SDMO R 340 U, R570U User And Maintenance Manual

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User and maintenance manual

for generating sets

R34

33504081101NE_0_1

CALIFORNIA

Proposition 65 Warning

Diesel engine exhaust and some of its

constituents are known to the State of

California to cause cancer, birth

defects, and other reproductive harm.

If this product contains a gasoline engine

WARNING

The engine from this product contains

chemicals known to the State of California to

cause cancer, birth defects or other

reproductive harm

The state of California requires the above two warnings.

1. Preface ............................................................................................................................................................................................ 3

1.1. General recommendations ................................................................................................................................................. 3

1.2. Pictograms and their meanings .......................................................................................................................................... 4

1.3. Instructions and safety regulations ..................................................................................................................................... 8

1.3.1 General advice ................................................................................................................................................................... 8

1.3.2 Risks related to exhaust gases and fuels ........................................................................................................................... 9

1.3.3 Risks related to toxic products ......................................................................................................................................... 10

1.3.4 Risk of fire, burns and explosion ...................................................................................................................................... 10

1.3.5 Risks related to electrical networks .................................................................................................................................. 11

1.3.6 Dangers presented by electric currents (first aid) ............................................................................................................. 11

1.3.7 Risks related to moving the set ........................................................................................................................................ 11

1.4. Identifying sets ................................................................................................................................................................. 12

2. General description ........................................................................................................................................................................ 14

2.1. Description ....................................................................................................................................................................... 14

2.2. Technical specifications ................................................................................................................................................... 17

2.3. Fuel and consumables ..................................................................................................................................................... 19

2.3.1 Specifications ................................................................................................................................................................... 19

2.3.1.1. Oil grades ............................................................................................................................................................ 19

2.3.1.2. Specifications of coolants .................................................................................................................................... 20

3. Installation ...................................................................................................................................................................................... 21

3.1. Unloading ......................................................................................................................................................................... 21

3.1.1 Safety during unloading ................................................................................................................................................... 21

3.1.2 Instructions for unloading ................................................................................................................................................. 21

3.1.2.1. Slings .................................................................................................................................................................. 21

3.1.2.2. Fork lift truck ........................................................................................................................................................ 22

3.2. Fluid retention ................................................................................................................................................................... 22

3.3. Choice of location ............................................................................................................................................................. 24

3.4. Electricity .......................................................................................................................................................................... 25

3.5. Special arrangements ...................................................................................................................................................... 26

4. Trailer ............................................................................................................................................................................................. 27

4.1. Trailer linkage ................................................................................................................................................................... 27

4.2. Check before towing ......................................................................................................................................................... 27

4.3. Operation ......................................................................................................................................................................... 28

4.4. Unhitching the trailer ........................................................................................................................................................ 28

4.5. Implementation for installation .......................................................................................................................................... 29

4.6. Break transmission adjustment ........................................................................................................................................ 29

4.7. Faults and repairs ............................................................................................................................................................. 31

4.8. Electrical connection diagram ........................................................................................................................................... 32

4.9. Complete wheels technical information ............................................................................................................................ 32

5. Preparation before operating the set ............................................................................................................................................. 33

5.1. Installation checks ............................................................................................................................................................ 33

5.2. Checks after starting the generating set ........................................................................................................................... 33

6. Using the generator set .................................................................................................................................................................. 33

6.1. Pre-Start Inspection .......................................................................................................................................................... 33

6.2. Generator set with TELYS control panel .......................................................................................................................... 35

6.2.1 Control panel presentation ............................................................................................................................................... 35

6.2.1.1. View of the front panel ......................................................................................................................................... 35

6.2.1.2. Description of the screen ..................................................................................................................................... 37

6.2.1.3. Description of the pictograms in zone 1 .............................................................................................................. 38

6.2.1.4. Description of the pictograms in zone 2 .............................................................................................................. 39

6.2.1.5. Description of the pictograms in zone 3 .............................................................................................................. 40

6.2.1.6. Display of messages in zone 4 ............................................................................................................................ 43

6.2.2 Starting ............................................................................................................................................................................. 47

6.2.3 Switching off ..................................................................................................................................................................... 48

6.2.4 Alarms and faults ............................................................................................................................................................. 48

6.2.4.1. Viewing alarms and faults ................................................................................................................................... 48

6.2.4.2. Activation of an alarm or fault .............................................................................................................................. 49

6.2.4.3. Activation of an alarm and a fault ........................................................................................................................ 50

6.2.4.4. Engine fault codes display ................................................................................................................................... 51

6.2.4.5. Horn reset ........................................................................................................................................................... 52

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6.3.

Generator set with KERYS control panel .......................................................................................................................... 53

6.3.1 Presentation of the KERYS............................................................................................................................................... 53

6.3.1.1. Operating conditions ............................................................................................................................................ 53

6.3.1.2. Conformity to legal and regulatory requirements ................................................................................................. 54

6.3.2 Description of the KERYS ................................................................................................................................................. 55

6.3.2.1. Identification of the hardware components .......................................................................................................... 55

6.3.2.2. Identification of the software components ............................................................................................................ 58

6.3.3 Description of the Man Machine Interface (IHM / MMI) ..................................................................................................... 59

6.3.3.1. The Man Machine Interface ................................................................................................................................. 59

6.3.3.2. Navigation in the screens ..................................................................................................................................... 62

6.3.4 Configurations ................................................................................................................................................................... 67

6.3.4.1. Operating principle ............................................................................................................................................... 67

6.3.4.2. Legends ............................................................................................................................................................... 68

6.3.4.3. Configuration in solo generating set..................................................................................................................... 68

6.3.4.4. Power plant configuration (Several generating sets in parallel) ........................................................................... 71

6.3.5 Connections of the generating sets .................................................................................................................................. 78

6.3.5.1. Recommendations before the connections .......................................................................................................... 78

6.3.5.2. Connections according to the configurations ....................................................................................................... 78

6.3.5.3. Earthing system (Standard only) .......................................................................................................................... 79

6.3.5.4. Facility power outlet ............................................................................................................................................. 83

6.3.5.5. Connecting cable between the generating sets (power plant) ............................................................................. 84

6.3.5.6. Power ................................................................................................................................................................... 85

6.3.5.7. Client terminal block ............................................................................................................................................. 85

6.3.6 Operation and setting menus ............................................................................................................................................ 86

6.3.6.1. Layout of the menus ............................................................................................................................................ 86

6.3.6.2. Setting of regional parameters ............................................................................................................................. 87

6.3.6.3. Information on the KERYS ................................................................................................................................... 89

6.3.6.4. Operating menus ................................................................................................................................................. 91

6.3.7 Rental configurations ........................................................................................................................................................ 93

6.3.7.1. Choice of application configuration ...................................................................................................................... 93

6.3.8 Use ................................................................................................................................................................................. 102

6.3.8.1. Choice of priority generating set in power plant (if equipped) ............................................................................ 102

6.3.8.2. Starting, tests and stop ...................................................................................................................................... 108

6.3.8.3. Rental options .................................................................................................................................................... 115

7. Maintenance schedule .................................................................................................................................................................. 117

7.1. Reminder of use .............................................................................................................................................................. 117

7.2. Engine ............................................................................................................................................................................. 117

7.3. Alternator ........................................................................................................................................................................ 118

8. Battery .......................................................................................................................................................................................... 119

8.1. Storage and transport ..................................................................................................................................................... 119

8.2. Battery setting into service .............................................................................................................................................. 120

8.3. Check .............................................................................................................................................................................. 120

8.4. Load preconization .......................................................................................................................................................... 121

8.5. Faults and remedies ....................................................................................................................................................... 122

9. Appendix ...................................................................................................................................................................................... 123

9.1. Appendix A – Engine user and maintenance manual ..................................................................................................... 123

9.2. Appendix B - Alternator user and maintenance manual .................................................................................................. 209

9.3. Appendix C - Common spare parts ................................................................................................................................. 269

9.4. Appendix D - List of John Deere - Volvo and Perkins fault codes ................................................................................... 271

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1. Preface

1.1. General recommendations

Thank you for choosing an electrical generating set from our company.

This manual has been designed to help you operate and maintain your electrical generating set correctly. The information contained in this manual is taken from technical data available at the time of print. In line with our policy of continually improving the quality of our products, this information may be amended without warning.

Read the safety instructions attentively in order to prevent any accidents, faults or damage. These instructions must always be followed.

You are likely to encounter several warning symbols in this manual.

This symbol indicates an immediate danger to human health and life in case of exposure. Failure to follow the corresponding advice entails serious consequences for human health and life in case of exposure.

Danger

This symbol draws attention to the potential risks to human health and life in case of exposure. Failure to follow the corresponding advice entails serious consequences for human health and life in case of exposure.

Warning

This symbol indicates a dangerous situation if the warning is not heeded. Failure to follow the corresponding advice risks resulting in minor injury of personnel or damage to any other object in case of exposure.

Important

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

Ensure that all repairs and adjustments are carried out by personnel who have received appropriate training. Dealers have this qualification, and can answer all of your questions. They can also supply you with spare parts and other services.

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

Our electrical generating sets have been designed so that damaged or worn parts can be replaced by new or reconditioned parts thereby reducing the out of action period to a minimum. For any replacement of parts, contact your nearest dealer for our company who will have the necessary equipment and can offer properly trained and informed staff to carry out maintenance, parts replacement and even total reconditioning of generating sets.

Contact your local dealer for the available repair manuals and to make the necessary arrangements for training personnel in implementation and maintenance.

Some user and maintenance manuals for the engines fitted to generating sets cover control units and include the start-up and shutdown procedures for the engines. As the generating sets are fitted with control units that are specific to the generating sets, only the information that appears in the documentation for the generating sets' control units should be taken into consideration. In addition, according to the manufacturing criteria of the generating sets, some engines may be fitted with specific electrical wiring different to that described in the engine documentation.

Important

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1.2. Pictograms and their meanings

Safety notices are clearly mounted on the equipment to draw the operator's or maintenance technician's attention to the potential dangers and explain the action to be taken in the interest of safety. These notices are reproduced in this publication for ease of identification by the operator. Replace any notice that is missing or illegible.

Caution: danger

Publications delivered with the generating set must be referred to

Caution: risk of explosion

Caution: risk of electric shock

Protective clothing must be worn

Naked flames and unprotected lights prohibited. No smoking

Caution: toxic materials

Eyes and ears must be protected

Entry prohibited to nonauthorised persons

Caution: pressurised fluids

Periodic maintenance must be carried out

Jet washing prohibited

Caution: high temperature, risk of burns

Battery level must be checked

Earth

Caution: rotating or moving parts (risk of getting caught in the machinery)

Lifting point must be used

Caution: corrosive product

Fork pockets for lifting

Retention tank level high

 Important: refer to the documentation accompanying the generating set.  Important: emission of toxic exhaust gases. Do not use in a confined or badly

ventilated area.

 

Figure 1.1 : Pictograms and their meanings

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WARNING: DANGER

This symbol warns of a safety hazard. The presence of this symbol indicates a risk of injury. Observe the safety instructions and precautions for use.

Important: Carefully read the instructions supplied with the generating set before using or servicing the equipment.

WARNING: DANGER

Risk of electrocution  Do not touch the cables or connections when the generating set is in

operation.

 Switch off the generating set for maintenance operations.

DANGER

Use diesel fuel only.  The fuel is highly flammable, handle with care. Do not smoke near the

generating set or expose it to a naked flame or sparks.

 Shut down the generating set engine before filling the fuel tank. Fill with fuel

outside.

 To prevent fire risks, clean the generating set regularly. Wipe away any dirt

and traces of grease or fuel.

WARNING: DANGER

 The exhaust gases from the engine are toxic and can affect health or even

cause death.

 Use the generating set outdoors only, in well ventilated areas, or fit an exhaust

extension to discharge the exhaust gases outside.

Figure 1.2 : Pictograms and their meanings

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WARNING: DANGER

 Hot coolant can cause serious burns.  Switch off the engine. Do not remove the filler cap until it is completely cold.  Do not open the radiator when it is hot.

DANGER

 Rotating parts can cause serious injury.  Do not operate the generating set with the doors open.  Do not remove the enclosures.  Shut down the generating set before any maintenance or servicing

operation.

DANGER

 Avoid any contact with the exhaust pipes, turbochargers and silencers.

Keep flammable materials away from hot parts.

 Wait for the machine to cool down completely before touching it.

WARNING: DANGER

 The gas from the battery electrolyte is explosive. Keep the batteries away

from any flames.

 The battery electrolyte (sulphuric acid) is toxic. Risk of poisoning.

Figure 1.2 (continued) : Pictograms and their meanings

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WARNING: DANGER

 A poor earth connection can lead to serious injuries or death.  Always connect the earth terminal of the generating set to an external earth

terminal.

WARNING

Voltage selector This function should be used by qualified persons only.

WARNING

Adjust the output voltage correctly before connecting a load.

WARNING

The voltage selector must not be used when the generating set is operating.

Figure 1.2 (continued) : Pictograms and their meanings

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1.3. Instructions and safety regulations

THESE SAFETY GUIDELINES ARE IMPORTANT

If you do not understand or have any questions about any point in this manual, contact your dealer who will explain it to you or give you a demonstration. A list of risks and precautionary measures to take follows. You should also refer to any local and national regulations that apply in accordance with your own jurisdiction.

KEEP THIS MANUAL

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

1.3.1 General advice

Use

 The operating and safety instructions must be made known to operating personnel. They will be regularly updated.  Read and understand the manuals provided with the generating set, pump unit or lighting column properly. The manufacturer's

instructions must remain at the disposal of technicians, if possible in situ.

 The facility must be operated under the direct or indirect supervision of a person appointed by the operator, who is familiar with

the operation of the facility, and the dangers and drawbacks of the products used or stored in the facility.

 Do not wear loose clothing, or get close to machines in operation. Note that the fans are not clearly visible when the engine is

running.

 Warn personnel present to keep their distance during operation.  Do not run the generating set, pump unit or lighting column without refitting the protective covers and closing all the access

doors.

 Never let a child touch the generating set, pump unit or lighting column, even when shut down.  Avoid operating the generating set, pump unit or lighting tower in the presence of animals (disturbance, scares, etc.).  Engage the parking brake when the generating set or lighting tower on its trailer is installed on the operating site. When

chocking the trailer on a slope; ensure that there is nobody in the path of the trailer.

 Never start the engine without an air filter or exhaust.  Engine with turbocharger: never start the engine without fitting the air filter. The compressor wheel rotating inside the

turbocharger may cause serious bodily injury. Foreign objects in the inlet pipe may cause mechanical damage.

 Engine with air preheating (starting components): never use a starting spray or any other similar starter assistance product.

Upon contact with the starting component, an explosion may occur in the inlet tube, causing bodily injury.

 Do not touch the lighting column lights when they are switched on.

Maintenance

 Follow the maintenance table and its instructions.  Always use tools in good condition which are suited to the work to be done. Ensure you have understood the instructions before

beginning any operation.

 Goggles should be worn when carrying out maintenance operations and watches, bracelets etc. should be removed.  Fit only original parts.  Disconnect the battery and the pneumatic starter (if fitted) before undertaking any repairs, to prevent the engine from starting

accidentally. Fit a panel over the controls to prevent any attempt to start.

 Only use the correct crankshaft turning techniques for turning the crankshaft manually. Do not try to turn the crankshaft by

pulling it or levering the fan. This method may cause serious bodily or material damage, or damage the vanes of the fan, reducing the service life of the fan.

 Clean off any trace of oil, fuel or coolant using a clean cloth.  Do not use a soapy solution containing either chlorine or ammonia, as these two chemicals prevent bubble formation.  Never use petrol or other inflammable substances to clean the parts. Use only approved cleaning solvents.  Do not use a high pressure cleaner for cleaning the engine and equipment. The radiator, hoses, electrical components, etc. may

be damaged.

 Avoid accidental contact with parts at high temperatures (exhaust manifold, exhaust).  Before any maintenance operation on a lighting column light, cut the electrical power supply and wait for the bulbs to cool down.

Consumables

 Observe regulations in force concerning use of fuel before using your generating set, pump unit or lighting tower.  Under no circumstances use seawater or any other corrosive or electrolytic product in the cooling circuit.

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Environment  The operator must take the necessary measures to comply with the aesthetics of the site of use. The whole site must be

maintained in a good state of cleanliness.

 The premises must be kept clean, and be regularly cleaned so as to avoid accumulation of dangerous materials or pollutants

and dust, which could ignite or cause an explosion. The cleaning equipment must be suited to the risks posed by the products and dust.

 The presence of dangerous or combustible materials inside premises housing combustion devices shall be limited to the

operating requirements.

 Facilities must be operated under the constant supervision of a qualified person, who must regularly check that the safety

devices are operating correctly and ensure that the combustion devices have the correct fuel supply.

 Apart from the combustion devices, it is prohibited to use fire in any form. This restriction must be clearly displayed.  Spreading of waste water, sludge and waste is prohibited.  The fuels to be used must correspond to those featured in the declaration file and the specifications recommended by the

combustion device manufacturer.

 The fuel is considered to remain in the same physical state as when it is introduced into the combustion chamber.  Burning of waste in the open air is prohibited.  Always protect your hands when checking for leaks. Pressurised liquids may penetrate body tissue and cause serious damage.

Risk of blood contamination.

 Drain and dispose of engine oil in a specially provided container (fuel distributors can collect your used oil).  Except by special agreement, once closed, the gas supply main unit must only be re-opened by the gas distributor. However,

the user may access it under certain conditions. Check these for each site.

1.3.2 Risks related to exhaust gases and fuels

The carbon monoxide present in exhaust gases may cause death if the concentration levels in the air breathed are too high. Always use generating sets, pump units or lighting towers in a well-ventilated place where gases cannot accumulate. In case of indoor use:

 Be sure to evacuate exhaust gases outdoors.  Provide appropriate ventilation so that personnel present are not affected.

Danger

 Observe the local regulations in force for generating sets, pump units or lighting towers, as well as local regulations for use of

fuel (petrol, diesel fuel and gas) before using your generating set, pump unit or lighting tower.

 Fuel filling should be carried out when the engine is off (except for generating sets with an automatic filling system).  Engine exhaust gases are toxic: do not run the generating set, pump unit or lighting column in unventilated premises. If installed

in a ventilated room, additional requirements for fire and explosion protection must be observed.

 A leaking burnt gas exhaust may increase the sound level of the generating set, pump unit or lighting column. To check on its

efficiency, regularly examine the burnt gas exhaust.

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

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1.3.3 Risks related to toxic products

The corrosion inhibitor contains alkali. Do not swallow it. This substance should not come into contact with the eyes. In the event of contact with the eyes, rinse immediately with plenty of water for at least 15 minutes. Avoid prolonged or repeated contact with the skin. In the event of contact with the skin, wash thoroughly with water and soap. CONSULT A DOCTOR IMMEDIATELY. KEEP THE PRODUCT OUT OF THE REACH OF CHILDREN.

The anti-rust product is toxic and dangerous if absorbed. Avoid all contact with the skin and eyes. Read the instructions on the packaging.

Glycol is a toxic product and dangerous if absorbed. Avoid all contact with the skin and eyes. Read the instructions on the packaging.

Warning

 Caution: fuels and oils are dangerous to inhale. Ensure proper ventilation, and use a protective mask.  Never expose the equipment to liquid splashes or rainfall, and do not place it on wet ground.  The battery electrolyte is harmful to skin and especially eyes. If splashes get into eyes, rinse immediately with running water

and/or a 10% diluted boric acid solution.

 Wear protective eyewear and strong base resistant gloves for handling the electrolyte.

1.3.4 Risk of fire, burns and explosion

The engine should not be operated in environments containing explosive products. As not all of the electrical and mechanical components are shielded, there is a risk of sparks forming.

Danger

 Make sure not to create sparks or flames, and not to smoke near the batteries, as the electrolyte gases are highly flammable

(especially if the battery is charging). Their acid also poses a risk to the skin, and in particular to the eyes.

 Never cover the generating set, pump unit or lighting tower with any material during operation or just after shutdown (wait for the

engine to cool).

 Do not touch hot parts such as the exhaust pipe, or put combustible materials on it.  Keep all flammable or explosive materials (e.g. petrol, oil, cloth, etc.) out of the way when the set is running.  Proper ventilation is required for your generating set, pump unit or lighting column to work properly. Without this ventilation, the

engine would very quickly rise to an excessively high temperature, causing accidents or damage to the equipment and to surrounding property.

 Do not remove the radiator cap if the engine is hot and the coolant is pressurised, due to risks of burns.  Depressurise the air, oil and cooling circuits before removing or disconnecting all the fittings, pipes or connected components.

Watch out for the possible presence of pressure when disconnecting a device from a pressurised system. Do not try to find pressure leaks by hand. Oil at high pressure can cause bodily damage.

 Some preservative oils are flammable. Also, some are dangerous to inhale. Ensure proper ventilation. Use a protective mask.  Hot oil causes burns. Avoid contact with hot oil. Check that the system is no longer pressurised before carrying out any

procedures. Never start or run the engine with the oil filler cap off (oil may splash out).

 Never coat the generating set, pump unit or lighting column with a thin layer of oil to protect it from rust.  Never top up the oil or coolant if the generating set, pump unit or lighting column is running, or if the engine is hot.  A generating set can only operate when stationary, and cannot be installed on a vehicle or other mobile equipment, without a

prior study taking into account the various specific features of using the generating set.

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1.3.5 Risks related to electrical networks

 The electrical equipment supplied with the generating set complies with standard NF C15.100 (France), or with the standards of

the countries in question.

 The earth connection must be installed in accordance with the standards in force in each country in question, and with the

neutral system sold.

 Read the manufacturer's identification plate carefully. The values for voltage, power, current and frequency are shown. Check

that these values match the supply use.

 Never accidentally touch stripped cables or loose connections.  Never handle a generating set with wet hands or feet.  Maintain electrical wires and connections in good condition. Using equipment in poor condition can lead to electrocution and

damage to equipment.



 Always disconnect the power to the equipment or facility (generating set voltage, battery voltage and network voltage) before

any operation.

 The electrical connections must be made in accordance with current standards and regulations in the country of use.  Do not use faulty, poorly insulated or provisionally connected wires.  Never reverse the positive and negative terminals on batteries when connecting them. This could cause severe damage to the

electrical equipment. Follow the wiring diagram supplied by the manufacturer.

 The generating set should not be connected to any other power sources, such as the mains supply network. In specific cases

where there is to be a connection to existing electrical networks, this must only be installed by a qualified electrician, who should take the operating differences of the equipment into account, according to whether the mains supply network or generating set is being used.

 Protection against electric shocks is ensured by an assembly of specific equipment. If this needs to be replaced, it should be by

components with identical nominal values and specifications.

 If the protective plates (blanking covers) need to be removed to route cables, the protector (blanking cover) must be refitted

when the operations are finished.

 Due to high mechanical stresses, use only strong flexible wiring with rubber sheathing, compliant with IEC 245-4, or equivalent

wiring.

1.3.6 Dangers presented by electric currents (first aid)

First aid

In the event of an electric shock, shut off the power immediately and activate the emergency stop on the generating set or lighting column. If the voltage has not yet been cut off, move the victim out of contact with the live conductor as quickly as possible. Avoid direct contact both with the live conductor and the victim's body. Use a dry plank of wood, dry clothes or other non-conductive materials to move the victim away. The live wire may be cut with an axe. Take great care to avoid the electric arc that will be generated by this.

Begin emergency procedures

Resuscitation If breathing has stopped, begin artificial respiration at once in the same place the accident took place unless the victim or operator's life could be endangered by this. In the event of cardiac arrest, carry out cardiac massage.

1.3.7 Risks related to moving the set

To unload the generating sets, pump units or lighting columns from their transport support brackets under optimum safety and efficiency conditions, you must ensure that the following points are observed:

 The lifting machinery or equipment is suited to the work required, in good condition and with sufficient lifting capacity.  The slings are positioned in the rings provided for this operation, the forklift arms are resting fully underneath all of the base

frame cross-beams, or the lifting bars are inserted in the apertures provided for this purpose in the base to lift the entire generating set (according to models).

 For completely safe working conditions and to prevent damage to the components fitted on the upper edge of the set, pump unit

or lighting column, the generating set, pump unit or lighting column must be lifted up with an adjustable boom. All the chains and cables must be parallel with each other, and as perpendicular as possible with the upper edge of the generating set, pump unit or lighting column.

 If other equipment fitted on the generating set, pump unit or lighting column alters its centre of gravity, special lifting devices

may be necessary to maintain correct balance and completely safe working conditions.

 The ground must be able to withstand the load of the generating set, pump unit or lighting column and its lifting machinery

without stress (otherwise, put down beams of sufficient strength in a stable configuration).

 Position the generating set, pump unit or lighting column as close as possible to its place of use or transport, in a clear space

with free access.

 Never perform work on a generating set, pump unit or lighting tower just hanging from a lifting device.

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1.4. Identifying sets

Generating sets and their components are identified by means of identification plates. The precise rules for identifying each major component (engine, alternator etc.) are set out in each manufacturer's documents contained in this manual.

Examples of identification plates

Generating set

Engines

Figure 1.2 : Examples of identification plates

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Alternator

Cabinet

Figure 1.3 : Examples of identification plates

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2. General description

2.1. Description

Overview

1 Control unit 4 Protective grilles 2 External emergency stop 5 Chassis 3 Expansion bottle 6 Circuit breakers

Figure 2.1 : General description of the generating set

2 1

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7 Battery charge alternator 8 Starter batteries

Figure 2.1 (continued): General description of the generating set

9 Coolant filter 12 External fuel supply combined tap (optional) 10 Filling with fuel 13 Circuit breaker 11 Oil filters 14 Interchangeable fuel pre-filters

Figure 2.1 (continued) : General description of the generating set

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Sockets ( voltage 208/120V )

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2.2. Technical specifications

Range / Generating set type RENTAL POWER / R340U

Weights and Dimensions

Dimensions with standard tank

Dimensions l x w x h:

4475 mm x 1410 mm x 2690 mm

Weight: 3830 kg dry weight 4300 kg in operating configuration

Hood: M228C

Noise level: 80 dB à 1 m (0.70) 70 dB à 7 m (0.70)

Dimensions with high autonomy tank

Dimensions l x w x h:

4527 mm x 1410 mm x 2780 mm

Weight: 4520 kg dry weight 5888 kg in operating configuration

Hood: M228C-DW

Noise level

: 80 dB à 1 m (0.70) 70 dB à 7 m (0.70)

Output

Voltage Hz Phase Load factor

Max current (A)

Emergency

Emergency power

kW / kVA

Prime power

kW / kVA 480/277 V 60 3 0.8 453 301.6 / 377 274.2 / 342.7 380/220 V 60 3 0.8 573 301.6 / 377 274.2 / 342.7 220/127 V 60 3 0.8 989 301.6 / 377 274.2 / 342.7 208/120 V 60 3 0.8 1046 301.6 / 377 274.2 / 342.7

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

overload available under these service conditions.

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

overload of 10% one hour every 12 hours is available, as per ISO3046-1.

Engine data

Manufacturer / model VOLVO TAD941GE Type Turbo Cylinder configuration 6 L Cubic capacity 9.36 L Rotation speed 1800 Rpm Max emergency/prime power at nominal speed 344 / 313 kW Adjustment type Electrical

Fuel consumption

110 % (emergency power) 79.2 L/h 100 % main power 70.8 L/h 75 % main power 52.8 L/h 50 % main power 37.0 L/h

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Fuel

Fuel type Diesel Standard fuel tank 470 L High autonomy fuel tank 1368 L

Lubrication

Oil capacity with filter 35 L Min. Oil pressure 0.7 bar Nominal oil pressure 6 bar Oil consumption (100 % load) 0,06 L/h Oil sump capacity 28 L Type of lubricant Genlub

Cooling

Engine capacity with radiator 41 L Max coolant temperature 103 °C Fan power 17.8 kW Ventilator air flow 7.2 m3/s Refrigerant type Gencool Thermostat 82-92°C

Alternator data

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

● The alternator is protected against short circuits

● Vacuum impregnation, epoxy winding, IP23 protection rating

Type LEROY SOMER LSA462VL12 Number of phases 3 Power factor (cos Phi) 0.8 Number of poles 4 Excitation type AREP Voltage regulator R450 Short-circuit current 3 IN Number of bearings 1 Coupling Direct

Control unit(s)

TELYS

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

KERYS

Coupling

: pre-programmed coupling mode selector.

Electrical measurements

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

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

:Coupling Website, Troubleshooting, Assistance and maintenance, plotting and logging, load impact, 8 configurations available, Compliance with international standards…

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2.3. Fuel and consumables

All specifications (product features) are given in the motor and alternator maintenance manuals attached to this manual. In addition, we recommend the consumables to be used in the "specifications" section.

2.3.1 Specifications

2.3.1.1. Oil grades

Engine Oil

Make Type Make Type

John Deere All

John Deere John Deere PLUS-50

GenPARTS GENLUB TDX 15W40

MITSUBISHI All GenPARTS GENLUB TDX 15W40

Volvo All GenPARTS GENLUB TDX 15W40

GENLUB TDX 15W-40

Top-of-the-range lubricant recommended for diesel engines: for generating sets used under severe conditions.

USES:

 Particularly suited to more modern engines with or without turbochargers, intercoolers, or sophisticated injection systems

(e.g. HEUI, injector-pumps).

 All types of use: can cope with the most demanding applications.  Depolluted engines: complies with EURO 2 and EURO 3 technology and can be used with all types of diesel fuel,

especially ecological diesel with low sulphur content.

PERFORMANCE: ACEA E3

API CH-4

 Meets level E3 of the specifications defined by European manufacturers in the ACEA standards 98 edition.

ADVANTAGES:

 Less frequent oil services: this product has been put to the test during thousands of hours of use on worksites under

varying conditions, demonstrating its high quality.

 Conformity with new environmental legislation: adherence to new anti-pollution standards required for new EURO 2

and EURO 3 engines.

SPECIFICATIONS:

SAE Grade 15W-40

Density at 15°C 0.883

Cinematic viscosity at 40 °C Cinematic viscosity at 100 °C

105

14.1

mm2/s (cSt)

mm2/s (cSt) Viscosity index 140 Dynamic viscosity at -15 °C 3000 mPa.s(cP) Pour point - 30 °C

Flash point 220 °C Sulphated ash content 1.4 % weight (Values given as examples only)

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2.3.1.2. Specifications of coolants

Engine Coolants

Make Type Make Type

John Deere All GenPARTS GENCOOL PC -26°C

MITSUBISHI All

Mitsubishi LLC

GenPARTS GENCOOL PC -26°C

Volvo All GenPARTS GENCOOL PC -26°C

GenCOOL PC -26

High-protection coolant, approved by manufacturers. GenCOOL PC -26 is a ready-to-use, highly protective coolant which is produced from an antifreeze recommended by the majority of European manufacturers.

 It is made from antifreeze and G 48 inhibitors.  It protects up to -26°C.  It is free from nitrates, amines and phosphates.  It is a clear, fluorescent orange liquid.

REFERENCES/APPROVALS (for the antifreeze):

HEAVY GOODS VEHICLE LIGHTER VEHICLES

Approved by MTU, MERCEDES BENZ, MAN, KHD, GENERAL MOTORS

Conforms with VOLVO, IVECO, VAN HOOL and STAYR TRUCK specifications

Approved by BMW, VOLKSWAGEN, MERCEDES, PORSCHE

Conforms with VOLVO, OPEL, SEAT and SKODA specifications

Conforms with the NF R 15.601 standard REINFORCED ANTI-CORROSION FEATURES:

 Protects against high-temperature corrosion by oxidisation of ethylene (cylinder head protection).  Protects against high-temperature cavitation (top of cylinder and coolant pump protection).  Non-corrosive for seals and hoses.  Improves the efficiency and longevity of the cooling system.  GenCOOL PC -26 is especially recommended for engines fitted with aluminium or light alloy radiators.

HIGH TEMPERATURE SUITABILITY:

 Provides good conditions for thermal exchange.  Perfect stability at high temperatures.  GenCOOL PC -26 is specially adapted for engines with high power densities.

LONG LASTING PROTECTION:

 High alkaline reserve/stability and longevity of corrosion inhibitors.  Maintains its technical properties during prolonged use at high temperatures (neutralisation of acids).  Ensures maximum heat transfer without the build up of deposits in the cooling system.  GenCOOL PC -26 ensures optimum protection against overheating and corrosion in extreme conditions of vehicle use.

PACKAGING/STORAGE:

 GenCOOL PC -26 is supplied in 210 l metallic barrels with smooth interior linings.  It can be stored for 2 years in its original container and packaging.  Avoid zinc coated containers.

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RECOMMENDATIONS FOR USE:

 Compatible with the original fluid.  It is recommended that the cooling system is completely drained when replacing the fluid.

SPECIFICATIONS UNITS SPECIFIED VALUES

TRIAL

METHODS

Density at 20°C

kg/m3

1,059 +/- 3

R 15-602-1

7.5 to 8.5

NF T 78-103

Alkalinity reserve

>=10

NF T 78-101

Boiling point

°C

105 +/- 2

R 15-602-4

Freezing point:

°C

-26 +/- 2

NF T 78-102

Glassware corrosion : (test with antifreeze)

mg/test piece

R 15-602-7

- Copper

+/- 2.6

- Weld

+/- 0.5

- Brass

+/- 2.3

- Steel

+/- 1.6

- Cast iron

+/- 0.8

- Cast aluminium

+/- 1.0

Corrosion on warm plate

(test with antifreeze)

mg/(cm²week)

+/- 0.17

R 15-602-8

3. Installation

3.1. Unloading

3.1.1 Safety during unloading

To unload electrical generating sets from their transport supports under optimum safety and efficiency conditions, you need to ensure that the following points are observed:

- Lifting machinery or equipment appropriate to the work required.

- Slings positioned in the eyes provided for this operation or lifting arms resting fully underneath the chassis cross members.

- Ground able to take the load of the set and the lifting machinery without stress (otherwise lay down beams of sufficient strength and stability).

- Set put down as close as possible to its point of use or transportation, in a clear area with free access.

Example of equipment to be used:

 crane, slings, cross bar, safety catch, shackles.  Fork lift truck.

3.1.2 Instructions for unloading

3.1.2.1. Slings

 Attach the lifting vehicle slings to the rings on the generating set designed for this procedure. Hang the slings carefully.  Check that the slings are correctly attached and the equipment is solid.  Lift the generating set carefully.  Direct and stabilise the set towards the chosen position.  Carefully set down the equipment while continuing to position it.  Release the slings, then detach and remove the lifting rings.

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3.1.2.2. Fork lift truck

 Position the forklift arms under the base frame (except with generating sets fitted with "forklift pockets", in which case position

the forklift arms in these pockets), making sure that only its cross-members are resting on the arms.

 Lift the equipment, handling it gently.  Set down the generating set in its unloading position.

Figure 3.1: Transporting a generating set using a forklift truck

3.2. 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 if the generating set is fitted with this option. The containers have a capacity which allows 110% of the fluids contained in the generating set fitted with this option to be collected. Three different fittings are available.

Figure 3.2: Fluid retention container integrated into the tank chassis.

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Figure 3.3: Offset fluid retention container underneath the generating set chassis.

Figure 3.4: Offset fluid retention container integrated into the chassis and tank.

Generating sets fitted with the offset tank option (DW) above also have a high level indicator in the retention container.

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

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

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3.3. Choice of location

It should be determined on the basis of use. There are no specific rules governing the choice of location, other than proximity to the electric distribution panel and disturbances caused by the noise. However, fuel supply, burnt gas evacuation, and the direction of these gases and the noises emitted should be taken into account. The choice of its position will be based on carefully considered compromise!

Examples of problems that may be encountered:

Incorrect exhaust and ventilation Ground too uneven or soft.

Set incorrectly positioned

Reduced access

Fuel filling impossible Opening cover doors impossible

Figure 3.5: Examples of problems that may be encountered

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3.4. Electricity

a) Connections - general information As with low voltage electrical installations, use and maintenance is governed by standard NFC 15.100 (France) or by the standards in the relevant country, based on international standard IEC 60364-6-61. They must also adhere to the regulations in the NFC 15.401 application guide (France) or to the regulations and standards in the relevant country.

b) Power cables These can be unipolar or multipolar according to the power of the generating set. Power cables should preferably be installed in ducts or on a cable tray for this purpose. The cable cross-section and number of cables should be determined according to the cable type and the current standards to be observed in the country of installation. The choice of conductors must comply with international standard IEC 30364-5-52.

Three phase - Calculation hypothesis

Fitting method = wiring in cable runs or non perforated trays. Permissible voltage drop = 5% Multiconductors or single conductor joined when precision 4X…(1) Cable type PVC 70°C (e.g. H07RNF). Ambient temperature = 30°C.

Circuit breaker

calibre

(A)

Cable sizes

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 - Calculation hypothesis

Fitting method = wiring in cable runs or non perforated trays. Permissible voltage drop = 5% Multiconductors. Cable type PVC 70°C (e.g. H07RNF). Ambient temperature = 30°C.

Circuit breaker

rating (A)

Cable sizes

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

c) Battery cables Install the battery or batteries in the immediate vicinity of the electric starter motor. The cables will be connected directly from the battery terminals to the starter motor terminals. The primary instruction to follow is to ensure that the polarities between the battery and starter motor match. Never reverse the positive and negative battery terminals when connecting them. This could cause severe damage to the electrical equipment. The minimum cross-section of the cables will be 70 mm2. It varies according to the power of the starter motor but also the distance between the batteries and the set (voltage drops on the line).

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d) Safety guidelines References: NFC 15-100:2002 (France) - IEC: 60364-5-54

In order to protect personnel against electric shocks, this generating set is equipped with a differential residual current protector "factory" set to trigger instantly, with a sensitivity of 30 mA.

Any modification to this setting could endanger personnel. Any modification would render the user liable, and must only be performed by qualified and authorised personnel. When the generating set is disconnected from a facility after use, the master differential protector must be returned to its "factory" settings, and this must be checked by trained personnel.

Important

For effective protection against electric shocks, the generating set needs to be earthed. To do this, use a copper wire, with a minimum cross-section of 25 mm2 for a stripped cable and 16 mm2 for an insulated cable, connected to the generating set earth socket and a galvanised steel earthing rod embedded vertically into the ground.

The earthing rod resistance value should comply with the values shown in the table below. Note: use the highest differential setting from the installation as a guideline.

The resistance value is calculated in the following way:

For a default voltage of 25 V and a default current of 30 mA, this rod must be of a minimum length of: see table below:

Nature of ground

Length of

rod in

metres

Thick arable land,

moist compact ballast

Lean arable land,

Gravel, coarse ballast

Bare stony soils, dry sand,

impermeable rock

3.6

To obtain an equivalent length, you can use several earthing rods connected in parallel and set apart by at least their length. Example: 4 interconnected 1 metre rods separated by 1 metre.

Note: For the United States (National Electrical Code reference NFPA-70). The generating set must be earthed. To do this, use a copper wire with a minimum cross-section of 13.3 mm² (or AWG 6, at most) connected to the generating set earth socket and a galvanised steel earthing rod fully embedded into the ground vertically. This earthing rod embedded fully in the ground must have a minimum length of 2.5 m.

3.5. Special arrangements

Generating sets are not fitted with protection against power surges caused by drops in atmospheric pressure or manoeuvring. The company does not accept any responsibility regarding damage caused by these occurrences. However, lightning conductors can be installed, on the understanding that this does not give total protection.

R = Ul I Δn

Maximum resistance value of the earth socket R (Ω) according to the differential unit operational current (operation time should not be longer than 1 second).

I Δn

differential

Earth R

(Ω)

Ul: 50 V

Earth R

(Ω)

Ul: 25 V

≤ 30 mA 500 > 500

100 mA 500 250 300 mA 167 83 500 mA 100 50

1A 50 25 3A 17 8 5A 10 5

10A 5 2.5

The Ul value: 25 V is required for work site installations, and livestock buildings, etc.

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4. Trailer

4.1. Trailer linkage

Before attaching the trailer, check the trailer hook on the tow vehicle; it should fit the trailer ring perfectly.

Trying to tow a trailer with a non-matching device (bar, wires, cords, etc.) could lead to serious accidents. Also check:

- no incipient fractures or excessive wear on the hitching system.

- locking system is operating properly.

Warning

To hitch the trailer, proceed as follows:

 Lock the wheels to stop the trailer from moving  Lift up the rear trailer supports and lock them  Release the parking brake  Release the locking levers for the draw bar arms and adjust the ring to the same height as the vehicle hook  Hitch the trailer, remove the locks on each side of the wheels then lift up the front wheel fully using its handle  Connect the electrical circuit of the trailer to that of the tow vehicle  Hook the handbrake safety wire onto the hook on the tow vehicle.

Figure 4.1 : Coupling a trailer

4.2. Check before towing

Before towing, check the following:

 Tightness of the generating set enclosure bolts.  Wheel tightness.  Hitching hook locked.  Tyre pressure.  Signalling lights working, for "on-road" trailers.  Enclosure doors closed.  Parking brake released, for "on-road" trailers.  Guide wheels (jockey wheels) and stands lifted (if fitted).  Towbar arm locking levers tightened and pinned (if fitted with an adjustable towbar).  Brake test, for "on-road" trailers.  Safety cable fitted, for "on-road" trailers.

Tow vehicl e

Trailer

CORRECT

To w ve h icle

Trai ler

CORRECT

To w ve h icle

Trailer

INCORRECT

To w ve h icle

Trai ler

INCORRECT

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4.3. Operation

"On-site" trailer These trailers are not fitted with a main brake, and so cannot be braked in motion; the tyres allow for a maximum speed of 27 km/h. So it is absolutely prohibited to exceed this speed. Nor are these trailers fitted with signalling lights. On-road use is prohibited. "On-road" trailer The driving speed must be suited to the condition of the road and the handling of the trailer. Driving at high speed causes heating of the tyres; so it is important to stop from time to time, and check them. Excessive heating may cause a puncture, and 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. 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. Nonetheless the tightness must be checked whenever you are about to tow the trailer.

Warning

Lights/signalling (only for "on-road" trailers) Warning lights are obligatory for on-road driving. Signalling must comply with regulations in force in the country of use.

Figure 4.2: Example of French signalling

4.4. Unhitching the trailer

This operation should be carried out on horizontal, flat, stable ground.

 Lock the wheels  Lower the front wheel  Disconnect the road signals wire  Refit the hitch using the wheel to release the hook ring from the tow vehicle,  Release the tow vehicle  Engage the handbrake.

Red rear lights + direction indicators + stop lights

Front reflective devices (white)

Side reflective devices (orange)

Rear reflective devices

(

red triangle)

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4.5. Implementation for installation

Operations to be carried out:

 Ensure that the ground is strong enough for the assembly not to sink into it.  Unhitch the trailer.  Immobilise the trailer by placing chocks under the wheels.  Fully engage the parking brake (if fitted).  Using the front wheel, position the generating set as close to horizontal as possible.  Lower the stands (if fitted), and lock them.

4.6. Break transmission adjustment

- The handbrake is used only as a parking brake.

- Setting is carried out starting with the brakes moving to the brake control.

Important

 After fitting the wheels on the axle, turn the wheels in the FORWARD direction (on all RA 2 type brakes, check that the

adjustment screw 8 reaches the “FORWARD” stop on the brake backing plate).

 Adjust the brake setting using screw 8, with the cables not connected to the cross bar(s). The shoes should rub the drum

slightly.

 Connect the brake cables to the cross bars(s) and tighten the nuts and lock nuts, leaving the end of the threaded end

protruding by around 10 mm (Fig. 4.4). IMPORTANT: Wherever possible, cables must cross over to achieve the highest possible gain curve (Fig. 4.5).

 Check that the parking lever 1 is in the ‘REST” position and that the compensating spring 4 is completely free on its rod

(unscrew the nuts 5 fully).

 Check that the hook slide 2 is not compressed and the yoke 3 is in the pulled out position.  Fit the transmission and adjust the assembly using the tensioner 6 until a gap (J1) of 1 mm max is obtained between the

linkage 9 and slide 2.

 Adjust the compensating spring 4 at one end pressing it against the anchorage plate, and at the other end leaving a 2 mm gap

(J2) max between the spring and nuts 5.

 Tighten all the lock nuts.

Checking the setting (trailer on axle stands):

 Pull the parking lever 2 notches - the wheels cannot turn in a FORWARD direction.

The wheels can turn in REVERSE (adjustment screw 8 switches to the REAR position).

 Pull the parking lever fully.

The wheels will not turn either in FORWARD or REVERSE and the cross bar(s) must remain parallel with the axle body.

 Check the transmission setting after 180 miles (300 km) (running in period) and if necessary adjust the gap (J1) using the

tensioner.

Parking

 The lever must be fully pulled up, so that the compensating spring is fully compressed.  Every 900 miles (1500 km), check the braking settings and distribution on all the wheels.

Important

 The brake controls are designed to draw trailers behind flexible suspension touring vehicles. If used behind an HGV, be

sure to provide the fitted ball joint with a shock absorber to prevent premature wear.

 During any manoeuvres with the trailer coupled, do not turn more than 90° or force reverse.  The specifications of our brake controls are indicated on a manufacturer's plate, and the items on this should be supplied

to us when requesting replacement parts, in particular for the shock absorber, of a special type, approved by the Service des Mines to correspond to European standards (it is advisable to have a spare shock absorber to enable instant repairs).

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Figure 4.3: Braking transmission

Figure 4.4: Cross bar fitting Figure 4.5: Tandem bearing fitting

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4.7. Faults and repairs

Fault observed Origin Solutions

Erratic braking of trailer - Faulty shock absorber Replace the shock absorber

Braking too weak

- Jaws worn Replace the jaws

- Jaws not run in Fault will disappear only after running in

- Incorrect linkage setting Adjust the setting

- Significant friction on the slide Grease the sliding parts

- Slide corrosion Remove the corrosion and grease

- Coupling height does not match that of the towing vehicle

Adjust the height so that the two parts are in the same horizontal plane

Drum temperature abnormally high

- Incorrect linkage setting Adjust the settings

- Incorrect brake setting Adjust the settings

- High levels of dust in the drums Remove the dust

- Jaws, springs, drums damaged Replace the damaged parts

- Brake cables or link rod damaged Replace the damaged parts

Jerky braking

- Incorrect linkage setting Adjust the settings

- Interfering parts on the slide Remove, clean and grease

- Corroded slide Remove the corrosion and grease

- Damage to slide guide rings

Replace the rings (and possibly the slide) and grease

- Faulty shock absorber Replace the shock absorber

Trailer tending to swerve upon braking

- Cross-bar(s) not balanced Adjust the cross-bar(s)

- Different brake setting on the two sides Adjust the brake settings

- Cables damaged or incorrectly fitted

Replace the damaged parts Refit the cables

- Poor load distribution Check the load distribution

When starting the trailer holds back the towing vehicle

- Damage to slide or to guide rings Replace the faulty parts and grease

- Slide corrosion Remove the corrosion and grease

- Tie rod damaged

Replace the tie rod and adjust the settings

- Linkage damaged or incorrectly set

Replace the damaged parts and adjust the settings

- Brake on Loosen the brake

Play in the coupling head

- Head worn (see wear indicator) Replace the head

- Ball joint worn Replace the ball joint

Parking braking too weak

- Compensating spring incorrectly set Adjust the setting

- Braking system incorrectly set Adjust the setting

- Notched sector damaged Replace the sector and adjust the setting

- Lever ratchet worn Replace the lever and adjust the setting

- Cable ruptured Replace the cable and adjust the setting

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4.8. Electrical connection diagram

Figure 4.6 : Electrical connection diagram

4.9. Complete wheels technical information

TYRES

COMPLETE

WHEELS

Dimensions Indices Diameter (mm)

Cross section

(mm)

Radius under

load (mm)

Load

(Kg)

Pressure

(bar) 135 R 13 70 T 550 134 265 335 2.4 145 R 13 75 T 566 145 272 387 2.4 155 R 13 79 T 578 150 277 437 2.4

145/70 R 13 71 T 534 150 259 345 2.5 155/70 R 13 75 T 548 147 263 387 2.5 185/70 R 13 86 T 594 185 285 530 2.5

165 R 14 C 98 N 622 172 284 650 3.8

155/70 R12 100 N 525 155 244

650

(1)

800

(2)

6.25

185 R 14 C 102 P 650 188 316

675

(1)

850

(2)

4.5

195 R 14 C 106 P 666 198 32 950 4.5 195/50 x 10 98 N 450 190 - 750 6.0

(1)

Wheel with 4 holes

(2)

Wheel with 5 holes

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5. Preparation before operating the set

The inspections referred to in this section enable the electrical generator set to operate. Specific skills are required to carry out these operations. They must only be entrusted to personnel with the necessary skills. Failure to follow these instructions in any way could result in malfunction or very serious accidents.

Danger

5.1. Installation checks

 Check that the general recommendations given in the installation section (ventilation, exhaust, fluids, etc.) are observed.  Carry out the level checks (oil, water, diesel fuel, battery).  Check the generating set earth connection is earthed.  Check that the electrical connections are in order.

5.2. Checks after starting the generating set

 Carry out the mechanical checks (oil pressure, water temperature, absence of noise etc.)  Carry out the electrical checks (voltage and frequency)  Carry out the safety checks (emergency stop, oil pressure, water temperature etc.)

6. Using the generator set

6.1. Pre-Start Inspection

• Engine and engine compartment, general check

Visually check the engine and engine compartment before starting the engine and after stopping the engine. Check:

 there are no oil, fuel or coolant leaks,  the screws are tightened,  the condition of the belts (wear, tension).

Fuel, oil and grease deposits on the engine or in the engine compartment are always a fire hazard and must be removed as soon as they are noticed.

Warning

If there are any oil, fuel or coolant leaks, locate the origin of the fault and repair it immediately before starting the engine.

Important

Never use a high pressure cleaner for cleaning the engine and equipment.

Important

• Oil level, check and top up

 Check the oil level every day before the first start-up.  Check that it is between the MAX and MIN marks on the oil dipstick.  If necessary, top up the oil through the filler opening, on the left-hand side of

the engine. Before checking the level again, wait a few minutes for the oil to drain into the sump.

Never fill oil past the maximum level. Only use oil of the recommended grade.

Important

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• Coolant level, check

Do not open the filler cap when the engine is hot, except in an emergency. Boiling liquid or vapour may be ejected.

Warning

The system must be filled up with liquid which has identical proportions to that already contained in the cooling system. Only open the filler cap (1).

Important

 The coolant level must be between the MIN and MAX marks. Top up the oil if

necessary.

• Checking the air filter clogging indicator

Special air filters must be used for extremely dusty conditions.

Important

 Replace the filter when the indicator remains in the red zone after the engine

has been stopped.

 Reset the indicator after the filter has been replaced by pressing the button.

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6.2. Generator set with TELYS control panel

6.2.1 Control panel presentation

6.2.1.1. View of the front panel

Figure 6.4 : 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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Figure 6.5 : 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 6.6: 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.

1 2 3

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6.2.1.2. 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 6.7: 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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6.2.1.3. Description of the pictograms in zone 1

Pictograms in zone 1

Pictograms Display

ctivation conditions

"MANU" Mode

Fixed TELYS in manual mode (MANU)

Flashing

For 5 seconds when switching from AUTO mode to MANU mode

"AUTO" Mode

Fixed TELYS in automatic mode (AUTO)

Flashing

For 5 seconds when switching from MANU mode to AUTO mode

Flashing Generating set in start-up phase

Fixed Generating set started

Fixed

Generating set stabilised (voltage and frequency)

Flashing (appearance of constant movement from left to right)

The generating set is powering the installation

Fixed The installation is supplied

Not used

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6.2.1.4. 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 / Fault

high fuel level

Coolant level / temperature indicator

Alarm

Low level

fault

High level fault alarm

Alarm High temperature fault

No preheating fault alarm

Battery

Min battery

voltage

(flashing)

Max battery voltage (flashing)

Battery charge

indicator

(flashing bars)

Oil pressure / temperature indicator

Oil pressure

Alarm / Fault

High or low oil

level

Alarm /

Fault

High or low oil

temperature

Alarm / Fault

Emergency stop

Emergency stop fault

Overload or short circuit

Tripping of circuit breaker following an overload

or short circuit

Engine speed

Underspeed fault

Overspeed fault

Non-starting fault

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6.2.1.5. Description of the pictograms in zone 3

Pictograms in zone 3

All the pictograms in these zones are activated when TELYS is initialised. The pictograms below are given as examples.

Generating set stopped

Screen no. Pictograms Data displayed

Fuel Level Indicator

Indication of Temperature of High Temperature coolant (HT) (units according to settings menu)

Indication of Battery Voltage

Indication of Oil Temperature (units according to settings menu)

Generating set start-up or generating set started or generating set switching off in progress

Screen no. Pictograms Data displayed

Engine Speed Indication

Indication of Temperature of High Temperature coolant (units according to settings menu)

Indication of Oil Pressure (units according to settings)

Indication of Oil Temperature (units according to settings menu)

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Generating set started

Screen no. Pictograms Data displayed

Default screen in operation

Fuel Level Indicator

Alternator composite Voltage Indicator

Total Active Power Indicator

Alternator Frequency Indicator

U12 Alternator composite Voltage Indicator

U23 Alternator composite Voltage Indicator

U31 Alternator composite Voltage Indicator

Alternator Frequency Indicator

V1 Alternator single Voltage Indicator

V2 Alternator single Voltage Indicator

V3 Alternator single Voltage Indicator

Alternator Frequency Indicator

U12 Alternator composite Voltage Indicator

V2 Alternator single Voltage Indicator

V1 Alternator single Voltage Indicator

Alternator Frequency Indicator

V1 Alternator single Voltage Indicator

Single phase Alternator current indicator

Alternator Frequency Indicator

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Screen no. Pictograms Data displayed

Single phase Alternator current indicator

Two phase Alternator current indicator

Three phase Alternator current indicator

Neutral Alternator current indicator

Total Active Power Indicator

Total Reactive Power Indicator

Total Effective Power Indicator

Total Power Factor Indicator (lagging or leading)

P10

Fuel Level Indicator

Indication of Battery Voltage

Indication of Battery Amps

Screen order of appearance according to network type with the generating set on.

Type of network

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

1 P3 P3 P3 P3 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

Change screens by using the scrolling and selection wheel. When the wheel is rotated clockwise, the screens scroll upwards and vice-versa. The screens scroll in a loop. E.g.: On three-phase + neutral network, then screen 7, then screen 1 and vice-versa.

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6.2.1.6. Display of messages in zone 4

The display (zone 4), among other things, displays messages relating to the operation of the generating set. The messages are as follows:

Initialisation of TELYS

Screen no. Screen Data displayed

G 1

Initialisation of TELYS when the power is switched on and/or when loading a configuration

G 2

SERIAL No.: 08030010000

SOFTWARE: 6.1.0

NOMINAL VOLTAGE: 400V

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

Generating set serial no. Software version of TELYS Alternator Nominal Voltage Alternator Nominal Frequency Nominal Active Output Neutral Point Bar graph indicating the display delay of the screen

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Generating set stopped

Screen no. Screen Data displayed

G 3

OPERATION

MANUAL

Press START

to start

24/08/2005 13:12

Operating mode - generating set in Manual Mode ready to start Date and time (depending on settings)

G 4

OPERATION

AUTO

WARNING

START-UP POSSIBLE

IMMEDIATELY

24/08/2005 13:12

Operating mode - generating set in Auto Mode ready to start Date and time (depending on settings)

G 5

WARNING

AUTOMATIC Start

19 min 30 sec

24/08/2005 13:12

Operating mode - generating set in Auto Mode with programmed start Countdown to micro disconnection delay or EJP notice delay (for France only) Date and time (depending on settings)

Generating set start-up

Screen no. Screen Data displa

G 6

START-UP

IN PROGRESS

24/08/2005 13:12

Operating phase - generating set in starting phase Date and time (depending on settings)

G 7

AIR PREHEATING

10 seconds

24/08/2005 13:12

Operating phase - air preheating prior to starting generating set Countdown for air preheating delay Date and time (depending on settings)

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Generating set started

Screen no. Screen Data displayed

G 8

Default

screen

AVAILABLE POWER

75%

24/08/2005 13:12

Operating phase – generating set in operation – stable voltage and frequency Available power Date and time (depending on settings)

G 9

AUTOMATIC STOP

IN PROGRESS

LOAD SUPPRESSION

1 min 30 sec

24/08/2005 13:12

Operating mode - operation in Auto Mode Opening of power supply device (motorised circuit breaker or source changeover switch controlled by TELYS) Countdown for the mains return delay OR the load test delay Date and time (depending on settings)

G 10

AUTOMATIC STOP

IN PROGRESS

COOLING DOWN

1 min 30 sec

24/08/2005 13:14

Operating mode - operation in Auto Mode Generation set cooling in progress Countdown for Engine Stop delay (cooling) OR Gradual Stop delay (Coolant temperature) OR Overload Gradual Stop delay OR OFF load test delay Date and time (depending on settings)

Generating setstop

Screen no. Screen Data displayed

G 11

OFF

IN PROGRESS

24/08/2005 13:16

Generating set stop in progress Date and time (depending on settings)

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Operating mode changeover (switching from Manual Mode to Auto Mode following auto start demand)

Screen no. Screen Data displayed

G 12

Start Demand

AUTO

Do you wish to change

to Auto Mode?

WARNING

Immediate start

OK Esc

Operating mode - operation in Manual Mode AUTOMATIC start demand

Generating set stop request due to fault or by pressing STOP in Auto Mode

Screen no. Screen Data displayed

G 13

Manual Mode

activated

Do you wish to change

to AUTO mode?

OK Esc

Operating mode - operation in Auto Mode (generating set in operation) Warning message for switching to Manual Mode after the STOP button has been pressed or a fault has appeared

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6.2.2 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)

1 ACTIONS

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11 MANUAL <> AUTO 12 CONTROL LOAD

13 TEST GENERATING SET

14 PROGRAMS

15 TEST LAMPS

12 OK Esc

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

OPERATION

MANUAL

Press START

to start

24/08/2005 13:12

 Check the battery voltage  Press START:

AIR PREHEATING

10 seconds

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).

START-UP

IN PROGRESS

24/08/2005 13:12

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

The following pictogram will flash

AVAILABLE POWER

100.0%

24/08/2005 13:12

The following pictogram is displayed

The following information is displayed

Speed of rotation

Coolant temperature

Options

Oil pressure

Oil Temperature

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6.2.3 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

OFF

IN PROGRESS

24/08/2005 13:12

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

6.2.4 Alarms and faults

6.2.4.1. Viewing alarms and faults

Alarms and faults are displayed as follows:

 Alarms

All alarms will cause:

 the yellow LED to flash "General alarm".

In conjunction with this LED:  a flashing pictogram appears on the LCD screen

representing the circuit affected by the alarm and the associated indicator, if present (example)

 message on graphic display (example)

FAULT

ALARM

Low Fuel Level

25/12/05 15:30

OK=HELP

 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".

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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)

 message on graphic display (example)

FAULT

Oil Pressure

25/12/05 15:30

OK=HELP

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

6.2.4.2. Activation of an alarm or fault

The appearance of an alarm o

a fault causes the corresponding screen to be displayed (examples below)

FAULT

ALARM

Low coolant Level

06/10/06 10:30

OK=HELP

FAULT

Emergency Stop

06/10/06 15:30

Esc=RESET OK=HELP

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

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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6.2.4.3. 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

Esc=RESET OK=LIST

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

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

FAULTS

1/2

FAULT 25/12/05 15:30 Emergency Stop

ALARM 25/12/05 15:30 Low Fuel Level

OK=HELP Esc

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

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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6.2.4.4. Engine fault codes display

Certain alarms and engine faults generate specific fault codes. These codes are standardised according to the J1939 and/or J1587 standards, except for MTU engines that have a specific transmission protocol (see appendix, if applicable).

Terminology used by the SAE CAN J1939 standard

SPN: Suspect Parameter

Number

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

FMI: Failure Mode identifier

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

Terminology used by VOLVO

SID: System Identifier

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

PID: Parameter Identifier

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

PPID: Parameter Identifier

This term, used in the J1587 standard, has an equivalent in the J1939 standard (SPN). PPID corresponds to PID, but is only used by VOLVO.

FMI: Failure Mode identifier

This represents the type of fault that has occurred. This may be an electrical, mechanical or equipment fault. VOLVO uses a SID-FMI or PID-FMI or PPID-FMI combination.

Terminology used by PERKINS

CID: Component parameter This term used by PERKINS has an equivalent in the J1939 standard (SPN).

FMI: Failure Mode identifier

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

Terminology used by JOHN DEERE

SPN: Suspect Parameter

Number

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

FMI: Failure Mode identifier

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

Terminology used by MTU

Displaying faults

The ADEC and MDEC general system faults are indicated on the equipment in the following

way: fault code numbers (generated by the ECU - Engine control unit).

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

FAULT

ALARM

ENGINE GENERAL 110 18

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.

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

6.2.4.5. Horn reset

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

HORN STOP

PRESS OK

25/12/2005 15:30

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

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6.3. Generator set with KERYS control panel

6.3.1 Presentation of the KERYS

The MICS Kerys system consists of a set of electronic modules in which each module performs a specific function.. These modules are interconnected according to a very precise architecture and exchange data to allow the following: the command, control, regulation and protection of one or more generating sets according to multiple configurations. The configurations range from the so-called “solo” generating set, with or without source inverter, to generating sets coupled to each other, enabling electrical power plants to be created that can be coupled to one or more distribution grids in low voltage (LV) and medium voltage (MV).

The MICS Kerys system consists of the following modules:

• man/machine interface module, also called MMI module,

• base module (heart of the system),

• regulation module,

• protection module,

• logic input/output module,

• analogue input/output module,

• temperature input module.

For the operation of a generating set in the smallest possible architecture, at least the following elements will be found:

• a man/machine interface module,

• a base module,

• a regulation module.

6.3.1.1. Operating conditions

 Operating temperatures: - 20 °C  + 70 °C

 Storage temperatures: - 20 °C  + 70 °C

 Relative humidity during operation: 10 % to 95 % without condensation

according to IEC 1131-2 and equivalent UL/CSA

 Relative humidity during storage: 5 % to 95% without condensation

according to IEC 1131-2 and equivalent UL/CSA

 Height: 2,000 m during operation (Transfer 3,000 m)

 Degree of protection: - Outside cabinet: IP54 (front of MMI modules).

- Inside cabinet: IP20 (BASE, ESTOR, ESANA, ETEMP, back of the MMI).

 Mechanical strength: Free falls (with packing), 5 random falls of:

1 m if p< 10 kg

0.5 m from 10 to 40 kg

0.25 m >40 kg

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6.3.1.2. Conformity to legal and regulatory requirements

The various components of the system comply with the following standards:

 Requirements specific to programmable controllers:

(Functional characteristics, immunity, robustness, safety, etc.)

 EN 61131-1/2/3 (IEC 1131-2, IEC 664), EN61326,  CSA 22-2,  UL508.

 Compliance with European directives (low voltage, electromagnetic compatibility, machinery). CE marking in

application of the safety requirements of standard EN 61131-2 – Programmable controllers, Part 2 – Equipment requirements and tests. To obtain the specific information prescribed by EN 61131-2, refer to the appropriate sections of that publication.

 Electrical and self-extinguishability properties of insulating materials:

 UL 746C,  UL 94.

 Pollution degree: 2

 Mechanical strength (details):

Vibration resistance: EN 61131-2 1994 (§2.1.3.2), Frequency range: 10 - 57 Hz, Continuous vibrations: 0.0375mm amplitude, Occasional vibrations: 0.075mm amplitude.

Frequency range: 57Hz - 150Hz, Continuous: 0.5 g constant acceleration, Occasional: 1 g constant acceleration. Complies with standard IEC 68-2-6, test Fc

Shock resistance Occasional shocks: 15g, 11ms, semi-sinus. Complies with standard IEC 68-2-27, test Fa

 Emissions: Complies with standard EN55022 class A

 Variation in supply voltage: EN61131-2 §6.3.7.3

 Immunity:

Complies with standard IEC 61000-4-2: Electrostatic discharge: 4 kV for contact discharge, 8 kV for air discharge. Complies with standard IEC 61000-4-3 Radiated field at 10V/m from 80MHz to 1GHz with sinusoidal modulation

AM 1kHz. Complies with standard IEC 61000-4-4: Rapid transients in waves of 2 kV on power cables, 1 Kv on signal cables. Complies with standard IEC 61000-4-5: Shock waves of 2 kV between wires and ground, 11 kV between wires for

the supplies and 1kV relative to ground for long signal circuits (lines from a

building or from a distance of over 30 m). Complies with standard IEC 61000-4-6: Immunity to current injected at 3V from 150 kHz to 80 MHz (could be

increased to 10V). Complies with standard IEC 61000-4-8: Immunity to the magnetic field at the grid frequency at 30 A/m.

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6.3.2 Description of the KERYS

6.3.2.1. Identification of the hardware components

KERYS Tactil MMI module

MMI Module

P/N: 31613391001

Module item reference

D346000/B1

D346000: manufacturer product reference B1: module hardware upgrade index

S/N: 1800

1800: serial number “not related” with a batch number

(1800 = the 1800

module manufactured since the start)

BATCH No.: 08/06

08: year of manufacture (year 2008) 06: week of manufacture (week 6)

Base module

P/N: 31613390901

Module item reference

D338000/B8

D338000: manufacturer product reference B8: Module hardware upgrade index

S/N: 3491

3491: serial number “not related” with a batch number

(3491 = the 3491st module manufactured since the start)

BATCH No.: 07/45

07: year of manufacture (year 2007) 45: week of manufacture (week 45)

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Regulation module

31613391501

Module item reference

A44Z1-G

A44Z1: manufacturer product reference G: “main” module hardware upgrade index

0408A519

04: week of manufacture (week 4) 08: year of manufacture (year 2008) A: “secondary” module hardware upgrade index 519: serial number “related” with a batch number (*)

(519 = the 519

module manufactured in week 04 of

the year 2008)

(*) i.e. a maximum of 999 modules that can be related with a batch number.

Protection module

31613391601

Module item reference

A44Z2-E

A44Z2: manufacturer product reference E : “main” module hardware upgrade index

4307A035

43: week of manufacture (week 43) 07: year of manufacture (year 2007) A: “secondary” module hardware upgrade index 035: serial number “related” with a batch number (*)

(035 = the 35

module manufactured in week 04 of

the year 2008)

(*) i.e. a maximum of 999 modules that can be related with a batch number.

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Logical inputs and outputs module

Logical inputs and outputs module (ESTOR –Binary inputs and outputs)

P/N :

31613391201

Module item reference

D341000/B1

D341000: manufacturer product reference B1: module hardware upgrade index

S/N: 0250

0250: serial number “not related” with a batch number

(0250 = le 250

module manufactured since the start)

Batch No.: 06/49

06: year of manufacture (year 2006) 49: week of manufacture (week 49)

Analogue inputs and outputs module

Analogue inputs and outputs module (ESANA)

P/N:

31613391301

Module item reference

D343000/B1

D343000: Manufacturer product reference B1: module hardware upgrade index

S/N: 0200

0200: serial number “not related” with a batch number

(0200 = the 200th module manufactured since the start)

BATCH No.:

06/49

06: year of manufacture (year 2006) 49: week of manufacture (week 49)

Temperature inputs module

Temperature inputs module (ETEMP)

P/N:

31613391401

Module item reference

D344000/B1

D344000: manufacturer product reference B1: module hardware upgrade index

S/N: 0150

0150: serial number “not related” with a batch number

(0150 = the 150

module manufactured since the start)

BATCH No.:

06/49

06: year of manufacture (year 2006) 49: week of manufacture (week 49)

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6.3.2.2. Identification of the software components

Only the components base module, MMI module, regulation module and protection module have embedded software. ”Software version” is referred to in order to identify a program implemented in one of the components.

V1.05c1

: as software version

1.05 : is the revision, which is a combination of 3 digits c : main revision index 1 : secondary revision index used for specific projects

2007_02_12

Date of software version in English (year, month, day).

For a modification of a software version during the life of one of the products (developments, corrections, etc.), the new software version implemented will be entered by hand in a space reserved for this. The old software version will then be deleted.

factory soft version

1.05c 2007 02 12

Location of the version labels

MMI

Base module

Regulation module Protection module

factory soft version

1.05c 2007 02 12

factory soft version

1.05c 2007 02 12

factory soft version

1.05c 2007 02 12

factory soft version

1.05c 2007 02 12

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6.3.3 Description of the Man Machine Interface (IHM/MMI)

6.3.3.1. The Man Machine Interface

Display

The display has the following specifications:

 7-inch colour TFT display, 16/9, 65536 colours  dimensions: 154 mm x 86 mm  neon backlighting  480 x 234 resolution  touch panel (8 columns x 8 rows).

Signalling control

keys

Operating buttons of the

generating set

Backlit display with touch-sensitive keypad

Alphanumeric keypad

Navigation keys

M.M.I. operation LED

(flashing)

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The generating set operational keys

1 Manual mode selection. The illuminated led indicates that the mode is active 2 Selecting stop mode. The illuminated led indicates that the mode is active 3 Automatic mode selection. The illuminated led indicates that the mode is active 4 Test in progress LED. 5 In auto mode: test sequence control (off load test / load test) (*)

In manual mode: engine start-up and stop 6 Generating set circuit breaker opening control 7 Led indicating that generating set circuit breaker is open 8 Grid circuit breaker opening control 9 Led indicating that grid circuit breaker is open

10 Grid circuit breaker closing control 11 Led indicating that grid circuit breaker is closed 12 Led indicating the presence of grid voltage 13 Led indicating that grid circuit breaker is closed 14 Closing control for generating set circuit breaker 15 Led indicating the presence of generating set voltage

(*) The test request brings up a screen which offers a choice between “load test” and “off load test”.

The signalling control keys

The

key clears the faults.

The

key stops the buzzer.

The

key commands testing of the LED’s on the front of the MMI.

678

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The navigation keys

It is also possible to navigate through the menus using the keypad.

It is possible to gain direct access to a menu by pressing the numerical key corresponding to its name.

The alphanumeric keys

They allow alphanumeric input by successive pressing of the keys. The characters entered appear in the order they were typed on the keypad.

Move to the right

Move up

Move down

Confirm function of selected key

Return to upper level or escape for

the dialogue boxes

Move to the left

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6.3.3.2. Navigation in the screens

There are three types:

 the home screen,  the navigation screens,  the operation and configuration screens.

Home screen

This screen is the entry point to the system. It enables the main functions of the navigation to be accessed.

15/10/03 19:10 :00 GS 1 Home Auto Faults Alarms

- 1 -

Operation

- 6 -

System

- 2 -

Fault finding

- 5 -

Configuration

- 3 -

Archiving/Metering

-4 -

Maintenance

Navigation screens

These screens enable the various sub-menus to be accessed.

15/07/09 19:10 :00 GS 1 System Auto Faults Alarms

- 0 -

Welcome

- 1 -

Operation

- 2 -

Function keys

- 7 -

User adjustments

- 3 -

Synchro. column

- 6 -

Alarms & Faults

- 4 -

Central measurements

summary

- 5 -

Measurements

When a key is selected the lower level sub-menu appears if available or the allocated operation screen. A sub-menu can also be accessed by pressing the corresponding key. E.g.: by pressing key “1” on the alphanumeric keypad, you can directly access the "Operation” screen.

Title of the active menu Upper level

Lower levels

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The operating and configuration screens

These screens bring up the information and commands relating to the active menu. They are divided into three zones:

 an upper band common to all types of screens.  the central section in which the specific information on the selected menu appears.  a lower band.

15/07/09 19:10 :00 GS 1 Event archive Auto Faults Alarms

- 1 -

Electrical archive

- 2 -

Mechanical archive

-3 –

Event metering

Upper band

Indications

15/07/09 19:10 :00 GS 1 Welcome Auto Faults Alarms

Upper band

Central section

Lower band

Date of the system

Time of the system

Reference of the GS with which the M.M.I. dialogues

Indication of the presence of a fault on the GS

concerned (flashing red)

Indication of the presence of an alarm on the GS

concerned (orange flashing)

Indication of the operating mode of the

GS concerned

Name of the active screen

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Controls

15/07/09 19:10 :00 GS 1 Welcome Auto Faults Alarms

Lower band

- 1 -

Function keys

- 2 -

Synchro. column

- 3 –

Measurements

The registration dialogue box

The registration dialogue boxes

To facilitate the entry of the information (parameters, texts), there are special screens, called “dialogue boxes”, which appear when the need arises.

Confirmation of an entry in a menu

After the modification of a value in a menu the following dialogue box appears:

Validation

Validation of data entered

Valid Esc.

The confirmation key “Valid” saves the modification, the escape key “Esc.” cancels the modification.

Access to the regional parameters screen

Access to the “Drive” or “TOR

variables” screen

Access to the “Alarms and Faults” screen

When configured in power plant with switches, displays a dialogue box enabling you to select the generating set to which you want to be connected

1st action: access to the home screen 2nd action: return to the menu previously

selected (before first pressing the button)

Return to the last active

operating screen

Return to the navigator menu

One or more shortcut keys to the functions associated with the active screen

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Entry of a text

Title configuration

CDE AERO

Insert Copy Paste

Valid Delete title Delete a character Esc.

You move within the text using the “right” or “left” arrows on the keypad. The characters are entered by means of the alphanumeric keys on the keypad.

Entering numerical values

The heading of the box provides information on the type of value entered, its unit and the variable concerned.

These indications are linked to the type of modified parameter.

Time in 1/10 second (6000)

0<= 0000 <=9999

Valid Esc.

Saves the changes and closes the dialogue box

Deletes the entire text

Deletes the letter shown by the cursor

Closes the menu without saving the changes

Name of the modified function

Text to be modified or created

Inserts a space to the left of the cursor

Saves the modifications and closes the screen

If it exists, indicates the lowest possible value

If it exists, indicates the highest possible value

Closes the screen without saving the modifications

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Selecting from a list

The box heading indicates the parameter which will be assigned from your selection.

Type of fault (6000)

Whithout

General

Alarm

Valid Esc.

Saving changes

After changing a parameter, the new data is stored in volatile memory, which means that in the event of a power failure, any changes will be lost. It is also necessary to transfer these values to permanent memory. This is the “Save in flash” operation. Following a modification a red “Sauvegarde à faire” (Save) indicator light flashes at the top left of the screen. Pressing this indicator light brings up one of the following dialogue boxes:

Save in flash

Valid Esc.

Save in flash

Custome

Factory

Valid Esc.

Always select “Client”

Pressing “Valid” confirms the operation, pressing “Esc.” cancels it.

List indicating possible selections

Arrows for moving the cursor

Active selection

Arrows only visible if the number of choices does not fit on the screen (enables you to go to the next page on the list or return to the previous page on the list)

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During saving, the following screen indicates that the operation in is progress:

6.3.4 Configurations

6.3.4.1. Operating principle

The operational modes are as follows:

SOLO

Genset

Without

coupling to

grid

With coupling

to grid

- Operation of a single genset without coupling.

- Normal/emergency switch (NES) not controlled by Kerys.

Without N/E

switch

(A612)

Temporary

coupling

(A651)

Power plant

Without

coupling to

grid

Without N/E

switch

(A633)

- Automatic operation of a single genset.

- Temporary coupling on grid return following interruption.

Without N/E

switch

(A632)

- Operation of a power plant without coupling to grid.

- Normal/emergency switch (NES) not controlled by Kerys.

- Power plant gensets interconnected by parallel lines.

- Operation of a power plant without coupling to grid.

- Normal/ermegency switch (NES) not controlled by Kerys.

- Power plant genset interconnected by CAN.

Note:

Without coupling: the switch is equipped with electrical and mechanical interlocking. With coupling: the switch is not equipped with an electrical and mechanical interlock.

Saving in flash…

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6.3.4.2. Legends

Electrically controlled circuit breaker

Exchange of information from A to B and from B to A

Transmission of information from A to B only

3 PH ”Current” information, 3 PH = 3 phases

3 PH + N ”Voltage” information, 3 PH + N = 3 Phases + Neutral

6.3.4.3. Configuration in solo generating set

Without Normal/Emergency inverter (A612)

This configuration is designed to provide:

 The generation of electricity for an installation from an external starting command (dry contact).  The generation of electricity for an installation in forced operation.

Regulation

module

Base

module

3PH + N

3PH

MMI module

Application (load)

Automatic operation (Kerys in “AUTO” mode) Loss of grid voltage

• Generating set start request (dry contact, switch, clock, etc.).

• The speed and voltage of the generating set increase.

• Generating set power unit switched off after voltage and frequency stabilisation.

Return of grid voltage

•

Dry contact, switch, clock, etc. switched on.

• Cooling delay.

• Generating set stopped and set to standby.

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FORCED OPERATION (Kerys in “AUTO” mode) Start of FORCED OPERATION

• Generating set start request (dry contact, switch, clock, etc.).

• The speed and voltage of the generating set increase.

• Generating set power unit switched off after voltage and frequency stabilisation.

The installation is supplied by the generating set

End of FORCED OPERATION

• Dry contact, switch, clock, etc. switched on.

• Generating set power unit switched on.

• Cooling delay.

• Generating set stopped and set to standby.

The Kerys remains in ”AUTO” mode

Manual operation of generating set

This mode of operation is selected with the “MANU” key (on the front of the MMI module). The operator is able to start and stop the generating set by using the MMI keypad. The generating set power unit is switched off by means of the MMI keys. The safety devices of the generating set remain active in this mode of operation.

This mode of operation is the responsibility of the operator.

Temporary coupling to the grid (A651)

This configuration is designed to provide:

 Emergency electricity supply to an installation following a grid loss. Return to the grid is achieved by a temporary coupling

with transfer of the generating set load to the grid.

 FORCED OPERATION with a generating set.  Temporary coupling for “Effacement Jour de Pointe” (EJP)* mode or other rates (Information transmitted by dry contacts).

Regulation

module

Base

module

3PH + N

3PH

Optional manual or motorised

circuit

breaker

MMI Module

Application

(load)

Grid

* the “EJP” (Peak Day Load Shedding) system is specific to the French power grid.

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Automatic operation (Kerys in “AUTO” mode) (temporary “grid return” coupling) Loss of grid voltage

•

Adjustable grid loss acquisition delay (controlled by the Kerys or by a mains detection module).

• Generating set start request.

•

The speed and voltage of the generating set increase.

• Power unit switched on, grid side.

•

Generating set power unit switched off after voltage and frequency stabilisation.

Return of grid voltage

•

Adjustable grid return acquisition delay (controlled by the Kerys or by a mains detection module).

• Synchronisation of the generating set to the grid.

• After synchronisation, the grid power unit is switched off.

• Transfer of the active and reactive power of the generating set to the grid according to a predetermined ramp. The ramp

does not exceed 10 seconds for transfer of the generating set’s rated output. The generating set power unit is disconnected when the power on the generating set reaches the lower limit.

• Generating set power unit switched on.

• Cooling delay.

• Generating set stopped and set to standby.

The Kerys remains in “AUTO” mode

FORCED OPERATION (Kerys in “AUTO” mode)

(temporary outward and return coupling)

Start of FORCED OPERATION

• Generating set start request.

• The generating set voltage and speed increase.

• When the generating set is stabilised in speed and voltage, synchronisation of the generating set to the grid is requested.

• After synchronisation, the generating set power unit is switched off.

• Transfer of the active and reactive power from the grid to the generating set according to a predetermined ramp. The ramp

does not exceed 10 seconds for transfer of the generating set’s rated output. The generating set power unit is disconnected when the power on the generating set reaches the lower limit.

• Power unit switched on, grid side.

The installation is supplied by the generating set

End of FORCED OPERATION

•

Opening of the forced operation order.

• Synchronisation of the generating set to the grid.

•

Grid power unit switched off.

•

Transfer of the generating set’s active and reactive power to the grid.

• Generating set power unit switched on.

• Cooling delay.

• Generating set stopped and set to standby.

The Kerys remains in “AUTO” mode

The installation is supplied by the grid

Manual generating set operation

This mode of operation is selected with the “MANU” key. The operator is able to start and stop the generating set via the MMI keypad. The power unit is switched off manually with the manual synchronisation of the generating set to the grid using the keys “+ F”, “- F”, “+V”, “-V”, the load transfer remains automatic. The safety devices of the generating set remain active in this mode of operation.

This mode of operation is the responsibility of the operator

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6.3.4.4. Power plant configuration (Several generating sets in parallel)

Without common part and without Normal/Emergency inverter (A632)

This configuration is designed to provide:

 Emergency electricity supply to an installation following a grid loss (The grid loss is not controlled by Kerys). Return to the

grid will be achieved by Normal / Emergency switchover by means of a self-driven inverter (not controlled by Kerys).

 FORCED OPERATION with a generating set.  Operation in “Effacement Jour de Pointe” (EJP)* mode or other rates.(Information transmitted by dry contacts).  An active power regulation (speed of the generating sets) by parallel lines connected between all the regulation modules.

Regulation

module

Base

module

3PH + N

3PH

Regulation

module

Base

module

3PH + N

3PH

Genset 1

Genset 2

Genset x

Parallel line

(*) the “EJP” (Peak Day Load Shedding) system is specific to the French power grid.

Note 1: In this operating mode there is no reactive power regulation (generating set voltage); the generating sets are static.

Note 2: In an installation of the power station type (several generating sets in parallel) two modes of coupling between generating

sets are possible

• Coupling when stopped.

• Coupling in normal operation.

Principle of coupling when stopped

- all the generating set power units are switched off,

- starting of all the generating sets,

- when the speed reaches 1450 rpm, activated excitation command on all the generating sets,

- the voltage generated by each generating set increases gradually and the voltage is therefore the same in all generating sets,

- the generating sets therefore reach 1500 rpm at 400 V 50 Hz.

At the end of global operation, if the power consumed by the installation does not require the operation of all the generating sets within the power plant, one or more generating sets will be stopped according to the wattmetric control. Restarting of the generating set (these generating sets) depends on the load and wattmetric control of the load. However, if a generating set is reconnected to a busbar already subjected to a load, the “recoupling” is carried out in normal operation and not when the generating set is stopped.

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Principle of coupling in normal operation

Coupling in normal operation enables all the generating sets to be coupled (in voltage and frequency) to a busbar supplied by a generating set designed as master at the output. A number (1 to 15) is assigned to each Kerys. This number serves solely to establish the IP address of each Kerys for communication by Ethernet and loading the programs. A second number (from 1 to 15) is also assigned to each Kerys and defines the priority.

Example: let us assume a plant of 8 generating sets

Gen set 1 2 3 4 5 6 7 8

Priority 08 07 06 05 04 03 02 01

The numbers on the first line enable the IP address of each Kerys to be allocated. The numbers on the second line define the priority. Therefore Kerys no. 8 with priority 01 is considered to be the master generating set and closes its flow first. The other generating sets then synchronise one by one to the central busbar, transmitting the information on voltage, frequency and phase difference to this busbar (see sketch).

CB1

GS1

CB2

GS2

CB3

GS3

Busbar U

Example for 3 GSs:

• DJ1 (Circuit breaker 1) is closed, the voltage is present on the busbar.

• Kerys 2 analyses the differences between U2 and U of the busbar before coupling.

• Kerys 3 analyses the differences between U3 and U of the busbar before coupling.

Each Kerys, independently of its neighbour, will close its discharge on the central busbar.

Wattmetric control

The wattmetric control is used when two generating sets are coupled. It provides optimum management of the number of generating sets operating by constantly analysing the power required by the user.

Let us take the example of a power plant of 4 x 600 kW generating sets. The threshold setting screen (1-7-3-3) supplies the following data:

Threshold 1 GS => 2 GS 75% 450 kW Threshold 2 GS => 1 GS 30 % 360 kW

Threshold 2 GS => 3 GS 75% 900 kW Threshold 3 GS => 2 GS 30 % 540 kW

Threshold 3 GS => 4 GS 75% 1350 kW Threshold 4 GS => 3 GS 30 % 720 kW

The maximum available power is 600 x 4 = 2400 kW. Assuming that a single generating set is operating, we will have the following sequence in the case of linear progression of the load.

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The second GS thus coupled initiates its power on ramp (adjustable delay) and the distribution of power among the two generating sets takes place. Each generating set will then take 50% of the required power, i.e. 225 kW.

When the power required for the application reaches 75% of the power of the two generating sets in operation (GSs at priority 01 and 02), i.e. 900 kW, the third GS (at priority 03) is then started and is synchronised with GS1 and GS2. Its flow is then closed. The third GS thus coupled initiates its power on ramp (adjustable delay), and the distribution of power among the three generating sets takes place. Each generating set will then take 33.33% of the required power, i.e. 300 kW, corresponding to 50% of its rated output (600 kW).

When the power required for the application reaches 75% of the power of the three GSs in operation (GSs at priority 01, 02 and

03), i.e. 1350 kW, the fourth GS (at priority 04) is then started and synchronised with GS1, GS2 and GS3. Its flow is then closed. The fourth GS thus coupled initiates its power on ramp (adjustable delay) and the distribution of power among the four generating sets takes place. Each generating set will then take 25% of the power required, i.e. 337.5 kW, corresponding to 56.25% of its rated output (600 kW).

The power required for the application may continue to increase up to the upper plant limit (95%) of 2400 kW, i.e. 2280 kW (the setting can be changed). This corresponds of course to the upper generating set limit, i.e. 570 kW (95% of 600 kW).

Automatic operation (All Kerys PLCs in “AUTO” mode) (coupling when stopped) Loss of grid voltage

• Grid loss acquisition delay (controlled by the mains detection module).

• Generating set power units switched off.

• Generating set start request.

• The generating sets’ speed increases.

• Speed stabilisation delay.

• Order of excitation for each generating set at nominal speed; the voltage is then quickly established on the busbar.

• Start of distribution of active power.

• Resumption of use at the rated power and frequency.

Wattmetric control

This wattmetric control will be activated after a global operation delay. This global operation enables the application to be resumed after power is restored to the different outputs, and ensures stability of the load before the wattmetric control is started. Depending on the power for the application, the number of generating sets in production may vary in order to optimise the production for consumption.

The procedure is as follows:

• End of the global operation delay.

• Start of analysis of the active power consumed.



Example: A generating set must be stopped according to the set thresholds.

• Power cut at the non-priority generating set, transfer of the power to the generating set(s) remaining in production.

• Uncoupling of the non-priority generating set, at zero power, by switching on the generating set power unit.

• Cooling delay.

• Generating set stopped and set to standby.

 Example of increase in power:

• Generating set start request.

• The speed of the generating set increases.

• Alternator excitation, the generating set establishes its voltage.

• Request for synchronisation of the generating set to the busbar (i.e. the other coupled generating sets).

• Generating set power unit switched off.

Return of grid voltage

•

Grid return acquisition delay (controlled by the mains detection module).

• Generating set power units switched on.

• Cooling delay.

• Generating sets stopped and set to standby.

The Kerys PLCs remain in “AUTO” mode

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FORCED OPERATION Start of FORCED OPERATION

• Generating set power units switched off.

• Generating set start request.

• The generating sets increase in speed.

• Speed stabilisation delay.

• Order of excitation for each generating set at nominal speed; the voltage is then quickly established on the busbar.

• Start of active power distribution.

• Resumption of application at rated voltage and frequency.

The Kerys PLCs remain in “AUTO” mode

The installation is supplied by the generating sets

End of FORCED OPERATION

• Generating set power units switched on.

• Cooling delay.

• Generating sets stopped and set to standby.

The Kerys PLCs remain in “AUTO” mode

The installation is supplied by the grid

Manual power plant operation

This mode of operation is selected with the “MANU” key. This enables the operator to start and stop the generating sets one by one via the MMI keypad. The generating set power unit is switched off manually with synchronisation of each generating set to the busbar using the MMI keys “+F”, “-F”, “+V” and “-V”. The distribution of power among the generating sets remains automatic. The safety devices of the generating sets remain active in this mode of operation.

This mode of operation is the responsibility of the operator.

Without common part and without Normal/Emergency inverter (A633)

This configuration is designed to provide:

 Emergency electricity supply to an installation following a grid loss (The grid loss is not controlled by the Kerys).

Return to

the grid can be achieved via Normal / Emergency switchover with a self-driven inverter (not controlled by the Kerys).

 FORCED OPERATION with a generating set.  Operation in “Effacement Jour de Pointe” (EJP)* mode or other rates. (Information transmitted by dry contacts).  Active power regulation (speed of the generating sets) by digital buses connected between all the regulation modules.

Regulation

module

Base

module

3PH + N

3PH

Regulation

module

Base

module

3PH + N

3PH

Genset 1

Genset 2

Genset x

Digital Bus

(*) the “EJP” system is specific to the French power grid.

Note 1: In this operating mode active and reactive power is distributed by a digital bus between the regulation modules (voltage of

the generating sets).

Note 2: In an installation of the power plant type (several generating sets connected by digital bus), two modes of coupling

between generating sets are possible

• Coupling when stopped.

• Coupling in normal operation.

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Principle of coupling when stopped

- all the generating set power units are switched off,

- starting of all the generating sets,

- when the speed reaches 1450 rpm, activated excitation command on all the generating sets,

- the voltage generated by each generating set increases gradually and the voltage is therefore the same in all generating sets,

- the generating sets therefore reach 1500 rpm at 400 V 50 Hz.

Principle of coupling in normal operation

Example: let us assume a plant of 8 generating sets

Gen set 1 2 3 4 5 6 7 8

Priority 08 07 06 05 04 03 02 01

The numbers on the first line enable the IP address of each Kerys to be allocated. The numbers on the second line define the priority.Therefore Kerys no. 8 with priority 01 is considered to be the master generating set and closes its flow first. The other generating sets then synchronise one by one to the central busbar, transmitting the information on voltage, frequency and phase difference to this busbar (see sketch).

CB1

GS1

CB2

GS2

CB3

GS3

Busbar U

Example for 3 GSs:

• DJ1 (Circuit breaker 1) is closed, the voltage is present on the busbar.

• Kerys 2 analyses the differences between U2 and U of the busbar before coupling.

• Kerys 3 analyses the differences between U3 and U of the busbar before coupling.

Each Kerys, independently of its neighbour, will close its discharge on the central busbar.

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Wattmetric control

The wattmetric control is used when two generating sets are coupled. It provides optimum management of the number of generating sets operating by constantly analysing the power required by the user.

Let us take the example of a power plant of 4 x 600 kW generating sets. The threshold setting screen (1-7-3-3) supplies the following data:

Threshold 1 GS => 2 GS 75% 450 kW Threshold 2 GS => 1 GS 30 % 360 kW

Threshold 2 GS => 3 GS 75% 900 kW Threshold 3 GS => 2 GS 30 % 540 kW

Threshold 3 GS => 4 GS 75% 1350 kW Threshold 4 GS => 3 GS 30 % 720 kW

The maximum available power is 600 x 4 = 2400 kW. Assuming that a single generating set is operating, we will have the following sequence in the case of linear progression of the load.

When the power required by the application reaches 75% of the power of the generating set in operation (GS at priority 01), i.e. 450 kW, the second GS (at priority 02) is started and is synchronised with GS 1. Its flow is then closed. The second GS thus coupled initiates its power on ramp (adjustable delay) and the distribution of power among the two generating sets takes place. Each generating set will then take 50% of the required power, i.e. 225 kW.

When the power required for the application reaches 75% of the power of the two generating sets in operation (GSs at priority 01 and 02), i.e. 900 kW, the third GS (at priority 03) is then started and is synchronised with GS1 and GS2. Its flow is then closed. The third GS thus coupled initiates its power on ramp (adjustable delay), and the distribution of power among the three generating sets takes place.Each generating set will then take 33.33% of the required power, i.e. 300 kW, corresponding to 50% of its rated output (600 kW).

When the power required for the application reaches 75% of the power of the three GSs in operation (GSs at priority 01, 02 and

The power required for the application may continue to increase up to the upper plant limit (95%) of 2400 kW, i.e. 2280 kW (the setting can be changed).This corresponds of course to the upper generating set limit, i.e. 570 kW (95% of 600 kW).

Automatic operation (All Kerys PLCs in “AUTO” mode) (coupling when stopped) Loss of grid voltage

•

Grid loss acquisition delay (controlled by the mains detection module).

• Generating set power units switched off.

• Generating set start request.

• The generating sets increase in speed.

• Speed stabilisation delay.

• Order of excitation for each generating set at nominal speed; the voltage is then quickly established on the busbar.

• Start of active power distribution.

• Resumption of application at rated voltage and frequency.

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Wattmetric control

The procedure is as follows:

• End of the global operation delay.

• Start of analysis of the active power consumed.



Example: A generating set must be stopped according to the set thresholds.

• Power cut at the non-priority generating set, transfer of the power to the generating set(s) remaining in production.

• Uncoupling of the non-priority generating set, at zero power, by switching on the generating set power unit.

• Cooling delay.

• Generating set stopped and set to standby.

 Example of increase in power:

• Generating set start request.

• The generating set increases in speed.

• Alternator excitation, the generating set establishes its voltage.

• Request for synchronisation of the generating set to the bus bar (i.e. the other coupled generating sets).

• Generating set power unit switched off.



Return of grid voltage

• Grid return acquisition delay (controlled by the mains detection module).

• Generating set power units switched on.

• Cooling delay.

• Generating sets stopped and set to standby.

The Kerys PLCs remain in “AUTO” mode

FORCED OPERATION Start of FORCED OPERATION

•

Generating set power units switched off.

• Generating set start request.

• The generating sets increase in speed.

• Speed stabilisation delay.

• Order of excitation for each generating set at nominal speed; the voltage is then quickly established on the busbar.

• Start of active power distribution.

• Resumption of application at rated voltage and frequency.

The Kerys PLCs remain in “AUTO” mode

The installation is supplied by the generating sets

End of FORCED OPERATION

• Generating set power units switched on.

• Cooling delay.

• Generating sets stopped and set to standby.

The Kerys PLCs remain in “AUTO” mode

The installation is supplied by the grid

Manual power plant operation

The

safety devices of the generating sets remain active in this mode of operation.

This mode of operation is the responsibility of the operator.

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6.3.5 Connections of the generating sets

6.3.5.1. Recommendations before the connections

Warning

Disconnect the battery cables before carrying out any work on the generating set.

To disconnect the battery disconnect the negative cable (-) first.

6.3.5.2. Connections according to the configurations

Solo generating set without inverter (A612)

Solo generating set, CRF coupling (A651)

Power plant without common part without inverter (A632)

Power plant without common part and without inverter

(A633)

Ground connection

X X

Ground connection box

X X

Facility power outlet

O O O O

Connecting cables between the generating sets (CAN BUS)

Connecting cables between the generating sets (Parallel line)

Power cables

X X X X

Customer terminal:

Remote operation

z z z z

External emergency stop

z z z z

EJP

z z z z

Switch grid detection

(1)

z z

Grid detection by regulation card

(1)

z z

Emergency N/E switch control

Emergency cutout

Normal N/E switch control

Summary of faults and alarms

z z z z

Generating set operation

z z z z

Generating set available in Auto

z z z z

X: to be connected O: if available

z: if necessary

(1)

Only one of the two grid detections needs to be cabled.

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6.3.5.3. Earthing system (Standard only)

• The ground of the generating set must be connected to earth. To do so, use a copper cable (Green / Yellow), 25 mm² minimum

for a bare cable and 16 mm² for an insulated cable, connected to the earth of the generating set, and to a ground rod of galvanised steel pushed vertically into the ground.

For a fault voltage of 25 V and a fault current of 30 mA.

Nature of the ground

Rod length (in

metres)

Rich arable land, moist compact hard core

Poor arable land 1 Poor arable land, gravel, coarse hard core

Stony bare soils, dry sand, impermeable rocks

3.6

To obtain an equivalent length several ground rods can be used connected in parallel and separated by at least their length. Example: Four 1 metre rods interconnected and separated by 1 metre respectively.

• Check the earthing connection before switching on the generating set.

• Check that the safety earthing system is working.

Single genset Earthing system

: IT

Active isolation controller

DISJONCTEUR

Ground

Ground rod

Interconnection

bar between

genset grounds

CIRCUIT

BREAKER

Current

transforme

Isolated neutral

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Earthing system: TNS

Earthing system: TT

Active differential circuit breaker

Type of earthing system: EDF application (On rental generating set only)

Active differential circuit breaker

DISJONCTEUR

Neutral

Ground

Ground rod

DISJONCTEUR

Neutral

Ground

Ground rod

DISJONCTEUR

Ground

Ground rod

Interconnection

bar between

genset grounds

Interconnection

bar between

genset grounds

Interconnection

bar between

genset grounds

CIRCUIT

BREAKER

Neutral connected to grounds

Current

transformer

Current

transformer

Current

transformer

CIRCUIT

BREAKER

CIRCUIT

BREAKER

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Power plant Connection of the generating sets to the box

One ground rod for one generating set power plant

Important

Genset 1

Genset 2

Ground rod

Neutral

Earth junction box

GS1 current transformer

link

GS2 current transformer

link

GSX current transformer

link

1 current

transformer per GS

Genset x

Genset 2

Genset 1

Genset x

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Earthing system: IT

Earthing system: TNS

Earthing system: TT

DISJONCTEUR

Neutral connected to grounds

Ground

Ground rod

DISJONCTEUR

Ground

Ground rod

DISJONCTEUR

Neutral

Ground

Ground rod

Junction box

If equipped

CIRCUIT

BREAKER

CIRCUIT

BREAKER

CIRCUIT

BREAKER

Current

transformer

Current

transformer

Isolated neutral

Current

transformer

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Connection of generating sets to client terminal boards

Reinsert the shunts of terminals 45 and 46 after having disconnected the current transformer from the junction box.

Important

6.3.5.4. Facility power outlet

The facility power outlet (if fitted) provides the emergency supply to the generating set from an external electrical source. It enables the different units (preheating, desk, etc.) to be powered without using their batteries.

464748

Xcbc3

464748

Xcbc3

Junction box

Remove the shunts at terminals 45-48 and 46-47

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6.3.5.5. Connecting cable between the generating sets (power plant)

The power cables and the generating set connecting cable may intersect

Important

Rental application

The generating set power cables and connecting cable cannot be placed in parallel less than 1 metre apart.

Important

The generating set power cables, the generating set connecting cable and the connections must be in perfect condition. Replace them if necessary.

Important

Generating set 1

019x04

019x12

Generating set 2

019x04

019x12

2 generating sets

Generating set 1

019x04

019x12

Generating set 2

019x04 019x12

Generating set 3

019x04

019x12

Generating set x

019x04 019x12

3 or more generating sets

Connecting cable

Power cable

Connecting cable

Power cable

1 metre MIN.

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6.3.5.6. Power

1. Pass the power cables through the access hatch to the power box of the generating set (AIPR or console, depending on the generating set).

2. Connect the power cables to the busbars.

3. Connect the power cables to the application.

Check that the direction of rotation of the phases between the generating set and the application is the same.

Important

Type of cables: Use H074NF type cables according to the standards in force in the country of use of the generating set (In

France refer to the standard C15.100).

6.3.5.7. Client terminal block

Refer to the wiring diagrams according to the configuration selected and the requirements.

GENERATING SET

APPLICATION

N R

S T

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6.3.6 Operation and setting menus

6.3.6.1. Layout of the menus

The diagram below shows the layout of the main menus.

-1 -

Operation

-2 -

Fault finding

-3 -

Archiving

& Metering

-4 -

Maintenance

-5 -

Configurations

-6 -

System

-0 -

Home

-1.2 -

Function keys

-1.3 -

Synchro.

Column

-1.4 -

Power plant

measurements

synthesis

-1.5 -

Measurements

-1.6 -

Alarms

& faults

-1.7 -

User settings

- 2.1 -

Digital

Variables

- 2.2 -

Analog variables

- 2.3 -

REG & PRO

variables

- 2.4 -

Curves

- 3.1 -

Events

SDMO R 340 U, R570U User And Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual