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Oil flows into the cylinder head via a hollow locating dowel in the top deck of the cylinder block. Oil
travels to the camshaft bearing journals and the three center rocker arm shaft supports through drilled
passages in the cylinder head. The supports supply oil to each rocker shaft. Oil flows to the bushings of
the injector rocker arm through holes in the rocker arm shaft. This same oil lubricates the valve and the
rollers. Oil flows through drilled passages in the rocker arms. This oil lubricates the roller, the valve
bridge and the contact surfaces of the actuator of the unit injector. The remaining valve system
components are lubricated by splash oil.
When all the components have been lubricated, the excess oil returns to the engine oil pan.

3.9.2 LUBRICATION SYSTEM COMPONENTS

The major components of the lubrication system are:

• Oil Pan

• Oil Pump

• Oil Cooler

• Oil Filter

• Turbocharger Oil Lines

• Oil Passages for the Cylinder-Head and Block

• Fume Disposal Collector

Each of these components are discussed in the following sections.

3.9.2.1 OIL PAN

Figure 3.9.2.1-1 illustrates the 3456 EPG Engine Oil Pan. The oil pan bolts to the bottom of the engine.
The oil pan assembly, being the lowest point of the engine assembly, provides a means for housing the
oil pump assembly, attachment of oil drain lines, and reservoir for the engine oil. It has a Sump Capacity
of 13 US gallon (49 Liters).

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FIGURE 3.9.2.1-1 3456 EPG ENGINE OIL PAN CUTAWAY

3.9.2.2 OIL PUMP

Figure 3.9.2.2-1 illustrates the 3456 EPG Engine Oil Pump. The Oil Pump is enclosed in the oil pan at
about the midway point. It provides continuous circulation of oil throughout the engine (Positive
displacement, two-gear type, 38/72 US gallons per minute at 2550 rpm. Also, there is an internal
pressure relief valve to protect pump that opens at about 88 PSI).

FIGURE 3.9.2.2-1 3456 EPG ENGINE OIL PUMP

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3.9.2.3 OIL COOLER


Figure 3.9.2.3-1 illustrates the 3456 EPG Engine Oil Cooler. The Oil Cooler is located on the side of
engine immediately below the turbocharger. Coolant circulates through the oil cooler providing heat
transfer from the oil to the coolant. This lowers the oil temperature and protects the oil properties (Oil
cooler delta T, approximately 25 degrees F). Also, there is an oil cooler bypass valve that opens at a
delta P of 37PSI ± 3 PSI).

FIGURE 3.9.2.3-1 3456 EPG ENGINE OIL COOLER

3.9.2.4 OIL FILTER

Figure 3.9.2.4-1 illustrates the 3456 EPG Engine Oil Filter. The Oil Filter is located on the
Engine/Alternator Skid facing the engine compartment access doors. This screw-on filter will hold
approximately 1 US gal of multi-viscosity CH-4 or equal oil. A bypass valve is located in filter base
housing and opens at 37PSI ± 3 PSI. The oil filter cleans the oil by collecting metal particles and other
debris that can damage engine parts.

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FIGURE 3.9.2.4-1 3456 EPG OIL FILTER

3.9.2.5 TURBOCHARGER OIL LINES

Figure 3.9.2.5-1 illustrates the Turbocharger Oil Lines. The turbocharger oil lines extend between the
turbocharger and the oil manifold and engine oil pan through the engine block to crankcase. The
turbocharger oil lines provide oil to cool and lubricate turbocharger bearings.

FIGURE 3.9.2.5-1 3456 EPG TURBOCHARGER OIL LINES

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3.9.2.6 OIL PASSAGES FOR THE CYLINDER HEAD AND BLOCK

Figure 3.9.2.6-1 illustrates the oil passages for the 3456 EPG Engine Cylinder Head. The oil passages
are located in the block and head of the engine. The passages provide a conduit for the oil to lubricate
bearings, gears, pistons, liners, valves, etc. The normal Oil pressure range is 38 PSI to 70 PSI.

FIGURE 3.9.2.6-1 3456 EPG CYLINDER HEAD

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3.9.2.7 FUME DISPOSAL COLLECTOR

Figure 3.9.2.7-1 illustrates the Fume Disposal Collector.

FIGURE 3.9.2.7-1 FUME DISPOSAL COLLECTOR

The Fume Disposal Collector is located on the Engine/Alternator Skid facing the engine compartment
access doors. Fume Disposal Collector, collects and provides a means of disposal of condensed liquids
from the crankcase (crankcase ventilation).

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3.9.3 LUBRICANT SPECIFICATIONS

3.9.3.1 API AUTHORIZED OILS

Caterpillar, Inc., the manufacturer of the DPDGS 3456 EPG Engine, recognizes The Engine Oil Licensing
and Certification System for engine oils by the American Petroleum Institute. For detailed information
about this system, see the thirteenth edition of the API publication No. 1509. API authorizes engine oils
that bear the API symbol.

3.9.3.2 ENGINE OIL: CATERPILLAR DIESEL ENGINE OIL

Caterpillar Oils have been developed and tested in order to provide the full performance and service life
that has been designed and built into Caterpillar Engines. Caterpillar Engine Oil is used to fill the 3456
EPG Engine at the factory. These oils are available by Caterpillar dealers worldwide for continued use
when the engine oil is changed.

Due to significant variations in the quality and in the performance of commercially available oils,
Caterpillar makes the following recommendations:

• Caterpillar Diesel Engine Oil (10W3O)


• Caterpillar Diesel Engine Oil (15W40)

Caterpillar multi-grade Diesel Engine Oil is formulated with the correct amounts of detergents,
dispersants, and alkalinity in order to provide superior performance in Caterpillar Diesel Engines.

Caterpillar multi-grade Diesel Engine Oil is available in two grades of viscosity (10W30 and 15W40). To
choose the correct grade for the ambient temperature, see Table 3.9.3.4-1. Multi-grade oils provide the
correct viscosity for a broad range of operating temperatures.

Multi-grade oils are effective in maintaining the following conditions:

• Proper engine lubrication


• Low oil consumption
• Low levels of piston deposits

3.9.3.3 ENGINE OILS: COMMERCIAL OILS

The performance of commercial diesel engine oils is based on classifications that were created by the
American Petroleum Institute (API). These API classifications are developed in order to provide
commercial lubricants for a broad range of diesel engines that operate in various conditions.

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If Caterpillar multigrade Diesel Engine Oil is not used, only use commercial oils that meet the following
classifications:

• EMA LRG-1 multigrade oil is Preferred Oil

• API CH-4 multigrade oil is Preferred Oil

• API CG-4 multigrade oil is Preferred Oil

• API CF-4 multigrade oil is Acceptable Oil

The following explanations of these API classifications can be used to make the proper choice when
commercial oil is chosen:

• CH-4 is the newest API classification for heavy-duty diesel engine oil. CH-4 oils can be used in
Caterpillar diesel engines that are recommended to use CF-4 oils.
• CG-4 is a new API classification for heavy-duty diesel engine oil. CG-4 oils can be used in
Caterpillar diesel engines that are recommended to use CF-4 oils.

In comparison to CF-4 oils, CG-4 oils provide improvements in the following performance:

• Cleanliness of the crankcase


• Cleanliness of the pistons
• Soot Dispersion
• Viscosity Control

CH-4 oils were developed primarily for diesel engines that use a .05 percent level of fuel sulfur. However,
CG-4 oils can be used with higher sulfur fuels. CH-4 oils were the first oils that passed the industry
standard tests for foam control and viscosity shear loss. CG-4 oils must also pass tests that were
recently developed for corrosion and wear.

These oils service a wide variety of modern diesel engines. CF-4 oils provide more stable oil control and
reduced piston deposits in comparison to the obsolete API CE oils. CF-4 oils provide improved soot
dispersion in comparison to API CF and obsolete CD oils. The API CF-4 classification was developed
with a 0.40 percent sulfur diesel fuel. This represents the type of diesel fuels that are commonly available
worldwide.

Some commercial oils that meet the API CG-4 and CF-4 classifications may require reduced oil change
intervals. To determine the oil change interval, closely monitor the condition of the oil and perform a wear
metal analysis. Caterpillar’s S.O.S. oil analysis program is the preferred method.

NOTE: Failure to follow these oil recommendations can cause shortened engine service life due to
deposits and/or excessive wear.

NOTE: Do not use CE-4 or lower grade oils.

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3.9.3.4 LUBRICANT VISCOSITY RECOMMENDATIONS

The minimum ambient temperature during cold engine start-up; and the maximum ambient temperature
during engine operation determine the proper SAE viscosity grade of oil. Table 3.9.3.4-1 presents the oil
viscosities required for starting in minimum and maximum temperatures.

Generally, use the highest oil viscosity that is available to meet the requirement for the temperature at
engine start-up.

TABLE 3.9.3.4-1 ENGINE OIL VISCOSITY


CATERPILLAR DEO API CG-4 AND CF4 VISCOSITY AMBIENT TEMPERATURE
GRADE MINIMUM MAXIMUM
SAE 0W20 -40°C (-40°F) 10°C (50°F)
SAE 5W30 -30°C (-22°F) 30°C (86°F)
SAE 5W40 -30°C (-22°F) 40°C (104°F)
SAE 10W30 -20°C (-4°F) 40 °C (104°F)
SAE 15W40 -15°C (+5°F) 50 °C (125°F)

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3.10 ENGINE/ALTERNATOR SYSTEM

The Engine/Alternator System is comprised on the Caterpillar 3456 EPG engine and the Caterpillar SR4B
Alternator mounted on a common skid.

3.10.1 CATERPILLAR 3456 EPG ENGINE

The MEP-PU-810 A/B Power Unit uses two Caterpillar 3456 EPG Engines. The two 3456 EPG engines
are electronically controlled, mechanically actuated, unit injector diesel engines.

The 3456 EPG Engine is an in-line six-cylinder engine with a bore of 5.5 inch (140 mm) and with a stroke
of 6.7 inch (171 mm). The 3456 EPG Engine has a total displacement of 964.18 Cubic Inches (15.8 L).
The engine is turbocharged and cooled with air-to-air after cooling with electronic unit injection (EUI).

Figure 3.10.1-1 through Figure 3.10.1-5 illustrates the 3456 EPG Engine through the series of Right Side,
Left Side, Top, Rear and Front Views.

Right Side View


(7) Exhaust manifold (8) Turbocharger (9) Temperature Regulator housing (10)
Water pump (11) Oil Cooler

FIGURE 3.10.1-1 CATERPILLAR 3456 EPG ENGINE, RIGHT SIDE VIEW

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Left Side View


(1) Fuel Priming Pump (2) Fuel Transfer Pump (3) Primary Fuel Filter (4) Fuel
Distribution Block (5) Secondary Fuel Filter (6) Electronic Control Module (ECM)

FIGURE 3.10.1-2 CATERPILLAR 3456 EPG ENGINE, LEFT SIDE VIEW

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Top View

(1) Fuel Priming Pump (2) Fuel Transfer Pump (7) Exhaust Manifold (8)
Turbocharger (13) Flywheel Housing

FIGURE 3.10.1-3 CATERPILLAR 3456 EPG ENGINE, TOP VIEW

Rear View

(13) Flywheel Housing (17) Flywheel

FIGURE 3.10.1-4 CATERPILLAR 3456 EPG ENGINE, REAR VIEW

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Front View

(14) Front Timing Gear Housing (15) Oil Check Gauge (16) Vibration Damper

FIGURE 3.10.1-5 CATERPILLAR 3456 EPG ENGINE, FRONT VIEW

The electronic control system was designed to provide electronic governing, automatic fuel ratio control,
torque rise shaping, injection timing control, and system diagnostics.

The Electronic Unit Injector system eliminates many of the mechanical components of an in-line pump
system. This system also provides increased control of the timing and of the fuel air ratio. The timing
advance is achieved by the precise control of the injector timing. Adjusting the duration of the injection
controls the engine rpm. A special pulse wheel provides information to the electronic control module for
the detection of the cylinder piston positions and of the engine rpm.

The engine has built-in diagnostics in order to ensure that all of the components are operating properly.
In the event of a system component failure, the operator will be alerted to the condition by the fault or
alarm lights on the GSC+. The GSC+ will display some diagnostic codes and the Caterpillar ET tool can
be used to read the numerical code of the faulty component or its condition. Intermittent faults are logged
and the information is stored in the memory of the ECM.

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3.10.2 STARTING THE ENGINE

The Electronic Control Module (ECM) will automatically provide the correct amount of fuel that is
necessary to start the engine. The ECM controls the starting-aid operation automatically. At engine
coolant temperatures below 32°F (0°C), the ECM will control ether injection. The Electronic Modular
Control Panel (EMCP+), controls the crank cycles and duration of the starter motor. If the engine fails to
start, the EMCP+ will cycle cranking to allow the starter motor to be cooled for the programmed cycle
time.

WARNING

DO NOT MANUALLY SPRAY ETHER INTO THIS ENGINE. EXCESSIVE ETHER


(STARTING FLUID) CAN CAUSE PISTON AND RING DAMAGE.

NOTE: Use ether for cold weather starting purposes only.

3.10.3 COLD MODE OPERATION

The engine control system performs a cold start strategy for the correct warm-up time after a cold engine
start. The temperature for a cold engine start is less than 64°F (18°C). This cold start strategy is called
cold mode. After being activated, this cold mode will remain active until the coolant temperature rises
above 64°F (18°C) or until the engine has been running for 12 minutes. Cold mode will also vary the fuel
injection amount, the timing for the maximum start-up, and the timing for the control of white smoke. The
time that is necessary for the engine to achieve the normal mode of operation is usually less than the time
that is required for a walk-around inspection of the engine.

3.10.4 MEP-PU-810 SPECIFIED PARAMETERS

The engine is capable of being programmed for several customer-specified parameters. Refer to Annex
B, C, E, and F for each of the DPGDS specified parameters.

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3.10.5 ALTERNATOR

3.10.5.1 SR4B ALTERNATOR

Figure 3.10.5.1-1 illustrates the DPGDS SR4B Alternator. The SR4B is a three-phase, alternating
current, brush less type generator. It is a four-pole design. The stationary main armature bolts to the
engine flywheel housing. A flexible plate type coupling connects the rotor shaft to the engine flywheel.
The rotating main field is keyed directly to the rotor shaft. The generator is self-ventilated with air entry
through screened openings at the rear of the generator and air discharge through screened openings at
the drive-coupling end. The fan attaches to the rotor shaft. A bearing supports the exciter end of the
rotor shaft.

FIGURE 3.10.5.1-1 DPGDS SR4B ALTERNATOR

3.10.5.2 GENERATOR THEORY OF OPERATIONS

The DPGDS SR4B Alternator is a Permanent Magnet Pilot Excited (PMPE) type.

Figure 3.10.5.1-1 illustrates the components of the SR4B Alternator. An engine supplies the power to
turn the Rotor Shaft. The Exciter Armature (Rotor) and Main Field (Rotor) attach to the Rotor Shaft.
As the Rotor Shaft turns, the Exciter Field (Stator) and Rectifiers generate DC current. This DC
current is supplied to the Main Field (Rotor) and creates a magnetic field around the poles of the Main
Field (Rotor). The Automatic Voltage Regulator (AVR) controls current. As the Main Field (Rotor) turns
with the Rotor Shaft, the magnetic field also rotates and induces an AC voltage into the Main Armature
(Stator). The Main Armature (Stator) is a coil with many turns of wire and the current that flows through
it also flows to the load. The Exciter Field (Stator) supplies DC current to the Main Field (Rotor). Load
(terminal) voltage is controlled, by varying the current to the Exciter Armature (Rotor).

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3.10.5.3 PERMANENT MAGNET PILOT EXCITER (PMPE)

Figure 3.10.5.3-1 illustrates the PMPE Generator Wiring Diagram. Permanent magnet pilot excited
generators receive power for the voltage regulator from a pilot exciter, rather than from the main armature
as in self-excited generators. The pilot exciter consists of permanent magnet (PM) and Pilot exciter
armature (L5). The pilot exciter operates independently from the generator output voltage. Constant
excitation during large load application is possible, because the irregularities that occur in generator
output voltage (caused by load conditions) are not fed back into the exciter. The independent operation
also allows the generator to supply and sustain excessive currents for short periods of time.

When the engine starts turning the rotating field assembly (RFA), a permanent magnet (PM) induces an
AC voltage in the pilot exciter armature (L5). The pilot exciter armature has three coils of wire and
generates three-phase AC. The resulting AC flows through wires T1 PMG, T2 PMG and T3 PMG to the
voltage regulator. Within the voltage regulator the three-phase AC is rectified to DC and a controlled
amount is fed to exciter field (L1) through terminals Fl and F2.

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(CR1-CR6) Diodes (CR7) (CR8) Varistors (L1) Exciter Field (stator)


(L2) Exciter Armature (rotor) (L3) Main Field (rotor) (L4) Main Armature (stator)
(L5) Pilot Exciter Armature (PM) Permanent Magnet (RFA) Rotating Field Assembly
(T1 PMG, T2 PMG, T3 PMG) Conductors that carry three phase AC power from the Pilot Exciter to the Digital
Voltage Regulator.
(TO, T1, T2, T3, T7, T8, T9) Generator Output Terminals and/or Generator Output Leads

FIGURE 3.10.5.3-1 PMPE GENERATOR WIRING DIAGRAM

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DC now flows to the exciter field (L1) and a magnetic field is created, in which exciter armature (L2) is
rotating. The exciter field (L1) and exciter armature (L2) generates three-phase AC. The AC is then
rectified to DC by three-phase full wave bridge rectifier circuit (diodes CR1-CR6). The DC output from the
bridge rectifier is carried to the main field (L3) by conductors, which are routed through a passage in the
generator shaft. Current through the main field (L3) creates the magnetic field of the generator. As the
main field (L3) rotates, it induces a three-phase AC voltage in the main armature (L4), which is sent to
terminals TO, T1, T2 and T3, which are connections for the load.

To keep the output voltage constant with changing loads, it is necessary to control the exciter current.
This control is the function of the voltage regulator. The voltage regulator senses the generator output
voltage at wires 20 GEN, 22 GEN and 24 GEN. The voltage regulator uses the current generated from
the permanent magnet (PM) and pilot exciter armature (L5) at wires T1 PMG, T2 PMG and T3 PMG. This
current is then controlled by the voltage regulator and sent to the exciter through wires Fl and F2.
Permanent magnets (PM) supply the initial magnetism required at start-up. Flashing the field is not
required for start-up of the generator.

3.10.5.4 GENERATOR COMPONENTS

The SR4B generator design includes:

• Power for the exciter field is provided by a Permanent Magnet Pilot Excited (PMPE) method of
excitation.
• Bearing location (inboard). The size and vibration characteristics of the engine and generator
determine whether the bearing is located inboard or outboard of the exciter. On the DPGDS, the
bearing is inboard of the exciter.
• On PMPE generators, the pilot exciter is either inboard or outboard of the exciter. On the
DPGDS, the pilot exciter is outboard of the exciter.
• The Rotating Field Assembly (RFA) components attach to rotor shaft, which is supported by the
engine flywheel and bearing.
• The Generator main field rotor is part of the rotating field assembly and rotates with the shaft.

Figure 3.10.5.4-1 illustrates the heat sink on the end of the Rotating Field Assembly (RFA). The 6-diode
rectifier block contains six diodes (CR1-CR6) of the bridge rectifier circuit and Varistor (CR7). The heat
sink also contains an additional varistor (CR8). The two varistors are used to protect the diodes by
suppressing any abnormal transient peak voltages in the generator circuit. The varistor is a voltage
dependant resistor that has a high resistance at low voltage and a low resistance at high voltage. This
allows current to pass through the varistor to ground when voltage spikes are present. The terminals,
marked AC, connect to the wires from the exciter armature (L2). The terminals marked + and – connect to
the main field (L3).

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FIGURE 3.10.5.4-1 RFA HEAT SINK

The 6-diode rectifier block (CR1-CR6) and Varistor CR7 are illustrated in Figure 3.10.5.4-2. The varistor
(CR8), is illustrated in Figure 3.10.5.4-3.

FIGURE 3.10.5.4-2 SIX DIODE RECTIFIER BLOCK WITH VARISTOR CR7

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FIGURE 3.10.5.4-3 VARISTOR CR8

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3.11 AIR INTAKE AND EXHAUST SYSTEM

The following topics are addressed:

• Air Intake and Exhaust System Operation


• System Components

3.11.1 AIR INTAKE AND EXHAUST SYSTEM OPERATION

The following topics are addressed;

• Combustion Air Flow

• Exhaust Gas Flow

• Power Unit Internal Cooling Air Flow

3.11.1.1 COMBUSTION AIR FLOW

Figure 3.11.1.1-1 illustrates the Combustion Air Flow within the Air Intake and Exhaust System. The
turbocharger pulls combustion air through the Air Cleaner Assembly into the compressor side of the
turbocharger. The combustion air is compressed which heats it to about 300°F before being pushed to
the aftercooler (ATAAC). The combustion air flows through the aftercooler core and the temperature of
the compressed combustion air is then reduced to around 110°F before entering the Air Inlet Manifold.

FIGURE 3.11.1.1-1 COMBUSTION AIR FLOW

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3.11.1.2 EXHAUST GAS FLOW

Figure 3.11.1.2-1 illustrates the Exhaust Gas Flow. Exhaust gases & noise are dispersed through top of
the Power Unit (PU). Exhaust gases flow through the exhaust manifold to the turbine side of the
turbocharger to drive the turbine wheel. Air is pulled into the system by the compressor wheel, which is
connected to the turbine wheel by means of a common shaft. After leaving the turbine, exhausted gases
pass out through the Muffler Assembly.

FIGURE 3.11.1.2-1 SYSTEM EXHAUST FLOW

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3.11.1.3 POWER UNIT INTERNAL COOLING AIR FLOW

Figure 3.11.1.3-1 illustrates the Power Unit Internal Cooling Air Flow. Cooling air is drawn into the interior
of the PU from two areas. One entry point is the rear of the trailer at the alternator end. Air removes
ambient heat from the Alternator and Engine and is drawn by hydraulic driven cooling fans, and pushed
through the top of the Power Unit above the radiator. The other entry point is below the radiator
assembly, where hydraulic driven fans push cool air up through for the Radiator and ATAAC then through
the top of the Power Unit.

FIGURE 3.11.1.3-1 EXTERNAL AIR FLOW

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3.11.2 SYSTEM COMPONENTS

The major components of the Air Intake and Exhaust System are:

• Air-to-Air After Cooler (ATAAC)

• Air Cleaner

• Turbocharger

• Air Intake and Exhaust Manifold

• Muffler Assembly

• Air Filter Service Indicator

3.11.2.1 AIR-TO-AIR AFTER COOLER (ATAAC)

Figure 3.11.2.1-1 illustrates the Air-to-Air After Cooler. The ATAAC is separate from the coolant radiator
by means of a sheet of metal that forms two separate compartments within Radiator/Air-to-Air After
Cooler Assembly. Contained within ATAAC compartment is the Fuel Cooler. The purpose of the ATAAC
is to cool the compressed combustion air. This makes the air denser so more air will be packed into each
cylinder during the engine intake cycle thereby increasing engine efficiency.

FIGURE 3.11.2.1-1 AIR-TO-AIR AFTER COOLER (ATAAC)

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3.11.2.2 AIR FILTER

Figure 3.11.2.2-1 illustrates the Air Filter Assembly. The Filter Housing is located on top of each engine
aft of the cylinder head and directly above the flywheel housing. Unfiltered combustion air is drawn
through an air plenum connected from the Filter Housing to the floor of the PU. The purpose of the Air
Filter is to collect contaminants and prevent dirt from entering the engine. There is only one Air Filter per
engine.

FIGURE 3.11.2.2-1 AIR FILTER ASSEMBLY

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3.11.2.3 TURBOCHARGER

Figure 3.11.2.3-1 illustrates the Turbocharger. The Turbocharger is situated next to the engine cylinder
head assembly above the Exhaust Manifold. The purpose of the turbocharger is to increase horsepower
output by pumping pressurized combustion air into the engine, allowing fuel to be burned more efficiently.

FIGURE 3.11.2.3-1 TURBOCHARGER

Exhaust gases flow through the exhaust manifold to the turbine side of the turbocharger to drive the
turbine wheel. Air is pulled into the system by the compressor wheel, which is connected to the turbine
wheel by means of a common shaft. After leaving the turbine, exhausted gases pass out through the
Muffler Assembly. The air is compressed and heated to about 300°F (150°C) before the air is forced
though the ATAAC and the temperature of the compressed air is lowered to about 110°F (43°C). The
combustion efficiency increases because of the cooler inlet manifold air. This helps to provide lowered
fuel consumption and increased horsepower output. The ATAAC is a separate cooler that is mounted in
behind the Radiator. Hydraulic driven fans force ambient air across both cores. This cools the
compressed combustion air and the engine coolant.

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3.11.2.4 AIR INLET AND EXHAUST MANIFOLDS

Figure 3.11.2.4-1 illustrates the Air Intake Manifold and Figure 3.11.2.4-2 illustrates the Exhaust Manifold.
The Air Inlet Manifold is located on the left side of the engine near the midway point. The Air Inlet
Manifold is cast integrally with the 3456 engine cylinder head. The Exhaust Manifold is situated on the
right side of the engine just below the turbocharger. The Exhaust Manifold connects directly to the
cylinder heads, whereas the Air Inlet Manifold connects to the cylinder heads through Air Inlet Manifold
Elbow. The Air Inlet Manifold distributes clean filtered air from the turbocharger and after cooler into each
cylinder, while the exhaust manifold collects exhaust gasses from each cylinder and directs them to the
turbocharger, then to the muffler.

AIR INLET MANIFOLD

AIR INLET MANIFOLD


ELBOW

FIGURE 3.11.2.4-1 AIR INLET MANIFOLD

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EXHAUST MANIFOLD

FIGURE 3.11.2.4-2 EXHAUST MANIFOLD

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3.11.2.5 MUFFLER ASSEMBLY

Figure 3.11.2.5-1 illustrates the Muffler Assembly (See Item 1). The Muffler Assembly reduces the
exhaust-gas noise level and vents exhaust gases to atmosphere. Rain caps automatically open by
exhaust gas pressure and close by use of counter weights. The rain cap is located at the end of the
exhaust system and the muffler is an integral part of the PU roof (See Item 9).

FIGURE 3.11.2.5-1 MUFFLER ASSEMBLY

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3.11.2.6 AIR FILTER HIGH DIFFERENTIAL PRESSURE ALARM (HAFDPA)

Figure 3.11.2.6-1 illustrates the Air Filter High Differential Pressure Alarm (HAFDPA), located on the
Generator Control Panel (GCP). The Alarm is activated after a fault is detected by continuous monitoring
provided by the Air Filter Differential Gauge as shown in Figure 3.11.2.6-2. The Air Filter Differential
Gauge is located inside the Power Unit below the engine-compartment cooling fan. The Air Filter
Differential Gauge monitors restriction across the Air Filter. When the Air Filter High Differential Pressure
Alarm light is lit, the Air Filter requires replacement.

FIGURE 3.11.2.6-1 AIR FILTER HIGH DIFFERENTIAL PRESSURE ALARM (HAFDPA)

AIR FILTER DIFFERENTIAL GAUGE

FIGURE 3.11.2.6-2 AIR FILTER DIFFERENTIAL GAUGE

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3.12 OPERATOR'S REMOTE TERMINAL (ORT)

The following topics are addressed:

• ORT Hardware/Software

• ORT Screens

• ORT Setup Procedures

• Power Plant Control and Monitoring

FIGURE 3.12-1 OPERATOR’S REMOTE TERMINAL

3.12.1 ORT HARDWARE/SOFTWARE

The ORT provides DPGDS operators with a capability to conduct operations remotely, and provides
maintainers with a capacity to conduct detailed maintenance diagnostics through communications with
the Caterpillar Electronic Modular Control Panel (EMCP+), as well as the Caterpillar Electronic Technician
(ET) Tool.

Figure 3.12-1 illustrates the Operator Remote Terminal (ORT). The ORT is a Panasonic “ToughBook”
notebook computer configured with software required to perform its functions as the ORT.

The ORT Operator’s monitoring software runs on a preinstalled version of Microsoft Windows 2000 or XP.
In addition to monitoring, the ORT includes the software and files necessary to configure and load the
following MEP-PU-810 components: the PLC system and the overcurrent relays. The ORT may be loaded
with Caterpillar’s Electronic Technician software to diagnose and troubleshoot the CAT 3456 engines.

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3.12.2 ORT SCREENS

3.12.2.1 OVERVIEW SCREEN

There are two main screen types used in the ORT. The first screen type is the Overview Screen. This
screen provides the operator with an overview of the complete DPGDS power plant system, up to a
maximum of 4 PUs installed and connected. From this screen, the operator monitors the overall status of
the system. No individual PU controlling is done from this screen. From this screen, the operator
monitors overall system KW, number of generators required, and the following individual generator
parameters: KW, total 3-phase voltage, total current, frequency, and power factor. Additionally, the
operator can tell if the individual generators are running and if they are in automatic or manual mode.

FIGURE 3.12.2-1 OPERATOR’S REMOTE TERMINAL

3.12.2.2 INDIVIDUAL PU SCREENS

The second type of main screen is the individual PU monitoring/control screens. There is a screen for
each individual PU, up to a maximum of 4. From the individual screen, the operator has control of the
individual generators installed in each PU. This screen provides the operator with all the necessary
information and controls to start, stop, parallel, or change lineup from the ORT. The operator also has
control over the operation of individual PU breakers. This screen also informs the operator as to whether

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the PU is in Battleshort, mode of voltage regulation, engine economizing status and control, and fuel
solenoid valve control.

With the system operating in the automatic mode, by connecting an ORT to the network, the operator can
monitor and control the Power Units from up to 150 feet away. From the ORT, the operator can operate
all breakers and start/stop generators. The ORT has the capability to monitor and control a full system of
four Power Units. From the ORT, the operator will receive indications that an alarm has occurred. The
ORT will display which generator has the alarm. The operators can then make corrections or repair the
problem before it causes the loss of a generator. The ORT also provides the operator with the capability
of changing the lineup of online generators, as long as the number online stays the same. In a multiple
PU lineup, the operator can disable engine economizing. This prevents the RTU from shutting down
lightly loaded generators; however, in the event the load exceeds 85% and additional units are required,
those units are added automatically by the RTU.

FIGURE 3.12.2.2-1 OPERATOR’S REMOTE TERMINAL

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3.12.3 POWER PLANT CONTROL AND MONITORING

3.12.3.1 POWER PLANT CONTROL & MONITORING PROGRAM

The following screens provide the Operator with information relative to control and monitoring of the
Power Unit:

(1) Overview Pop-up Screen

(2) PU Control & Monitoring Pop-up Screen

(3) Hardware Alarm Pop-up Screen

(4) Alarm Pop-up Screen

(5) Alarm Summary Pop-up Screen

(6) Base Load Pop-up Screen

(7) Equipment Identification Pop-up Screen

(8) Low Fuel Elapsed Time Pop-up Indicator Screen

(9) Eight Hour Archive Pop-up Screen

(10) Shutdown Archive Pop-up Screen

(11) DPGDS One-Line Pop-up Screen

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3.12.3.2 OVERVIEW POP-UP SCREEN

Table 3.12.3.2-1 lists Overview Pop-up Screen icons, their titles and functionality. Figure 3.12.3.2-1
illustrates the Overview Pop-up Screen.

TABLE 3.12.3.2-1 OVERVIEW POP-UP SCREEN ICONS


ICON TITLE/FUNCTION
1 Engine Control Switch position (Off, Cool down, Auto, Manual).
2 Engine operating status (Running, Cool down, Off).
3 Breaker status (green – open, red – closed), typical of the five breakers.
4 Generator operating parameters.
5 Total KW load on the system lineup.
Left margin icons:
a. DPGDS
Calls Overview Monitoring Page
<Home>
b. PUA - <F1>: Calls PU-A control/monitoring screen
c. PUC - <F2>: Calls PU-B control/monitoring screen
d. PUC - <F3>: Calls PU-C control/monitoring screen
e. PUD - <F4>: Calls PU-D control/monitoring screen
6
f. 1Line - <F5>: Displays system lineup One line overview page
g. <F6>: Displays Alarm page
h. <F7>: Displays Alarm Summary page
i. <F8>: Displays the Hardware Alarm page
j. <F9>: Displays the Disabled Alarms page
k. <esc> Displays last page

7 # of Generators required

8 Log to disk Archive

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6 5 7

4
2

FIGURE 3.12.3.2-1 OVERVIEW POP-UP SCREEN

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3.12.3.3 PU CONTROL & MONITORING POP-UP SCREEN

Table 3.12.3.3-1 lists PU Control and Monitoring Pop-up Screen icons, their titles and functionality.
Figure 3.12.3.3-1 illustrates the PU Control and Monitoring Pop-up Screen.

TABLE 3.12.3.3-1 PU CONTROL & MONITORING POP-UP SCREEN ICONS


ICON TITLE/FUNCTION

1 Engine and generator operating parameters.

2 Indicates PU Battleshort switch label is in the BATTLESHORT position.

3 Engine Control Switch position (Off, Cool down, Auto, Manual).

4 Engine operating status (Running, Cool down, Off).

Displays remaining engine cool down time on engine in cool down, time in seconds. (Timer not
5
shown in Figure 3.12.3.3-1).
Engine Immediate Stop icon. Click once to stop engine, again to reset. ECS must be put in the
6
OFF/RESET position to clear the remote shutdown.

7 Engine Control Switch position (Off/Reset, Stop/Cool down, Auto, Manual).

Engine Start/Stop icon. Functional only when ECS is in AUTO. Text indicates action that will be
8 taken when “clicked” on. Stopping the engine will automatically trip the associated breaker before
putting the engine into cool down.

9 Breaker status (green – open, red – closed), typical of the five breakers.

10 Fuel solenoid/pump status (green – closed/off, red/yellow – AUTO/enabled).

Toggles the fuel solenoid/pump permissive. Text indicates action that will be taken when “clicked”
11
on.

Engine Economize Mode. This is a global icon – activating it on one screen affects all screens. .
12 Text indicates action that will be taken when “clicked” on. Text below the icon indicates current
mode status.

Tie breaker control icon. Text indicates action that will be taken when “clicked” on. The icon is
13
only active when the SMS is in AUTO.

Generator breaker control icon. . Text indicates action that will be taken when “clicked” on. The
14 icon is only active when the SMS is in AUTO. Opening the breaker with this icon keeps the
breaker open until “clicked” or the engine is shutdown.

Feeder breaker control switch. Text indicates action that will be taken when “clicked” on. The icon
15
is only active when the SMS is in AUTO.

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TABLE 3.12.3.3-1 PU CONTROL & MONITORING POP-UP SCREEN ICONS (CONTINUED)


ICON TITLE/FUNCTION

16 Indicates the current position of the AVRS (Prime Power or Utility Parallel).

17 Indicates the current position of the GMS (Prime Power or Utility Parallel).
18 Indicates the current position of the SMS (Auto, Off, or Manual).

Left margin icons:


a. DPGDS - Home>: Calls Overview monitoring page
b. PUB - <F2>: Calls PU-B control/monitoring screen
c. PUC - <F3>: Calls PU-C control/monitoring screen
d. PUD - <F4>: Calls PU-D control/monitoring screen
e. 1Line - <F5>: Displays system lineup One line overview
19 page
f. <F6>: Displays Alarm page
g. <F7>: Displays Alarm Summary page
h. <F8>: Displays the Hardware Alarm page
i. <F9>: Displays the Disabled Alarms page
j. <Esc>: Displays last page

OL Timer
This timer displays the type of overload timer that is active, whether it is the 2 minute
20 timer or the 8 minute timer. It also displays the remaining time until the timer trips off the
affected generator and places it in cooldown.

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1
2

19

3 10
12
20
11

5
13
6
7
9 15
14
18
17

8
16

FIGURE 3.12.3.3-1 PU CONTROL & MONITORING POP-UP SCREEN

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3.12.3.4 HARDWARE ALARM POP-UP SCREEN

Figure 3.12.3.4-1 illustrates the Hardware Alarm Pop-up Screen. This pop-up screen is only visible
whenever a new alarm or fault occurs. This screen also activates the ORT buzzer. Clicking on the
uppermost listed alarm acknowledges that alarm. Acknowledging all alarms silences the buzzer and
allows the Operator to exit the pop-up screen. The 2 minute generator overload alarm can not be
silenced. As long as there is an unacknowledged alarm the exit button is grayed out. Acknowledged
alarms can be reviewed on the Alarm Summary Pop-up Screen.

FIGURE 3.12.3.4-1 CRITICAL ALARM POP-UP SCREEN

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3.12.3.5 ALARM POP-UP SCREEN

Table 3.12.3.5-1 lists the Alarm Pop-up Screen icons, their titles and functionality. Figure 3.12.3.5-1
illustrates the Alarm Pop-up Screen. The screen logs past and current alarms.

TABLE 3.12.3.5-1 ALARM POP-UP SCREEN ICONS


ICON TITLE/FUNCTION
Left margin icons:
a. DPGDS<Home>: Calls Overview monitoring page
b. PUA - <F1>: Calls PU-A control/monitoring system
c. PUB - <F2>: Calls PU-B control/monitoring screen
d. PUC - <F3>: Calls PU-C control/monitoring screen
1 e. PUD - <F4>: Calls PU-D control/monitoring screen
f. <F6>: Displays Alarm page
g. <F7>: Displays Alarm Summary Page
h. <F8>: Displays the Hardware Alarm page
i. <F9>: Displays the Disabled Alarms page
j. <Esc>: Displays last page.
2 Tag - Unit that had an alarm
3 Description - Equipment that had alarm
4 Date/Time of alarm

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3
4 2

FIGURE 3.12.3.5-1 ALARM POP-UP SCREEN

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3.12.3.6 ALARM SUMMARY POP-UP SCREEN

Table 3.12.3.6-1 lists Alarm Summary Pop-up Screen icons, their titles and functionality. Figure 3.12.3.6-
1 illustrates the Alarm Summary Pop-up Screen.

TABLE 3.12.3.6-1 ALARM SUMMARY POP-UP SCREEN ICONS


ICON TITLE/FUNCTION
Left margin icons:
a. DPGDS - <Home>: Calls Overview monitoring page
b. PUA - <F1> Calls PU-A control/monitoring screen
c. PUB - <F2>: Calls PU-B control/monitoring screen
d. PUC - <F3>: Calls PU-C control/monitoring screen
1 e. PUD - <F4>: Calls PU-D control/monitoring screen
f. <F6>: Displays Alarm page
g. <F7>: Displays Alarm Summary Page
h. <F8>: Displays the Hardware Alarm page
i. <F9>: Displays the Disabled Alarms page
j. <Esc>: Displays last page.
2 Date and time of alarm
3 Tag – Unit that had alarm
4 Unit and type of alarm
5 Shows if the alarm has been acknowledged by the operator
6 Summary of alarm

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11

2 3 4
5 6

FIGURE 3.12.3.6-1 ALARM SUMMARY POP-UP SCREEN

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3.12.3.7 BASE-LOAD POP-UP SCREEN

Table 3.12.3.7-1 lists Base-Load Pop-up Screen icons, their titles and functionality. Figure 3.12.3.7-1
illustrates the Base Load Pop-up Screen.

TABLE 3.12.3.7-1 BASE-LOAD POP-UP SCREEN ICONS


ICON TITLE/FUNCTION
Base-Load Icon. After the power plant has been setup to operate in Utility Parallel. By clicking on
1
F12 will bring the ORT to this screen.
Base-Load Slide Icon. Click the right mouse key on the touchpad on the arrow keys below the
red and blue arrows. Clicking on the right key will increase the KW load on each generator
2 connected to the load. Clicking on the left key will decrease the load. The blue numbers shows
how much load has been dialed into the ORT. The red numbers shows the actual load per
generator. The green numbers show plant load.

Left margin icons:

a. PUA - <F1>: Calls PU-A control/monitoring screen


b. PUB - <F2>: Calls PU-B control/monitoring screen
c. PUC - <F3>: Calls PU-C control/monitoring screen
d. PUD - <F4>: Calls PU-D control/monitoring screen
3
e. 1 Line - <F5>: Displays system lineup One line overview page
f. <F6>: Displays Alarm page
g. <F7>: Displays Alarm Summary page
h. <F8>: Displays the Hardware Alarm page
i. <F9>: Displays the Disabled Alarms page
j. <Esc>: Displays last page

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FIGURE 3.12.3.7-1 BASE-LOAD POP-UP SCREEN

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3.12.3.8 EQUIPMENT IDENTIFICATION POP-UP SCREEN

Table 3.12.3.8-1 lists the Equipment Identification Pop-up Screen icons, their titles and functionality.
Figure 3.12.3.8-1 illustrates the Equipment Identification Pop-up Screen.

TABLE 3.12.3.8-1 EQUIPMENT IDENTIFICATION POP-UP SCREEN ICONS


ICON TITLE/FUNCTION

Left margin icons:

a. PUA - <F1>: Calls PU-A control/monitoring screen


b. PUB - <F2>: Calls PU-B control/monitoring screen
c. PUC - <F3>: Calls PU-C control/monitoring screen
d. PUD - <F4>: Calls PU-D control/monitoring screen
1
e. 1 Line - F5>: Displays system lineup One line overview page
f. <F6>: Displays Alarm page
g. <F7>: Displays Alarm Summary page
h. <F8>: Displays the Hardware Alarm page
i. <F9>: Displays the Disabled Alarms page
j. <Esc>: Displays last page

2 PU A Engine 2 ID Number (User Entered)


3 PU A Generator 2 ID Number (User Entered)
4 PU A Engine 1 ID Number (User Entered)
5 PU A Generator 1 ID Number (User Entered)
6 PU Trailer ID Number (User Entered)
7 RTU automatically enters this Number

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6
7

FIGURE 3.12.3.8-1 EQUIPMENT IDENTIFICATION POP-UP SCREEN

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3.12.3.9 LOW FUEL ELAPSED TIME POP-UP INDICATOR SCREEN

Figure 3.12.3.9-1 illustrates the Low Fuel Elapsed Time Pop-up Indicator Screen. The Low Fuel Timer
pop-up appears whenever the Fuel Tank Low Level Fuel Switch (LFTL) closes (See Item 1). The elapsed
time accumulates to 10 minutes. After 10 minutes the timer stops and shuts down both generators.
Neither generator will auto restart until the LFTL resets.

ITEM 1

FIGURE 3.12.3.9-1 LOW FUEL ELAPSED TIME POP-UP INDICATOR SCREEN

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3.12.3.10 EIGHT-HOUR ARCHIVE POP-UP SCREEN

Figure 3.12.3.10-1 illustrates the Eight Hour Archive Pop-Up Screen. The Archive pop-up appears every
8 hours at 0800, 1600, and 2400 hrs. This copies, the previous eight hours of archived data to a floppy
disk. The disk to receive the data must be blank or the data will not be copied. Canceling skips copying
the data to the floppy disk; however, the file is saved to the hard drive. The hard drive will hold up to 60,
8-hour archives (20 days), after which the oldest file will begin to be overwritten.

FIGURE 3.12.3.10-1 EIGHT HOUR ARCHIVE POP-UP SCREEN

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3.12.3.11 SHUTDOWN ARCHIVE POP-UP SCREEN

Figure 3.12.3.11-1 illustrates the Shutdown Archive Pop-Up Screen. The Shutdown Archive Pop-Up
Screen appears when the END key is pressed to shutdown the ORT. A blank floppy is requested to
shutdown the software. The operator can Save to the floppy or hit Cancel and the Data will be saved to
the hard drive.

FIGURE 3.12.3.11-1 SHUTDOWN ARCHIVE POP-UP SCREEN

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3.12.3.12 DPGDS ONE-LINE POP-UP SCREEN

Figure 3.12.3.12-1 illustrates the DPGDS One-Line Pop-Up Screen. This screen provides the operator
with a one-line view of the power plant distribution status. The operational status of each generator is
displayed (red – running, green – off) as well as the status of each breaker (red – closed, green – open).
Additionally, the operator may enter text into the boxes under each PU to describe the load connected to
that breaker. Placing the mouse pointer over the box and typing in the desired data enters the
description. (pressing <Enter> writes that data to the box). The box is limited to 10 characters.

FIGURE 3.12.3.12-1 DPGDS ONE-LINE

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3.12.3.13 PDC AND ORT LOAD LIMITING SOFTWARE

The following topics are addressed in this section:

• PLC and ORT load limiting software description


• Power monitor
• 60 Hz operation
• 50 Hz operation
• Warnings
• Battle short
• ORT load monitoring pop-up screens

3.12.3.13.1 PDC AND ORT LOAD LIMITING SOFTWARE DESCRIPTION

The PLC and ORT overload software does not change the control/operation of the power unit under
normal operating conditions. All operating procedures should be followed as specified in this technical
manual, noting the power rating of the set is 420 kW prime for 60 Hz operation and 350 kW prime for 50
Hz operation. Software updates allow both the ORT and the PLC to warn the operator of an excessive
load applied to the power unit. Additionally, the service pack adds additional functions and features to the
ORT for improved operator interaction.

3.12.3.13.2 POWER MONITOR

The primary overload protection for continuous loads on the engine/generator is provided using the
existing Generator Set Controller (GSC) and Programmable Logic Controller (PLC) in the PDC. New
software has been added to the PU that will monitor the load and warn the operator if the power capability
of the engine has been exceeded. If normal load levels are not established through load shedding or
additional generators brought on line within the time allotted the unit will shut down to protect the
engine/generator.

3.12.3.13.3 60 HZ OPERATION

Based on the 420 kW prime, 460 kW (110%) maximum rating of the generator, the load limits
implemented are:

(1) At 470 kW or 600 kVA the load limiting software warns the operator of an overload and the generator
will shutdown in 8 minutes. *

(2) At 480 kW or 615 kVA, the load limiting software warns the operator of an overload and the generator
will shutdown in 2 minutes. *

(3) At 500 kW or 630 kVA the generator will shutdown in 5 seconds.

* The load must exceed this level for 5 seconds to activate the warning.

When the generator load drops below 465 kW and 595 kVA the warnings will be extinguished.

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3.12.3.13.4 50 HZ OPERATION

Based on the 350 kW prime, 385 kW maximum rating of the generator, the load limits implemented are:

(1) At 390 kW or 500 kVA the load limiting software warns the operator of an overload and the generator
will shutdown in 8 minutes. *

(2) At 400 kW or 512 kVA the load limiting software warns the operator of an overload and the generator
will shutdown in 2 minutes. *

(3) At 415 kW or 525 kVA the generator will shutdown in 5 seconds.

* The load must exceed these levels for 5 seconds to activate the warning.

When the generator load drops below 385 kW and 495 kVA the warnings will be extinguished.

3.12.3.13.5 WARNINGS

The operator warning is given in two ways. Additional fault lights indicating an overload have been added
to the PU. When an overload is detected by the PLC, the existing PU fault annunciator will be turned on
and the associated GENERATOR OVERLOAD light(s) will flash. A warning and countdown timer will be
displayed on the Operator Remote Terminal (ORT) if it is in use. Two unique audible alarms have been
implemented on the ORT signaling the 8-minute (470kW) or 2-minute (480kW) countdown periods.

If the load on the unit is not reduced before expiration of the overload countdown timers the generator
breaker will open and the engine will enter cooldown mode. The GENERATOR OVERLOAD lights on the
PU will remain illuminated (steady state). See Figure 3.12.3.13.5-1.

A generator overload fault can only be cleared from the PU using the MSES switch, Not from the ORT.

If the Load is reduced to the 465 kW threshold for 5 seconds before the timers time out, the timers
will reset and the audible alarm/faults will clear.

GENERATOR
OVERLOAD
GEN. 1

GEN. 2

FIGURE 3.12.3.13.5-1 PU GENERATOR OVERLOAD INDICATOR LIGHTS

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3.12.3.13.6 BATTLE SHORT

Activation of the Battle Short switch on the PU will override the shutdown of the unit except for Over
Speed, Generator Basler Over Current Protection Relays, and Emergency Stop. If an overload condition
is present the overload warning will be present but the overload timer will remain at 8 minutes and/or 2
minutes.

WARNING

Operating the unit in Battle Short can result in catastrophic failure of the engine and generator.
When operating in Battle Short mode all PU’s are required to be placed in Battle Short mode.

3.12.3.13.7 ORT OVERLOAD POP-UP SCREENS

Two ORT load monitoring pop-up screens have been added to reflect over load timing functions and one
new screen was added that details new features to the Overview Screen.

Upon reaching an overload condition, as outlined above, the following will occur:

(1) An alarm on the ORT is logged that must be acknowledged by the operator and warns of an overload
condition.

(2) An audible alarm on the ORT is activated and remains active as long as the generator is in an
overload condition.

(3) On the Plant Overview Screen, the overloaded generator(s) will flash and an overload countdown
timer will be present as shown in Figure 3.12.3.13.7-1.

(4) Upon reaching the second level of overload detection (480 kW for 60 Hz), a 2-minute warning will be
displayed and a second audible warning (different tone) will sound on the ORT. This audible warning can
only be extinguished by lowering the load on the generator below 465 kW.

(5) When the overload condition reaches the 2-minute load level (480 kW at 60 HZ), this timer will
override the 8-minute timer unless the generator is within 2 minutes of shutdown on the 8-minute timer.
The timer that has the shortest shutdown time will then be displayed on the ORT screen. This means that
if the generator is in an overload condition, (470 kW) and the load increases to 480 kW, the 2-minute
timer will then activate, unless the generator is within 2 minutes of shutdown. If there are 2 minutes or
less on the 8-minute timer, the 2-minute timer will not activate as that will add more time to the engine
shutdown.

(6) If the load is not reduced before the overload period expires the generator breaker opens and the
generator enters the cooldown cycle. To re-enable the generator the fault must be cleared on the PU by
toggling the Master Start Enable Switch for three seconds. The fault is then cleared and normal operation
can resume.

If the operator displays the PU Control and Monitoring Screen, during an overload condition, the screen
will be shown as in Figure 3.12.3.13.7-2:

Figure 3.12.3.13.7-3 shows new features added to the Plant Overview Screen

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Overload timer will display here showing


remaining time till PLC trips breaker. The time
displayed is the lesser of either the 8-minute or
2-minute timer.
Additionally, the generator image flashes.

FIGURE 3.12.3.13.7-1 PLANT OVERLOAD OVERVIEW SCREEN

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The text was changed on the button


to reflect actual button function and
avoid confusion with button for
normal cooldown and shutdown of
the engine.

Overload timer:
Displays remaining time until PLC trips breaker due
to overload condition.

Whichever timer has less time to breaker trip is


displayed.

FIGURE 3.12.3.13.7-2 PU CONTROL & MONITORING SCREEN

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Item added to provide the operator with


the number of generators required for
the current kW and kVA readings.

Added immediate archive current log file


to a blank floppy disk to allow reviewing
datafiles without having to wait for
scheduled archive.

Value displayed is total


generator current, 3 phases, as
displayed on GSC+ module.

FIGURE 3.12.3.13.7-3 ORT SERVICE PACK-3 SCREEN

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3.13 TRAILER RUNNING GEAR SYSTEMS

This section provides information and component descriptions for the MEP-PU-810A and MEP-PU-810B
trailer running gear systems. Data on the tires, wheels, brake systems, and lighting systems for each
type of unit is included.

3.13.1 TIRES

3.13.1.1 MEP-PU-810A TIRES

The tires specified for the MEP-PU810A are size LT235/85R16, load range E. The specified cold inflation
pressure is 80 PSI. Each tire has a rated load capacity of 3,667 lbs at 25 MPH in a dual configuration at
this inflation pressure. Replacement tires must be of this same size and equal or greater load capacity in
a dual configuration at 25 MPH and at 80 PSI, cold inflation pressure.

3.13.1.2 MEP-PU-810B TIRES

The tires specified for the MEP-PU810B are size 11R22.5, load range G. The specified cold inflation
pressure is 105 PSI. Each tire has a rated load capacity of 5630 lbs at 60 mph in a dual configuration at
this inflation pressure. Replacement tires must be of this same size and equal or greater load capacity in
a dual configuration at 60 MPH and at 105 PSI, cold inflation pressure.

3.13.2 WHEELS

3.13.2.1 MEP-PU-810A WHEELS

The wheels specified for the MEP-PU-810A are size 14.5” x 7.00”, 8 studs on 6.50” bolt circle, with dual
wheel configuration offset.

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3.13.2.1.1 MEP-PU-810A WHEEL TORQUE REQUIREMENTS

1
8 6

3 4

5 7
2
8 BOLT
FIGURE 3.13.2.1.1-1 MEP-PU-810A TORQUE PATTERN

It is extremely important to apply and maintain proper wheel mounting torque. The torque requirement for
the MEP-PU-810A wheel nuts is 200-250 Ft-Lbs.

CAUTION

WHEEL NUTS OR BOLTS MUST BE APPLIED AND MAINTAINED AT THE PROPER TORQUE
LEVELS TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSIBLE DANGEROUS
SEPARATION OF WHEELS FROM YOUR AXLE.

NOTE: A Special Tool is required for this task; refer to Annex H for recommended tool.

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3.13.2.2.1 MEP-PU-810B WHEELS

The wheels specified for the MEP-PU-810B are size 16 1/2 ” x 7”, 10 studs on an 11 1/4” bolt circle, with
dual wheel configuration offset.

3.13.2.2.2 MEP-PU-810B WHEEL TORQUE REQUIREMENTS

1
10 7

4 5

6 3

8 9
2
10 BOLT

FIGURE 3.13.2.2.2-1 MEP-PU-810B TORQUE PATTERN

It is extremely important to apply and maintain proper wheel mounting torque. Torque wrenches are the
best method to assure the proper amount of torque is being applied to a fastener. The torque
requirement for the MEP-PU-810B wheel nuts is 450-500 Ft-Lbs.

CAUTION

WHEEL NUTS OR BOLTS MUST BE APPLIED AND MAINTAINED AT THE PROPER TORQUE
LEVELS TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSIBLE DANGEROUS
SEPARATION OF WHEELS FROM YOUR AXLE.

NOTE: Roadside wheel lug nuts on the MEP-PU-810B are left hand threads. Therefore, to
remove the lug nut you must turn the nut clockwise and to tighten the lug nut you
must turn the nut counterclockwise.

NOTE: A Special Tool is required for this task; refer to Annex H for recommended tool.

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3.13.3 BRAKE SYSTEMS

3.13.3.1 MEP-PU-810A BRAKE SYSTEM

The hydraulic brakes on the MEP-PU-810A are much like those on a car. The hydraulic fluid from a
master cylinder is used to actuate the wheel cylinder, which, in turn, applies force against the brake shoes
and drum. The main difference between automotive hydraulic brakes and hydraulic trailer brakes are the
actuation systems, which transfer the braking signal from the tow vehicle to the brakes.

3.13.3.1.1 SURGE BRAKING SYSTEM

Figure 3.13.3.1-1 illustrates the MEP-PU-810A Hydraulic Brake Actuator. The Surge Braking System
uses a specially designed trailer hitch coupler, which has a built in master cylinder. When the tow
vehicle applies its brakes, the tow vehicle decelerates causing the trailer to apply a pushing force against
the towing vehicle hitch. This force actuates the surge hitch master cylinder, transferring high-pressure
brake fluid to the wheel cylinder. The trailer brakes are now applied (See Figure 3.13.3.1-1).

FIGURE 3.13.3.1-1 HYDRAULIC BRAKE ACTUATOR

Figure 3.13.3.1-2 illustrates the Break-Away Lever and Chain positions. The surge brake system
incorporates a safety breakaway lever and chain that activates the surge brake if the trailer separates
from the tow vehicle. The actuator’s breakaway chain S-hook should be securely attached to one of the
tow vehicle safety chain connection points. Before towing, check that the breakaway lever and chain are
properly positioned as shown in (Figure 3.13.3.1-2). If the breakaway lever and chain are not located
correctly, due to either the chain being pulled during use or by accident, it must be reset prior to moving
the trailer.

Resetting the lever is accomplished by first removing the two rearward bolts, located on each side of the
breakaway lever. These two bolts hold down the breakaway locks. Loosen, but do not remove the
remaining two bolts. This will allow the two locks to be swung aside and the lever can be pushed back
into its resting position. Replace the breakaway locks to their original positions and retighten the four
bolts using a torque wrench to 90-120 inch-pounds of torque.

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FIGURE 3.13.3.1-2 BREAK-AWAY LEVER AND CHAIN POSITIONS

3.13.3.1.2 BRAKE FLUID

DOT4 Brake Fluid is recommended. The Brake Fluid should be checked periodically for the correct level,
dirt, rust, or water contamination. Flush and replace fluid if contamination is present.

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3.13.3.1.3 HYDRAULIC BRAKE OPERATION

Figure 3.13.3.1.3-1 illustrates the Hydraulic Brake Function Diagram. The Hydraulic Brake utilizes a single
acting cylinder. Upon actuation, the primary shoe is pressed against the brake drum, which causes the
shoe to move in the direction of rotation. This movement in turn actuates the secondary shoe through the
adjuster link assembly.

FIGURE 3.13.3.1.3-1 HYDRAULIC BRAKE FUNCTION DIAGRAM

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3.13.3.1.4 HYDRAULIC BRAKE COMPONENTS

Figure 3.13.3.1.4-1 illustrates the Hydraulic Brake Components used in the MEP-PU-810A.

FIGURE 3.13.3.1.4-1 HYDRAULIC BRAKE COMPONENTS

3.13.3.1.5 SELF-ADJUSTING MECHANISM FOR HYDRAULIC BRAKES

The brakes adjust on both forward and reverse stops. Components include a new adjuster, adjuster lever
arm, adjuster return springs, cable, cable anchor bracket, and an extension spring. The new cable
anchor bracket fits over the anchor post and has a slotted hole. The extension spring attaches the cable
anchor bracket to the primary brake shoe. The brake adjuster cable is routed from the cable anchor
bracket, over the cable guide, to the adjuster lever. The forward stop adjustment is accomplished when
the primary shoe lifts sufficiently far off the anchor post. The extension spring connecting the primary
shoe to the slotted cable anchor bracket pulls the bracket and the cable causing the adjuster lever to
rotate the adjuster screw star wheel. This will continue on each brake until the shoe clearance is
sufficiently small so that the primary shoe movement is insufficient to pull the cable to engage the next
tooth on the adjuster star wheel.

3.13.3.1.6 PARKING BRAKE

The parking feature for the MEP-PU-810A is a positive mechanical device that clamps against the inside
rear tires when applied. The parking brake is engaged and disengaged using a crank handle located at
the rear of the unit.

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3.13.3.2 MEP-PU-810B BRAKE SYSTEM

Trailer air brakes are operated by the tractor air supply through a series of relays and check valves.
When braking is desired, the air is supplied to the axle air chamber, which applies a force that is
multiplied by the slack adjuster lever arm length. This force is transmitted rotationally through the
camshaft, which, through the geometry of the S-head, spreads the brake shoes to contact the brake drum
surface.

3.13.3.2.1 AIR CHAMBERS

Figure 3.13.3.2.1-1 illustrates the S-Cam Brake Assembly. The air chambers convert the tractor
compressed air into mechanical force on the slack adjuster. The force on the slack adjuster operates on
the end of the lever and converts the chamber output force to a torque on the S-cam. Federal and state
regulations state the maximum pushrod stroke length as an indication of brake adjustment. The stroke
length is indicated by the Maximum Stroke Indicator, located on the Air Chamber Pushrod. Maximum
allowable stroke is achieved when the indicator is fully extended from the air chamber housing.

FIGURE 3.13.3.2.1-1 S-CAM BRAKE ASSEMBLY

3.13.3.2.2 SPRING BRAKES

For parking and emergency braking, a spring brake chamber is used in conjunction with the standard air
chamber. The Spring Brake contains an additional air diaphragm and a very strong spring. When air
pressure is applied to the spring brake, the spring is held in the off position by the air diaphragm. When
the air pressure is released, the spring provides the braking force to the air chamber pushrod, thus
activating the brakes.

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3.13.3.2.3 SLACK ADJUSTERS

The Slack Adjuster performs two functions: (1) the slack adjuster acts as a lever arm to convert the linear
pushrod force to rotational camshaft torque. The length of the slack adjuster determines the amount of
torque multiplication provided from the pushrod. (2) Allows a simple external adjustment of the lining to
drum clearance to compensate for shoe lining wear. Slack adjusters require manual adjustment to make
up for the brake lining wear and the associated drum to lining gap that results. Adjustment is usually
performed by rotating the hex nut on the slack adjuster body to set a lining to drum clearance of about
.020-.030”.

SPRING BRAKE ASSEMBLY

SLACK ADJUSTER

AIR CHAMBER

FIGURE 3.13.3.2.2-1 BRAKE SYSTEM COMPONENTS

3.13.3.2.4 ANTI-LOCK BRAKE SYSTEM (ABS)

Figure 3.13.3.2.4-1 illustrates the Anti-Lock Brake System (ABS) Wiring Layout. The ABS is made up of
Wheel Speed Sensors, an ABS Relay Valve, an integral Electronic Control Unit (ECU), mounted on the
relay valve, and an ABS indicator light. The ECU monitors wheel speed through two-wheel speed
sensors mounted on the hubs of the axle. When the ECU detects that a wheel is stopping too fast, during
a brake application, the air pressure in the brake chambers of the wheels is reduced via the ABS Relay
Valve, allowing the wheels to recover. The ECU then commands the relay valve to apply additional
pressure unit maximum braking potential is produced. This ABS cycle is repeated roughly five times per
second as needed, or until the vehicle is traveling at less than six miles per hour.

NOTE: The ABS system only functions when the PU is connected to the Tow Vehicles 12VDC
electrical system; ABS will not function when connected to a 24VDC system.

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8 6

1
2
7
8

1. Standard SAE J560 2. Power Cord 5 pin 3. Power Cord 5 pin


4. ECU Connector 19 Pin
Connector Connector Connector
7. Speed Sensor/Exciter 8. Sensors 1A and 1B
5. ABS Valve with ECU 6. Solenoid Connector
Ring Connectors

FIGURE 3.13.3.2.4-1 ABS WIRING LAYOUT

3.13.3.2.5 HUB ODOMETER

Figure 3.13.3.2.5-1 illustrates the Hub Odometer. The MEP-PU-810B trailer has one hub odometer
mounted on the curbside rim. This hub odometer has a 500,000-mile warranty and requires no service or
maintenance, for the life of the odometer. If the unit is damaged, replace it with a new one.

FIGURE 3.13.3.2.5-1 B MODEL HUB ODOMETER

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3.13.4 LIGHTING SYSTEMS

3.13.4.1 MEP-PU-810A LIGHTING SYSTEM

The MEP-PU-810A is not equipped with any exterior lighting.

3.13.4.2 MEP-PU-810B LIGHTING SYSTEM

The MEP-PU-810B has lights for clearance, reflectors, turn signals, and tail/stop-lights in accordance with
Department Of Transportation (DOT) and Federal Motor Vehicle Safety Standard (FMVSS), 121, 571.124
standards for commercial operations. For movement using a commercial vehicle, commercial lights are
powered by the vehicles 12VDC electrical system and is provided with a 7-way inter-vehicular cable.

In addition, included for towing with a military vehicle, a set of blackout lights, including clearance,
reflectors, turn signal, and tail/stop-lights. These lights are powered by the vehicles 24VDC electrical
system using a 12-way inter-vehicular cable. When in the blackout mode of operation, the commercial
lights are non-operational.

DOT LIGHTING

BLACK OUT LIGHTING COMBO

FIGURE 3.13.4.2-1 MEP-PU-810B LIGHTING

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CHAPTER 4
RECEIPT AND MOVEMENT
TABLE OF CONTENTS

SECTION TITLE PAGE


4.1 INTRODUCTION 5

4.2 INSPECTION ON RECEIPT 5

4.2.1 INSPECTION REQUIREMENTS UPON RECEIPT 5

4.2.2 SERVICE REQUIREMENTS 7

4.2.2.1 BATTERY 7

4.2.2.2 FUEL SYSTEM 7

4.2.2.3 COOLING SYSTEM 8

4.2.2.4 LUBRICATION SYSTEM 8

4.2.2.5 HYDRAULIC SYSTEM 9

4.3 MOVEMENT 10

4.3.1 MOVEMENT PREPARATION CHECKLIST 10

4.3.2 MEP-PU-810A HOOK-UP PROCEDURES 12

4.3.3 MEP-PU-810B HOOK UP PROCEDURES 16

4.3.4 TOWING PROCEDURES 18

4.3.5 BACKING UP PROCEDURES 20

4.3.6 DISCONNECTING PROCEDURES 21

4.3.6.1 MEP-PU-810A DISCONNECTING PROCEDURES 21

4.3.6.2 MEP-PU-810B DISCONNECTING PROCEDURES 21

4.3.6.3 LOADING PROCEDURES 22

4.3.6.4 UNLOADING PROCEDURES 23

4.4 MEP-PU-810A AND MEP-PU-810B TIE-DOWN POINTS 26

4.4.1 MEP-PU-810A TIE-DOWN POINTS 26

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4.4.2 MEP-PU-810B TIE-DOWN POINTS 27

4.5 MEP-PU-810A AND MEP-PU-810B ISO LIFT POINTS USING ISO


EXTENDER 28

4.6 ISO EXTENDER STORAGE PROCEDURES 30

4.6.1 MEP-PU-810A ISO EXTENDER STORAGE PROCEDURES 30

4.6.2 MEP-PU-810B ISO EXTENDER STORAGE PROCEDURES 33

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LIST OF FIGURES

FIGURE TITLE PAGE


FIGURE 4.3.1-1 CHECKING BRAKE FLUID LEVEL 11

FIGURE 4.3.2-1 MEP-PU-810A TOWING CONNECTION 13

FIGURE 4.3.2-2 LUNETTE EYE 14

FIGURE 4.3.2-3 BREAK-AWAY CHAIN S-HOOK 15

FIGURE 4.3.3-1 MEP-PU-810B TOWING CONNECTION 16

FIGURE 4.3.3-2 12VDC AND 24VDC LIGHTING CONNECTION 17

FIGURE 4.3.4-1 PARKING BRAKE 19

FIGURE 4.4.1-1 MEP-PU-810A TIE-DOWN POINTS, SIDE AND BOTTOM VIEW 26

FIGURE 4.4.2-1 MEP-PU-810B TIE-DOWN POINTS 27

FIGURE 4.5-1 ISO EXTENDER 28

FIGURE 4.5-2 ISO EXTENDER INSTALLED AND LOCKED INTO POSITION 29

FIGURE 4.6.1-1 ISO EXTENDER SHOWN IN LOCKED POSITION 30

FIGURE 4.6.1-2 ISO EXTENDERS PROPERLY PLACED IN STORAGE BOX 31

FIGURE 4.6.1-3 ISO EXTENDER STORAGE BOX IN TRANSPORTATION POSITION 31

FIGURE 4.6.1-4 ISO EXTENDER STORAGE BOX IN OPERATION POSITION 32

FIGURE 4.6.2-1 ISO EXTENDER SHOWN IN LOCKED POSITION 33

FIGURE 4.6.2-2 ISO EXTENDERS PROPERLY PLACED IN STORAGE BOX 34

FIGURE 4.6.2-3 ISO EXTENDER STORAGE BOX IN TRANSPORTATION/ OPERATION


POSITION 35

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LIST OF TABLES

TABLE TITLE PAGE


TABLE 4.2.1-1 GENERAL INSPECTION REQUIREMENTS 6

TABLE 4.2.2.1-1 BATTERY SERVICING REQUIREMENTS 7

TABLE 4.2.2.2-1 FUEL SYSTEM SERVICING REQUIREMENTS 7

TABLE 4.2.2.3-1 COOLING SYSTEM SERVICING REQUIREMENTS 8

TABLE 4.2.2.4-1 LUBRICATION SYSTEM SERVICING REQUIREMENTS 8

TABLE 4.2.2.5-1 HYDRAULIC SYSTEM SERVICING REQUIREMENTS 9

TABLE 4.3.1-1 MOVEMENT PREPARATION CHECKLIST


(MEP-PU-810A & B MODELS) 10

TABLE 4.3.2-1 MEP-PU-810A HOOK-UP PROCEDURES 12

TABLE 4.3.3-1 MEP-PU-810B HOOK-UP PROCEDURES 16

TABLE 4.3.4-1 MEP-PU-810A TOWING PROCEDURES AND SPEED RATINGS 18

TABLE 4.3.4-2 MEP-PU-810B TOWING PROCEDURES AND SPEED RATINGS 19

TABLE 4.3.5-1 MEP-PU-810 A/B BACKING UP PROCEDURES 20

TABLE 4.3.6-1 MEP-PU-810A DISCONNECTION PROCEDURES 21

TABLE 4.3.6-2 MEP-PU-810B DISCONNECTION PROCEDURES 21

TABLE 4.3.6.3-1 MEP-PU-810A/B LOADING PROCEDURES 22

TABLE 4.3.6.4-1 MEP-PU-810A/B UNLOADING POCEDURES 23

TABLE 4.5-1 ISO EXTENDER INSTALLATION PROCEDURES 29

TABLE 4.6.1-1 MEP-PU-810A ISO EXTENDER STORAGE PROCEDURES 30

TABLE 4.6.2-1 MEP-PU-810B ISO EXTENDER STORAGE PROCEDURES 33

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CHAPTER 4
RECEIPT AND MOVEMENT
4.1 INTRODUCTION

This Chapter addresses the requirements for:

• Inspection and servicing of the MEP-PU-810A/B Power Unit upon receipt.


• Preparation for movement, connection, towing, and disconnection.
• MEP-PU-810A and MEP-PU-810B Tie-down Points.
• MEP-PU-810A and MEP-PU-810B Tie-down Points using ISO Extenders.

4.2 INSPECTION ON RECEIPT

There are significant differences between the MEP-PU-810A and MEP-PU-810B trailering that requires
specific instructions for each version.

Inspection of the following items is required:

• Batteries
• Fuel system
• Cooling system
• Lubrication system
• Hydraulic system

4.2.1 INSPECTION REQUIREMENTS UPON RECEIPT

WARNING

MAINTENANCE OF THE POWER UNIT INVOLVES SERVICING OF BATTERIES,


FUEL, HYDRAULIC SYSTEMS AND ELECTRICAL SYSTEMS THAT MAY SUBJECT
THE MAINTAINER TO HAZARDOUS MATERIALS AS WELL AS POTENTIALLY
HAZARDOUS CONDITIONS.

WARNING

HIGH VOLTAGE MAY CAUSE SEVERE SHOCK OR DEATH UPON CONTACT


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

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WARNING

WHEN CONNECTING BATTERY CABLES ALWAYS CONNECT POSITIVE CABLE


FIRST. FAILURE TO COMPLY MAY CAUSE SPARKING OR EXPLOSION,
RESULTING IN SERIOUS BURNS.

WARNING

BATTERY ELECTROLYTE CONTAINS SULFURIC ACID. AVOID USING NEAR OPEN


FLAME, HEAT OR SPARKS. AVOID ANY CONTACT WITH SKIN, EYES, OR
CLOTHES. AVOID BREATHING FUMES. USE ONLY IN WELL-VENTILATED AREAS.
FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY OR ILLNESS.

Table 4.2.1-1 lists general inspection requirements.

TABLE 4.2.1-1 GENERAL INSPECTION REQUIREMENTS

STEP ACTION DONE

Remove all tape covering engine openings such as Oil Filler Caps, or Air
1
Filters. Refer to Chapter 20 for reference.
Check for any loose or missing hardware. Refer to Chapter 8 through Chapter
2
19 for reference.
Check for broken or missing fuses and bulbs. Refer to Chapter 12 for
3
reference.
Open and inspect all compartments for proper component mounting, and
4
tightness. Refer to Chapter 8 through Chapter 19 for reference.

5 Review all historical, and packing data.

Remove the Air Filter Cover and inspect the Air Filter condition. Refer to
6
Chapter 16 for reference.

7 Open access doors and ground high voltage components.

8 Check unit for visible leaks.

9 Check for correct Tire air pressure. Refer to Chapter 18 for reference.

Check chassis for damage. Refer to Chapter 8 through Chapter 18 for


10
reference.

11 Insure parking brake is functioning. Refer to Chapter 18 for reference.

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4.2.2 SERVICE REQUIREMENTS

4.2.2.1 BATTERY

WARNING

BATTERY ELECTROLYTE CONTAINS SULFURIC ACID. AVOID ANY CONTACT


WITH SKIN, EYES, OR CLOTHES. AVOID BREATHING FUMES. USE ONLY IN
WELL-VENTILATED AREAS. FAILURE TO COMPLY MAY RESULT IN SERIOUS
INJURY OR ILLNESS.

WHEN CONNECTING BATTERY CABLES ALWAYS CONNECT POSITIVE CABLE


FIRST. FAILURE TO COMPLY MAY CAUSE SPARKING OR EXPLOSION,
RESULTING IN SERIOUS BURNS.

Table 4.2.2.1-1 lists Battery servicing requirements.

TABLE 4.2.2.1-1 BATTERY SERVICING REQUIREMENTS

STEP ACTION DONE

Connect battery cables to proper Positive (+), and Negative (-) terminal posts
1
(See FO - 37A for additional information).

2 Close Battery Charger circuit breakers (If the PU is connected to a live bus).

3 Connect shore power to the on-board battery chargers and charge as needed.

4.2.2.2 FUEL SYSTEM

Table 4.2.2.2-1 lists Fuel System servicing requirements.

TABLE 4.2.2.2-1 FUEL SYSTEM SERVICING REQUIREMENTS


STEP ACTION DONE

1 Connect to the external fuel supply.

2 Insure fuel shutoff valves to the fuel supply are open.

3 Insure fuel pump transfer switch is in the “AUTO” position.

4 Insure fuel pump transfer G1 – G2 switch is in the “G1” position.

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4.2.2.3 COOLING SYSTEM

WARNING

DO NOT OPEN OR REMOVE THE COOLANT EXPANSION TANK CAP IF THE


COOLANT IS HOT OR THE ENGINE IS RUNNING. OPEN THE CAP TO THE FIRST
INDENT AND STOP TO ALLOW ANY COOLING SYSTEM PRESSURE TO VENT
BEFORE REMOVING THE CAP. SERIOUS INJURY FROM HOT COOLANT CAN
RESULT FROM FAILURE TO OBSERVE THIS WARNING.

WARNING

THE MEP-PU-810 IS SHIPPED FROM THE FACTORY WITH THE COOLING SYSTEM
FILLED WITH EXTENDED LIFE COOLANT (ELC). DO NOT MIX WITH ETHYLENE
GLYCOL. ENGINE DAMAGE MAY RESULT.

Table 4.2.2.3-1 lists Cooling System servicing requirements.

TABLE 4.2.2.3-1 COOLING SYSTEM SERVICING REQUIREMENTS


STEP ACTION DONE

1 Open the expansion tank caps on each generator set and check coolant level.

Check coolant level from the coolant tank sight gauge. The level should be midway
2
in sight glass.
Add ELC or appropriate coolant if required. Read Shipping Documentation to see
3
what type of coolant was in the system prior to shipment.

4.2.2.4 LUBRICATION SYSTEM

Table 4.2.2.4-1 lists Lubrication System servicing requirements.

TABLE 4.2.2.4-1 LUBRICATION SYSTEM SERVICING REQUIREMENTS


STEP ACTION DONE

Check the engine oil level by pulling the dipstick from Generator #1 and
1 Generator #2 wiping clean, re-inserting completely, and removing and observing
the oil level.

2 Add oil If required.

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4.2.2.5 HYDRAULIC SYSTEM

WARNING

DO NOT OPEN OR REMOVE THE HYDRAULIC FLUID FILL FITTING CAP OR


ATTEMPTING TO ADD HYDRAULIC FLUID TO THE SYSTEM WHILE THE ENGINE IS
RUNNING. SERIOUS INJURY FROM HOT HYDRAULIC FLUID CAN RESULT FROM
FAILURE TO OBSERVE THIS WARNING.

Table 4.2.2.5-1 lists Hydraulic System servicing requirements.

TABLE 4.2.2.5-1 HYDRAULIC SYSTEM SERVICING REQUIREMENTS


STEP ACTION DONE

Check hydraulic fluid levels in Generator #1 and Generator #2 by using the


1 sight-glasses on the front of the hydraulic reservoirs. The level should be
midway in sight glass.

2 Add or remove hydraulic fluid as required.

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4.3 MOVEMENT

The following topics are addressed:

• Movement Preparation Checklist


• MEP-PU-810A Hook Up Procedures
• MEP-PU-810B Hook Up Procedures
• Towing Procedures
• Backing Up Procedures
• Disconnection Procedures
• Installation Criteria
• Loading Procedures
• Unloading Procedures

4.3.1 MOVEMENT PREPARATION CHECKLIST

Table 4.3.1-1 lists the basic inspection actions required prior to movement of the Power Unit.

TABLE 4.3.1-1 MOVEMENT PREPARATION CHECKLIST (MEP-PU-810A & B MODELS)


STEP ACTION DONE

1 Check the maintenance schedule and be sure the equipment is up-to-date.

2 Check steering for freedom of movement (MEP-PU-810A only).

3 Inspect towing hookup for secure attachment.

Fasten the Breakaway Switch Actuating Chain (MEP-PU-810A Only) to the tow
4
vehicle.

Check the Tire Pressure. Inflate to specifications; inspect tires for cuts,
5
excessive wear, etc.

Check brake fluid level in master cylinder. Insure cylinder is filled to proper
6
level (MEP-PU-810A Only). See Figure 4.3.1-1 for additional information.

Check wheel-mounting nuts/bolts with a torque wrench. Torque, in proper


sequence, to the levels specified in this manual (Refer to Section 18.3.1.2.2 for
7
the MEP-PU-810A and Section 18.3.2.3.2.1 for the MEP-PU-810B for
additional information).

NOTE: Refer to Chapter 18 for reference.

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FIGURE 4.3.1-1 CHECKING BRAKE FLUID LEVEL

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4.3.2 MEP-PU-810A HOOK-UP PROCEDURES

WARNING

THE HYDRAULIC PRESSURE HELD IN THE BREAKAWAY LEVER MAY CAUSE THE
LEVER TO SNAP QUICKLY. KEEP HANDS AND FINGERS CLEAR, AS YOU RESET
THE BREAKAWAY MECHANISM. WHEN TOWING, AVOID SHARP TURNS THAT
CAN CAUSE THE ACTUATOR TO BIND AGAINST THE TOW VEHICLE. THIS CAN
DAMAGE THE ACTUATOR AND TRAILER, CAUSING BRAKE FAILURE.

WARNING

DO NOT CONNECT THE MEP-PU-810A TO A VEHICLE WITH A TOW PINTLE MORE


THAN 46 INCHES ABOVE THE GROUND. FAILURE TO COMPLY MAY CAUSE
DAMAGE TO EQUIPMENT.

CAUTION

CHECK THAT THE PINTLE IS LOCKED AND ANY SAFETY PINS ARE INSERTED TO
PREVENT ACCIDENTAL UN-COUPLING. DON’T PULL THE TRAILER IF EITHER
THE LUNETTE EYE OR PINTLE IS DAMAGED.

CAUTION

INSURE THAT THE TOWING VEHICLE AND PINTLE HAVE A RATING EQUAL TO
OR GREATER THAN THE MEP-PU-810A GROSS VEHICLE WEIGHT OF 25,740 LBS.

Table 4.3.2-1 lists MEP-PU-810A hook-up procedures. See Figure 4.3.2-1 through Figure 4.3.2-4 for
reference.

TABLE 4.3.2-1 MEP-PU-810A HOOK-UP PROCEDURES


STEP ACTION DONE

Couple the power unit to the tow vehicle. Make certain that the lunette eye is
in proper position and secured to the tow vehicle. Check that the pintle is
1
locked and any safety pins are inserted to prevent accidental un-coupling.
Don’t pull the trailer if either the lunette eye or pintle is damaged.

Connect Fasten the Breakaway Switch Actuating Chain to the tow vehicle. see
2
Figure 4.3.2-3 for reference.
Connect breakaway chain S-hook to bumper or hitch. Allow slack for turning,
3 but avoid letting the chain drag on pavement. Provide as straight a connection
as possible.

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FIGURE 4.3.2-1 MEP-PU-810A TOWING CONNECTION

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FIGURE 4.3.2-2 LUNETTE EYE

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FIGURE 4.3.2-3 BREAK-AWAY CHAIN S-HOOK

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4.3.3 MEP-PU-810B HOOK UP PROCEDURES

CAUTION

INSURE THAT THE TOWING VEHICLE AND 5TH WHEEL HAVE A RATING EQUAL
TO OR GREATER THAN THE MEP-PU-810B GROSS VEHICLE WEIGHT OF 29,100
LBS.

Table 4.3.3-1 lists MEP-PU-810B hook up procedures. Figure 4.3.3-1 illustrates the MEP-PU-810B
towing connection.

TABLE 4.3.3-1 MEP-PU-810B HOOK-UP PROCEDURES

STEP ACTION DONE

Raise landing gear of the PU until the plate is level with the horizontal position
1
of the 5th wheel of the towing vehicle see Figure 4.3.3-1for reference.
2 Unlatch and open the fifth wheel locking mechanism.
Back the towing vehicle until the kingpin engages into the 5th-wheel, latch the
3
5th wheel locking mechanism.
Connect the towing vehicle brake air hoses to the air connections on the PU
4
see and Figure 4.3.3-2 for reference.
Connect the towing vehicle lighting cable assembly to the PU see and Figure
5
4.3.3-2 for reference.
6 Raise the PU landing gear to its highest position.

FIGURE 4.3.3-1 MEP-PU-810B TOWING CONNECTION

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FIGURE 4.3.3-2 12VDC AND 24VDC LIGHTING CONNECTION

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4.3.4 TOWING PROCEDURES

WARNING

MEP-PU-810B SPEED RATING

DO NOT EXCEED A SPEED OF 55 MILES PER HOUR ON PAVED ROAD OR 5 MILES


PER HOUR ON UNPAVED ROAD. FAILURE TO COMPLY MAY RESULT IN DEATH,
SERIOUS INJURY OR DAMAGE TO POWER UNIT.

WARNING

MEP-PU-810A SPEED RATING

DO NOT EXCEED A SPEED OF 20 MILES PER HOUR ON AN IMPROVED ROAD OR


5 MILES PER HOUR ON UNPAVED ROAD. FAILURE TO COMPLY MAY RESULT IN
SERIOUS INJURY OR DAMAGE TO POWER UNIT.

CAUTION

MEP-PU-810B ONLY
THE ABS BRAKING SYSTEM DOES NOT FUNCTION WHEN SUPPLIED WITH 24VDC.

Table 4.3.4-1 and Table 4.3.4-2 list towing procedures and speed ratings for the MEP-PU-810 A and
MEP-PU-810B.

TABLE 4.3.4-1 MEP-PU-810A TOWING PROCEDURES AND SPEED RATINGS


STEP ACTION DONE

1 Release the MEP-PU-810A, parking brake (See Figure 4.3.4-1).

2 Tow Power Unit, observing limitations on speed and turning angle.

NOTE: The tires supplied with the MEP-PU-810A power units are:

• Over-The-Road-Truck-Tires (Light Truck Tires) - Part No. - LT235/85R16.


• The tires are rated at 2778 pounds at 65 MPH.
• The MEP-PU-810A has four (4) tires per axle, and is rated for a maximum speed of 20
MPH. The maximum axle load (each) of the power unit is 13,000 pounds.
• Per Goodyear® handbook, the percent increase in the load is 32 % at 16 to 25 MPH.
• Four (4) tires per axle X 2778 Lbs. X 1.32 = 14,668 Pounds (which meets the Power Unit
tire rating requirements).
• Replacement Tires must meet the minimum or higher load rating.

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FIGURE 4.3.4-1 PARKING BRAKE

TABLE 4.3.4-2 MEP-PU-810B TOWING PROCEDURES AND SPEED RATINGS


STEP ACTION DONE

Check for proper operation of lights and brakes. Operation of the ABS is
indicated by the small yellow cone shaped lamp located above the axle on the
1
left side of the PU. If the ABS is functioning properly, the ABS light will be on.
Refer to Figure 18.2.1.2.5-3 for reference.

2 Tow Power Unit, observing limitations on speed and turning angle.

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4.3.5 BACKING UP PROCEDURES

Table 4.3.5-1 lists backing up procedures for both the MEP-PU-810A and MEP-PU-810B.

TABLE 4.3.5-1 MEP-PU-810 A/B BACKING UP PROCEDURES


STEP ACTION DONE

1 Always use a ground guide when backing up the PU.

On the MEP-PU-810A, insure the parking brakes are released and the safety
2
chain is connected to the tow vehicle.

On the MEP-PU-810B trailer, insure the air hoses are connected to the tow
3
vehicle and the spring brakes release before attempting to back up.

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4.3.6 DISCONNECTING PROCEDURES

4.3.6.1 MEP-PU-810A DISCONNECTING PROCEDURES

WARNING

THE HYDRAULIC PRESSURE HELD IN THE BREAKAWAY LEVER MAY CAUSE THE
LEVER TO SNAP QUICKLY. KEEP HANDS AND FINGERS CLEAR, AS YOU RESET
THE BREAKAWAY MECHANISM. WHEN TOWING, AVOID SHARP TURNS THAT
CAN CAUSE THE ACTUATOR TO BIND AGAINST THE TOW VEHICLE. THIS CAN
DAMAGE THE ACTUATOR AND TRAILER, CAUSING BRAKE FAILURE.

Table 4.3.6-1 lists Disconnection Procedures for the MEP-PU-810A.

TABLE 4.3.6-1 MEP-PU-810A DISCONNECTION PROCEDURES


STEP ACTION DONE

Set parking brakes by rotating parking brake handle clockwise until the brake
1
bar is firmly lodged against the inner wheels of the trailer.

2 Remove breakaway chain from towing vehicle.

Open the tow vehicle pintle hook, move the tow bar to one side, and lower the
3
tow bar to the ground.

4 Drive the tow vehicle slowly forward until it is completely free of the Power Unit.

4.3.6.2 MEP-PU-810B DISCONNECTING PROCEDURES

Table 4.3.6-2 lists Disconnection Procedures for the MEP-PU-810B.

TABLE 4.3.6-2 MEP-PU-810B DISCONNECTION PROCEDURES


STEP ACTION DONE

1 Disconnect air hoses and insure the spring Parking Brake is set.

2 Crank down landing gear until the trailer weight is removed from the fifth wheel.

3 Release fifth wheel locking latch.


Drive the tow vehicle slowly straight forward it is completely free of the Power
4
Unit.

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4.3.6.3 LOADING PROCEDURES

Table 4.3.6.3-1 lists MEP-PU-810A and MEP-PU-810B Loading Procedures.

TABLE 4.3.6.3-1 MEP-PU-810A/B LOADING PROCEDURES


STEP ACTION DONE

Insure the DC control circuit breaker on the Master Control Panel (MCP) is in
1
the “OFF” position.

2 Insure fuel shutoff valves to the fuel supply are closed.

3 Insure fuel pump transfer switch is in the “Off” position.

4 Drain onboard fuel tank.

5 Check all fluid levels and adjust as necessary.

6 Check all compartments for loose material and secure any loose equipment.

Tape up all air filter vents inside the PDC to prevent the ingress of dirt and
7
moisture during transport.
Attach a CAUTION tag to the DC Control Power Circuit Breaker in the Master
8 Control Panel to alert the operator to remove the tape from the air filter vents
prior to starting the unit.

9 Close and lock all compartment doors.

10 Secure the tow bar in the raised position using the chain and hook provided.

Without ISO Lifting Device:


Secure the lifting chains or wire straps to the ISO corner castings, 4 places.
11 Lifting chains or wire straps will be rated for 20 tons and be a minimum of 15
feet high using a single point pickup to prevent damage to the PU. Refer to
Figure 4.4.1-1, Figure 4.4.1-2 and Figure 4.4.2-1.
With ISO Lifting Device:

12 Install the four ISO Extenders into the four ISO Fittings located on the PU and
lock them into place. Lower the ISO Frame and guide it into the ISO
Extenders and lock in place. Lift the PU. Refer to Table 4.5-1 for reference.

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TABLE 4.3.6.3-1 MEP-PU-810A/B LOADING PROCEDURES (CONTINUED)


STEP ACTION DONE

WARNING

THE CRANE MUST BE RATED 20 TONS OR ABOVE WITH A


13
MINIMUM OF A 20 FOOT BOOM. USE GROUND GUIDE.

Lift the power unit from the ground and set the PU on the trailer. Refer to
Figure 4.4.1-1 and Figure 4.4.2-1 for reference.
The Power Unit must be oriented with the PDC end of the PU facing the rear of
14
the trailer to prevent water incursion into the PDC.

15 Insure that the Power Unit is secured to the trailer using the tie-down points.

4.3.6.4 UNLOADING PROCEDURES

Table 4.3.6.4-1 lists MEP-PU-810A and MEP-PU-810B Unloading Procedures.

TABLE 4.3.6.4-1 MEP-PU-810A/B UNLOADING POCEDURES


STEP ACTION DONE

1 Inspect the PU for any visible signs of damage during shipment.

2 Remove the tie-down straps, chains and packing dunnage.

3 Secure the tow bar in the raised position using the chain and hook provided.

Without ISO Lifting Device:


Secure the lifting chains or wire straps to the ISO corner castings, 4 places.
4 Lifting chains will be rated for 20 tons and be a minimum of 15 feet high using a
single point pickup to prevent damage to the PU. Refer to Figure 4.4.1-1 and
Figure 4.4.2-1.
With ISO Lifting Device:

5 Install the four ISO Extenders into the four ISO Fittings located on the PU and
lock them into place. Lower the ISO Frame and guide it into the ISO
Extenders and lock in place. Lift the PU. Refer to Table 4.5-1 for reference.

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TABLE 4.3.6.4-1 MEP-PU-810A/B UNLOADING POCEDURES (CONTINUED)


STEP ACTION DONE

WARNING

THE CRANE MUST BE RATED 20 TONS OR ABOVE WITH A


6
MINIMUM OF A 20 FOOT BOOM. USE GROUND GUIDE.

Lift the power unit from the trailer and set the PU on the ground. Refer to
Figure 4.4.1-1, and Figure 4.4.2-1 for reference.

CAUTION

FAILURE TO REMOVE THE TAPE FROM THE PDC AIR


7 FILTER VENTS PRIOR TO STARTING THE UNIT WILL
CAUSE OVERHEATING AND DAMAGE TO THE PDC

Remove the tape from all of the PDC air filter vents.

Remove the caution tag from the DC Control Power Circuit Breaker in the
8
Master control panel prior to starting the unit.

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THIS PAGE IS INTENTIONALLY BLANK

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4.4 MEP-PU-810A AND MEP-PU-810B TIE-DOWN POINTS

4.4.1 MEP-PU-810A TIE-DOWN POINTS

Figure 4.4.1-1 illustrates the MEP-PU-810A Tie-down Points.

FIGURE 4.4.1-1 MEP-PU-810A TIE-DOWN POINTS, SIDE AND BOTTOM VIEW

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4.4.2 MEP-PU-810B TIE-DOWN POINTS

Figure 4.4.2-1 illustrates the MEP-PU-810B Tie-down Points.

FIGURE 4.4.2-1 MEP-PU-810B TIE-DOWN POINTS

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4.5 MEP-PU-810A AND MEP-PU-810B ISO LIFT POINTS USING ISO EXTENDER

This section covers how to properly install the ISO Extender to the PU.

WARNING

WHEN AN ISO LIFTING DEVICE IS USED TO LIFT THE PU, THE ISO EXTENDERS
MUST BE USED TO PREVENT DAMAGE TO THE COOLANT TANK, COOLANT FILL
CAPS AND MUFFLER.

FIGURE 4.5-1 ISO EXTENDER

Figure 4.5-1 illustrates the ISO Extender. Four ISO Extenders are required for lifting the PU with a
standard ISO Lifting Frame.

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WARNING

THE ISO EXTENDER MUST BE INSTALLED SO THAT THE LOCKING MECHINASM


IS FACING INBOARD TO THE PU. THIS WILL HELP PREVENT ACCIDENTALLY
RELEASING THE ISO EXTENDER FROM THE PU.

ISO
ISO EXTENDER
EXTENDER
REA
R OF
POW
ER U
NIT

FRO
NT O
F POW
ER U
NIT

FIGURE 4.5-2 ISO EXTENDER INSTALLED AND LOCKED INTO POSITION

Figure 4.5-2 illustrates the ISO Extender in the locked position. This ISO Extender is installed to illustrate
the position of the locking mechanism, however to be properly mounted for lifting the PU, the ISO
Extender would need to be rotated 90 degrees so that the “INSIDE” is always facing inboard to prevent
accidentally unlocking the ISO Extender.

Table 4.5-1 lists the ISO Installation Procedures.

TABLE 4.5-1 ISO EXTENDER INSTALLATION PROCEDURES


STEP ACTION DONE

1 Inspect the ISO Extender for damage, see Figure 4.5-1

2 Place the ISO Extender into the ISO Fitting on the PU; see Figure 4.5-2.

Move the ISO Extender Locking Handle into the “LOCKED” position, see Figure
3
4.5-2.

4 Perform steps 1 and 2, until all four ISO Extenders are installed, see Figure 4.5-2.

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4.6 ISO EXTENDER STORAGE PROCEDURES

This section covers how to properly store the ISO Extender Storage containers during transportation and
plant operations.

4.6.1 MEP-PU-810A ISO EXTENDER STORAGE PROCEDURES

Table 4.6.1-1 lists the MEP-PU-810A, ISO Extender Storage Procedures.

TABLE 4.6.1-1 MEP-PU-810A ISO EXTENDER STORAGE PROCEDURES


STEP ACTION DONE

1 Inspect each ISO Extender for damage, see Figure 4.5-1.

Move the ISO Extender Locking Handle into the “LOCKED” position, see Figure
2
4.6.1-1.
Carefully place two ISO Extenders into each ISO Extender storage box; see
3
Figure 4.6.1-2.
For transportation place one ISO Extender storage box into each side of the PU in
4 the alternator compartment and secure with 2 rubber stretch cords per box as
illustrated in Figure 4.6.1-3.
During Plant operations place one ISO Extender storage box on each side of the
5 PU below the alternator compartment and place two rubber stretch cords per box
as illustrated in Figure 4.6.1-4.

FIGURE 4.6.1-1 ISO EXTENDER SHOWN IN LOCKED POSITION

Figure 4.6.1-1 illustrates an ISO Extender in the LOCKED position. The Locking Handle must be in the
locked position prior to placement in the storage box. This placement will allow easy removal of the ISO
Extenders from the storage box.

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FIGURE 4.6.1-2 ISO EXTENDERS PROPERLY PLACED IN STORAGE BOX

Figure 4.6.1-2 illustrates the packing arrangement of 2 ISO Extenders in each storage box. The Locking
Handle must be in the locked position prior to placement in the storage box. This placement will allow
easy removal of the ISO Extenders from the storage box.

FIGURE 4.6.1-3 ISO EXTENDER STORAGE BOX IN TRANSPORTATION POSITION

Figure 4.6.1-3 illustrates 1 of 2 ISO Extender storage boxes in the stored position for transportation. The
ISO Extender storage boxes are mounted one on each side of the PU in the alternator compartment, and
secured with 2 rubber stretch cords per box as illustrated.

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FIGURE 4.6.1-4 ISO EXTENDER STORAGE BOX IN OPERATION POSITION

Figure 4.6.1-4 illustrates 1 of 2 ISO Extender storage boxes in the stored position for operation. The ISO
Extender storage boxes are placed one on each side of the PU on the ground with the 2 rubber stretch
cords placed in each box.

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4.6.2 MEP-PU-810B ISO EXTENDER STORAGE PROCEDURES

Table 4.6.2-1 lists the MEP-PU-810B, ISO Extender Storage Procedures.

TABLE 4.6.2-1 MEP-PU-810B ISO EXTENDER STORAGE PROCEDURES


STEP ACTION DONE

1 Inspect the ISO Extender for damage, see Figure 4.5-1

Move the ISO Extender Locking Handle into the “LOCKED” position, see Figure
2
4.6.2-1.
Properly place two ISO Extenders into each ISO Extender storage box; see Figure
3
4.6.2-2.
For transportation place both ISO Extender storage boxes into PU storage
4
compartment as illustrated in Figure 4.6.2-3.
During Plant operations place both ISO Extender storage boxes into PU storage
5
compartment as illustrated in Figure 4.6.2-3.

FIGURE 4.6.2-1 ISO EXTENDER SHOWN IN LOCKED POSITION

Figure 4.6.2-1 illustrates an ISO Extender in the LOCKED position. The Locking Handle must be in the
locked position prior to placement in the storage box. This placement will allow easy removal of the ISO
Extenders from the storage box.

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FIGURE 4.6.2-2 ISO EXTENDERS PROPERLY PLACED IN STORAGE BOX

Figure 4.6.2-2 illustrates the packing arrangement of 2 ISO Extenders in each storage box. The Locking
Handle must be in the locked position prior to placement in the storage box. This placement will allow
easy removal of the ISO Extenders from the storage box.

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FIGURE 4.6.2-3 ISO EXTENDER STORAGE BOX IN TRANSPORTATION/ OPERATION POSITION

Figure 4.6.2-3 illustrates the packing arrangement of 2 ISO Extender storage boxes within the PU. This
arrangement is used for transportation and plant operations.

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CHAPTER 5
OPERATING INSTRUCTIONS
TABLE OF CONTENTS

CHAPTER TITLE PAGE


5.1 SINGLE PU, PRIME POWER, NO EXTERNAL SWITCH, MANUAL MODE 5-3

5.2 SINGLE PU, PRIME POWER, NO EXTERNAL SWITCH, AUTOMATIC


MODE 5-33

5.3 TWO PU, PRIME POWER, NO EXTERNAL SWITCH, MANUAL MODE 5-51

5.4 TWO PU, PRIME POWER, NO EXTERNAL SWITCH, AUTOMATIC MODE 5-69

5.5 SINGLE OR MULTIPLE PU, PRIME POWER, EXTERNAL SWITCH,


MANUAL MODE 5-87

5.6 SINGLE OR MULTIPLE PU, PRIME POWER, EXTERNAL SWITCH,


AUTOMATIC MODE 5-107

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


AUTOMATIC MODE 5-131

5.8 UTILITY PARALLEL CONFIGURATION 5-171

5.9 SPECIFIC OPERATING PROCEDURES 5-193

5.10 PARALLELING MULTIPLE PU PLANTS, EXTERNAL SWITCH, AUTOMATIC


MODE 5-225

5.11 TWO PLANT, MULITPLE POWER UNIT, PRIME POWER,


EXTERNAL SWITCH, AUTOMATIC MODE 5-289

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CHAPTER 5.1
OPERATING INSTRUCTIONS
SINGLE PU, PRIME POWER, NO EXTERNAL SWITCH, MANUAL
MODE
TABLE OF CONTENTS
SECTION TITLE PAGE
5.1 SINGLE PU, PRIME POWER, NO EXTERNAL SWITCH, MANUAL MODE 6

5.1.1 SAFETY PROCEDURES 6

5.1.2 POSITIONING THE PU 6

5.1.3 INITIAL PLANT SETUP 7

5.1.3.1 GROUNDING 7

5.1.3.2 FUEL MANIFOLD 9

5.1.3.3 DISTRIBUTION AND CONTROL CABLING 10

5.1.3.4 SETPOINT VERIFICATION 11

5.1.3.5 PRE-OPERATION CHECKS 24

5.1.3.6 PRE-OPERATION RUN 26

5.1.3.7 ORT SETUP 28

5.1.3.8 CONTROLS SETUP 29

5.1.4 PLANT STARTUP 30

5.1.5 PLANT OPERATIONS 31

5.1.6 POWER PLANT TEARDOWN 31

5.1.6.1 SHUT DOWN GENERATORS 31

5.1.6.2 DISCONNECT CABLES 31

5.1.6.3 DISCONNECT FUEL LINES 32

5.1.6.4 DISCONNECT GROUNDING 32

5.1.6.5 PREPARE PU FOR TRANSPORTATION 32

5.1.6.6 FUEL, OIL, AND COOLANT DRAINAGE 32

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LIST OF FIGURES

FIGURE TITLE PAGE


FIGURE 5.1.3.1-1 MEP-PU-810A GROUND POINTS 8

FIGURE 5.1.3.1-2 MEP-PU-810B GROUND POINTS 8

FIGURE 5.1.3.2-1 EXTERNAL FUEL SUPPLY 9

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LIST OF TABLES

TABLE TITLE PAGE


TABLE 5.1.3.4-1 CT RATIO SETTINGS 11

TABLE 5.1.3.4-2 INSTANTANEOUS TRIP SETTINGS 11

TABLE 5.1.3.4-3 TIME OVERCURRENT TRIP SETTINGS 12

TABLE 5.1.3.4-4 OP5-0 SETPOINTS 14

TABLE 5.1.3.4-4 OP5-0 SETPOINTS (CONTINUED) 15

TABLE 5.1.3.4-5 OP5-1 SETPOINTS 17

TABLE 5.1.3.4-5 OP5-1 SETPOINTS (CONTINUED) 18

TABLE 5.1.3.4-5 OP5-1 SETPOINTS (CONTINUED) 19

TABLE 5.1.3.4-6 OP6 SETPOINTS 20

TABLE 5.1.3.4-6 OP6 SETPOINTS (CONTINUED) 21

TABLE 5.1.3.4-7 DVR PARAMETERS/SETPOINTS 22

TABLE 5.1.3.4-7 DVR PARAMETERS/SETPOINTS (CONTINUED) 23

TABLE 5.1.3.5-1 PRE-OPERATION CHECKLIST 24

TABLE 5.1.3.5-1 PRE-OPERATION CHECKLIST (CONTINUED) 25

TABLE 5.1.3.6-1 PRE-OPERATION RUN INSTRUCTION SEQUENCE 27

TABLE 5.1.3.8-1 CONTROL SWITCH SETUP 29

TABLE 5.1.4-1 SWITCH SETUP – MANUAL MODE 30

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5.1 SINGLE PU, PRIME POWER, NO EXTERNAL SWITCH, MANUAL MODE

5.1.1 SAFETY PROCEDURES

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

• Hot engine parts


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

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

5.1.2 POSITIONING THE PU

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

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

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

WARNING

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

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

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5.1.3 INITIAL PLANT SETUP

5.1.3.1 GROUNDING

WARNING

THERE CAN ONLY BE ONE GROUNDING POINT FOR THE PU.

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

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

c. Using a #2 AWG copper conductor, secure one end of a ground cable to one of the slotted
ground studs on the PU, see Figure 5.1.3.1-1 or Figure 5.1.3.1-3. Secure the other end of the
ground cable to the ground rod.

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

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

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

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GROUND POINT GROUND POINT

FIGURE 5.1.3.1-1 MEP-PU-810A GROUND POINTS

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

GROUND POINT GROUND POINT

FIGURE 5.1.3.1-2 MEP-PU-810B GROUND POINTS

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

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5.1.3.2 FUEL MANIFOLD

WARNING

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

a. Lay out the fuel hoses between the PU, the fuel manifold, and the fuel bladders to establish the
fuel supply system see Figure 5.1.3.2-1.

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

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

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

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

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

FIGURE 5.1.3.2-1 EXTERNAL FUEL SUPPLY

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5.1.3.3 DISTRIBUTION AND CONTROL CABLING

WARNING

DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS


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

WARNING

HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT


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

WARNING

VERIFY THAT CONNECTION POINTS ARE DE-ENERGIZED BEFORE MAKING ANY


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

a. Lay out and park the load cables for each phase (A, B, & C) between the PU feeder output
parking stations and the load (if used).

b. Connect each power cable’s drain wire to the grounding grid.

c. Open the feeder output connection covers.

d. Connect the feeder cables to the appropriate phase connector at the PU and the load; ensure
there are no cross-phase connections.

e. Close and lock the feeder output connection cover.

f. Lay out and park the load cables for each phase (A, B, & C) between the PU tie output parking
stations and the load (if used).

g. Connect each power cable’s drain wire to the grounding grid.

h. Open the tie output connection covers.

i. Connect the load cables to the appropriate connector at the PU and the load; ensure there are
no cross-phase connections.

j. Close and lock the tie output connection cover.

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5.1.3.4 SETPOINT VERIFICATION

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

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

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

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

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

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

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

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

TABLE 5.1.3.4-1 CT RATIO SETTINGS


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

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


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

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

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

TABLE 5.1.3.4-2 INSTANTANEOUS TRIP SETTINGS


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

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

(12) Verify the “50TN” settings in Table 5.1.3.4-2.

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

(14) Verify the “50TQ” settings

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

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

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

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

TABLE 5.1.3.4-3 TIME OVERCURRENT TRIP SETTINGS


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

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

(20) Verify the “51N” settings in Table 5.1.3.4-3.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

(17) Press SELECT key.

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

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

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

(21) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing.
Use “OP6” Setpoints, Table 5.1.3.4-6 for the parameter values to be verified. Repeat until
all the desired setpoints are verified.

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

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

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

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

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

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


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

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TABLE 5.1.3.4-4 OP5-0 SETPOINTS


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

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

0-for engine shutdown.


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

P013② - Low Oil Pressure Shutdown At Rated Speed:


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

P014② - Low Oil Pressure Shutdown At Idle Speed:


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

P015③ - High Water Temperature Shutdown: coolant


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

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TABLE 5.1.3.4-4 OP5-0 SETPOINTS (CONTINUED)


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

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

P022⑤ - GSC+ Engine Number: informs other devices on


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

SETPOINTS - OP5-0-ENGINE/GENERATOR PROGRAMMING①


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

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

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TABLE 5.1.3.4-5 OP5-1 SETPOINTS


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

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


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

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


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

5-17
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254

TABLE 5.1.3.4-5 OP5-1 SETPOINTS (CONTINUED)


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

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


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

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


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

5-18
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254

TABLE 5.1.3.4-5 OP5-1 SETPOINTS (CONTINUED)


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

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


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

5-19
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USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254

TABLE 5.1.3.4-6 OP6 SETPOINTS


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

1-active SP1 fault②

2-active SP2 fault②

3-active SP3 fault②

4-active SP4 fault②


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

9-coolant loss mode②

10-high oil temp fault②


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

5-20
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DRS RADIAN CTM 01646.1R0253/1R0254

TABLE 5.1.3.4-6 OP6 SETPOINTS (CONTINUED)


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

1-active SP1 fault②

2-active SP2 fault②

3-active SP3 fault②

4-active SP4 fault②


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

9-coolant loss mode②

10-high oil temp fault②


11-CCM control
0-unused

1-active SP1 fault②

2-active SP2 fault②

3-active SP3 fault②


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

SP3 or SP4 faults②

6-Coolant loss fault②

7-high oil temperature fault②


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

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

② Either alarm or shutdown faults are valid trigger conditions

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

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

NOTE: Use up or down keys to change values.

f. At the AVR verify the operation settings using Table 5.1.3.4-7:

(1) Open the GCPG1 cabinet door.

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

5-21
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DRS RADIAN CTM 01646.1R0253/1R0254

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

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

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

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

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

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

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

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

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

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

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

TABLE 5.1.3.4-7 AVR PARAMETERS/SETPOINTS


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

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


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

06 Knee Frequency Program Hz 045.0-065.0 050.0 59.8 49.8


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

16⑤ Integral Gain Program 001.0-020.0 006.0 6.0 6.0

17⑥ Proportional Gain Program 001.0-020.0 005.0 5.0 5.0


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

5-22
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TABLE 5.1.3.4-7 AVR PARAMETERS/SETPOINTS (CONTINUED)


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

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

32③ Pf Reference Program 00.60-01.10 01.00 0.8 0.8

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

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

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


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

57③ Power Factor View


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

60 Hours View Hours 0000-9999


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

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

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

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

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

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

5-23
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DRS RADIAN CTM 01646.1R0253/1R0254

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

(17) Close the GCPG1 cabinet door.

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

5.1.3.5 PRE-OPERATION CHECKS

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

TABLE 5.1.3.5-1 PRE-OPERATION CHECKLIST


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

5-24
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DRS RADIAN CTM 01646.1R0253/1R0254

TABLE 5.1.3.5-1 PRE-OPERATION CHECKLIST (CONTINUED)


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

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

5-25
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DRS RADIAN CTM 01646.1R0253/1R0254

5.1.3.6 PRE-OPERATION RUN

WARNING

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

WARNING

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND


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

WARNING

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND


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

WARNING

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


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

5-26
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USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254

TABLE 5.1.3.6-1 PRE-OPERATION RUN INSTRUCTION SEQUENCE


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

1 Verify System Mode Switch (SMS) is in MANUAL

2 Verify DC Control Power is on

3 Verify Emergency Stop is pulled out

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

5 Start engine 1 by placing ECS1 in MANUAL

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

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

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

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

10 Shutdown engine 1 by placing ECS1 in OFF/RESET

11 Start engine 2 by placing ECS2 in MANUAL

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

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

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

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

16 Shutdown engine 2 by placing ECS2 in OFF/RESET

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

5-27
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5.1.3.7 ORT SETUP

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

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

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

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

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

f. Turn on the ORT.

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

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

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

h. Return to the Overview pop-up screen.

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5.1.3.8 CONTROLS SETUP

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

TABLE 5.1.3.8-1 CONTROL SWITCH SETUP


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

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

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5.1.4 PLANT STARTUP


Starting up a Single Unit Prime Power Plant in Manual Mode

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

TABLE 5.1.4-1 SWITCH SETUP – MANUAL MODE


PANEL SWITCH POSITION OR INDICATION
BCS-T Green Target
SMS MANUAL
MASTER CONTROL PANEL MCP USS A
MSES Enable①
USI A①
BCS-G1 Green Target
GENERATOR CONTROL PANEL 1
BCS-F1 Green Target
GCPG1
ECS-1 OFF
BCS-G2 Green Target
GENERATOR CONTROL PANEL 2
BCS-F2 Green Target
GCPG2
ECS-2 OFF
① Hold the MSES in an ENABLE position until the selected USI indicator illuminates. The switch
returns to the center position when released. This sets the PU networking address and enables
the control and monitoring.

b. At GCPG1, place the Engine Control Switch (ECS) in MANUAL.

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

d. At the MCP, place the Sync Source Switch (SSS) in the GEN 1 position.

e. Close Generator 1 breaker by cycling BCSG1 to the CLOSE position.

f. Observe that the BCSG1 closes.

g. Return the SSS to the OFF position.

h. At GCPG2, place the ECS in MANUAL.

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

j. At the MCP, place the SSS in the GEN 2 position.

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

l. Observe that the BCSG2 closes.

m. Return the SSS to the OFF position.

n. Close the required Feeder/Tie Breaker(s) from the Local Control Panel (LCP).

o. Ensure generators have assumed load.

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5.1.5 PLANT OPERATIONS

Refer to Section 5.9 for specific operating procedures.

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

5.1.6 POWER PLANT TEARDOWN

5.1.6.1 SHUT DOWN GENERATORS

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

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

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

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

e. Place all ECS switches in OFF/RESET.

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

5.1.6.2 DISCONNECT CABLES

WARNING

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

CAUTION

ALLOW ALL OPERATING ENGINES TO SHUT DOWN AND COOL DOWN


COMPLETELY.

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

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

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

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5.1.6.3 DISCONNECT FUEL LINES

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

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

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

5.1.6.4 DISCONNECT GROUNDING

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

b. Disconnect the parking stations from the ground grid.

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

5.1.6.5 PREPARE PU FOR TRANSPORTATION

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

b. Verify DC Control power is off.

c. Close and lock the LCP access doors.

d. Close and lock all PU side doors.

5.1.6.6 FUEL, OIL, AND COOLANT DRAINAGE

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

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CHAPTER 5.2
OPERATING INSTRUCTIONS

SINGLE PU, PRIME POWER, NO EXTERNAL SWITCH,


AUTOMATIC MODE
TABLE OF CONTENTS

SECTION TITLE PAGE


5.2 SINGLE PU, PRIME POWER, NO EXTERNAL SWITCH, AUTOMATIC MODE 37

5.2.1 SAFETY PROCEDURES 37

5.2.2 POSITIONING THE PU 37

5.2.3 INITIAL PLANT SETUP 38

5.2.3.1 GROUNDING 38

5.2.3.2 FUEL MANIFOLD 39

5.2.3.3 DISTRIBUTION AND CONTROL CABLING 40

5.2.3.4 SETPOINT VERIFICATION 41

5.2.3.5 PRE-OPERATION CHECKS 44

5.2.3.6 PRE-OPERATION RUN 44

5.2.3.7 ORT SETUP 45

5.2.3.8 CONTROLS SETUP 45

5.2.4 PLANT STARTUP 46

5.2.5 PLANT OPERATIONS (AUTOMATIC MODE) 47

5.2.5.1 OPERATION SAFETY PROCEDURE 47

5.2.5.2 DESCRIPTION 47

5.2.6 POWER PLANT TEARDOWN 48

5.2.6.1 SHUT DOWN GENERATORS 48

5.2.6.2 DISCONNECT CABLES 48

5.2.6.3 DISCONNECT FUEL LINES 48

5.2.6.4 DISCONNECT GROUNDING 49

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TABLE OF CONTENTS

SECTION TITLE PAGE


5.2.6.5 PREPARE PU FOR TRANSPORTATION 49

5.2.6.6 FUEL, OIL, AND COOLANT DRAINAGE 49

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LIST OF FIGURES

FIGURE TITLE PAGE


FIGURE 5.2.3.1-1 MEP-PU-810A GROUND POINTS 38

FIGURE 5.2.3.1-2 MEP-PU-810B GROUND POINTS 39

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LIST OF TABLES

TABLE TITLE PAGE


TABLE 5.2.3.8-1 PDC CONTROL SWITCHES SETUP 45

TABLE 5.2.4-1 SWITCH SETUP – AUTOMATIC MODE 46

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5.2 SINGLE PU, PRIME POWER, NO EXTERNAL SWITCH, AUTOMATIC MODE

5.2.1 SAFETY PROCEDURES

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

• Hot engine parts


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

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

5.2.2 POSITIONING THE PU

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

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

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

WARNING

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

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

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5.2.3 INITIAL PLANT SETUP

5.2.3.1 GROUNDING

WARNING

THERE CAN ONLY BE ONE GROUNDING POINT FOR THE PU.

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

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

c. Using a #2 AWG copper conductor, secure one end of a ground cable to one of the slotted
ground studs on the PU, see Figure 5.2.3.1-1 or Figure 5.2.3.1-3. Secure the other end of the
ground cable to the ground rod.

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

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

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

GROUND POINT GROUND POINT

FIGURE 5.2.3.1-1 MEP-PU-810A GROUND POINTS

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

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GROUND POINT GROUND POINT

FIGURE 5.2.3.1-2 MEP-PU-810B GROUND POINTS

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

5.2.3.2 FUEL MANIFOLD

WARNING

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

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

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

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

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

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

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

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5.2.3.3 DISTRIBUTION AND CONTROL CABLING

WARNING

DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS


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

WARNING

HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT


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

WARNING

VERIFY THAT CONNECTION POINTS ARE DE-ENERGIZED BEFORE MAKING ANY


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

a. Lay out and park the load cables for each phase (A, B, & C) between the PU feeder output
parking stations and the load (if used).

b. Connect each power cable’s drain wire to the grounding grid.

c. Open the feeder output connection covers.

d. Connect the feeder cables to the appropriate phase connector at the PU and the load; ensure
there are no cross-phase connections.

e. Close and lock the feeder output connection cover.

f. Lay out and park the load cables for each phase (A, B, & C) between the PU tie output
parking stations and the load (if used).

g. Connect each power cable’s drain wire to the grounding grid.

h. Open the tie output connection covers.

i. Connect the load cables to the appropriate connector at the PU and the load; ensure there
are no cross-phase connections.

j. Close and lock the tie output connection cover.

k. Connect the (A) (B) communication cable to the “B” side of the PU. Leave the loose end
capped.

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5.2.3.4 SETPOINT VERIFICATION

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

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

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

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

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

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

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

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

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


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

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

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

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

(12) Verify the 50TN settings.

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

(14) Verify the “50TQ” settings

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

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

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

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

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

(20) Verify the 51N settings.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

(14) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is
showing. Use Chapter 5.1 Table 5.1.3.4-4 OP5-0 Setpoints for the parameter values to
be verified. Repeat until all OP5-0 setpoints are verified.

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

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

(17) Press SELECT key.

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

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

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

(21) Press SELECT key.

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

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

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

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

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

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

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

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

NOTE: Use up or down keys to change values.

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

(1) Open the GCPG1 cabinet door.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

(17) Close the GCPG1 cabinet door.

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(18) Repeat steps ‘1 ‘through ‘17’ for Generator 2.

5.2.3.5 PRE-OPERATION CHECKS

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

5.2.3.6 PRE-OPERATION RUN

Perform the pre-operation run using Chapter 5.1 Table 5.1.3.6-1 Pre-Operation Run Instruction
Sequence.

WARNING

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

WARNING

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND


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

WARNING

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND


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

WARNING

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


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

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5.2.3.7 ORT SETUP

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

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

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

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

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

f. Turn on the ORT.

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

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

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

h. Return to the Overview pop-up screen.

5.2.3.8 CONTROLS SETUP

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

TABLE 5.2.3.8-1 PDC CONTROL SWITCHES SETUP


PANEL SWITCH 1ST PU
DC Power Pushed In (ON)
SMS OFF
GMS PRIME POWER
AVRS PRIME POWER
MASTER CONTROL PANEL MCP 60Hz Light ON①
USS A
BSS NORMAL
SSS OFF
SSL Lights All OFF
INSIDE MCP FSS 50/60 Hertz①
Emergency Stop Pulled-Out
GENERATOR CONTROL PANEL GCPG1
ECS OFF
Emergency Stop Pulled-Out
GENERATOR CONTROL PANEL GCPG2
ECS OFF

① With the SMS in the OFF position, the 50/60Hz lights indicate the position of the Frequency
Selector Switch (FSS). If the wrong light is on, open the door and change the switch position.

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5.2.4 PLANT STARTUP


Starting up a Single Unit Prime Power Plant in Automatic Mode

WARNING

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

WARNING

ONLY ONE PU MAY BE SELECTED TO ANY ONE USS POSITION DURING


MULTIPLE PU OPERATIONS. OPERATING WITH MORE THAN ONE UNIT AT THE
SAME ID MAY CAUSE UNSAFE AND ERRATIC OPERATIONAL CONDITIONS.

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

TABLE 5.2.4-1 SWITCH SETUP – AUTOMATIC MODE


PANEL SWITCH 1ST PU
BCS-T Red Target
MASTER CONTROL PANEL
MCP
SMS AUTO③
USS A
BCS-G1 Red Target
GENERATOR CONTROL
BCS-F1 Red Target
PANEL 1 GCPG1
ECS-1 AUTO
BCS-G2 Red Target
BCS-F2 Red Target
GENERATOR CONTROL
ECS-2 AUTO
PANEL 2 GCPG2
GREEN (Verify System Status
SYSTEM STATUS LIGHTS
Light turns Green)
MASTER CONTROL PANEL MSES Enable①
MCP USI A①, ②

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

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

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

d. At A-unit, observe the Tie Breaker automatically closes.

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

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

5.2.5 PLANT OPERATIONS (AUTOMATIC MODE)

5.2.5.1 OPERATION SAFETY PROCEDURE

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

5.2.5.2 DESCRIPTION

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

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5.2.6 POWER PLANT TEARDOWN

5.2.6.1 SHUT DOWN GENERATORS

a. Unload all generators by opening all Feeder/Tie Breakers. This must be done locally from the
LCP or ORT.

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

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

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

e. Place all ECS switches in OFF/RESET.

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

5.2.6.2 DISCONNECT CABLES

WARNING

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

CAUTION

ALLOW ALL OPERATING ENGINES TO SHUT DOWN AND COOL DOWN


COMPLETELY.

a. Disconnect the (A)(B) communication cable from the PU, install the cable receptacle cover,
and store inside the PU (one per unit).

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

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

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

5.2.6.3 DISCONNECT FUEL LINES

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

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

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

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5.2.6.4 DISCONNECT GROUNDING

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

b. Disconnect the parking stations from the ground grid.

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

5.2.6.5 PREPARE PU FOR TRANSPORTATION

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

b. Verify DC Control power is off.

c. Close and lock the LCP access doors.

d. Close and lock all PU side doors.

5.2.6.6 FUEL, OIL, AND COOLANT DRAINAGE

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

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CHAPTER 5.3
OPERATING INSTRUCTIONS
TWO PU, PRIME POWER, NO EXTERNAL SWITCH, MANUAL MODE
TABLE OF CONTENTS

SECTION TITLE PAGE


5.3 TWO PU, PRIME POWER, NO EXTERNAL SWITCH, MANUAL MODE 54

5.3.1 SAFETY PROCEDURES 54

5.3.2 POSITIONING THE PU 54

5.3.3 INITIAL PLANT SETUP 55

5.3.3.1 GROUNDING 55

5.3.3.2 FUEL MANIFOLD 56

5.3.3.3 DISTRIBUTION AND CONTROL CABLING 57

5.3.3.4 SETPOINT VERIFICATION 58

5.3.3.5 PRE-OPERATION CHECKS 61

5.3.3.6 PRE-OPERATION RUN 61

5.3.3.7 ORT SETUP 63

5.3.3.8 CONTROLS SETUP 63

5.3.4 PLANT STARTUP 64

5.3.5 PLANT OPERATIONS 66

5.3.6 POWER PLANT TEARDOWN 66

5.3.6.1 SHUTDOWN GENERATORS 66

5.3.6.2 DISCONNECT CABLES 66

5.3.6.3 DISCONNECT FUEL LINES 67

5.3.6.4 DISCONNECT GROUNDING 67

5.3.6.5 PREPARE PU FOR TRANSPORTATION 67

5.3.6.6 FUEL, OIL, AND COOLANT DRAINAGE 67

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LIST OF FIGURES

FIGURE TITLE PAGE


FIGURE 5.3.3.1-1 MEP-PU-810A GROUND POINTS 55

FIGURE 5.3.3.1-2 MEP-PU-810B GROUND POINTS 56

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LIST OF TABLES

TABLE TITLE PAGE


TABLE 5.3.3.6-1 PRE-OPERATION RUN INSTRUCTION SEQUENCE 62

TABLE 5.3.3.8-1 CONTROL SWITCH SETUP 63

TABLE 5.3.4-1 SWITCH SETUP – MANUAL MODE 64

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5.3 TWO PU, PRIME POWER, NO EXTERNAL SWITCH, MANUAL MODE

5.3.1 SAFETY PROCEDURES

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

• Hot engine parts


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

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

5.3.2 POSITIONING THE PU

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

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

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

WARNING

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

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

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5.3.3 INITIAL PLANT SETUP

5.3.3.1 GROUNDING
WARNING

THERE CAN ONLY BE ONE GROUNDING POINT FOR THE PU.

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

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

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

d. Using a #2 AWG copper conductor, secure one end of a ground cable to one of the slotted
ground studs on the PU, see Figure 5.3.3.1-1 or Figure 5.3.3.1-3. Secure the other end of the
ground cable to the ground rod.

e. Repeat step “d” for every PU.

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

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

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

GROUND POINT GROUND POINT

FIGURE 5.3.3.1-1 MEP-PU-810A GROUND POINTS

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

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GROUND POINT GROUND POINT

FIGURE 5.3.3.1-2 MEP-PU-810B GROUND POINTS

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

5.3.3.2 FUEL MANIFOLD

WARNING

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

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

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

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

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

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

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

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5.3.3.3 DISTRIBUTION AND CONTROL CABLING

WARNING

DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS


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

WARNING

HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT


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

WARNING

VERIFY THAT CONNECTION POINTS ARE DE-ENERGIZED BEFORE MAKING ANY


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

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

b. Connect each power cable’s drain wire to the grounding grid.

c. Lay out and park the load cables for each phase (A, B, & C) between the PU Feeder Output
parking stations and the load (if used).

d. Connect each power cable’s drain wire to the grounding grid.

e. Open the Tie Output connector loadbreak covers on one PU.

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

g. Close and lock the Tie Output connector covers.

h. Open the Feeder Output connector loadbreak covers.

i. Connect the Feeder cables to the appropriate phase connectors; ensure there are no cross-
phase connections.

j. Close and lock the Feeder Output connector covers.

k. Repeat steps ‘e’ through ‘j’ on the second PU.

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l. Connect the (A) (B) communication cable to the (B) side of the first PU.

m. Route (A) (B) communication cable to second PU and Connect to the (A) side of the PU.

n. Connect the (A) (B) communication cable to the (B) side of the second PU. Leave the end of
second cable loose and capped.

5.3.3.4 SETPOINT VERIFICATION

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

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

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

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

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

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

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

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

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


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

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

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

(12) Verify the “50TN” settings.

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

(14) Verify the “50TQ” settings.

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

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

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

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

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

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(20) Verify the 51N settings.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

(17) Press SELECT key.

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

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

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

(21) Press SELECT key.

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

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

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

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

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

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

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


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

NOTE: Use up or down keys to change values.

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

(1) Open the GCPG1 cabinet door.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

(17) Close the GCPG1 cabinet door.

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

5.3.3.5 PRE-OPERATION CHECKS

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

5.3.3.6 PRE-OPERATION RUN

WARNING

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

WARNING

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND


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

WARNING

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND


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

WARNING

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


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

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TABLE 5.3.3.6-1 PRE-OPERATION RUN INSTRUCTION SEQUENCE


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

1 Verify System Mode Switch (SMS) is in MANUAL

2 Verify DC Control Power is on

3 Verify Emergency Stop is pulled out

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

5 Start engine 1 by placing ECS1 in MANUAL

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

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

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

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

10 Shutdown engine 1 by placing ECS1 in OFF/RESET

11 Start engine 2 by placing ECS2 in MANUAL

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

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

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

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

16 Shutdown engine 2 by placing ECS2 in OFF/RESET

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

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5.3.3.7 ORT SETUP

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

b. Remove the mouse from the case and plug it into the mouse (PS2) port on the back of the
ORT.
c. If 120VAC power is available, connect the ORT power supply cord to the 120 VAC power.
The ORT can operate up to three hours on its batteries.

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

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

f. Turn on the ORT..

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

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

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

h. Return to the Overview pop-up screen.

5.3.3.8 CONTROLS SETUP

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

TABLE 5.3.3.8-1 CONTROL SWITCH SETUP


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

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5.3.4 PLANT STARTUP


Starting up a Two Unit Prime Power Plant in Manual Mode

WARNING

ONLY ONE PU MAY BE SELECTED TO ANY ONE USS POSITION DURING


MULTIPLE PU OPERATIONS. OPERATING WITH MORE THAN ONE UNIT AT THE
SAME ID CAUSE UNSAFE AND ERRATIC OPERATIONAL CONDITIONS.

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

TABLE 5.3.4-1 SWITCH SETUP – MANUAL MODE


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

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

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

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

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

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

f. Observe that BCSG1 closes.

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g. Place the SSS to the TIE position.

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

i. Return the SSS to the OFF position.

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

k. Observe that the generator starts and accelerates to operating voltage and frequency.

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

m. Close BCSG2 when the two green triangular LEDs at 12 o’clock on the Synchroscope are
energized by cycling BCS-G2 to the CLOSE position. For detailed instructions on manual
synchronizing, refer to Chapter 5.9, Section 5.9.6.14.

n. Observe that the BCSG2 closes.

o. Return the SSS to the OFF position.

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

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

r. Return the SSS to the OFF position.

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

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

u. At the B-unit MCP, place the Sync Source Switch (SSS) in the GEN1 position.

v. Close BCSG1 when the two green triangular LEDs at 12 o’clock on the Synchroscope are
energized by cycling BCS-G1 to the CLOSE position. For detailed instructions on manual
synchronizing, refer to Chapter 5.9, Section 5.9.6.14.

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

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

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

z. Close BCSG2 when the two green triangular LEDs at 12o’clock on the Synchroscope are
energized by cycling BCS-G2 in the CLOSE position. For detailed instructions on manual
synchronizing refer to Chapter 5.9 Section 5.9.6.14.

aa. Return the SSS to the OFF position.

bb. Close the required feeder breaker(s) from the Local Control Panels.

cc. Ensure generators have assumed load.


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

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

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

5.3.5 PLANT OPERATIONS

See Chapter 5.9 for specific operating procedures.

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

5.3.6 POWER PLANT TEARDOWN

5.3.6.1 SHUTDOWN GENERATORS

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

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

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

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

e. Place all ECS switches in OFF/RESET.

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

5.3.6.2 DISCONNECT CABLES

WARNING

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

CAUTION

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

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

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b. Reinstall the (A)(B) communication cable receptacle covers.

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

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

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

5.3.6.3 DISCONNECT FUEL LINES

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

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

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

5.3.6.4 DISCONNECT GROUNDING

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

b. Disconnect the parking stations from the ground grid.

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

5.3.6.5 PREPARE PU FOR TRANSPORTATION

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

b. Verify DC Control power is off.

c. Close and lock the LCP access doors.

d. Close and lock all PU side doors.

5.3.6.6 FUEL, OIL, AND COOLANT DRAINAGE

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

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CHAPTER 5.4
OPERATING INSTRUCTIONS

TWO PU, PRIME POWER, NO EXTERNAL SWITCH,


AUTOMATIC MODE

TABLE OF CONTENTS

SECTION TITLE PAGE


5.4 TWO PU, PRIME POWER, NO EXTERNAL SWITCH, AUTOMATIC MODE 73

5.4.1 SAFETY PROCEDURES 73

5.4.2 POSITIONING THE PU 73

5.4.3 INITIAL PLANT SETUP 74

5.4.3.1 GROUNDING 74

5.4.3.2 FUEL MANIFOLD 75

5.4.3.3 DISTRIBUTION AND CONTROL CABLING 76

5.4.3.4 SETPOINT VERIFICATION 77

5.4.3.5 PRE-OPERATION CHECKS 80

5.4.3.6 PRE-OPERATION RUN 80

5.4.3.7 ORT SETUP 82

5.4.3.8 CONTROLS SETUP 82

5.4.4 PLANT STARTUP 83

5.4.5 PLANT OPERATIONS (AUTOMATIC MODE) 84

5.4.5.1 PRECAUTIONS AND WARNINGS 84

5.4.5.2 DESCRIPTION 85

5.4.5.3 DEFAULT OPERATING SEQUENCE 85

5.4.6 POWER PLANT TEARDOWN 85

5.4.6.1 SHUT DOWN GENERATORS 85

5.4.6.2 DISCONNECT CABLES 85

5.4.6.3 DISCONNECT FUEL LINES 86

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TABLE OF CONTENTS

SECTION TITLE PAGE


5.4.6.4 DISCONNECT GROUNDING 86

5.4.6.5 PREPARE PU FOR TRANSPORTATION 86

5.4.6.6 FUEL, OIL, AND COOLANT DRAINAGE 86

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LIST OF FIGURES

FIGURE TITLE PAGE


FIGURE 5.4.3.1-1 MEP-PU-810A GROUND POINTS 74

FIGURE 5.4.3.1-2 MEP-PU-810B GROUND POINTS 75

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LIST OF TABLES

TABLE TITLE PAGE


TABLE 5.4.3.6-1 PRE-OPERATION RUN INSTRUCTION SEQUENCE 81

TABLE 5.4.3.8-1 CONTROL SWITCH SETUP 82

TABLE 5.4.4-1 SWITCH SETUP – AUTOMATIC MODE 83

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5.4 TWO PU, PRIME POWER, NO EXTERNAL SWITCH, AUTOMATIC MODE

5.4.1 SAFETY PROCEDURES

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

• Hot engine parts


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

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

5.4.2 POSITIONING THE PU

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

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

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

WARNING

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

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

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5.4.3 INITIAL PLANT SETUP

5.4.3.1 GROUNDING

WARNING

THERE CAN ONLY BE ONE GROUNDING POINT FOR THE PU.

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

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

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

d. Using a #2 AWG copper conductor, secure one end of a ground cable to one of the slotted
ground studs on the PU, see Figure 5.4.3.1-1 or Figure 5.4.3.1-3. Secure the other end of the
ground cable to the ground rod.

e. Repeat step “d” for every PU.

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

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

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

GROUND POINT GROUND POINT

FIGURE 5.4.3.1-1 MEP-PU-810A GROUND POINTS

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

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GROUND POINT GROUND POINT

FIGURE 5.4.3.1-2 MEP-PU-810B GROUND POINTS

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

5.4.3.2 FUEL MANIFOLD

WARNING

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

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

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

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

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

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

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

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5.4.3.3 DISTRIBUTION AND CONTROL CABLING

WARNING

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

WARNING

HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT DURING
CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION AND AVOID
CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN LOAD CABLES ARE
HANDLED.

WARNING

VERIFY THAT CONNECTION POINTS ARE DE-ENERGIZED BEFORE MAKING ANY


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

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

b. Connect each power cable’s drain wire to the grounding grid.

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

d. Connect each power cable’s drain wire to the grounding grid.

e. Open the Tie Output connector loadbreak covers on one PU.

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

g. Close and lock (when required) the Tie Output connector covers.

h. Open the Feeder Output connector loadbreak covers.

i. Connect the Feeder cables to the appropriate phase connectors; ensure there are no cross-
phase connections.

j. Close and lock the Feeder Output connector covers.

k. Repeat steps ‘e’ through ‘j’ on the second PU.

l. Connect the (A) (B) communication cable to the (B) side of the first PU.

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m. Route (A) (B) communication cable to second PU and Connect to the (A) side of the PU.

n. Connect the (A) (B) communication cable to the (B) side of the second PU. Leave the end of
second cable loose and capped.

5.4.3.4 SETPOINT VERIFICATION

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

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

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

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

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

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

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

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

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


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

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

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

(12) Verify the “50TN” settings.

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

(14) Verify the “50TQ” settings.

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

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

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

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

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

(20) Verify the 51N settings.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

(17) Press SELECT key.

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

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

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

(21) Press SELECT key.

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

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

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

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

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

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

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


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

NOTE: Use up or down keys to change values.

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

(1) Open the GCPG1 cabinet door.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

(17) Close the GCPG1 cabinet door.

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

5.4.3.5 PRE-OPERATION CHECKS

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

5.4.3.6 PRE-OPERATION RUN

WARNING

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

WARNING

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND ENFORCED.
NOISE LEVELS IN EXCESS OF 85 DB EXIST WITHIN AN 88-FOOT RADIUS OF AN
OPERATING DPGDS. PERSONNEL MUST WEAR SINGLE HEARING PROTECTION WITHIN
88 FEET OF AN OPERATING DPGDS.

WARNING

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND ENFORCED.
DURING MAINTENANCE ACTIVITIES WITH THE SIDEDOORS OPEN, NOISE LEVELS IN
EXCESS OF 113 DB EXIST WITHIN A 12-FOOT RADIUS OF AN OPERATING DPGDS.
PERSONNEL MUST WEAR DOUBLE HEARING PROTECTION WITHIN 12 FEET OF AN
OPERATING DPGDS. EXPOSURE MUST BE LIMITED TO UNDER 2.5 HOURS.

WARNING

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


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

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TABLE 5.4.3.6-1 PRE-OPERATION RUN INSTRUCTION SEQUENCE


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

1 Verify System Mode Switch (SMS) is in MANUAL

2 Verify DC Control Power is on

3 Verify Emergency Stop is pulled out

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

5 Start engine 1 by placing ECS1 in MANUAL

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

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

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

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

10 Shutdown engine 1 by placing ECS1 in OFF/RESET

11 Start engine 2 by placing ECS2 in MANUAL

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

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

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

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

16 Shutdown engine 2 by placing ECS2 in OFF/RESET

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

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5.4.3.7 ORT SETUP

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

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

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

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

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

f. Turn on the ORT.

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

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

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

h. Return to the Overview pop-up screen.

5.4.3.8 CONTROLS SETUP

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

TABLE 5.4.3.8-1 CONTROL SWITCH SETUP


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

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

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5.4.4 PLANT STARTUP


Starting up a Two Unit Prime Power Plant in Automatic Mode

WARNING

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

WARNING

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

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

TABLE 5.4.4-1 SWITCH SETUP – AUTOMATIC MODE


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

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

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

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

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

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

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

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

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

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

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

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

l. Ensure generators have assumed load.


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

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

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

5.4.5 PLANT OPERATIONS (AUTOMATIC MODE)

5.4.5.1 PRECAUTIONS AND WARNINGS

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

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5.4.5.2 DESCRIPTION

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

5.4.5.3 DEFAULT OPERATING SEQUENCE

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

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


b. Remaining generator from PU “A”.
c. Remaining generator from PU “B”.

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

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


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

5.4.6 POWER PLANT TEARDOWN

5.4.6.1 SHUT DOWN GENERATORS

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

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

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

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

e. Place all ECS switches in OFF/RESET.

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

5.4.6.2 DISCONNECT CABLES

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WARNING

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

CAUTION

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

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

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

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

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

5.4.6.3 DISCONNECT FUEL LINES

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

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

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

5.4.6.4 DISCONNECT GROUNDING

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

b. Disconnect the parking stations from the ground grid.

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

5.4.6.5 PREPARE PU FOR TRANSPORTATION

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

b. Verify DC Control power is off.

c. Close and lock the LCP access doors.

d. Close and lock all PU side doors.

5.4.6.6 FUEL, OIL, AND COOLANT DRAINAGE

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

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CHAPTER 5.5
OPERATING INSTRUCTIONS
SINGLE OR MULTIPLE PU, PRIME POWER, EXTERNAL SWITCH,
MANUAL MODE

TABLE OF CONTENTS

SECTION TITLE PAGE


5.5 SINGLE OR MULTIPLE PU, PRIME POWER, EXTERNAL SWITCH, MANUAL MODE 91

5.5.1 SAFETY PROCEDURES 91

5.5.2 POSITIONING THE PU 91

5.5.3 INITIAL PLANT SETUP 92

5.5.3.1 GROUNDING 92

5.5.3.2 FUEL MANIFOLD 93

5.5.3.3 DISTRIBUTION AND CONTROL CABLING 94

5.5.3.4 SETPOINT VERIFICATION 95

5.5.3.5 PRE-OPERATION CHECKS 98

5.5.3.6 PRE-OPERATION RUN 98

5.5.3.7 ORT SETUP 100

5.5.3.8 CONTROLS SETUP 100

5.5.3.9 PSC RELAY SETTING VERIFICATION 101

5.5.4 PLANT STARTUP 102

5.5.5 PLANT OPERATIONS 105

5.5.6 POWER PLANT TEARDOWN 105

5.5.6.1 SHUTDOWN GENERATORS 105

5.5.6.2 DISCONNECT CABLES 105

5.5.6.3 DISCONNECT FUEL LINES 106

5.5.6.4 DISCONNECT GROUNDING 106

5.5.6.5 PREPARE PU FOR TRANSPORTATION 106

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LIST OF FIGURES

FIGURE TITLE PAGE


FIGURE 5.5.3.1-1 MEP-PU-810A GROUND POINTS 92

FIGURE 5.5.3.1-2 MEP-PU-810B GROUND POINTS 93

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LIST OF TABLES

TABLE TITLE PAGE


TABLE 5.5.3.6-1 PRE-OPERATION RUN INSTRUCTION SEQUENCE 99

TABLE 5.5.3.8-1 CONTROL SWITCH SETUP 101

TABLE 5.5.3.9-1 PSC RELAY SETTINGS 102

TABLE 5.5.4-1 SWITCH SETUP – MANUAL MODE 103

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5.5 SINGLE OR MULTIPLE PU, PRIME POWER, EXTERNAL SWITCH, MANUAL MODE

5.5.1 SAFETY PROCEDURES

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

• Hot engine parts


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

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

5.5.2 POSITIONING THE PU

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

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

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

WARNING

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

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

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5.5.3 INITIAL PLANT SETUP

5.5.3.1 GROUNDING

WARNING

THERE CAN ONLY BE ONE GROUNDING POINT FOR THE PU.

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

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

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

d. Using a #2 AWG copper conductor, secure one end of a ground cable to one of the slotted
ground studs on the PU, see Figure 5.5.3.1-1 or Figure 5.5.3.1-3. Secure the other end of the
ground cable to the ground rod.

e. Repeat step “d” for every PU.

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

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

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

GROUND POINT GROUND POINT

FIGURE 5.5.3.1-1 MEP-PU-810A GROUND POINTS

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

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GROUND POINT GROUND POINT

FIGURE 5.5.3.1-2 MEP-PU-810B GROUND POINTS

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

5.5.3.2 FUEL MANIFOLD

WARNING

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

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

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

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

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

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

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

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