QSV91G Containerized Specification:

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 Contents
GAS GENERATOR SET MODULE SPECIFICATION 4

MECHANICAL SPECIFICATION 5

1.1 General 5
1.1.1 Description 5

1.2 Engine 5
1.2.1 Description 5
1.2.2 Baseframe 5
1.2.3 Flexible Coupling 5
1.2.4 Anti Vibration Mounts (AVM’s) 5
1.2.5 Engine Protection 5
1.2.6 Engine Starter 6
1.2.7 Gas Train 6
1.2.8 Lubricating Oil Sump Automatic Filling / Level Switch 6
1.2.9 Engine Pre-heating 6

1.3 Alternator 7
1.3.1 Description 7
1.3.2 Alternator Protection 7

1.4 Cooling Systems 7

1.4.1 Cooling System 7

1.5 Exhaust System 8

1.6 Tests 8

ELECTRICAL SPECIFICATION 9

2.1 Generator Control System 9

2.1.1 General Description 9
2.1.2 Generator Control Panel 9
2.1.3 AC auxiliary enclosure 9
2.1.4 Generator Set Interconnection Enclosure 9
2.1.5 Paralleling Circuit Breaker 9

2.2 Engine Control System 9

2.2.1 General 9
2.2.2 Features 10
2.2.3 CENSE Sensors & Connections 10

2.3 QSV91G Genset Control Panel Incorporating PCSTM 11

2.3.1 GCP System Configuration 11
2.3.2 Control Panel - Environmental Hardening 11
2.3.3 Construction 12
2.3.5 PowerCommand Supervisor TM 13
2.3.6 PLC (Programmable Logic Controller) 20
2.3.7 Codes and Standards 23
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ACOUSTIC CONTAINER 23

3.1 General 23
3.1.1 Basic unit 23
3.1.2 Floor 23
3.1.3 Walls & roof 23
3.1. 4 Attenuation 23
3.1.6 Louvers 24
3.1.7 Internal cabling 24
3.1.8 Fire and gas system 24
3.1.9 Gas Pipework 24
3.1.10 Water pipework 24
3.1.11 Lubricating oil pipework 24
3.1.12 Access doors. 24
3.1.13 Gland Plates 24
3. 1.14 Exhaust system 24
3.1.15 Lighting 24
3.1.16 Ancillary Equipment 24

3.2 Container Size and Weight 25

FINISHING 25

4.1 General 25

MANUALS 25

5.1 General 25

PROJECT SERVICES 25

6.1 Documentation 25

6.2 Engineering 25

6.3 Packing & Transport 26

6.4 Construction 26

6.5 Commissioning 26

6.6 Tools & Spare Parts 26

TERMINATION POINTS 26

7.1 Gas Supply 26

7.2 Power Cabling 26

7.3 Small Power Cabling 26

7.4 Others 26
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 Gas Generator Set Module Specification

Equipment proposed:

a) QSV91G, COP rated at 1250kW, 1560kVA at 0.8 power

factor (lagging), 480 volts, 60 Hz, 1200 rpm

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 Mechanical Specification
1.1 General
1.1.1 Description
The generator sets proposed are designed for continuous (COP) operation as defined in ISO
8528. Design parameters prior to any derating are as follows:

Maximum aspiration air inlet 95°F

temperature
Maximum altitude, 3000 feet
Maximum cooling water inlet 122°F
temperature
Minimum gas pressure 4 psi
Minimum LCV 800 btu/scf
Minimum Methane Index 65

1.2 Engine
1.2.1 Description
The engine is 18V configuration. Cylinder bore is 180mm giving a displacement of 91 litres. The
standard engine includes a pre-lubrication engine oil pump, oil filtration, and air inlet filters suitable
for normal operating conditions.

1.2.2 Baseframe
The coupled engine and alternator assembly are mounted on a welded, structural steel baseframe.
This provides the assembly with a stable and torsion resistant platform.

1.2.3 Flexible Coupling

The engine torque is transmitted to the alternator by a flexible coupling, which reduces vibration
and provides torque damping characteristics.

1.2.4 Anti Vibration Mounts (AVM’s)

The generator set is supplied with spring type anti vibration mounts (AVM’s). These are fitted
between the bedframe and the container floor.

1.2.5 Engine Protection

The engine is continuously monitored by means of the Cummins Engine Sensors Equipment
(CENSE) module which is an environmentally hardened digital controller mounted on the
generator set. It is connected to dedicated engine sensors and senders via engine looms. CENSE
is as fully detailed later in this specification.

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1.2.6 Engine Starter
The generator set is supplied with an electric starter motor as standard that engages onto the
engine flywheel starter ring when the starter solenoid receives a start signal from the Generator
Control Panel. Starting batteries are included in the container and the batteries are connected to
the engine starting system by flexible cables.

1.2.7 Gas Train

The Gas Train is an inline gas inlet manifold (approximately 2.5 feet long) which incorporates a
hand valve, dust filter, pressure regulator and a valve pressure regulator. The flange sizes of the
inlet and outlet flanges are 3” NB.

Three gas train modules are available the correct selection being made in accordance with the
inlet supply pressures. Gas Train Standard State Inlet Pressures are as follows:

- inlet pressure up to 18 psi

- inlet pressure up to 26 psi
- inlet pressure up to 45 psi

The Gas Train has to be mounted and installed in the plant room and connects to the engine
mounted generator set gas inlet solenoid valve by means of a 1.5 feet flexible pipe, which has 3”
flanges.

All pipework, etc. between the gas train and the engine is connected inside the container.

1.2.8 Lubricating Oil Sump Automatic Filling / Level Switch

This system allows the generator set to have continuous availability. The system keeps the
optimum engine oil level by means of a float mechanism and a flexible connection (1.5 feet of inlet
hose which has a 1” straight female hose adapter fitting) which is connected inside the container to
a gravity fed engine lubricating oil make up tank. A site glass is included on the gauge for the
operator to visually check. Electrical switch contacts are provided which will initiate a low level
warning indication displayed on the GCP.

The engine lubricating oil make up tank is positioned above the lubricating oil level regulator with a
maximum inlet pressure of 75 psi.

1.2.9 Engine Pre-heating

Whilst stationary the engine temperature is maintained at a constant 104°F for instant start and
load acceptance. This is achieved by the provision of thermostatically controlled water heaters (2
heaters of 6 kW each) integrated as a module in to the engine block. In addition to the heating
elements, a water circulation pump ( 0.3 kW) is included to circulate the cooling water through the
block. This allows for an even heat transfer through the engine block. The heating elements and
pumps are controlled from the GCP.

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1.2.10 Flexible Connections
All connections to the engine that are required are supplied with flexible connections. These
connections are: coolant water circuits, air starter turbine, crankcase breather filter drains,
lubricating oil sump drain, gas inlet, cooling system venting, etc..

Fittings are as per the following table:

Connection Fittings
Coolant Water Circuits (Dual Circuit) 3” Weldable Flange
Flexible Cooling System Venting ½” Female Swivel
Flexible Gas Fuel Inlet 3” Flange
Gas Fuel Inlet Solenoid Vent Line 3/4” Gas
Flexible Crankcase Breather filter drains (to spill tank) ½”

1.2.12 Finish
The generator set is finished to our standard colour, Munsell Jade Green, in high gloss. The plant
will be complete with safety and warning labels, in English.

1.3 Alternator
1.3.1 Description
The six pole, two bearing alternators are of the brushless, rotating field design. Insulation and
temperature rise is class ‘H’. The Newage alternators use a permanent magnetic generator (PMG)
excitation system which provides power excitation for the exciter field via the automatic voltage
regulator (AVR). The automatic voltage regulator (AVR) and power factor control (PFC) are
TM
controlled through the Power Command Supervisor based GCP.

1.3.2 Alternator Protection

The alternator has an IP23 Enclosure and includes:
- bearing resistive temperature devices (RTDs), one per bearing
- winding resistive temperature devices (RTDs), two per phase
- anti-condensation heater, thermostatically controlled
TM
The GCP also houses Amp Sentry which guards the electrical integrity of the alternator and the
power system from the effects of overcurrent, short circuit, over / under voltage, under frequency
and overload. Current is regulated to 300 % for both single phase and 3 phase faults when a short
circuit condition is sensed.

1.4 Cooling Systems

1.4.1 Cooling System
The engine cooling system comprises low temperature and high temperature circuits each
requiring an external cooling system. The external system comprises a flat bed twin core cooler
mounted on the roof of the enclosure. 6 electric motor driven fans ( 3 kW each) will draw the
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cooling air up through the high and low temperature cooling cores. All pipework, valves, flexible
connectors etc are fitted to connect the system to the engine in the container. The system is
designed so that the noise emitted from the cooling system meets the overall design criteria of 85
dB(A) at 1 metre distance. 4 Ventilation fans ( 4.5 kW each)

1.5 Exhaust System

10” bore exhaust bellows provide a flexible connection to the exhaust system which allows for
some generator set movement / vibration. The exhaust bellows connect to a twin inlet residential
exhaust gas silencer mounted on the roof of the container. The system is designed so that the
noise emitted from the exhaust system meets the overall design criteria of 85 dB(A) at 3 feet
distance.

1.6 Tests
The generating sets will be fully tested at our works prior to despatch. Our standard tests in
accordance with our Quality Procedures will be undertaken. Tests are of approximately four hours
duration and will include:

- 0 – 100% load testing

- controls / engine protection / safety testing

All tests will be conducted at unity power factor. Copies of our works test certificates will be
provided.

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 Electrical Specification

2.1 Generator Control System

2.1.1 General Description
The generator control system consists of three main components:
- the generator control panel (GCP)
- an AC auxiliary enclosure
- generator set interconnection enclosure.

2.1.2 Generator Control Panel

This is a free-standing control panel and is as fully detailed later in this specification.

2.1.3 AC auxiliary enclosure

This is a separate enclosure mounted on the generator set baseframe. It interfaces with the GCP
and houses the equipment which controls / monitors and protects the generator set a.c. systems
which is not located in the GCP.

2.1.4 Generator Set Interconnection Enclosure

This enclosure is mounted on the generator set baseframe. It interfaces with the GCP and is the
termination box for all engine controls, etc., which are not located in the a.c. auxiliary enclosure.

2.1.5 Paralleling Circuit Breaker

Paralleling Circuit Breaker
2500 Amp
480 Volt
4 pole

2.2 Engine Control System

2.2.1 General
The engine control system consists of environmentally hardened, digital controllers, which are
mounted directly on the generator set. The engine control system continuously monitors the
engine and generator set. The control system provides engine protection as well as controlling the
fueling, ignition, and speed of the generator set. The engine control system is continuously
monitoring all of the on-engine systems, which include the fuel, lubrication, intake, exhaust, and
cooling systems. The control systems monitors these systems via generator set mounted sensors
and a fabricated wiring loom.

The module has built in test equipment, constantly performing self checks, and also includes a
lithium back-up battery that maintains fault data in the event of power loss to the control system.
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2.2.2 Features
2.2.2.1 Monitoring Functions
The functions monitored are:

Lubricating Oil System: oil filter inlet and outlet pressure, main oil rifle pressure, oil
temperature, pre-lubrication pressure
Start Air System: start air pressure
Air Induction System: intake restriction pressure, intake air temperature, turbo
compressor outlet pressure, intake manifold pressure and
temperature
Cooling System: coolant level in expansion tanks (gen-set), HT and LT circuits
temperature and pressure
Exhaust System: individual cylinder exhaust port temperature
Engine Speed: overspeed

2.2.2.2 Diagnostics
The engine control system supports a standard Cummins J1939 datalink. A personal computer
can be used to interrogate the control system. With a PC and service software, the user can:
view data in real-time mode
review and clear fault codes for troubleshooting
log data
tune basic engine operating parameters
2.2.3 CENSE Sensors & Connections
2.2.3.1 Engine Sensors
High & low coolant temperature and pressure
Intake manifold temperature and pressure
Front intake restriction
Post filter oil pressure
Front turbocharger inlet temperature
Oil temperature
Rear turbocharger inlet temperature
Rear intake air restriction
Engine speed
Fuel rail pressure
Engine exhaust left & right bank temperature sensors

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QSV91-G engine only - additional engine exhaust left & right bank individual temperature
sensors

2.2.3.2 Connectors
2 x 40 pin Deutsch
4 pin Deutsch
23 pin Deutsch
31 pin Deutsch
RS422 Data Link

2.3 QSV91G Genset Control Panel Incorporating PCSTM

2.3.1 GCP System Configuration

The Generator set Control Panel is designed to be specifically integrated with QSV81G – 91G
range of CPG engines. It will be located within the container.

Standard components used to provide the system control comprise :

- control batteries and charger
- PC based HMI (touchscreen)
- PLC based auxiliary control
- PLC based engine control interface
- Power Command SupervisorTM
- auxiliary a.c. enclosure
- engine interface enclosure

The system is intended for use in single or multi-set isolated bus or single set base load utility
paralleling applications whilst providing both isolated bus paralleling control (set to set
synchronising, isochronous KW and KVAR load sharing) and base load utility paralleling
(synchronising to utility, base load KW control, VAR/PF control). It provides compatibility with
master controllers for multi set utility paralleling applications requiring supervisory system control,
i.e. load demand, multi-level load shed/add etc, whilst enabling data control and monitoring via an
optional (Modbus) communications interface.

2.3.2 Control Panel - Environmental Hardening

The control system touchscreen, PCS and other optional door mounted equipment are provided
with sealed front faces to minimise the effects of dust and moisture on the equipment.

Operating range of the complete GCP is:

0
Operating Temperature: 0 to +50 C
Storage Temperature: -10 to 60 oC
Humidity: 95%
Rating: IP54

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2.3.3 Construction
The control system is housed in a rigid, free standing, metal enclosure designed to require front
access only. The enclosure is constructed of minimum 14 gauge (2mm) steel sheet metal, primed
and finished in colour RAL 7032. All other sheet metal components of the system are primed and
finished black enamel. Control and external interface voltages are segregated by means of
trunking and any components operating at more than 50 volts are shielded to prevent inadvertent
contact. Each wire, device and functional component is identified by silk-screen or similar
permanent identification.

Circuit breakers are installed to allow more effective overload and short circuit protection to be
provided. Terminals for field connection are provided with removable plugs for ease of installation.
The internal components of the GCP require a 24V d.c. power supply. This is derived from the
battery and charger system located within the GCP. The power supply to the GCP requires a
permanent single phase AC supply (determined by the site application) via the fused supply from
the AC Genset mounted auxiliary enclosure or the customers power distribution board.

2.3.4.1 PC Based HMI (Touchscreen)

A micro-processor based graphic interface (touchscreen) package is provided to allow operator
monitoring and control. Data from the generator set is displayed to the operator in layered menus
so that it is easy to understand and allows operators to easily learn the functionality and diagnostic
facilities of the unit

The touchscreen provides data and graphics on an EL monochrome display. The microprocessor
TM
is 80486SXLC2-50 technology and includes a DOS based operating system and ‘Interact ’
application software. It is complete with a real time clock, (month/day/year/hour/min/sec) with
separate battery backup and holds an extensive 5MB of FlashDisk memory. The screen is
mounted on a console on the front of the GCP with gaskets between the touchscreen and the
enclosure for environmental protection. The HMI is interconnected to the PLC via serial
communications utilising a Modbus protocol.

2.3.4.1 PC Based HMI (Touchscreen) Specification

Processor: 80486SXLC2-50, 8MB DRAM, 256 kB static RAM, 5 MB
FlashDisk, 4 serial and 1 parallel interface (LPT1), CAN Bus
interface, 2 PCMCIA type II slots.
Screen Type: Amber electroluminescent (EL) flat panel. The screen surface
is hard coated, durable and anti-glare to allow ease of use in
any lighting condition and long life. A screen save facility is
provided to enhance life and save power.
Screen Size: 10.4” (264mm) diagonal with 640 x 480 pixel resolution.
Operating System: DOS 6.22.
TM
Application Software: ‘Interact ’ Runtime System III.
PLC Interface: Serial communication port slot with Modbus protocol.
Protection: Nema 4.
o o
Temperature Rating: -5 C to + 55 C.
External Optional Connectivity: VGA monitor, disk drive, mouse interface, IBM AT keyboard
port.

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2.3.4.2 System Screens
The main screen is designed to enable the operator to determine the current generator set status.
It further allows access to the data embedded in the layered screens. Data includes :
- voltage per phase
- current per phase
- current per phase
- kW
- MW/hr
- frequency
- power factor
- oil pressure
- speed
- engine hours.

Touchscreen activities allow access to the following data via other screens:
- engine data
- alternator data
- a.c. auxiliaries mimic
- alarm activities
- GCP user level configuration
- related plant data

The main screen is designed to include an alarm capability so that the operator is immediately
advised of all alarm and shutdown conditions.

2.3.5 PowerCommand Supervisor TM

This unit is a microprocessor based genset monitoring, metering and control system. It is
integrated into the GCP and incorporates the following key features ;
· voltage regulator
· synchroniser (frequency, phase & volts)
· Iso-Bus kW and kVAR load sharing
· Utility paralleling kW load control
· Utility paralleling PF control
· AmpSentry™ alternator protection
· overload
· overcurrent [51]
· short circuit [50]
· high AC Volts [59]
· low AC Volts [27]
· underfrequency [81u]
· sync check, fail to sync
· reverse power [32]
· loss of excitation [40
· phase rotation
· CB fail to close
· Alternator metering

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2.3.5.1 Enclosure Environmental Hardening
The front panel of the unit is formed by a single membrane that covers the entire surface. The
fascia is easy to clean and impervious to water spray, dust and oil/exhaust residue. Switches for
control are incorporated into the door which is gasketted with a dual moisture and RFI/EMI
gasket to protect internal components from airborne contaminants.

2.3.5.2 Controls and Adjustment Switches

An oil tight, three position switch starts and stops the generator set locally or enables start/stop
control from a remote position. It provides the following functions:
· The ‘OFF’ position de-energises all primary DC circuits. When the switch is in this position, the
non-automatic indicator will flash continuously.
· The ‘RUN’ position energises the control and initiates the genset starting operation.
Note : the non-automatic indicator will flash when the switch is in the ‘run’ position.
· The ‘AUTO’ position enables the control to receive a start signal from a remote location.

Emergency Stop Switch.

A two position safety ‘mushroom’ head switch provides an easy and obvious means to
immediately shut down the genset in the event of an emergency condition.
System Control.
Control arrows on the screen lead the operator to information. The control switches provide
the operator with a positive indication that the switch is operated. The switches are totally
sealed and designed to provide reliable service.
Menu selection Switches.
These four switches allow the operator to select menu-driven control and monitoring
information.
Menu ‘HOME’ Switch.
Returns the operator to the main menu selections screen regardless of the position in the
menu logic.
Panel Lights Switch.
Turns the back-lit panel illumination on and off for easy reading of the entire facia in dark
conditions. This feature automatically switches off after 5 minutes.
Test Switch.
Prompts the PowerCommand Control to perform a self test and displays all fault
messages.
Reset Switch.
Clears the digital display and status panel and allows the genset to start after a fault
condition has been corrected.

2.3.5.3 Adjustment Menu.

Allows the operator to set basic genset parameters. Adjustments are limited to help prevent
operator error and potential damage to equipment. Critical parameters are adjustable only via a
security access code. Adjustments include:
· Voltage (+/- 5%)
· Frequency (+/- 5%)
· Automatic voltage regulator gain (access code protected)
Critical service level adjustments are possible only after entering an access code. All adjustments
are made through digital raise/lower switches from the front of the fascia, the adjustment being
digitally displayed.
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2.3.5.4 External Control Adjustments.
Adjustments for automatic voltage regulation are performed directly at the control fascia by using
the security code without the need to enter the GCP enclosure.

2.3.5.5 Alarm and Status Message Display.

To compliment the HMI screen displays, PCS check data displays are provided for all critical
genset parameters. Digital messages provide a clear indication of potential problems. A two line
16 character-per-line, LED alphanumeric screen displays alarm and status messages along with
data regarding AC output.

2.3.5.6 Status Indicators.

Three dual element LED indicating lamps provide basic genset status data on the facia. Solid state
indicators on internal circuit boards provide further status and diagnostic data.
Non-Automatic Indicator.
When the Run/Off/Auto switch is in the OFF or RUN position the red non-automatic
indicator will flash on and off.
Warning Indicator.
An amber light indicates the status screen is displaying a warning condition. The reset
switch is used to clear the message after the warning condition is corrected.
Shutdown Indicator.
A red light indicates the status screen is displaying a shutdown condition. The reset switch
is used to clear the message after the shutdown condition is corrected.

2.3.5.7 Generator Set Monitoring - Warning and Shutdown Messages.

The digital display provides status of the following critical engine functions :
· battery voltage
· speed
· overspeed (shutdown, engine speed >= 115% of nominal)
· emergency stop (shutdown).
· magnetic pick up failure (shutdown)

On sensing a warning or shutdown condition the control displays the warning or shutdown
message, lights the warning or shutdown indicator lamp on the front of the fascia and displays a
code number which is interpreted by the PLC and displayed at the HMI in an easy to understand
format. These codes are also displayed on the PCS fascia and can be cross-referenced using the
genset manual.

The control has provisions for four programmable fault conditions. These may be either warning or
shutdown conditions. Labels for customer faults can be programmed into the control.

The control maintains an historical data log of the latest alarm and status conditions on the genset.

2.3.5.8 Historical data

The control displays the last 20 alarm and/or shutdown messages.
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2.3.5.9 AC Output Metering
Combines digital and analogue metering to provide accurate digital readouts plus analogue
indication of trends and operating conditions.

2.3.5.9.1 Analog Meters.

Analog metering on the control fascia provides clear indication of generator set stability from a
‘walk by’ perspective and saves re-establishing the HMI screen if it is in screen save mode.

The kilowatt meter and ammeter are scaled in percent of AC output for easy recognition of genset
status and load level
0 - 90% of rating ; green
90 - 100% of rating ; amber
> 100% of rating ; red.

Kilowatt Meter.
Indicates 3-phase AC power output as a percent of rated load. Provides a true indication of
total kW load on the genset, regardless of the load power factor. Scale is 0 - 125%
Accuracy is +/- 5%
Frequency Meter.
Indicates genset output frequency in hertz. Calculated frequency is based on engine speed
and alternator voltage zero-crossing and is not affected by voltage waveform distortion
caused by non-linear loads. Scale is 45 - 65 Hz. Accuracy is +/- 5%.
AC Voltmeter.
Dual scale AC voltmeter indicates alternator output voltage. Accuracy is +/- 2%. Scales are
0 - 300VAC, 0 - 600VAC, 0 - 400 VAC, 0 - 750VAC, 0 - 5260VAC, 0 - 15,000VAC.
AC Ammeter.
Indicates current output in percent of maximum rated standby current. Accuracy is +/- 2%.
Scale is 0 - 125%
Phase Select Switch.
Allows the operator to select the phase monitored by the analogue ammeter and voltmeter.
LED indicators display which phase is being monitored and which voltage scale is applied.

2.3.5.10 Digital Metering

The digital metering display provides access to alternator performance data and a more accurate
readout of the AC output information displayed on the analogue meters. The following outputs are
displayed:
· generator set output voltage (3-phase, line to line or line to neutral)
· generator set output current (3-phase)
· power factor (0 to 1, leading or lagging)
· a.c. kilowatts
· a.c. kilowatt-hours
· alternator exciter duty and governor duty (%)
· generator set output frequency (Hz)

The voltage and current data for all three phases is displayed simultaneously on a single screen so
lead and voltage balance is readily apparent.
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2.3.5.11 Digital Voltage Regulation, Synchronizing and Load Sharing Controls
The PCS module includes all voltage regulation, synchronizing and load sharing control required
for isolated or infinite bus paralleling applications, including demanding UPS and non-linear load
applications.

2.3.5.11.1 Paralleling.
Isolated Bus Paralleling control (set to set synchronising, isochronous kW and kVAR load sharing)
and Base Load Utility Paralleling (synchronising to utility, base load kW control, VAR/PF control)
features are provided.

2.3.5.11.2 Isochronous real load sharing.

Load sharing to within as low as 1% of equal. Load sharing controls operate directly on the engine
governor actuator to provide zero droop in frequency for loads from zero to 100% of rated genset
capacity.

2.3.5.11.3 Droop real load sharing.

Control may be configured for operation in droop mode, adjustable for no load to full load droop
from 1% to 10%

2.3.5.11.4 Isochronous reactive load sharing.

Load sharing to within as low as 1% of equal.
Load sharing controls operate directly on the excitation system to provide zero droop in voltage for
loads to 100% of rated genset capacity.

2.3.5.11.5 Droop reactive load sharing.

Control may be configured for operation in droop mode, adjustable for no load to full load droop
from 1% to 10%.

2.3.5.11.6 Synchronizer.
Range:
The synchroniser can drive the genset frequency and voltage to a bus value which is 40%
to +10% of selected voltage and frequency. Ramp speed for matching is 4% per second.

Frequency differential :
The set is controlled to match the bus frequency.
Voltage differential :
The set voltage is controlled to within 1% of system bus voltage with checks for correct
phase rotation to bus.
Permissive protection :
Adjustable for a phase difference of 5 to 20 degrees with phase difference decreasing.
Time delay is adjustable from 0.5 to 5 seconds.
Control System :
Automatically resets bus frequency and voltage to preset values after the paralleling
breaker closes.
‘Dead Bus’ Sensor :
Allows closure of the generator set to an inactive system bus.

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2.3.5.11.7 Digital Biasing Performance.
The PCS provides a biasing signal to the MCM700 speed governor to perform load control,
synchronising and load govern operations. Variation of the ‘Duty Cycle’ output, between 10 and
90%, by the PCS determines the required change in load/speed rating of the engine governor.
This required change can be between -40% and +10% of rated value.

2.3.5.11.8 Voltage Regulation Performance.

Voltage Regulation :
+/- 5% from no load to full load.
Voltage Drift :
o o
+/- 0.5% for 60 F (33 C) change in ambient over 8 hours with temperature stabilisation at
each point.
Random Voltage Variation :
For constant loads from no load to full load will not exceed +/- 0.5% of its mean value.

2.3.5.12 Battery Monitoring System

The control continually monitors the battery charging system for low and high DC
voltage and runs a battery load test every time the engine is started. Functions and messages
include:
· low d.c. voltage (battery voltage less than 25VDC except during engine cranking)
· high d.c. voltage (battery voltage greater than 32 VDC)
· weak battery (battery voltage less than 14.4 VDC for more than 2 seconds during engine
cranking)

2.3.5.13 AmpSentry™ Protection

AmpSentry™ protection is a comprehensive power monitoring and control system integral to the
PCSthat guards the electrical integrity of the alternator and power system from the effects of
overcurrent, short circuit, over/under voltage, underfrequency and overload. Current is regulated to
300% for both single phase and 3 phase faults when a short circuit condition is sensed. An
overcurrent alarm will sound if the genset is operating for an extended period at a potentially
damaging current level, to warn the operator of an impending problem before it causes a system
failure. If an overcurrent condition persists for the time pre-programmed in the time current
characteristic for the alternator, the PMG excitation system is de-energised to avoid alternator
damage. The overcurrent protection is time delayed in accordance with the alternator thermal
capacity allowing current to flow until secondary fuses or circuit breakers operate, isolating the
fault and thus achieving selective co-ordination (discrimination). This enhances power service
continuity by eliminating the need for a main line breaker mounted on the genset for genset
protection and the possibility of nuisance tripping of that breaker.

After the fault is cleared AmpSentry™ Protection softly loads the genset by a controlled ramping of
output voltage to rated level, allowing the genset to resume normal operation without potentially
damaging voltage overshoot.

Fixed over/under voltage and under frequency time delayed set points also provide a degree of
protection for lead equipment. Over/under voltage conditions trigger a shutdown message on the
digital display screen. Under frequency condition prompts both a warning and shutdown message
depending upon the length of time and magnitude of variance under rated frequency.

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AmpSentry™ Protection includes an overload signal that can be used in conjunction with
proprietary transfer switches to automatically shed load, preventing a potential genset shutdown.
The overload signal is programmable for operation at a specific kW level, on the basis of an under
frequency condition, or both.

2.3.5.15 Battery Charger plus Batteries

The control batteries and charger unit are housed within the GCP.
2.3.5.15.1 Charger:
The 10 Amp charger is of the constant voltage, current limited type designed for the charging of
vented or sealed lead acid or NiCad batteries. It is capable of supplying a standing load whilst
simultaneously maintaining the battery to its fully charged state. Its features include :
· boost charge facility
· charge fail facility
· short circuit protected
· reverse power protected
· constant voltage
· current limited
· R.F. suppression

The charger is in accordance with the following specification:

Supply Voltage: 220 to 257 Volts 50 - 60 Hz AC as standard, up to 277 Volts 50 - 60 Hz AC
upon request.
Output Transistors: Rated at 15 amps RMS electronically regulated to the current set by control
circuitry.
Boost: Increase of 0.35V per cell on connection of the “Boost” terminals.
Charge Failure: Relay energises 10 seconds after charge failure.
Temp Range: -10 to +600 C.

2.3.5.15.2 Batteries:
Two off sealed lead acid maintenance free batteries. These batteries use a thixotropic gel
electrolyte which holds the acid in contact with the flat plate electrodes, maximising the contact
surface area therefore the available capacity. They are supplied with safety vents which enable the
battery to to gas if misused and then re-seal automatically.

Max Discharge Current: 80 Amps.

Discharge Current for 20h: 500 mA.

2.3.5.16 Warning and Shutdown Messages

Overload: When total kW load exceeds 100% of the standby rating of the
generator set (110% of prime rating) for 5 seconds a load shed
signal is issued and a warning alarm activated.
Overcurrent (51): When the current on any phase exceeds 110% of the generator set
rated current for more than 60 seconds a warning alarm is activated.
Overcurrent (51): The generator set is shutdown when the current on any phase is
between 110 - 175% of rated and the time/current integral
approaches alternator thermal limits.

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Short Circuit (50):
High AC Voltage (59):
Low AC Voltage (27):
UnderFrequency (81U):
Reverse Power (32):
Loss of Excitation (40):
The generator set is shutdown when the current on any phase
exceeds 175% of rated and the time/current integral approaches
alternator thermal limits.
Generator set is shutdown when AC voltage exceeds 110% for 10
seconds or with no delay when voltage exceeds 130% of nominal.
Generator set is shutdown when AC voltage falls below 85% of rated
voltage for more than 10 seconds.
Generator set is shutdown when AC frequency fals below 90% of
rated frequency for more than 20 seconds.
Generator set is shut down when kW flow into the genset exceeds
an adjustable set point (5 - 15% of genset rating) for an adjustable
amount of time (1 - 15 seconds).
Generator set is shut down when kVAR is less than 0.16 - 0.41 per
unit kVAR (adjustable) for more than 2 - 10 seconds (adjustable).

2.3.6 PLC (Programmable Logic Controller)

Auxiliary generator set controls, the communication handling procedures and the protocol
interfaces are all provided by a programmable logic controller.

Auxiliary control is provided for the following functions :

· engine heater control
· alternator heater control
· coolant circulation pump
· oil priming pump
· alarm/data handling

The PLC directly interfaces with the system touchscreen (HMI) as well as both PCS and the
engine protection module (CENSE). It interfaces with the PCS via a CPG developed RS232
(MON) protocol and to the CENSE module via a CPG developed RS422 medium. Communication
to the HMI is provided by means of a MODBUS RTU, RS485 link.

The PLC uses a DIN rail mounted card and rack arrangement to allow easy servicing and
identification of system components. Other features to enhance serviceability include:
· capability for on-line program/data changes using a personal computer directly connected to
the PLC,
· LED status indicators on each board for use in diagnosis of system condition and board level
service,
· I/O cards include integral surge suppressors for greater system reliability,
· program output information is available in the form of an easy to understand flow chart as
well as the more common fully annotated ladder logic.

2.3.6.1 PLC Specification.

Manufacturer: Groupe Schneider
Processor: Type: TSX Premium type 57-20
Temperature - operation: 0oC to +60oC.
- storage -25oC to +70oC.
Humidity (without condensation)
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 - operation 30% to 95%.
- storage 5% to 90%.
Memory: 48K words
Power Supply Unit: Input Voltage: 24VDC non-isolated
Output Voltage : 5VDC/24VDC
Output Power: 15 watts @ 5VDC
Input Modules: Type: TSX DEY 64D2K
Input Voltage: 24VDC
No of Inputs: 64 isolated channels
Type: TSXDEY 16A2
Input Voltage 24VDC
No of Inputs: 16
Type: TSXAEY 414
Input: Pt 100 Temperature probes
No of Inputs: 4
Output Modules: Type: TSX DSY 16R5
Output Voltage: 24VDC
Current: 3 amp (per channel)
No of Outputs:16
Communications Modules: Type: TSX SCY 21600
Physical Layer: RS485 isolated MODBUS:
Mode: Master or Slave
Service: 19 Modbus functions
Configuration: Multi-drop

2.3.6.2 Interconnections

The following is a list of available GCP to client interactions. The client shall provide volt-free
contacts in order to enable the available listed functions:
· circuit breaker position
· circuit Breaker Inhibit
· utility parallel enable
· emergency stop
· load demand stop
· remote fault reset
· remote start
· HT coolant tank low level alarm
· radiator fan tripped alarm
· low lubricating oil alarm
· high gas pressure alarm
· LT tank low coolant level alarm
· a.c. external trip shutdown
· fire protection trip shutdown
· HT tank low coolant level shutdown
· LT tank low coolant level shutdown
· louvres closed alarm
· air compressor tripped
· vent fan tripped
· earth fault
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 · ready to load
· load dump

In addition to these inputs there are 4 customer configurable inputs :

· customer fault No 1 (alarm)
· customer fault No 2 (shutdown)
· customer fault No 3 (controlled shutdown)
· customer fault No 4 (configurable for alarm, shutdown or controlled shutdown)

Non volt-free signal interfaces comprise:

· master first start input (pulsed input to enable Genset as first on-line, <50mA)
· PCS kVAR load share (+),(0-1mA)
· PCS kVAR load share (-),(0-1mA)
· PCS kW load share (+),(0-1mA)
· PCS kW load share (-),(0-1mA)
· PCS load share line (shield)
· load set (0 - 5VDC)

The PCS provides further volt -free contacts for interfacing with the following features :
· common warning
· common shutdown
· common fault
· fire bell
· coolant radiator fan control
· vent fan control
· louvre control
· close output circuit breaker
· open output circuit breaker
· generator set running

2.3.6.3 GCP to Generator Set Cable Connections

The interconnecting cables are installed between the alternator and GCP.

1. Auxiliary control/monitor (28 core screened 1.5mm2)

2
2. Control/monitor (29 core screened 1.5mm )
2
3. Power supply (2 core screened 4.0mm (option))
2
4. Analogue (6 x screened twisted pair 1.5mm )
2
5. Magnetic pick-up (2 core screened 1.0mm )
6. Pro-Act (2 core screened twisted pair 1.0mm2)
2
7. DC signal (3 core screened 1.5mm )
8. DC signal (3 core screened 1.5mm2)
9. DC signal (3 core screened 1.5mm2)
10.DC signal (3 core screened 1.5mm2
11.DC signal (3 core screened 1.5mm2)
12.CT’s & 18VAC (12 core screened 1.5mm2)
13.3.0kHZ (2 core screened 1.5mm2)
14.RS422 Comms (4 core screened 1.5mm2)
15.Power supply (2 core screened 4.0mm2 (option))

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2.3.6.4 Container Small Power Cabling

See section 3.0 Container

2.3.6.5 Container 480 Volt Power Cabling

See section 3.0 Container

2.3.7 Codes and Standards

The Genset Control Panel meets or exceeds the requirements of the following codes and
standards:
UL508A: for US and Canadian Usage
NFPA 110: Emergency Power Systems
CE: Pending Approval

Acoustic Container
3.1 General
The complete system will be installed within a container which will
3.1.1 Basic unit be treated to give an external noise level of 85 dB(A) at 1 meter .

Steel chequer plate floor.

3.1.2 Floor
Steel formed wall and roof construction lined with 50mm thick
3.1.3 Walls & roof mineral wool retained by perforated, galvanised, steel sheet.

Air inlet acoustic louver at the alternator end.

3.1. 4 Attenuation Air outlet acoustic louver at the engine end.

3.1.5 Air Handling The heat generated by the equipment installed in the container is
expelled through 4 pusher type, electric motor driven fans
(4.5 kW each) designed for the heat pick-up and the cooling air
flow requirements of the system

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 Fixed blade air inlet and outlet louver units on the radiator
3.1.6 Louvers compartment.

Flexible load cables for connection between the alternator

3.1.7 Internal terminals and the free standing air circuit breaker box will be
cabling installed on cable trays at high level. Cables between the ACB
and the voltage transformer will run at low level on ladder
racking. Multi-core cables for control will run in the trays between
the floor mounted GCP panel and the ACB cubicle. Small wiring
to lighting and power sockets will run from the consumer unit in
trunking. Power cables will run on cable trays between the
voltage transformer and the radiator and ventilation fans.
Fire and gas detectors will send a signal to the control system to
3.1.8 Fire and gas initiate an alarm and shut the generator down.
system
External connection to the gas train will be by a 3” flange inside
3.1.9 Gas the container, accessed through a gland plate in the container
Pipework side wall.
Flow and return pipes will run between the engine and the roof
3.1.10 Water mounted flat bed coolers. Adequate valves will be fitted to
pipework facilitate maintenance and flexible bellows will be fitted to
accommodate expansion.
The lub oil make-up tank will be installed at high level in the
3.1.11 Lubricating engine compartment and will be connected to the engine through
oil pipework an isolating valve.
Personnel access doors complete with internal panic release will
3.1.12 Access be strategically fitted to allow adequate access for maintenance.
doors.
An aluminium gland plate will be located in the base of the
3.1.13 Gland container and will be suitably sized to accept the LV cables for
Plates connection on to the circuit breaker.

Sound level matching exhaust silencers will be mounted on the

3. 1.14 Exhaust roof of the engine compartment. Internal pipework is lagged and
system clad to reduce heat input into the cooling air stream.

AC lighting is installed using strategically located bulkhead

3.1.15 Lighting fittings switched from each access door.
A multi-way consumer unit will be installed at high level supplied
from the low voltage side of the voltage transformer.
Power sockets will be located at each access door.
All wired using galvanised steel conduit to current IEE
regulations.

A flashing beacon will be installed on the roof of the container to

3.1.16 Ancillary warn of a fault condition.
Equipment
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3.2 Container Size and Weight
40’L x 10’W x 10’H
Weight: 70,550 lbs

Radiator and silencer shipped in separate open top container.

Finishing
4.1 General

The generating set will be painted to our standard paint procedure in Munsell Jade green.
The transformer and other proprietary equipment will be finished in the manufacturer’s standard
paint finish.
The container will be finished in two pack epoxy paint in Munsell Jade Green
The exhaust silencers will be hot dip galvanised.

Manuals
5.1 General
A hard back 4 ring binder will include the parts and instruction manuals for the engine,
alternator and control system in our standard format. A job specific description of the system
functionality will be include included.

Project Services

6.1 Documentation

One set of documentation, in English, in our standard format will be provided per generator set.
This will comprise:

- operating and maintenance manuals

- spare parts manuals
- generator set general arrangement drawings
- P&ID diagrams
- electrical single line diagrams

6.2 Engineering

We have assumed that all installation project management will be undertaken by others.

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6.3 Packing & Transport

The equipment will be supplied on an unpacked, FOB US Port

6.4 Construction

It is assumed that all installation and construction services will be to the care of others.

6.5 Commissioning

We have allowed for the services of a factory commissioning engineer for a total of 5 days per
unit, all necessary lubricants, coolant, cooling system inhibitors, etc., will be to the care of
others.

6.6 Tools & Spare Parts

We have not included for any tools or spares.

Termination Points

7.1 Gas Supply

External connection to the gas train will be by a 3” flange inside the container, accessed through
a gland plate in the container side wall.

7.2 Power Cabling

LV power Cables 480 Volt at output terminals of container mounted synchronising breaker,
accessed through a gland plate in the container side wall.

7.3 Small Power Cabling

Wall mounted consumer unit requires customer provided 3 phase power supply for radiator
fans, air start compressor and small power i.e. lighting, battery chargers etc

7.4 Others
All other systems such as exhaust and cooling are self-contained and integral with the power
module.

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