Technical Manuel 60 Kva

Document No.
: Revision: Date: Created by: Approved by:
M020252 D 25/01/2010 J.McKell S.Doherty
USER MANUAL FOR NEF45 60kVA (AI & AUS) Document M02.0252
Document No.: Revision: Date: Created by: Approved by:
TABLE OF CONTENTS
1.0 SAFETY
1.1. GENERAL INFORMATION .....................................................................................................1 1.2. ELECTRICAL POWER ...........................................................................................................1 1.3. MATERIALS ............................................................................................................................1 1.4. OPERATIONAL PRECAUTIONS ...........................................................................................1 1.5. SAFETY LABELS ...................................................................................................................2
2.0
NOISE EMISSION
2.1. NOISE CONTROL PROHIBITED ACTS.................................................................................4 2.2. GENERATOR NOISE EMISSION CONTROL INFORMATION .............................................4
3.0
HANDLING
3.1. LIFTING / HANDLING .............................................................................................................5 3.2. STORAGE / TRANSPORT .....................................................................................................5
4.0
INSTALLATION
4.1. UNPACKING ...........................................................................................................................6 4.2. LOCATION OF THE PLANT ...................................................................................................6 4.3. COMMISSIONING ...................................................................................................................6 4.4. PRIOR TO STARTING ............................................................................................................6 4.5. ELECTRICAL CONNECTION .................................................................................................6 4.6. EARTHING ..............................................................................................................................6
5.0
GENERAL DATA
5.1. GENERAL OPERATION .........................................................................................................7 5.2. DESIGN LOAD CAPACITY ....................................................................................................7 5.3. DESIGN TEMPERATURES ....................................................................................................7 5.4. CANOPY & BASE FRAME .....................................................................................................7 5.5. DIESEL ENGINE .....................................................................................................................8 5.6. ENGINE LUBRICATION SYSTEM .........................................................................................8 5.7. ENGINE COOLING SYSTEM .................................................................................................8 5.8. ENGINE FUEL SYSTEM .........................................................................................................8 5.9. EXHAUST SYSTEM ................................................................................................................9 5.10. ENGINE CONTROL SYSTEM ................................................................................................9 5.11. GENERATOR ..........................................................................................................................9 5.12. MAIN CIRCUIT BREAKER .....................................................................................................9
6.0
OPERATING INSTRUCTIONS
6.1. OPERATING CONTROLS AND INSTRUMENTS ................................................................11
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6.2. DESCRIPTION OF 5310 GENERATOR CONTROLLER .....................................................13 6.3. OPERATING PROCEDURE .................................................................................................15 6.4. ALARM FUNCTIONS ............................................................................................................16 6.5. CHANGING PARAMETERS .................................................................................................16
7.0
MAINTENANCE
7.1. GENERAL .............................................................................................................................18 7.2. MAINTENANCE SCHEDULE ...............................................................................................19 7.3. WEEKLY MAINTENANCE ....................................................................................................21
8.0
LUBRICATION
8.1. GENERAL INFORMATION ...................................................................................................22 8.2. GENERATOR OIL CHANGE ................................................................................................22 8.3. OIL SPECIFICATION ............................................................................................................22
9.0
TROUBLE SHOOTING
9.1. INTRODUCTION ...................................................................................................................23 9.2. ACTION PLAN ......................................................................................................................23 9.3. TROUBLE SHOOTING CHART ...........................................................................................24
APPENDIX A: APPENDIX B:
Document No. G080316 SHT. 1 to 3
Material Safety Data Sheets Equipment Data Sheet

Rev. A
APPENDIX C:
Drawing No. A050215 SHT. 1 of 1
Installation Outline Drawing

Rev. B
APPENDIX D:
Drawing No. D210654 SHT. 1 of 1
Control Panel Layout

Rev. A
APPENDIX E:
Alternator & AVR Schematic Diagram

Rev. A Title Alternator & AVR Schematic Diagram
APPENDIX F:
Main Load & Metering Schematic Diagram

Rev. A Title Main Load & Metering Schematic Diagram
APPENDIX G:
DC Control Schematic Diagram

Rev. A Title DC Control Schematic Diagram
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APPENDIX H:
Terminal Layout & Engine Wiring

Rev. B Title Terminal Layout & Engine Wiring
APPENDIX J:
Drawing No. D200191 SHT. 1 of 1 D200192 SHT. 1 of 1
Livery Layout
Rev. A A Title Livery Layout AI Livery Layout - AUS
APPENDIX K:
Document No. M040131 SHT. 1 of 1
Manufacturers Component Data

Rev. B
APPENDIX L: APPENDIX M: APPENDIX N:
Lifting Beam Certificate 152061/001 DNV Spark Arrestor Certificate M11070 International Contact Information
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1.0
SAFETY
1.1. GENERAL INFORMATION
Ensure that the operator reads and understands the decals and consults the manuals before maintenance or operation. Ensure that the Operation and Maintenance manual, and the manual holder, are not removed permanently from the machine. Ensure that maintenance personnel are adequately trained, competent and have read the Maintenance Manuals. Make sure that all protective covers are in place and that the canopy/doors are closed during operation. The specification of this machine is such that the machine is not suitable for use in flammable gas risk areas. WARNING: NO ATTEMPT SHOULD BE MADE TO OPERATE IN SUCH AREAS WITHOUT THE EXPRESS AUTHORITY FROM AGGREKO. Installation of this generator must be in accordance with recognised electrical codes and any local Health and Safety Codes.
1.2.
ELECTRICAL POWER
Prior to installation of the generating set you should check that the electrical load to be applied is within the rated output of the machine at the site ambient conditions. Before carrying out any maintenance or repairs to the Engine/Alternator assembly disconnect the starting battery and isolate the alternator from the switchboard. Before carrying out any maintenance repair to the AC and DC circuits, isolate these from external control panel and power supplies. Ensure that the generator set and the load it is connected to are properly earthed. The generating set should be connected to the load only by a qualified electrician and in accordance with the applicable regulations.
1.3.
MATERIALS
The following substances are used in the manufacture of this machine and may be hazardous to health if used incorrectly:
Antifreeze Engine Lubricating Oil Preservative Grease Rust Preventative Diesel Fuel Battery Electrolyte. AVOID INGESTION, SKIN CONTACT AND INHALATION OF FUMES. When handling fuel, lubricating oil, cooling fluid and battery electrolyte, wear appropriate personal protection equipment. For further information, consult Material Safety Data Sheet contained in this manual. Avoid build-up of Engine Exhaust Fumes in confined spaces. Avoid breathing Exhaust Fumes.
1.4.
OPERATIONAL PRECAUTIONS
Never operate unit without first observing all safety warnings and carefully reading the operation and maintenance manual shipped from the factory with this machine. IF IN DOUBT CONTACT AGGREKO. Never operate the engine of this machine inside a building without adequate ventilation. Avoid breathing exhaust fumes when working on or near the machine. Do not alter or modify this machine.
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A battery contains sulphuric acid and can give off gases, which are corrosive and potentially explosive. Avoid contact with skin, eyes and clothing. In case of contact, flush area immediately with water. Exercise extreme caution when using booster battery. To jump battery, connect ends of one booster cable to the positive (+) terminal of each battery. Connect one end of other cable to the negative (-) terminal of the booster battery and other end to a ground connection away from dead battery (to avoid a spark occurring near any explosive gases that may be present). After starting unit, always disconnect cables in reverse order. Never operate unit without first observing all safety warnings and carefully reading the operation manual. This machine may include such materials as oil, diesel fuel, antifreeze, oil/air filters and batteries which may require proper disposal when performing maintenance and service tasks. Contact local authorities for proper disposal of these materials. This machine produces loud noise with the doors open. Extended exposure to loud noise can cause hearing loss. Always wear hearing protection when doors are open. Never inspect or service unit without first disconnecting battery cable(s) or using the battery isolator switch to prevent accidental starting. Do not remove the pressure cap from a HOT radiator. Allow radiator to cool down before removing pressure cap. Do not use petroleum products (solvents or fuels) under high pressure as this can penetrate the skin and result in serious illness. Wear eye protection while cleaning unit with compressed air to prevent debris from injuring eye(s). Hot pressurized fluid can cause serious burns. Do not open radiator while hot. Rotating fan blade can cause serious injury. Do not operate without guard in place. Use care to avoid contacting hot surfaces (engine exhaust manifold and piping, etc.). Never operate unit with guards, covers or screens removed. Keep hands, hair, clothing, tools, etc. well away from moving parts.
1.5.
SAFETY LABELS
Look for these signs on machine, which point out potential hazards to the safety of you and others. Read and understand thoroughly. Heed warnings and follow instructions.
DANGER FIRE RISK Risk of Electric Shock

)
DO NOT STAND IN FRONT OF ALTERNATOR AIR OUTLETS WHEN UNIT IS RUNNING
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CAUTION Hot
DISCONNECT STARTING BATTERY AND ISOLATE LOAD BEFORE WORKING ON ENGINE / ALTERNATOR ASSEMBLY
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2.0
NOISE EMISSION
2.1. NOISE CONTROL PROHIBITED ACTS
WARNING
Tampering with noise control system prohibited
The following acts or misuse of the unit are prohibited: 1) The removal or rendering inoperative by any persons, other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new generator for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use Or 2) The use of the generator after such device or element of design has been removed or rendered inoperative by any person. Among those acts included in the prohibition against tampering are these: Removal or rendering inoperative any of the following: a) The engine exhaust system or parts thereof. b) The air intake system or parts thereof. c) Enclosure or parts thereof. Removal of any of the following: a) Fan shroud b) Vibration mounts c) Sound absorption material Operation of the generator with any of the enclosure doors open.
2.2.
GENERATOR NOISE EMISSION CONTROL INFORMATION

A. The removal or rendering inoperative, other than for the purpose of maintenance, repair, or replacement of any noise control device or element of design incorporated into this generator in compliance with the noise control act; B. The use of this generator after such device or element of design has been removed or rendered inoperative. THIS GENERATOR HAS BEEN SPECIFICALLY DESIGNED WITH A SOUND ATTENUATING ENCLOSURE. THE CANOPY DOORS SHOULD REMAIN LOCKED SHUT UNDER NORMAL OPERATING CONDITIONS. UNDER ANY OTHER CONDITIONS EXCESSIVE NOISE LEVELS CAN BE PRODUCED AND PROLONGED EXPOSURE IS HAZARDOUS TO HEARING.
FOR SAFETY, EAR PROTECTION SHOULD ALWAYS BE WORN WHEN WORKING IN THE VICINITY OF AN OPERATING GENERATOR SET.
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3.0
HANDLING
3.1. LIFTING / HANDLING
The generator set includes 1 lifting beam and forklift pockets. All lifting and handling equipment must be adequately rated for applicable weights. During all lifting and handling operations the following weights must be considered. Complete Package Max. Fuel Complete Package Without Fuel 4147 lbs 3527 lbs (1881 kg) (1600 kg)
Bolt on steel plate buffers are located at the front and rear of the base to protect the body of the generator. Where 2 point lifting is provided, ensure that the correct length of strap / wire rope is used on each lifting beam to ensure a level lift. Also ensure that the included angle does not exceed 90. CAUTION: THE GENERATOR SET SHOULD NOT BE LIFTED OR DRAGGED BY THE END BUFFERS.
3.2.
STORAGE / TRANSPORT
Carry out the following points before transporting the generator or preparing the generator for storage. Empty the fuel tank (in case of overseas transport). Disconnect the battery terminals (in case of overseas transport). Ensure that the radiator cap is fitted securely and the exhaust rain cap is closed. Close all doors. All units are to be loaded flat onto transport and properly secured.
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4.0
INSTALLATION
4.1. UNPACKING
Ensure that the correct fork lift truck slots or marked lifting / tie down points are used whenever the machine is lifted or transported.
4.2.
LOCATION OF THE PLANT

The generator can be installed on any solid, flat and level surface capable of supporting the full operating load of the package. A dry, well-ventilated area where the atmosphere is as clean as possible is recommended. Ensure that the machine is positioned securely and on a stable foundation. CAUTION: A minimum of 1 metre (3 ft) all round the generator is recommended. Hot air will exit from the roof outlet. It is important that this hot air does not re-circulate to the package inlet. The generator must be allowed sufficient space all round and above, to enable the effective removal of the cooling air which, in turn, will reduce the risk of re circulating the cooling air back through the generator. Adequate clearance needs to be allowed around and above the machine to permit safe access for specified maintenance tasks. Hard surfaces may reflect noise with an apparent increase in the decibel level. It is recommended that provision be made for lifting heavy components during major overhaul. NOTE: When operating at elevated altitude please refer to engine manufacturers guidelines for power deration.
4.3.
COMMISSIONING
Upon receipt of the unit, and prior to putting it into service, it is important to adhere strictly to the instructions given below in section 4.4 PRIOR TO STARTING.
Ensure all persons concerned are suitably competent with generator installations. Ensure that the operator reads and understands the decals and consults the manuals before maintenance or operation. Ensure that the position of the emergency stop device is known and recognised by its markings. Ensure that it is functioning correctly and that the method of operation is known.
4.4.
PRIOR TO STARTING
Ensure that the unit is clean, free from debris and fluids. All connections, joints, seals must be correctly fitted and tightened. All filters, louvers and air inlets are free and open. Ensure that there is a safe working procedure which has been issued by supervisory personnel, and that all persons concerned with the operation of the generator understand it. Ensure that the safety procedure to be applied is based on the appropriate national and local regulations. Ensure that the safety procedure is followed at all times.
4.5.
ELECTRICAL CONNECTION
A suitably trained electrician should carry out all electrical connections. Ensure the generator main isolator is off and that the power cables are in good condition. Ensure that the phases are correct after the cables have been connected. Ensure all safety covers are back in place after electrical connection is complete.
4.6.
EARTHING
An external earthing boss is fitted onto the base frame. This allows a dedicated earthing connection if required.
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5.0
GENERAL DATA
NOTE: Each generator of this type is uniquely identified by a Plant Number and Serial Number indicated on the identification plate affixed to the outside of the control panel. This information is required when ordering spare parts. Major component serial numbers are contained within the manual. The technical data defining the generator and the limits on its operating environment are tabulated in the Equipment Data Sheet. A copy of the Equipment Data Sheet has been included in the manual. In order to assist in the operation and maintenance of the generator, a full set of electrical and installation drawings has been included in the manual.
5.1.
GENERAL OPERATION
The generator is a diesel engine driven alternator with control electronics, mounted on a bedplate with internal fuel tank. The standard package is composed of the following:
Alternator and engine assembly Pressurised oil system Automated control system Instrumentation Safety provisions Engine cooler pack Spark arrestor / Silencer Internal fuel tank The engine and alternator are integrally mounted. This assembly is isolated from the base by rubber isolation mounts.
5.2.
DESIGN LOAD CAPACITY

The GHP/NEF45 (60kVA) generator set can be run up to a maximum of 59.4 kVA at prime power rating 50hZ.
5.3.
DESIGN TEMPERATURES
The GHP/NEF45 (60kVA) generator set can operate through an ambient temperature range of:
-10C (14F) to 35C (95F)
5.4.
CANOPY & BASE FRAME

The overall dimensions for the generator set are AI AUS = = 2660 X 1000 X 1775 mm 3034 X 1000 X 1775 mm
The canopy is manufactured from folded and bolted Zintec and has access to the inside of the generator through lockable doors. The base frame has 120% capacity of the fuel tank to prevent fuel leaking out of the generator set in the event of a fuel leakage inside the generator.
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5.5.
DIESEL ENGINE
The generator set uses an Iveco NEF45 diesel engine, which is capable for either 50 Hz or 60 Hz. Details of the engine are outlined below. Type: Model: RPM: Nominal Engine Output @ 1500rpm: Governor: Starting System: Fuel Consumption @ Continuous 1500rpm: Four Stroke, 4 Cylinder In-line, Water Cooled, Turbo Charged Iveco NEF45 1500 / 1800 53.5kW @ Prime Power GAC Electronic 12V Battery System 13.7 L/Hr @ 100% Prime Power
5.6.
ENGINE LUBRICATION SYSTEM

The engine oil lubrication system includes pump, strainer, oil-water heat exchanger and sump all fitted internally within the engine block. Oil filtration is fitted to the side of the engine block for ease of access and maintenance. Sump Capacity: 11.5 Litres
The Lube oil specification is as per API/ASTM/SAE/CD (equivalent to series MIL-L-415993). Recommended oils are Castrol Tection T 15W-40 (previously called RX Super Plus), Shell Rimula 15W 40. Refer to manufacturers data for all filter information.
5.7.
ENGINE COOLING SYSTEM

The engine cooling consists of a pump, thermostat, heater and radiator assembly. Cooling fluid is from the radiator, through the pump, which is belt driven from the engine pulley. The thermostat controls the flow to the radiator. The radiator assembly is mounted at the front of the engine, with the fan mounted on the front of the pump. Cooling air enters the generator through the canopy end louvers and noise attenuation baffles. This air then passes into the canopy space then across the radiator assembly. The heated air from the radiator exits through the roof of the package. The coolant is factory filled with Shell anti-freeze and anti-corrosion coolant, in 50-50 water-coolant concentration, providing protection to 38C. Please consult Aggreko if filling is required.
5.8.
ENGINE FUEL SYSTEM

The engine fuel system consists of an internal fuel tank, Racor filter (see Figure 5.1), fine fuel filter, fuel pump, injection pump & nozzles. Fuel can be taken from either an external or the internal fuel tank. Fuel is pumped through the Racor filter to the fine fuel filters and then passed to the injectors and then to the injection nozzles. The internal fuel tank has a fuel capacity of 330 Litres. A fuel level sensor is fitted in the internal fuel tank. The fuel tank fill point is internal. There is 1 cleaning port on the fuel tank that is accessible through the canopy doors. External fuel supply can be connected to the package by disconnecting the internal tank supply and return hoses at the Racor filter and the internal tank connection. Internal supply and return fittings/valves must be re-configured to ensure that the engine fuel is not drawn from the onboard supply. The use of ASTM No. 2D fuel is recommended for optimum engine performance. At operating temperatures below 0C, acceptable performance can be obtained using blends of No. 1 and No. 2D. The use of lighter fuels can reduce economy. The viscosity of fuels must be kept above 1.3 cSt to provide adequate lubrication. Refer to manufacturers data for all filter information.
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5.9.
EXHAUST SYSTEM
The exhaust system consists of the exhaust ducting, exhaust silencer complete with spark arrestor and rain cap assembly. The exhaust gases exit the engine and are passed through the exhaust ducting and exhaust, out the top of the canopy through the rain cap assembly. Insulation and heat shields are fitted to the exhaust ducting to prevent user contact with high temperature surfaces. Manufacturer: Spark Arrestor: IMS DNV Certificate No M10084
5.10. ENGINE CONTROL SYSTEM

An Electronic GAC governor controls the engine output. A Deep Sea Electronic 5310 protection module is used to monitor the safety circuits and set the operation mode of the generator. See section 6.1.2 Safety Module for more detail.
5.11. GENERATOR
Manufacturer: Type: Voltage Range 50Hz: 60Hz: Newage Stamford UCI224E14 380-440 Volts 440-480 Volts Self Excited
Excitation System:
Voltage Regulator within 1% from no load to full load SX460 1 Phase configurable on Alternator TB
5.12. MAIN CIRCUIT BREAKER

Manufacturer: Type: Merlin Gerin NS 250N Fixed Four Pole, Electronic Overload Protection STR22SE
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Battery Isolator Switch Sump Pump
Oil Pressure Gauge
Racor Filter
Figure 5.1 - 60 kVA Generator Part Locations
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6.0
OPERATING INSTRUCTIONS
6.1. OPERATING CONTROLS AND INSTRUMENTS 6.1.1. CONTROL PANEL
The operating controls and instruments are arranged on the control panel as shown in figure 6.1. A description of each panel device is given in table 6.1.
Figure 6.1 Control Panel Exterior

1 2 3 4
Deep Sea 5310 controller DC on/off switch Earth Leakage Key Switch Circuit breaker handle Key for figure 6.1
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Figure 6.2 Control Panel Internals 1 2 3 Governor Controller AVR Current Transformer 4 5 6 Earth Leakage MCCB MCB1 Key for figure 6.2 7 8 9 MCB2 Diodes & Terminals Run Relay
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6.2.
DESCRIPTION OF 5310 GENERATOR CONTROLLER
6.2.1. GENERAL
The control module used on Aggreko canopy generator sets is the 5310 control module by Deep Sea. Figure 6.3 below shows the front panel layout of the 5310 control module.
10
4 5
Figure 6.3 5310 Generator controller 1 2 3 4 5 Display scroll buttons CB indication Stop button/alarm accept 1. Manual select 2. Scroll down/reduce setpoint 1. 2. Scroll up/increase setpoint 1 in normal mode 2 in configuration mode Key for figure 6.3 The 5310 generator control module has the following features: Text based LCD (supporting multiple languages) Comprehensive metering of electrical parameters (voltage, current, power) Engine parameter monitoring Manual and remote/standby operation Basic control of motorised circuit breakers Comprehensive range of alarms Compatible with different alternator configurations Support of electronic engines via J1939 CANBUS interface 6 7 8 9 10 1. Auto select 2. Accept setpoint value Mute alarm/lamp test Manual start Generator available indication Status LEDs
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On Aggreko canopy sets, binary inputs are configured for remote start input, circuit breaker status and alarms, e.g. Low fuel level or Air flap closed. Where a motorised breaker is fitted, 2 binary inputs are configured for circuit breaker open and circuit breaker close. Analogue inputs are configured for low oil pressure, high water temperature (either senders or discrete switches) and fuel gauge (where fitted). Binary outputs are configured for Air flap closed (on offshore sets) and, where a motorised breaker is fitted, for circuit breaker open and close outputs. In addition, one output is dedicated to provide a common alarm output which provides a positive DC signal in the event of any alarm.
6.2.2. DISPLAY PAGES

The 5310 module displays the following pages on the LCD. Pressing the green info button will scroll between these pages. 1. Status page This shows the current status of the generator; e.g. stop mode, waiting in manual, running in manual. When the generator is running, generator parameters are also shown (as displayed in figure 6.3). 2. Parameter pages The following parameters are displayed via the parameter pages. Pressing the Down arrow button will scroll between the parameter pages. Holding down the Down arrow button for 2 seconds will start auto-scroll through the parameter pages. RPM Frequency Engine run time Battery voltage Generator phase voltages Generator line voltages Generator currents Generator real power/apparent power and power factor Number of starts Oil pressure (if sensor fitted) Coolant temperature (if sensor fitted) If used in conjunction with an electronic engine (e.g. Cummins QSM11 or Scania DC12), a range of engine parameters are also displayed. 3. Current alarm page Displays the current alarms in clear text. Shutdowns which have not been acknowledged are displayed as flashing text. Shutdowns which have been acknowledged and warnings are displayed as constantly lit text. 4. Alarm log page Stores the last 15 shutdown conditions. Pressing the Down arrow button will scroll through the shutdown log.
6.2.3. FRONT PANEL LEDS

The following LEDs are provided. Green LED to indicate circuit breaker closed [symbol 2 in figure 6.3] Green LED to indicate Generator available (lit after warm-up timer has expired) [symbol 9 in figure 6.3] Red LEDs for stop, manual and auto indication Status LEDs to indicate: Remote start input signal present.
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Alternative voltage selected. When alternative voltage is selected, under and overvoltage protection is halved. In addition, overcurrent protection is doubled. Alternative voltage is intended for use when the generator set alternator windings are configured in parallel, as opposed to series configuration. Alternative frequency selected. For US generator sets, normal frequency is 60Hz and alternative frequency is 50Hz. For European and AI generator sets, normal frequency is 50Hz and alternative frequency is 60Hz. When alternative frequency is selected protection settings for over/under frequency and over/under speed are moved accordingly. Common alarm indication. This LED is lit if any alarm condition is detected.
6.3.
OPERATING PROCEDURE
CAUTION: - Always open the battery isolator switch to avoid unauthorised starting during transport and maintenance.
6.3.1. MANUAL OPERATION

To start generator: a. b. c. d. e. f. g. h. Prior to starting, exercise daily maintenance. See section 7.1. Turn on DC power. Check that no alarms are present. If a shutdown condition is present, the generator set will not be allowed to start. Press the manual select button. The display will read Waiting in Manual Press the manual start button. Once the generator has run-up to speed, check the frequency and voltage and adjust if necessary, either using the potentiometers or the Governor/AVR adjustment. Walk around the engine and check for any leakages. After the warm-up timer has expired, close the circuit breaker.
To stop generator: 1. 2. 3. Open circuit breaker. Allow the engine to cool down for at least 5 minutes, especially when the set has been running with a high load. Press engine stop.
6.3.2. REMOTE/STANDBY OPERATION

1. 2. 3. 4. 5. 6. Turn on DC power Check for alarms Press Auto select. The display will read Waiting in Auto The generator set can be started by providing a connection between terminals 2 and 3. Generator set can be stopped by removing the connection between terminals 2 and 3. A test run should be carried out at least once a week.
NOTE: When setting up for remote operation with a manual breaker, the generator set should be started with the breaker closed. Remove the link between terminals 18 and 19 so that the breaker can be closed when the generator set is stopped. CAUTION: In remote operation, motorised breakers will close automatically after the warm-up period. The 5310 controller is for single set use only and no synchronising facility is provided. When synchronising capability is required, POWERLINK, or an alternative system, must be used.
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6.4.
ALARM FUNCTIONS
When an alarm condition has been detected, the alarm page will be automatically displayed. Depending upon the severity of the alarm, the 5310 control module will take one of the following courses of action. 1. Warning Display the alarm in clear text and sound an audible alarm
2. -
Shutdown Display the alarm in clear text and sound an audible alarm Trip the circuit breaker Shutdown the generator set
3. -
Controlled shutdown Display the alarm in clear text and sound an audible alarm Trip the circuit breaker Cooldown the generator set for the cooldown period and shutdown the machine Figure 6.4 Alarm page display
Shutdowns which have not been acknowledged are displayed as flashing text. Shutdowns which have been acknowledged and warnings are displayed as constantly lit text. The audible alarm can be muted using the mute alarm button [symbol 7 in figure 6.3]. Warnings will be automatically removed when the relevant parameter has returned to within its normal operating range. Shutdowns require to be acknowledged using the stop button. If the shutdown condition is still present, the shutdown will continue to be displayed. When a shutdown condition is still present after the machine has shutdown, e.g. Emergency stop or Air flap closed, the module will prevent the generator set from cranking and starting until the condition has been removed and the shutdown has been acknowledged. Generator Locked -out will be displayed on the LCD. In the event of an alarm, the Common alarm LED will light A common alarm output, terminal 8, is provided, which will turn high (+12v DC or +24V DC) when any alarm is detected. The last 15 shutdown conditions will be stored in the shutdown log.
6.5.
CHANGING PARAMETERS
For most applications, required parameter changes can be undertaken from the front fascia. Full configuration can be undertaken using the configuration software.
To access the front panel editor Press the Stop/Reset and Info buttons simultaneously. Enter PIN Number
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With the limited access pin number, the following can be adjusted: Language Alternative Frequency Enable/Disable Alternative Voltage Enable/Disable AC System Droop Enable/Disable (electronic engines only) Droop percentage (electronic engines only) Contrast Date and Time
With the full access pin number, in addition to the above, the full range of alarm setpoints and timers can also be adjusted. Pressing the + and - buttons will scroll up and down through the parameters.
To adjust a parameter Scroll to the desired parameter using the + and - buttons Press the tick button and the parameter will start to flash Press the + or - button to adjust the parameter to the desired value Press the tick button to save the value To select another parameter to edit, press the + or button To exit the front panel configuration editor at any time, press the Stop/Reset button When adjusting the date and time, the Down arrow is used to scroll between minutes, hours, day, month and year
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7.0
MAINTENANCE
7.1. GENERAL
In addition to periodic inspections, many of the components in these units require periodic servicing to provide maximum output and performance. Servicing may consist of pre-operation and postoperation procedures to be performed by the operating or maintenance personnel. The primary function of preventive maintenance is to prevent failure, and consequently, the need for repair. Preventive maintenance is the easiest and the least expensive type of maintenance. Maintaining your unit and keeping it clean at all times will facilitate servicing. Ensure that maintenance personnel are adequately trained, competent and have read the Maintenance Manuals. Prior to attempting any maintenance work, be aware of the following: Any unauthorized modification or failure to maintain this equipment may make it unsafe and out of factory warranty. Use extreme care to avoid contacting hot surfaces (engine exhaust manifold and piping, etc.). Never operate this machine with any guards removed. Imperial and Metric hardware was used in the design and assembly of this unit. Consult the parts manual for clarification of usage. The machine cannot be started accidentally or otherwise, by posting warning signs and/or fitting appropriate antistart devices. All residual electrical power sources (mains and battery) are isolated. Prior to opening or removing panels or covers to work inside a machine, ensure that: Anyone entering the machine is aware of the reduced level of protection and the additional hazards, including hot surfaces and intermittently moving parts. The machine cannot be started accidentally or otherwise, by posting warning signs and/or fitting appropriate antistart devices. Prior to attempting any maintenance work on a running machine, ensure that: The work carried out is limited to only those tasks which require the machine to run. The work carried out with safety protection devices disabled or removed is limited to only those tasks which require the machine to be running with safety protection devices disabled or removed. All hazards present are known (e.g. pressurised components, electrically live components, removed panels, covers and guards, extreme temperatures, inflow and outflow of air, intermittently moving parts, safety valve discharge etc.). Appropriate personal protective equipment is worn. Loose clothing, jewellery, long hair etc. is made safe. Warning signs indicating that Maintenance Work is in Progress are posted in a position that can be clearly seen. Upon completion of maintenance tasks and prior to returning the machine into service, ensure that: The machine is suitably tested. All guards and safety protection devices are refitted. All panels are replaced, canopy and doors closed. Hazardous materials are effectively contained and disposed of. To assist with ordering spare parts and other service activities, a short form list of Component Manufacturers data has been included in this manual. Prior to engine starting, check the oil and coolant levels. Carry out a visual check of the following: Leaks.
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Loose or damage parts. Worn or damaged belts, change in engine appearance. Refer to the Maintenance Schedule for quick reference. Report unusual noise/vibration and/or exhaust smoke and ensure the generator set is kept clean, both inside and out.
7.2.
MAINTENANCE SCHEDULE
7.2.1. INSPECTION CRITERIA

Daily Engine Oil Level Fuel Tank (Fill at end of day) Gauges / Lamps Air Filter Fuel / Water Separator Drain Battery Connections / Electrolyte Radiator Coolant Level Fan / Alternator Belts Hoses (oil, air, intake, etc.) Automatic Shutdown System Visual Fasteners / Guards Engine Coolant Test Shutdown Switch Settings Test C=check (adjust if necessary) Refer to manufacturers operating and maintenance instructions for additional information and all other maintenance. C C C C C C C C C C C C C Weekly Monthly 3 Months / 500 Hrs Up to 6 Months / 1000 Hrs 12 Months / 2000 hrs
7.2.2. SERVICE CRITERIA

Daily Engine Oil & Filters Air Filter Element Fuel / Water Separator Element Fine Fuel Element Engine Coolant R=replace Refer to manufacturers operating and maintenance instructions for additional information and all other maintenance. * This figure should be in line with current service best practise. Weekly Monthly 3 Months / 400 Hrs* R R R R R Up to 6 Months / 1000 Hrs 12 Months / 2000 hrs
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7.2.3. DAILY MAINTENANCE

1) Check the engine oil level: 2) Stop the engine and wait 5 minutes to allow the oil to drain to the oil pan. 3) Remove the dipstick and check the oil level. 4) Replenish if necessary using a recommended grade of engine oil (see section 8). CAUTION: Never operate the engine with the oil level below the L mark or above the H mark. See FIG. 7.1 below.
Figure 7.1 - Engine Oil Level Check
7.2.4. CHECK THE FUEL TANK LEVEL.

Check the fuel level gauge on the control panel. Replenish as necessary using clean, good quality, diesel/Derv/Gas Oil that conforms to ISO or equivalent. Always ensure that the filler cap is replaced after replenishment.
7.2.5. CHECK THAT ALL METERS AND GAUGES FUNCTION CORRECTLY.

Start the generator and inspect the following items: Oil pressure gauge is between 65 & 75psi. After 5 minutes check that the engine oil temperature gauge reads between 45C & 55C. The voltage and frequency gauges are within specification. Fuel gauge indicates the tank is not empty. Engine hours display increases after 10 minutes. Safety module has no alarm indicators on. Press the LAMP TEST button on the control panel and confirm that all indicator lamps are working.
7.2.6. CHECK THE AIR FILTER.

NOTE: In dusty conditions clean the primary filters regularly. Check the air filter restriction indicator (if fitted) next to the air filter above the engine. If this has changed to the restricted position, then the filter will need replaced.
7.2.7. CHECK THE BATTERY.
- 20 -
Check that the battery connections are properly installed and that the electrolyte level in each cell covers the top plates. If necessary, top up with clean distilled water.
7.2.8. CHECK FOR LEAKS.

There are several fluids used inside the generator, e.g. diesel, oil, coolant. Look for signs of leakage all around the engine. Any source of leak should be checked and fixed. Clean up any fluid lying inside the generator and dispose of according to the appropriate local regulations. Recurring leaks should be reported to AGGREKO.
7.3.
WEEKLY MAINTENANCE
7.3.1. CHECK THE WATER/ANTIFREEZE LEVEL.

Stop the engine and wait for the temperature to cool before checking the coolant level. Remove the pressure cap slowly to relieve the pressure of the cooling system. Failure to do so could result in personal injury from heated coolant spray (See Figure 7.2). Check the coolant level. Replenish with the correct coolant fluid as necessary (see section 8).
Figure 7.2 - Coolant Level Check
7.3.2. CARRY OUT A VISUAL CHECK OF THE DRIVE BELTS.

The cooling pump, alternator and radiator fan are driven by a dual belt arrangement from the engine pulley. Check the belts for signs of wear. Check the belt tension. NOTE: Do not remove guards.
- 21 -
8.0
LUBRICATION
8.1. GENERAL INFORMATION
Lubrication is an essential part of preventive maintenance, affecting to a great extent the useful life of the unit. Different lubricants are needed and some components in the unit require more frequent lubrication than others. Therefore, it is important that the instructions regarding types of lubricants and the frequency of their application be explicitly followed. Periodic lubrication of the moving parts reduces to a minimum the possibility of mechanical failures. The Preventive Maintenance Schedule shows those items requiring regular service and the interval in which they should be performed. A regular service program should be developed to include all items and fluids. These intervals are based on average operating conditions. In the event of extremely severe (hot, cold, dusty or wet) operating conditions, more frequent lubrication than specified may be necessary. Details concerning lubrication of the running gear are in Maintenance Section.
8.2.
GENERATOR OIL CHANGE

These units are normally furnished with an initial supply of oil sufficient to allow operation of the unit for approximately 3 months or up to 400 hours in line with current service recommendations, whichever comes first. The unit will however need to be topped up with oil during this period. If a unit has been completely drained of all oil, it must be refilled with new oil before it is placed in operation. Refer to specifications in Lubrication Table. NOTICE: Some oil types are incompatible when mixed and result in the formation of varnishes, shellacs, or lacquers that may be insoluble. Such deposits can cause serious problems including clogging of the filters. Where possible, do NOT mix oils of different types and avoid mixing different brands. A type or brand change is best made at the time of a complete oil drain and refill. If the unit has been operated for the time/ hours mentioned above, it should be completely drained of oil. If the unit has been operated under adverse conditions, or after long periods in storage, an earlier change period may be necessary as oil deteriorates with time as well as by operating conditions. An oil change is good insurance against the accumulation of dirt, sludge, or oxidized oil products. Completely drain the reservoir and piping. If the oil is drained immediately after the unit has been run for some time, most of the sediment will be in suspension and, therefore, will drain more readily. However, the fluid will be hot and care must be taken to avoid contact with the skin or eyes. After the unit has been completely drained of all old fluid, close the drain valve. Add oil in the specified quantity at the filler plug. Tighten the filler plug and run the machine to circulate the oil. Check the oil level when unit is warm and not running. If not near the middle of the dipstick, stop the unit and make corrections. DO NOT OVERFILL.
8.3.
OIL SPECIFICATION
The oil required for this engine is: Manufacturer: Product Name: Relative Density @ 25C Viscosity @ 40C Viscosity @ 100C Viscosity Index CCS 20C Total Base Number (TBN) Flash Point (COC) Pour Point Sulphated Ash Castrol Tection T 15W-40 (Formerly RX Super Plus) 0.89 g/cm 110 mm/s 14.5 mm/s 135 6450 mPA.s 11.6 mgKOH/g 228 C -36 C 1.5 %m
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9.0
TROUBLE SHOOTING
9.1. INTRODUCTION
Trouble shooting for a generator set is an organized study of a particular problem or series of problems and a planned method of procedure for investigation and correction. The trouble-shooting chart that follows in Section 9.3 includes some of the problems that an operator may encounter during the operation of a generator set. The chart does not attempt to list all of the troubles that may occur, nor does it attempt to give all of the answers for correction of the problems. The chart does give those problems that are most probable to occur. To use the trouble shooting chart: 1) Find the problem being experienced in the Symptom column on the far left. 2) Proceed to work through the possible causes in the next column, instigating the appropriate corrective action where required from the next column.
9.2.
ACTION PLAN
A. Think Before Acting: Study the problem thoroughly and ask yourself these questions: 1) What were the warning signals that preceded the trouble? 2) Has a similar trouble occurred before? 3) What previous maintenance work has been done? If the generator will still operate, is it safe to continue operating it to make further checks? B. Do The Simplest Things First: Most problems are simple and easily corrected. Always check the easiest and most obvious things first, following this simple rule will save time and trouble. Note: For trouble shooting electrical problems, refer to the Wiring Diagram Schematic found in logbook. C. Double Check Before Disassembly: The source of most generator troubles can be traced not to one component alone, but to the relationship of one component with another. Too often, a generator can be partially disassembled in search of the cause of a certain trouble and all evidence is destroyed during disassembly. Check again to be sure an easy solution to the problem has not been overlooked. D. Find And Correct Basic Cause: After a mechanical failure has been corrected, be sure to locate and correct the cause of the trouble so the same failure will not be repeated. A complaint of "premature breakdown" may be corrected by repairing any improper wiring connections, but something caused the defective wiring. The cause may be excessive vibration.
- 23 -
9.3.
TROUBLE SHOOTING CHART

SYMPTOM POSSIBLE CAUSE Batteries flat or bad. Read value on battery voltage meter (must be 12V or more). ENGINE DOES NOT CRANK WITH 12V ELECTRIC MOTOR Mini circuit breaker of 10A in terminal box is open. Start relay at cranking motor defective. Fuel tank empty. Air in the fuel system. Dirty fuel filters. ENGINE CRANKS BUT DOES NOT START Check voltage (12V) over fuel shut-off valve during crank. Optional air shutdown valve closed. Overspeed protection is activated. Air in the fuel system. Dirty fuel filters. ENGINE STARTS UP BUT STOPS AFTERWARDS Overspeed during acceleration. CORRECTIVE ACTION Replace or charge batteries.
Reset. Measure the voltage over the start relay. Fill up fuel tank. Check system for leaks. Bleed the fuel system. Replace fuel filters. Call for AGGREKO support. Open air shutdown valve. Put key back to 0 and try to start the engine again. Check system for leaks. Bleed the fuel system. Replace fuel filters. Decrease frequency setting. Check safeties: Oil pressure Water temperature Water pressure Oil temperature (option) Adjust frequency to the correct level. Repair connection. Check system for leaks. Bleed the fuel system. Wait until engine has reached the normal operating temperature of 80-90C. Replace fuel filters. Replace ball eyes. Replace air filters. Replace fuel filters. Check system for leaks. Bleed the fuel system. Check load. Measure voltage at outlet terminals of alternator. If voltage measured replace voltmeter. Replace voltage regulator,
Shutdown after 6 seconds.
Frequency too high. ENGINE OVERSPEEDS Connection between governor and fuel pump interrupted. Air in the fuel system. Engine not yet at operating temperature. ENGINE SPEED NOT STABLE Dirty fuel filters. Wear in ball eyes, linkage governor / fuel pump. Dirty air filters. ENGINE SHOWS EXCESS SMOKE AND / OR LACK OF POWER Dirty fuel filters. Air in the fuel system. Overload. ALTERNATOR DOESNT GENERATE VOLTAGE Voltmeter defective. Voltage regulator defective.
- 24 -
SYMPTOM
POSSIBLE CAUSE Air in the fuel system. Speed frequency too high / low. Incorrect voltage setting. No identifiable cause.
CORRECTIVE ACTION Check system for leaks. Bleed the fuel system. Check frequency meter and adjust if required. Adjust voltage regulator. Consult AGGREKO. Check stability of engine speed. Adjust stability on the voltage regulator. Select local position. Reset circuit breaker. Remove load.
ALTERNATOR VOLTAGE TOO HIGH / LOW
ALTERNATOR VOLTAGE NOT STABLE
Engine speed not stable. Incorrect stability adjustment. Circuit breaker control switch (Figure 6.1) set remote control. Circuit breaker tripped.
MAIN CIRCUIT BREAKER WILL NOT CLOSE MAIN CIRCUIT BREAKER CLOSES BUT TRIPS AGAIN
Switch on overload or short circuit.
- 25 -
MATERIAL SAFETY DATA SHEETS
Appendix A - i
APPENDIX A
CASTROL TECTION T 15W-40
Appendix A - ii
Appendix A - iii
Appendix A - iv
Appendix A - v
LEAD ACID BATTERIES
HEALTH & SAFETY LEAD ACID BATTERIES

##################################### The handling and proper use of lead-acid batteries is not hazardous provided sensible precautions are observed and that Operatives having been trained in their use are adequately supervised. The purpose of this letter is threefold:[ i] to indicate potential hazards that may arise. [ ii] to outline the precautions to be taken to minimise such hazards. [iii] to indicate action to be taken in the event of an accident. 1. SULPHURIC ACID [S.G. 1.260 - 1.300] Batteries contain sulphuric acid which may leak for a variety of reasons and may be given off as droplets and/or spray during recharging. [The Hazards] Sulphuric Acid is a poisonous and corrosive clear liquid which can burn/irritate skin and eyes and could burn clothing. [Precautions] Always handle batteries with care Always store upright Never over-fill with acid Always charge in a well ventilated area. Maximum voltage 15v per each 12v Battery. Use eye protection and protective clothing if there is any risk of acid splashing. [Emergency Action] Skin Contact: Immediately wash the affected area with copious amounts of clean water. Remove any contaminated clothing. Eye Contact Immediately irrigate eyes for at least 10 minutes with clean water. Swallowing Make the victim drink volumes of water, milk or milk of magnesia. DO NOT GIVE EMETIC In all cases seek medical attention. Speed of action is vital. [Spillages] Small spillages can be swilled away with volumes of water. [Disposal] See Section 5. 2. ELECTRICAL ENERGY [The Hazards] The accidental connection of battery terminals by conductive objects, e.g. metal tools or metal personal jewellery etc., may generate sufficient heat to cause burns, create arcing or cause molten metal to splash.
Appendix A - vi
[PAGE TWO]. [Precautions] Always ensure correct installation. The positive cable must be attached to the terminal marked [+] and the negative to the terminal marked [-]. Cables and terminals should be kept clean and securely fitted. Before using metallic tools on a battery remove metallic objects from hands and wrists. Before working on a vehicle electrical system disconnect the Battery, disconnecting the earth strap first and reconnecting last. Do not place tools on top of batteries. [Emergency Action] Burns: Electric Shock: Apply sterile bandage. Approach victim with care. Switch off or otherwise break current. If not possible, detach victim from contact by means of insulating material [wood, rubber or plastic hosepipe, folded newspaper etc] Do not touch with bare hands. In each case seek medical advice. Speed of action is vital. 3. EMISSION OF GASES A mixture of oxygen and hydrogen is emitted during charging and may be emitted if a battery is moved or shaken. [The Hazards] An explosive atmosphere exists if the concentration of hydrogen exceeds 4%. [Precautions] Always charge in a well ventilated environment. No naked flames NO SMOKING Be certain that current is switched off before making breaking connection. Always remove earth strap first and reconnect last. [Emergency Action] Explosion: Seek medical advice remembering that acid may have been sprayed. 4. WEIGHT In general terms batteries are heavy and awkward to handle. Care should be taken and correct lifting techniques employed. 5. DISPOSAL Batteries, Battery Acid, Lead and Lead compounds must be disposed of in accordance with: [a] The deposit of Poisonous Waste Act 1972 [b] The Control of Pollution Act 1974 [c] Consumer Protection Act 1987 If in doubt, consult the Environmental Department of your Local Authority. For further information refer to:BRITISH STANDARD BS 6604; 1985 SAFE OPERATION OF STARTER BATTERIES.
Appendix A - vii
VALVOLINE HD EXTENDED LIFE RTU
Appendix A - viii
Appendix A - ix
Appendix A - x
Appendix A - xi
Appendix A - xii
Appendix A - xiii
EQUIPMENT DATA SHEET
Appendix B - i
APPENDIX B

Manufacturing Birch Road Dumbarton, G82 2RF Tel: 0044 (0)1389 742214 Fax: 0044 (0)1389 742554 1 2 3 4 5 6 Model Part Number Specification Installation Drawing Maximum Ambient Electrical Output ISO 8528-1 - Continuous Power - Prime Power (COP) (PRP) kW (kVA) kW (kVA) %
Diesel Generating Set 50Hz 60 kVA 60Hz

Ref Ref Ref Ref C (F) Hz
No. Rev. Date Page
G080316 A June 2007 1 of 3
60 kW
GHP/NEF45 60kVA AI & Aus 601234A, 601242A G320042 A050215.1 43 (109) 50 45 (113) 60
38.0 (47.5) 47.5 (59) 70
42.4 (53) 52.6 (66) 70
- Permissible average of PRP ISO3046/1 - Fuel Stop Power/Standby Single Step load application 7 Alternator Class H Temp. Rise (125C) - Three phase - Single phase Ends Out Make & Type AVR Regulation 8 Circuit Breaker Make & Type Number of poles Rating Trip Unit Type Overload Protection Range Short Circuit Protection Range 9 Load Terminals Type 10 Fuel Consumption Standby/Fuel Stop 100% Prime Power 80% 50%
kW (kVA) %
52.3 (65) 40
57.2 (71) 40
kW (kVA) kW (kVA)
48 (60) 32 (40) 12 Newage UCI224E14 SX460
56 (70) 34.5 (45)
1.5
NS250N Merlin Gerin (31780) 4 Amps 250 STR22SE Amps Amps 100-250 400-2500
M12 Bolts
lit/hr(US gal/hr) " " " " " "
15.1 (4.0) 13.7 (3.6) 10.2 (2.7) 7.0 (1.8)
17.1 (4.5) 15.5 (4.1) 11.7 (3.1) 8.2 (2.2)
Technical Department Dumbarton Approved by
Appendix B - ii

Manufacturing Birch Road Dumbarton, G82 2RF Tel: 0044 (0)1389 742214 Fax: 0044 (0)1389 742554 11 Running Hours 100% Prime Power 75% 50% 12 Exhaust Emissions Measurement Method Specific Load NOx - Oxides of Nitrogen PM - Particulate Matter CO - Carbon Monoxide HC - Unburnt Hydrocarbons 13 Exhaust Silencer Make & Type Certificate Permissible back pressure 14 Noise Sound Pressure at 1 metre Sound Pressure at 7 metre 15 Engine Make & Type Cylinders & Form Aspiration Fuel Pump Governor Type Make & Model Steady State frequency Battery Voltage 16 Overall Dimensions - Length - Width - Height 17 Weight - Without fuel - With fuel Kg (lbs) Kg (lbs) Metres (feet) Metres (feet) AI Aus AI Aus % Volts dBA dBA 76 68 mm (ins) Hg IMS TA-Luft Hours 24.1 32.4 47.1
Diesel Generating Set 50Hz 60 kVA 60Hz 60 kW
No. Rev. Date Page
G080316 A June 2007 2 of 3
21.3 28.2 40.2
EPA-MOH/CARB 2% IS0 8178D2 5,69 gr/kWh 0,25 gr/kWh 2,1 gr/kWh 0,25 gr/kWh
100% Load 1908 mg/m3 5,73 gr/kWh 11,5 mg/m3 0,145 gr/kWh 82 mg/m3 0,69 gr/kWh 0,51 gr/kWh
DNV M-10084 12.7 (0.5)
79 71
Iveco NEF45SM1.A001 4 in Line Turbocharged and Charge Air Cooled Stanadyne Electronic GAC 0.5 12 2.660(87) 3.034(10) 1.0 (33) 1.0 (33) 1.775 (58) 1.775 (58) ESD 5500
Metres (feet) AI Aus
1600 (3528) 1881 (4147)
Appendix B - iii

Manufacturing Birch Road Dumbarton, G82 2RF Tel: 0044 (0)1389 742214 Fax: 0044 (0)1389 742554 18 Capacities - Fuel gross Usable - Lub oil total pan - Coolant 19 External fuel supply - maximum above base - maximum below base Metres (feet) Metres (feet) 1.5 (50) 0.3 (10) Litres (US gall) 367 (97) 330 (87) 12.8 (6.8) 11.5 (3.0) 18.5 (4.9)
Diesel Generating Set 50Hz 60 kVA 60Hz 60 kW
No. Rev. Date Page
G080316 A June 2007 3 of 3
Appendix B - iv
INSTALLATION OUTLINE DRAWING
Appendix C - i
APPENDIX C
Appendix C - ii
CONTROL PANEL LAYOUT
Appendix D - i
APPENDIX D
Appendix D - ii
ALTERNATOR & AVR SCHEMATIC DIAGRAM
Appendix E - i
APPENDIX E
Appendix E - ii
MAIN LOAD & METERING SCHEMATIC DIAGRAM
Appendix F - i
APPENDIX F
Appendix F - ii
DC CONTROL SYSTEM SCHEMATIC DIAGRAM
Appendix G - i
APPENDIX G
Appendix G - ii
TERMINAL LAYOUT & ENGINE WIRING
Appendix H - i
APPENDIX H
Appendix H - ii
LIVERY LAYOUT DRAWING
Appendix J - i
APPENDIX J
Appendix J - ii
Appendix J - iii
MANUFACTURERS COMPONENT DATA
Appendix K - i
APPENDIX K
Document No.: M040131 Rev: Title: B
Date:
25/06/07
GHP / NEF N45 60kVA (AI & Australia) Spares List & Manufacturers Data. SUPPLIER / SUPPLIER PART No. MANUFACTURER Iveco 8048895 Iveco Newage Iveco Iveco Iveco Deep Sea Electronics 504005039 45-0759 504013617 504031929 504010576 5310 AGGREKO PART No. N/A N/A N/A N/A N/A N/A 5310
DESCRIPTION Radiator Radiator Fan Coupling, Disc Charging Belt / Fan Belt Starter Motor Battery Charging Alternator Engine Protection Module Circuit Breaker 4P NS250N with Trip Unit (STRE22SE) 250A (31780) (31480) (31480) (29382) (29450) (29322) (29315) CB Aux (29450) Current Transformer 250/5A 3-in-1 Earth Leakage Relay Water Temperature Switch Oil Pressure Switch Lube Oil Filter Combustion Air Filter Secondary Fuel Filter Primary Fuel Filter for 500FGS/S
QTY 1 1 2 1 1 1 1
Merlin Gerin
Refer to Description
11-0011364
1 1 1 1 1 1 1 1 1
Merlin Gerin Hobut Broyce Iveco Iveco Iveco Iveco Iveco Racor
Refer to Description CT353 ELRV 30/289 12~60V DC 8030937 8104140 2992242 8041642 504107584 2010-PM
29450 11-0012706 ELRV-30/Z89 N/A N/A N/A N/A N/A N/A
Appendix K - ii
LIFTING BEAM CERTIFICATE
Appendix L - i
APPENDIX L
Appendix L - ii
DNV SPARK ARRESTOR CERTIFICATE
Appendix M - i
APPENDIX M
Appendix M - ii
Appendix M - iii
INTERNATIONAL CONTACT INFORMATION
Appendix N - i
APPENDIX N
In case of emergencies please contact the nearest service department of AGGREKO. They can be reached 24 hours a day and are operational at any place in the world BELGIUM FRANCE GREAT BRITAIN Aggreko N.V. Aggreko S.a.r.l. Aggreko Generators Ltd. Smallandlaan 7 1 Chemin de lAncien Parc Overburn Avenue 2660 Hoboken 91220 Bretigny Sur Orge DUMBARTON Belgium France G82 2RL Tel: (+32) 03 825 02 71 Tel: +33 (0)825 008007 Tel: (+44) 1389 767821 Fax: (+32) 03 825 11 81 Fax: +33 (0)1 69 737119 Fax: (+44) 1389 761577 NETHERLANDS NORWAY SPAIN Aggreko International (Ned) Aggreko Norway A.S. Aggreko Iberia S.A. B.V. Sorlandsveien 318 Avda. Torre Mateu, 35-37 Ketelweg 77 Postboks 543 Polg. Industrial Can Salvatella 3356 LD Papendrecht EGERSUND 08210 Barbera del Valles EUROPE Netherlands N-4379 BARCELONA Tel: (+31) 078 64 41 441 Norway Tel: (+34) 93 747 93 90 Fax: (+31) 078 642 80 83 Tel: (+47) 810 00 333 Fax: (+34) 93 729 02 83 Fax: (+47) 051 46 45 90 GERMANY GERMANY ITALY Frankfurt Mulheim Aggreko Italia srl (Central Europe South East) (Central Europe North) Via Copernico, 60 Aggreko Deutschland GmbH Aggreko Deutschland GmbH 20090 Trezzano sul Naviglio Darmstadter Strae 66-68 Ruhrorter Strae 112 (Milano) 64572 Bttelborn 45478 Mlheim/Ruhr Italy Germany Germany Tel: +39 02 4846 3024 Tel: +49 (0)61 52 93 93 0 Tel: +49 (0)208 58 09 70 Fax: +39 02 4451 243 Fax: +49 (0)61 52 93 93 99 Fax: +49 (0)208 58 09 798 CANADA U.S.A. Aggreko Inc. Aggreko LLC 300 Clarence Street 4607 W Admiral Doyle Drive NORTH Brampton, PO Box 10004 AMERICA ONTARIO NEW IBERIA, LA 70562-0004 L6W 1T5 Tel: (+1) 337 365 5479 Tel: (+1) 905 459 3321 Fax: (+1) 337 367 0870 Fax: (+1) 905 459 3392 REPUBLIC OF SINGAPORE Aggreko Singapore Pte Ltd 10 Pioneer Sector 1 ASIA SINGAPORE 62844 Tel: (+65) 6862 1501 Fax: (+65) 6862 0182 UNITED ARAB EMIRATES Aggreko Inc. PO Box 17576 MIDDLE Jebel Ali EAST DUBAI Tel: (+971) 04 834059 Fax: (+971) 04 834145 AUSTRALIA/PACIFIC Aggreko Generator Rentals Pty Ltd 101 Woodlands Drive AUSTRALIA / Braeside Victoria PACIFIC 3195 MELBOURNE Tel: (+61) 03 586 5050 Fax: (+61) 03 586 50514
Appendix N - ii

Technical Manuel 60 Kva

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Document No.

: Revision: Date: Created by: Approved by:

M020252 D 25/01/2010 J.McKell S.Doherty

Document No.: Revision: Date: Created by: Approved by:

M020252 D 25/01/2010 J.McKell S.Doherty

Document No.: Revision: Date: Created by: Approved by:

M020252 D 25/01/2010 J.McKell S.Doherty

Material Safety Data Sheets Equipment Data Sheet

Installation Outline Drawing

Control Panel Layout

Alternator & AVR Schematic Diagram

Main Load & Metering Schematic Diagram

DC Control Schematic Diagram

Document No.: Revision: Date: Created by: Approved by:

M020252 D 25/01/2010 J.McKell S.Doherty

Terminal Layout & Engine Wiring

Manufacturers Component Data

APPENDIX L: APPENDIX M: APPENDIX N:

Document No.: Revision: Date: Created by: Approved by:

M020252 D 25/01/2010 J.McKell S.Doherty

Document No.: Revision: Date: Created by: Approved by:

M020252 D 25/01/2010 J.McKell S.Doherty

DANGER FIRE RISK Risk of Electric Shock

DO NOT STAND IN FRONT OF ALTERNATOR AIR OUTLETS WHEN UNIT IS RUNNING

Document No.: Revision: Date: Created by: Approved by:

M020252 D 25/01/2010 J.McKell S.Doherty

Document No.: Revision: Date: Created by: Approved by:

M020252 D 25/01/2010 J.McKell S.Doherty

GENERATOR NOISE EMISSION CONTROL INFORMATION

Document No.: Revision: Date: Created by: Approved by:

M020252 D 25/01/2010 J.McKell S.Doherty

Document No.: Revision: Date: Created by: Approved by:

M020252 D 25/01/2010 J.McKell S.Doherty

LOCATION OF THE PLANT

Document No.: Revision: Date: Created by: Approved by:

M020252 D 25/01/2010 J.McKell S.Doherty

DESIGN LOAD CAPACITY

-10C (14F) to 35C (95F)

CANOPY & BASE FRAME

Document No.: Revision: Date: Created by: Approved by:

M020252 D 25/01/2010 J.McKell S.Doherty

ENGINE LUBRICATION SYSTEM

ENGINE COOLING SYSTEM

ENGINE FUEL SYSTEM

Document No.: Revision: Date: Created by: Approved by:

M020252 D 25/01/2010 J.McKell S.Doherty

5.10. ENGINE CONTROL SYSTEM

5.12. MAIN CIRCUIT BREAKER

Document No.: Revision: Date: Created by: Approved by:

M020252 D 25/01/2010 J.McKell S.Doherty

Battery Isolator Switch Sump Pump

Oil Pressure Gauge

Figure 5.1 - 60 kVA Generator Part Locations

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M020252 D 25/01/2010 J.McKell S.Doherty

Figure 6.1 Control Panel Exterior

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M020252 D 25/01/2010 J.McKell S.Doherty

Document No.: Revision: Date: Created by: Approved by:

M020252 D 25/01/2010 J.McKell S.Doherty

DESCRIPTION OF 5310 GENERATOR CONTROLLER

Document No.: Revision: Date: Created by: Approved by:

M020252 D 25/01/2010 J.McKell S.Doherty