2825 Gpu 90 Kva Ai-Sats Operational Manual1

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OPERATION AND MAINTENANCE MANUAL Air+Mak

90KVA AC/DC GPU Industries Inc.
OPERATION AND MAINTENANCE

MANUAL FOR 90KVA AC/DC GPU
DESIGNED & MANUFACTURED BY:
AIR + MAK INDUSTRIES INC.

11154, WILDWOOD DRIVE, OLIVE BRANCH, MS 38654
PHONE : (662) 893 3444;FAX : (662) 893 3476
E-MAIL : info@airmak.com;WEB:www.airmak.com
CLIENT: AI SATS-BANGALORE.
THIS MANUAL SHOULD BE REFERRED FOR THE GPU SL.NO: 2825.
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CONTENTS
CHAPTER PAGE NO
CHAPTER I
INTRODUCTION …………………...……..………………………….. 1
1. Introduction ……………………………………………….. 2
2. Special Features ………………………………………….. 2
3. Detailed Description ……………….…………………….. 4
4. Specifications …………………………………………….... 17
5. Major Components Details ……………...……………….. 18
CHAPTER II
OPERATION ………………………....……………………………….. 1
1. General …………………………………………………….. 2
2. Pre commissioning Check ……………………………….. 2
3. Do's and Don'ts …………………………………………... 3
4. Operating Instructions ……………………….…………... 4
5. Caution .……………………………………….…………... 6
6. MAK GSE MONITOR V8 Description ……………….. 7
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CHAPTER III
MAINTENANCE AND TROUBLE SHOOTING …………..……….. 1
1. Maintenance …………………………….……………….. 2
2. Trouble Shooting ………………………………………….. 6
3. Replacing of PCB’s ……………………………………….. 30
CHAPTER IV
PCB DESCRIPTIONS AND DIAGRAMS … ……………...……….. 1
CHAPTER V
RECOMMENDED SPARES & FIRST AID ……………….……….. 1
1. Recommended spares ………………………..………….. 2
2. First aid for electrical accident ……………….………….. 4
CHAPTER VI
MANUFACTURER APPENDIX …………………………….……….. 1
1. Automatic voltage regulator …………………..………….. 2
2. Alternator…………………………………….…………….. 16
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CHAPTER I
INTRODUCTION
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CHAPTER I
1. INTRODUCTION
MAK GROUND POWER UNITS are available in standard models of 40-180 KVA range
with AC 400Hz, with or without DC 28V supply. Options for variable and single DC
outputs can be incorporated for special applications.
This is the rotary machine comprising of a prime mover and alternator of 90KVA capacity
with an output of 200/115V AC 3 phase, 400 Hz at 0.8-power factor (lag) with DC power
of 28.5V supply.
This system is designed and manufactured to provide electrical power to the aircraft’s in
the tarmac area.
2. SPECIAL FEATURES
 EMI/EMC Compliance for MIL STD.
 IP 65 Protected System
 Cloud Networking Enabled System for Remote Diagnosis &

Monitoring.
 Advanced 32 bit Control System with operating capability @ 60 MHz
 Single Touch options for all System Controls.
 Graphical rich High Intensity Display for Parameters in both Analog &
Digital Format for better readability.
 Tested with Highly rugged Environmental Conditions Such as

Operating Temp, Thermal Shocks, Vibration, Socking, Bump Test,
ESD, EMI /EMC.
 Facilitated with Field programmable option with password protection

only for MAK.
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 Last 10 years Logged data can be retrieved from Cloud within
fraction of seconds using Internet.
 Last 10 Faults will be logged within the System with date & time
stamp.
 Tracking of GPU based on Location using GPS, based on Serial

Numbers from Remote using Cloud Web link.
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3. DETAILED DESCRIPTION
MANUFACTURE
The GPU is designed and manufactured for the application to provide electrical power
supplies to the aircraft, through the cable and socket assembly, when the aircraft is on
tarmac. The manufacturing standards we adopted and resulting system performance, in
general, confirms to relate AEROSPACE RECOMMENDED PRACTICE also.
The base frame with engine and alternator coupled is mounted on the inbuilt trailer
through anti vibration mounts, which is designed to take care of the weights and
vibrations. Battery and other components are mounted at convenient locations on the
chassis. The engine and its accessories, alternator, control panel and contactor plate are
protected from the outside environment by steel sheet canopy.
a) ENGINE
A Liquid -cooled Diesel engine is used as a prime mover. The engine is DEUTZ make,
Model TCD 2013. The engine is capable of delivering 120KW at rated speed of 2300rpm
for continuous operation and can withstand for 110% load for 10 minutes. An EMR
Controller is provided to regulate the engine speed and to control the engine.
Note: Please refer the engine manual for more details.
b) ALTERNATOR
A brushless self excited alternator of MAK Make, Model MA300M, which provides
200/115V, 3Phase and 400Hz. The alternator generates 90KVA, at 0.8pf lagging, at
rated speed of 2000rpm. It can withstand 110% load for 60 minutes.
c) BASE FRAME
The base frame is welded structure, fabricated out of Rectangular steel tubes of
5.4mmthickness. The base frame accommodates the cable stowage and silencer. Spark
Arrester inbuilt with silencer assy.
d) CANOPY
The canopy is designed to protect the entire configuration from the outside environment.
The canopy is made out of MS Sheet. The canopy is designed for better accessibility and
maintenance of each and every components of the equipment. Sound attenuation
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materials are pasted inside the canopy and in hot air duct to reduce the noise level of the
GPU.
e) COUPLING OF ENGINE AND ALTERNATOR
The Engine and Alternator are coupled with flexible coupling. Centric flex make SAE 11.5
coupling is used for engine and Alternator coupling. This system of coupling is fail-safe
due to its perfect alignment.
f) METERING CONTROLS, PROTECTION AND OUTPUTS
The above comprises of Control panel V8, Contactor plate, EMR Plate, and output
cable assembly.
1) MAK GSE MONITOR V8:

The GSE Monitor V8 is designed with powerful micro-controller based technology for
a very fine-tuned and with precise measurement of outputs. The control system is an
integrated system that takes care of monitoring various engine/output parameters as
well as protecting the engine and Alternator against various faults. Operating backups
like voltage, current, engine parameters and faults of alternator and engine can be
stored through cloud networking. It also consists of Control board, Touch Screen
Display Emergency stop push button, Panel on/off illuminated switch, Obstruction
lamp illuminated switch.
MAK GSE Monitor is a control panel with a Touch Screen Interface for the user to
control, configure and to operate GPU in simple manner. The Control Panel is
operating with an Advanced 32 bit Microcontroller (AT32UC3C0128C) which is
operating a frequency @ 16MHz and is capable up to 66 MHz with this microcontroller
Board. Refer the below mentioned Block Diagram and List of Peripherals available in
the Board.
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2) AC Contactor plate
This connects the alternator output to the load (aircraft) and it’s comprises of followings:
 AC Power contactor
 Current transformers
 Line Drop Compensation Relays
 AVR Field resistor
 AVR Field transformer
 AVR
 FET
 Relay Board
 MWM board
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3) EMR plate
This EMR plate comprises the followings:
 EMR
 Control switch
 Circuit breaker
4) Auxiliary supply MCB’s: (Optional)

This Auxiliary comprises the followings:
 Single Phase 115V, 400HZ, 10Amps
 3 Phase 200V, 400HZ, 10Amps
5) DC rectifier Bank:
This connects the alternator output to the load (Aircraft) and comprises:
 DC Power Contactor
 Rectifier Bank
 DC Shunt
 Snubber Card
 Filter Card
(i). AC Power Contactor:
It is used for to interconnecting the alternator output. During the fault condition Contactor
tripped and also disconnects the output AC supply.
(ii). Current Transformer:
It is used for to measure the output AC current.
(iii). Line Drop Relays:
It is used to maintain the AC voltages at cable end during all load conditions.
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g) Output Cable Assembly

The above consists of AC supply cables with NATO sockets.
AC Output cable Assembly:

Two set of AC power cable is provided which is capable of handling 90 KVA output.
This is an assembly of six cables connecting output terminals and load. Four cables for
power, three-core cable for interlock sensing and another three-core for line drop
compensation. All the cable assemblies housed in a standard six-pin NATO socket
assembly.
DC Output cable Assembly:
This is an assembly of two cables connecting of the DC output. The cable assemblies
housed in a standard three-pin NATO socket assembly.
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h). GPU Details:

1) G.P.U.
Model : MAK GPU 90-A/D-1-5-V8
Rated output : 90KVA, 200/115V, 3phase, 400HZ at 0.8 power factor (lag).
Prime Mover : DEUTZ Liquid-cooled Diesel engine,
with EMR.
Alternator : MAK, Brush less, 3 phase constant voltage alternator.
2) MECHANICAL DETAILS WITH TRUCK:

Length (mm) : 3056mm(Tow Bar Fold Condition)
Width (mm) : 1700mm
Height : 1925mm
Weight : 2850 Kgs Dry (Approx.)
Fuel /Tank capacity : 200 Ltrs.
3) ENGINE
Make/Model : TCD 2013
Type : Liquid-cooled,
Power : 120 KW
Rated RPM : 2300 RPM
4) ALTERNATOR
Make : MAK
Rated output : 90 KVA at 0.8 PF
Phase/Frequency : 3/400 Hz
Voltage : 200/115 VAC
Speed : 2000 RPM
Insulation : Class-H
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5) MAK GSE MONITOR V8:

Engine monitoring parameters:
Displays through LCM
OP – Oil pressure
CT – Coolant Temperature
BV – Battery Voltage
Fuel Level
Engine RPM and Engine hours.
Engine Protections:
Indication through LCM
LOP - Low Oil Pressure
HCT - High Coolant Temperature
LF - Low Fuel
OS - Over Speed
CF - Charge Fail (Only annunciation, no trip)
AFC – Air Filter Clog (Only annunciation, no trip)
Output Monitoring parameters:
3 Phase AC Voltage with line-to-line or line-to-neutral

3 Phase AC Load current
DC Voltage and Current
Frequency
Mode selection- AC, ACDC, DC
BYP/INT for AC and ACDC mode
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Output Protections:
AC Protections:
OV - Over Voltage
UV - Under Voltage
OL - Over Load
OF - Over Frequency
UF - Under Frequency
PR - Phase Reversal
NO - Neutral Open
DC Protections:
OV - Over Voltage
UV - Under Voltage
OL - Over Load
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MAK GSE MONITOR V8
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i) TRIP LIMITS FOR 90 KVA ACDC GPU
CONDITIONS LIMITS TIME DELAY
AC TRIP LEVEL
UNDER VOLTAGE (L- N)

100V 3 SECONDS
99V 2 SECONDS
98V 1 SECONDS
97V & <97V IMMEDIATE
OVER VOLTAGE (L- N) 130V 5 SECONDS

131V 4 SECONDS
132V 3 SECONDS
133V 2 SECONDS
134V 1 SECONDS
135V & below IMMEDIATE
UNDER FREQUENCY 383 5 SECONDS

382-380 3 SECONDS
379 1 SECONDS
378 & below IMMEDIATE
OVER FREQUENCY 420 3 SECONDS

422 1 SECONDS
421 & below IMMEDIATE
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OVER LOAD FOR AC PWR SOCKET
100% (0 – 260A) NO TRIP

101-110% (261 – 286A) 1 HOUR
111-115% (287 – 325A) 5 MINUTES
126 – 150% (326-390A) 10 SECOND
>151% (391A&ABOVE) IMMEDIATE
NEUTRAL OPEN 5 SECONDS
PHASE REVERSE 5 SECONDS
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ENGINE PROTECTIONS
TRIPS:
LOW COOLANT 20 SECONDS
LOW E. OIL PRE. IMMEDIATE
HI. COOL.TEMP IMMEDIATE
OVER SPEED IMMEDIATE (Above 2100RPM)
LOW FUEL (20% & BELOW) 5 SECONDS
ANNUNCIATION:
AF CLOG 2 SECONDS
CHARGE FAIL 1 SEC: ON, 10 SEC: OFF
E&F1 FAIL 3 SECONDS
DC TRIP LEVEL
UNDER VOLTAGE
25V 20 SECONDS
24V 15 SECONDS
23V 12 SECONDS
22V 10 SECONDS
21V 8 SECONDS
20V 6 SECONDS
18V 4 SECONDS
16V 2 SECONDS
15V 1 SECONDS
14V & BELOW IMMEDIATE
OVER VOLTAGE
31V 10 SECONDS
32V 5 SECONDS
33V 2 SECONDS
34V & ABOVE IMMEDIATE
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OVER LOAD
0 - 500A NO TRIP
501 – 550A 1 HOUR
551 – 1000A 40 SECONDS
1001 – 1500A 12 SECONDS
1500 – 1600A 5 SECONDS
1601A & ABOVE IMMEDIATE
OVER LOAD IN ACDC MODE

100% NO TRIP
101-110% (224-246) 1 HOUR
111-125% (247-280) 5 MINUTES
126% (281 & ABOVE) 75 SECONDS
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4. SPECIFICATIONS:
AC SPECIFICATIONS:
AC Output : AC Output power provided with Power rating of 90 KVA 0.8PF
lagging.
Voltage : 115V (Line to Neutral) and 200V (Line to Line). (112 -118)
Volts under all load conditions.
Phase Diff : 120° + 1.5°
Voltage unbalance : a. 1% at Balance load
b. 4% with 0, 0, 33% load
Voltage regulation : +1.5%
Voltage modulation : + 1.5%
Voltage Transient (30% Load Changes): + 20% and recovery to within +1% of the
steady state value with in 200 milliseconds.
Crest Factor : 1.41 + 0.07

Total harmonic content. : Within 3%.
Frequency : 400 Hz
Frequency regulation : + 2 Hz
Frequency modulation : + 1%
Frequency Transient (30% Load Changes): 385 to 415 Hz and recovery to within +1% of
steady state value in less than 2 second.
Overload rating : 111 – 115 % load for 5 MINUTES, ABOVE 151% load
IMMEDIATE.
Output cable / socket : (i) AC cable with NATO 6Pin socket – 1 No
DC SPECIFICATIONS:
Output voltage / current : a) 28.5 V DC Nominal
b) 27.5 to 29.5 V DC at 400 A continuous
c) Peak load for engine starting up to 1500 Amps
Ripple Content : Less than 2% at rated load
Output Cable / socket : DC cable with 3-pin NATO socket – 1 No
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5. MAJOR COMPONENTS DETAILS

5.1. STARTER MOTOR
Make : BOSCH
Operating voltage : 24 V
Model : 0 001 231 005, 0118 0999KZ
Rotation : Clockwise
5.2. EMR
Make : DEUTZ
Model : EMR - II
Voltage : 24 DC
Qty : 1No
5.3. CHARGING ALTERNATOR

Make : DEUTZ
Model : AAK 1337
Volts : 14V / 35A
Qty : 1No
5.4. AC POWER CONTACTOR

Make : TELEMECANIQUE
Model : LC1 F265
Rating : 350 Amps (ITH)
Qty : 1 No
Coil:
Coil Voltage : 220/230V AC (40-400Hz)
Model : LX9 FH2202
Qty : 1 No
Add on Block for AC contactor:

Part no : LADN22
Type : 2 NO, 2 NC
Qty : 1 No
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5.5. LINE DROP COMPENSATION (LDC) RELAY

Make : FINDER
Part No : 62.33.9.024.00.40
Part No – Base : 92.03 SMA
Coil Voltage : 24V DC
Qty : 1 No
5.6. AC SOCKET ASSEMBLY

Make : ANDERSON AIRMOTIVE
Model : R67G100E
Length of Cable : 30 Feet
Qty : 1 No
5.7. DC SOCKET ASSEMBLY

Make : ANDERSON AIRMOTIVE
Model : R65GDS – 20M
Length of Cable : 30 Feet
Qty : 1 No
5.8. CONTROL CABLE (Control wiring inside Panel)

Make : R.J industrial
Type : 0.5 Sq. mm, 1.0 Sq.mm
Type : PTFE,Teflon
5.9. CURRENT TRANSFORMER (CT)

Make : KAPPA
Ratio : 400/1A
VA Rating : 5VA
Class : 1.0%
Qty : 4 Nos
5.10. BATTERY CHARGING AMMETER
Make : MURPHY
Size : 53mm Dia
Voltage : 12VDC
Range : 60 – 0 – 60A
Qty : 1No
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5.11. ANTI VIBRATION MOUNT

Make : ISO TECH
Type : IT-SB-10275; Shore Hardness: 60+5 A
Qty : 6 Nos (For Engine & Alternator mounting)
Type : IT-SW-1107040; Shore Hardness: 60+5 A
Qty : 4 Nos (For Contactor frame mounting)
5.12. BATTERY
Make : EXIDE / SF/ PRESTOLITE
Volts : 100AH - 12V
Qty : 2 No
5.13. OBSTRUCTION LAMP ASSEMBLY

Make : CURTIS
Model : Amber Color 12-80 V
Part No : 18435010
Quantity : 1 No
5.14. CABIN & PANEL LAMP ASSEMBLY

Make : ALTOS
Model : LED TYPE
Voltage : 24 V DC
Qty : 4 Nos
5.15. CORNER LAMP ASSEMBLY

Make : VASKO / YEMES
Type : WHILE LED
Model : MSIL – 12, ORANGE
Voltage : 24V DC
Qty : 4Nos
5.16. LINE DROP COMPENSATION (LDC) RELAY

Model : LC1 D09
Coil voltage : 24 V DC
Qty : 1 No
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5.17. SHUNT
Make : EIC
Rating : 3000A/ 75mV
Qty : 1No
5.18. POWER TRANSFORMER

Make : PROCON CONTROLS
Rating : 30KW
Primary connection : Delta
Primary voltage tapping : 0 – 200V – 208V – 215V – 223V
Secondary connection : Star – Delta
Secondary Star voltage : 14V (P-N)
Secondary Star voltage : 23V (P-P)
Qty : 1No
5.19. DIODE
Make : RUTTONSHA
Part no. : 600 V 100 (Normal)
Part no. : 600 VR 100 (Reverse)
Model : THREAD TYPE
Qty : 6 Nos, Normal & 6 Nos, Reverse
5.20. HEAT SINK

Make : MAK
Part no. : MAK 3DH
Qty : 4 Nos
5.21. BATTERY ISOLATOR SWITCH

Make : ALBRIGHT (CURTIS)
Rating : 125A continuous, 1000A Peak
Part no. : ED125
Qty : 1No
5.22. FUEL FLOAT

Make : Wema
Size : 12 inch SSS/SSL
Qty : 1no
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5.23. FIRE EXTINGUISHER
Make : TERMINATOR / HITECH

Type : ABC
Capacity : 2 Kg
Qty : 1 No
5.24. TOGGLE SWITCH

(Obstruction, Cabin, Panel Lamp Switches & INT/BYP1, ALARM On/Off)
Make : OTTO CONTROLS
Part No. : T7-231A5
Type : DPST
Qty : 5 Nos
Speed Increase/Decrease Switch :
Make : OTTO CONTROLS
Part No. : T7-231E5
Type : DP Momentary On-Off-On
Qty : 1 No
5.25. ALARM
Make : ROOTS
Voltage/ watts : 24 V DC / 48W
Qty : 1 No.
5.26. FINDER RELAYS

Make : FINDER
Voltage : 24 V DC
Base : 94.74
Qty : 7 Nos
RLTIMER:
Make : FINDER
Voltage : 24 V DC, 4 C/O
Relay Part No. : 85.04.0.0.012.0000
Qty : 1 No.
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RLIDLE/RUN, RLALARM, RLFLASH, RLACCON1, RLDCCON:
Make : FINDER
Voltage : 24 V DC, 4 C/O
Relay Part No. : 55.34.9.012.0074
Qty : 6 Nos
5.27. FUSES (Thermal Circuit Breakers – Push to Reset):

Make: : TYCO
Model : W 58 series
Amps Ratings : 30
Part No. : W58-XB1A4A-30
Qty : 2 Nos
Amps Ratings : 20
Qty : 1 No
Amps Ratings : 15
Qty : 1 No
Amps Ratings :5
Qty : 3 Nos
Amps Ratings :2
Qty : 1 No
5.28. AVR FIELD TRANSFORMER

Make : MAK
Rating : 1 KVA
Primary Voltage Tapping : 0 – 115 – 135 – 150V
Secondary Voltage : 0 – 50 – 85 – 94 – 100 – 108V
Qty : 1No
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5.29. DC POWER CONTACTOR
Make : ABB
Model : AF95-30
Rating : 95 Amps
Coil voltage : 200V DC
Qty : 1 No
5.30. ADDON BLOCK FOR LDC CONTACTOR:

Part no : LADN 04
Type : 4 NC
Qty : 1 No
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GENERAL ARRANGEMENT DRAWING
1700mm(UNIT WIDTH)
1827mm(GROUND SURFACE TO CANOPY TOP) 2550mm(CANOPY LENGTH) 1100mm
1925mm(UNIT HEIGHT)
170mm(GROUND CLEARENCE)
3056mm(UNIT LENGTH WHEN TOWBAR FOLD CONDITION)
4057mm(UNIT LENGTH WHEN TOWBAR UNFOLD CONDITION)
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CHAPTER II
OPERATION
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CHAPTER II
OPERATION
1. GENERAL
The alternator is driven by Engine through flexible coupling. The output of the alternator
is connected to aircraft through contactors, current transformers, cable assembly and
socket.
Functionally, the system output is fine tuned for voltage and frequency regulations.
These two functional parameters in principle are achieved through:
I. Alternator delivers constant voltage irrespective of load conditions by virtue of design

of automatic voltage regulator (AVR).
II. Emr Controller for speed, frequency regulation and safety aspects of ENGINE.
For more details, Please refer corresponding manuals.
2. PRE COMMISSIONING CHECKS
 Check the foundation bolts of the engine and alternator for firm mounting.
 Check the bell housing bolts and nuts for their uniform tightening.
 Ensure diesel availability in the tank.
 Check the engine oil level.
 Check for any loose wires & PCB fitment.
 Check the output cable terminals and contactors for their proper disposition.
 If the batteries are not connected before delivery, the same may be connected.
 Check for the output cable socket is in its proper place (Cable Stowage).
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3. DO’S AND DON’T’S:
DO’S
Kindly study the Operation and Maintenance manual in detail:
 Only authorized person should handle the system and operate the GPU strictly as
per the operating instructions in the manual.
 Check the fuel availability in the tank before starting the system.
 Engine oil level should be checked before the 1st start of the unit on every day.
 Free passage at air intake is to be ensured.
 Ensure availability and condition of fire extinguisher always in the GPU.
 Engine should be allowed to run at normal speed in no load condition before
shutting off.
 In case of deficiency in the output parameters, only authorized person should go
through the trouble-shooting chart for any adjustments.
 Any adjustment in the system should be done with the help of the Manual and
detailed circuit diagram.
 Ensure battery is always in charged condition and disconnect the same if there is
any welding to be carried out on the GPU.
 Ensure use of correct tools, calibrated instruments and proper spares.
 Ensure proper maintenance as per manual.
DON’T’S
 Never fill the fuel tank when the GPU is running.
 Unit should not be shifted in running condition.
 Never plug in the output cable to the aircraft before the system is started and
before reading the correct parameters.
 Never bypass any protection system for starting the unit, without correcting the
fault.
 Never open the coolant cap when engine is hot / running condition.
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4. OPERATING INSTRUCTION:
STARTING OF GPU
 Switch ON the Battery Power by Pulling out the “BATTERY ISOLATOR”

 Ensure that the “EMERGENCY STOP PUSH BUTTON” in released position
 Switch on the “Power ON SWITCH” and wait for “SYSTEM READY TO START”
message on MAK GSE MONITOR V8. If any fault indication in MAK GSE
MONITOR V8 display, rectify the fault then wait for “READY TO START” message
 Touch the “ENGINE - START” icon in MAK GSE MONITOR V8 display to start the
Engine. Once the Engine is running MAK GSE MONITOR V8 will display Engine
and Alternator parameters
POWER ON CHECKING
AC POWER
 Check for proper voltages in all the three phases in MAK GSE MONITOR V8
 Select the required mode AC or AC/DC in MAK GSE MONITOR V8.
 Select the required mode BYPASS or INTERLOCK in MAK GSE MONITOR V8.
 Touch the “AC PWR ON” icon in MAK GSE MONITOR V8 to switch ON the AC
POWER contactor.
Control Action:
 In Bypass mode regardless of E & F signal the contactor will hold when the
contactor on switch is pressed in MAK GSE MONITOR V8 screen
 In interlock mode contactor will hold only if E & F signal is available
 Select the required mode through BYPASS /INTERLOCK icon provided in the
MAK GSE MONITOR V8 screen
Note: In Bypass / Interlock mode after plugging the connector to A/C and the output
contactor is switched ON, the display will indicate the following:

“CHECK PLUGGING OR E & F “if the E & F Signal 28V is not available.

“AWAITING SEL FROM AIRCRAFT “if E & F signal 28V is available. The display will
automatically reset when power starts flowing from the ground power.
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DC POWER
 Select the required mode DC or AC/DC in MAK GSE MONITOR V8.

 Touch the “DC PWR ON” icon in MAK GSE MONITOR V8 display to switch on DC
power.
 Touch the “DC PWR OFF” icon in MAK GSE MONITOR V8 display to switch off
DC power.
POWER TO AIRCRAFT
 Plug the required AC / DC output socket to the Aircraft receptacle and switch 'ON'
the respective powers.
GPU POWER OFF PROCEDURE
 Touch the “AC/DC PWR OFF” icon in MAK GSE MONITOR V8 display to switch
OFF the AC/DC POWER contactor
 Disconnect the output socket from the aircraft receptacle and place it in respective
cable stowage.
 Run the GPU on NO LOAD at least 5 minutes, after switching “OFF” the
contactor.
GPU SHUTTING OFF
 Touch the “ENGINE-STOP” icon in MAK GSE MONITOR V8 display to stop the
Engine. Shut down count begins to automatic shut down.
 The engine will run on Idle Speed for pre-defined time and then it will
automatically switch OFF.
 Switch OFF the BATTERY ISOLATOR.
Note: In case of any Emergency Shut off, hit the “EMERGENCY OFF” mushroom
actuator on the GPU Control panel.
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5. CAUTION:
 REFER MANUAL / OPERATING INSTRUCTION BEFORE UNIT IS PUT IN TO
OPERATION.
 ONLY AUTHORIZED PERSONS CAN HANDLE.
 CHECK ENGINE OIL, COOLANT, FUEL AND BATTERY VOLTAGE BEFORE

START.
 CHECK THE BATTERY DISTILLED WATER LEVEL AND TOP UP IF

REQUIRED.
 DO NOT SHUTDOWN ENGINE WITH LOAD.
 DISCONNECT THE BATTERIES IF THERE IS ANY WELDING TO BE CARRIED

ON THE GPU.
 FIRE EXTINGUISHER SHOULD BE IN CONDITION.
 ENSURE THAT THE STARTING KEY AND BATTERY ISOLATOR ARE IN OFF
POSITION WHEN THE UNIT IS NOT IN USE.
Page 6
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6. MAK GSE MONITOR V8 DESCRIPTION: -
The MAK GSE MONITOR V8 control panel consists of touch screen display and other
control accessories.
A) ENGINE SECTION: -
The MAK GSE MONITOR V8 displays the following engine parameters & protections
through Touch Screen display (LCM).
ENGINE PARAMETERS: -
i) Oil pressure (OP): Engine Oil Pressure will be taken from Oil Pressure Sensor. It is
processed and displayed by MAK GSE MONITOR V8. Oil Pressure readings in ‘Bar ’.
ii) Coolant temperature (CT): Engine Coolant Oil Temperature will be taken from
PT1000 RTD sensor. It is processed and displayed by MAK GSE MONITOR V8. Engine
Coolant temperature readings in ‘° C ’.
iii) Fuel Level: A fuel float is attached with fuel tank, which is used to sense the Fuel
Level. Fuel float movement will cause variation in resistance and the values will be
Processed and displayed by MAK GSE MONITOR V8. Fuel level readings in ‘% ’.
iv) Battery Voltage (BV): Voltage sense taken from batteries will be displayed and
ensures battery is in charge condition in MAK GSE MONITOR V8. Battery voltage
reading is in ‘Volts’.
v) RPM: Engine RPM has been taken from Frequency and converted into Speed and
displayed on MAK GSE MONITOR V8.
vi) Engine Running Hour: Engine running hours can be displayed on the MAK
GSE MONITOR V8.
Page 7
RESTRICTED

ENGINE PROTECTIONS: -
i) LOW ENGINE OIL PRESSURE (LOW E. OIL PR.): A pressure switch is provided to
protect the Engine from the low oil pressure. If the pressure goes down to less than 1.5
bar then the ‘NO’ contact of the switch will be closed, which in turn switch “OFF” the
engine with “LOW E. OIL PR.” fault indication in MAK GSE MONITOR V8. During engine
cranking this fault is ignored by software interlock.
ii) HIGH COOLANT TEMPERATURE (HCT): If the engine coolant temperature is more
than the specified level, the NO contact of the switch will be closed, which in turn switch
“OFF” the engine with “HI. COOL. TEMP” fault indication in MAK GSE MONITOR V8.
iii) LOW COOLANT (LC): If the coolant level is too low, the ‘NO’ contact will be closed,
which in turn “ off ” the engine with indication of “ LOW COOLANT “ fault in the MAK
GSE MONITOR V8.
iv) OVER SPEED (OS): When the engine RPM exceeds safe operating speed, the
engine will shutdown with “OVER SPEED” indication.
v) CHARGE FAIL (CF): This is detected by sensing the voltage from charging alternator
terminal D+. If the voltage is not available in running condition then “CHARGE FAIL” fault
will be displayed in MAK GSE MONITOR V8. This faults will not shutdown the engine.
vi) LOW FUEL (LF): If the fuel level is less than 20% “LOW FUEL” fault indication will be
displayed in control panel and the corner lamps will start to flash. When the fuel level
goes to 10% level, the engine will be tripped OFF with LF fault.
vii) AIR FILTER CLOGGING (E AF CLOG): If the air filter in engine clogs due to excess
dust in the filter, the NO contacts in the switch will close MAK GSE MONITOR V8
displays “AIR FITER CLOG “fault indication. The output will not shut down the engine.
Page 8
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SPECIAL FEATURES:
a) Auto Inhibition OF LP:
The GPU operation is single key operation, which means there is no need to inhibit on
existing fault such as LOW OIL PRESSURE during starting. The software driven micro
controller system automatically inhibits the fault and enables the RLEF relay once the
cranking is sensed. This delay is bypassed only during the cranking period for about 5
Sec. Only “LOW OIL PRESSURE” is ignored during cranking and if there are any other
faults, then the engine cannot be cranked until the fault is cleared.
b) Protection of engine cranking during engine run:

The starter motor actuating through the engine starter relay “RLS” and RLS relay
controlling by starting key through RLEF relay. Start button in LCM itself will not allow
going to start mode once the engine is cranked.
c) Speed Adjustment:
Using this speed adjustment switch provided on the EMR, the engine RPM can be
increased or decreased in sequence.
d) Engine switch off by pre-defined time (optional)

After switching off the units through Stop button, the unit will continue to run for a pre-
defined time of 5 seconds.
e) Bypass / Interlock Mode selector switch:

User can select BYPASS or INTER LOCK mode in desired AC POWER by using
BYP/INT Mode selection button provided in the Touch screen display.
The AC POWER Contactor can be switched ON in the following manner:

i) Bypass Mode: In this mode the AC POWER Contactor can be Switched ON / OFF by
pressing the AC PWR ON / OFF button.
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ii) Interlock Mode: In Interlock mode the AC POWER Contactor will not hold when the
Sensing voltage 24VDC (at Aircraft socket terminals E & F) is not provided. i.e., while
pressing the button the contactor will be energized and when it is released the Contactor
will be switched OFF. When 24VDC sensing is provided, the contactor will hold when AC
PWR ON/OFF button is pressed and contactor can be switched OFF either by pressing
the AC PWR ON/OFF button again or by disconnecting / removing the sensing voltage
24VDC.
B) OUTPUT SECTION:
All parameters are monitored, displayed and appropriate protection is activated by
centralized micro controller based control system. All engine parameters, output three
phases voltage, three-phase current, O/P frequency and phase rotation, are sensed
through digital circuit’s, which provides better reliability and accuracy. Liquid Crystal
Monitor(Touch Screen display) are provided for monitoring voltage, current, frequency,
fault annunciations of the AC/DC output and Engine parameters.
METERS:
AC SYSTEM:
Voltage : 0 - 175V Line to Neutral or 0 – 300V Line to Line
Current : 0 - 400A
Frequency: 0 - 999 Hz
PROTECTIONS:
Over voltage (OV)
Under voltage (UV)
Over load (OL)
Over frequency (OF)
Under frequency (UF)
Phase reversal (PR)
Page 10
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DC SYSTEM:
Voltage : 0 - 35V
Current : 0 - 3000A
PROTECTIONS:
Over voltage (OV)
Under voltage (UV)
Over load (OL)
OPERATING CONTROLS:
I. MAK GSE MONITOR V8:
Liquid Crystal Monitor(LCM) are provided to indicate Engine parameters, AC Parameters
and DC Parameters, Fault log, Faults and Engine Maintenance.
II. Touch Screen Display:
a). START:
When pressing the Start button, engine can be cranked if there is no fault. The supply
from this terminal is taken through starter interlock relay RLST, engine fault relay RLEF
(for disabling engine cranking if there is any existing engine faults) and actuates starter
relay RLS. This relay in turn actuates starter solenoid there by energizing starter motor.
b). STOP:
When pressing the Stop button, engine can be stopped.
c) AC PWR ON / OFF KEY:
When pressing the AC PWR ON Button, energizes the output contactor so that the
power is available at the socket end, if the GPU is running under normal condition. Again
by pressing the AC PWR OFF Button the supply link of the contactor coil supply is
broken there by de-energizing the contactor.
Page 11
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d) DC PWR ON / OFF KEY:

When pressing the DC PWR ON Button, energizes the output contactor so that the
power is available at the socket end if the GPU is running under normal condition. Again
by pressing the DC PWR OFF Button the supply link of the contactor coil supply is
broken there by de-energizing the contactor.
e) OUTPUT CONTROL:
This button is used to switch the display to another screen. On that screen we select the
modes like AC, AC/DC, DC and also we can power on the ac and dc contactors.
f) FAULT RESET:
The control system latches the fault that occurs during operation. In order to clear this
fault after attending the failure the user has to press this RESET Button.
III. CONTROL PANEL:

The Control panel consists of the following comprises.
a) ILLUMINATION SWITCHES:
1. Obstruction lamp switch.
2. Panel On switch.
b) Liquid Crystal Monitor (LCM):

Touch Screen Display used to Control the unit and also monitor the parameters
and Faults.
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c) Emergency Push Button:

This Button is used to switch off the entire power supply to the MAK GSE MONITOR V8.
IV. CONTROL FUSES:

These fuses are connected series with the circuit. It will protect the control circuit from
short circuit and over current operation.
Page 13
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MAK GSE MONITOR V8 WIRING DIAGRAM
PANEL
CN4 EMERGENCY STOP ON/OFF SWITCH
COMMON ALL 1 AND GND
4 4 8 8A EARTH
A HAS TO BE SHORTED
1 1
B
8A
D
OBSTRUCTION
LAMP SWITCH
47 8B D1
CN1 DETAILS
8A
CN2 DETAILS
1
C
FR606 26 PIN SOURIAU CONNECTOR 26 PIN SOURIAU CONNECTOR
CN2
4
1
3
2
D38999-20W-E-26-PN D38999-20W-E-26-PN
CN1 CN14
CN1
GND
12V
GND
12V
61 61 SI NO PIN NO FERROL NO SI NO PIN NO FERROL NO
1 UNREG R PH 1 A
CN2 2 GROUND AC VOLTAGE Y PH 2
62 62
B 1 A 61 1 A 92
92 92 SENSE 63 63
AC CON1 SENSE B PH 3 C 115
A 3 DI1 2 B 62 2 B
44 44
115 DC CON SENSE 115 N 4 D
B 4 DI2 51 51 3 C 63 3 C 93
93 AC CON2 SENSE 93 RCT_P 5 E
C 5 DI3 52 44 29
4 D 4 D
29 LOW COOLANT LEVEL SENSE (LC) 29 RCT_S 6 F
D 52 53
6 DI4 YCT_P 7 G 5 E 51 5 E 22
22 LOW OIL PRESSURE (LOP) 22 57
DIGITAL INPUT (DI)

E 7 DI5 YCT_S 8 H
AC CURRENT 6 F 52 6 F 21
21 HIGH COOLANT TEMPERATURE (HCT) 21 SENSE 53 1
F 8 DI6 BCT_P 9 c
26 AIR FILTER CLOG SENSE (AFC) 26 119 7 G 53 7 G 26
BCT_S 10 J
G 9 DI7 111
27 27 57 8 57 8 27
AVR ON SENSE (OPTIONAL) NCT_P 11 K H H
H 10 DI8 1
17A D+ SENSE 17A NCT_S 12 9 J 119 9 J 17A
J 11 DI9
D7 RESERVE D7 10 K 111 10 K D7
K 12 DI10 CN16
73 E&F1 SENSE 73 119
13 DI11 DC VOLTAGE DC +VE 1 11 L 20 11 L 73
L
74 E&F2 SENSE 74 SENSE
DC -VE 2
111 CN2
MAK PCB 553B

M 14 DI12 109 12 M 12 12 M 74
109
DC CURRENT SH +VE 3 N
SENSE 120 120 13 N 58 13 N 109
SH -VE 4 P
DCR +VE 5 14 P 31 14 P 120
DCR -VE 6 15 R 114 15 R 23

CN15 NOT USED
23 ENGINE OIL PRESSURE SENSE (+) 23 DCF +VE 7
R 1 AI 1P 16 S 32 16 S 1A
1A ENGINE OIL PRESSURE SENSE (-) 1A DCF -VE 8
S 2 AI 1N 17 T D1 17 T 24
ANALOG INPUT (AI)

25 FUEL LEVEL SENSE (+) 25
V 3 AI 2P CN3 18 U 84 18 U 1B
1C FUEL LEVEL SENSE (-) 1C
W 4 AI 2N UNREG 1 19 V 56 19 V 25
T
24 ENGINE COOLANT TEMPERATURE SENSE (+) 24
5 AI 3P GROUND 2
CN1
20 20 W 116 20 W 1C
1B ENGINE COOLANT TEMPERATURE SENSE (-) 1B 20 RLEF
U 6 AI 3N DO1 3 L
D8 D8 12 12 21 X 94 21 X D8
RESERVE RLST
X 7 AI 4P DO2 4 M
D9 RESERVE D9 58 RLI/R 58 22 Y D2 22 Y D9
Y 8 AI 4N DO3 5 N
31 RLAC1 31 23 Z 90 23 Z D10
DO4 6 P
114 RLDC1 114 24 88 24 D11
DO5 7 R
a a
32 RLAC2 32 1
DIGITAL OUTPUT (DO) & PWM

DO6 8 S 25 b D3 25 b
D1 RLDC2 D1
DO7 9 T 26 c 1 26 c D12
ANALOG OUTPUT (AO)
84 RLALARM 84
CN13 DO8 10 U
D10 RESERVE D10 56
Z 56 RLFAULT
1 AO1 DO9 11 V
D11 RESERVE D11 116
a 116 RLBLEED
2 AO2 DO10 12 W
1 RESERVE 1 94 94
b 3 GND RLCF
DO11 13 X CN3 DETAILS
CN4 DETAILS
c D12 D2 RESERVE D2
DO12 14 Y 4 PIN SOURIAU CONNECTOR 10 PIN SOURIAU CONNECTOR
90 RLLDC2 90 D38999-20W-11-04-PN D38999-20W-C-98-PN
DO13/PWM1 15 Z
88 RLLDC3 88
DO14/PWM2 16 a SI NO PIN NO FERROL NO SI NO PIN NO FERROL NO
D3 RESERVE D3
DO15/PWM3 17 b 1 A 4 1 A 1
D4
DO16/PWM4 18 2 B 1 2 B B
A
RS485 - (A)
47
RS485_ (B)
3 C 3 C
GROUND
RXD_232
TXD_232
UNREG
CN10
4 D 8A 4 D CH
1 CANH
CANL
USB 5 E CL
CN4
8A
CN8
6
5
4
3
2
1
6 F 1
CH
C2
CL
U3
C1
U1
U2
A
1
B
1
8A 7 G U1
Vin
CN3
1 8 H U2
K
C2 U3 9 J U3
RX J
RS232
U3 10 K 1
H
C1 U1
HMI TX G
1
Touch Screen F
A CL
A E
RS485
CH
D
B A
B C
B
B
1 1
GND A
CN1 - 26PIN SOURIAU CONNECTOR

PCB 553B - MCU THYRISTOR BOARD
Page-14
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POWER MODULE WIRING DIAGRAM
CN5 CN7
61 61
A A SW1 FST01
62 62 62 62A F1 62B 75
SY PY
B B 135V 70V
63 63 3A
C C 65V
64 64 115V 60V
D D 64 76
67A 67A SW2 0V 0V
e e
67B
f
F1A
E
F2
F
3
G
M1 10E/300W R1
H
M2
I
A1
J
F1
F2
61
62
63
44
62
44
75
76
A2
200E POT
CN1
K 1 2 3 4 5 6 7 8 9 10 11 12
66 SW4
L
AUX1
FAC1
F1
N
B
DC +VE
DC -VE
C
AUX2
FAC2
F2
A
M
47 SW5 1
P
N 2
17A AVR CARD
CN4 P PCB NO: 299B
1 1
U U
CN3
1
A R
B B
B S
A A
C T
CN5
33 33
a a
RLG1 RLG2
1 33 33 1
2C SW3
3 F2 3A 33A 33C 33C
10A 33D
33B
CN1 CN2
P 17A
1 1
2 BRIDGE CARD 2
CN1 CN2
33D
M1
M2
1 1
A1
A2
1
3 PCB NO: 249 3 33A 33B
1 1 1 DC-DC 1
4 4 1 2 3 4 5 6 7 8
2 CONVERTER 2 + - +VE -VE
1 1A
3 PCB No:573 3
MPU
VOLTAGE
VOLTAGE
SPEED
BATTERY
ACTUATOR
8A
GOVERNOR
CN4
1 8A 8A
4 1 A
A
5 2
MWM Card
PCB NO:552
SW1 - AVR ON/OFF SWITCH

SW2 - ALARM ON/OFF SWITCH
SW3 - BATTERY/DC TO DC CON SELECTOR SWITCH
SW4 - PANEL LAMP ON/OFF SWITCH
SW5 - CABIN LAMP ON/OFF SWITCH
RLG1, RLG2 - OEN 741-24-1C
POT - 200? POTMETER
CN7 - 35PIN ALLIED CONNECTOR
Page-15
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DC BRIDGE WIRING DIAGRAM
119
D1 D2 D3 D4 D5 D6
DC POWER TRANSFORMER
PY SY
BLEEDCON1
A 0
200
208
215
223
FROM B 0
DCCON 200
208
RESISTOR
BLEEDER
215 DC OUTPUT SOCKET
1KW
223
POSITIVE
C 0
D7 D8 D9 D10 D11 D12
200
208
SHUNT 111 NEGATIVE
215
223
109
120
+ +
C1 C2
- -
+22000MFD/100V
CN1
119 119 119
2 J
111 111 111
1 K
CN2
120 120 120
3 P
109 109 109
FAN 1 4 N
B
119 RED
CN1 119
119
120
120
120
D5
D1
D2
D3
D6
120 BLACK
D6D12 10
+VE 1
+VE 2
-VE 3
-VE 4
5
D2D8 6
D3D9 7
D4D10 8
D5D11 9
D1D7
FAN 1
119 RED
SNUBBER CARD
PCB NO: 240A
120 BLACK
BLEEDCON - BLEED CONTACTOR

CN1 - 26 PIN SOURIAU CONNECTOR
CN2 - 26 PIN SOURIAU CONNECTOR
CN5 - 35 PIN ALLIED CONNECTOR
FAN1, FAN2 - COOLING FANS FOR TRU (24V)
SHUNT - DC SHUNT (2000/75mV)
WC1 - SINGLE WAY WAGO
Page-16
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ENGINE SIDE WIRING DIAGRAM
17A
CN7 BI CN4
P 2B 2A F1 3 F1 4
N A A
17A 30A 30A
P B
STARTER MOTOR
67B 67B +
F 12V
1 BATTERY
3 -
ALARM
G
M1
b
M2 MPU
c
A1
J
A2 ACTUATOR
K
66 L1
L
47 L2
M 1
CN2
29 LC
D
22 22 LOP
E
21 HCT
F 1
26
G TO ENGINE AFC L1 - PANEL LAMP
23 L2 - CABIN LAMP
ENGINE OIL PRESSURE SENSOR
R L3 - FAULT LAMP
L4 - OBSTRUCTION LAMP
1A LC - LOW COOLANT
S LOP - LOW OIL PRESSURE
23 HCT - HIGH COOLANT TEMPERATURE
COOLANT TEMP SENSOR
T
1B
U
24 FUEL FLOAT
V
1C
W
CN5 L3
66
d
L4
47
b 1
Page-17
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CONTACTOR PLATE WIRING DIAGRAM
5
RLLDC1
ACCON1
1 91
CN1 CN5
61 61 61 67
A A
41
62 62
B B 62 68
63 63
C C 42 41 42
DCPWRCON
63 69 RLDC1
D D
90 43 41A 42
90 90
Z E
A A1
F
G POWER B B1 ACCON1
51 51 TXR INPUT INPUT
E H C C1
52 52
F L
53 53
G J
54 54
H K 8A
20 20 RLEF
L M
12 12 RLST
M N
31 31 RLAC1
P P 5
BLEEDCON1
R 117
84 84 RLALARM 1
U S
56 56 RLFAULT
V T
94 94 RLCF
X U
58 58 RLLAMP 28
N V ACCON1
116 116 RLBLEEDER
W W 28 1
114 114 RLDC1
R X 41 67
OUTPUT SOCKET
A
Y
42 68
B
CN2 43 69
C
51
S1
92 92 AC CON1 ON SENSE AC CON1 1
CT1
A F
N
S2
C G 5 52
S1
13 RLST
CT2
Z
33
S2
RLEF
a
47 53
S1
RLLAMP
b
CT3
17A FR606 D14 17 RLCF
S2
c 54
S1
66 RLFAULT
CT4
d
67A
S2
RLALARM
e RLAC1 - AC1 CONTACTOR CONTROL RELAY
1
117 RLBLEEDER RLALARM - ALARM RELAY
f
RLCF - CHARGE FAIL RELAY
g DC1
RLEF - ENGINE FAULT RELAY
h DC1 RLF - FAULT RELAY
j DC2 R Y B RLLAMP - RL LAMP RELAY
RLLDC1 - LINE DROP COMPENSATION RELAY 1
k DC2
73 73
RLST - STARTING INTERLOCK RELAY
L 1 EMI FILTER RLBLEEDER - BLEEDER RELAY
74 74 RLDC1 - DC1 CONTACTOR CONTROL RELAY
M 2 CN4
8A 8A PWC - POWER WAGO CONNECTOR
3 D R Y B
5 F5 4 WC1 - WAGO CONNECTOR
4 A FILTER 1,2, 3 & 4 - 115V AC, 400Hz, 150A
1 15A 1
5 B EMI FILTER - 150A, 400Hz, MF423-3-3D-B5
SUPPRESSOR - 220V AC, 400A, RF1-RC-4
WC1 ACCON - 265A CONTACTOR, LC1-F265
EMI FILTER
CN7
FILTER1
DCPWRCON - 200A CONTACTOR, AF95-30

FILTER2
FILTER3
FILTER4
F1A BLEEDCON1 - BLEEDER CONTACTOR, LC1-D80

E
F2 CN5 - 35PIN ALLIED CONNECTOR MALE & FEMALE
F
ALTERNATOR
R PHASE
R
Y PHASE
F1A
Y RF1
FIELD 1
B PHASE SUPPRESSOR
GS
F2
B
FIELD 2 NEUTRAL
N
Page-18
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CHAPTER III
MAINTENANCE AND
TROUBLE SHOOTING
RESTRICTED CHAPTER - III

Page 1
RESTRICTED

CHAPTER – III
A. MAINTENANCE SHEDULE FOR ENGINE

Page 2
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MAINTENANCE SCHEDULE FOR MAK GPU’S
DAILY MAINTENANCE CHECKS:

 Check the Battery voltage.
 Check the Battery terminal tightness.
 Check the engine oil level.
 Check the Diesel level.
 Check the serviceability of all lamps.
 Check the fuel pipelines for any leakage.
 Check the Oil pipelines for any leakage.
 Check the exhaust pipe for any leakage.
 Check the GPU output parameters.
WEEKLY MAINTENANCE CHECKS:

 Do the daily maintenance checks.
 Check the wiring for any loose contact. And also check the wiring tightness at the
power contactors input and output terminals
 Apply the petroleum jelly on battery terminals.
 Check all switches / push buttons for serviceability.
 Check the engine coolant level and top up if required.
MONTHLY MAINTENANCE CHECKS:

 Do the weekly maintenance checks.
 Apply the grease in trailer assembly wherever required.
 Check all nuts, fasteners and mounting accessories for rigidity in engine.
 Check the alternator mounting bolts and tighten if necessary.
 Clean all the major components of the GPU by blowing clean and dry compressed
air.
 Check all fuse element for serviceability and replace if necessary.
 Check all electrical components mounting for rigidity.
 Check all PCB’s mounting for rigidity.
 Check and Clean the Air filter elements.

Page 3
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AT 500 HRS:
 Change the lubricating oil and oil filter element at every 500Hrs or once in 06
months whichever is earlier.
 Change the Fuel, Water Separator filter elements at every 500Hrs or once in 06
months whichever is earlier.
 Check the fan belt and charging alternator belt for proper tension and alignment. If
wear and tear observed replace the belt.
 Clean the Alternator with dry compressed air.
AT 1000 HRS:
 Do the 500 hrs servicing.
 Replace the air filter elements.
 Clean the charge air cooler and Radiator.
 Check all the fuel pipelines and replace if required.
AT 1500 HRS:
 Do the 500 hrs servicing.

 Adjust the engine valve clearance if necessary.
AT 2000 HRS:
 Do the 500 and 1000 hrs servicing.
 Check cooling system bearing and replace if necessary.
 Replace the coolant liquid or once in two years which ever is earlier.
 Replace all V belts after 2000 Hrs or once in Two years.
 Replace all fuel lines after 2000Hrs or once in Two years.

Page 4
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AT 3000 HRS:
 Do the 500,1000 and 1500 hrs servicing.
 Replace the injection valve.
AT 6000 HRS (Partial Repair):
 Check the Compression pressure and repair if damaged.
 Check the Injector pressure and repair if damaged.
 Check the Fuel injection pump and repair if damaged.
AT 12000 HRS (Major Repair):
 Dismantling of complete engine and assembling the same with the new
components, which have been damaged due to wear and tear for engine.
 Replacement of main and connecting rod bearing, all shaft seals, piston rings,
inlet and exhaust valves etc.
“For more details on engine service refer Deutz Engine manual”.

Page 5
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2. TROUBLE SHOOTING
INTRODUCTION:
It is strongly recommended to go thoroughly all the chapters and sections of Operation &
maintenance, Engine, Alternator, EMR, AVR & Illustrated Parts catalogue manuals
before attending to any of the problems.
Much care is taken to present the Trouble shooting chart, so that, it is easy to follow for
the user.
The trouble-shooting chart handles all each sections. However there can be link for any
specified fault from one section to another. So we recommend the user to study the
trouble-shooting chart thoroughly before coming to the conclusion.
It is assumed that the person attending the trouble is a qualified engineer.
EQUIPMENT FOR TROUBLE SHOOTING
There are certain equipments necessary for servicing the unit as listed below:
i) Digital multi meter (true RMS) Capable of reading AC voltage/DC voltage, Frequency,
Resistance etc.
ii) Clamp-on ammeter range: 0-800 AC.
iii) Continuity tester
iv) Digital storage oscilloscope 100 mhz
v) Phase sequence meter
vi) AC Load bank up to 100KW
Problems and solutions are given in this section. However the user is advised to go
through the illustrated parts catalogue for any specific components / sub - assembly for
details description and understanding.
WARNING
Qualified Electrical Person Must Conduct The Following Test. Lethal Voltage May
Be Present At Both The Generator And Voltage Regulator Terminals During This
Procedure. Caution Must Be Exercised Not To Come Into Personal Contact With
Live Terminals Link, Or Studs. Serious Injury Or Death Could Result.

Page 6
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TROUBLE SHOOTING CHART
TROUBLE,
Sl. TEST, CHECK, AND / OR
no SYMPTOM AND PROBABLE CAUSE
REMEDY
CONDITION
1 No Display found in Step a: Check 24/12V w.r.t GND i.e
Control panel. LCM Display connection ferrule no.8A in PCB wago
may be faulty. connector. If voltage is
Note: available then precede step.
If not, check with the
Ensure Master Key is connection
in “ON” condition.
Step b: Check 24/12V w.r.t GND on
Ensure F3 circuit Circuit Breaker – F3 may “circuit breaker (F3)” output
breaker is in healthy be Faulty. (Ferrule No.4). If Voltage is
condition. available then precede step
d. If not, check with F3.
Ensure Panel
ON/OFF switch in
“ON’ Position. Step c: Check 24/12V w.r.t GND on
Souriau Connector “CN4 Souriau connector
*Ensure the circuit Connection – CN4 may be “(Pin no. A w.r.t pin no B). If
breaker is reset- Faulty. Voltage is available then
table. If it reset’s then precede step c. If not, check
it gets projected with Souriau connector
towards else been connection male / female.
found to be surface.
Step d: Check 24/12V w.r.t GND on
Emergency stop may be “Emergency stop “i.e.
Faulty. Ferrule No.8 If Voltage is
available then precedes
step e. If not, check with the
connection.
Step e: Check 24/12V w.r.t GND on

Panel ON/OFF switch may “Panel ON/OFF switch” i.e.
be Faulty. Ferrule No. 8A. If voltage is
available then precede step.
Step f: Check 24/12V w.r.t GND i.e.

PCB No: 553B ferrule no.8A in PCB wago
connections may be connector. If voltage is
Faulty. available then precede step.
If not, check with the
connection.

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.
Step g: Check 24/12V in battery
Master Key may be Faulty. points w.r.t GND, if voltage
is available then check for
12V in output of master key
w.r.t GND i.e. ferrule No.3 If
voltage is available precede
step b. If not check with
Master key.
Ensure Master Key is in
“ON” condition.
2 Notable crank the

Engine. Step a: Check 12/24V w.r.t GND on
RLEF Relay may be faulty. Relay changeover point
Check there should Ferrule No. 12A, If voltage
not be any Engine is available then precede
Faults. (Ensure next step. If not, check with
RLEF Relay is in ON relay and connection.
Condition) (Before that ensure RLEF
should be in ON condition.)
Note: Check 24/12V w.r.t GND on

Ensure Master Key Step b: Relay changeover point
is in “ON” condition. RLST Relay may be faulty. Ferrule No. 13, If voltage is
available then precede next
Ensure Battery step. If not, check with relay
Charge Condition. and connection.
Ensure Circuit Check 24/12V w.r.t GND on

Breaker F2, F6 is in Step c: CN2 Souriau connector”
healthy condition. Souriau connector (pin no. M, L). If Voltage is
connection – CN1 may be available then precede
Ensure Panel Faulty. step f. If not, check with the
ON/OFF Switch Souriau connector
should not be crank connection male / female.
previously.
Check 24/12V w.r.t GND on
Ensure the fuel level Step d: CN6 Souriau connector”
and its necessary Souriau connector (pin no. E, N). If Voltage is
condition. connection – CN5 may be available then precede
Faulty. step f. If not, check with the
Souriau connector
*Ensure the circuit connection male / female.
breaker is reset-
table. If it reset’s

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then it gets projected Check 24/12V w.r.t GND on

towards else been Step e: Relay changeover point
found to be surface. RLST Relay may be faulty. Ferrule No. 13B & 13C, If
voltage is available then
precede next step. If not,
check with relay and
connection.
Check 24/12V w.r.t GND on

Step f: “Starter motor solenoid coil”,
Starter motor may be while cranking. If Voltage is
Faulty. available but the motor fails
to start the engine then
check and replace the
starter motor.
Ensure the battery charge
condition
3 Able to start but not Step a: Ensure RLEF should be in

reaches to its rated RLEF relay may be Faulty. ON condition.)
RPM.
Note: Check Governor supply

Ensure Battery voltage i.e. Ferrule no. 33D.
Charge Condition. If voltage is available but the
engine is not runs in rated
Ensure circuit speed then check and
Breaker F6, F7 is in replace with the Governor.
healthy condition. \ If the voltage is not available
check the Governor supply
Ensure with Isolator switch. It is in
Governor connector Step b: battery mode and the
in Governor as well Governor may be Faulty. voltage is available replace
as on Engine side. the Governor. If Voltage is
not available check the
Ensure the fuel level Governor relay RLG and
and its necessary replace it..
condition. If the switch is in isolation
mode, check the DC – Dc
*Ensure the circuit convertor card output.
breaker is reset- Output is ok, engine is not
table. If it reset’s reaches the rated speed
then it gets projected adjust the Governor speed
towards else been adjust potentiometer. Still
found to be surface. not reaches the rated speed
replace the Governor.

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4 Able to Crank the Step a: Check and clean the fuel

Engine but Can’t Fuel System may be faulty. line connections like filters,
Pickup. fuel hoses…etc. If found ok,
then proceed step b.
Step b: Check 24/12V w.r.t GND on

RLEF Relay may be faulty. Relay changeover point
Note: Ferrule No. 12A, If voltage is
available then precede next
Ensure Battery step. If not, check with relay
Charge Condition. and connection.
(Before that ensure RLEF
Ensure Circuit should be in ON condition.)
Breaker F1,F2 is in
healthy condition. Step c: Check and ensure with the
MPU may be Faulty. MPU connector and
Ensure the fuel level connection. If found then
and its necessary proceed step g. If not, then
condition. check and replace with the
sensor.
Ensure with
Governor connector Step d: Check 24/12V between
in Governor as well Governor may be Faulty. input supply on Governor
as on Engine side. i.e. Ferrule no. 33D with
respect to ground point. If
*Ensure the circuit voltage is available but the
breaker is reset engine is fails to start then
table. If it reset’s check and replace with the
then it gets Governor.
projected towards
else been found to
be surface.
Engine starts at its Step a: Check and clean the fuel

rated RPM but the Fuel system may be faulty. filters, fuel hoses…etc.
5 speed fluctuates.
Note: Step b: Check and tune the
Governor control may be necessary controls in the
Ensure the fuel level
and its necessary faulty. engine governing system. If
condition. found, but still the engine
fails then check and replace
Ensure with actuator with the Governor.
and MPU connection.
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No proper alternator Step a:

6
output is found on AVR card may be faulty. Check for proper voltage at
display. Alternator output. If voltage
is found available proper
Normal output : then precede step b. If not,
115V L - N and then tune for the voltage
200V L - L. adjust pot meter.
Note: Step b:
PCB No: 553B Check 115V AC at CN14
Ensure the unit is at
connections may be pin no 1, 2&3 with respect
rated speed Faulty. (Input feedback) to pin no 4 on pcb no 553b.
Operation.
Step c:
Ensure for proper PCB No: 553B Check 2.5 V DC w.r.t GND
connections may be on PCB 553B. I.e.TP22 test
Alternator output at Faulty. (ADC Reference point. If voltage is available
its terminals. voltage) but the display still found
erractic, then precede next
Ensure for the step.
Step d:
Calibration date.
PCB No: 553B Check 1.710V DC w.r.t
connections may be GND on PCB 553B.
Ensure, Faulty.(Controller i.e.TP11, TP12 and TP13
1.60V AC = 2.5V DC feedback) test points. If voltage is not
= 160V L-N display. available check and replace
the card if necessary.
Step a:
7 No output frequency PCB No: 553B Check 115V AC at CN14
is found on display. connections may be pin no 1, 2&3 with respect
Faulty. (Input feedback) to pin no 4 on pcb no 553b.
Note: Step b:
Ensure the unit is at PCB No: 553B Check 400Hz frequency
rated Speed connections may be w.r.t GND on PCB 553B.
Operation. Faulty.(Controller I.e.TP18 test point. If
feedback) Frequency is not available
Ensure with any check and replace the card
loose connection in if necessary.
the sensing.
Step a:
8 No alternator output Field transformer may be Check for the voltage in
is found on display. faulty. primary and secondary of
the transformer. If voltage is

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Normal output: available then precede step

115V L - N and b. If not, check with the
200V L - L. transformer and its
connection.
Note: Ensure with F5 circuit
Ensure the unit runs breaker and RLIDLE/RUN
at rated Speed. relay is in ON condition.
Step b:
Ensure for Alternator AVR card may be faulty. Check for proper voltage at
output by using Alternator output. If voltage
digital multi meter. is available then precede
step c. If not, check with the
Ensure for the fuse in AVR and its connection like
the AVR (8A) is in FET and adjust pot meter.
good condition. Step c:
PCB No: 553B Check 1.710V DC w.r.t
Ensure Circuit connections may be GND on PCB 553B.
Breaker F5 is in Faulty.(Controller i.e.TP11, TP12 and TP13
healthy condition. feedback) test points. If voltage is not
available check and replace
Ensure the Alternator the card if necessary.
field connections (F1 Step d:
and F2). Bridge rectifier may be Check the DC voltage
faulty. across the pin 9 & pin 10 of
Ensure with any the AVR card. If DC voltage
loose connection in not available check the
the sensing. bridge rectifier condition. If
the bridge rectifier found
open or short. Change the
*Ensure the circuit new bridge.
breaker is reset-
table. If it reset’s then
it gets projected
towards else been
found to be surface.
No output found Step a: Check for the residual

9
(Zero volt) on Rotating rectifier may be voltage in the alternator
alternator. faulty. output. If voltage is not
available (zero volt) then
Ensure for any short check and replace with the
circuit in alternator rotating rectifier.
output terminals.

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Ensure any loose Note:

connection. Still snag not rectified, then
contact MAK.
Step a:
Found only residual Exciter stator may be Check for the field ohms
10 output on alternator. faulty. between F1 and F2. i.e
approx it should be of 10E .
Residual output: If the respective ohm is
found then proceed step e.
16V L - N and If not, then check with the
26V L - L. Step b: exciter.
Field transformer may be
Note: faulty. Check for the voltage
between primary and
Ensure for Alternator secondary of the
output thru some transformer. If voltage is
Digital Multi-meter. available then precede step
f. If not, check with the
Ensure for the fuse in transformer and its
the AVR (8A) is in connection.
good condition. Ensure with F5 circuit
breaker and RLIDLE/RUN
Ensure Circuit relay in ON condition.
Breaker F5 is in Step c:
healthy condition. AVR card may be faulty. Check for residual voltage
at Alternator output. If
Ensure with voltage is available but not
Alternator F1 and F2 regulating to the rated
field connections. voltage, then check with
AVR and its related
Ensure for any loose connections like FET and
connection in the adjust pot meter and field
sensing. connections.
Alternator output Step a: Check for voltage at

11
voltage found high. Check and Adjust the Alternator output. If voltage
output voltage adjust is found not proper then
Normal output: potmeter. tune the voltage adjust pot
115V L - N and meter. If not, Check the
200V L - L. ohms value of the potmeter.
If potmeter founds good
then proceed to step (b).

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Note: Step b: Check the FET whether it is

FET may be faulty. in good condition If there is
Ensure for Alternator short with respect to drain
output thru some and source then replace
Digital Multi-meter. FET. If FET is in good
condition then proceed to
Ensure for the step(c).
Calibration date. Step c:
AVR card may be faulty. If the output voltage found
Ensure, high after replacing FET
115V AC = 1.71V and Potmeter then check
DC = 115V L-N
the AVR and replace the
display.
AVR if it is not in good
condition.
Step d: Check 1.69-1.74V DC at

Controller card PCB the TP11, TP12, TP13 with
no:553B may be faulty respect to ground. If voltage
is not available then
proceed step d.

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Check for voltage at

Step a:
13 Alternator output
AVR card may be faulty. Alternator output. If voltage
voltage gets
fluctuates. is found not proper then
check and replace AVR card
with the accessories like
FET and adjust pot meter. If
not, then proceed step b.
A. Check the input voltage

Step b:
Note: of 553B at CN14 pin
Controller card PCB
no.1,2,3 w.r.t pin no.4.
Ensure for proper no.553B may be faulty
B.Check secondary voltage
alternator output thru
some Digital Multi- of the transformer and also
meter. 1.69-1.73V DC at TP11,
TP12 and TP13 test points
Ensure for any loose
with respect to ground. If
connection in the
sensing. voltage is not available then
replace the controller card.
Engine Oil Pressure Step a: Check and top up the Oil if

14
found erratic on display Insufficient Oil level may be necessary. If oil level found
caused. ok, then proceed step b. If
not, then check for Oil
Note: condition.
Ensure the unit is at Step b: Check and ensure on

rated speed Operation. Oil Pressure sensor may sensor terminals. If found
be faulty. ok, then proceed step c. If
Ensure Sufficient Oil in not, then check and replace
the engine. the Sensor.

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Ensure Oil Condition. Step c: Check and ensure with PCB

Controller card PCB 553B and EMR. If found ok
no.553B or EMR may be but still found erractic then
faulty. check and replace the PCB
or EMR.
Ensure the Oil pressure in
engine diagnostic.
High Coolant Step a: Check and ensure on sensor

15
Temperature (HCT) Coolant temperature terminals. If found, then
fault occurs. sensor may be faulty. proceed step c. If not, then
check and replace the
Note: Sensor.
Ensure the unit is at Step b: Check the high coolant

rated speed Ensure coolant switch is in switch whether it is shorted
Operation. closed condition. with ground. If it is in open
condition, then proceed to
Ensure Sufficient next step.
Coolant level in the
engine. Step c: a. If governor Engine, Check
Controller card PCB no. the voltage at TP23 the w.r.t
Ensure the wiring 553B or EMR for the faulty ground.
connections as per
wiring diagram. b.If EMR engine, check the
EMR and if not found ok
then replace the EMR.
c.Check for voltage at pin

no.8 in the ferrule no.21 of
CN1 HCT switch sense and
if it glows even the switch is
open then replace controller
card.

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Low Oil Pressure Step a:

16 (LP) Sensor may be faulty. Check and ensure with the oil
pressure sensor terminal. If
found ok, then proceed step
Note: b. If not, then check and
replace the sensor.
Ensure the system is
at Rated speed. Step b: Check the switch whether it is
LP Switch may be faulty in open condition or closed
Ensure with oil level condition (shorted with
and its condition. ground). If it is in open
condition and the problem
persists,then proceed to next
step.
Step c: a. If EMR engine ,Check and

Controller card or EMR ensure with the EMR and
may be faulty. related connections. If still
found to fails, then check and
replace the EMR.
b. Check for voltage at pin

no.7 at CN1 in ferrule no.22
in controller card if voltage
not available then, replace
the card.
17 Low coolant level Step a: Check 24V w.r.t VRL on

(LC). Switch Sensor may be coolant level sensor.. If
Note: faulty. voltage is available then
ensure the level of the
Ensure with the coolant. If not, then check
Coolant level and and replace the Sensor and
condition. proceed step b.
Ensure with the wago Step b: Check for voltage at the pin
connector near to the Check whether the no.6 at the connector CN1

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sensor. controller is faulty. in ferrule no.29. if the

voltage is not available then
Note: replace the card.
I/p Low sense (OV) –
Fault,
I/p High sense (open)

– No Fault.
Only for EMR

18 engine. Step a: Check for voltage at CH and
Found appearance Controller card may be CL w.r.t ground. If the
like, Communication faulty. voltage available then
fails (EMR not replace the controller card
response) PCB no.553B. If the voltage
not available then proceed
to next step.
Note: Step b: CAN protector card may be

CAN protector card PCB faulty. If the voltage
Ensure no fault in the no. 521A may be faulty. available at input and there
System. is no output then replace
the card or else proceed to
Ensure for any loose next step.
connection.
Ensure with the EMR Step c: Check 24V w.r.t GND on

CAN wire Relay card (RLEF) may be relay card. I.e. Ferrule no.
connections. faulty. 20. If voltage is available
then proceed step e. If not,
then check and replace the
PCB.
Step d:
EMR relay may be faulty. Check 24V between EMR
Power supply (Pin no. 14

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and 1). If voltage is

available but still the
communication fails then
check and replace the EMR.
19
Found appearance
like, Step a: Check the RS-485 wiring
Check the wiring connections in the 2nd and
MWM connections as per the 5th pin of 6-pin Molex
Communication fails wiring diagram. connector in MWM with the
indication status in 4th and 5th pin of the CN4
GSE LCM monitor connector in controller card.
Indication:
Green-communicated Step b: a. Check the supply in the

Red-Not MWM card may be faulty MWM with respect to pin 1
communicated and pin4 of 6-pin Molex
connector.
b. Jumper JP5 and JP6
position is w.r.t pin 2 ,3 in
Note: the card. If not place the
jumper in that position. If it
Ensure for any loose is correct, then
connection. communication IC may be
faulty.
Step c: Communication IC may be

Controller card PCB problem. Replace the
no.553B may be faulty. controller card and continue
the testing.

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20 Load current (AC Step a: a. Check and ensure

POWER 1) found Ensure the wiring whether there are loose
erractic on display. connections as per the connections in the wiring.
wiring diagram b. Check whether the
connections are given as
per wiring diagram.
Note:
Step b: a. Check whether CT’s are
Ensure Output Current transformers (CT1, in open condition. If it is in
Contactor (AC CT2, CT3) may be faulty. good condition then
POWER1) is in ON proceed to (b).
Condition. b .Check for proper current
400:1A on CT outputs. If
Ensure with the output available in all the
Loaded output. CT’s, then proceed step b. If
not, check with the CT and
replace if necessary.
Ensure,
400:1A = CT, Step c: Check DC volts w.r.t GND
2V AC = 2.5V DC = Controller card PCB on the test points TP14,
400A display. no.553B may be faulty. TP16, TP17. If respected
voltage is not available for
the given current, then
replace the controller card.
21.
Load current (AC Step a: a. Check and ensure
POWER2) found Ensure the wiring whether there is loose
erractic on display. connections as per the connections in the wiring.
wiring diagram b. Check whether the
connections are given as
per wiring diagram.

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Note:
Ensure Output Step b: a).Check whether CT’s are

Contactor (AC Current transformers (CT4, in open condition. If it is in
POWER1) is in ON CT5, CT6) may be faulty. good condition then
Condition. proceed to (b).
b).Check for proper current
Ensure with the 400:1A on CT outputs. If
Loaded output. output available in all the
CT’s, then proceed step b. If
not, check with the CT and
replace if necessary.
Ensure,
400:1A = CT, Step c: Check DC volts w.r.t GND
2V AC = 2.5V DC = Current sensing card on the test points TP4, TP5,
400A display. PCB no.597 card may be TP6. If respected voltage is
faulty. not available for the given
current, then replace the
current sense card. If the
voltage is available then
proceed to next step(d).
Step d: a). Ensure the power supply

Check whether MWM card and the voltage output of
is faulty. the second socket current
from PCB no.597 to the
MWM card PCB no.552A/B.
b). Ensure whether the

MWM is communicated with
the controller card. This can
be ensured with green
indication in the right top of
the LCM display. Check for
loose connections in
communication side.

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c). If the problem persists,

then replace MWM card
with the new card.
Step e: If the problem occurs even

Controller card PCB after replacing the MWM
no.553B may be faulty. card then replace the
controller card PCB
no.553B.

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Replacing of Modules & PCB’s:
For replacing of PCB Modules in GPU, kindly follow the procedure in listed below,
Replacing of Controller card (PCB NO: 553B)
1. Ensure the panel is in off condition.
2. Remove all the connectors from the board.
3. Unscrew the PCB from the control panel.
4. Fix the new PCB in the control panel and screw them.
5. Insert all connectors in the respective places.
6. Switch ON the Panel & check the proper display.
Replacing of Controller card (PCB NO: 552A or 552B)
1. Ensure the panel is in off condition.
2. Remove the module from the Panel.
3. Remove all the connectors from the board.
4. Unscrew the module to remove the PCB from the module.
5. Fix the new PCB in the control panel and screw them.
6. Insert all connectors in the respective places.
7. Switch ON the Panel & check the proper display.

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CHAPTER IV
PCB DESCRIPTIONS AND
DIAGRAMS
RESTRICTED CHAPTER - IV
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PCB DESCRIPTION, CIRCUIT DIAGRAMS & ASSEMBLING DETAILS
In this chapter the description of all PCB’s along with assembling details has been
provided. The GSE Monitor V8 is designed with powerful micro-controller based
technology for a very fine-tuned and with precise measurement of outputs. The control
system is an integrated system that takes care of monitoring various engine/output
parameters as well as protecting the engine and Alternator against various faults.
Operating backups like voltage, current, engine parameters and faults of alternator and
engine can be stored through cloud networking
The Control Panel is operating with a Advanced 32bit Microcontroller which is operating
a frequency @ 16MHz and is capable up to 66 MHz with this microcontroller the Board.
The PCB’s used in Ground Power Unit are
A. Central Processing Unit (CPU) PCB No.553B
B. MAK Wireless Module (MWM) PCB No.552A
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PCB TECHNICAL DESCRIPTION:
A. CENTRAL PROCESSING UNIT (CPU)

APPLICATION:
This card is the heart of the GPU protection / monitoring system. This is advanced 32 Bit
Micro controller is used to Display, Actuate relays, Store data etc functions that required
for the GPU control panel. It has data flash memory, RTC etc., IC’s to store the GPU
datas.
It consists of the following sections:
1. Power Supply
2. Reset circuit
3. Controller circuit
4. RS232 & 485 Communications.
5. Serial Flash
6. RTC
7. AC/DC voltage and current sensing Circuits.
8. Relay Driving circuit
9. Analog and Digital circuits
Inputs:
1. Battery supply input. (12VDC/24VDC)
2. Sensing input signals for metering / protection.
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Outputs:
1. Metering and protection display signals to LCD card.
2. Relay driving outputs for protection.
1. POWER SUPPLY CIRCUIT:
Power Supply circuits are used for source input of IC’s in controller board.
Inputs:
An unregulated +12 V /24V DC from battery output is fed through the pin nos. 1 & 2 of
Connector CN2 as the Input source for Power Supply Circuits.
Outputs:
1. Regulated +3.3V DC (VDD) is obtained at Test Point TP2.

2. Regulated +5V DC (VCC) is obtained at Test Point TP5.
3. Regulated -5V DC (VCC) is obtained at Test Point TP4.
Description:
Using a Integrated input rail power supply technique, +12V DC supply from the diode /
bridge output is regulated by U3, U1 & U2 to provide +3.3V, -5V & +5V DC respectively.
This technique provides a noise free pure DC supply for IC’s & control circuits in CPU
module.
2. Reset circuit:
An auto-reset circuit IC (U31) is provided to safe guards the micro controller circuit from
operating at low power supply voltages. If the VDD goes less than 2.93V then the output
of the reset IC will pull down the reset pin of the controller.
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3. Micro Controller Circuit:
All the sensing inputs will be given to the corresponding input connectors of the controller
boards. The output data’s are fed to the LCM for displaying the output parameters.
4. RS232 Communication Circuit:
An RS232 converter circuit IC (U7) is used to Transmit & Receive the data’s between
CPU to LCM in RS232 Format.
RS485 Communication:
An RS485 converter circuit IC (U5) is used to Transmit & Receive the data’s between
CPU & MWM in RS485 Format.
5. Serial Flash Circuit:

The input of chip select sense from the Microcontroller is given to the serial flash memory
IC (U39). It is used to store the Gpu data’s. It saves every minute & store the data’s in
flash memory. It stores the Gpu data’s for the last 30 days in its 1MB serial flash
memory. The Read / Write operation on this flash memory is done through the SPI lines
of the Mcore Chip.
6. RTC Circuit (optional)

In this real time clock (RTC) circuit IC (U6) is used for counting the actual time. Using the
internal Battery (BAT) provided on the CPU module, the time counting is made continues
even when the panel is in switched OFF condition.
ADC reference circuit:

An ADC reference circuit is provided as a reference circuit for all the signals, which is to
be measured and controlled. Ultra low Noise high accuracy voltage reference IC U33 is
used to set as reference voltage is 2.50 V. This reference voltage is given to AREF pin
of Micro controller IC. The corresponding output can be measured at the test point
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CAN Transceiver & CAN Controller Circuit:

The EMR CAN signals output will be given to the CAN Transceiver (U34). This IC is used
to Transmit & Receive the data’s from EMR. The output of CAN transceiver is given to
the CAN Controller (U32). This will collect the data’s from CAN transceiver & the output
will be given to the Micro-Controller Thro SPI lines.
OUTPUT DRIVING CIRCUITS:

The output driving circuits contains 16 outputs from the controller which are used for
controlling the relay operations through the controller card. All the outputs are given with
unregulated supply and output sense is controlled by controller. The U36 & U37 are the
two IC’s used for relay driving functions.
The each output is low sense output and when low is available at the ouput the
corresponding relay get energized in relay card. There are totally 16 outputs from DO1-
DO16 including 3 reserve outputs.
DO 01 – RLEF
DO 02 - RLST
DO 03 – RLIDLE/RUN
DO 04 – RLACCON1
DO 05 – RLDCCON1
DO 06 – RLACCON2
DO 07 – RLDCCON2
DO 08 – RLALARM
DO 09 – RLFLASH
DO 10 – RLBLEEDER
DO 11 – RLCF
DO 12 – RESERVE
DO 13 – RLLDC2
DO 14 – RLLDC3
DO 15 – RESERVE
DO 16 – RESERVE
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SWITCH SENSING CIRCUITS:
The switch signals are high / low sense, which indicates open or close condition.
Potential divider circuits are used to achieve these functions. These high / low sense
signals are multiplexed to Micro-controller.
AC Contactor ON sense Circuits:
The signals are low sense, which indicates the whether the contactor is ON/OFF.
OPTO-coupler circuit U22 is used to achieve these functions. Normal condition the
output of this circuit is high, while switch on the Contactor ground sense is given to this
circuit. Now the output of this circuit is low. These high / low sense signals are given to
micro controller ports. The output can be ensured at corresponding LED indications.
1. AC Contactor1 Sense - LED 6.
2. AC Contactor2 sense - LED 8.
DC Contactor ON sense Circuits:
The signals are low sense, which indicates the whether the contactor is ON/OFF.
OPTO-coupler circuit U22 is used to achieve these functions. Normal condition the
output of this circuit is high, while switch on the Contactor ground sense is given to this
circuit. Now the output of this circuit is low. These high / low sense signals are given to
micro controller ports. The output can be ensured at corresponding LED indications.
1. AC Contactor1 Sense - LED 7.
Engine Protection sense circuit:
Low Engine Oil Pressure (E. LLOP), High Coolant Temperature (HCT), Engine Air
Filter Clog (E.AFC) & Low Coolant (LC):
These signals are low sense, which indicates the Engine protection problem. Opto
coupler circuits U24 & U22 are used to achieve these functions. Normal condition the
output of this circuit is high. When fault condition ground sense is given to this circuit.
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Now the output of this circuit is low. Controller will trip the GPU through appropriate
relays. These high / low sense signals are given to micro controller ports the output can
be ensured at corresponding LED indications,
1. E. LLOP Sense - LED 10
2. HCT sense - LED 11
3. LC sense - LED 9
4. E. AFC sense - LED 12
AVR ON Sense Circuit: (optional)
The signals are low sense, which indicates the whether the AVR is ON/OFF.
OPTP-coupler circuit U24 is used to achieve these functions. During Normal condition
the output of this circuit is high; during switch on ground sense is given to this circuit to
switch ON the AVR. Now the output of this circuit is low. These high / low sense signals
are given to micro controller ports. The output can be ensured at corresponding LED
indications.
1. AVR ON sense - LED 13.
D+ Sensing circuit:
The signals are high sense, which indicates the Charging Alternator is working or not.
Normal condition the 24V DC input is given to circuit and sensing output of 3.3V DC is
used. During Normal condition the high sense is given to micro controller port. If
controller gets low signal, it will indicates the CF fault. The output can be measured at
corresponding LED indication.
Charge fails - LED 14.
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Bypass/interlock Circuits:
The signals are high sense, which indicates the whether the mode is BYP/INT.
OPTO coupler circuit U23 is used to achieve these functions. Normal condition the
output of this circuit is low. While connect the output ac socket to aircraft, the 24V dc
voltage is given to CN1 of 13 & 14th pin. Output of this circuit high sense is given to micro
controller ports. The output can be ensured at corresponding LED indications,
1. Byp/Int1 Sense - LED 16

2. Byp/Int 2 Sense - LED 17.
AC Voltage Sensing Circuits:
Inputs:
1. Three Phase voltage samples from PT’s (3 x 0-1.6V AC)
Outputs:
1. DC output voltage (0-2.5V DC-160V)
Alternator Output 115V AC – 1.15V SY – 1.80V DC
Description:
Transformers receive the alternator output AC output voltage and step down to the same
to 0 - 1.6V AC respectively. The output of the transformers is measured at the Test
points TP5, TP6, TP7. Three phase output voltages from the Transformer are given to
individual precision half wave rectified amplifier circuits (U20) and the amplified DC
output of the circuits are fed to the controller. The gain will be adjusted by using the Trim
pots P4, P5, P6. The corresponding DC output can be measured at Test points TP11,
TP12, TP13 respectively.
AC Current Sensing Circuits:
Inputs:
1. Three Phase Current samples from CT’s (3 x 0 -1A = 400A)
Outputs:
1. DC output voltage (0 - 2.5V DC)
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Description:
Current transformers (400/1A) receive the output current and step down to the same of
(0-1A) respectively. The output is fed into the voltage divider circuit. Three phases
current are given to individual precision half wave rectified amplifier circuits (U21) and
the amplified DC output of the circuits is fed to the controller. The gain will be adjusted by
using the Trim pots P7, P8, P9, P10.The corresponding Dc output can be measured at
Test points TP14, TP15, TP16 respectively.
Neutral Current sensing circuit:
The neutral current ac signal is given to high gain amplifier circuit U21. By this high gain
amplifier even a small neutral current is amplified to high-level signal and sensed. This
high signal is given to Micro controller. The corresponding output can be measured at the
test point TP17.
Phase Difference sensing circuit:
The two-phase PT sample signals are given to U14 as inputs and the same converts the
ac signals into square pulses. These square pulses are fed to NOT gate U16 and the
output of the U16 is given to the flip-flop circuit U26. This circuit gives a pulse output
when there is no phase difference and it gives a ‘low’ signal output if there is phase
difference. The output of this circuit is given to Micro controller. The corresponding output
can be measured at the test point TP20.
Frequency Sensing Circuit:
The pulse output of the potential transformer is used for frequency measurement. The
pulse output is given to U16 and given to Micro controller. The corresponding output can
be measured at the test point TP18.
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DC voltage sensing circuit:
Inputs:
1. Rectifier voltage (0-35V DC)
Outputs:
1. DC output voltage (0-2.5V DC)
The rectifier output (0-35) is given to the amplifier circuit U13 and fed to secondary
amplifier circuit of U13 which produces output voltage of (0-2.5V) DC respectively. The
output can be measured at the Test point TP9 respectively.
DC current sensing circuits:
Inputs:
1. DC shunt input (0-75mv)
Outputs:
1. DC output voltage (0-2.5V DC)
The shunt output (0-75mv) is given to the OP27 IC U19 and output is fed to secondary
amplifier circuit of U18 which produces output voltage of (0-2.5V) DC respectively. The
output can be measured at the Test point TP10 respectively. The corresponding current
will be displayed in the display.
ANALOG SENSING CIRCUTS:
Oil pressure sense (OP):
EMR is monitored and control the oil pressure.
Coolant Temperature Sense (CT):
EMR is monitored and control the Coolant Temperature.
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Fuel Level:
Fuel float is used for fuel level measurement. The float resistance varies from 62Ω to
230Ω for 0 to 100% of fuel level of the tank. The output of the sensor is connected to the
control circuit. The corresponding output can be measured at test point TP23.
Resistance variations for corresponding fuel level are given below. If fuel level goes to
below 20%, LF indication will appear on panel display.
At 10% fuel level the Resistance of the pressure sensor will be 56Ω
At 100% fuel level the float Resistance is 230Ω
For 0% - 0 Volt.
For 100% - 2.5Volt.
Battery Voltage (BV):

The Battery voltage is being sensed for the battery charging status monitoring.
Whenever the batteries are getting charged the battery voltage will be above 26 volts.
The battery voltage sensed from battery is conditioned and fed to Controller. The output
of the conditioned signal will be 2.50V for 35V DC. The corresponding output can be
measured at test point TP27.
MWM card (PCB NO: 552A)
This Module collects data’s from GPU & send to the MAK Web server or Mobile.
1. Power supply circuit:
a) Unregulated power supply circuit:
The power supply 24V is given to 1st and 4th pin of the connector CN6 in the MWM card
and output is measured at the test point TP8.
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b) +3.3V Circuit:
The unregulated power supply voltage is given to U11 IC and 3.3V output is measured at
the test point TP9.
2. Reset circuit:
An auto-reset circuit IC (U8) is provided to safe guards the micro controller circuit from
operating at low power supply voltages. If the VDD goes less than 2.93V then the output
of the reset IC will pull down the reset pin of the controller.
3. RS485 Communication circuit:
This circuit transmits/receives the parameters from/to the GPU using 2nd & 5th pin of the
CN6 connector. And the same is given to MWM module.
4. Controller circuit:
This circuit transmits/receives the GPU parameters through the RS485 communication
circuit. Same data is processed suitable for wireless transmission and is transfer to
cloud. We can access this data anywhere using MAK RDMS software through internet.
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CHAPTER V
RECOMMENDED SPARES
& FIRST AID
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CHAPTER V
1. RECOMMENDED SPARES:
A. Central Processing Unit (Cpu) Pcb No.553B
B. Bridge card Pcb No.547
C. MWM card Pcb no: 552A
D. Automatic Voltage Regulator Pcb No. 299B
E. DC-Dc convertor card Pcb No. 573
F. Relay board 1 (2c/o UL) 1 NO
G. Relay board 2 (4 c/o UL) 1 NO
H. Liquid crystal monitor (LCM) 1 NO
I. OEN relay RLS, RLG1, RLG2 1 NO
J. Circuit breaker 30,20, 15, 5A 1 NO
K. Contactor 265A 1 NO
L. Current transformer 400/1A 1 NO
M. LDC relay (AC) 1 NO
N. LDC relay (DC) 1 NO
O. Emergency stop Pushbutton 1 NO
P. Obstruction lamp 1 NO
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Q. Power ON switch 1 NO
R. Cabin lamp 1 NO
S. Obstruction lamp on/off PB 1NO
T. Engine Oil Filter 2 NOs
U. Engine Fuel Filters 2 Sets
V. Radiator Coolant Filling Cap 1 No.
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2. FIRST AID FOR ELECTRICAL ACCIDENT:
INTRODUCTION:
The passage of electrical current through the body can cause cardiac arrest, burning, and
shock. Many injuries result from faulty switches, frayed cables or defects in electrical
appliances.
Whatever the cause of an electrical accident, never touch the casualty with bare
hands unless you are sure there is no danger to yourself.
Treatment:
 Switch off the electrical supply/GPU.
 Remove the casualty from contact with electrical source, using non-conductive
articles such as a dry brush handle, dry rope or piece of clothing.
 Call for help.
 If breathing and heartbeat have stopped, begin the A-B-C ( A= Airway B =

Breathing C = Circulation ) of resuscitation immediately.
 If the casualty is breathing, but unconscious, place him in the recovery position.
 Treat any electrical burns.
 Treat for shock.
Remove to hospital in all cases.
Electrical Burn
An electrical burn may appear minor, but the damage can extend deep into the tissues
beneath the skin. If the amount of electrical current that passed through the body was
large, internal damage such as a heart rhythm disturbance or cardiac arrest can occur.
Sometimes the jolt associated with the electrical injury can cause you to be thrown or to
fall, resulting in fractures or other associated injuries. Call for emergency medical
assistance.
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While waiting for medical help, follow these steps:
1. Ensure the person is breathing. If breathing has stopped or you suspect the
person's airway is blocked, begin cardiopulmonary resuscitation (CPR).
2. If the person is breathing, cover any burned areas with a sterile gauze bandage, if
available, or a clean cloth. Don't use a blanket or towel. Fluffy fibers can be
irritating.
Resuscitation
Warning !
This is not a replacement for a first aid or CPR course; it is just a quick guide in first aid
and CPR techniques. You should go to your local first aid organization and do a course
in these life saving skills.
In cases of heart attack, drowning, suffocation, electric shock and overdoses of drugs,
either the heart or breathing may stop.
This is called cardio-respiratory arrest. ('Cardio' means heart, 'respiratory' means
breathing).
In many cases a life can be saved if resuscitation can be performed quickly and
correctly. A minority of heart attack cases will actually collapse with a cardio-respiratory
arrest. But everyone should know the early signs of a heart attack, and have an
emergency plan of action,
Signs of cardio-respiratory arrest.
 Collapse with loss of consciousness.
 Absence of breathing.
 No pulse (carotid).
What to do.
Basic cardio-pulmonary resuscitation (CPR) is a simple procedure, as simple a A-B-C.

A= Airway B = Breathing C = Circulation
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Precaution:
In electrocution, switch off current before starting CPR.
Recover Position.
The Recover Position ensures that a casualty maintains an open airway,

that the tongue cannot fall to the back of the throat, that the head and neck
remain in an extended position so that the air passage is widened, and any
vomit or fluid will drain freely.
IF THE VICTIM IS UNCONSCIOUS DO NOT GIVE ANYTHING BY

MOUTH.
You will notice the casualty

is lying on his side,
supported by one leg and one arm. In the case of head or ear injury, keep
the injured side down.
Where there are fractures in

the upper or lower body,
where the casualty is lying in a confined space, or
where it is not possible to use the bent limbs as
supports, the Recover Position can be modified. In such cases, a rolled
blanket can be laid down the front of the body.
This method can also be used to transport a casualty on a stretcher

in the Recover Position.
N.B.: When moving the casualty, always do so as a total unit

i.e. keep the casualty's head and trunk aligned at all times
Shock
Shock is a condition of general body weakness caused by loss of circulating bodily fluids,
such as loss of blood through internal or external bleeding, or loss of plasma from major
burns, or through extreme pain or fear. The shocked casualty may feel weak, faint, giddy,
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may be anxious or restless, may feel sick and may vomit. Skin may become pale, cold
and clammy, sweating may develop. Breathing can be shallow and rapid, and
unconsciousness may develop. Shock is present in all cases of accident to a varying
degree.
Treatment:
 If breathing and heart-beat stop, begin the A-B-C of resuscitation immediately.
 If breathing becomes difficult, if vomiting seems likely or if the casualty becomes

unconscious, place in the recovery position, and maintain an observing brief.
 Check breathing and pulse every ten minutes.
 Search for, and if possible, treat the cause of shock,
i.e. Fractures | Burns | Bleeding | Electrocution.
 If the casualty is conscious, reassure and comfort him. Lie him down, raise and
support legs, keep him warm and loosen tight clothing to help circulation and assist
breathing.
 Send for medical aid and remove to hospital.
 DO NOT give a hot water bottle.
 DO NOT move him unnecessarily.
 DO NOT give anything to eat or drink.
 DO NOT allow the casualty to smoke.
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CHAPTER VI
MANUFACTURER
APPENDIX
RESTRICTED CHAPTER - VI
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INSTRUCTION MANUAL
FOR
VOLTAGE REGULATOR
MODEL: M11-06-90
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INTRODUCTION
This manual provides information concerning the operation and installation of M11-06-
140 Voltage regulator. To accomplish this, the following is provided.
 Specifications
 Installation
 Operation
 Maintenance
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CONTENTS
SUBJECTS
GENERAL INFORMATION
DESCRIPTION
SPECIFICATION
ACCESSORY ITEMS
INSTALLATION
OPERATION
GENERAL
PRELIMINARY SETUP
OPERATION AT REDUCED SPEED
SYSTEM START-UP
ADJUSTMENTS
Field Flashing
P-I-D Settings
Voltage Adjustment
Protections
MAINTENANCE
PREVENTIVE MAINTENANCE
TROUBLE SHOOTING
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SECTION 1
GENERAL INFORMATION
GENERAL DESCRIPTION:
The M11-06-140 voltage regulator regulates the output voltage of 400HZ brushless
alternator by controlling exciter field current. The M11-06-140 is specially designed for
400Hz alternators and it provides optimum response time for various load conditions. All
components are so chosen to work in critical environmental conditions.
SPECIFICATIONS:
Dc output power 8A at 105V DC

Ac power input 115V AC
Sensing input 115V, 4 wire system
Sensing burden 2VA
Voltage adjust range  15V
Regulation accuracy 1.0%
Field Fuse rating 8A
Operating temperature -20C to +75C
Storage temperature -40C to +125C
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ACCESSORY ITEMS:
EXTERNAL POWER ISOLATION TRANSFORMER:
A power isolation transformer is required to operate the AVR. This is used as field supply
transformer.
BRIDGE RECTIFIER:
A Bridge Rectifier is used to rectify the Field Transformer secondary AC voltage in to DC

voltage.
VOLTAGE ADJUST POTENTIOMETER:
A Voltage adjust potentiometer is provided to adjust the output voltage for required level.
(+ 15V)
SWITCHING TRANSISTOR (FET):
A switching Field Effect Transistor is given for AVR internal PWM switching circuitry
purpose.
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SECTION 2
INSTALLATION
Inter connection:
a. The voltage regulator inter connection is provided by fig 2.2.

b. An external voltage adjust potentiometer should be connected to the connector
CN3.
c. A PWM switching Field Effect Transistor (FET) should be connected to the
connector T5.
d. Connect the Alternator exciter terminals to AVR terminals F+ (F1) and F- (F2).
e. A flashing source may be required (Refer field flashing section).
f. Install fuses and shutdown switch.
g. Connect the field power transformer as shown in Fig 2.2. The Field transformer
primary is to be connected to 135V AC source and secondary is to be connected
to 94V AC source.
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AVR WIRING DIAGRAM
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COMPONENT LAYOUT
FIG 2.3
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SECTION 3
OPERATION
GENERAL
The following system operation procedures provide instructions for adjusting the M11-06-
140 voltage regulator. Symptoms resulting from a faulty regulator and certain alternator
system problems are included together with suggested remedies
CAUTION
MEGGERS AND HIGH POTENTIAL TEST EQUIPMENT MUST
NOT BE USED. INCORRECT USE OF SUCH EQUIPMENT
COULD DAMAGE THE SEMICONDUCTORS CONTAINED IN
REGULATOR.
PRELIMINARY SET-UP:
a. Verify that the voltage regulator specifications confirm with the alternator system
requirements.
b. Ensure the voltage regulator is correctly connected to the alternator system.
c. Ensure voltage adjust potentiometer properly connected with regulator.
d. Make sure the fuses that are connected with regulator, are within the specified
ratings.
OPERATION AT REDUCED SPEEDS:
During periods of prime mover idling and speed <=900RPM, excitation power from the
voltage regulator is made cut-off to avoid damage of regulator/ control panel.
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SYSTEM START-UP:
a. Perform preliminary set-up as described previously.
b. Start prime mover and bring up to rated speed.
RESULT: Voltage should buildup. If not, proceed to field flashing.
c. Slowly adjust the output voltage adjust potentiometer until the alternator output
voltage reaches the nominal value.
RESULT: Voltage should buildup to nominal value. If voltage does not build up to
nominal value, check alternator for short or excessive load.
If necessary perform field flashing.
d. Check regulator under normal operating and loading conditions.
RESULT: Voltage regulation should be less than +/-1.0 % no load to full load. If
regulation is not within the range, please proceed as follows.
1. Please check prime mover speed, if low rectify the prime mover problem.
2. If the prime mover speed is constant, check the regulator replace if necessary.
ADJUSTMENTS:
Field flashing:
If the alternator output voltage is less than the residual voltage (i.e. 10VAC L-N; 17VAC
L-L approximately). It may be necessary to add a flashing circuit as shown in fig 2.2.
Care should be taken to avoid applying excessive flashing voltage as damage may
result. If the available DC voltage source is too high, a series-limiting resistor is required.
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P-I-D Settings:
P-I-D Setting is a factory set value. There is no need to adjust the P-I-D settings in the
field.
Voltage Adjustment:
Adjustment of the alternator output voltage may be accomplished by external

potentiometer. By adjusting the potentiometer the output voltage can be
increased/decreased.
Protection:
Over Voltage protection:
If the alternator output voltage exceeds 155VL-N the over voltage protection circuit will
blow-off the field fuse by means of inbuilt crowbar circuit.
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SECTION 4
MAINTENANCE
PREVENTIVE MAINTENANCE
A periodic inspection of the unit should be made to ensure that it is kept clean and free
from accumulations of dust and moisture. Ensure that all the wire connections to the
voltage regulator are clean, secure and properly insulated.
TROUBLESHOOTING
In case of failure / defective operation of the unit the following table is provided to aid in
the determination of the cause and the possible solution.
Symptom Possible cause Remedy

1. Voltage does not a. No voltage (or) incorrect a. Refer wiring diagram 2.2
buildup. isolation transformer voltage and check the connections
to input terminals are as per the drawing. If OK
go to step b.
b. Check RLIDLE/RUN relay

NO point position. It should be
in ‘on’ condition. If it is OK,
then go to step c. If not, check
the same.
c. Check regulator input and

output fuses replace if
necessary or go to step d.
d. Check whether the AVR

switching Transistor (FET) is
connected. If connected, go to
step e.
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e. Flash the exciter field
(Refer fig.2.2 for connection
details)
f. Regulator may be faulty.

Replace the regulator & FET.
2. Voltage does not 1. Prime mover speed too a. Check the RPM &
buildup to rated slow. Frequency reading in the
value. control panel. If it is OK then
go to step 2.
2. Output voltage adjustment a. Check the output voltage

is improperly set. with true RMS Multimeter. If
the panel reading matches
with DMM reading then go to
step b. If not display reading
may be faulty.
b. Adjust the output voltage

adjust potentiometer
(clockwise) to set the nominal
value. If not OK go to step c.
c. Regulator faulty, replace

the regulator
3. Field switching FET a. Check and fix it.

connector may be
disconnected.
3. Voltage high and a. No sensing input. a. Refer with wiring diagram
uncontrollable. 2.2 check the wire
connections and tightness of
wires. If it is OK then go to
step b.
b. Regulator faulty.
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4. Voltage oscillation. a. Voltage adjusts a. Check the potentiometer is

potentiometer disconnected. connected in CN3 of the
regulator. If disconnected, fix
it. If not OK go to step b.
b. Regulator faulty, replace it
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MAK CONTROLS
OPERATION AND MAINTENANCE MANUAL and Systems(P)Ltd
FOR 90KVA AC/DC GPU GROUND POWER
SYNCHRONOUS AC GENERATOR
INSTALLATION, OPERATION AND

MAINTENANCE MANUAL
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MAK CONTROLS
CONTENTS
DESCRIPTION PAGE NO
1. SAFETY ---------------------------------------------------------------------------------18
2. RECEIVING AND STORAGE ---------------------------------------------------- 19
3. PRINCIPLES OF OPERATION -------------------------------------------------- 20
4. INSTALLATION--------------------------------------------------------------------- 22
5. OPERATION-------------------------------------------------------------------------- 24
6. MAINTENANCE---------------------------------------------------------------------- 28
7. TESTING------------------------------------------------------------------------------- 30
8. SERVICE------------------------------------------------------------------------------- 34
9. TROUBLE SHOOTING ------------------------------------------------------------ 37
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MAK CONTROLS
1. SAFETY
PLEASE REMEMBER THE SAFETY FIRST. If you are not sure of the instructions or
procedures contains herein, seek qualified help before continuing.
This service manual emphasizes the safety precautions necessary during the installation,
operation and maintenance of your MAK synchronous generator. Each section of this
manual has caution and warning messages. These messages are for your safety , and
the safety of the equipment involved. If any of these cautions or warnings are not readily
understood, seek clarification from qualified personnel before proceeding.
Before any service work is done, disconnect all power sources and lock out all controls to
prevent an unexpected start-up of the generator set driver. Proper grounding (earthing)
of the generator frame and distribution system in compliance with local and national
electrical codes and specific site requirements must be provided. These safety
precautions are necessary to prevent potential serious personal injury, or even death.
The hazards associated with lifting or moving your MAK generators are pointed out in the
installation and maintenance sections. Incorrect and lifting or moving can result in
personal injury or damage to the unit.
Prior to start-up of the unit ensure that all generator leads properly connected to the
relevant places. Always assume that there will be voltage present at the generator
terminals whenever the generator’s shaft is rotating, and proceed accordingly. Caution
must be exercised, or serious injury or death can result.
This manual is not intended to be a substitute for properly trained personnel. Qualified,
trained people should only attempt installation and repairs. The cautions and warnings
point out known conditions and situations that are potentially hazardous. Each
installation may well create its own set of hazards.
When in doubt, ask. Questions are much easier to handle than mistakes caused by a
misunderstanding of the information presented in this manual.
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MAK CONTROLS
2. RECEIVING AND STORAGE

Upon the receipt of the generator, it is recommended that it be carefully examined for
possible transport/ shipping damage. The generator was given to the freight carrier in
good condition; thus, the carrier is responsible for the product from the factory dock to
the destination. Any damage should be noted on the freight bill before accepting the
shipment. Any claims for damage must be promptly filed with the delivering carrier.
I. UNPACKING AND HANDLING

Carefully read all instruction tags shipped with the unit. When lifting, attach an overhead
crane to the lifting lug(s) on the generator frame. Apply lifting forces in a vertical
direction.
WARNING
THE LIFTING LUG(S) ON THE GENERATOR ARE DESIGNED TO SUPPORT

THE GENERATOR ONLY. DO NOT LIFT A COMPLETE GENERATOR AND
DRIVER ASSEMBLY BY MEANS OF LIFING LUG(S) ON THE GENERATOR.
PERSONAL INJURY OR EQUIPMENT DAMAGE MAY RESULT.
II. STORAGE
In the event that the generator is not immediately installed on its prime mover, it is
recommended that the unit be stored indoors in a clean, dry area, which is not subject to
rapid changes in temperature and humidity. If the generator is stored for a long period of
time, the generator should be tested, cleaned and dried as required before being put into
service. See the maintenance section of this manual for further information. If the unit
has been stored in an area where it has been subject to vibration, it is recommended that
the bearing be inspected and replaced as necessary.
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MAK CONTROLS
3. PRINCIPLES OF OPERATION
MAK generators are a brushless, self-excited externally voltage regulated, synchronous
AC generator. The generator is made up of six major components: main stator
(armature) , main rotor (field), exciter stator (field), exciter rotor (armature), rectifier
assembly, and voltage regulator. In understanding the above technology, note the
following: stators are stationary, rotors rotate, a field is an electrical input, and an
armature is an electrical output.
The generator’s exciter consists of a stationary field and a rotating armature. The
stationary field (exciter stator) is designed to be the primary source of the generator’s
residual magnetism. The residual magnetism allows the exciter rotor (armature) to
produce AC voltage even when the exciter stator (field) is not powered. This AC voltage
is rectified to DC by the rotating rectifier assembly and fed directly to the main rotor
(field). As the generator shaft continuous to rotate, the main rotor (field) induces a
voltage into the generator’s main stator (armature). At rated speed, the main stator’s
voltage produced by the residual magnetism of the exciter allows the automatic voltage
regulator to function. The regulator provides voltage to the exciter resulting in a build-up
of generator terminal voltage. This system of using residual magnetism eliminates the
need for a special field flashing circuit in the regulator. After the generator has
established the initial
residual voltage, the regulator provides a controlled DC field voltage to the exciter stator
resulting in a controlled generator terminal voltage.
VOLTAGE REGULATION
the automatic voltage regulator receives both its input power and voltage sensing from
the generator’s output terminals. The regulator automatically monitors the generator’s
output voltage against an internal reference set point and provides the necessary DC
output voltage to the exciter field required to maintain constant generator voltage is
changed by adjusting the regulator’s reference set point. Consult the regulator manual
for specific adjustment and operating instructions.
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MAK CONTROLS
NONLINEAR LOADING
Solid state electronic control devices (variable frequency drives, precision motor controls,
battery chargers, etc.,) utilize electronic switching circuits (Thyristors, SCRs, Diodes,
etc.,). These switching circuits introduce high frequency harmonics, which distort the
normal waveform of the generator. This creates additional hear in the generator to the
over-heat problems which can occur are not limited to the generator. Poor wave shape
may adversely effect various loads connected to the generator. Consult MAK
CONTROLS AND SYSTEMS (P) LTD for further information relative to nonlinear loads.
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MAK CONTROLS
4. INSTALLATION
I. PREPARATION FOR USE
Although the generator has been carefully inspected and tested in operation prior to
shipment from the factory, it is recommended that the generator be thoroughly inspected.
Check all bolts for tightness and examine the insulation on lead wires for chafing prior to
proceeding with installation. Remove all shipping tapes, bags, skids and rotor support
blocking.
WARNING
DISABLE AND LOCKOUT ANY ENGINE CRANKING DEVICES BEFORE

ATTEMPTING TO INSTALL OR SERVICE THE GENERATOR. FOR
ELECTRIC START SETS, DISCONNECT THE CRANKING BATTERY. FOR
AIR START, DISCONNECT THE AIR SUPPLY. FOR MOTOR GENERATOR
SETS, OPEN THE POWER SUPPLY TO THE DRIVE MOTOR. FAILURE TO
COMPANY WITH THESE SAFETY PROCEDURES COULD RESULT IN
SEVERE PERSONAL INJURY OR EQUIPMENT DAMAGE.
NEVER “BAR OVER” THE ENGINE GENERATOR SET USING THE

GENERATOR’S FAN. THE FAN IS NOT DESIGNED FOR THIS PURPOSE.
BARRING OVER THE SET WITH THE FAN COULD DAMAGE THE FAN AND
RESULT IN PERSONAL INJURY OR EQUIPMENT DAMAGE.
II. GENERATOR MOUNTING
Generators are provided with an SAE flywheel housing adapter flange and drive shaft.
Coupling the generator’s shaft to the engine flywheel is accomplished with special type
flexible coupling.
The SAE flywheel housing adapter ring and the engine flywheel housing and
designed to match each other with no further alignment necessary. Use grade 5
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or greater mounting bolts. MAK generator frames are constructed with two or
three boltholes per foot. The feet should be shimmed where necessary to obtain
solid contact with the sub-base. With the frame securely bolted to the engine
flywheel housing, there is no outside thrust or pull on the generator frame, thus no
real need to secure the feet with more than one bolt per foot.
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5. OPERATION
I. PRE-START INSPECTION
Before starting the generator for the first time, the following inspection checks are
recommended:
1. A visual inspection should be made for any loose parts, bad connections, or foreign
materials.
2. Bar the set over by hand for at least 2 revolutions to be sure that there is no
interference and that the set turns freely. If the set does not turn freely, check for
clearance in the generator and exciter air gap.
3. Check all wiring against the proper connection diagrams, and ensure that all
connections and terminations are tight and properly insulated.
WARNING
MAK GENERATORS MAY HAVE VOLTAGE PRESENT AT THE LEAD

TERMINAL WHEN THE SHAFT IS ROTATING. DO NOT PERMIT
OPERATION OF THE GENERATOR UNTIL ALL LEADS HAVE BEEN
CONNECTED AND INSULATED. FAILURE TO DO THIS MAY RESULT IN
PERSONAL INJURY OR EQUIPMENT DAMAGE
4. Verify that all equipment is properly grounded (earthed).
5. Clear the surrounding area of any materials that could be drawn into the generator.
6. Check all fasteners for tightness.
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7. Check all access plates, covers, screens and guards. If they have been removed for
assembly or inspection, reinstall and check for security.
8. Review all prime mover pre start-up instructions, and ensure that all recommended
steps and procedures have been followed.
9. Remove any masking materials affixed during painting. Inspect the generator, prime
mover, and any accessory equipment to ensure that nameplates, and all safety
warning / caution sign and decals provided with the equipment are in place and
clearly visible.
Note:
It is strongly recommended that the authority having jurisdiction over the
installation site be consulted to determine if any additional warning or
caution notices, or additional safety devices are required by local codes /
standards. Any such required notices or devices should be installed prior to
initial startup.
II. START-UP
The following procedure should be followed when starting the generator set for the
first time.
1. The generator output must be disconnected from the load. Be sure that the
main circuit breaker or fused disconnect is in the open position.
2. Open the input power to the automatic voltage regulator. Remove the fuse or
disconnect and insulate one of the regulator inputs power leads. (See separate
regulator manual)
3. Verify that all prime mover start-up procedure have been followed.
4. Start the prime mover, and adjust it for proper speed. See generator
nameplate.
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5. The purpose of this initial test with the regulator out of the circuit is to detect
any wiring mistakes without exposing the units to undue risk. Check all line to
line and line to neutral voltages for balanced voltage. If voltages are balanced
shut down the set and reconnect the regulator. If voltages are unbalanced shut
down the equipment and check for improper wiring. If the problem persists,
consult the factory.
With the regulator de-energized, the residual voltage should be 10-25% of rated
value. It is recommended that this residual voltage and drive RPM be recorded for
use as a future trouble shooting benchmark.
WARNING
QUALIFIED ELECTRICAL PERSONNEL MUST CONDUCT THE FOLLOWING

TEST. LETHAL VOLTAGE MAY BE PRESENT AT BOTH THE GENERATOR AND
VOLTAGE REGULATOR TERMINALS DURING THIS PROCEDURE. CAUTION
MUST BE EXERCISED NOT TO COME INTO PERSONAL CONTACT WITH LIVE
TERMINALS LINK, OR STUDS. SERIOUS INJURY OR DEATH COULD RESULT.
6. Start the set and adjust the terminal voltage to the desired value by means of the
regulator voltage adjustment. If the regulator is equipped with a stability
adjustment, follow the instructions in the regulator manual to adjust the stability.
Again, check all line to line and line to neutral voltages for balance. It is
recommended practice to record the no load excitation (DC voltage to the exciter
stator), generator terminal voltage and drive speed as a benchmark for future
troubleshooting.
7. Close the main circuit breaker to the load.
8. Monitor the generator output current to verify that it is at or below nameplate

value.
9. Check generator speed (frequency) under load. Adjust as necessary. (Refer to

prime mover or governor manuals)
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III. SHUTDOWN PROCEDURE
There are no specific instructions for shutting down the generator; however, several good
practices should be observed to prolong equipment life.
1. It is advisable to disconnect all loads (open main circuit breaker or disconnect) prior
to shutdown.
2. Isolate all conditions that could apply voltage to the generator terminals while the
generator is at rest. Failure to comply could result in personnel injury or equipment
damage.
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6. MAINTENANCE
The following maintenance procedures should be followed to ensure long equipment life
and satisfactory performance. Maintenance intervals will depend upon operating
conditions.
1. Every 1000 hours check the bearing for smooth, quiet operation. For
continuous duty generators, recommended practice is to replace the bearing
during the major overhauls of the engine.
I. WARNING
QUALIFIED ELECTRICAL PERSONNEL MUST CONDUCT THE

FOLLOWING TEST. LETHAL VOLTAGE MAY BE PRESENT AT BOTH
THE GENERATOR AND VOLTAGE REGULATORT ERMINALS DURING
THIS PROCEDURE. CAUTION MUST BE EXERCISED NOT TO COME
INTO PERSONAL CONTACT WITH LIVE TERMINALS, LIMKS, OR
STUDS. SERIOUS INJURY OR DEATH COULD RESULT.
2. Periodically inspect the unit for any buildup of contamination (dirt, oil, etc.) on
the windings. If the wound components have become coated with heavy
concentrations of oil and grime, the unit should be disassembled and
thoroughly cleaned. This operation is not one that can be accomplished
effectively on site, but rather one that should be conducted by an authorized
service center equipped with the appropriate apparatus and solvents necessary
to properly clean and dry the generator.
3. Every 2000 operating hours or in conjunction with scheduled engine

maintenance, check the DC no load excitation voltage . Compare this voltage
with the value recorded during initial startup. If this value of no load excitation
voltage is markedly higher than the bench mark reading, it is an indication of
problems in either the exciter, main field or the rotating rectifier assembly.
Ensure that RPM is the same as initial test.
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4. Monitor and record insulation resistance with a 500 volt mega-ohm meter.
The minimum acceptable reading is 2 mega-ohms. If the reading drops
below the minimum, the generator should be cleaned and dried at an
authorized service shop. Consult MAK CONTROLS AND SYSTEMS (P)
LTD more information.
I. DRYING WINDINGS
Generators in service may inadvertently have their windings exposed to splashing

or sprayed water. Units that have been in transit or storage for long periods of
time may be subjected to extreme temperature and moisture changes causing
excessive condensation. Regardless of the source of moisture, wet windings
should be thoroughly dried out before operating the unit. If this precaution is not
taken, serious damage to the generator can result.
Method to dry the generator is to run the set with no excitation. The natural flow
of ambient air through the generator will tend to dry the windings. This method
can be accelerated by adding a source of heat at the air intake to the generator.
Heat at point of entry should not exceed 80 C (180Deg. F).
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7. TESTING
I. VISUAL INSPECTION
Remove covers and look for any obvious problems: burnt windings, loose
connections, broken wires, frayed insulation, cracked brackets, missing hardware,
etc. Check for foreign objects which may have been drawn into the generator.
Verify that the generator’s air gaps (main rotor and exciter) are free from
obstructions. If possible, rotate the generator manually to ensure free rotation.
Never “bar over” the engine generator set using the generator fan.
WARNING
QUALIFIED ELECTRICAL PERSONNEL MUST CONDUCT THE
FOLLOWING TEST. LETHAL VOLTAGE MAY BE PRESENT AT BOTH
THE GENERATOR AND VOLTAGE REGULATOR TERMINALS DURING
THIS PROCEDURE. CAUTION MUST BE EXERCISED NOT TO COME
INTO PERSONAL CONTACT WITH LIVE TERMINALS, LINKS, OR
STUDS. SERIOUS INJURY OR DEATH COULD RESULT
II. CONSTANT EXCITATION TEST (24 V BATTERY TEST)

The generator “no load” voltage is dependent on exciter input voltage and
generator speed. With the generator operating at rated speed and 24 volt DC
applied to the exciter field, the generators terminal voltage will be near rated
value.
1. Shutdown the generator set and connects a voltmeter on the generator
terminals.
2. Disconnect the regulators F+ (F1) and F- (F2) leads and connect them to a
24V battery. Caution should be taken to ensure that the battery is not
exposed to any potential arcing.
3. With no load on the generator (main breaker open) run the generator at
rated speed. Measure the generator’s terminal voltage and compare this
value with values recorded during installation.
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If voltage readings are normal, the main generator and excitation are operating
properly. Troubleshooting should continue with the regulator. If readings are not
normal the problem is in the generator. Continue testing diodes, surge
suppressor, and windings.
III. CONTINUITY / RESISTANCE TEST
The generator has four components which can be checked using an ohm meter;
exciter stator, exciter rotor, main stator and main rotor. Each of these
components are comprised of various windings which form a complete electrical
path of relatively low resistance. Using an ohm meter measure the loop
resistance of each component. Compare these measured values with the values
listed in the specification section of this manual.
Note that very small resistance values require precision equipment to make
accurate measurement; however, a standard ohm meter will provide a good
indication of winding continuity.
IV. INSULATION TEST

Insulation resistance is a measure of the integrity of the insulating materials that
separate the electrical windings from the generator’s steel core. This resistance
can degrade over time or be degraded by contaminants: dust, dirt, oil, grease, and
especially moisture. Most winding failures are due to a breakdown in the
insulation system.
In many cases, low insulation resistance is caused by moisture. Most winding
failures are due to a breakdown in the insulation system. In many causes, low
insulation resistance is caused by moisture collected when the generator is
shutdown.
Insulation resistance is measured with a megger (mega-ohm meter). A megger
measures insulation resistance by placing 500 volts between the winding and the
frame of the generator. Caution must be taken to remove all electronic devices
(regulators, diodes, surge protectors, capacitors, protective relays, etc.) from the
winding circuit before on the main stator, main rotor, exciter stator, and exciter
rotor. Minimum resistance is 2 mega-ohms. If the winding resistance is low it
must be dried (see maintenance section) or repaired.
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V. DIODE TESTING
If the generator is close coupled to an engine, it may be necessary to “bar over”

the engine in order to gain access to a given area of the rectifier assembly.
NEVER use the generator’s fan as a fulcrum to accomplish this. Use the engine
manufacturer’s recommended practice to manually turn over the engine. To
prevent possible injury to personnel, and damage to the equipment, ensure that
the engine cannot start during this procedure.
Remove the two main rotor leads and the three exciter rotor leads from the
rectifier assembly. The rectifier assembly is now electrically isolated from the
generator. The diodes remain mounted and the diode leads remain connected to
the terminal posts. Using an ohmmeter or a battery light continuity tester, place
one test probe on the diode lead terminal post. In succession, touch the other test
probe to the lead screw hole in each heat sink. Reverse the probes and repeat
the procedure. You have now tested the three diodes connected to this terminal
post in both the forwarded and reverse direction. Repeat the procedure using the
other diode terminal post.
When the positive test probe is connected to the diode’s anode and the negative
test probe is connected to the diode’s cathode (forward biased), the diode will
switch on and conduct electricity. This is observed by a low resistance reading
when using an ohm meter or the lighting of the bulb when using a battery light
continuity tester.
Reversing the test leads (reverse biased) will result in the diode switching off and
no electricity will be conducted. The results of these tests should indicate one of
three conditions:
1. Good diode: Will have a much greater resistance in one direction than the
other. Typical reverse biased resistance will be 30,000 ohms or greater,
while forwarded biased resistance will be less than 10 ohms. The battery-
light tester will have the light “on” in one direction and “off” in the other.
2. Shorted condition: Ohmmeter reading will be Zero, or very low in both

directions. The continuity tester will have the light “on” in both directions.
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3. Open condition: Ohmmeter will have a maximum (infinity) reading in both

directions. Continuity tester light will be off in both directions.
Diode failure after a 25hour “run-in” period is generally traceable to external

causes such as a lightning strike, reverse current, line voltage spikes, etc. All 6
diodes are essentially in the same circuit. When a diode is stressed to failure,
there is no easy method to determine remaining life in the other diodes.
To avoid possible continued failures, it is recommended that the entire rectifier
assembly be replaced rather than replacing individual diodes.
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8. SERVICE
I. GENERAL
The service procedures given in this section are those which can reasonably be
conducted on-site with a minimum number of special tools and equipment.
Qualified maintenance personnel should conduct all service procedures.
Replacement parts may be ordered through an authorized service center or
directly from the factory.
II. FIELD FLASHING
Restoring Residual Magnetism

To restore residual-magnetism to the generator, connect a 24 volt battery to the
exciter field while the generator using the following procedure:
1. Shutdown the generator set. Remove the exciter field leads F+ and F-
from the regulator.
CAUTION:
Failure remove the exciter field leads from the automatic voltage
regulator during flashing procedures may destroy the regulator.
2. Connect the F+ and F- leads to the battery’s corresponding positive and
negative terminals. This should be done using an appropriate length of
lead wire to separate the battery from the point of connection (batteries may
explode which exposed to an electric arc). After 3 to 5 seconds, remove
the F- lead. An inductive arc should result. If no arc is drawn, repeat the
procedure.
3. Reconnect the F+ and F- leads to the regulator. Restart the generator and
verify that terminal voltage is developed. If terminal voltage does not
develop, repeat the field flashing procedure and / or consult the trouble
shooting section.
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III. BEARING REMOVAL
Prior to performing this operation, it is suggested that the alternator’s shaft be

rotated until two of the main rotor poles are in a vertical position. Once the
bearing bracket is backed out, the rotor will drop on the main stator core.
Having the rotor in this position will limit the amount of rotor drop to that of the
air gap. Visually inspect the bearing bore for damage or wear. If worn or
damaged, replace prior to reassemble.
Visually inspect the bearing bore for damage or wear. If worn or damaged,
repair or replace prior to reassembly.
IV. BEARING REPLACEMENT
Using a bearing puller, remove the existing bearing. It is strongly

recommended that the bearing be replaced any time the it is removed from the
shaft. ALWAYS install the same type and size bearing that was supplied as
original equipment. Order by part number from the parts list, and include the
unit serial number and part number when ordering. Heat the bearing to a
maximum of 100 Deg.C (212 Deg.F) in an oven. Apply a thin coat of clean
lubricating oil Press-fit area of the rotor shaft.
Using suitable heat resistant gloves, install the bearing over the end of the
shaft until it seats against the shaft shoulder. The bearing should slide on the
shaft and be seated without excessive force. Should the bearing bind on the
shaft prior to being seated against the shoulder, a spice of tubing slightly larger
than the press fit area can be used to drive the bearing to its final position.
Using light taps with a soft mallet, apply pressure to the inner race only.
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V. RECTIFIER ASSEMBLY REMOVAL
The rectifier assembly cannot be removed until the opposite drive end bearing
bracket and bearing have been removed (see bearing removal procedure).
Remove the three exciter rotor leads and the two main rotor leads from the
posts. Remove the screws securing the rectifier assembly and pull the
assembly free from the shaft.
VI. DIODE REPLACEMENT
Prior to installing a replacement diode on the heat sink, apply a thin film of
conductive heat sink compound around the base of the diode. When installing
a diode on the heat sink, care should be taken not to over torque the retaining
nut which could cause damage to the device. The failed diode lead may be
unsoldered from assembly, and re-soldered on the replacement diode.
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9. TROUBLE SHOOTING
RESTORING RESIDUAL MAGNETISM (FLASHING THE EXCITER FIELD)
To restore the small amount of residual magnetism necessary to begin voltage buildup,
kindly follow the below mentioned steps. While the alternator set is at rest as follows:
This however will be required in cases where unit remained unused for long period.
1. Remove exciter field leads F+ and F- from the voltage regulator.
CAUTION: Failure to remove the field leads from the regulator during flashing
procedures may destroy the regulator.
2. Measure the exciter field resistance from the F+ to the F- lead. It should be about
11 ohms. Also, check to be sure there is no path to ground.
3. Connect F+ to the positive pole of the battery with 5Amps fuse in series (+24V).
4. Hold the F- lead by the insulated portion of the lead wire, touch F- to the negative pole
of the battery for about 5 to 10 seconds, then remove.
5. Reconnect F+ and F- to the regulator. Repeat the procedure if the alternator fails to
build voltage.
The first and perhaps most important step of trouble shooting should to be to gather as
much first hand information as is possible from personnel who may have been present
when the failure occurred. Information as to how long the unit had been operating, what
loads were on line, weather conditions, if any protective equipment or devices
functioned, etc., can help isolate the problem.
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TROUBLE, SYMPTOM PROBABLE CAUSE TEST, CHECK, AND/OR

AND CONDITION REMEDY
1.Alternator produces a. Regulator Fuse or  Check fuse with an
no voltage or residual Field Transformer fuse ohmmeter. Replace bad
voltage Blown fuse refer to regulator
manual.
b. AVR Shutdown switch  Check and replace if faulty.
may be in OFF
position/faulty
c. Incorrect Connection  Verify alternator connections.
Refer to drawings supplied
with alternator set and/or this
manual.
d. Defective  Inspect all wiring for grounds
Connections/Wiring open circuits, short circuits.
e. No regulator input  Check connections and
measure voltage at regulator
input.
f. Defective diodes, surge  Test alternator with constant
suppressor of alternator excitation (24 volt battery
windings test).
g. Voltage regulator  Replace regulator.
inoperative
2.Alternator Produces a. Under speed  Check speed using
Low Voltage - No Load Operation tachometers/frequency
meters.
b. Defective metering Verify operation of panel meter
with another meter that is known
to be accurate. If the metering
panel is defective, please refer
metering troubleshooting.
c. Incorrect Alternator Verify alternator connections,
Connections refer to drawings supplied with
alternator set.
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d. Defective Connections  Inspect all wiring for
/ Wiring grounds, open circuits, short
circuit, loose connections,
and dirty connections.
e. Regulator Adjustments  Adjust regulator. Refer to
regulator manual.
f. Defective Diodes,  Test alternator with constant
Surge Suppressor, or excitation (24 Volt battery
Alternator Windings. test).
 Check no load DC excitation

across regulator terminals
F+ & F-.If greater than value
recorded, proceed with diode
and winding checks. If data
not available conduct 24 V
battery test detailed.
g. Voltage Regulator not  Adjust or replace regulator.
Operating Properly. Refer to regulator manual.
3.Alternator produces a. Overload  Measure amps and verify
low voltage when load is that the load does not
applied exceed the nameplate rating
of the alternator.
b. Defective metering Verify operation of metering
panel ammeter by using a
separate meter that is known to
be accurate. If the metering
panel is faulty please refer
metering panel trouble shooting
chart
d. Faulty Main Rotor  Check DC excitation voltage
across regulator terminals
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F+ and F- compare to full
load excitation on
nameplate. If regulator is
producing DC voltage
considerably above the full
load level, have service shop
check main rotor for
defective pole windings.
4.Alternator produces a. Defective metering  Verify operation of metering
high voltage - No Load panel with another meter that
is known to be accurate
b. Incorrect Operating  Verify speed with tachometer
Speed or frequency meter.
c. Incorrect Connections  Verify alternator connections.
Refer to drawings supplied
with alternator set and/or this
manual.
d. Defective  Inspect all wiring for ground,
Connections/Wiring open circuits, short circuits.
e. Regulator Adjustments  Adjust regulator. Refer to
regulator manual.
f. Diode Polarity Incorrect  Check diodes verify proper
diodes are installed and
polarity is correct.
g. Voltage Regulator not  Adjust or replace regulator.
Operating Properly. Refer to regulator instruction
manual.
5.Alternator Produces a. Leading power factor  Correct load power factor.
high voltage when load load.
is applied
6.Alternator voltage is a. Incorrect speed  Verify speed with tachometer
fluctuating or frequency meter.
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b. Unstable speed  Verify prime mover stability
c. Defective/Loose  Inspect all wiring for loose or
wiring Connections dirty connections
d. Defective regulator  Replace regulator. Refer to
regulator manual.
e. Defective diodes,  Test alternator with constant
Surge Suppressor, or excitation (24 volt battery
Alternator windings test)
f. Defective bearing or  Replace worn bearing.
worn bearing carrier Check bearing carrier for
causing an uneven air wear. Replace as
gap. necessary.
7.Alternator builds a. Regulator protective  Check for output voltage with
voltage from start-up circuit is operating known meter. If output
then goes to low voltage is above 250V (P-P)
(residual) voltage proceed to step b. If not,
replace the regulator.
b. Output voltage 250V  Check for loose connections
in AVR sensing wires. If
found ok, AVR is faulty
replace the same.
8.Equipment runs a. Voltage waveform is  Analyze load. Excessive
normally on utility distorted. SCR (Thyristor) loading will
power, but will not run cause distortion. Some
on alternator set equipment may be sensitive
to distorted waveforms.
Refer to Mak.
b. Improper alternator  Check alternator output
voltage and/or frequency voltage and frequency.
Compare to utility. If
alternator does not match
with utility, adjust as
necessary.
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c. Phase Sequence is  Compare alternator phase
Wrong sequence with utility. If
alternator phase sequence is
improper, reverse two
alternator leads at circuit
power contactor.
Page 42

2825 Gpu 90 Kva Ai-Sats Operational Manual1

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OPERATION AND MAINTENANCE MANUAL Air+Mak

OPERATION AND MAINTENANCE

DESIGNED & MANUFACTURED BY:

AIR + MAK INDUSTRIES INC.

OPERATION AND MAINTENANCE MANUAL Air+Mak

2. Special Features ………………………………………….. 2

3. Detailed Description ……………….…………………….. 4

5. Major Components Details ……………...……………….. 18

2. Pre commissioning Check ……………………………….. 2

3. Do's and Don'ts …………………………………………... 3

4. Operating Instructions ……………………….…………... 4

6. MAK GSE MONITOR V8 Description ……………….. 7

OPERATION AND MAINTENANCE MANUAL Air+Mak

2. Trouble Shooting ………………………………………….. 6

3. Replacing of PCB’s ……………………………………….. 30

1. Recommended spares ………………………..………….. 2

2. First aid for electrical accident ……………….………….. 4

1. Automatic voltage regulator …………………..………….. 2

OPERATION AND MAINTENANCE MANUAL Air+Mak

OPERATION AND MAINTENANCE MANUAL Air+Mak

 Cloud Networking Enabled System for Remote Diagnosis &

 Advanced 32 bit Control System with operating capability @ 60 MHz

 Single Touch options for all System Controls.

 Tested with Highly rugged Environmental Conditions Such as

 Facilitated with Field programmable option with password protection

OPERATION AND MAINTENANCE MANUAL Air+Mak

 Tracking of GPU based on Location using GPS, based on Serial

OPERATION AND MAINTENANCE MANUAL Air+Mak

Note: Please refer the engine manual for more details.

OPERATION AND MAINTENANCE MANUAL Air+Mak

e) COUPLING OF ENGINE AND ALTERNATOR

f) METERING CONTROLS, PROTECTION AND OUTPUTS

1) MAK GSE MONITOR V8:

OPERATION AND MAINTENANCE MANUAL Air+Mak

OPERATION AND MAINTENANCE MANUAL Air+Mak

4) Auxiliary supply MCB’s: (Optional)

OPERATION AND MAINTENANCE MANUAL Air+Mak

g) Output Cable Assembly

AC Output cable Assembly:

OPERATION AND MAINTENANCE MANUAL Air+Mak

h). GPU Details:

2) MECHANICAL DETAILS WITH TRUCK:

OPERATION AND MAINTENANCE MANUAL Air+Mak

5) MAK GSE MONITOR V8:

Output Monitoring parameters:

3 Phase AC Voltage with line-to-line or line-to-neutral

OPERATION AND MAINTENANCE MANUAL Air+Mak

OPERATION AND MAINTENANCE MANUAL Air+Mak

MAK GSE MONITOR V8

OPERATION AND MAINTENANCE MANUAL Air+Mak

i) TRIP LIMITS FOR 90 KVA ACDC GPU

CONDITIONS LIMITS TIME DELAY

UNDER VOLTAGE (L- N)

OVER VOLTAGE (L- N) 130V 5 SECONDS

UNDER FREQUENCY 383 5 SECONDS

OVER FREQUENCY 420 3 SECONDS

OPERATION AND MAINTENANCE MANUAL Air+Mak

OVER LOAD FOR AC PWR SOCKET

100% (0 – 260A) NO TRIP

NEUTRAL OPEN 5 SECONDS

PHASE REVERSE 5 SECONDS