SDMO R33C3 User And Maintenance Manual

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User and maintenance manual

for generating sets

33504023701NE_2_1

Translation of the original instructions

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CONTENTS

1. Preface .................................................................................................................................................................................................. 4

1.1. General recommendations ....................................................................................................................................................... 4

1.2. Warnings .................................................................................................................................................................................. 4

1.3. Pictograms and their meanings ................................................................................................................................................ 5

1.4. Safety instructions .................................................................................................................................................................... 8

1.4.1 General guidelines .................................................................................................................................................................... 8

1.4.2 Electrical safety precautions ................................................................................................................................................... 10

1.4.3 Safety precautions in case of electrical shock ........................................................................................................................ 11

1.4.4 Safety precautions relating to fire, burns and explosions ....................................................................................................... 11

1.4.5 Toxic risk safety precautions .................................................................................................................................................. 13

1.4.6 Precautions for risks relating to handling phases ................................................................................................................... 14

1.4.7 Precautions for risks relating to noise ..................................................................................................................................... 14

2. General description .............................................................................................................................................................................. 15

2.1. Description ............................................................................................................................................................................. 15

2.2. Technical specifications ......................................................................................................................................................... 18

2.3. Identifying sets ....................................................................................................................................................................... 20

2.4. Fluid retention ........................................................................................................................................................................ 21

2.5. Fuels, lubricants and coolants ................................................................................................................................................ 22

2.5.1 Fuel specifications .................................................................................................................................................................. 22

2.5.2 Lubricant specifications .......................................................................................................................................................... 24

2.5.3 Coolant specifications ............................................................................................................................................................. 25

3. Transporting the equipment ................................................................................................................................................................. 27

3.1. Warnings concerning transport .............................................................................................................................................. 27

3.2. Preparing for transport ........................................................................................................................................................... 27

3.3. Road transport ....................................................................................................................................................................... 27

3.3.1 Generating sets with and without an enclosure ...................................................................................................................... 27

3.3.2 Generating sets on trailers...................................................................................................................................................... 28

3.3.2.1. Hitching and unhitching the trailer ............................................................................................................................. 28

3.3.2.2. Check before towing ................................................................................................................................................. 32

3.3.2.3. Operation .................................................................................................................................................................. 32

3.4. Rail transport .......................................................................................................................................................................... 33

3.4.1 Generating sets with and without an enclosure ...................................................................................................................... 33

3.5. Shipping ................................................................................................................................................................................. 34

3.5.1 Generating sets with and without an enclosure ...................................................................................................................... 34

3.6. Air transport ........................................................................................................................................................................... 34

4. Installation - Connections .................................................................................................................................................................... 35

4.1. Unloading the generating set ................................................................................................................................................. 35

4.1.1 Choosing the location ............................................................................................................................................................. 35

4.1.2 Safety during unloading .......................................................................................................................................................... 36

4.1.3 Unloading the generating set .................................................................................................................................................. 36

4.1.3.1. Slings ........................................................................................................................................................................ 36

4.1.3.2. Fork lift truck ............................................................................................................................................................. 37

4.1.4 Moving the generating set ...................................................................................................................................................... 37

4.2. Connecting the generating set ............................................................................................................................................... 38

4.2.1 Connection summary .............................................................................................................................................................. 38

4.2.2 Protecting people and equipment ........................................................................................................................................... 39

4.2.2.1. Earthing system principle .......................................................................................................................................... 39

4.2.2.2. TT system ................................................................................................................................................................. 39

4.2.2.3. Installing the differential protection ........................................................................................................................... 40

4.2.2.4. Setting the generating set differential protection ....................................................................................................... 41

4.2.2.5. Earthing the generating set ....................................................................................................................................... 43

4.2.3 Making the connections .......................................................................................................................................................... 44

4.2.3.1. Connections - general information ............................................................................................................................ 44

4.2.3.2. Selecting the power cables ....................................................................................................................................... 45

4.2.3.3. Connecting the generating set to the installation ...................................................................................................... 46

4.2.3.4. Connecting the battery or batteries to the generating set ......................................................................................... 48

4.2.4 Overvoltage ............................................................................................................................................................................ 48

5. Installation............................................................................................................................................................................................ 48

5.1. Warnings concerning commissioning ..................................................................................................................................... 48

5.2. Checking the generating set installation ................................................................................................................................ 48

5.3. Preparing for operation of the generating set ......................................................................................................................... 49

5.4. Checking the generating set before startup ........................................................................................................................... 49

5.5. Checking the generating set after startup .............................................................................................................................. 49

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6. Using the generator set ....................................................................................................................................................................... 50

6.1. Pre-Start Inspection ............................................................................................................................................................... 50

6.2. Generator set with NEXYS control panel ............................................................................................................................... 53

6.2.1 Control panel presentation ..................................................................................................................................................... 53

6.2.1.1. Introduction to pictograms ......................................................................................................................................... 54

6.2.2 Manual starting ....................................................................................................................................................................... 55

6.2.3 Switching off ........................................................................................................................................................................... 56

6.2.4 Alarms and faults .................................................................................................................................................................... 56

6.2.5 Faults and alarms - Details ..................................................................................................................................................... 56

6.2.6 MURPHY diagnostic module .................................................................................................................................................. 58

6.3. Generator set with TELYS control panel ................................................................................................................................ 64

6.3.1 Control panel presentation ..................................................................................................................................................... 64

6.3.1.1. View of the front panel .............................................................................................................................................. 64

6.3.1.2. Description of the screen .......................................................................................................................................... 66

6.3.1.3. Description of the pictograms in zone 1 .................................................................................................................... 67

6.3.1.4. Description of the pictograms in zone 2 .................................................................................................................... 68

6.3.1.5. Description of the pictograms in zone 3 .................................................................................................................... 69

6.3.1.6. Display of messages in zone 4 ................................................................................................................................. 71

6.3.2 Starting ................................................................................................................................................................................... 76

6.3.3 Switching off ........................................................................................................................................................................... 77

6.3.4 Alarms and faults .................................................................................................................................................................... 77

6.3.4.1. Viewing alarms and faults ......................................................................................................................................... 77

6.3.4.2. Activation of an alarm or fault ................................................................................................................................... 78

6.3.4.3. Activation of an alarm and a fault .............................................................................................................................. 79

6.3.4.4. Engine fault codes display ........................................................................................................................................ 80

6.3.4.5. Horn reset ................................................................................................................................................................. 81

7. Maintenance schedule ......................................................................................................................................................................... 81

7.1. Reminder of use ..................................................................................................................................................................... 81

7.2. Maintenance safety instructions ............................................................................................................................................. 81

7.3. Table of maintenance operations ........................................................................................................................................... 82

7.4. Cover maintenance ................................................................................................................................................................ 83

7.5. Trailer maintenance ............................................................................................................................................................... 83

7.6. Fault finding ........................................................................................................................................................................... 84

7.7. No load and under load tests ................................................................................................................................................. 84

8. Starter batteries ................................................................................................................................................................................... 85

8.1. Checking the electrolyte level ................................................................................................................................................ 85

8.2. Checking the voltage/acid density .......................................................................................................................................... 85

8.3. Charging the battery .............................................................................................................................................................. 86

8.4. Cleaning the battery ............................................................................................................................................................... 86

8.5. Fault finding ........................................................................................................................................................................... 87

9. Options ................................................................................................................................................................................................ 88

9.1. Dual frequency ....................................................................................................................................................................... 88

9.2. Neutral system ....................................................................................................................................................................... 91

9.3. Fuel supply valve ................................................................................................................................................................... 91

10. Appendix ............................................................................................................................................................................................ 93

10.1. Appendix A – Engine user and maintenance manual ............................................................................................................ 93

10.2. Appendix B - Alternator user and maintenance manual ........................................................................................................191

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TABLE OF ILLUSTRATIONS

Figure 1 : Warning pictograms .................................................................................................................................................................. 5

Figure 2 : Pictograms indicating prohibited activities ................................................................................................................................. 5

Figure 3 : Pictograms indicating compulsory operations ........................................................................................................................... 6

Figure 4 : Information pictograms .............................................................................................................................................................. 6

Figure 5 : Specific pictograms ................................................................................................................................................................... 7

Figure 6 : Pictograms relating to battery operations .................................................................................................................................. 7

Figure 7 : General description of the generating set ................................................................................................................................ 15

Figure 8 : General description of the generating set (Continuation) ........................................................................................................ 16

Figure 9 : General description of the generating set (control) .................................................................................................................. 17

Figure 10 : Example of a generating set identification plate .................................................................................................................... 20

Figure 11 : Fluid retention container ........................................................................................................................................................ 21

Figure 12 : Example of French signalling ................................................................................................................................................ 33

Figure 13 : Examples of problems that may be encountered .................................................................................................................. 35

Figure 14 : Points used for lifting and moving .......................................................................................................................................... 37

Figure 15 : TT earthing system ................................................................................................................................................................ 39

Figure 16 : View of the front side ............................................................................................................................................................. 53

Figure 17 : Description of the LEDs ......................................................................................................................................................... 54

Figure 18 : View of pictograms ................................................................................................................................................................ 54

Figure 19 : View of the front panel ........................................................................................................................................................... 64

Figure 20 : Description of the LEDs ......................................................................................................................................................... 65

Figure 21 : Close-up of USB ports ........................................................................................................................................................... 65

Figure 22 : Description of the screen (example) ...................................................................................................................................... 66

Figure 23 : Trailer lubrication/greasing points .......................................................................................................................................... 83

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1. Preface

1.1. General recommendations

The information contained in this manual is taken from technical data available at the time of print. In line with our policy of continually improving the quality of our products, this information may be amended without warning.

Read the safety instructions attentively in order to prevent any accident, incident or damage. These instructions must be adhered to constantly.

In order to obtain optimum efficiency and the longest possible service life for the generating sets, maintenance operations must be carried out according to the periods indicated in the attached maintenance tables. If the generating set is used under dusty or unfavourable conditions, some of these periods will be shorter.

Ensure that all adjustments and repairs are carried out by personnel who have received appropriate training. Our agents possess this qualification, and can answer all of your questions. They can also supply you with spare parts and other services and they have qualified staff to carry out preventive and corrective maintenance or even total reconditioning of generating sets.

The left and right sides can be seen from the back of the generating set (the radiator is at the front).

: some user and maintenance manuals for engines fitted to gener ating sets cover control units and include the start-up and sh ut

Note down procedures for the engines.

As our generating sets are fitted with control units that are specific to the generating sets; only the i nformation that appears in the documentation for the generating set control units should be taken into consideration.

In addition, depending on the manufacturing criteria of the generating sets, some engines may be fitted with specific electrical wiring different to that described in the engine documentation.

1.2. Warnings

In this manual, the warning messages are used as follows:

Immediate danger.

Indicates an imminent danger which may result in death or serious injury. Failure to follow the instruction shown may pose serious risks to the health and life of those concerned.

DANGER

Potential danger.

IMPORTANT

Indicates a dangerous situation if the warning is not heeded. Failure to follow the instruction indicated may cause minor injuries to those concerned or damage to equipment.

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1.3. Pictograms and their meanings

The aim of the pictograms is as follows:

- To draw the attention of the operator or maintenance technician to the potential dangers.

- To explain how to act in the interest of personal safety and to avoid damaging the equipment.

The safety pictograms present on the equipment are explained below.

Warning: danger

Important, toxic materials

Important, high temperature

Important, Electrical risk

Important, rotating or moving parts

Important, corrosive product

Important, risk of explosion

Important, pressurised fluids

Danger: automatic start-up

Figure 1 : Warning pictograms

Entry prohibited to unauthorised persons

Figure 2 : Pictograms indicating prohibited activities

Jet washing prohibited

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Reading the manual for the equipment is compulsory

Lifting point required

Periodic maintenance compulsory

Figure 3 : Pictograms indicating compulsory operations

Earth

Wearing suitable protective clothing is compulsory

Forklift required for lifting

Battery isolating switch

Wearing suitable protective goggles and ear defenders is compulsory

Battery charge must be checked

External fuel connections

Diesel fuel

Fill the coolant

Fill the oil

Retention container high level

Drain the fuel

Drain the coolant

Drain the oil

Drain the retention container

Figure 4 : Information pictograms

Inspection flap

Mains supply connection prohibited before filling with water

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Flammable product,

Do not smoke or create sparks or flames

Fuel supply

- Selection valve -

Figure 5 : Specific pictograms

Reading the manual for the equipment is

compulsory

Securing straps routing point

Rinse any splashes of acid on the skin or

in the eyes using clean water.

Wearing suitable protective clothing and

goggles is compulsory

Consult a doctor immediately.

Wash contaminated clothing with water.

Figure 6 : Pictograms relating to battery operations

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1.4. Safety instructions

RETAIN THIS MANUAL

This manual contains important instructions which must be followed when installing or carrying out maintenance on a generating set and batteries.

IMPORTANT - SAFETY ADVICE

If any parts of this manual are not understood, or in case of doubt, contact your nearest agent in order to receive an explanation or demonstration to allow the equipment to be used correctly. The guidelines listed below must always be respected to ensure the safety of personnel and equipment. In addition to this information, it is essential to refer to the local and national regulations applicable according to the jurisdiction.

1.4.1 General guidelines

Installing the equipment

The installer of the equipment must create a document describing any modifications made to the equipment during installation.

Using the equipment

- Before starting any operations on the equipment:

 Nominate an operations manager.

 The role of the operations manager is to monitor, either directly or indirectly, any operations performed on the equipment

and to ensure that the safety and operating instructions are respected.

 The operations manager should read and understand all the documentation supplied with the equipment.

- Information for personnel:

 Regularly reiterate the safety and operating instructions to the operating personnel.

 Contact your dealer if you have any questions regarding the equipment and any training requests for personnel.

 Make the manufacturer's instructions available to the users (if possible on site).

- Protection for individuals and equipment:

 Wear suitable clothing.

 Move away from equipment in operation.

 Ensure that persons who are not authorised to intervene as well as animals are kept away from the equipment. Observe

this guideline regardless of whether the equipment is in operation or stopped.

 Protect the equipment from any fluid splashes and bad weather.

 Before starting the equipment, refit the enclosures and close all the access doors.

 Before starting the engine, check that the air filter is present and the correct extraction circuit for the exhaust gas.

 Respect the current regulations relating to fuel use.

 Under no circumstances use seawater or any other corrosive or electrolytic product in the cooling circuit.

 Adjust the equipment according to the manufacturer's prescriptions.

 Check that the equipment operates correctly.

 Engage the parking brake when the equipment is installed on the operating site on its trailer. When chocking the trailer on

a slope, ensure that there is nobody in the path of the trailer.

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Maintaining the equipment

- Personnel skills:

 Ensure that the maintenance operations are performed on the equipment by appropriately trained personnel.

- Personnel protection:

 Wear suitable clothing and protective goggles.

 Remove any personal belongings that may hinder the operation: watch, bracelet, etc.

 Fit a panel over the controls of the equipment to prevent any attempt to start.

 Disconnect the battery (and pneumatic starter if fitted) before beginning any maintenance operation.

 Handle the equipment according to best practices, using techniques which do not endanger the personnel.

 It is essential to wear gloves when detecting leaks.

 Regularly check that the safety devices are operating correctly.

- Equipment protection:

 Use tools in good condition and suited to the work to be done. Ensure you have understood the instructions before

beginning any operation.

 Respect the maintenance table and its recommendations. In dusty or unfavourable conditions, certain maintenance

intervals will need to be reduced.

 Check that the spare parts fitted on the equipment are supplied only by the dealer.

 Handle the equipment according to best practices, using techniques which do not risk damaging the equipment.

 Replace any safety pictograms that are missing or illegible on the equipment.

Note

: the mounting bolts on the protective devices of t he rotating parts are captive bolts equipped with retaining washers. Also, in order to ensure the integrity of this assembly, it is prohibited to use elec tric or pneumatic screwdrivers to undo these mounting bolts.

- Cleaning the equipment:

 Clean off any trace of oil, fuel or coolant using a clean cloth.

 Use only approved cleaning solvents.

 Cleaning products and methods that are strictly prohibited:

• petrol or other flammable substances;

• soapy solution containing chlorine or ammonia;

• high pressure cleaner.

- Additional instruction:

 If necessary, contact the dealer for the following reasons:

• answers to any questions relating to the equipment;

• training requests for personnel;

• supplying the relevant documentation for maintenance operations;

• supplying spare parts;

• corrective or preventive maintenance operations.

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Operating site

- Maintenance:

 Clean the entire operating site regularly with suitable cleaning materials.

 The presence of dangerous or combustible materials inside premises must be limited to the operating requirements.

- Access:

 Prohibit free access to persons who are not part of the establishment, except for those designated by the user.

- Respecting the environment:

 Drain and dispose of engine oil in a specially provided container (fuel distributors can collect your used oil).

 Burning of waste in the open air is prohibited.

 Remove waste water, sludge and other waste in a specialised processing centre.

1.4.2 Electrical safety precautions

DANGER

- Read the manufacturer's identification plate carefully. The values for voltage, power, current and frequency are shown. Check that these values match the installation being supplied.

- The electrical connections must be made in accordance with current standards and regulations in the country of use and the neutral system sold.

- Ask a qualified electrician to intervene when there are specific cases requiring equipment to be connected to an existing electrical network.

- Disconnect the power to the equipment (equipment voltage, battery voltage and network voltage) before any installation or maintenance operation is performed.

- Connect the equipment wires by respecting the wiring diagram supplied by the manufacturer.

- Always handle the equipment with dry hands and feet.

- Take all the necessary precautions to avoid touching stripped cables or disconnected connectors.

- Use and maintain the cables in good condition, well insulated and connected correctly and securely.

- Only replace equipment that provides protection against electric shock with identical equipment (specifications and nominal values).

- Only use flexible durable cables with a rubber covering, which conform to ECI 245-4, or equivalent cables.

- Refit the protective plates (blanking covers) after each maintenance operation.

ELECTRICAL EQUIPMENT - RISK OF ELECTRIC SHOCKS

Note

: The electrical equipment supplied with the equipment co mplies with standard NF C15.100 (F rance), or with the standards of th e

countries in question.

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1.4.3 Safety precautions in case of electrical shock

In the event of an electric shock, observe the following instructions:

1. Avoid direct contact both with the live conductor and the victim's body.

2. Shut off the power immediately and activate the emergency stop for the

equipment concerned. Note care to avoid the electric arc that will be generated by this.

3. If it is impossible to access the equipment: move the victim away from the live conductor using a dry piece of wood, dry clothing or other non-conducting material.

4. Move the victim away from any situations where there is a danger of death.

5. Contact the emergency services.

6. If breathing has stopped, begin artificial respiration at once.

7. In the event of cardiac arrest, carry out cardiac massage.

1.4.4 Safety precautions relating to fire, burns and explosions

: the live wire may be cut with an axe. Take extreme

DANGER

FUELS / FLAMMABLE PRODUCTS / PRESSURISED FLUID

- RISK OF BURNS -

- RISK OF FIRE -

- RISK OF EXPLOSION -

1. Before starting the equipment, move any flammable or explosive products away (petrol, oil, cloth, etc.).

2. It is prohibited to put combustible materials on the hot parts of the equipment (for example: exhaust pipe).

3. Avoid any contact with the hot parts of the equipment (for example: exhaust pipe).

4. Use appropriate ventilation to allow the equipment to cool correctly.

5. Wait for the engine to stop and cool down completely before removing the radiator cap.

6. Wait for the equipment to stop and cool down completely before covering the equipment (if necessary).

7. Depressurise the air, oil and cooling circuits before removing or disconnecting all the fittings, pipes or connected components.

8. Ensure that the equipment in operation is fixed (in a stationary position).

When installing the equipment on a vehicle or other mobile equipment, a study must be conducted beforehand in order to take into account the various specific uses of the generating set.

IMPORTANT

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Fuels

- Respect current local regulations regarding the equipment and fuel used (petrol, diesel and gas).

- Top up the engine with fuel when the engine has stopped (except for equipment with an automatic filling system).

- Smoking, using a flame or producing sparks are forbidden while the fuel tank is being filled.

- Use protection suitable against fires and explosions.

- Pipes must be replaced as soon as their condition demands it.

Oils

1. Check that the system is no longer pressurised before carrying out any procedures.

2. Avoid contact with hot oil.

3. Wait for the engine to stop and cool down completely before topping up the oil.

4. Before starting the engine, refit the oil filler cap.

5. It is prohibited to cover the generating set with a fine layer of oil for anti-rust protection.

Battery

- Smoking, using a flame or producing sparks are forbidden close to batteries (particularly when the batteries are being charged).

Supply gas

(concerns generating sets running on gas)

- Request the user technical notes and LPG or NG safety data sheets from your gas supplier.

- For any operation on a gas installation, ask a recognised specialist to intervene.

- Gas supply procedures must be carried out in the open air (outside) in accordance with local regulations, in an area well away from fires, people or animals.

- Check the sealing of the gas supply circuit using soapy water with the circuit pressurised, or using a leak detector.

- It is forbidden to smoke, bring flames near or create sparks when the tank is being filled, and near to the generating set.

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1.4.5 Toxic risk safety precautions

DANGER

EXHAUST GAS - TOXIC PRODUCTS

- TOXIC RISK -

Exhaust gas

- Use suitable ventilation to release the exhaust gas outside and prevent it from accumulating.

- Respect current local regulations regarding the equipment and fuel used (petrol, diesel and gas).

- Periodically examine the burnt gas exhaust.

- Pipes must be replaced as soon as their condition demands it.

Note

: the carbon monoxide present in the exhaust gas may lead to death by inhalation if the concentration l evels i n the atmosphere are

too high.

Corrosion inhibitor in the coolant

(contains alkali)

- Read the instructions on the packaging.

- Keep the product out of the reach of children.

- Do not swallow it.

- Avoid prolonged or repeated contact with the skin.

- Never allow contact with the eyes.

In the event of contact with the eyes:

1. Rinse immediately with plenty of water for at least 15 minutes.

2. Consult a doctor immediately.

In the event of contact with the skin:

1. Wash thoroughly with water and soap.

2. Consult a doctor immediately.

Fuels and oils

- Do not swallow it.

- Ensure proper ventilation.

- Use a suitable protective mask.

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Battery electrolyte

- Avoid all contact with the skin and eyes.

- Wear suitable protective goggles and clothing and strong alkali-resistant gloves for handling the electrolyte .

If splashes get into the eyes:

1. Rinse immediately with running water and/or a 10% diluted boric acid solution.

2. Consult a doctor immediately.

1.4.6 Precautions for risks relating to handling phases

DANGER

HANDLING PHASES - RISK OF DROPPING

1. Select the appropriate handling equipment and apparatus according to the type of equipment being handled. Check that there is sufficient handling capacity.

2. Check that the handling equipment and apparatus are in good operating condition.

3. Respect the handling instructions described in the present documentation and the pictograms displayed on the equipment to be handled.

4. Be sure never to stand under the load being handled.

Note

: the lifting rings provided on the equipment are designed to handle the generating set alone. If additional equipment is fitted to the generating set, a study should be conducted in order to define the centre of gravity of the assembly and to check the correct mechanical performance of the structure and its lifting rings.

1.4.7 Precautions for risks relating to noise

HIGH SOUND LEVEL - RISK OF HEARING LOSS

DANGER

- Always use suitable ear defenders when working in close proximity to a generating set which is in operation.

Note

: for generating sets used inside, for which the ambient noise levels are dependent upon the installation conditions, it is not possible to specify these ambient noise levels in the oper ating instructions. As prolonged exposure to high sound pressure leve ls can cause permanent damage to hearing, it is necessary to measure the acoustics after installation in order to determine the sound pressure level and, if necessary, to implement the appropriate preventive measures.

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2. General description

2.1. Description

Overview

Figure 7 : General description of the generating set

1 Acces to maintenance area 4 Acces to control unit 2 Lifting ring 5 Acces to power connections 3 Forklift grooves 6 Drawbar

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Figure 8 : General description of the generating set (Continuation)

1 Protective grille 4 Alternator

2 Battery isolating switch 5

External fuel supply combined tap (optional)

3 Starter battery 6 Charging alternator

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Control

Figure 9 : General description of the generating set (control)

1 Control unit 4 Working hours counter 2 Emergency stop 5 Power circuit breaker 3 Socket control panel 6 Connection terminal block

Note : Photo presented with the Nexys control unit.

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2.2. Technical specifications

Range / Generating set type RENTAL POWER / R33C3

Weights and Dimensions

Dimensions with high autonomy tank

Dimensions l x w x h

2200 mm x 1000 mm x 1528 mm

Weight: 1100 kg à vide / 1300 kg en ordre de marche

Hood: M3127

Sound pressure level at 1 m

Measurement uncertainty : 0.66

Output

Voltage Hz Phase Load factor Max current (A)

400/230 50 3 0.8 48 26.4 / 33 24 / 30

(1) ESP: Stand-by output available for emergency use under variable charge up to 200hrs per year as per lSO 8528-1, no overload availabl

under these service conditions.

(2) PRP: Main output available continuously under variable load for an unlimited time peri od per year as per ISO 8528-1, an overload of 10

one hour every 12 hours is available, as per ISO 3046-1.

Term of use :

Standard reference conditions ESP/PRP 40° / 40°, Air Intlet Temp, 1000m / 1000m mA.S.L. 60 % relative humidity.

Engine data

Manufacturer / model MITSUBISHI S4S-Z361SD Type 4 Cycles Naturally aspirated Cylinder configuration 4 XL Cubic capacity 3.33 L Rotation speed 1500 Rpm Max emergency/prime power at nominal speed 31.3 / 28.3 kW Adjustment type Mechanical

Fuel consumption

100 % main power 8.60 L/h

Fuel

Fuel type Diesel High autonomy fuel tank 220 L

Lubrication

Oil capacity 10 L Min. Oil pressure 1 bar Nominal oil pressure 3.9 bar Oil consumption (100 % load) 0.08 L/h Oil sump capacity 9 L Type of lubricant Genlub

Cooling

Engine capacity with radiator 8.5 L Max coolant temperature 105 °C Fan power 0.8 kW Refrigerant type Gencool Thermostat 76.5 – 90 °C

: 72 dB(A)

Emergency

power

kW / kVA

Prime power

kW / kVA

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Alternator data

● Compliant with NEMA MG21 standards, UTE NF C51 111, VDE 0530, BS 4999, IEC 34.1, CSA

Type LEROY SOMER LSA42.2L9 Number of phases 3 Power factor (cos Phi) 0.8 Number of poles 4 Excitation type AREP Regulation R438 Number of bearings 1 Coupling Direct

Control unit(s)

NEXYS

● The alternator is protected against short circuits

● Vacuum impregnation, epoxy winding, IP23 protection rating

TELYS

Standard specifications

: Frequency meter, Voltmeter, Ammeter Alarms and faults

: Oil pressure, Coolant temperature, Fail to start, Overspeed, Alternator min/max, Fuel level low, Emergency shutdown Engine parameters

: Working hours counter, Engine speed, Battery voltage, Fuel Level, Air Preheating

Standard specifications: Voltmeter, Ammeter, Frequency meter Alarms and faults: Oil pressure, Water temperature, Start failure, Overspeed, Alternator min/max, Battery voltage min/max, Emergency stop Engine parameters

: Timer, Oil pressure, Water temperature, Fuel level, Engine speed, Battery voltage

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2.3. Identifying sets

Generating sets and their components are identified by means of identification plates.

The precise rules for identifying each major component (engine, alternator, etc.) are set out in each manufacturer's documentation contained in the appendices of this manual.

1 - Generating set

2 - Manufacturer name

3 - Model

4 - Serial number

5 - Year of manufacture

6 - Rated output (kVA and kW) according to the ISO

8528-1 standard

PRP: main power

ESP: emergency power

7 - Rated power factor

8 - Maximum altitude of the site above sea level (m)

for the rated power

Figure 10 : Example of a generating set identification plate

9 - Maximum ambient temperature for the rated

power (°C)

10 - Rated frequency (Hz)

11 - Generating set rotation speed (RPM)

12- Rated voltage (V)

13 - Rated current (A)

14 - Weight (kg)

15 - CE marking

16 - Non CE standard marking

(e.g.: GOSSTANDART)

17 - Sound pressure

18 - Sound power

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2.4. Fluid retention

Any outflow of the fluids contained in the generating sets (fuel, oil and coolant, or rainwater or condensation) will be collected in a retention container. The containers have a capacity which allows 110% of the fluids contained in the generating set fitted with this option to be collected.

Figure 11 : Fluid retention container

The generating sets are fitted with a visual alarm warning when the upper limit of the retention container has been reached.

In all cases, the retention containers must be regularly checked to ensure they contain no fluid (fuel, oil and coolant, or rainwater or condensation). If necessary, drain the containers via the drain port.

 Note: Never allow these fluids to drain onto the ground; ensure they are collected in a designated container.

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2.5. Fuels, lubricants and coolants

All specifications (product features) are given in the engine and alternator maintenance manuals attached to this manual.

In addition to these, we recommend the fuels, lubricants and coolants mentioned in the "Specifications" section.

2.5.1 Fuel specifications

General quality requirements

The quality of the fuel is essential for engine performance. It affects the technical performances such as the service life, power supplied and fuel consumption as well as the ability to respect the requirements issued by authorities relating to pollutant emissions. Only fuels which conform to the current legal requirements and national and international standards should be used. Consult the local fuel distributor to find out the characteristics of the diesel fuel available in the area.

Examples of standards and requirements:

EN 590

ASTM D 975 1-D and 2-D

European standard (CEN) for vehicle fuel - fuels for diesel engines (diesel fuel) requirements and test methods

American Society for Testing and Materials: basic requirement in the United States and Canada

JIS KK 2204 Japanese Industrial Standards: Japanese industrial standards

Respecting pollutant emissions

The certification measures confirming that the legal emission value limits are respected are performed with certified fuels which conform to the standards and requirements stated above.

Resistance to low temperatures

When the external temperature is low, the fluidity of diesel fuel may no longer be sufficient due to paraffin deposits. Also, in the winter in order to avoid malfunctions (for example, clogged filters), use diesel fuels which are fluid enough in cold weather.

The requirements to respect for the various geographical regions and various seasons (winter/summer) are specified in the standards and/or national regulations. Petrol companies should always supply fuels with the correct flow properties regardless of the time of year. In general, diesel fuel is treated with additives so that the fuel can be used at low temperatures in the region where it is marketed.

Treating fuel with additives must respect the engine manufacturer's recommendations and maintain a suitable lubricity for the injection systems. It is recommended to favour fuels whose additives have been added in a refinery over those modified in the storage tank.

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General specifications for diesel fuel

The fuel used must have the following characteristics (non-exhaustive list):

The sulphur content must meet the current emissions regulations in the region where the generating set is used.

For the United States and countries respecting the EPA regulation

Only use Ultra Low Sulphur Diesel (ULSD) fuel with a maximum sulphur content of 15 mg/kg for Interim Tier 4 and Tier 4 certified engines.

Sulphur content

For the European Union

Directive 2009/30/CE whose aim is to limit atmospheric pollution, imposes the use of a diesel fuel with a very low sulphur content of 10 mg/kg, for non road mobile machinery

In France, this obligation has resulted in the development of a diesel fuel called "off road diesel

fuel" or "GNR". The maximum admissible sulphur content is 10 mg/kg. However, member

states allow these diesel fuels to contain up to 20 mg/kg of sulphur when they are distributed to the final users. It is recommendable to avoid storing off road diesel fuel for long periods of time (over 6 months).

The viscosity and density directly affect the performance (power and fuel consumption), emissions and service life of the engine. A low level of viscosity and density reduces engine power and increases fuel consumption. Too high a level of viscosity and density seriously

Viscosity and

reduces the service life and operation of the fuel injection system.

density

In order to maintain adequate technical and environmental performance, the viscosity and density must conform to the specifications indicated in the manufacturer's instructions for the engines fitted to our generating sets.

Lubricity (or capacity for lubrication or oiliness)

In order to protect the fuel injection system against excessive wear, the fuel must have satisfactory lubricity (refer to the manufacturer's instructions for the engines fitted to our generating sets).

The ignition behaviour of diesel fuels is described by the cetane index. The cetane index is

Cetane index

important for emissions, the ability to start in cold weather and engine noises. The minimum technical requirements are 45.

The fuel and tank must not contain any water. Water causes the engine parts to corrode and

wear more rapidly, particularly the injection system parts. In addition, water promotes the Water and contaminants

growth of bacteria and fungi in the tank, which can clog the fuel filter. The fuel must not contain

any type of residue. Organic contaminants (bacteria, fungi, etc.) can block the fuel filters;

inorganic material in the fuel (dust, sand) can cause serious damage to the injection

equipment.

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2.5.2 Lubricant specifications

Essential for the correct operation of the engine. The oil should be selected according to its use. Besides the lubrication function, oil should also:

- cool certain parts;

- protect metal parts against corrosion;

- improve the sealing, in particular between pistons, piston rings and cylinders;

- remove impurities (to the filter).

It is recommendable to use a top of the range lubricant for diesel engines. The table below lists the oils recommended for each engine manufacturer.

Engine

Make Type Make Type

Cummins All GenPARTS GENLUB TDX 15W40

John Deere All

MTU All GenPARTS GENLUB TDX 15W40

Mitsubishi All GenPARTS GENLUB TDX 15W40

Fuel GenPARTS GENLUB TDX 15W40

Perkins

Gas MOBIL PEGASUS 705

Volvo All GenPARTS GENLUB TDX 15W40

Doosan All GenPARTS GENLUB TDX 15W40

Lombardini

All

Kohler

John Deere John Deere PLUS-50

GenPARTS GENLUB TDX 15W40

GenPARTS

or Kohler

GENLUB TDX 15W40 or Kohler 5W40,

according to the model of the engine

Viscosity

Viscosity is a measure of the flow resistance of a fluid. The viscosity of an engine oil is expressed by 2 SAE (Society of Automotive Engineers) grades. One grade for cold weather and one grade for hot weather. The grade for cold weather appears before the letter W.

The 1st grade represents dynamic viscosity in cold weather, namely the ability to start the engine and to prime the oil pump (and therefore to lubricate the various components quickly). The lower the number, the more fluid the oil.

The 2nd grade represents the kinematic viscosity in hot weather. The higher the number, the thicker the film of oil when hot (which aids protection and sealing). The lower the number, the less friction there will be in hot weather (it helps to save fuel).

In order to ensure immediate protection when starting the engine, the choice of viscosity grade when cold is essential. More fluid oil is quicker to flow when oil begins to circulate through the engine. It should be selected according to the ambient temperature. See the table below.

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Characteristics of GENLUB TDX 15W40 oil

Performance

GENLUB TDX oil is a 15W40 multigrade mineral oil which meets the following specifications: ACEA E3 and API CG-4.

ACEA E3: oil with superior viscosity stability, suited to extended oil change intervals and severe conditions of use.

API CG-4: oil particularly effective to meet the emissions requirements.

ACEA = European Automobile Manufacturers' Association API = American Petroleum Institute

Specifications

Specifications Units Grade SAE 15W-40

Density at 15°C kg/m3 883

Kinematic viscosity at 100°C mm2/s (cSt) 14

Viscosity index – 130

Flow point °C - 27°

Flash point °C >200

TBN* mgKOH/g 9.7

Typical values given for information purposes

* TBN (Total Base Number – degree of alkalinity): a measure of a lubricant's reserve alkalinity according to standard ASTMD 2896. This check makes it possible to assess the ability of the product to remain in service and to check the ’capacity of the lubricant to neutralise the acidity contained in the oil, which may corrode the metallic elements of the lubricated component.

2.5.3 Coolant specifications

The engine's internal cooling system allows the engine to operate at a precise temperature.

The table below lists the coolants recommended for each engine manufacturer.

Engine

Make Type Make Type

Mitsubishi LLC

Mitsubishi All

GenPARTS GENCOOL PC -26

MTU All GenPARTS GENCOOL PC -26

John Deere All GenPARTS GENCOOL PC -26

Volvo All GenPARTS GENCOOL PC -26

Doosan All GenPARTS GENCOOL PC -26

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Specifications of GENCOOL PC -26 coolant

Performance

GENCOOL PC -26 coolant is a ready-to-use cooling fluid which provides a high level of protection and is produced from an antifreeze approved by the majority of manufacturers (Power Cooling concentrated antifreeze).

It offers the following:

- Improved anticorrosion: improves the effectiveness and service life of the cooling system.

- High temperature feature: promotes heat exchange.

- Long-term protection: against overheating and corrosion under extreme conditions of use.

- Compatible with the original fluid (however, it is recommended to drain the entire cooling system when replacing the fluid).

Specifications

Specifications Units Characteristics

Density at 20°C kg/m3 1053 ± 3

pH pH 7.5 to 8.5

Alkalinity reserve ML ≥ 10

Boiling temperature °C 105 ± 2

Freezing temperature °C -26 ± 2

Typical values given for information purposes

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3. Transporting the equipment

3.1. Warnings concerning transport

It is prohibited to operate generating sets whilst they are being transported.

IMPORTANT

3.2. Preparing for transport

Before the equipment is transported, perform the following operations:

1. Close the tap on the oil top up tank outlet.

2. Fill up the oil top up tank with oil.

3. Fill up the crankcase with oil.

4. Fill up the on-board tank with fuel.

5. Check that the batteries are fitted and filled with electrolyte.

3.3. Road transport

3.3.1 Generating sets with and without an enclosure

Generating sets must be transported by road in accordance with the regulations of the countries concerned.

When transporting generating sets in containers by road, the following steps must be observed:

1. Put a plastic cover over non-enclosed generating sets during transportation.

2. Select transport equipment (trailer, semi-trailer, etc.) suitable for this usage and having all the safety guarantees in terms of load bearing capacity and of the securing devices.

3. Chock and fix the generating sets to the floor of the transport equipment.

4. Strap the generating sets to the transport equipment.

5. Select a transport route which makes it possible to travel on roads suitable for vehicles, and whose quality will not damage the on-board generating sets.

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3.3.2 Generating sets on trailers

3.3.2.1. Hitching and unhitching the trailer

Jockey wheel for M3126 and M3127 type trailers

Before hitching the trailer, check the hitching system on the towing vehicle; this must be perfectly compatible with the trailer.

Jockey wheel for

M3128

and M3129

type trailers

Towing a trailer with a non-compliant device (bar, cables, lashing, etc.) runs the risk of serious accidents.

IMPORTANT

Also check:

- That there are no incipient ruptures or significant wear on the hitching system.

- That the locking system is working properly.

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Hitching a trailer fitted with a hitching ring

1. Drive the towing vehicle or bring the trailer up to the hitching point, then:

- With the jockey wheel touching the ground, place the stabiliser (1) in the top position:

 Loosen the jaw of the stabiliser (2) with its lever;

 Raise the stabiliser fully;

 Tighten the jaw of the stabiliser (2) with its lever.

- Remove the wheel chocks if necessary and store them.

2. Position the trailer parallel to the ground using the guide wheel handle (jockey wheel).

3. Place the hitching ring above the towing vehicle's hitching system:

After this adjustment, the trailer must remain parallel to the ground.

Make any necessary height adjustments to the towbar using the jockey wheel to enable hitching.

IMPORTANT

- Remove the safety pin from the towbar (3);

- Undo the nut with the lever (4);

- Use the adjustable towbar handle to place the ring above the hitching system;

- Tighten the nut to lock the towbar;

- Fit the towbar safety pin.

4. Attach the ring to the hitching system:

- Lower the trailer by moving the jockey wheel away from the ground using its handle (5).

5. Lock the jockey wheel in the towing position:

When in the towing position, the jockey wheel must not:

- obstruct the unlocking cable's movement;

- trap any electrical cables.

IMPORTANT

M3126/M3127 type trailers

- Position the jockey wheel at the rear.

- Raise the jockey wheel with its handle (5) into the notches on its tube (6).

- Loosen the jaw of the tube (7) with its lever.

- Raise the tube fully.

- Tighten the jaw of the tube (7) with its lever.

M3128/M3129 type trailers

- Remove the safety pin from the position lock (8).

- Remove the position lock (8).

- Place the jockey wheel in the towing position.

- Fit the position lock (8).

- Fit the safety pin in the position lock (8).

- Raise the jockey wheel with its handle fully and at right angles to the towbar.

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6. Attach the unlocking cable to the hitching plate on the towing vehicle.

Examples of how to attach the hitching cable

If the hitching ring is not correctly connected to the hitching hook, the trailer will become separated from the

IMPORTANT

towing vehicle. In this case the unlocking cable actuates the parking brake (which then becomes an emergency brake).

To ensure that the device fulfils its function correctly, the unlocking cable:

- MUST NOT be wound around the jockey wheel, as this will disable emergency braking;

- MUST NOT be taut or obstructed, as this could activate emergency braking during towing;

- MUST be routed as straight as possible and not be obstructed at any point;

- MUST be sufficiently long to allow cornering.

7. Connect the electrical cable plug controlling the lamps, indicators, etc. to the socket on the towing vehicle.

8. Remove the parking brake:

- Remove the wheel chocks if necessary and store them;

- Perform the following operations simultaneously on the parking brake:

 Press the unlocking button (9);

 Lower the handle (10) fully.

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Unhitching a trailer fitted with a hitching ring

1. Immobilise the trailer:

- Chock the wheels;

- Apply the parking brake:

 Raise the parking brake lever (10) fully.

2. Disconnect the electrical cable plug controlling the lights, indicators, etc. from the socket on the towing vehicle.

3. Remove the unlocking cable on the towing vehicle.

4. Release the hitching ring:

M3126/M3127 type trailers

- Disengage the jockey wheel from the notches in the tube (6) with its handle (5).

- Loosen the jaw of the tube (7) with its lever.

- Lower the tube until the jockey wheel touches the ground.

- Tighten the jaw of the tube (7) with its lever.

- Support the load on the jockey wheel:

 Lower the jockey wheel with its handle;

 When you are sure that the wheel can bear the load (the towbar rises), unhitch the trailer from the vehicle.

5. Fit the stabiliser (1):

- Loosen the jaw of the stabiliser (2) with its lever;

- Place the stabiliser in contact with the ground;

- Tighten the jaw of the stabiliser (2) with its lever.

- Remove the safety pin from the position lock (8) on the jockey wheel.

- Remove the position lock (8).

- Place the jockey wheel in the bottom position.

- Fit the position lock (8).

- Fit the position lock pin.

- Lower the jockey wheel to the ground with its handle.

M3128/M3129 type trailers

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3.3.2.2. Check before towing

Before first use, it is essential to check the tightness of the wheel bolts.

IMPORTANT

Before towing, check the following:

- Wheel tightness.

- Hitching hook locked.

- Tyre pressure.

- Signalling lights working.

- Enclosure doors closed.

- Parking brake released.

- Guide wheels (jockey wheels) and stands lifted and locked.

- Safety cable fitted.

INFLATION PRESSURE (BAR) 145R13 2.2 185R14C 4.5 155 / 70R13 2.5 195R14C 4.5 185 / 70R13 2.5 215R14C 4.5 175R14C 4.5 215 / 75R14C 4.5

TIGHTENING TORQUE WHEELS Axis of 10 60 Nm Axis of 14 and 16 120 Nm

3.3.2.3. Operation

The driving speed must be suited to the condition of the road and the handling of the trailer.

Maximal speed on road: 140km/h.

Driving at high speed causes the tyres to heat; it is therefore important to stop from time to time and check them. Excessive heating may cause a puncture, and therefore a serious accident. For reversing manoeuvres, remember to lock the inertia brake.

Particular attention must be paid to the tightness of the wheels on new vehicles.

IMPORTANT

In the first few miles' driving, heating of the brake hubs and drums will actually reduce the wheel tightness. It is therefore essential to check the tightness every 6 miles (10 kilometres) until no further loosening is noted.

The tightness check must nonetheless be carried out whenever you have towed the trailer.

(

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Lights / signalling

Warning lights are obligatory for on-road driving. Signalling must comply with regulations in force in the country of use.

Red rear lights + direction indicators + stop lights

Rear reflective devices

red triangle)

Front reflective devices (white)

Side reflective devices (orange)

Figure 12 : Example of French signalling

3.4. Rail transport

3.4.1 Generating sets with and without an enclosure

Generating sets must be transported by rail in accordance with the specific rules governing rail transport.

When transporting generating sets in containers by rail, the following steps must be observed:

1. Put a plastic cover over non-enclosed generating sets during transportation.

2. Choose transport equipment appropriate for this usage, and having all the safety guarantees both in terms of load-bearing capacity and securing devices.

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3.5. Shipping

3.5.1 Generating sets with and without an enclosure

Transportation must be carried out in accordance with the rules of shipping. Generating sets must be transported in a shipping container.

When shipping generating sets in containers, the following steps must be observed:

1. Choose transport equipment appropriate for this usage, and having all the safety guarantees both in terms of load-bearing capacity and securing devices.

2. In the case of a grouped load container, SEI cases must be used for packing.

3.6. Air transport

Containers must be transported by air in accordance with the specific rules governing air transport.

The UN has classified generating sets as "dangerous goods" listed under UN code 3166 - class 9 - "Engine, internal combustion (flammable liquid powered)".

Any air shipment of generating sets must be subject to prior declaration to the air freight company, in accordance with form MOD3909.

For air transport, observe the following steps:

1. Choose transport equipment appropriate for this usage, and having all the safety guarantees both in terms of load-bearing capacity and securing devices.

2. For control boxes, packing in an SEI 4 C case (solid case with waterproof cover) is obligatory.

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4. Installation - Connections

4.1. Unloading the generating set

4.1.1 Choosing the location

When choosing where to site the generating set, bear in mind the:

- proximity to the electrical distribution panel;

- nuisance caused by the noise;

- fuel supply;

- burnt gas evacuation;

- direction of these gases and the noise generated.

1 m min.

Incorrect ventilation and exhaust Building or terrain too rough

Generating set incorrectly seated

Impossible to open enclosure doors Impossible to fill with fuel

Figure 13 : Examples of problems that may be encountered

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4.1.2 Safety during unloading

Always follow the safety instructions before unloading

IMPORTANT

- The lifting machinery or equipment is suitable for the work required and the weight of the generating set. This is indicated on the generating set's identification plate.

- The sling is correctly positioned in the central lifting eye or the lifting arms are correctly positioned in the fork-lift pockets intended for this purpose.

- The ground is able to bear the load of the generating set and its lifting machinery without stress (otherwise lay down stabilising beams of sufficient strength).

- The generating set is put down as close as possible to its place of use or transport, in a clear space with free access.

Example of equipment to be used:

 crane;

 slings;

 lifting beam;

 safety hook;

 shackles;

 Forklift truck.

4.1.3 Unloading the generating set

Before unloading or moving generating set, check that the handling equipment used is able to bear the weight of

IMPORTANT

the generating set (shown on the generating set's identification plate.

4.1.3.1. Slings

1. Attach the sling on the lifting equipment to the ring on the generating set (no. 1) provided for this purpose. Tension the slings slightly.

2. Check that the sling is correctly attached and the equipment is steady.

3. Lift the generating set carefully.

4. Direct the generating set towards the chosen location and stabilise it.

5. Carefully set down the equipment while continuing to position it.

6. Release the sling, then detach it.

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4.1.3.2. Fork lift truck

1. Position the arms of the forklift truck in the forklift pockets (no. 2).

2. Lift the equipment, handling it gently.

3. Set down the generating set in its unloading position.

Figure 14 : Points used for lifting and moving

4.1.4 Moving the generating set

Whenever moving the generating set, ensure suitable equipment is used (e.g. sling, forklift, etc.) and identify those parts on the generating set which can be used to move it:

- lifting eye (no.1);

- forklift grooves (no.2);

- tow bar (no.3).

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4.2. Connecting the generating set

4.2.1 Connection summary

This diagram can be used to retrace the different steps enabling the generating set to be correctly connected.

Identify the type of differential protection

TT earthing system

fitted on the generating set

"EDF application" option (France

onl

Fixed differential protection Adjustable differential protection

30 mA 30 mA 300 mA 300 mA

No operation required:

terminal circuits protected

Add differential protection

set to 30 mA to the terminal

circuit output(s)

Set the differential protection

of the generating set

No operation required:

terminal circuits protected

Add differential protection

set to 30 mA to the terminal

circuit output(s)

Earth the generating set

Connect the generating set to the installation

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4.2.2 Protecting people and equipment

4.2.2.1. Earthing system principle

The Earthing system, or SLT (formerly Neutral system) of the electrical installation defines the situation of the generating set neutral in relation to earth and the grounds of the electrical installation at the user end.

Our generating sets are designed to operate with the TT system (or EDF application depending on the option, for France only).

4.2.2.2. TT system

In the TT earthing system, automatic power cut-off via a Residual Current Device (RCD) is obligatory at the upstream part of the installation, to ensure that personnel are protected (additionally, a maximum 30 mA device must be installed on outlet circuits).

Ph 1

Ph 2

Ph 3

Neutral connected

to earth

Ground connected

to earth

Ph 1

Ph 2

Ph 3

Neutral earth

Ground earth

Equipment

Figure 15 : TT earthing system

The alternator neutral is earthed, the grounds of the user equipment have their own earth connection.

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4.2.2.3. Installing the differential protection

The generating set is equipped with a residual current device in order to guarantee individuals are protected from electric shocks with the TT system. This may be fixed ("vigi" unit) or adjustable (Resys) depending on the option chosen.

• If the generating set's residual current device is fixed and the activation threshold is set to 30 mA, it is guaranteed to protect people.

• If the generating set's residual current device is fixed and the activation threshold has been set at 300 mA, a 30mA residual current

device must be added to each of the circuit outlets in use.

• If the generating set's residual current device is adjustable, (located upstream) this must be above those devices located downstream (terminal circuits); this means that continuity on clean circuits will be maintained in the event of a fault on one of the terminal circuits (see the following point on setting the residual current device).

Example:

0.03A

30mA

0.3A

(300mA)

Residual current device Terminal circuit 1

0.03A 30mA

Risk of electric shock. The generating set's differential relay is factory-set with a current threshold of 0.03 A (30 mA) and with an automatic time delay (0 s). Any change to the setting on the residual current device could pose a risk to personal safety. The user will be held liable - any changes must only be made by trained, qualified engineers. If the setting is modified, it is essential to restore the original settings after use.

Generating set

Generating set's residual current device

Residual current device Terminal circuit 2

0.03A 30mA

Residual current device Terminal circuit 3

(1)

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4.2.2.4. Setting the generating set differential protection

The setting of the generating set's residual current device is guaranteed by a differential relay fitted near the control unit (type A / AC or B depending on the generating sets). As a result, two parameters relating to the downstream device (terminal circuit) must be set:

- Current threshold: the generating set's differential relay must be three times more sensitive than that of the terminal circuit.

- Time delay: the cut-off of the generating set's differential relay must be longer than that of the terminal circuit.

- Type A / AC differential relay:

 Use:

 Setting:

Differential relay for which operation is guaranteed:

• for residual sinusoidal alternating currents;

• for continuous pulsed residual currents;

• for continuous pulsed residual currents with a continuous component of 0.006 A with or without phase check,

independent of the polarity.

1. Use a screwdriver to set the current threshold potentiometer (1) to 0.03 A (30 mA).

2. Use a screwdriver to set the time delay potentiometer (2) to 0s (automatic).

3. Test the residual current device using the "Test" button on the relay (3).

Time setting potentiometer

Test Button

(3)

(2)

Current threshold potentiometer

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- Type B differential relay:

 Use:

Differential relay for which operation is guaranteed:

• as in the case of type A;

• for residual sinusoidal currents up to 1000 Hz;

• for residual sinusoidal currents superimposed on a pure continuous current;

• for continuous pulsed currents superimposed on a pure continuous current;

• for residual currents which could come from rectifier circuits i.e.:- three phase half-wave rectifier or a three-phase full-

wave bridge rectifier, full-wave bridge rectifier between phases, with or without phase angle check, independent of the polarity.

 Setting:

1. Use a screwdriver to adjust the current threshold using the setting potentiometer (1) and the micro-switches (4) to 0.03 A (30 mA).

2. Use a screwdriver to adjust the time delay using the setting potentiometer (2) and the micro-switches (4) to 0s (automatic).

3. Test the residual current device using the "Test" button on the relay.

DANGER

If the setting is modified, it is essential to restore the original settings after use.

Test Button

(3)

Sensitive area (4)

(white = position of micro-

switches)

Time setting

potentiometer (2)

Current threshold potentiometer

(1)

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4.2.2.5. Earthing the generating set

Risk of electric shock. Before use, the generating set must always be earthed. Protection against electric shocks is only effective once the earthing connection has been made.

DANGER

1. Open the door to the power section (no.1) then the access door to the cable router flap and to the connection terminal box (no.2).

Disconnect the battery leads, starting with the negative lead (-), or use the battery isolating switch before carrying out any operations on the generating set.

2. Connect the earth cable (supplied) to the terminal (rep.3) on the generating set located on the connection terminal box.

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3. Check the length of the earthing rod depending on the nature of the ground and adapt if necessary.

The equipment supplied is not suitable for

IMPORTANT

bare stony soils, dry sand or impermeable

rock.

4. Plant the earthing rod in the ground and connect it to the earth cable.

Nature of ground

Thick arable land, damp

compact backfill

Thin arable land, gravel, rough

backfill

Bare stony soils, dry sand,

impermeable rock

Length of earthing

rod (in metres)

4 or 4 x 1

Earth cable

ground

1 meter

Note: For the United States (National Electrical Code ref. NFPA-70), use a copper wire with a minimum cross-section of 13.3 mm² (or AWG 6 at most) connected to the generating set's earth connection and a galvanised steel earthing rod completely buried in the ground in an upright position. This earthing rod must be at least 2.5 m long (of which at least 1 m must be in the ground).

4.2.3 Making the connections

4.2.3.1. Connections - general information

When connecting, always comply with standard NFC 15-100 and the application guide NFC 15-401 (in France) or follow standards based on the international standard IEC 60364 (countries outside France). The cable cross-section and number of connection cables should be determined according to the type of connection cable and the current standards to be observed in the country of installation. The choice of connection cables must comply with international standard IEC 60364-5-52.

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4.2.3.2. Selecting the power cables

The calculation rules used to choose the power connection cable size are defined below:

- Identify the current shown on the generating set's identification plate.

- From the table below, select the circuit breaker rating directly above the current shown on the generating set's identification plate.

- Choose the corresponding cable size. .

Three-phase

Permitted drop in voltage = 5% / Multi-core conductors or connected single-core conductors where rating = 4X…(1) / Cable type PVC 70°C (e.g. H07RNF) / Ambient temperature = 30°C.

Circuit breaker

rating

(A)

0 - 50m 51 - 100m 101 - 150m

mm²/AWG* mm²/AWG* mm²/AWG* 10 1.5 / 14 2.5 / 12 4 / 10 16 2.5 / 12 4 / 10 6 / 9 20 2.5 / 12 4 / 10 6 / 9 25 4 / 10 6 / 9 10 / 7 32 6 / 9 6 / 9 10 / 7 40 10 / 7 10 / 7 16 / 5 50 10 / 7 10 / 7 16 / 5 63 16 / 5 16 / 5 25 / 3 80 25 / 3 25 / 3 35 / 2

100 35 / 2 35 / 2 4X(1X50) / 0 125 (1) 4X(1X50) / 0 4X(1X50) / 0 4X(1X70) / 2/0 160 (1) 4X(1X70) / 2/0 4X(1X70) / 2/0 4X(1X95) / 4/0 250 (1) 4X(1X95) / 4/0 4X(1X150) / 2350MCM 4X(1X150) / 2350MCM 400 (1) 4X(1X185) / 0400MCM 4X(1X185) / 0400MCM 4X(1X185) / 0400MCM 630 (1) 4X(2X1X150) / 2x 2350MCM 4X(2X1X150) / 2x 2350MCM 4X(2X1X150) / 2x 2350MCM

Single phase

Permitted drop in voltage = 5% / Multi-core conductors / Cable type PVC 70°C (e.g. H07RNF) / Ambient temperature =30°C.

Cable sizes

Circuit breaker

rating (A)

0 - 50m 51 - 100m 101 - 150m

mm²/AWG* mm²/AWG* mm²/AWG*

10 4 / 10 10 / 7 10 / 7 16 6 / 9 10 / 7 16 / 5

20 10 / 7 16 / 5 25 / 3 25 10 / 7 16 / 5 25 / 3 32 10 / 7 25 / 3 35 / 2 40 16 / 5 35 / 2 50 / 0 50 16 / 5 35 / 2 50 / 0 63 25 / 3 50 / 0 70 / 2/0 80 35 / 2 50 / 0 95 / 4/0

100 35 / 2 70 / 2/0 95 / 4/0 125 50 / 0 95 / 4/0 120 / 2250MCM

* : AWG. American Wire Gauge, American standard for electrical cables.

Cable sizes

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4.2.3.3. Connecting the generating set to the installation

Risk of electric shock.

Before use, the generating set must always be earthed . Protection against electric shocks is onl y effecti ve once the earthing connection has been made.

DANGER

1. Open the door to the power section (no.1) then the

access door to the power connection cable router flap and to the connection terminal box (no.2).

Disconnect the battery leads, starting with the negative lead (-), or use the battery isolating switch before carrying out any operations on the generating set.

2. Loosen the two knobs (no.3) of the power connection

cable router flap then slide the flap (no 4) towards the outside of the generating set.

3. Feed the power connection cables through the cable router flap.

Power cables

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4. Connect the power connection cables onto the bars (N/L0-L1-L2-L3 or N2-R2-S2-T2) using the terminals (no.5) or clamps (no.6).

5. Slid e the cable router flap towards the inside of the generating set until it makes contact with the power connection cables then retighten the two knobs; close the access door to the power section back up again.

6. Con nect the power connection cables to the installation to be powered ensuring the live and neutral wires are correctly connected.

Our generating sets are factory-set with a conventional direction of phase rotation. A

IMPORTANT

phase converter (not supplied) can be used to ensure correspondence of phases between the generating set and the installation..

N/L0

ou N2

L2 ou R2

L3 ou T2

Installation to be powered

(e.g.: cabinet, distribution

box, installation etc.)

To limit the risk of falls caused by obstacles on the floor, it is recommended to suspend cables and ventilation ducts. As necessary, ensure that cables which remain on the floor are protected by burying or covering them.

IMPORTANT

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4.2.3.4. Connecting the battery or batteries to the generating set

Always ensure that the polarities of the battery and starter motor correspond. Never swap the positive and

IMPORTANT

4.2.4 Overvoltage

Generating sets are not equipped with devices that protect against voltage surges from atmospheric discharges or due to handling operations.

negative battery terminals when connecting them. This could cause severe damage to the electrical equipment.

To connect the battery:

1. Connect the red connecting cable (+) to the positive battery terminal.

2. Then connect the black cable (-) to the negative battery terminal.

To disconnect the battery:

1. First disconnect the black cable (-)

2. Then disconnect the red cable (+).

The company disclaims all liability for any accidents caused by these phenomena.

However, it is possible to install surge protectors considering that this assembly does not provide complete protection.

5. Installation

5.1. Warnings concerning commissioning

The inspections referred to in this section enable the electrical generator set to operate. Specific skills are required to carry out these operations.

IMPORTANT

They must only be entrusted to personnel with the necessary skills.

Failure to follow these instructions in any way could result in malfunction or very serious accidents.

5.2. Checking the generating set installation

- Check the position of the generating set (stability, mounting, available space, ventilation, exhaust, etc.).

- Check the electrical connections :

 earthing;

 electrical control connections;

 electrical power connections;

 starter battery charging system (rating and voltage) if fitted to the generating set.

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5.3. Preparing for operation of the generating set

- Become familiar with the controls useful to operate the generating set.

- Read and understand the "user" menus of the control unit.

- Become familiar with the maintenance plans for the generating set .

- Become familiar with the operation of the generating set at no load or under load.

- Become familiar with the fluid specifications (fuel, lubricant and coolant).

5.4. Checking the generating set before startup

- Check that the plugs, blanking covers and protective adhesive strips have been removed.

- Ensure that the anti-humidity bags have been removed from the electrical sections (cabinet or control console, alternator, etc.).

- Check the insulation of the alternator see the alternator's maintenance manual.

- Check the levels see the engine's maintenance manual:

 coolant;

 oil;

 fuel.

- Open the oil filler tap (if fitted to the generating set).

- Check the starter battery or batteries (connecting and charge) see the paragraph entitled "Starter batteries".

- Check the starter battery charging system (if fitted to the generating set).

5.5. Checking the generating set after startup

Off-load tests

- Carry out the safety checks (emergency shutdown, oil pressure, coolant temperature, etc.).

- Check the mechanical parameters:

 engine parameters (oil pressure, coolant temperature);

 absence of abnormal vibrations;

 absence of abnormal noises;

 absence of leaks.

- Check the electrical parameters:

 voltage, frequency, current;

 rotating field.

On-load tests

- Check the mechanical parameters:

 engine parameters (oil pressure, coolant temperature);

 absence of abnormal vibrations;

 absence of abnormal noises;

 absence of leaks.

- Check the electrical parameters:

 voltage, frequency, current;

 rotating field.

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6. Using the generator set

6.1. Pre-Start Inspection

Inspecting the engine compartment

 Make sure there is no combustible material near the engine or battery. Also, check to

make sure that the engine and battery are clean. If combustible materials or dust are found near the engine or battery, remove them.

 Check the electrical wiring for such components as the starter and alternator for

looseness

 Check the entire engine for fuel leakage, engine oil or coolant. If leakages are found,

repair.

 Make sure the following valves, plugs and cocks are open or closed (tightened) properly:

 Fuel feed valve: Open  Coolant drain cock (plug): Closed (Tightened)  Oil drain valve: Closed

Checking the engine oil level

- Do not top up the oil if the oil level is not below the low level marker.

Important

 Pull out the oil level gauge and wipe it clean using a waste cloth.  Insert the oil level gauge fully into the oil level gauge guide, then pull out the gauge again.  The proper oil level is between the high and low marks on the oil level gauge. If the oil level is low, add engine oil of the specified

type.

 Install the oil filler cap after refilling.  Check the oil pan and other area for oil leakage.

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Checking the coolant level

Remove the radiator filler cap only after the engine has cooled to room temperature. Place a waste cloth over the cap, and loosen the cap about a half-turn or stand the lever to the upright position to release internal pressure. Never open the radiator filler cap while the engine is hot, otherwise the steam or hot

Warning

coolant spurts out and you may be scald with it.

 Open the radiator filler cap and check the coolant level.  If the coolant level is low, add coolant to the speci-fied level.  Check for leaks in the cooling circuit.

Checking the air filter

A clogged filter element limits the engine's air intake and a reduced air supply to the engine.

Important

If the air filter is fitted with a dust control valve (A), press the tip of the valve to evacuate any accumulated dust particles.

Check the air filter clogging indicator (B). If the indicator is red, clean the air filter.

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Checking the fuel pre-filter

The fuel is highly flammable and its vapours are combustible. The fuel pre-filter must only be bled when the engine is stopped and cold.

Danger

 Check that there is no water or sediment at the bottom of the pre-filter.  If necessary, drain the pre-filter using the following procedure:

 Place a suitable container under the drain plug prefilter  Undo the drain plug (A) at the bottom of the pre-filter by two or three turns.  Collect the water and/or sediment in the container.  When fuel starts to flow out, tighten the drain plug.  Check that there are no leaks.  If necessary, reprime the fuel circuit.

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6.2. Generator set with NEXYS control panel

6.2.1 Control panel presentation

Figure 16 : View of the front side

 Emergency stop button for switching off the generating set in the event of a fault which could endanger personnel or damage

equipment

 Key switch for starting up/shutting down the module and RESET function  Electronic card protection fuse  Screen-scroll button, press successively to access the various screens which are available  STOP button, press to switch off the generating set  START button, press to switch on the generating set  Normal operation LEDs and alarm and fault warning LEDs  Slot reserved for panel fascia options  Mounting bolt.  LCD for displaying alarms and faults, operating states, electrical and mechanical quantities

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1 2 3 4 5

Figure 17 : Description of the LEDs

A lit LED indicates:

 Module being supplied (green, lights up and remains lit)  Emergency stop activated (control panel or external emergency stop) (red, lights up and remains lit)  Visualisation of starting phase and speed/voltage stabilisation (flashing) and generating set operating OK or set ready to

generate (green, lights up and remains lit)

 General alarm (orange, flashing)  General fault (red, flashing).

6.2.1.1. Introduction to pictograms

The pictograms are as follows:

Operating temperature

Fuel

Overspeed

Non-starting fault

Starting on external command

Preheating

Air intake

Figure 18 : View of pictograms

 The "fuel level" pictogram is used to display the fault, the alarm and the fuel level.  The "operating temperature" and "oil pressure" pictograms are used to display the fault and analog value  The "overspeed" and "non-starting fault" pictograms are used to display the fault.  The "battery" pictogram is used to display the "alternator charge" fault and to indicate the battery voltage.

Oil pressure

Symbols for electric and mechanical sizes

Battery

Delay

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6.2.2 Manual starting

Check that the generating set circuit breaker has triggered.

Danger

 connect the generating set battery.  turn the key switch to the ON position (without forcing it)

 All of the LEDs light up for 2 seconds, to confirm that they are operating correctly.  If the LEDs do not light up, check the protection fuse and replace it if necessary.  All the items on the screen are displayed for 2 seconds.  Only the "ON" LED remains lit to indicate that the module is powered up.  The following screen appears.

The first line displays the motor speed in RPM. The second line displays the battery voltage in volts (V).

 Check the battery voltage (min. 12 V)

 Press (once briefly) the green "START" button.

 If the motor is equipped with an air preheating system, there is a 10-second delay before the motor starts (preheating

activation period).

 The following screen appears

The third line displays the air preheating time remaining (with pictograms representing a resistor and an hourglass).

 If the motor is not fitted with an air preheating system or once the preheating delay has elapsed, the engine starts up

(start of a cycle comprising 3 attempts to start up the engine).

 The following screen appears.

The number of successive and automatic starting attempts is limited to 3.

Warning

Note: the LED flashes as soon as the START button is pressed and continues to flash until the frequency stabilises if

a "measurements" card has not been inserted and until the frequency and voltage stabilise if a "measurements" card has been inserted.

Following stabilisation, the LED light comes on continuously.

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6.2.3 Switching off



trigger the circuit breaker located at the base of the centre console

 Let the motor run under no load for 1 to 2 minutes to allow it to cool.  press the "STOP" button to stop the generating set.  switch off the MICS Nexys module by switching the key to "OFF" (without forcing it).

6.2.4 Alarms and faults

The appearance of a fault or an alarm causes the following screen to be displayed (one or more pictograms or a fault code along with the SOS message are displayed).

The user can access the following screens by pressing the key

The fault or alarm screen will disappear once the fault or alarm has been removed. Only one fault is displayed on this screen (the fault which caused the generating set to stop). If one or more faults have appeared after the first fault, they can only be displayed after the first fault has been reset (press "Reset" as many times as the number of faults present). Note: an alarm can appear at the same time as a fault.

6.2.5 Faults and alarms - Details

List of faults which will cause the generating set to stop and generate a pictogram

Associated pictogram

Oil pressure fault: Indicates that the oil pressure is incorrect

Associated pictogram

Engine temperature fault: Indicates that the engine temperature is too high.

Associated pictogram

Non-starting fault: Indicates that there have been three consecutive unsuccessful starting attempts.

Associated pictogram

Overspeed fault: Indicates an excessive generating set running speed.

Associated pictogram

Low fuel level fault: Indicates the need to top up the fuel.

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List of faults which will cause the generating set to stop and generate a fault code

Associated message Low coolant level fault: indicates that the level of coolant is low in the radiator (linked to a two second time delay). Or Overload or short-circuit fault (optional): with the circuit breaker SD contact closing (overload or short-circuit), the generating set switches off immediately also causing the main circuit breaker to be triggered.

Additional fault linked to message opposite: is displayed in the following two cases:

 Differential fault (1)  insulation fault (2)

(1) Differential fault (optional): with a differential fault

causing the activation of the differential relay, the generating set stops immediately also causing the main circuit breaker to be tripped.

(2) Insulation fault (optional): with an insulation fault

causing the activation of the control unit performing insulation, the generating set stops immediately.

Underspeed fault: indicates an incorrect rotation speed (below 1000 rpm).

Emergency stop or external emergency stop fault

"STOP" fault activated if the "STOP" button is pressed whilst the "AUT" LED is flashing to indicate that the generating set is operating in automatic mode.

List of alarms associated with a pictogram

Low fuel level alarm: Indicates the need to fill up with fuel.

"Alternator charging fault" alarm indicates a problem affecting the alternator charging rate.

Associated message

Associated pictogram

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6.2.6 MURPHY diagnostic module

The fault finding module (MDDM) is an indicator for analysis and fault finding designed and manufactured for reading information available on the J1939 CAN Bus. The fault finding module is easy to use and will enable you to view the values of the various engine parameters and engine operating status codes. It shows two lines, each of 8 characters, on a backlit LCD display. Two scroll buttons enable you to navigate in the menus and parameters. Two LEDs, one red and one orange, indicate the fault or alarm status of the engine or ECU.

LED

DISPLAY

SCROLL BUTTONS

A- Machine Parameters

The following parameters are available on the Murphy fault finding module:

- working hours counter

- engine speed

- battery voltage

- engine speed

- coolant temperature

- oil pressure

- fuel economy

- air manifold temperature

- actual consumption

- active status codes

- status codes recorded coming from the engine

- MDDM20 parameter configuration for display

- display of the engine configuration parameters

-etc. depending on the type of engine.

B-Use

The Murphy module (MDDM) offers simple menu navigation:

1.To browse the list of parameters, press the Up and Down buttons.

2.To enter or exit a sub-menu, press both arrows simultaneously.

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The following diagram shows the structure of the main menu and how to go to each parameter:

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The Parameter menu: to navigate in this menu simply use the arrow buttons separately.

The sub-menus: The sub-menus are available at the end of the parameter menu. To go to these sub-menus, scroll through the

parameters using the ▲ and ▼ buttons until you reach the required sub-menu.

C- The Sub-menus.

The sub-menus enable certain aspects of the fault finding module display to be modified.

Changing the unit of measurement:

There are two display modes available for units: English or metric. To change your units of measurement, use the ▲ and ▼ scroll buttons until you get to the sub-menu:

Press the ▲ and ▼ arrows simultaneously if you want to retain the current designation.

Press one of the scroll buttons to show the second mode for displaying units. If you want to retain the second display mode, confirm this by pressing the ▲ and ▼ buttons simultaneously.

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D-Displaying the active service codes:

The fault finding module enables the machine faults and alarms to be displayed in real time. When a fault appears, the display shows the message "SrvcCode" every five seconds between displaying the current parameters.

The orange LED will light up when an alarm code is displayed (engine does not stop), the red LED will light up when a fault code is displayed. SPN and FMI codes are used in standard J1939 to identify faulty equipment SPN: Suspect Parameter Number. FMI: Failure Mode Indicator.

In the event that there are no active fault codes, the following screen will appear:

Depending on the SPN/FMI code, refer to the attached "List of engine fault codes" and "Engine user and maintenance manual" for help on fault finding and maintenance. Note that the manufacturer documents do not always stipulate the SPN used, for example:

-Volvo uses a set of codes called PID (Parameter Identifier) or SID (System Identifier); these two names relate to standards J1587 or J1979, but in the case of VOLVO engines they relate to standard J1587. These two codes find their equivalent in standard J1939 (SPN). The attached "List of engine fault codes" indicates the SPN equivalent to Volvo's SID and PID.

- John DEERE complies with standard J1939 and uses SPN codes.

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E-display of machine codes programmed:

The MDDM can display the codes of services programmed in the ECU memory. These programmed service codes are useful for generating set fault finding and maintenance. To display the programmed codes, scroll through the parameters until you reach the following sub-menus:

In the event that there are no programmed codes to display, the following screen will appear:

The purpose of programmed codes is to create a fault log, which is used to determine recurrent faults and thereby carry out effective corrective and preventive maintenance on the engine; also it not desirable to delete these when the generating set is in operation onsite. Note that at the test bench outlets the EEPROM memory, in which the programmed codes are stored, is reset to zero. The following diagram shows the structure of the STORCODE (programmed code) menu and how to go to each parameter:

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F)-Fault finding module internal errors.

Like any equipment using internal memory and a program, the fault finding module generates fault codes. Two types of code can be recognised:

- Address Claim Procedure Errors

- Run Time Bus Errors.

Address Claim Procedure Errors (ACP-Err):

The following fault codes relate to the switching on of the fault finding module.

Error Code 1:

When switched on, the fault finding module must issue a request to the ECU for the network addresses used in order to exploit them; this screen appears when:

- an address cannot be used.

- the fault finding module cannot find the default addresses.

- an address cannot be found in the correct register.

Error Code 2:

Passive Bus Error: this code appears when:

- the fault finding module cannot detect the ECU: in this case the CAN Bus is open.

- the CAN_hi and CAN_lo run time bus connection is reversed between the source (ECU) and the fault finding module.

Error Code 3:

This code is the result of the following problems:

- the CAN_Hi or CAN_lo bus, or both, are connected to an electrical ground or an external source of current.

- data is being not transmitted at a standard baud rate.

This type of fault generally requires repairs to be carried out on the CAN BUS connection and therefore involves work on the engine wiring harness, i.e. on the fault finding module extension.

Run Time Bus Errors:

Fault codes can only be active if the fault finding module has been able to obtain the network addresses when it was switched on, see Address Claim Procedure Errors (ACP-err).

Error Code 1:

EP=Passive Error, this screen appears when the fault finding module loses contact with the ECU, there may be two causes of this:

- one connector on the bus connection is disconnected.

- the CAN Bus is open.

Error Code 2:

BO=Bus Off, in this case, the case is identical to Error code 3 of the ACP.

Error Code 3:

BR=Bus Reset, this error code is similar to Error code 3 of the ACP, as are its causes. In this case the fault finding module has encountered problems on the CAN Bus and it tries to automatically re-establish the network connection.

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6.3. Generator set with TELYS control panel

6.3.1 Control panel presentation

6.3.1.1. View of the front panel

Figure 19 : View of the front panel

1 Emergency stop button (AU) for switching off the generating set in the event of a fault which could endanger personnel or damage

equipment.

2 Key switch for switching the module on/off. 3 Electronic board protection fuse. 4 Scrolling and selection wheel for scrolling through the menus and screens and selecting items simply by pressing the wheel. 5 STOP button, press to switch off the generating set. 6 START button, press to switch on the generating set. 7 Power ON LEDs and alarm/fault warning LEDs. 8 Location of USB ports. 9 Mounting bolt. 10 LCD for displaying alarms and faults, operating statuses, electrical and mechanical quantities. 11 ESC button: for returning to the previous selection and for default RESET function. 12 MENU button for accessing the menus. 13 Lighting for the emergency stop button.

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1 2 3

Figure 20 : Description of the LEDs

A lit LED indicates:

1 Alarm activated (flashing yellow). 2 Fault found (flashing red). 3 Module on (green, on continuously).

Figure 21 : Close-up of USB ports

1 USB key connection (HOST): file transfer between USB key and TELYS and vice versa. 2 Connection for microcomputer (DEVICE):

 file transfer between PC and TELYS and vice versa,  main module power supply.

3 Protective cover.

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6.3.1.2. Description of the screen

The screen is backlit and requires no contrast adjustments. This screen is divided into 4 zones.





SERIAL No.: 08030010000

SOFTWARE: 5.3.5

NOMINAL VOLTAGE: 400V

FREQUENCY: 50Hz NOMINAL KW: 320kW EARTH SYSTEM: TNS





Figure 22 : Description of the screen (example)

 Zone 1: in this zone, the status of the generating set is displayed  Zone 2: in this zone, pictograms relating to dimensions measured are displayed, as well as Alarm and Fault pictograms  Zone 3: in this zone, the measured values corresponding to the measured dimensions are displayed with the corresponding units

of measurement

Zone 4: in this zone, messages relating to the control of the generating set and the menus are displayed.

Note: the information displayed on measurements, alarms and faults as well as messages and menus relating to control of the generating set will depend on the equipment level of each generating set. Certain screens may therefore not be present.

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6.3.1.3. Description of the pictograms in zone 1

Zone 1 pictograms

Pictograms Display

Fixed TELYS in manual mode (MAN)

Flashing

"MAN" mode

"AUTO" mode

Fixed TELYS in automatic mode (AUTO)

Flashing

Flashing Genset starting

Fixed Genset started

ctivation conditions

For 5 seconds when switching from AUTO to MAN mode

For 5 seconds when switching from MAN to AUTO mode

Fixed

Genset stabilised (voltage and frequency)

Flashing (impression of constant movement from left to right)

The genset is generating and in use

Fixed Usage supplied

Not used

Fixed

Synchronisation

Flashing

Fixed Genset synchronised or coupled

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6.3.1.4. Description of the pictograms in zone 2

Alarm and fault pictograms in zone 2 All the pictograms in this zone are activated when TELYS is initialised.

Data displayed

Fuel level indicator

Alarm / Fault low fuel level

Alarm

Low level

fault

Min battery

voltage

(flashing)

Oil pressure

Alarm / Fault

Coolant level / temperature indicator

Alarm High temperature fault

High level fault alarm

Battery

Oil pressure / temperature indicator

High or low oil

level

Alarm /

Fault

Emergency stop

Emergency stop fault

Overload or short circuit

Tripping of circuit breaker following an overload

or short circuit

Engine speed

Alarm / Fault

high fuel level

Max battery voltage (flashing)

No preheating fault alarm

High or low oil

temperature

Alarm / Fault

Battery charge

indicator

(flashing bars)

Underspeed fault

Overspeed fault

Non-starting fault

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6.3.1.5. Description of the pictograms in zone 3

Zone 3 pictograms

All the pictograms for these zones are activated when the TELYS is initialised. The pictograms below are shown for information only.

Generating set stopped

Screen No. Pictograms Data displayed

Fuel Level Indication

High-temperature (HT) coolant temperature indication (units as per settings menu)

Genset start-up or genset started or genset stoppage in progress

Screen No. Pictograms Data displayed

Battery Voltage indication

Oil Temperature Indication (units as per settings menu)

Engine Speed Indication

High-temperature (HT) coolant temperature indication (units as per settings menu)

Oil Pressure Indication (units as per settings menu)

Oil Temperature Indication (units as per settings menu)

Genset started

Screen No. Pictograms Data displayed

Fuel Level Indication

Alternator Compound Voltage Indication

Operation

default screen

Total Active Power Indication

Alternator Frequency Indication

Alternator U12 compound Voltage Indication

Alternator U23 compound Voltage Indication

Alternator U31 compound Voltage Indication

Alternator Frequency Indication

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Screen No. Pictograms Data displayed

Alternator V1 single Voltage Indication

Alternator V2 single Voltage Indication

Alternator V3 single Voltage Indication

Alternator Frequency Indication

Alternator U12 compound Voltage Indication

Alternator V2 single Voltage Indication

Alternator V1 single Voltage Indication

Alternator Frequency Indication

Alternator V1 single Voltage Indication

Alternator phase 1 Current Indication

Alternator Frequency Indication

Alternator phase 1 Current Indication

Alternator phase 2 Current Indication

Alternator phase 3 Current Indication

Alternator Neutral Current Indication

Total Active Power Indication

Total Reactive Power Indication

Total Apparent Power Indication

Total Output Factor Indication (inductive or capacitive)

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Screen No. Picto

P10

P11

Order of appearance of screens based on the type of network with the genset started.

Type of line

Order of appearance 3P+N 3P 2P+N 1P+N

P3 if genset started

P11 if genset

coupled

2 P4 P4 P6 P7 3 P5 P8 P8 P9 4 P8 P9 P9 P2 5 P9 P2 P2 P10 6 P2 P10 P10 7 P10

The screen is changed using the scrolling and validation wheel. When the wheel is turned clockwise, the screens scroll upwards and backwards. The screens scroll in a loop. Example: in a 3P+N network after screen 7, then screen 1 and in reverse.

rams Data displayed

Fuel Level Indication

Battery Voltage indication

Battery Ammeter Indication

Total Reactive Power Indication

Alternator U12 compound Voltage Indication

Total Active Power Indication

Alternator Frequency Indication

P3 if genset

started

P11 if genset

P3 if genset started

P11 if genset

coupled

P3 if genset started

P11 if genset

coupled

6.3.1.6. Display of messages in zone 4

The graphic zone (zone 4) is used to display messages relating to the generating set's operation. These messages are as follows:

Initialisation of the TELYS

Screen No. Screen Data displayed

G 1

G 2

SERIAL No.: 08030010000

SOFTWARE: 6.1.0

NOMINAL VOLTAGE: 400V

FREQUENCY: 50Hz NOMINAL KW: 320kW EARTH SYSTEM: TNS

Initialisation of the TELYS when switching on and/or when loading a configuration

Generating set serial number TELYS software version Alternator nominal voltage Alternator nominal frequency Nominal active power Neutral speed Bar graph indicating the screen display time

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Generating set stopped

Screen

No.

G 3

G 4

Screen

No.

G 5

Screen Data displayed

MANUAL

OPERATION

Press START

to start

24/08/2005 13:12

AUTOMATIC OPERATION

IMPORTANT

IMMEDIATE START-UP

POSSIBLE

24/08/2005 13:12

Screen Data displayed

IMPORTANT

AUTOMATIC starting

19min30

24/08/2005 13:12

Operation mode - genset in MAN mode ready to start Date and time (depending on settings)

Operation mode - genset in AUTO mode ready to start Date and time (depending on settings)

Operation mode - genset in AUTO mode with programmed start Countdown of micro disconnection delay OR EJP (for France only) Date and time (depending on settings)

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Generating set start-up

Screen

No.

G 6

G 7

Generating set started

No.

G 8

Default

screen

G 9

een

Screen Data displayed

STARTING

IN PROGRESS

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AIR PREHEATING

10sec

24/08/2005 13:12

Screen

AVAILABLE POWER

75%

24/08/2005 13:12

AUTOMATIC STOP

IN PROGRESS

LOAD SUPPRESSION

1min30

24/08/2005 13:12

Operating phase - genset starting Date and time (depending on settings)

Operating phase - air preheating prior to genset starting Countdown of the air preheating delay Date and time (depending on settings)

Data displayed

Operating phase – genset operating – stable voltage and frequency Available power Date and time (depending on settings)

Operation mode - operation in AUTO mode Power supply device opens (motorised circuit breaker or changeover switch controlled by the TELYS) Countdown of the Mains Return delay OR Test on load delay Date and time (depending on settings)

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Screen

No.

AUTOMATIC STOP

G 10

24/08/2005 13:14

G-10/1

24/08/2005 13:14

POWER TRANSFER

Grid

G-10/2

Screen

IN PROGRESS

COOLING

1min30

COUPLING

IN PROGRESS

Generating set

Data displayed

Operation mode - operation in AUTO mode Genset cooling in progress Countdown of the Engine Stop delay (cooling) OR Gradual Stop delay (Water temperature) OR Overload Gradual Stop delay OR No Load Test delay Date and time (depending on settings)

Operation mode - operation in AUTO mode Synchronisation of the genset with the grid or another genset Date and time (depending on settings)

Operation mode - operation in AUTO mode Transfer of power from the generating set to the grid Date and time (depending on settings)

G-10/3

24/08/2005 13:16

POWER TRANSFER

Grid

Generating set

24/08/2005 13:16

Operation mode - operation in AUTO mode Transfer of power from the grid to the generating set Date and time (depending on settings)

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Generating set stoppage

Screen

No.

G 11

Change of operation mode (switch from MAN mode to AUTO mode when an automatic start demand is issued)

Screen

No.

G 12

Generating set stop demand if a fault occurs or if STOP is pressed in AUTO mode

Screen

No.

G 13

G 13/1

Screen

STOPPAGE

IN PROGRESS

24/08/2005 13:16

Screen

AUTOMATIC start demand

Do you want to switch

to AUTO mode?

IMPORTANT

Immediate start

OK Esc

Screen

MAN mode

activated

Do you want to switch

to AUTOMATIC mode?

OK Esc

The "

51 Hz

" offset

must be applied to

all of the power plant's

gensets

Esc

Data displayed

Genset stoppage Date and time (depending on settings)

Data displayed

Operation mode - operation in MAN mode AUTOMATIC start demand

Data displayed

Operation mode - operation in AUTO mode (genset running) Warning message for switch to MAN mode if STOP is pressed or if a fault occurs

Operating phase – genset operating – stable voltage and frequency Warning message for setting offset on all of the power plant's generating sets

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6.3.2 Starting

Check that the generating set circuit breaker has triggered.

Danger

 Connect the generating set battery  Turn the key switch to the ON position (without forcing it to the ON position), the ON lamp will light up (if the lamp does not

light up, check and replace the fuse if necessary)

 Test the Alarm and Fault LEDs (menu 15 – TEST LAMPS)

11 MANUAL <> AUTO 12 CONTROL LOAD

13 TEST GENERATING SET

14 PROGRAMS

 Press "Esc" several times to return to the following home menu

24/08/2005 13:12

Check the battery voltage  Press START:

24/08/2005 13:12

 If the engine is equipped with an

air preheating system, there is a delay (adjustable) before the engine starts (preheating activation period).

 If the motor is not fitted with an

air preheating system or once the preheating delay has elapsed, the engine starts up (start of a cycle comprising 3 attempts to start up the engine).

1 ACTIONS

1/5

15 TEST LAMPS

12 OK Esc

OPERATION

MANUAL

Press START

to start

AIR PREHEATING

10 seconds

24/08/2005 13:12

Warning: the number of successive and automatic starting attempts is limited to 3.

The following pictogram will flash

START-UP

IN PROGRESS

AVAILABLE POWER

24/08/2005 13:12

100.0%

The following pictogram is displayed

The following information is displayed

Speed of rotation

Coolant temperature

Oil pressure

Options

Oil Temperature

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6.3.3 Switching off

 Open the circuit breaker

 manually OR  by selecting menu 12 "CONTROL LOAD"

The following display will disappear (supply stopped)

 Press the STOP button

 The following screen is displayed and the generating set will stop

IN PROGRESS

24/08/2005 13:12

 Switch TELYS off by turning the key to "OFF" (without forcing it to the "OFF" position).

6.3.4 Alarms and faults

OFF

6.3.4.1. Viewing alarms and faults

Alarms and faults are displayed as follows:

 Alarms

All alarms will cause:

 the yellow LED to flash "General alarm".

In conjunction with this LED:

 a flashing pictogram

representing the circuit affected by the alarm and the associated indicator

(example)

appears on the LCD screen

, if present

 message on graphic display (example)

FAULT

ALARM

Low Fuel Level

25/12/05 15:30

OK=HELP

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 Faults

All faults will cause:

 the generating set to stop: immediate or gradual stop (coolant temperature and overload or short circuit)

 the red LED to flash "General fault".

In conjunction with this LED:

 a flashing pictogram appears on the LCD screen

representing the circuit affected by the fault and the associated indicator, if present

(example)

Faults have priority over alarms. Faults are displayed in the descending order of their appearance (from the most recent to the oldest).

 message on graphic display (example)

FAULT

Oil Pressure

25/12/05 15:30

OK=HELP

6.3.4.2. Activation of an alarm or fault

The appearance of an alarm or a fault causes the corresponding screen to be displayed (examples below)

FAULT

ALARM

Low coolant Level

06/10/06 10:30

OK=HELP

Press OK (on the scrolling and selection wheel) to access the help message if it is available (example below)

HELP

FAULT

Emergency Stop

06/10/06 15:30

Esc=RESET OK=HELP

Check the level

fuel

Esc=EXIT

If the alarm is no longer active, it is reset automatically (cause disappears). Press Esc to reset a fault:

- reset acknowledged if the cause of the fault has been removed

- reset not performed if the cause of the fault is still present.

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6.3.4.3. Activation of an alarm and a fault

The appearance of an alarm and a fault causes:

 The yellow and red LEDs to flash  the related screen to be displayed (example below)

FAULTS 1/2

FAULT

Emergency Stop

25/12/05 15:30

If several faults are present, the number of faults is displayed at the top of the screen.

Esc=RESET OK=LIST

The faults list can be accessed by pressing OK (of the scrolling and selection wheel) (examples below)

FAULTS

1/2

FAULT 25/12/05 15:30 Emergency Stop

ALARM 25/12/05 15:30

Press Esc to return to the previous screen. Press OK to go to the HELP screen (help on the highlighted fault) Use the scrolling and selection wheel to scroll through the list of faults.

Low Fuel Level

12 OK=HELP Esc

HELP

Check:

- Emerg. Stop Pos.

- Connector(s)

Esc

If the alarm is no longer active, it is reset automatically (cause disappears). Press Esc to reset a fault:

- reset acknowledged if the cause of the fault has been removed

- reset not performed if the cause of the fault is still present.

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6.3.4.4. Engine fault codes display

Certain alarms and engine faults generate specific fault codes. These codes are standardised according to the J1939 and/or J1587 standards.

Terminology used by the SAE CAN J1939 standard

SPN: Suspect Parameter

Number

FMI: Failure Mode identifier

Terminology used by VOLVO

SID: System Identifier

PID: Parameter Identifier

This represents the system or component at fault, for example: SPN 100, indicates an oil pressure problem or a problem with the oil pressure sensor.

This represents the type of fault that has occurred. This may be an electrical, mechanical or equipment fault.

This term, used in the J1587 standard, has an equivalent in the J1939 standard (SPN). However, this term corresponds, more particularly, to an assembly of components, for example, the injection system.

This term, used in the J1587 standard, has an equivalent in the J1939 standard (SPN). However, this term corresponds, more particularly, to a specific component, for example, a sensor.

This term, used in the J1587 standard, has an equivalent in the J1939 standard

PPID: Parameter Identifier

(SPN). PPID corresponds to PID, but is only used by VOLVO.

This represents the type of fault that has occurred. This may be an electrical,

FMI: Failure Mode identifier

mechanical or equipment fault. VOLVO uses a SID-FMI or PID-FMI or PPID-FMI combination.

Terminology used by JOHN DEERE

SPN: Suspect Parameter

Number

FMI: Failure Mode identifier

This represents the system or component at fault, for example: SPN 100, indicates an oil pressure problem or a problem with the oil pressure sensor.

This represents the type of fault that has occurred. This may be an electrical, mechanical or equipment fault.

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In the event of a fault, the screen will display the following message:

ENGINE GENERAL 110 18

For JOHN DEERE (JD) and VOLVO (VO) engines, the codes displayed are SPN and FMI codes.

FAULT

ALARM

25/12/2005 15:30

OK=HELP

Engine fault code Pressing OK will display fault finding information. In addition, appendix D indicate the meaning of the code. The checking and maintenance operations to carry out in order to solve the fault are included in the user and maintenance manuals of the engines supplied with the generating set documentation.

6.3.4.5. Horn reset

Depending on the settings made (menu 363 - HORN), the activation of an alarm and/or a fault leads to the horn sounding and the following screen appearing:

HORN STOP

PRESS OK

This screen will display first any messages relating to the alarms and faults that appear as soon as OK is pressed.

25/12/2005 15:30

7. Maintenance schedule

7.1. Reminder of use

The maintenance interval frequency and the operations to be carried out are outlined in the maintenance schedule, given as a guideline. N.B. the environment in which the generating set is operating determines this schedule. If the generating set is used in extreme conditions, shorter intervals between maintenance procedures should be observed These maintenance intervals only apply to generating sets running on fuel, oil and coolant which conform to the specifications given in this manual.

7.2. Maintenance safety instructions

Before each operation, please observe the following maintenance safety instructions:

 read the safety instructions carefully (chapter 1),  refer systematically to the maintenance instructions,  the battery isolating switch must be in the open position,  no operations must be carried out while the motor is running,  wear protective equipment (gloves, goggles, safety shoes etc.),  before operating on a pressurised circuit, ensure that the circuit pressure has been reduced (atmospheric pressure),  after the operations, ensure that the equipment is clean, or clean it if necessary.

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7.3. Table of maintenance operations

10 h

OPERATIONS

250 h 500 h 1000 h 1500 h 3000 h 2 years

Daily

Generator set

• Check the general condition

• Check the tightening torques

• Check the absence of leaks

• Check the condition of battery charge

• Clean the battery terminals

• Check condition and connections of

electrical equipment

• Clean with compressed air the relays and contactors

●

Engine

• Check engine oil and coolant level

• Check fuel filter / Water bowl

• Check air cleaner

• Replace engine oil and oil filtera

• Inspect belt and adjust and belt tension

• Check and Clean radiator fins

• Add grease to link joints, etc.

• Replace fuel filter (in-line type fuel injection

pump)

• Inspect valve clearance

• Check glow plug

• Inspect starter

• Inspect alternator

• Retighten bolts and nuts on the enginea

• Clean nozzle tip

• Check and Clean fuel injection nozzle

• Inspect turbocharger

• Change coolant

●

Alternator

• Check the tightening torques

• Check the general condition

• Check the various electrical connections of

After the first 20 hours

the installation

• Grease the bearings

After the first 50 service hours for a new or overhauled engine

20 000 h

3 years

●

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7.4. Cover maintenance

IMPORTANT

Users must maintain the enclosures and base frames to ensure that the paintwork retains all its protective properties.

The sealing between the cover and the frame and between the frame and the retention tank is ensured by a gasket. It is essential to replace the gasket if the cover has been removed.

7.5. Trailer maintenance

Frequency

Operations

General condition of the vehicle Tyre pressure Tighten the wheel nuts Efficiency of the automatic brake Efficiency of the parking

Check

Lubricate

Lubricate or grease the moving parts on the coupling device (see lubrication point examples in the Figure 23).

 Recommended lubricant: general purpose grease compliant with DIN 51825 KTA 3KA.

brake Braking adjustment and distribution across all wheels Wear on brake linings and drums No play in the hubs Play in the clamping tube Play in the ball socket or ring Braking control hinges and joints Stabilising

Figure 23 : Trailer lubrication/greasing points

When commissioning

and before towing



 

Every 6 months Every year

 



  

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7.6. Fault finding

Refer to the user manual and engine and alternator maintenance manuals appended. Additionally, in the event of an abnormal rise in engine temperature, check that the radiator is clean.

7.7. No load and under load tests

Notes on operation at no load and under load: When operating at no load or low load (< 30% of nominal power), the operating conditions do not allow optimum running of the engine. The main causes are as follows:  The low volume of fuel burned in the combustion chamber leads to incomplete combustion; the resulting thermal energy means that

the optimum engine operating temperature cannot be reached.

 Overheated engines have lower compression ratios (low compression ratio without turbocharging), which are defined for full load

and not suitable for good combustion at low load.

All of these factors lead to choking of the engine, in particular the piston rings and valves, which leads to:

 Accelerated wear and glazing of the cylinder liners  Loss of sealing of seats, and sometimes sticking of valve stems.

Consequently, operating any turbocharged engine at low load (< 30%) can only have adverse repercussions on an engine's operation and its service life. Maintenance intervals will have to be shortened to accompany harsh operating conditions. Shortening draining intervals, among other things, will enable you to change the oil more frequently, which will tend to be choked with unburnt particles and contaminated with fuel. Adding a load bench is generally used to limit low load phases, and obtain the periodic full loads necessary to unchoke the engine. Finally, when operating under load, we advise vigilance towards the oil breather circuit, and more particularly towards engines which have the crankcase vent connected to the turbocharger inlet (risk of oil or oil vapour absorption and accelerated engine speed).

On load tests: It is recommended to conduct an on load test on the generating set monthly, for a period of around 1 hour after stabilisation of the parameters. The load must be greater than 50% of nominal power (ideally 80%), to ensure unchoking of the engine and to obtain a decent picture of the generating set operation.

Off load test (no load): This test is not recommended; it must not exceed 10 minutes, and must not be repeated without a monthly on load test. This test only allows you to check for correct engine start-up. It does not allow you to check that the generating set is working properly.

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8. Starter batteries

DANGER

Risk of explosion or fire (oxygen and hydrogen present). The battery must never be

exposed to any naked flames or sparks.

Risk of sparks forming and an explosion. When fitting the battery, never invert the polarities. Do not short the battery terminals with a tool or other metal object.

Risk of injury. Battery electrolyte is extremely corrosive. Always protect your eyes, skin and clothing when handling batteries. Always wear protective goggles and gloves. In the event of contact with the skin, wash thoroughly with water and soap. If the eyes are splashed, rinse thoroughly with water and consult a doctor immediately.

8.1. Checking the electrolyte level

The electrolyte level must be approximately 10 mm above the battery plates.

1. Top up with distilled water if necessary.

2. Pour the distilled water carefully to avoid any splashes.

Wear protective goggles and rubber gloves when handling the battery (adding water, charging, etc.).

Note

: some batteries requiring no maintenance form the subj ect of specific instructions

which must be respected.

After the battery has been topped up, it must be recharged for at least 30 minutes.

8.2. Checking the voltage/acid density

Every 2 months, the following checks must be performed:

1. Check the density of the acid contained in the cells (all the battery cells must have the same density; if this is not the case, the battery must be replaced)

2. Check the voltage when idle.

Acid density Charge status Voltage when idle Observation / action

1.27 100% Above 12.60 V

1.25 80% 12.54 V

1.20 60% 12.36 V

1.19 40% 12.18 V

1.13 20% Below 11.88 V

From 60% recharge

Risk of sulphation

Unusable

The results of the density and voltage measurements make it possible to define the charge status of the battery. If the charge status is less than 60%, the battery must be recharged.

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8.3. Charging the battery

Highly discharged or sulphated batteries (formation of whitish lead sulphate deposit on the plates, which becomes hard) can no longer regenerate or be charged in a generating set.

A discharged battery should be recharged immediately, or else it will suffer irreparable damage.

IMPORTANT

Battery charge

Example of charge:

- 12V 60 Ah battery = 6 A charging current;

- Charge status: 50% (acid density 1.19 and voltage when idle 12.30V);

- The battery is short 30 Ah, and this must be recharged.

- Charge factor: 1.2;

- 30 Ah x 1.2 = 36 Ah to be charged;

- Charging current: 6A, approximately 6 hours charging required; the charging current must always be 1/10

of the nominal capacity of the battery.

Recharging is complete when the battery voltage and the acid density stop increasing.

The power of the charger must be suitable for the battery to be charged and the charging time available.

: if several batteries connected together are being recharged, the following points must be checked:

Note

- Are the batteries connected in series?

- Is the voltage chosen exact? 1 battery x 12 V, 3 x 36V batteries.

- Adjust the charge current to the lowest battery.

- The power difference between the batteries must be as low as possible.

8.4. Cleaning the battery

Keep the batteries clean and dry. The presence of impurities and rust on the battery and terminals may cause the current jumps, voltage drops and the battery to discharge, particularly in humid weather.

1. Clean any signs of oxidation on the battery terminals and the cable terminals using a brass brush.

2. Fully tighten the cable terminals and lubricate them with grease for battery terminals or vaseline. A terminal which is not secured correctly may cause sparks and therefore lead to an explosion.

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8.5. Fault finding

Fault observed Probable origin Measures or observations

The acid heats up when a new battery is filled

The acid escapes through the filler holes

Acid level too low

Acid level too low Incorrect operation from start-up

Acid density too high

Starting problems Starting test incorrect

Battery terminals melted

One or two cells release a lot of gas at high charge

The battery discharges very quickly

Short service life

High water consumption

The battery explodes

Incorrect composition Incorrect storage Prolonged storage in a damp place

The battery is too full

Battery tray not leaktight Considerable formation of gas due to a

very high charging voltage

Insufficient charge Short circuit in the power circuit Consumption fault

The battery has been filled with acid instead of water

Battery empty

Battery exhausted or faulty Capacity too low Battery sulphated

Incorrect electrical connection Battery cabling incorrect

Faulty cell(s)

Charge status too low

Short circuit in the power circuit High self-discharge (for example:

through electrolyte contamination) Sulphation (storage of discharged

battery)

Incorrect battery part no

Repeated deep discharging Battery stored too long without charge Overload Charging voltage too high Sparks after battery charging Short circuit Connection or disconnection during

charging Internal fault (for example: interruption)

and low electrolyte level

Cool

Charge the battery

Check the acid density

Reduce the battery fluid level

Replace the battery

Check the charger and repair if necessary

Recharge the battery

Check the electrical installation

Reduce the acid level and fill with distilled water. Repeat the operation if necessary

Recharge the battery

Replace the battery

Tighten the ends of the battery cables or replace them if necessary and replace the battery

Replace the battery

Check the load

Replace the battery

Define the correct battery part no. for the recommended use

It is recommended to charge the battery using a regulator

Check the charger (voltage regulator).

Replace the battery

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9. Options

9.1. Dual frequency

This operation must be carried out by a qualified electrician. These operations must only be carried out when the generating set is stopped, until you are instructed to start up the generating set.

IMPORTANT

• Close the battery isolating switch to turn on the TELYS 2.

• Turn the supply switch of the TELYS 2 to the "ON" position.

• Press the "MENU" key.

• Using the knob, select "3 SETTINGS" and press the knob to

confirm.

12 OK Esc

MENUS

3/4

1 ACTIONS 2 INFORMA TION

3 SETTINGS

4 COUNTRY

89/242

• As not all the settings are available, go to the "37 INSTALLER ACCESS" menu to enter the code "1966" using the knob to call up the desired menus.

• Using the knob, select "34 50Hz<>60Hz" and press the knob to confirm.

• Select and confirm the desired frequency using the knob to scroll and confirm (50 Hz or 60 Hz).

• Return to the "3 SETTINGS" screen and use the knob to select "35 NOMINAL VOLTAGE" then press the knob to confirm.

• Set the desired voltage then confirm using the scroll and confirm knob.

34 50Hz <> 60Hz 35 NOMIN AL VOLTA GE 36 PARAMETERS

37 INSTALLER ACCESS

3 SETTINGS

4/7

12 OK Esc

INSTALLER ACCESS

Enter password

* * * *

12 OK Esc

31 COMMUNICATION 32 FRE QUENCY 33 VOLTAGE

34 50Hz <> 60Hz

35 NOMIN AL VOLTA GE

36 PARAMETERS 37 INSTALLER ACCESS

3 SETTINGS

2/2

12 OK Esc

50Hz <> 60Hz

NOMINAL VOLTAGE

Min.: 38 0

Max.: 480

12 OK Esc

50Hz

12 OK Esc

400

3 SETTINGS

4/7

Vac

90/242

• Select the desired configuration using the configuration option selector located next to the TELYS 2 control unit.

• Start up the generating set by pressing the "START" button.

Configuration selector

• Adjust the voltage after starting up the generating set using the 2003R08 potentiometer.

Potentiometer

Warning: when switching to 60Hz, do not use sockets if fitted to the generating set.

IMPORTANT

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9.2. Neutral system

Turn the switch to the desired neutral system.

Select the neutral system with the generating set switched off.

Important

9.3. Fuel supply valve

The 3-way valve is used to select between the generating set fuel tank and an external fuel supply.

EDF

Valve in vertical position (no. 1): generating set supplied by the daily service tank. Valve in horizontal position (no. 2): generating set supplied by the external tank.