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Oil flows into the cylinder head via a hollow locating dowel in the top deck of the cylinder block. Oil travels to the camshaft bearing journals and the three center rocker arm shaft supports through drilled passages in the cylinder head. The supports supply oil to each rocker shaft. Oil flows to the bushings of the injector rocker arm through holes in the rocker arm shaft. This same oil lubricates the valve and the rollers. Oil flows through drilled passages in the rocker arms. This oil lubricates the roller, the valve bridge and the contact surfaces of the actuator of the unit injector. The remaining valve system components are lubricated by splash oil. When all the components have been lubricated, the excess oil returns to the engine oil pan. 3.9.2 LUBRICATION SYSTEM COMPONENTS

The major components of the lubrication system are: • • • • • • • Oil Pan Oil Pump Oil Cooler Oil Filter Turbocharger Oil Lines Oil Passages for the Cylinder-Head and Block Fume Disposal Collector

Each of these components are discussed in the following sections. 3.9.2.1 OIL PAN

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

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FIGURE 3.9.2.1-1 3.9.2.2 OIL PUMP

3456 EPG ENGINE OIL PAN CUTAWAY

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

FIGURE 3.9.2.2-1

3456 EPG ENGINE OIL PUMP

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3.9.2.3

OIL COOLER

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

FIGURE 3.9.2.3-1 3.9.2.4 OIL FILTER

3456 EPG ENGINE OIL COOLER

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

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FIGURE 3.9.2.4-1 3.9.2.5 TURBOCHARGER OIL LINES

3456 EPG OIL FILTER

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

FIGURE 3.9.2.5-1

3456 EPG TURBOCHARGER OIL LINES

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3.9.2.6

OIL PASSAGES FOR THE CYLINDER HEAD AND BLOCK

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

FIGURE 3.9.2.6-1

3456 EPG CYLINDER HEAD

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3.9.2.7

FUME DISPOSAL COLLECTOR

Figure 3.9.2.7-1 illustrates the Fume Disposal Collector.

FIGURE 3.9.2.7-1

FUME DISPOSAL COLLECTOR

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

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3.9.3 3.9.3.1

LUBRICANT SPECIFICATIONS API AUTHORIZED OILS

Caterpillar, Inc., the manufacturer of the DPDGS 3456 EPG Engine, recognizes The Engine Oil Licensing and Certification System for engine oils by the American Petroleum Institute. For detailed information about this system, see the thirteenth edition of the API publication No. 1509. API authorizes engine oils that bear the API symbol. 3.9.3.2 ENGINE OIL: CATERPILLAR DIESEL ENGINE OIL

Caterpillar Oils have been developed and tested in order to provide the full performance and service life that has been designed and built into Caterpillar Engines. Caterpillar Engine Oil is used to fill the 3456 EPG Engine at the factory. These oils are available by Caterpillar dealers worldwide for continued use when the engine oil is changed. Due to significant variations in the quality and in the performance of commercially available oils, Caterpillar makes the following recommendations: • • Caterpillar Diesel Engine Oil (10W3O) Caterpillar Diesel Engine Oil (15W40)

Caterpillar multi-grade Diesel Engine Oil is formulated with the correct amounts of detergents, dispersants, and alkalinity in order to provide superior performance in Caterpillar Diesel Engines. Caterpillar multi-grade Diesel Engine Oil is available in two grades of viscosity (10W30 and 15W40). To choose the correct grade for the ambient temperature, see Table 3.9.3.4-1. Multi-grade oils provide the correct viscosity for a broad range of operating temperatures. Multi-grade oils are effective in maintaining the following conditions: • • • Proper engine lubrication Low oil consumption Low levels of piston deposits

3.9.3.3

ENGINE OILS: COMMERCIAL OILS

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

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If Caterpillar multigrade Diesel Engine Oil is not used, only use commercial oils that meet the following classifications: • • • • EMA LRG-1 multigrade oil is Preferred Oil API CH-4 multigrade oil is Preferred Oil API CG-4 multigrade oil is Preferred Oil API CF-4 multigrade oil is Acceptable Oil

The following explanations of these API classifications can be used to make the proper choice when commercial oil is chosen: • • CH-4 is the newest API classification for heavy-duty diesel engine oil. CH-4 oils can be used in Caterpillar diesel engines that are recommended to use CF-4 oils. CG-4 is a new API classification for heavy-duty diesel engine oil. CG-4 oils can be used in Caterpillar diesel engines that are recommended to use CF-4 oils. In comparison to CF-4 oils, CG-4 oils provide improvements in the following performance: • • • • Cleanliness of the crankcase Cleanliness of the pistons Soot Dispersion Viscosity Control

CH-4 oils were developed primarily for diesel engines that use a .05 percent level of fuel sulfur. However, CG-4 oils can be used with higher sulfur fuels. CH-4 oils were the first oils that passed the industry standard tests for foam control and viscosity shear loss. CG-4 oils must also pass tests that were recently developed for corrosion and wear. These oils service a wide variety of modern diesel engines. CF-4 oils provide more stable oil control and reduced piston deposits in comparison to the obsolete API CE oils. CF-4 oils provide improved soot dispersion in comparison to API CF and obsolete CD oils. The API CF-4 classification was developed with a 0.40 percent sulfur diesel fuel. This represents the type of diesel fuels that are commonly available worldwide. Some commercial oils that meet the API CG-4 and CF-4 classifications may require reduced oil change intervals. To determine the oil change interval, closely monitor the condition of the oil and perform a wear metal analysis. Caterpillar’s S.O.S. oil analysis program is the preferred method. NOTE: NOTE: Failure to follow these oil recommendations can cause shortened engine service life due to deposits and/or excessive wear. Do not use CE-4 or lower grade oils.

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3.9.3.4

LUBRICANT VISCOSITY RECOMMENDATIONS

The minimum ambient temperature during cold engine start-up; and the maximum ambient temperature during engine operation determine the proper SAE viscosity grade of oil. Table 3.9.3.4-1 presents the oil viscosities required for starting in minimum and maximum temperatures. Generally, use the highest oil viscosity that is available to meet the requirement for the temperature at engine start-up. TABLE 3.9.3.4-1 ENGINE OIL VISCOSITY AMBIENT TEMPERATURE MINIMUM -40°C (-40°F) -30°C (-22°F) -30°C (-22°F) -20°C (-4°F) -15°C (+5°F) MAXIMUM 10°C (50°F) 30°C (86°F) 40°C (104°F) 40 °C (104°F) 50 °C (125°F)

CATERPILLAR DEO API CG-4 AND CF4 VISCOSITY GRADE SAE 0W20 SAE 5W30 SAE 5W40 SAE 10W30 SAE 15W40

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3.10

ENGINE/ALTERNATOR SYSTEM

The Engine/Alternator System is comprised on the Caterpillar 3456 EPG engine and the Caterpillar SR4B Alternator mounted on a common skid. 3.10.1 CATERPILLAR 3456 EPG ENGINE

The MEP-PU-810 A/B Power Unit uses two Caterpillar 3456 EPG Engines. The two 3456 EPG engines are electronically controlled, mechanically actuated, unit injector diesel engines. The 3456 EPG Engine is an in-line six-cylinder engine with a bore of 5.5 inch (140 mm) and with a stroke of 6.7 inch (171 mm). The 3456 EPG Engine has a total displacement of 964.18 Cubic Inches (15.8 L). The engine is turbocharged and cooled with air-to-air after cooling with electronic unit injection (EUI). Figure 3.10.1-1 through Figure 3.10.1-5 illustrates the 3456 EPG Engine through the series of Right Side, Left Side, Top, Rear and Front Views.

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

Right Side View

FIGURE 3.10.1-1

CATERPILLAR 3456 EPG ENGINE, RIGHT SIDE VIEW

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

Left Side View

FIGURE 3.10.1-2

CATERPILLAR 3456 EPG ENGINE, LEFT SIDE VIEW

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

FIGURE 3.10.1-3

CATERPILLAR 3456 EPG ENGINE, TOP VIEW

Rear View
(13) Flywheel Housing (17) Flywheel

FIGURE 3.10.1-4

CATERPILLAR 3456 EPG ENGINE, REAR VIEW

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

FIGURE 3.10.1-5

CATERPILLAR 3456 EPG ENGINE, FRONT VIEW

The electronic control system was designed to provide electronic governing, automatic fuel ratio control, torque rise shaping, injection timing control, and system diagnostics. The Electronic Unit Injector system eliminates many of the mechanical components of an in-line pump system. This system also provides increased control of the timing and of the fuel air ratio. The timing advance is achieved by the precise control of the injector timing. Adjusting the duration of the injection controls the engine rpm. A special pulse wheel provides information to the electronic control module for the detection of the cylinder piston positions and of the engine rpm. The engine has built-in diagnostics in order to ensure that all of the components are operating properly. In the event of a system component failure, the operator will be alerted to the condition by the fault or alarm lights on the GSC+. The GSC+ will display some diagnostic codes and the Caterpillar ET tool can be used to read the numerical code of the faulty component or its condition. Intermittent faults are logged and the information is stored in the memory of the ECM.

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3.10.2

STARTING THE ENGINE

The Electronic Control Module (ECM) will automatically provide the correct amount of fuel that is necessary to start the engine. The ECM controls the starting-aid operation automatically. At engine coolant temperatures below 32°F (0°C), the ECM will control ether injection. The Electronic Modular Control Panel (EMCP+), controls the crank cycles and duration of the starter motor. If the engine fails to start, the EMCP+ will cycle cranking to allow the starter motor to be cooled for the programmed cycle time. WARNING DO NOT MANUALLY SPRAY ETHER INTO THIS ENGINE. EXCESSIVE ETHER (STARTING FLUID) CAN CAUSE PISTON AND RING DAMAGE. NOTE: 3.10.3 Use ether for cold weather starting purposes only. COLD MODE OPERATION

The engine control system performs a cold start strategy for the correct warm-up time after a cold engine start. The temperature for a cold engine start is less than 64°F (18°C). This cold start strategy is called cold mode. After being activated, this cold mode will remain active until the coolant temperature rises above 64°F (18°C) or until the engine has been running for 12 minutes. Cold mode will also vary the fuel injection amount, the timing for the maximum start-up, and the timing for the control of white smoke. The time that is necessary for the engine to achieve the normal mode of operation is usually less than the time that is required for a walk-around inspection of the engine. 3.10.4 MEP-PU-810 SPECIFIED PARAMETERS

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

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3.10.5 3.10.5.1

ALTERNATOR SR4B ALTERNATOR

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

FIGURE 3.10.5.1-1 3.10.5.2

DPGDS SR4B ALTERNATOR

GENERATOR THEORY OF OPERATIONS

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

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3.10.5.3

PERMANENT MAGNET PILOT EXCITER (PMPE)

Figure 3.10.5.3-1 illustrates the PMPE Generator Wiring Diagram. Permanent magnet pilot excited generators receive power for the voltage regulator from a pilot exciter, rather than from the main armature as in self-excited generators. The pilot exciter consists of permanent magnet (PM) and Pilot exciter armature (L5). The pilot exciter operates independently from the generator output voltage. Constant excitation during large load application is possible, because the irregularities that occur in generator output voltage (caused by load conditions) are not fed back into the exciter. The independent operation also allows the generator to supply and sustain excessive currents for short periods of time. When the engine starts turning the rotating field assembly (RFA), a permanent magnet (PM) induces an AC voltage in the pilot exciter armature (L5). The pilot exciter armature has three coils of wire and generates three-phase AC. The resulting AC flows through wires T1 PMG, T2 PMG and T3 PMG to the voltage regulator. Within the voltage regulator the three-phase AC is rectified to DC and a controlled amount is fed to exciter field (L1) through terminals Fl and F2.

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(CR1-CR6) Diodes (L2) Exciter Armature (rotor) (L5) Pilot Exciter Armature

(CR7) (CR8) Varistors (L3) Main Field (rotor) (PM) Permanent Magnet

(L1) Exciter Field (stator) (L4) Main Armature (stator) (RFA) Rotating Field Assembly

(T1 PMG, T2 PMG, T3 PMG) Conductors that carry three phase AC power from the Pilot Exciter to the Digital Voltage Regulator. (TO, T1, T2, T3, T7, T8, T9) Generator Output Terminals and/or Generator Output Leads

FIGURE 3.10.5.3-1

PMPE GENERATOR WIRING DIAGRAM

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DC now flows to the exciter field (L1) and a magnetic field is created, in which exciter armature (L2) is rotating. The exciter field (L1) and exciter armature (L2) generates three-phase AC. The AC is then rectified to DC by three-phase full wave bridge rectifier circuit (diodes CR1-CR6). The DC output from the bridge rectifier is carried to the main field (L3) by conductors, which are routed through a passage in the generator shaft. Current through the main field (L3) creates the magnetic field of the generator. As the main field (L3) rotates, it induces a three-phase AC voltage in the main armature (L4), which is sent to terminals TO, T1, T2 and T3, which are connections for the load. To keep the output voltage constant with changing loads, it is necessary to control the exciter current. This control is the function of the voltage regulator. The voltage regulator senses the generator output voltage at wires 20 GEN, 22 GEN and 24 GEN. The voltage regulator uses the current generated from the permanent magnet (PM) and pilot exciter armature (L5) at wires T1 PMG, T2 PMG and T3 PMG. This current is then controlled by the voltage regulator and sent to the exciter through wires Fl and F2. Permanent magnets (PM) supply the initial magnetism required at start-up. Flashing the field is not required for start-up of the generator. 3.10.5.4 GENERATOR COMPONENTS

The SR4B generator design includes: • • Power for the exciter field is provided by a Permanent Magnet Pilot Excited (PMPE) method of excitation. Bearing location (inboard). The size and vibration characteristics of the engine and generator determine whether the bearing is located inboard or outboard of the exciter. On the DPGDS, the bearing is inboard of the exciter. • • • On PMPE generators, the pilot exciter is either inboard or outboard of the exciter. DPGDS, the pilot exciter is outboard of the exciter. The Rotating Field Assembly (RFA) components attach to rotor shaft, which is supported by the engine flywheel and bearing. The Generator main field rotor is part of the rotating field assembly and rotates with the shaft. On the

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

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FIGURE 3.10.5.4-1

RFA HEAT SINK

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

FIGURE 3.10.5.4-2

SIX DIODE RECTIFIER BLOCK WITH VARISTOR CR7

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FIGURE 3.10.5.4-3

VARISTOR CR8

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3.11

AIR INTAKE AND EXHAUST SYSTEM

The following topics are addressed: • • Air Intake and Exhaust System Operation System Components

3.11.1

AIR INTAKE AND EXHAUST SYSTEM OPERATION

The following topics are addressed; • • • Combustion Air Flow Exhaust Gas Flow Power Unit Internal Cooling Air Flow COMBUSTION AIR FLOW

3.11.1.1

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

FIGURE 3.11.1.1-1

COMBUSTION AIR FLOW

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3.11.1.2

EXHAUST GAS FLOW

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

FIGURE 3.11.1.2-1

SYSTEM EXHAUST FLOW

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3.11.1.3

POWER UNIT INTERNAL COOLING AIR FLOW

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

FIGURE 3.11.1.3-1

EXTERNAL AIR FLOW

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3.11.2

SYSTEM COMPONENTS

The major components of the Air Intake and Exhaust System are: • • • • • • Air-to-Air After Cooler (ATAAC) Air Cleaner Turbocharger Air Intake and Exhaust Manifold Muffler Assembly Air Filter Service Indicator

3.11.2.1

AIR-TO-AIR AFTER COOLER (ATAAC)

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

FIGURE 3.11.2.1-1

AIR-TO-AIR AFTER COOLER (ATAAC)

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3.11.2.2

AIR FILTER

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

FIGURE 3.11.2.2-1

AIR FILTER ASSEMBLY

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3.11.2.3

TURBOCHARGER

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

FIGURE 3.11.2.3-1

TURBOCHARGER

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

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3.11.2.4

AIR INLET AND EXHAUST MANIFOLDS

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

AIR INLET MANIFOLD

AIR INLET MANIFOLD ELBOW

FIGURE 3.11.2.4-1

AIR INLET MANIFOLD

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EXHAUST MANIFOLD

FIGURE 3.11.2.4-2

EXHAUST MANIFOLD

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3.11.2.5

MUFFLER ASSEMBLY

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

FIGURE 3.11.2.5-1

MUFFLER ASSEMBLY

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

FIGURE 3.11.2.6-1

AIR FILTER HIGH DIFFERENTIAL PRESSURE ALARM (HAFDPA)

AIR FILTER DIFFERENTIAL GAUGE

FIGURE 3.11.2.6-2

AIR FILTER DIFFERENTIAL GAUGE

3-151

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The following topics are addressed: • • • • ORT Hardware/Software ORT Screens ORT Setup Procedures Power Plant Control and Monitoring

FIGURE 3.12-1 3.12.1

OPERATOR’S REMOTE TERMINAL

ORT HARDWARE/SOFTWARE

The ORT provides DPGDS operators with a capability to conduct operations remotely, and provides maintainers with a capacity to conduct detailed maintenance diagnostics through communications with the Caterpillar Electronic Modular Control Panel (EMCP+), as well as the Caterpillar Electronic Technician (ET) Tool. Figure 3.12-1 illustrates the Operator Remote Terminal (ORT). The ORT is a Panasonic “ToughBook” notebook computer configured with software required to perform its functions as the ORT. The ORT Operator’s monitoring software runs on a preinstalled version of Microsoft Windows 2000 or XP. In addition to monitoring, the ORT includes the software and files necessary to configure and load the following MEP-PU-810 components: the PLC system and the overcurrent relays. The ORT may be loaded with Caterpillar’s Electronic Technician software to diagnose and troubleshoot the CAT 3456 engines.

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3.12.2 3.12.2.1

ORT SCREENS OVERVIEW SCREEN

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

FIGURE 3.12.2-1 3.12.2.2

OPERATOR’S REMOTE TERMINAL

INDIVIDUAL PU SCREENS

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

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USAF TO 35C2-3-518-1 USA TM 9-5115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 the PU is in Battleshort, mode of voltage regulation, engine economizing status and control, and fuel solenoid valve control. With the system operating in the automatic mode, by connecting an ORT to the network, the operator can monitor and control the Power Units from up to 150 feet away. From the ORT, the operator can operate all breakers and start/stop generators. The ORT has the capability to monitor and control a full system of four Power Units. From the ORT, the operator will receive indications that an alarm has occurred. The ORT will display which generator has the alarm. The operators can then make corrections or repair the problem before it causes the loss of a generator. The ORT also provides the operator with the capability of changing the lineup of online generators, as long as the number online stays the same. In a multiple PU lineup, the operator can disable engine economizing. This prevents the RTU from shutting down lightly loaded generators; however, in the event the load exceeds 85% and additional units are required, those units are added automatically by the RTU.

FIGURE 3.12.2.2-1

OPERATOR’S REMOTE TERMINAL

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3.12.3 3.12.3.1

POWER PLANT CONTROL AND MONITORING POWER PLANT CONTROL & MONITORING PROGRAM

The following screens provide the Operator with information relative to control and monitoring of the Power Unit: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) Overview Pop-up Screen PU Control & Monitoring Pop-up Screen Hardware Alarm Pop-up Screen Alarm Pop-up Screen Alarm Summary Pop-up Screen Base Load Pop-up Screen Equipment Identification Pop-up Screen Low Fuel Elapsed Time Pop-up Indicator Screen Eight Hour Archive Pop-up Screen Shutdown Archive Pop-up Screen DPGDS One-Line Pop-up Screen

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3.12.3.2

OVERVIEW POP-UP SCREEN

Table 3.12.3.2-1 lists Overview Pop-up Screen icons, their titles and functionality. Figure 3.12.3.2-1 illustrates the Overview Pop-up Screen. TABLE 3.12.3.2-1 ICON 1 2 3 4 5 OVERVIEW POP-UP SCREEN ICONS TITLE/FUNCTION Engine Control Switch position (Off, Cool down, Auto, Manual). Engine operating status (Running, Cool down, Off). Breaker status (green – open, red – closed), typical of the five breakers. Generator operating parameters. Total KW load on the system lineup. Left margin icons: a. DPGDS <Home> b. PUA - <F1>: c. PUC - <F2>: d. PUC - <F3>: 6 e. PUD - <F4>: f. 1Line - <F5>: g. <F6>: h. <F7>: i. j. k. 7 8 <F8>: <F9>: <esc> Calls Overview Monitoring Page Calls PU-A control/monitoring screen Calls PU-B control/monitoring screen Calls PU-C control/monitoring screen Calls PU-D control/monitoring screen Displays system lineup One line overview page Displays Alarm page Displays Alarm Summary page Displays the Hardware Alarm page Displays the Disabled Alarms page Displays last page

# of Generators required Log to disk Archive

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6

5

7

8

3 1 4 FIGURE 3.12.3.2-1 OVERVIEW POP-UP SCREEN

2

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3.12.3.3

PU CONTROL & MONITORING POP-UP SCREEN

Table 3.12.3.3-1 lists PU Control and Monitoring Pop-up Screen icons, their titles and functionality. Figure 3.12.3.3-1 illustrates the PU Control and Monitoring Pop-up Screen. TABLE 3.12.3.3-1 ICON 1 2 3 4 5 6 7 8 9 10 11 PU CONTROL & MONITORING POP-UP SCREEN ICONS TITLE/FUNCTION Engine and generator operating parameters. Indicates PU Battleshort switch label is in the BATTLESHORT position. Engine Control Switch position (Off, Cool down, Auto, Manual). Engine operating status (Running, Cool down, Off). Displays remaining engine cool down time on engine in cool down, time in seconds. (Timer not shown in Figure 3.12.3.3-1). Engine Immediate Stop icon. Click once to stop engine, again to reset. ECS must be put in the OFF/RESET position to clear the remote shutdown. Engine Control Switch position (Off/Reset, Stop/Cool down, Auto, Manual). Engine Start/Stop icon. Functional only when ECS is in AUTO. Text indicates action that will be taken when “clicked” on. Stopping the engine will automatically trip the associated breaker before putting the engine into cool down. Breaker status (green – open, red – closed), typical of the five breakers. Fuel solenoid/pump status (green – closed/off, red/yellow – AUTO/enabled). Toggles the fuel solenoid/pump permissive. Text indicates action that will be taken when “clicked” on. Engine Economize Mode. This is a global icon – activating it on one screen affects all screens. . Text indicates action that will be taken when “clicked” on. Text below the icon indicates current mode status. Tie breaker control icon. Text indicates action that will be taken when “clicked” on. The icon is only active when the SMS is in AUTO. Generator breaker control icon. . Text indicates action that will be taken when “clicked” on. The icon is only active when the SMS is in AUTO. Opening the breaker with this icon keeps the breaker open until “clicked” or the engine is shutdown. Feeder breaker control switch. Text indicates action that will be taken when “clicked” on. The icon is only active when the SMS is in AUTO.

12

13

14

15

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TABLE 3.12.3.3-1 ICON 16 17 18

PU CONTROL & MONITORING POP-UP SCREEN ICONS (CONTINUED) TITLE/FUNCTION

Indicates the current position of the AVRS (Prime Power or Utility Parallel). Indicates the current position of the GMS (Prime Power or Utility Parallel). Indicates the current position of the SMS (Auto, Off, or Manual). Left margin icons: a. b. c. d. e. DPGDS - Home>: PUB - <F2>: PUC - <F3>: PUD - <F4>: 1Line - <F5>: <F6>: <F7>: <F8>: <F9>: <Esc>: Calls Overview monitoring page Calls PU-B control/monitoring screen Calls PU-C control/monitoring screen Calls PU-D control/monitoring screen Displays system lineup One line overview page Displays Alarm page Displays Alarm Summary page Displays the Hardware Alarm page Displays the Disabled Alarms page Displays last page

19

f. g. h. i. j.

20

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

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1

2

19 4 3 20 12 10 11

5 6 7 9 18 17 14

13 15

8

16

FIGURE 3.12.3.3-1

PU CONTROL & MONITORING POP-UP SCREEN

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3.12.3.4

HARDWARE ALARM POP-UP SCREEN

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

FIGURE 3.12.3.4-1

CRITICAL ALARM POP-UP SCREEN

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3.12.3.5

ALARM POP-UP SCREEN

Table 3.12.3.5-1 lists the Alarm Pop-up Screen icons, their titles and functionality. Figure 3.12.3.5-1 illustrates the Alarm Pop-up Screen. The screen logs past and current alarms. TABLE 3.12.3.5-1 ICON Left margin icons: a. DPGDS<Home>: b. PUA - <F1>: c. 1 PUB - <F2>: d. PUC - <F3>: e. PUD - <F4>: f. <F6>: g. <F7>: h. <F8>: i. j. 2 3 4 <F9>: <Esc>: Calls Overview monitoring page Calls PU-A control/monitoring system Calls PU-B control/monitoring screen Calls PU-C control/monitoring screen Calls PU-D control/monitoring screen Displays Alarm page Displays Alarm Summary Page Displays the Hardware Alarm page Displays the Disabled Alarms page Displays last page. ALARM POP-UP SCREEN ICONS TITLE/FUNCTION

Tag - Unit that had an alarm Description - Equipment that had alarm Date/Time of alarm

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1

3 4 2

FIGURE 3.12.3.5-1

ALARM POP-UP SCREEN

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3.12.3.6

ALARM SUMMARY POP-UP SCREEN

Table 3.12.3.6-1 lists Alarm Summary Pop-up Screen icons, their titles and functionality. Figure 3.12.3.61 illustrates the Alarm Summary Pop-up Screen. TABLE 3.12.3.6-1 ICON Left margin icons: a. b. c. d. 1 e. f. g. h. i. j. 2 3 4 5 6 DPGDS - <Home>: PUA - <F1> PUB - <F2>: PUC - <F3>: PUD - <F4>: <F6>: <F7>: <F8>: <F9>: <Esc>: Calls Overview monitoring page Calls PU-A control/monitoring screen Calls PU-B control/monitoring screen Calls PU-C control/monitoring screen Calls PU-D control/monitoring screen Displays Alarm page Displays Alarm Summary Page Displays the Hardware Alarm page Displays the Disabled Alarms page Displays last page. ALARM SUMMARY POP-UP SCREEN ICONS TITLE/FUNCTION

Date and time of alarm Tag – Unit that had alarm Unit and type of alarm Shows if the alarm has been acknowledged by the operator Summary of alarm

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1 1

2

3

4

5

6

FIGURE 3.12.3.6-1

ALARM SUMMARY POP-UP SCREEN

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3.12.3.7

BASE-LOAD POP-UP SCREEN Figure 3.12.3.7-1

Table 3.12.3.7-1 lists Base-Load Pop-up Screen icons, their titles and functionality. illustrates the Base Load Pop-up Screen. TABLE 3.12.3.7-1 ICON 1 BASE-LOAD POP-UP SCREEN ICONS TITLE/FUNCTION

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

2

Left margin icons: a. PUA - <F1>: b. PUB - <F2>: c. 3 PUC - <F3>: d. PUD - <F4>: e. 1 Line - <F5>: f. <F6>: g. <F7>: h. <F8>: i. j. <F9>: <Esc>: Calls PU-A control/monitoring screen Calls PU-B control/monitoring screen Calls PU-C control/monitoring screen Calls PU-D control/monitoring screen Displays system lineup One line overview page Displays Alarm page Displays Alarm Summary page Displays the Hardware Alarm page Displays the Disabled Alarms page Displays last page

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1

3

2

FIGURE 3.12.3.7-1

BASE-LOAD POP-UP SCREEN

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3.12.3.8

EQUIPMENT IDENTIFICATION POP-UP SCREEN

Table 3.12.3.8-1 lists the Equipment Identification Pop-up Screen icons, their titles and functionality. Figure 3.12.3.8-1 illustrates the Equipment Identification Pop-up Screen. TABLE 3.12.3.8-1 ICON Left margin icons: a. b. c. 1 d. e. f. g. h. i. j. 2 3 4 5 6 7 PU A PU A PU A PU A PUA - <F1>: PUB - <F2>: PUC - <F3>: PUD - <F4>: 1 Line - F5>: <F6>: <F7>: <F8>: <F9>: <Esc>: Calls PU-A control/monitoring screen Calls PU-B control/monitoring screen Calls PU-C control/monitoring screen Calls PU-D control/monitoring screen Displays system lineup One line overview page Displays Alarm page Displays Alarm Summary page Displays the Hardware Alarm page Displays the Disabled Alarms page Displays last page EQUIPMENT IDENTIFICATION POP-UP SCREEN ICONS TITLE/FUNCTION

Engine 2 ID Number (User Entered) Generator 2 ID Number (User Entered) Engine 1 ID Number (User Entered) Generator 1 ID Number (User Entered)

PU Trailer ID Number (User Entered) RTU automatically enters this Number

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1

7

6

5

3 4 2

FIGURE 3.12.3.8-1

EQUIPMENT IDENTIFICATION POP-UP SCREEN

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3.12.3.9

LOW FUEL ELAPSED TIME POP-UP INDICATOR SCREEN

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

ITEM 1

FIGURE 3.12.3.9-1

LOW FUEL ELAPSED TIME POP-UP INDICATOR SCREEN

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3.12.3.10

EIGHT-HOUR ARCHIVE POP-UP SCREEN

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

FIGURE 3.12.3.10-1

EIGHT HOUR ARCHIVE POP-UP SCREEN

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3.12.3.11

SHUTDOWN ARCHIVE POP-UP SCREEN

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

FIGURE 3.12.3.11-1

SHUTDOWN ARCHIVE POP-UP SCREEN

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3.12.3.12

DPGDS ONE-LINE POP-UP SCREEN

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

FIGURE 3.12.3.12-1

DPGDS ONE-LINE

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3.12.3.13

PDC AND ORT LOAD LIMITING SOFTWARE

The following topics are addressed in this section: • • • • • • • 3.12.3.13.1 PLC and ORT load limiting software description Power monitor 60 Hz operation 50 Hz operation Warnings Battle short ORT load monitoring pop-up screens PDC AND ORT LOAD LIMITING SOFTWARE DESCRIPTION

The PLC and ORT overload software does not change the control/operation of the power unit under normal operating conditions. All operating procedures should be followed as specified in this technical manual, noting the power rating of the set is 420 kW prime for 60 Hz operation and 350 kW prime for 50 Hz operation. Software updates allow both the ORT and the PLC to warn the operator of an excessive load applied to the power unit. Additionally, the service pack adds additional functions and features to the ORT for improved operator interaction. 3.12.3.13.2 POWER MONITOR

The primary overload protection for continuous loads on the engine/generator is provided using the existing Generator Set Controller (GSC) and Programmable Logic Controller (PLC) in the PDC. New software has been added to the PU that will monitor the load and warn the operator if the power capability of the engine has been exceeded. If normal load levels are not established through load shedding or additional generators brought on line within the time allotted the unit will shut down to protect the engine/generator. 3.12.3.13.3 60 HZ OPERATION

Based on the 420 kW prime, 460 kW (110%) maximum rating of the generator, the load limits implemented are: (1) At 470 kW or 600 kVA the load limiting software warns the operator of an overload and the generator will shutdown in 8 minutes. * (2) At 480 kW or 615 kVA, the load limiting software warns the operator of an overload and the generator will shutdown in 2 minutes. * (3) At 500 kW or 630 kVA the generator will shutdown in 5 seconds. * The load must exceed this level for 5 seconds to activate the warning. When the generator load drops below 465 kW and 595 kVA the warnings will be extinguished.

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3.12.3.13.4

50 HZ OPERATION

Based on the 350 kW prime, 385 kW maximum rating of the generator, the load limits implemented are: (1) At 390 kW or 500 kVA the load limiting software warns the operator of an overload and the generator will shutdown in 8 minutes. * (2) At 400 kW or 512 kVA the load limiting software warns the operator of an overload and the generator will shutdown in 2 minutes. * (3) At 415 kW or 525 kVA the generator will shutdown in 5 seconds. * The load must exceed these levels for 5 seconds to activate the warning. When the generator load drops below 385 kW and 495 kVA the warnings will be extinguished. 3.12.3.13.5 WARNINGS

The operator warning is given in two ways. Additional fault lights indicating an overload have been added to the PU. When an overload is detected by the PLC, the existing PU fault annunciator will be turned on and the associated GENERATOR OVERLOAD light(s) will flash. A warning and countdown timer will be displayed on the Operator Remote Terminal (ORT) if it is in use. Two unique audible alarms have been implemented on the ORT signaling the 8-minute (470kW) or 2-minute (480kW) countdown periods. If the load on the unit is not reduced before expiration of the overload countdown timers the generator breaker will open and the engine will enter cooldown mode. The GENERATOR OVERLOAD lights on the PU will remain illuminated (steady state). See Figure 3.12.3.13.5-1. A generator overload fault can only be cleared from the PU using the MSES switch, Not from the ORT. If the Load is reduced to the 465 kW threshold for 5 seconds before the timers time out, the timers will reset and the audible alarm/faults will clear.

GENERATOR OVERLOAD GEN. 1 GEN. 2

FIGURE 3.12.3.13.5-1 PU GENERATOR OVERLOAD INDICATOR LIGHTS

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3.12.3.13.6

BATTLE SHORT

Activation of the Battle Short switch on the PU will override the shutdown of the unit except for Over Speed, Generator Basler Over Current Protection Relays, and Emergency Stop. If an overload condition is present the overload warning will be present but the overload timer will remain at 8 minutes and/or 2 minutes. WARNING Operating the unit in Battle Short can result in catastrophic failure of the engine and generator. When operating in Battle Short mode all PU’s are required to be placed in Battle Short mode. 3.12.3.13.7 ORT OVERLOAD POP-UP SCREENS

Two ORT load monitoring pop-up screens have been added to reflect over load timing functions and one new screen was added that details new features to the Overview Screen. Upon reaching an overload condition, as outlined above, the following will occur: (1) An alarm on the ORT is logged that must be acknowledged by the operator and warns of an overload condition. (2) An audible alarm on the ORT is activated and remains active as long as the generator is in an overload condition. (3) On the Plant Overview Screen, the overloaded generator(s) will flash and an overload countdown timer will be present as shown in Figure 3.12.3.13.7-1. (4) Upon reaching the second level of overload detection (480 kW for 60 Hz), a 2-minute warning will be displayed and a second audible warning (different tone) will sound on the ORT. This audible warning can only be extinguished by lowering the load on the generator below 465 kW. (5) When the overload condition reaches the 2-minute load level (480 kW at 60 HZ), this timer will override the 8-minute timer unless the generator is within 2 minutes of shutdown on the 8-minute timer. The timer that has the shortest shutdown time will then be displayed on the ORT screen. This means that if the generator is in an overload condition, (470 kW) and the load increases to 480 kW, the 2-minute timer will then activate, unless the generator is within 2 minutes of shutdown. If there are 2 minutes or less on the 8-minute timer, the 2-minute timer will not activate as that will add more time to the engine shutdown. (6) If the load is not reduced before the overload period expires the generator breaker opens and the generator enters the cooldown cycle. To re-enable the generator the fault must be cleared on the PU by toggling the Master Start Enable Switch for three seconds. The fault is then cleared and normal operation can resume. If the operator displays the PU Control and Monitoring Screen, during an overload condition, the screen will be shown as in Figure 3.12.3.13.7-2: Figure 3.12.3.13.7-3 shows new features added to the Plant Overview Screen

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

FIGURE 3.12.3.13.7-1 PLANT OVERLOAD OVERVIEW SCREEN

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The text was changed on the button to reflect actual button function and avoid confusion with button for normal cooldown and shutdown of the engine.

Overload timer: Displays remaining time until PLC trips breaker due to overload condition. Whichever timer has less time to breaker trip is displayed.

FIGURE 3.12.3.13.7-2 PU CONTROL & MONITORING SCREEN

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Item added to provide the operator with the number of generators required for the current kW and kVA readings.

Added immediate archive current log file to a blank floppy disk to allow reviewing datafiles without having to wait for scheduled archive.

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

FIGURE 3.12.3.13.7-3 ORT SERVICE PACK-3 SCREEN

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This section provides information and component descriptions for the MEP-PU-810A and MEP-PU-810B trailer running gear systems. Data on the tires, wheels, brake systems, and lighting systems for each type of unit is included. 3.13.1 3.13.1.1 TIRES MEP-PU-810A TIRES

The tires specified for the MEP-PU810A are size LT235/85R16, load range E. The specified cold inflation pressure is 80 PSI. Each tire has a rated load capacity of 3,667 lbs at 25 MPH in a dual configuration at this inflation pressure. Replacement tires must be of this same size and equal or greater load capacity in a dual configuration at 25 MPH and at 80 PSI, cold inflation pressure. 3.13.1.2 MEP-PU-810B TIRES

The tires specified for the MEP-PU810B are size 11R22.5, load range G. The specified cold inflation pressure is 105 PSI. Each tire has a rated load capacity of 5630 lbs at 60 mph in a dual configuration at this inflation pressure. Replacement tires must be of this same size and equal or greater load capacity in a dual configuration at 60 MPH and at 105 PSI, cold inflation pressure. 3.13.2 3.13.2.1 WHEELS MEP-PU-810A WHEELS

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

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3.13.2.1.1

MEP-PU-810A WHEEL TORQUE REQUIREMENTS

1 8 6

3

4

5 2

7

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

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

CAUTION
WHEEL NUTS OR BOLTS MUST BE APPLIED AND MAINTAINED AT THE PROPER TORQUE LEVELS TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSIBLE DANGEROUS SEPARATION OF WHEELS FROM YOUR AXLE. NOTE: A Special Tool is required for this task; refer to Annex H for recommended tool.

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3.13.2.2.1

MEP-PU-810B WHEELS

The wheels specified for the MEP-PU-810B are size 16 1/2 ” x 7”, 10 studs on an 11 1/4” bolt circle, with dual wheel configuration offset. 3.13.2.2.2 MEP-PU-810B WHEEL TORQUE REQUIREMENTS
1 10 4 7

5

6 8 2

3 9

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

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

CAUTION
WHEEL NUTS OR BOLTS MUST BE APPLIED AND MAINTAINED AT THE PROPER TORQUE LEVELS TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSIBLE DANGEROUS SEPARATION OF WHEELS FROM YOUR AXLE. NOTE: Roadside wheel lug nuts on the MEP-PU-810B are left hand threads. Therefore, to remove the lug nut you must turn the nut clockwise and to tighten the lug nut you must turn the nut counterclockwise. A Special Tool is required for this task; refer to Annex H for recommended tool.

NOTE:

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3.13.3 3.13.3.1

BRAKE SYSTEMS MEP-PU-810A BRAKE SYSTEM

The hydraulic brakes on the MEP-PU-810A are much like those on a car. The hydraulic fluid from a master cylinder is used to actuate the wheel cylinder, which, in turn, applies force against the brake shoes and drum. The main difference between automotive hydraulic brakes and hydraulic trailer brakes are the actuation systems, which transfer the braking signal from the tow vehicle to the brakes. 3.13.3.1.1 SURGE BRAKING SYSTEM

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

FIGURE 3.13.3.1-1

HYDRAULIC BRAKE ACTUATOR

Figure 3.13.3.1-2 illustrates the Break-Away Lever and Chain positions. The surge brake system incorporates a safety breakaway lever and chain that activates the surge brake if the trailer separates from the tow vehicle. The actuator’s breakaway chain S-hook should be securely attached to one of the tow vehicle safety chain connection points. Before towing, check that the breakaway lever and chain are properly positioned as shown in (Figure 3.13.3.1-2). If the breakaway lever and chain are not located correctly, due to either the chain being pulled during use or by accident, it must be reset prior to moving the trailer. Resetting the lever is accomplished by first removing the two rearward bolts, located on each side of the breakaway lever. These two bolts hold down the breakaway locks. Loosen, but do not remove the remaining two bolts. This will allow the two locks to be swung aside and the lever can be pushed back into its resting position. Replace the breakaway locks to their original positions and retighten the four bolts using a torque wrench to 90-120 inch-pounds of torque.

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FIGURE 3.13.3.1-2 3.13.3.1.2 BRAKE FLUID

BREAK-AWAY LEVER AND CHAIN POSITIONS

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

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3.13.3.1.3

HYDRAULIC BRAKE OPERATION

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

FIGURE 3.13.3.1.3-1

HYDRAULIC BRAKE FUNCTION DIAGRAM

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3.13.3.1.4

HYDRAULIC BRAKE COMPONENTS

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

FIGURE 3.13.3.1.4-1 3.13.3.1.5

HYDRAULIC BRAKE COMPONENTS

SELF-ADJUSTING MECHANISM FOR HYDRAULIC BRAKES

The brakes adjust on both forward and reverse stops. Components include a new adjuster, adjuster lever arm, adjuster return springs, cable, cable anchor bracket, and an extension spring. The new cable anchor bracket fits over the anchor post and has a slotted hole. The extension spring attaches the cable anchor bracket to the primary brake shoe. The brake adjuster cable is routed from the cable anchor bracket, over the cable guide, to the adjuster lever. The forward stop adjustment is accomplished when the primary shoe lifts sufficiently far off the anchor post. The extension spring connecting the primary shoe to the slotted cable anchor bracket pulls the bracket and the cable causing the adjuster lever to rotate the adjuster screw star wheel. This will continue on each brake until the shoe clearance is sufficiently small so that the primary shoe movement is insufficient to pull the cable to engage the next tooth on the adjuster star wheel. 3.13.3.1.6 PARKING BRAKE

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

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3.13.3.2

MEP-PU-810B BRAKE SYSTEM

Trailer air brakes are operated by the tractor air supply through a series of relays and check valves. When braking is desired, the air is supplied to the axle air chamber, which applies a force that is multiplied by the slack adjuster lever arm length. This force is transmitted rotationally through the camshaft, which, through the geometry of the S-head, spreads the brake shoes to contact the brake drum surface. 3.13.3.2.1 AIR CHAMBERS

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

FIGURE 3.13.3.2.1-1 3.13.3.2.2 SPRING BRAKES

S-CAM BRAKE ASSEMBLY

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

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3.13.3.2.3

SLACK ADJUSTERS

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

SPRING BRAKE ASSEMBLY

SLACK ADJUSTER

AIR CHAMBER

FIGURE 3.13.3.2.2-1 3.13.3.2.4

BRAKE SYSTEM COMPONENTS

ANTI-LOCK BRAKE SYSTEM (ABS)

Figure 3.13.3.2.4-1 illustrates the Anti-Lock Brake System (ABS) Wiring Layout. The ABS is made up of Wheel Speed Sensors, an ABS Relay Valve, an integral Electronic Control Unit (ECU), mounted on the relay valve, and an ABS indicator light. The ECU monitors wheel speed through two-wheel speed sensors mounted on the hubs of the axle. When the ECU detects that a wheel is stopping too fast, during a brake application, the air pressure in the brake chambers of the wheels is reduced via the ABS Relay Valve, allowing the wheels to recover. The ECU then commands the relay valve to apply additional pressure unit maximum braking potential is produced. This ABS cycle is repeated roughly five times per second as needed, or until the vehicle is traveling at less than six miles per hour. NOTE: The ABS system only functions when the PU is connected to the Tow Vehicles 12VDC electrical system; ABS will not function when connected to a 24VDC system.

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5

8

6

4

1 2 7 8 3

1. 5.

Standard SAE J560 Connector ABS Valve with ECU

2. 6.

Power Cord 5 pin Connector Solenoid Connector

3. 7.

Power Cord 5 pin Connector Speed Sensor/Exciter Ring

4. 8.

ECU Connector 19 Pin Sensors 1A and 1B Connectors

FIGURE 3.13.3.2.4-1 3.13.3.2.5 HUB ODOMETER

ABS WIRING LAYOUT

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

FIGURE 3.13.3.2.5-1

B MODEL HUB ODOMETER

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3.13.4 3.13.4.1

LIGHTING SYSTEMS MEP-PU-810A LIGHTING SYSTEM

The MEP-PU-810A is not equipped with any exterior lighting. 3.13.4.2 MEP-PU-810B LIGHTING SYSTEM

The MEP-PU-810B has lights for clearance, reflectors, turn signals, and tail/stop-lights in accordance with Department Of Transportation (DOT) and Federal Motor Vehicle Safety Standard (FMVSS), 121, 571.124 standards for commercial operations. For movement using a commercial vehicle, commercial lights are powered by the vehicles 12VDC electrical system and is provided with a 7-way inter-vehicular cable. In addition, included for towing with a military vehicle, a set of blackout lights, including clearance, reflectors, turn signal, and tail/stop-lights. These lights are powered by the vehicles 24VDC electrical system using a 12-way inter-vehicular cable. When in the blackout mode of operation, the commercial lights are non-operational.

DOT LIGHTING

BLACK OUT LIGHTING COMBO

FIGURE 3.13.4.2-1

MEP-PU-810B LIGHTING

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CHAPTER 4 RECEIPT AND MOVEMENT
TABLE OF CONTENTS SECTION
4.1 4.2 4.2.1 4.2.2 4.2.2.1 4.2.2.2 4.2.2.3 4.2.2.4 4.2.2.5 4.3 4.3.1 4.3.2 4.3.3 4.3.4 4.3.5 4.3.6 4.3.6.1 4.3.6.2 4.3.6.3 4.3.6.4 4.4 4.4.1

TITLE
INTRODUCTION INSPECTION ON RECEIPT INSPECTION REQUIREMENTS UPON RECEIPT SERVICE REQUIREMENTS BATTERY FUEL SYSTEM COOLING SYSTEM LUBRICATION SYSTEM HYDRAULIC SYSTEM MOVEMENT MOVEMENT PREPARATION CHECKLIST MEP-PU-810A HOOK-UP PROCEDURES MEP-PU-810B HOOK UP PROCEDURES TOWING PROCEDURES BACKING UP PROCEDURES DISCONNECTING PROCEDURES MEP-PU-810A DISCONNECTING PROCEDURES MEP-PU-810B DISCONNECTING PROCEDURES LOADING PROCEDURES UNLOADING PROCEDURES MEP-PU-810A AND MEP-PU-810B TIE-DOWN POINTS MEP-PU-810A TIE-DOWN POINTS

PAGE
5 5 5 7 7 7 8 8 9 10 10 12 16 18 20 21 21 21 22 23 26 26

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LIST OF FIGURES FIGURE
FIGURE 4.3.1-1 FIGURE 4.3.2-1 FIGURE 4.3.2-2 FIGURE 4.3.2-3 FIGURE 4.3.3-1 FIGURE 4.3.3-2 FIGURE 4.3.4-1 FIGURE 4.4.1-1 FIGURE 4.4.2-1 FIGURE 4.5-1 FIGURE 4.5-2 FIGURE 4.6.1-1 FIGURE 4.6.1-2 FIGURE 4.6.1-3 FIGURE 4.6.1-4 FIGURE 4.6.2-1 FIGURE 4.6.2-2 FIGURE 4.6.2-3

TITLE
CHECKING BRAKE FLUID LEVEL MEP-PU-810A TOWING CONNECTION LUNETTE EYE BREAK-AWAY CHAIN S-HOOK MEP-PU-810B TOWING CONNECTION 12VDC AND 24VDC LIGHTING CONNECTION PARKING BRAKE MEP-PU-810A TIE-DOWN POINTS, SIDE AND BOTTOM VIEW MEP-PU-810B TIE-DOWN POINTS ISO EXTENDER ISO EXTENDER INSTALLED AND LOCKED INTO POSITION ISO EXTENDER SHOWN IN LOCKED POSITION ISO EXTENDERS PROPERLY PLACED IN STORAGE BOX

PAGE
11 13 14 15 16 17 19 26 27 28 29 30 31 31 32 33 34

ISO EXTENDER STORAGE BOX IN TRANSPORTATION POSITION ISO EXTENDER STORAGE BOX IN OPERATION POSITION ISO EXTENDER SHOWN IN LOCKED POSITION ISO EXTENDERS PROPERLY PLACED IN STORAGE BOX

ISO EXTENDER STORAGE BOX IN TRANSPORTATION/ OPERATION POSITION 35

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LIST OF TABLES TABLE
TABLE 4.2.1-1 TABLE 4.2.2.1-1 TABLE 4.2.2.2-1 TABLE 4.2.2.3-1 TABLE 4.2.2.4-1 TABLE 4.2.2.5-1 TABLE 4.3.1-1 TABLE 4.3.2-1 TABLE 4.3.3-1 TABLE 4.3.4-1 TABLE 4.3.4-2 TABLE 4.3.5-1 TABLE 4.3.6-1 TABLE 4.3.6-2 TABLE 4.3.6.3-1 TABLE 4.3.6.4-1 TABLE 4.5-1 TABLE 4.6.1-1 TABLE 4.6.2-1

TITLE
GENERAL INSPECTION REQUIREMENTS BATTERY SERVICING REQUIREMENTS FUEL SYSTEM SERVICING REQUIREMENTS COOLING SYSTEM SERVICING REQUIREMENTS LUBRICATION SYSTEM SERVICING REQUIREMENTS HYDRAULIC SYSTEM SERVICING REQUIREMENTS MOVEMENT PREPARATION CHECKLIST (MEP-PU-810A & B MODELS) MEP-PU-810A HOOK-UP PROCEDURES MEP-PU-810B HOOK-UP PROCEDURES MEP-PU-810A TOWING PROCEDURES AND SPEED RATINGS MEP-PU-810B TOWING PROCEDURES AND SPEED RATINGS MEP-PU-810 A/B BACKING UP PROCEDURES MEP-PU-810A DISCONNECTION PROCEDURES MEP-PU-810B DISCONNECTION PROCEDURES MEP-PU-810A/B LOADING PROCEDURES MEP-PU-810A/B UNLOADING POCEDURES ISO EXTENDER INSTALLATION PROCEDURES MEP-PU-810A ISO EXTENDER STORAGE PROCEDURES MEP-PU-810B ISO EXTENDER STORAGE PROCEDURES

PAGE
6 7 7 8 8 9 10 12 16 18 19 20 21 21 22 23 29 30 33

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CHAPTER 4 RECEIPT AND MOVEMENT
4.1 INTRODUCTION This Chapter addresses the requirements for: • • • • Inspection and servicing of the MEP-PU-810A/B Power Unit upon receipt. Preparation for movement, connection, towing, and disconnection. MEP-PU-810A and MEP-PU-810B Tie-down Points. MEP-PU-810A and MEP-PU-810B Tie-down Points using ISO Extenders.

4.2

INSPECTION ON RECEIPT

There are significant differences between the MEP-PU-810A and MEP-PU-810B trailering that requires specific instructions for each version. Inspection of the following items is required: • • • • • Batteries Fuel system Cooling system Lubrication system Hydraulic system

4.2.1

INSPECTION REQUIREMENTS UPON RECEIPT WARNING MAINTENANCE OF THE POWER UNIT INVOLVES SERVICING OF BATTERIES, FUEL, HYDRAULIC SYSTEMS AND ELECTRICAL SYSTEMS THAT MAY SUBJECT THE MAINTAINER TO HAZARDOUS MATERIALS AS WELL AS POTENTIALLY HAZARDOUS CONDITIONS. WARNING HIGH VOLTAGE MAY CAUSE SEVERE SHOCK OR DEATH UPON CONTACT DURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION AND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE A HOT STICK WHEN LOAD CABLES ARE HANDLED.

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WARNING WHEN CONNECTING BATTERY CABLES ALWAYS CONNECT POSITIVE CABLE FIRST. FAILURE TO COMPLY MAY CAUSE SPARKING OR EXPLOSION, RESULTING IN SERIOUS BURNS. WARNING BATTERY ELECTROLYTE CONTAINS SULFURIC ACID. AVOID USING NEAR OPEN FLAME, HEAT OR SPARKS. AVOID ANY CONTACT WITH SKIN, EYES, OR CLOTHES. AVOID BREATHING FUMES. USE ONLY IN WELL-VENTILATED AREAS. FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY OR ILLNESS. Table 4.2.1-1 lists general inspection requirements. TABLE 4.2.1-1 STEP 1 2 3 4 5 6 7 8 9 10 11 GENERAL INSPECTION REQUIREMENTS ACTION Remove all tape covering engine openings such as Oil Filler Caps, or Air Filters. Refer to Chapter 20 for reference. Check for any loose or missing hardware. Refer to Chapter 8 through Chapter 19 for reference. Check for broken or missing fuses and bulbs. Refer to Chapter 12 for reference. Open and inspect all compartments for proper component mounting, and tightness. Refer to Chapter 8 through Chapter 19 for reference. Review all historical, and packing data. Remove the Air Filter Cover and inspect the Air Filter condition. Refer to Chapter 16 for reference. Open access doors and ground high voltage components. Check unit for visible leaks. Check for correct Tire air pressure. Refer to Chapter 18 for reference. Check chassis for damage. Refer to Chapter 8 through Chapter 18 for reference. Insure parking brake is functioning. Refer to Chapter 18 for reference. DONE

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4.2.2 4.2.2.1

SERVICE REQUIREMENTS BATTERY WARNING BATTERY ELECTROLYTE CONTAINS SULFURIC ACID. AVOID ANY CONTACT WITH SKIN, EYES, OR CLOTHES. AVOID BREATHING FUMES. USE ONLY IN WELL-VENTILATED AREAS. FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY OR ILLNESS. WHEN CONNECTING BATTERY CABLES ALWAYS CONNECT POSITIVE CABLE FIRST. FAILURE TO COMPLY MAY CAUSE SPARKING OR EXPLOSION, RESULTING IN SERIOUS BURNS.

Table 4.2.2.1-1 lists Battery servicing requirements. TABLE 4.2.2.1-1 STEP 1 2 3 BATTERY SERVICING REQUIREMENTS ACTION Connect battery cables to proper Positive (+), and Negative (-) terminal posts (See FO - 37A for additional information). Close Battery Charger circuit breakers (If the PU is connected to a live bus). Connect shore power to the on-board battery chargers and charge as needed. DONE

4.2.2.2

FUEL SYSTEM

Table 4.2.2.2-1 lists Fuel System servicing requirements. TABLE 4.2.2.2-1 STEP 1 2 3 4 Connect to the external fuel supply. Insure fuel shutoff valves to the fuel supply are open. Insure fuel pump transfer switch is in the “AUTO” position. Insure fuel pump transfer G1 – G2 switch is in the “G1” position. FUEL SYSTEM SERVICING REQUIREMENTS ACTION DONE

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4.2.2.3

COOLING SYSTEM WARNING DO NOT OPEN OR REMOVE THE COOLANT EXPANSION TANK CAP IF THE COOLANT IS HOT OR THE ENGINE IS RUNNING. OPEN THE CAP TO THE FIRST INDENT AND STOP TO ALLOW ANY COOLING SYSTEM PRESSURE TO VENT BEFORE REMOVING THE CAP. SERIOUS INJURY FROM HOT COOLANT CAN RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING THE MEP-PU-810 IS SHIPPED FROM THE FACTORY WITH THE COOLING SYSTEM FILLED WITH EXTENDED LIFE COOLANT (ELC). DO NOT MIX WITH ETHYLENE GLYCOL. ENGINE DAMAGE MAY RESULT.

Table 4.2.2.3-1 lists Cooling System servicing requirements. TABLE 4.2.2.3-1 STEP 1 2 3 COOLING SYSTEM SERVICING REQUIREMENTS ACTION Open the expansion tank caps on each generator set and check coolant level. Check coolant level from the coolant tank sight gauge. The level should be midway in sight glass. Add ELC or appropriate coolant if required. Read Shipping Documentation to see what type of coolant was in the system prior to shipment. DONE

4.2.2.4

LUBRICATION SYSTEM

Table 4.2.2.4-1 lists Lubrication System servicing requirements. TABLE 4.2.2.4-1 STEP LUBRICATION SYSTEM SERVICING REQUIREMENTS ACTION Check the engine oil level by pulling the dipstick from Generator #1 and Generator #2 wiping clean, re-inserting completely, and removing and observing the oil level. Add oil If required. DONE

1 2

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4.2.2.5

HYDRAULIC SYSTEM WARNING DO NOT OPEN OR REMOVE THE HYDRAULIC FLUID FILL FITTING CAP OR ATTEMPTING TO ADD HYDRAULIC FLUID TO THE SYSTEM WHILE THE ENGINE IS RUNNING. SERIOUS INJURY FROM HOT HYDRAULIC FLUID CAN RESULT FROM FAILURE TO OBSERVE THIS WARNING.

Table 4.2.2.5-1 lists Hydraulic System servicing requirements. TABLE 4.2.2.5-1 STEP 1 2 HYDRAULIC SYSTEM SERVICING REQUIREMENTS ACTION Check hydraulic fluid levels in Generator #1 and Generator #2 by using the sight-glasses on the front of the hydraulic reservoirs. The level should be midway in sight glass. Add or remove hydraulic fluid as required. DONE

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4.3

MOVEMENT

The following topics are addressed: • • • • • • • • • Movement Preparation Checklist MEP-PU-810A Hook Up Procedures MEP-PU-810B Hook Up Procedures Towing Procedures Backing Up Procedures Disconnection Procedures Installation Criteria Loading Procedures Unloading Procedures

4.3.1

MOVEMENT PREPARATION CHECKLIST

Table 4.3.1-1 lists the basic inspection actions required prior to movement of the Power Unit. TABLE 4.3.1-1 STEP 1 2 3 4 5 6 MOVEMENT PREPARATION CHECKLIST (MEP-PU-810A & B MODELS) ACTION Check the maintenance schedule and be sure the equipment is up-to-date. Check steering for freedom of movement (MEP-PU-810A only). Inspect towing hookup for secure attachment. Fasten the Breakaway Switch Actuating Chain (MEP-PU-810A Only) to the tow vehicle. Check the Tire Pressure. Inflate to specifications; inspect tires for cuts, excessive wear, etc. Check brake fluid level in master cylinder. Insure cylinder is filled to proper level (MEP-PU-810A Only). See Figure 4.3.1-1 for additional information. Check wheel-mounting nuts/bolts with a torque wrench. Torque, in proper sequence, to the levels specified in this manual (Refer to Section 18.3.1.2.2 for the MEP-PU-810A and Section 18.3.2.3.2.1 for the MEP-PU-810B for additional information). Refer to Chapter 18 for reference. DONE

7

NOTE:

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FIGURE 4.3.1-1

CHECKING BRAKE FLUID LEVEL

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4.3.2

MEP-PU-810A HOOK-UP PROCEDURES WARNING THE HYDRAULIC PRESSURE HELD IN THE BREAKAWAY LEVER MAY CAUSE THE LEVER TO SNAP QUICKLY. KEEP HANDS AND FINGERS CLEAR, AS YOU RESET THE BREAKAWAY MECHANISM. WHEN TOWING, AVOID SHARP TURNS THAT CAN CAUSE THE ACTUATOR TO BIND AGAINST THE TOW VEHICLE. THIS CAN DAMAGE THE ACTUATOR AND TRAILER, CAUSING BRAKE FAILURE. WARNING DO NOT CONNECT THE MEP-PU-810A TO A VEHICLE WITH A TOW PINTLE MORE THAN 46 INCHES ABOVE THE GROUND. FAILURE TO COMPLY MAY CAUSE DAMAGE TO EQUIPMENT. CAUTION CHECK THAT THE PINTLE IS LOCKED AND ANY SAFETY PINS ARE INSERTED TO PREVENT ACCIDENTAL UN-COUPLING. DON’T PULL THE TRAILER IF EITHER THE LUNETTE EYE OR PINTLE IS DAMAGED. CAUTION INSURE THAT THE TOWING VEHICLE AND PINTLE HAVE A RATING EQUAL TO OR GREATER THAN THE MEP-PU-810A GROSS VEHICLE WEIGHT OF 25,740 LBS.

Table 4.3.2-1 lists MEP-PU-810A hook-up procedures. See Figure 4.3.2-1 through Figure 4.3.2-4 for reference. TABLE 4.3.2-1 STEP MEP-PU-810A HOOK-UP PROCEDURES ACTION Couple the power unit to the tow vehicle. Make certain that the lunette eye is in proper position and secured to the tow vehicle. Check that the pintle is locked and any safety pins are inserted to prevent accidental un-coupling. Don’t pull the trailer if either the lunette eye or pintle is damaged. Connect Fasten the Breakaway Switch Actuating Chain to the tow vehicle. see Figure 4.3.2-3 for reference. Connect breakaway chain S-hook to bumper or hitch. Allow slack for turning, but avoid letting the chain drag on pavement. Provide as straight a connection as possible. DONE

1

2

3

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FIGURE 4.3.2-1

MEP-PU-810A TOWING CONNECTION

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FIGURE 4.3.2-2

LUNETTE EYE

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FIGURE 4.3.2-3

BREAK-AWAY CHAIN S-HOOK

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MEP-PU-810B HOOK-UP PROCEDURES ACTION DONE

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

FIGURE 4.3.3-1

MEP-PU-810B TOWING CONNECTION

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FIGURE 4.3.3-2

12VDC AND 24VDC LIGHTING CONNECTION

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4.3.4

TOWING PROCEDURES WARNING MEP-PU-810B SPEED RATING DO NOT EXCEED A SPEED OF 55 MILES PER HOUR ON PAVED ROAD OR 5 MILES PER HOUR ON UNPAVED ROAD. FAILURE TO COMPLY MAY RESULT IN DEATH, SERIOUS INJURY OR DAMAGE TO POWER UNIT. WARNING MEP-PU-810A SPEED RATING DO NOT EXCEED A SPEED OF 20 MILES PER HOUR ON AN IMPROVED ROAD OR 5 MILES PER HOUR ON UNPAVED ROAD. FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY OR DAMAGE TO POWER UNIT. CAUTION MEP-PU-810B ONLY THE ABS BRAKING SYSTEM DOES NOT FUNCTION WHEN SUPPLIED WITH 24VDC.

Table 4.3.4-1 and Table 4.3.4-2 list towing procedures and speed ratings for the MEP-PU-810 A and MEP-PU-810B. TABLE 4.3.4-1 STEP 1 2 NOTE: MEP-PU-810A TOWING PROCEDURES AND SPEED RATINGS ACTION Release the MEP-PU-810A, parking brake (See Figure 4.3.4-1). Tow Power Unit, observing limitations on speed and turning angle. The tires supplied with the MEP-PU-810A power units are: • • • • • • Over-The-Road-Truck-Tires (Light Truck Tires) - Part No. - LT235/85R16. The tires are rated at 2778 pounds at 65 MPH. The MEP-PU-810A has four (4) tires per axle, and is rated for a maximum speed of 20 MPH. The maximum axle load (each) of the power unit is 13,000 pounds. Per Goodyear® handbook, the percent increase in the load is 32 % at 16 to 25 MPH. Four (4) tires per axle X 2778 Lbs. X 1.32 = 14,668 Pounds (which meets the Power Unit tire rating requirements). Replacement Tires must meet the minimum or higher load rating. DONE

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FIGURE 4.3.4-1 TABLE 4.3.4-2 STEP

PARKING BRAKE

MEP-PU-810B TOWING PROCEDURES AND SPEED RATINGS ACTION DONE

1

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

2

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4.3.5

BACKING UP PROCEDURES

Table 4.3.5-1 lists backing up procedures for both the MEP-PU-810A and MEP-PU-810B. TABLE 4.3.5-1 STEP 1 2 MEP-PU-810 A/B BACKING UP PROCEDURES ACTION Always use a ground guide when backing up the PU. On the MEP-PU-810A, insure the parking brakes are released and the safety chain is connected to the tow vehicle. On the MEP-PU-810B trailer, insure the air hoses are connected to the tow vehicle and the spring brakes release before attempting to back up. DONE

3

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4.3.6 4.3.6.1

DISCONNECTING PROCEDURES MEP-PU-810A DISCONNECTING PROCEDURES WARNING THE HYDRAULIC PRESSURE HELD IN THE BREAKAWAY LEVER MAY CAUSE THE LEVER TO SNAP QUICKLY. KEEP HANDS AND FINGERS CLEAR, AS YOU RESET THE BREAKAWAY MECHANISM. WHEN TOWING, AVOID SHARP TURNS THAT CAN CAUSE THE ACTUATOR TO BIND AGAINST THE TOW VEHICLE. THIS CAN DAMAGE THE ACTUATOR AND TRAILER, CAUSING BRAKE FAILURE.

Table 4.3.6-1 lists Disconnection Procedures for the MEP-PU-810A. TABLE 4.3.6-1 STEP 1 2 3 4 MEP-PU-810A DISCONNECTION PROCEDURES ACTION Set parking brakes by rotating parking brake handle clockwise until the brake bar is firmly lodged against the inner wheels of the trailer. Remove breakaway chain from towing vehicle. Open the tow vehicle pintle hook, move the tow bar to one side, and lower the tow bar to the ground. Drive the tow vehicle slowly forward until it is completely free of the Power Unit. DONE

4.3.6.2

MEP-PU-810B DISCONNECTING PROCEDURES

Table 4.3.6-2 lists Disconnection Procedures for the MEP-PU-810B. TABLE 4.3.6-2 STEP 1 2 3 4 MEP-PU-810B DISCONNECTION PROCEDURES ACTION Disconnect air hoses and insure the spring Parking Brake is set. Crank down landing gear until the trailer weight is removed from the fifth wheel. Release fifth wheel locking latch. Drive the tow vehicle slowly straight forward it is completely free of the Power Unit. DONE

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4.3.6.3

LOADING PROCEDURES

Table 4.3.6.3-1 lists MEP-PU-810A and MEP-PU-810B Loading Procedures. TABLE 4.3.6.3-1 STEP 1 2 3 4 5 6 7 8 9 10 MEP-PU-810A/B LOADING PROCEDURES ACTION Insure the DC control circuit breaker on the Master Control Panel (MCP) is in the “OFF” position. Insure fuel shutoff valves to the fuel supply are closed. Insure fuel pump transfer switch is in the “Off” position. Drain onboard fuel tank. Check all fluid levels and adjust as necessary. Check all compartments for loose material and secure any loose equipment. Tape up all air filter vents inside the PDC to prevent the ingress of dirt and moisture during transport. Attach a CAUTION tag to the DC Control Power Circuit Breaker in the Master Control Panel to alert the operator to remove the tape from the air filter vents prior to starting the unit. Close and lock all compartment doors. Secure the tow bar in the raised position using the chain and hook provided. Without ISO Lifting Device: 11 Secure the lifting chains or wire straps to the ISO corner castings, 4 places. Lifting chains or wire straps will be rated for 20 tons and be a minimum of 15 feet high using a single point pickup to prevent damage to the PU. Refer to Figure 4.4.1-1, Figure 4.4.1-2 and Figure 4.4.2-1. With ISO Lifting Device: 12 Install the four ISO Extenders into the four ISO Fittings located on the PU and lock them into place. Lower the ISO Frame and guide it into the ISO Extenders and lock in place. Lift the PU. Refer to Table 4.5-1 for reference. DONE

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WARNING THE CRANE MUST BE RATED 20 TONS OR ABOVE WITH A MINIMUM OF A 20 FOOT BOOM. USE GROUND GUIDE. Lift the power unit from the ground and set the PU on the trailer. Refer to Figure 4.4.1-1 and Figure 4.4.2-1 for reference. 14 15 The Power Unit must be oriented with the PDC end of the PU facing the rear of the trailer to prevent water incursion into the PDC. Insure that the Power Unit is secured to the trailer using the tie-down points.

13

4.3.6.4

UNLOADING PROCEDURES

Table 4.3.6.4-1 lists MEP-PU-810A and MEP-PU-810B Unloading Procedures. TABLE 4.3.6.4-1 STEP 1 2 3 MEP-PU-810A/B UNLOADING POCEDURES ACTION Inspect the PU for any visible signs of damage during shipment. Remove the tie-down straps, chains and packing dunnage. Secure the tow bar in the raised position using the chain and hook provided. Without ISO Lifting Device: 4 Secure the lifting chains or wire straps to the ISO corner castings, 4 places. Lifting chains will be rated for 20 tons and be a minimum of 15 feet high using a single point pickup to prevent damage to the PU. Refer to Figure 4.4.1-1 and Figure 4.4.2-1. With ISO Lifting Device: 5 Install the four ISO Extenders into the four ISO Fittings located on the PU and lock them into place. Lower the ISO Frame and guide it into the ISO Extenders and lock in place. Lift the PU. Refer to Table 4.5-1 for reference. DONE

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WARNING THE CRANE MUST BE RATED 20 TONS OR ABOVE WITH A MINIMUM OF A 20 FOOT BOOM. USE GROUND GUIDE. Lift the power unit from the trailer and set the PU on the ground. Refer to Figure 4.4.1-1, and Figure 4.4.2-1 for reference. CAUTION 7 FAILURE TO REMOVE THE TAPE FROM THE PDC AIR FILTER VENTS PRIOR TO STARTING THE UNIT WILL CAUSE OVERHEATING AND DAMAGE TO THE PDC Remove the tape from all of the PDC air filter vents. Remove the caution tag from the DC Control Power Circuit Breaker in the Master control panel prior to starting the unit.

6

8

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

FIGURE 4.4.1-1

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

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

FIGURE 4.4.2-1

MEP-PU-810B TIE-DOWN POINTS

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4.5

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

This section covers how to properly install the ISO Extender to the PU. WARNING WHEN AN ISO LIFTING DEVICE IS USED TO LIFT THE PU, THE ISO EXTENDERS MUST BE USED TO PREVENT DAMAGE TO THE COOLANT TANK, COOLANT FILL CAPS AND MUFFLER.

FIGURE 4.5-1

ISO EXTENDER

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

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WARNING THE ISO EXTENDER MUST BE INSTALLED SO THAT THE LOCKING MECHINASM IS FACING INBOARD TO THE PU. THIS WILL HELP PREVENT ACCIDENTALLY RELEASING THE ISO EXTENDER FROM THE PU.

ISO EXTENDER
REA R OF

ISO EXTENDER
POW ER U NIT

FRO NT O F

POW ER U NIT
ISO EXTENDER INSTALLED AND LOCKED INTO POSITION

FIGURE 4.5-2

Figure 4.5-2 illustrates the ISO Extender in the locked position. This ISO Extender is installed to illustrate the position of the locking mechanism, however to be properly mounted for lifting the PU, the ISO Extender would need to be rotated 90 degrees so that the “INSIDE” is always facing inboard to prevent accidentally unlocking the ISO Extender. Table 4.5-1 lists the ISO Installation Procedures. TABLE 4.5-1 STEP 1 2 3 4 ISO EXTENDER INSTALLATION PROCEDURES ACTION Inspect the ISO Extender for damage, see Figure 4.5-1 Place the ISO Extender into the ISO Fitting on the PU; see Figure 4.5-2. Move the ISO Extender Locking Handle into the “LOCKED” position, see Figure 4.5-2. Perform steps 1 and 2, until all four ISO Extenders are installed, see Figure 4.5-2. DONE

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4.6

ISO EXTENDER STORAGE PROCEDURES

This section covers how to properly store the ISO Extender Storage containers during transportation and plant operations. 4.6.1 MEP-PU-810A ISO EXTENDER STORAGE PROCEDURES

Table 4.6.1-1 lists the MEP-PU-810A, ISO Extender Storage Procedures. TABLE 4.6.1-1 STEP 1 2 3 4 MEP-PU-810A ISO EXTENDER STORAGE PROCEDURES ACTION Inspect each ISO Extender for damage, see Figure 4.5-1. Move the ISO Extender Locking Handle into the “LOCKED” position, see Figure 4.6.1-1. Carefully place two ISO Extenders into each ISO Extender storage box; see Figure 4.6.1-2. For transportation place one ISO Extender storage box into each side of the PU in the alternator compartment and secure with 2 rubber stretch cords per box as illustrated in Figure 4.6.1-3. During Plant operations place one ISO Extender storage box on each side of the PU below the alternator compartment and place two rubber stretch cords per box as illustrated in Figure 4.6.1-4. DONE

5

FIGURE 4.6.1-1

ISO EXTENDER SHOWN IN LOCKED POSITION

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

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FIGURE 4.6.1-2

ISO EXTENDERS PROPERLY PLACED IN STORAGE BOX

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

FIGURE 4.6.1-3

ISO EXTENDER STORAGE BOX IN TRANSPORTATION POSITION

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

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FIGURE 4.6.1-4

ISO EXTENDER STORAGE BOX IN OPERATION POSITION

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

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4.6.2

MEP-PU-810B ISO EXTENDER STORAGE PROCEDURES

Table 4.6.2-1 lists the MEP-PU-810B, ISO Extender Storage Procedures. TABLE 4.6.2-1 STEP 1 2 3 4 5 MEP-PU-810B ISO EXTENDER STORAGE PROCEDURES ACTION Inspect the ISO Extender for damage, see Figure 4.5-1 Move the ISO Extender Locking Handle into the “LOCKED” position, see Figure 4.6.2-1. Properly place two ISO Extenders into each ISO Extender storage box; see Figure 4.6.2-2. For transportation place both ISO Extender storage boxes into PU storage compartment as illustrated in Figure 4.6.2-3. During Plant operations place both ISO Extender storage boxes into PU storage compartment as illustrated in Figure 4.6.2-3. DONE

FIGURE 4.6.2-1

ISO EXTENDER SHOWN IN LOCKED POSITION

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

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FIGURE 4.6.2-2

ISO EXTENDERS PROPERLY PLACED IN STORAGE BOX

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

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FIGURE 4.6.2-3

ISO EXTENDER STORAGE BOX IN TRANSPORTATION/ OPERATION POSITION

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

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CHAPTER 5 OPERATING INSTRUCTIONS
TABLE OF CONTENTS CHAPTER
5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11

TITLE
SINGLE PU, PRIME POWER, NO EXTERNAL SWITCH, MANUAL MODE SINGLE PU, PRIME POWER, NO EXTERNAL SWITCH, AUTOMATIC MODE TWO PU, PRIME POWER, NO EXTERNAL SWITCH, MANUAL MODE TWO PU, PRIME POWER, NO EXTERNAL SWITCH, AUTOMATIC MODE SINGLE OR MULTIPLE PU, PRIME POWER, EXTERNAL SWITCH, MANUAL MODE SINGLE OR MULTIPLE PU, PRIME POWER, EXTERNAL SWITCH, AUTOMATIC MODE MEP-PU-810 AND MEP-012 PARALLEL OPERATIONS, MANUAL AND AUTOMATIC MODE UTILITY PARALLEL CONFIGURATION SPECIFIC OPERATING PROCEDURES

PAGE
5-3 5-33 5-51 5-69 5-87 5-107 5-131 5-171 5-193

PARALLELING MULTIPLE PU PLANTS, EXTERNAL SWITCH, AUTOMATIC MODE 5-225 TWO PLANT, MULITPLE POWER UNIT, PRIME POWER, EXTERNAL SWITCH, AUTOMATIC MODE

5-289

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CHAPTER 5.1 OPERATING INSTRUCTIONS
SINGLE PU, PRIME POWER, NO EXTERNAL SWITCH, MANUAL MODE
TABLE OF CONTENTS SECTION
5.1 5.1.1 5.1.2 5.1.3 5.1.3.1 5.1.3.2 5.1.3.3 5.1.3.4 5.1.3.5 5.1.3.6 5.1.3.7 5.1.3.8 5.1.4 5.1.5 5.1.6 5.1.6.1 5.1.6.2 5.1.6.3 5.1.6.4 5.1.6.5 5.1.6.6

TITLE
SINGLE PU, PRIME POWER, NO EXTERNAL SWITCH, MANUAL MODE SAFETY PROCEDURES POSITIONING THE PU INITIAL PLANT SETUP GROUNDING FUEL MANIFOLD DISTRIBUTION AND CONTROL CABLING SETPOINT VERIFICATION PRE-OPERATION CHECKS PRE-OPERATION RUN ORT SETUP CONTROLS SETUP PLANT STARTUP PLANT OPERATIONS POWER PLANT TEARDOWN SHUT DOWN GENERATORS DISCONNECT CABLES DISCONNECT FUEL LINES DISCONNECT GROUNDING PREPARE PU FOR TRANSPORTATION FUEL, OIL, AND COOLANT DRAINAGE

PAGE
6 6 6 7 7 9 10 11 24 26 28 29 30 31 31 31 31 32 32 32 32

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LIST OF FIGURES FIGURE
FIGURE 5.1.3.1-1 FIGURE 5.1.3.1-2 FIGURE 5.1.3.2-1

TITLE
MEP-PU-810A GROUND POINTS MEP-PU-810B GROUND POINTS EXTERNAL FUEL SUPPLY

PAGE
8 8 9

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LIST OF TABLES TABLE
TABLE 5.1.3.4-1 TABLE 5.1.3.4-2 TABLE 5.1.3.4-3 TABLE 5.1.3.4-4 TABLE 5.1.3.4-4 TABLE 5.1.3.4-5 TABLE 5.1.3.4-5 TABLE 5.1.3.4-5 TABLE 5.1.3.4-6 TABLE 5.1.3.4-6 TABLE 5.1.3.4-7 TABLE 5.1.3.4-7 TABLE 5.1.3.5-1 TABLE 5.1.3.5-1 TABLE 5.1.3.6-1 TABLE 5.1.3.8-1 TABLE 5.1.4-1

TITLE
CT RATIO SETTINGS INSTANTANEOUS TRIP SETTINGS TIME OVERCURRENT TRIP SETTINGS OP5-0 SETPOINTS OP5-0 SETPOINTS (CONTINUED) OP5-1 SETPOINTS OP5-1 SETPOINTS (CONTINUED) OP5-1 SETPOINTS (CONTINUED) OP6 SETPOINTS OP6 SETPOINTS (CONTINUED) DVR PARAMETERS/SETPOINTS DVR PARAMETERS/SETPOINTS (CONTINUED) PRE-OPERATION CHECKLIST PRE-OPERATION CHECKLIST (CONTINUED) PRE-OPERATION RUN INSTRUCTION SEQUENCE CONTROL SWITCH SETUP SWITCH SETUP – MANUAL MODE

PAGE
11 11 12 14 15 17 18 19 20 21 22 23 24 25 27 29 30

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5.1 5.1.1

SINGLE PU, PRIME POWER, NO EXTERNAL SWITCH, MANUAL MODE SAFETY PROCEDURES

a. Safety precautions must be observed while operating or maintaining the PU. Safety precautions must be observed to ensure that the operator/technician cannot have contact with the following: • • • • • • • Hot engine parts Hot engine fluids Medium Voltage AC electricity Low Voltage AC electricity Low Voltage DC electricity Rotating Parts High noise levels

b. Minor Troubleshooting can be performed while both engines are running as long as safety precautions are taken. Refer to the appropriate troubleshooting section for recommendations. 5.1.2 POSITIONING THE PU

a. Position the PU in such a way as to allow the plant operator to have full vision of the operator control panels on the unit. b. Level the MEP-PU-810B front to rear with the trailer leveling hand crank. c. Position the PU to provide a minimum of 10 feet of clearance for maintenance access on all sides of each unit. Ensure that there are no overhead obstructions around the exhaust outlets. WARNING FUEL SPILLAGE CAN OCCUR IF THE POWER UNIT LEVEL IS GREATER THAN + 5 DEGREES. d. Ensure that the ground is capable of supporting the weight of the PU. The site surface should be as level as possible (+ 5 degrees).

5-6

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d. Test Ground Resistance using Ground Resistance Test Equipment. Resistance must be 25Ω or less. Refer to Annex H for special equipment required for this task. e. Remove parking stand plates from their transportation positions inside each rear, side PU door and slide them into their respective operating positions on the sides of the PDC. f. Connect the parking stand ground wires to either of the two chassis ground lugs on the PU.

5-7

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

GROUND POINT

GROUND POINT

FIGURE 5.1.3.1-1 NOTE:

MEP-PU-810A GROUND POINTS

Connect only one ground point to the ground grid.

GROUND POINT

GROUND POINT

FIGURE 5.1.3.1-2 NOTE:

MEP-PU-810B GROUND POINTS

Connect only one ground point to the ground grid.

5-8

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 5.1.3.2 FUEL MANIFOLD WARNING ENSURE THAT THE FUEL LINES ARE PROTECTED FROM ALL ELECTRICAL CABLES AND ARE ROUTED TO MINIMIZE THE POTENTIAL FOR PHYSICAL DAMAGE OR CAUSING A TRIPPING HAZARD. a. Lay out the fuel hoses between the PU, the fuel manifold, and the fuel bladders to establish the fuel supply system see Figure 5.1.3.2-1. b. Install the external fuel hose for the PU to the Fuel Transfer Pump at the Tow end of the PU. c. Connect the other end of the fuel hose to the fuel manifold outlets.

d. Connect the 3” hose, with quick-disconnect hose ends, from the fuel manifold to the fuel bladders. e. Connect the fuel manifold ground wire to the ground grid. f. Open only the appropriate fuel manifold valves (once connected to the PU) to supply fuel to the power units and check for leaks.

FIGURE 5.1.3.2-1

EXTERNAL FUEL SUPPLY

5-9

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 5.1.3.3 DISTRIBUTION AND CONTROL CABLING

WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT DURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION AND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN LOAD CABLES ARE HANDLED.

WARNING VERIFY THAT CONNECTION POINTS ARE DE-ENERGIZED BEFORE MAKING ANY CONNECTIONS. FAILURE TO CHECK THAT CONNECTORS ARE DE-ENERGIZED MAY RESULT IN INJURY OR DEATH. a. Lay out and park the load cables for each phase (A, B, & C) between the PU feeder output parking stations and the load (if used). b. Connect each power cable’s drain wire to the grounding grid. c. Open the feeder output connection covers.

d. Connect the feeder cables to the appropriate phase connector at the PU and the load; ensure there are no cross-phase connections. e. Close and lock the feeder output connection cover. f. Lay out and park the load cables for each phase (A, B, & C) between the PU tie output parking stations and the load (if used).

g. Connect each power cable’s drain wire to the grounding grid. h. Open the tie output connection covers. i. j. Connect the load cables to the appropriate connector at the PU and the load; ensure there are no cross-phase connections. Close and lock the tie output connection cover.

5-10

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 5.1.3.4 SETPOINT VERIFICATION

a. Turn on PU DC control power by pushing in on the DC Control Power breaker. b. On each of the five overcurrent relays, verify the settings: (1) (2) (3) (4) (5) (6) Press the [▲] key to get to the top-level menu “1 REPORT STATUS”. Press the [►] key 5 times to display “6 GENERAL SETTINGS”. Press the [▼] key to display “6.1 COM SETTINGS”. Press the [►] key 2 times to display “6.3 POWER SYSTEM SETTINGS”. Press the [▼] key to display “6.3.1 CT RATIO”. Verify the “P” and “N” values match the following table: CT RATIO SETTINGS CT RATIO 100:5 200:5 200:5 “P” VALUE 20 40 40 “N” VALUE 20 40 40

TABLE 5.1.3.4-1 BREAKER RELAY GENERATOR FEEDER TIE (7) (8) (9)

Press the [▲] key 2 times to display “6 GENERAL SETTINGS”. Press the [◄] key to display “5 PROTECTION LOGIC USER”. Press the [▼] key 3 times to display “5.1.1.1 50TP”.

(10) Verify the 50TP “PU” and “TD” settings in Table 5.1.3.4-2. In order to edit values, Press the “Edit” key. Select correct value and press “Edit” again to save changes. Ensure light is off otherwise you can accidentally change value again. TABLE 5.1.3.4-2 BREAKER RELAY GENERATOR FEEDER TIE INSTANTANEOUS TRIP SETTINGS PHASE NEUTRAL INSTANTANEOUS INSTANTANEOUS TRIP 50TP TRIP 50TN PU TD PU TD 0.0 0m 3.0 0m 7.5 84m 1.25 84m 0.0 0m 0 0m NEGATIVE SEQUENCE TRIP 50 TQ PU TD 3.0 0m 0 0m 0.0 0m

(11) Press the [►] key to display “5.1.1.2 50TN”. (12) Verify the “50TN” settings in Table 5.1.3.4-2. (13) Press the [►] key to display “5.1.1.3”. (14) Verify the “50TQ” settings (15) Press the [▲] key to display “5.1.1 50T SETTINGS”. (16) Press the [►] key to display “5.1.2 51 SETTINGS”.

5-11

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (17) Press the [▼] key to display “5.1.2.1 51P”. (18) Verify the 51P “PU”, “TD”, and “C” settings in Table 5.1.3.4-3. TABLE 5.1.3.4-3 BREAKER RELAY GENERATOR FEEDER TIE TIME OVERCURRENT TRIP SETTINGS PHASE TIME OVERCURRENT TRIP 51P PU TD C 4.50 0.5 VV2 2.50 1.0 VV2 5.00 2.0 VV2 NEUTRAL TIME OVERCURRENT TRIP 51N PU TD C 1.25 0.5 VV2 1.00 1.0 VV2 1.50 2.0 VV2

(19) Press the [►] key to display “5.1.2.2 51N”. (20) Verify the “51N” settings in Table 5.1.3.4-3. (21) Press the [▲] key 3 times to display “5 PROTECTION LOGIC USER”. c. NOTE: (1) (2) (3) (4) (5) (6) (7) (8) (9) Use the following procedure to verify the Generator 1 and Generator 2 GSC+ settings in step “d”: Refer to the “EMCPII+ Reference Chart”, located on the interior Generator Control Panel Door (Look-up) Place ECS in the COOLDOWN/STOP position. Press SERVICE MODE key to enter service mode. OP1 is showing on the lower display. Press SCROLL UP key until “OP3” is showing. Press SELECT key. “PE -“with the first dash flashing is showing. Press SCROLL RIGHT key. “PE 1”-with the second dash flashing is showing. Press SCROLL DOWN key. “PE 13–“with the third dash flashing is showing. Press SCROLL UP key. “PE 132–“with the fourth dash flashing is showing. Press SCROLL DOWN key. “PE 1323–“with the fifth dash flashing is showing. Press SCROLL RIGHT key. “PE13231” -with all digits not flashing is showing.

(10) Press ENTER key. “PE PASS” is showing. (11) Press EXIT key. “OP4” is showing. (12) Press SCROLL UP key until “OP5-0” is showing on the lower display. (13) Press SELECT key. “POO1” followed with the value of the setpoint is showing. (14) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing. Use Table 5.1.3.4-4 for the parameter values to be verified. Repeat until the desired setpoints are verified. (15) Press EXIT key. “OP5-0” is showing on the lower display.

5-12

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (16) Press SCROLL UP key until “OP5-1” is showing. (17) Press SELECT key. (18) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing. Use Table 5.1.3.4-5 OP5-1 Setpoints for the parameter values to be verified. Repeat until all the desired setpoints are verified. (19) Press EXIT key. “OP5-1” is showing. (20) Press SCROLL UP key until “OP6” is showing. (21) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing. Use “OP6” Setpoints, Table 5.1.3.4-6 for the parameter values to be verified. Repeat until all the desired setpoints are verified. (22) Press EXIT Key twice. The display returns to normal. NOTE: If an incorrect setpoint value is displayed, the value must be changed to match the DPGDS setpoint value as follows: (a) (b) (c) (d) With the setpoint with the incorrect value showing on the display, press the SELECT key. The incorrect value flashes on the display. Press SCROLL UP or SCROLL DOWN key until the correct value appears flashing on the display. Press ENTER. The correct value stops flashing on the display.

Press SCROLL UP or SCROLL DOWN key to continue to verify the remaining parameter values. d. At GSCG1 and GSCG2, verify the operation settings using the following tables:

5-13

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 TABLE 5.1.3.4-4 OP5-0 SETPOINTS SETPOINTS OP5-0 ENGINE/GENERATOR PROGRAMMING① FACTORY DPGDS SETPOINT-NAME-DESCRIPTIONS RANGE OF VALUES DEFAULT SETPOINT
P001 - Fuel Solenoid Type: type of fuel system solenoid used on the genset. P002 - Units Shown: type of measurement units shown on the GSC+ display. P003 - Shutdown Override For Engine Fault: GSC+ response to a low engine oil pressure or high coolant temperature fault. P004 - Shutdown Override For Sensor Fault: GSC+ response to a diagnostic fault with the engine oil pressure sensor, coolant temperature sensor, oil temperature sensor, sensor power supply or coolant loss sensor. P005 - Coolant Loss Sensor Installed: tells whether or not the optional engine coolant loss sensor is installed on the genset. P006 - Shutdown Override For Coolant Loss Fault: GSC+ response to an engine coolant loss fault. P007 - System Voltage, 24 Or 32 Volts: system voltage (battery voltage) of the genset. P008 - This setpoint is not currently being used by the GSC+ and cannot be programmed. P009 - Number Of Ring Gear Teeth: number of teeth on the ring gear of the engine. Used by the GSC+ to determine engine speed. P010 - Engine Overspeed: engine speed used by the GSC+ to declare that an engine overspeed fault exists. The engine overspeed setpoint (for all 60 Hz applications) is 1.18 times the rated speed. P011 - Crank Terminate Speed: engine speed used by the GSC+ to disengage the starting motor during engine cranking. P012 - Oil Step Speed: engine speed used by the GSC+ for distinguishing between rated speed and idle speed when a low oil pressure fault exists. P013② - Low Oil Pressure Shutdown At Rated Speed: oil pressure used by the GSC+ to declare that a low oil pressure shutdown fault exists with engine at rated speed (the engine speed must have exceeded the oil step speed for nine seconds). P014② - Low Oil Pressure Shutdown At Idle Speed: oil pressure used by the GSC+ to declare that a low oil pressure shutdown fault exists with the engine at idle speed (the engine must have been running for at least 9 seconds and the engine speed must be less than oil step speed). P015③ - High Water Temperature Shutdown: coolant temperature used by the GSC+ to declare a high coolant temperature shutdown fault exists (after a 10 second delay). P016 - Low Water Temperature Alarm: coolant temperature used by the GSC+ to declare that a low coolant temperature alarm fault exists (after a 2 second delay). 0- ETR fuel solenoid 1- ETS fuel solenoid 0-for English units (PSI, ºF) 1-for metric units (kPa, ºC). 0-for engine shutdown 1-for alarm only (shutdown override, no engine shutdown). 0-for alarm only shutdown override, no engine shutdown). 1-for engine shutdown. 0-for gensets without a coolant loss sensor 1-for gensets with coolant loss sensor 0-for engine shutdown. 1-for alarm only (shutdown override, no engine shutdown). 24 or 32. N/A 95 to 350 teeth in increments of one tooth. 0 0 0 0 0 0

0

0

0

1

0

0

24 N/A 136 teeth

24 N/A 136 teeth

500 to 4330 rpm in increments of 10 rpm.

2120 rpm

2120 rpm

100 to 1000 rpm in increments of 10 rpm.

400 rpm

400 rpm

400 to 1800 rpm in increments of 10 rpm.

1350 rpm

1350 rpm

5 to 61PSI (34 to 420kPa) in increments of 1

30 PSI (205 kPa)

30 PSI (205 kPa)

20 to 336kPa (3 to 49PSI) in increments of 1

10 PSI (70 kPa)

10 PSI (70 kPa)

185 to 253ºF (85 to 123ºC) in increments of 1

225ºF (107ºC)

225ºF (107ºC)

32 to 97ºF (0 to 36ºC) in increments of 1

70ºF (21ºC)

70ºF (21ºC)

5-14

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 TABLE 5.1.3.4-4 OP5-0 SETPOINTS (CONTINUED) DPGDS SETPOINT
90 seconds 10 seconds 5 minutes

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

P019 - Cooldown Time: amount of time the GSC+ allows the 0 to 30 minutes in increments of 1 engine to run after a normal shutdown is initiated. minute. P020④ - AC Voltage: nominal AC voltage of the generator. The GSC+ measures the AC voltage and shows it on the display. P021 - AC Current Full Scale: nominal full scale AC current of the generator. AC current full scale is equal to the ratio of the external current transformers in the generator housing. P022⑤ - GSC+ Engine Number: informs other devices on the CAT Data Link of the engine number for the GSC+. 700, 150, 300, 500, 600, 750, 3.0k, 4.5k, 5.20k, 5.25k, 9.0k, 15.0k, 18.0k, 30.0k 75, 100, 150, 200, 300, 400, 600, 800, 1000, 1200, 1500, 2000, 2500, 3000, and 4000A 01 through 08

700

5.20k

600A

100A 01 (Gen 1) 02 (Gen 2)

01

SETPOINTS - OP5-0-ENGINE/GENERATOR PROGRAMMING① RANGE OF FACTORY 60HZ 50HZ SETPOINT-NAME-DESCRIPTIONS DEFAULT SETPOINT SETPOINT VALUES
P023 - Engine Type: identifies the engine as a mechanical unit injector (MUI) diesel, spark ignited (gas), or electronic unit injector (EUI) diesel engine. P024 - Crank Time Delay: amount of time the GSC+ delays activation of the fuel control relay (FCR) during a crank cycle. This setpoint is for Gas engines only. The P024 setpoint only functions when the P023 setpoint is set to 1 (gas engine). 0 - MUI diesel 1 - Gas 2 - EUI diesel 0 2 2

0 to 20 seconds in increments of 1 second.

5 Seconds

5 Seconds

5 Seconds

0 - for gensets without an oil P025 - Oil Temperature Sensor Installed: tells temperature sensor whether or not the optional engine oil temperature 1 - for gensets with an oil sensor is installed on the genset. temperature sensor P026 - High Oil Temperature Shutdown: oil temperature used by the GSC+ to declare a high 185 to 253ºF (85 to 123ºC) in increments of 1 oil temperature shutdown fault exists (after a 10 second delay). Refer to the panel model number. 0 - for alarm only (shutdown override, P027 - Shutdown Override For High Oil Temperature Fault: GSC+ response to an engine no engine shutdown). high oil temperature fault. 1 - for engine shutdown. P028 - Nameplate Voltage: rated voltage of the generator. This setpoint is used for protective relaying functions. P029 - Nameplate Current: rated current output of the generator. 100 to 25kV in increments of 1 0 to 4000 A in increments of 1

0

0

0

225ºF (107ºC)

225ºF (107ºC) 225ºF (107ºC)

0

0

0

480V 600A 400kW 60Hz 0 4

4160V 80 420kW 60Hz 0 4

3800V 73A 350kW 50Hz 0 4

P030 - Nameplate Power: rated power capability 0 through 10MW in increments of of the generator. 1kW. P031 - Rated Frequency: nominal frequency 50 or 60Hz rating of genset. P032 - Connection Configuration Of Generator: 0 - wye wye or delta configuration of generator. 1 – delta P033 - Number Of Generator Poles. 0 through 254 in increments of 2.

5-15

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254
① The setpoints (stored or being programmed) must match the specified DPGDS setpoints.

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

5-16

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

TABLE 5.1.3.4-5

OP5-1 SETPOINTS

SETPOINTS OP5-1 PROTECTIVE RELAYING PROGRAMMING① FACTORY 60HZ 50HZ SETPOINT-NAME-DESCRIPTION RANGE OF VALUES DEFAULT SETPOINT SETPOINT
P101 - Generator Overvoltage Alarm Enable: the 0 - disabled GSC+ enables or disables the generator 1 – enabled overvoltage alarm function. P102 - Generator Overvoltage Alarm Threshold: voltage the GSC+ uses to issue an overvoltage alarm. P103 - Generator Overvoltage Alarm Time Delay: amount of time the GSC+ waits before issuing an overvoltage alarm. P104 - Generator Overvoltage Shutdown Enable: the GSC+ enables or disables the generator overvoltage shutdown function. P105 - Generator Overvoltage Shutdown Threshold: voltage the GSC+ uses to issue an overvoltage shutdown. P106 - Generator Overvoltage Shutdown Time Delay: amount of time the GSC+ waits before issuing an overvoltage shutdown. P107 - Generator Undervoltage Alarm Enable: the GSC+ enables or disables the generator undervoltage alarm function. P108 - Generator Undervoltage Alarm Threshold: voltage the GSC+ uses to issue an undervoltage alarm. P109 - Generator Undervoltage Alarm Time Delay: amount of time the GSC+ waits before issuing an undervoltage alarm. P110 - Generator Undervoltage Shutdown Enable: the GSC+ enables or disables the generator undervoltage shutdown function. P111 - Generator Undervoltage Shutdown Threshold: voltage the GSC+ uses to issue an undervoltage shutdown. P112 - Generator Undervoltage Shutdown Time Delay: amount of time the GSC+ waits before issuing an undervoltage shutdown. P113 - Generator Overfrequency Alarm Enable: the GSC+ enables or disables the generator overfrequency alarm function. P114 - Generator Overfrequency Alarm Threshold: frequency the GSC+ uses to issue an overfrequency alarm. P115 - Generator Overfrequency Alarm Time Delay: amount of time the GSC+ waits before issuing an overfrequency alarm. P116 - Generator Overfrequency Shutdown Enable: the GSC+ enables or disables the generator overfrequency shutdown function. P117 - Generator Overfrequency Shutdown Threshold: frequency the GSC+ uses to issue an overfrequency shutdown. 100 to 125% of nameplate voltage in increments of 1%. 0 through 120 seconds② in increments of 1 0 - disabled 1 – enabled 100 to 125% of nameplate voltage in increments of 1%. 0 through 120 seconds② in increments of 1 0 - disabled 1 – enabled 60 to 100% of nameplate voltage in increments of 1%. 0 through 120 seconds② in increments of 1 0 - disabled 1 – enabled 60 through 100% of rated voltage in increments of 1%. 0 through 120 seconds② in increments of 1 0 - disabled 1 – enabled 50-60Hz, for 50Hz Gen 60-70Hz, for 60Hz Gen 400-480, for 400Hz Gen 0 through 120 seconds② in increments of 1 0 - disabled 1 – enabled 50-60Hz, for 50Hz Gen 60-70Hz, for 60Hz Gen 400-480, for 400Hz Gen 1 1 1

105%

105%

105%

10 seconds

10 seconds

10 seconds

1

1

1

110%

110%

110%

10 seconds

10 seconds

10 seconds

1

1

1

90%

90%

90%

10 seconds

10 seconds

10 seconds

1

1

1

85%

85%

85%

15 seconds

03 seconds

03 seconds

1 53Hz 63Hz 422Hz 10 seconds

1

1

63 Hz

53 Hz

10 seconds

10 seconds

1 55Hz 66Hz 440Hz

1

1

66Hz

55Hz

5-17

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 TABLE 5.1.3.4-5 OP5-1 SETPOINTS (CONTINUED) 50HZ SETPOINT
10 seconds

SETPOINTS OP5-1 PROTECTIVE RELAYING PROGRAMMING① FACTORY 60HZ SETPOINT-NAME-DESCRIPTION RANGE OF VALUES DEFAULT SETPOINT
P118 - Generator Overfrequency Shutdown Time Delay: amount of time the GSC+ waits before issuing an overfrequency shutdown. P119 - Generator Underfrequency Alarm Enable: the GSC+ enables or disables the generator underfrequency alarm function. P120 - Generator Underfrequency Alarm Threshold: frequency the GSC+ uses to issue an underfrequency alarm. P121 - Generator Underfrequency Alarm Time Delay: amount of time the GSC+ waits before issuing an underfrequency alarm. P122 - Generator Underfrequency Shutdown Enable: the GSC+ enables or disables the generator underfrequency shutdown function. P123 - Generator Underfrequency Shutdown Threshold: frequency the GSC+ uses to issue an underfrequency shutdown. P124 - Generator Underfrequency Shutdown Time Delay: amount of time the GSC+ waits before issuing an underfrequency shutdown. P125 - Generator Reverse Power Shutdown Enable: the GSC+ enables or disables the generator reverse power shutdown function. P126 - Generator Reverse Power Shutdown Threshold: level of reverse power the GSC+ uses to issue a reverse power shutdown. P127 - Generator Reverse Power Shutdown Time Delay: amount of time the GSC+ waits before issuing a reverse power shutdown. P128 - Generator Overcurrent Alarm Enable: the GSC+ enables or disables the overcurrent alarm. P129 - Generator Phase Overcurrent Alarm Threshold: level of current the GSC+ uses to issue a phase overcurrent alarm. P130 - Generator Phase Overcurrent Alarm Time Delay: amount of time the GSC+ waits before issuing a phase overcurrent alarm. P131 - Generator Total Overcurrent Alarm Threshold: level of current the GSC+ uses to issue a total overcurrent alarm. P132 - Generator Total Overcurrent Alarm Time Delay: amount of time the GSC+ waits before issuing a total overcurrent alarm. 0 through 120 seconds② in increments of 1 0 - disabled 1 – enabled 30-50Hz, for 50Hz Gen 36-60Hz, for 60Hz Gen 240-400, for 400Hz Gen 0 through 120 seconds② in increments of 1 0 - disabled 1 – enabled 30-50Hz, for 50Hz Gen 36-60Hz, for 60Hz Gen 240-400, for 400Hz Gen 0 through 120 seconds② in increments of 1 0 - disabled 1 – enabled 0 through 20% of rated power in increments of 1%. 0 through 30 seconds② in increments of 1 0 - disabled 1 – enabled 100 through 160% of nameplate current in increments of 5% 0 through 250 seconds② in increments of 1 100 through 160% of three times nameplate current in increments of 5% 0 through 250 seconds② in increments of 1 10 seconds 10 seconds

1 48Hz 57Hz 378Hz 10 seconds

1

1

57Hz

48Hz

10 seconds

10 seconds

1 45Hz 54Hz 360Hz 15 seconds

1

1

54Hz

45Hz

03 seconds

03 seconds

1

1

1

15%

4%

4%

10 seconds 1 105%

4 seconds 1 150%

4 seconds 1 150%

0 seconds

0 seconds

0 seconds

105%

150%.

150%

0 seconds

0 seconds

0 seconds

P133 – Generator Overcurrent Shutdown Enable: 0 – disabled the GSC+ enables or disables the overcurrent 1 – enabled shutdown. P134 – Generator Phase Overcurrent Shutdown 100 through 160% in increments of 5% Threshold: level of current the GSC+ uses to issue a phase overcurrent shutdown. P135 – Generator Phase Overcurrent Shutdown Time Delay: amount of time the GSC+ waits before issuing a phase overcurrent shutdown. 0 through 250 seconds② in increments of 1

1

1

1

110%

150%

150%

0 seconds

10 seconds

10 seconds

5-18

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 TABLE 5.1.3.4-5 OP5-1 SETPOINTS (CONTINUED)

SETPOINTS OP5-1 PROTECTIVE RELAYING PROGRAMMING①
SETPOINT-NAME-DESCRIPTION
P136 - Generator Total Overcurrent Shutdown Threshold: level of current the GSC+ uses to issue a total overcurrent shutdown. P137 - Generator Total Overcurrent Shutdown Time Delay: amount of time the GSC+ waits before issuing a total overcurrent shutdown. P138 - KW Level Relay Enable : the GSC+ enables or disables the kW level relay function. P139 - KW Level Relay Threshold: level of power the GSC+ uses to activate the kW level relay function. P140 - KW Level Relay Time Delay: amount of time the GSC+ waits before activating the kW level relay function. P141 - KW Level Relay Disengage Threshold: level of power the GSC+ uses to deactivate the kW level relay function. P142 - KW Level Relay Disengage Time Delay: amount of time the GSC+ waits before deactivating the kW level relay function.

RANGE OF VALUES
100 through 160% of three times nameplate current in increments of 5% 0 through 250 seconds② in increments of 1 0 - disabled 1 – enabled 0 through 110% of nameplate power in increments of 1% 0 through 120 seconds② in increments of 1 0 through 110% of nameplate power in increments of 1%. 0 through 120 seconds② in increments of 1

FACTORY DEFAULT
110%

60HZ SETPOINT
150%.

50HZ SETPOINT
150%

0 seconds

10 seconds

10 seconds

1

1

1

105%

105%

105%

0 seconds

0 seconds

0 seconds

100%

100%

100%

10 seconds

10 seconds

10 seconds

① The setpoints are programmed at the factory to the default value. ② When programmed to 0 seconds, the actual time is from 0.5 to 1.0 seconds.

5-19

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

TABLE 5.1.3.4-6

OP6 SETPOINTS SETPOINTS OP6 SPARE INPUT/OUTPUT PROGRAMMING RANGE OF VALUES
0-active low 1-active high 0-shutdown 1-alarm 0 - 250 seconds in increments of 1 0-active low 1-active high 0-shutdown 1-alarm 0 - 250 seconds in increments of 1 0-active low 1-active high 0-shutdown 1-alarm 0 - 250 seconds in increments of 1 0-active low 1-active high 0-shutdown 1-alarm 0 - 250 seconds in increments of 1 0-active low 1-active high 0-unused 1-active SP1 fault② 2-active SP2 fault② 3-active SP3 fault②

SETPOINT-NAME-DESCRIPTIONS
SP01 - Spare Input 1 Active State. Input state used by the GSC+ to declare a SP1 fault exists. SP02 - Spare Input 1 Response: GSC+ response to a SP1 fault. SP03 - Spare Input 1 Time Delay: Amount of time the GSC+ waits before responding to a SP1 fault. SP04 - Spare Input 2 Active State. Input state used by the GSC+ to declare a SP2 fault exists. SP05 - Spare Input 2 Response: GSC+ response to a SP2 fault. SP06 - Spare Input 2 Time Delay: Amount of time the GSC+ waits before responding to a SP2 fault. SP07 - Spare Input 3 Active State. Input state used by the GSC+ to declare a SP3 fault exists. SP08 - Spare Input 3 Response: GSC+ response to a SP3 fault. SP09 - Spare Input 3 Time Delay: Amount of time the GSC+ waits before responding to a SP3 fault. SP10 - Spare Input 4 Active State. Input state used by the GSC+ to declare a SP4 fault exists. SP11 - Spare Input 4 Response: GSC+ response to a SP4 fault. SP12 - Spare Input 4 Time Delay: Amount of time the GSC+ waits before responding to a SP4 fault. SP13 - Spare Output Response: GSC+ response to the spare output trigger condition.

FACTORY DPGDS DEFAULT SETPOINT
0 0 0 seconds 0 0 0 seconds 0 0 0 seconds 0 0 0 seconds 0 0 0 1 second 1 0 0 seconds 0 0 0 seconds 0 0 0 seconds 0

SP14 - Spare Output Trigger Condition: The condition used by the GSC+ to trigger the spare output response

4-active SP4 fault② 5-any combination of active SP faults② 6-any active shutdown 7-any active alarm or shutdown 8-cooldown mode 9-coolant loss mode② 8 8

10-high oil temp fault② 11-CCM control SP15 – Spare Relay Output Response: GSC+ response to the 0-relay inactive when triggered spare relay trigger condition. 1-relay active when triggered

1

1

5-20

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 TABLE 5.1.3.4-6 OP6 SETPOINTS (CONTINUED) SETPOINTS OP6 SPARE INPUT/OUTPUT PROGRAMMING RANGE OF VALUES
0-unused 1-active SP1 fault② 2-active SP2 fault② 3-active SP3 fault② SP16 - Spare Relay Output Trigger Condition: The condition used by the GSC+ to trigger the spare relay. 4-active SP4 fault② 5-any combination of active SP faults② 6-any active shutdown 7-any active alarm or shutdown 8-cooldown mode 9-coolant loss mode② 10-high oil temp fault② 11-CCM control 0-unused 1-active SP1 fault② 2-active SP2 fault② 3-active SP3 fault② SP17 - Spare Indicator 1 Trigger Condition: The condition used by the GSC+ to trigger spare indicator①. 4-active SP4 fault② 5-any combination of active SP1, SP2, SP3 or SP4 faults② 6-Coolant loss fault② 7-high oil temperature fault② SP18 - Spare Indicator 2 Trigger Condition: The condition used by the GSC+ to trigger spare indicator②. SP19 - Spare Indicator 3 Trigger Condition: The condition used by the GSC+ to trigger spare indicator③. Battle Short mode. Not in 60 Hz mode. 0 0 0 Battleshort③ 0 In 50Hz Mode③ 0 6 8 1

SETPOINT-NAME-DESCRIPTIONS

FACTORY DPGDS DEFAULT SETPOINT

① The setpoints are programmed at the factory to the default value. ② Either alarm or shutdown faults are valid trigger conditions ③ Battleshort and 50Hz Mode are unique features to DPGDS for spare indicators 2 and 3.

e. Return ECS1 and ECS2 to the OFF/RESET position. NOTE: f. Use up or down keys to change values. At the AVR verify the operation settings using Table 5.1.3.4-7: (1) (2) Open the GCPG1 cabinet door. Press the [▼] key to display parameter “90”.

5-21

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (3) (4) (5) (6) (7) (8) (9) Press the [◄►] key to display the current value. Press the [▲] key to change the value to “0015” enables parameter editing. Press the [◄►] key to accept change and display the parameter number. Press the [▲] key to the next parameter needed to change. Press the [◄►] key to display the current value. Press the [▲] or [▼] key to change the value. Press the [◄►] key to accept change and display the parameter number.

(10) Repeat steps ‘5’ through ‘9’ for the each parameter needing to be changed. (11) When complete, press the [▼] to display parameter “01”. NOTE: NOTE: Parameters 20, 21, 22, 36, 37, and 38 are displayed but not used. Parameters 23 to 29, 39 to 49, 59 and 61 to 89 are not displayed and not used. AVR PARAMETERS/SETPOINTS DPGDS AVR PARAMETERS
PARAMETER 01 02 03 04 05② 06 07 08 09 10 11 12 13 14 15 16⑤ 17⑥ 18 19 TITLE Generator Output Voltage Ratio of Output Voltage To Sensing Voltage Generator Type Rated Generator Output Current CT Voltage At Rated Generator Current Knee Frequency Decreasing Volts/Hz Slope I Decreasing Volts/Hz Slope 2 Minimum Voltage Under Frequency Point Overvoltage Trip Point Overvoltage Trip Time Under Voltage Trip Point Under Voltage Trip Time Voltage Gain (IR Compensation) Integral Gain Proportional Gain Single Phase Sensing Select (0=three phase, 1=single phase) Diode Monitor Trip Point TYPE Program Program Program Program Program Program Program Program Program Program Program Program Program Program Program Program Program Program Program Amps Amps Volts Hz Volts/Hz Volts/Hz % Hz % Seconds % Seconds % UNITS Volts RANGE OF VALUES 0080-9999 001.0-100.0 0000-0004 0000-9999 01.00-05.00 045.0-065.0 001.0-010.0 001.0-010.0 050.0-100.0 020.0-040.0 0105-0140 0002-0030 0060-0095 0030-0120 000.0-0 10.0 001.0-020.0 001.0-020.0 0000,0001 001.0-010.0 DEFAULT VALUE 480① 001.0 0004 0600 05.00 050.0 002.0 002.0 050.0 025.0 014.0 0002 0060 0030 0000 006.0 005.0 0000 002.0

TABLE 5.1.3.4-7

DPGDS SETPOINTS
60HZ OPS 4160 17.3 4 80 4.00 59.8 2.0 2.0 50.0 25.0 125.0 5 75 30 0 6.0 5.0 0000 2.0 50HZ OPS 3800 17.3 4 73 3.66 49.8 2.0 2.0 50.0 25.0 125.0 5 75 30 0 6.0 5.0 0000 2.0

5-22

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 TABLE 5.1.3.4-7 AVR PARAMETERS/SETPOINTS (CONTINUED) DPGDS AVR PARAMETERS
PARAMETER 30 31③ 32③ 33③ 34③ 35③ 50 51 52 53 54 55 56③ 57③ 58③, ④ 60 90 91 92 93 94 96 TITLE Droop Percentage pf/Kvar Select (0=pf, 1=Kvar) Pf Reference KVAR Reference Reverse Power Trip Point Reverse Power Trip Time Generator Output Frequency Generator Output Voltage Generator Output Current Generator Reactive Output Current Generator Real Current Exciter Field Current Three Phase Kilowatts (KB and later) Power Factor Three Phase Kvar (KE and later) Hours Password Software ID Latest Fault Previous Fault Fault Clear Shutdown Fault Reset TYPE Program Program Program Program Program Program View View View View View View View View View View Program View View View View Switch Hours 0000-9999 0009 0000 0000 0000 0000 0009 0000 0000 Per Unit % Seconds Hz Volts Amps Amps Amps Amps KW UNITS % RANGE OF VALUES 000.0-010.0 0000, 0001 00.60-01.10 00.00-01.00 000.0-020.0 000.0-020.0 DEFAULT VALUE 0000 0000 01.00 0000 010.0 010.0

DPGDS SETPOINTS
60HZ OPS 3 0 0.8 0.10 15 5 50HZ OPS 3 0 0.8 0.10 15 5

①- Default value for output voltage is different depending on regulator sensing voltage. If the regulator is

designed for 120 volts sensing, then the default output voltage is 4160 volts. All other sensing types have the default output voltage set to 480 volts.
②- Digital Voltage Regulators with earlier software (KD and earlier) have 1 less digit to the right of the

decimal point.
③- Optional feature. ④- New parameter on serial number prefixes KE and later Digital Voltage Regulators. ⑤- Previous range of 0001-099.9 and default value of 002.0

⑥-Previous range of 0001-099.9 and default value of 002.0 (12) When complete, press the [▼] to display parameter “90”. (13) Press the [◄►] key to display the current value. (14) Press the [▼] key to change the value to “0009”. disables DVR parameter editing. (15) Press the [◄►] key to accept change and display the parameter number.

5-23

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (16) Press the [▲] key to change to display parameter “01”. (17) Close the GCPG1 cabinet door. (18) Repeat steps ‘1 ‘through ‘16’ for Generator 2. 5.1.3.5 PRE-OPERATION CHECKS

Starting from the left rear of the PU and working around the PU in a clockwise direction, perform the following checks (Gen. 1 is on the left and Gen. 2 is on the right): TABLE 5.1.3.5-1 PRE-OPERATION CHECKLIST ITEM ACTION REQUIRED NUMBER Ensure the parking brake is set. Rotate the crank in a clockwise rotation 1 (PU-810 A) to set. Ensure that the wheels are properly chocked or the Spring Brakes are 1 (PU-810-B) set by opening the petcock on the air tank and evacuating all the air. Check the ground connection. 2 Check that the ORT communication cable is connected properly. 3 Ensure the feeder output cables, if used, are properly connected and 4 that the concentric neutrals are connected to ground. Ensure that the feeder output cover is secured. (Locked) 5 Check Parking Stands for proper mounting and connection. 6 Check the two 120-Volt auxiliary duplex receptacles and the 60 amp 3 7 phase receptacle cables are securely connected or the covers are properly installed / closed. Open the left rear PU side access door and inspect the area for cleanliness, loose electrical connections, loose hardware, and leaks 8 around the oil filter and lines. Check for signs of heat damage or other abnormalities. Check all high voltage panels for security Ensure that the battery charger voltmeter displays (24 VDC), is plugged into the battery charger receptacle, and that all circuit breakers are 9 turned on. Return to this step after a generator breaker is closed to ensure charger is supplying current to the batteries. Visually inspect the air intake duct for obstructions or foreign objects. 10 Close the left rear PU door. 11 Open the left front PU side access door and inspect the area for 12 cleanliness, loose electrical connections, loose hardware, leaks around oil and fuel lines, signs of heat damage or other abnormalities. Drain the crankcase vent reservoir (fumes box) into a proper container. 13 If necessary, open the Primary Fuel Filter Drain Valve and drain any 14 accumulated water into an appropriate container. Check oil level for Generator 1. 15 Ensure fuel shutoff valve is in the open position (valve handle is parallel 16 to the fuel hose). Close the left front PU side access door. 17 Remove the Gen. 1 splashguard (PU-810 B). 18 Check the fuel tank, hydraulic tank, and radiator fill tank for signs of 19 damage or leaks. Check fuel level with the built-in dipstick, coolant levels through the 20 coolant sightglass and hydraulic fluid levels with the sightglass. CHECK COMPLETED

5-24

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 TABLE 5.1.3.5-1 PRE-OPERATION CHECKLIST (CONTINUED) ITEM ACTION REQUIRED NUMBER Check the fuel transfer pump assembly for mounting security and leaks. Place the fuel transfer mode switch in “A” (automatic mode) position. 21 Place the fuel transfer pump power switch in the G1 position. Check the condition of the batteries for cleanliness and signs of damage. Check the battery electrical connections for tightness and 22 signs of corrosion. Check to ensure that the battery isolation switch is in the OFF 23 position.① Remove the Gen. 2 splashguard (PU-810B only). 24 Open the PU right side front access door and inspect the area for cleanliness, loose electrical connections, loose hardware, leaks around 25 oil and fuel lines, signs of heat damage or other abnormalities. Check oil level for Generator 2. 26 Drain the crankcase vent reservoir (fumes box) into a proper container. 27 If necessary open the Primary Fuel Filter Drain Valve and drain any 28 water accumulated into an appropriate container Ensure manual fuel cutoff valve is in the open position; valve handle is 29 parallel to the fuel hose. Close the right front PU side access door. 30 Open the right rear PU side access door and inspect the area for cleanliness, loose electrical connections, loose hardware, leaks, around 31 the oil filter, and for signs of heat damage or other abnormalities. Check all high voltage access panels for security. Visually inspect the air intake for obstructions or foreign objects. 32 Ensure that the battery charger voltmeter displays (24 VDC), is plugged into the battery charger receptacle, and that all circuit breakers are 33 turned on. Return to this step after a generator breaker is closed to ensure charger is supplying current to the batteries. Check Parking Stands for proper mounting and connection. 34 Check with a flashlight between generator sets G1 and G2 for leaks, 35 loose hardware, and any other potential problem. Close the right rear PU side access door. 36 Ensure the tie output cables are properly connected and that the 37 concentric neutrals are connected to ground. Ensure that the tie-output cover is secured. (Locked) 38 Check PU equipment grounds for proper connection. 39 Check that the PU interconnect control cable is properly connected to 40 the “B” connector. Inspect the exterior fuel system for proper connection, leaks, and 41 availability of fuel. Open all three PDC doors. Check for damage, loose connections, and 42 foreign objects. Position the 50/60 Hz selector switch in the proper mode. 43 Close all PDC doors. 44

CHECK COMPLETED

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

5-25

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 5.1.3.6 PRE-OPERATION RUN WARNING ENSURE ALL PERSONNEL ARE CLEAR AND THE PU DOORS ARE CLOSED PRIOR TO STARTING A GENERATOR. WARNING HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND ENFORCED. NOISE LEVELS IN EXCESS OF 85 DB EXIST WITHIN AN 88-FOOT RADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR SINGLE HEARING PROTECTION WITHIN 88 FEET OF AN OPERATING DPGDS. WARNING HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND ENFORCED. DURING MAINTENANCE ACTIVITIES WITH THE SIDEDOORS OPEN, NOISE LEVELS IN EXCESS OF 113 DB EXIST WITHIN A 12-FOOT RADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR DOUBLE HEARING PROTECTION WITHIN 12 FEET OF AN OPERATING DPGDS. EXPOSURE MUST BE LIMITED TO UNDER 2.5 HOURS. WARNING BY CLOSING THE FEEDER OR TIE BREAKER, HIGH VOLTAGE WILL BE PRESENT ON THE LOAD CABLES. ENSURE ALL PERSONNEL ARE CLEAR OF ALL LOAD CABLES PRIOR TO CLOSING FEEDER OR TIE BREAKERS.

5-26

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 TABLE 5.1.3.6-1 PRE-OPERATION RUN INSTRUCTION SEQUENCE (Perform on each PU in the power plant)
STEP

-- 60HZ OPERATIONS --

-- 50HZ OPERATIONS --

1 2 3 4① 5 6 7 8 9 10 11 12 13 14 15 16

Verify System Mode Switch (SMS) is in MANUAL Verify DC Control Power is on Verify Emergency Stop is pulled out Verify the 60Hz light is on ① Verify the 50Hz light is on①

Start engine 1 by placing ECS1 in MANUAL Verify the engine accelerates to 1800RPM Adjust the generator frequency to 60Hz using the Frequency Adjust Rheostat (FAR) Adjust the generator voltage to 4295VAC using the Voltage Adjust Rheostat (VAR) Verify the engine accelerates to 1500RPM Adjust the generator frequency to 50Hz using the Frequency Adjust Rheostat (FAR) Adjust the generator voltage to 3915VAC using the Voltage Adjust Rheostat (VAR)

Close BCSG1, toggle the Phase Rotation Test Light switch, verify that light ABC lights, open BCSG1 Shutdown engine 1 by placing ECS1 in OFF/RESET Start engine 2 by placing ECS2 in MANUAL Verify the engine accelerates to 1800RPM Adjust the generator frequency to 60Hz using the Frequency Adjust Rheostat (FAR) Adjust the generator voltage to 4295VAC using the Voltage Adjust Rheostat (VAR) Verify the engine accelerates to 1500RPM Adjust the generator frequency to 50Hz using the Frequency Adjust Rheostat (FAR) Adjust the generator voltage to 3915VAC using the Voltage Adjust Rheostat (VAR)

Close BCSG2, toggle the Phase Rotation Test Light switch, verify that light ABC lights, open BCSG2 Shutdown engine 2 by placing ECS2 in OFF/RESET

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

5-27

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 5.1.3.7 ORT SETUP

a. Remove the ORT from its case and set it up on a flat and level surface. b. Remove the mouse from the case and plug it into the mouse (PS2) port on the back of the ORT. c. If 120 VAC power is available, connect the ORT power supply cord to the 120 VAC power. The ORT can operate up to three hours on its batteries.

d. Connect one end of the 150-foot patch cable to the ORT networking port on the PU. e. Route the cable from the PU to the ORT and connect the cable to the ORT port. f. Turn on the ORT.

g. Observe that the ORT boots to the operator’s Overview screen. h. Select the Equip ID pop-up screen and enter the necessary information for the units. This includes the Trailer ID number, the Engine ID number, and the Generator ID number for each PU. i. Select the One line pop-up screen and enter the descriptor for the main load connected to the feeders.

h. Return to the Overview pop-up screen.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 5.1.3.8 CONTROLS SETUP

Complete the switch arrangements according to the following Table, and verify the lamp indicators: TABLE 5.1.3.8-1 PANEL CONTROL SWITCH SETUP SWITCH DC Control Breaker SMS GMS AVRS 60Hz Light MASTER CONTROL PANEL MCP USS BSS SSS SSL Lights FSS Emergency Stop ECS Emergency Stop ECS SETUP Pushed In (ON) OFF PRIME POWER PRIME POWER ON① A② NORMAL OFF All OFF 50/60 Hertz① Pulled-Out OFF Pulled-Out OFF

INSIDE MCP GENERATOR CONTROL PANEL GCPG1 GENERATOR CONTROL PANEL GCPG2

① With the SMS in the OFF position, the 50/60Hz lights indicate the position of the Frequency

Selector Switch (FSS). If the wrong light is on, open the door and change the switch position.

No more than one switch can be in the same position in any multi-PU line-up. With the SMS in OFF, none of the USI lights will be on and any previously set address on the PU is cleared.

5-29

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 5.1.4 PLANT STARTUP Starting up a Single Unit Prime Power Plant in Manual Mode a. Complete the switch arrangements according to the following Table, and verify the lamp indicators: TABLE 5.1.4-1 SWITCH SETUP – MANUAL MODE PANEL SWITCH BCS-T SMS USS MASTER CONTROL PANEL MCP MSES USI BCS-G1 BCS-F1 ECS-1 BCS-G2 BCS-F2 ECS-2 POSITION OR INDICATION Green Target MANUAL A Enable① A① Green Target Green Target OFF Green Target Green Target OFF

GENERATOR CONTROL PANEL 1 GCPG1 GENERATOR CONTROL PANEL 2 GCPG2

Hold the MSES in an ENABLE position until the selected USI indicator illuminates. The switch returns to the center position when released. This sets the PU networking address and enables the control and monitoring.

b. At GCPG1, place the Engine Control Switch (ECS) in MANUAL. c. Observe the generator starts and accelerates to operating voltage and frequency.

d. At the MCP, place the Sync Source Switch (SSS) in the GEN 1 position. e. Close Generator 1 breaker by cycling BCSG1 to the CLOSE position. f. Observe that the BCSG1 closes.

g. Return the SSS to the OFF position. h. At GCPG2, place the ECS in MANUAL. i. j. k. Observe the generator starts and accelerates to operating voltage and frequency. At the MCP, place the SSS in the GEN 2 position. Close BCSG2 when the two green triangular LEDs at 12 o’clock on the Synchroscope are energized, by cycling BCSG2 to the CLOSE position. For detailed instructions on manual synchronizing, refer to Section 5.9.6.14. Observe that the BCSG2 closes.

l.

m. Return the SSS to the OFF position. n. Close the required Feeder/Tie Breaker(s) from the Local Control Panel (LCP). o. Ensure generators have assumed load.

5-30

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 5.1.5 PLANT OPERATIONS

Refer to Section 5.9 for specific operating procedures. In this mode of operation the ORT provides no remote operation capability. It will provide monitoring of the generator parameters. 5.1.6 5.1.6.1 POWER PLANT TEARDOWN SHUT DOWN GENERATORS

a. Unload all generators by opening all feeder breakers. This must be done locally from the LCP or ORT. b. Open both generator breakers using the respective BCS switches. c. Place both generators in cooldown by placing both ECS switches in STOP/COOLDOWN.

d. Allow all engines to complete cooldown and shut down (5 minutes). e. Place all ECS switches in OFF/RESET. f. 5.1.6.2 Pull out the DC Control Power breaker on the PU. DISCONNECT CABLES WARNING NEVER REMOVE POWER CABLES BY HAND, USE HOT STICK AND HIGH VOLTAGE GLOVES. NEVER TOUCH A HIGH VOLTAGE LEAD OR TERMINAL UNTIL IT HAS BEEN DISCHARGED TO GROUND. FAILURE TO OBSERVE THIS WARNING MAY RESULT IN DEATH BY ELECTROCUTION. CAUTION ALLOW ALL OPERATING ENGINES TO SHUT DOWN AND COOL DOWN COMPLETELY. a. Disconnect the ORT cable and store it in the ORT case. b. Close and latch the ORT port on the PU. c. Disconnect all load cables used in operation of the PUs.

5-31

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 5.1.6.3 DISCONNECT FUEL LINES

a. Turn all fuel system valves to the off position. b. Disconnect the fuel hose from the PU fuel connection and the fuel supply. c. 5.1.6.4 a. b. c. Drain any fuel from the hoses into an auxiliary fuel supply and store the hoses. DISCONNECT GROUNDING Remove ground connections from the PU and store with the ground rod. Disconnect the parking stations from the ground grid. Remove the parking stations from their operating positions and reinstall them in their transportation locations on the inside of the PU rear side access doors. PREPARE PU FOR TRANSPORTATION

5.1.6.5

a. Reinstall the four radiator splashguards (PU-810B only). b. Verify DC Control power is off. c. Close and lock the LCP access doors.

d. Close and lock all PU side doors. 5.1.6.6 FUEL, OIL, AND COOLANT DRAINAGE

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

5-32

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

CHAPTER 5.2 OPERATING INSTRUCTIONS
SINGLE PU, PRIME POWER, NO EXTERNAL SWITCH, AUTOMATIC MODE
TABLE OF CONTENTS SECTION
5.2 5.2.1 5.2.2 5.2.3 5.2.3.1 5.2.3.2 5.2.3.3 5.2.3.4 5.2.3.5 5.2.3.6 5.2.3.7 5.2.3.8 5.2.4 5.2.5 5.2.5.1 5.2.5.2 5.2.6 5.2.6.1 5.2.6.2 5.2.6.3 5.2.6.4

TITLE
SAFETY PROCEDURES POSITIONING THE PU INITIAL PLANT SETUP GROUNDING FUEL MANIFOLD DISTRIBUTION AND CONTROL CABLING SETPOINT VERIFICATION PRE-OPERATION CHECKS PRE-OPERATION RUN ORT SETUP CONTROLS SETUP PLANT STARTUP PLANT OPERATIONS (AUTOMATIC MODE) OPERATION SAFETY PROCEDURE DESCRIPTION POWER PLANT TEARDOWN SHUT DOWN GENERATORS DISCONNECT CABLES DISCONNECT FUEL LINES DISCONNECT GROUNDING

PAGE
37 37 37 38 38 39 40 41 44 44 45 45 46 47 47 47 48 48 48 48 49

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

5-33

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

TABLE OF CONTENTS SECTION
5.2.6.5 5.2.6.6

TITLE
PREPARE PU FOR TRANSPORTATION FUEL, OIL, AND COOLANT DRAINAGE

PAGE
49 49

5-34

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

LIST OF FIGURES FIGURE
FIGURE 5.2.3.1-1 FIGURE 5.2.3.1-2

TITLE
MEP-PU-810A GROUND POINTS MEP-PU-810B GROUND POINTS

PAGE
38 39

5-35

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

LIST OF TABLES TABLE
TABLE 5.2.3.8-1 TABLE 5.2.4-1

TITLE
PDC CONTROL SWITCHES SETUP SWITCH SETUP – AUTOMATIC MODE

PAGE
45 46

5-36

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

5.2 5.2.1

SINGLE PU, PRIME POWER, NO EXTERNAL SWITCH, AUTOMATIC MODE SAFETY PROCEDURES

a. Safety precautions must be observed while operating or maintaining the PU. Safety precautions must be observed to ensure that the operator/technician cannot have contact with the following: • • • • • • • Hot engine parts Hot engine fluids Medium Voltage AC electricity Low Voltage AC electricity Low Voltage DC electricity Rotating Parts High noise levels

b. Minor Troubleshooting can be performed while both engines are running as long as safety precautions are taken. Refer to the appropriate troubleshooting section for recommendations. 5.2.2 POSITIONING THE PU

a. Position the PU in such a way as to allow the plant operator to have full vision of the operator control panels on the unit. b. Level the MEP-PU-810B front to rear with the trailer leveling hand crank. c. Position the PU to provide a minimum of 10 feet of clearance for maintenance access on all sides of each unit. Ensure that there are no overhead obstructions around the exhaust outlets. WARNING FUEL SPILLAGE CAN OCCUR IF THE POWER UNIT LEVEL IS GREATER THAN + 5 DEGREES. d. Ensure that the ground is capable of supporting the weight of the PU. The site surface should be as level as possible (+ 5 degrees).

5-37

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 5.2.3 5.2.3.1 INITIAL PLANT SETUP GROUNDING WARNING THERE CAN ONLY BE ONE GROUNDING POINT FOR THE PU. a. Drive an 8-foot ground rod into the earth and should be within 6 feet of the PU and at a location that minimizes the tripping hazard, until only 6 inches (15 cm) protrudes above the surface. b. Connect all of the grounding rods together with a #2 AWG copper conductor creating a central ground grid. c. Using a #2 AWG copper conductor, secure one end of a ground cable to one of the slotted ground studs on the PU, see Figure 5.2.3.1-1 or Figure 5.2.3.1-3. Secure the other end of the ground cable to the ground rod.

d. Test Ground Resistance using Ground Resistance Test Equipment. Resistance must be 25Ω or less. Refer to Annex H for special equipment required for this task. e. Remove parking stand plates from their transportation positions inside each rear, side PU door and slide them into their respective operating positions on the sides of the PDC. f. Connect the parking stand ground wires to either of the two chassis ground lugs on the PU.

GROUND POINT

GROUND POINT

FIGURE 5.2.3.1-1 NOTE:

MEP-PU-810A GROUND POINTS

Connect only one ground point to the ground grid.

5-38

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

GROUND POINT

GROUND POINT

FIGURE 5.2.3.1-2 NOTE: 5.2.3.2

MEP-PU-810B GROUND POINTS

Connect only one ground point to the ground grid. FUEL MANIFOLD WARNING ENSURE THAT THE FUEL LINES ARE PROTECTED FROM ALL ELECTRICAL CABLES AND ARE ROUTED TO MINIMIZE THE POTENTIAL FOR PHYSICAL DAMAGE OR CAUSING A TRIPPING HAZARD.

a. Lay out the fuel hoses between the PU, the fuel manifold, and the fuel bladders to establish the fuel supply system see Chapter 5.1 Figure 5.1.3.2-1 External Fuel Supply. b. Install the external fuel hose for the PU to the Fuel Transfer Pump at the Tow end of the PU. c. Connect the other end of the fuel hose to the fuel manifold outlets.

d. Connect the 3” hose, with quick-disconnect hose ends, from the fuel manifold to the fuel bladders. e. Connect the fuel manifold ground wire to the ground grid. f. Open only the appropriate fuel manifold valves (once connected to the PU) to supply fuel to the power units and check for leaks.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 5.2.3.3 DISTRIBUTION AND CONTROL CABLING WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT DURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION AND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN LOAD CABLES ARE HANDLED. WARNING VERIFY THAT CONNECTION POINTS ARE DE-ENERGIZED BEFORE MAKING ANY CONNECTIONS. FAILURE TO CHECK THAT CONNECTORS ARE DE-ENERGIZED MAY RESULT IN INJURY OR DEATH. a. Lay out and park the load cables for each phase (A, B, & C) between the PU feeder output parking stations and the load (if used). b. Connect each power cable’s drain wire to the grounding grid. c. Open the feeder output connection covers.

d. Connect the feeder cables to the appropriate phase connector at the PU and the load; ensure there are no cross-phase connections. e. Close and lock the feeder output connection cover. f. Lay out and park the load cables for each phase (A, B, & C) between the PU tie output parking stations and the load (if used).

g. Connect each power cable’s drain wire to the grounding grid. h. Open the tie output connection covers. i. j. k. Connect the load cables to the appropriate connector at the PU and the load; ensure there are no cross-phase connections. Close and lock the tie output connection cover. Connect the (A) (B) communication cable to the “B” side of the PU. Leave the loose end capped.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 5.2.3.4 SETPOINT VERIFICATION

a. Turn on PU DC control power by pushing in on the DC Control Power breaker. b. On each of the five overcurrent relays, verify the settings: (1) (2) (3) (4) (5) (6) (7) (8) (9) Press the [▲] key to get to the top-level menu “1 REPORT STATUS”. Press the [►] key 5 times to display “6 GENERAL SETTINGS”. Press the [▼] key to display “6.1 COM SETTINGS”. Press the [►] key 2 times to display “6.3 POWER SYSTEM SETTINGS”. Press the [▼] key to display “6.3.1 CT RATIO”. Verify the “P” and “N” values match Chapter 5.1 Table 5.1.3.4-1, CT Ratio Settings. Press the [▲] key 2 times to display “6 GENERAL SETTINGS”. Press the [◄] key to display “5 PROTECTION LOGIC USER”. Press the [▼] key 3 times to display “5.1.1.1 50TP”.

(10) Verify the 50TP “PU” and “TD” settings match Chapter 5.1 Table 5.1.3.4-2, Instantaneous Trip Settings. In order to edit values, Press the “Edit” key. Select correct value, and press “Edit” again to save changes. Ensure light is off otherwise you can accidentally change value again. (11) Press the [►] key to display “5.1.1.2 50TN”. (12) Verify the 50TN settings. (13) Press the [►] key to display “5.1.1.3”. (14) Verify the “50TQ” settings (15) Press the [▲] key to display “5.1.1 50T SETTINGS”. (16) Press the [►] key to display “5.1.2 51 SETTINGS”. (17) Press the [▼] key to display “5.1.2.1 51P”. (18) Verify the 51P “PU”, “TD”, and “C” settings in Chapter 5.1 Table 5.1.3.4-3 Time Overcurrent Settings. (19) Press the [►] key to display “5.1.2.2 51N”. (20) Verify the 51N settings. (21) Press the [▲] key 3 times to display “5 PROTECTION LOGIC USER”. c. NOTE: Use the following procedure to verify the Generator 1 and Generator 2 GSC+ settings: Refer to the “EMCPII+ Reference Chart”, located on the interior Generator Control Panel Door (Look-up)

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (1) (2) (3) (4) (5) (6) (7) (8) (9) Place ECS in the COOLDOWN/STOP position. Press SERVICE MODE key to enter service mode. display. Press SCROLL UP key until “OP3” is showing. Press SELECT key. “PE “ with the first dash flashing is showing. Press SCROLL RIGHT key. “PE 1 “ with the second dash flashing is showing. Press SCROLL DOWN key. “PE 13 “ with the third dash flashing is showing. Press SCROLL UP key. “PE 132 “ with the fourth dash flashing is showing. Press SCROLL DOWN key. “PE 1323 “ with the fifth dash flashing is showing. Press SCROLL RIGHT key. “PE13231” with all digits not flashing is showing. OP1 is showing on the lower

(10) Press ENTER key. “PE PASS” is showing. (11) Press EXIT key. “OP4” is showing. (12) Press SCROLL UP key until “OP5-0” is showing on the lower display. (13) Press SELECT key. “POO1” followed with the value of the setpoint is showing. (14) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing. Use Chapter 5.1 Table 5.1.3.4-4 OP5-0 Setpoints for the parameter values to be verified. Repeat until all OP5-0 setpoints are verified. (15) Press EXIT key. “OP5-0” is showing on the lower display. (16) Press SCROLL UP key until “OP5-1” is showing. (17) Press SELECT key. (18) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing. Use Chapter 5.1 Table 5.1.3.4-5 OP5-1 Setpoints for the parameter values to be verified. Repeat until all OP5-1 Setpoints are verified. (19) Press EXIT key. “OP5-1” is showing. (20) Press SCROLL UP key until “OP6” is showing. (21) Press SELECT key. (22) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing. Using Chapter 5.1 Table 5.1.3.4-6 OP6 Setpoints for the parameter values to be verified. Repeat until all OP6 Setpoints are verified. (24) Press EXIT Key twice. The display returns to normal. NOTE: If an incorrect setpoint value is displayed, the value must be changed to match the DPGDS setpoint value as follows:

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (a) (b) (c) (d) With the setpoint with the incorrect value showing on the display, press the SELECT key. The incorrect value flashes on the display. Press SCROLL UP or SCROLL DOWN key until the correct value appears flashing on the display. Press ENTER. The correct value stops flashing on the display. Press SCROLL UP or SCROLL DOWN key to continue to verify the remaining parameter values.

d. Return ECS1 and ECS2 to the OFF/RESET position. NOTE: Use up or down keys to change values.

e. At the AVR verify the operation settings using Chapter 5.1 Table 5.1.3.4-7 AVR Parameter/Setpoints: (1) (2) (3) (4) (5) (6) (7) (8) (9) Open the GCPG1 cabinet door. Press the [▼] key to display parameter “90”. Press the [◄►] key to display the current value. Press the [▲] key to change the value to “0015”. Enables parameter editing. Press the [◄►] key to accept change and display the parameter number. Press the [▲] key to the next parameter needed to change. Press the [◄►] key to display the current value. Press the [▲] or [▼] key to change the value. Press the [◄►] key to accept change and display the parameter number.

(10) Repeat steps ‘5’ through ‘9’ for the each parameter needing to be changed. (11) When complete, press the [▼] to display parameter “01”. NOTE: Parameters 20, 21, 22, 36, 37, and 38 are displayed but not used. (12) When complete, press the [▼] to display parameter “90”. (13) Press the [◄►] key to display the current value. (14) Press the [▼] key to change the value to “0009”. Disables DVR parameter editing. (15) Press the [◄►] key to accept change and display the parameter number. (16) Press the [▲] key to change to display parameter “01”. (17) Close the GCPG1 cabinet door.

5-43

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (18) Repeat steps ‘1 ‘through ‘17’ for Generator 2. 5.2.3.5 PRE-OPERATION CHECKS

Starting from the left rear of the PU and working around the PU in a clockwise direction, perform the checks identified in Chapter 5.1 Table 5.1.3.5-1 Pre-Operation Checklist. (Gen. 1 is on the left and Gen. 2 is on the right): 5.2.3.6 PRE-OPERATION RUN

Perform the pre-operation run using Chapter 5.1 Table 5.1.3.6-1 Pre-Operation Run Instruction Sequence. WARNING ENSURE ALL PERSONNEL ARE CLEAR AND THE PU DOORS ARE CLOSED PRIOR TO STARTING A GENERATOR. WARNING HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND ENFORCED. NOISE LEVELS IN EXCESS OF 85 DB EXIST WITHIN AN 88-FOOT RADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR SINGLE HEARING PROTECTION WITHIN 88 FEET OF AN OPERATING DPGDS. WARNING HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND ENFORCED. DURING MAINTENANCE ACTIVITIES WITH THE SIDEDOORS OPEN, NOISE LEVELS IN EXCESS OF 113 DB EXIST WITHIN A 12-FOOT RADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR DOUBLE HEARING PROTECTION WITHIN 12 FEET OF AN OPERATING DPGDS. EXPOSURE MUST BE LIMITED TO UNDER 2.5 HOURS. WARNING BY CLOSING THE FEEDER OR TIE BREAKER, HIGH VOLTAGE WILL BE PRESENT ON THE LOAD CABLES. ENSURE ALL PERSONNEL ARE CLEAR OF ALL LOAD CABLES PRIOR TO CLOSING FEEDER OR TIE BREAKERS.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 5.2.3.7 ORT SETUP

a. Remove the ORT from its case and set it up on a flat and level surface. b. Remove the mouse from the case and plug it into the mouse (PS2) port on the back of the ORT. c. If 120 VAC power is available, connect the ORT power supply cord to the 120 VAC power. The ORT can operate up to three hours on its batteries.

d. Connect one end of the 150-foot patch cable to the ORT networking port on the PU. e. Route the cable from the ORT to the PU and connect the cable to the ORT port. f. Turn on the ORT.

g. Observe that the ORT boots to the operator’s Overview screen. h. Select the EquipID pop-up screen and enter the necessary information for the units. This includes the Trailer ID number, the Engine ID number, and the Generator ID number for each PU. i. Select the Oneline pop-up screen and enter the descriptor for the main load connected to the feeders.

h. Return to the Overview pop-up screen. 5.2.3.8 CONTROLS SETUP

Complete the switch arrangements according to the following Table, and verify the lamp indicators: TABLE 5.2.3.8-1 PDC CONTROL SWITCHES SETUP PANEL SWITCH DC Power SMS GMS AVRS 60Hz Light USS BSS SSS SSL Lights FSS Emergency Stop ECS Emergency Stop ECS 1ST PU Pushed In (ON) OFF PRIME POWER PRIME POWER ON① A NORMAL OFF All OFF 50/60 Hertz① Pulled-Out OFF Pulled-Out OFF

MASTER CONTROL PANEL MCP

INSIDE MCP GENERATOR CONTROL PANEL GCPG1 GENERATOR CONTROL PANEL GCPG2

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

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 5.2.4 PLANT STARTUP Starting up a Single Unit Prime Power Plant in Automatic Mode WARNING ONCE THE SYSTEM STATUS LIGHTS TURN GREEN AND THE MSES IS ENABLED, THE PU WILL START. ENSURE PERSONNEL ARE CLEAR OF THE PU. WARNING ONLY ONE PU MAY BE SELECTED TO ANY ONE USS POSITION DURING MULTIPLE PU OPERATIONS. OPERATING WITH MORE THAN ONE UNIT AT THE SAME ID MAY CAUSE UNSAFE AND ERRATIC OPERATIONAL CONDITIONS. a. Complete the switch arrangements according to the following Table, and verify the lamp indicators: TABLE 5.2.4-1 SWITCH SETUP – AUTOMATIC MODE PANEL SWITCH BCS-T MASTER CONTROL PANEL SMS MCP USS BCS-G1 GENERATOR CONTROL BCS-F1 PANEL 1 GCPG1 ECS-1 BCS-G2 BCS-F2 GENERATOR CONTROL ECS-2 PANEL 2 GCPG2 SYSTEM STATUS LIGHTS MASTER CONTROL PANEL MCP MSES USI

1ST PU Red Target AUTO③ A Red Target Red Target AUTO Red Target Red Target AUTO GREEN (Verify System Status Light turns Green) Enable① A①, ②

① Hold the MSES in an ENABLE position until the selected USI indicator energizes. The switch

returns to the center position when released. enables the control and monitoring.

This sets the PU networking address and

② No more than one of each indicator can be on for multi-PU operations. The light on should

match USS position. The USI light will de-energize after the SMS has been in OFF for 3 seconds.
③ With the SMS in AUTO any generator started, manually or automatically, will automatically

parallel to the bus. To prevent the generator from paralleling to the bus put the generator’s breaker in the Pull-To-Lock position. NOTE: The automatic economizing feature will shutdown one generator every 3 minutes until the system load is at or below the 360kW/450kVA per generator threshold.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 b. At A-unit, observe Generator 1 automatically starts and accelerates to operating voltage and frequency. c. At A-unit, observe Generator 1 automatically closes to the system bus.

d. At A-unit, observe the Tie Breaker automatically closes. e. At A-unit, observe Generator 2 automatically starts and accelerates to operating voltage and frequency. f. 5.2.5 5.2.5.1 At A-unit, observe Generator 2 automatically parallels to the system bus. PLANT OPERATIONS (AUTOMATIC MODE) OPERATION SAFETY PROCEDURE

This mode of operation places control of all generator starting, stopping, synchronizing, and load management under the auspices of the Remote Terminal Unit (RTU) system. As long as the SMS is in AUTO, any generator started, manually or automatically, is automatically synchronized to the system bus. Care must be taken when starting a generator manually when the SMS is in AUTO. Either place the associated BCS in Pull-To-Lock (prevent closing to the bus) or ensure it has the red target visible (allow paralleling to the bus) before starting the engine. The only exception is automatic operation of the feeder breakers. Auto Mode does not automatically close feeder breakers; it only enables remote operation of the feeder breakers from the ORT. 5.2.5.2 DESCRIPTION

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

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 5.2.6 5.2.6.1 POWER PLANT TEARDOWN SHUT DOWN GENERATORS

a. Unload all generators by opening all Feeder/Tie Breakers. This must be done locally from the LCP or ORT. b. Open both generator breakers using the respective BCS switches. c. Place both generators in cooldown by placing both ECS switches in STOP/COOLDOWN.

d. Allow all engines to complete cooldown and shut down (5 minutes). e. Place all ECS switches in OFF/RESET. f. 5.2.6.2 Pull out the DC Control Power breaker on the PU. DISCONNECT CABLES WARNING NEVER REMOVE POWER CABLES BY HAND, USE HOT STICK AND HIGH VOLTAGE GLOVES. NEVER TOUCH A HIGH VOLTAGE LEAD OR TERMINAL UNTIL IT HAS BEEN DISCHARGED TO GROUND. FAILURE TO OBSERVE THIS WARNING MAY RESULT IN DEATH BY ELECTROCUTION. CAUTION ALLOW ALL OPERATING ENGINES TO SHUT DOWN AND COOL DOWN COMPLETELY. a. Disconnect the (A)(B) communication cable from the PU, install the cable receptacle cover, and store inside the PU (one per unit). b. Disconnect the ORT cable and store it in the ORT case. c. Close and latch the ORT port on the PU.

d. Disconnect all load cables used in operation of the PUs. 5.2.6.3 DISCONNECT FUEL LINES

a. Turn all fuel system valves to the off position. b. Disconnect the fuel hose from the PU fuel connection and the fuel supply. c. Drain any fuel from the hoses into an auxiliary fuel supply and store the hoses.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 5.2.6.4 a. b. c. DISCONNECT GROUNDING Remove ground connections from the PU and store with the ground rod. Disconnect the parking stations from the ground grid. Remove the parking stations from their operating positions and reinstall them in their transportation locations on the inside of the PU rear side access doors. PREPARE PU FOR TRANSPORTATION

5.2.6.5

a. Reinstall the four radiator splashguards (PU-810B only). b. Verify DC Control power is off. c. Close and lock the LCP access doors.

d. Close and lock all PU side doors. 5.2.6.6 FUEL, OIL, AND COOLANT DRAINAGE

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

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

THIS PAGE INTENTIONALLY BLANK

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

CHAPTER 5.3 OPERATING INSTRUCTIONS
TWO PU, PRIME POWER, NO EXTERNAL SWITCH, MANUAL MODE
TABLE OF CONTENTS SECTION
5.3 5.3.1 5.3.2 5.3.3 5.3.3.1 5.3.3.2 5.3.3.3 5.3.3.4 5.3.3.5 5.3.3.6 5.3.3.7 5.3.3.8 5.3.4 5.3.5 5.3.6 5.3.6.1 5.3.6.2 5.3.6.3 5.3.6.4 5.3.6.5 5.3.6.6

TITLE
TWO PU, PRIME POWER, NO EXTERNAL SWITCH, MANUAL MODE SAFETY PROCEDURES POSITIONING THE PU INITIAL PLANT SETUP GROUNDING FUEL MANIFOLD DISTRIBUTION AND CONTROL CABLING SETPOINT VERIFICATION PRE-OPERATION CHECKS PRE-OPERATION RUN ORT SETUP CONTROLS SETUP PLANT STARTUP PLANT OPERATIONS POWER PLANT TEARDOWN SHUTDOWN GENERATORS DISCONNECT CABLES DISCONNECT FUEL LINES DISCONNECT GROUNDING PREPARE PU FOR TRANSPORTATION FUEL, OIL, AND COOLANT DRAINAGE

PAGE
54 54 54 55 55 56 57 58 61 61 63 63 64 66 66 66 66 67 67 67 67

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

LIST OF FIGURES FIGURE
FIGURE 5.3.3.1-1 FIGURE 5.3.3.1-2

TITLE
MEP-PU-810A GROUND POINTS MEP-PU-810B GROUND POINTS

PAGE
55 56

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

LIST OF TABLES TABLE
TABLE 5.3.3.6-1 TABLE 5.3.3.8-1 TABLE 5.3.4-1

TITLE
PRE-OPERATION RUN INSTRUCTION SEQUENCE CONTROL SWITCH SETUP SWITCH SETUP – MANUAL MODE

PAGE
62 63 64

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

5.3 5.3.1

TWO PU, PRIME POWER, NO EXTERNAL SWITCH, MANUAL MODE SAFETY PROCEDURES

a. Safety precautions must be observed while operating or maintaining the PU. Safety precautions must be observed to ensure that the operator/technician cannot have contact with the following: • • • • • • • Hot engine parts Hot engine fluids Medium Voltage AC electricity Low Voltage AC electricity Low Voltage DC electricity Rotating Parts High noise levels

b. Minor Troubleshooting can be performed while both engines are running as long as safety precautions are taken. Refer to the appropriate troubleshooting section for recommendations. 5.3.2 POSITIONING THE PU

a. Position the PU in such a way as to allow the plant operator to have full vision of the operator control panels on the unit. b. Level the MEP-PU-810B front to rear with the trailer leveling hand crank. c. Position the PU to provide a minimum of 10 feet of clearance for maintenance access on all sides of each unit. Ensure that there are no overhead obstructions around the exhaust outlets. WARNING FUEL SPILLAGE CAN OCCUR IF THE POWER UNIT LEVEL IS GREATER THAN + 5 DEGREES. d. Ensure that the ground is capable of supporting the weight of the PU. The site surface should be as level as possible (+ 5 degrees).

5-54

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 5.3.3 5.3.3.1 INITIAL PLANT SETUP GROUNDING WARNING THERE CAN ONLY BE ONE GROUNDING POINT FOR THE PU. a. Drive an 8-foot ground rod into the earth and should be within 6 feet of the PU and at a location that minimizes the tripping hazard, until only 6 inches (15 cm) protrudes above the surface. b. Repeat step “a” for each PU being used. c. Connect all of the grounding rods together with a #2 AWG copper conductor creating a central ground grid.

d. Using a #2 AWG copper conductor, secure one end of a ground cable to one of the slotted ground studs on the PU, see Figure 5.3.3.1-1 or Figure 5.3.3.1-3. Secure the other end of the ground cable to the ground rod. e. Repeat step “d” for every PU. f. Test Ground Resistance using Ground Resistance Test Equipment. Resistance must be 25Ω or less. Refer to Annex H for special equipment required for this task.

g. Remove parking stand plates from their transportation positions inside each rear, side PU door and slide them into their respective operating positions on the sides of the PDC. h. Connect the parking stand ground wires to either of the two chassis ground lugs on the PU.

GROUND POINT

GROUND POINT

FIGURE 5.3.3.1-1 NOTE:

MEP-PU-810A GROUND POINTS

Connect only one ground point to the ground grid.

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

GROUND POINT

GROUND POINT

FIGURE 5.3.3.1-2 NOTE: 5.3.3.2

MEP-PU-810B GROUND POINTS

Connect only one ground point to the ground grid. FUEL MANIFOLD WARNING ENSURE THAT THE FUEL LINES ARE PROTECTED FROM ALL ELECTRICAL CABLES AND ARE ROUTED TO MINIMIZE THE POTENTIAL FOR PHYSICAL DAMAGE OR CAUSING A TRIPPING HAZARD.

a. Lay out the fuel hoses between the PU, the fuel manifold, and the fuel bladders to establish the fuel supply system see Chapter 5.1, Figure 5.1.3.2-1 External Fuel Supply. b. Install the external fuel hose for the PU to the Fuel Transfer Pump at the Tow end of the PU. c. Connect the other end of the fuel hose to the fuel manifold outlets.

d. Connect the 3” hose, with quick-disconnect hose ends, from the fuel manifold to the fuel bladders. e. Connect the fuel manifold ground wire to the ground grid. f. Open only the appropriate fuel manifold valves (once connected to the PU) to supply fuel to the power units and check for leaks.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 5.3.3.3 DISTRIBUTION AND CONTROL CABLING WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT DURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION AND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN LOAD CABLES ARE HANDLED.

WARNING VERIFY THAT CONNECTION POINTS ARE DE-ENERGIZED BEFORE MAKING ANY CONNECTIONS. FAILURE TO CHECK THAT CONNECTORS ARE DE-ENERGIZED MAY RESULT IN INJURY OR DEATH. a. Lay out and park the load cables for each phase (A, B, & C) between the PU Tie Output parking stations on all Power Units. b. Connect each power cable’s drain wire to the grounding grid. c. Lay out and park the load cables for each phase (A, B, & C) between the PU Feeder Output parking stations and the load (if used).

d. Connect each power cable’s drain wire to the grounding grid. e. Open the Tie Output connector loadbreak covers on one PU. f. Connect the Tie Output Cables to the appropriate phase connectors; ensure there are no cross-phase connections.

g. Close and lock the Tie Output connector covers. h. Open the Feeder Output connector loadbreak covers. i. j. k. Connect the Feeder cables to the appropriate phase connectors; ensure there are no crossphase connections. Close and lock the Feeder Output connector covers. Repeat steps ‘e’ through ‘j’ on the second PU.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 l. Connect the (A) (B) communication cable to the (B) side of the first PU.

m. Route (A) (B) communication cable to second PU and Connect to the (A) side of the PU. n. Connect the (A) (B) communication cable to the (B) side of the second PU. Leave the end of second cable loose and capped. 5.3.3.4 SETPOINT VERIFICATION

a. Turn on PU DC control power by pushing in on the DC Control Power breaker. b. On each of the five overcurrent relays, verify the settings: (1) (2) (3) (4) (5) (6) (7) (8) (9) Press the [▲] key to get to the top-level menu “1 REPORT STATUS”. Press the [►] key 5 times to display “6 GENERAL SETTINGS”. Press the [▼] key to display “6.1 COM SETTINGS”. Press the [►] key 2 times to display “6.3 POWER SYSTEM SETTINGS”. Press the [▼] key to display “6.3.1 CT RATIO”. Verify the “P” and “N” values match Chapter 5.1 Table 5.1.3.4-1 CT Ratio Settings. Press the [▲] key 2 times to display “6 GENERAL SETTINGS”. Press the [◄] key to display “5 PROTECTION LOGIC USER”. Press the [▼] key 3 times to display “5.1.1.1 50TP”.

(10) Verify the 50TP “PU” and “TD” settings in Chapter 5.1 Table 5.1.3.4-2 Instantaneous Trip Settings. In order to edit values, Press the “Edit” key. Select correct value, and press “Edit” again to save changes. Ensure light is off otherwise you can accidentally change value again. (11) Press the [►] key to display “5.1.1.2 50TN”. (12) (13) (14) (15) (16) (17) (18) 19) Verify the “50TN” settings. Press the [►] key to display “5.1.1.3”. Verify the “50TQ” settings. Press the [▲] key to display “5.1.1 50T SETTINGS”. Press the [►] key to display “5.1.2 51 SETTINGS”. Press the [▼] key to display “5.1.2.1 51P”. Verify the 51P “PU”, “TD”, and “C” settings in Chapter 5.1 Table 5.1.3.4-3 Time Overcurrent Settings. Press the [►] key to display “5.1.2.2 51N”.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (20) (21) c. NOTE: (1) (2) (3) (4) (5) (6) (7) (8) (9) Verify the 51N settings. Press the [▲] key 3 times to display “5 PROTECTION LOGIC USER”.

Use the following procedure to verify the Generator 1 and Generator 2 GSC+ settings: Refer to the “EMCPII+ Reference Chart”, located on the interior Generator Control Panel Door (Look-up) Place ECS in the COOLDOWN/STOP position. Press SERVICE MODE key to enter service mode. display. Press SCROLL UP key until “OP3” is showing. Press SELECT key. “PE -“ with the first dash flashing is showing. Press SCROLL RIGHT key. “PE 1 -“ with the second dash flashing is showing. Press SCROLL DOWN key. “PE 13 –“ with the third dash flashing is showing. Press SCROLL UP key. “PE 132 –“ with the fourth dash flashing is showing. Press SCROLL DOWN key. “PE 1323 –“ with the fifth dash flashing is showing. Press SCROLL RIGHT key. “PE13231” with all digits not flashing is showing. OP1 is showing on the lower

(10) Press ENTER key. “PE PASS” is showing. (11) Press EXIT key. “OP4” is showing. (12) Press SCROLL UP key until “OP5-0” is showing on the lower display. (13) Press SELECT key. “POO1” followed with the value of the setpoint is showing. (14) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing. Use Chapter 5.1 Table 5.1.3.4-4 OP5 Settings for the parameter values to be verified. Repeat until the desired setpoints are verified. (15) Press EXIT key. “OP5-0” is showing on the lower display. (16) Press SCROLL UP key until “OP5-1” is showing. (17) Press SELECT key. (18) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing. Use Chapter 5.1 Table 5.1.3.4-5 OP5-1 Settings for the parameter values to be verified. Repeat until the desired setpoints are verified. (19) Press EXIT key. “OP5-1” is showing. (20) Press SCROLL UP key. “OP6” is showing. (21) Press SELECT key.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (22) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing. Use Chapter 5.1 Table 5.1.3.4-6 OP6 Settings for the parameter values to be verified. Repeat until the desired setpoints are verified. (23) Press EXIT key twice. The display returns to normal. NOTE: If an incorrect setpoint value is displayed, the value must be changed to match the DPGDS setpoint value as follows: (a) (b) (c) (d) With the setpoint with the incorrect value showing on the display, press the SELECT key. The incorrect value flashes on the display. Press SCROLL UP or SCROLL DOWN key until the correct value appears flashing on the display. Press ENTER. The correct value stops flashing on the display.

Press SCROLL UP or SCROLL DOWN key to continue to verify the remaining parameter values. d. Return ECS1 and ECS2 to the OFF/RESET position. NOTE: Use up or down keys to change values.

e. At the AVR verify the operation settings using Chapter 5.1 Table 5.1.3.4-7 AVR Parameter/Setpoints: (1) (2) (3) (4) (5) (6) (7) (8) (9) Open the GCPG1 cabinet door. Press the [▼] key to display parameter “90”. Press the [◄►] key to display the current value. Press the [▲] key to change the value to “0015”. Enables parameter editing. Press the [◄►] key to accept change and display the parameter number. Press the [▲] key to the next parameter needed to change. Press the [◄►] key to display the current value. Press the [▲] or [▼] key to change the value. Press the [◄►] key to accept change and display the parameter number.

(10) Repeat steps ‘5’ through ‘9’ for the each parameter needing to be changed. (11) When complete, press the [▼] to display parameter “01”. NOTE: NOTE: Parameters 20, 21, 22, 36, 37, and 38 are displayed but not used. Parameters 23 to 29, 39 to 49, 59 and 61 to 89 are not displayed and not used. (12) When complete, press the [▼] to display parameter “90”.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (13) Press the [◄►] key to display the current value. (14) Press the [▼] key to change the value to “0009”. Disables DVR parameter editing. (15) Press the [◄►] key to accept change and display the parameter number. (16) Press the [▲] key to change to display parameter “01”. (17) Close the GCPG1 cabinet door. (18) Repeat steps ‘1 ‘through ‘16’ for Generator 2. 5.3.3.5 PRE-OPERATION CHECKS

Starting from the left rear of the PU and working around the PU in a clockwise direction, perform the checks identified in Chapter 5.1 Table 5.1.3.5-1 Pre-Operation Checklist. (Gen. 1 is on the left and Gen. 2 is on the right): 5.3.3.6 PRE-OPERATION RUN WARNING ENSURE ALL PERSONNEL ARE CLEAR AND THE PU DOORS ARE CLOSED PRIOR TO STARTING A GENERATOR. WARNING HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND ENFORCED. NOISE LEVELS IN EXCESS OF 85 DB EXIST WITHIN AN 88-FOOT RADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR SINGLE HEARING PROTECTION WITHIN 88 FEET OF AN OPERATING DPGDS. WARNING HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND ENFORCED. DURING MAINTENANCE ACTIVITIES WITH THE SIDEDOORS OPEN, NOISE LEVELS IN EXCESS OF 113 DB EXIST WITHIN A 12-FOOT RADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR DOUBLE HEARING PROTECTION WITHIN 12 FEET OF AN OPERATING DPGDS. EXPOSURE MUST BE LIMITED TO UNDER 2.5 HOURS. WARNING BY CLOSING THE FEEDER OR TIE BREAKER, HIGH VOLTAGE WILL BE PRESENT ON THE LOAD CABLES. ENSURE ALL PERSONNEL ARE CLEAR OF ALL LOAD CABLES PRIOR TO CLOSING FEEDER OR TIE BREAKERS.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 TABLE 5.3.3.6-1 PRE-OPERATION RUN INSTRUCTION SEQUENCE (Perform on each PU in the power plant)
STEP

-- 60HZ OPERATIONS --

-- 50HZ OPERATIONS --

1 2 3 4① 5 6 7 8 9 10 11 12 13 14 15 16

Verify System Mode Switch (SMS) is in MANUAL Verify DC Control Power is on Verify Emergency Stop is pulled out Verify the 60Hz light is on① Verify the 50Hz light is on①

Start engine 1 by placing ECS1 in MANUAL Verify the engine accelerates to 1800RPM Adjust the generator frequency to 60Hz using the Frequency Adjust Rheostat (FAR) Adjust the generator voltage to 4295VAC using the Voltage Adjust Rheostat (VAR) Verify the engine accelerates to 1500RPM Adjust the generator frequency to 50Hz using the Frequency Adjust Rheostat (FAR) Adjust the generator voltage to 3915VAC using the Voltage Adjust Rheostat (VAR)

Close BCS-G1, toggle the Phase Rotation Test Light switch, verify that light ABC lights, open BCSG1 Shutdown engine 1 by placing ECS1 in OFF/RESET Start engine 2 by placing ECS2 in MANUAL Verify the engine accelerates to 1800RPM Adjust the generator frequency to 60Hz using the Frequency Adjust Rheostat (FAR) Adjust the generator voltage to 4295VAC using the Voltage Adjust Rheostat (VAR) Verify the engine accelerates to 1500RPM Adjust the generator frequency to 50Hz using the Frequency Adjust Rheostat (FAR) Adjust the generator voltage to 3915VAC using the Voltage Adjust Rheostat (VAR)

Close BCSG2, toggle the Phase Rotation Test Light switch, verify that light ABC lights, open BCSG2 Shutdown engine 2 by placing ECS2 in OFF/RESET If the wrong frequency light is on, open the Master Control Door and change the Frequency Selector Switch (FSS) to the desired frequency.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 5.3.3.7 ORT SETUP

a. Remove the ORT from its case and set it up on a flat and level surface. b. Remove the mouse from the case and plug it into the mouse (PS2) port on the back of the ORT. c. If 120VAC power is available, connect the ORT power supply cord to the 120 VAC power. The ORT can operate up to three hours on its batteries. d. Connect one end of the 150-foot patch cable to the ORT networking port on the PU. e. Route the cable from the ORT to the PU and connect the cable to the ORT port. f. Turn on the ORT..

g. Observe that the ORT boots to the operator’s Overview screen. h. Select the EquipID pop-up screen and enter the necessary information for the units. This includes the Trailer ID number, the Engine ID number, and the Generator ID number for each PU. i. Select the Oneline pop-up screen and enter the descriptor for the main load connected to the feeders.

h. Return to the Overview pop-up screen. 5.3.3.8 CONTROLS SETUP

Complete the switch arrangements according to the following Table, and verify the lamp indicators: TABLE 5.3.3.8-1 PANEL CONTROL SWITCH SETUP SWITCH DC Power SMS GMS AVRS MASTER CONTROL PANEL 60Hz Light MCP USS BSS SSS SSL lights FSS INSIDE MCP Emergency Stop GENERATOR CONTROL PANEL GCPG1 ECS Emergency Stop GENERATOR CONTROL PANEL GCPG2 ECS
① ②

1ST PU Pushed In (ON) OFF PRIME POWER PRIME POWER ON① A② NORMAL OFF All OFF 50/60 Hertz① Pulled-Out OFF Pulled-Out OFF

2ND PU Pushed In (ON) OFF PRIME POWER PRIME POWER ON① B② NORMAL OFF All OFF 50/60 Hertz① Pulled-Out OFF Pulled-Out OFF

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

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 5.3.4 PLANT STARTUP Starting up a Two Unit Prime Power Plant in Manual Mode WARNING ONLY ONE PU MAY BE SELECTED TO ANY ONE USS POSITION DURING MULTIPLE PU OPERATIONS. OPERATING WITH MORE THAN ONE UNIT AT THE SAME ID CAUSE UNSAFE AND ERRATIC OPERATIONAL CONDITIONS. a. Complete the switch arrangements according to the following Table, and verify the lamp indicators: TABLE 5.3.4-1 SWITCH SETUP – MANUAL MODE PANEL SWITCH BCS-T SMS MASTER CONTROL PANEL MSES MCP GENERATOR CONTROL PANEL 1 GCPG1 GENERATOR CONTROL PANEL 2 GCPG2 USI BCS-G1 BCS-F1 ECS-1 BCS-G2 BCS-F2 ECS-2 1ST PU Green Target MANUAL Enable① A①, ② Green Target Green Target OFF Green Target Green Target OFF 2ND PU Green Target MANUAL Enable① B①, ② Green Target Green Target OFF Green Target Green Target OFF

Hold the MSES in an ENABLE position until the selected USI indicator illuminates. The switch returns to the center position when released. This sets the PU networking address and enables the control and monitoring. No more than one of each indicator can be on for multi-PU operations. The light on should match USS position. The USI light will de-energize after the SMS has been in OFF for 3 seconds.

b. At the A-unit GCPG1, place the Engine Control Switch (ECS) in MANUAL. c. Observe the generator starts and accelerates to operating voltage and frequency.

d. At the A-unit MCP, place the Sync Source Switch (SSS) in the GEN 1 position. e. Close BCSG1 by cycling BCSG1 to the CLOSE position. f. Observe that BCSG1 closes.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 g. Place the SSS to the TIE position. h. Close the BCST by cycling BCST to the CLOSE position. i. j. k. l. Return the SSS to the OFF position. At the A-unit GCPG2, place the Engine Control Switch (ECS) in MANUAL. Observe that the generator starts and accelerates to operating voltage and frequency. At the A-unit MCP, place the Sync Source Switch (SSS) in the GEN 2 position.

m. Close BCSG2 when the two green triangular LEDs at 12 o’clock on the Synchroscope are energized by cycling BCS-G2 to the CLOSE position. For detailed instructions on manual synchronizing, refer to Chapter 5.9, Section 5.9.6.14. n. Observe that the BCSG2 closes. o. Return the SSS to the OFF position. p. At B-unit MCP, place the SSS in the TIE position. q. Close the BCST by cycling BCST to the CLOSE position. r. s. t. Return the SSS to the OFF position. At B-unit GCPG1, place the Engine Control Switch (ECS) in MANUAL. Observe the engine starts and accelerates to operating voltage and frequency.

u. At the B-unit MCP, place the Sync Source Switch (SSS) in the GEN1 position. v. Close BCSG1 when the two green triangular LEDs at 12 o’clock on the Synchroscope are energized by cycling BCS-G1 to the CLOSE position. For detailed instructions on manual synchronizing, refer to Chapter 5.9, Section 5.9.6.14.

w. At B-unit GCPG2 place the Engine Control Switch (ECS) in MANUAL. X y. z. Observe the engine starts and accelerates to operating voltage and frequency. At the B-unit MCP, place the Sync Source Switch (SSS) in the GEN 2 position. Close BCSG2 when the two green triangular LEDs at 12o’clock on the Synchroscope are energized by cycling BCS-G2 in the CLOSE position. For detailed instructions on manual synchronizing refer to Chapter 5.9 Section 5.9.6.14.

aa. Return the SSS to the OFF position. bb. Close the required feeder breaker(s) from the Local Control Panels. cc. Ensure generators have assumed load. dd. Observe the KW, PF and KVAR of each generator at the LCP.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 Note: If adjustment is needed for KVAR balance, start with the generator that is the furthest from the average KVAR (either too low or too high). Make minor adjustments of the Voltage Adjust Rheostat (VAR) until the KVAR sharing between generators are within +/– 10% of the average plant KVAR load. This adjustment will typically be required only once during initial power plant setup and is intended to compensate for meter variations among generators.

CAUTION
Improper adjustment of the VAR can cause a reverse KVAR shutdown of a generator.

5.3.5

PLANT OPERATIONS

See Chapter 5.9 for specific operating procedures. In this mode of operation the ORT provides no remote operation capability. It will provide monitoring of the generator parameters. 5.3.6 5.3.6.1 POWER PLANT TEARDOWN SHUTDOWN GENERATORS

a. Unload all generators by opening all feeder breakers. This must be done locally from the LCP. b. Open both generator breakers using the respective BCS switches. c. Place both generators in cooldown by placing both ECS switches in STOP/COOLDOWN.

d. Allow all engines to complete cooldown and shut down (5 minutes). e. Place all ECS switches in OFF/RESET. f. 5.3.6.2 Pull out the DC Control Power breaker on the PU. DISCONNECT CABLES

WARNING NEVER REMOVE POWER CABLES BY HAND, USE HOT STICK AND HIGH VOLTAGE GLOVES. NEVER TOUCH A HIGH VOLTAGE LEAD OR TERMINAL UNTIL IT HAS BEEN DISCHARGED TO GROUND. FAILURE TO OBSERVE THE WARNING MAY RESULT IN DEATH BY ELECTROCUTION. CAUTION ALLOW ALL OPERATING ENGINES TO SHUT DOWN AND COOL DOWN COMPLETELY. a. Disconnect the (A)(B) communication cables from between the PUs and store inside the PUs (one per unit).

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 b. Reinstall the (A)(B) communication cable receptacle covers. c. Disconnect the ORT cable and store it in the ORT case.

d. Close and latch the ORT port on the PU. e. Disconnect all load cables used in operation of the PUs. 5.3.6.3 DISCONNECT FUEL LINES

a. Turn all fuel system valves to the off position. b. Disconnect the fuel hose from the PU fuel connection and the fuel supply. c. 5.3.6.4 a. b. c. Drain any fuel from the hoses into an auxiliary fuel supply and store the hoses. DISCONNECT GROUNDING Remove ground connections from the PU and store with the ground rod. Disconnect the parking stations from the ground grid. Remove the parking stations from their operating positions and reinstall them in their transportation locations on the inside of the PU rear side access doors. PREPARE PU FOR TRANSPORTATION

5.3.6.5

a. Reinstall the four radiator splashguards (PU-810B only). b. Verify DC Control power is off. c. Close and lock the LCP access doors.

d. Close and lock all PU side doors. 5.3.6.6 FUEL, OIL, AND COOLANT DRAINAGE

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

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

THIS PAGE INTENTIONALLY BLANK

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

CHAPTER 5.4 OPERATING INSTRUCTIONS
TWO PU, PRIME POWER, NO EXTERNAL SWITCH, AUTOMATIC MODE
TABLE OF CONTENTS SECTION
5.4 5.4.1 5.4.2 5.4.3 5.4.3.1 5.4.3.2 5.4.3.3 5.4.3.4 5.4.3.5 5.4.3.6 5.4.3.7 5.4.3.8 5.4.4 5.4.5 5.4.5.1 5.4.5.2 5.4.5.3 5.4.6 5.4.6.1 5.4.6.2 5.4.6.3

TITLE
TWO PU, PRIME POWER, NO EXTERNAL SWITCH, AUTOMATIC MODE SAFETY PROCEDURES POSITIONING THE PU INITIAL PLANT SETUP GROUNDING FUEL MANIFOLD DISTRIBUTION AND CONTROL CABLING SETPOINT VERIFICATION PRE-OPERATION CHECKS PRE-OPERATION RUN ORT SETUP CONTROLS SETUP PLANT STARTUP PLANT OPERATIONS (AUTOMATIC MODE) PRECAUTIONS AND WARNINGS DESCRIPTION DEFAULT OPERATING SEQUENCE POWER PLANT TEARDOWN SHUT DOWN GENERATORS DISCONNECT CABLES DISCONNECT FUEL LINES

PAGE
73 73 73 74 74 75 76 77 80 80 82 82 83 84 84 85 85 85 85 85 86

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

TABLE OF CONTENTS SECTION
5.4.6.4 5.4.6.5 5.4.6.6

TITLE
DISCONNECT GROUNDING PREPARE PU FOR TRANSPORTATION FUEL, OIL, AND COOLANT DRAINAGE

PAGE
86 86 86

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

LIST OF FIGURES FIGURE
FIGURE 5.4.3.1-1 FIGURE 5.4.3.1-2

TITLE
MEP-PU-810A GROUND POINTS MEP-PU-810B GROUND POINTS

PAGE
74 75

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LIST OF TABLES TABLE
TABLE 5.4.3.6-1 TABLE 5.4.3.8-1 TABLE 5.4.4-1

TITLE
PRE-OPERATION RUN INSTRUCTION SEQUENCE CONTROL SWITCH SETUP SWITCH SETUP – AUTOMATIC MODE

PAGE
81 82 83

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 5.4 5.4.1 TWO PU, PRIME POWER, NO EXTERNAL SWITCH, AUTOMATIC MODE SAFETY PROCEDURES

a. Safety precautions must be observed while operating or maintaining the PU. Safety precautions must be observed to ensure that the operator/technician cannot have contact with the following: • • • • • • • Hot engine parts Hot engine fluids Medium Voltage AC electricity Low Voltage AC electricity Low Voltage DC electricity Rotating Parts High noise levels

b. Minor Troubleshooting can be performed while both engines are running as long as safety precautions are taken. Refer to the appropriate troubleshooting section for recommendations. 5.4.2 POSITIONING THE PU

a. Position the PU in such a way as to allow the plant operator to have full vision of the operator control panels on the unit. b. Level the MEP-PU-810B front to rear with the trailer leveling hand crank. c. Position the PU to provide a minimum of 10 feet of clearance for maintenance access on all sides of each unit. Ensure that there are no overhead obstructions around the exhaust outlets. WARNING FUEL SPILLAGE CAN OCCUR IF THE POWER UNIT LEVEL IS GREATER THAN + 5 DEGREES. d. Ensure that the ground is capable of supporting the weight of the PU. The site surface should be as level as possible (+ 5 degrees).

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 5.4.3 5.4.3.1 INITIAL PLANT SETUP GROUNDING WARNING THERE CAN ONLY BE ONE GROUNDING POINT FOR THE PU. a. Drive an 8-foot ground rod into the earth and should be within 6 feet of the PU and at a location that minimizes the tripping hazard, until only 6 inches (15 cm) protrudes above the surface. b. Repeat step “a” for each PU being used. c. Connect all of the grounding rods together with a #2 AWG copper conductor creating a central ground grid.

d. Using a #2 AWG copper conductor, secure one end of a ground cable to one of the slotted ground studs on the PU, see Figure 5.4.3.1-1 or Figure 5.4.3.1-3. Secure the other end of the ground cable to the ground rod. e. Repeat step “d” for every PU. f. Test Ground Resistance using Ground Resistance Test Equipment. Resistance must be 25Ω or less. Refer to Annex H for special equipment required for this task.

g. Remove parking stand plates from their transportation positions inside each rear, side PU door and slide them into their respective operating positions on the sides of the PDC. h. Connect the parking stand ground wires to either of the two chassis ground lugs on the PU.

GROUND POINT

GROUND POINT

FIGURE 5.4.3.1-1 NOTE:

MEP-PU-810A GROUND POINTS

Connect only one ground point to the ground grid.

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

GROUND POINT

GROUND POINT

FIGURE 5.4.3.1-2 NOTE: 5.4.3.2

MEP-PU-810B GROUND POINTS

Connect only one ground point to the ground grid. FUEL MANIFOLD WARNING ENSURE THAT THE FUEL LINES ARE PROTECTED FROM ALL ELECTRICAL CABLES AND ARE ROUTED TO MINIMIZE THE POTENTIAL FOR PHYSICAL DAMAGE OR CAUSING A TRIPPING HAZARD.

a. Lay out the fuel hoses between the PU, the fuel manifold, and the fuel bladders to establish the fuel supply system see Chapter 5.1 Figure 5.1.3.2-1 External Fuel Supply. b. Install the external fuel hose for the PU to the Fuel Transfer Pump at the Tow end of the PU. c. Connect the other end of the fuel hose to the fuel manifold outlets.

d. Connect the 3” hose, with quick-disconnect hose ends, from the fuel manifold to the fuel bladders. e. Connect the fuel manifold ground wire to the ground grid. f. Open only the appropriate fuel manifold valves (once connected to the PU) to supply fuel to the power units and check for leaks.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 5.4.3.3 DISTRIBUTION AND CONTROL CABLING WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT DURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION AND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN LOAD CABLES ARE HANDLED.

WARNING VERIFY THAT CONNECTION POINTS ARE DE-ENERGIZED BEFORE MAKING ANY CONNECTIONS. FAILURE TO CHECK THAT CONNECTORS ARE DE-ENERGIZED MAY RESULT IN INJURY OR DEATH. a. Lay out and park the load cables for each phase (A, B, & C) between the PU Tie Output parking stations on all Power Units. b. Connect each power cable’s drain wire to the grounding grid. c. Lay out and park the load cables for each phase (A, B, & C) between the PU Feeder Output parking stations and the load. d. Connect each power cable’s drain wire to the grounding grid. e. Open the Tie Output connector loadbreak covers on one PU. f. Connect the Tie Output Cables to the appropriate phase connectors; ensure there are no crossphase connections. g. Close and lock (when required) the Tie Output connector covers. h. Open the Feeder Output connector loadbreak covers. i. Connect the Feeder cables to the appropriate phase connectors; ensure there are no crossphase connections. j. k. l. Close and lock the Feeder Output connector covers. Repeat steps ‘e’ through ‘j’ on the second PU. Connect the (A) (B) communication cable to the (B) side of the first PU.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 m. Route (A) (B) communication cable to second PU and Connect to the (A) side of the PU. n. Connect the (A) (B) communication cable to the (B) side of the second PU. Leave the end of second cable loose and capped. 5.4.3.4 SETPOINT VERIFICATION a. Turn on PU DC control power by pushing in on the DC Control Power breaker. b. On each of the five overcurrent relays, verify the settings: (1) (2) (3) (4) (5) (6) (7) (8) (9) Press the [▲] key to get to the top-level menu “1 REPORT STATUS”. Press the [►] key 5 times to display “6 GENERAL SETTINGS”. Press the [▼] key to display “6.1 COM SETTINGS”. Press the [►] key 2 times to display “6.3 POWER SYSTEM SETTINGS”. Press the [▼] key to display “6.3.1 CT RATIO”. Verify the “P” and “N” values match Chapter 5.1 Table 5.1.3.4-1 CT Ratio Settings. Press the [▲] key 2 times to display “6 GENERAL SETTINGS”. Press the [◄] key to display “5 PROTECTION LOGIC USER”. Press the [▼] key 3 times to display “5.1.1.1 50TP”.

(10) Verify the 50TP “PU” and “TD” settings in Chapter 5.1 Table 5.1.3.4-2 Instantaneous Trip Settings. In order to edit values, Press the “Edit” key. Select correct value, and press “Edit” again to save changes. Ensure light is off otherwise you can accidentally change value again. (11) Press the [►] key to display “5.1.1.2 50TN”. (12) (13) (14) (15) (16) (17) (18) 19) (20) (21) Verify the “50TN” settings. Press the [►] key to display “5.1.1.3”. Verify the “50TQ” settings. Press the [▲] key to display “5.1.1 50T SETTINGS”. Press the [►] key to display “5.1.2 51 SETTINGS”. Press the [▼] key to display “5.1.2.1 51P”. Verify the 51P “PU”, “TD”, and “C” settings in Chapter 5.1 Table 5.1.3.4-3 Time Overcurrent Settings. Press the [►] key to display “5.1.2.2 51N”. Verify the 51N settings. Press the [▲] key 3 times to display “5 PROTECTION LOGIC USER”.

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c. NOTE:

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 Use the following procedure to verify the Generator 1 and Generator 2 GSC+ settings: Refer to the “EMCPII+ Reference Chart”, located on the interior Generator Control Panel Door (Look-up) (1) (2) (3) (4) (5) (6) (7) (8) (9) Place ECS in the COOLDOWN/STOP position. Press SERVICE MODE key to enter service mode. OP1 is showing on the lower display. Press SCROLL UP key until “OP3” is showing. Press SELECT key. “PE -“ with the first dash flashing is showing. Press SCROLL RIGHT key. “PE 1 “ with the second dash flashing is showing. Press SCROLL DOWN key. “PE 13 “ with the third dash flashing is showing. Press SCROLL UP key. “PE 132 “ with the fourth dash flashing is showing. Press SCROLL DOWN key. “PE 1323 “ with the fifth dash flashing is showing. Press SCROLL RIGHT key. “PE13231” with all digits not flashing is showing.

(10) Press ENTER key. “PE PASS” is showing. (11) Press EXIT key. “OP4” is showing. (12) Press SCROLL UP key until “OP5-0” is showing on the lower display. (13) Press SELECT key. “POO1” followed with the value of the setpoint is showing. (14) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing. Use Chapter 5.1 Table 5.1.3.4-4 OP5 Settings for the parameter values to be verified. Repeat until the desired setpoints are verified. (15) Press EXIT key. “OP5-0” is showing on the lower display. (16) Press SCROLL UP key until “OP5-1” is showing. (17) Press SELECT key. (18) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing. Use Chapter 5.1 Table 5.1.3.4-5 OP5-1 Settings for the parameter values to be verified. Repeat until the desired setpoints are verified. (19) Press EXIT key. “OP5-1” is showing. (20) Press SCROLL UP key. “OP6” is showing. (21) Press SELECT key. (22) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing. Use Chapter 5.1 Table 5.1.3.4-6 OP6 Settings for the parameter values to be verified. Repeat until the desired setpoints are verified. (23) Press EXIT key twice. The display returns to normal.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 NOTE: If an incorrect setpoint value is displayed, the value must be changed to match the DPGDS setpoint value as follows: (a) (b) (c) (d) With the setpoint with the incorrect value showing on the display, press the SELECT key. The incorrect value flashes on the display. Press SCROLL UP or SCROLL DOWN key until the correct value appears flashing on the display. Press ENTER. The correct value stops flashing on the display.

Press SCROLL UP or SCROLL DOWN key to continue to verify the remaining parameter values. d. Return ECS1 and ECS2 to the OFF/RESET position. NOTE: Use up or down keys to change values.

e. At the AVR verify the operation settings using Chapter 5.1 Table 5.1.3.4-7 AVR Parameter/Setpoints: (1) (2) (3) (4) (5) (6) (7) (8) (9) Open the GCPG1 cabinet door. Press the [▼] key to display parameter “90”. Press the [◄►] key to display the current value. Press the [▲] key to change the value to “0015”. Enables parameter editing. Press the [◄►] key to accept change and display the parameter number. Press the [▲] key to the next parameter needed to change. Press the [◄►] key to display the current value. Press the [▲] or [▼] key to change the value. Press the [◄►] key to accept change and display the parameter number.

(10) Repeat steps ‘5’ through ‘9’ for the each parameter needing to be changed. (11) When complete, press the [▼] to display parameter “01”. NOTE: NOTE: Parameters 20, 21, 22, 36, 37, and 38 are displayed but not used. Parameters 23 to 29, 39 to 49, 59 and 61 to 89 are not displayed and not used. (12) When complete, press the [▼] to display parameter “90”. (13) Press the [◄►] key to display the current value. (14) Press the [▼] key to change the value to “0009”. Disables DVR parameter editing. (15) Press the [◄►] key to accept change and display the parameter number.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (16) Press the [▲] key to change to display parameter “01”. (17) Close the GCPG1 cabinet door. (18) Repeat steps ‘1 ‘through ‘16’ for Generator 2. 5.4.3.5 PRE-OPERATION CHECKS

Starting from the left rear of the PU and working around the PU in a clockwise direction, perform the checks identified in Chapter 5.1 Table 5.1.3.5-1 Pre-Operation Checklist. (Gen. 1 is on the left and Gen. 2 is on the right): 5.4.3.6 PRE-OPERATION RUN WARNING ENSURE ALL PERSONNEL ARE CLEAR AND THE PU DOORS ARE CLOSED PRIOR TO STARTING A GENERATOR. WARNING HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND ENFORCED. NOISE LEVELS IN EXCESS OF 85 DB EXIST WITHIN AN 88-FOOT RADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR SINGLE HEARING PROTECTION WITHIN 88 FEET OF AN OPERATING DPGDS. WARNING HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND ENFORCED. DURING MAINTENANCE ACTIVITIES WITH THE SIDEDOORS OPEN, NOISE LEVELS IN EXCESS OF 113 DB EXIST WITHIN A 12-FOOT RADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR DOUBLE HEARING PROTECTION WITHIN 12 FEET OF AN OPERATING DPGDS. EXPOSURE MUST BE LIMITED TO UNDER 2.5 HOURS. WARNING BY CLOSING THE FEEDER OR TIE BREAKER, HIGH VOLTAGE WILL BE PRESENT ON THE LOAD CABLES. ENSURE ALL PERSONNEL ARE CLEAR OF ALL LOAD CABLES PRIOR TO CLOSING FEEDER OR TIE BREAKERS.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 TABLE 5.4.3.6-1 PRE-OPERATION RUN INSTRUCTION SEQUENCE (Perform on each PU in the power plant)
STEP

-- 60HZ OPERATIONS --

-- 50HZ OPERATIONS --

1 2 3 4① 5 6 7 8 9 10 11 12 13 14 15 16

Verify System Mode Switch (SMS) is in MANUAL Verify DC Control Power is on Verify Emergency Stop is pulled out Verify the 60Hz light is on ① Verify the 50Hz light is on①

Start engine 1 by placing ECS1 in MANUAL Verify the engine accelerates to 1800RPM Adjust the generator frequency to 60Hz using the Frequency Adjust Rheostat (FAR) Adjust the generator voltage to 4295VAC using the Voltage Adjust Rheostat (VAR) Verify the engine accelerates to 1500RPM Adjust the generator frequency to 50Hz using the Frequency Adjust Rheostat (FAR) Adjust the generator voltage to 3915VAC using the Voltage Adjust Rheostat (VAR)

Close BCS-G1, toggle the Phase Rotation Test Light switch, verify that light ABC lights, open BCSG1 Shutdown engine 1 by placing ECS1 in OFF/RESET Start engine 2 by placing ECS2 in MANUAL Verify the engine accelerates to 1800RPM Adjust the generator frequency to 60Hz using the Frequency Adjust Rheostat (FAR) Adjust the generator voltage to 4295VAC using the Voltage Adjust Rheostat (VAR) Verify the engine accelerates to 1500RPM Adjust the generator frequency to 50Hz using the Frequency Adjust Rheostat (FAR) Adjust the generator voltage to 3915VAC using the Voltage Adjust Rheostat (VAR)

Close BCS-G2, toggle the Phase Rotation Test Light switch, verify that light ABC lights, open BCSG2 Shutdown engine 2 by placing ECS2 in OFF/RESET

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

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 5.4.3.7 ORT SETUP a. Remove the ORT from its case and set it up on a flat and level surface. b. Remove the mouse from the case and plug it into the mouse (PS2) port on the back of the ORT. c. If 120VAC power is available, connect the ORT power supply cord to the 120VAC power. The ORT can operate up to three hours on its batteries.

d. Connect one end of the 150-foot patch cable to the ORT networking port on the PU. e. Route the cable from the ORT to the PU and connect the cable to the ORT port. f. Turn on the ORT.

g. Observe that the ORT boots to the operator’s Overview screen. h. Select the EquipID pop-up screen and enter the necessary information for the units. This includes the Trailer ID number, the Engine ID number, and the Generator ID number for each PU. i. Select the Oneline pop-up screen and enter the descriptor for the main load connected to the feeders.

h. Return to the Overview pop-up screen. 5.4.3.8 CONTROLS SETUP

Complete the switch arrangements according to the following Table, and verify the lamp indicators: TABLE 5.4.3.8-1 PANEL CONTROL SWITCH SETUP SWITCH DC Power SMS GMS AVRS MASTER CONTROL PANEL 60Hz Light MCP USS BSS SSS SSL FSS INSIDE MCP Emergency Stop GENERATOR CONTROL PANEL GCPG1 ECS Emergency Stop GENERATOR CONTROL PANEL GCPG2 ECS 1ST PU Pushed In (ON) OFF PRIME POWER PRIME POWER ON① A② NORMAL OFF All OFF 50/60 Hertz1 Pulled-Out OFF Pulled-Out OFF 2ND PU Pushed In (ON) OFF PRIME POWER PRIME POWER ON① B② NORMAL OFF All OFF 50/60 Hertz1 Pulled-Out OFF Pulled-Out OFF

① With the SMS in the OFF position, the 50/60Hz lights indicate the position of the Frequency

Selector Switch (FSS). If the wrong light is on, open the door and change the switch position.

No more than one switch can be in the same position in any multi-PU line-up. With the SMS in OFF, none of the USI lights will be on and any previously set address on the PU is cleared.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 5.4.4 PLANT STARTUP

Starting up a Two Unit Prime Power Plant in Automatic Mode WARNING ONCE THE SYSTEM STATUS LIGHTS TURN GREEN AND THE MSES IS ENABLED, THE PU WILL START. ENSURE PERSONNEL ARE CLEAR OF THE PU. WARNING ONLY ONE PU MAY BE SELECTED TO ANY ONE USS POSITION DURING MULTIPLE PU OPERATIONS. OPERATING WITH MORE THAN ONE UNIT AT THE SAME ID MAY CAUSE UNSAFE AND ERRATIC OPERATIONAL CONDITIONS. a. Complete the switch arrangements according to the following Table, and verify the lamp indicators: TABLE 5.4.4-1 PANEL SWITCH SETUP – AUTOMATIC MODE SWITCH 1ST PU BCS-T Red Target MASTER CONTROL SMS AUTO③ PANEL MCP USS A BCS-G1 Red Target GENERATOR CONTROL PANEL 1 BCS-F1 Red Target GCPG1 ECS-1 AUTO BCS-G2 Red Target GENERATOR CONTROL PANEL 2 BCS-F2 Red Target GCPG2 ECS-2 AUTO MSES Enable① MASTER CONTROL PANEL MCP USI A①, ② 2ND PU Red Target AUTO③ B Red Target Red Target AUTO Red Target Red Target AUTO Enable① B①, ②

① Hold the MSES in an ENABLE position until the selected USI indicator energizes. The switch

returns to the center position when released. This sets the PU networking address and enables the control and monitoring.
② No more than one of each indicator can be on for multi-PU operations. The light on should match

USS position. The USI light will de-energize after the SMS has been in OFF for 3 seconds.
③ With the SMS in AUTO any generator started, manually or automatically, will automatically

parallel to the bus. To prevent the generator from paralleling to the bus put the generator’s breaker in the Pull-To-Lock position. NOTE: The automatic economizing feature will shutdown one generator every 3 minutes until the system load is at or below the 360KW/450KVA per generator threshold.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 b. At A-unit, observe Generator 1 automatically starts and accelerates to operating voltage and frequency. c. At A-unit, observe Generator 1 automatically closes to the system bus.

d. At A-unit, observe the Tie breaker automatically closes. e. At B-unit, observe the Tie breaker automatically closes. f. At A-unit, observe Generator 2 automatically starts and accelerates to operating voltage and frequency.

g. At A-unit, observe Generator 2 automatically parallels to the system bus. h. At B-unit, observe Generator 1 automatically starts and accelerates to operating voltage and frequency. i. j. k. l. At B-unit, observe Generator 1 automatically parallels to the system bus. At B-unit, observe Generator 2 automatically starts and accelerates to operating voltage and frequency. At B-unit, observe Generator 2 automatically parallels to the system bus. Ensure generators have assumed load.

n. Observe the KW, PF and KVAR of each generator at the LCP. Note: If adjustment is needed for KVAR balance, start with the generator that is the furthest from the average KVAR (either too low or too high). Make minor adjustments of the Voltage Adjust Rheostat (VAR) until the KVAR sharing between generators are within +/– 10% of the average plant KVAR load. This adjustment will typically be required only once during initial power plant setup and is intended to compensate for meter variations among generators.

CAUTION
Improper adjustment of the VAR can cause a reverse KVAR shutdown of a generator.

5.4.5 5.4.5.1

PLANT OPERATIONS (AUTOMATIC MODE) PRECAUTIONS AND WARNINGS

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

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 5.4.5.2 DESCRIPTION The master controller (the designated “A” unit) will control all connected generators based on the total system KW/KVA load. The controller shuts down one of the generators after 3 minutes should the system load drop below a level where the remaining generator load would not exceed 85% (360kW) if a generator is shutdown. If the load of the remaining generator exceeds 85% (360kW) for one minute, a standby generator is started and paralleled to the bus. A change of system load is recognized by the control system and appropriate action is taken to maintain generator load in the 85% (360 KW/450 KVA) range. The system never automatically shuts down the final generator under normal operating conditions. The shutdown of the final generator must be done following manual operating procedures. The default configuration is Economizing Mode on. The economizing mode can be turned off from the ORT. Through the ORT, the AUTO shut down is disabled but the AUTO start-up remains active to prevent overloading the online generator(s). 5.4.5.3 DEFAULT OPERATING SEQUENCE

Start-Up Sequence: The automatic controls will continuously monitor the system load. As load on the system increases, the controls automatically start and place additional units on line in the following sequence at 1-minute intervals: a. One generator from PU “B” based on lower engine runtime. b. Remaining generator from PU “A”. c. Remaining generator from PU “B”. Shutdown Sequence: Based on the loading experienced, the controller shuts down generator sets that are not needed. For the purpose of explanation, we will assume that all generator sets are on line following an initial startup. Based on load, the controls shut down generator sets in the following sequence at 3-minute intervals: a. One generator from PU “B” based on higher engine runtime. b. One generator from PU “A” based on higher engine runtime. c. Remaining generator from PU “B”. 5.4.6 5.4.6.1 POWER PLANT TEARDOWN SHUT DOWN GENERATORS

a. Unload all generators by opening all feeder breakers. This must be done locally from the LCP or ORT. b. Open both generator breakers using the respective BCS switches. c. Place both generators in cooldown by placing both ECS switches in STOP/COOLDOWN.

d. Allow all engines to complete cooldown and shut down (5 minutes). e. Place all ECS switches in OFF/RESET. f. 5.4.6.2 Pull out the DC Control Power breaker on the PU. DISCONNECT CABLES

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 WARNING NEVER REMOVE POWER CABLES BY HAND, USE HOT STICK AND HIGH VOLTAGE GLOVES. NEVER TOUCH A HIGH VOLTAGE LEAD OR TERMINAL UNTIL IT HAS BEEN DISCHARGED TO GROUND. FAILURE TO OBSERVE THE WARNING MAY RESULT IN DEATH BY ELECTROCUTION. CAUTION ALLOW ALL OPERATING ENGINES TO SHUT DOWN AND COOL DOWN COMPLETELY. a. Disconnect the (A)(B) communication cables from between the PUs, Reinstall the communication cable receptacle covers and store inside the PUs (one per unit). b. Disconnect the ORT cable and store it in the ORT case. c. Close and latch the ORT port on the PU.

d. Disconnect all load cables used in operation of the PUs. 5.4.6.3 DISCONNECT FUEL LINES

a. Turn all fuel system valves to the off position. b. Disconnect the fuel hose from the PU fuel connection and the fuel supply. c. 5.4.6.4 a. b. c. 5.4.6.5 Drain any fuel from the hoses into an auxiliary fuel supply and store the hoses. DISCONNECT GROUNDING Remove ground connections from the PU and store with the ground rod. Disconnect the parking stations from the ground grid. Remove the parking stations from their operating positions and reinstall them in their transportation locations on the inside of the PU rear side access doors. PREPARE PU FOR TRANSPORTATION

a. Reinstall the four radiator splashguards (PU-810B only). b. Verify DC Control power is off. c. Close and lock the LCP access doors.

d. Close and lock all PU side doors. 5.4.6.6 FUEL, OIL, AND COOLANT DRAINAGE

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

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

CHAPTER 5.5 OPERATING INSTRUCTIONS
SINGLE OR MULTIPLE PU, PRIME POWER, EXTERNAL SWITCH, MANUAL MODE
TABLE OF CONTENTS SECTION
5.5 5.5.1 5.5.2 5.5.3 5.5.3.1 5.5.3.2 5.5.3.3 5.5.3.4 5.5.3.5 5.5.3.6 5.5.3.7 5.5.3.8 5.5.3.9 5.5.4 5.5.5 5.5.6 5.5.6.1 5.5.6.2 5.5.6.3 5.5.6.4 5.5.6.5

TITLE

PAGE
91 91 91 92 92 93 94 95 98 98 100 100 101 102 105 105 105 105 106 106 106

SINGLE OR MULTIPLE PU, PRIME POWER, EXTERNAL SWITCH, MANUAL MODE SAFETY PROCEDURES POSITIONING THE PU INITIAL PLANT SETUP GROUNDING FUEL MANIFOLD DISTRIBUTION AND CONTROL CABLING SETPOINT VERIFICATION PRE-OPERATION CHECKS PRE-OPERATION RUN ORT SETUP CONTROLS SETUP PSC RELAY SETTING VERIFICATION PLANT STARTUP PLANT OPERATIONS POWER PLANT TEARDOWN SHUTDOWN GENERATORS DISCONNECT CABLES DISCONNECT FUEL LINES DISCONNECT GROUNDING PREPARE PU FOR TRANSPORTATION

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5.5.6.6

FUEL, OIL, AND COOLANT DRAINAGE

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 106

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

LIST OF FIGURES FIGURE
FIGURE 5.5.3.1-1 FIGURE 5.5.3.1-2

TITLE
MEP-PU-810A GROUND POINTS MEP-PU-810B GROUND POINTS

PAGE
92 93

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

LIST OF TABLES TABLE
TABLE 5.5.3.6-1 TABLE 5.5.3.8-1 TABLE 5.5.3.9-1 TABLE 5.5.4-1

TITLE
PRE-OPERATION RUN INSTRUCTION SEQUENCE CONTROL SWITCH SETUP PSC RELAY SETTINGS SWITCH SETUP – MANUAL MODE

PAGE
99 101 102 103

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 5.5 5.5.1 SINGLE OR MULTIPLE PU, PRIME POWER, EXTERNAL SWITCH, MANUAL MODE SAFETY PROCEDURES

a. Safety precautions must be observed while operating and or maintaining the power unit. Safety precautions must be observed to ensure that the operator/technician cannot have contact with the following: • • • • • • • Hot engine parts Hot engine fluids Medium Voltage AC electricity Low Voltage AC electricity Low Voltage DC electricity Rotating Parts High noise levels

b. Minor Troubleshooting can be performed while both engines are running as long as safety precautions are taken. Refer to the appropriate troubleshooting section for recommendations. 5.5.2 POSITIONING THE PU

a. Position the PU in such a way as to allow the plant operator to have full vision of the operator control panels on the unit. b. Level the MEP-PU-810B front to rear with the trailer leveling hand crank. c. Position the PU to provide a minimum of 10 feet of clearance for maintenance access on all sides of each unit. Ensure that there are no overhead obstructions around the exhaust outlets. WARNING FUEL SPILLAGE CAN OCCUR IF THE POWER UNIT LEVEL IS GREATER THAN + 5 DEGREES. d. Ensure that the ground is capable of supporting the weight of the PU. The site surface should be as level as possible (+ 5 degrees).

5-91

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 5.5.3 5.5.3.1 INITIAL PLANT SETUP GROUNDING WARNING THERE CAN ONLY BE ONE GROUNDING POINT FOR THE PU. a. Drive an 8-foot ground rod into the earth and should be within 6 feet of the PU and at a location that minimizes the tripping hazard, until only 6 inches (15 cm) protrudes above the surface. b. Repeat step “a” for each PU being used. c. Connect all of the grounding rods together with a #2 AWG copper conductor creating a central ground grid.

d. Using a #2 AWG copper conductor, secure one end of a ground cable to one of the slotted ground studs on the PU, see Figure 5.5.3.1-1 or Figure 5.5.3.1-3. Secure the other end of the ground cable to the ground rod. e. Repeat step “d” for every PU. f. Test Ground Resistance using Ground Resistance Test Equipment. Resistance must be 25Ω or less. Refer to Annex H for special equipment required for this task.

g. Remove parking stand plates from their transportation positions inside each rear, side PU door and slide them into their respective operating positions on the sides of the PDC. h. Connect the parking stand ground wires to either of the two chassis ground lugs on the PU.

GROUND POINT

GROUND POINT

FIGURE 5.5.3.1-1 NOTE:

MEP-PU-810A GROUND POINTS

Connect only one ground point to the ground grid.

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

GROUND POINT

GROUND POINT

FIGURE 5.5.3.1-2 NOTE: 5.5.3.2

MEP-PU-810B GROUND POINTS

Connect only one ground point to the ground grid. FUEL MANIFOLD WARNING ENSURE THAT THE FUEL LINES ARE PROTECTED FROM ALL ELECTRICAL CABLES AND ARE ROUTED TO MINIMIZE THE POTENTIAL FOR PHYSICAL DAMAGE OR CAUSING A TRIPPING HAZARD.

a. Lay out the fuel hoses between the PU, the fuel manifold, and the fuel bladders to establish the fuel supply system. See Chapter 5.1 Figure 5.1.3.2-1 External Fuel Supply. b. Install the external fuel hose for the PU to the Fuel Transfer Pump at the Tow end of the PU. c. Connect the other end of the fuel hose to the fuel manifold outlets.

d. Connect the 3” hose, with quick-disconnect hose ends, from the fuel manifold to the fuel bladders. e. Connect the fuel manifold ground wire to the ground grid. f. Open only the appropriate fuel manifold valves (once connected to the PU) to supply fuel to the power units and check for leaks.

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