8 ABNORMAL FREQUENCY OR PULSE WIDTH OR PERIOD To be considered in cases of FMI 4 and 5 Any frequency or PWM signal that is outside the predefined limits which bound the
130. ches have been correctly configured with AREP SHUNT or PMG excitation a Initial potentiometer settings see table below Action Factory setting Pot ie 400 V 50 Hz S a e Stability Notset EP29 centre position F Excitation ceiling 10A Factory sealed maximum Voltage minimum fully anti clockwise Voltage quadrature droop operation with C T 0 quadrature droop fully anti clockwise Not set 7 mY fully e anti clockwise Stability adjustments in standalone operation b Install a D C analogue voltmeter needle dial cal 100 V on terminals F F and an A C voltmeter cal 300 500 or 1000 V on the alternator output terminals c Check the rotating switch selection d Voltage potentiometer P1 at minimum fully anti clockwise e Stability potentiometer P2 around 1 3 in from the anti clockwise stop f Start the engine and set its speed to a frequency of 48 Hz for 50 Hz or 58 for 60 Hz g Set the output voltage to the desired value using P1 Rated voltage Uy for solo operation eg 400 V Or Un 2 to 4 for parallel operation with C T eg 410 V If the voltage oscillates use P2 to make adjustments try both directions observing the voltage between F and F approx 10 V D C The best response time is obtained at the limit of the instability If no stable position can be obtained try selecting the fast positio
131. city before handling the batteries by first touching an earthed metal surface Do not use the battery when the fluid level is below the minimum required level Using a battery with a low electrolyte level could result in an explosion Do not short the battery terminals with a tool or other metal object When disconnecting battery cables remove the cable from the negative terminal first When reconnecting the battery connect the positive lead first Charge the battery in a well ventilated place with all the filler caps opened Ensure that the battery terminals are correctly tightened A loose cable clamp can cause sparks that could result in an explosion Before servicing electrical components or performing electric welding set the battery switch to the OFF position or disconnect the battery negative cable to cut off the electrical current Electrolyte contains dilute sulphuric acid Careless handling of the battery causing contact with sulphuric acid could damage your eyesight or cause burns Wear safety goggles and rubber gloves when working with the battery topping up fluid charging etc If electrolyte comes into contact with your skin or clothes wash it off immediately with plenty of water then carefully wash the area with soap Danger If electrolyte comes into contact with your eyes rinse immediately with plenty of water and seek medical attention as soon as possible If electrolyte is accidentally swallowed gargle with plenty o
132. ck that the connections are fully tightened DC 12V 1 Stop the unit disconnect and isolate the AVR wires 2 There are two ways of creating an assembly with separate excitation 13 215 276 LEROY SOMER Installation and maintenance 3856 2011 01 h LSA 46 2 4 POLES ALTERNATORS 4 6 Dismantling reassembly see sections 5 4 1 amp 5 4 2 WARNING During the warranty period this operation should only be carried out in an LEROY SOMER approved workshop or in our factory otherwise the warranty may be invalidated Whilst being handled the machine should remain horizontal rotor not locked in position Check how much the machine weighs see 4 8 3 before choosing the lifting method 4 6 1 Tools required To fully dismantle the machine we recommend using the tools listed below 1 ratchet spanner extension 1 torque wrench 1 set of flat spanners 8 mm 10 mm 18 mm 1socket set 8 10 13 16 18 21 24 30mm 1 socket with male ferrule 5 mm 1 puller 4 6 2 Screw tightening torque See section 5 4 4 6 3 Access to diodes Open the air intake grille 51 Disconnect the diodes Check the 6 diodes change the diode bridges if necessary 4 6 4 Access to connections and the regulation system Access directly by removing the top of the cover
133. crew Torque Ye Screw Torque Ref Qty Description Nm Ref Qty Description N m 1 1 Stator assembly 90 1 Exciter field 4 1 Rotor assembly 91 4 Fixing screws M6 10 15 1 Fan 100 1 Exciter armature 21 1 Lifting ring 120 1 Terminal plate support 22 1 Shaft extension key 122 1 Plate support 28 1 Earth terminal M10 20 124 1 Terminal plate M12 35 30 1 _ Drive end shield 177 2 AVR support bracket 31 6 or 4 Fixing screws M14 80 198 1 ARE regulator d 33 1 Protective grille 284 1 Circlips 34 2 Fixing screws M6 5 320 1 Coupling sleeve 36 1 _ Exciter end shield 321 1 Sleeve key 37 4 Fixing screws M12 50 322 3 Coupling disc 41 1 Cover front panel 323 6 Fixing screw M16 230 48 1 Cover top panel 325 Spacer shim Diode bridge 49 Cover screws M6 5 343 1 assembly M6 4 51 1 Airintake grille T 47 1 Hec Vatistor 53 1 Plug 349 1 O ring 60 1 Drive end bearing 364 1 AVR support 62 3 or 4 Fixing screws M8 20 365 1 Cover rear panel 68 1 Inner bearing retainer 367 2 Side panel 70 1 Non drive end bearing 371 4 Damper 71 1 Cover 416 1 Filter 72 2 Fixing screws M8 20 417 1 Filter support 78 1 Inner bearing retainer 466 2 AVR inspection door Preloading wavy 79 1 washer E 80 N m in M 190 N m inL VL LEROY Sato 21 2
134. cted in accordance with the following drawing Move the strap as the rotor moves in order to distribute the weight over it WARNING When dismantling the rotor involves changing parts or rewinding the rotor must be rebalanced 4 6 8 Reassembling the machine Mount the rotor 4 in the stator 1 see drawing above taking care not to knock the windings LEROY 15 217 276 LEROY SOMER Installation and maintenance 3856 en 2011 01 h LSA 46 2 4 POLES ALTERNATORS If using a single bearing or double bearing To replace follow the instructions in reverse machine with the regreasable bearing order option Mount the new preloading wavy washer 79 the new O ring seal 349 in the shield 36 Screw a threaded rod into the thrust bearing 78 Refit the shield 36 on the machine using a dowel and nut in the shaft extension see diagram Slide the threaded rod into the shield hole to make it easier to assemble see diagram Fit the thrust bearing screws 78 remove the threaded rod fit the other screw and tighten up the assembly Tighten the 4 bearing screws 37 Reconnect exciter wires E E Finish reassembling the cover Refit the flange 30 on the stator 1 Tighten the screws 31 If using a double bearing machine Mount the new preloading wavy washer 79 the new O ring seal 349 in the Installation and ma
135. ctions and expensive repairs AN WARNING Deposits of fuel oils and grease on the engine or in the engine bay are a fire hazard and must be removed as soon as they are dis covered AN IMPORTANT If you discover a leakage of oil fuel or coolant investigate the cause and fix the fault before you start the engine AN IMPORTANT Remember the following when washing with a high pressure washer Never aim the water jet at radiators intercoolers seals rub ber hoses or electrical components Charge air pipe leakage check Inspect the condition of the charge air hoses hose unions and clamp condition for cracks and other dam age Change as necessary IMPORTANT Torque the clamps to 9 2 Nm 6 5 51 4 Ibf ft 27 Maintenance 28 Drive belt Alternator belt inspection Inspection should be done after operation when the belts are hot It should be possible to press the alternator belts and drive belts down about 3 4 mm 0 12 0 16 between the pulleys The alternator belts and drive belts have automatic belt tensioners and do not need to be adjusted Check the condition of the drive belts Change as necessary please refer to Alternator belt change and Drive belt change Alternator belts changing IMPORTANT Always change a drive belt which appears worn or cracked 1 Disconnect the main switch es and check that the engine is not connected to system voltage 2 Remove the protective gra
136. ctors required Injector outside the specifications Recalibration of the injectors required Short circuit high side to B Short circuit high side to low side or low side to B Short circuit high or low side to ground Cylinder 4 circuit open Cylinder 4 circuit shorted Cylinder 4 balancing error mechanical failure Cylinder 4 unknown error mechanical failure 268 276 N SPN CID SID PID PPID FMI John Deere Volvo Perkins Description Comment 655 655 Cylinder 5 injector status Injector outside the specifications Recalibration of the injectors required Injector outside the specifications Recalibration of the injectors required Short circuit high side to B Short circuit high side to low side or low side to B Short circuit high or low side to ground Cylinder 5 circuit open N N 656 656 Cylinder 5 circuit shorted Cylinder 5 balancing error mechanical failure Cylinder 5 unknown error mechanical failure Cylinder 6 injector status Injector outside the specifications Recalibration of the injectors required Injector outside the specifications Recalibration of the injectors required Short circuit high side to B Short circuit high side to low side or low side to B
137. d Charge factor 1 2 Ah x 1 2 36 Ah to be charged Charging current 6A approximately 6 hours charging required SSA 5 Recharging is complete when the battery voltage and the acid density stop increasing The charging current must always be 1 10 of the nominal capacity of the battery The power of the charger must be suitable for the battery to be charged and the charging time available You need to use an automatic charger able to provide a sufficient voltage and charging current as well as a compensation voltage to handle spontaneous battery discharge 121 276 8 5 Faults and remedies EN Fault observed Probable origin Measures or observations The acid heats up when a new battery is filled Incorrect composition Incorrect storage Prolonged storage in a damp place Cool Charge Check the acid density The acid escapes through the filler holes Battery overflow during filling Reduce the battery fluid level Acid level too low Battery tray not leaktight Significant gas formation caused by too high a charging voltage Replace the battery Check the charger and repair if necessary Acid level too low Incorrect operation from start up Insufficient charge Short circuit in the current circuit Consumption fault Recharge Check the electrical installation Acid density too high The battery has been filled with acid instead of water Red
138. d check cylinder 6 185 276 Fault codes Code 7 7 PID SPN 153 Crankcase ventilation pressure NOTE Only TAD950 952VE Cause e Crankcase ventilation pressure too high Reaction The engine is shut down if the protection has not been shut off by the parameter tool Remedy e Check whether the crankcase ventilation is bloc ked e Check whether cylinder liner piston or piston rings are worn or damaged Code 7 8 PID SPN 153 Crankcase ventilation pressure sensor Cause e Shorted to plus or minus Break Reaction None Remedy e Check that the crankcase ventilation pressure sensor contact is correctly installed Check that the cable harness to the crankcase ventilation pressure sensor has not been dam aged Check crankcase ventilation pressure sensor function Code 9 2 SID250 SPN 608 Faulty data link J1587 Cause Faulty data link Reaction None Remedy e Check that the 8 pin connector is not damaged e Check that the cables between the CIU DCU and the engine management unit are not damaged 59 Fault codes Code 9 3 SID 232 SPN 620 Power supply to sensor Cause e Shortcut Faultin sensor Reaction Faulty values in oil pressure and charge air pres sure sensors Fault code for oil pressure and charge air pres sure sensor Low engine output instrument shows zero oil pressure and boost pressure Remedy e
139. d off by disconnecting the A V R power supply 1 wire or 110V Contact rating 16A 250V AC Do notreclose the power supply until the voltage has reached a value lt 15 of the rated voltage approximately 5 seconds after opening 3 2 2 2 R250 field forcing 400V 10A K Diode iol t an es B M Excitation Inducer The battery must be isolated from the mass Exciter field may be at line potential LEROY SOMER 234 276 LEROY SOMER Installation and maintenance 4067 en 2009 05 b R250 A V R 3 3 Electrical faults Effect Check cause No voltage at no load on start up Connect a new battery of 4 to 12 volts to terminals E and E respecting the polarity for 2 to 3 seconds The alternator starts up and its voltage is still correct when the battery is removed Lack of residual magnetism The alternator starts up but its voltage does not reach the rated value when the battery is removed Check the connection of the voltage reference to the A V R Faulty diodes Induced short circuit The alternator starts up but its voltage disappears when the battery is removed Faulty A V R Exciter field short circuited Short circuit in the main field Check the resistance Voltage too low Check the drive speed Correct speed Check the A V R connections A V R may be faulty Field w
140. de with the SEL button Diagnostics shows the error list containing the 10 latest active and inactive faults The fault code are shown as text on the display Scroll through the error list with the arrow keys Trip reset resets trip data such as fuel consumption e Press the SEL button to reset trip data 140 276 Introduction Setup Setu p Set Application Versatile i parameter setting in the engine s control systems Dif Units Metric Language English ferent menus appear under Customer parameter de pending on whether you select Versatile or Genset from Set application The parameters that can be set selected choice is made with the SEL button are Set application setting of Versatile or Genset Different menus appear under Customer param eter depending on what is chosen here Unit selection of units of measurement metric or US units Language selection of the language shown in the display You can choose between English French German and Spanish Stop energized to setting for the external stop input Activated at Stop or Run Stop The stop input must be connected to voltage to stop the engine Run The stop input must be connected to volt age to run the engine Customer parameter alarm limit setting Please refer to Customer parameter Versatile and Customer parameter Genset Throttle input setting se
141. e depending on settings 24 08 2005 13 12 WARNING Operating mode generating set in Auto Mode with AUTOMATIC Start programmed start G5 19 min 30 sec Countdown to micro disconnection delay or EJP notice delay for France only Date and time depending on settings 24 08 2005 Generating set start up m Screen Data displayed G6 START UP Operating phase generating set in starting phase IN PROGRESS Date and time depending on settings 24 08 2005 45 276 EN a Screen Data displayed AIR PREHEATING Operating phase air preheating prior to starting generating set 10 seconds 24 08 2005 Countdown for air preheating delay Date and time depending on settings Generating set started Screen Screen Data displayed no AVAILABLE POWER Operating phase generating set in operation acus 75 stable voltage and frequency ise Available power Screg Date and time depending on settings 24 08 2005 AUTOMATIC STOP Operating mode operation in Auto Mode IN PROGRESS Opening of power supply device motorised circuit breaker or source changeover switch controlled by G9 TELYS LOAD SUPPRESSION Countdown for the mains return delay OR the load 1 min 30 sec test delay Date and time depending on settings 24 08 2005 13 12 AUTOMATIC STOP Operating mode operation in Auto Mode IN PROGRESS Generation set cooling in progress Countdown for Engine
142. e nameplate 3 3 1 Terminal connection 12 wire The connection accessories are detailed in section 5 3 3 Any intervention on the alternator terminals during reconnection or checks should be performed with the machine stopped Connection codes Voltage L L Factory connection L1 U Winding 50 Hz 60 Hz Ti T7 T 3 3 phase 6 190 208 190 240 gw 5 L3 W 7 220 5 it s o a L2 V eg sg o 8 190 208 E UG I o T4 17 L1 U R 250 voltage detection K j amp 0 gt 8 110 V gt 11 C R 450 voltage detection Us I 0 gt T3 220 V gt T2 NDE Winding 50 Hz 60 Hz T3 6 380 415 380 480 I12 p qQG o L3 W 7 440 9 2 11 L2 V 8 380 416 AJ o R 250 voltage detection T10 74 7714 0 gt T8 110 V gt T11 e amp d lo ol R 450 voltage detection 0 gt 3 380 V gt 2 L3 W L2 V Ms 9 500 600 Winding 9 R 450 voltage detection transformer See specific diagram AREP or SHUNT In case of reconnection ensure that AVR voltage detection is correct The factory can supply a set of flexible shunts and special connection links as an option for making these connections S QE SOMER 209 276
143. e there will be no risk of malfunctions caused by operation at low load Reduce operation at low load to a minimum If the engine is regularly test run without load once a week operation duration should be limited to 5 minutes Run the engine at full load for about 4 hours once a year Carbon deposits in the engine and exhaust pipe can then be burned off 23 Stopping the engine During longer breaks in operation the engine must be warmed up at least once every fortnight This prevents cor rosion att acks in the engine If you expect the engine to be unused for two months or more it must be laid up Please refer to the chapter entitled Laying up IMPORTANT If there is a risk of frost the coolant in the cooling system must have sufficient frost protec tion Please refer to the Maintenance cooling system chapter A poorly charged battery can freeze and burst Before stopping Let the engine run for a few minutes without loading before stopping it This permits the temperature inside the engine to even up after boiling is avoided at the same time as the turbocharger cools somewhat This contributes to long service life without malfunctions Stop Disengage the clutch if possible e Press the STOP button turn the key to S After stopping e Check the engine and engine bay for leakage e Turn off the main switches before any long stop page e Carry out maintenance in
144. e connected directly from the battery terminals to the starter motor terminals The primary instruction to follow is to ensure that the polarities between the battery and starter motor match Never reverse the positive and negative battery terminals when connecting them This could cause severe damage to the electrical equipment The minimum cross section of the cables will be 70 It varies according to the power of the starter motor but also the distance between the batteries and the set voltage drops on the line d Safety guidelines References NFC 15 100 2002 France IEC 60364 5 54 In order to protect personnel against electric shocks this generating set is equipped with a differential residual current protector factory set to trigger instantly with a sensitivity of 30 mA must only be performed by qualified and authorised personnel Any modification to this setting could endanger personnel Any modification would render the user liable and When the generating set is disconnected from a facility after use the master differential protector must be returned to its factory settings and this must be checked by trained personnel Important For effective protection against electric shocks the generating set needs to be earthed To do this use a copper wire with a minimum cross section of 25 mm for a stripped cable and 16 mm for an insulated cable connected to the generating set earth socket and a galva
145. e e Emergency N E switch control e Emergency cutout e Normal N E switch control e Summary of faults and alarms Generating set operation Generating set available in Auto e X to be connected if available 9 Only of the two grid detections needs to be cabled if necessary 79 276 EN 6 3 5 3 Earthing system Standard only e The ground of the generating set must be connected to earth To do so use a copper cable Green Yellow 25 mm minimum for a bare cable and 16 mm for an insulated cable connected to the earth of the generating set and to a ground rod of galvanised steel pushed vertically into the ground For a fault voltage of 25 V and a fault current of 30 mA Nature of the ground Rod length in metres 1 Rich arable land moist compact hard core 1 Poor arable land 1 Poor arable land gravel coarse hard 1 To obtain an equivalent length several ground rods can be Stony bare soils dry used connected in parallel and separated by at least their impermeable rocks length Example Four 1 metre rods interconnected and separated by 1 metre respectively e Check the earthing connection before switching on the generating set e Check that the safety earthing system is working Single genset Earthing system IT Active isolation controller Isolated neutral Interconnection bar between
146. e generating set symbol flashes and then lights up permanently once the phase is complete e E f p 2 Tests If no faults are present automatic mode can be activated by pressing Auto o Lg 9 The test starting phase is then initiated after pressing 1 on the test keypad LA 9 A e 110 276 EN Pressing 1 on the test keypad brings up the following window for selecting the test type 15 07 09 19 10 00 Operation 326 456 640 Under load test Q kVAr vvv TR Power plant Function keys Synchronisation column measurements summar Using the KERYS Tactil Man Machine Interface the under Using the KERYS Tactil Man Machine Interface the off load load test is started by pressing the corresponding key test is started by pressing the corresponding key After validation of the test the orange LED on the test keypad lights up steady el During the start up phase and until the alternator voltage and generating set speed E J stabilise the green LED underneath the symbol for the generating set flashes and becomes steady at the end of this phase The installation is then controlled via the programmable controller in accordance with the configuration of the application gt normal emergency source switchover gt grid coupling gt etc The Norma
147. e generating set will stop OFF IN PROGRESS 24 08 2005 Switch TELYS off by turning the key to OFF without forcing it to the OFF position 6 2 4 Alarms and faults 6 2 4 1 Viewing alarms and faults Alarms and faults are displayed as follows Alarms All alarms will cause gt the yellow LED to flash General alarm In conjunction with this LED gt flashing pictogram appears on the LCD screen message on graphic display example representing the circuit affected by the alarm and the associated indicator if present FAULT example ALARM Low Fuel Level 25 12 05 15 30 OK HELP 49 276 Faults All faults will cause gt the generating set to stop immediate or gradual stop coolant temperature and overload or short circuit gt the red LED to flash General fault In conjunction with this LED gt flashing pictogram appears on the LCD screen message on graphic display example FAULT representing the circuit affected by the fault and the associated indicator if present example FAULT Oil Pressure gt 25 12 05 15 30 OK HELP Faults have priority over alarms Faults are displayed in the descending order of their appearance from the most recent to the oldest 6 2 4 2 Activation of an alarm or fault The appearance of an alarm or a fault causes the corresponding screen to be displayed examples below FAULT FAULT ALARM FAULT Low coolant Level
148. e sensing 200 to 500 V compatible with parallel operation in balanced installations R 734 module 3 phase current and voltage sensing for parallel operation on unbalanced installations unbalance gt 15 R 726 module regulation system changed to 4 function see the maintenance manual and connection diagram PF regulation 2F Equalization of voltages before paralleling 3 F Possibility of coupling to the mains of alternators already running in parallel 4F LEROY SOMER 13 251 276 LEROY SOMER Installation and maintenance 4531 en 2010 10 c R 450 AVRs 4 INSTALLATION COMMISSIONING 4 1 Electrical checks on the AVR Check that all connections have been made properly as shown in the attached wiring diagram Check the rotating switches selections frequency type of alternator normal position response time external potentiometer rated voltage secondary current of the CT used type of excitation R450 optional operating modes 4 2 Setting up The various adjustments during tests must be made by a qualified engineer It is essential that the drive speed specified on the nameplate is reached before commencing adjustment After operational testing replace all access panels or covers The AVR is used to make any adjustments to the machine 4 2 1 Setting up the R450 Before using the AVR make sure that the rotating swit
149. e trailer to that of the tow vehicle Hook the handbrake safety wire onto the hook on the tow vehicle CORRECT CORRECT Tow vehicle Tow vehicle Trailer Trailer INCORRECT INCORRECT Tow vehicle Diagram 4 1 Coupling a trailer Tow vehicle Trailer 4 2 Check before towing Before towing check the following lt lt 4 lt 44 lt lt 454 lt Tightness of the generating set enclosure bolts Wheel tightness Hitching hook locked Tyre pressure Signalling lights working for on road trailers Enclosure doors closed Parking brake released for on road trailers Guide wheels jockey wheels and stands lifted if fitted Towbar arm locking levers tightened and pinned if fitted with an adjustable towbar Brake test for on road trailers Safety cable fitted for on road trailers 29 276 N 4 3 Operation On site trailer These trailers are not fitted with a main brake and so cannot be braked in motion the tyres allow for a maximum speed of 27 km h So it is absolutely prohibited to exceed this speed Nor are these trailers fitted with signalling lights On road use is prohibited On road trailer The driving speed must be suited to the condition of the road and the handling of the trailer Driving at high speed causes heating of the tyres so it is important to stop from time to time and check them Excessive heating may cause a puncture and therefo
150. e type PVC 70 C e g HO7RNF Ambient temperature 30 C Circuit breaker Cable sizes calibre 0 50m 51 100m 101 150m A mmZ AWG mmZ AWG mm2 AWG 10 1 5 14 25 12 4 10 16 25 12 4 10 6 9 20 25 12 4110 6 9 25 4 10 6 9 10 7 32 6 9 6 9 10 7 40 10 7 10 7 16 5 50 10 7 10 7 16 5 63 16 5 16 5 25 3 80 25 3 25 3 35 2 100 35 2 35 2 4 1 50 0 125 1 4X 1X50 0 4X 1X50 0 4X 1X70 2 0 160 1 4X 1X70 2 0 4X 1X70 2 0 4X 1X95 4 0 250 1 4X 1X95 4 0 4X 1X150 2250MCM 4X 1X150 2350MCM 400 1 4X 1X185 0400MCM 4X 1X185 0400MCM 4X 1X185 0400MCM 630 1 4X 2X1X150 2x 2350MCM 4X 2X1X150 2x 2350MCM 4X 2X1X150 2x 2350MCM Single phase Calculation hypothesis Fitting method wiring in cable runs or non perforated trays Permissible voltage drop 5 Multiconductors Cable type PVC 70 C e g HO7RNF Ambient temperature 30 C He Cable sizes A 0 50m 51 100m 101 150m mm2 AWG mm2 AWG mm2 AWG 10 4 10 10 7 10 7 16 6 9 10 7 16 5 20 10 7 16 5 25 3 25 10 7 16 5 25 3 32 10 7 25 3 35 2 40 16 5 35 2 50 0 50 16 5 35 2 50 0 63 25 3 50 0 70 2 0 80 35 2 50 0 95 4 0 100 35 2 70 2 0 95 4 0 125 50 0 95 4 0 120 2250MCM 26 276 N Battery cables Install the battery or batteries in the immediate vicinity of the electric starter motor The cables will b
151. e voltage potentiometer Connections ORKO 1 1 T1 T2 T2 T2 73 T3 NI N J dT ST4 Voltage adjustment via remote potentiometer Coupling D PH 1 In Secondary 1A Neutral link Coupling D amp A PH 1 In Secondary 1A coupl D Neutral link Pay T10 Ej 12 wire 211 276 Anti condensation heater Thermistor PTC temperature 101 250W 220 V 103 SSP h1 130C blue wiro Ph2 150C black wire 192 104 Ph3 180 C red white wire ILEROY LEROY SOMER Installation and maintenance 3856 2011 01 h LSA 46 2 4 POLES ALTERNATORS 3 3 4 Connection checks Electrical installations must comply with the current legislation in force in the country of use Check that The residual circuit breaker conforms to legislation on protection of personnel in force in the country of use and has been correctly installed on the alternator power output as close as possible to the alternator In this case disconnect the wire of the interference suppression module linking the neutral Any protection devices in place have not been tripped If there is an external AVR the connections between the alternator and the cabinet are
152. eat menu press the SEL button 7 to select pre heating The text Preheat active please wait is shown in the display 5 Wait until the text has gone out and then press the START button 2 Without pre heating 1 Depress the ON OFF button 6 2 Press the START button 2 Leave the engine to idle for the first 10 seconds Then warm the engine up at low speed and under low load IMPORTANT Never race the engine when it is cold 19 145 276 Starting the engine 20 Volvo Penta starter switch standard pre heating setting 1 Turn the key to position I and check the warning lamps 2 Position Il Pre heating is activated pre heating is optional Wait until the pre heating indication lamp goes out Pre heating time depends on en gine temperature 3 Start the engine in position III Release the key back to position I immediately after the engine has started NOTE The engine has a built in starter interlock to prevent involuntary engagement of the starter motor when the engine is running To do a new start attempt the key must first be turned back to position Let the engine run at 500 700 rpm for the first 10 sec onds Then warm the engine up at low speed and un der low load AN IMPORTANT Never race the engine when it is cold Alternative pre heating set by the supplier 1 Turn the key to position I and check the indica tion lamps Pre heating is acti
153. ecessary Test the Alarm and Fault LEDs menu 15 TEST LAMPS 1 ACTIONS us 11 MANUAL AUTO 12 CONTROL LOAD 13 TEST GENERATING SET 14 PROGRAMS 15 TEST LAMPS GS OK Esc Press Esc several times to return to the following home menu OPERATION MANUAL Press START to start 24 08 2005 G Check the battery voltage Q Press START D AVAILABLE POWER AIR PREHEATING START UP 100 0 IN PROGRESS 10 seconds 24 08 2005 24 08 2005 24 08 2005 The following pictogram is displayed If the engine is equipped with Warning the number of successive air preheating system there is a and automatic starting attempts is oki delay adjustable before the limited to 3 engine starts preheating UM activation period The following pictogram will flash The following information is displayed f the motor is not fitted with an air preheating System or once the ete o Speed of rotation preheating delay has elapsed the engine starts up start of a cycle comprising 3 attempts to e Coolant temperature start up the engine 2 Oil pressure 2 Oil Temperature 48 276 N 6 2 3 Switching off Open the circuit breaker manually OR gt by selecting menu 12 CONTROL LOAD 7 The following display will disappear supply stopped gt r Press the STOP button The following screen is displayed and th
154. ed as shown in the drawing below once the machine has been fully installed WARNING The alternators must not be put into service until the machines in which they are to be incorporated have been declared compliant with Directives EC and plus any other directives that may be applicable Note LEROY SOMER reserves the right to modify the characteristics of its products at any time in order to incorporate the latest technological developments The informa tion contained in this document may therefore be changed without notice Copyright 2005 MOTEURS LEROY SOMER This document is the property of MOTEURS LEROY SOMER It may not be reproduced in any form without prior authorization All brands and models have been registered and patents applied for LEROY SOMER 204 276 LEROY SOMER Installation and maintenance 3856 en 2011 01 h LSA 46 2 4 POLES ALTERNATORS CONTENTS VeRECEIP Ti ue EID diui 1 1 Standards and safety measures sss entere nnne 1 2 Inspectiori 2 reor eene e pudo SER REN ORE Ira ela See RAS PORE bo eS oA ez eu 1 3 Identification ccc sce ie iet denne tete dene idee ie denne e er dereud IA SIOFage ciii m aan 1 5 Applications erre epigr Er E ee EE ERE 1 6 Contraindications to USS gia a nennen rne 2 TECHNICAL CHARACTERISTICS eese eee ee
155. ed fluids Caution high temperature risk of burns Periodic maintenance must be carried out Battery level must be checked Jet washing prohibited Earth Caution rotating or moving parts risk of getting caught in the machinery Lifting point must be used Caution corrosive product Fork pockets for lifting Retention tank level high O Important refer to the documentation accompanying the generating set Important emission of toxic exhaust gases Do not use in a confined or badly ventilated area Figure 1 1 Pictograms and their meanings 4 276 Thisis a safety dert symbol When you see this symbol on your genset be alert to the potential for personal injury Follow recommanded Precautions and safe operating practices Important Read the operator s manua supplied with the gense before operation or servicing ELECTRIC SHOCK HAZARD Do not touch internal wiring of connections while the genset is operating Disconnect power before servicing e USE DIESEL FUEL ONLY Handle fuel with care itis highly flammable Do not refuel the genset while smoking or when near open flame or sparks Always stop the engine before refueling the genset Fill fuel tank outdoors Prevent fires by keeping genset clean of accumulated trash and grease Always clean up spilled fuel Engine exhaust can cause sickness or death Use only in open well ventilated a
156. el system 48 11 12 13 14 15 16 17 18 19 Water contamination in fuel Faulty unit injector Insufficient air supply to engine blocked air filter air leakage between turbo and engine inlet manifold fouled compressor section in turbocharger compressor faulty turbocharger compressor poor engine bay ventilation Excessive coolant temperature Too low coolant temperature Too low oil level Coolant level too low Air in the coolant system Faulty circulation pump 174 276 20 21 22 23 24 25 26 Defective thermostat Blocked intercooler Too high oil level Alternator drive belt slips Water entry into engine High back pressure in exhaust sys tem Break in Pot cable to pedal Diagnostic function The diagnostic function monitors and checks that the EMS 2 system functions normally The diagnostic function has the following tasks e Discover and localize malfunctions e Notify that malfunctions have been discovered e Give advice in fault finding Fault code If the diagnostic function discovers a malfunction in the EMS 2 system this is reported by means of fault codes fault cause on the instruments Both inactive rectified and active un mended faults are stored in the control unit Please refer to the Operation heading for reading fault codes All fault codes are found in the fault code list with in formation about the reason reaction and measure
157. en 2010 10 c R 450 AVRs When the excitation current is set to the rated value a voltage dip is observed in excitation current limit when the limitation is activated and the current limit is reached 4 2 3 Special type of use The excitation circuit F F must not be left open when the machine is running this will irreparably damage the AVR 4 2 3 1 R450 SHUNT field weakening The exciter is switched off by disconnecting the AVR power supply 1 wire X1 or X2 Contact rating 16 A 250 V A C 4 2 3 2 R450 AREP PMG field weakening The exciter is switched off by disconnecting the AVR power supply 1 wire on each auxiliary winding contact rating 16 A 250 VA C Connection is identical for resetting the AVR internal protection If field weakening is used provide field forcing 4 2 3 3 R450 field forcing 400V m Exciter field winding E Diode B um Field forcing Time Applications Guaranteed voltage build up Parallel operation de energized Parallel operation at standstill Frequency starting Sustained voltage on overload 16 LEROY SOMER 254 276 LEROY SOMER Installation and maintenance 4531 en 2010 10 c R 450 AVRs 4 3 Electrical faults Measurements Check Cause No voltage at Connect a new battery of 4 to 12 V to
158. en removed reset not performed if the cause of the fault is still present 51 276 EN 6 2 4 4 Engine fault codes display Certain alarms and engine faults generate specific fault codes These codes are standardised according to the J1939 and or J1587 standards except for MTU engines that have a specific transmission protocol see appendix if applicable Terminology used by the SAE CAN J1939 standard SPN Suspect Parameter Number This represents the system or component at fault for example SPN 100 indicates an oil pressure problem or a problem with the oil pressure sensor FMI Failure Mode identifier This represents the type of fault that has occurred This may be an electrical mechanical or equipment fault Terminology used by VOLVO SID System Identifier This term used in the J1587 standard has an equivalent in the J1939 standard SPN However this term corresponds more particularly to an assembly of components for example the injection system PID Parameter Identifier This term used in the J1587 standard has an equivalent in the J1939 standard SPN However this term corresponds more particularly to a specific component for example a sensor PPID Parameter Identifier This term used in the J1587 standard has an equivalent in the J1939 standard SPN PPID corresponds to PID but is only used by VOLVO FMI Failure Mode identifier This represents the type
159. ensive network of service centres can dispatch the necessary parts without delay To ensure correct operation and the safety of our machines we recommend the use of original manufacturer spare parts In the event of failure to comply with this advice the manufacturer cannot be held responsible for any damage LEROY 18 9 256 276 LEROY SOMER Installation and maintenance 4531 en 2010 10 c R 450 AVRs LEROY SOMER 257 276 19 LEROY SOMER 258 276 9 3 Appendix C Common spare parts GENLUB GENCOOL N Radiator filler cap 330051142 Radiator pressure cap 330052078 Thermostat 330051467 Thermostat seal 330051539 Fan belt 330051419 Rocker cover seal 330051468 Water temperature sensor 330051466 Oil pressure sensor 330051465 Alternator belt 330051418 330910094 330910095 330910098 330910099 259 276 330910100 ALTERNATOR N 330560243 330570109 330570110 330510015 330560617 330560551 330560634 Diode bridge 330410126 Varistor 330410109 Note For all technical assistance or spare part requests contact your nearest SDMO agent 260 276 EN 9 4 Appendix D List of John Deere Volvo and Perkins fault codes
160. equired to carry out these operations They must only be entrusted to personnel with the necessary skills Failure to follow these instructions in any way could result in malfunction or very serious accidents Danger 5 1 Installation checks Y check that the general recommendations given in the installation section ventilation exhaust fluids etc are observed Y carry out the level checks oil water diesel fuel battery Y check the generating set earth connection is earthed Y check that the electrical connections are in order 5 2 Checks after starting the generating set Y carry out the mechanical checks oil pressure water temperature absence of noise etc Y carry out the electrical checks voltage and frequency Y carry out the safety checks emergency stop oil pressure water temperature etc 6 Using the generating set 6 1 Pre Start Inspection e Engine and engine compartment general check Visually check the engine and engine compartment before starting the engine and after stopping the engine Check there are no oil fuel or coolant leaks the screws are tightened the condition of the belts wear tension ue A Fuel oil and grease deposits on the engine or in the engine compartment are always a fire hazard and must be removed as soon as they are noticed Warning A If there are any oil fuel or coolant leaks locate the origin of the fault and repair
161. er to the Maintenance Schedule The cooling system should be flushed when the coolant is changed please refer to Cooling system Flushing Volvo Penta Coolant is concentrated coolant that should be mixed with water It has been prepared to work best with Volvo Penta engines and offers excel lent protection against frost and cavitation damage plus frost bursting Volvo Penta Coolant Ready Mixed is ready mixed coolant 40 Volvo Penta Coolant and 60 water This mixture protects the engine from corrosion damage cavitation damage and frost bursting down to 28 18 4 F 33 159 276 Maintenance 34 Coolant Mixing WARNING All glycol is hazardous and pollutes the environment Do not swallow it Glycol is flammable IMPORTANT Ethylene glycol must not be mixed with other types of glycol Mix 40 Volvo Penta Coolant conc coolant 60 water This mixture prevents against internal corrosion cavi tation and frost bursting down to about 28 C 18 4 F at 60 glycol concentration the freezing point is low ered to 54 C 65 2 F Never mix more than 60 con centrate Volvo Penta Coolant in the coolant This will give reduced frost protection and poorer cooling effect with a consequent risk of overheating IMPORTANT The coolant must be mixed with pure water use distilled de ionized water The water must comply with the requirements speci
162. es have clean water in lakes and seas and be able to enjoy the sunlight without fearing for our health Unfor tunately this is not a matter of course these days it is something all of us must work for As an engine manufacturer Volvo Penta has particu lar responsibility and for this reason environmental care is an obvious foundation of our product develop ment Volvo Penta has a wide engine program these days where considerable progress has been made in reducing exhaust fumes fuel consumption engine noise etc We hope that you will want to preserve these values Always observe the advice in the instruction book about fuel grades operation and maintenance to avoid unnecessary environmental impact Please con tact your Volvo Penta dealer if you notice any chang es such as increased fuel consumption or increased exhaust smoke Please remember to always hand in hazardous waste such as drained oil coolant old batteries etc for de struction at an approved recycling facility If we all pull together we can make a valuable contri bution to the environment together Running in The engine must be run in during its first 10 hours as follows Use the engine in normal operation Full load should only be applied for short periods Never run the engine for a long period of time at constant speed during this period Higher oil consumption is normal during the first 100 200 hours of operation For this reason check
163. es are given for 50 Hz 70V 10V no load operation and operation at rated 60 Hz 85V 12V load with separate field excitation All values are given to within 10 and may be changed without prior notification for 4 8 3 Table of weights exact values consult the test report values given for information only 4 8 1 LSA46 2 average values LSA46 2 Total weight kg Rotor kg Resistances at 20 C Q M3 600 250 LSA 46 2 Stator L N Rotor Field Armature 5 700 260 M3 0 022 0 23 88 0 035 L6 800 290 M5 0 0182 0 24 8 8 0 035 L9 850 320 L6 0 0148 0 264 8 8 0 035 VL12 1000 380 L9 0 012 0 295 8 8 0 035 VL12 0 0085 0 343 10 0 037 Resistance of AREP auxiliary windings at 20 C Q LSA 46 2 Auxil wdg X1 X2 Auxil wdg 21 22 M3 0 24 0 4 M5 0 215 0 36 L6 0 185 0 36 L9 0 19 0 32 VL12 0 17 0 32 Field excitation current i exc A Symbols i exc excitation current of the exciter field LSA 46 2 No load At rated load M3 1 1 4 M5 1 1 3 8 L6 1 1 4 1 L9 1 2 4 VL12 1 1 3 5 For 60 Hz machines the i exc values are approximately 5 to 10 lower After operationaltesting itis essentialto replace all access panels or covers ER 219 276 17 LEROY SOMER Installation and maintenance 3856 en 2011 01 h LSA 46 2 4 POLES ALTERNATORS 5 SPARE PARTS 5 1 First maintenance parts Emerge
164. et the excitation current ceiling Turns off when the excitation current is less than the setting value lt 110 In Flashes when the excitation current is above the continuous operation threshold during less than 90 s Green LED stays on flashes when the excitation current has reached the ceiling in lt 10s with PMG excitation ftays on if lexc Shutdown If the overload protection is activated a voltage drop possibly exceeding 10 of the reference voltage will be observed The AVR does not provide undervoltage protection The customer will need to make sure that their installation is correctly protected against under voltages During load shedding an overvoltage is observed which will disappear in a few seconds LEROY 10 MER 248 276 LEROY SOMER Installation and maintenance 4531 en 2010 10 c R 450 AVRs 3 2 2 Rotating switch selection LAM and U F Pos 0 Change in the voltage according to the U F ratio knee point position at 48 Hz Pos 1 Change in the voltage according to the 2U F knee point position at 48 Hz Pos 2 Change in the voltage according to the self auto adaptating LAM combined with 2U F knee point position at 48 Hz Pos 3 Change in the voltage according to the U F ratio knee point position at 58 Hz Pos 4 Change in the voltage according to the 2U F knee point position at 58 Hz Pos 5 Change in the voltage according to t
165. etection using an external contact and connect the external switch to the terminals Xcbc3 32 33 Y For solo starting in the absence of a mains connection you must select the configuration Mains supply detection using an external contact No connection is necessary N B selecting detection depends on the connection made according to Section Connections of the generating sets Important 15 07 09 19 10 00 GS 1 Rental application Faults A612 Single Genset without N E Mains supply detection using the adjustment card Validation 6 Press Validation on the touch screen 95 276 Back up to perform Rental application Faults A612 Single Genset without N E 7 The KERYS saves your new configuration 8 After return to the KERYS home screen A The configuration will only be taken into account if the following operations are carried out Y Turn on the battery isolator switch v 5 seconds v Turn off the battery isolator switch Important Solo generating set CRF coupling A651 1 Turn off the battery isolator switch 2 Check that the emergency stop buttons are activated 3 Press the STOP button of the KERYS 4 Turn the changeover switch to positio 4 SOLO GENERATING SET WITH GRID COUPLING APPLICATION A651 If the switch is already set to 4 turn the switch and return to position 4 1 SOLO GENERATING SET WITHOUT GRID COUPLING
166. f water and drink large quantities of water Consult a doctor immediately Large quantities of electrolyte should be rinsed off using a neutralising agent A common method is to use a solution of 500g of bicarbonate of soda diluted in 4 litres of water The bicarbonate of soda solution should be added until the reaction has finished lather The remaining liquid should be rinsed off with water and left to dry Y Dry batteries do not require any servicing Y Batteries ready for use must be recharged at the latest when the acid density drops below 1 20 8 1 Storage and transport Y Batteries ready for use must be stored in a cool and dry place frost free protected from the sun self discharge Y Batteries must be transported and stored vertically risk of acid spillage Y Leave the terminal cover on the positive terminal 119 276 8 2 Battery setting into service v Batteries filled with acid have a density of 1 28 g ml and are charged v For dry batteries fill each part of the battery with acid to the maximum level marker or to 15 mm above the plates Leave the battery to rest for 20 minutes Y Before fitting the battery switch off the engine and any current consumer clean the terminals and coat them slightly with grease EN When connecting first connect the positive terminal and then the negative terminal The battery heats up no Temperature during activation gt 10 Fill with acid up to the m
167. factory can supply a set of flexib le shunts and special connection links as an ption for making these connections LEROY SOMER 210 276 LEROY SOMER Installation and maintenance 3856 en 2011 01 h ALTERNATORS 3 3 2 Terminal connection 6 wire not possible with the R 250 Connection codes Voltage L L Factory connection L1 U Windi U inding 50 Hz 60 Hz E T 6S 380 415 380 480 7S 440 E XO Ow 8S 380 416 9 I a R 450 voltage detecti a Y o HU voltage detection O 0 gt T3 P380 V gt 2 Oo E 600 Winding 9 450 voltage detection L3 W Lav 9S transformer See specific diagram E L1 U Winding 50 Hz 60 Hz T5 T8 1 phase or 3 phase 6S 220 240 220 277 a Jom L3 W 7S 240 254 i S 5 T2 L2 V 220 240 8S 09 5 L1 U R 450 voltage detection NDE T5 T2 0 gt T3 220 V gt T2 L3 W L2 V Operating phases L2 V L3 W single phase In case of reconnection ensure that the AVR voltage detection is correct The factory can supply a set of flexible shunts and special connection links as an option for making these connections 3 3 3 Option connection diagram R791 T interference suppression kit standard for CE marking Remot
168. frequency to a busbar supplied by a generating set designed as master at the output A number 1 to 15 is assigned to each Kerys This number serves solely to establish the IP address of each Kerys for communication by Ethernet and loading the programs A second number from 1 to 15 is also assigned to each Kerys and defines the priority Example let us assume a plant of 8 generating sets Gen set 1 2 3 4 5 6 7 8 Priority 08 07 06 05 04 03 02 01 The numbers on the first line enable the IP address of each Kerys to be allocated The numbers on the second line define the priority Therefore Kerys no 8 with priority 01 is considered to be the master generating set and closes its flow first The other generating sets then synchronise one by one to the central busbar transmitting the information on voltage frequency and phase difference to this busbar see sketch Busbar U Example for 3 GSs e DJ1 Circuit breaker 1 is closed the voltage is present on the busbar e Kerys 2 analyses the differences between U2 and U of the busbar before coupling e Kerys analyses the differences between U of the busbar before coupling Each Kerys independently of its neighbour will close its discharge on the central busbar Wattmetric control The wattmetric control is used when two generating sets are coupled It provides optimum management of the number of generating sets operating by constant
169. ge Adjustment ineffective Faulty AVR high potentiometer Adiust the Check the speed possibility of cyclic irregularity Voltage AVR stabilit If no effect try normal or fast stability Loose connections oscillations otentiom i T modes ST2 Faulty AVR Speed too low when on load or AVR LAM set too high Voltage Voltage between E and E DC k cOrrec ae Ao SHUNT lt 10V Check the speed or AVR LAM set too high load and too Faulty rotating diodes E and E n y 9 low when on ae Ne E pied Ea F 5V Short circuit in the revolving field coil Check the resistance load Faulty exciter armature Check the resistance Voltage AE dn idis Exciter winding open circuit disappears the rotating diodes and The voltage does not return tothe Faulty exciter armature during rated value Faulty AVR replace any defective operation Revolving field coil open circuit or short circuited components LEROY 12 SOMER 214 276 LEROY SOMER Installation and maintenance 3856 en 2011 01 h LSA 46 2 4 POLES ALTERNATORS 4 5 1 Checking the winding You can check the winding insulation by performing a high voltage test In this case you must disconnect all AVR wires WARNING Damage caused to the AVR in such conditions is not covered by our warranty 4 5 2 Checking the diode bridge A diode in good working order should allow the curre
170. ge pressure sensor Cause Short circuit to positive or earth ground e Open circuit Reaction Engine smokes more than normally during accel eration load increase Remedy e Check that the charge pressure sensor connector is correctly installed e Check that the charge pressure sensor cable is not damaged e Check that the charge pressure sensor is correct ly installed e Check charge pressure sensor function Code 3 5 PID SPN 106 102 Charge pressure Cause e Charge pressure too high Reaction Engine control module reduces engine power un less the protection has been shut off with the VODIA diagnostic tool Remedy e Check turbocharger compressor function e Check charge pressure sensor function e Check fuel volume injector 54 Code 3 6 PID SPN 94 Fuel pressure sensor Cause Shor circuit to positive or earth ground e Open circuit Reaction None Remedy e Check that the fuel pressure sensor connector is correctly installed e Check that the fuel pressure sensor cable is not damaged e Check that the fuel pressure sensor is correctly installed e Check fuel pressure sensor function Code 3 7 PID SPN 175 Oil temperature sensor Cause e Shorted to plus or minus Break Reaction None Remedy e Check that the cable harness to the oil tempera ture sensor has not been damaged Check that the oil temperature sensor has been con
171. ged e Check that the injector connections are not dam aged e Check fuel supply pressure e Check the valve clearance Do a compression test and check cylinder 3 Code 7 4 SID 4 SPN 654 Injector cylinder 4 Cause Electrical fault Faulty compression or injector Reaction Engine runs on 5 cylinders Abnormal sound e Reduced performance Remedy e Checkthatthe injector cables are not damaged e Check that the injector connections are not dam aged e Check fuel supply pressure e Check the valve clearance Do a compression test and check cylinder 4 184 276 Code 7 5 SID 5 SPN 655 Injector cylinder 5 Cause Electrical fault Faulty compression or injector Reaction Engine runs on 5 cylinders Abnormal sound Reduced performance Remedy e Check that the injector cables are not damaged e Check that the injector connections are not dam aged e Check fuel supply pressure e Check the valve clearance Do a compression test and check cylinder 5 Code 7 6 SID 6 SPN 656 Injector cylinder 6 Cause Electrical fault Faulty compression or injector Reaction Engine runs on 5 cylinders Abnormal sound Reduced performance Remedy e Check that the injector cables are not damaged e Check that the injector connections are not dam aged e Check fuel supply pressure e Check the valve clearance Do a compression test an
172. gh 2659 Flow level of the EGR valve 2 Calculated EGR flow not valid 15 Calculated EGR flow rather high 17 Calculated EGR flow rather low 2790 at turbo compressor 16 Temperature at compressor outlet moderately high 2791 19 Statuses of the EGR valve 2 Valve position signal not valid 3 Input voltage of the position sensor high Short to V 4 Input voltage of the position sensor low Short to V 7 Inability of the EGR valve to reach the expected position 13 The EGR valve is out of calibration 31 Error in position of the EGR valve 272 276 N SPN CID SID PID PPID FMI John Deere Volvo Perkins Description Comment 2795 Position of TGV actuator The actuator does not respond or is not in the expected position 3509 Common supply voltage of the sensors output 1 Supply voltage of the sensor too high Exceeding 5 volts Supply voltage of the sensor shorted to ground 3510 Common supply voltage of the sensors output 2 Supply voltage of the sensor too high Exceeding 5 volts Supply voltage of the sensor shorted to ground 3511 Common supply voltage of the sensors output 3 Supply voltage of the sensor too high Exceeding 5 volts Supply voltage of the sensor shorted to ground 3512 Common supply voltage of the sensors output 4 Supply voltage of the sensor too h
173. gine not operating engine can not be started Engine operating engine idles and can only be stopped with the auxiliary stop AUX stop Remedy e Check that the 8 pin connector is not damaged e Check that the cables between the CIU and the engine management unit are not damaged e Check that sleeves 11 and 12 in the connector on the CIU are not damaged Code 6 6 PID SPN 100 Oil pressure Cause Oil pressure is too low Reaction Engine control module reduces engine power un less the protection has been shut off with the VODIA diagnostic tool Remedy e Check oil level e Check that the air filters are not blocked e Check system pressure valves and safety valves in the oil system e Check oil pressure sensor function Code 6 7 PPID 8 SPN 520192 Piston cooling pressure Cause e Piston cooling pressure is too low Reaction Engine stopped The fault code is de activated at engine speeds below 1000 rpm Remedy e Check that the oil pressure in the engine exceeds 175 kPa 25 4 psi 183 276 Fault codes Code 6 8 PPID 8 SPN 520192 Piston cooling pressure sensor Cause e Shorted to plus or minus Break Reaction None Remedy Check that the piston cooling pressure sensor contact is correctly installed Check that the cable harness to the piston cooling pressure sensor has not been damaged e Check the piston cooling pressure sensor func tionality Code 6 9
174. gnostic function A fault message in the form of a fault code is always generated when a malfunction is discovered by the di agnostic function Engines are affected differently depending on the se verity of the fault The engine is not affected Engine idles Engine torque is restricted to a certain amount Engine is stopped 49 Operation When a malfunction has occurred and the diagnostic system has generated one or more fault codes these are read out differently depending on the equipment used Please refer to Fault codes If the system indicates that a fault code has been set 1 Cut engine speed to idle or shut the engine off 2 ForDCU DU Read the fault code set from the display please refer to Reading fault cause via the DCU or Reading fault cause via DU For CIU Press the diagnostic button and read the fault code that has been set by observing the flashing of the diagnostic lamp Please refer to Reading fault codes via the diagnostic lamp CIU 3 Look up the fault code cause in the Fault Code chapter and take the recommended measures Reading fault cause via the DCU Display Control Unit When a fault code is set the following text is shown on the display I ENGINE WARNING alternated with Press SEL for information NOTE You can choose the language used for the in formation presented on the Read the fault code as follows 1 Press the SEL bu
175. goes out to indicate that the generating set has stopped 6 3 8 3 Rental options Damper valve Optional if the generating set stops when the valve damper is closed repair the fault Display the fault according Press Reset to clear the fault after it has been repaired If faults persist repair them 116 276 N Air preheating Optional Turn the switch to ON to initiate preheating of the generating set AIR PREHEATING OFF ON In the case of a power plant the position of the air preheating switches must NECESSARILY be the same on all the switches of the generating sets in the power plant Important Bi frequency Optional Turn the switch to the desired frequency and voltage Earthing system FREQUENCY 50Hz 50Hz 440V 60Hz 400V 480 Turn the switch to the desired earthing system EARTHING SYSTEM TT IT TN IT 2 TN TNS 3 TT or EDF APPLICATION Important The EDF earthing system is only used in the so called rental configurations The switch must necessarily correspond to the wiring described in the section on Connection of the generating sets 117 276 7 Maintenance schedule 7 1 Reminder of use EN The maintenance interval frequency and the operations to be carried out are outlined in the maintenance schedule given as a guideline N B the environment in which the generating set is operating determines
176. guration 6L Cubic capacity 9 36 L Rotation speed 1500 Rem Max emergency prime power at nominal speed 320 290 kW Adjustment type Electronical Fuel consumption 110 emergency power 75 9 L h 100 main power 68 1 L h 75 main power 50 6 L h 50 main power 35 1 L h Fuel Fuel type Diesel Standard fuel tank 470L High autonomy fuel tank 1368 L 18 276 EN Lubrication Oil capacity with filter 33 L Min Oil pressure 0 7 bar Nominal oil pressure 6 bar Oil consumption 100 load 0 06 L h Oil sump capacity 28 L Type of lubricant Genlub Cooling Engine capacity with radiator 41L Max coolant temperature 103 C Fan power 15 kW Ventilator air flow 5 9 m3 s Refrigerant type Gencool Thermostat 82 92 Emissions HC 30 mg Nm3 CO 340 mg Nm3 NoX 2200 mg Nm3 PM 30 mg Nm3 Alternator data e Compliant with NEMA MG21 standards UTE NF C51 111 VDE 0530 BS 4999 IEC 34 1 CSA e The alternator is protected against short circuits e Vacuum impregnation epoxy winding IP23 protection rating Type LEROY SOMER LSA462VL12 Number of phases 3 Power factor cos Phi 0 8 Number of poles 4 Excitation type AREP Voltage regulator R448 Short circuit current 3 IN Number of bearings 1 Coupling Direct Conirol unit s TELYS Standard specifications Voltmeter Ammeter Frequency meter Alarms and
177. he setting Lever ratchet worn Replace the lever and adjust the setting Cable ruptured Replace the cable and adjust the setting 33 276 EN 4 8 Electrical connection diagram 2 white side lights on 2 two coloured flexible support side marker lights 2 x 6 function rear lights depending on model depending on model depending on model fo 7 metal pin male plug 7 2 2 conductor cables 2 plate lights AU Metal socket 3 x connector 7 conductor cable 2 x 2 conductor cables depending on model 2 x 2 conductor cables depending on model Figure 4 6 Electrical connection diagram 4 9 Complete wheels technical information TYRES COMPLETE WHEELS Dimensions Indices Diameter mm Cross section Radius under Load Pressure mm load Kg bar mm 135 R 13 550 134 265 335 2 4 145 R 13 75T 566 145 272 387 2 4 155 R13 79 T 578 150 277 437 2 4 145 70 R 13 71T 534 150 259 345 2 5 155 70 R 13 75T 548 147 263 387 2 5 185 70 R 13 86 T 594 185 285 530 2 5 165R14C 98 N 622 172 284 650 3 8 155 70 R12 100 N 525 155 244 650 6 25 800 185R14C 102 P 650 188 316 675 4 5 850 195R14C 106 P 666 198 32 950 4 5 195 50 x 10 98 N 450 190 750 6 0 34 276 EN 5 Preparation before operating the set The inspections referred to in this section enable the electrical generator set to operate Specific skills are r
178. he self auto adaptating LAM combined with 2U F knee point position at 58 Hz Pos 6 Change in the voltage according to the U F ratio knee point position at 65 Hz Tractelec application and variable speed above 1800 rpm Pos 7 Special not used Pos 8 Change in the voltage according to the U F ratio knee point position at 48 Hz or 58 Hzaccording to selection ofthe frequency by an external contact Pos 9 Change in the voltage according to LAM 1 knee point position at 48 Hz or 58 Hz according to selection of the frequency by an external contact For Pavers and hydraulic applications select positions 0 50 Hz or 3 60 Hz 3 2 3 Rotating switch excitation type and time response 0 AREP excitation and normal time response 3 AREP excitation and fast time response 1 PMGexcitationandnormaltime response 2 PMG excitation and fast time response ForSHUNTapplications AREPexcitation must be selected 3 2 4 Rotating switch voltage sensing 1 PHASE SENSING SERES Ys SERIES SA49 1 50 2 SA46 2 47 2 7000 8000 5000 6000 0 Single phase sensing LSA46 2 47 2 series 3 Single phase sensing LSA49 1 50 2 series 1 Three phase sensing with optional module R731 LSA46 2 47 2 series 2 Three phase sensing with optional module R731 LSA49 1 50 2 series LEROY SOMER 11 249 276 LEROY SOMER Installation and maintenance 4531 en 2010 10 c R 450 AVRs 3 3
179. hine 10 LEROY SOMER 212 276 LEROY SOMER Installation and maintenance 3856 en 2011 01 h LSA 46 2 4 POLES ALTERNATORS 4 SERVICING MAINTENANCE 4 1 Safety measures Servicing or troubleshooting must be carried out strictly in accordance with instructions so as to avoid the risk of accidents and to maintain the machine in its original state All such operations performed on the alternator should be undertaken by personnel trained in the commissioning servicing and maintenance of electrical and mechanical components who must wear personal protective equipment appropriate for mechanicaland electrical hazards Before any intervention on the machine ensure that it cannot be started by a manual or automatic system and that you have understood the operating principles of the system 4 2 Routine maintenance 4 2 1 Checks after start up After approximately 20 hours of operation check that all fixing screws on the machine are still tight plus the general state of the machine and the various electrical connections in the installation 4 2 2 Bearings As standard the alternator is fitted with permanently greased bearings As an option they may be regreasable It is advisable to lubricate the alternator during operation Time intervals and quantity of grease are given in the table below NDE DE bearing 6316 C3 6315 C3 Quantity of grease 33g 30g Regrea
180. his symbol indicates a dangerous situation if the warning is not heeded Failure to follow the corresponding advice risks resulting in minor injury of personnel or damage to any other object in case of exposure Important In order to obtain optimum efficiency and the longest possible life for the electrical generating sets maintenance operations must be carried out according to the periods indicated in the attached preventative maintenance tables If the electrical generating set is used under dusty or unfavourable conditions some of these periods will be shorter Ensure that all repairs and adjustments are carried out by personnel who have received appropriate training Dealers have this qualification and can answer all of your questions They can also supply you with spare parts and other services The left and right sides can be seen from the back of the electrical generating set the radiator is at the front Our electrical generating sets have been designed so that damaged or worn parts can be replaced by new or reconditioned parts thereby reducing the out of action period to a minimum For any replacement of parts contact your nearest dealer for our company who will have the necessary equipment and can offer properly trained and informed staff to carry out maintenance parts replacement and even total reconditioning of generating sets Contact your local dealer for the available repair manuals and to make the necessary arrangements
181. igh Exceeding 5 volts Supply voltage of the sensor shorted to ground 3513 Common supply voltage of the sensors output 5 52019 Supply voltage of the sensor too high Exceeding 5 volts Supply voltage of the sensor shorted to round Cooling status of the piston 52019 Status of the starting request input 52019 Stop request on CIU 273 276 N SAE J1939 73 March 2004 FMI and Description FMIZ0 DATA VALID BUT ABOVE NORMAL OPERATIONAL RANGE MOST SEVERE LEVEL The signal communicating information is within a defined acceptable and valid range but the real world condition is above what would be considered normal as determined by the predefined most severe level limits for that particular measure of the real world condition Region e of the signal range definition Broadcast of data values is continued as normal Broadcast of data values is continued as normal FMl 1 DATA VALID BUT BELOW NORMAL OPERATIONAL RANGE MOST SEVERE LEVEL The signal communicating information is within a defined acceptable and valid range but the real world condition is below what would be considered normal as determined by the predefined least severe level limits for that particular measure of the real world condition Region e of the signal range definition Broadcast of data values is continued as normal FMIl 2 DATA ERRATIC INTERMITTENT OR INCORRECT Errati
182. ihid d Ee eit 18 All servicing or repair operations performed on the AVR should be undertaken by personnel trained in the commissioning servicing and maintenance of electrical and mechanical components Copyright 2005 LEROY SOMER MOTORS This document is the property of LEROY SOMER It may not be reproduced in any form without prior authorization All brands and models have been registered and patents applied for LEROY SOMER 3 241 276 LEROY SOMER Installation and maintenance 4531 en 2010 10 c R 450 AVRs 1 GENERAL INFORMATION 1 1 Description The R450 AVR is supplied in a casing designed to be mounted on a panel with dampers Operating temperature 30 C to 65 C Storage temperature 55 C to 85 C Shocks on the base 9 g depending on the 3 axes Vibrations less than 10 Hz 2 mm half peak amplitude 10 Hz to 100 Hz 100 mm s above 100 Hz 8 g The AVR is IP00 it must be incorporated in an environment which ensures it a IP20 protection 1 2 Characteristic The connection is realised by Faston connectors and the voltage sensing is single phase A d P1 Seah te Rotating switch fie 4 L d U F P2 T Valtage _ Stability Bj J Excitation excitation E n a 7 gee indications _ D _ 10
183. ilise the trailer by placing chocks under the wheels Fully engage the parking brake if fitted Using the front wheel position the generating set as close to horizontal as possible Lower the stands if fitted and lock them lt lt 4 lt lt 5 4 6 Break transmission adjustment A The handbrake is used only as a parking brake Setting is carried out starting with the brakes moving to the brake control Important After fitting the wheels on the axle turn the wheels in the FORWARD direction on all RA 2 type brakes check that the adjustment screw 8 reaches the FORWARD stop on the brake backing plate Adjust the brake setting using screw 8 with the cables not connected to the cross bar s The shoes should rub the drum slightly Connect the brake cables to the cross bars s and tighten the nuts and lock nuts leaving the end of the threaded end protruding by around 10 mm Fig 4 4 IMPORTANT Wherever possible cables must cross over to achieve the highest possible gain curve Fig 4 5 Check that the parking lever 1 is in the REST position and that the compensating spring 4 is completely free on its rod unscrew the nuts 5 fully Check that the hook slide 2 is not compressed and the yoke 3 is in the pulled out position Fit the transmission and adjust the assembly using the tensioner 6 until a gap J1 of 1 mm max is obtained between the linkage 9 and slide 2 Adjust the compensa
184. in stalled Check that the engine speed sensor cable is not damaged e Check that the engine speed sensor is correctly installed in the flywheelhousing Check engine speed sensor function Code 2 5 SID22 SPN 636 Camshaft drive speed sensor Cause No signal Abnormal frequency Fault in sensor Reaction Engine takes longer to start than normal Engine runs normally when running Remedy Check that the engine speed sensor connector is correctly installed e Check that the engine speed sensor cable is not damaged e Check that the engine speed sensor is correctly installed in the upper timing gear cover Check engine speed sensor function Code 2 6 PID SPN 190 Code 2 6 Engine speed Cause Engine speed too high Reaction None Remedy After the engine has stopped look for the reason for the high speed Code 2 8 PPID 132 SPN 608 Speed potentiometer connected to CIU Cause e Shorted to plus or minus Jtaultin sensor Reaction Engine goes to idle If you release the accelerator first and the press it down again the engine can be forced to run us ing the idle contact Remedy e Check that the potentiometer has been connected correctly e Check that the cable harness to the potentiometer has not been damaged e Check the potentiometer function 179 276 Fault codes Code 2 9 PID SPN 97 Indicator for water in fuel Cause e Short circui
185. in nipple only as an option on VE en gines 1 Activate the electric drain nipple 2 at the base of the primary fuel filter to open it NOTE Put a collection vessel under the fuel filter collect the condensate and fuel 2 Press the electric feed pump switch until water free fuel starts to run out Please refer to Compo nent positions 3 Switch off the electric drain nipple 2 at the base of the primary fuel filter to close it Venting the fuel system 1 Check whether there is enough fuel in the tank and that any fuel taps are open Turn the ignition on The fuel system is vented by depressing the elec tric feed pump switch for 1 to 2 minutes Please refer to Component positions Air is vented to the tank via the fuel return pipe No venting nipples need to be opened 4 Startthe engine Let the engine run at slow idle for about 10 minutes 5 Doaleakage and function check 41 167 276 Maintenance Electrical system The engine is equipped with a 2 pole electrical system and an alternator System voltage is 24V WARNING Before any work is done on the electrical system the engine must be stopped and the current cut by switching off the main switch es All connections to equipment such as battery chargers or other aux iliary equipment must be broken Main switch The main switches must never be disconnected be fore the engine has been stopped If the circuit be tween the al
186. indings short circuited Rotating diodes burnt out Main field winding short circuited Check the resistance Speed too low Increase the drive speed Do not touch the A V R pot P1 before returning to the correct speed Voltage too high Adjust A V R potentiometer Adjustment ineffective Faulty A V R 1 faulty diode Voltage oscillations Adjust A V R stability potentiometer Check the speed possibility of cyclic irregularity Loose terminals Faulty A V R Speed too low on load or U F gradient set too high Voltage correct at no load and too low when on load Run at no load and check the voltage between E and E on the A V R Check the speed or U F gradient set too high Faulty rotating diodes Short circuit in the main field Check the resistance Faulty induced excitaion Warning For single phase operation check that the sensing wires coming from the A V R are correctly connected to the operating terminals see the alternator manual Voltage disappears during operation Check the A V R the surge suppressor the rotating diodes and replace any defective components The voltage does not return to the rated value Exciter winding open circuit Faulty induced excitation Faulty A V R Main field open circuit or short circuited Warning after setting up or trouble shooting replace all access panels or
187. ines to correspond to European standards it is advisable to have a spare shock absorber to enable instant repairs 31 276 N PARKING LEVER 1 NUT 5 COMPENSATING TENSIONER6 CROSS BAR 7 BRAKE CABLE _ SPRING 5 d E 5 5 SLIDE 2 eaae LINKAGE CASING STOP SETTING SCREW 8 AUTOMATIC AS BACKWARD JAW XE NN SIMPLEJAW Jo o RETRACTOR Figure 4 3 Braking transmission Figure 4 4 Cross bar fitting Figure 4 5 Tandem bearing fitting 32 276 4 7 Faults and repairs N Fault observed Origin Solutions Erratic braking of trailer Faulty shock absorber Replace the shock absorber Braking too weak Jaws worn Replace the jaws Jaws not run in Fault will disappear only after running in Incorrect linkage setting Adjust the setting Significant friction on the slide Grease the sliding parts Slide corrosion Remove the corrosion and grease Coupling height does not match that of the towing vehicle Adjust the height so that the two parts are in the same horizontal plane Drum temperature abnormally high Incorrect linkage setting Adjust the settings Incorrect brake setting Adjust the settings High levels of dust in the drums Remove the dust Jaws springs drums damaged Replace the damaged parts Brake cables or l
188. ink rod damaged Replace the damaged parts Jerky braking Incorrect linkage setting Adjust the settings Interfering parts on the slide Remove clean and grease Corroded slide Remove the corrosion and grease Damage to slide guide rings Replace the rings and possibly the slide and grease Faulty shock absorber Replace the shock absorber Trailer tending to swerve upon braking Cross bar s not balanced Adjust the cross bar s Different brake setting on the two sides Adjust the brake settings Cables damaged or incorrectly fitted Replace the damaged parts Refit the cables Poor load distribution Check the load distribution When starting the trailer holds back the towing vehicle Damage to slide or to guide rings Replace the faulty parts and grease Slide corrosion Remove the corrosion and grease Tie rod damaged Replace the tie rod and adjust the settings Linkage damaged or incorrectly set Replace the damaged parts and adjust the settings Brake on Loosen the brake Play in the coupling head Head worn see wear indicator Replace the head Ball joint worn Replace the ball joint Parking braking too weak Compensating spring incorrectly set Adjust the setting Braking system incorrectly set Adjust the setting Notched sector damaged Replace the sector and adjust t
189. intenance of shield 36 the PMG Refit the shield 36 on the machine using D a dowel and nut in the shaft extension see dus LSA 46 2 the PMG reference is diagram Tighten the 4 shield screws 37 SEP ie Reconnect exciter wires E E Finish reassembling the cover Screw a threaded rod into the thrust bearing 68 Refit the shield 30 on the machine Slide the threaded rod into the shield hole to make it easier to assemble see basic diagram Fit the thrust bearing screws 68 remove the threaded rod fit the other screw and tighten up the assembly Tighten the 6 shield screws 31 Refit the air outlet grille 33 Check that the machine assembly is correctly mounted and that all screws are tightened 4 6 9 Dismantling and reassembly of the filters Remove the grille 417 then take out the filter 418 Change the filter if necessary please refer to section 4 2 5 for cleaning the filter LEROY 16 ROR 218 276 LEROY SOMER Installation and maintenance 3856 en 2011 01 h LSA 46 2 4 POLES ALTERNATORS 4 8 Table of characteristics 4 8 2 Voltage of auxiliary windings at Table of average values no load Alternator 4 poles 50 Hz Standard windingNo 6 LSA 46 2 Auxil wdg X1 X2 Auxil 21 Z2 400V for the excitation values The voltage and current valu
190. ints Drain the coolant from the radiator and engine block using the drain hose The drain nipples are situated under the radiator on the right side of the engine block Check that all coolant drains out Deposits may be found inside the drain plug tap and need to be cleared away There is otherwise a risk that cool ant could remain and cause frost damage Check whether the installation has any further taps or plugs at the lowest points of the cooling water pipes Shut any taps and check that the spring loaded covers on the nipples close completely Install the rubber plugs Maintenance Coolant filter changing 1 Turn the tap 1 90 to stop the flow through the coolant filter 2 Remove the coolant filter with a suitable extractor Make sure that no residue from the old seal re mains in the housing 3 Puta thin layer of engine oil on the new coolant filter seal Screw the coolant filter on by hand until the seal comes into contact with the mating sur face of the filter bracket Then tighten the coolant filter a further 1 2 turn 4 Turn the tap 1 90 to release the flow through the coolant filter again e Start the engine and do a leakage check Switch the engine off and check the coolant level Please refer to Coolant level check Intercooler External cleaning Remove guards as necessary to access the radiator Clean with water and a mild detergent Use a soft brush Be careful to ensure
191. ion preparations Remove any covers from the engine air filter and exhaust pipe Top the engine up with the correct grade of oil if necessary Install a new oil filter if the filter was not changed during conservation Install new fuel filters and vent the fuel system Check the drive belt s Check the condition of all rubber hoses and check the tightness of the hose clamps Laying up Close the drain taps and install any draining plugs Check the coolant level Top up as necessary Connect the fully charged batteries Start the engine and warm it up at fast idle with no loading Check that no oil fuel or coolant leakage occurs Conservation of the lubrication and fuel systems for more than 8 months stoppage Drain the engine oil and fill up with conserva tion oil to just over the MIN marking on the dipstick Connect the fuel suction and return hoses to a 1 8 full jerrican containing conservation oil and 2 3 diesel fuel Vent the fuel system 173 276 Start the engine and run at a fast idle until about 2 liters 2 US quart of the fluid in the jerrican have been used Stop the engine and connect the ordinary fuel pipes Drain the engine s conservation oil Follow the other instructions on the previous page Conservation oils are sold by oil companies Fault tracing A number of symptoms and possible causes of engine malfunctions are described in the table below Always con tact your Volvo Pen
192. ion index used for specific projects 2007 02 12 Date of software version in English year month day For a modification of a software version during the life of one of the products developments corrections etc the new software version implemented will be entered by hand in a space reserved for this The old software version will then be deleted Location of the version labels MICS KERYS TACTIL viosc Volts 15 to 36V PIN 3161338100 Almanakon Watts TZW Power supply 24 ETHERNET Base module A 0 Courant OF ou contrate Correction epilation viesse Ret Speed cepas correcta Out C fen grep n ittm m z mj Lac s In m m BH Pl Yu Cory Courant jeu de barres ow risens sas Ean menee ceri et a wt ore yess Regulation module Protection module 59 276 6 3 3 Description of the Man Machine Interface IHM MMI 6 3 3 1 The Man Machine Interface Signalling control keys Operating buttons of the generating set za e DRE NU BERN ML DL LLLS Alphanumeric keypad Navigation keys Backlit display with touch sensitive keypad M M I operation LED flashing Display The display has the following specifications 7 inch colour TFT display 16 9 65536 colours dimensions 154 mm x 86 mm neon backlighting 480 x 234 resolution
193. isma es v l YOLWO da siempre que haya existencias PENTA Si grazie desidero ricevere gratuitamente un manuale d istruzioni in lingua italiana Public No 7745264 N Nome e Cognome e o 2 Indirizzo e e 17 N S Paese Notare che la validit dell offerta garantita solo per 12 mesi dalla consegna del motore dopodich si procedera fino ad esaurimento scorte VOLVO PENTA a _ o lt a Ja tack jag vill kostnadsfritt ha en instruktionsbok pa svenska Publikationsnummer 7745258 gt Namn e e o Adress T T e e wo gt L N S Land Observera att erbjudandet g ller i 12 m nader fran motorns leveransdatum d refter endast i m n av tillg ng VOLVO 196 276 Stuur of fax de coupon naar Document amp Distribution Center Order Department ARU2 Dept 64620 SE 405 08 G teborg Zweden Fax 446 31 545 772 U kunt ook bestellen via internet http www volvopenta com manual coupon Gy Postita tai faksaa kuponki osoitteella Document amp Distribution Center Order Department ARU2 Dept 64620 SE 405 08 G te
194. it immediately before starting the engine Important A Never use a high pressure cleaner for cleaning the engine and equipment Important 35 276 Oil level check and top up N gt Check the oil level every day before the first start up gt Check that it is between the MAX and MIN marks on the oil dipstick gt f necessary top up the oil through the filler opening on the left hand side of the engine Before checking the level again wait a few minutes for the oil to drain into the sump ol A Never fill oil past the maximum level Only use oil of the recommended grade Important Coolant level check A Do not open the filler cap when the engine is hot except in an emergency Boiling liquid or vapour may be ejected Warning A The system must be filled up with liquid which has identical proportions to that already contained in the cooling system Only open the filler cap 1 Important The coolant level must be between the MIN and MAX marks Top up the oil if necessary Checking the air filter clogging indicator A Important Special air filters must be used for extremely dusty conditions Replace the filter when the indicator remains in the red zone after the engine has been stopped j Reset the indicator after the filter has been replaced by pressing the button 36 276 6 2 Generator set with TELYS control panel 6 2
195. ke mm inch 138 5 43 138 5 43 138 5 43 138 5 43 Swept volume dm US quart 9 36 9 89 9 36 9 89 9 36 9 89 9 36 9 89 Weight dry kg Ib 1015 2238 1015 2238 1015 2238 1015 2238 Weight wet kg Ib 1065 2348 1065 2348 1065 2348 1065 2348 Injection sequence 1 5 3 6 2 4 1 5 3 6 2 4 1 5 3 6 2 4 1 5 3 6 2 4 62 188 276 Technical data Type designation TAD950VE TAD951VE TAD952VE Power Please refer to the sales literature Torque Please refer to the sales literature Compression ratio 20 2 1 20 2 1 20 2 1 Low idle rpm 600 600 600 High idle rpm 2250 2250 2250 No of valves 24 24 24 No of cylinders 6 6 6 Cylinder bore mm inch 120 4 72 120 4 72 120 4 72 Stroke mm inch 138 5 43 138 5 43 138 5 43 Swept volume dm US quart 9 36 9 89 9 36 9 89 9 36 9 89 Weight dry kg Ib 1015 2238 1015 2238 1015 2238 Weight wet kg Ib 1065 2348 1065 2348 1065 2348 Injection sequence 1 5 3 6 2 4 1 5 3 6 2 4 1 5 3 6 2 4 189 276 63 Technical data Lubrication system Oil change volume including filter change 35 liter 37 0 US quart Oil pressure hot engine at operating speed TAD940 943VE TAD940 941GE 300 550 kPa 44 80 psi TAD950 952VE 3 iidinenuitene 350 600 kPa 51 87 psi
196. king conditions The ground must be able to withstand the load of the generating set pump unit or lighting column and its lifting machinery without stress otherwise put down beams of sufficient strength in a stable configuration Position the generating set pump unit or lighting column as close as possible to its place of use or transport in a clear space with free access Never perform work on a generating set pump unit or lighting tower just hanging from a lifting device 11 276 N 1 4 Identifying sets Generating sets and their components are identified by means of identification plates The precise rules for identifying each major component engine alternator etc are set out in each manufacturer s documentation contained in the appendices of this manual 6 I2 10 21 7 3 4 16 n GROWPE GENERATING SET PRESSION ACOUSTIQUE SOUND PRESSURE PLAQUE CONSTRUCTEUR MANUFACTURER PLATE 1m 7m 15m C Type Execution Version m PUISSANCE ACOUSTIQUE SOUND POWER 7 5 ia Lwa 91 dB 15 18 MT20 dB A ae et 60 HZ 78 676 64 3 Iv 4330700805 1 13 5 Ill 4 9 8 1 Generating set 9 Maximum ambient temperature for the rated power 2 Manufacturer name C 3 Model 10 Rated frequency Hz 4 Serial number 11 Generating set rotation speed RPM 5 Year of manufacture 12 Rated voltage V 6 Rated output
197. l Emergency switchover with grid coupling is only possible by carrying out a load test The purpose of the off load test is to start a single GS or to couple a power plant x generating sets to the emergency busbar Important 111 276 N At any time the generating set may be stopped by pressing Stop or by pressing 0 on the test keypad Pressing Stop may interrupt the power supply depending on its status when the key is pressed e g isolated grid operation The generating set will stop after a cooling delay 180 seconds by default Important The green LED underneath the generating set symbol goes out to indicate that the generating set has stopped Switching off The generating set may be stopped at any time by pressing Stop or 0 on the test keypad The green LED underneath the generating set symbol goes out to indicate that the generating set has stopped A Pressing Stop stops the generating set immediately Pressing 0 does not stop the generating set immediately generating set stabilisation time delay Important 112 276 In automatic mode Starting Check there are no faults grey no fault red fault present 370470 22240 ONW grey no alarm orange alarm present If faults are present the fault management screen can be accessed by pressing Reset Refer to the section Alarms and Faults in the Operating menus to elimina
198. lation following a grid loss The grid loss is not controlled by the Kerys Return to the grid can be achieved via Normal Emergency switchover with a self driven inverter not controlled by the Kerys FORCED OPERATION with a generating set Operation in Effacement Jour de Pointe EJP mode or other rates Information transmitted by dry contacts Active power regulation speed of the generating sets by digital buses connected between all the regulation modules lt lt lt Regulation Regulation module module Genset x the EJP system is specific to the French power grid Note 1 In this operating mode active and reactive power is distributed by a digital bus between the regulation modules voltage of the generating sets 75 276 EN Note 2 In an installation of the power plant type several generating sets connected by digital bus two modes of coupling between generating sets are possible e Coupling when stopped e Coupling in normal operation Principle of coupling when stopped all the generating set power units are switched off Starting of all the generating sets when the speed reaches 1450 rpm activated excitation command on all the generating sets the voltage generated by each generating set increases gradually and the voltage is therefore the same in all generating sets the generating sets therefore reach 1500 rpm at 400 V 50 Hz At the end of global operation if the power consu
199. llage A Cooling system Avoid opening the coolant filling cap when the engine is hot Steam or hot coolant can spray out at the same time as the pressure built up is lost If the filler cap coolant hose etc still has to be opened or removed when the engine is hot undo the filler cap slowly and carefully to let the pressure out before removing the filler cap completely and starting work Note that the coolant can still be hot and cause scalding Z Fuel system Always protect your hands when searching for leaks Fluids which leak under pressure can force their way into body tissue and cause severe injury There is a risk of blood poisoning septicemia Always cover the alternator if it is located beneath the fuel filters Fuel spillage can damage the alternator 131 276 Safety information A Electrical system Cut the current Before any work is done on the electrical system the engine must be stopped and the current cut by switch ing off the main switch es External current supply for engine heaters battery chargers or other auxiliary equipment connected to the engine must be discon nected Batteries Batteries contain a highly corrosive electrolyte Pro tect your eyes skin and clothes during charging and other handling of batteries Always use protective gog gles and gloves If acid comes into contact with your skin wash at once with soap and a lot of water If you get battery acid in your eyes flush at
200. lter can be cleaned using compressed air and or replaced if itis clogged After cleaning the alternator it is essential to check the winding insulation see sections 3 2 and 4 8 4 3 Fault detection If when commissioned the alternator does not work normally the source of the malfunction must be identified see sections 4 4 and 4 5 LEROY Ss 11 213 276 LEROY SOMER Installation and maintenance 3856 en 2011 01 h LSA 46 2 4 POLES ALTERNATORS 4 4 Mechanical defects Fault Action Excessive temperature rise in one or Ifthe bearing has turned blue or if the grease has turned black change the bearing Bearin both bearings bearing temperature more Bearing not fully locked abnormal play in the bearing cage 9 than 80 C with or without abnormal Check the end shield alignment flange not properly fitted bearing noise Excessive temperature rise in the d ano e QR partially clogged or hot air is being recycled from the alternator temperature alternator housing more than 40 Alternator operating at too high a voltage gt 105 of Un on load above the ambient temperature Alternator overloaded Misalignment coupling Excessive vibration Defective mounting or play in coupling Vibration Rotor balancing fault Engine Alternator Excessive vibration and humming noise Phase imbalance coming from the machine Stator short circuit System short circuit
201. ly analysing the power required by the user Let us take the example of a power plant of 4 x 600 kW generating sets The threshold setting screen 1 7 3 3 supplies the following data Threshold 1 GS gt 2 GS 75 450 kW Threshold 2 GS gt 1 GS 30 360 kW Threshold 2 GS gt 3 GS 75 900 kW Threshold 3 GS gt 2 GS 30 540 kW Threshold 3 GS gt 4 GS 75 1350 kW Threshold 4 GS gt GS 30 720 kW The maximum available power is 600 x 4 2400 kW Assuming that a single generating set is operating we will have the following sequence in the case of linear progression of the load When the power required by the application reaches 75 of the power of the generating set in operation GS at priority 01 i e 450 kW the second GS at priority 02 is started and is synchronised with GS 1 Its flow is then closed 73 276 EN The second GS thus coupled initiates its power on ramp adjustable delay and the distribution of power among the two generating sets takes place Each generating set will then take 50 of the required power i e 225 kW When the power required for the application reaches 75 of the power of the two generating sets in operation GSs at priority 01 and 02 i e 900 kW the third GS at priority 03 is then started and is synchronised with GS1 and GS2 Its flow is then closed The third GS thus coupled initiates its power on ramp adjustable delay and the distribution of power among
202. made in accordance with the connection diagram There is no short circuit phase phase or phase neutral between the alternator output terminals and the generator set control cabinet part of the circuit not protected by circuitbreakers or relays in the cabinet The machine should be connected with the busbar separating the terminals as shown in the terminal connection diagram UT aoe 3 4 Commissioning The machine can only be started up and used if the installation is in accordance with the regulations and instructions defined in this manual The machine is tested and set up at the factory When first used with no load make sure that the drive speed is correct and stable see the nameplate With the regreasable bearing option we recommend greasing the bearings at the time of commissioning see 4 2 3 On application of the load the machine should achieve its rated speed and voltage however in the event of abnormal operation the machine setting can be altered follow the adjustment procedure in section 3 5 If the machine still operates incorrectly the cause of the malfunction must be located see section 4 4 3 5 Setting up The various adjustments during tests must be made by a qualified engineer Ensure that the drive speed specified on the nameplate is reached before commencing adjustment After operational testing replace all access panels or covers The AVR is used to make any adjustments to the mac
203. main in AUTO mode 74 276 FORCED OPERATION Start of FORCED OPERATION e Generating set power units switched off Generating set start request The generating sets increase in speed Speed stabilisation delay Order of excitation for each generating set at nominal speed the voltage is then quickly established on the busbar Start of active power distribution Resumption of application at rated voltage and frequency The Kerys PLCs remain in AUTO mode The installation is supplied by the generating sets End of FORCED OPERATION e Generating set power units switched on e Cooling delay e Generating sets stopped and set to standby The Kerys PLCs remain in AUTO mode The installation is supplied by the grid Manual power plant operation This mode of operation is selected with the MANU key This enables the operator to start and stop the generating sets one by one via the MMI keypad The generating set power unit is switched off manually with synchronisation of each generating set to the busbar using the MMI keys F F V and V The distribution of power among the generating sets remains automatic The safety devices of the generating sets remain active in this mode of operation This mode of operation is the responsibility of the operator Without common part and without Normal Emergency inverter A633 This configuration is designed to provide Y Emergency electricity supply to an instal
204. med by the installation does not require the operation of all the generating sets within the power plant one or more generating sets will be stopped according to the wattmetric control Restarting of the generating set these generating sets depends on the load and wattmetric control of the load However if a generating set is reconnected to a busbar already subjected to a load the recoupling is carried out in normal operation and not when the generating set is stopped Principle of coupling in normal operation Coupling in normal operation enables all the generating sets to be coupled in voltage and frequency to a busbar supplied by a generating set designed as master at the output A number 1 to 15 is assigned to each Kerys This number serves solely to establish the IP address of each Kerys for communication by Ethernet and loading the programs A second number from 1 to 15 is also assigned to each Kerys and defines the priority Example let us assume a plant of 8 generating sets Gen set 1 2 3 4 5 6 7 8 Priority 08 07 06 05 04 03 02 01 The numbers on the first line enable the IP address of each Kerys to be allocated The numbers on the second line define the priority Therefore Kerys no 8 with priority 01 is considered to be the master generating set and closes its flow first The other generating sets then synchronise one by one to the central busbar transmitting the information on volt
205. ms eu Beth Ae tuc d agen citra ue dieta aad ten Tea Abd E ode Be De PEERS 14 2 22 Technical specifications ia aoo cedet t es c tite re at MAGE rite set ee D A ute pet mire 18 2 3 Fuel and consurmables 2 45 52 ete Ger t e a d iere eee itr 20 2 331 Specificatiornis e be oe ao e Uu aet n UE Oa etm te bee triv dette te oboe wae rco EEES 20 2 3 T 1 Oll grad s inue eae davies aeo Dui dia rto Be IR d re nete Ro adeste 20 23 125 Specifications f coolants 52 tno D nA ero qe e EE RE Beginn a D DOE E Se die nes 21 3 Installations ertet ote en Basics ncs etse Ot sore ee ei abd P a ent epe diete rre dritto rues 23 3 1 Unloading 5 mr eee neum o Ete ttem 23 3 1 f Safety during ote eee RR cedit eene ober dene sean eto TE Ree Een 23 3 12 Instructions for eee itte reti desse be eaten eres 23 EE 23 3 1 2 22 E a EEA ed Ck oet E teet pee E E 23 3 2 Eluidaetentlon oui osten getreten Ric eric er eerte rnit oeste rie tree testet D 24 3 3 Choice of location i ee e tret eoe edtetite etia ent br genit tot toe 25 3 4 Bl ctricity o etd A MR PERI Cents 26 3 5 Special arrangemients eene te iter turtles tense vtae eer eee ash nie tese evt A e a rE R EnS 28 MCI MR EE 29
206. n h Check LAM operation depending on the rotating switch selection 14 LEROY SOMER 252 276 LEROY SOMER Installation and maintenance 4531 en 2010 10 c R 450 AVRs i Vary the frequency speed around 48 or 58 Hz according to the operating frequency and check the change in voltage from that observed previously 15 j Readjust the speed of the genset to its rated no load value Adjustments in parallel operation Before starting work on the alternator make sure that the speed droop is identical for all engines k Preset for parallel operation with C T connected to 1 S2 Potentiometer P4 quadrature droop in 1 4 position in the case of 5A CT and at 1 2 position in the case of 1A CT Apply the rated load PF 0 8 inductive The voltage should drop by 2 to 3 400 V If it increases check that neither V and W nor S1 and S2 have been reversed I The no load voltages should be identical for all the alternators intended to run in parallel Couple the machines in parallel By adjusting the speed try to obtain 0 kW power exchange By altering the voltage setting P1 on one of the machines try to cancel or minimise the current circulating between the machines From now on do not touch the voltage settings m Apply the available load the setting is only correct if a reactive load is available By altering the speed match the kW or divide the ra
207. n Do not operate with guards removed Stop genset before servicing Avold skin contact with exhaust manifolds turbochargers and mufflers Keep flammable materials clear of the hot parts D Not touch until the machine has sufficiently cooled Battery gas can explode Keep sparks and flames away from batteries Sulfuric acid in battery electrolyteis poisonous WARNING DANGER Hot coolant can cause serious burns Switch off the engine Do not remove the filler cap until it is completely cold Do not open the radiator when it is hot DANGER Rotating parts can cause serious injury Do not operate the generating set with the doors open Do not remove the enclosures Shut down the generating set before any maintenance or servicing operation DANGER Avoid any contact with the exhaust pipes turbochargers and silencers Keep flammable materials away from hot parts Wait for the machine to cool down completely before touching it WARNING DANGER The gas from the battery electrolyte is explosive Keep the batteries away from any flames The battery electrolyte sulphuric acid is toxic Risk of poisoning Figure 1 2 continued Pictograms and their meanings 6 276 Improper grounding can cause serious injury or death Always complete the grounding path from the ground terminal on this genset to an external grounding source See operator s manual for instructions as NOT
208. n Sensor shorted to earth Short to V Speed signal invalid 105 105 Intermittent problem with speed information Manifold air temperature sensor Manifold air temperature extremely high Manifold air temperature sensor input voltage high Manifold air temperature sensor input voltage low Manifold air temperature sensor open circuit Air temperature very high 106 106 Manifold air temperature moderately high Air inlet pressure sensor Air inlet pressure above normal Air inlet pressure sensor input voltage high Air inlet pressure sensor open circuit 262 276 N SPN CID SID PID PPID FMI 5 Perkins Description Comment 107 107 Air filter differential pressure sensor Air filter restriction high Air filter differential pressure sensor input voltage high Air filter differential pressure sensor input voltage low 108 274 108 Air filter differential pressure sensor open circuit Air filter restriction high Barometric pressure sensor Not use with EDC Ill and EMS2 Air pressure invalid High barometric pressure sensor short to high High barometric pressure sensor short to low 110 110 110
209. n activated Please refer to Governor droop in the main menu for activation Overspeed limit 96 setting the speed for the excess speed alarm 96 of set engine speed e Overspeed shutdown activation of engine shut down when the excess speed alarm is activated Please refer to Overspeed limit to activate the alarm limit for the excess speed alarm Oil temp warning limit C setting the alarm limit for the oil temperature Coolant temp limit C setting the alarm limit for the coolant temperature Throttle input setting speed control setting throttle operation Set throttle mode OFF engine speed is controlled via the DCU panel ext throttle input engine speed is controlled with a potentiometer accelerator ext voltage input engine speed is controlled by an external unit Setidle voltage V setting the voltage level at idle Set max voltage V setting the voltage level at maximum speed Potentiometer value 96 100 1 0 Voltage V 7 Voltage V Max Idling 142 276 Introduction Setup Display Display setting gt e udo M dun settings for the display Adjustment is done with the my A Set backlight brightness 10 7 and 9 buttons please refer to the DCU panel in the illustration Set contrast display contrast adjustment e Set backlight time sec sets the time
210. n be read as long as the malfunction remains You can find information about cause reaction and actions in the Fault Code chapter Read the fault code as follows 1 Press the diagnostic button 2 Release the diagnostic button and make a note of the fault that is flashed out 3 Repeatitems 1 2 A new fault code is flashed out if more are stored Repeat until the first fault code is repeated 4 Look up the fault code in the Fault Code chapter and take the recommended measures NOTE When the first fault code is repeated all fault codes have been read out If the diagnostic button is pressed after the fault has been mended and the fault codes have been erased code 1 1 No fault will be displayed 177 276 Reading fault codes via Easy Link in strument only with CIU When the system has discovered a malfunction the diagnostic lamp starts to flash and the fault code will show in the display of the tachometer 1 Pressthe diagnostic button the fault code will show in the display of the tachometer 2 Look up the fault code in the Fault Code chapter and take the recommended measures 3 When the fault has been attended to the fault code disappears from the display and the diagnos tic lamp goes out Erasing fault codes Fault codes must be erased by means of the VODIA tool Fault codes WARNING Read through the safety advice for care and maintenance work in the Safety information chap
211. n cable harness boost pressure sensor e Mechanical fault on the IEGR Reaction Engine control module reduces engine power un less the protection has been shut off with the VODIA diagnostic tool Remedy e Check cable harness boost pressure sensor e Check the IEGR 61 Technical data General Type designation TAD940GE TAD941GE Power Prime Stand by Please refer to the sales literature Torque Prime Stand by Please refer to the sales literature Compression ratio 20 2 1 17 4 1 Low idle rpm 600 1200 600 1200 High idle rpm 1500 1620 1500 1620 1800 1920 1800 1920 Highest full load speed rpm 1500 1800 1500 1800 No of valves 24 24 No of cylinders 6 6 Cylinder bore mm inch 120 4 72 120 4 72 Stroke mm inch 138 5 43 138 5 43 Swept volume dm US quart 9 36 9 89 9 36 9 89 Weight dry kg Ib 1015 2238 1015 2238 Weight wet kg 16 1065 2348 1065 2348 Injection sequence 1 5 3 6 2 4 1 5 3 6 2 4 Type designation TAD940VE TAD941VE TAD942VE TAD943VE Power Please refer to the sales literature Torque Please refer to the sales literature Compression ratio 20 2 1 20 2 1 20 2 1 20 2 1 Low idle rpm 600 600 600 600 High idle rpm 2250 2250 2250 2250 No of valves 24 24 24 24 No of cylinders 6 6 6 6 Cylinder bore mm inch 120 4 72 120 4 72 120 4 72 120 4 72 Stro
212. n power plant 2 censa Number of gen sets in power plant 0 lt Vali 7 Enter the number of generating sets in the power plant using the numeric keypad Start with O if the number is less than 10 generating sets E g 2 generating sets gt enter 0 then 2 10 generating sets gt enter 1 then 0 8 Press Valid to confirm the entry 100 276 EN Back up to perform GS 1 Rental application Faults A633 Power plant without shared switching unit without Normal Emergency Digital Bus Number of gen sets in power plant Genset number PN Validation 9 Press the generating set number on the touch screen Back up to perform GS 1 Rental application A633 Power pla z aoe without Nor 22151 Number of gen s 10 Select the number of the generating set with the arrows connections Important The number of the generating set determines its type of connection see the section Electrical 11 Press Valid to confirm the entry 101 276 N Back up to perform Rental application Faults A633 Power plant without shared switching unit without Normal Emergency Digital Bus Number of gen sets in power plant 2 Genset number Validation 12 Press Validation on the touch screen Back up to perform GS 1 Rental application A633 Power plant without shared switching unit without Normal Emergency Digi
213. n t Agee De nde eerte e eor Pep dee eae 37 6 211 View of the front panel 2 ue a eri ce nde i be arte rdg erc E PR E e Hee barat 37 6 22 12 Descrption of th Scr n sce etie ee HIR Ale aide t eee VISE det qae Eee coo do eeu Vae Pug EE Ee 39 6 2 1 3 Description of the pictograms in zone 1 eene nre nnne tnen nenne tnnn reinen 40 6 2 1 4 Description of the pictograms in zone 2 sese enne trennen innen 41 6 2 1 5 Description of the pictograms in zone 3 nennen trennen enne 42 6 2 1 6 Display of messages 1n zone e e a eia nter bee deed vea 44 6 2 2 E 48 6 23 Switching Off arcs sha een een orto Batre lee aie abd 49 6 2 4 Alarms and erp etel e p gerettet Ip ied Pese titi hu beu eee a RARE vd etoile 49 624 L1 Viewing alarms and faults npe o EDU E PE ER ER eee 49 6 2 4 2 Activation of oen e eee ehe e en Te 50 6 2 4 3 Activation of an alarm and a fault s tn nn teen nennen nnne 51 6 244 Engin faultcodes display seie epe ER eo eu delete rt re ee Pea i betel anaes 52 ES PEMUshinp c MH m 53 1 276 6 3 Generator set with KERYS control 1
214. ncy repair kits are available as an option They contain the following items Emergency kit SHUNT ALT 472 KS 001 AVR R 250 Diode bridge assembly Surge suppressor Emergency kit AREP ALT 461 KS 001 AVR R 450 Diode bridge assembly Surge suppressor Single bearing kit ALT 471 KB 002 Non drive end bearing ring Preloading wavy washer Double bearing kit ALT 471 KB 001 Non drive end bearing Drive end bearing ring Preloading wavy washer 5 2 Technical support service Our technical support service will be pleased to provide any additional information you may require When ordering spare parts you should indicate the complete machine type its serial number and the information given on the nameplate Address your enquiry to your usual contact Part numbers should be identified from the exploded views and their description from the parts list Our extensive network of service centres can dispatch the necessary parts without delay To ensure correct operation and the safety of our machines we recommend the use of original manufacturer spare parts In the event of failure to comply with this advice the manufacturer cannot be held responsible for any damage 5 3 Accessories 5 3 1 Space heater for use when stopped The space heater must run as soon as the alternator stops It is installed at the rear
215. ne ener nenne nnn nnn 2 1 Electrical characteristics oec ride esed e 2 2 Mechanical characteristics sss enne S INSTALLATION E SEETACI CE 3 2 Checks prior toTirst se ido pedet Denia dee eate rd aede eode eo 3 3 Terminal connection diagrams essseseeeeen eme eee 3 4 COMMISSIONING ss ives scooter teens iet ERE Te dee Ft ecce nece base dede sty acea ete e 10 3 5 ettilig Up er e ei terrd laus Hetil 10 4 SERVICING MAINTENANTCE ener nnn nennen inneren entretenir tenens 11 4 1 Safety 11 4 2 ener tenen nne tenens 11 4 3 Fault detectlon ete t dete Oe Res RU eee Dee Rein 11 4 4 Mechanical defects 5 triente dateien ches seen cede eden ned ean 12 AS Electrical faults oreet 12 4 6 Dismantling reassembly sse enne 14 4 7 Installation and maintenance of the PMG 16 4 8 Table of characteristics innn aa aaa e aeaa a aaa 17 5 5 18 5 1 First maintenance parts eee 18 5 2 Technical
216. nected correctly Code 3 8 PID SPN 94 Fuel pressure Cause Low supply pressure Reaction None Remedy e Check if it is possible to build up pressure with the hand pump e Check the fuel filter e Check the fuel pre filter 180 276 Code 3 9 PID SPN 158 Battery voltage EMS Cause Faulty alternator Faulty battery battery cables Reaction None Remedy e Check the supply voltage from the control unit Code 4 8 PPID 6 SPN 520195 Stop input EMS Cause e Short circuit to negative e Open circuit Reaction Engine can only be stopped with the auxiliary stop Remedy e Check that the starter switch connections are not damaged Code 5 2 PPID 4 SPN 520194 Starter input CIU Cause Shorted to minus e Activated for too long Reaction The engine cannot be started The engine starts immediately when ignition is tur ned on Remedy e Check that connections to the ignition key have not been damaged Check that the cable harness to the ignition key has not been damaged 181 276 Fault codes Code 5 3 PPID 6 SPN 970 Stop input CIU Cause e Short circuit to negative e Open circuit e Activated for too long time Reaction Engine can only be stopped with the auxiliary stop AUX STOP on engine Engine stops A fault code is displayed for 40 seconds and the engine can not be started during this time When a fault code is active the engine
217. ng Y Proper ventilation is required for your generating set pump unit or lighting column to work properly Without this ventilation the engine would very quickly rise to an excessively high temperature causing accidents or damage to the equipment and to surrounding property Y Do not remove the radiator cap if the engine is hot and the coolant is pressurised due to risks of burns Y Depressurise the air oil and cooling circuits before removing or disconnecting all the fittings pipes or connected components Watch out for the possible presence of pressure when disconnecting a device from a pressurised system Do not try to find pressure leaks by hand Oil at high pressure can cause bodily damage Y Some preservative oils are flammable Also some are dangerous to inhale Ensure proper ventilation Use a protective mask Y Hotoil causes burns Avoid contact with hot oil Check that the system is no longer pressurised before carrying out any procedures Never start or run the engine with the oil filler cap off oil may splash out Y Never coat the generating set pump unit or lighting column with a thin layer of oil to protect it from rust Y Never top up the oil or coolant if the generating set pump unit or lighting column is running or if the engine is hot Y A generating set can only operate when stationary and cannot be installed on a vehicle or other mobile equipment without a prior study taking into account the various specific features of
218. nised steel earthing rod embedded vertically into the ground The earthing rod resistance value should comply with the values shown in the table below Note use the highest differential setting from the installation as a guideline The resistance value is calculated in the following way R Er n Maximum resistance value of the earth socket R Q according to the differential unit operational current operation time should not be longer than 1 second IAn Earth R Earth R differential UL 50 V Ul 25 V lt 30 mA 500 gt 500 100 mA 500 250 300 mA 167 83 500 mA 100 50 1A 50 25 3A 17 8 5 10 5 10 5 2 5 The UI value 25 V is required for work site installations and livestock buildings etc 27 276 For a default voltage of 25 V and a default current of 30 mA this rod must be of a minimum length of see table below impermeable rock Length of Nature of ground rod in metres Thick arable land 1 moist compact ballast Lean arable land 1 Gravel coarse ballast Bare stony soils dry sand To obtain an equivalent length you can use several earthing rods i 3 6 connected in parallel and set apart by at least their length Example 4 interconnected 1 metre rods separated by 1 metre Note For the United States National Electrical Code reference NFPA 70 The generating set must be earthed To do this use a copper wire with a minimum cr
219. nly measures the oil lev el at the time when the ignition is turned on In other words not continually during operation Engine oil changing AN WARNING Hot oil and hot surfaces can cause burns NOTE Oil changes must be done when the engine is warm 1 Connectthe drain hose to the oil drain pump and check that no leakage can occur 2 Pumpthe oil out or remove the bottom drain plug and drain the engine oil NOTE Collect the old oil and oil filters and hand them to a re cycling station for destruction 3 Remove the drain hose or install the bottom drain plug 4 Fillup with engine oil Change volume please re fer to the Technical Data chapter 31 157 276 Maintenance 32 Oil filter By pass filter change WARNING Hot oil and hot surfaces can cause 158 276 burns Clean the oil filter bracket Remove all oil filters with a suitable oil filter remover 1 Clean the mating surface of the oil filter bracket Make sure that no pieces of old oil seal are left behind Carefully clean round the inside of the pro tective rim 2 Put a thin layer of engine oil on the seal rings of the new fuel filters Install the new oil filters Tighten the two full flow fil ters on the right of the illustration 1 2 3 4 turns af ter they just touch Tighten the bypass filter 3 4 1 turn after it just touches Top up with engine oil start the engine and let it run for 20 30 seconds
220. not exceed 10 seconds for transfer of the generating set s rated output The generating set power unit is disconnected when the power on the generating set reaches the lower limit Generating set power unit switched on Cooling delay Generating set stopped and set to standby The Kerys remains in AUTO mode FORCED OPERATION Kerys in AUTO mode temporary outward and return coupling Start of FORCED OPERATION Generating set start request The generating set voltage and speed increase When the generating set is stabilised in speed and voltage synchronisation of the generating set to the grid is requested After synchronisation the generating set power unit is switched off Transfer of the active and reactive power from the grid to the generating set according to a predetermined ramp The ramp does not exceed 10 seconds for transfer of the generating set s rated output The generating set power unit is disconnected when the power on the generating set reaches the lower limit Power unit switched on grid side The installation is supplied by the generating set End of FORCED OPERATION Opening of the forced operation order Synchronisation of the generating set to the grid Grid power unit switched off Transfer of the generating set s active and reactive power to the grid Generating set power unit switched on Cooling delay Generating set stopped and set to standby The Kerys remains in AUTO mode The installation is
221. nt to flow only in the anode to cathode direction A C Anode p e Cathode ccc tt I EI 25 09999 Oeoe C c c 4 5 3 Checking the windings and rotating diodes using separate excitation During this procedure make sure that the alternator is disconnected from any external load and inspect the terminal Assembly A Connect a 12 V battery in series with a rheostat of approximately 50 ohms 300 W and a diode on both exciter field wires 5 and 6 ASSEMBLY A 6 Exciterfield 5 Rh 509 300W 12V battery Assembly B Connect a Variac variable power supply and a diode bridge on both exciter field wires 5 and 6 Both these systems should have characteristics which are compatible with the field excitation power of the machine see the nameplate 3 Run the unit at its rated speed 4 Gradually increase the exciter field current by adjusting the rheostat or the variac and measure the output voltages on L1 L2 L3 checking the excitation voltage and current at no load see the machine nameplate or ask for the factory test report When the output voltage is at its rated value and balanced within 1 for the rated excitation level the machine is in good working order The fault therefore comes from the AVR or its associated wiring ie sensing auxiliary windings ASSEMBLY B 6 Exciter field 5 Diode 1A box to che
222. ntion Any outflow of the fluids contained in the generating sets fuel oil and coolant or rainwater or condensation will be collected in a retention container if the generating set is fitted with this option The containers have a capacity which allows 110 of the fluids contained in the generating set fitted with this option to be collected Three different fittings are available Diagram 3 2 Fluid retention container integrated into the tank chassis Diagram 3 3 Offset fluid retention container underneath the generating set chassis 24 276 Diagram 3 4 Offset fluid retention container integrated into the chassis and tank Generating sets fitted with the offset tank option DW above also have a high level indicator in the retention container In all cases the retention containers must be regularly checked to ensure they contain no fluid fuel oil and coolant or rainwater or condensation If necessary drain the containers either via the drain port or by using the drain pump for containers fitted with this pump Y Note Never allow these fluids to drain onto the ground ensure they are collected in a designated container 3 3 Choice of location It should be determined on the basis of use There are no specific rules governing the choice of location other than proximity to the electric distribution panel and disturbances caused by the noise However fuel supply burnt gas evacuation and the direction of these gases and
223. o cases where this will be used 1 for emission related diagnostics where the particular failure cannot be separated between a sensor out of range and the case where the actual value is at the edge of a diagnostic region and 2 for the older SPN 611 to 615 where the problem is in determining which of two or more circuits which may interact is the one that needs repair SPNs 611 through 615 are defined as System Diagnostic Codes and are used to identify failures that cannot be tied to a specific field replaceable component Specific subsystem fault isolation is the goal of any diagnostic system but for various reasons this cannot always be accomplished These SPNs allow the manufacturer some flexibility to communicate non specific component diagnostic information Since SPNs 611 615 use the standard SPN FMI format it allows the use of standard diagnostic tools electronic dashboards satellite systems and other advanced devices that scan Parameter Groups containing the SPN FMI formats Because manufacturer defined codes are not desirable in terms of standardization the use of these codes should only occur when diagnostic information cannot be communicated as a specific component and failure mode Possible reasons for using a System Diagnostic Code include 1 Cost of specific component fault isolation is not justified or 2 New concepts in Total Vehicle Diagnostics are being developed or 3 New diagnostic strategies that are not component s
224. of fault that has occurred This may be an electrical mechanical or equipment fault VOLVO uses a SID FMI or PID FMI or PPID FMI combination Terminology used by PERKINS CID Component parameter This term used by PERKINS has an equivalent in the J1939 standard SPN FMI Failure Mode identifier This represents the type of fault that has occurred This may be an electrical mechanical or equipment fault Terminology used by JOHN DEERE SPN Suspect Parameter Number This represents the system or component at fault for example SPN 100 indicates an oil pressure problem or a problem with the oil pressure sensor FMI Failure Mode identifier This represents the type of fault that has occurred This may be an electrical mechanical or equipment fault 52 276 Terminology used by MTU The ADEC and MDEC general system faults are indicated on the equipment in Displaying faults the following way fault code numbers generated by the ECU Engine control unit In the event of a fault the screen will display the following message Engine fault code Pressing OK will display fault finding information In addition appendix indicate the meaning of 252 2005 15 30 the code The checking and maintenance operations to carry out in order to solve the fault are included in the user and maintenance manuals of the engines supplied with the generating set document
225. om 150 kHz to 80 MHz could be increased to 10V Complies with standard IEC 61000 4 8 Immunity to the magnetic field at the grid frequency at 30 A m 55 276 EN 6 3 2 Description of the KERYS 6 3 2 1 Identification of the hardware components KERYS Tactil MMI module ICS KERYS TACTIL Volts 15 to 36V P N 31613391001 Alimentation Watts 12W IND CONT EQ Power supply 10W2 Type 12 242 MMI Module P N 31613391001 Module item reference D346000 manufacturer product reference D346000 B1 B1 module hardware upgrade index 1800 serial number not related with a batch number 1800 1800 the 1800 module manufactured since the start 08 year of manufacture year 2008 06 week of manufacture week 6 BATCH No 08 06 Base module Base module P N 31613390901 Module item reference D338000 manufacturer product reference D338000 B8 B8 Module hardware upgrade index 3491 serial number not related with a batch number pen 3491 the 3491 module manufactured since the start 07 year of manufacture year 2007 45 week of manufacture week 45 BATCH No 07 45 56 276 Regulation module NO Relsis num ro 1 dV 10A zowa Alimentation 24 Volts c Relay number 1 Power Supply 24 Volts Bus CAN num ro 1 Relais num ro 2 240V 8A CAN bus number 1 NC Relay number 2 B
226. ombustion devices have the correct fuel supply Apart from the combustion devices it is prohibited to use fire in any form This restriction must be clearly displayed Spreading of waste water sludge and waste is prohibited The fuels to be used must correspond to those featured in the declaration file and the specifications recommended by the combustion device manufacturer The fuel is considered to remain in the same physical state as when it is introduced into the combustion chamber Burning of waste in the open air is prohibited Always protect your hands when checking for leaks Pressurised liquids may penetrate body tissue and cause serious damage Risk of blood contamination Drain and dispose of engine oil in a specially provided container fuel distributors can collect your used oil Except by special agreement once closed the gas supply main unit must only be re opened by the gas distributor However the user may access it under certain conditions Check these for each site 1 3 2 Risks related to exhaust gases and fuels The carbon monoxide present in exhaust gases may cause death if the concentration levels in the air breathed are too high Always use generating sets pump units or lighting towers in a well ventilated place where gases cannot accumulate In case of indoor use Y sure to evacuate exhaust gases outdoors Danger Y Provide appropriate ventilation so that personnel present are not affected
227. on of electricity for an installation in forced operation Regulation module Base module Application load Automatic operation Kerys in AUTO mode Loss of grid voltage e Generating set start request dry contact switch clock etc e The speed and voltage of the generating set increase e Generating set power unit switched off after voltage and frequency stabilisation Return of grid voltage e Dry contact switch clock etc switched on e Cooling delay e Generating set stopped and set to standby 69 276 EN FORCED OPERATION Kerys in AUTO mode Start of FORCED OPERATION e Generating set start request dry contact switch clock etc e The speed and voltage of the generating set increase e Generating set power unit switched off after voltage and frequency stabilisation The installation is supplied by the generating set End of FORCED OPERATION e Dry contact switch clock etc switched on e Generating set power unit switched on e Cooling delay e Generating set stopped and set to standby The Kerys remains in AUTO mode Manual operation of generating set This mode of operation is selected with the MANU key on the front of the MMI module The operator is able to start and stop the generating set by using the MMI keypad The generating set power unit is switched off by means of the MMI keys The safety devices of the generating set remain active in this mode of operation
228. once with a lot of cold wa ter and get medical assistance at once AN Electric welding Remove the positive and negative cables from the batteries Then disconnect all cables connected to the alternator Disconnect both connectors from the engine control module Always connect the welder earth clamp to the compo nent to be welded and as close as possible to the weld site The clamp must never be connected to the engine or in such a way that current can pass through a bearing When welding is completed Always connect the al ternator cables to the alternator and connectors to the engine control module before the battery cables are put back Introduction This instruction book has been prepared to give you the greatest possible benefit from your Volvo Penta industrial engine It contains the information you need to be able to operate and maintain the engine safely and correctly Please read the instruction book carefully and learn to handle the engine controls and other equipment in a safe manner before you start the engine IMPORTANT This instruction book describes the engine and equipment sold by Volvo Penta Variations in appearance and function of the controls and instruments may occur in certain variants In these cases please refer to the instruction book for the relevant application Environmental responsibility All of us want to live in a clean healthy environment where we can breathe clean air see healthy tre
229. ork required Slings positioned in the eyes provided for this operation or lifting arms resting fully underneath the chassis cross members Ground able to take the load of the set and the lifting machinery without stress otherwise lay down beams of sufficient strength and stability Set put down as close as possible to its point of use or transportation in a clear area with free access Example of equipment to be used Y crane slings cross bar safety catch shackles Y Fork lift truck 3 1 2 Instructions for unloading 3 1 2 1 Slings Attach the lifting vehicle slings to the rings on the generating set designed for this procedure Hang the slings carefully Check that the slings are correctly attached and the equipment is solid Direct and stabilise the set towards the chosen position Carefully set down the equipment while continuing to position it e generating set carefully e Release the slings then detach and remove the lifting rings 3 1 2 2 Fork lift truck Position the forklift arms under the base frame except with generating sets fitted with forklift pockets in which case position the forklift arms in these pockets making sure that only its cross members are resting on the arms Lift the equipment handling it gently set down the generating set in its unloading position Figure 3 1 Transporting a generating set using a forklift truck 23 276 N 3 2 Fluid rete
230. oss section of 13 3 mm or AWG 6 at most connected to the generating set earth socket and a galvanised steel earthing rod fully embedded into the ground vertically This earthing rod embedded fully in the ground must have a minimum length of 2 5 m 3 5 Special arrangements Generating sets are not fitted with protection against power surges caused by drops in atmospheric pressure or manoeuvring The company does not accept any responsibility regarding damage caused by these occurrences However lightning conductors can be installed on the understanding that this does not give total protection 28 276 N 4 Trailer 4 1 Trailer linkage Before attaching the trailer check the trailer hook on the tow vehicle it should fit the trailer ring perfectly Trying to tow a trailer with a non matching device bar wires cords etc could lead to serious accidents Also check no incipient fractures or excessive wear on the hitching system Danger locking system is operating properly To hitch the trailer proceed as follows Lock the wheels to stop the trailer from moving Litt up the rear trailer supports and lock them Release the parking brake Release the locking levers for the draw bar arms and adjust the ring to the same height as the vehicle hook Hitch the trailer remove the locks on each side of the wheels then lift up the front wheel fully using its handle Connect the electrical circuit of th
231. ower unit e Cooling delay e Generating set stopped and set to standby Y Example of increase in power e Generating set start request The generating set increases in speed Alternator excitation the generating set establishes its voltage Request for synchronisation of the generating set to the bus bar i e the other coupled generating sets Generating set power unit switched off Y Return of grid voltage e Grid return acquisition delay controlled by the mains detection module e Generating set power units switched on e Cooling delay e Generating sets stopped and set to standby The Kerys PLCs remain in AUTO mode FORCED OPERATION Start of FORCED OPERATION e Generating set power units switched off Generating set start request The generating sets increase in speed Speed stabilisation delay Order of excitation for each generating set at nominal speed the voltage is then quickly established on the busbar Start of active power distribution Resumption of application at rated voltage and frequency The Kerys PLCs remain in AUTO mode The installation is supplied by the generating sets End of FORCED OPERATION e Generating set power units switched on e Cooling delay e Generating sets stopped and set to standby The Kerys PLCs remain in AUTO mode The installation is supplied by the grid Manual power plant operation This mode of operation is selected with the MANU key This enables the operator to
232. pecific are being developed Due to the fact that SPNs 611 615 are manufacturer defined and are not component specific FMIs 0 13 and 15 31 have little meaning Therefore FMI 14 Special Instructions is usually used The goal is to refer the service personnel to the manufacturer s troubleshooting manual for more information on the particular diagnostic code This failure mode does not relate to the signal range definition as do many of the FMls This type of fault may or may be directly associated with the value of general broadcast information FMI 15 DATA VALID BUT ABOVE NORMAL OPERATING RANGE LEAST SEVERE LEVEL The signal communicating information is within a defined acceptable and valid range but the real world condition is above what would be considered normal as determined by the predefined least severe level limits for that particular measure of the real world condition Region i of the signal range definition Broadcast of data values is continued as normal FMI 16 DATA VALID BUT ABOVE NORMAL OPERATING RANGE MODERATELY SEVERE LEVEL The signal communicating information is within a defined acceptable and valid range but the real world condition is above what would be considered normal as determined by the predefined moderately severe level limits for that particular measure of the real world condition Region k of the signal range definition Broadcast of data values is continued as normal FMl 17 DATA VALID BUT BELOW NORMAL OPERAT
233. ponents can cause fires Store fuel soaked rags in a fire proof manner 165 276 Fuel specification The fuel must at least comply with national and internationalstandards for commercially supplied fuels such as EN590 with nationally adapted environmental and coldrequirements ASTM D 975 No 1 D and 2 D JIS KK 2204 Sulfur content Complying with legal requirements in each country content exceeds 0 5 percent by weight the oil change intervals must be changed Please re fer to the Lubrication system heading Extremely low sulfur content fuel urban diesel in Swe den and city diesel in Finland can cause a loss of up to 5 of power and an increase in fuel consumption of about 2 3 39 Maintenance 40 Fuel filter changing NOTE Do not fill the new fuel filter with fuel before assembly There is a risk that contamination could get into the system and cause malfunctions or damage WARNING The fuel filter must be changed when the engine is cold to avoid the risk of fire due to spilled fuel on hot surfaces 1 Clean round the fuel filter 2 Remove the filter with a suitable filter remover Collect any spilled fuel in a collection vessel 3 Clean the filter mating surface on the filter bracket 4 Lubricate the seal with diesel fuel and install the new fuel filter Tighten the fuel filter in accordance with the instructions on the fuel filter 5 If necessary vent the fuel system
234. quires the replacement of the ECU used here to mean the packaged unit that includes some microprocessor and its associated components and circuits It can be assumed that the communications subsystem is not the part that has failed and the manufacturer has determined that there is no serviceable component smaller than the ECU involved in the failure Broadcast of data value is substituted with the error indicator value if appropriate as there may or may not be any broadcast involved This error is to include all internal controller trouble codes that can not be caused by connections or systems external to the controller FMl 13 OUT OF CALIBRATION A failure that can be identified to be the result of not being properly calibrated This may be the case for a subsystem which can identify that the calibration attempting to be used by the controller is out of date Or it may be the case that the mechanical subsystem is determined to be out of calibration This failure mode does not relate to the signal range definition as do many of the FMls FMl 14 SPECIAL INSTRUCTIONS Special Instructions is the FMI to be used when the on board system can isolate the failure to a small number of choices but not to a single point of failure When the FMI is used there is clear necessity for the service technician to take some action to complete the specific diagnosis and the manufacturer has provided instructions for the completion of that diagnosis There are tw
235. r plant configuration Several generating sets in parallel 72 6 3 5 Connections of the eneratins Sets 4 e oai aom etre ches settle e ete Rem este esc eee trie e euet rint hee dedu Ra 79 6 3 5 1 Recommendations before the connections eese nennen nennen trennt ne enne 79 6 3 5 2 Connections according to the configurations 79 6 3 5 3 Earthing Standard eene 80 6 3 54 Facility power outlet oer ego e ge t EE RE e Deut ta PE Eu eure Pe EH 84 6 3 5 5 Connecting cable between the generating sets power plant esee eene rennen 85 0 3 5 6 POWT Li eot e oer eren Roe eo ciet eet e et T eee t ere bie Eee 86 6 3 5 7 Ghentt ermmal block pene emet tiere ee e atrii e oS Te eee 86 6 3 6 Operation and see Menus eec oe re etos eoe Os pies He ton te be NR rin s 87 6 3 6 L bEdyoutof the menus aet ER PR RM aiite ie erit reete ast ao Tie ERR rE 87 6 3 6 2 Setting of regional parameters sce eet e teme eee er eie de etos fe foeni pee e ese Io pie Reti 88 6 3 6 3 Intormation on the KERYS once eiie recte er im tree teer aute te tere Nb lenis e HER 90 6 3 6 4 Operatine THelUS eoe Unete ot Pon eese feet re n pee e Mene IRE PARA 92 6 37 Rental COnfIBUTAtlons ein eot e e po
236. r supply voltage problem For 6125HF070 only ECU unswitched power missing For 6068HF275 VP44 only 628 240 Battery voltage below the operating voltage For John DEERE Tiers III Memory fault in EMS2 629 254 ECU status controller error CIU module status RAM cell test failure CPU watchdog reset test failure 11 12 13 19 Main and fuelling ASIC test fail RAM address test failure Watchdog trip failure ECU to injection pump communication error Possible only with 6068HF475 VP44 630 253 Data set memory EEPROM 632 Injection status Fuel shutoff error Fuel shutoff non functional 636 21 Pump position sensor Cam position sensor Speed sensor CAM Pump position sensor cam position sensor input noise Pump position or CAM position in function of the type of injection Permanent loss of signal High impedance of the position sensor or circuit open o a j Sensor short to ground Pump position sensor cam position sensor input missing Not informed by VOLVO 4 Pump position sensor cam position sensor input pattern error 266 276 SPN 637 CID SID 22 PID PPID FMI John Deere Volvo Perkins EN Description Crank position sensor Speed sensor flywheel Comment
237. rating at full power Avoid sudden throttle openings and operation at high engine speeds Checking instruments Check all instruments directly after starting and then regularly during operation AN IMPORTANT On engines which operate continu ously the lubrication oil level must be checked at least every 24 hours Please refer to the Maintenance lubrication system chapter Fault indication If the EMS 2 system receives abnormal signals from the engine the control unit generates fault codes and alarms in the form of lamps and audible warnings This is done by means of CAN signals to the instru ment More information about fault codes and fault tracing is found in the Diagnostic function chapter 149 276 Operation at low load Avoid long term operation at idle or at low load since this can lead to increased oil consumption and even tually to oil leakage from the exhaust manifold since oil will seep past the turbocharger seals and accompa ny the induction air into the inlet manifold at low turbo boost pressure One consequence of this is that carbon builds up on valves piston crowns exhaust ports and the exhaust turbine At low load the combustion temperature is so low that full combustion of the fuel can not be ensured which means that the lubrication oil can be diluted by diesel fuel and the exhaust manifold will eventually leak oil If the following points are done as a complement to normal maintenanc
238. re a serious accident For reversing manoeuvres remember to lock the inertia brake In the first few miles driving heating of the brake hubs and drums will actually reduce the wheel tightness It is therefore essential to check the tightness every 6 miles 10 kilometres until no further loosening is noted Particular attention must be paid to the tightness of the wheels on vehicles Nonetheless the tightness must be checked whenever you are about to tow the trailer Warning Lights signalling only for on road trailers Warning lights are obligatory for on road driving Signalling must comply with regulations in force in the country of use Red rear lights Front reflective devices white direction indicators stop lights Rear reflective devices red triangle Side reflective devices orange Figure 4 2 Example of French signalling 4 4 Unhitching the trailer This operation should be carried out on horizontal flat stable ground Lock the wheels Lower the front wheel Disconnect the road signals wire Refit the hitch using the wheel to release the hook ring from the tow vehicle Engage the handbrake 000000 Release the tow vehicle 30 276 EN 4 5 Implementation for installation Operations to be carried out Ensure that the ground is strong enough for the assembly not to sink into it Unhitch the trailer as per paragraph 5 2 1 Hitching and unhitching the trailer Immob
239. re starting Re install all guards which have been removed during service work before re starting the engine Make sure that there are no tools or other objects left behind on the engine Never start a turbocharged engine without the air filter in place The rotating compressor turbine in the turbo charger can cause severe injury There is also a risk that foreign bodies could be sucked in and cause ma chinery damage Z Fire and explosion Fuel and lubrication oil All fuel most lubricants and many chemicals are flammable Always read and observe the advice on the packages Work on the fuel system must be done with the en gine cold Fuel leakage and spills on hot surfaces or electrical components can cause fires Store oil and fuel soaked rags and other flammable material in a fire proof manner In certain circumstanc es oil soaked rags can self ignite Never smoke when filling fuel lubrication oil or when close to fuel filling stations or the engine bay Non original spare parts Components in fuel systems and electrical systems on Volvo Penta engines are designed and manufac tured to minimize the risk of explosions and fire in ac cordance with applicable legal requirements The use of non original spare parts can cause an ex plosion or fire Batteries Batteries contain and give off an explosive gas espe cially when charged This gas is very flammable and highly explosive Smoking open flames or sparks m
240. reas or vent exhaust outside with an exhaust pipe extension N WARNING DANGER This symbol warns of a safety hazard The presence of this symbol indicates a risk of injury Observe the safety instructions and precautions for use Important Carefully read the instructions supplied with the generating set before using or servicing the equipment WARNING DANGER Risk of electrocution Do not touch the cables or connections when the generating set is in operation Switch off the generating set for maintenance operations DANGER Use diesel fuel only The fuel is highly flammable handle with care Do not smoke near the generating set or expose it to a naked flame or sparks Shut down the generating set engine before filling the fuel tank Fill with fuel outside prevent fire risks clean the generating set regularly Wipe away any dirt and traces of grease or fuel WARNING DANGER The exhaust gases from the engine are toxic and can affect health or even cause death Use the generating set outdoors only in well ventilated areas or fit an exhaust extension to discharge the exhaust gases outside Figure 1 2 Pictograms and their meanings 5 276 ally Het coolant ean cause serious burns Shut off engine Only remove filler cap when cool enough to touch with bare hands Do not open radiator while hot Moving parts can cause serious injury Do not operate with doors ope
241. round the cooling fan 11 Start the engine and do a function check Air filter Check change Change the air filters when the indicator remains in the red field after the engine has been stopped Reinstate the pressure drop indicator after changing the filter by pressing in the button NOTE Scrap the old filters No cleaning or re use is permissible IMPORTANT In continuous operation the filters should be checked every 8 hours When used in extremely dirty environments such as coal mines rock crushing mills you must use special air filters 29 155 276 Maintenance Lubrication system Oil change intervals can vary from 50 to 600 hours depending on the grade of lubrication oil and the sulfur con tent of the fuel Note that oil change intervals must never exceed a period of 12 months If you want longer oil change intervals than given in the table below the condition of the oil must be checked by the oil manufacturers through regular oil testing NOTE The oil filters must be changed during each oil change Sulfur content in fuel by weight 05 10 Oil grade Oil change interval Reached first in operation VDS 3 600 hours 12 month 300 hours 12 month 150 hours 12 month VDS 2 and ACEA E7 2 400 hours 12 month 200 hours 12 month 100 hours 12 month VDS 2 and Global DHD 1 VDS 2 and API CI 4 2 VDS 2 and API 4 2 VDS and ACEA 2 200 hours 12 month 100 hours 12 month
242. round x 0 5 96 Supply range voltage detection 85 to 139 V 50 60 2 Rapid response time 500 ms for a transient voltage variation amplitude of 20 Voltage setting 1 Stability setting P2 Power supply protected by 8 A fuse replacement product Ferraz Shawmut T084013T fast blow fuse 8 A FA 250 V breaking capacity 30 kA 2 2 U F Fonction and LAM The threshold position 50 Hz 60 Hz to action the U F fonction as well as the LAM setting type is selected using the potentionmeter WARNING The jumper settings must correspond to the rated operating The threshhold position and LAM fonction settings are done with the jumper Operating at 50 Hz U F gradient 0 threshold at 48 Hz without LAM for impacts between 30 and 40 of the rated load 1 threshold at 48 Hz with LAM 13 for impacts between 40 and 70 of the rated load 2 threshold at 48 Hz with LAM 25 for impacts gt 70 of the rated load Operating at 60 Hz U F gradient 3 threshold at 58 Hz without LAM for impacts between 30 and 40 of the rated load 4 threshold at 58Hz with LAM 13 for impacts 40 and 70 of the rated load 5 threshold at 58Hz with LAM 25 for impacts gt 70 of the rated load Specific operating 6 threshold at 57Hz without LAM for speed variations at a steady state gt 2 Hz 7 threshold at 65Hz without LAM for variable speed and tractelec gearlec U F gradient 8 special the facto
243. rust product is toxic and dangerous if absorbed Avoid all contact with the skin and eyes Read the instructions on the packaging Y Y Caution fuels and oils are dangerous to inhale Ensure proper ventilation and use a protective mask Never expose the equipment to liquid splashes or rainfall and do not place it on wet ground 9 276 EN Y The battery electrolyte is harmful to skin and especially eyes If splashes get into eyes rinse immediately with running water and or a 10 diluted boric acid solution Y Wear protective eyewear and strong base resistant gloves for handling the electrolyte 1 3 4 Risk of fire burns and explosion The engine should not be operated in environments containing explosive products As not all of the electrical and mechanical components are shielded there is a risk of sparks forming Danger Y Make sure not to create sparks or flames and not to smoke near the batteries as the electrolyte gases are highly flammable especially if the battery is charging Their acid also poses a risk to the skin and in particular to the eyes Y Never cover the generating set pump unit or lighting tower with any material during operation or just after shutdown wait for the engine to cool Y Do not touch hot parts such as the exhaust pipe or put combustible materials on it Y Keep all flammable or explosive materials e g petrol oil cloth etc out of the way when the set is runni
244. ry setting 48Hz 2U F gradient a special programme is possible on request This programme must be specified before ordering during the project study 9 threshold at 47 5 Hz without LAM for speed variations at a steady state gt 2 Hz For hydraulic applications it is advisable to select frequency see the nameplate on the position 0 for 50 Hz alternator position 3 for 60 Hz Risk of destruction for the alternator LEROY SMER 5 231 276 LEROY SOMER Installation and maintenance 4067 en 2009 05 b R250 A V R 2 3 R250 A V R option Potentiometer for voltage setting 1000 W 0 5 W min setting range 5 Remove the STA jumper For wiring upthe external potentiometer the earth wires must be isolated as well as the potentiometer terminals wires at the same voltage as the power 2 4 LAM characteristics Load Acceptance Module 2 4 1 Voltage drop The LAM system is integrated in the A V R Itis active as standard It can be adjusted to 13 or 25 Role of the LAM Load Adjustment Module On application of a load the rotation speed of the generator set decreases When it passes below the preset frequency threshold the LAM causes the voltage to drop by approximately 13 or 25 and consequently the amount of active load applied is reduced by approximately 25 to 50 until the speed reaches its rated value again Hence the LAM can be used either
245. s During this operation do not allow anyone to stand under the load 3 1 2 Coupling 3 1 2 1 Single bearing alternator Before coupling the machines check that they are compatible by undertaking a torsional analysis of the transmission checking the dimensions of the flywheel and its housing the flange coupling discs and offset WARNING When coupling the alternator to the prime mover do not use the fan to turn the alternator or rotor The holes of the coupling discs should be aligned with the flywheel holes by cranking the engine Make sure the alternator is securely bedded in position during coupling Check that there is lateral play on the crankshaft 3 1 2 2 Double bearing alternator Semi flexible coupling Careful alignment of the machines is recommended checking that the lack of concentricity and parallelism of both parts ofthe coupling do not exceed 0 1 mm This alternator has been balanced with a 1 2 key 3 1 3 Location The room where the alternator is placed must be ventilated to ensure that the ambient temperature cannot exceed the data on the nameplate 3 2 Checks prior to first use 3 2 1 Electrical checks Under no circumstances should an alternator new or otherwise be operated if the insulation is less than 1 megohm for the stator and 100 000 ohms for the other windings
246. s 54 64 Safety features Printing 6 5 Access management 6 6 Web access management Tom Factory Important Only the menu functions on a white background are described in this manual 87 276 6 3 6 2 Setting of regional parameters Without an input access code this screen allows gt input of the display language gt setting of date and time Navigation reference 6 1 15 07 09 Language English Espanol Deutsch Portugues option Inhibit the keys Identification application 2 23 5 Software versions Printing To clean the touch screen dust hydrocarbons etc the key inhibition function prevents keys on the screen from being pressed for some twenty seconds A special screen shows the time elapsing 88 276 EN When an access code of a sufficient level is validated this screen also allows gt Setting of the module synchronisation time gt Selection of the logo displayed on the Kerys home screen When the time setting by the SNTP protocol is not active the screen looks like this 15 07 09 19 10 00 GS 1 Regional parameters Stop Faults Alarms Language Portugues option English Espanol Deutsch hours Minutes Seconds Inhibit the keys welcome ogo KOHLER welcome logo 1 p Software versions application In this case the transmission of a signal to the bus enabling the different real time clocks to be rese
247. s keys on the upper band This screen allows the user to view the list of faults present on the installation The first two columns give details of the date and time that the fault appeared The Status column indicates whether the fault is still present 1 or not present 0 The column gives the address of the variable associated with the fault The Text column identifies the type of fault A line with a red background characterises a fault and a line with an orange background characterises an alarm 92 276 Navigation reference 15 07 09 19 10 00 ost Alarms amp Faults Date EN Status Title Time ea Function keys Synchro column summary 2 3 2 Central unit measure v Active line Keys for scrolling when the list is longer than the number of lines possible on the screen i e 4 lines To clear a fault it is necessary to checkthat the fault has disappeared status 0 and whether it is necessary to eliminate its causes select the line in question the text on the line is displayed in white press the Reset key on the keypad the line is deleted A Important When a fault is displayed its effect on the operation remains active even if its cause has disappeared When in Manu or Auto mode if the user wants to clear a fault with a stopped clearance mode a screen will inform the user to switch to stop mode 93 276 6 3 7
248. s Use only approved cleaning solvents Do not use a high pressure cleaner for cleaning the engine and equipment The radiator hoses electrical components etc may be damaged Avoid accidental contact with parts at high temperatures exhaust manifold exhaust Before any maintenance operation on a lighting column light cut the electrical power supply and wait for the bulbs to cool down lt lt 54 lt lt lt lt Consumables Y Observe regulations in force concerning use of fuel before using your generating set pump unit or lighting tower Y Under no circumstances use seawater or any other corrosive or electrolytic product in the cooling circuit Environment Y The operator must take the necessary measures to comply with the aesthetics of the site of use The whole site must be maintained in a good state of cleanliness Y The premises must be kept clean and be regularly cleaned so as to avoid accumulation of dangerous materials or pollutants and dust which could ignite or cause an explosion The cleaning equipment must be suited to the risks posed by the products and dust Y The presence of dangerous or combustible materials inside premises housing combustion devices shall be limited to the operating requirements 8 276 S SS lt lt lt Facilities must be operated under the constant supervision of a qualified person who must regularly check that the safety devices are operating correctly and ensure that the c
249. s where there is to be a connection to existing electrical networks this must only be installed by a qualified electrician who should take the operating differences of the equipment into account according to whether the mains supply network or generating set is being used 10 276 Protection against electric shocks is ensured by an assembly of specific equipment If this needs to be replaced it should be by components with identical nominal values and specifications If the protective plates blanking covers need to be removed to route cables the protector blanking cover must be refitted when the operations are finished Due to high mechanical stresses use only strong flexible wiring with rubber sheathing compliant with IEC 245 4 or equivalent wiring 1 3 6 Dangers presented by electric currents first aid First aid In the event of an electric shock shut off the power immediately and activate the emergency stop on the generating set or lighting column If the voltage has not yet been cut off move the victim out of contact with the live conductor as quickly as possible Avoid direct contact both with the live conductor and the victim s body Use a dry plank of wood dry clothes or other non conductive materials to move the victim away The live wire may be cut with an axe Take great care to avoid the electric arc that will be generated by this Begin emergency procedures Resuscitation If breathing has stopped begin
250. s to be taken Please refer to the Fault codes chapter NOTE All instruments are optional Active faults DCU Display Control Unit DU Display Unit text ENGINE WARNING is shown on the display NOTE You can choose the language used for the in formation presented on the CIU Control Interface Unit the diagnostic lamp starts to flash Easy link instrument requires a CIU warning lamp on the alarm panel lights up afterthe diagnostic button has been pressed the fault code is shown as text on the tachom eter display DU Display Unit Either WARNING or ALARM STOP a buzzer sounds will be shown on the display depending on the severity of the fault NOTE You can choose the language used for the in formation presented on the 175 276 Fault codes can also be read by means of the VODIA tool Please refer to the VODIA User s Guide for advice on use At the same time the fault is stored in the control unit memory When the fault has been attended to and the ignition is switched off and on again the fault disap pears as active Inactive faults e DCU the fault is indicated as passive e CIU the diagnostic lamp goes out DU the fault message disappears inactive faults can not be read Easy Link the warning lamp on the alarm panel turns off Effect on engine Engines are affected differently depending on the se verity of the fault discovered by the dia
251. sing interval 4000 H 4500 H Lubrication intervals are given for grease type LITHIUM standard NLGI 3 In the factory the grease used for lubrication is ESSO Unirex N3 Before using another grease check for compatibility with the original one Monitor the temperature rise in the bearings see section 4 4 4 2 3 Electrical servicing Commercially available volatile degreasing agents can be used WARNING Do not use trichlorethylene perchlo rethylene trichloroethane or any alkaline products These operations must be performed at a cleaning station equipped with a vacuum system that collects and flushes out the products used The insulating components and the impregnation system are not at risk of damage from solvents Avoid letting the cleaning product run into the slots Apply the product with a brush sponging frequently to avoid accumulation in the housing Dry the winding with a dry cloth Let any traces evaporate before reassembling the machine 4 2 4 Mechanical servicing WARNING Cleaning the machine using water or a highpressure washer is strictly prohi bited Any problems arising from such treatment are not covered by our warranty Degreasing Use a brush and detergent suitable for paintwork Dusting Use an air gun If the machine is fitted with air inlet and outlet filters the maintenance personnel should clean them routinely at regular intervals In the case of dry dust the fi
252. so called CAN link All data related to instruments indication lamps connectors and po tentiometers is controlled by this link The slow link manages diagnostic information for flashing codes etc DU Display Unit The DU is an instrument panel which shows engine working values graphically on an LCD screen It con sists of an computerised unit for permanent installa tion in a control panel The DU is connected between the engine control unit and the CIU or DCU Easy Link instrument only together with a CIU The following Easy Link instruments are available Engine speed hours counter fault codes are also displayed on the tachometer display when the di agnostic button is pressed Coolant temperature Oil pressure Oiltemperature Battery voltage Alarm panel Turbo pressure 11 Introduction DCU Display Control Unit The DCU Diesel Control System control panel is available as an optional accessory for the EMS Engine Man agement System electronic control system The DCU is a digital instrument panel which communicates with the engine control unit DCU has several functions such as engine control monitoring diagnostics and parameter setting The menus in the DCU system can be used to check and in some cases to set a number of different functions in the EMS system NOTE The menus and illustrations shown here are the English version The language can be changed however
253. speed sensor data intermittent 9 Engine speed sensor abnormal update 11 Engine speed sensor signal lost 12 Engine speed sensor signal lost 15 Overspeed Overspeed moderate 264 276 N round c SPN CID SID PID PPID x Description Comment gt 9 228 261 Speed sensor calibration 13 Engine timing abnormal calibration 252 252 Software 11 i Incorrect engine software 234 253 Check system parameters 2 mH Incorrect parameters 281 281 Action alert output status 3 Action alert output open short to B 4 Action alert output short to ground Action alert output open circuit 282 282 Overspeed output status 3 Overspeed output open short to B 4 Overspeed output short to ground 285 285 Coolant temperature output status 3 EC temperature lamp open short to 4 Coolant temperature lamp short to 286 286 Oil pressure output status 3 Oil pressure output open short to B 4 Oil pressure output short to ground Oil pressure output open circuit 323 323 Shutdown output status 3 Shutdown output open short to B 4 Shutdown output short to ground Shutdown output open circuit 324 324 Warning output status 3 Warning output open short to B 4 Warning output short to ground
254. stem voltage Alternator voltage max current density power app eco Alternative generating equipment optional voltage max current density powWer appz voltage max current density power APD teeth eia tea its Battery Pressurized sealed 75 kPa 10 8 psi 17 liter 17 9 US quart 24 liter 25 3 US quart 1 pcs 82 C 179 5 F 24V 28V 80A 2200 W 28V 100A 2800 W 28V 140A 4000 W 2 pcs series connected 12V max 180 Ah Battery electrolyte specific gravity at 25 C 77 0 F fully charged battery re charge battery Note Applies to batteries with tropical acid 66 1 28 g cm 1 24 g cm 1 20 g cm 1 20 g cm 192 276 193 276 194 276 Ene Post or fax this coupon to Document amp Distribution Cen ter Order Department ARU2 Dept 64620 SE 405 08 G teborg Sweden Fax 46 31 545 772 Orders can also be placed via the Internet http www volvopenta com manual coupon Schicken Sie den Coupon per Post oder als Fax an Document amp Distribution Center Order Department ARUA Dept 64620 SE 405 08 G teborg Schweden Fax 46 31 545 772 Die Bestellung kann auch ber das Internet erfolgen http www volvopenta com manual co
255. suggest you write its specifications on the nameplate below 1 4 Storage Prior to commissioning machines should be stored Away from humidity 9096 after a long period of storage check the machine insulation section 3 2 1 To prevent the bearings from becoming marked do not store in an environment with significant vibration 1 5 Application These alternators are mainly designed to produce electricity in the context of applications involving the use of generators 1 6 Contraindications to use Useofthe machineis restricted to operating conditions environment speed voltage power etc compatible with the characteri stics indicated on the nameplate IS VEIT T ALTERNATORS LSA Date N Hz Min 1 R P M Protection Cos P F CI ther Th class R gulateur A V R m jMasse Weight RItAV D E bearing Rit AR N D E bearing Continuous KW PUISSANCE RATING Tension Voltage Connex Continue KA 40C Graisse Grease Valeurs excit Excit values charge full load vide 1 load Secours Std by 27C in France 1024 959 a Tension maxi maximum voltage 90 C Conforme C E I 60034 1
256. t e Open circuit Fault in indicator Reaction None Remedy e Check the indicator cables for breaks and short circuits e Check indicator function Change indicator as nec essary Code 3 1 PID SPN 100 Oil pressure sensor Cause Short circuit to positive or earth ground e Open circuit Reaction None Remedy Check that the oil pressure sensor cable is not damaged Check that the oil pressure sensor is correctly connected Code 3 2 PID SPN 105 Charge airtemperature sensor Cause e Short circuit to positive or earth ground e Open circuit Reaction None Remedy e Check that the charge air temperature sensor con nector is correctly installed e Check that the charge air temperature sensor ca ble is not damaged e Check that the charge air temperature sensor is correctly installed e Check charge air temperature sensor function 53 Fault codes Code 3 3 PID SPN 110 Coolant temperature sensor Cause Short circuit to positive or earth ground e Open circuit Reaction Preheating is also activated when the engine is hot Remedy e Check that the coolant temperature sensor con nector is correctly installed e Check that the coolant temperature sensor cable is not damaged e Check that the coolant temperature sensor is cor rectly installed e Check coolant temperature sensor function Code 3 4 PID SPN 106 102 Char
257. t is defined by the synchronisation time Pressing the KOHLER home logo key alters the appearance of the home screen by replacing the KOHLER logo with the SDMO logo as default The home screen then looks like this 15 07 09 19 10 00 KOHLER POVVER SYSTEMS zs Operation 252 Fault finding Configuration gi ten Archiving Metering Maintenance 89 276 In the second case the screen has this appearance Language English Espanol Deutsch Portugues option Day Month E OE 2 ago Identification MS application Software versions Printing 6 3 6 3 Information on the KERYS Indication of the application Navigation reference 6 2 This screen enables SDMO to identify the project This information is required for queries sent to SDMO s customer service so that the associated file can be consulted 15 07 09 19 10 00 Site name Dealership number 000000 OM number 000000 Connection number 1 2 3 Software versions Printing Access management Project number reference of the production file for the control equipment OM number reference of the production file for the generating set Connection number reference used to identify the site at the time of the telephone connection 90 276 Software version Navigation reference 6 3 The information relating to the software versions installed in the different modules is accessible from this menu Only
258. t exists indicates the highest possible value Closes the screen without saving the modifications Saves the modifications and closes the screen 66 276 N Selecting from a list The box heading indicates the parameter which will be assigned from your selection Arrows for moving the cursor List indicating possible selections Whithout General A Alarm Active selection Arrows only visible if the number of choices does not fit on the screen enables you to go to the next page on the list or return to the previous page on the Saving changes After changing a parameter the new data is stored in volatile memory which means that in the event of a power failure any changes will be lost It is also necessary to transfer these values to permanent memory This is the Save in flash operation Following a modification a red Sauvegarde faire Save indicator light flashes at the top left of the screen Pressing this indicator light brings up one of the following dialogue boxes Customer Factory Always select Client Pressing Valid confirms the operation pressing Esc cancels it 67 276 N During saving the following screen indicates that the operation in is progress Saving in flash 6 3 4 Configurations 6 3 4 1 Operating principle The operational modes are as follows Without Without N E coupling to Switch grid A612 lt g SOLO Genset Wi
259. t is below the continuous operation threshold It signals the AVR normal operation Turns off when the excitation current ceiling used to obtain short circuit operation is reached and when the excitation current is reduced to the shutdown value Flashes when the over excitation counter is decrementing NB After an obvious short circuit the voltage is limited to 7096 ofthe rated voltage This avoids overvoltages on machines whose no load excitation current is below the lower current threshold only in AREP Diagram 1 Activation Nisi 10s Nisi 10s tempo Ns shutdown Ns Red led 55060665555 Green led 0000000000000900000006000000000000090000000000 S SMER 9 247 276 LEROY SOMER Installation and maintenance 4531 en 2010 10 c R 450 AVRs 2 9x threshold max 9 5 A 9 5 threshol Shutdown 0 5 0 7 Activation of 90 s tempo Diagram 2 t s 90 s tempo elapsed application of permanent limitation i Redled BOOOOOO80600806906080060906080690609000900060999 Grenied 00000000000000000000000000000000000000000099 One red LED Lights up simultaneously with the green led when the continuous operation threshold is reached for more than 90s and the excitation current is reduced to the continuous operation threshold It is used to s
260. ta dealer if any problems occur which you can not solve by yourself WARNING Read through the safety advice for care and maintenance work in the chapter entitled Safety information before you start work Symptoms and possible causes amp The diagnosis button lamp flashes Please refer to the Diagnostic information chapter Engine can not be stopped 2 5 Starter motor does not rotate 1 2 3 4 5 6 7 24 Starter motor rotates slowly 1 2 Starter motor rotates normally but engine does not start 8 9 10 11 Engine starts but stops again 8 9 10 11 13 Engine does not reach correct operating speed at full throttle 9 10 11 12 13 21 25 26 Engine runs roughly 10 11 High fuel consumption 12 13 15 25 Black exhaust smoke 12 13 Blue or white exhaust smoke 14 15 22 Too low lubrication oil pressure 16 Excessive coolant temperature 17 18 19 20 Too low coolant temperature 20 No or poor charge 2 23 ONO Flat batteries Poor contact open circuit in cables Main switch turned off Circuit breaker in junction box faulty Faulty ignition lock Faulty main relay Faulty starter motor solenoid Lack of fuel fuel taps closed fuel tank empty wrong tank connected Blocked primary fuel filter sec ondary fuel filter because of contamination or paraffin frac tion separation in fuel at low tem perature 10 Air in the fu
261. tal Bus Number of g 13 The Kerys saves your new configuration 102 276 N 14 After returning to the Kerys home screen The configuration will only be taken into account if the following operations are carried out Y Turn on the battery isolator switch v Wait 5 seconds Y Turn off the battery isolator switch Important A Operations to be carried out on each generating set of the power plant Important 6 3 8 Use 6 3 8 1 Choice of priority generating set in power plant if equipped 1 15 07 09 19 10 00 asi Welcome Mnemonic aid info for menus 1 7 4 3 GS selection Priority selection Valid Alarms 500 Global Power Solution Mom Fault finding Configuration 3 Archiving amp Metering 4 Maintenance Press Operation on the touch screen 103 276 2 3 N 190709 19 10 00 Gs Welcome 1 Operation mom Function keys 23 Synchro column Central unit measure summary LLM 3 4 27 User adjustments 2165 Alarms amp Faults Measurements Press User settings on the touch screen 15 07 09 19 10 00 User adjustments 21 Set point 22 Output threshold 23 Wattmetric Control A r parameters 1 2 Alarms Press User parameters
262. te the faults If no faults are present manual mode can be activated by pressing Auto In AUTO mode except for the test functions the generating set starts as a result of an external command which may be triggered by various sources gt power loss gt EJP command France only gt client command 113 276 EN The installation is then controlled via the automatic systems in accordance with the configuration of the application gt inversion of normal emergency source gt grid coupling gt etc Tests If no faults are present automatic mode can be activated by pressing Auto The test starting phase is then initiated after pressing 1 on the test keypad Pressing 1 on the test keypad brings up the following window for selecting the test type 15 07 09 19 10 00 Operation 320 488 Under load test kVAr d 2 Power plant Function keys Synchronisation column S summar Using the KERYS Tactil Man Machine Interface the under Using the KERYS Tactil Man Machine Interface the off load load test is started by pressing the corresponding key test is started by pressing the corresponding key 114 276 During the start up phase and until the alternator voltage and generating set speed becomes steady at the end of this phase N After validation of the test the orange LED on the test keypad lights up steady J S19
263. ted power of the units proportionally By altering the quadrature droop potentiometer P4 match or divide the currents 4 2 2 Max excitation adjustment excitation ceiling In standard setting the potentiometer P3 is in maximum position However for applications requiring an overload protection see 3 2 1 4 the excitation ceiling must be adjusted by using the following procedures in AREP and PMG Method 1 Connect the AVR to the alternator apply load to 110 of rated machine rated at PF 0 8 the green led is on and the red one is off record the excitation current value adjust P3 until obtainingthe red led flashing the green one is always on decrease the load to 10096 and make sure that the red led is off Increase the load at 11596 check that the red LED flashes during 90 seconds and that the excitation current is brought back to the above adjusted value lex adjusted Method 2 The rated excitation current see machine plate must be multiplied by 1 1 and the obtained value is used to set the potentiometer P3 at the right position The following table must be used P3 12H an 35 hu P3 NB Inthe case of a permanent short circuit the excitation current must reach 2 9 x lex adjusted limited to 9 5A during 1 second in AREP or 10 seconds in PMG and shuts down to a value less than 1A LEROY SOMER 15 253 276 LEROY SOMER Installation and maintenance 4531
264. terminals F and F respecting the polarity for 2 to 3 seconds The alternator builds up and its voltage is still correct when the battery is removed Lack of residual magnetism The alternator builds up but its voltage does not reach the rated value when the battery is removed Check the connection of the voltage reference to the AVR Faulty diodes Armature short circuit The alternator builds up but its voltage disappears when the battery is removed Faulty AVR Field windings disconnected Revolving field coil open circuit Check the resistance Check the drive speed Correct speed Check the AVR connections and settings AVR faulty Field windings short circuited Rotating diodes burnt out Revolving field coil short circuited Check the resistance Speed too low Increase the drive speed Do not touch the AVR voltage pot P1 before running at the correct speed Adjust AVR voltage potentiometer Adjustment ineffective Faulty AVR 1 faulty diode oscillations Adjust AVR stability potentiometer If no effect try normal fast recovery modes Check the speed possibility of cyclic irregularity Loose connections Faulty AVR Speed too low when on load or U F knee point set too high Voltage correct at no load and too low when on load Run at no load and check the voltage between F and F on the AVR Voltage between F and F
265. ternator and the battery is disconnected when the engine is running the alternator and elec tronics can be damaged The charging circuits must never be re connected with the engine running for the same reason x at e l IMPORTANT Never disconnect the current with the main switch es when the engine is running Circuit breaker The engine is equipped with a 10 A circuit breaker which cuts the current if overloaded The circuit breaker is located on the left hand side of the engine on the left of the control unit Note The engine stops if the fuse trips If the circuit breaker trips frequently an authorized Volvo Penta workshop should be contacted to investi gate the cause of the overload Electrical connections Check that electrical connections are dry free from oxide and that they are securely tightened Spray i these connections as necessary with water repellent hiversal all spray Volvo Penta universal oil 42 168 276 Maintenance Battery Maintenance WARNING Fire and explosion hazard Batteries must never be exposed to open flames or Ke sparks Sy WARNING Never confuse the positive and negative poles on the batteries Risk of arcing and explosion AN WARNING Battery electrolyte is highly corro sive Always protect your eyes skin and clothes when handling batteries Always use protective goggles and gloves If acid comes into contact with your skin wash at once with soap
266. th coupling to grid A651 Without N E switch A632 Without Power plant coupling to grid lt f Without N E gt switch A633 Note Operation of a single genset without coupling Normal emergency switch NES not controlled by Kerys Automatic operation of a single genset Temporary coupling on grid return following interruption Operation of a power plant without coupling to grid Normal emergency switch NES not controlled by Kerys Power plant gensets interconnected by parallel lines Operation of a power plant without coupling to grid Normal ermegency switch NES not controlled by Kerys Power plant genset interconnected by CAN Without coupling the switch is equipped with electrical and mechanical interlocking With coupling the switch is not equipped with an electrical and mechanical interlock 68 276 6 3 4 2 Legends Electrically controlled circuit breaker gt Exchange of information from A to B and from to A E 2 Transmission of information from A to only 3 PH Current information 3 PH 3 phases 3 PH Voltage information 3 PH N 3 Phases Neutral 6 3 4 3 Configuration in solo generating set Without Normal Emergency inverter A612 This configuration is designed to provide v The generation of electricity for an installation from an external starting command dry contact Y generati
267. the French power grid Note 1 Note 2 In this operating mode there is no reactive power regulation generating set voltage the generating sets are static In an installation of the power station type Several generating sets in parallel two modes of coupling between generating sets are possible e Coupling when stopped e Coupling in normal operation Principle of coupling when stopped all the generating set power units are switched off Starting of all the generating sets when the speed reaches 1450 rpm activated excitation command on all the generating sets the voltage generated by each generating set increases gradually and the voltage is therefore the same in all generating sets the generating sets therefore reach 1500 rpm at 400 V 50 Hz At the end of global operation if the power consumed by the installation does not require the operation of all the generating sets within the power plant one or more generating sets will be stopped according to the wattmetric control Restarting of the generating set these generating sets depends on the load and wattmetric control of the load However if a generating set is reconnected to a busbar already subjected to a load the recoupling is carried out in normal operation and not when the generating set is stopped 72 276 EN Principle of coupling in normal operation Coupling in normal operation enables all the generating sets to be coupled in voltage and
268. the alphanumeric keypad you can directly access the Operation screen The operating and configuration screens These screens bring up the information and commands relating to the active menu They are divided into three zones gt anupper band common to all types of screens the central section in which the specific information on the selected menu appears gt alower band Upper band Central section Er 3a Electrical archive Mechanical archive Event metering Lower band Upper band Indications Indication of the presence of an alarm on the GS Date of the system concerned orange flashing Time of the system Indication of the presence of a fault on the GS concerned flashing red Reference of the GS with which the dialogues Indication of the operating mode of the GS concerned Name of the active screen 15 07 09 Faults Alarms 64 276 Controls Access to the regional parameters screen Access to the Alarms and Faults screen Access to the Alarms and Faults screen Access to the Drive or TOR variables screen Access to the regional parameters screen 15 07 09 19 10 00 When configured in power plant with switches displays a dialogue box enabling you to select the generating set to which you want to be connected 1st action access to the home screen 2nd action return to the menu previously selected before first pressing the button Lower band One or
269. the lines corresponding to the installed equipment appear Module Software versions Software version dates IHM 0 00 00 00 00 Base 00 00 00 Resident logic d 00 00 00 Regulation Protection aa 2 Printing Access management sd Identification application 91 276 6 3 6 4 Operating menus Operation This main screen displays all the main electrical parameters of the generating set It is the general operating and monitoring screen for the generating set This screen can also be displayed by pressing the indicator displaying the operation mode of the generating set The frequency U23 voltage active and reactive power indicators can be displayed in analog or digital form Switching from one mode to another is performed by pressing the desired indicator Navigation reference 1 1 15 07 09 19 10 00 EN Operation 328 488 i288 Operating time F BAe 225 Function keys Synchro column summary Control of alternator voltage Control of speed of rotation of the engine Indication of the genset output position The dial is automatically scaled beyond 46Hz In the needle dials the nominal values are in blue A The speed and voltage adjustment keys are only displayed for coupled applications in manual mode Important Alarms and faults This menu can also be called directly by pressing the flashing Alarms and Fault
270. the noises emitted should be taken into account The choice of its position will be based on carefully considered compromise Examples of problems that may be encountered Incorrect exhaust and ventilation Ground too uneven or soft Reduced access Set incorrectly positioned Fuel filling impossible Opening cover doors impossible Diagram 3 5 Examples of problems that may be encountered 25 276 N 3 4 Electricity a Connections general information As with low voltage electrical installations use and maintenance is governed by standard NFC 15 100 France or by the standards in the relevant country based on international standard IEC 60364 6 61 They must also adhere to the regulations in the NFC 15 401 application guide France or to the regulations and standards in the relevant country b Power cables These can be unipolar or multipolar according to the power of the generating set Power cables should preferably be installed in ducts or on a cable tray for this purpose The cable cross section and number of cables should be determined according to the cable type and the current standards to be observed in the country of installation The choice of conductors must comply with international standard IEC 30364 5 52 Three phase Calculation hypothesis Fitting method wiring in cable runs or non perforated trays Permissible voltage drop 5 Multiconductors or single conductor joined when precision 4X 1 Cabl
271. the oil level more frequently than normally recommended When an opening clutch is installed this should be checked more carefully during the first days Adjust ment may need to be done to compensate bedding in of the friction plates Fuel and oils Only use the grades of fuels and oils recommended in the instruction book please refer to the Maintenance chapter under the fuel and lubrication system head ings Other grades of fuel and oils can cause mal functions increased fuel consumption and eventually even shorten the life of the engine Always change the oil oil filter and fuel filter at the specified intervals Maintenance and spare parts Volvo Penta engines are designed for maximum reli ability and long life They are built to withstand a de manding environment but also to have the smallest possible environmental impact These qualities are re tained through regular service and use of Volvo Penta original spare parts Volvo Penta has a world wide network of authorized dealers They are Volvo Penta product specialists and have the accessories original spares test equip ment and special tools needed for high quality service and repair work Always observe the maintenance intervals in the instruction book and remember to note the en gine transmission identification number when you order service and spare parts 132 276 Certified engines If you own an emission certified engine which is used in an
272. the screen The screen is backlit and requires no contrast adjustments This screen is divided into 4 zones KR 1 1 1 t t t t t t Ge MAS p i N F cal um um ZBARF fs SERIAL No 08030010000 E r SOFTWARE 5 3 5 F NOMINAL VOLTAGE 400V L FREQUENCY 50Hz gt NOMINAL KW 320kW p 1 EARTH SYSTEM TNS Fig 6 4 description of the screen example Zone 1 in this zone the status of the generating set is displayed Zone 2 in this zone pictograms relating to dimensions measured are displayed as well as Alarm and Fault pictograms Zone 3 in this zone the measured values corresponding to the measured dimensions are displayed with the corresponding units of measurement Zone 4 in this zone messages relating to the control of the generating set and the menus are displayed Note the information displayed on measurements alarms and faults as well as messages and menus relating to control of the generating set will depend on the equipment level of each generating set Certain screens may therefore not be present 39 276 6 2 1 3 Pictograms in zone 1 EN Description of the pictograms in zone 1 Pictograms Display Activation conditions Fixed TELYS in manual mode MANU SE Flashing For 5 seconds when switching from MANU Mode AUTO mode to MA
273. this schedule If the generating set is used in extreme conditions shorter intervals between maintenance procedures should be observed These maintenance intervals only apply to generating sets running on fuel oil and coolant which conform to the specifications given in this manual 7 2 Engine 50 600 50 hrs 400 hrs 800 hrs Component Operation Every 12 First neS 12 12 day months 1205 1 months months months Engine and engine compartment Inspect Air filter indicator Check 1 e Oil level ds top Coolant level ud top Fuel Brecfiltar Drain the water P and sediment Engine oil Drain 2 Oil filter by pass filter Replace 3 Fuel pre filter Replace Fuel filter Replace e Driven unit belts Check adjust Batteries Check the electrolyte level Check that Turbocharging air pipe there are no leaks Fuel pre filters Check 1 The filter should be replaced every 12 months 2 First recommended oil change The oil used must be of a good quality The oil service intervals vary depending on the oil grade and the fuel sulphur content see engine appendix 3 The filters must be replaced every time the oil is changed EMS 2 system service tool 1000 hrs 8000 hrs 10000 hrs Component Operation 6 months 2000 hrs 12 months 36 months 48 months Coolant filter Replace 4 Turbocharger Check Valve clearance
274. ting and the outer fan ring round the cooling fan 3 Remove the protective plates round the drive belts 4 Inserta 1 2 spanner in the belt tensioner 1 Lift the wrench up and lift the water pump drive belt off 5 Inserta 1 2 spanner in the belt tensioner 2 Press the wrench down and remove the alternator belt Check that the pulleys are clean and undamaged Press the 1 2 wrench in the belt tensioner 2 down and install the new alternator drive belt 8 Liftthe 1 2 wrench in the belt tensioner 1 and re install the water pump drive belt 9 Install the protective plates round the drive belts 10 Install the protective grating and the outer fan ring round the cooling fan 11 Start the engine and do a function check 154 276 Maintenance Drive belt changing 1 Disconnect the main switch es and check that the engine is not connected to system voltage 2 Remove the protective grating and the outer fan ring round the cooling fan 3 Remove the protective plates round the drive belts 4 Insert a 1 2 spanner in the belt tensioner 1 Lift the wrench and remove the drive belt Thread the drive belt round the fan and remove it Check that the pulleys are clean and undamaged Thread the new drive belt over the fan Lift the 1 2 wrench and install the new drive belt Install the protective plates round the drive belts Oo OND gm 0 Install the protective grating and the outer fan ring
275. ting spring 4 at one end pressing it against the anchorage plate and at the other end leaving a 2 mm gap J2 max between the spring and nuts 5 00 6 Tighten all the lock nuts Checking the setting trailer on axle stands Pull the parking lever 2 notches the wheels cannot turn in a FORWARD direction The wheels can turn in REVERSE adjustment screw 8 switches to the REAR position Pull the parking lever fully The wheels will not turn either in FORWARD or REVERSE and the cross bar s must remain parallel with the axle body gt Check the transmission setting after 180 miles 300 km running in period and if necessary adjust the gap J1 using the tensioner Parking gt lever must be fully pulled up so that the compensating spring is fully compressed gt Every 900 miles 1500 km check the braking settings and distribution on all the wheels Important The brake controls are designed to draw trailers behind flexible suspension touring vehicles If used behind an HGV be sure to provide the fitted ball joint with a shock absorber to prevent premature wear gt During any manoeuvres with the trailer coupled do not turn more than 90 or force reverse gt specifications of our brake controls are indicated on a manufacturer s plate and the items on this should be supplied to us when requesting replacement parts in particular for the shock absorber of a special type approved by the Service des M
276. tion 122 276 N 9 Appendix 9 1 Appendix A Engine user and maintenance manual 123 276 124 276 Users guide and and maintenance manual VOLVO Generating set and industrial engines 9 liter EMS 2 TAD941GE 7745269 11 2005 33522062701_1_1 125 276 OPERATORS MANUAL Generating set and industrial engines 9 liter EMS 2 126 276 Table of contents Safety information 2 Safety rules for operation and maintenance 3 Introduction cr 6 Environmental responsibility 6 la rege 6 Euelandiolls ett te ttes 6 Maintenance and spare parts 6 Certified engines sssesssese 7 Warranty AS 7 Introduction siiani aiia 8 Technical description 8 Identification numbers 9 EMS 2 ice tane urbes necs 10 Instrument EMS 2 11 DCU Display Control 12 Starting the 18 Before Starting 18 Starting method EMS 2 19 Volvo Penta starter switch 20 Starting in extreme cold
277. to reduce the speed variation frequency and its duration for a given applied load or to increase the applied load possible for one speed variation turbo charged engines To avoid voltage oscillations the trip threshold for the LAM function should be set approximately 2 Hz below the lowest frequency in steady state Itis advised to use the LAM at 25 for load impacts gt at 70 of the genset rated power Voltage 4 Voltage 085U M f 1 i i D P 1 48 or 58 Hz 50 60 Hz 9 fN ST3 2 4 2 Gradual voltage return function During load impacts the function helps the genset to return to its rated speed faster thanks to a gradual increase in voltage according to the following principles if the speed drops between 46 Hz and 50 Hz the rated voltage follows a fast gradient as it is restored if the speed drops below 46 Hz since the engine needs more help the voltage follows a slow gradient as it returns to the reference value prop lt 46 Hz Drop N gt 46 Hz Time LEROY SOMER 232 276 LEROY SOMER Installation and maintenance 4067 en 2009 05 6 R250 A V R 2 5 Typical effects of the LAM with a diesel engine or without a LAM U F only 2 5 1 Voltage Un d 4 without eee LAM 08 i 4 Time Load on shaft kW i LEROY SOMER
278. tric feed pump switch Extra stop Charge pressure charge temperature sensor Coolant temperature sensor NOTE Please note that there are different loca tions depending on model Main relay Diagnostic connector 2 pin TAD940 43VE TAD940 TAD941 GE 6 pin TAD950 52VE Fuel pressure sensor Maintenance TAD940 943GE VE 171 276 TAD950 952VE 10 Sensor water in fuel 10a Solenoid valve drainage water trap optional not shown in illustration 11 Oil level and temperature sensor installed inside the oil pan 12 Main circuit breaker 10 A 13 Air pre heater with pre heating relay 14 Camshaft position sensor 15 Oil pressure sensor 16 Flywheel position and speed sensor 45 Laying up The engine and other equipment must be laid up to prevent damage if they are not used for two months or more It is important that this is done in the correct manner and nothing is forgotten For this reason we have compiled a check list of the most important points Before the engine is taken out of service for a long period of time an authorized Volvo Penta workshop should check it over Have any faults and deficiencies attended to so that the equipment is in order ready for the next start WARNING Before you start to do any maintenance work read the Maintenance chapter carefully This contains instructions for doing work in a safe and correct manner WARNING Some conservation oils are flammable Some
279. ts To obtain the specific information prescribed by EN 61131 2 refer to the appropriate sections of that publication Y Electrical and self extinguishability properties of insulating materials c UL 746C gt UL 94 Y Pollution degree 2 Y Mechanical strength details Vibration resistance EN 61131 2 1994 82 1 3 2 Frequency range 10 57Hz Continuous vibrations 0 0375mm amplitude Occasional vibrations 0 075mm amplitude Frequency range 57Hz 150Hz Continuous 0 5 g constant acceleration Occasional 1 g constant acceleration Complies with standard IEC 68 2 6 test Fc Shock resistance Occasional shocks 15g 11ms semi sinus Complies with standard IEC 68 2 27 test Fa Y Emissions Complies with standard EN55022 class A Y Variation in supply voltage EN61131 2 6 3 7 3 Y Immunity Complies with standard IEC 61000 4 2 Electrostatic discharge 4 kV for contact discharge 8 kV for air discharge Complies with standard IEC 61000 4 3 Radiated field at 10V m from 80MHz to 1GHz with sinusoidal modulation AM 1kHz Complies with standard IEC 61000 4 4 Rapid transients in waves of 2 kV on power cables 1 Kv on signal cables Complies with standard IEC 61000 4 5 Shock waves of 2 kV between wires and ground 11 kV between wires for the supplies and 1kV relative to ground for long signal circuits lines from a building or from a distance of over 30 m Complies with standard IEC 61000 4 6 Immunity to current injected at 3V fr
280. ts during installation use and servicing of your A V R you can look forward to many years of trouble free operation SAFETY MEASURES Before using your machine for the first time it is important to read the whole of this installation and maintenance manual All necessary operations and interventions on this machine must be performed by a qualified technician Ourtechnical support service will be pleased to provide any additional information you may require The various operations described in this manual are accompanied by recommendations or symbols to alert the user to potential risks of accidents It is vital that you understand and take notice of the following warning symbols WARNING Warning symbol for an operation capable of damaging or destroying the machine or surrounding equipment Warning symbol for general danger to personnel Warning symbol for electrical danger to personnel Note LEROY SOMER reserves the right to modify the characteristics of its products at any time in order to incorporate the latest technological developments The information contained in this document may therefore be changed without notice LEROY SOMER 228 276 LEROY SOMER Installation and maintenance 4067 en 2009 05 b R250 A V R SUMMARY DS SUPPLY dE 4 1 1 SHUNT excitation system aa a E a a a nennen nnne nennen ener rentrer 4 2 RO50 MADE
281. tting of speed control and voltage limits See Throttle input setting Display setting display setting See Display set ting Setup Versatile Customer parameter Versatile b Idle engine speed rpm Preheat on ignition Idle engine speed setting idling speed Governor gradient Nm rpm Preheat on ignition activation of automatic pre heating The engine control system senses if pre heating is needed and activates it directly when switched on Governor gradient Nm rpm setting the droop level when this has been activated Please refer to Governor droop in the main menu for activa tion Oil temp warning limit C setting the alarm limit for the oil temperature Coolant temp warning limit C setting the alarm limit for the coolant temperature 15 141 276 Introduction Setup Genset gt Primary engine speed Preheat on ignition Governor droop Setup Throttle Setup throttle mode Setup Throttle gt Set throttle mode Set idle voltage Set mx voltage OFF Potentiometer value 100 0 Idling 16 Max Customer parameter Genset Primary engine speed selection of engine speed 1500 or 1800 rpm Preheat on ignition activation of automatic pre heating The engine control system senses if pre heating is needed and activates it directly when switched on Governor droop 96 setting the droop level when this has bee
282. tton to come to the error list The fault list shows Operation hours Fault cause Active inactive 2 Look up the fault code in the Fault Code chapter and take the recommended measures 3 Press the ESC button to leave the fault list NOTE To enter the fault list when no fault code has been set press the SEL button and select Diagnos tics from the menu Reading fault cause via the DU Display Unit Depending on the severity of the faults one of the fol lowing messages will appear on the display WARN ING or ALARM STOP a buzzer sounds 1 Press any button to come to the fault list The fault list shows Operation hours Fault cause 2 Look up the fault code in the Fault Code chapter and take the recommended measures 3 Press ACK to confirm the fault code The display background will change color the buzzer stops sounding 4 Press EXIT to leave the fault list 176 276 Reading fault codes via the diagnostic lamp on the instrument panel CIU When the system has discovered a malfunction the diagnostic lamp starts to flash If the diagnostic but ton is depressed and then released a fault code is flashed out The fault code consists of two groups of flashes sepa rated by a pause of two seconds A fault code is ob tained by counting the number of flashes in each group Example amp amp pause 3 W 3 Fault code 2 4 The fault code is stored and ca
283. uce the acid level and fill with distilled water Repeat the operation if need be Starting problems Starting test incorrect Battery empty Battery used up or faulty Capacity too low Battery sulphated Recharge the battery Fit a new battery Battery terminals melted Incorrect electrical connection Incorrect battery wiring Tighten the ends of the battery cables or replace them if necessary One or two cells release a lot of gas at high charge Cell s faulty Fit a new battery The battery discharges very quickly Charge status too low Short circuit in the current circuit High self discharge for example through electrolyte contamination Sulphation storage of discharged battery Check the charge Replace the battery Short service life Incorrect battery part no Too many repeated deep discharges Battery stored too long without charge Define the correct battery part no for the recommended use Think about charging the battery using a regulator High water consumption Overload Charging voltage too high Check the charger voltage regulator The battery explodes Spark after battery charging Short circuit Connection or disconnection during charging Internal fault for example interruption and low electrolyte level Replace the battery beware of fire and sparks Ensure there is sufficient ventila
284. under the conditions and instruc tions compiled in the Warranty and Service book Please note that AB Volvo Penta s liability is limited to the specification in the Warranty and Service book Read it carefully as soon as possible after delivery This contains important information such as the warranty card service intervals maintenance which it is the responsibility of the owner to know check and carry out If this is not done AB Volvo Penta may fully or partly refuse to honor its warranty undertakings Please contact your Volvo Penta dealer if you have not received a Warranty and Service book or a customer copy of the warranty card 133 276 Introduction TAD940GE TAD941GE TAD940VE TAD941VE TAD942VE TAD943VE TAD950VE TAD951VE and TAD952VE are in line direct injected 6 cylinder industrial diesel engines TAD950VE TAD951VE have TAD952VE have internal EGR Exhaust Gas Recirculation All engines are equipped with electronically controlled fuel management EMS 2 turbocharger intercooler ther mostatically controlled cooling systems and electronic speed control Technical description Engine and engine block The engine block and cylinder head are manufac tured of alloyed cast iron Seven bearing induction hardened crankshaft Replaceable wet cylinder liners Cast aluminum pistons with oil cooling Three piston rings with a keystone type top ring Induction hardened overhead seven bearing camshaft
285. upon Envoyez ou faxez le bon de commande Document amp Distribution Center Order Department ARU2 Dept 64620 SE 405 08 G teborg Su de Fax 446 31 545 772 Vous pouvez galement passer la commande par Internet http www volvopenta com manual coupon Yes please would like an operator s manual in English at no charge Publication number 7745259 Name Address 42200 615001 155099900192 Country Please note that this offer is valid for 12 months from the date of deli very of the engine after this it is subject to availability Ja danke ich will Kostenlos eine Betriebsanleitung in deutscher Sprache erhalten Publikationsnummer 7745261 Name An schrift 42200 615001 155099900192 Land Bitte beachten Sie dass das Angebot f r die Dauer von 12 Monaten ab dem Lieferdatum des Motors gilt danach nur noch bis zum Aufbrauchen des La VOLVO gerbestandes PENTA RUE e CR P gg SE QE TR URL COO UN RENE V cdi d 4 Oui merci Je souhaite recevoir un manuel d instructions gratuit en francais Num ro de publication 7745262 e e o g Adresse 2 17 e e 17 T S e N Pays
286. us CAN num ro 2 CAN bus number 2 Lt Tension GE ou centrale Lignes parali les Parallel ines Genset or power plant voltage Correction vitesse Spood Courant GE ou centrale Correction r gulation vitesse Ref a Speed regulation correction Correction r gulation tension ENO Voltage regulation correction RE Regulation module 31613391501 Module item reference MAZ1 G ATE manufacturer product reference G main module hardware upgrade index 04 week of manufacture week 4 08 year of manufacture year 2008 A secondary module hardware upgrade index 03085319 519 serial number related with a batch number 519 the 519 module manufactured in week 04 of the year 2008 a maximum of 999 modules that can be related with a batch number Genset or power plant current Module de r gulation Regulation module 4421 31613527401 Tension jou de barres ou r seau L3 Busbar cv Mains voltage P ls si il n Courant jeu de barres ou r seau 480 Volts maxi UL 240 Volts maxi u WSA Classe 0 5 Class 0 5 Busbar or Mains current 20 C 70 C Protection module NO Relais num ro 1 NC 240V BA Protection module M Lun unas irena s 31613391601 Module item reference fem fap N
287. ust never occur in or near to batteries or the battery locker Incorrect connection of a battery cable or start cable can cause a spark which can be sufficient in its turn to make the battery explode Start spray Never use start spray or similar preparations to help in starting an engine with air pre heating glow plugs starting heater They may cause an explosion in the inlet manifold Danger of personal injury A Hot surfaces and fluids A hot engine always offers the risk of burns Be on your guard against hot surfaces the exhaust mani fold turbocharger oil pan charge air pipe starting heater hot coolant and hot lubricating oil in pipes hoses etc 130 276 A Chemicals Most chemicals such as glycol rust preventer con servation oils degreasers etc are hazardous Always read and observe the advice on the packages Some chemicals such as conservation oils are flam mable and alsodangerous to breathe Ensure good ventilation and use a protective mask for spraying Al ways read and observe the advice on the packages Store chemicals and other hazardous material out of the reach of children Hand in surplus or used chemi cals to a recycling station for destruction A Lubrication system Hot oil can cause burns Avoid skin contact with hot oil Make sure that the oil system is de pressurized before starting work Never start or run the engine with the oil filler cap removed because of the risk of oil spi
288. vated automatically pre heating is optional Pre heating time depends on engine temperature 2 Start the engine in position Release the key back to position I immediately after the engine has started 146 276 147 276 Starting the engine Starting in extreme cold Certain preparations must be made to facilitate engine starting and in some cases to make starting possible at all Use a winter grade fuel of a well known make which has been approved for the relevant temperature This reduces the risk of wax deposits in the fuel system At extremely low temperatures the use of a fuel heat er is recommended For fully acceptable lubrication a synthetic engine oil of recommended viscosity for the relevant tempera ture should be used Please refer to the Maintenance lubrication system chapter Synthetic lubricants are able to manage a wider temperature range than miner al based lubricants Pre heat the coolant with a separately installed elec tric engine heater In extreme cases a diesel burning engine heater may be needed Ask your Volvo Penta dealer for advice AN IMPORTANT Make sure that the cooling sys tem is filled with a glycol mixture Please refer to the Maintenance cooling system chapter The batteries should be in good condition Cold weath er reduces battery capacity Increased battery capaci ty may be necessary 21 Starting the engine 22 Never use start spray
289. verspeed fault Non starting fault 41 276 6 2 1 5 Description of the pictograms in zone 3 Pictograms in zone 3 All the pictograms in these zones are activated when TELYS is initialised The pictograms below are given as examples Generating set stopped Screen Pictograms Data displayed no B H 7 Fuel Level Indicator Indication of Temperature of High Temperature el i coolant HT units according to settings menu P1 a a P ca o Indication of Battery Voltage Indication of Oil Temperature units according to settings menu Generating set start up or generating set started or generatin set switching off in progress Screen Pictograms Data displayed no n RPM Engine Speed Indication Indication of Temperature of High Temperature H coolant units according to settings menu P2 3 O ei Indication of Oil Pressure units according to settings Indication of Oil Temperature units according to settings menu Generating set started Screen Pictograms Data displayed no a H t 7 Fuel Level Indicator P3 M n e Alternator composite Voltage Indicator Default screen in Lf operation k Total Active Power Indicator 5 H Alternator Frequency Indicator n M U12 Alternator composite Voltage Indicator e n i U23 Alternator composite Voltage Indicator P4 e3
290. wel Nut NDE shield Fit the thrust bearing screws 78 remove the threaded rod fit the other screw and tighten up the assembly Tighten the 4 bearing screws 37 Reconnect wires Fit the 2 support screws 122 Fit the air inlet louvre 51 Replace the cover WARNING When dismantling the shields you will need to change the antifriction bearings the O ring seal the preloading wavy washer and adhesive paste 4 6 6 Replacing the DE bearing Remove the air outlet grille 33 Remove the 6 screws 31 from the DE shield and the 3 screws 62 from the inner bearing retainer Remove the shield 30 Take out the ball bearing 60 using a puller with a central screw see section 4 6 5 Fit the new bearing after heating it by induction to approximately 80 C Screw a threaded rod into the thrust bearing 68 Refit the shield 30 on the machine Slide the threaded rod into the shield hole to make it easier to assemble see basic diagram Tighten the bottom thrust bearing screws 78 remove the threaded rod and fit the other screws Tighten the 6 shield screws 31 Refit the air outlet grille 33 4 6 7 Dismantling the rotor assembly Remove the NDE shield 36 as described in section 4 6 5 Remove the DE shield 30 as described in section 4 6 6 if it is a double bearing machine Support the DE rotor 4 with a strap or with a support constru
291. with Four valves per cylinder Replaceable valve seats and valve guides Fuel system Microprocessor based fuel supply control unit EMS 2 Gear driven fuel supply pump Centrally located unit injectors with electromag netically controlled fuel valves Spin on secondary fuel filter and water trap IEGR Internal Exhaust Gas Recirculation TAD950VE TAD951VE TAD952VE Lubrication system Water cooled oil cooler Gear driven oil pump Two full flow filters and a spin on bypass filter Turbocharging system Turbocharger Cooling system Radiator with expansion tank Air cooled intercooler Belt driven water pump Piston thermostat Electrical system 24V electrical system Alternator with charge sensor 80 A 110 A and 140 A optional Engine mounted extra stop AUX STOP 134 276 Introduction Identification numbers Location of engine signs CHASSIS ID VP 000125 a SERIAL NO The sign above shows examples of The sign above shows examples of Engine designation Engine designation Serial number Engine power net without fan Specification number Max engine speed Main software Dataset 1 Dataset 2 Product number Explanation of engine designation E g TAD940GE TAD940VE T Turbo Air to air intercooler Diesel engine Cylinder volume liter Generation Version Generator unit engine Stationary and mobile operation A D
292. y Foreign objects in the inlet pipe may cause mechanical damage Y Engine with air preheating starting components never use a starting spray or any other similar starter assistance product Upon contact with the starting component an explosion may occur in the inlet tube causing bodily injury Y Do not touch the lighting column lights when they are switched on Maintenance Y Follow the maintenance table and its instructions Y Always use tools in good condition which are suited to the work to be done Ensure you have understood the instructions before beginning any operation Y Goggles should be worn when carrying out maintenance operations and watches bracelets etc should be removed Y Fitonly original parts Y Disconnect the battery and the pneumatic starter if fitted before undertaking any repairs to prevent the engine from starting accidentally Fit a panel over the controls to prevent any attempt to start Only use the correct crankshaft turning techniques for turning the crankshaft manually Do not try to turn the crankshaft by pulling it or levering the fan This method may cause serious bodily or material damage or damage the vanes of the fan reducing the service life of the fan Clean off any trace of oil fuel or coolant using a clean cloth Do not use a soapy solution containing either chlorine or ammonia as these two chemicals prevent bubble formation Never use petrol or other inflammable substances to clean the part

Generating set R350C2 (CE) - User manual - SDMO

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