IN THE NAME OF ALLAH

THE MOST GRACIOUS AND MERCIFULL

A demonstration about trouble shooting at the

Gas mixer of GE Jenbacher 6 series engine

Muhammad Asim
Senior Service Engineer Electrical
Orient Energy system Pakistan
 Gas Mixer
GE Jenbacher 6 series Engines

Trouble shooting at the problem

(A1083)Control carburetor defective
 If
Diane.XT screen is showing Gas mixer position 100%

It can come back at 0% according to

following procedures
 But

This procedure is not applied if your following

hardware are faulty

 Gas mixer motor drive card one or both are faulty

 Gas mixer position card one or both are faulty
 Gas mixer motor one or both are faulty

 In these conditions, we will change

the faulty hardware
Here we will discuss the troubleshooting
procedure about subjected problem, if gas
mixer goes to 100% actually

By the reason s of

 Signal disturbance from Diane.XT to gas mixer

 During reset the power supply of all control system
 Disturbance of control system during tripping
We can solve the said problem
by following three procedures

1st .From Diane.XT through software command

2nd .From interface panel through manually command

via G.M Motor drive card

3rd .From Gas mixer by hand turning clock wise

(G.M close)
(1)From Diane.XT

In case of following problems due to

any disturbance in the system

(A 1083) control carburetor defective

(W2086) Gas mixer position signal missing)

And the gas mixer has been touched to 100% actually,

and on the screen also
As following picture
ENGINE CONTROLLER
For solve the problem from Diane.XT, we will go to
LEANOX CONTROLLER (CTR 1+F3)

And will insert the 0% value in G.M rated option,

Gas mixer will not decrease but we will wait maximum 15 minutes
after insert the 0% value,

Approximately With in fifteen minutes maximum, gas mixer will

decrease and will stay at 70 to 75 %.(as per max. G.M set point)
When gas mixer will have stop at
any fix value, then we will reboot
the Diane.XT,

After rebooting, the controller will

calibrate the Gas mixer according
to set point in the gas mixer recipe.
NOTE: - If your command via software does
not work or software does not support to your
command, its mean your any relevant hardware
Is not working properly due to malfunctioning,
in this case we can solve the problem with 2nd
method

Next we will discuss at second procedure

 (2) From Interface panel

For solve the problem from interface panel,

we need to study electrical drawing regarding
Gas mixer control
 Gas mixer Control circuit

Remove the opening command out put card

Remove the opening command out put card

Gas mixer drive cards

2 # terminal behind
the 8 # terminal
In above mention drawing, gas mixer opening
and closing commands are going to
motor’s drive cards,
From digital output cards.

Zu = gas mixer closing command

auf =gas mixer opening command
Written on Drive cards
We know that both gas mixers are 100% open
therefore we will send the manually commands
one by one, by the 24vdc external at the
terminal number 2 (zu) of motor drive cards,
but before connect the 24vdc at the drive cards,
closing/opening commands from the digital
output cards should be remove,
as above picture
When we will give the 24vdc voltage
at motor’s drive card, its mean we are
giving the manually closing
command to Gas mixer and gas mixer
will decrease from 100% to 0%
Now we will connect 24vdc at the 1st gas
mixer drive card terminal # 2(zu) and this gas
mixer will decrease, we can see in following
picture, gas mixer is decreasing.
When 1st gas mixer touch to 0% completely as following
picture, remove 24vdc from the drive card,
now 1st gas mixer has been come down at 0%.
Now we will connect the 24vdc at 2nd gas
mixer drive card terminal # 2(zu) and this
gas mixer also will come down from
100% to 0%,
Now 2nd gas mixer has been completely com down at
0%, so remove the 24vdc from the drive card
As following picture.
Now both gas mixers have adjusted at 0%
as following picture
We can verify the actual 0% position of gas mixer
by hand, after open the both gas mixer cover,

As following picture
Now we will reboot to Diane.XT, after rebooting controller will adjust
the gas mixer according to set point in the lube oil temperature base
recipe
as following picture
Now we can start the Engine normally
 3-Manually by hand
•In this procedure open the gas mixer supply fuse and remove the following parts

•Air intake pipes

•G.M position cards
•Loose the G.M gear box tightening plate (drive mechanism)

•G.M Motor
 As per following picture
(2)Remove coupling between card and mixer

(1) Remove
Position Card
(4)Loose the plate

(3)Loose long
size bolt

(5)Remove mixer motor

(6)Screw driver “Optional”
insert point For
clockwise movement
 After remove the mentioned parts from both sides,
turn the gas mixers clockwise for fully closing
and adjusted the G.M position cards at 4mA
After manually closing to gas mixer, install G.M
position cards on the gas mixers but it should be
at 4mA because gas mixers are also at 0%.

4mA = 0%
Install all remaining parts step by step

Reboot the Diane XT, Now the controller

will adjust the gas mixer as per own set point
NOTE:- This procedure is some lengthy and
difficult from other first and second procedure,
so it is advise you, that first apply 1st and 2nd
procedure, if you fail to solve the problem by
1st and 2nd then you apply the third procedure.
 Care full point in the 3rd procedure

This turn able knob is fix in the

mechanism without any screw
G.M position card
Coupling
If we will turn it clock wise by screw driver,
it can be free in the mechanism, so turn it carefully.
It is a very important point during the working as per 3rd procedure.

If you feel free movement of this turning knob during

turning, so remove it and readjust in the mechanism with lock
tight compound.
Observation and some checks before starting trouble shooting

If….

Alarm of Control carburetor defective is active

Warning of Gas mixer position measuring signal failure
Both Gas mixers are fix at 100%

Here you will apply explained procedures

.If one gas mixer is fix at 100% and second is normal at
52%, 48%, 58%, etc.

 .Then you will apply this procedure if problem does not

solve, its mean this relevant side’s G.M position card,
Motor drive card or motor is faulty

.If you feel dangerous to give the 24 Vdc supply at Zu

point of motor drive card,
So, you can give the supply at the removed cable of closing
command from PLC out put card
 If engine is trips at the alarm of control carburetor
defective but gas mixer position is also normal,

so you have to diagnose the faulty part,

its mean it is a malfunctioning of G.M position card,
Motor drive card or motor of relevant side, we can take
help from win server’s trending

If warning of gas mixer signal missing is active and

position is showing **** ,
its mean G.M position card can faulty
NOTE: - Please study this document with fully
concentration and try to improve these explained
procedures,

so don’t hesitate to improve this document and

feedback.
Any Question ?
Thank you very much