TM 9-6115-484-14 MEP-PU-810A/B PART 4

February 7, 2018 | Author: Advocate | Category: Fuel Injection, Turbocharger, Valve, Diesel Engine, Vehicle Parts
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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254

THIS PAGE INTENTIONALLY BLANK

10-80

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

CHAPTER 11 FUEL SYSTEM REPAIR TABLE OF CONTENTS SECTION

TITLE

PAGE

11.0

REPAIR OF FUEL SYSTEM

5

11.1

SAFETY INSTRUCTIONS

5

11.2

FUEL SYSTEM DESCRIPTION

7

11.2.1

FUEL INJECTION

8

11.2.2

THE UNIT INJECTOR MECHANISM

10

11.2.3

SYSTEM MAINTENANCE

11

11.3

SERVICE REQUIREMENTS OF THE FUEL SYSTEM

12

11.3.1

PRIMARY FUEL FILTER

12

11.3.1.1

INSPECT THE PRIMARY FUEL FILTER

12

11.3.1.2

SERVICE THE PRIMARY FUEL FILTER

13

11.3.2

SECONDARY FUEL FILTER

16

11.3.2.1

INSPECT THE SECONDARY FUEL FILTER

16

11.3.2.2

SERVICE THE SECONDARY FUEL FILTER

17

11.3.3

FUEL STRAINER

18

11.3.3.1

INSPECT THE FUEL STRAINER

18

11.3.3.2

SERVICE THE FUEL STRAINER

19

11.3.4

ETHER INJECTION

21

11.3.4.1

INSPECT THE ETHER INJECTION ASSEMBLY

21

11.3.4.2

SERVICE THE ETHER INJECTION ASSEMBLY

21

11.3.5

FUEL SYSTEM PRIMING PROCEDURE

23

11.4

COMPONENT REPAIR PROCEDURES

26

11.4.1

FUEL SOLENOID VALVE (L3)

26

11.4.1.1

INSPECT THE FUEL SOLENOID VALVE (L3)

27

11-1

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

TABLE OF CONTENTS SECTION

TITLE

PAGE

11.4.1.2

REMOVE THE FUEL SOLENOID VALVE (L3)

27

11.4.1.3

INSTALL THE FUEL SOLENOID VALVE (L3)

28

11.4.2

EXTERNAL FUEL TRANSFER PUMP ASSEMBLY

30

11.4.2.1

INSPECT THE EXTERNAL FUEL TRANSFER PUMP ASSEMBLY

31

11.4.2.2

TEST THE EXTERNAL FUEL TRANSFER PUMP ASSEMBLY

31

11.4.2.3

REMOVE THE EXTERNAL FUEL TRANSFER PUMP ASSEMBLY

31

11.4.2.4

INSTALL THE EXTERNAL FUEL TRANSFER PUMP ASSEMBLY

33

11.4.3

FUEL PRIMER PUMP

34

11.4.3.1

INSPECT THE FUEL PRIMER PUMP

34

11.4.3.2

REMOVE THE FUEL PRIMER PUMP

35

11.4.3.3

INSTALL THE FUEL PRIMER PUMP

36

11.4.4

ENGINE MOUNTED FUEL PUMP

37

11.4.4.1

INSPECT THE ENGINE MOUNTED FUEL PUMP

37

11.4.4.2

REMOVE THE ENGINE MOUNTED FUEL PUMP

38

11.4.4.3

INSTALL THE ENGINE MOUNTED FUEL PUMP

39

11.4.5

FUEL FLOAT SWITCH ASSEMBLY

40

11.4.5.1

INSPECT THE FUEL FLOAT SWITCH ASSEMBLY

41

11.4.5.2

TEST THE FUEL FLOAT SWITCH ASSEMBLY

41

11.4.5.3

REMOVE THE FUEL FLOAT SWITCH ASSEMBLY

42

11.4.5.4

INSTALL THE FUEL FLOAT SWITCH ASSEMBLY

43

11-2

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

LIST OF FIGURES FIGURE

TITLE

PAGE

FIGURE 11.2-1

FUEL SYSTEM COMPONENTS

7

FIGURE 11.2.1-1

UNIT INJECTOR MECHANISM

9

FIGURE 11.2.2-1

UNIT INJECTOR COMPONENTS

10

FIGURE 11.3.1-1

PRIMARY FUEL FILTER

12

FIGURE 11.3.1.2-1

PRIMARY FUEL FILTER DRAIN VALVE

15

FIGURE 11.3.2-1

SECONDARY FUEL FILTER

16

FIGURE 11.3.3-1

FUEL STRAINER ASSEMBLY

18

FIGURE 11.3.4-1

ETHER INJECTION ASSEMBLY

21

FIGURE 11.3.5-1

CYLINDER HEAD AIR BLEED CAP

24

FIGURE 11.3.5-2

FUEL PRIMING PUMP

24

FIGURE 11.3.5-3

FUEL SYSTEM AIR BLEED PLUG

25

FIGURE 11.4.1-1

FUEL SOLENOID VALVE (L3)

26

FIGURE 11.4.2-1

FUEL TRANSFER PUMP

30

FIGURE 11.4.3-1

FUEL PRIMER PUMP

34

FIGURE 11.4.4-1

ENGINE MOUNTED FUEL PUMP

37

FIGURE 11.4.5-1

FUEL FLOAT SWITCHES

40

11-3

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

LIST OF TABLES TABLE

TITLE

PAGE

TABLE 11.4.5-1

FFS CONTACT POSITION

11-4

42

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 11.0

REPAIR OF FUEL SYSTEM

Maintenance procedures are provided for the following Fuel System Components: •

Primary Fuel Filter



Secondary Fuel Filter



Fuel Strainer



Ether Injection



Fuel System Priming Procedures



Filter Monitoring Panel



Fuel Solenoid Valve (L3)



External Fuel Transfer Pump Assembly



Fuel Primer Pump



Engine Mounted Fuel Transfer Pump

11.1

SAFETY INSTRUCTIONS

a. Safety precautions must be observed while any maintenance is being performed. Safety precautions must be observed to ensure that the operator/technician cannot have contact with the following: • • • • • • •

Hot engine parts Hot engine fluids Medium Voltage AC electricity Low Voltage AC electricity Low Voltage DC electricity Rotating Parts High noise levels

b. Minor troubleshooting can be performed while both engines are running as long as safety precautions are taken. c.

Minor maintenance can be performed while one generator set is running and the other generator set has been shutdown. Some examples of this maintenance are: Lubrication System – Oil and Filter Change. Hydraulic System – Oil and Filter Change. Fuel System – Primary and Secondary Filter Change. Coolant System – Coolant Change. Minor Troubleshooting. Check Fluid levels and add required fluids.

• • • • • •

(1) The generator set that has been shut down must be rendered unable to start, and cool enough for the maintenance to be performed. Procedures to render a generator set unable to start are: (a)

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (b) (c) (d) (e) (f) (g) (h) (i) (j) (k)

Push to OPEN the Emergency Stop Switch. Place the Engine Control Switch (ECS) in the OFF position. Place a DO NOT OPERATE tag on the generator control panel. Turn the Battery Bank Parallel Switch to the OFF position. De-energize the Battery Charger. Disconnect the negative and positive cables from the Battery Bank for the engine due maintenance. Place a DO NOT OPERATE tag on the Battery Bank. Place the generator Circuit Breaker in the LOCK OUT position. Disconnect the 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock the generator set control panel.

The fuel transfer pump electrical power is normally fed directly from the G1 generator set battery bank. If you disconnect the G1 battery bank, the external fuel transfer pump will not function. Place the Fuel Pump Source Switch (S2) into the (G1 or G2 position). Place the S2 in the (G1 or G2) position, for the generator set not receiving maintenance.

NOTE:

d. Major maintenance or service requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14)

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant or utility connection in accordance with Section 5.9.6.15, Unit Isolation Procedure with PSC. See Note 1 and 2. Isolate the PU from any power plant control system in accordance with Note 3. Pull to open the PU DC Power Control Breaker. Push to OPEN both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels.

NOTE 1:

Also the PU must be completely electrically isolated from the power distribution bus and any other electrical source that can back feed into the PU. All medium voltage cables need to be placed on the standoff insulators by use of hot sticks and other safety gear.

NOTE 2:

Ensure cables are not energized by opening the circuit breaker of the Primary Switching Center (PSC), then disconnect Load Cables (Using the proper safety gear) on the PU and place them on the Parking Stands.

NOTE 3:

When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

11-6

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 11.2

FUEL SYSTEM DESCRIPTION

FIGURE 11.2-1

FUEL SYSTEM COMPONENTS

a. The fuel supply circuit is a conventional design for unit-injected engines. Refer to Figure 11.2-1 for reference. The External Fuel Transfer Pump, of the circuit is a 24VDC, gear type pump with fixed clearance. The Engine Fuel Transfer Pump pulls fuel from the PU 120 Gallon Fuel Tank, and delivers it to the EUI Fuel Injectors. The Engine Fuel Transfer Pump pulls fuel from the fuel tank. The Engine Fuel Transfer Pump incorporates a check valve in order to permit a fuel flow around the gears for hand priming. The Engine Fuel Transfer Pump also incorporates a Relief Valve in order to protect the system from extreme pressure. The excess fuel flow that is provided by the fuel transfer pump cools the fuel from the unit injectors. The excess fuel flow purges the air from the unit injectors. NOTE:

The inlet fuel temperature to the fuel transfer pump must not exceed 175°F (79°C) when the engine has reached normal operating temperature. Fuel temperatures above 175°F (79°C) will reduce the life of the electronics in the ECM and the fuel transfer pump check valves. The fuel efficiency and the engine power output are reduced when the fuel temperature increases from 86°F (30°C) to 158° (70°C) F. The GSC+ will give an AL4 Alarm after 30 seconds.

11-7

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 b. The fuel in the fuel transfer pump flows through the cored passages in the Fuel Block and through a 2-micron fuel filter. The Fuel Priming Pump is positioned on the fuel filter base in order to fill the system after the fuel supply and the return manifolds are drained. The fuel supply and the return passages in the cylinder head are drained in order to reinstall the unit injectors. The filtered fuel enters the housing for the Electronic Control Module (ECM). This fuel cools the module as the fuel passes through the ECM. The fuel enters the fuel manifold at the rear of the cylinder head. The fuel flows continuously from the fuel supply through the Cylinder Head Fuel Gallery through the EUI Fuel Injectors. This fuel then returns to the fuel tank through the Fuel Cooler by the return line on the fuel manifold. c.

Fuel is displaced by the EUI Fuel Injector Plunger when the fuel is not being injected into the cylinder. A Fuel Pressure Regulator is located in the Fuel Block. The Fuel Pressure Regulator maintains a sufficient amount of backpressure in the system in order to fill the EUI Fuel Injectors. The Engine Fuel Transfer Pump is located in the front of the engine at the lower left corner. The Engine Fuel Transfer Pump is mounted to either the front timing gear cover or a plate. The Engine Fuel Transfer Pump is driven by the gear train.

d. The injection pump, the fuel lines, and the nozzles that are used in the traditional Caterpillar diesel engines have been replaced with an electronically controlled, mechanically actuated EUI Fuel Injectors in each cylinder. A solenoid on each injector controls the amount of fuel that is delivered by the injector and Electronic Control Module (ECM), sends a signal to each injector solenoid in order to provide complete control of the engine. 11.2.1

FUEL INJECTION

a. The Electronic Control Module (ECM) controls the amount of fuel that is injected by varying the signals to the injectors. The injectors will inject fuel only if the injector solenoid is energized. The Electronic Control Module (ECM) sends a 90-volt signal to the solenoid in order to energize the solenoid. By controlling the timing and the duration of the 90-volt signal, the Electronic Control Module (ECM) can control injection timing and the amount of fuel that is injected. b. The Electronic Control Module (ECM) sets certain limits on the amount of fuel that can be injected “FRC Fuel Pos” is a limit which controls the amount of air and of fuel for the purpose of emission control. This limit is based on the boost pressure When the Electronic Control Module (ECM) senses a higher boost pressure, the Electronic Control Module (ECM) increases the ‘FRC Fuel Pos” limit “Rated Fuel Pos” is a limit that is based on the horsepower rating of the engine. This is similar to the rack stops and to the torque spring on a mechanically governed engine “Rated Fuel Pos” provides horsepower and torque curves for a specific engine family and for a specific engine rating. All of these limits are programmed into the personality module by the factory. These limits are not programmable in the field. c.

Injection timing depends on three factors: (1) (2) (3)

The Engine rpm The Engine Load Other operational conditions including: •

Fuel Temperature



Ambient Temperature



Altitude



Boost Pressure (Turbocharger)

11-8

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 d. The Electronic Control Module (ECM) can determine the top center position of cylinder number 1 from the signal that is provided by the engine speed-timing sensor. The Electronic Control Module (ECM) decides when the injection should occur relative to the top center position. The Electronic Control Module (ECM) then provides the signal to the injector at the desired time.

(1) Unit Injector, (2) Adjusting Nut, (3) Rocker Arm Assembly, (4) Camshaft FIGURE 11.2.1-1

UNIT INJECTOR MECHANISM

The rocker arm lobe provides the downward force that is required to pressurize the fuel in the unit injector pump. The unit injector (1) allows fuel to be injected into the combustion chamber at the precise time. The camshaft gear is driven by two idler gears and a cluster gear that is driven off the crankshaft gear. The timing marks on the crankshaft gear, on the cluster gear, and on the housing of the timing cover are aligned in order to provide the correct relationship between the piston and the valve movement. The camshaft has three lobes for each cylinder. Two lobes operate the inlet valves and the exhaust valves, and one lobe operates the unit injector mechanism (See Figure 11.2.1-1 Unit Injector Mechanism). Force is transmitted from the unit injector lobe on the camshaft (4) to the top of the unit injector (1) through the rocker arm assembly (3). The adjusting nut (2) allows the injector lash to be set.

11-9

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 11.2.2

THE UNIT INJECTOR MECHANISM

(1) Spring, (2) Solenoid Connection to ECM, (3) Solenoid Valve Assembly, (4) Plunger, (5) Barrel, (6) Seal, (7) Seal, (8) Spring, (9) Spacer, (10) Body, (11) Check Valve, (12) Seal FIGURE 11.2.2-1

UNIT INJECTOR COMPONENTS

a. The fuel exits the fuel supply manifold. The fuel flows through the drilled passages in the cylinder head. This fuel enters the unit injector at the fill port. Refer to Figure 11.2.2-1 for reference: As the unit injector mechanism produces force to the top of the unit injector, spring (1) and plunger (4) is moved downward this causes fuel to be displaced through the valve in the solenoid valve assembly (3), and into the return manifold to the tank. The fuel passage into barrel (5) is closed by the outside diameter of the plunger (4). The passages to the injector tip within the body (10) and along the check valve (11) are filled with fuel as the plunger moves down. After the fuel passage in the plunger barrel is closed, fuel can be injected at any time. These requirements are programmed into the electronic control module. b. When the solenoid valve assembly (3) is energized from a signal across the solenoid connection (2), the solenoid valve closes and the pressure in the injector tip is increased. Injection starts at 5000 ± 275 PSI (34474 ± 1896 kPa) as the force of spring (8) is overcome. This causes the check valve to rise from the seat. The pressure continues to increase as the plunger cycles through the full stroke. After the correct amount of fuel has been discharged into the cylinder, the electronic control module signals across the solenoid connection. This signal indicates that the solenoid valve assembly is de-energized and that the solenoid valve is opened. The highpressure fuel is dumped through the spill port, to the fuel return manifold and then to the tank.

11-10

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

The length of time for the injection will meter the fuel that is consumed during the fuel injection into the cylinder. Injection length is controlled by the governor logic that is programmed into the electronic control module of the fuel system electronic control circuit.

d. After the maximum lift point is achieved, the force to the top of the unit injector is removed as spring (1) expands. The plunger returns to the original position. This uncovers the fuel supply passage to the plunger barrel in order to refill the injector pump body. The low-pressure fuel circulates through the injector body. The fuel then exits through the spill port. This occurs until solenoid valve assembly (3) is again energized. 11.2.3

SYSTEM MAINTENANCE

a. Fuel System Inspection: (1)

Check the fuel level in the fuel tank.

(2)

Check the vent in the cap for the fuel tank for dirt.

(3)

Check the fuel lines for fuel leakage.

(4)

Check the fuel lines for a defective bend or a restriction.

(5)

Check that the fuel return line has not collapsed within the sections that are exposed to heat.

(6)

Remove any air that may be in the fuel system. Priming Procedure”.

Refer to Section 11.3.5 “Fuel System

b. Fuel System Pressure

c.

(1)

The typical fuel pressure of the engine at operating temperature can vary. At low idle, the fuel pressure can be 45 PSI (310 kPa). At high rpm, the fuel pressure can be 65 PSI (448 kPa). The check valve is designed to open between 60 PSI (413 kPa) and 65 PSI (448 kPa). This will control the fuel system pressure. The fuel transfer pump contains an internal relief valve that is designed to open around 90 PSI (620 kPa). This valve will not open during normal operation.

(2)

The performance of the unit injector deteriorates when the fuel pressure drops below 35 PSI (241 kPa). Low power complaints and erratic operation can occur in this situation. Check for a plugged fuel filter or air in the fuel lines as possible causes for these problems before replacing fuel system components.

Fuel Pressure (1)

To check the engine mounted fuel transfer pump pressure, remove the plug from the fuel filter base. Install a pressure gauge, and start the engine. •

Tools Needed: The 1U-5470 Engine Pressure Group can be used to check the fuel pressure of the engine. The engine pressure group includes Special Instruction, SEHS89O7. This instruction provides information about the usage of the group and installation of the group to the engine.

11-11

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 11.3

SERVICE REQUIREMENTS OF THE FUEL SYSTEM

11.3.1

PRIMARY FUEL FILTER

FUEL SHUTOFF VALVE (SHOWN IN CLOSED POSITION)

PRIMARY FUEL FILTER FUEL/WATER SEPARATOR BOWL

FIGURE 11.3.1-1 11.3.1.1

PRIMARY FUEL FILTER

INSPECT THE PRIMARY FUEL FILTER

Inspect the primary fuel assembly for the following conditions using Figure 11.3.1-1 as a reference: a. Check for fuel leakage. b. Check for security of attachment. c.

Empty sediment trap daily. See Figure 11.3.1.2-1 for reference.

d. Inspect connecting hoses and fittings for damage and tightness.

11-12

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 11.3.1.2

SERVICE THE PRIMARY FUEL FILTER WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING DIESEL FUEL IS FLAMMABLE (WHEN ATOMIZED) AND MODERATELY TOXIC TO EYES, SKIN, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN WELL-VENTILATED AREA. FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY OR ILLNESS. WARNING TURN MAIN FUEL VALVE INTO THE OFF POSITION. IT IS LOCATED IN THE FRONT ENGINE COMPARTMENT UNDER THE ENGINE MONITORING GAUGES. CAUTION CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO LOCAL REGULATIONS AND MANDATES. To service the Primary Fuel Filter, proceed as follows: a. This maintenance can be performed while the generator set not requiring maintenance is running and the generator set requiring maintenance has been shutdown. b. The generator set that requires the maintenance (G1 or G2) has been shut down, and must be rendered unable to start, and be cool enough for the maintenance to be performed. Procedures to render a generator set unable to start are: (1) (2) (3) (4)

Shutdown the generator set (G1 or G2) in accordance with Section 5.1.6.1 Shutdown Generators. Push to OPEN the Emergency Stop Switch. Place the Engine Control Switch (ECS) in the OFF position. Place a DO NOT OPERATE tag on the generator control panel.

11-13

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (5) (6) (7) (8) (9) (10) (11) NOTE:

c.

Turn the Battery Bank Parallel Switch to the OFF position. De-energize the Battery Charger. Disconnect the negative and positive cables from the Battery Bank for the engine due maintenance. Place a DO NOT OPERATE tag on the Battery Bank. Place the generator Circuit Breaker in the LOCK OUT position. Disconnect the 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock the generator set control panel. The fuel transfer pump electrical power is normally fed directly from the G1 generator set battery bank. If you disconnect the G1 battery bank, the external fuel transfer pump will not function. Place the Fuel Pump Source Switch (S2) into the (G1 or G2 position), for the generator set not receiving maintenance.

Turn-Off the fuel supply to the engine by placing the Fuel Shut-Off Valve to the closed position.

d. The 3456 EPG Engine is equipped with a Primary Fuel Filter and a Bowl. Use Figure 11.3.1-1 and Figure 11.3.1.2-1 for reference. Primary Fuel Filter consists of an Element. The Element includes the larger upper beveled seal and the smaller lower seal. The Bowl includes the smaller lower seal. e. Loosen the Primary Fuel Filter Drain Valve and empty the fuel from the filter into a suitable container; dispose of the fuel properly. Close the Primary Fuel Filter Drain Valve. f.

Disconnect the Fuel Water Separator Sensor

g. Unscrew the Fuel Filter Bowl and wash the Primary Fuel Filter Bowl with clean diesel fuel. Use Figure 11.3.1-1 for reference. h. Unscrew the Primary Fuel Filter Element from the Filter Head Assembly. i.

Clean the gasket-sealing surface of all the old gasket material.

j.

Apply clean diesel fuel to the new Primary Fuel Filter Gasket.

NOTE: k.

NOTE: l.

Do not fill the fuel filters with fuel before installing them. The fuel would not be filtered and could be contaminated. Contaminated fuel will cause accelerated wear to fuel systems parts. Install the new Primary Fuel Filter. Spin the Primary Fuel Filter onto the Fuel Filter Base. Use the Rotation Index marks on the filter as a guide for proper tightening. Tighten the filter for an additional ¾ turn by hand. Do not over tighten the filter. The water separator is under suction during normal engine operation. Ensure that the drain plug is tightened securely to prevent air from entering the fuel system. Install the clean Fuel Filter Bowl on the Primary Fuel Filter.

m. Install the clean Fuel Water Separator Sensor. n. Open the fuel tank supply valve. NOTE:

Leaks are difficult to detect while the engine is running. The Primary Fuel Filter/Water Separator Bowl is under suction. A leak will allow air to enter the fuel. The air in the fuel can cause low power due to aeration of the fuel. If air enters the fuel, check the components for over tightening or under tightening.

11-14

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 o. Start the Engine and check for leaks. Run the engine for one minute. Stop the engine and check the engine for leaks again. p. The water the Primary Fuel Filter/Water Separator Bowl removes from the fuel accumulates in the Water Separator Bowl. A drain valve is part of the bowl. The drain valve allows any water that accumulates in the bowl to be drained. If the water is not drained when the bowl becomes full, an increased resistance to fuel flow will result.

PRIMARY FUEL FILTER DRAIN VALVE

FIGURE 11.3.1.2-1

PRIMARY FUEL FILTER DRAIN VALVE

90 inch pounds of torque is required to tighten the bowl to the bottom of the fuel filter

NOTE:

q. Maintenance Schedule for the Primary Fuel Filter is as follows:

NOTE:



Every 10 hours of operation or daily, drain the water separator bowl as needed.



Change the Primary Fuel Filter every 250 hours of operation or annually.



Check Filter Monitoring Panel gauge range. The Primary Fuel Filter must be replaced if 5 PSID is reached.



Annually, drain sediment from the Fuel Tank. Fuel quality is very important. The fuel supply should be maintained properly and kept free of contamination by water and sediment. Water contamination of the fuel can be minimized by obtaining fuel from reliable sources and by draining the fuel tank regularly.

11-15

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 11.3.2

SECONDARY FUEL FILTER

SECONDARY FUEL FILTER

FIGURE 11.3.2-1 11.3.2.1

SECONDARY FUEL FILTER

INSPECT THE SECONDARY FUEL FILTER

Inspect the Secondary Fuel Filter for the following conditions using Figure 11.3.2-1 as a reference: a. Check the Filter Head Assembly for leakage. b. Check hoses connection for leakage and security of attachment. c.

Check the Secondary Fuel Filter Differential Gauge mounted on the Filter Monitoring Panel Gauge for proper operation and setting. The setpoint for the Secondary Fuel Differential Gauge is 30 PSID.

11-16

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 11.3.2.2

SERVICE THE SECONDARY FUEL FILTER

To service the Secondary Fuel Filter, proceed as follows: a. This maintenance can be performed while the generator set not requiring maintenance is running and the generator set requiring maintenance has been shutdown. b. The generator set that requires the maintenance (G1 or G2) has been shut down, and must be rendered unable to start, and be cool enough for the maintenance to be performed. Procedures to render a generator set unable to start are: See procedures and warnings in paragraph 11.3.1.2. c.

Turn-Off the fuel supply by placing the Fuel Shut-Off Valve to the closed position.

d. Unscrew the Secondary Fuel Filter from the Filter Head Assembly and discard properly. e. Lightly coat the new Secondary Fuel Filter Gasket with clean fuel. f.

Do not pre-fill the Secondary Fuel Filter before installation. Unfiltered fuel will cause damage to the fuel system.

g. Tighten the new Secondary Fuel Filter until the gasket makes contact with the base; use the index marks on the filter as a guide, continue to tighten for ¾ of a turn. h. Fill the Secondary Fuel Filter by priming the fuel system. See Section 11.3.5 for reference. i.

Maintenance Schedule for the Secondary Fuel Filter Element is as follows: •

Change the Secondary Fuel Filter every 250 hours of operation or annually.



Check the Secondary Fuel Filter Differential Gauge mounted on the Filter Monitoring Panel Gauge for proper operation and setting. The setpoint for the Secondary Fuel Differential Gauge is 30 PSID.

11-17

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 11.3.3

FUEL STRAINER

FUEL STRAINER

FIGURE 11.3.3-1 11.3.3.1

FUEL STRAINER ASSEMBLY

INSPECT THE FUEL STRAINER

Inspect the External Fuel Transfer Pump Assembly for the following conditions using Figure 11.3.3-1 as a reference: a. Check the Fuel Lines and Fittings for cracks, leaks, and security of attachment. b. Check for dirt, dust, oil, or other foreign matter.

11-18

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 11.3.3.2

SERVICE THE FUEL STRAINER WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE HANGING CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE BURNS, LOSS OF LIMB AND OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING DIESEL FUEL IS FLAMMABLE (WHEN ATOMIZED) AND MODERATELY TOXIC TO EYES, SKIN, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN WELL-VENTILATED AREA. FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY OR ILLNESS. CAUTION CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO LOCAL REGULATIONS AND MANDATES. To service the Fuel Strainer, proceed as follows: a.

This maintenance can be performed while the generator set is running. The fuel storage tank on the PU contains enough fuel to operate both engines for approximately 2 hours. If service requires longer than this time you will receive a low fuel level alarm and the operator will have to take steps to prevent shutdown.

NOTE:

b.

Turn fuel transfer pump off by setting the pump control switch to the center postion (OFF).

c.

Close the Fuel Shut-Off Valve on the External Fuel Manifold before continuing. Failure to comply may result in serious injury and fuel spill.

d.

Unscrew the Cap for the Fuel Strainer. See Figure 11.3.3-1 for reference.

e.

Pullout the Fuel Strainer and clean the Fuel Strainer and Cap with clean diesel fuel.

f.

Reinstall the Fuel Strainer and Cap.

11-19

g.

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 Open the Fuel Shut-Off Valve on the External Fuel Manifold.

h.

Turn the Fuel Transfer Pump on by setting the pump control switch to “A” (Automatic).

i.

Maintenance Schedule for the Fuel Strainer Element is as follows: •

Clean the strainer every 250 hours of operation or annually.

11-20

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 11.3.4

ETHER INJECTION MOUNTING STRAP

ETHER BOTTLE

PROTECTIVE CAP

FIGURE 11.3.4-1 11.3.4.1

ETHER INJECTION ASSEMBLY

INSPECT THE ETHER INJECTION ASSEMBLY

Inspect the ether injection assembly for the following conditions using Figure 11.3.4-1 as a reference: a. Check the Ether tank for amount of ether left in the cylinder. b. Check the Ether tank for security of attachment. c.

Check the Ether lines for damage, kinks, ruptures, or breaks.

d. Check for missing or damaged clamps and brackets and hardware. 11.3.4.2

SERVICE THE ETHER INJECTION ASSEMBLY WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE HANGING CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE BURNS, LOSS OF LIMB AND OR DEATH.

11-21

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING ETHER IS HIGHLY FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. USE ONLY IN AN ADEQUATELY VENTILATED AREA. SKIN, EYE. AND RESPIRATORY PROTECTION IS REQUIRED. FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY OR ILLNESS. To Service the Ether Injection Assembly, proceed as follows: NOTE:

When ether injection assembly is not required, remove ether start tank and store in a safe designated area. The Protective Cap must be installed on the Solenoid Valve when the Ether Bottle has been removed to prevent contamination and damage to the valve.

a. Remove Ether Bottle from Solenoid Valve and Bottle Clamp. Install the Protective Cap if a new Bottle is not being installed. b. Determine the amount of Ether left in the bottle by shaking the bottle back and forth. If there is fluid in it you will feel it move. If you don’t feel fluid moving back and forth while shaking the bottle, replace the Ether Bottle with a new one. c.

If required, install new Ether Bottle on the Solenoid Valve Assembly. Tighten the bottle Clamp wing nut.

11-22

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 11.3.5

FUEL SYSTEM PRIMING PROCEDURE WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE HANGING CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE BURNS, LOSS OF LIMB AND OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING.

WARNING DIESEL FUEL IS FLAMMABLE (WHEN ATOMIZED) AND MODERATELY TOXIC TO EYES, SKIN, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN WELLVENTILATED AREA. FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY OR ILLNESS. CAUTION CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO LOCAL REGULATIONS AND MANDATES.

Fuel Priming Procedure

Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters or water separator elements. Clean up fuel spills immediately.

11-23

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

NOTICE Use a suitable container to catch any fuel that might spill. Clean up any spilled fuel immediately.

NOTICE Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over disconnected fuel system component. NOTE:

Each time the fuel system is run out of fuel or air is introduced into the system the following procedure must be followed. Use steps a to c if a filter has been changed for maintenance. (System is otherwise operable)

a. Turn the Fuel Supply Valve to the on position. b. Loosen the Air Bleed Cap at rear of Cylinder Head use Figure 11.3.5-1 for reference.

FIGURE 11.3.5-1

CYLINDER HEAD AIR BLEED CAP

c. Unlock and operate the Fuel-Priming Pump until fuel appears at the Air Bleed Cap. Tighten the Air Bleed Cap. Use Figure 11.3.5-2 for reference.

FIGURE 11.3.5-2

FUEL PRIMING PUMP

11-24

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

d. Loosen the fuel system Air Bleed Plug two full turns. Continue operating the Fuel Priming Pump until fuel appears at Air Bleed Plug. Tighten the Air Bleed Plug. Use Figure 11.3.5-3 for reference.

FIGURE 11.3.5-3

FUEL SYSTEM AIR BLEED PLUG

e. Continue operating the Fuel Priming Pump until a resistance is felt. Push in and re-lock the Fuel Priming Pump. f.

Start the engine as soon as you can after pressurizing the system. It should start within 15 seconds. If not started after 30 seconds, stop and wait two minutes for the Engine Starter to cool.

g. Repeat the entire procedure if needed to start the engine.

11-25

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 11.4

COMPONENT REPAIR PROCEDURES

11.4.1

FUEL SOLENOID VALVE (L3)

The following maintenance procedures are provided for the Fuel Solenoid Valve (L3): Inspect Remove Install

FUEL SOLENOID VALVE NEW STYLE

FUEL SOLENOID VALVE OLD STYLE

FIGURE 11.4.1-1

FUEL SOLENOID VALVE (L3) (NEW AND OLD STYLE )

11-26

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 11.4.1.1

INSPECT THE FUEL SOLENOID VALVE (L3)

Note: There are two versions of the fuel transfer pump assembly, both are interchangeable. Inspect the Fuel Solenoid Valve for the following conditions using Figure 11.4.1-1 for a reference: a. Check for Excessive noise or sluggish operation and security of attachment. b. Check the Fuel Lines and Fittings for cracks, leaks, and security of attachment. c.

Check the Fuel Solenoid Valve for broken or frayed wires and evidence of overheating.

d. Check for dirt, dust, oil, or other foreign matter. 11.4.1.2

REMOVE THE FUEL SOLENOID VALVE (L3) WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE HANGING CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE BURNS, LOSS OF LIMB AND OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING DIESEL FUEL IS FLAMMABLE (WHEN ATOMIZED) AND MODERATELY TOXIC TO EYES, SKIN, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN WELL-VENTILATED AREA. FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY OR ILLNESS. CAUTION CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO LOCAL REGULATIONS AND MANDATES. To remove the Fuel Solenoid Valve (L3), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following:

11-27

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) NOTE 1:

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels. When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Shut off respective hand valve on External Fuel Transfer Distribution Manifold. c.

Place a drain pan under the External Fuel Transfer Hose connection point at the PU.

d. Disconnect the supply fuel hose, then plug the hose to prevent contamination of the fuel system. e. Place a cap fitting on the Fuel Strainer to protect against contamination. f.

Tag and disconnect the Solenoid Valve wires from inside the External Fuel Transfer Pump Controls. Use FO – 43A through FO – 44C for reference.

g. Remove the 4 bolts securing the External Fuel Transfer Pump Assembly to fuel tank. h. Slide the External Fuel Transfer Pump Assembly forward several inches. i.

Place a drain pan under the Solenoid Valve.

j.

Disconnect the fuel lines on either side of the Solenoid Valve and drain the fuel.

k.

Remove the mounting hardware securing the Solenoid Valve to the bracket.

l.

Remove the Solenoid Valve.

m. Remove electrical connection conduit and elbow. 11.4.1.3

INSTALL THE FUEL SOLENOID VALVE (L3)

To install the Fuel Solenoid Valve (L3), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 11.3.4.2. b. Attach the conduit elbow to the Solenoid Valve.

11-28

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

Attach the longer leads to the Solenoid Coil.

d. Slip the Flex Conduit over the wires and secure at the elbow. e. Position the Solenoid Valve on the bracket and secure with the previously removed mounting hardware. f.

Attach the External Fuel Transfer Pump Assembly to the fuel tank with the previously removed 4 bolts and washers.

g. Using Teflon tape or sealing compound, connect the hose from the fuel pump to the solenoid valve. Connect the remaining fuel hose to the Solenoid Valve at the flare joint. h. Un-cap the External Fuel Manifold Hose and Fuel Strainer and connect the External Fuel Manifold Hose to the PU. i.

Connect the Solenoid Valve wires inside the External Fuel Transfer Pump Controls. Use FO – 43A through FO – 44C for reference. Remove the wire tags.

j.

Open the External Fuel Distribution Manifold valve.

k.

After installing the Fuel Solenoid Valve, prepare the PU for operation and inspect the Fuel Solenoid Valve according to Section 11.4.1.1.

11-29

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 11.4.2

EXTERNAL FUEL TRANSFER PUMP ASSEMBLY

The following maintenance procedures are provided for the External Fuel Transfer Pump Assembly: Inspect Test Remove Install

POSITIVE DISPLACEMENT PUMP 24VDC FUEL TRANSFER PUMP MOTOR

POSITIVE DISPLACEMENT PUMP 24VDC FUEL TRANSFER PUMP MOTOR

FIGURE 11.4.2-1

FUEL TRANSFER PUMP ASSEMBLY (NEW AND OLD STYLE)

The Fuel Transfer Pump is 24VDC, 1/3 hp and 2.25 GPM. The Fuel Transfer Pump works in conjunction with the Fuel Level Float Switches and Fuel Transfer Solenoid Valve. Use Figure 11.4.2-1 for reference.

11-30

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 11.4.2.1

INSPECT THE EXTERNAL FUEL TRANSFER PUMP ASSEMBLY

Inspect the External Fuel Transfer Pump Assembly for the following conditions using Figure 11.4.2-1 for reference: a. Check for Excessive noise or sluggish operation and security of attachment. b. Check the Fuel Lines and Fittings for cracks, leaks, and security of attachment. c.

Check the External Fuel Transfer Pump Motor for broken or frayed wires and evidence of overheating.

d. Check for dirt, dust, oil, or other foreign matter. 11.4.2.2

TEST THE EXTERNAL FUEL TRANSFER PUMP ASSEMBLY

To test the External Fuel Transfer Pump Assembly, proceed as follows: a. Place the fuel transfer pump control switch to the TEST position. Observe the fuel transfer pump operating. Release the toggle switch. If the pump does not operate proceed with the next step. b. With a multimeter on the VDC Scale, check for voltage at the motor terminals. If there is voltage between 18 to 24 volts and the motor is not operating, this indicates a defective motor, replace the motor. 11.4.2.3

REMOVE THE EXTERNAL FUEL TRANSFER PUMP ASSEMBLY WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE HANGING CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE BURNS, LOSS OF LIMB AND OR DEATH.

WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING.

11-31

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 WARNING DIESEL FUEL IS FLAMMABLE (WHEN ATOMIZED) AND MODERATELY TOXIC TO EYES, SKIN, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN WELLVENTILATED AREA. FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY OR ILLNESS. CAUTION CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO LOCAL REGULATIONS AND MANDATES. To remove the External Fuel Transfer Pump Assembly, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) NOTE 1:

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels. When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Tag and disconnect the wiring from the External Fuel Transfer Pump Assembly. c.

Remove the fuel lines.

d. Remove External Fuel Transfer Pump Assembly by removing machine bolts, washers, and lock washers.

11-32

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 11.4.2.4

INSTALL THE EXTERNAL FUEL TRANSFER PUMP ASSEMBLY

To install the External Fuel Transfer Pump Assembly, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 11.4.2.3. b.. Place the Fuel Transfer Pump in mounted position then, reinstall the mounting hardware. c.

Reconnect the fuel lines.

d. Remove tags and connect wiring to the External Fuel Transfer Pump Assembly. d. Reconnect the batteries. e. Test the Fuel Transfer Pump for operation.

11-33

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 11.4.3

FUEL PRIMER PUMP

The following maintenance procedures are provided for the Fuel Primer Pump: Inspect Remove Install

MOUNTING BOLTS

FUEL PRIMER PUMP

MOUNTING BOLTS

FIGURE 11.4.3-1 11.4.3.1

FUEL PRIMER PUMP

INSPECT THE FUEL PRIMER PUMP

Inspect the Fuel Primer Pump for the following conditions using Figure 11.4.3-1 for a reference: a. Check for fuel leakage. b. Check for dirt, dust, oil, or other foreign matter that could damage the pump. c.

Check for damage, and loose connections.

11-34

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 11.4.3.2

REMOVE THE FUEL PRIMER PUMP WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE HANGING CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE BURNS, LOSS OF LIMB AND OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING DIESEL FUEL IS FLAMMABLE (WHEN ATOMIZED) AND MODERATELY TOXIC TO EYES, SKIN, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN WELL-VENTILATED AREA. FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY OR ILLNESS. CAUTION CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO LOCAL REGULATIONS AND MANDATES. To remove the Fuel Primer Pump, perform the following: a. This maintenance can be performed while the generator set not requiring maintenance is running and the generator set requiring maintenance has been shutdown. b. The generator set that requires the maintenance (G1 or G2) has been shut down, and must be rendered unable to start, and be cool enough for the maintenance to be performed. Procedures to render a generator set unable to start are: (1) (2) (3) (4) (5) (6) (7) (8)

Shutdown the generator set (G1 or G2) in accordance with Section 5.1.6.1 Shutdown Generators. Push to OPEN the Emergency Stop Switch. Place the Engine Control Switch (ECS) in the OFF position. Place a DO NOT OPERATE tag on the generator control panel. Turn the Battery Bank Parallel Switch to the OFF position. De-energize the Battery Charger. Disconnect the negative and positive cables from the Battery Bank for the engine due maintenance. Place a DO NOT OPERATE tag on the Battery Bank.

11-35

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (9) (10) (11)

Place the generator Circuit Breaker in the LOCK OUT position. Disconnect the 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock the generator set control panel. The fuel transfer pump electrical power is normally fed directly from the G1 generator set battery bank. If you disconnect the G1 battery bank, the external fuel transfer pump will not function. Place the Fuel Pump Source Switch (FPSS) into the (G1 or G2 position), for the generator set not receiving maintenance.

NOTE:

c.

Remove the two mounting bolts.

d. Separate the Fuel Primer Pump from the Fuel Primer Pump Base. e. Clean gasket material from mating surfaces. 11.4.3.3

INSTALL THE FUEL PRIMER PUMP

To install the Fuel Primer Pump, perform the following: a. This maintenance can be performed while the generator set not requiring maintenance is running and the generator set requiring maintenance has been shutdown. b. The generator set that requires the maintenance (G1 or G2) has been shut down, and must be rendered unable to start, and be cool enough for the maintenance to be performed. See Procedures and warnings in paragraph 11.4.3.2 c.

Install a new gasket on the Fuel Primer Pump Base.

d. Place the Fuel Primer Pump in position on the Fuel Primer Pump Base. Make sure the gasket is in the proper position then reinstall and tighten the mounting bolts. Torque to 21 + 5 Ft-Lbs (28 + 7 Nm).

11-36

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 11.4.4

ENGINE MOUNTED FUEL PUMP

The following maintenance procedures are provided for the Engine Mounted Fuel Pump: Inspect Remove Install

2

4

3

1

FIGURE 11.4.4-1 11.4.4.1

ENGINE MOUNTED FUEL PUMP

INSPECT THE ENGINE MOUNTED FUEL PUMP

Inspect the Engine Mounted Fuel Pump for the following: a. Check for fuel leakage. b. Check for dirt, dust, oil, or other foreign matter that could damage the pump. c. NOTE:

Check for damage, and loose connections. This procedure is covered in the Caterpillar Manual SENR1068-01, or later version SMCS CODE 1256-010.

11-37

11.4.4.2

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 REMOVE THE ENGINE MOUNTED FUEL PUMP WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE HANGING CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE BURNS, LOSS OF LIMB AND OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING DIESEL FUEL IS FLAMMABLE (WHEN ATOMIZED) AND MODERATELY TOXIC TO EYES, SKIN, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN WELL-VENTILATED AREA. FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY OR ILLNESS. CAUTION CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO LOCAL REGULATIONS AND MANDATES. To remove the Engine Mounted Fuel Pump, proceed as follows: a. This maintenance can be performed while the generator set not requiring maintenance is running and the generator set requiring maintenance has been shutdown. b. The generator set that requires the maintenance (G1 or G2) has been shut down, and must be rendered unable to start, and be cool enough for the maintenance to be performed. Procedures to render a generator set unable to start are: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10)

Shutdown the generator set (G1 or G2) in accordance with Section 5.1.6.1 Shutdown Generators. Push to OPEN the Emergency Stop Switch. Place the Engine Control Switch (ECS) in the OFF position. Place a DO NOT OPERATE tag on the generator control panel. Turn the Battery Bank Parallel Switch to the OFF position. De-energize the Battery Charger. Disconnect the negative and positive cables from the Battery Bank for the engine due maintenance. Place a DO NOT OPERATE tag on the Battery Bank. Place the generator Circuit Breaker in the LOCK OUT position. Disconnect the 7P1 and 7P2 Connectors located on the inside panel of the PDC.

11-38

(11)

The fuel transfer pump electrical power is normally fed directly from the G1 generator set battery bank. If you disconnect the G1 battery bank, the external fuel transfer pump will not function. Place the Fuel Pump Source Switch (S2) into the (G1 or G2 position). Place the S2 in the (G1 or G2) position, for the generator set not receiving maintenance.

NOTE:

c.

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 Close and Lock the generator set control panel.

Remove the fuel lines (1) and (2). Refer to Figure 11.4.4-1 for reference.

d. Plug and cap all openings to prevent fuel system contamination. e. Remove the mounting bolts (3) and the Engine Mounted Fuel Pump (4). f.

Check condition of the O-ring seal on the Engine Mounted Fuel Pump. If the O-ring seal is worn or damaged, replace with a new seal.

11.4.4.3

INSTALL THE ENGINE MOUNTED FUEL PUMP

To install the Engine Mounted Fuel Pump, proceed as follows: a. This maintenance can be performed while the generator set not requiring maintenance is running and the generator set requiring maintenance has been shutdown. b. The generator set that requires the maintenance (G1 or G2) has been shut down, and must be rendered unable to start, and be cool enough for the maintenance to be performed. See procedures and warnings in paragraph 11.4.4.2. c.

Place the O-ring seal on the Engine Mounted Fuel Pump. If the O-ring seal is worn or damaged, replace with a new seal. Put clean engine oil on the O-ring seal. Refer to Figure 11.4.4-1 for reference.

d. Put the Engine Mounted Fuel Pump (4) into position, and Reinstall the mounting bolts (3) that hold the Engine Mounted Fuel Transfer Pump into place. e. Remove the protective caps from the Engine Mounted Fuel Pump openings. Reinstall the fuel lines (1) and (2). NOTE:

Refer to Caterpillar Manual SENR3130-06 or later version for torque specifications.

11-39

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 11.4.5

FUEL FLOAT SWITCH ASSEMBLY

FIGURE 11.4.5-1

FUEL FLOAT SWITCHES

The fuel tank float switch assembly is located in the top of the fuel tank. The switches are used to turn the fuel transfer pump on and off and give a warning indication if fuel is low or high, and unit timed shutdown before the PU runs out of fuel. The External Fuel Transfer Pump is turned off if fuel level is too high. Use Figure 11.4.5-1 for reference. There are four Fuel Float Switches mounted inside of the 120-gallon fuel tank. The Fuel Float Switches are mounted in the fuel tank at the end of tubes whose lengths are determined by specific fuel level. A. Low Fuel Level Alarm Switch/Timed shutdown: Functions at 20% Fuel. B. Fuel Transfer Pump Start Switch: Functions at 40% Fuel. C. Fuel Transfer Pump Stop Switch: Functions at 90% Fuel. D. High Fuel Level Alarm Switch: Functions at 95% Fuel.

11-40

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 11.4.5.1

INSPECT THE FUEL FLOAT SWITCH ASSEMBLY

Inspect the Fuel Float Switch Assembly for the following: a. Check for fuel leakage. b. Check for dirt, dust, oil, or other foreign matter that could damage the pump. c.

Check for damage, and loose electrical and mechanical connections.

11.4.5.2

TEST THE FUEL FLOAT SWITCH ASSEMBLY WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE HANGING CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE BURNS, LOSS OF LIMB AND OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING DIESEL FUEL IS FLAMMABLE (WHEN ATOMIZED) AND MODERATELY TOXIC TO EYES, SKIN, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN WELLVENTILATED AREA. FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY OR ILLNESS. CAUTION CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO LOCAL REGULATIONS AND MANDATES. To test the Fuel Float Switch Assembly, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2)

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1.

11-41

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels.

(3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) NOTE 1:

When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Leave the switches mounted to the Inspection Plate for testing. c.

Disconnect the two switch wires for each switch. Refer to FO-43A, FO-43B, FO-44A, FO-44B and FO44C for reference.

d. Using a multimeter set to OHMS (Ω) Rx1 scale, test switch’s wires for contact continuity in the switch positions specified. Multimeter should indicate zero ohms at points marked in chart as shown in Table 11.4.5-1. e. Multimeter should indicate infinite ohms at all open contacts in chart as shown in Table 11.4.5-1. f.

Replace any Fuel Float Switch if it fails any of the above requirements.

TABLE 11.4.5-1 FLOAT POSITION NORMALLY OPEN NORMALLY CLOSED 11.4.5.3

FFS CONTACT POSITION S3 S4 (START) (STOP) MINIMUM FUEL MAXIMUM FUEL LEVEL SWITCH LEVEL SWITCH

S5 (HFTL) HIGH FUEL TANK LEVEL SWITCH

S6 (LFTL) LOW FUEL TANK LEVEL SWITCH

X X

X

X

REMOVE THE FUEL FLOAT SWITCH ASSEMBLY

To remove the Fuel Float Switch Assembly, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 11.4.5.2. b. Remove the 2 retaining screws from the cover of the Fuel Float Assembly and remove cover. c.

Remove the 8 mounting bolts from the inspection cover.

11-42

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 d. Tag and disconnect the Fuel Float Switch (FFS). Refer to FO-43A, FO-43B, FO-44A, FO-44B and FO44C for reference. e. Remove the Inspection Cover from the fuel tank. f.

Remove the Fuel Float Switch Assembly.

g. Remove the Fuel Float Switch by unscrewing them from their mounting tubes, and then pulling the wiring out of the mounting tubes. 11.4.5.4

INSTALL THE FUEL FLOAT SWITCH ASSEMBLY

To install the Fuel Float Switch Assembly, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 11.4.5.2. b. If any of the Fuel Float Switches were replaced, start by reinstalling the Fuel Float Switch (FFS) by pushing the Fuel Float Switch wiring into the mounting tubes then by screwing them to the mounting tubes. c.

Reinstall the Fuel Float Switch Assembly.

d. Reinstall the inspection cover and Reinstall the 8 mounting bolts. e. Connect and remove the tags of the Fuel Float Switch (FFS). Refer to FO-43A, FO-43B, FO44A, FO-44B and FO44C for reference. f.

Reinstall the 2 retaining screws from the electrical inspection plate mounted on the fuel tank inspection cover.

g. Test Fuel Float Switch Assembly for operation.

11-43

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

THIS PAGE INTENTIONALLY BLANK

11-44

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

CHAPTER 12 CONTROLS AND INSTRUMENTS REPAIR TABLE OF CONTENTS SECTION

TITLE

PAGE

12.0

CONTROLS AND INSTRUMENTS REPAIR

13

12.1

SAFETY INSTRUCTIONS

13

12.2

BRIEF DESCRIPTION

14

12.3

SERVICE REQUIREMENTS

14

12.4

COMPONENT REPAIR PROCEDURES

15

12.4.1

ENGINE CONTROL DEVICES

15

12.4.1.1

COOLANT TEMPERATURE SENSOR

16

12.4.1.1.1

INSPECT COOLANT TEMPERATURE SENSOR

16

12.4.1.1.2

TEST COOLANT TEMPERATURE SENSOR

16

12.4.1.1.3

REMOVE COOLANT TEMPERATURE SENSOR

17

12.4.1.1.4

INSTALL COOLANT TEMPERATURE SENSOR

18

12.4.1.2

COOLANT LEVEL SENSOR

20

12.4.1.2.1

INSPECT COOLANT LEVEL SENSOR

20

12.4.1.2.2

TEST COOLANT LEVEL SENSOR

21

12.4.1.2.3

REMOVE COOLANT LEVEL SENSOR

21

12.4.1.2.4

INSTALL COOLANT LEVEL SENSOR

22

12.4.1.3

FILTERED ENGINE OIL PRESSURE SENSOR

24

12.4.1.3.1

INSPECT FILTERED ENGINE OIL PRESSURE SENSOR

24

12.4.1.3.2

TEST FILTERED ENGINE OIL PRESSURE SENSOR

25

12.4.1.3.3

REMOVE FILTERED ENGINE OIL PRESSURE SENSOR

25

12.4.1.4

FLYWHEEL MOUNTED ENGINE SPEED SENSOR

27

12.4.1.4.1

INSPECT FLYWHEEL MOUNTED ENGINE SPEED SENSOR

27

12.4.1.4.2

REMOVE FLYWHEEL MOUNTED ENGINE SPEED SENSOR

28

12.4.1.4.3

INSTALL FLYWHEEL MOUNTED ENGINE SPEED SENSOR

30

12.4.1.5

COLD START STRATEGY

31

12.4.1.6

ENGINE SPEED GOVERNING

31

12.4.1.7

PASSIVE SPEED/TIMING SENSORS

32

12-1

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.1.7.1

INSPECT PASSIVE SPEED/TIMING SENSORS

32

12.4.1.7.2

TEST PASSIVE SPEED/TIMING SENSORS

33

12.4.1.7.3

REMOVE PASSIVE SPEED/TIMING SENSORS

33

12.4.1.7.4

INSTALL PASSIVE SPEED/TIMING SENSORS

35

12.4.1.8

INLET MANIFOLD AIR TEMPERATURE SENSOR

36

12.4.1.8.1

INSPECT INLET MANIFOLD AIR TEMPERATURE SENSOR

36

12.4.1.8.2

TEST INLET MANIFOLD AIR TEMPERATURE SENSOR

37

12.4.1.8.3

REMOVE INLET MANIFOLD AIR TEMPERATURE SENSOR

37

12.4.1.8.4

INSTALL INLET MANIFOLD AIR TEMPERATURE SENSOR

38

12.4.1.9

TURBOCHARGER COMPRESSOR OUTLET PRESSURE SENSOR

39

12.4.1.9.1

INSPECT TURBOCHARGER COMPRESSOR OUTLET PRESSURE SENSOR 39

12.4.1.9.2

TEST TURBOCHARGER COMPRESSOR OUTLET PRESSURE SENSOR

12.4.1.9.3

REMOVE TURBOCHARGER COMPRESSOR OUTLET PRESSURE SENSOR 40

12.4.1.9.4

INSTALL TURBOCHARGER COMPRESSOR OUTLET PRESSURE SENSOR 42

12.4.1.10

ATMOSPHERIC PRESSURE SENSOR

43

12.4.1.10.1

INSPECT ATMOSPHERIC PRESSURE SENSOR

43

12.4.1.10.2

TEST ATMOSPHERIC PRESSURE SENSOR

44

12.4.1.10.3

REMOVE ATMOSPHERIC PRESSURE SENSOR

44

12.4.1.10.4

INSTALL ATMOSPHERIC PRESSURE SENSOR

45

12.4.1.11

FUEL TEMPERATURE SENSOR

46

12.4.1.11.1

INSPECT FUEL TEMPERATURE SENSOR

46

12.4.1.11.2

TEST FUEL TEMPERATURE SENSOR

47

12.4.1.11.3

REMOVE FUEL TEMPERATURE SENSOR

47

12.4.1.11.4

INSTALL FUEL TEMPERATURE SENSOR

48

12.4.1.12

ENGINE DIAGNOSTICS

49

12.4.1.12.1

SELF-DIAGNOSTICS

49

12.4.1.12.2

PERMANENT FAULT LOGGING

49

12.4.1.12.3

ENGINE OPERATION WITH ACTIVE DIAGNOSTIC CODES

49

12.4.1.13

FILTER MONITORING PANEL

51

12.4.1.13.1

INSPECT FILTER MONITORING PANEL

52

12.4.1.13.2

REMOVE FILTER MONITORING PANEL

52

12.4.1.13.3

INSTALL FILTER MONITORING PANEL

53

12-2

40

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.1.13.4

SERVICE FILTER MONITORING PANEL

54

12.4.2

PDC CONTROLS AND INSTRUMENTS

55

12.4.2.1

GENERATOR CONTROL PANEL CONTROLS AND INSTRUMENTS

56

12.4.2.1.1

GENERATOR SET CONTROLLER (GSC+)

57

12.4.2.1.1.1

INSPECT GENERATOR SET CONTROLLER (GSC+)

58

12.4.2.1.1.2

TEST GENERATOR SET CONTROLLER (GSC+)

58

12.4.2.1.1.3

REMOVE GENERATOR SET CONTROLLER (GSC+)

58

12.4.2.1.1.4

INSTALL GENERATOR SET CONTROLLER (GSC+)

59

12.4.2.1.1.5

GSC+ SET POINTS

59

12.4.2.1.2

GENERATOR / FEEDER OVERCURRENT RELAY

60

12.4.2.1.2.1

INSPECT GENERATOR / FEEDER OVERCURRENT RELAY

62

12.4.2.1.2.2

TEST GENERATOR / FEEDER OVERCURRENT RELAY

62

12.4.2.1.2.3

REMOVE GENERATOR / FEEDER OVERCURRENT RELAY

62

12.4.2.1.2.4

INSTALL GENERATOR / FEEDER OVERCURRENT RELAY

63

12.4.2.1.2.5

SERVICE GENERATOR / FEEDER OVERCURRENT RELAY

63

12.4.2.1.2.6

OVERCURRENT RELAY SET POINTS

64

12.4.2.1.3

GENERATOR AND FEEDER BREAKER CONTROL SWITCHES (BCS)

65

12.4.2.1.3.1

INSPECT GENERATOR AND FEEDER BREAKER CONTROL SWITCHES

66

12.4.2.1.3.2

TEST GENERATOR AND FEEDER BREAKER CONTROL SWITCHES

66

12.4.2.1.3.3

REMOVE GENERATOR AND FEEDER BREAKER CONTROL SWITCHES

68

12.4.2.1.3.4

INSTALL GENERATOR AND FEEDER BREAKER CONTROL SWITCHES

68

12.4.2.1.4

ENGINE CONTROL SWITCH (ECS)

69

12.4.2.1.4.1

INSPECT ENGINE CONTROL SWITCH (ECS)

70

12.4.2.1.4.2

TEST ENGINE CONTROL SWITCH (ECS)

70

12.4.2.1.4.3

REMOVE ENGINE CONTROL SWITCH (ECS)

71

12.4.2.1.4.4

INSTALL ENGINE CONTROL SWITCH (ECS)

72

12.4.2.1.5

EMERGENCY STOP PUSHBUTTON (ESPB)

73

12.4.2.1.5.1

INSPECT EMERGENCY STOP PUSHBUTTON (ESPB)

73

12.4.2.1.5.2

TEST EMERGENCY STOP PUSHBUTTON (ESPB)

74

12.4.2.1.5.3

REMOVE EMERGENCY STOP PUSHBUTTON (ESPB)

75

12.4.2.1.5.4

INSTALL EMERGENCY STOP PUSHBUTTON (ESPB)

75

12.4.2.1.6

EMERGENCY STOP ACTUATOR (ESA)

76

12-3

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.1.6.1

INSPECT EMERGENCY STOP ACTUATOR (ESA)

76

12.4.2.1.6.2

TEST EMERGENCY STOP ACTUATOR (ESA)

77

12.4.2.1.6.3

REMOVE EMERGENCY STOP ACTUATOR (ESA)

78

12.4.2.1.6.4

INSTALL EMERGENCY STOP ACTUATOR (ESA)

78

12.4.2.1.7

AUTOMATIC VOLTAGE REGULATOR (AVR)

79

12.4.2.1.7.1

INSPECT AUTOMATIC VOLTAGE REGULATOR (AVR)

83

12.4.2.1.7.2

TEST AUTOMATIC VOLTAGE REGULATOR (AVR)

83

12.4.2.1.7.3

REMOVE AUTOMATIC VOLTAGE REGULATOR (AVR)

83

12.4.2.1.7.4

INSTALL AUTOMATIC VOLTAGE REGULATOR (AVR)

84

12.4.2.1.7.5

SERVICE AUTOMATIC VOLTAGE REGULATOR (AVR)

85

12.4.2.2

MASTER CONTROL PANEL

86

12.4.2.2.1

SYNCHROSCOPE / SYNCH-CHECK RELAY (SC/25M)

87

12.4.2.2.1.1

INSPECT SYNCHROSCOPE / SYNCH-CHECK RELAY (SC/25M)

88

12.4.2.2.1.2

TEST SYNCHROSCOPE / SYNCH-CHECK RELAY (SC/25M)

88

12.4.2.2.1.3

REMOVE SYNCHROSCOPE / SYNCH-CHECK RELAY (SC/25M)

88

12.4.2.2.1.4

INSTALL SYNCHROSCOPE / SYNCH-CHECK RELAY (SC/25M)

89

12.4.2.2.2

TIE OVERCURRENT RELAY

90

12.4.2.2.2.1

INSPECT TIE OVERCURRENT RELAY

92

12.4.2.2.2.2

TEST TIE OVERCURRENT RELAY

92

12.4.2.2.2.3

REMOVE TIE OVERCURRENT RELAY

92

12.4.2.2.2.4

INSTALL TIE OVERCURRENT RELAY

93

12.4.2.2.2.5

SERVICE TIE OVERCURRENT RELAY

93

12.4.2.2.2.6

OVERCURRENT RELAY SET POINTS

94

12.4.2.2.3

BUS VOLT / FREQUENCY METER

95

12.4.2.2.3.1

INSPECT BUS VOLT / FREQUENCY METER

95

12.4.2.2.3.2

TEST BUS VOLT / FREQUENCY METER

96

12.4.2.2.3.3

REMOVE BUS VOLT/FREQUENCY METER

96

12.4.2.2.3.4

INSTALL BUS VOLT / FREQUENCY METER

97

12.4.2.2.3.5

SERVICE BUS VOLT/FREQUENCY METER

98

12.4.2.2.4

TIE BREAKER CONTROL SWITCH (BCST)

100

12.4.2.2.4.1

INSPECT TIE BREAKER CONTROL SWITCH (BCST)

101

12.4.2.2.4.2

TEST TIE BREAKER CONTROL SWITCH (BCST)

101

12-4

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.2.4.3

REMOVE TIE BREAKER CONTROL SWITCH (BCST)

103

12.4.2.2.4.4

INSTALL TIE BREAKER CONTROL SWITCH (BCST)

103

12.4.2.2.5

SYSTEM MODE SWITCH (SMS)

104

12.4.2.2.5.1

INSPECT SYSTEM MODE SWITCH (SMS)

105

12.4.2.2.5.2

TEST SYSTEM MODE SWITCH (SMS)

105

12.4.2.2.5.3

REMOVE SYSTEM MODE SWITCH (SMS)

106

12.4.2.2.5.4

INSTALL SYSTEM MODE SWITCH (SMS)

107

12.4.2.2.6

SYSTEM SYNCHRONIZING SWITCH (SSS)

108

12.4.2.2.6.1

INSPECT SYSTEM SYNCHRONIZING SWITCH (SSS)

108

12.4.2.2.6.2

TEST SYSTEM SYNCHRONIZING SWITCH (SSS)

109

12.4.2.2.6.3

REMOVE SYSTEM SYNCHRONIZING SWITCH (SSS)

111

12.4.2.2.6.4

INSTALL SYSTEM SYNCHRONIZING SWITCH (SSS)

111

12.4.2.2.7

GENERATOR MODE SWITCH (GMS)

112

12.4.2.2.7.1

INSPECT GENERATOR MODE SWITCH (GMS)

112

12.4.2.2.7.2

TEST GENERATOR MODE SWITCH (GMS)

113

12.4.2.2.7.3

REMOVE GENERATOR MODE SWITCH (GMS)

114

12.4.2.2.7.4

INSTALL GENERATOR MODE SWITCH (GMS)

114

12.4.2.2.8

MASTER SYSTEM ENABLE SWITCH (MSES)

115

12.4.2.2.8.1

INSPECT MASTER SYSTEM ENABLE SWITCH (MSES)

116

12.4.2.2.8.2

TEST MASTER SYSTEM ENABLE SWITCH (MSES)

116

12.4.2.2.8.3

REMOVE MASTER SYSTEM ENABLE SWITCH (MSES)

117

12.4.2.2.8.4

INSTALL MASTER SYSTEM ENABLE SWITCH (MSES)

117

12.4.2.2.9

BATTLESHORT SWITCH (BSS)

118

12.4.2.2.9.1

INSPECT BATTLESHORT SWITCH (BSS)

118

12.4.2.2.9.2

TEST BATTLESHORT SWITCH (BSS)

119

12.4.2.2.9.3

REMOVE BATTLESHORT SWITCH (BSS)

120

12.4.2.2.9.4

INSTALL BATTLESHORT SWITCH (BSS)

120

12.4.2.2.10

AUTOMATIC VOLTAGE REGULATOR SWITCH (AVRS)

121

12.4.2.2.10.1

INSPECT AUTOMATIC VOLTAGE REGULATOR SWITCH (AVRS)

121

12.4.2.2.10.2

TEST AUTOMATIC VOLTAGE REGULATOR SWITCH (AVRS)

122

12.4.2.2.10.3

REMOVE AUTOMATIC VOLTAGE REGULATOR SWITCH (AVRS)

123

12.4.2.2.10.4

INSTALL AUTOMATIC VOLTAGE REGULATOR SWITCH (AVRS)

123

12-5

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.2.11

UNIT SELECTOR SWITCH (USS)

124

12.4.2.2.11.1

INSPECT UNIT SELECTOR SWITCH (USS)

125

12.4.2.2.11.2

TEST UNIT SELECTOR SWITCH (USS)

125

12.4.2.2.11.3

REMOVE UNIT SELECTOR SWITCH (USS)

127

12.4.2.2.11.4

INSTALL UNIT SELECTOR SWITCH (USS)

127

12.4.2.2.12

UNIT SELECTOR INDICATORS (USI)

128

12.4.2.2.12.1

INSPECT UNIT SELECTOR INDICATORS (USI)

128

12.4.2.2.12.2

TEST UNIT SELECTOR INDICATORS (USI)

128

12.4.2.2.12.3

REMOVE UNIT SELECTOR INDICATORS (USI)

129

12.4.2.2.12.4

INSTALL UNIT SELECTOR INDICATORS (USI)

130

12.4.2.2.13

BUZZER SILENCE PUSHBUTTON (SIL)

131

12.4.2.2.13.1

INSPECT BUZZER SILENCE PUSHBUTTON (SIL)

132

12.4.2.2.13.2

TEST BUZZER SILENCE PUSHBUTTON (SIL)

132

12.4.2.2.13.3

REMOVE BUZZER SILENCE PUSHBUTTON (SIL)

133

12.4.2.2.13.4

INSTALL BUZZER SILENCE PUSHBUTTON (SIL)

134

12.4.2.2.14

SYSTEM STATUS LIGHT (SSL)

135

12.4.2.2.14.1

INSPECT SYSTEM STATUS LIGHT (SSL)

136

12.4.2.2.14.2

TEST SYSTEM STATUS LIGHT (SSL)

136

12.4.2.2.14.3

REMOVE SYSTEM STATUS LIGHT (SSL)

137

12.4.2.2.14.4

INSTALL SYSTEM STATUS LIGHT (SSL)

138

12.4.2.2.15

50/60 HERTZ INDICATOR LIGHTS

139

12.4.2.2.15.1

INSPECT 50/60 HERTZ INDICATOR LIGHTS

139

12.4.2.2.15.2

TEST 50/60 HERTZ INDICATOR LIGHTS

140

12.4.2.2.15.3

REMOVE 50/60 HERTZ INDICATOR LIGHTS

140

12.4.2.2.15.4

INSTALL 50/60 HERTZ INDICATOR LIGHTS

141

12.4.2.2.16

PHASE ROTATION TEST LIGHTS (PRL)

142

12.4.2.2.16.1

INSPECT PHASE ROTATION TEST LIGHTS (PRL)

143

12.4.2.2.16.2

TEST PHASE ROTATION TEST LIGHTS (PRL)

143

12.4.2.2.16.3

REMOVE PHASE ROTATION TEST LIGHTS (PRL)

144

12.4.2.2.16.4

INSTALL PHASE ROTATION TEST LIGHTS (PRL)

146

12.4.2.2.17

ALARM / FAULT BUZZER

147

12.4.2.2.17.1

INSPECT ALARM/FAULT BUZZER

149

12-6

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.2.17.2

TEST ALARM/FAULT BUZZER

149

12.4.2.2.17.3

REMOVE ALARM/FAULT BUZZER

150

12.4.2.2.17.4

INSTALL ALARM/FAULT BUZZER

152

12.4.3

CONTROLS AND INSTRUMENTS WITHIN CABINET A, B, AND C

153

12.4.3.1

FREQUENCY SELECTOR SWITCH (FSS)

153

12.4.3.1.1

INSPECT FREQUENCY SELECTOR SWITCH (FSS)

154

12.4.3.1.2

TEST FREQUENCY SELECTOR SWITCH (FSS)

154

12.4.3.1.3

REMOVE FREQUENCY SELECTOR SWITCH (FSS)

155

12.4.3.1.4

INSTALL FREQUENCY SELECTOR SWITCH (FSS)

155

12.4.3.2

AUTOMATIC SYNCHRONIZER (SPMA)

156

12.4.3.2.1

INSPECT AUTOMATIC SYNCHRONIZER (SPMA)

157

12.4.3.2.2

TEST AUTOMATIC SYNCHRONIZER (SPMA)

157

12.4.3.2.3

REMOVE AUTOMATIC SYNCHRONIZER (SPMA)

157

12.4.3.2.4

INSTALL AUTOMATIC SYNCHRONIZER (SPMA)

158

12.4.3.3

LOAD SHARING MODULE (LSM)

159

12.4.3.3.1

INSPECT LOAD SHARING MODULE (LSM)

160

12.4.3.3.2

TEST LOAD SHARING MODULE (LSM)

160

12.4.3.3.3

REMOVE LOAD SHARING MODULE (LSM)

160

12.4.3.3.4

INSTALL LOAD SHARING MODULE (LSM)

161

12.4.3.4

REMOTE TERMINAL UNIT (RTU)

162

12.4.3.4.1

INSPECT REMOTE TERMINAL UNIT (RTU)

163

12.4.3.4.2

TEST REMOTE TERMINAL UNIT (RTU)

164

12.4.3.4.3

REMOVE REMOTE TERMINAL UNIT (RTU)

165

12.4.3.4.4

INSTALL REMOTE TERMINAL UNIT (RTU)

166

12.4.3.4.4.1

INSTALL RTU SOFTWARE (NEW INSTALL)

167

12.4.3.5

MODULAR DIN RAIL (I/O)

193

12.4.3.5.1

INSPECT MODULAR DIN RAIL (I/O)

194

12.4.3.5.2

TEST MODULAR DIN RAIL (I/O)

194

12.4.3.5.3

REMOVE MODULAR DIN RAIL (I/O)

195

12.4.3.5.4

INSTALL MODULAR DIN RAIL (I/O)

196

12.4.3.6

HUB

197

12.4.3.6.1

INSPECT HUB

197

12-7

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.3.6.2

TEST HUB

198

12.4.3.6.3

REMOVE HUB

198

12.4.3.6.4

INSTALL HUB

199

12.4.3.7

PROTOCOL COMMUNICATION MODULE (PCM)

200

12.4.3.7.1

INSPECT PROTOCOL COMMUNICATION MODULE (PCM)

200

12.4.3.7.2

TEST PROTOCOL COMMUNICATION MODULE (PCM)

201

12.4.3.7.3

REMOVE PROTOCOL COMMUNICATION MODULE (PCM)

201

12.4.3.7.4

INSTALL PROTOCOL COMMUNICATION MODULE (PCM)

202

12.4.3.8

CUSTOMER COMMUNICATION MODULE (CCM)

203

12.4.3.8.1

INSPECT CUSTOMER COMMUNICATION MODULE (CCM)

203

12.4.3.8.2

TEST CUSTOMER COMMUNICATION MODULE (CCM)

204

12.4.3.8.3

REMOVE CUSTOMER COMMUNICATION MODULE (CCM)

204

12.4.3.8.4

INSTALL CUSTOMER COMMUNICATION MODULE (CCM)

205

12.4.3.8.5

SERVICE CUSTOMER COMMUNICATION MODULE (CCM)

205

12.4.3.9

POWER CONVERTER

206

12.4.3.9.1

POWER CONVERTER (P15)

206

12.4.3.9.1.1

INSPECT POWER CONVERTER (P15)

207

12.4.3.9.1.2

TEST POWER CONVERTER P15

207

12.4.3.9.1.3

REMOVE POWER CONVERTER (P15)

207

12.4.3.9.1.4

INSTALL POWER CONVERTER P15

209

12.4.3.10

TRANSDUCER (XD)

210

12.4.3.10.1

INSPECT TRANSDUCER (XD)

210

12.4.3.10.2

TEST TRANSDUCER (XD)

211

12.4.3.10.3

REMOVE TRANSDUCER (XD)

211

12.4.3.10.4

INSTALL TRANSDUCER (XD)

212

12.4.3.10.5

SERVICE TRANSDUCER (XD)

213

12.4.3.11

AC TRANSFORMER BOX (ATB)

214

12.4.3.11.1

INSPECT AC TRANSFORMER BOX (ATB)

215

12.4.3.11.2

TEST AC TRANSFORMER BOX (ATB)

215

12.4.3.11.3

REMOVE AC TRANSFORMER BOX (ATB)

215

12.4.3.11.4

INSTALL AC TRANSFORMER BOX (ATB)

216

12-8

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

LIST OF FIGURES FIGURE

TITLE

FIGURE 12.4.1.1-1

COOLANT TEMPERATURE SENSOR

PAGE 16

FIGURE 12.4.1.2-1

COOLANT LEVEL SENSORS

20

FIGURE 12.4.1.2.4-1

COOLANT SYSTEM AIR BLEED VALVE

23

FIGURE 12.4.1.3-1

FILTERED ENGINE OIL PRESSURE SENSOR

24

FIGURE 12.4.1.4-1

FLYWHEEL MOUNTED ENGINE SPEED SENSOR

27

FIGURE 12.4.1.4.4-1

FLYWHEEL MOUNTED ENGINE SPEED SENSOR DIAGRAM

30

FIGURE 12.4.1.7-1

ELECTRONIC TIMING SENSOR

32

FIGURE 12.4.1.8-1

AIR INLET TEMPERATURE SENSOR

36

FIGURE 12.4.1.9-1

TURBOCHARGER COMMPRESSOR OUTLET PRESSURE SENSOR

39

FIGURE 12.4.1.10-1

ATMOSPHERIC PRESSURE SENSOR CONNECTOR

43

FIGURE 12.4.1.11-1

FUEL TEMPERATURE SENSOR

46

FIGURE 12.4.1.13-1

FILTER MONITORING PANEL

51

FIGURE 12.4.2-1

PDC LOCAL CONTROL PANEL (LCP)

55

FIGURE 12.4.2.1-1

GENERATOR CONTROL PANEL CONTROLS / INSTRUMENTS

56

FIGURE 12.4.2.1.1-1

GENERATOR SET CONTROLLER (GSC+)

57

FIGURE 12.4.2.1.2-1

GENERATOR AND FEEDER OVERCURRENT RELAY

60

FIGURE 12.4.2.1.3-1

BREAKER CONTROL SWITCHES

65

FIGURE 12.4.2.1.4-1

ENGINE CONTROL SWITCH (ECS)

69

FIGURE 12.4.2.1.5-1

EMERGENCY STOP PUSHBUTTON (ESPB)

73

FIGURE 12.4.2.1.6-1

EMERGENCY STOP ACTUATOR (ESA)

76

FIGURE 12.4.2.1.7-1

AUTOMATIC VOLTAGE REGULATOR (AVR)

79

FIGURE 12.4.2.1.7-2

AUTOMATIC VOLTAGE REGULATOR (AVR)

81

FIGURE 12.4.2.1.7-3

AUTOMATIC VOLTAGE REGULATOR KEY PAD

82

FIGURE 12.4.2.1.7-4

AUTOMATIC VOLTAGE REGULATOR KEY PAD

85

FIGURE 12.4.2.2-1

MASTER CONTROL PANEL (MCP)

86

FIGURE 12.4.2.2.1-1

SYNCHROSCOPE / SYNCH-CHECK RELAY (SC/25M)

87

FIGURE 12.4.2.2.2-1

TIE OVERCURRENT RELAY

90

FIGURE 12.4.2.2.3-1

BUS VOLT / FREQUENCY METER

95

FIGURE 12.4.2.2.3.5-1

BUS VOLT/FREQUENCY METER (WITH FRONT COVER REMOVED)

98

FIGURE 12.4.2.2.4-1

TIE BREAKER CONTROL SWITCH (BCST)

100

FIGURE 12.4.2.2.5-1

SYSTEM MODE SWITCH (SMS)

104

FIGURE 12.4.2.2.6-1

SYSTEM SYNCHRONIZING SWITCH (SSS)

108

12-9

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 FIGURE 12.4.2.2.7-1

GENERATOR MODE SWITCH (GMS)

112

FIGURE 12.4.2.2.8-1

MASTER SYSTEM ENABLE SWITCH (MSES)

115

FIGURE 12.4.2.2.9-1

BATTLESHORT SWITCH (BSS)

118

FIGURE 12.4.2.2.10-1

AUTOMATIC VOLTAGE REGULATOR SWITCH (AVRS)

121

FIGURE 12.4.2.2.11-1

UNIT SELECTOR SWITCH (USS), UNIT SELECTOR INDICATORS (USI)

124

FIGURE 12.4.2.2.13-1

BUZZER SILENCE PUSHBUTTON (SIL)

131

FIGURE 12.4.2.2.14-1

SYSTEM STATUS LIGHT (SSL)

135

FIGURE 12.4.2.2.15-1

50/60 HERTZ INDICATOR LIGHTS

139

FIGURE 12.4.2.2.16-1

PHASE ROTATION TEST LIGHTS (PRL)

142

FIGURE 12.4.2.2.17-1

ALARM / FAULT BUZZER

147

FIGURE 12.4.3.1-1

FREQUENCY SELECTOR SWITCH (FSS)

153

FIGURE 12.4.3.2-1

AUTOMATIC SYNCHRONIZER (SPMA)

156

FIGURE 12.4.3.3-1

LOAD SHARING MODULE

159

FIGURE 12.4.3.4-1

REMOTE TERMINAL UNIT (RTU)

162

FIGURE 12.4.3.4.4.1-1

IO TOOLKIT ICON

167

FIGURE 12.4.3.4.4.1-2

DEVICE SCREEN

168

FIGURE 12.4.3.4.4.1-3

USE COMM PORT SCREEN

168

FIGURE 12.4.3.4.4.1-4

PDC 1 SCREEN

169

FIGURE 12.4.3.4.4.1-5

NULL MODEM/GENDER CHANGER

169

FIGURE 12.4.3.4.4.1-6

FILE OPERATIONS SCREEN

170

FIGURE 12.4.3.4.4.1-7

RTU CONTENTS SCREEN

170

FIGURE 12.4.3.4.4.1-8

ISA11.X6M SCREEN

171

FIGURE 12.4.3.4.4.1-9

DELETE FILE SCREEN

171

FIGURE 12.4.3.4.4.1-10 FILE DELETED SCREEN

172

FIGURE 12.4.3.4.4.1-11 ACTION. 6TL SCREEN

172

FIGURE 12.4.3.4.4.1-12 CLEAR ACTION TABLE SCREEN

173

FIGURE 12.4.3.4.4.1-13 CLOSE SCREEN

173

FIGURE 12.4.3.4.4.1-14 OPERATIONS SCREEN

174

FIGURE 12.4.3.4.4.1-15 DIRECT CONTROL SCREEN

174

FIGURE 12.4.3.4.4.1-16 CLEAR CONFIGURATION SCREEN 1

175

FIGURE 12.4.3.4.4.1-17 CLEAR CONFIGURATION SCREEN 2

175

FIGURE 12.4.3.4.4.1-18 STATION CONFIGURATION SCREEN

176

FIGURE 12.4.3.4.4.1-19 ADVANCED OPERTIONS SCREEN

177

FIGURE 12.4.3.4.4.1-20 FIRMWARE VERSION SCREEN

178

FIGURE 12.4.3.4.4.1-21 LOAD NOW SCREEN

178

12-10

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 FIGURE 12.4.3.4.4.1-22 LOADING PROGRESSION SCREEN

179

FIGURE 12.4.3.4.4.1-23 UPGRADE FIRMWARE SCREEN

179

FIGURE 12.4.3.4.4.1-24 DIRECT CONNECT SCREEN

180

FIGURE 12.4.3.4.4.1-25 SELECT FIRMWARE SCREEN

180

FIGURE 12.4.3.4.4.1-26 LOADING FIRMWARE SCREEN

181

FIGURE 12.4.3.4.4.1-27 FIRMWARE LOAD COMPLETE SCREEN

181

FIGURE 12.4.3.4.4.1-28 CONFIGURE STATION SCREEN

182

FIGURE 12.4.3.4.4.1-29 ADVANCED TAB SCREEN

183

FIGURE 12.4.3.4.4.1-30 ASSIGN RESOURCES SCREEN

183

FIGURE 12.4.3.4.4.1-31 SET MEMORY SCREEN

184

FIGURE 12.4.3.4.4.1-32 RESOURCE ALLOCATION SCREEN

185

FIGURE 12.4.3.4.4.1-33 OPERATION/LINK SCREEN

186

FIGURE 12.4.3.4.4.1-34 LINKING INSTRUCTION SCREEN

186

FIGURE 12.4.3.4.4.1-35 MODULES ASSIGNED SCREEN

187

FIGURE 12.4.3.4.4.1-36 MODULE PROGRESSION SCREEN

187

FIGURE 12.4.3.4.4.1-37 LINKING COMPLETE SCREEN 1

188

FIGURE 12.4.3.4.4.1-38 LINKING COMPLETE SCREEN 2

188

FIGURE 12.4.3.4.4.1-39 FILE OPERATIONS SCREEN

189

FIGURE 12.4.3.4.4.1-40 LOAD ISAGRAF SCREEN

189

FIGURE 12.4.3.4.4.1-41 ISAGRAF PROGRAM SCREEN

190

FIGURE 12.4.3.4.4.1-42 APPLI.X6M FILE SCREEN

190

FIGURE 12.4.3.4.4.1-43 LOADING APPLI.X6M FILE SCREEN

191

FIGURE 12.4.3.4.4.1-44 APPLI.X6M FILE COMPLETE SCREEN

191

FIGURE 12.4.3.5-1

MODULAR DIN RAIL I/O DIM 1, DIM 2, DIM 3, DOM 1, DOM 2

193

FIGURE 12.4.3.5-2

MODULAR DIN RAIL I/O BASE

193

FIGURE 12.4.3.6-1

HUB

197

FIGURE 12.4.3.7-1

PCM LOCATION

200

FIGURE 12.4.3.8-1

CUSTOMER COMMUNICATION MODULE

203

FIGURE 12.4.3.9.1-1

POWER CONVERTER (P15)

206

FIGURE 12.4.3.10-1

TRANSDUCER LOCATION

210

FIGURE 12.4.3.10.3-1

TRANSDUCER (XD) CONFIGURATION

212

FIGURE 12.4.3.10.5-1

OPENING THE TRANSDUCER

213

FIGURE 12.4.3.10.5-2

SETTING THE DIP SWITCHES

213

FIGURE 12.4.3.11-1

AC TRANSFORMER BOX (ATB)

214

12-11

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

LIST OF TABLES CHAPTER

TITLE

PAGE

TABLE 12.4.2.1.3.2-1

GENERATOR AND FEEDER BREAKER CONTROL SWITCHES

67

TABLE 12.4.2.1.4.2-1

ENGINE CONTROL SWITCH (ECS)

71

TABLE 12.4.2.1.5.2-1

EMERGENCY STOP PUSHBUTTON (ESPB)

75

TABLE 12.4.2.1.7-1

AVR FAULT AND ALARM CODES

80

TABLE 12.4.2.2.4.2-1

TIE BREAKER CONTROL SWITCH (BCST)

102

TABLE 12.4.2.2.5.2-1

SYSTEM MODE SWITCH (SMS)

106

TABLE 12.4.2.2.6.2-1

SYSTEM SYNCHRONIZING SWITCH (SSS)

110

TABLE 12.4.2.2.7.2-1

GENERATOR MODE SWITCH (GMS)

114

TABLE 12.4.2.2.8.2-1

MASTER SYSTEM ENABLE SWITCH (MSES)

117

TABLE 12.4.2.2.9.2-1

BATTLESHORT SWITCH (BSS)

120

TABLE 12.4.2.2.10.2-1

AUTOMATIC VOLTAGE REGULATOR SWITCH (AVRS)

123

TABLE 12.4.2.2.11.2-1

USS CONTACT TARGET TABLE

126

TABLE 12.4.2.2.13.2-1

BUZZER SILENCE PUSHBUTTON (SIL)

133

TABLE 12.4.2.2.17-1

FAULT MATRIX

148

TABLE 12.4.2.2.17-2

ALARMS MATRIX

148

TABLE 12.4.3.1.2-1

FREQUENCY SELECTOR SWITCH (FSS)

155

TABLE 12.4.3.4.2-1

RTU MAINTENANCE INFORMATION

164

TABLE 12.4.3.5.2-1

I/O MAINTENANCE INFORMATION

194

12-12

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.0

CONTROLS AND INSTRUMENTS REPAIR

12.1

SAFETY INSTRUCTIONS

a. Safety precautions must be observed while any maintenance is being performed. Safety precautions must be observed to ensure that the operator/technician cannot have contact with the following: • • • • • • •

Hot engine parts Hot engine fluids Medium Voltage AC electricity Low Voltage AC electricity Low Voltage DC electricity Rotating Parts High noise levels

b. Minor troubleshooting can be performed while both engines are running as long as safety precautions are taken. c.

Minor maintenance can be performed while one generator set is running and the other generator set has been shutdown. Some examples of this maintenance are: • • • • • •

Lubrication System – Oil and Filter Change. Hydraulic System – Oil and Filter Change. Fuel System – Primary and Secondary Filter Change. Coolant System – Coolant Change. Minor Troubleshooting. Check Fluid levels and add required fluids.

(1) The generator set that has been shut down must be rendered unable to start, and cool enough for the maintenance to be performed. Procedures to render a generator set unable to start are: (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) NOTE:

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Push to OPEN the Emergency Stop Switch. Place the Engine Control Switch (ECS) in the OFF position. Place a DO NOT OPERATE tag on the generator control panel. Turn the Battery Bank Parallel Switch to the OFF position. De-energize the Battery Charger. Disconnect the negative and positive cables from the Battery Bank for the engine due maintenance. Place a DO NOT OPERATE tag on the Battery Bank. Place the generator Circuit Breaker in the LOCK OUT position. Disconnect the 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock the generator set control panel.

The fuel transfer pump electrical power is normally fed directly from the G1 generator set battery bank. If you disconnect the G1 battery bank, the external fuel transfer pump will not function. Place the Fuel Pump Source Switch (S2) into the (G1 or G2 position). Place the S2 in the (G1 or G2) position, for the generator set not receiving maintenance.

12-13

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

Major maintenance or service requires that the PU MUST be shutdown, isolated from any power plant electrical bus or utility connection, isolated from any power plant control system, and rendered unable to start. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14)

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant or utility connection in accordance with Section 5.9.6.15, Unit Isolation Procedure with PSC. See Note 1 and 2. Isolate the PU from any power plant control system in accordance with Note 3. Pull to open the PU DC Power Control Breaker. Push to OPEN both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels.

NOTE 1:

Also the PU must be completely electrically isolated from the power distribution bus and any other electrical source that can back feed into the PU. All medium voltage cables need to be placed on the standoff insulators by use of hot sticks and other safety gear.

NOTE 2:

Ensure cables are not energized by opening the circuit breaker of the Primary Switching Center (PSC), then disconnect Load Cables (Using the proper safety gear) on the PU and place them on the Parking Stands.

NOTE 3:

When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

12.2

BRIEF DESCRIPTION

This Section covers the Engine and PDC controls and instrument Inspect, Test (if applicable), Remove, Repair and Service (if applicable). The engine controls and instruments sense engine parameters and send these parameters to the GSC+ and Engine Control Module (ECM), which control the way each engine runs. The PDC controls and instruments provide control over generator control, multi-PU plant control (through a network) and medium distribution system control and protection. 12.3

SERVICE REQUIREMENTS

There is no Engine/PDC System maintenance requirement. Each device that has a specific service requirement has that service is listed with that device.

12-14

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4

COMPONENT REPAIR PROCEDURES

12.4.1

ENGINE CONTROL DEVICES Additional reference material required for maintenance is Caterpillar Manual RENR2227-01 or later version, Troubleshooting 3406E Generator Set Engine.

NOTE:

a. Sensors and Electrical Components Description •

The engine is equipped with various optional engine features and controls. This section discusses the general information about these engine control devices and the operation of these devices.

b. Alarm Switches •

The Engine is equipped with alarms in order to alert the operator when undesirable operating conditions occur. When an alarm is activated, corrective measures must be made before the situation becomes an emergency.



Alarm systems are electrically operated. The operations of all electric alarms use components that actuate switches in a sensing unit. Alarms are set at critical operating temperatures, operating pressures, operating levels, or operating speeds.



A history of all of the engine faults is maintained in the Electronic Control Module (ECM). These faults can be either Active Codes or Logged Codes. Refer to the Caterpillar Systems Operation, Testing, and Adjusting; RENR1200-01 or later version, for the definitions of the codes.



The Battle Short switch bypasses all alarms except Overspeed and Short Circuit (50), Ground Fault (50N) and Emergency Stop. Ensure that the Battle Short switch is reset after repairs have been made.

12-15

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.1.1

COOLANT TEMPERATURE SENSOR

The following maintenance procedures are provided for the Coolant Temperature Sensor: Inspect Test Remove Install

FIGURE 12.4.1.1-1 12.4.1.1.1

COOLANT TEMPERATURE SENSOR

INSPECT COOLANT TEMPERATURE SENSOR

Inspect the Coolant Temperature Sensor for the following: a. Inspect for proper mounting. b. Inspect for loose connections, leaks. c.

Inspect for physical and heat damage.

12.4.1.1.2

TEST COOLANT TEMPERATURE SENSOR

To test the Coolant Temperature Sensor, proceed as follows: a. See Caterpillar Manual RENR2227-01 or latest version, Section P – 516 Coolant Temperature Sensor, for the latest testing instructions.

12-16

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 b. This sensor monitors engine coolant temperature. This feature is used for engine system diagnostics with an output from the Electronic Control Module (ECM). The output of the ECM can indicate a high coolant temperature through a relay or a lamp. In addition, the sensor activates the Cold Start Strategy in Section 12.4.1.5, which improves the starting ability of the engine. c.

The minimum coolant temperature that will activate the alarm is 216°F (104°C). The switch opens as the coolant cools. A resetting procedure is not required. •

At 225°F the Generator Breaker will open.

d. Failure of the Coolant Temperature Sensor: If one of the following conditions exists, a failure of the coolant temperature sensor may have occurred: •

Sensor output is open.



Sensor output is shorted to ground or supply



Measured reading of the coolant temperature is out of specification.

e. The ECM will detect a failure of the coolant temperature sensor. The diagnostic code will warn the operator about the status of the coolant temperature sensor. Strategies that are related to the coolant temperature will be disabled. A failure of the coolant temperature sensor will not cause a shutdown of the engine or any horsepower change. 12.4.1.1.3

REMOVE COOLANT TEMPERATURE SENSOR WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT. MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS USER.

12-17

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 CAUTION CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO LOCAL REGULATIONS AND MANDATES. To replace the Coolant Temperature Sensor, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) NOTE 1:

Shutdown the PU in accordance with chapter 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels. When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Disconnect the wiring harness J21/P21. c.

Drain coolant low enough so that coolant does not come out of the coolant sensor well.

d. Unscrew the Coolant Temperature Sensor using a wrench. Screw in a counter-clock-wise direction until it comes free. 12.4.1.1.4

INSTALL COOLANT TEMPERATURE SENSOR

To install the Coolant Temperature Sensor, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.1.1.3.

12-18

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 b. Reinstall new Coolant Temperature Sensor and with a wrench. Screw the sensor in a clockwise direction until it is tight. c.

Reinstall the wiring harness J21/P21.

d. Refill the coolant system.

12-19

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.1.2

COOLANT LEVEL SENSOR

The following maintenance procedures are provided for the Coolant Level Sensor: Inspect Test Remove Install

G1 COOLANT LEVEL SENSOR G2 COOLANT LEVEL SENSOR

J34

FIGURE 12.4.1.2-1 12.4.1.2.1

COOLANT LEVEL SENSORS

INSPECT COOLANT LEVEL SENSOR

Inspect the Coolant Level Sensor for the following: a. Inspect for proper mounting. b. Inspect for loose connections, leaks. c.

Inspect for physical and heat damage.

12-20

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.1.2.2

TEST COOLANT LEVEL SENSOR

To test the Coolant Level Sensor, proceed as follows: a. See Caterpillar Manual RENR2227-01 or latest version, Section P – 525 Coolant Level Sensor for the latest testing instructions. b. The coolant level sensor monitors the engine coolant level in order to detect a low coolant level condition. The coolant level sensor provides information to the GSC+. The output from the GSC+ indicates a low coolant level indicator lamp. Coolant must be added to the cooling system in order to correct the condition. c.

Coolant Level Sensor Failure. •

When the coolant level sensor output is open, shorted to ground or shorted to supply, a coolant level sensor failure may have occurred.



The coolant level sensor failure will not cause a shutdown of the engine or any horsepower change.

12.4.1.2.3

REMOVE COOLANT LEVEL SENSOR WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT. MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS USER.

12-21

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 CAUTION CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO LOCAL REGULATIONS AND MANDATES. To remove the Coolant Level Sensor, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) NOTE 1:

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels. When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Disconnect the wiring harness J34/P34. c.

Drain coolant low enough so that coolant does not come out of the coolant sensor well.

d. Unscrew the Coolant Level Sensor using a wrench. Screw in a counter-clock-wise direction until it comes loose. 12.4.1.2.4

INSTALL COOLANT LEVEL SENSOR

To install the Coolant Level Sensor, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.1.2.3.

12-22

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

FIGURE 12.4.1.2.4-1

COOLANT SYSTEM AIR BLEED VALVE

b. Reinstall new Coolant Level Sensor and with a wrench. Screw the sensor in a clock-wise direction until it is tight. c.

Reinstall the wiring harness J34/P34.

d. Refill the coolant system. e. Open the Coolant System Air Bleed Valve during the refill process. Close the Coolant System Air Bleed Valve when a steady stream of coolant is observed. Refer to Figure 12.4.1.2.4-1 for reference.

12-23

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.1.3

FILTERED ENGINE OIL PRESSURE SENSOR

The following maintenance procedures are provided for the Filtered Engine Oil Pressure Sensor: Inspect Test Remove Install

FILTERED ENGINE OIL PRESSURE SENSOR

ATMOSPHERIC PRESSURE SENSOR

FIGURE 12.4.1.3-1 12.4.1.3.1

FILTERED ENGINE OIL PRESSURE SENSOR

INSPECT FILTERED ENGINE OIL PRESSURE SENSOR

Inspect the Filtered Engine Oil Pressure Sensor for the following: a. Inspect for proper mounting. b. Inspect for loose connections, leaks. c.

Inspect for physical and heat damage (discolored insulation and or bare conductor).

12-24

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.1.3.2

TEST FILTERED ENGINE OIL PRESSURE SENSOR

To test the Filtered Engine Oil Pressure Sensor, proceed as follows: a. See Caterpillar Manual RENR2227-01 or latest version, Section P – 520 Filtered Engine Oil Sensor for the latest testing instructions. b. Low Oil Pressure Warning: The set point is dependent upon the engine rpm. The fault will be active and logged only if the engine has been running for more than 15 seconds. The low oil pressure switches may close at 7 to 9 PSI (48 to 62 kPa) below the actual trip point.

NOTE: c.

Failure Of The Engine Oil Pressure Sensor: If one of the following conditions occurs, a failure of the engine oil pressure sensor may have occurred: • • •

Sensor output is open. Sensor output is shorted to ground or supply Measured reading of the oil pressure is out of specification.

d. The ECM will detect a failure of the engine oil pressure sensor. The diagnostic code warns the user about the status of the engine oil pressure sensor. The alarms that are related to oil pressure will be disabled. A failure of the engine oil pressure sensor will not cause a shutdown of the engine or any horsepower change. e. The engine oil pressure sensor can detect engine oil pressure for diagnostic purposes. The engine oil pressure sensor sends a signal to the Electronic Control Module (ECM). 12.4.1.3.3

REMOVE FILTERED ENGINE OIL PRESSURE SENSOR WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT. MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS USER.

12-25

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 CAUTION CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO LOCAL REGULATIONS AND MANDATES. To remove the Filtered Engine Oil Pressure Sensor, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) NOTE 1:

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels. When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Disconnect the wiring harness J22/P22. c.

Unscrew the sensor using a wrench. Screw in a counter-clock-wise direction until it comes loose.

12.4.1.3.4 INSTALL FILTERED ENGINE OIL PRESSURE SENSOR a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.1.3.3. b. Reinstall the Filtered Engine Oil Pressure Sensor and with a wrench. Screw the sensor in a clock-wise direction until it is tight. c.

Reinstall the wiring harness J22/P22.

12-26

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.1.4

FLYWHEEL MOUNTED ENGINE SPEED SENSOR (MPU)

The following maintenance procedures are provided for the Flywheel Mounted Engine Speed Sensor, sometimes referred to as the Magnetic Pick-Up (MPU): Inspect Test Remove Install

FIGURE 12.4.1.4-1 12.4.1.4.1

FLYWHEEL MOUNTED ENGINE SPEED SENSOR (MAGNETIC PICK-UP)

INSPECT FLYWHEEL MOUNTED ENGINE SPEED SENSOR

NOTE:

Engine Over-speed protection is provided by the EMCP II+ control. The flywheel housing mounted Engine Speed Sensor is the input for engine speed to the EMCPII+ for this function.

NOTE:

For additional reference, refer to SEBU7163-01 or later version, SMCS CODE: 1907-040; 7400-040; 7400-070.

a. Speed Sensing Loss Alarm: •

The speed-timing sensor output has opened.

12-27

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

The speed-timing sensor is shorted to ground.



The speed-timing sensor is shorted to supply.



The speed-timing sensor is missing pulses.



The speed-timing sensor has extra pulses.

b. Intermittent failure causes erratic engine control. The electronic control system will detect a failure of the flywheel mounted speed-timing sensor. The operator will be warned through the “DIAGNOSTIC” lamp. c.

If flywheel mounted speed-timing sensor (1) cannot sense engine speed, the “DIAGNOSTIC” lamp will indicate a diagnostic fault code, which will be logged in the Electronic Control Module memory.

Inspect the Flywheel Mounted Engine Speed Sensor for the following: a. Inspect for proper mounting. b. Inspect for loose connections. c.

Inspect for physical and heat damage.

d. Inspect for debris.

To inspect the Flywheel Mounted Engine Speed Sensor, proceed as follows: a. Remove access cover to expose flywheel and speed sensor. b. Clean any debris from tip of sensor with clean lint-free cloth as necessary. c.

Re-install access cover.

12.4.1.4.2

REMOVE FLYWHEEL MOUNTED ENGINE SPEED SENSOR WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING.

12-28

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 WARNING WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT. MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS USER. CAUTION CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO LOCAL REGULATIONS AND MANDATES. To remove the Flywheel Mounted Engine Speed Sensor, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) NOTE 1:

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels. When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Disconnect the wiring harness J14/P14. c.

Unscrew the sensor using a wrench. Screw in a counter-clock-wise direction until it comes loose.

12-29

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.1.4.3

INSTALL FLYWHEEL MOUNTED ENGINE SPEED SENSOR

To install the Flywheel Mounted Engine Speed Sensor, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.1.4.2.

(A) Air Gap, (1) Speed Sensor (2) Locknut FIGURE 12.4.1.4.4-1

FLYWHEEL MOUNTED ENGINE SPEED SENSOR DIAGRAM

b. Use the Flywheel Mounted Engine Speed Sensor Diagram illustrated in Figure 12.4.1.4.4-1 to make adjustments. The Flywheel Mounted Engine Speed Sensor must be adjusted after it is installed and prior to use. The following instructions need to be followed for this procedure: (1) Remove all debris from the tip of the speed sensor. Align a ring gear tooth directly in the center of the threaded sensor opening. (2) By hand, screw the speed sensor (1) into the hole until the end of the sensor contacts the gear tooth. (3) Turn the sensor (1) in the counterclockwise direction through 270 degrees (three-fourths turn). (4) Tighten locknut (2) to 18 + 4 Ft-Lbs (25 + 5 Nm). NOTE: c.

Do not allow speed sensor (1) to turn as locknut (2) is tightened. Reinstall the wiring harness J14/P14.

12-30

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.1.5

COLD START STRATEGY

The cold start strategy utilizes the input of the coolant temperature sensor. The cold start strategy helps to provide the following features: quicker cold starts, white smoke cleanup, decreased deep cycling of the battery, and extended engine life. When the coolant temperature is below 63°F (17°C), the cold start strategy is activated. The cold mode deactivates because of the following items: •

The coolant temperature reaches 82°F (28°C).



The engine has run for 12 minutes.

12.4.1.6

ENGINE SPEED GOVERNING

a. See Caterpillar Manual RENR7163-01 or latest version, SMCS CODE 1000; 1900; 1901; and 1902. b. The engine speed governor monitors the throttle position and the actual engine rpm in order to help control the following items: engine rpm, response, torque output, and smoke limiting. The engine speed governor also helps to maintain constant engine rpm. Governing the fuel injection duration to the cylinders through the electronic unit injectors controls the engine rpm. Throttle input is used to calculate the engine rpm that is desired.

12-31

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.1.7

PASSIVE SPEED/TIMING SENSORS

The following maintenance procedures are provided for the Passive Speed/Timing Sensors: Inspect Test Remove Install

UPPER SPEED/TIMING SENSOR

LOWER SPEED/TIMING SENSOR

Speed/Timing Sensor close-up With harness disconnected

Engine Front (Left side): Upper and Lower Speed/Timing Sensors. FIGURE 12.4.1.7-1 12.4.1.7.1

ELECTRONIC TIMING SENSOR

INSPECT PASSIVE SPEED/TIMING SENSORS

Inspect the Passive Speed/Timing Sensors for the following: a. Inspect for proper mounting. b. Inspect for loose connections. c.

Inspect for physical and heat damage.

12-32

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 d. Disconnect the speed/timing connectors “P44/J44 Upper Speed/Timing Sensor & J20/P20 Lower Speed/Timing Sensor” and disconnect the harness “pigtail” ends of the sensor harness (2). Inspect the connectors for the following conditions (Tag the harness connections before disconnecting to ensure proper reconnection of the Speed/Timing Sensor harness connectors). •

Corrosion



Bent pins



Missing pins



Damaged sockets



Mismating



Broken wires

12.4.1.7.2

TEST PASSIVE SPEED/TIMING SENSORS

To test the Passive Speed/Timing Sensors, proceed as follows: a. See Caterpillar Manual RENR2227-01 or latest version, Section P – 514 Passive Speed/Timing Sensor for the latest testing instructions. b. An Over-speed condition is detected by the primary speed/timing sensor, when the engine rpm exceeds 2500 RPM, the Electronic Control Module (ECM) will shut off the electronic unit injectors. The electronic unit injectors will be shut off until the engine speed drops below 2500 RPM. A diagnostic fault code will be logged into the ECM memory and the “DIAGNOSTIC” lamp will indicate a diagnostic fault code. 12.4.1.7.3

REMOVE PASSIVE SPEED/TIMING SENSORS WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING.

12-33

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 WARNING WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT. MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS USER. CAUTION CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO LOCAL REGULATIONS AND MANDATES. To remove the Passive Speed/Timing Sensors, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) NOTE 1:

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels. When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Disconnect the wiring harness J44/P44 for the upper speed/timing sensor. Disconnect the wiring harness J20/P20 for the lower speed/timing sensor. c.

Unscrew the retaining clamp bolt that holds each sensor in place, using a wrench, in a counterclock-wise direction until it comes loose. Pull the sensor free from the engine.

12-34

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.1.7.4

INSTALL PASSIVE SPEED/TIMING SENSORS

To install the Passive Speed/Timing Sensors, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.7.4.3. b. While installing the Passive Speed/Timing Sensors: •

The Top and Bottom Speed/Timing Sensors must be serviced as a pair. The two sensors are not interchangeable and must have correct placement on the engine.



Lubricate the O-rings with oil.



Inspect to ensure both sensors have connector face seals inside the connector body. If a seal is damaged or missing, use a 126-5011 replacement seal.



Inspect to ensure both sensors are fully seated and the seal is in place before tightening the bracket bolt.

c.



Inspect to ensure the connector is properly latched.



Inspect to ensure the harness is attached to the engine harness clip.

Reinstall speed-timing sensor into place, then the retaining clamp. With a wrench tighten the sensor retaining clamp bolt to18 + 3 Ft-Lbs (24 + 4 Nm).

d. Reinstall the wiring harness J44/P44 for the upper speed/timing sensor. Reinstall the wiring harness J20/P20 for the lower speed/timing sensor. e. The speed/timing sensors do not need to be Calibrated after they have been installed. See Caterpillar Manual RENR2227-01 or latest version, Section P – 614 Passive Speed/Timing Calibration for the latest instructions. Engine Timing Calibration is only required if the ECM is replaced or if repairs have been made to the engine front drive train.

12-35

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.1.8

INLET MANIFOLD AIR TEMPERATURE SENSOR

The following maintenance procedures are provided for the Inlet Manifold Air Temperature Sensor: Inspect Test Remove Install

FIGURE 12.4.1.8-1 12.4.1.8.1

AIR INLET TEMPERATURE SENSOR

INSPECT INLET MANIFOLD AIR TEMPERATURE SENSOR

Inspect the Inlet Manifold Air Temperature Sensor for the following: a. Inspect for proper mounting. b. Inspect for loose connections. c.

Inspect for physical and heat damage.

12-36

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.1.8.2

TEST INLET MANIFOLD AIR TEMPERATURE SENSOR

To test the Inlet Manifold Air Temperature Sensor, proceed as follows: a. See Caterpillar Manual RENR2227-01 or latest version, Section P – 5100 Inlet Air Temperature Sensor for the latest testing instructions. The conducted heat from the inlet manifold air will affect the inlet manifold air temperature sensor when the engine is idling, and after the engine is shut off. This warm-up is due to the lack of coolant circulation through the engine. The reading from the inlet manifold air temperature sensor may be significantly higher than the actual temperature of the air inside the inlet manifold until the inlet manifold cools.

NOTE:

b. The inlet manifold air temperature sensor measures the temperature of the inlet manifold air. The Electronic Control Module (ECM) monitors the inlet manifold air temperature sensor signal. The output of the ECM can indicate high inlet manifold air temperature through a relay or a lamp. The inlet manifold air temperature sensor will not cause a shutdown of the engine or any horsepower change. 12.4.1.8.3

REMOVE INLET MANIFOLD AIR TEMPERATURE SENSOR WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT. MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS USER. CAUTION CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO LOCAL REGULATIONS AND MANDATES.

12-37

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 To remove the Inlet Manifold Air Temperature Sensor, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) NOTE 1:

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels. When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Disconnect the wiring harness J89/P89. c.

Unscrew the sensor using a wrench. Screw in a counter-clock-wise direction until it comes loose.

12.4.1.8.4

INSTALL INLET MANIFOLD AIR TEMPERATURE SENSOR

To install the Inlet Manifold Air Temperature Sensor, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.1.8.3. b. Reinstall Inlet Manifold Air Temperature Sensor and with a wrench. Screw the sensor in a clockwise direction until it is tight. c.

Reinstall the wiring harness J89/P89.

12-38

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.1.9

TURBOCHARGER COMPRESSOR OUTLET PRESSURE SENSOR

The following maintenance procedures are provided for the Turbocharger Compressor Outlet Pressure Sensor: Inspect Test Remove Install

TURBOCHARGER OUTLET PRESSURE SENSOR

FIGURE 12.4.1.9-1 12.4.1.9.1

TURBOCHARGER COMMPRESSOR OUTLET PRESSURE SENSOR

INSPECT TURBOCHARGER COMPRESSOR OUTLET PRESSURE SENSOR

Inspect the Turbocharger Compressor Outlet Pressure Sensor for the following: a. Inspect for proper mounting. b. Inspect for loose connections. c.

Inspect for physical and heat damage.

12-39

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.1.9.2

TEST TURBOCHARGER COMPRESSOR OUTLET PRESSURE SENSOR

To test the Turbocharger Compressor Outlet Pressure Sensor, proceed as follows: a. See Caterpillar Manual RENR2227-01 or latest version, Section P – 517 Turbocharger Compressor Outlet Pressure Sensor for the latest testing instructions. b. The air/fuel ratio control utilizes actual engine speed and actual boost pressure (inlet manifold air pressure) in order to control the transient smoke level. When the throttle is increased and when the engine demands more fuel, the fuel limit is controlled in order to reduce overall smoke levels of the engine exhaust. c.

If the timing and the duration of the 90-volt signal are controlled, the Electronic Control Module (ECM) can control injection timing and the amount of fuel that is injected. The Turbocharger Compressor Outlet Pressure Sensor is located on the top left side of the engine.

NOTE:

d. The boost pressure is determined from the difference in pressure between the Turbocharger Compressor Outlet Pressure Sensor (See Figure 12.4.1.9-1) and the Atmospheric Pressure Sensor (See Figure 12.4.1.10-1). e. Turbocharger Compressor Outlet Pressure Sensor Failure: (1) A Turbocharger Compressor Outlet Pressure Sensor failure may have occurred if any of the following conditions are present: •

The output of the Turbocharger Compressor Outlet Pressure Sensor is open.



The output of the Turbocharger Compressor Outlet Pressure Sensor is shorted to ground or to supply.



The reading of the Turbocharger Compressor Outlet Pressure Sensor is out of specification.

(2) The ECM will detect the Turbocharger Compressor Outlet Pressure Sensor failure. The operator will be warned of the problem through the EMCP II+ panel. Turbocharger Compressor Outlet Pressure Sensor failure will not cause a shutdown of the engine. The engine may de-rate in power due to a failure of the Turbocharger Compressor Outlet Pressure Sensor. 12.4.1.9.3

REMOVE TURBOCHARGER COMPRESSOR OUTLET PRESSURE SENSOR WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.

12-40

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT. MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS USER. CAUTION CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO LOCAL REGULATIONS AND MANDATES. To remove the Turbocharger Compressor Outlet Pressure Sensor, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) NOTE 1:

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels. When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Disconnect the wiring harness J23/P23.

12-41

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

Unscrew the sensor using a wrench. Screw in a counter-clock-wise direction until it comes loose.

12.4.1.9.4

INSTALL TURBOCHARGER COMPRESSOR OUTLET PRESSURE SENSOR

To install the Turbocharger Compressor Outlet Pressure Sensor, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.1.9.3. b. Reinstall Turbocharger Compressor Outlet Pressure Sensor and with a wrench screw the sensor in a clock-wise direction until it is tight. c.

Reinstall the wiring harness J23/P23.

12-42

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.1.10

ATMOSPHERIC PRESSURE SENSOR

The following maintenance procedures are provided for the Atmospheric Pressure Sensor: Inspect Test Remove Install

FILTERED ENGINE OIL PRESSURE SENSOR

ATMOSPHERIC PRESSURE SENSOR

FIGURE 12.4.1.10-1 12.4.1.10.1

ATMOSPHERIC PRESSURE SENSOR CONNECTOR

INSPECT ATMOSPHERIC PRESSURE SENSOR

Inspect the Atmospheric Pressure Sensor for the following: a. Inspect for proper mounting. b. Inspect for loose connections. c.

Inspect for physical and heat damage.

12-43

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.1.10.2

TEST ATMOSPHERIC PRESSURE SENSOR

To test the Atmospheric Pressure Sensor, proceed as follows: a. See Caterpillar Manual RENR2227-01 or latest version, Section P – 519 Atmospheric Pressure Sensor for the latest testing instructions. b. The Atmospheric Pressure Sensor measures the atmospheric pressure in the crankcase. A signal is sent to the Electronic Control Module (ECM). c.

The Atmospheric Pressure Sensor is an absolute pressure sensor measuring crankcase pressure. Both the Boost Pressure and Oil Pressure communicated to service tools and over the data link are calculated by subtracting the Atmospheric Pressure Sensor reading. The Atmospheric Pressure Sensor measures pressure from 0 PSI (0 kPa) to 16.8 PSI (116 kPa) absolute. The ECM uses the Atmospheric Pressure Sensor as a reference to perform an automatic calibration of other pressure sensors. The ECM with 5VDC supplies the sensor. Failure of the Atmospheric Pressure Sensor could affect engine speed, power or shutdown could occur.

12.4.1.10.3

REMOVE ATMOSPHERIC PRESSURE SENSOR WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT. MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS USER. CAUTION CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO LOCAL REGULATIONS AND MANDATES.

12-44

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 To remove the Atmospheric Pressure Sensor, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) NOTE 1:

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels. When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Disconnect the wiring harness J27/P27. c.

Unscrew the sensor using a wrench. Screw in a counter-clock-wise direction until it comes loose.

12.4.1.10.4

INSTALL ATMOSPHERIC PRESSURE SENSOR

To install the Atmospheric Pressure Sensor, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.1.10.3. b. Reinstall Atmospheric Pressure Sensor and with a wrench. Screw the sensor in a clock-wise direction until it is tight. c.

Reinstall the wiring harness J27/P27.

12-45

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.1.11

FUEL TEMPERATURE SENSOR

The following maintenance procedures are provided for the Fuel Temperature Sensor: Inspect Test Remove Install

FUEL TEMPERATURE SENSOR

FIGURE 12.4.1.11-1 12.4.1.11.1

FUEL TEMPERATURE SENSOR

INSPECT FUEL TEMPERATURE SENSOR

Inspect the Fuel Temperature Sensor for the following: a. Inspect for proper mounting. b. Inspect for loose connections. c.

Inspect for physical and heat damage.

12-46

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.1.11.2

TEST FUEL TEMPERATURE SENSOR

To test the Fuel Temperature Sensor, proceed as follows: a. A full range of testing procedures for the temperature sensor is located in RENR2227-01, Troubleshooting, 3406E Generator Set Engines, section P-548. b. The Fuel Temperature Sensor provides a fuel temperature signal to the ECM. The ECM adjusts Engine-Operating parameters to compensate for changes in fuel temperature. 12.4.1.11.3

REMOVE FUEL TEMPERATURE SENSOR WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT. MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS USER. CAUTION CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO LOCAL REGULATIONS AND MANDATES. To remove the Fuel Temperature Sensor, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following:

12-47

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) NOTE 1:

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels. When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Disconnect the wiring harness J43/P43. c.

Unscrew the sensor using a wrench. Screw in a counter-clock-wise direction until it comes loose.

12.4.1.11.4

INSTALL FUEL TEMPERATURE SENSOR

To install the Fuel Temperature Sensor, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.1.11.3. b. Reinstall Fuel Temperature Sensor and with a wrench. direction until it is tight. c.

Reinstall the wiring harness J43/P43.

12-48

Screw the sensor in a clock-wise

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.1.12

ENGINE DIAGNOSTICS

12.4.1.12.1

SELF-DIAGNOSTICS

Caterpillar Electronic Engines have the capability to perform a self-diagnostic test. When the system detects a problem, the GSC+ display “DIAG” is activated. Diagnostic codes will be stored in permanent memory in the Electronic Control Module (ECM). Using the following components can retrieve the diagnostic codes: •

Caterpillar electronic service tools. (ET Tool).



GSC+ Upper Display.

a. Active codes represent problems that currently exist. These problems should be investigated first. If a code is active, the “DIAG” will flash on GSC+ display. b. Logged codes represent the following items:

c.



Intermittent Problems



Recorded Events



Performance History

The problems may have been repaired since the logging of the code. These codes do not indicate that a repair is needed. The codes are guides or signals when a situation exists. Codes may be helpful to troubleshoot problems.

12.4.1.12.2

PERMANENT FAULT LOGGING

The system provides the capability of Permanent Fault Logging. When the Electronic Control Module (ECM) generates a diagnostic code, the code will be logged in the permanent memory. The logged codes can then be retrieved using Caterpillar electronic service tools (CAT ET Tool). 12.4.1.12.3

ENGINE OPERATION WITH ACTIVE DIAGNOSTIC CODES

a. If the EMCP+ starts to flash codes during normal engine operation, the system has identified a situation that is not within the specification. Check the following conditions: •

Engine oil pressure



Coolant temperature

b. Use the GSC+ to retrieve the active codes or use the Electronic Technician Tool to retrieve the active diagnostic code. Refer to the Chapter 5 and Chapter 6 for the following actions of the operator: •

Shutdown the engine.



Service the engine.



Schedule service for the engine.

12-49

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

The active diagnostic code should be investigated. The cause of the problem should be corrected as soon as possible. If the cause of the active diagnostic code is repaired and there is only one active diagnostic code, the active diagnostic code will turn off.

d. Operation of the engine and performance of the engine can be limited as a result of the active diagnostic code that is generated. Acceleration rates may be significantly slower. Refer to the Operation and Maintenance Manual for more information on the relationship between these active diagnostic codes and engine performance.

12-50

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.1.13

FILTER MONITORING PANEL

The following Maintenance procedures are provided for the Filter Monitoring Panel: Inspect Remove Install Service

FIGURE 12.4.1.13-1

FILTER MONITORING PANEL

The alarm setpoints are determined by the position of the needle/pointer within each gauge except for the radiator circuit and air-vent gauges. When the gauge setpoints have been reached; an alarm in the Auxiliary Alarm Panel illuminates and ORT sounds an audible alarm, alerting the operator of a problem.

12-51

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.1.13.1

INSPECT FILTER MONITORING PANEL

Inspect the Filter Monitoring Panel for the following conditions: a. Inspect the gauge range; the Air Filter Element shall be set at 25 inches of water. b. Inspect the gauge range; the Oil Differential Pressure shall be set at 30 PSID. c.

Inspect the gauge range; Primary Fuel Filter Differential Pressure Separator / Filter shall be set at 5 PSID.

d. Inspect the gauge range; the Secondary Fuel Filter Differential Pressure shall be set at 30 PSID. e. Inspect the Hydraulic System Gauge ranges: (1) The Radiator Circuit pressure gauge operates between 2,100 and 3,100 PSI (While Running). (2) The Air-Vent pressure gauge operates between 2,300 and 3,100 PSI (While Running). f.

Inspect for proper operation.

g. Inspect for dents, cracks, breaks, leaks or other physical damage. h. Inspect for security of attachment. i.

Inspect for missing Hardware.

12.4.1.13.2

REMOVE FILTER MONITORING PANEL WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE HANGING CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE BURNS, LOSS OF LIMB AND OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING DIESEL FUEL IS FLAMMABLE (WHEN ATOMIZED) AND MODERATELY TOXIC TO EYES, SKIN, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN WELLVENTILATED AREA. FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY OR ILLNESS.

12-52

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 CAUTION CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO LOCAL REGULATIONS AND MANDATES. To remove the Filter Monitoring Panel, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) NOTE 1:

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels. When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Unplug electrical harness connector on side of panel. c.

Tag and disconnect hoses. Cap both ends to prevent dirt from entering.

d. Remove four bolts and washers from outer vibration mounts. e. With a slight pressure, push gauge bracket until vibration mount studs clear mounting bracket and remove assembly. 12.4.1.13.3

INSTALL FILTER MONITORING PANEL

To install the Filter Monitoring Panel, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.1.13.2.

12-53

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 b. Reinstall the vibration mount studs into the bottom of the bracket. With a slight pressure, push gauge bracket until vibration mount studs clear the mounting bracket and align with holes and release. c.

Reinstall bracket with four nuts and washers on vibration mounts.

d. Remove caps and reinstall hoses. Remove tags. e. Reinstall electrical wire harness into receptacle. 12.4.1.13.4

SERVICE FILTER MONITORING PANEL

To service the Filter Monitoring Panel, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.1.13.2. b. Using the proper adjusting tool, carefully adjust the needle/pointer to the following setpoints:

NOTE:



Oil Differential Pressure – 30 PSID.



Primary Fuel Filter Differential Pressure Separator / Filter – 5 PSID.



Secondary Fuel Filter Differential Pressure – 30 PSID.



Air Cleaner / Filter – 25 inches of water. Do not over-adjust the needle / pointer.

12-54

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2

PDC CONTROLS AND INSTRUMENTS

FIGURE 12.4.2-1

PDC LOCAL CONTROL PANEL (LCP)

a. This section will describe the maintenance procedures for the PDC controls and instruments in the following sequence: •

Covers controls and instruments located on the interior and exterior doors of the Generator Control Panels (GCP).



Covers controls and instruments located on the interior and exterior door of the Master Control Panel (MCP).



Covers controls and instruments within the interior of cabinet A, B, and C.

b. Generator set controls and instruments that are panel-mounted in the PDC mounted on the rear of the PU. These three main control panels are: •

The Panel, generator number 1 control panel, located on the outer left of the Power Unit (GCP1).



The Panel, generator number 2 control panel, located on the outer right of the Power Unit (GCP2).



The Master Control Panel located in the outer center panel of the Power Unit (MCP).

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.1

1.

GENERATOR CONTROL PANEL CONTROLS AND INSTRUMENTS

10.

System In Battle Short Mode Light (SBL) Primary Fuel Filter High Differential Pressure Alarm Light (HPFFDPL) Secondary Fuel Filter High Differential Pressure Alarm Light (HSFFDPL) Primary Fuel Filter High Water Level Alarm Light (PFFHWLL) Oil Filter High Differential Pressure Alarm Light (HOFDPL) Air Filter High Differential Pressure Alarm Light (HAFDPL) Fuel Tank High Level Alarm Light (HFTLL) Fuel Tank Low Level Alarm Light (LFTLL) Hydraulic Tank Low Level Shutdown Light (HTLLL) Generator Set Control (GSC+)

11.

Generator Breaker Control Switch (BCSG1/G2)

2. 3. 4. 5. 6. 7. 8. 9.

FIGURE 12.4.2.1-1

12.

Feeder Breaker Control Switch (BCSF1/F2)

13.

Generator Over Current Relay (50/51G1/G2)

14.

Feeder Over Current Relay (50/51F1/F2)

15.

Emergency Stop Push Button (ESPB)

16.

Engine Control Switch (ECS)

17.

Panel Light Switch (PLS)

18. 19.

Frequency Adjust Rheostat (FAR) Voltage Adjust Rheostat (VAR)

20.

Red Breaker Closed LED

21.

Green Breaker Closed LED

GENERATOR CONTROL PANEL CONTROLS / INSTRUMENTS

12-56

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.1.1

GENERATOR SET CONTROLLER (GSC+)

The following maintenance procedures are provided for the Generator Set Controller: Inspect Test Remove Install GSC+ Set Points

FIGURE 12.4.2.1.1-1

GENERATOR SET CONTROLLER (GSC+)

The Caterpillar GSC+ provides the local metering for its associated generator set. parameters are available from the GSC+.

All metering

a. The main component of the EMCPII+ system is the Generator Set Control (GSC+). The GSC+ is designed to operate when powered by 24VDC battery systems. The GSC+ monitors and controls many of the generator set functions. The Display of the GSC+ is seen in Figure 12.4.2.1.1-1. The functions and features of the GSC+ are: •

Provides generator output information including power metering.



Controls normal starting and stopping of the engine.



Shows engine conditions and generator output information on two displays. The displays also show fault codes and GSC+ programming information.



Monitors the system for faults.

If a fault occurs, the GSC+ performs a controlled fault

shutdown or provides a fault alarm annunciation. The GSC+ uses indicators and displays to describe the fault to the operator or service technician. •

Contains programmable features for certain applications or customer requirements.

b. Primary Function: The primary function of upper display is to show AC voltage, current and frequency information of the generator output. There are several options available on the upper display for AC metering. These options can be viewed one at a time by pressing the AC Meter key on the keypad. The options are: 12-57

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

c.



Voltage (average), generator frequency, current (total).



Voltage (line-line), generator frequency, current (line) for any one phase.



Voltage (line-line) for all three phases at once.



Current (line) for all three phases at once.



Voltage (line-neutral) for all three phases at once.

Upper display is also used to show the various fault codes for system faults.

12.4.2.1.1.1

INSPECT GENERATOR SET CONTROLLER (GSC+)

Inspect the Generator Set Controller GSC+ for the following: a. Inspect for proper mounting. b. Inspect for loose connections. c.

Inspect for physical and heat damage.

12.4.2.1.1.2

TEST GENERATOR SET CONTROLLER (GSC+)

See Caterpillar Manual RENR1200-01 or latest version, for the latest testing instructions. 12.4.2.1.1.3

REMOVE GENERATOR SET CONTROLLER (GSC+)

a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) NOTE 1:

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock the generator set control panels that will not be worked on. When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Open the door of the GSC+ to be replaced in order to gain access to the rear of the GSC+.

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

Disconnect the 40-pin connecter at the GSC+, using the appropriate Allen wrench.

d. Tag and disconnect all terminated wiring to the terminals on the GSC+. e. Remove the six (6) retaining nuts holding the GSC+ in place on the door. Be careful to restrain the GSC+ from falling when removing the last nut.

NOTE: 12.4.2.1.1.4

INSTALL GENERATOR SET CONTROLLER (GSC+) The Caterpillar GSC+ must have software flashed into its memory, specific to DPGDS. The CUSTOMER Version ET Tool supplied with the DPGDS equipment does not contain the software required to perform this task. When ordering a replacement GSC+, ensure that it is the appropriate GSC+ for the DPGDS system. If a commercial GSC+ is installed, a CAT dealer must flash the correct software.

NOTE:

a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures in paragraph 12.4.2.1.1.3. b. Reinstall the GSC+ into the opening, insuring the gasket is in place to provide proper sealing. c.

Reinstall the retaining nuts while holding the GSC+ in place.

d. Reinstall the retaining nuts to seal the GSC+ in place. e. Reinstall all terminated wiring to their respective points on the GSC+ terminal board using FO-15 as a reference. Remove all wire tags. f.

Reinstall the 40-pin connector and tighten it in place using the appropriate allen-wrench.

g. Energize the GSC+ by pushing in the DC Control Breaker. h. Reinstall in the ATB bar code numbers into the GSC+ using the EMCP+ service Manual (SENR5827) for programming OP8 parameters. i.

Program the necessary setpoints into the GSC+, using DPGDS GSC+ Programmable Setpoints in Annex B.

j.

Perform pre-operation checks, according to Section 5.1.3.5, to verify operation on the generator.

12.4.2.1.1.5

GSC+ SET POINTS

GSC+ Set Points are contained in Annex B.

12-59

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.1.2

GENERATOR / FEEDER OVERCURRENT RELAY

The following maintenance procedures are provided for the Generator / Feeder Overcurrent Relay: Inspect Test Remove Install Generator / Feeder Overcurrent Relay Set Points

FIGURE 12.4.2.1.2-1

GENERATOR AND FEEDER OVERCURRENT RELAY

There is one Basler BE1-851 Overcurrent relay for each Generator, Feeder, and Tie Circuit Breaker. The LCD display on each over current relay provides a display of the current flow through each phase of the associated breaker. The display also shows the total current flow through that breaker. Additionally, the display may be used to monitor and/or program the relay see Figure 12.4.2.1-1 Generator Control Panel for reference. a. Front Panel Display: (1) The Front Panel: Human-machine interface (HMI) for a BE1-851 Overcurrent Relay in an FT-11 Case Configuration, see Figure 12.4.2.1.2-1 for reference. (2) Two line by 16-character LCD display with backlighting: Is the Primary source for receiving information from the relay or when locally programming settings to the relay. Displays active logic scheme name, targets, metering values, demand values, communications parameters, diagnostic information, and the menu tree steps or branches.

12-60

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (3) Power LED: When this LED is ON, indicates operating power is applied to the relay. (4) Relay Trouble LED: When this LED is ON, indicates that the relay is off-line due to start-up condition or a relay failure alarm. (5) Minor Alarm LED: Not used in this application. (6) Major Alarm LED: Not used in this application. (7) Trip LED: When this LED is flashing ON, indicates that a protective element is picked up. When this LED is ON continuously, indicates that a trip output is closed. The LED is sealed-in if a protective trip has occurred and there are targets being displayed. (8) Communications Port 0: RS-232 serial communications port. A computer terminal or PC running a terminal emulation program such as Windows TM Terminal can be connected to this port so that the user may send commands to the relay or receive reports from the relay. Communication with the relay uses a simple ASCII command language. (9) Reset Pushbutton Switch: Resets report data including: sealed-in Trip targets, Trip LED, peak demand currents, and alarms. (10) Scrolling Pushbuttons (keys): Scrolls UP/DOWN/LEFT/RIGHT through the menu tree or when in the Edit mode, the LEFT/RIGHT scrolling pushbuttons select the variable to change and the UP/DOWN scrolling pushbuttons change the variable. (11) Edit Pushbutton Switch: Enables settings changes. When the Edit pushbutton is first pushed, an LED on the pushbutton turns ON to indicate the edit mode is active. When changes are complete (using the scrolling pushbuttons) and the Edit pushbutton is pushed again, the LED turns OFF indicating that the changes are saved. If changes are not completed and saved within five minutes, the edit mode is exited without saving changes. (12) Identification Plate: Shows sensing input current range, power supply type, and serial number. (13) MENU TREE: The menu tree has six branches. These branches are: •

REPORT STATUS: Display and resetting of general status information such as targets, and alarms status, etc.



CONTROL: Operation of control functions such as controlling virtual switches, selection of active setting group, etc.



METERING: Display of real time metering values.



REPORTS: Display and resetting of report information such as time and date, demand registers, breaker duty statistics, etc.



PROTECTION LOGIC: Display and setting of protective function setting parameters such as pickups, time delays, etc.



GENERAL SETTINGS: Display and setting of non-protective function setting parameters such as communication.

12-61

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (14) Each screen in the menu tree is numbered in the upper left hand corner of the screen. This number indicates the current branch and level in the menu tree structure so that you do not loose track of where you are when you have left the top level of the menu tree. You scroll through each level of the menu tree by using the right and left scrolling keys. To go to a level of greater detail, you use the down scrolling key. Each time you go to a lower level in the menu tree, another number is added to the screen number separated by a period. 12.4.2.1.2.1

INSPECT GENERATOR / FEEDER OVERCURRENT RELAY

Inspect the Generator / Feeder Overcurrent Relay for the following: a. Inspect for proper mounting. b. Inspect for loose connections. c.

Inspect for physical and heat damage.

12.4.2.1.2.2

TEST GENERATOR / FEEDER OVERCURRENT RELAY

To test the Generator / Feeder Overcurrent Relay, proceed as follows: a. Testing is performed by internal diagnostics during start up. b. Refer to Basler Publication 9-2899-00-990, Section 13 Testing and Maintenance, for reference. 12.4.2.1.2.3

REMOVE GENERATOR / FEEDER OVERCURRENT RELAY WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT. MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS USER.

12-62

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 To remove the Generator / Feeder Overcurrent Relay, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) NOTE 1:

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels. When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Remove the two front mounting screws located on the front lower corner of the relay. c.

Slide the Generator / Feeder Overcurrent Relay towards you and pull it from its mounting case.

12.4.2.1.2.4

INSTALL GENERATOR / FEEDER OVERCURRENT RELAY

To install the Generator / Feeder Overcurrent Relay, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.2.1.2.3. b. Reinstall the Generator / Feeder Overcurrent Relay carefully, insuring that the circuit board goes into the proper grove; push forward to replace the relay into its mounting case. c.

Reinstall the relay’s mounting screws.

12.4.2.1.2.5

SERVICE GENERATOR / FEEDER OVERCURRENT RELAY

Setting Overcurrent Relay: In order make changes to the Basler Overcurrent Relay use the following instructions: a. Connect the ORT Control Cable to the Basler Relay. b. Start the ORT.

12-63

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 c. At the “Windows” logon screen, Enter “Administrator” as username , Press “Tab”, Enter Small Case “dpgds” as the password. d. Click the “Ok” button or Press “Enter”.e. On the desktop, Left Click twice on the “BESTCOMS” Icon. Wait for the program to open. f.

If it is a New Basler Overcurrent Relay, perform the following: (1)

Left click on “File”.

(2)

Left click on “Open”. Left click on “FDR” for the preset feeder settings or “GEN” for preset generator settings. Left click on the setting required, then left click on “Select”.

(3)

Left click on “Communications”.

(4)

Left click on “Upload Settings to Relay”.

(5)

At “Password” screen press “Enter”.

(6)

Left click on “Yes”.

(7)

Left click on “OK”. At this time the relay has been properly setup for service.

g. If the relay needs to have it’s setting changed, perform the following: (1)

Left Click on “Communications”.

(2)

Left click on “Download Settings from Relay”.

(3)

Wait until the transfer is complete.

(4)

Left click on “Screens”.

(5)

Left Click on “Overcurrent”.

(6)

There are three screens. On the 51 Time Overcurrent screen, click on the “Pickup” and change to “Pri.Amps”.

(7)

Make changes according to Annex C

(8)

Left Click “File”.

(9)

Press “Save As”.

(10)

Name the File and click “save”.

(11)

Left click “Communications”.

(12)

Left click “Upload Settings to Relay”.

(13)

At Password screen press “Enter”.

(14)

Left click on “Yes”.

(15)

Left click on “OK”. At this time the relay has been properly setup for service.

12.4.2.1.2.6

OVERCURRENT RELAY SET POINTS

Generator / Feeder Overcurrent Relay Set Points are contained in Annex D.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.1.3

GENERATOR AND FEEDER BREAKER CONTROL SWITCHES (BCS)

The following maintenance procedures are provided for the Generator and Feeder Control Switches: Inspect Test Remove Install

FIGURE 12.4.2.1.3-1

BREAKER CONTROL SWITCHES

a. There are Breaker Control Switches for each breaker mounted in the MEP-PU-810, these are: •

Generator 1 (G1) Breaker Control Switch (BCSG1)



Generator 2 (G2) Breaker Control Switch (BCSG2)



Feeder 1 (F1) Breaker Control Switch (BCSF1)



Feeder 2 (F2) Breaker Control Switch (BCSF2)

12-65

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 b. These switches have two momentary positions (Trip and Close), and two maintained positions (Center and Lockout). There is also a target to indicate the last operation performed by the switch. These switches are used for local operation of the breakers, setting up the breakers for automatic operation, and disabling breaker operation. 12.4.2.1.3.1

INSPECT GENERATOR AND FEEDER BREAKER CONTROL SWITCHES

Inspect the Generator and Feeder Control Switches (BCS), for the following: a. Inspect for proper mounting. b. Inspect for loose connections. c.

Inspect for physical and heat damage.

12.4.2.1.3.2

TEST GENERATOR AND FEEDER BREAKER CONTROL SWITCHES WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT. MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS USER.

12-66

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 To test the Generator and Feeder Control Switches (BCS), proceed as follows: TABLE 12.4.2.1.3.2-1 DECK

CONTACTS

12 & 13 16 & 17 21 & 26 24 & 25 33 & 34 37 & 38 41 & 42 45 & 46 52 & 53 56 & 57 61 & 62 65 & 66

1 2 3 4 5 6

GENERATOR AND FEEDER BREAKER CONTROL SWITCHES POSITION NAT NAC TRIP TRIP (NORMAL (NORMAL CLOSE (LOCKOUT) (MOMENTARY) AFTER AFTER (MOMENTARY) TRIP) CLOSE) X X X X X X X X X X X X X X X X X X

a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) NOTE 1:

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels. When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Remove Breaker Control Switch (BCS), in accordance with Section 12.4.2.1.3.3. c.

Using a multimeter set to OHMS (Ω) Rx1 scale, test for contact continuity in switch positions specified. Multimeter should indicate zero ohms at points marked in chart as shown in Table 12.4.2.1.3.2-1.

12-67

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 d. Multimeter should indicate infinite ohms at all open contacts in chart as shown in Table 12.4.2.1.3.2-1. An integral spring return mechanism returns handle to normal-vertical position except in pullto-lock position. Slip contacts are incorporated to maintain contact closure in last commanded position.

NOTE:

e. Target window opening on face of switch plate should show green when last command operation was TRIP. f.

Target window should show red when last command operation was CLOSE.

g. Switch handle should always return to normal vertical position following either command operation, TRIP or CLOSE. h. Replace Generator and Feeder Control Switches (BCS) if any fail any of the above requirements. 12.4.2.1.3.3

REMOVE GENERATOR AND FEEDER BREAKER CONTROL SWITCHES

To remove Generator and Feeder Control Switches (BCS), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.2.1.3.2. b. Remove screw from center of handle and slide handle from switch. c.

Remove the three retaining screws securing the Breaker Control Switch (BCS) to the generator control panel.

d. Remove the Breaker Control Switch (BCS) from rear of panel. e. Tag and disconnect wiring (do not remove jumpers) from Breaker Control Switch (BCS). 12.4.2.1.3.4

INSTALL GENERATOR AND FEEDER BREAKER CONTROL SWITCHES

To install the Generator and Feeder Breaker Control Switch (BCS), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.2.1.3.2. b. Reinstall wiring to the Breaker Control Switch (BCS) and discard tags. c.

Reinstall the Breaker Control Switch (BCS) and secure with three screws.

d. Reinstall the handle on the switch and secure with retaining screw. e. Close control panel door and tighten captive screws (1).

12-68

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.1.4

ENGINE CONTROL SWITCH (ECS)

The following maintenance procedures are provided for the Engine Control Switch (ECS): Inspect Test Remove Install

ENGINE CONTROL SWITCH (ECS)

FIGURE 12.4.2.1.4-1

ENGINE CONTROL SWITCH (ECS)

There is a switch for each generator set mounted in the MEP-PU-810. These rotary snap switches have four maintained positions. The switch may be rotated 360° in either direction. The switch is used for local operation of the generator, setting up the generator for automatic operation, and disabling generator operation.

12-69

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.1.4.1

INSPECT ENGINE CONTROL SWITCH (ECS)

Inspect the Engine Control Switch (ECS) for the following: a. Inspect for proper mounting. b. Inspect for loose connections. c.

Inspect for physical and heat damage.

12.4.2.1.4.2

TEST ENGINE CONTROL SWITCH (ECS) WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT. MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS USER. To test the Engine Control Switch (ECS), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10)

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks.

12-70

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels.

(11) (12) (13) NOTE 1:

When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Using a multimeter set to OHMS (Ω) Rx1 scale, test for contact continuity in switch positions specified. Multimeter should indicate zero ohm at points marked in chart as shown in Table 12.4.2.1.4.2-1. c.

Multimeter should indicate infinite ohms at all open contacts in chart as shown in Table 12.4.2.1.4.2-1.

d. Replace Engine Control Switch (ECS) if it fails any of the above requirements. TABLE 12.4.2.1.4.2-1 CONTACT 1 2 3 4 5 6 7 8 9 10 12.4.2.1.4.3

ENGINE CONTROL SWITCH (ECS) 0° 90° 180° OFF/RESET AUTOMATIC MANUAL START X X X X X X

270° COOLDOWN/STOP X

X X X X X X REMOVE ENGINE CONTROL SWITCH (ECS)

To remove the Engine Control Switch (ECS), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.2.1.4.2. b. Remove screw from center of handle and slide handle from switch. c.

Remove 4 retaining screws that hold the Engine Control Switch (ECS) to the control panel.

d. Remove the Engine Control Switch (ECS) from rear of panel. e. Tag and disconnect the Engine Control Switch (ECS).

12-71

12.4.2.1.4.4

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 INSTALL ENGINE CONTROL SWITCH (ECS)

To install the Engine Control Switch (ECS), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.2.1.4.2. b. Reinstall Engine Control Switch (ECS) from rear of the control panel, and secure it with the four retaining screws. c.

Reinstall the handle and secure it with the mounting screw.

d. Reinstall the wiring to Engine Control Switch (ECS) and discard tags. e. Close the control panel door.

12-72

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.1.5

EMERGENCY STOP PUSHBUTTON (ESPB)

The following maintenance procedures are provided for the Emergency Stop Pushbutton (ESPB): Inspect Test Remove Install

FIGURE 12.4.2.1.5-1

EMERGENCY STOP PUSHBUTTON (ESPB)

There is a pushbutton for each generator mounted in the Generator Control Panel of the PU. The Emergency Stop Pushbutton (ESPB) has two maintained positions. 12.4.2.1.5.1

INSPECT EMERGENCY STOP PUSHBUTTON (ESPB)

Inspect the Emergency Stop Pushbutton (ESPB) for the following: a. Inspect for proper mounting. b. Inspect for loose connections. c.

Inspect for physical and heat damage.

12-73

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.1.5.2

TEST EMERGENCY STOP PUSHBUTTON (ESPB) WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT. MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS USER. To test Emergency Stop Pushbutton (ESPB), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) NOTE 1:

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels. When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

12-74

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 b. Using a multimeter set to OHMS (Ω) Rx1 scale, test for contact continuity in switch positions specified. Multimeter should indicate zero ohm at points marked in chart as shown in Table 12.4.2.1.5.2-1. c.

Multimeter should indicate infinite ohms at all open contacts in chart as shown in Table 12.4.2.1.5.2-1.

d. Replace Emergency Stop Pushbutton (ESPB) if it fails any of the above requirements. TABLE 12.4.2.1.5.2-1 SWITCH POSITION NORMAL - OUT PUSHED-IN

EMERGENCY STOP PUSHBUTTON (ESPB) EMERGENCY STOP PUSHBUTTON (ESPB) WIRE NUMBER R18B & 4B ESPB & 30 X X

16B & 12B X

e. Using a multimeter set to OHMS (Ω) Rx1 scale, test for contact continuity in switch positions specified. Multimeter should indicate zero ohm at points marked in chart as shown in Table 12.4.2.1.5.2-1. f.

Multimeter should indicate infinite ohms at all open contacts in chart as shown in Table 12.4.2.1.5.2-1.

12.4.2.1.5.3

REMOVE EMERGENCY STOP PUSHBUTTON (ESPB)

To remove the Emergency Stop Pushbutton (ESPB), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.2.1.5.2. b. Twist red handle to the left until it comes off. c.

Twist black retaining nut to the left until it comes off.

d. Remove Emergency Stop Pushbutton (ESPB) from rear of panel. e. Tag and disconnect wires on the Emergency Stop Pushbutton (ESPB). 12.4.2.1.5.4

INSTALL EMERGENCY STOP PUSHBUTTON (ESPB)

To install the Emergency Stop Pushbutton (ESPB), proceed as follows a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.2.1.5.2 b. Reinstall the Emergency Stop Pushbutton (ESPB) from rear of the control panel, and secure retaining nut. c.

Reinstall wiring to Emergency Stop Pushbutton (ESPB) and discard tags.

d. Close control panel door and tighten captive screws.

12-75

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.1.6

EMERGENCY STOP ACTUATOR (ESA)

The following maintenance procedures are provided for the Emergency Stop Actuator (ESA): Inspect Test Remove Install

FIGURE 12.4.2.1.6-1

EMERGENCY STOP ACTUATOR (ESA)

There is a emergency stop actuator pushbutton for each generator mounted in the generator control panel of the MEP-PU-810. The pushbutton is momentary operated. Depressing the pushbutton will cause it to operate the associated generators (ESPB). Although the actuator is only momentary, the (ESPB) must be manually reset (pulled-out) by opening the associated generator control panel door. 12.4.2.1.6.1

INSPECT EMERGENCY STOP ACTUATOR (ESA)

Inspect the Emergency Stop Actuator (ESA) for the following: a. Inspect for proper mounting. b. Inspect for loose connections. c.

Inspect for physical and heat damage.

12-76

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.1.6.2

TEST EMERGENCY STOP ACTUATOR (ESA) WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT. MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS USER. To test, the Emergency Stop Actuator (ESA), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) NOTE 1:

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels. When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

12-77

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 b. Push the Emergency Stop Actuator (ESA) in. The Emergency Stop Pushbutton (ESPB) should be in the Pushed in Position. c.

Adjust the Emergency Stop Actuator (ESA) (Screw-in or Screw-out) until Emergency Stop Pushbutton (ESPB) closes fully (Pushed-in), when the ESA is pressed.

12.4.2.1.6.3

REMOVE EMERGENCY STOP ACTUATOR (ESA)

To remove, the Emergency Stop Actuator (ESA), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.2.1.6.2. b. Twist red handle to the left until it comes off. c.

Twist black retaining nut to the left until it comes off.

d. Remove Emergency Stop Actuator (ESA) from rear of panel. 12.4.2.1.6.4

INSTALL EMERGENCY STOP ACTUATOR (ESA)

To install the Emergency Stop Actuator (ESA), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.2.1.6.2. b. Reinstall the Emergency Stop Actuator (ESA) from rear of the control panel, and reinstall the retaining nut.

12-78

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.1.7

AUTOMATIC VOLTAGE REGULATOR (AVR)

The following maintenance procedures are provided for the Automatic Voltage Regulator (AVR): Inspect Test Remove Install Service

FIGURE 12.4.2.1.7-1

AUTOMATIC VOLTAGE REGULATOR (AVR)

The Automatic Voltage Regulator is a microprocessor based voltage regulator. The main purpose of the Automatic Voltage Regulator is to regulate output voltage of a generator used with an engine generator set. Service personnel can modify (program) certain regulation characteristics. This will allow the engine generator set to function in the most efficient manner. The Automatic Voltage Regulator can also integrate into one package many options that were previously panel mounted; such as KVAR/PF controller, over-excitation protection, fault detection, over voltage protection, under voltage protection, diode monitor, reverse power relay and system parameter monitoring. Refer to Table for 12.4.2.1.7-1 for AVR Fault and Alarm codes.

12-79

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 a. The programmable parameters of the Automatic Voltage Regulator are: • • • • • • • •

Voltage verses frequency (V/Hz) characteristic, two slope ranges adjustable from 1 to 10 V/Hz for optimum performance. Droop adjustment (up to 10% at 0.8 pf). Over voltage trip point (105% to 140% of nominal) with adjustable trip time. Under voltage trip point (60% to 95% of nominal) with adjustable trip time. Gain (0-10% of nominal). Single-phase or three-phase true RMS sensing. Under frequency trip point (15 to 40 Hz). Knee frequency (45 to 65 Hz).

b. The protective functions that the Automatic Voltage Regulator provides are: • • • • • •

Over voltage protection, under voltage protection, Loss of sensing. Rotating diode monitor (monitors the status of the rotating diodes and operates the alarm relay in the event of failure of one or more of the diodes), Over-excitation protection. Loss of excitation (monitors excitation and will initiate a shutdown of the unit if excitation is lost). Under frequency protection to avoid overheating of the rotor. Instantaneous field over current trip to protect the Automatic Voltage Regulator in the event of output short circuit or improper connections. Optional reverse power relay (monitors generator output power and initiates a shutdown of the unit if a reverse power condition is detected.

TABLE 12.4.2.1.7-1

AVR FAULT AND ALARM CODES ACTIVE SHUTDOWN FAULTS (PARAMETER :92)

FAULT CODE 0000 701 702 703 704 705 801 802 803 FAULT CODE 0000 601 602 603 604

DESCRIPTION CLASSIFICATION (1) No Fault Present Under Voltage Resettable Shutdown Fault Over Voltage Resettable Shutdown Fault Over Excitation Resettable Shutdown Fault Reverse VAR(2) Resettable Shutdown Fault Reverse Power Resettable Shutdown Fault Instantaneous Trip Non-Resettable Shutdown Fault Loss of Sensing Non-Resettable Shutdown Fault Loss of Frequency Non-Resettable Shutdown Fault ALARM FAULTS (PARAMETER :95) DESCRIPTION CLASSIFICATION (3) No Fault Present Internal Memory Failure Alarm Fault Internal Watchdog Failure Alarm Fault Rotating Diode Fault Alarm Fault Reverse VAR(2) Alarm Fault

(1) Resettable shutdown faults are reset by selecting parameter :96 (shutdown fault reset) on the display and pressing the function key. Non-resettable shutdown faults are reset by opening the DC Control Power Circuit Breaker (CBCP). (2) The AVR looks for 0.4 and greater leading power factor for shutdown. (3) Alarm faults are cleared by selecting parameter :94 (fault clear) on the display and pressing the function key.

For additional information refer to SENR5833-02 or later version, SMCS CODE: 4467

12-80

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 c. Automatic Voltage Regulator Components:

(1) Display

(2) KeyPad

FIGURE 12.4.2.1.7-2

(3) J1 Connector

(4) Screw Terminals

AUTOMATIC VOLTAGE REGULATOR (AVR)

12-81

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

(1) Display

(2) KeyPad

FIGURE 12.4.2.1.7-3

(5) Function Key

(6) ScrolL-Down Key

(7) Scroll-Up Key

AUTOMATIC VOLTAGE REGULATOR KEY PAD



Display (1) of the Automatic Voltage Regulator, shows numbers that represent the different parameters of the Automatic Voltage Regulator system. Keypad (2) is used to change the information that is shown on display (1). J1 connector (3) is used to join the Automatic Voltage Regulator to a personal computer. Screw terminals (4) are used to join the Automatic Voltage Regulator to the generator and various customer options.



Display (1) and keypad (2) are used to select and manipulate parameter values that control the operation of the Automatic Voltage Regulator. Display (1) of the Automatic Voltage Regulator has four digits. A colon in the display indicates that the number showing is a parameter code. If a colon is not present, then the number showing is a parameter value. A decimal point in the display is used to indicate the precision of the parameter value.



Keypad (2) has three keys. The keys are: function key (5), scroll down key (6) and scroll up key (7).



Display (1) has two modes, parameter code mode and parameter value mode. Function key (5) is used to toggle back and forth between the two modes. Scroll down key (6) and scroll up key (7) are used to decrease and increase the parameter number or value number that is showing on display (1).



The operation of display (1) and keypad (2) can be described as a table. Pressing function key (5) toggles the display back and forth between the two columns of the table (parameter code and parameter value). If a colon is present, the display is in parameter code mode. If a colon is not present, the display is in parameter value mode.



Pressing a scroll up key (7) or scroll down key (6) will increase or decrease the display to the next number within a column. Use of the scroll keys cannot cause the display to change columns of the table.

12-82

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.1.7.1

INSPECT AUTOMATIC VOLTAGE REGULATOR (AVR)

Inspect the Automatic Voltage Regulator (AVR) for the following: a. Inspect for proper mounting. b. Inspect for loose connections. c.

Inspect for physical and heat damage.

12.4.2.1.7.2

TEST AUTOMATIC VOLTAGE REGULATOR (AVR)

To test the Automatic Voltage Regulator (AVR), proceed as follows: Refer to Caterpillar Manual SENR5833-02 or later version, SMCS CODE: 4467 for reference. 12.4.2.1.7.3

REMOVE AUTOMATIC VOLTAGE REGULATOR (AVR) WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT. MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS USER. To remove the Automatic Voltage Regulator (AVR), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2)

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1.

12-83

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) NOTE 1:

Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels. When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Tag and disconnect wires from the Automatic Voltage Regulator (AVR). c.

Remove 4 retaining nuts and washers that hold the Automatic Voltage Regulator (AVR) to the door panel.

d. Remove the Automatic Voltage Regulator (AVR) from rear of panel. 12.4.2.1.7.4

INSTALL AUTOMATIC VOLTAGE REGULATOR (AVR)

To install the Automatic Voltage Regulator (AVR), proceed as follows: This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.2.1.7.3.

a.

b. Place the Automatic Voltage Regulator (AVR) back into place on the door panel, and secure it with the four retaining washers and nuts. c.

Connect the wiring to Automatic Voltage Regulator (AVR) and discard tags.

12-84

12.4.2.1.7.5

(1) Display

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 SERVICE AUTOMATIC VOLTAGE REGULATOR (AVR)

(2) KeyPad

FIGURE 12.4.2.1.7-4

(5) Function Key

(6) ScrolL-Down Key

(7) Scroll-Up Key

AUTOMATIC VOLTAGE REGULATOR KEY PAD

a. Changing Parameter Codes. b. To program a parameter code (change the value): •

Select the desired parameter code by pressing the scroll down key (6) or scroll up key (7).



Access the parameter value by pressing the function key (5).



Select the desired parameter value by pressing the scroll down key (6) or scroll up key (7).



Enter the chosen value into the memory of the Automatic Voltage Regulator by pressing the function key (5).

12-85

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.2

. 2. 3. 4. 5. 6. 7. 8. 9. 10.

MASTER CONTROL PANEL

Synchroscope / Synchcheck Relay (SC/25M) Phase Rotation Test Light (PRL) Tie Over current Relay (50/51T) Tie Breaker Open (Green) LED (TOL) Tie Breaker Closed (Red) LED (TCL) Bus Voltage/Frequency Meter (BVFM) 50/60 Hertz Status Lights (50L/60L) DC Control Power Breaker (CBCP) Generator Mode Switch (GMS) Automatic Voltage Regulator Switch (AVRS)

FIGURE 12.4.2.2-1

11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.

Breaker Control Switch, Tie (BCST) Master Start Enable Switch (MSES) System Status Light (SSL) Buzzer Silence Push Button (BSPB) Generator Overload Indicator Lights Battle Short Switch (BSS) System Synchronizing Switch (SSS) Panel Lights Switch (PLS) System Mode Switch (SMS) Unit Selector Switch (USS) Unit Selector Indicators (USI)

MASTER CONTROL PANEL (MCP)

12-86

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.2.1

SYNCHROSCOPE / SYNCH-CHECK RELAY (SC/25M)

The following maintenance procedures are provided for the Synchroscope / Synch-Check Relay (SC/25M): Inspect Test Remove Install

FIGURE 12.4.2.2.1-1

SYNCHROSCOPE / SYNCH-CHECK RELAY (SC/25M)

This meter provides a digital representation of a Synchroscope during manual synchronizing sequences. There are 24 red LED’s arranged in a ring simulating the traditional 360° movement of an analog Synchroscope. Only one LED is lit at a time indicating the phase difference between the incoming and running signals. The display will “rotate” clockwise or counter clockwise and fast or slow depending on the frequency difference between incoming and running. Once the incoming and running are synchronized, the ring LED’s will go out and the green triangular LED’s will be lit. The green LED’s at 3 o’clock and at 9 o’clock indicate the status of the voltage. Red is out of allowed synchronizing range and green is in range.

12-87

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.2.1.1

INSPECT SYNCHROSCOPE / SYNCH-CHECK RELAY (SC/25M)

Inspect the Synchroscope / Synch-Check Relay (SC/25M) for the following: a. Inspect for proper mounting. b. Inspect for loose connections. c.

Inspect for physical and heat damage.

12.4.2.2.1.2

TEST SYNCHROSCOPE / SYNCH-CHECK RELAY (SC/25M)

To test Synchroscope / Synch-Check Relay (SC/25M), proceed as follows: This is no field-testing for this device. There are NO field adjustments for this device. It comes preset from the manufacturer.

NOTE: 12.4.2.2.1.3

REMOVE SYNCHROSCOPE / SYNCH-CHECK RELAY (SC/25M) WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT. MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS USER. To remove Synchroscope / Synch-Check Relay (SC/25M), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1)

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators.

12-88

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) NOTE 1:

Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels. When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Remove the four front retaining screws and remove the cover. c.

Remove the four-meter retaining bolts and nuts.

d. Tag and remove the wires and remove the meter. 12.4.2.2.1.4

INSTALL SYNCHROSCOPE / SYNCH-CHECK RELAY (SC/25M)

To install Synchroscope / Synch-Check Relay (SC/25M), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.2.2.1.3. b. Reinstall the meter and the four retaining bolts and nuts. c.

Reinstall the front cover and the four front retaining screws.

d. Reinstall the wires and remove the Tags. e. Close the Master Control Panel (MCP) door.

12-89

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.2.2

TIE OVERCURRENT RELAY

The following maintenance procedures are provided for the Tie Overcurrent Relay: Inspect Test Remove Install Service Tie Overcurrent Relay Set Points

FIGURE 12.4.2.2.2-1

TIE OVERCURRENT RELAY

There is one Basler BE1-851 Overcurrent Relay for the Tie Circuit Breaker. The LCD display on each overcurrent relay provides a display of the current flow through each phase of the associated breaker. The display also shows the total current flow through that breaker. Additionally, the display may be used to monitor and/or program the relay. (See Figure 12.4.2.2.2-1) a. Front Panel Display: (1)

The front panel human-machine interface (HMI) for a BE1-851 Overcurrent Relay in an FT-11 Case configuration. See Figure 12.4.2.2.2-1 for reference.

12-90

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (2)

Two line by 16-character LCD display with backlighting: Is the primary source for receiving information from the relay or when locally programming settings to the relay. Displays active logic scheme name, targets, metering values, demand values, communications parameters, diagnostic information, and the menu tree steps or branches.

(3)

Power LED: When this LED is ON, indicates operating power is applied to the relay.

(4)

Relay Trouble LED: When this LED is ON, indicates that the relay is off-line due to start-up condition or a relay failure alarm.

(5)

Minor Alarm LED: Not used in this application.

(6)

Major Alarm LED: Not used in this application.

(7)

Trip LED: When this LED is flashing ON, indicates that a protective element is picked up. When this LED is ON continuously, indicates that a trip output is closed. The LED is sealed-in if a protective trip has occurred and there are targets being displayed.

(8)

Communications Port 0. RS-232 Serial Communications Port: A computer terminal or PC running a terminal emulation program such as Windows TM Terminal can be connected to this port so that the user may send commands to the relay or receive reports from the relay. Communication with the relay uses a simple ASCII command language.

(9)

Reset pushbutton switch: Resets report data including: Sealed-in Trip targets, Trip LED, peak demand currents, and alarms.

(10)

Scrolling pushbuttons (keys): Scrolls UP/DOWN/LEFT/RIGHT through the menu tree or when in the Edit mode, the LEFT/RIGHT scrolling pushbuttons select the variable to change and the UP/DOWN scrolling pushbuttons change the variable.

(11)

Edit Pushbutton Switch: Enables settings changes. When the Edit pushbutton is first pushed, an LED on the pushbutton turns ON to indicate the edit mode is active. When changes are complete (using the scrolling pushbuttons) and the Edit pushbutton is pushed again, the LED turns OFF indicating that the changes are saved. If changes are not completed and saved within five minutes, the edit mode is exited without saving changes.

(12)

Identification plate showing sensing input current range, power supply type, and serial number.

(13)

MENU TREE: The menu tree has six branches. These branches are: • • • • • •

REPORT STATUS: Display and resetting of general status information such as targets, and alarms status, etc. CONTROL: Operation of control functions such as controlling virtual switches, selection of active setting group, etc. METERING: Display of real time metering values. REPORTS: Display and resetting of report information such as time and date, demand registers, breaker duty statistics, etc. PROTECTION LOGIC: Display and setting of protective function setting parameters such as pickups, time delays, etc. GENERAL SETTINGS: Display and setting of non-protective function setting parameters such as communication. 12-91

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

12.4.2.2.2.1

Each screen in the menu tree is numbered in the upper left hand corner of the screen. This number indicates the current branch and level in the menu tree structure so that you do not loose track of where you are when you have left the top level of the menu tree. You scroll through each level of the menu tree by using the right and left scrolling keys. To go to a level of greater detail, you use the down scrolling key. Each time you go to a lower level in the menu tree, another number is added to the screen number separated by a period. INSPECT TIE OVERCURRENT RELAY

Inspect the Tie Overcurrent Relay for the following: a. Inspect for proper mounting. b. Inspect for loose connections. c.

Inspect for physical and heat damage.

12.4.2.2.2.2

TEST TIE OVERCURRENT RELAY

To test the Load Tie Overcurrent Relay, proceed as follows: a. Testing is performed by internal diagnostics during start up. b. Refer to Basler Publication 9-2899-00-990, Section 13 Testing and Maintenance, for reference. 12.4.2.2.2.3

REMOVE TIE OVERCURRENT RELAY WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT. MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS USER.

12-92

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 To remove the Tie Overcurrent Relay, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) NOTE 1:

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels. When the DC Control Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Remove the two front mounting screws located on the front lower corner of the relay. c.

Slide the relay towards you and remove the relay from its mounting case.

12.4.2.2.2.4

INSTALL TIE OVERCURRENT RELAY

To install the Tie Overcurrent Relay, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.2.2.2.3. b. Reinstall the Tie Overcurrent Relay carefully, ensuring that the circuit board goes into the proper grove; forward to Reinstall the relay into its mounting case. c.

Reinstall the relay mounting screws.

d. Close the Master Control Panel (MCP) door. 12.4.2.2.2.5

SERVICE TIE OVERCURRENT RELAY

Setting Overcurrent Relay: In order make changes to the Basler Overcurrent Relay use the following instructions: a. Connect the ORT Control Cable to the Basler Overcurrent Relay. b. Start the ORT.

12-93

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

At the “Windows” log on screen, Enter “Administrator” as username, Press “Tab”, Enter lower case “dpgds” for the password.

d. Click in the “Ok” button or Press “Enter”. e. On the “Windows” desktop, Left Click twice on the “BESTCOMS” Icon. Wait for the program to open. f.

If it is a New Basler Overcurrent Relay, perform the following: (1)

Left click on “File”.

(2)

Left click on “Open”. Left click on “TIE” for the preset Load Tie settings. Left click on the setting required, then left click on “Select”.

(3)

Left click on “Communications”.

(4)

Left click on “Upload Settings to Relay”.

(5)

At “Password” screen press “Enter”.

(6)

Left click on “Yes”.

(7)

Left click on “OK”. At this time the relay has been properly setup for service.

g. If the relay needs to have it’s setting changed, perform the following: (1)

Left Click on “Communications”.

(2)

Left click on “Download Settings from Relay”.

(3)

Wait until the transfer is complete.

(4)

Left click on “Screens”.

(5)

Left Click on “Overcurrent”.

(6) (7)

There are three screens. On the 51 Time Overcurrent screen, click on the “Pickup” and change to “Pri.Amps”. Make changes according to Annex C

(8)

Left Click “File”.

(9)

Press “Save As”.

(10)

Name the File and click “save”.

(11)

Left click “Communications”.

(12)

Left click “Upload Settings to Relay”.

(13)

At Password screen press “Enter”.

(14)

Left click on “Yes”.

(15)

Left click on “OK”. At this time the relay has been properly setup for service.

12.4.2.2.2.6

OVERCURRENT RELAY SET POINTS

Tie Overcurrent Relay Set Points are contained in Annex D.

12-94

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.2.3

BUS VOLT / FREQUENCY METER

The following maintenance procedures are provided for the Bus Volt / Frequency Meter: Inspect Test Remove Install Service

FIGURE 12.4.2.2.3-1

BUS VOLT / FREQUENCY METER

This meter provides a digital display of the system bus during manual synchronizing sequences. The upper display shows bus voltage while the lower display shows bus frequency. See Figure 12.4.2.2.3-1. 12.4.2.2.3.1

INSPECT BUS VOLT / FREQUENCY METER

Inspect the Bus Volt / Frequency Meter for the following: a. Inspect for proper mounting. b. Inspect for loose connections. c.

Inspect for physical and heat damage.

12-95

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.2.3.2

TEST BUS VOLT / FREQUENCY METER

To test the Bus Volt / Frequency Meter, proceed as follows: There are no field tests that can be performed on this device. 12.4.2.2.3.3

REMOVE BUS VOLT/FREQUENCY METER WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT. MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS USER. To remove the Bus Volt / Frequency Meter, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13)

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels.

12-96

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

When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Remove the four front retaining screws and remove the cover. c.

Remove the four-meter retaining bolts and nuts.

d. Tag and remove the wires and remove the meter. 12.4.2.2.3.4

INSTALL BUS VOLT / FREQUENCY METER

To install the Bus Volt / Frequency Meter, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.2.2.3.3. b. Reinstall the meter and the four retaining bolts and nuts. c.

Reinstall the front cover and the four front retaining screws.

d. Reinstall the wires and remove the tags. e. Close the Master Control Panel (MCP) door.

12-97

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.2.3.5

SERVICE BUS VOLT/FREQUENCY METER

1

2

3

4

(1) Mode Key (2) Right Key (3) Up Key (4) Enter Key FIGURE 12.4.2.2.3.5-1

BUS VOLT/FREQUENCY METER (WITH FRONT COVER REMOVED)

a. Listed below are the Bus Volt/Frequency Meter adjustment procedures, refer to Figure 12.4.2.2.3.5-1 for reference. b. Setting the PT ratio for voltage display: (1)

Remove the front faceplate by removing the four (4) screws recessed in the corners of the meter.

(2)

Press the “Mode” key. The meter will display “SET”.

(3)

Press the “En” key. The upper display shows “PT”.

(4)

Press the “En” key. The upper display shows “PT P”.

(5)

Press the “En” key. The upper display shows the current primary setting and the leftmost digit is flashing.

(6)

Using the “f” key change the left digit to 3.

(7)

Press the “d” key to select the next digit.

(8)

Using the “f” key change the digit to 5.

(9)

Press the “d” key to select the next digit.

12-98

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (10)

Using the “f” key change the left digit to 5.

(11)

Press the “d” key to select the next digit.

(12)

Using the “f” key change the left digit to 0.

(13)

Press the “En” key. An LED will flash.

(14)

Use the “f” key to move the decimal point so the reading is 35.50.

(15)

Press the “En” key. The new primary ratio, decimal point and LED will flash.

(16)

Press the “En” key to save the change.

(17)

Press the “Mode” key twice to return to the voltage display.

For further information on configuring the meter see the Yokogawa instruction booklet (IM2492VF-1).

12-99

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.2.4

TIE BREAKER CONTROL SWITCH (BCST)

The following maintenance procedures are provided for the Tie Breaker Control Switch (BCST): Inspect Test Remove Install

FIGURE 12.4.2.2.4-1

TIE BREAKER CONTROL SWITCH (BCST)

This switch has two momentary positions (Trip and Close), and two maintained positions (Center and Lockout). There is also a target to indicate the last operation performed by the switch. This switch is used for local operation of the breakers, setting up the breaker for automatic operation, and disabling breaker operation.

12-100

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.2.4.1

INSPECT TIE BREAKER CONTROL SWITCH (BCST)

Inspect the Tie Breaker Control Switch (BCST) for the following: a. Inspect for proper mounting. b. Inspect for loose connections. c.

Inspect for physical and heat damage.

12.4.2.2.4.2

TEST TIE BREAKER CONTROL SWITCH (BCST) WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT. MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS USER. To test the Tie Breaker Control Switch (BCST), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10)

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks.

12-101

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (11) (12) (13) NOTE 1:

Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels. When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Remove Tie Breaker Control Switch (BCST). TABLE 12.4.2.2.4.2-1 DECK

1 2 3 4 5 6 c.

CONTACTS

12 & 13 16 & 17 21 & 26 24 & 25 33 & 34 37 & 38 41 & 42 45 & 46 52 & 53 56 & 57 61 & 62 65 & 66

TIE BREAKER CONTROL SWITCH (BCST) POSITION NAT NAC (NORMAL (NORMAL TRIP TRIP (LOCKOUT) (MOMENTARY) AFTER AFTER TRIP) CLOSE)

CLOSE (MOMENTARY) X X

X X X X X X

X X

X X X X

X X

X X

Using a multimeter set to OHMS (Ω) Rx1 scale, test for contact continuity in switch positions specified. Multimeter should indicate zero ohms at points marked in chart as shown in Table 12.4.2.2.4.2-1.

d. Multimeter should indicate infinite ohms at all open contacts in chart as shown in Table 12.4.2.2.4.2-1. NOTE:

An integral spring return mechanism returns handle to normal-vertical position except in pullto-lock position. Slip contacts are incorporated to maintain contact closure in last commanded position.

e. Target window opening on face of switch plate should show green when last command operation was TRIP. f.

Target window should show red when last command operation was CLOSE.

g. Switch handle should always return to normal vertical position following either command operation, TRIP or CLOSE. h. Replace the Tie Breaker Control Switch (BCST) if it fails any of the above requirements. i.

If the Tie Breaker Control Switch (BCST) meets above requirements, install in accordance step d.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.2.4.3

REMOVE TIE BREAKER CONTROL SWITCH (BCST)

To remove the Tie Breaker Control Switch (BCST), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.2.2.4.2. b. Remove retaining screw from center of handle and slide handle from switch. c.

Remove the three retaining screws securing the Tie Breaker Control Switch (BCST) to the generator control panel.

d. Remove the Tie Breaker Control Switch (BCST) from rear of panel. e. Tag and disconnect wiring (do not remove jumpers) from Tie Breaker Control Switch (BCST). 12.4.2.2.4.4

INSTALL TIE BREAKER CONTROL SWITCH (BCST)

To install the Tie Breaker Control Switch (BCST), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.2.2.4.2. b. Reinstall wiring to the Tie Breaker Control Switch (BCST) and discard tags. c.

Reinstall the Tie Breaker Control Switch (BCST) and secure with three screws

d. Reinstall the handle on switch and secure with retaining screw e. Close the Master Control Panel (MCP) door.

12-103

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.2.5

SYSTEM MODE SWITCH (SMS)

The following maintenance procedures are provided for the System Mode Switch (SMS): Inspect Test Remove Install

FIGURE 12.4.2.2.5-1

SYSTEM MODE SWITCH (SMS)

This switch is located on the Master Control Panel. It is a maintained, three-position switch. This switch is used to determine the PU mode of operation.

12-104

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.2.5.1

INSPECT SYSTEM MODE SWITCH (SMS)

Inspect the System Mode Switch (SMS) for the following: a. Inspect for proper mounting. b. Inspect for loose connections. c.

Inspect for physical and heat damage.

12.4.2.2.5.2

TEST SYSTEM MODE SWITCH (SMS) WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT. MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS USER. To test the System Mode Switch (SMS), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10)

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks.

12-105

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (11) (12) (13) NOTE 1:

Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels. When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Using a multimeter set to OHMS (Ω) Rx1 scale, test for contact continuity in switch positions specified. Multimeter should indicate zero ohm at points marked in chart as shown in Table 12.4.2.2.5.2-1. c.

Multimeter should indicate infinite ohms at all open contacts in chart as shown in Table 12.4.2.2.5.2-1.

d. Replace the System Mode Switch (SMS) if it fails any of the above requirements. TABLE 12.4.2.2.5.2-1 SWITCH POSITION MAN

OFF

AUTO

12.4.2.2.5.3

COMMON TERMINALS 11 & 12 15 & 16 21 & 22 25 & 26 11 & 12 15 & 16 21 & 22 25 & 26 11 & 12 15 & 16 21 & 22 25 & 26

SYSTEM MODE SWITCH (SMS) SYSTEM MODE SWITCH (SMS) TERMINALS 13 14 17 18 23 X X

24

27

28

X X

X X X X

REMOVE SYSTEM MODE SWITCH (SMS)

To remove the System Mode Switch (SMS), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.2.2.5.2. b. Remove the handle retaining screw. c.

Remove the 3 retaining screws from the front of the switch.

d. Remove the System Mode Switch (SMS) from rear of panel. e. Tag and disconnect the System Mode Switch (SMS).

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.2.5.4

INSTALL SYSTEM MODE SWITCH (SMS)

To install the System Mode Switch (SMS), proceed as follows a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.2.2.5.2. b. Reinstall the System Mode Switch (SMS) from rear of the control panel, and secure with 3 retaining screws. c.

Reinstall the handle with mounting screw.

d. Reinstall wiring to the System Mode Switch (SMS) and discard tags. e. Close the Master Control Panel (MCP) door.

12-107

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.2.6

SYSTEM SYNCHRONIZING SWITCH (SSS)

The following maintenance procedures are provided for the System Synchronizing Switch (SSS): Inspect Test Remove Install

FIGURE 12.4.2.2.6-1

SYSTEM SYNCHRONIZING SWITCH (SSS)

This switch is located on the center door control section. It is a maintained, three-position switch. This switch is used to determine which generator is to be manually synchronized to the system bus. 12.4.2.2.6.1

INSPECT SYSTEM SYNCHRONIZING SWITCH (SSS)

Inspect the System Synchronizing Switch (SSS) for the following: a. Inspect for proper mounting. b. Inspect for loose connections. c.

Inspect for physical and heat damage.

12-108

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.2.6.2

TEST SYSTEM SYNCHRONIZING SWITCH (SSS) WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT. MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS USER. To test the System Synchronizing Switch (SSS), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) NOTE 1:

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels. When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

12-109

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 b. Using a multimeter set to OHMS (Ω) Rx1 scale, test for contact continuity in switch positions specified. Multimeter should indicate zero ohm at points marked in chart as shown in Table 12.4.2.2.6.2-1. Leave jumpers in place during the test. Multimeter should indicate infinite ohms at all open contacts in chart as shown in Table 12.4.2.2.6.2-1.

c.

d. Replace the System Synchronizing Switch (SSS) if it fails any of the above requirements. TABLE 12.4.2.2.6.2-1 DECK 1

2 3 4 5 6

CONTACTS 11 & 12 11 & 18 11 & 13 21 & 22 21 & 28 21 & 23 31 & 32 31 & 38 31 & 33 41 & 42 41 & 48 41 & 43 51 & 52 51 & 58 51 & 53 61 & 62 61 & 68 61 & 63

SYSTEM SYNCHRONIZING SWITCH (SSS) POSITION GEN 1 OFF GEN 2 X X

TIE

X X X X X X X X X X X X X X X X

1. Using a multimeter set to OHMS (Ω) Rx1 scale, test for contact continuity in switch positions specified. Multimeter should indicate zero ohm at points marked in chart as shown in Figure 12.4.2.2.6.2-1. 2. Multimeter should indicate infinite ohms at all open contacts in chart as shown in Figure 12.4.2.2.6.2-1.

12-110

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.2.6.3

REMOVE SYSTEM SYNCHRONIZING SWITCH (SSS)

To remove the System Synchronizing Switch (SSS), proceed as follows a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.2.2.6.2. b. Remove handle-retaining screw. c.

Remove the 3 front mounting screws.

d. Remove the System Synchronizing Switch (SSS) from the rear of the Master Control Panel. e. Tag and disconnect the System Synchronizing Switch (SSS). 12.4.2.2.6.4

INSTALL SYSTEM SYNCHRONIZING SWITCH (SSS)

To install the System Synchronizing Switch (SSS), proceed as follows a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.2.2.6.2. b. Reinstall the System Synchronizing Switch (SSS) from rear of the control panel, and secure retaining nut. c.

Reinstall wiring to the System Synchronizing Switch (SSS) and discard tags.

d. Close the Master Control Panel (MCP) door.

12-111

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.2.7

GENERATOR MODE SWITCH (GMS)

The following maintenance procedures are provided for the Generator Mode Switch (GMS): Inspect Test Remove Install

FIGURE 12.4.2.2.7-1

GENERATOR MODE SWITCH (GMS)

This switch is located on the center door control section. It is a maintained, two-position switch. switch is used to determine generator load sharing method of operation. 12.4.2.2.7.1

INSPECT GENERATOR MODE SWITCH (GMS)

Inspect the Generator Mode Switch (GMS) for the following: a. Inspect for proper mounting. b. Inspect for loose connections. c.

Inspect for physical and heat damage.

12-112

This

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.2.7.2

TEST GENERATOR MODE SWITCH (GMS) WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT. MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS USER. To test the Generator Mode Switch (GMS), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) NOTE 1:

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels. When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

12-113

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 b. Using a multimeter set to OHMS (Ω) Rx1 scale, test for contact continuity in switch positions specified. Multimeter should indicate zero ohms at points marked in chart as shown in Table 12.4.2.2.7.2-1. c.

Multimeter should indicate infinite ohms at all open contacts in chart as shown in Table 12.4.2.2.7.2-1.

d. Replace the Generator Mode Switch (GMS) if it fails any of the above requirements. TABLE 12.4.2.2.7.2-1

GENERATOR MODE SWITCH (GMS) GENERATOR MODE SWITCH (GMS) SWITCH POSITION TERMINALS 1 & 2 UTILITY POWER X PRIME POWER

12.4.2.2.7.3

REMOVE GENERATOR MODE SWITCH (GMS)

To remove the Generator Mode Switch (GMS), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.2.2.7.2. b. From the rear of the switch turn the open tab until the switch releases. c.

Tag and disconnect the Generator Mode Switch (GMS).

d. Remove the Generator Mode Switch (GMS) from rear of panel. 12.4.2.2.7.4

INSTALL GENERATOR MODE SWITCH (GMS)

To install the Generator Mode Switch (GMS), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.2.2.7.2. b. Reinstall the Generator Mode Switch (GMS) from rear of the control panel, and secure retaining nut. c.

Reinstall wiring to the Generator Mode Switch (GMS) and discard tags.

d. Close control panel door and tighten captive screws. e. Ensure all equipment is not energized prior to reconnecting cables. f.

Reinstall Tie and Load cables to the Output Terminals.

12-114

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.2.8

MASTER SYSTEM ENABLE SWITCH (MSES)

The following maintenance procedures are provided for the Master System Enable Switch (MSES): Inspect Test Remove Install

FIGURE 12.4.2.2.8-1

MASTER SYSTEM ENABLE SWITCH (MSES)

This switch is located on the center door control section. It is a momentary, three position spring-loaded switch. The Master System Enable Switch (MSES), switch enables the system to function in Automatic. •

By toggling the Master System Enable Switch (MSES) it will start any idle engine on the PU.



Can be used as a local start switch.



Used to clear lockouts as indicated by the red light on the System Status Light being on.

12-115

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.2.8.1

INSPECT MASTER SYSTEM ENABLE SWITCH (MSES)

Inspect the Master System Enable Switch (MSES) for the following: a. Inspect for proper mounting. b. Inspect for loose connections. c.

Inspect for physical and heat damage.

12.4.2.2.8.2

TEST MASTER SYSTEM ENABLE SWITCH (MSES) WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT. MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS USER. To test the Master System Enable Switch (MSES), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10)

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks.

12-116

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (11) (12) (13)

Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels. When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

NOTE 1:

b. Using a multimeter set to OHMS (Ω) Rx1 scale, test for contact continuity in switch positions specified. Multimeter should indicate zero ohm at points marked in chart as shown in Table 12.4.2.2.8.2-1. c.

Multimeter should indicate infinite ohms at all open contacts in chart as shown in Table 12.4.2.2.8.2-1.

d. Replace the Master System Enable Switch (MSES) if it fails any of the above requirements. TABLE 12.4.2.2.8.2-1

MASTER SYSTEM ENABLE SWITCH (MSES) MASTER SYSTEM ENABLE SWITCH (MSES) SWITCH POSITION TERMINALS 1 & 2 ENABLE (MOMENTARY LEFT) X CENTER ENABLE (MOMENTARY RIGHT)

12.4.2.2.8.3

REMOVE MASTER SYSTEM ENABLE SWITCH (MSES)

To remove the Master System Enable Switch (MSES), proceed as follows a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.2.2.8.2. b. From the rear of the switch move the Open Tab to the left and remove the switch. c.

Tag and disconnect Master System Enable Switch (MSES).

d. Remove Master System Enable Switch (MSES) from rear of panel. 12.4.2.2.8.4

INSTALL MASTER SYSTEM ENABLE SWITCH (MSES)

To install the Master System Enable Switch (MSES), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.2.2.8.2. b. Reinstall the MSES from rear of the Master Control Panel, push until it clicks into place. c.

Reinstall wiring to the Master System Enable Switch (MSES) and discard tags.

d. Close the Master Control Panel (MCP) door.

12-117

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.2.9

BATTLESHORT SWITCH (BSS)

The following maintenance procedures are provided for the Battleshort Switch (BSS): Inspect Test Remove Install

FIGURE 12.4.2.2.9-1

BATTLESHORT SWITCH (BSS)

This switch is located on the center door control section. It is a maintained, two-position toggle switch. This switch has a flip cover that will return the BSS to OFF when it is closed. 12.4.2.2.9.1

INSPECT BATTLESHORT SWITCH (BSS)

Inspect the Battleshort Switch (BSS) for the following: a. Inspect for proper mounting. b. Inspect for loose connections. c.

Inspect for physical and heat damage.

12-118

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.2.9.2

TEST BATTLESHORT SWITCH (BSS) WARNING

REMOVE ALL RING, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT. MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS USER. To test the Battleshort Switch (BSS), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) NOTE 1:

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels. When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

12-119

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 b. Using a multimeter set to OHMS (Ω) Rx1 scale, test for contact continuity in switch positions specified. Multimeter should indicate zero ohm at points marked in chart as shown in Table 12.4.2.2.9.2-1. c.

Multimeter should indicate infinite ohms at all open contacts in chart as shown in Table 12.4.2.2.9.2-1.

d. Replace the Battleshort Switch (BSS) if it fails any of the above requirements. TABLE 12.4.2.2.9.2-1 SWITCH POSITION NORMAL BATTLESHORT 12.4.2.2.9.3

1 X

BATTLESHORT SWITCH (BSS) BATTLESHORT SWITCH (BSS) TERMINALS 2 3 X X X

4 X

5 X X

REMOVE BATTLESHORT SWITCH (BSS)

To remove the Battleshort Switch (BSS), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.2.2.9.2. b. Remove the front Battleshort Switch (BSS) retaining nut. c.

Remove the Battleshort Switch (BSS) from rear of panel.

d. Tag and disconnect the Battleshort Switch (BSS). Do not remove the Jumpers. 12.4.2.2.9.4

INSTALL BATTLESHORT SWITCH (BSS)

To install the Battleshort Switch (BSS), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.2.2.9.2. b. Reinstall the Battleshort Switch (BSS) from rear of the control panel, and reinstall the retaining nut. c.

Reinstall wiring to Battleshort Switch (BSS) and discard tags.

d. Close the Master Control Panel (MCP) door.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.2.10

AUTOMATIC VOLTAGE REGULATOR SWITCH (AVRS)

The following maintenance procedures are provided for the Automatic Voltage Regulator Switch (AVRS): Inspect Test Remove Install Service

FIGURE 12.4.2.2.10-1

AUTOMATIC VOLTAGE REGULATOR SWITCH (AVRS)

This switch is located on the center door control section. It is a maintained, two-position switch. switch is used to determine which method of voltage control the automatic voltage regulator is in. 12.4.2.2.10.1

INSPECT AUTOMATIC VOLTAGE REGULATOR SWITCH (AVRS)

Inspect the Automatic Voltage Regulator Switch (AVRS) for the following: a. Inspect for proper mounting. b. Inspect for loose connections. c.

Inspect for physical and heat damage.

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This

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.2.10.2

TEST AUTOMATIC VOLTAGE REGULATOR SWITCH (AVRS) WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT. MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS USER. To test the Automatic Voltage Regulator Switch (AVRS), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) NOTE 1:

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels. When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 b. Using a multimeter set to OHMS (Ω) Rx1 scale, test for contact continuity in switch positions specified. Multimeter should indicate zero ohm at points marked in chart as shown in Table 12.4.2.2.10.2-1. c.

Multimeter should indicate infinite ohms at all open contacts in chart as shown in Table 12.4.2.2.10.2-1.

d. Replace the Automatic Voltage Regulator Switch (AVRS) if it fails any of the above requirements. TABLE 12.4.2.2.10.2-1

AUTOMATIC VOLTAGE REGULATOR SWITCH (AVRS) AUTOMATIC VOLTAGE REGULATOR SWITCH (AVRS) SWITCH POSITION TERMINALS 1 & 2 UTILITY PARALLEL X PRIME POWER

12.4.2.2.10.3

REMOVE AUTOMATIC VOLTAGE REGULATOR SWITCH (AVRS)

To remove the Automatic Voltage Regulator Switch (AVRS), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.2.2.10.2. b. From rear of the Master Control Panel move the Open retaining tab to the left until the switch disconnects. c.

Remove the Automatic Voltage Regulator Switch (AVRS) from rear of the panel.

d. Tag and disconnect the Automatic Voltage Regulator Switch (AVRS). 12.4.2.2.10.4

INSTALL AUTOMATIC VOLTAGE REGULATOR SWITCH (AVRS)

To install the Automatic Voltage Regulator Switch (AVRS), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.2.2.10.2. b. Reinstall the Automatic Voltage Regulator Switch (AVRS) from rear of the Master Control panel, and push the switch into the socket until it clicks into place. c.

Reinstall wiring to Automatic Voltage Regulator Switch (AVRS) and discard tags.

d. Close the Master Control Panel (MCP) door.

12-123

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.2.11

UNIT SELECTOR SWITCH (USS)

The following maintenance procedures are provided for the Unit Selector Switch (USS): Inspect Test Remove Install

FIGURE 12.4.2.2.11-1

UNIT SELECTOR SWITCH (USS), UNIT SELECTOR INDICATORS (USI)

This switch is located on the Master Control Panel (MCP). It is a maintained, four-position switch. This switch is used in conjunction with the MSES to select the identifier for multiple PU and automatic operation. WARNING ONLY ONE PU MAY BE SELECTED TO ANY ONE USS POSITION DURING MULTIPLE PU OPERATIONS. OPERATING WITH MORE THAN ONE UNIT AT THE SAME ID MAY CAUSE UNSAFE AND ERRATIC OPERATIONAL CONDITIONS.

12-124

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 “A” This position selects the PU to be identified as PU ‘A’. This designates this PU as the master unit. It coordinates the operation of the other online Units. In single unit operation this is the position required for the PU to operate properly in automatic. In multiple PU lineups this should be the left most PU. “B” This position selects the PU to be identified as PU ‘B’. This designates this PU a slave unit. It operates independently except during the generator economizing and dead bus closure when it requires commands or permission from the ‘A’ PU. This PU should be the second PU from the left in the physical lineup. “C” This position selects the PU to be identified as PU ‘C’. This designates this PU a slave unit. It operates independently except during the generator economizing and dead bus closure when it requires commands or permission from the ‘A’ PU. This PU should be the third PU from the left in the physical lineup. “D” This position selects the PU to be identified as PU ‘D’. This designates this PU a slave unit. It operates independently except during the generator economizing and dead bus closure when it requires commands or permission from the ‘A’ PU. This PU should be the fourth and last PU from the left in the physical lineup. 12.4.2.2.11.1

INSPECT UNIT SELECTOR SWITCH (USS)

Inspect the Unit Selector Switch (USS) for the following: a. Inspect for proper mounting. b. Inspect for loose connections. c.

Inspect for physical and heat damage.

12.4.2.2.11.2

TEST UNIT SELECTOR SWITCH (USS) WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING.

12-125

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 WARNING WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT. MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS USER. To test the Unit Selector Switch (USS), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) NOTE 1:

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels. When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Using a multimeter set on OHMS (Ω) Rx1 scale; measure the resistance across the switch contacts. The resistance should be less than 1-ohm when closed and infinite when open. Use Table 12.4.2.2.11.2-1 to determine which contacts are closed in each position. TABLE 12.4.2.2.11.2-1 DECK A (1) B (2) c.

USS CONTACT TARGET TABLE SWITCH POSITION CONTACTS A B C 1 – 2 (NC) 3 – 4 (NO) X 1 – 2 (NC) X 3 – 4 (NO) X

D X

If any of the contact block tests fail, replace that contact block with one of the same type.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.2.11.3

REMOVE UNIT SELECTOR SWITCH (USS)

To remove the Unit Selector Switch (USS), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.2.2.11.2. b. Remove the contact assembly; disconnect wires from the terminals on the contact block to remove. c.

Release the contact assembly’s locking tangs with a small flathead screwdriver and remove.

d. Remove the Operator; disconnect the contact block from the operator by pushing the locking lever slightly forward and to the right. This releases the contact block from the operator. e. From the front of the door, carefully loosen the lock-ring from the rest of the operator. f.

Slide the operator out through the back of the door.

12.4.2.2.11.4

INSTALL UNIT SELECTOR SWITCH (USS)

To install the Unit Selector Switch (USS), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.2.2.11.2. a. Reinstall the contact assembly; snap the contact assembly into the appropriate slot and verify it is firmly locked in. b. Reinstall the wiring harness to the appropriate terminals based on the associated wiring drawing(s). c.

Reinstall the Operator; reinstall the Operator through the hole in the door.

d. Reinstall the lock-ring onto the operator and tighten it so that the operator is tight and aligned with the position indications when operated. e. Close the Master Control Panel (MCP) door.

12-127

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.2.12

UNIT SELECTOR INDICATORS (USI)

The following maintenance procedures are provided for the Unit Selector Indicators (USI): Inspect Test Remove Install

Use Figure 12.4.2.2.11-1 for reference. These four white indicators reflect the set selection of the PU during operation. The indicators are off whenever the unit’s network ID has not been set. Depending on the position of the Unit Selector Switch (USS) when the Master System Enable Switch (MSES) is cycled, the associated LED will energize. These indicators provide positive indication that the control system has energized the current setup parameters and the unit is starting operation. Note: in MANUAL mode the indicators only reflect that the unit’s ID has been set; in AUTO mode, the control system will also proceed with a normal startup. Whenever the System Mode Switch (SMS) has been in the OFF position for 3 or more seconds the unit ID is cleared and the indicator is de-energized until the SMS is placed in MANUAL or AUTO and the MSES is cycled. 12.4.2.2.12.1

INSPECT UNIT SELECTOR INDICATORS (USI)

Inspect the Unit Selector Indicators (USI) for the following: a. Inspect for proper mounting. b. Inspect for loose connections. c.

Inspect for physical and heat damage.

12.4.2.2.12.2

TEST UNIT SELECTOR INDICATORS (USI) WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. To test the Unit Selector Indicators (USI), proceed as follows: a. Ensure the PU is isolated from other PU’s by disconnecting both (A) (B) communication cables. b. Turn on the DC control power by pushing-in the DC-Control Power Breaker. c.

Place both Engine Control Switches ECS in the OFF position.

d. Place the System Mode Switch in OFF and ensure there are no Unit Selector Indicators on. e. Place the SMS in MANUAL. f.

Place the USS in position A and cycle the Master System Enable Switch (MSES).

12-128

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 g. Verify the “A” USI energizes. h. Place the SMS in OFF for a minimum of 3 seconds and observe the ‘A” USI de-energizes. i.

Repeat steps “e” through “g” for positions ‘B, ‘C’, and ‘D’ USI’s, substituting the position testing for ‘A’ position. When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

NOTE:

12.4.2.2.12.3

REMOVE UNIT SELECTOR INDICATORS (USI)

To remove the Unit Selector Indicators (USI), proceed as follows: WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT. MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS USER. a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7)

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position.

12-129

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels.

(8) (9) (10) (11) (12) (13) NOTE 1:

When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Remove the indicator’s lens cap by unscrewing it in a counter-clockwise direction. c.

Disconnect wiring from the indicator base.

d. Remove the indicator LED by carefully unscrewing it in a counter-clockwise direction. 12.4.2.2.12.4

INSTALL UNIT SELECTOR INDICATORS (USI)

To install the Unit Selector Indicators (USI), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.2.2.12.3. b. Reinstall the replacement LED by screwing it into the socket in a clockwise direction. c.

Reinstall the indicator wiring per the associated wiring diagram.

d. Reinstall the lens cap by screwing it onto the socket in a clockwise direction.

12-130

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.2.13

BUZZER SILENCE PUSHBUTTON (SIL)

The following maintenance procedures are provided for the Buzzer Silence Pushbutton (SIL): Inspect Test Remove Install

FIGURE 12.4.2.2.13-1

BUZZER SILENCE PUSHBUTTON (SIL)

This pushbutton is located on Master Control Panel (MCP). The pushbutton is used to silence the audible buzzer whenever an alarm or fault signal is activated. The pushbutton will only acknowledge one alarm or fault at a time. Multiple alarms and faults require the operator to press the pushbutton for each active alarm or fault. The operator cannot press the button beyond the number of active alarms and faults. The buzzer works in conjunction with the System Status Lights. Whenever the amber or red light is flashing the buzzer is activated. Once the alarm is silenced the buzzer de-energizes and the amber or red light stay on solid until the condition clears. The pushbutton also silences the ORT buzzer if there are no other active alarms or faults on other PUs on the ORT network.

12-131

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.2.13.1

INSPECT BUZZER SILENCE PUSHBUTTON (SIL)

Inspect the Buzzer Silence Pushbutton (SIL) for the following: a. Inspect for proper mounting. b. Inspect for loose connections. c.

Inspect for physical and heat damage.

12.4.2.2.13.2

TEST BUZZER SILENCE PUSHBUTTON (SIL) WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT. MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS USER. To test the Buzzer Silence Pushbutton (SIL), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10)

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks.

12-132

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels.

(11) (12) (13) NOTE 1:

When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Using a multimeter set to OHMS (Ω) Rx1 scale, test for contact continuity in switch positions specified. Multimeter should indicate zero ohm at points marked in chart as shown in Figure 12.4.2.2.13.2-1. c.

Multimeter should indicate infinite ohms at all open contacts in chart as shown in Figure 12.4.2.2.13.2-1.

d. Replace Buzzer Silence Pushbutton (SIL) if it fails any of the above requirements. TABLE 12.4.2.2.13.2-1

BUZZER SILENCE PUSHBUTTON (SIL) BUZZER SILENCE PUSHBUTTON (SIL) WIRE NUMBER SWITCH POSITION 100 & 160 NORMAL - OUT PUSHED-IN X

e. Using a multimeter set to OHMS (Ω) Rx1 scale, test for contact continuity in switch positions specified. Multimeter should indicate zero ohms at points marked in chart as shown in Figure 12.4.2.2.13.2-1. f.

Multimeter should indicate infinite ohms at all open contacts in chart as shown in Figure 12.4.2.2.13.2-1.

12.4.2.2.13.3

REMOVE BUZZER SILENCE PUSHBUTTON (SIL)

To remove the Buzzer Silence Pushbutton (SIL), proceed as follows: This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.2.2.13.2.

a.

b. Twist the pushbutton retaining ring to the left until it comes off. c.

Unscrew the contact block from the operator.

d. Remove the Buzzer Silence Pushbutton (SIL) from rear of panel. e. Tag and disconnect Buzzer Silence Pushbutton (SIL).

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12.4.2.2.13.4

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 INSTALL BUZZER SILENCE PUSHBUTTON (SIL)

To install the Buzzer Silence Pushbutton (SIL), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.2.2.13.2. b. Reinstall the Buzzer Silence Pushbutton (SIL) from rear of the control panel, secure retaining nut, and Reinstall contact block. c.

Reinstall wiring to the Buzzer Silence Pushbutton (SIL) and discard tags.

d. Close the Master Control Panel (MCP) door.

12-134

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.2.14

SYSTEM STATUS LIGHT (SSL)

The following maintenance procedures are provided for the System Status Light (SSL): Inspect Test Remove Install

FIGURE 12.4.2.2.14-1

SYSTEM STATUS LIGHT (SSL)

This indicator consists of four individual lights, integrated into a single cluster housing. The individually colored LEDs are arranged red, green, amber, and green starting with the upper LED. •

Amber – Located at the lower position on the cluster. This LED indicates the presence of an alarm condition. The LED flashing indicates a new un-silenced alarm. Once the alarm has been silenced, the LED remains on solid. After the alarm condition clears the LED extinguishes. Used in conjunction with the green LED’s, the operator can determine which associated generator has the active alarm and/or fault.

12-135

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

Red – Located at the upper position on the cluster. This LED indicates the presence of a fault/shutdown condition. The LED flashing indicates a new un-silenced alarm. Once the alarm has been silenced, the LED remains on solid. After the alarm condition clears the LED extinguishes. Used in conjunction with the green LED’s, the operator can determine which associated generator has the active alarm and/or fault.



Green – Located at the left and right positions on the cluster. These LED’s indicates the status of their respective generators (left for Gen. 1, right for Gen. 2). An on-solid LED indicates that that generator is ready for operation and has no active alarms or faults. A flashing LED indicates that that generator has an active alarm or fault condition. Used in conjunction with the amber and red LED’s, the operator can determine whether the associated generator has an active alarm and/or fault.

12.4.2.2.14.1

INSPECT SYSTEM STATUS LIGHT (SSL)

Inspect the System Status Light (SSL) for the following: a. Inspect for proper mounting. b. Inspect for loose connections. c.

Inspect for physical and heat damage.

12.4.2.2.14.2

TEST SYSTEM STATUS LIGHT (SSL) WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT. MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS USER. To test the System Status Light (SSL), proceed as follows:

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels.

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) NOTE 1:

When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Remove the LED lens cap. c.

Carefully slide out the LED in question from the lens cap.

d. Using an ohmmeter check the LED. With the leads connected one way to the LED there should be high resistance, reversing the leads there should be no resistance on a good LED. Replace any LEDs that are high resistance both ways (Open) or low resistance both ways (Shorted). 12.4.2.2.14.3

REMOVE SYSTEM STATUS LIGHT (SSL)

To replace the System Status Light (SSL), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.2.2.14.2. b. Disconnect all wiring to the back of the light fixture c.

Remove the lens cap from the base by unscrewing it counter-clockwise.

d. Carefully remove the base assembly from the door by unscrewing the locknut from the front of the door. e. Slide the base assembly out of the door.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.2.14.4

INSTALL SYSTEM STATUS LIGHT (SSL)

To install the System Status Light (SSL), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.2.2.14.2. b. Reinstall the base assembly through the door from the back of the door. c.

Reinstall the lock nut positioning the base assembly so the terminals are on the sides.

d. Reinstall the lens cap lining up the lenses so the red lens is at the top. If the cap will not seat properly, the base assembly is upside down. Loosen the locknut and invert it. e. Reinstall the wiring to the base assembly. Remove Tags. f.

Close the Master Control Panel (MCP) door.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.2.15

50/60 HERTZ INDICATOR LIGHTS

The following maintenance procedures are provided for the 50/60 Hertz Indicator Lights: Inspect Test Remove Install

FIGURE 12.4.2.2.15-1

50/60 HERTZ INDICATOR LIGHTS

These two indicators reflect the current frequency that the control system expects. This is independent of the setups required to configure both the AVR’s and GSC’s. The 50/60HZ lights reflect the Frequency Selector Switch position while there are no Unit Selection Indicators (USI) on. Once a USI light is on the FSS has no effect on the 50/60Hz lights. The selected light is set whenever the MSES is cycled to set the USI lights or the System Mode Switch (SMS) is not in the off position. 12.4.2.2.15.1

INSPECT 50/60 HERTZ INDICATOR LIGHTS

Inspect the 50/60 Hertz Indicator Lights for the following: a. Inspect for proper mounting. b. Inspect for loose connections. c.

Inspect for physical and heat damage.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.2.15.2

TEST 50/60 HERTZ INDICATOR LIGHTS WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. To test the 50/60 Hertz Indicator Lights, proceed as follows: a. Ensure the PU is isolated from other PU’s by disconnecting both (A) (B) communication cables. b. Turn on the DC control power by pushing-in the DC-Power Switch. c.

Place both Engine Control Switches (ECS) in the OFF position.

d. Place the SMS in OFF. Observe any lit USI’s de-energize. e. Open the Master Control Panel (MCP) door. f.

Check the position of the Frequency Selector Switch (FSS). It should match the current lit Frequency Indicator.

g. Change the position of the FSS. Observe the Frequency Indicator lit also changes. NOTE:

When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

12.4.2.2.15.3

REMOVE 50/60 HERTZ INDICATOR LIGHTS

To remove the 50/60 Hertz Indicator Lights, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.2.2.15.2. b. Remove the indicator’s lens cap by unscrewing it in a counter-clockwise direction. c.

Remove the indicator LED by carefully unscrewing it in a counter-clockwise direction.

d. Tag and Disconnect the wiring from the base of the indicator. e. Remove the base locknut from the front of the base and slide the base out to the back of the door.

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12.4.2.2.15.4

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 INSTALL 50/60 HERTZ INDICATOR LIGHTS

To install the 50/60 Hertz Indicator Lights, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.2.2.15.2. b. Reinstall the replacement base from the back of the door and tighten the locknut. c.

Reinstall the wiring to the base of the indicator. Remove Tags.

d. Reinstall the LED by screwing it into the socket in a clockwise direction. e. Reinstall the lens cap by screwing it onto the socket in a clockwise direction.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.2.16

PHASE ROTATION TEST LIGHTS (PRL)

The following maintenance procedures are provided for the Phase Rotation Test Lights (PRL): Inspect Test Remove Install

FIGURE 12.4.2.2.16-1

PHASE ROTATION TEST LIGHTS (PRL)

The Phase Rotation Test Lights indicate the phase rotation of the system bus. There are two independent indicators. One indicates an A-B-C sequence and the other indicates an A-C-B sequence. Under normal operating conditions the A-B-C sequence is proper. These indicators are used to verify all sources are operating on the same phase sequence, which is required for parallel operation. The indicators work along with an internally mounted phase sequence relay (device-47). The system bus must be energized from only one source at a time for the check to work properly.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.2.16.1

INSPECT PHASE ROTATION TEST LIGHTS (PRL) WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT. MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS USER. Inspect the Phase Rotation Test Lights (PRL) for the following: a. Inspect for proper mounting. b. Inspect for loose connections. c.

Inspect for physical and heat damage.

d. When the PU is connected to a live bus, and the Tie Breaker in the open position, push the test switch to the test position and check the Phase Rotation Test Lights to see if ABC or CBA lights. 12.4.2.2.16.2

TEST PHASE ROTATION TEST LIGHTS (PRL) WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 WARNING WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT. MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS USER. To test the Phase Rotation Test Lights (PRL), proceed as follows: a. This maintenance requires that the PU be connected to a live bus through the Load Tie Breaker. The Load Tie breaker must be in the OPEN position to perform this test. b. When the PU is connected to a live bus, and the Tie Breaker in the open position, push the test switch to the test position and check the Phase Rotation Lights to see if ABC or CBA lights. c.

If neither ABC nor CBA light illuminates, inspect both bulbs by: (1) Remove the lens cap by unscrewing it in the counter-clockwise direction. (2) Remove the light bulb by unscrewing it in the counter-clockwise direction. (3) Visually inspect the filament of the light bulb to see if it is broken. If necessary check the bulbs with a multimeter set on OHMS, and check for an (Open) circuit. (4) Replace the bulb if it is found to be defective.

d. If neither bulb is defective, check for 24VDC with a multimeter set in the DC range, at the back of the test switch, with the switch in the OFF position. e. With the test leads still connected, push the test switch into the TEST position. If there is still 24VDC at the switch in the test position, replace the defective switch. 12.4.2.2.16.3

REMOVE PHASE ROTATION TEST LIGHTS (PRL) WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING.

12-144

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 WARNING WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT. MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS USER. To remove the Phase Rotation Test Lights (PRL), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) NOTE 1:

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels. When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Remove the lock ring and loosen the locknut on the back of the door. c.

Remove the lens by screwing it in a counterclockwise direction.

d. Remove the bulb by screwing it on in a counterclockwise direction. e. Remove the base from the rear of the door. f.

Remove and Tag the wiring from the base.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.2.16.4

INSTALL PHASE ROTATION TEST LIGHTS (PRL)

To install the Phase Rotation Test Lights (PRL), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.2.2.16.3. b. Reinstall the base from the rear of the door. c.

Reinstall the lock ring and tighten the locknut on the back of the door.

d. Reinstall the replacement bulb by screwing it in a clockwise direction. e. Reinstall the lens cap by screwing it on in a clockwise direction. f.

Reinstall the locknut so there is just sufficient threads to allow the lens cap to be firmly screwed onto the base.

g. Reinstall the wiring to the base. Remove Tags.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.2.17

ALARM / FAULT BUZZER

The following maintenance procedures are provided for the Alarm / Fault Buzzer: Inspect Test Remove Install

FIGURE 12.4.2.2.17-1 a.

ALARM / FAULT BUZZER

The buzzer is located at the top center of the Master Control Section. The buzzer actuates whenever the control system sees a new alarm or fault activated. The buzzer will remain on as long as there is an un-silenced alarm or fault. Pressing the Silence pushbutton for each active alarm or fault silences the buzzer. The buzzer may also be silenced from a networked ORT.

b. Table 12.4.2.2.17-1 and Table 12.4.2.2.17-2 presents the Alarms and Fault matrix that activate the buzzer during a fault.

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FAULT MATRIX

FAULTS ACTIVATING BUZZER High Coolant Temperature Emergency Stop Low Oil Pressure Overcrank Overspeed Under Frequency Over Frequency Under Voltage Over Voltage Reverse Power Frequency Sensing Low Fuel Level Neutral Ground Resistor (NGR) Phase Time Overcurrent Phase Instantaneous Overcurrent (Short Circuit) Ground Time Overcurrent Ground Instantaneous Overcurrent (Ground Fault) ORT Immediate Stop Generator Overload

TABLE 12.4.2.2.17-2

ALARMS MATRIX

ALARMS ACTIVATING BUZZER High Coolant Temperature Low Coolant Temperature Low Oil Pressure ECM Control Low Battery Voltage Under Frequency Over Frequency Under Voltage Over Voltage Reverse Power Frequency Sensing Low Fuel Level Generator Overload

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.2.17.1

INSPECT ALARM/FAULT BUZZER WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT. MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS USER. Inspect the Alarm/Fault Buzzer for the following: a. Check the interior wire connections for loose connections. b. Verify both setscrews are tight. c.

Check gasket for leaks by loosening the setscrews and removing the buzzer from its base.

12.4.2.2.17.2

TEST ALARM/FAULT BUZZER WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING.

12-149

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 WARNING WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT. MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS USER. To test the Alarm/Fault Buzzer, proceed as follows: a. This maintenance requires that the PU be set in Manual Mode Mode, and not running. b. Turn on DC control power by pushing in the DC Power breaker. c.

Place one (ECS) in the STOP/COOLDOWN position.

d. Press in that engines local Emergency - Stop pushbutton. e. Observe the EMCP II+ for the Emergency - Stop LED illuminates. f.

Observe that the alarm buzzer energizes.

g. Press the Silence Pushbutton to silence the buzzer; this may take 2 actions on the pushbutton. h. Pull the Emergency - Stop button back out. I.

Place the (ECS) in OFF/RESET.

12.4.2.2.17.3

REMOVE ALARM/FAULT BUZZER WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING.

12-150

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 WARNING WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT. MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS USER. To remove the alarm/Fault Buzzer, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) NOTE 1:

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels. When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Loosen both setscrews on the external sides of the buzzer. c.

Carefully pull out the buzzer assembly.

d. Remove and Tag the wires from the terminals inside the door. e. Remove the conduit lock ring from the inside of the door. f.

Remove the mounting screws from the base of the buzzer.

g. Remove the buzzer from the door.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.2.2.17.4

INSTALL ALARM/FAULT BUZZER

To install the alarm/Fault Buzzer, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.2.2.17.3. b. Reinstall the conduit fitting to the base. c.

Reinstall the Alarm / Fault Buzzer in the door by tightening its mounting screws.

d. Reinstall the conduit to the door by tightening its lock nut from the inside of the door. e. Reinstall the wiring to the base terminals and Remove tags. f.

Loosen the setscrews on the sides of the base.

g. Reinstall the Alarm / Fault Buzzer assembly into the base insuring proper alignment. h. Tighten both setscrews.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.3

CONTROLS AND INSTRUMENTS WITHIN CABINET A, B, AND C

12.4.3.1

FREQUENCY SELECTOR SWITCH (FSS)

The following maintenance procedures are provided for the Frequency Selector Switch (FSS): Inspect Test Remove Install

FIGURE 12.4.3.1-1

FREQUENCY SELECTOR SWITCH (FSS)

This switch is located on the inside of the center door. It is a maintained, two-position, lever-lock toggle switch. The lever-lock feature provides the switch with a positive position lock. This switch is only functional while the PU status indicators are flashing. For the RTU to recognize a change, place the (SMS) in off until the PU status indicators flash, then select MAN or AUTO and cycle the (MSS).

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.3.1.1

INSPECT FREQUENCY SELECTOR SWITCH (FSS)

Inspect the Frequency Selector Switch (FSS) for the following: a. Inspect for proper mounting. b. Inspect for loose connections. c.

Inspect for physical and heat damage.

12.4.3.1.2

TEST FREQUENCY SELECTOR SWITCH (FSS) WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT. MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS USER. To test the Frequency Selector Switch (FSS), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 (12) (13) NOTE 1:

Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels. When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Using a multimeter set to OHMS (Ω) Rx1 scale, test for continuity in switch positions specified. Multimeter should indicate zero ohms at points marked in chart as shown in Table 12.4.3.1.2-1. c.

Multimeter should indicate infinite ohms at all open contacts as shown in Table 12.4.3.1.2-1.

d. Replace the Frequency Selector Switch (FSS) if it fails any of the above requirements. TABLE 12.4.3.1.2-1

FREQUENCY SELECTOR SWITCH (FSS) FREQUENCY SELECTOR SWITCH (FSS) SWITCH POSITION TERMINALS 2 & 3 60 HERTZ 50 HERTZ X

12.4.3.1.3

REMOVE FREQUENCY SELECTOR SWITCH (FSS)

To remove the Frequency Selector Switch (FSS), proceed as follows a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.3.1.2. b. Remove the 2-switch bracket retaining screws. c.

Remove the front switch-retaining nut.

d. Remove the Frequency Selector Switch (FSS) from rear of the bracket. e. Tag and disconnect wires on the Frequency Selector Switch (FSS). 12.4.3.1.4

INSTALL FREQUENCY SELECTOR SWITCH (FSS)

To install the Frequency Selector Switch (FSS), proceed as follows a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.3.1.2. b. Reinstall the FSS from rear of the mounting bracket, and secure with the retaining nut. c.

Reinstall wiring to the Frequency Selector Switch (FSS) and discard tags.

d. Reinstall the mounting bracket with 2 retaining screws. e. Close the Master Control Panel (MCP) door.

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AUTOMATIC SYNCHRONIZER (SPMA)

The following maintenance procedures are provided for the Automatic Synchronizer (SPMA): Inspect Test Remove Install

FIGURE 12.4.3.2-1

AUTOMATIC SYNCHRONIZER (SPMA)

This solid-state device provides the automatic speed-matching synchronizing of its associated generator. The Automatic Synchronizer (SPMA) will either increase the engine speed or decrease engine speed in order to speed-match with the bus. There are two units provided, one for each generator. They are installed on the insider of the center door.

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INSPECT AUTOMATIC SYNCHRONIZER (SPMA)

Inspect the Automatic Synchronizer (SPMA) for the following: a. Inspect for proper mounting. b. Inspect for loose connections. c.

Inspect for physical and heat damage.

12.4.3.2.2

TEST AUTOMATIC SYNCHRONIZER (SPMA)

To test the Automatic Synchronizer (SPMA), proceed as follows: Refer to the Woodard SPM-A Synchronizer Manual, 82384R, Chapter 4, Calibration and checkout procedures. 12.4.3.2.3

REMOVE AUTOMATIC SYNCHRONIZER (SPMA) WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT. MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS USER. To remove the Automatic Synchronizer (SPMA), proceed as follows a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2)

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1.

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Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels. When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Tag and disconnect the wiring from the Automatic Synchronizer (SPMA). Refer to FO-18. c.

Remove the four mounting bolts and remove the Automatic Synchronizer (SPMA) from the cabinet.

12.4.3.2.4

INSTALL AUTOMATIC SYNCHRONIZER (SPMA)

To install the Automatic Synchronizer (SPMA), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.3.2.3. b. Reinstall the Automatic Synchronizer (SPMA) from rear of the control panel, and secure with retaining nuts. c.

Reinstall wiring to the Automatic Synchronizer (SPMA) and discard tags.

d. Calibrate the Automatic Synchronizer (SPMA) using instructions found in the Woodard SPM-A Synchronizer Manual, 82384R for Chapter 4, Calibration and checkout procedures.

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LOAD SHARING MODULE (LSM)

The following maintenance procedures are provided for the Load Sharing Module (LSM): Inspect Test Remove Install

FIGURE 12.4.3.3-1

LOAD SHARING MODULE

There are two units provided, one for each generator. They are installed on the inside of the center door. The load-sharing module receives input from current transformers (CT) and potential transformers (PT), to calculate power from the generator, assuming constant voltage. It generates an output that biases the speed reference of the speed control. The load-sharing module uses paralleling lines to ensure proportional load sharing with other generators that are isochronously paralleled. Refer to FO-18 for LSM wiring diagram.

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INSPECT LOAD SHARING MODULE (LSM)

Inspect the Load Sharing Module (LSM) for the following: a. Inspect for proper mounting. b. Inspect for loose connections. c.

Inspect for physical and heat damage.

12.4.3.3.2

TEST LOAD SHARING MODULE (LSM)

To test the Load Sharing Module (LSM), proceed as follows: See Caterpillar SENR6565-02, SMCS Code: 4490-035, or later version for the most current procedures. SENR6565-02 is broken into two separate manuals. For this LSM refer to RENR2471-01.

NOTE: 12.4.3.3.3

REMOVE LOAD SHARING MODULE (LSM) WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT. MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS USER. To remove the Load Sharing Module (LSM), proceed as follows a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2) (3)

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker.

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Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels. When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Tag and disconnect the wiring from the Load Sharing Module (LSM). Refer to FO-18. c.

Remove the four mounting bolts and remove the Load Sharing Module (LSM) from the cabinet.

12.4.3.3.4

INSTALL LOAD SHARING MODULE (LSM)

To install the Load Sharing Module (LSM), proceed as follows a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.3.3.3. b. Reinstall the Load Sharing Module (LSM) from rear of the control panel, and secure with retaining nuts. c.

Reinstall wiring to the Load Sharing Module (LSM) and discard tags.

d. Calibrate the Load Sharing Module (LSM) using instructions found in See Caterpillar SENR656502, SMCS Code: 4490, or later version for the most current procedures.

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REMOTE TERMINAL UNIT (RTU)

The following maintenance procedures are provided for the Remote Terminal Unit (RTU): Inspect Test Remove Install: •

RTU



RTU Software

FIGURE 12.4.3.4-1

REMOTE TERMINAL UNIT (RTU)

This microprocessor based controller and its associated input/output modules are located on the center section swing out sub panel. The Remote Terminal Unit (RTU) provides the control logic for automatic operation. Additionally, it retrieves all operating parameters from both GSC + modules on the PU and provides the networked controlling between MEP-PU-810s. During Manual operations the Remote Terminal Unit (RTU) only provides monitoring capability. During automatic operations, however, the Remote Terminal Unit (RTU) provides all the control algorithms for the various control routines within the PU system. It also allows the ORT to function with the PU(s).

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Each Remote Terminal Unit (RTU) has a Power LED, and a status LED that indicates configuration and communication status by blinking in different ways.



Every on-board discrete I/O channel is isolated from logic circuitry and from any expansion I/O modules for fault-free operation. WARNING EXPLOSION HAZARD – WHEN IN HAZARDOUS LOCATIONS, DISCONNECT POWER BEFORE REPLACING OR WIRING MODULES.

12.4.3.4.1

INSPECT REMOTE TERMINAL UNIT (RTU)

Inspect the Remote Terminal Unit (RTU) for the following: a. Inspect for proper mounting. b. Inspect for loose connections. c.

Inspect for physical and heat damage.

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TEST REMOTE TERMINAL UNIT (RTU)

To test the Remote Terminal Unit (RTU), proceed as follows: Refer to Table 12.4.3.4.2-1 and Sixnet, Versa TRAK, Remote Terminal Units, Installation and Maintenance Manual, Section 10, Dated September 1998 or later. TABLE 12.4.3.4.2-1 DIAGNOSTICS LOCAL DIAGNOSTICS VERATRAK STATUS LED SIXTRAK I/O STATUS LED ON OFF LONG BLINK .75 SECONDS ON, .25 SECONDS OFF SHORT BLINK .25 SECONDS ON, .75 SECONDS OFF WINKING 10 BLINKS/SECOND

RTU MEMORY

RTU BATTERY

RTU MAINTENANCE INFORMATION MAINTENANCE INFORMATION INFORMATION Local diagnostics can be performed through any available port while the versatrak is responding to messages from other ports. Diagnostic software, such as Ioview and I/O TOOLKIT, can be used to display the status of the I/O registers. The “Status” LED on a Versa TRAK should be ON continuously within 3 seconds of power up. The “Status” LED on each SIXTRAK expansion I/O module may be observed in one of five states: The module is configured properly and communicating with the RTU. There is no power to the module, or the status LED is being turned off intentionally by Plant Floor during the module linking operation. Long blinking indicates one of two conditions. Either the module has lost its communication with the RTU for more than 10 seconds, or the module has not received configuration data from the RTU. Upon initial system startup (no configuration in the RTU) this should be the observed LED state on each module, Short blinking indicates a failure of the module self test upon power up. A Status LED may be winked by the Plant Floor utility to bring attention to the module. This winking occurs during module linking procedure. Refer to the online help in Plant Floor for more information. The Versa TRAK RTU has nonvolatile (battery-free) memory for storing configuration data from the Plant Floor utility. They also have batterybacked memory for storage of program variables and logged data. The battery is a rechargeable lithium cell that is kept fresh by the power circuitry in the RTU. The memory retention time will be shorter at higher temperatures. The life expectancy of the lithium battery is approximately 10 years. The RTU battery will remain charged for no longer than 1 year while in storage. To ensure battery-backed memory storage of programmed variables the battery must be recharged periodically. See service procedures in Chapter 6.

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REMOVE REMOTE TERMINAL UNIT (RTU) WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT. MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS USER. To remove the Remote Terminal Unit (RTU), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) NOTE 1:

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels. When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Tag and disconnect the wiring from the Remote Terminal Unit (RTU).

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 c. Remove the four mounting screws and remove the Remote Terminal Unit (RTU) from the cabinet. 12.4.3.4.4

INSTALL REMOTE TERMINAL UNIT (RTU)

To install the Remote Terminal Unit (RTU), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.3.4.3. b. Reinstall the Remote Terminal Unit (RTU) on the control panel, and secure with retaining screws.. c.

Reinstall wiring to the Remote Terminal Unit (RTU) and discard tags.

d. Place DC Control Power Circuit Breaker to ON. e. Reinstall the RTU software. Follow the procedures listed in Section 12.4.3.4.4.1:

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INSTALL RTU SOFTWARE (NEW INSTALL)

To install the RTU software, proceed as follows: This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: 1. 2. 3. 4. 5. 6. 7 8. 9. 10.

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. Place all Circuit Breakers in the LOCK OUT position. The (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network. Turn “ON” the ORT. At the login enter the following: a. Username: Administrator b. Password: dpgds (case sensitive) Start IO Toolkit by double-clicking on the IO Toolkit icon. Refer to Figure 12.4.3.4.4.1-1 for reference.

FIGURE 12.4.3.4.4.1-1

IO TOOLKIT ICON

a. From the Main Menu select “Device”, then “Select”.

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FIGURE 12.4.3.4.4.1-2

DEVICE SCREEN

b. Select the “Use comm port” radio button. This sets up the ORT to communicate with the RTU via the serial port.

FIGURE 12.4.3.4.4.1-3

USE COMM PORT SCREEN

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 11. Prepare PDC a. Place SMS switch in the OFF position. b. Place both ECS switches in the OFF/RESET position. c. Turn on DC power on the PDC. 12. Connect the computer to the RTU a. Connect the Null Modem/Gender Changer (located in the ORT case) into the male end of the DB9 connector of the serial cable located in the ORT case (See Figure 12.4.3.4.4.1-5). b. Plug one end of the serial cable to the computer’s serial port and the other into the RTU’s Plant Floor port (See location in Figure 12.4.3.4-1). 13. Delete existing files a. Select “pdc1” from the Station Names on the Stations tab of the main window.

FIGURE 12.4.3.4.4.1-4

PDC 1 SCREEN

b. From the Main Menu select “Operations”, then “File Operations”.

FIGURE 12.4.3.4.4.1-5

NULL MODEM/GENDER CHANGER

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FIGURE 12.4.3.4.4.1-6 c.

FILE OPERATIONS SCREEN

Observe window displaying file contents of RTU.

FIGURE 12.4.3.4.4.1-7

RTU CONTENTS SCREEN

d. Select the “isa11.x6m” file.

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FIGURE 12.4.3.4.4.1-8

ISA11.X6M SCREEN

e. Click the “Delete” button to delete the file. f. Acknowledge “Yes” when prompted.

FIGURE 12.4.3.4.4.1-9

DELETE FILE SCREEN

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 g. Observe the isa.x6m file is deleted.

FIGURE 12.4.3.4.4.1-10

FILE DELETED SCREEN

h. When the files clears from the window, select the “Action.6TL” file.

FIGURE 12.4.3.4.4.1-11

ACTION. 6TL SCREEN

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Click the “Clear” button to clear the file. Acknowledge “Yes” when prompted.

FIGURE 12.4.3.4.4.1-12 k.

CLEAR ACTION TABLE SCREEN

When the file size is 0, click “Close”.

FIGURE 12.4.3.4.4.1-13

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CLOSE SCREEN

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

From the Main Menu select “Operations”, then “Advanced Operations”, “Clear Configuration”.

FIGURE 12.4.3.4.4.1-14

OPERATIONS SCREEN

m. Acknowledge Yes on the “Direct Control” pop-up.

FIGURE 12.4.3.4.4.1-15

DIRECT CONTROL SCREEN

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 n. Acknowledge Yes on the “Clear Configuration” pop-up.

FIGURE 12.4.3.4.4.1-16

CLEAR CONFIGURATION SCREEN 1

o. Observe the “Clear Configuration” status pop-up.

FIGURE 12.4.3.4.4.1-17

CLEAR CONFIGURATION SCREEN 2

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 p. Observe the proper completion of the Station Configuration cleared as indicated in the IO Toolkit status window (lower left hand corner of the screen).

FIGURE 12.4.3.4.4.1-18

STATION CONFIGURATION SCREEN

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 14. Firmware Update a. From the Main Menu select “Operations”, then “Advanced Operations”, then “Read Firmware Version”.

FIGURE 12.4.3.4.4.1-19

ADVANCED OPERTIONS SCREEN

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 b. If version is 2.23X, then skip to step 15 – Configuration Update, otherwise continue.

FIGURE 12.4.3.4.4.1-20 c.

FIRMWARE VERSION SCREEN

From the Main Menu select “Operations”, then “Load”, “Load Now”.

FIGURE 12.4.3.4.4.1-21

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LOAD NOW SCREEN

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 d. Observe the loading progression.

FIGURE 12.4.3.4.4.1-22

LOADING PROGRESSION SCREEN

e. From the Main Menu select “Operations”, then “Advanced Operations”, “Upgrade Firmware”.

FIGURE 12.4.3.4.4.1-23

UPGRADE FIRMWARE SCREEN

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Acknowledge “Yes” on the Direct Connect screen.

FIGURE 12.4.3.4.4.1-24

DIRECT CONNECT SCREEN

g. Navigate to C:\....\PLC_Files, select the “STPR223X.6FW” file.

FIGURE 12.4.3.4.4.1-25

SELECT FIRMWARE SCREEN

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 h. Click “OK”. i. Observe progression (approx. 5 minutes).

FIGURE 12.4.3.4.4.1-26 j.

LOADING FIRMWARE SCREEN

Observe the “Firmware load complete” in the lower status window.

FIGURE 12.4.3.4.4.1-27

FIRMWARE LOAD COMPLETE SCREEN

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 15. Configuration Update a. From the Main Menu select “Configure”, then “Configure Station/Module”.

FIGURE 12.4.3.4.4.1-28

CONFIGURE STATION SCREEN

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 b. Select the “Advanced” tab.

FIGURE 12.4.3.4.4.1-29 c.

ADVANCED TAB SCREEN

Click on “Assign Resources” button.

FIGURE 12.4.3.4.4.1-30

ASSIGN RESOURCES SCREEN

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 d. Verify the File System memory allocation is 512 Kbytes. e. Click on “Set Memory”

FIGURE 12.4.3.4.4.1-31

SET MEMORY SCREEN

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 f. Acknowledge “OK” to any pop-up windows. g. Verify you receive a “Memory matches” message in green text beneath the action buttons.

FIGURE 12.4.3.4.4.1-32

RESOURCE ALLOCATION SCREEN

h. Click “OK” once completed to close window. i. Click “OK” to close “Sixtrak/VERSAtrak Configuration” window. 16. Load new files a. From the Main Menu select “Operations”, then “Link”.

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FIGURE 12.4.3.4.4.1-33

OPERATION/LINK SCREEN

b. Follow the linking instructions on the screen to link the input and output modules.

FIGURE 12.4.3.4.4.1-34

LINKING INSTRUCTION SCREEN

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When all modules have been assigned, click the “Apply” button.

FIGURE 12.4.3.4.4.1-35

MODULES ASSIGNED SCREEN

d. Observe the progression.

FIGURE 12.4.3.4.4.1-36

MODULE PROGRESSION SCREEN

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FIGURE 12.4.3.4.4.1-37 f.

LINKING COMPLETE SCREEN 1

Click “OK”.

FIGURE 12.4.3.4.4.1-38

LINKING COMPLETE SCREEN 2

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 g. From the Main Menu select “Operations”, then “File Operations”.

FIGURE 12.4.3.4.4.1-39

FILE OPERATIONS SCREEN

h. Click the “Load Isagraf” button.

FIGURE 12.4.3.4.4.1-40

LOAD ISAGRAF SCREEN

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Acknowledge “Yes” when prompted.

FIGURE 12.4.3.4.4.1-41 j.

ISAGRAF PROGRAM SCREEN

Select the “Appli.X6M” file.

FIGURE 12.4.3.4.4.1-42

APPLI.X6M FILE SCREEN

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Click the “Open” button. Observe the progression.

FIGURE 12.4.3.4.4.1-43

LOADING APPLI.X6M FILE SCREEN

m. Click the “Close” button.

FIGURE 12.4.3.4.4.1-44

APPLI.X6M FILE COMPLETE SCREEN

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 n. Close IO Toolkit, do not save changes. 17. Check RTU loading a. Cycle DC power. b. Insure SMS switch is in the OFF position. c. Place both ECS switches in the AUTO position. d. “Red flag” both generator BCS switches. e. Place the SMS switch in the AUTO position. f. Observe both green ready lights on SSL energize. g. Return the SMS to the OFF position. h. Return both ECS switches to the OFF/RESET position. i. Turn off DC power. j. Disconnect the serial cable from the RTU. k. Place the RTU software/firmware sticker horizontally on the lower right side of the RTU.

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MODULAR DIN RAIL (I/O)

The following maintenance procedures are provided for the Modular DIN Rail (I/O): Inspect Test Remove Install

FIGURE 12.4.3.5-1

MODULAR DIN RAIL I/O DIM 1, DIM 2, DIM 3, DOM 1, DOM 2

MODULAR DIN RAIL I/O BASE

FIGURE 12.4.3.5-2

MODULAR DIN RAIL I/O BASE

See Figure 12.4.3.5-1 and Figure 12.4.3.5-2 for reference. The DIM and DOM modules provide direct wiring to all devices within the PU controlled by the microprocessor based controller (RTU).

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INSPECT MODULAR DIN RAIL (I/O)

Inspect the Modular DIN Rail (I/O) for the following: a. Inspect for proper mounting. b. Inspect for loose connections. c.

Inspect for physical and heat damage.

12.4.3.5.2

TEST MODULAR DIN RAIL (I/O)

To test the Modular DIN Rail (I/O), proceed as follows: Refer to the Sixnet, SixTrak, Modular DIN Rail I/O, Installation and Maintenance Manual, Section 10, Dated September 1998 or later. TABLE 12.4.3.5.2-1 DIAGNOSTICS LOCAL DIAGNOSTICS

I/O MAINTENANCE INFORMATION MAINTENANCE INFORMATION INFORMATION Local Diagnostics can be performed through any available port while the RTU is responding to messages from the other port. Diagnostic software, such as I/Oview and I/O Toolkit, can be used to display the status of the I/O registers. The “Status” LED on each module may be observed in one of five states: ON: The module is configured properly and communicating with the RTU. OFF: There is no power to the module, or the status LED is being turned off intentionally by I/O Toolkit during the module linking operation.

STATUS LED

LONG BLINK .75 SECONDS ON, .25 SECONDS OFF: Long blinking indicates one of two conditions. Either the module has lost its communication with the RTU for more than 10 seconds, or the module has not received configuration data from the RTU. Upon initial system startup (no configuration in the RTU) this should be the observed LED state on each module, SHORT BLINK .25 SECONDS ON, .75 SECONDS OFF: Short blinking indicates a failure of the module self test upon power up. WINKING 10 BLINKS/SECOND: A Status LED may be winked by the I/O Toolkit utility to bring attention to the module. This winking occurs during module linking procedure. Refer to the online help in I/O Toolkit for more information.

HOT SWAP FEATURE

I/O modules may be unplugged from their bases, even in live systems. SixTrak I/O modules automatically self-configure from system memory.

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REMOVE MODULAR DIN RAIL (I/O) WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT. MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS USER. To remove the Modular DIN Rail (I/O), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) NOTE 1:

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels. When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Squeeze the center of the Modular DIN Rail I/O and pull the relay free of the base.

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INSTALL MODULAR DIN RAIL (I/O)

To install the Modular DIN Rail (I/O), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.3.5.3. Squeeze the center of the Modular DIN Rail I/O and Reinstall the relay into of the base. This can be performed while the DC Control circuit breaker is on.

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HUB

The following maintenance procedures are provided for the HUB: Inspect Test Remove Install

FIGURE 12.4.3.6-1

HUB

See Figure 12.4.3.6-1 for reference. These micro-hubs provide the networking capability used by the th PU’s and the ORT. The hubs can be either a 9-port unit with the 5 port being used for up linking to another PU or a five-port unit. This device is located in the center section on the swing out sub panel. 12.4.3.6.1

INSPECT HUB

Inspect the HUB for the following: a. Inspect for proper mounting. b. Inspect for loose connections. c.

Inspect for physical and heat damage.

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TEST HUB

a. There is no field-testing on the HUB. b. The HUB performs internal diagnostics during start up. c.

Ensure that the power light is on.

d. Check power supply to the HUB, if there is 24VDC present and the green power light is not illuminated, replace the HUB. Refer to FO-23 for reference. 12.4.3.6.3

REMOVE HUB WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT. MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS USER. To remove the HUB, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9)

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks.

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Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels. When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Tag and disconnect the wiring from the HUB. c.

Release the latch on the bottom of the hub with a small screwdriver by pushing down and then pulling the hub up and out from the Modular Din Rail.

12.4.3.6.4

INSTALL HUB

To install the (HUB), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.3.6.3. b. Reinstall the HUB into the control panel by sliding into the Modular Din Rail and pushing down to engage the locking tab. c.

Reinstall wiring to the HUB. Remove tags.

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PROTOCOL COMMUNICATION MODULE (PCM)

The following maintenance procedures are provided for the Protocol Communication Module (PCM): Inspect Test Remove Install

PROTOCOL COMMUNICATION MODULE (PCM)

FIGURE 12.4.3.7-1

PCM LOCATION

This micro-controller constantly polls the Caterpillar CCM for the parameters required by the control system. These parameters are then converted from their Caterpillar M5X protocol to Modbus addresses and stored on board for access by the RTU. This device is located in the center section swingout subpan. It is installed below the CCM. 12.4.3.7.1

INSPECT PROTOCOL COMMUNICATION MODULE (PCM)

Inspect the Protocol Communication Module (PCM) for the following: a. Inspect for proper mounting. b. Inspect for loose connections. c.

Inspect for physical and heat damage.

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TEST PROTOCOL COMMUNICATION MODULE (PCM)

To test the Protocol Communication Module (PCM), proceed as follows: a. Check that the Uplink Port LEDS “ACT/LNK – 10/100” are flashing on the RTU. b. Check with a multi-meter on the VDC scale, at pins J2 “DCIN” and “GRD” for 15VDC. Refer to FO-21 more information. c.

The Protocol Communication Module (PCM) translates the M5X CAT protocol that is transferred by the Customer Communication Module (CCM) through the DB25 connector, into MODBUS PLC Language.

d. Check that both LED’s “4” and “6” of the Customer Communication Module are flashing, indicating that data is being transmitted and received by the Protocol Communication Module (PCM). Refer to Illustration 3, SMCS Code 1926 “Display Description”, of the “Operation Section” in the Operation and Maintenance Manual “SEBU6874-04”, March 2000, for more information. e. The Remote Terminal Unit (RTU) receives the MODBUS PLC Language from the Customer Communication Module (CCM) through the DB9 connector that is connected to the RTU’s main port connector. NOTE 1:

12.4.3.7.3

The PCM battery is not utilized for this configuration. However, if the battery has a short, the PCM will cease to function. REMOVE PROTOCOL COMMUNICATION MODULE (PCM) WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT. MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS USER.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 To remove the Protocol Communication Module (PCM), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) NOTE 1:

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels. When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Tag and disconnect the wiring from the PCM. c.

Remove the mounting bolts and remove the PCM from the cabinet.

12.4.3.7.4

INSTALL PROTOCOL COMMUNICATION MODULE (PCM)

To install the Protocol Communication Module (PCM), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.3.7.3. b. Reinstall the Protocol Communication Module (PCM) from the control panel, and secure with retaining nuts. c.

Reinstall wiring to the Protocol Communication Module (PCM) and discard tags.

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CUSTOMER COMMUNICATION MODULE (CCM)

The following maintenance procedures are provided for the Customer Communication Module (CCM): Inspect Test Remove Install Service

CUSTOMER COMMUNICATION MODULE (CCM)

FIGURE 12.4.3.8-1

CUSTOMER COMMUNICATION MODULE

This Caterpillar device provides a two-way communication link between the electronic controller (generator set) and a host device (PCM). This component is installed on the center section swing-out sub panel (See Figure 12.4.3.7-1 and Figure 12.4.3.8-1). 12.4.3.8.1

INSPECT CUSTOMER COMMUNICATION MODULE (CCM)

Inspect the Customer Communication Module (CCM) for the following: a. Inspect for proper mounting. b. Inspect for loose connections. c.

Inspect for physical and heat damage.

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TEST CUSTOMER COMMUNICATION MODULE (CCM)

To test the Customer Communication Module (CCM), proceed as follows: a. This device performs a self-diagnostic test each time it is energized. b. For troubleshooting instructions, see SEBU6874-04 or later version, SCMS CODE: 1926. 12.4.3.8.3

REMOVE CUSTOMER COMMUNICATION MODULE (CCM) WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT. MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS USER. To remove the Customer Communication Module (CCM), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13)

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels.

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When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Tag and disconnect the wiring from the Customer Communication Module (CCM). c.

Remove the mounting bolts and remove the Customer Communication Module (CCM) from the cabinet.

12.4.3.8.4

INSTALL CUSTOMER COMMUNICATION MODULE (CCM)

To install the Customer Communication Module (CCM), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 12.4.3.8.3. b. Reinstall the Customer Communication Module (CCM) from the control panel, and secure with retaining nuts. c.

Reinstall wiring to the Customer Communication Module (CCM) and discard tags.

12.4.3.8.5

SERVICE CUSTOMER COMMUNICATION MODULE (CCM)

a. The CCM contains a 101-1 785 Battery that supplies power for internal memory whenever the CCM is powered-down. In single unit installations, the CCM power is OFF whenever the GSC+ power is OFF. The battery has an expected life of five years. The battery is mounted to the inside of the front plate of the CCM behind the three-digit display. b. Replacing the CCM Battery (1)

Remove the four screws securing the front plate to the housing.

(2)

The battery is held in place by two small tabs on the upper and lower side of the battery. A tie-wrap provides additional support.

(3)

Remove the tie-wrap.

(4)

With a small screwdriver, carefully pry one tab and lift that side of the battery slightly.

(5)

Repeat for the other tabs and remove the battery.

(6)

Carefully press the replacement battery into holder until tabs are securing the battery.

(7) (8)

The battery has one corner that is angled to make sure proper polarity is maintained during installation. Make sure the battery pins are entering the sockets of the holder properly.

(9)

Install the new tie-wrap.

(10)

Reinstall the front plate of the CCM.

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POWER CONVERTER

12.4.3.9.1

POWER CONVERTER (P15)

The following maintenance procedures are provided for the Power Converter (P15): Inspect Test Remove Install

FIGURE 12.4.3.9.1-1

POWER CONVERTER (P15)

This device converts 24VDC to 15VDC for use by the micro-hub. It is located on the center section swing out sub panel.

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INSPECT POWER CONVERTER (P15)

Inspect the Power Converter (P15) for the following: a. Inspect for proper mounting. b. Inspect for loose connections. c.

Inspect for physical and heat damage.

12.4.3.9.1.2

TEST POWER CONVERTER P15

To test the Power Converter (P15), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) NOTE 1:

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels. When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. With a multimeter in the VDC mode, check the Input and Output voltage terminals. Input should read 24VDC and the output should read 15VDC. 12.4.3.9.1.3

REMOVE POWER CONVERTER (P15) WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 WARNING DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM FAILURE TO OBSERVE THIS WARNING. WARNING WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT. MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS USER. To remove the Power Converter P15, proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) NOTE 1:

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Isolate the PU from any power plant control system in accordance with Note 1. Pull to open the PU DC Power Control Breaker. Push to open both Emergency Stop Switches. Place both Engine Control Switches (ECS) in the OFF position. Place a DO NOT OPERATE tag on both generator control panels. Turn the Battery Bank Parallel Switch to the OFF position. De-energize both Battery Chargers. Disconnect the negative and positive cables from both Battery Banks. Place a DO NOT OPERATE tag on both Battery Banks. Place all Circuit Breakers in the LOCK OUT position. Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. Close and Lock both generator set control panels. When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.

b. Tag and disconnect the wiring from the (P15). c.

Release the locking tab on the bottom of the Power Converter with a small screwdriver, push up and remove the assembly from the Modular Din Rail.

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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 12.4.3.9.1.4

INSTALL POWER CONVERTER P15

To install the Power Converter (P15), proceed as follows: a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. b. Reinstall the Power Converter (P15) on the control panel by sliding into the Modular Din Rail and pushing down to engage the locking tab. c.

Reinstall wiring to the Power Converter (P15), and discard tags.

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