TM 9-6115-484-14 MEP-PU-810A/B PART 6

February 7, 2018 | Author: Advocate | Category: Mechanical Fan, Bearing (Mechanical), Pump, Valve, Waste Management
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USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254

FIGURE 18.3.2.6.1-2

SUPPORT AND SPIDER BUSHING LUBRICATION POINTS

Lubricate the Support and Spider Bushings (both sides) with NLGI Grade 2 grease through the Zerk fittings using Figure 18.3.2.6.1-2 as reference. For camshaft roller journals and anchor pins: Lubricate with high temperature anti-seize grease

18-35

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 18.3.2.6.2

HUB LUBRICATION

a. Check oil level in the Wheel Hub Site Glass. Ensure oil level is at the full mark. Add oil if required by removing the rubber oil cap and filling through the opening in the site glass. Refer to Annex G for type of oil. b. Recommended Lubrication: See Annex G for Specifications. 18.3.2.6.3

SERVICE BEARINGS WARNING

DO NOT MIX LITHIUM, CALCIUM, SODIUM OR BARIUM COMPLEX GREASES DUE TO POSSIBLE COMPATIBILITY PROBLEMS. WHEN CHANGING FROM ONE TYPE OF GREASE TO ANOTHER, IT IS NECESSARY TO ENSURE ALL THE OLD GREASE HAS BEEN REMOVED. The following schedule is appropriate: a. Replace grease annually. b. Prior to repacking bearings, all old grease should be removed from the wheel hub cavity and bearings. c.

Bearings should be packed by machine if possible.

d. If a machine is unavailable, packing by hand method is acceptable, using the following method: (1) Place a quantity of grease onto the palm of your hand. (2) Press a section of the widest end of bearing into the outer edge of the grease pile closest to the thumb forcing grease into the interior of the bearing between two adjacent rollers. (3) Repeat this while rotating the bearing from roller to roller. (4) Continue this process until you have the entire bearing completely filled with grease. (5) Before reinstalling, apply a light coat of grease onto the bearing cup mating surface.

18-36

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 18.3.2.6.4

LANDING GEAR ASSEMBLY LUBRICATION

FIGURE 18.3.2.6.4-1

ZERK FITTINGS (GREASE POINTS)

a. Two lubrication points are located on each landing leg. They must be lubricated every 90 days. Zerk fittings are installed to facilitate lubrication use Figure 18.3.2.6.4-1 as reference. b. The retractable landing legs require a medium coating of general-purpose grease, apply as necessary. c.

Recommended Grease: See Appendix G for Specifications.

18-37

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

THIS PAGE INTENTIONALLY BLANK

18-38

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

CHAPTER 19 HYDRAULIC SYSTEM REPAIR TABLE OF CONTENTS SECTION

TITLE

PAGE

19.0

HYDRAULIC SYSTEM REPAIR

6

19.1

SAFETY INSTRUCTIONS

6

19.2

HYDRAULIC SYSTEM DESCRIPTION

9

19.2.1

HYDRAULIC FLUID RESERVOIR

9

19.2.2

HYDRAULIC SYSTEM PUMP

13

19.2.3

PRESSURE RELIEF/CONTROL BLOCK AND PRESSURE GAUGES

14

19.2.4

HYDRAULIC SYSTEM FAN MOTORS

16

19.2.5

HYDRAULIC SYSTEM COOLER

17

19.3

SERVICE REQUIREMENTS FOR HYDRAULIC SYSTEM

18

19.3.1

SERVICE THE RETURN-LINE FILTER, STRAINER, AND HYDRAULIC FLUID

18

19.3.1.1

REPLACING THE FILTER ELEMENT

20

19.3.1.2

CHANGING HYDRAULIC FLUID, VENT CAP, CLEANING THE STRAINERS

23

19.4

COMPONENT REPAIR PROCEDURES

26

19.4.1

PRESSURE RELIEF/CONTROL BLOCK

26

19.4.1.1

INSPECTING PRESSURE RELIEF/CONTROL BLOCK

27

19.4.1.2

REMOVE PRESSURE RELIEF/CONTROL BLOCK

28

19.4.1.3

INSTALL PRESSURE RELIEF/CONTROL BLOCK

29

19.4.2

HYDRAULIC PUMP

30

19.4.2.1

INSPECT HYDRAULIC PUMP

30

19.4.2.2

REMOVE HYDRAULIC PUMP

31

19.4.2.3

INSTALL HYDRAULIC PUMP

32

19.4.3

RADIATOR HYDRAULIC MOTOR

34

19.4.3.1

INSPECT RADIATOR HYDRAULIC MOTOR

34

19.4.3.2

REMOVE RADIATOR HYDRAULIC MOTOR

35

19.4.3.3

INSTALL RADIATOR-HYDRAULIC MOTOR

36

19.4.4

AIR TO AIR AFTER COOLER (ATAAC) HYDRAULIC MOTOR

38

19.4.4.1

INSPECT AIR TO AIR AFTER COOLER (ATAAC) MOTOR

38

19.4.4.2

REMOVE AIR TO AIR AFTER COOLER (ATAAC) HYDRAULIC MOTOR

39

19.4.4.3

INSTALL AIR TO AIR AFTER COOLER (ATAAC) MOTOR

40

19.4.5

ENGINE COMPARTMENT VENT-HYDRAULIC MOTOR

41

19-1

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.5.1

INSPECT ENGINE COMPARTMENT VENT-HYDRAULIC MOTOR

41

19.4.5.2

REMOVE ENGINE COMPARTMENT VENT-HYDRAULIC MOTOR

42

19.4.5.3

INSTALL ENGINE COMPARTMENT VENT-HYDRAULIC MOTOR

43

19.4.6

RADIATOR-MOTOR FAN ASSEMBLY

44

19.4.6.1

INSPECT RADIATOR-MOTOR FAN ASSEMBLY

45

19.4.6.2

REMOVE RADIATOR-MOTOR FAN ASSEMBLY

45

19.4.6.3

INSTALL RADIATOR-MOTOR FAN ASSEMBLY

46

19.4.7

AFTER COOLER-MOTOR FAN ASSEMBLY

47

19.4.7.1

INSPECT AFTER COOLER-MOTOR FAN ASSEMBLY

47

19.4.7.2

REMOVE AFTER COOLER-MOTOR FAN ASSEMBLY

48

19.4.7.3

INSTALL AFTER COOLER-MOTOR FAN ASSEMBLY

49

19.4.8

ENGINE COMPARTMENT VENT-MOTOR FAN ASSEMBLY

50

19.4.8.1

INSPECT ENGINE COMPARTMENT VENT-MOTOR FAN ASSEMBLY

51

19.4.8.2

REMOVE ENGINE COMPARTMENT VENT-MOTOR FAN ASSEMBLY

51

19.4.8.3

INSTALL ENGINE COMPARTMENT VENT-MOTOR FAN ASSEMBLY

52

19.4.9

RADIATOR-MOTOR FAN BLADES

53

19.4.9.1

REMOVE RADIATOR-MOTOR FAN BLADES

54

19.4.9.2

INSTALL RADIATOR-MOTOR FAN BLADES

56

19.4.10

AFTER COOLER-MOTOR FAN BLADES

58

19.4.10.1

REMOVE AND INSTALL AFTER COOLER-MOTOR FAN BLADES

59

19.4.11

ENGINE COMPARTMENT VENT-MOTOR FAN BLADES

60

19.4.11.1

REMOVE AND INSTALL ENGINE COMPARTMENT VENT-MOTOR FAN BLADES

60

19.4.12

HYDRAULIC TANK LOW LEVEL SHUTDOWN SWITCH (HTLL)

61

19.4.12.1

TEST HYDRAULIC TANK LOW LEVEL SHUTDOWN SWITCH (HTLL)

61

19.4.12.2

REMOVE HYDRAULIC TANK LOW LEVEL SHUTDOWN SWITCH (HTLL)

63

19.4.12.3

INSTALL HYDRAULIC TANK LOW LEVEL SHUTDOWN SWITCH (HTLL)

66

19-2

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 19.2-1 HYDRAULIC SYSTEM SCHEMATIC

9

FIGURE 19.2.1-1

HYDRAULIC FLUID RESERVOIR

10

FIGURE 19.2.1-2

HYDRAULIC TANK

11

FIGURE 19.2.1-3

FLUID LEVEL/TEMPERATURE SIGHT GAUGE

11

FIGURE 19.2.1-4

HYDRAULIC TANK SHUTOFF VALVE

12

FIGURE 19.2.2-1

HYDRAULIC SYSTEM PUMP

13

FIGURE 19.2.3-1

PRESSURE RELIEF/CONTROL BLOCK DIAGRAM

14

FIGURE 19.2.3-2

PRESSURE RELIEF/CONTROL BLOCK

15

FIGURE 19.2.3-3

HYDRAULIC SYSTEM PRESSURE GAUGES

15

FIGURE 19.2.4-1

HYDRAULIC SYSTEM FAN MOTORS

16

FIGURE 19.2.5-1

HYDRAULIC SYSTEM COOLER

17

FIGURE 19.3.1.1-1

FILTER CAP, FILL HOLE, AND JIC FILL PORT

20

FIGURE 19.3.1.1-2

FILTER CAP AND BYPASS ASSEMBLY

21

FIGURE 19.3.1.1-3

FILTER CAP ASSEMBLY WITH O-RING AND BYPASS

21

FIGURE 19.3.1.1-4

3-MICRON ABSOLUTE HYDRAULIC FILTER

22

FIGURE 19.3.1.1-5

HYDRAULIC FILTER GASKET

22

FIGURE 19.3.1.2-1

TANK ACCESS COVER AND VENT CAP

24

FIGURE 19.3.1.2-2

TANK ACCESS COVER O-RING

24

FIGURE 19.3.1.2-3

100-MESH STRAINER (141 MICRON)

25

FIGURE 19.3.1.2-4

JIC FILL PORT

25

FIGURE 19.4.1-1

PRESSURE RELIEF/CONTROL BLOCK

26

FIGURE 19.4.2-1

HYDRAULIC PUMP

30

FIGURE 19.4.2-2

HYDRAULIC PUMP, O-RING, FLANGE, AND GASKET

32

FIGURE 19.4.3-1

RADIATOR HYDRAULIC MOTOR

34

FIGURE 19.4.3.2-1

RADIATOR / AIR TO AIR AFTER COOLER (ATAAC) COMPARTMENT

36

FIGURE 19.4.4-1

AFTER COOLER HYDRAULIC MOTOR

38

FIGURE 19.4.5-1

ENGINE COMPARTMENT VENT-HYDRAULIC MOTOR

41

FIGURE 19.4.6-1

MOUNTING AND UN-MOUNTING HOLES

44

FIGURE 19.4.6-2

SHAFT MOUNTING HUB

44

FIGURE 19.4.7-1

MOUNTING AND UN-MOUNTING HOLES

47

FIGURE 19.4.8-1

MOUNTING AND UN-MOUNTING HOLES

50

FIGURE 19.4.8-2

SHAFT MOUNTING HUB

50

FIGURE 19.4.9-1

RADIATOR FAN HUB DISASSEMBLY

53

19-3

FIGURE 19.4.9.1-1

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 RADIATOR FAN ASSEMBLY (TOP HALF REMOVED) 54

FIGURE 19.4.9.1-2

RADIATOR FAN ASSEMBLY (BOTTOM HALF WITH KEEPER INSTALLED) 54

FIGURE 19.4.9.2-1

FAN BLADE WITH FAN PITCH

56

FIGURE 19.4.9.2-2

RADIATOR FAN ASSEMBLY (TOP HALF MATED WITH BOTTOM HALF)

56

FIGURE 19.4.10-1

AFTERCOOLER FAN HUB DISASSEMBLY

58

FIGURE 19.4.10.1-1 AFTERCOOLER FAN ASSEMBLY (TOP HALF REMOVED)

59

FIGURE 19.4.10.1-2 AFTERCOOLER FAN ASSEMBLY (BOTTOM HALF W/ KEEPER INSTALLED)59 FIGURE 19.4.11-1

VENT FAN HUB DISASSEMBLY

60

FIGURE 19.4.11.1–1 VENT FAN ASSEMBLY (BOTTOM HALF WITH KEEPER INSTALLED)

60

FIGURE 19.4.11.1-2 FAN BLADE WITH FAN PITCH

61

FIGURE 19.4.12.2-1 TANK ACCESS COVER

63

FIGURE 19.4.12.2-2 TANK ACCESS COVER O-RING

63

FIGURE 19.4.12.2-3 HTLL SWITCH DEUTSCH CONNECTOR

64

19-4

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 19.4.12.1-1

HTLL SWITCH CONTACT POSITIONS

19-5

62

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.0

HYDRAULIC SYSTEM REPAIR

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

Filter



Strainer



Fluid



Control Block



Hydraulic Pump



Hydraulic Motors



Fan Hub Assemblies



Fan Blade Assemblies



Hydraulic Tank Low Level Shutdown Switch (HTLL)

19.1

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)

Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. Push to OPEN the Emergency Stop Switch.

19-6

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

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.

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.

NOTE 4:

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.

19-7

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 e. Material safety information: Composition and Information on Ingredients: This information is not formulated to contain ingredients, which have exposure limits established by U.S. agencies. It is not hazardous to health as defined by the European Union Dangerous Substance/Preparation Directives. Hazards Identification: (1) US OSHA HAZARDS COMMUNICATION STANDARDS: Product assessed in accordance with OSHA 29 CFR 1910.1200 and determined not to be hazardous. (2) EFFECT OF OVEREXPOSURE: No significant effect expected. (3) EMERGENCY RESPONSE DATA: Amber liquid. DOT REG No.-NA. f.

First aid measures: (1) EYE CONTACT: Flush thoroughly with cool water. If irritation occurs, call a physician. (2) SKIN CONTACT: Wash contact areas with soap and water. High-pressure accidental injection through the skin requires immediate attention for incision and/or debridgment. (3) INHALATION: Not expected to be a problem. (4) INGESTION: Not expected to be a problem. However, if greater than ½ liter (pint) is ingested, immediately give 1 to 2 glasses of water and call a physician, hospital emergency room or poison control center for assistance. Do not induce vomiting or give anything by mouth to an unconscious person. (5) EXPOSURE LIMITS: This product does not contain any components that have recognized exposure limits. However, an exposure limit of 5.00 mg/m3 is suggested for oil mist.

g. Fire fighting measures: (1) EXTINGUISHING MEDIA: Carbon dioxide, foam, dry chemical, and water fog. (2) SPECIAL FIRE FIGHTING PROCEDURES: Water or foam may cause frothing. Use water to keep fire exposed containers cool. Water spray may be used to flush spills away from exposure. Prevent runoff from fire control or dilution from entering streams, sewers, or drinking water supply. (3) UNUSUAL FIRE AND EXPLOSION HAZARDS: None. Flash point 176ºC, 349ºF. (4) ASTM D-92: Flammable limits-LEL-NA. UEL-NA. (5) NFPA HAZARD ID: Health-0. Flammability-1. Reactivity-0. (6) HAZARDOUS DECOMPOSITION PRODUCTS: Carbon Monoxide. h. Disposal considerations: (1) WASTE DISPOSAL: The product is suitable for burning in an enclosed, controlled burner for fuel value or disposal by supervised incineration. Such burning may be limited to the Recovery Conservation and Recovery Act (RCRA). In addition, the product is suitable for processing by an approved recycling facility or can be disposed of at an appropriate government waste disposal facility. Use of these methods is subject to user compliance with applicable laws and regulations and consideration of product characteristics at time of disposal. (2) RCRA INFORMATION: The unused product, in our opinion, is not specifically listed by the EPA as a hazard waste (40CFR, Part261D), nor is it formulated to contain materials which are listed hazardous waste. It does not exhibit the hazardous characteristics of ignitability, corrosivity, or reactivity and is not formulated with contaminants as determined by the Toxicity Characteristic Leaching Procedures (TCLP). However used product may be regulated.

19-8

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.2

HYDRAULIC SYSTEM DESCRIPTION

Figure 19.2-1 illustrates the Hydraulic System Schematic. The hydraulic system used in Power Unit provides the required power to cool the Power Unit. An engine mounted hydraulic gear pump takes lowpressure hydraulic fluid from the reservoir, through one 100-mesh strainer (141 Micron) with a 3 PSI bypass mounted inside the tank, and provides high-pressure fluid to the hydraulic fan motors that drive the system. The high-pressure fluid from the hydraulic pumps is then forced through a Pressure Relief/Control Block, which contains a 3,200 + 100-PSI pressure relief valve. From the control block the high-pressure fluid is transferred through the hydraulic motors, which drive the cooling fans. After the fluid passes through the hydraulic motors, the low-pressure fluid is then carried through a hydraulic fluid heat exchanger. The cycle is completed when the fluid returns to the reservoir, through the tank top 3micron absolute filter. The case drain on the After Cooler Motor allows hydraulic fluid, from the seal cavity in the motor, to drain back to the reservoir at atmospheric pressure.

FIGURE 19.2-1 19.2.1

HYDRAULIC SYSTEM SCHEMATIC

HYDRAULIC FLUID RESERVOIR

a. Figure 19.2.1-1 and Figure 19.2.1-2 illustrate the Hydraulic Fluid Reservoir. The 18-gallon reservoir has an internal strainer; a top mounted 3- micron absolute hydraulic filter, and vent cap. The reservoir also has two top mounted fill ports, a 25 PSI bypass setting and Filter Differential Gauge.

19-9

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

The reservoir is not pressurized. It is very important that the reservoir is filled through the top of the Filter or through the 1” JIC Fill-Port, see Figure 19.2.1-2 for reference.

b. Adding Hydraulic Fluid from the top of the filter assembly or JIC Fill-Port will ensure that contaminants are not introduced into the system. Keep the fluid level between the red and black lines on the sight gauge (See Figure 19.2.1-3) and do not overfill. This will ensure that the Air Vent Cap is kept open and the reservoir does not overflow. The reservoir also includes a Hydraulic Tank Low Level (HTLL) shutdown switch installed in the back of the reservoir, which is activated at 33% fluid remaining. This switch is wired to the GSC+ and the Hydraulic Tank Low Level Light (HTLLL) (Red LED) on the Generator Control Panel. When activated, it will automatically shut down the generator set and illuminate the HTLLL. Refer to fold out FO-12A and FO-12B for the schematic wiring of the switch and light. The reservoir also has a fluid shutoff valve, located in the rear of the Hydraulic Reservoir, where the fluid line is connected (See Figure 19.2.1-4). These valves are held open during normal operation. NOTE: c.

Prior to disconnecting any hose from a component of the system, the valves must be closed to prevent draining the reservoir. For hose connections, refer to Hose Connection Drawings FO-45, FO-46 and FO-47.

FIGURE 19.2.1-1

HYDRAULIC FLUID RESERVOIR

19-10

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

JIC FILL PORT DIFFERENTIAL GAUGE

TANK BREATHER

SIGHT GLASS

FIGURE 19.2.1-2

HYDRAULIC TANK

FULL LEVEL

FIGURE 19.2.1-3

FLUID LEVEL/TEMPERATURE SIGHT GAUGE

19-11

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

Fluid Level should be centered within the sight gauge inspection window. Under normal operating conditions, the hydraulic fluid (being measured by this site gauge) temperature should not exceed 150 ºF. The temperature gauge is important to determine the ambient temperature (prior to plant start up) in order to ensure that the correct type of hydraulic fluid is being used. Refer to Annex G for the required hydraulic fluid in regards to seasonal ambient temperature.

FIGURE 19.2.1-4

HYDRAULIC TANK SHUTOFF VALVE

19-12

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.2.2

HYDRAULIC SYSTEM PUMP

Figure 19.2.2-1 illustrates the Hydraulic System Pump. The hydraulic pump is a positive displacement pump. This means that the pump delivers a constant flow rate at a constant RPM. The engine’s front accessory drive gears drive the pump. The pump rotates at 2,160 RPM, when the engine speed is 1,800 RPM. At this speed, the pump will deliver approximately 17.05 gallons per minute optimum flow. The pump delivers high-pressure fluid, through the control block, to the radiator cooling fan motor, to the engine air after-cooler fan motor, and the area ventilation motor. See Figure 19.2-1 for additional information.

HYDRAULIC PUMP

FIGURE 19.2.2-1

HYDRAULIC SYSTEM PUMP

19-13

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.2.3

PRESSURE RELIEF/CONTROL BLOCK AND PRESSURE GAUGES

Figure 19.2.3-1 illustrates the Pressure Relief/Control Block Diagram. Figure 19.2.3-2 illustrates the actual Pressure Relief/Control Block. The Pressure Relief/Control Block includes one high-pressure input (P1), two high-pressure outputs for the fan circuits (A1, A2), one low pressure return line (T), one relief valve (RV), that is factory set to relieve the system pressure at 3,200 ± 100 PSI to ensure that the positive displacement pump is not damaged, if there is a blockage in the system, and a low flow unloading valve (UV) that bypasses the fan circuits when the pump flow rate is less than 4 GPM. This provides a soft pump start feature before the engine reaches rated RPM during start up. The Pressure Relief/Control Block also has two pressure gauge connections (G1, G2). G1 measures the pressure on the Air-Vent Circuit and G2 measures the pressure on the Radiator Circuit. Figure 19.2.3-3 illustrates the Hydraulic System Pressure Gauges. The pressure gauges are mounted on the Engine Filter Differential Gauge Panel. The Radiator Circuit pressure gauge reads between 2,100 and 3,100 PSI, during normal operations. The Air-Vent pressure gauge reads between 2,300 and 3,100 PSI, during normal steady-state operations. The hydraulic gauges are 0 – 5000 PSI rated liquid filled gauges for anti-vibration and long life.

FIGURE 19.2.3-1

PRESSURE RELIEF/CONTROL BLOCK DIAGRAM

19-14

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 A2 A1 G2 UV RV P1 G1 T

FIGURE 19.2.3-2

FIGURE 19.2.3-3

PRESSURE RELIEF/CONTROL BLOCK

HYDRAULIC SYSTEM PRESSURE GAUGES

19-15

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.2.4

HYDRAULIC SYSTEM FAN MOTORS

Figure 19.2.4-1 illustrates the Hydraulic System Fan Motors. The hydraulic gear motors are also fixed displacement. This means that the motors will operate at a constant RPM under a constant flow rate. The high-pressure fluid delivered by the pumps drives the motors. There are three motors per cooling system: Radiator Coolant, After Cooler, and Ventilation Fan Motors. These motors are part of two separate circuits. One circuit is for the Radiator Cooling Motor only. The other includes both the After Cooler and Ventilation Fan Motors in series. All cooling motors operate between 1,750 and 2,400 RPM.

ENGINE COMPARTMENT VENT MOTOR

RADIATOR HYDRAULIC MOTOR

ATAAC HYDRAULIC MOTOR

FIGURE 19.2.4-1

HYDRAULIC SYSTEM FAN MOTORS

19-16

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.2.5

HYDRAULIC SYSTEM COOLER

Figure 19.2.5-1 illustrates the Hydraulic System Cooler. The Hydraulic System is equipped with a hydraulic-oil heat exchanger, which cools the fluid prior to the fluid returning to the reservoir. It is located in the engine coolant side of the radiator assembly. The air inlet side of the Air to Air After Cooler (ATAAC) should be blown out at the same time the air filter is changed. Under particularly dusty conditions, daily cleaning may be necessary.

HYDRAULIC SYSTEM COOLER

FIGURE 19.2.5-1

HYDRAULIC SYSTEM COOLER

19-17

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.3

SERVICE REQUIREMENTS FOR HYDRAULIC SYSTEM

19.3.1

SERVICE THE RETURN-LINE FILTER, STRAINER, AND HYDRAULIC FLUID WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING HYDRAULIC FLUID PRESSURES CAN REACH 3,000 PSI WHILE THE PU IS OPERATING. DO NOT TOUCH ANY SUSPECTED LEAKS OF THE HYDRAULIC SYSTEM. SERIOUS INJURIES COULD OCCUR TO UNPROTECTED SKIN OR EYES. CAUTION DO NOT OVERFILL THE HYDRAULIC SUMP. KEEP THE FLUID LEVEL BETWEEN THE RED AND BLACK LINES ON THE SIGHT GAUGE. IF THE TANK IS TOO FULL, IT COULD CAUSE AN OVER FLOW SITUATION. 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. CAUTION HYDRAULIC FLUIDS MAY BE HOT

a. This maintenance 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)

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.

19-18

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

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.

b. The Hydraulic System: incorporates an In-tank fluid strainer, (Figure 19.3.1.2-3), and an In-tank return line filter (Figure 19.3.1.1-4). The In-tank Return Line Filter is located inside the hydraulic filter assembly at the top of the reservoir. The In-tank Return Line Filter has a color-coded pressure differential gauge, (Figure 19.2.1-2), on the side. This Differential Pressure Gauge is used to determine In-tank Return Line Filter replacement time. The Return-Line Filter also has a bypass built into the housing (Figure 19.3.1.1-3). This bypass is set to 25 PSI and will open when the pressure drop across the element exceeds 25 PSI. The Return-Line Filter is designed to have a very low pressure drop when new and at operating temperatures. As contaminants collect on the element’s surface, the pressure drop across it increases. c.

When to Service: You should replace the filter when the indicating gauge reads 20 PSI (top of green area) and the pressure should be checked at normal operating pressure. Checking the filter during cold start up will result in substantially higher readings than at normal operating temperatures. The reason for changing the filter at 20 PSI rather than 25 PSI (bypass setting) is to make sure the filter does not go into bypass, allowing fluid to return unfiltered. •

Replace: the Return-Line Filter and O-ring after every 8,000 hours of use, during any complete fluid change or every 12 months. This must be done even if the indicator gauge is in the green (below 20 PSI).



Inspect: the new Return-Line Filter element for any damage; prior to installation see Figure 19.3.1.1-4. The 100-mesh strainer (141 Micron) must be removed and cleaned annually. Inspect the strainer for any damage, prior to installation. The reason for having a 100-mesh (141 Micron) strainer and a 3-micron filter in the hydraulic system is to take out microscopic contaminants. The size particles this filter element removes are smaller than the human eye can see. Caution must be taken during the cleaning and replacement process not to introduce any contaminates into the system. The strainer must be removed and cleaned every time the hydraulic fluid is changed and the hydraulic fluid should be changed every 16,000 hours, or 3 years. Yearly hydraulic fluid samples should be taken and analyzed to determine fluid contamination levels. Complete fluid change may increase based on analysis findings.

19-19

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.3.1.1

REPLACING THE FILTER ELEMENT

Replace Filter every 8,000 hours of use or annually. a. Clean the area around the In-tank Return Line Filter Assembly of contaminants that could fall into the tank, during change out. You should also have a clean work area for components and elements. b. Unscrew the four mounting bolts holding the filter cap, rotate filter cap counter clockwise and remove the cap (see Figures 19.3.1.1-1 and 19.3.1.1-2 for reference). c.

Inspect the filter cap for nicks or signs of damage. Reuse if acceptable, replace if necessary (see Figure 19.3.1.1-3).

d. Discard the old O-ring and replace with new e. Remove the In-tank Return Line Filter from the housing (see Figure 19.3.1.1-4 for reference). NOTE: The solid basket remains in the filter housing. f.

Lubricate the rubber gasket on each end of the new filter with hydraulic fluid and place the filter into the basket and housing (see Figure 19.3.1.1-5).

g. Reinstall the filter cap and tighten the four bolts in an alternating fashion. Tighten each bolt in a 3-step progression. First hand tighten. Then torque each bolt to 11 ± 2 Ft-Lbs. Then torque each bolt to 22 ± 2 Ft-Lbs.

FIGURE 19.3.1.1-1

FILTER CAP, FILL HOLE, AND JIC FILL PORT

19-20

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

FIGURE 19.3.1.1-2

FILTER CAP AND BYPASS ASSEMBLY

O-RING BYPASS

FIGURE 19.3.1.1-3

FILTER CAP ASSEMBLY WITH O-RING AND BYPASS

19-21

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

FIGURE 19.3.1.1-4

3-MICRON ABSOLUTE HYDRAULIC FILTER

FIGURE 19.3.1.1-5

HYDRAULIC FILTER GASKET

19-22

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.3.1.2

CHANGING HYDRAULIC FLUID, VENT CAP, CLEANING THE STRAINERS

Replace the Hydraulic Fluid and clean the internal strainers every 16,000 hours or three years, sooner if yearly sampling indicates fluid contamination. a. Start engine until the hydraulic fluid reaches normal operating temperature, then shutdown the generator set. Do not allow fluid to cool. b. Remove the Drain Plug in the bottom of the Hydraulic Reservoir; see Figure 19.2.1-1 for reference. c.

Drain fluid into an appropriate container (20 gal).

d. Clean and reinstall the Hydraulic Reservoir Drain Plug. e. Remove the eight ¼-20 bolts from the Hydraulic Reservoir Access Cover, attached to the vent cap. See Figure 19.4.12.2-1 for reference. Remove the cover and O-ring f.

Unscrew the 100-mesh (141 Micron) strainer from inside the tank. Take care not to damage the strainer during removal, see Figure 19.3.1.2-3 for reference.

g. Clean the strainer thoroughly and reinstall it the Hydraulic Reservoir. Hand tighten only, do not use a wrench. h. Discard the old O-ring and reinstall a new one. See Figure 19.3.1.2-2 i.

Reinstall the Hydraulic Reservoir Access Cover and torque the eight 1/4" bolts to 10 ± 2 lb ft, see Figure 19.4.12.2-1 for reference.

j.

Unscrew the Vent Cap and install a new Vent Cap every time the hydraulic filter is changed, see Figure 19.3.1.2-1 for reference.

k.

Gravity-fill clean, filtered hydraulic fluid (approx. 18 gallons) into the reservoir through the In-tank Return Line Filter Assembly Fill Port or through the 1” JIC Fill Port, see Figure 19.2.1-2 for reference.

19-23

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

FIGURE 19.3.1.2-1

FIGURE 19.3.1.2-2

TANK ACCESS COVER AND VENT CAP

TANK ACCESS COVER O-RING

19-24

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

100-MESH STRAINER

FIGURE 19.3.1.2-3

100-MESH STRAINER (141 MICRON)

JIC FILL PORT

FIGURE 19.3.1.2-4

19-25

JIC FILL PORT

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4

COMPONENT REPAIR PROCEDURES

19.4.1

PRESSURE RELIEF/CONTROL BLOCK

The following maintenance procedures are provided for the Pressure Relief/Control Block: Inspect Remove Install

FIGURE 19.4.1-1

PRESSURE RELIEF/CONTROL BLOCK

19-26

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.1.1

INSPECTING PRESSURE RELIEF/CONTROL BLOCK

To inspect the Pressure Relief/Control Block using Figure 19.4.1-1, 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) (11) NOTE:

c.

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. 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.

Prior to starting the Power Unit, inspect the engine compartment for any hydraulic fluid leaks. Correct any leaks as necessary.

d. Check the Hydraulic Fluid level and add fluid as necessary. e. Start the Power Unit according to Chapter 5. Allow the Power Unit to reach operating temperature and shutdown the Power Unit according to Chapter 5. f.

Check under the Power Unit for any hydraulic fluid leaks. Correct any leaks as necessary.

g. Check the Pressure Relief/Control Block for leaks, missing or loose hardware.

19-27

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.1.2

REMOVE PRESSURE RELIEF/CONTROL BLOCK

To remove the Pressure Relief/Control Block using Figure 19.4.1-1, proceed as follows: a. This maintenance 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.

b. Close the Hydraulic Fluid Shutoff Valve. See Figure 19.2.1-4 for reference. c.

Tag the 6 input and output hoses for proper reinstallation.

d. Disconnect the 6 input and output hoses. See Figure 19.4.1-1 for reference. NOTE:

Use proper procedures to collect any hydraulic fluid left in the hoses to prevent spills.

e. Remove the Pressure Relief/Control Block mounting bolts and lift the Pressure Relief/Control Block from the engine.

19-28

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.1.3

INSTALL PRESSURE RELIEF/CONTROL BLOCK

To install the Pressure Relief/Control Block perform the following: a. This maintenance 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. See procedures in paragraph 19.4.1.2. b. Reinstall the Pressure Relief/Control Block and reinstall the Pressure Relief/Control Block mounting bolts. Torque the mounting bolts to 30 + 5 Ft-Lbs. c.

Reinstall and torque the hydraulic hoses according to specifications found in Caterpillar Manual SENR3130-6 or later version.

d. Remove hydraulic hose tags. e. Refill the hydraulic system according to procedures found in Section 19.3.1.2. NOTE: f.

Use proper procedures to collect any hydraulic fluid left in the hoses to prevent spills. Open the Hydraulic Fluid Shut Off Valve. Secure the valve handle in the open position.

g. Prepare the PU to be started. All lockout and tag-out, tags must be removed. h. Inspect the Hydraulic System starting at Section 19.4.1 and ending at Section 19.4.12. i.

Start the Power Unit and allow it to reach operating temperature.

j.

Shut-down the Power Unit and inspect the hydraulic system starting at Section 19.4.1 and ending at Section 19.4.12.

k.

The unit is now ready to operate.

19-29

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.2

HYDRAULIC PUMP

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

HYDRAULIC PUMP

FIGURE 19.4.2-1 19.4.2.1

HYDRAULIC PUMP

INSPECT HYDRAULIC PUMP

To inspect the Hydraulic Pump use Figure 19.4.2-1 as reference, proceed as follows: a. Prior to starting the Power Unit, inspect the engine compartment for any hydraulic fluid leaks. Correct any leaks as necessary.

19-30

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 b. Check the hydraulic fluid level and add fluid as necessary. c.

Start the Power Unit according to Chapter 5. Allow the Power Unit to reach operating temperature and shutdown the Power Unit according to Chapter 5.

d. Check under the PU for any hydraulic fluid leaks. Correct any leaks as necessary. e. Check the Hydraulic Pump for leaks, missing or loose hardware. Note: See Figure 19.4.2-2. The hydraulic pump internal cavity between the adapter plate and pump mounting surface gets hot and must breathe (vent to the outside). As a result, small bubbles can form on the outer surface of the adapter plate or pump mounting surface. This is normal and is not an oil seep or leak. 19.4.2.2

REMOVE HYDRAULIC PUMP

To remove the Hydraulic Pumps, perform the following: a. This maintenance 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.

b. Close the Hydraulic Fluid Shutoff Valve. See Figure 19.2.1-4 for reference.

19-31

c.

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 Tag the two input and output hoses for proper replacement.

d. Disconnect the two input and output hoses. See Figure 19.4.2-1 for reference. Use proper procedures to collect any hydraulic fluid left in the hoses to prevent spills.

NOTE:

e. Remove the two pump mounting bolts and lift the pump from the engine. The procedure is the same for either an inboard or outboard hydraulic pump.

NOTE: f.

Remove and discard old gasket material from the pump and engine surfaces.

g. Remove flange and O-ring, Inspect O-ring for damage and replace as necessary.

GASKET

FLANGE

HYDRAULIC PUMP

ENGINE HOUSING

FIGURE 19.4.2-2 19.4.2.3

O-RING

HYDRAULIC PUMP, O-RING, FLANGE, AND GASKET

INSTALL HYDRAULIC PUMP

To install the Hydraulic Pump perform the following: a. This maintenance 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. See procedures in paragraph 19.4.2.2. b. Install a new gasket for the pump. NOTE: c.

Do Not use the old gasket use a new gasket. Coat both contact surfaces of the new gasket with appropriate Gasket Sealant following manufacturer’s instructions. Install flange and O-ring, Apply clean engine oil to the new O-ring and ensure seal is not damaged or pinched during installation. See Figure 19.4.2-2 for reference.

NOTE: The adapter has a beveled edge. The beveled edge of the adapter must face towards the pump.

19-32

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 d. Reinstall the pump assembly and reinstall the two, pump mounting bolts. Torque the pump mounting bolts mounting bolts to 75 + 5 Ft-Lbs. e. Reinstall and torque the hydraulic hoses according to specifications found in Table 7, Torques for flared and O-Ring fittings, Caterpillar Manual SENR3130. f.

Tighten the spring clamps to 16 ± 2 in. lbs

g. Remove the hose tags. NOTE:

Use proper procedures to collect any hydraulic fluid left in the hoses to prevent spills.

h. Refill the hydraulic system according to procedures found in Section 19.3.1.2. i.

Open the Hydraulic Fluid Shut Off Valve. Secure the valve handle in the open position.

j.

Prepare the PU to be started. All lockout and tag-out, tags must be removed.

k.

Inspect the Hydraulic System starting at Section 19.4.1 and ending at Section 19.4.12.

l.

Start the Power Unit and allow it to reach operating temperature.

m. Shut-down the Power Unit and inspect the hydraulic system starting at Section 19.4.1 and ending at Section 19.4.12. n. The unit is now ready to operate.

19-33

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.3

RADIATOR HYDRAULIC MOTOR

The following maintenance procedures are provided for the Radiator Hydraulic Motor: Inspect Remove Install

FIGURE 19.4.3-1 19.4.3.1

RADIATOR HYDRAULIC MOTOR

INSPECT RADIATOR HYDRAULIC MOTOR

To inspect the Radiator Hydraulic Motor see Figure 19.4.3-1 as reference, proceed as follows: a. Prior to starting the Power Unit, inspect the engine compartment for any hydraulic fluid leaks. Correct any leaks as necessary. b. Check the hydraulic fluid level and add fluid as necessary. c.

Start the Power Unit according to Chapter 5. Allow the Power Unit to reach operating temperature and shutdown the Power Unit according to Chapter 5.

d. Check under the Power Unit for any hydraulic fluid leaks. Correct any leaks as necessary. e. Check the Radiator Hydraulic Motor for leaks, missing or loose hardware.

19-34

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.3.2

REMOVE RADIATOR HYDRAULIC MOTOR

To remove the Radiator-Hydraulic Motor, perform the following: a. This maintenance 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.

b. Remove the Front Side Panel from the PU. See Figure 19.4.3.2-1 for reference.

19-35

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

FIGURE 19.4.3.2-1

RADIATOR / AIR TO AIR AFTER COOLER (ATAAC) COMPARTMENT

c.

Remove the Radiator Fan Motor Access panel.

c.

Close the Hydraulic Fluid Shutoff Valves. See Figure 19.2.1-4 for reference.

d. Tag the input and output hoses for proper replacement. See Figure 19.4.3-1 for reference. e. Disconnect the input and output hoses. Use proper procedures to collect any hydraulic fluid left in the hoses to prevent spills.

NOTE: f.

Remove the Radiator-Hydraulic Motor Fan Assembly. See Section 19.4.6.2 for reference.

g. Remove the two motor mounting bolts and lift the motor off of its mounting bracket. 19.4.3.3

INSTALL RADIATOR-HYDRAULIC MOTOR

To install the Radiator-Hydraulic Motor, perform the following: a. This maintenance 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. See procedures in paragraph 19.4.3.2. b. Place the motor back on the mounting bracket and reinstall the mounting bolts. Torque the 3/8” bolts to 35 + 7 Ft-Lbs per Caterpillar SENR3130, Torque Specifications. c.

Reinstall the Radiator-Hydraulic Motor Fan Assembly see Section 19.4.6.3 for reference.

19-36

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 d. Reinstall the input and output hoses and torque the hydraulic fittings according to specifications found in Table 7, (Torques for flared and O-Ring fittings), Caterpillar Manual SENR3130. Torque the 3/4” input hose fitting to 37 + 5 ft. lbs, and 5/8” output fitting to 26 + 4 Ft-Lbs. e. Reinstall the Radiator and ATAAC access covers. See Figure 19.4.3.2-1 for reference. f.

Reinstall the Front Side Panel from the Power Unit. See Figure 19.4.3.2-1 for reference.

g. Refill the Hydraulic System. See Section 19.3.1.2 for procedures. h. Prepare the Power Unit to be started. All lockout and tag-out tags must be removed, the battery bank reconnected. i.

Inspect the Hydraulic System starting at Section 19.4.1 and ending at Section 19.4.12.

j.

Open the Hydraulic Fluid Shut Off Valves. Secure the valve handles in the open position.

k.

Start the Power Unit and allow it to reach operating temperature.

l.

Shut-down the Power Unit and inspect the hydraulic system starting at Section 19.4.1 and ending at Section 19.4.12.

m. The unit is now ready to operate.

19-37

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.4

AIR TO AIR AFTER COOLER (ATAAC) HYDRAULIC MOTOR

The following maintenance procedures are provided for the ATAAC Hydraulic Motor: Inspect Remove Install

FIGURE 19.4.4-1 19.4.4.1

AFTER COOLER HYDRAULIC MOTOR

INSPECT AIR TO AIR AFTER COOLER (ATAAC) MOTOR

To inspect the Air to Air After Cooler-Hydraulic Motor, proceed as follows: a. Prior to starting the PU, check the engine compartment for any hydraulic fluid leaks. Correct any leaks as necessary. b. Check the hydraulic fluid level and add fluid as necessary. c.

Start the Power Unit according to Chapter 5. Allow the Power Unit to reach operating temperature and shutdown the Power Unit according to Chapter 5.

d. Check under the Power Unit for any hydraulic fluid leaks. Correct any leaks as necessary. e. Check the Air to Air After Cooler-Hydraulic Motor for leaks, missing or loose hardware.

19-38

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.4.2

REMOVE AIR TO AIR AFTER COOLER (ATAAC) HYDRAULIC MOTOR

To remove the Air to Air After Cooler-Hydraulic Motor, perform the following: a. This maintenance 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.

b. Remove the Front Side Panel from the PU. See Figure 19.4.3.2-1 for reference. c.

Remove the Radiator and ATAAC Access Covers. See Figure 19.4.3.2-1 for reference.

d. Close the Hydraulic Fluid Shutoff Valves. See Figure 19.2.1-4 for reference. CAUTION THE HYDRAULIC MOTORS FOR G1 AND G2 ATAAC ARE INSTALLED DIFFERENTLY TO ENSURE THAT THE FAN ROTATES IN THE CORRECT DIRECTION. NOTE WHICH WAY THE RELIEF PORT ON TOP OF THE MOTOR IS FACING, (FRONT OR REAR OF MOTOR AS INSTALLED). ENSURE THE NEW HYDRAULIC MOTOR IS INSTALLED IN THE SAME DIRECTION AS REMOVED. FAILURE TO OBSERVE THIS CAUTION MAY CAUSE THE FAN TO ROTATE IN THE WRONG DIRECTION.

19-39

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 e. Tag the input/output and case drain hoses for proper replacement. See Figure 19.4.4-1 for reference. f.

Disconnect the input/output and case drain hoses. See Figure 19.4.4-1 for reference. Use proper procedures to collect any hydraulic fluid left in the hoses to prevent spills.

NOTE:

g. Remove the Air to Air After Cooler-Hydraulic Motor Fan Assembly. See Section 19.4.7.2 for reference. h. Remove the two Air to Air After Cooler-Hydraulic Motor Fan Assembly mounting bolts and lift the motor off of its mounting bracket. 19.4.4.3

INSTALL AIR TO AIR AFTER COOLER (ATAAC) MOTOR

To install the Air to Air After Cooler-Hydraulic Motor, perform the following: a. This maintenance 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. See procedures in paragraph 19.4.4.2. CAUTION IF THE ATAAC HYDRAULIC FAN MOTOR IS INSTALLED INCORRECTLY THE FAN WILL ROTATE IN THE WRONG DIRECTION. ENSURE THE FAN MOTOR IS INSTALLED IN THE SAME DIRECTION AS THE ONE REMOVED (RELIEF PORT ORIENTATION). b. Reinstall the motor back on the mounting bracket and reinstall mounting bolts. Torque the 3/8” bolts to 35 + 7 Ft-Lbs per Caterpillar SENR3130, Torque Specifications. c.

Reinstall and torque the hydraulic hoses according to specifications found in Table 7, Torques for flared and O-Ring fittings, Caterpillar Manual SENR3130. Torque the 5/8” fittings to 26 + 4 Ft-Lbs Torque the 3/8” fitting to 8 + 1 Ft-Lbs. Remove hose tags.

d. Reinstall the After Cooler- Motor Fan Assembly. See Section 19.4.7.3 for reference. e. Reinstall the Radiator and ATAAC Access Covers. See Figure 19.4.3.2-1 for reference. f.

Reinstall the Front Side Panel from the Power Unit. See Figure 19.4.3.2-1 for reference.

g. Open the Hydraulic Fluid Shut Off Valves. Secure the valve handles in the open position. h. Prepare the Power Unit to be started. All lockout and tag-out, tags must be removed, and the battery bank reconnected. i.

Inspect the Hydraulic System starting at Section 19.4.1 and ending at Section 19.4.12.

j.

Start the Power Unit and allow it to reach operating temperature.

k.

Ensure the fan blades are rotating correctly (

l.

Shut-down the Power Unit and inspect the hydraulic system starting at Section 19.4.1 and ending at Section 19.4.12.

19-40

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 m. The unit is now ready to operate. 19.4.5

ENGINE COMPARTMENT VENT-HYDRAULIC MOTOR

The following maintenance procedures are provided for the Engine Compartment Vent-Hydraulic Motor: Inspect Remove Install

FIGURE 19.4.5-1 19.4.5.1

ENGINE COMPARTMENT VENT-HYDRAULIC MOTOR

INSPECT ENGINE COMPARTMENT VENT-HYDRAULIC MOTOR

To inspect the Engine Compartment Vent-Hydraulic Motor, proceed as follows: a. Prior to starting the Power Unit, check the engine compartment for any hydraulic fluid leaks. Correct any leaks as necessary. b. Check the hydraulic fluid level and add fluid as necessary. c.

Start the Power Unit according to Chapter 5. Allow the Power Unit to reach operating temperature and shutdown the Power Unit according to Chapter 5.

d. Check under the Power Unit for any hydraulic fluid leaks. Correct any leaks as necessary. e. Check the Engine Compartment Vent-Hydraulic Motor for leaks, missing or loose hardware.

19-41

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.5.2

REMOVE ENGINE COMPARTMENT VENT-HYDRAULIC MOTOR

To remove the Engine Compartment Vent-Hydraulic Motor, proceed as follows: a. This maintenance 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.

b. Remove the bolts and keeper washers from the Top Plenum Screen on the top of the Power Unit. Remove the Top Plenum Screen and Front Side Panel. See Section 8.4.1.2 and Section 8.4.2.2 for reference. c.

Close the Hydraulic Fluid Shutoff Valves. See Figure 19.2.1-4 for reference.

d. Remove the Fan Guard and Air Deflector assembly from around the motor and fan. e. Tag and Disconnect the two input and output hoses for proper replacement. See Figure 19.4.51 for reference. NOTE:

Use proper procedures to collect any hydraulic fluid left in the hoses to prevent spills.

g. Remove the Engine Compartment Vent-Motor Fan Assembly. reference.

See Section 19.4.8.2 for

h. Remove the two motor mounting bolts and then lift the motor off of its mounting bracket.

19-42

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.5.3

INSTALL ENGINE COMPARTMENT VENT-HYDRAULIC MOTOR

To install the Engine Compartment Vent-Hydraulic Motor, proceed as follows: a. This maintenance 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. See procedures in paragraph 19.4.5.2. b. Reinstall the motor back on the mounting bracket and reinstall mounting bolts. Torque the 3/8” bolts to 35 + 7 Ft-Lbs per Caterpillar SENR3130, Torque Specifications. c.

Reinstall the input and output hoses and torque the fittings according to specifications found in Table 7, Torques for flared and O-Ring fittings, Caterpillar Manual SENR3130. Torque the 1” fittings to 75 + 7 Ft-Lbs Torque the 5/8” fitting to 26 + 4 Ft-Lbs. Remove hose tags.

d. Reinstall the Engine Compartment Vent-Hydraulic Motor Fan Assembly. See Section 19.4.8.3 for reference. e. Reinstall the Fan Guard and Air Deflector assembly from around the motor and fan. f.

Reinstall the Front Side Panel from the Power Unit. See Figure 19.4.3.2-1 for reference.

g. Open the hydraulic fluid shut off valves. Secure the valve handles in the open position. h. Reinstall the PU Top Plenum Screen. i.

Prepare the Power Unit to be started. All lockout and tag-out, tags must be removed, the battery bank reconnected.

j.

Inspect the Hydraulic System starting at Section 19.4.1 and ending at Section 19.4.12.

k.

Start the Power Unit and allow it to reach operating temperature.

l.

Shut-down the Power Unit and inspect the hydraulic system starting at Section 19.4.1 and ending at Section 19.4.12.

m. The unit is now ready to operate.

19-43

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.6

RADIATOR-MOTOR FAN ASSEMBLY

The following maintenance procedures are provided for the Radiator-Motor Fan Assembly: Inspect Remove Install

FIGURE 19.4.6-1

MOUNTING AND UN-MOUNTING HOLES

FIGURE 19.4.6-2

SHAFT MOUNTING HUB

19-44

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.6.1

INSPECT RADIATOR-MOTOR FAN ASSEMBLY

To inspect the Radiator-Motor Fan Assembly, proceed as follows: a. Prior to starting the Power Unit, check the engine compartment for any hydraulic fluid leaks. Correct any leaks as necessary. b. Check the hydraulic fluid level and add fluid as necessary. c.

Start the Power Unit according to Chapter 5. Allow the Power Unit to reach operating temperature and shutdown the Power Unit according to Chapter 5.

d. Check under the Power Unit for any hydraulic fluid leaks. Correct any leaks as necessary. e. Check the Radiator-Motor Fan Assembly for leaks, missing or loose hardware. f.

Check the Radiator-Motor Fan Blades for broken fan blades, missing or loose hardware.

19.4.6.2

REMOVE RADIATOR-MOTOR FAN ASSEMBLY

To remove the Radiator-Motor Fan Assembly, proceed as follows: a. This maintenance 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. 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

19-45

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network. b. Remove the bolts and keeper washers from the Bottom Plenum Screen on the bottom of the Power Unit. Remove the Bottom Plenum Screen and Front Side Panel. See Section 8.4.1.2 and Section 8.4.2.2 for reference. c.

Close the Hydraulic Fluid Shutoff Valves. See Figure 19.2.1-4 for reference.

d. Remove the three pull-up bolts and screw them into the tapped holes in and insert them into the three un-mounting holes and tighten each screw one 360º degree turn and then move to the next screw and tighten 360º degree turn, continue until the fan assembly falls free from the shaft mounting hub. See Figure 19.4.6-1 and Figure 19.4.6-2 for reference. 19.4.6.3

INSTALL RADIATOR-MOTOR FAN ASSEMBLY

To install the Radiator-Motor Fan Assembly, proceed as follows: a. This maintenance 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. See procedures in paragraph 19.4.6.2. b. Reinstall the fan assembly onto the shaft-mounting hub with the flat side of the fan blade assembly facing down. c.

Reinstall the three mounting bolts into the unthreaded mounting holes in the fan blade hub, and insert them into the threaded holes on the shaft-mounting hub. See Figure 19.4.6-1 for reference and torque to 108 inch lbs.

d. Reinstall the Bottom Plenum Screen. e. Prepare the Power Unit to be started. All lockout and tag-out, tags must be removed, the battery bank reconnected. f.

Inspect the Hydraulic System starting at Section 19.4.1 and ending at Section 19.4.12.

g. Start the Power Unit and allow it to reach operating temperature. h. Shut-down the Power Unit and inspect the hydraulic system starting at Section 19.4.1 and ending at Section 19.4.12. i.

The unit is now ready to operate.

19-46

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.7

AFTER COOLER-MOTOR FAN ASSEMBLY

The following maintenance procedures are provided for the After Cooler Fan Assembly: Inspect Remove Install

FIGURE 19.4.7-1 19.4.7.1

MOUNTING AND UN-MOUNTING HOLES

INSPECT AFTER COOLER-MOTOR FAN ASSEMBLY

To inspect the After Cooler-Motor Fan Assembly, proceed as follows: a. Prior to starting the Power Unit, inspect the engine compartment for any hydraulic fluid leaks. Correct any leaks as necessary b. Check the hydraulic fluid level and add fluid as necessary. c.

Start the Power Unit according to Chapter 5. Allow the Power Unit to reach operating temperature and shutdown the Power Unit according to Chapter 5.

d. Check under the Power Unit for any hydraulic fluid leaks. Correct any leaks as necessary. e. Check the After Cooler-Motor Fan Assembly for leaks, missing or loose hardware. f.

Check the After Cooler-Motor Fan Blades for broken fan blades, missing or loose hardware.

19-47

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.7.2

REMOVE AFTER COOLER-MOTOR FAN ASSEMBLY

To remove the After Cooler-Motor Fan Assembly, proceed as follows: a. This maintenance 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.

b. Remove the bolts and keeper washers from the Bottom Plenum Screen on the bottom of the Power Unit. Remove the Bottom Plenum Screen and Front Side Panel. See Section 8.4.1.2 and Section 8.4.2.2 for reference. c.

Remove the PU Top Plenum Screen.

d. Close the Hydraulic Fluid Shutoff Valves. See Figure 19.2.1-4 for reference. e. Remove the three pull-up bolts and screw them into the tapped holes in and insert them into the three un-mounting holes and tighten each screw one 360º degree turn and then move to the next screw and tighten 360º degree turn, continue until the fan assembly falls free from the shaft mounting hub. See Figure 19.4.7-1 for reference.

19-48

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.7.3

INSTALL AFTER COOLER-MOTOR FAN ASSEMBLY

To install the After Cooler-Motor Fan Assembly, proceed as follows: a. This maintenance 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. See procedures in paragraph 19.4.7.2. b. Reinstall the fan assembly onto the shaft-mounting hub with the flat side of the fan blade assembly facing down. c.

Reinstall the three mounting bolts into the unthreaded mounting holes in the fan blade hub, and insert them into the threaded holes on the shaft-mounting hub. See Figure 19.4.6-1 for reference and torque to 108 inch lbs.

d. Reinstall the Bottom Plenum Screen. e. Open the hydraulic fluid shut-off valves and Secure handles. f.

Reinstall the PU Top Plenum Screen.

g. Prepare the Power Unit to be started. All lockout and tag-out, tags must be removed, the battery bank reconnected. h. Inspect the Hydraulic System starting at Section 19.4.1 and ending at Section 19.4.12. i.

Start the Power Unit and allow it to reach operating temperature.

j.

Shut-down the Power Unit and inspect the hydraulic system starting at Section 19.4.1 and ending at Section 19.4.12.

k.

The unit is now ready to operate.

19-49

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.8

ENGINE COMPARTMENT VENT-MOTOR FAN ASSEMBLY

The following maintenance procedures are provided for the Engine Compartment Vent-Motor Fan Assembly: Inspect Remove Install

MOUNTING UNTHREADED HOLE

UN-MOUNTING THREADED HOLE

FIGURE 19.4.8-1

MOUNTING AND UN-MOUNTING HOLES

FIGURE 19.4.8-2

SHAFT MOUNTING HUB

19-50

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.8.1

INSPECT ENGINE COMPARTMENT VENT-MOTOR FAN ASSEMBLY

To inspect the Engine Compartment Vent-Motor Fan Assembly, proceed as follows: a. Prior to starting the Power Unit, check the engine compartment for any hydraulic fluid leaks. Correct any leaks as necessary. b. Check the hydraulic fluid level and add fluid as necessary. c.

Start the Power Unit according to Chapter 5. Allow the Power Unit to reach operating temperature and shutdown the Power Unit according to Chapter 5.

d. Check under the Power Unit for any hydraulic fluid leaks. Correct any leaks as necessary. e. Check the Engine Compartment Vent-Motor Fan Assembly for leaks, missing or loose hardware. f.

Check the Engine Compartment Vent-Motor Fan blades for broken fan blades, missing or loose hardware.

19.4.8.2

REMOVE ENGINE COMPARTMENT VENT-MOTOR FAN ASSEMBLY

To remove the Engine Compartment Vent-Motor Fan Assembly, proceed as follows: a. This maintenance 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

19-51

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network. b. Remove the bolts and keeper washers from the Top Plenum Screen on the Top of the Power Unit. Remove the Top Plenum Screen and Front Side Panel. See Section 8.4.1.2 and Section 8.4.2.2 for reference. c.

Remove the Air Deflector Assembly.

d. Remove the three mounting allen-head machine screws and insert them into the three unmounting holes and tighten each screw one 360º turn and then move to the next screw and tighten 360º turn, continue until the fan assembly pulls free from the shaft mounting hub. See Figure 19.4.8.2-1 and Figure 19.4.8.2-2 for reference. 19.4.8.3

INSTALL ENGINE COMPARTMENT VENT-MOTOR FAN ASSEMBLY

To install the Engine Compartment Vent-Motor Fan Assembly, proceed as follows: a. This maintenance 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. See procedures in paragraph 19.4.8.2. b. Reinstall the fan assembly onto the shaft-mounting hub with the flat side of the fan assembly facing the Radiator Assembly. c.

Reinstall the three mounting bolts into the unthreaded mounting holes in the fan blade hub, and insert them into the threaded holes on the shaft-mounting hub. See Figure 19.4.8-1 for reference and torque to 60 inch lbs.

d. Reinstall the Air Deflector Assembly. e. Prepare the Power Unit to be started. All lockout and tag-out, tags must be removed, the battery bank reconnected. f.

Inspect the Hydraulic System starting at Section 19.4.1 and ending at Section 19.4.12.

g. Start the Power Unit and allow it to reach operating temperature. h. Shut-down the Power Unit and inspect the hydraulic system starting at Section 19.4.1 and ending at Section 19.4.12. i.

The unit is now ready to operate.

19-52

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.9

RADIATOR-MOTOR FAN BLADES

The following maintenance procedures are provided for the Radiator-Motor Fan Blades: Remove Install

FIGURE 19.4.9-1

RADIATOR FAN HUB DISASSEMBLY

19-53

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.9.1 NOTE:

REMOVE RADIATOR-MOTOR FAN BLADES Care must be taken to keep track of the location of the flat washers removed during this process and during assembly the washers must be returned to the same place. The washers are used to balance the Fan Hub assembly.

FIGURE 19.4.9.1-1

RADIATOR FAN ASSEMBLY (TOP HALF REMOVED)

PLASTIC KEEPER

FIGURE 19.4.9.1-2

RADIATOR FAN ASSEMBLY (BOTTOM HALF WITH KEEPER INSTALLED)

To remove the Radiator-Motor Fan Blades, proceed as follows: a. This maintenance 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. See procedures in paragraph 19.4.8.2. b. Remove the Radiator-Motor Fan Assembly. See Section 19.4.6.2 for reference.

19-54

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

Place the fan hub assembly on a flat surface.

d. Remove the 9 hub assembly bolts. See Figure 19.4.9-1 for reference. e. Remove the top half of fan hub assembly. See Figure 19.4.9.1-1 for reference. f.

Remove the broken or damaged fan blade.

g. Ensure plastic keeper is still in place. See Figure 19.4.9.1-2 for reference.

19-55

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.9.2 NOTE:

INSTALL RADIATOR-MOTOR FAN BLADES Care must be taken to keep track of the location of the flat washers removed during this process and during assembly the washers must be returned to the same place. The washers are used to balance the Fan Hub assembly.

FIGURE 19.4.9.2-1

FIGURE 19.4.9.2-2

FAN BLADE WITH FAN PITCH

RADIATOR FAN ASSEMBLY (TOP HALF MATED WITH BOTTOM HALF)

To install the Radiator-Motor Fan Blades, proceed as follows: a. This maintenance 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. See procedures in paragraph 19.4.8.2. b. Ensure that the keeper is in the correct slot. See Figure 19.4.9.1-2 for reference. c.

Install the new blade at a 40° angle. This is accomplished by placing the blade so that the keeper and the 40° angle indentation on the blade are mated together. See Figure 19.4.9.2-1 and Figure 19.4.9.2-2 for reference.

19-56

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 d. Place the top half of the hub assembly on to the bottom half of the hub assembly. See Figure 19.4.9.2-2 for reference. e. Ensure that the fan hub assembly fits together and all blades have the same pitch. f.

Reinstall all 9 of the fan hub assembly bolts. Torque to 108 inch lbs. See Figure 19.4.9-1 for reference.

g. Reinstall the Radiator-Motor Fan Assembly. See Section 19.4.6.3 for reference.

19-57

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.10

AFTER COOLER-MOTOR FAN BLADES

The following maintenance procedures are provided for the After Cooler-Motor Fan Blades: Remove Install

FIGURE 19.4.10-1

AFTERCOOLER FAN HUB DISASSEMBLY

19-58

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.10.1 NOTE:

REMOVE AND INSTALL AFTER COOLER-MOTOR FAN BLADES Care must be taken to keep track of the location of the flat washers removed during this process and during assembly the washers must be returned to the same place. The washers are used to balance the Fan Hub assembly.

FIGURE 19.4.10.1-1

AFTERCOOLER FAN ASSEMBLY (TOP HALF REMOVED)

PLASTIC KEEPER

FIGURE 19.4.10.1-2

AFTERCOOLER FAN ASSEMBLY (BOTTOM HALF W/ KEEPER INSTALLED)

To remove the Aftercooler-Motor Fan Blades, proceed as follows: a. This maintenance 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. See procedures in paragraph 19.4.8.2.

19-59

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 b. After the Aftercooler-Motor Fan Assembly has been removed, Disassembly and Reassembly procedures are the same as the Radiator Fan Motor. See Section 19.4.9.1 and 19.4.9.2 for reference. 19.4.11

ENGINE COMPARTMENT VENT-MOTOR FAN BLADES

The following maintenance procedures are provided for the Engine Compartment Vent Motor Fan Blades: Remove Install

FIGURE 19.4.11-1 19.4.11.1 NOTE:

VENT FAN HUB DISASSEMBLY

REMOVE AND INSTALL ENGINE COMPARTMENT VENT-MOTOR FAN BLADES Carefully observe the location of the flat washers removed during this process and during assembly. The washers must be returned to the same place to balance the Fan Hub assembly.

P L A S T IC K E E P E R

FIGURE 19.4.11.1–1

VENT FAN ASSEMBLY (BOTTOM HALF WITH KEEPER INSTALLED)

19-60

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

FIGURE 19.4.11.1-2

FAN BLADE WITH FAN PITCH

To remove the Engine Compartment Vent-Motor Fan Blades, proceed as follows: a. This maintenance 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. See procedures in paragraph 19.4.8.2. b. After the Engine Compartment Vent-Motor Fan Assembly has been removed, Disassembly and Reassembly procedures are the same as the Radiator Fan Motor. See Section 19.4.9.1 and 19.4.9.2 for reference. 19.4.12

HYDRAULIC TANK LOW LEVEL SHUTDOWN SWITCH (HTLL)

The following maintenance procedures are provided for the Hydraulic Tank Low Level Shutdown Switch (HTLL): Test Remove Install There is one low fluid level shutdown switch mounted inside of each of the 18-gallon hydraulic tanks. The “float type” switch is mounted on the back of the hydraulic tank. See Figure 19.2.1-1 and refer to Section 19.2.1 for an explanation on the operation of the switch. 19.4.12.1

TEST HYDRAULIC TANK LOW LEVEL SHUTDOWN SWITCH (HTLL)

To test the Hydraulic Tank Low Level Shutdown Switch (HTLL) Switch, proceed as follows: a. Using a multimeter, set to OHMS (Ω) Rx1 scale. Test the HTLL switch wires for contact continuity in the switch positions specified in Table 19.4.12.1-1. The multimeter should indicate zero ohms when the hydraulic tank is empty. The switch is normally open.

19-61

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 b. The multimeter should indicate infinite ohms when the hydraulic tank is full. c.

Replace the switch if it fails any of the above requirements.

TABLE 19.4.12.1-1

HTLL SWITCH CONTACT POSITIONS

HYDRAULIC TANK LOW LEVEL SHUTDOWN SWITCH (HTLL) SWITCH SWITCH POSITION

SWITCH CONTACTS

HYDRAULIC TANK FULL

Infinite OHMS

HYDRAULIC TANK BELOW 33%

Ø OHMS

19-62

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 19.4.12.2

REMOVE HYDRAULIC TANK LOW LEVEL SHUTDOWN SWITCH (HTLL)

FIGURE 19.4.12.2-1

FIGURE 19.4.12.2-2

TANK ACCESS COVER

TANK ACCESS COVER O-RING

19-63

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

HTLL DEUTSCH CONNECTION

FIGURE 19.4.12.2-3

HTLL SWITCH DEUTSCH CONNECTOR

19-64

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 To remove the Hydraulic Tank Low Level Shutdown Switch (HTLL) Switch, proceed as follows a. This maintenance 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. 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.

b. Remove the 9 mounting bolts from the Top Plenum Screen Assembly and remove the screen. The screen can be slid over to the adjoining radiator screen. See Section 8.4.2 for reference. c.

Close the Hydraulic Fluid Shutoff Valve see Figure 19.2.1-4 for reference.

d. Drain the hydraulic tank of all fluid, into an appropriate container. Refer to Section 19.3.1.2 for draining the reservoir. e. Clean the area around the tank access cover of contaminants that could fall into the tank, during change out. You should also have a clean work area for components and elements. f.

Remove the eight mounting bolts from the tank access cover, attached to the breather cap. Discard the old O-ring and replace with new. See Figure 19.4.12.2-1 and 19.4.12.2-2 for reference.

19-65

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 g. Disconnect the switch from the wiring harness, at the DEUTSCH connector. 19.4.12.2-3 for details.

Se Figure

h. Unscrew the lock nut on the backside of the switch and unscrew the switch from the unit. 19.4.12.3

INSTALL HYDRAULIC TANK LOW LEVEL SHUTDOWN SWITCH (HTLL)

To install the Hydraulic Tank Low Level Shutdown Switch (HTLL) Switch, proceed as follows a. This maintenance 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. See procedures and warnings in paragraph 19.4.12.2. b. Screw the switch into the mounting hole while insuring the switch does not bind on the bottom of the tank. The switch’s moveable plastic float should be pointed at the top of the tank. Check the switch for binding. c.

Connect the switch to the Power Unit wiring harness.

d. Reinstall the eight mounting bolts from the tank access cover, attached to the breather cap. See previous instructions for access cover installation. See Figure 19.4.12.2-1 for reference. e. Open the hydraulic fluid shutoff valve. f.

Fill the hydraulic tank with the appropriate fluid as listed in Annex G.

g. Check for leaks. h. Reinstall the Top Plenum Screen Assembly and 9 mounting bolts. i.

Inspect the hydraulic system starting at Section 19.4.1 and ending at Section 19.4.12.

j.

Start the engine and check for proper operation of fans and for fluid leaks.

k.

Shut-down the Power Unit and Inspect the hydraulic system starting at Section 19.4.1 and ending at Section 19.4.12.

l.

Place the DC Control Power Circuit Breaker (CBCP) to ON.

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CHAPTER 20 PU STORAGE PROCEDURES TABLE OF CONTENTS SECTION

TITLE

PAGE

20.0

PU STORAGE PROCEDURES

3

20.1

SAFETY PROCEDURES

3

20.2

PRESERVATION/STORAGE PROCEDURES FOR THE PU

5

20.2.1

PU AND TRAILER ASSEMBLY

6

20.2.2

GENERAL REQUIREMENTS: 3456 EPG ENGINE

6

20.2.2.1

COOLING SYSTEMS

6

20.2.2.1.1

CATERPILLAR COOLANT AND ANTIFREEZE

7

20.2.2.1.2

SUPPLEMENTAL COOLANT ADDITIVE

7

20.2.2.1.3

COOLING SYSTEM CLEANER

7

20.2.2.2

NECESSARY EQUIPMENT AND CONSUMABLES

7

20.3

LONG TERM STORAGE

10

20.3.1

ENGINE STORAGE - UP TO ONE YEAR

10

20.3.2

ALTERNATOR STORAGE - UP TO ONE YEAR

12

20.3.2.1

REMOVAL FROM STORAGE

12

20.3.2.2

INSULATION RESISTANCE CHECKS: (MEGGER)

12

20.3.2.3

INITIAL OPERATION AFTER STORAGE

12

20-1

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 20.2-1

STORAGE PROCEDURES FOR 3456 ENGINE AND SR-4B GENERATORS

20-2

5

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 20.0

PU STORAGE PROCEDURES

20.1

SAFETY PROCEDURES

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.

20-3

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.

20-4

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 20.2

PRESERVATION/STORAGE PROCEDURES FOR THE PU

TABLE 20.2-1 STORAGE PROCEDURES FOR 3456 ENGINE AND SR-4B GENERATORS PRE-STORAGE ACTIVITIES

SUBSYSTEM



Clean exterior of engine of any dirt, rust, grease, and oil.

▪ ▪ ▪

Paint areas that contain paint damage with good quality paint. Remove any dirt from the air cleaners.

POSTSTORAGE ACTIVITIES Remove protective covers.

Sprayer, Paint Filters

Apply lubricant to all points identified in this manual.

ƒ Drain and replace the crankcase oil, add VCI at the rate of 34% by volume, and replace the oil filters.

3456 Engine EPG

EQUIPMENT NEEDED

▪ ▪

Remove the air filter element.

▪ ▪

Reinstall serviceable air filter

▪ ▪ ▪ ▪ ▪ ▪

Seal the exhaust pipe including any drain holes in the muffler.



Apply a small amount of oil to the threads on the fuel tank filler.



Seal all openings to the tank to prevent evaporation of the fuel and preservative.



Remove the fuel nozzles and apply a mixture of VCI oil mixture in each cylinder. Turn the engine over slowly to put the oil on each cylinder.



Spray a thin amount of VCI oil mixture on the flywheel, ring gear teeth, and start pinion. Install the covers to keep in the VCI vapors.

Turn the engine at cranking speed with the fuel off and spray a 50% VCI oil/50% engine oil mixture into the air inlet. Spray the same 50% VCI oil/50% engine oil mixture into the exhaust openings.

VCI Oil filters

Change oil and filters

VCI Air filters

VCI

Clean the primary fuel filter. Fill with calibration fluid or kerosene. Install the primary fuel filter and operate the priming pump. Drain any water or dirt from inside the fuel tank. Apply a spray inside the tank to prevent rust and add a commercial biocide to the fuel.



Install all covers and ensure that tape has been installed over all openings.



Apply a small amount of multipurpose grease to all moving parts.

VCI Biocide

VCI Oil

Test the cooling system.

Diesel Fuel Biocide

Prime the engine with diesel fuel.

VCI



If the stored engine will be subjected to below-freezing temperatures, completely drain the system by removing the drain plugs from the engine block, oil cooler, and radiator. Clean the system and refill with a mixture of ELC antifreeze and distilled water. See Section. 4.5.3

SR-4B Generator

Test the cooling system

Sealing Tape/plastic wrap



Seal all openings with tape.



Perform a resistance check of the windings and record the measurement. Ensure resistance is one megohm or greater.



Dry generator windings if necessary.

20-5

Megohmmeter

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 20.2.1

PU AND TRAILER ASSEMBLY

a. Prior to starting any preservation and or storage procedures for the Power Unit obtain and fill out a Preservation Form. b. Follow all Caterpillar instructions dealing with engine and alternator storage procedures. See Section 20.2.2 for reference. c.

Cover all exterior vents and screens with tarps or plastic.

d. Disconnect and remove the batteries from the PU if, the PU will be stored for longer than three months. 20.2.2

GENERAL REQUIREMENTS: 3456 EPG ENGINE

(See Caterpillar Manual SEHS9031-03, Storage Procedures For Caterpillar Products, Dated 4/97 or later).

WARNING TO AVOID PERSONAL INJURY, READ AND UNDERSTAND ALL DIRECTIONS AND HAZARDS DESCRIBED ON THE LABELS OF ANY PRODUCT USED TO PRESERVE YOUR EQUIPMENT. The following procedures are required to prepare the MEP-PU-810 for storage and/or transport. Included are instructions for preserving and packaging the engine fuel system, cooling system, lubrication system, and housing as follows: Caterpillar recommends the use of volatile corrosion inhibitors (VCI oil) in order to prevent internal engine damage due to moisture during storage. These inhibitors act by evaporating inside the engine, then condensing over the inside surfaces. This evaporation and condensing process offers full protection to surfaces that cannot be reached with preservatives that require direct application. This process also makes it easier to clean from the engine when removing the engine from storage. The volatile vapors are removed by simply running the engine to operating temperature. A mineral oil base is left behind after the volatile vapors are removed. The oil should then be drained and new oil and filters installed. 20.2.2.1

COOLING SYSTEMS

Cooling systems should be preserved with Caterpillar coolant or equivalent. Caterpillar coolant contains the necessary inhibitors to prevent corrosion and pitting. When used in the proper mixture, the coolant will prevent damage due to rust and freezing. It is common in warm climates to store the engine with water in the cooling system. In such cases, distilled or de-ionized water is recommended for use in engine cooling systems. DO NOT use hard tap water or salt softened tap water in engine cooling systems. If distilled or de-ionized water is not available, use water that meets the minimum acceptable requirements listed in Annex G.

20-6

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

NOTE: The Caterpillar engines are equipped with air-to-air after-cooling (ATAAC), and require a minimum of 30 percent glycol (60% maximum) to prevent water pump cavitation. When approved water (distilled, de-ionized, or water that meets minimum acceptable Caterpillar requirements) is used, the water MUST be treated with six to eight percent by volume Caterpillar Supplemental Coolant Additive (SCA), also called Caterpillar Cooling System Conditioner, or equivalent. Under NO circumstances should the engine be stored without the addition of the Caterpillar Supplemental Coolant Additive or equivalent. Always fill the radiator completely full to prevent rusting of the top tank. Do not leave any exposed air space within the radiator. All exposed surface areas will rust. 20.2.2.1.1

CATERPILLAR COOLANT AND ANTIFREEZE

Caterpillar Extended Life Coolant (ELC) is the preferred coolant to use in cooling systems. Caterpillar ELC provides the best coolant service life, corrosion protection, water pump seal service life, and radiator service life. 20.2.2.1.2

SUPPLEMENTAL COOLANT ADDITIVE

Use a six to eight percent concentration of Caterpillar Cooling System Conditioner on engines that will be stored with only water in the cooling system. If the engine is stored with Caterpillar Antifreeze (ELC), there is no need to add conditioner before storage. For Caterpillar Cooling System Conditioner part numbers (See Annex G). 20.2.2.1.3

COOLING SYSTEM CLEANER

Caterpillar Cooling System Cleaner is designed to clean the cooling system of harmful scale and corrosion. It is available in 1 gal (5 gal U.S.) containers. Directions for its use are included on the container. For Caterpillar Cooling System Cleaner (Annex G) 20.2.2.2

NECESSARY EQUIPMENT AND CONSUMABLES

Use all the necessary personal protective equipment needed to perform any of the following jobs: a. Sprayer: A 1P-0540 Flow Checking Tool Group or an air compressor with a sprayer attachment can be used to prepare the engine for storage. It should be possible to change the nozzle adjustment to provide either a spray or a fog pattern. The fog adjustment pattern is better if access to components is difficult. The spray pattern is better for parts on the outside of the engine. b. Paint: Outside parts of the engine can best be protected by thorough use of good quality paint. Paint provides good protection for a storage period up to two years. Before painting, thoroughly clean the engine.

20-7

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

c.

Plastic Bags: Use black or dark plastic bags. periods of time.

Clear plastic bags will deteriorate over long

d. Sealing Tape: Use a sealing tape with good adhesive properties. DO NOT use duct tape because it will loosen over a short period of time. Two- inch wide rolls of sealing tape are recommended. e. Coolant Conditioner Test Kit: Use the 8T-5296 Conditioner Test Kit to check the concentration of conditioner in the cooling system. Maintain the cooling system with a three to six percent concentration of conditioner. Instructions are included with the kit. f.

Coolant And Battery Tester: The tester is used for checking coolant freezing point and battery fluid condition. Instructions are provided with the tester. The 5P-0957 Coolant And Battery Tester Group is available with the temperature scale in degrees Fahrenheit. The 5P-3514 Coolant And Battery Tester Group is available with the temperature scale in degrees Celsius.

g. VCI Oil: (1) Volatile Corrosion Inhibitor (VCI) oil can be used in all tanks, engine, fuel tank, hydraulic tank, power steering tank, transmission, differential, etc. It is an oil stabilizer and rust preventative. It can be used in combination with any petrochemical. Apply by using a spraying or fogging pattern. Caterpillar recommends the use of VCI oil in order to prevent internal engine damage due to moisture during storage. These inhibitors act by evaporating inside the engine then condensing over the inside surfaces. This evaporation and condensing process offers full protection to surfaces that cannot be reached with preservatives that require direct application. This process also makes it easier to clean from the engine when removing the engine from storage. The volatile vapors are removed by running the engine to operating temperature. A mineral oil base is left behind after the volatile vapors are removed. The oil should then be drained and new oil and filters installed. VCI oil should not be used full strength on non-ferrous metals where it will have direct, prolonged contact. (2) To be successful when treating an engine with VCI oil, the engine must be completely sealed when stored. VCI oil is so volatile that any opening left unsealed will allow the vapors to escape, causing the engine to lose its protection. Volatile corrosion inhibitor (VCI), NOXRUST VCI #10 oil or equivalent oil, provides both liquid and vapor protection to ferrous metal surfaces against corrosion caused by moisture. In a closed compartment, protection is either by direct contact with VCI oil or by contact with VCI vapors. Refer to Annex G for quantities required. The VCI oil and regular oil are a 50/50 mix. h. Diesel Fuel: Diesel fuel left in fuel tanks and fuel injection systems will sometimes cause problems due to the growth of small organisms. This may result in plugged fuel filters, corrosion, sticking fuel pumps, or malfunctioning fuel injection valves. Draining the fuel injection pump and refilling it with Caterpillar Calibration Fluid can minimize this problem. NOTE:

Refer to Annex G for quantities available.

20-8

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i.

Caterpillar Calibration Fluid: Is the preferred choice as a preservation fluid because it contains Rust and Oxidation (R&O) inhibitors. If Caterpillar Calibration Fluid is not available, kerosene is a second consideration. However, kerosene does not contain Rust and Oxidation inhibitors and, as the result, is far from the best choice. Kerosene is preferred over diesel fuel (another alternative) because kerosene is not as prone to oxidation as diesel fuel. Kerosene also will not thicken as much as diesel fuel during long storage periods.

j.

Fuel tanks should be protected internally with VCI oil and then sealed. The fuel tank must be drained completely. All vents must sealed airtight. Spray VCI oil/regular oil at a 50/50 mix into the fuel tank filler hole, then seal with the fuel tank filler cap.

k.

Diesel Fuel Biocide: To prevent the growth of small organisms in the diesel fuel, use diesel fuel biocide such as Biobor JF or equivalent.

20-9

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LONG TERM STORAGE

20.3.1

ENGINE STORAGE - UP TO ONE YEAR

NOTE:

If long-term storage for a period of time exceeding one year is necessary, contact your local Caterpillar Dealer for the preferred procedure to use in your specific case.

NOTE:

Upon completion of preservation, attach tag near engine start controls stating: “ENGINE PRESERVED. DO NOT CRANK UNTIL ISSUED TO USER”. Affix a red warning tag stating:

NOTE:

“DEPROCESS THIS ENGINE IN ACCORDANCE WITH INSTRUCTIONS CONTAINED ON DA FORM 2258 OR AFTO FORM 20 (ATTACHED TO THIS EQUIPMENT). IN ADDITION, AIR CLEANERS, FILL CAPS, EXHAUST STACKS, BREATHER TUBES, DIPSTICK TUBES, AND ACCESSORIES HAVE BEEN SEALED. REMOVE ALL SEALS PRIOR TO CRANKING ENGINE”. Attach tag near engine start controls.

NOTE:

a. Clean the engine of any dirt, rust, grease, and oil. Inspect the exterior. Paint areas that contain paint damage with good quality paint. b. Remove any dirt from the air cleaner(s). Check all seals, gaskets, and the filter element for damage. c.

Apply lubricant to all points shown in the chart “Lubrication & Maintenance” within the Operation & Maintenance Manual for your equipment.

d. Drain and replace the crankcase oil and change the oil filter(s). For the proper procedure (See Section 14.3.1) e. Add VCI oil to the crankcase at the rate of three to four percent by volume. If the engine crankcase is full, drain enough engine oil so the mixture can be added.

NOTE: f.

NOTE:

Remove the air filter element(s). Turn the engine at cranking speed with the P91/J91 Electronic Unit Injector Engine Harness Deutsch Connector disconnected at the engine valve cover base. •

Disconnecting the P91/J91 will keep the engine from starting during cranking. Reference: P91/J91 connector, Radian Engine Schematic, drawing number FO-37)



Reconnect the P91/J91 after this procedure. Use a sprayer to add a mixture of 50 percent VCI oil and 50 percent engine oil into the air inlet or turbocharger inlet. VCI oil mixture can also be added to the inlet by removing the plug for checking turbocharger boost pressure. The minimum application rate is 5.5 mL per L (3 oz per 1000 cu in) of engine displacement. The minimum application rate is critical to prevent loss of protective vapors.

g. Install the air filter element(s) and completely enclose the element(s) with dark, plastic bags. Seal them with tape. Replace the air filter covers. Place tape over all openings to seal VCI vapors in the engine.

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h. Use a sprayer to apply a 50 percent VCI oil and 50 percent engine oil mixture into the exhaust openings. The minimum application rate is 5.5 mL per L (3 oz per 1000 cu in) of engine displacement. Seal the exhaust pipe, including any drain holes in the muffler. i.

Remove the fuel from the secondary fuel filter housing or empty and reinstall the spin-on fuel filter element to remove any dirt and water. Drain the fuel injection pump (sleeve metering only). Clean the primary fuel filter. Fill with calibration fluid or kerosene. Install the primary fuel filter and operate the priming pump. This will send clean oil to the secondary filter and engine. Open the fuel tank drain valve and allow any water or dirt to drain from inside the fuel tank. Apply a spray of 30 mL per 30 L (1 oz per 7.50 gal U.S.) of fuel tank capacity to prevent rust in the fuel tank. Add 0.15 mL per L (.02 oz per 1 gal U.S.) of commercial biocide (such as Biobor UF or equivalent) to the fuel. Apply a small amount of oil to the threads on the fuel tank filler neck and install the cap. Seal all openings to the tank to prevent evaporation of the fuel and preservative.

j.

Remove the Electronic Unit Injectors and apply 30 mL (1 oz) of VCI oil mixture (50 percent VCI oil and 50 percent engine oil) in each cylinder. Use a Caterpillar 9S9082 Engine Turning Tool to turn the engine over slowly to put the oil on the cylinder walls. Re-install all Electronic Unit Injectors with new O-ring seals. Using the correct procedure, tighten the EUI hold down clamp with the correct torque. After re-installation of the rocker shaft assemblies, check/adjust the valve lash and the injector timing using the correct procedures.

k.

Spray a thin amount of VCI oil mixture (50 percent VCI oil and 50 percent engine oil) on the flywheel, ring gear teeth, and starter pinion. Install the covers to keep in the VCI vapors.

l.

Apply a heavy amount of multipurpose grease (MPGM) to all outside parts that move, such as rod threads, ball joints, linkage, etc.

NOTE:

Install all covers and ensure that tape has been installed over all openings, air inlet, exhaust openings, flywheel housing, crankcase breather(s), dipstick tubes, etc.

m. Ensure that all covers are air tight and weatherproof. Use a waterproof, weather resistant type tape (such as Kendall No. 231 or equivalent). Do not use duct tape. Duct tape will only seal for a short period of time. n. Under most conditions it is best to remove the batteries and use them in another application. As an alternative, place them in storage where they can be periodically checked and electrically charged again when needed. If the batteries are not removed, wash the tops of the batteries until clean. Apply an electrical charge to the batteries to obtain a specific gravity of 1.225. Disconnect the battery terminals. Place a plastic cover over the batteries. o. Place a waterproof cover over the engine. Ensure the engine cover is secure, but loose enough to allow air to circulate around the engine to prevent damage from condensation. p. Attach a tag to the engine with a notation of the date that the unit was preserved. q. Remove the waterproof cover every two or three months and check the engine for corrosion. If the engine has signs of corrosion at the check period, repeat the protection procedure.

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20.3.2

ALTERNATOR STORAGE - UP TO ONE YEAR

When a generator is in storage, moisture condenses in the windings. To minimize condensation, always place the generator in a dry storage area. Seal all openings with tape. Perform a resistance check of the windings. Record this reading. The purpose of this check is to provide a base line to determine if moisture or winding deterioration occurs during storage. (See Table 20.2-1) If long-term storage for a period of time exceeding one year is necessary, contact your local Caterpillar Dealer for the preferred procedure to use in your specific case.

NOTE:

20.3.2.1

REMOVAL FROM STORAGE

a. Remove all protective covers. b. Before start-up of a generator, use a megohmmeter to check insulation resistance for moisture and/or foreign material. Refer to (Section 10.4.5) for the procedure. A resistance reading of one megohm or less is an indication that the winding has absorbed too much moisture. 20.3.2.2

INSULATION RESISTANCE CHECKS: (MEGGER)

a. Test the main stator windings with a megohmmeter in the following situations: (1) Before initial startup of the generator set. (2) Every three months if the generator is operating in a humid environment. (3) If the generator has not been run under load for three months or more. This is a guideline only. It may be necessary to megger test more frequently if the environment is extremely humid, salty, or if the last megger test was close to one megohm.

NOTE:

20.3.2.3

INITIAL OPERATION AFTER STORAGE

a. The quality of oil control components used in Caterpillar engines is such that, following engine storage, only an operational check at initial start is necessary before operation. The purpose of this operational check is to ensure that the correct pressures and temperatures are kept in the lubrication, cooling, and fuel systems, and any leaks are corrected. To ensure a safe uniform check at initial start, use the following procedure: (1) Operate the engine for 30 minutes at rated speed. (2) Check frequently for leaks such as oil, coolant, and fuel during the first few hours of operation. Repair any leaks as soon as detected.

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CHAPTER 21 ENGINE/ALTERNATOR REMOVAL AND INSTALLATION PROCEDURES TABLE OF CONTENTS SECTION

TITLE

PAGE

21.0

ENGINE/ALTERNATOR REMOVAL AND INSTALLATION PROCEDURES

3

21.1

SAFETY PROCEDURES

3

21.2

ENGINE/ALTERNATOR REMOVAL PROCEDURES

4

21.3

ENGINE/ALTERNATOR INSTALLATION

7

21-1

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LIST OF TABLES TABLE

TITLE

TABLE 21.2-1

MEP-PU-810A/B ENGINE/GENERATOR REMOVAL PROCEDURE

5

TABLE 21.2-1

MEP-PU-810A/B ENGINE/GENERATOR REMOVAL PROCEDURE (CONTINUED)

6

MEP-PU-810A/B ENGINE/GENERATOR INSTALLATION PROCEDURE TABLE

8

MEP-PU-810A/B ENGINE/GENERATOR INSTALLATION PROCEDURE TABLE (CONTINUED)

9

TABLE 21.3-1 TABLE 21.3-1

PAGE

21-2

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ENGINE/ALTERNATOR REMOVAL AND INSTALLATION PROCEDURES

21.1

SAFETY PROCEDURES

a. This maintenance 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.

21-3

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ENGINE/ALTERNATOR REMOVAL PROCEDURES WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT DURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION AND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN LOAD CABLES ARE HANDLED. WARNING PRIOR TO TROUBLESHOOTING THE POWER UNIT (PU), ENSURE THE TIE AND FEEDER CABLES ARE ALL INSTALLED ON PARKING STANDS, TO PREVENT THE POSSIBILITY OF UTILITY POWER BEING FED BACK INTO GENERATOR SET. ENSURE EQUIPMENT IS PROPERLY TAGGED AND NOT ENERGIZED. RESIDUAL VOLTAGE IS PRESENT AT THE GENERATOR LEADS WITH THE REGULATOR TURNED OFF, REACHING SEVERAL HUNDRED VOLTS ON THE GENERATOR SET. PROPER INSULATION AND ISOLATION OF METERING EQUIPMENT MUST BE OBSERVED WHEN TESTING GENERATOR. USE PROPER TEST EQUIPMENT TO CHECK FOR VOLTAGE BEFORE PROCEEDING. FAILURE TO COMPLY MAY RESULT IN DEATH BY ELECTROCUTION. CAUTION SIGNIFICANT DIFFERENCES BETWEEN THE MEP-PU-810A AND MEP-PU-810B REQUIRE SPECIFIC INSTRUCTIONS FOR EACH VERSION. 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.

21-4

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MEP-PU-810A/B ENGINE/GENERATOR REMOVAL PROCEDURE

STEP

PROCEDURE

1

Lock-out and tag-out the PU per Section 21.1.

2

Remove the PU housing side panel ("H" panel).

3

Remove the air inlet duct assembly.

4

Tag the hydraulic pressure gauge lines and fittings at the hydraulic control block.

5

Disconnect the hydraulic pressure gauge lines from the hydraulic control block.

6

Leaving the hoses connected, unbolt the hydraulic control block from the engine and secure it to the PU housing in a location, which permits engine/generator removal.

7

Leaving the hoses connected, unbolt the hydraulic pump assembly from the engine and position in a location, which permits engine/generator removal.

8

Leaving the lines connected, unbolt the engine gauge assembly from the PU housing and secure the assembly and lines to the engine.

9

Disconnect the fuel return line from the engine and secure the free end to the top of the engine compartment cooling fan guard.

10

Close the fuel inlet supply valve.

11

Disconnect the fuel inlet line at the Primary Fuel Filter and drain.

12

Open and remove the radiator cap.

13

Open the engine coolant drain valve and drain the coolant from the engine.

14

Remove the engine coolant drain hose from the engine.

15

Remove the coupling from the engine coolant supply line.

16

Remove the coupling from the engine coolant return line.

17

Remove the coupling from the charge-air hot line at the turbocharger.

18

Remove the coupling from the charge-air cold line at the intake manifold.

19

Disconnect and remove the exhaust pipe completely from the PU.

20

Tag the electrical wires and connections at the starter motor.

21

Disconnect the electrical wires at the starter motor.

22

Ensure that the crankcase oil drain valve is closed.

23

Disconnect, drain, and remove the crankcase oil drain hose.

24

Open the PDC generator connection access panel.

25

Tag the four generator high voltage output wires and the bus connections inside the PDC..

26

Disconnect the four generator high voltage output wires from the buses inside the PDC.

27

Tag the ground wire and ground bus connection inside the PDC.

28

Disconnect the ground wire from the ground bus inside the PDC.

29

Disconnect the generator wire conduit from the PDC, feed the generator and ground wires through the conduit hole, and secure the free ends to the generator.

21-5

TABLE 21.2-1 STEP

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 MEP-PU-810A/B ENGINE/GENERATOR REMOVAL PROCEDURE (CONTINUED) PROCEDURE

30

Disconnect the 40P, 7P1 and 7P2 harnesses from the PDC and secure the free end to the generator.

31

Disconnect the PU chassis ground wire from the generator mounting foot.

32

Remove the engine/generator skid from the PU chassis mounting hardware.

33

Carefully position the forks of a 10,000 lb minimum capacity forklift under the marked provisions on the engine/generator skid.

34

Using the forklift, lift the engine/generator slightly until it is just clear of the PU mounts.

35

Remove the engine/generator from the PU by carefully backing the forklift away from the PU. Be sure the engine/generator does not snag any PU components during the process.

36

Set the engine/generator down on blocks on the ground in a protected location.

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ENGINE/ALTERNATOR INSTALLATION WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT DURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION AND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN LOAD CABLES ARE HANDLED. WARNING PRIOR TO TROUBLESHOOTING THE POWER UNIT (PU), ENSURE THE TIE AND FEEDER CABLES ARE ALL INSTALLED ON PARKING STANDS, TO PREVENT THE POSSIBILITY OF UTILITY POWER BEING FED BACK INTO GENERATOR SET. ENSURE EQUIPMENT IS PROPERLY TAGGED AND NOT ENERGIZED. RESIDUAL VOLTAGE IS PRESENT AT THE GENERATOR LEADS WITH THE REGULATOR TURNED OFF, REACHING SEVERAL HUNDRED VOLTS ON THE GENERATOR SET. PROPER INSULATION AND ISOLATION OF METERING EQUIPMENT MUST BE OBSERVED WHEN TESTING GENERATOR. USE PROPER TEST EQUIPMENT TO CHECK FOR VOLTAGE BEFORE PROCEEDING. FAILURE TO COMPLY MAY RESULT IN DEATH BY ELECTROCUTION. CAUTION SIGNIFICANT DIFFERENCES BETWEEN THE MEP-PU-810A AND MEP-PU-810B REQUIRE SPECIFIC INSTRUCTIONS FOR EACH VERSION. 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.

21-7

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MEP-PU-810A/B ENGINE/GENERATOR INSTALLATION PROCEDURE TABLE

STEP

PROCEDURE

1

Carefully position the forks of a 10,000 lb minimum capacity forklift under the marked provisions on the engine/generator skid.

2

Using the forklift, lift the engine/generator until it is just clear of the PU mounts.

3

Insert the engine/generator into the PU by carefully moving the forklift toward the PU. Be sure the engine/generator does not snag any PU components during the process.

4

Position the engine/generator on the PU chassis mounting provisions, set in place, and remove the forklift.

5

Reinstall the engine/generator skid to PU chassis mounting hardware.

6

Reinstall the PU chassis ground wire to the generator mounting foot.

7

Reinstall the 40P, 7P1 and 7P2 harnesses from the engine/generator to the PDC.

8

Reinstall the generator and ground wires through the conduit hole in the PDC and reinstall the conduit end into the PDC.

9

Reinstall the ground wire to the ground bus inside the PDC.

10

Reinstall the four generator high voltage output wires to the buses inside the PDC.

11

Reinstall the PDC generator connection access cover.

12

Reinstall the crankcase oil drain hose.

13

Reinstall the electrical wires at the starter motor.

14

Reinstall the exhaust pipe to the muffler and the turbocharger.

15

Reinstall the coupling to the charge-air cold line at the intake manifold.

16

Reinstall the coupling to the charge air hot line at the turbocharger.

17

Reinstall the coupling to the engine coolant return line.

18

Reinstall the coupling to the engine coolant supply line.

19

Reinstall the engine coolant drain hose.

20

Close the engine coolant drain valve.

21

Refill the engine cooling system with coolant. Open the engine cooling system vent valve as necessary to release entrapped air from the engine block.

22

Reinstall the radiator cap.

23

Reinstall the fuel inlet line to the Primary fuel filter.

24

Reinstall the fuel return line.

25

Open the fuel inlet supply valve.

26

Using the fuel system hand-priming pump, prime the engine fuel system.

27

Reinstall the engine gauge assembly onto the PU housing.

28

Reinstall the hydraulic pump assembly onto the engine.

29

Reinstall the hydraulic control block onto the engine.

21-8

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MEP-PU-810A/B ENGINE/GENERATOR INSTALLATION PROCEDURE TABLE

STEP

PROCEDURE

30

Reinstall the hydraulic pressure gauge lines to the hydraulic control block.

31

Reinstall the air inlet duct assembly.

32

Reinstall the PU housing side panel ("H" panel).

33

Reinstall both negative and positive cables on both Battery Banks and untag.

34

Un tag and reinstall both Battery Charger input power cables.

35

Check both Battery Chargers for proper operation.

21-9

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THIS PAGE INTENTIONALLY BLANK

21-10

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CHAPTER 22 PDC REMOVAL AND INSTALLATION PROCEDURES TABLE OF CONTENTS SECTION

TITLE

PAGE

22.0

PDC REMOVAL AND INSTALLATION PROCEDURES

4

22.1

SAFETY PROCEDURES

4

22.2

PRIMARY DISTRIBUTION PANEL (PDC) REMOVAL

5

22.3

PRIMARY DISTRIBUTION PANEL (PDC) INSTALLATION

8

22-1

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LIST OF FIGURES FIGURE

TITLE

PAGE

FIGURE 22.2-1

PDC REMOVAL PROCEDURES

22-2

6

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LIST OF TABLES TABLE

TITLE

PAGE

TABLE 22.2-1

MEP-PU-810A PDC REMOVAL PROCEDURE

6

TABLE 22.2-1

MEP-PU-810A PDC REMOVAL PROCEDURE (CONTINUED)

7

TABLE 22.2-2

MEP-PU-810B PDC REMOVAL PROCEDURE

7

TABLE 22.3-1

MEP-PU-810A PDC INSTALLATION PROCEDURE

9

TABLE 22.3-2

MEP-PU-810B PDC INSTALLATION PROCEDURE

9

22-3

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 22.0 NOTE:

PDC REMOVAL AND INSTALLATION PROCEDURES This is a DEALER Level Task. It is included in this manual for EMERGENCY USE ONLY.

22.1

SAFETY PROCEDURES

a. This maintenance 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.

22-4

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 22.2

PRIMARY DISTRIBUTION PANEL (PDC) REMOVAL WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT DURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION AND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN LOAD CABLES ARE HANDLED. WARNING PRIOR TO TROUBLESHOOTING THE POWER UNIT (PU), ENSURE THE TIE AND FEEDER CABLES ARE ALL INSTALLED ON PARKING STANDS, TO PREVENT THE POSSIBILITY OF UTILITY POWER BEING FED BACK INTO GENERATOR SET. ENSURE EQUIPMENT IS PROPERLY TAGGED AND NOT ENERGIZED. RESIDUAL VOLTAGE IS PRESENT AT THE GENERATOR LEADS WITH THE REGULATOR TURNED OFF, REACHING SEVERAL HUNDRED VOLTS ON THE GENERATOR SET. PROPER INSULATION AND ISOLATION OF METERING EQUIPMENT MUST BE OBSERVED WHEN TESTING GENERATOR. USE PROPER TEST EQUIPMENT TO CHECK FOR VOLTAGE BEFORE PROCEEDING. FAILURE TO COMPLY MAY RESULT IN DEATH BY ELECTROCUTION. WARNING DAMAGE TO PDC WILL OCCUR IF 7P1 AND 7P2 ARE TRANSPOSED. CAUTION SIGNIFICANT DIFFERENCES BETWEEN THE MEP-PU-810A AND MEP-PU-810B REQUIRE SPECIFIC INSTRUCTIONS FOR EACH VERSION. 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.

NOTE:

This is a DEALER Level Task. It is included in this manual for EMERGENCY USE ONLY.

22-5

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FIGURE 22.2-1

PDC REMOVAL PROCEDURES

PDC removal and installation procedures are presented in Table 22.2-1, Table 22.2-2, Table 22.3-1, and Table 22.3-2. Figure 22.2-1 illustrates the removable parts on the PDC. TABLE 22.2-1

MEP-PU-810A PDC REMOVAL PROCEDURE

STEP

PROCEDURE

1

De-energize and disconnect feeder output cables, tie output cables, and the ground cables.

2

Disconnect the battery cables from the batteries.

3

Remove Pin Plug 40P, with an Allen wrench, from the PDC, for both GEN 1 and GEN 2 units.

4

Remove Pin Plugs 7P1 and 7P2. Twist the plugs and pull out, for both GEN 1 and GEN 2 units.

5

Remove the access cover on the back of the control panel for GEN 1 and GEN 2. Tag and Disconnect generator leads T1, T2, T3, neutral and ground from the bus bars.

6

Remove the curbside cover from the transformer. Tag and Disconnect H1, H2, H3, and ground and disconnect the Seal - Tight connector.

7

Remove feeder protective covers.

8

Remove the Mounting Hardware from the PDC flashing on the right, left and top, and remove the flashing see Figure 22.2-1 for reference.

22-6

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TABLE 22.2-1

MEP-PU-810A PDC REMOVAL PROCEDURE (CONTINUED)

STEP

PROCEDURE

9

Remove (2) 3/8” x 1” inch bolts from the front bottom of the PDC, from under the trailer frame see Figure 22.2-1 for reference.

10

Remove (4) 3/8” x 2” inch bolts from the rear of the PDC, under the trailer frame.

11

With a 4000 lb forklift lift the PDC to clear the PU trailer frame, and remove the Korfund Pads (Packing between the PDC and Frame). Lower the panel slightly and remove the PDC.

TABLE 22.2-2

MEP-PU-810B PDC REMOVAL PROCEDURE

STEP

PROCEDURE

1

Disconnect battery cables from batteries.

2

Remove Pin Plug 40P, with an Allen wrench, from the PDC, for both units.

3

Remove Pin Plugs 7P1 and 7P2. Twist the plugs and pull out, for both units.

4

Remove access cover and filter on back of the control panel for GEN 1 and GEN 2. Disconnect generator leads T1, T2, T3, neutral and ground from the bus bars.

5

Remove cover from the transformer. Disconnect H1, H2, H3, and ground and disconnect the Seal-Tight connector.

6

Remove the Mounting Hardware from the flashing on the right, left and top of the control panel and remove the flashing.

7

Remove (2) 3/8” x 1” inch bolts from the front bottom of the PDC, from under the trailer frame.

8

Remove (2) 3/8” x 2” inch bolts from the rear of the PDC, under the trailer frame.

9

Remove the tail light assemblies.

10

With a 4000lb forklift lift the PDC to clear the PU trailer frame, and remove the Korfund Pads (Packing between the PDC and Frame). Lower the panel slightly and remove the PDC.

NOTE:

To remove or install the PDC a minimum of a 4000 lb forklift is required.

22-7

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PRIMARY DISTRIBUTION PANEL (PDC) INSTALLATION WARNING REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH. WARNING HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT DURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION AND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN LOAD CABLES ARE HANDLED. WARNING PRIOR TO TROUBLESHOOTING THE POWER UNIT (PU), ENSURE THE TIE AND FEEDER CABLES ARE ALL INSTALLED ON PARKING STANDS, TO PREVENT THE POSSIBILITY OF UTILITY POWER BEING FED BACK INTO GENERATOR SET. ENSURE EQUIPMENT IS PROPERLY TAGGED AND NOT ENERGIZED. RESIDUAL VOLTAGE IS PRESENT AT THE GENERATOR LEADS WITH THE REGULATOR TURNED OFF, REACHING SEVERAL HUNDRED VOLTS ON THE GENERATOR SET. PROPER INSULATION AND ISOLATION OF METERING EQUIPMENT MUST BE OBSERVED WHEN TESTING GENERATOR. USE PROPER TEST EQUIPMENT TO CHECK FOR VOLTAGE BEFORE PROCEEDING. FAILURE TO COMPLY MAY RESULT IN DEATH BY ELECTROCUTION. CAUTION SIGNIFICANT DIFFERENCES BETWEEN THE MEP-PU-810A AND MEP-PU-810B REQUIRE SPECIFIC INSTRUCTIONS FOR EACH VERSION. 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.

22-8

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM 01646.1R0253/1R0254 TABLE 22.3-1

MEP-PU-810A PDC INSTALLATION PROCEDURE

STEP

PROCEDURE

1

With a 4000lb forklift lift the PDC into the PU trailer slightly above the frame and reinstall the Korfund Pads (Packing between the PDC and Frame). Lower the panel and reinstall the panel.

2

Reinstall (4) 3/8” x 2” inch bolts from the rear of the PDC, under the trailer frame.

3

Reinstall (2) 3/8” x 1” inch bolts from the front bottom of the PDC, from under the trailer frame.

4

Reinstall the flashing on the right, left and top of the control panel using Mounting Hardware. Reinstall gasket as required.

5

Reinstall generator leads T1, T2, T3, neutral and ground to the bus bars. Reinstall the access cover on back of the control panel for GEN 1 and GEN 2.

6

Reinstall Pin Plugs 7P1 and 7P2. Twist the plugs and push in, for both units.

7

Reinstall H1, H2, H3 and ground in the transformer and Reinstall the Seal-Tight connector and Reinstall the transformer cover.

8

Reinstall feeder protective covers.

9

Reinstall Pin Plug 40P, to the PDC with an Allen wrench, for both units.

10

Reinstall battery cables to the batteries. See Foldout (FO 35)

TABLE 22.3-2

MEP-PU-810B PDC INSTALLATION PROCEDURE

STEP

PROCEDURE

1

With a 4000lb forklift lift the PDC slightly above the frame and reinstall the Korfund Pads (Packing between the PDC and Frame). Lower the panel and install the panel.

2

Reinstall (2) 3/8” x 2” inch bolts from the rear of the PDC, under the trailer frame.

3

Reinstall (2) 3/8” x 1” inch bolts from the front bottom of the PDC, from under the trailer frame.

4

Reinstall the flashing on the right, left and top of the control panel using Mounting Hardware.

5

Reinstall generator leads T1, T2, T3, neutral and ground to the bus bars. Reinstall the access cover and filter on back of the control panel for GEN 1 and GEN 2.

6

Reinstall Pin Plugs 7P1 and 7P2. Twist the plugs and push in, for both units.

7

Reinstall H1, H2, H3 and ground in the transformer and reinstall the Seal-Tight connector and reinstall the transformer cover.

8

Reinstall Pin Plug 40P, to the PDC with an Allen wrench, for both units.

9

Reinstall the tail light assemblies.

10

Reinstall battery cables to the batteries. See Foldout (FO 35)

22-9

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22-10

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COMMERCIAL TECHNICAL MANUAL BOOK 2 OF 2 GENERATOR – 840 KW MEP-PU-810A/B Radian Part Numbers: 1R0253-3/1R0254-3

OPERATION AND MAINTENANCE ANNEXES A THROUGH J

© 2007 DRS RADIAN ALL RIGHTS RESERVED 5845 RICHMOND HWY. SUITE 725 ALEXANDRIA, VIRGINIA 22303-1865 FEBRUARY 23, 2007 (REVISION 5) * DISTRIBUTION STATEMENT: Approved for public release; distribution is unlimited. Questions pertaining to technical content shall be referred to 542 SEVSG/GBZFM, Robins AFB, GA 31098. Other requests for this document shall be referred to 542 MSUG/GBMUDE, Robins AFB, GA 31098. *This manual supersedes USAF TO 35C2-3-518-1/ USA TM 9-6115-484-14, JUNE 9, 2006, including all changes

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

THIS PAGE INTENTIONALLY BLANK

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

ANNEX A OTHER MANUAL REFERENCES FOR THE POWER UNIT The following is a list of vender reference manuals and additional DRS Radian manuals for the Power Unit: CATERPILLAR NUMBER NOVEMBER 1998, or later NOVEMBER 1998, or later REHS 0148-01, or later RENR 1200-01, or later RENR 2227-02, or later SEBP 3201-01, or later SEBU 6874-04, or later SEBU 6918-03, or later SEBU 6959-02, or later SEBU 7163-01, or later SENR 1067-02, or later SENR 1068-01, or later SENR 2995-04, or later SENR 3130-06, or later SENR 5359-01, or later SENR 5833-02, or later SENR 6565-02, or later SEHS 9615-02, or later SEHS 9124-01, or later SEHS 9031-03, or later

TITLE TROUBLESHOOTING (3456 DPGDS GENERATOR SET ENGINESUPPLEMENT) SERVICE MANUAL 3456 DPGDS GENERATOR SET ENGINESUPPLEMENT (EMCP II+ FOR EUI ENGINES) SPECIAL INSTRUCTION (PARTS LISTING OF THE DEUTSCH CONNECTORS AND COMPONENTS) SYSTEMS OPERATION TESTING AND ADJUSTING (EMCP II+ FOR EUI ENGINES) TROUBLESHOOTING (3406E GENERATOR SET ENGINES) PARTS MANUAL – 3456 DPGDS GENERATOR SET – MILITARY OPERATION AND MAINTENANCE MANUAL (CUSTOMER COMMUNICATION MODULE FOR DIESEL ENGINES) OPERATION AND MAINTENANCE MANUAL (SR4B GENERATORS AND CONTROL PANELS) CAT O&M 3406E, 3456 INDUSTRIAL ENGINE OPERATION AND MAINTENANCE MANUAL ELECTRIC SET GENERATORS SYSTEMS OPERATION TESTING AND ADJUSTING (3406E AND 3456 INDUSTRIAL ENGINES) DISASSEMBLY AND ASSEMBLY (3406E & 3456 INDUSTRIAL ENGINE) PRODUCT SAFETY SPECIFICATIONS (TORQUE SPECIFICATIONS) SERVICE MANUAL-(SR4B GENERATOR) SPECIFICATIONS SYSTEM OPERATION, TESTING AND ADJUSTING (DIGITAL VOLTAGE REGULATOR) SYSTEM OPERATION, TESTING, AND ADJUSTING (GENERATOR SET LOAD SENSOR AND LOAD SHARING MODULE) TOOL OPERATING MANUAL (SERVICING DEUTSCH HD & DT STYLE CONNECTORS) SPECIAL INSTRUCTION-CLEANING AND DRYING OF GENERATORS AND CONTROL PANELS SPECIAL INSTRUCTION (STORAGE PROCEDURE FOR CATERPILLAR PRODUCTS)

A-1

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

MANUAL NUMBER 82384R

WOODWARD

02036 CUTLER-HAMMER

I.B. 48018N 9 2899 00 990 REV: D

BASLER Z-WORLD

REVISION E

SIXNET MASTER CONTROL SYSTEMS

TITLE SPM-A SYNCHRONIZER (INSTALLATION, OPERATION, AND CALIBRATION MANUAL) LOAD SHARING MODULE (INSTALLATION, OPERATION, AND CALIBRATION MANUAL) INSTRUCTION MANUAL, FOR THE INSTALLATION, OPERATION, AND MAINTENANCE OF TRITON, SL 160/200/360/400, MEDIUM VOLTAGE VACUUM CONTACTORS BE1 – 851 OVER CURRENT RELAY INSTRUCTION MANUAL BL1600 C-PROGRAMMABLE CONTROLLER, USERS MANUAL VERSATRAK AND MINI-VERSATRAK USER MANUAL (REMOTE TERMINAL UNITS INSTALLATION AND MAINTENANCE) SIXNET USER MANUAL (MODULAR DIN RAIL I/O, INSTALLATION AND MAINTENANCE) INSTRUCTION MANUAL, BATTERY CHARGER, MODEL MBC6X-24V-20A-LA

DRS RADIAN SUPPLEMENTAL MANUALS NUMBER CTM 01646.1R0253/1R0254 TR JULY 6, 2006 CTM 01646.1R0253P/1R0254P R1 AUGUST 9, 2006, (Revision 1)

TITLE TROUBLESHOOTING PROCEDURES FOR POWER UNIT-840KW MEP-PU-810A/B POWER UNIT, 840 KW, MEP-PU-810A/B PARTS MANUAL

A-2

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ANNEX B DPGDS GSC+ PROGRAMMABLE SETPOINTS OP5-0 SETPOINTS

SETPOINTS OP5-0 ENGINE/GENERATOR PROGRAMMING① SETPOINT-NAME-DESCRIPTIONS

RANGE OF VALUES

FACTORY DPGDS DEFAULT SETPOINT

P001 - Fuel Solenoid Type: type of fuel system solenoid used on the genset.

0- ETR fuel solenoid 1- ETS fuel solenoid

0

0

P002 - Units Shown: type of measurement units shown on the GSC+ display.

0-for English units (PSI, ºF) 1-for metric units (kPa, ºC).

0

0

0-for engine shutdown P003 - Shutdown Override For Engine Fault: GSC+ response 1-for alarm only (shutdown override, no engine to a low engine oil pressure or high coolant temperature fault. shutdown).

0

0

P004 - Shutdown Override For Sensor Fault: GSC+ response 0-for alarm only shutdown override, no engine to a diagnostic fault with the engine oil pressure sensor, coolant shutdown). temperature sensor, oil temperature sensor, sensor power supply 1-for engine shutdown. or coolant loss sensor.

0

0

P005 - Coolant Loss Sensor Installed: tells whether or not the optional engine coolant loss sensor is installed on the genset.

0-for gensets without a coolant loss sensor 1-for gensets with coolant loss sensor

0

1

P006 - Shutdown Override For Coolant Loss Fault: GSC+ response to an engine coolant loss fault.

0-for engine shutdown. 1-for alarm only (shutdown override, no engine shutdown).

0

0

24

24

N/A

N/A

P007 - System Voltage, 24 Or 32 Volts: system voltage (battery 24 or 32. voltage) of the genset. P008 - This setpoint is not currently being used by the GSC+ and cannot be programmed.

N/A

P009 - Number Of Ring Gear Teeth: number of teeth on the ring gear of the engine. Used by the GSC+ to determine engine speed.

95 to 350 teeth in increments of one tooth.

136 teeth

136 teeth

P010 - Engine Overspeed: engine speed used by the GSC+ to declare that an engine overspeed fault exists. The engine overspeed setpoint (for all 60 Hz applications) is 1.18 times the rated speed.

500 to 4330 rpm in increments of 10 rpm.

2120 rpm

2120 rpm

P011 - Crank Terminate Speed: engine speed used by the GSC+ to disengage the starting motor during engine cranking.

100 to 1000 rpm in increments of 10 rpm.

400 rpm

400 rpm

P012 - Oil Step Speed: engine speed used by the GSC+ for distinguishing between rated speed and idle speed when a low oil pressure fault exists.

400 to 1800 rpm in increments of 10 rpm.

1350 rpm

1350 rpm

P013② - Low Oil Pressure Shutdown At Rated Speed: oil pressure used by the GSC+ to declare that a low oil pressure shutdown fault exists with engine at rated speed (the engine speed must have exceeded the oil step speed for nine seconds).

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

30 PSI (205 kPa)

30 PSI (205 kPa)

P014② - Low Oil Pressure Shutdown At Idle Speed: oil pressure used by the GSC+ to declare that a low oil pressure shutdown fault exists with the engine at idle speed (the engine must have been running for at least 9 seconds and the engine speed must be less than oil step speed).

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

10 PSI (70 kPa)

10 PSI (70 kPa)

P015③ - High Water Temperature Shutdown: coolant temperature used by the GSC+ to declare a high coolant temperature shutdown fault exists (after a 10 second delay).

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

225ºF (107ºC)

225ºF (107ºC)

P016 - Low Water Temperature Alarm: coolant temperature used by the GSC+ to declare that a low coolant temperature alarm fault exists (after a 2 second delay).

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

70ºF (21ºC)

70ºF (21ºC)

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SETPOINTS OP5-0 ENGINE/GENERATOR PROGRAMMING① SETPOINT-NAME-DESCRIPTIONS

RANGE OF VALUES

FACTORY DEFAULT

DPGDS SETPOINT

90 seconds

90 seconds

10 seconds

10 seconds

5 minutes

5 minutes

P017 - Total Cycle Crank Time: cycle crank time used by the GSC+ to declare that an overcrank fault exists.

5 to 120 seconds in increments of 1 second.

P018 - Cycle Crank Time: amount of time the GSC+ cranks and then rests the starting motor during a single crank cycle. P019 - Cooldown Time: amount of time the GSC+ allows the engine to run after a normal shutdown is initiated.

5 to 60 seconds in increments of 1 second.

P020④ - AC Voltage: nominal AC voltage of the generator. The GSC+ measures the AC voltage and shows it on the display. P021 - AC Current Full Scale: nominal full scale AC current of the generator. AC current full scale is equal to the ratio of the external current transformers in the generator housing.

700, 150, 300, 500, 600, 750, 3.0k, 4.5k, 5.20k, 5.25k, 9.0k, 15.0k, 18.0k, 30.0k

700

5.20k

75, 100, 150, 200, 300, 400, 600, 800, 1000, 1200, 1500, 2000, 2500, 3000, and 4000A

600A

100A

01

01 (Gen 1) 02 (Gen 2)

P022⑤ - GSC+ Engine Number: informs other devices on the CAT Data Link of the engine number for the GSC+.

0 to 30 minutes in increments of 1 minute.

01 through 08

SETPOINTS - OP5-0-ENGINE/GENERATOR PROGRAMMING① SETPOINT-NAME-DESCRIPTIONS P023 - Engine Type: identifies the engine as a mechanical unit injector (MUI) diesel, spark ignited (gas), or electronic unit injector (EUI) diesel engine.

RANGE OF VALUES 0 - MUI diesel 1 - Gas 2 - EUI diesel

P024 - Crank Time Delay: amount of time the GSC+ delays activation of the fuel control relay (FCR) during 0 to 20 seconds in increments of 1 a crank cycle. This setpoint is for Gas engines only. second. The P024 setpoint only functions when the P023 setpoint is set to 1 (gas engine).

FACTORY DEFAULT

60HZ 50HZ SETPOINT SETPOINT

0

2

2

5 Seconds

5 Seconds

5 Seconds

P025 - Oil Temperature Sensor Installed: tells whether or not the optional engine oil temperature sensor is installed on the genset.

0 - for gensets without an oil temperature sensor 1 - for gensets with an oil temperature sensor

0

0

0

P026 - High Oil Temperature Shutdown: oil temperature used by the GSC+ to declare a high oil temperature shutdown fault exists (after a 10 second delay). Refer to the panel model number.

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

225ºF (107ºC)

225ºF (107ºC)

225ºF (107ºC)

0

0

0

480V

4160V

3800V

600A

80A

73A

400kW

420kW

350kW

60Hz

60Hz

50Hz

0

0

0

4

4

4

0 - for alarm only (shutdown override, no P027 - Shutdown Override For High Oil Temperature Fault: GSC+ response to an engine high engine shutdown). oil temperature fault. 1 - for engine shutdown. P028 - Nameplate Voltage: rated voltage of the generator. This setpoint is used for protective relaying 100 to 25kV in increments of 1 functions. P029 - Nameplate Current: rated current output of the 0 to 4000 A in increments of 1 generator. P030 - Nameplate Power: rated power capability of 0 through 10MW in increments of 1kW. the generator. P031 - Rated Frequency: nominal frequency rating of 50 or 60Hz genset. P032 - Connection Configuration Of Generator: wye or delta configuration of generator. P033 - Number Of Generator Poles.

0 - wye 1 - delta 0 through 254 in increments of 2.

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The setpoints (stored or being programmed) must match the specified DPGDS setpoints.



When oil pressure drops to within 5PSI (34kPa) of the P013 or P014 setpoint, a low oil pressure alarm is issued by the GSC+.



When coolant temperature rises to within 11ºF (6ºC) of the P015 setpoint, a high coolant temperature alarm is issued by the GSC+.





The values other than the default (700V) are for switchgear applications and require the use of external potential transformers and the removal of the AC voltage range jumper located in the relay module. The DPGDS unit is factory configured for the 5.20 K value. See the Caterpillar Electronic Modular Control Panel II+ manual topic AC Voltage Range Selection in the Testing and Adjusting section. After setpoint P022 is reprogrammed, the GSC+ must be power cycled (powered down and then powered up)

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SETPOINTS OP5-1 PROTECTIVE RELAYING PROGRAMMING① SETPOINT-NAME-DESCRIPTION

RANGE OF VALUES

P101 - Generator Overvoltage Alarm Enable: the GSC+ enables or disables the generator overvoltage alarm function.

0 - disabled 1 - enabled

P102 - Generator Overvoltage Alarm Threshold: voltage the GSC+ uses to issue an overvoltage alarm.

100 to 125% of nameplate voltage in increments of 1%.

P103 - Generator Overvoltage Alarm Time Delay: amount of time the GSC+ waits before issuing an overvoltage alarm.

0 through 120 seconds② in increments of 1

P104 - Generator Overvoltage Shutdown Enable: the GSC+ enables or disables the generator overvoltage shutdown function.

0 - disabled 1 - enabled

P105 - Generator Overvoltage Shutdown Threshold: voltage the GSC+ uses to issue an overvoltage shutdown.

100 to 125% of nameplate voltage in increments of 1%.

P106 - Generator Overvoltage Shutdown Time Delay: amount of time the GSC+ waits before issuing an overvoltage shutdown.

0 through 120 seconds② in increments of 1

P107 - Generator Undervoltage Alarm Enable: the GSC+ enables or disables the generator undervoltage alarm function.

0 - disabled 1 - enabled

P108 - Generator Undervoltage Alarm Threshold: voltage the GSC+ uses to issue an undervoltage alarm.

60 to 100% of nameplate voltage in increments of 1%.

P109 - Generator Undervoltage Alarm Time Delay: amount of time the GSC+ waits before issuing an undervoltage alarm.

0 through 120 seconds② in increments of 1

P110 - Generator Undervoltage Shutdown Enable: the GSC+ enables or disables the generator undervoltage shutdown function.

0 - disabled 1 - enabled

P111 - Generator Undervoltage Shutdown Threshold: voltage the GSC+ uses to issue an undervoltage shutdown.

60 through 100% of rated voltage in increments of 1%.

P112 - Generator Undervoltage Shutdown Time Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments of 1 issuing an undervoltage shutdown. P113 - Generator Overfrequency Alarm Enable: 0 - disabled the GSC+ enables or disables the generator 1 - enabled overfrequency alarm function. P114 - Generator Overfrequency Alarm Threshold: frequency the GSC+ uses to issue an overfrequency alarm.

50-60Hz, for 50Hz Gen 60-70Hz, for 60Hz Gen 400-480, for 400Hz Gen

P115 - Generator Overfrequency Alarm Time Delay: amount of time the GSC+ waits before issuing an overfrequency alarm.

0 through 120 seconds② in increments of 1

P116 - Generator Overfrequency Shutdown Enable: the GSC+ enables or disables the generator overfrequency shutdown function.

0 - disabled 1 - enabled

P117 - Generator Overfrequency Shutdown Threshold: frequency the GSC+ uses to issue an overfrequency shutdown.

50-60Hz, for 50Hz Gen 60-70Hz, for 60Hz Gen 400-480, for 400Hz Gen

B-4

FACTORY DEFAULT

60HZ SETPOINT

50HZ SETPOINT

1

1

1

105%

105%

105%

10 seconds

10 seconds

10 seconds

1

1

1

110%

110%

110%

10 seconds

10 seconds

10 seconds

1

1

1

90%

90%

90%

10 seconds

10 seconds

10 seconds

1

1

1

85%

85%

85%

15 seconds

03 seconds

03 seconds

1

1

1

53Hz 63Hz 422Hz

63 Hz

53 Hz

10 seconds

10 seconds

10 seconds

1

1

1

55Hz 66Hz 440Hz

66Hz

55Hz

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

SETPOINTS OP5-1 PROTECTIVE RELAYING PROGRAMMING① RANGE OF VALUES

FACTORY DEFAULT

60HZ SETPOINT

50HZ SETPOINT

P118 - Generator Overfrequency Shutdown Time Delay: amount of time the GSC+ waits before issuing an overfrequency shutdown.

0 through 120 seconds② in increments of 1

10 seconds

10 seconds

10 seconds

P119 - Generator Underfrequency Alarm Enable: the GSC+ enables or disables the generator underfrequency alarm function.

0 - disabled 1 - enabled

1

1

1

P120 - Generator Underfrequency Alarm Threshold: frequency the GSC+ uses to issue an underfrequency alarm.

30-50Hz, for 50Hz Gen 36-60Hz, for 60Hz Gen 240-400, for 400Hz Gen

48Hz 57Hz 378Hz

57Hz

48Hz

P121 - Generator Underfrequency Alarm Time Delay: amount of time the GSC+ waits before issuing an underfrequency alarm.

0 through 120 seconds② in increments of 1

10 seconds

10 seconds

10 seconds

P122 - Generator Underfrequency Shutdown Enable: the GSC+ enables or disables the generator underfrequency shutdown function.

0 - disabled 1 - enabled

1

1

1

P123 - Generator Underfrequency Shutdown Threshold: frequency the GSC+ uses to issue an underfrequency shutdown.

30-50Hz, for 50Hz Gen 36-60Hz, for 60Hz Gen 240-400, for 400Hz Gen

45Hz 54Hz 360Hz

54Hz

45Hz

P124 - Generator Underfrequency Shutdown Time Delay: amount of time the GSC+ waits before issuing an underfrequency shutdown.

0 through 120 seconds② in increments of 1

15 seconds

03 seconds

03 seconds

P125 - Generator Reverse Power Shutdown Enable: the GSC+ enables or disables the generator reverse power shutdown function.

0 - disabled 1 - enabled

1

1

1

P126 - Generator Reverse Power Shutdown Threshold: level of reverse power the GSC+ uses to issue a reverse power shutdown.

0 through 20% of rated power in increments of 1%.

15%

4%

4%

P127 - Generator Reverse Power Shutdown Time Delay: amount of time the GSC+ waits before issuing a reverse power shutdown.

0 through 30 seconds② in increments of 1

10 seconds

4 seconds

4 seconds

P128 - Generator Overcurrent Alarm Enable: the GSC+ enables or disables the overcurrent alarm.

0 - disabled 1 - enabled

1

1

1

105%

150%

150%

0 seconds

0 seconds

0 seconds

105%

150%.

150%

0 seconds

0 seconds

0 seconds

1

1

1

110%

150%

150%

0 seconds

10 seconds

10 seconds

SETPOINT-NAME-DESCRIPTION

P129 - Generator Phase Overcurrent Alarm 100 through 160% of nameplate current in Threshold: level of current the GSC+ uses to issue increments of 5% a phase overcurrent alarm. P130 - Generator Phase Overcurrent Alarm Time Delay: amount of time the GSC+ waits before issuing a phase overcurrent alarm.

0 through 250 seconds② in increments of 1

P131 - Generator Total Overcurrent Alarm 100 through 160% of three times nameplate Threshold: level of current the GSC+ uses to issue current in increments of 5% a total overcurrent alarm. P132 - Generator Total Overcurrent Alarm Time Delay: amount of time the GSC+ waits before issuing a total overcurrent alarm.

0 through 250 seconds② in increments of 1

P133 – Generator Overcurrent Shutdown Enable: the GSC+ enables or disables the overcurrent shutdown.

0 – disabled 1 – enabled

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

B-5

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SETPOINTS OP5-1 PROTECTIVE RELAYING PROGRAMMING① SETPOINT-NAMEFACTORY 60HZ RANGE OF VALUES SETPOINT DESCRIPTION DEFAULT P136 - Generator Total Overcurrent Shutdown 100 through 160% of three times nameplate Threshold: level of current the GSC+ uses to issue current in increments of 5% a total overcurrent shutdown. P137 - Generator Total Overcurrent Shutdown Time Delay: amount of time the GSC+ waits before issuing a total overcurrent shutdown.

0 through 250 seconds② in increments of 1

P138 - KW Level Relay Enable : the GSC+ enables or disables the kW level relay function.

0 - disabled 1 - enabled

P139 - KW Level Relay Threshold: level of 0 through 110% of nameplate power in power the GSC+ uses to activate the kW level relay increments of 1% function. P140 - KW Level Relay Time Delay: amount of time the GSC+ waits before activating the kW level 0 through 120 seconds② in increments of 1 relay function. P141 - KW Level Relay Disengage Threshold: 0 through 110% of nameplate power in level of power the GSC+ uses to deactivate the kW increments of 1%. level relay function. P142 - KW Level Relay Disengage Time Delay: amount of time the GSC+ waits before deactivating 0 through 120 seconds② in increments of 1 the kW level relay function.

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

B-6

50HZ SETPOINT

110%

150%.

150%

0 seconds

10 seconds

10 seconds

1

1

1

105%

105%

105%

0 seconds

0 seconds

0 seconds

100%

100%

100%

10 seconds

10 seconds

10 seconds

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SETPOINTS OP6 SPARE INPUT/OUTPUT PROGRAMMING SETPOINT-NAME-DESCRIPTIONS

RANGE OF VALUES

FACTORY DPGDS DEFAULT SETPOINT

SP01 - Spare Input 1 Active State. Input state used by the GSC+ to declare a SP1 fault exists.

0-active low 1-active high

0

0

SP02 - Spare Input 1 Response: GSC+ response to a SP1 fault.

0-shutdown 1-alarm

0

0

SP03 - Spare Input 1 Time Delay: Amount of time the GSC+ waits before responding to a SP1 fault.

0 - 250 seconds in increments of 1

0 seconds

1 second

0

1

0

0

0 seconds

0 seconds

0

0

0

0

0 seconds

0 seconds

0

0

0

0

0 seconds

0 seconds

0

0

8

8

1

1

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

0-active low 1-active high 0-shutdown 1-alarm 0 - 250 seconds in increments of 1 0-active low 1-active high 0-shutdown 1-alarm 0 - 250 seconds in increments of 1 0-active low 1-active high 0-shutdown 1-alarm 0 - 250 seconds in increments of 1 0-active low 1-active high 0-unused 1-active SP1 fault② 2-active SP2 fault② 3-active SP3 fault②

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

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

SP15 – Spare Relay Output Response: GSC+ response to the spare relay trigger condition.

10-high oil temp fault② 11-CCM control 0-relay inactive when triggered 1-relay active when triggered

B-7

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SETPOINTS OP6 SPARE INPUT/OUTPUT PROGRAMMING SETPOINT-NAME-DESCRIPTIONS

RANGE OF VALUES

FACTORY DPGDS SETPOINT DEFAULT

0-unused 1-active SP1 fault② 2-active SP2 fault② 3-active SP3 fault② SP16 - Spare Relay Output Trigger Condition: The condition used by the GSC+ to trigger the spare relay.

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

8

1

0

6

Battle Short mode.

0

0 Battleshort③

Not in 60 Hz mode.

0

9-coolant loss mode② 10-high oil temp fault② 11-CCM control 0-unused 1-active SP1 fault② 2-active SP2 fault② 3-active SP3 fault② SP17 - Spare Indicator 1 Trigger Condition: The condition used by the GSC+ to trigger spare indicator①.

4-active SP4 fault② 5-any combination of active SP1, SP2, SP3 or SP4 faults② 6-Coolant loss fault② 7-high oil temperature fault②

SP18 - Spare Indicator 2 Trigger Condition: The condition used by the GSC+ to trigger spare indicator②. SP19 - Spare Indicator 3 Trigger Condition: The condition used by the GSC+ to trigger spare indicator③.

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

B-8

0 In 50Hz Mode③

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ANNEX C ENGINE/GENERATOR ALARM AND SHUTDOWN POINTS

ENGINE – GSC CONDITION

ALARM POINT

SHUTDOWN POINT

Low Oil Pressure: 1



At Rated Speed

N/A

30 psi



At Idle Speed

N/A

10 psi

2

Engine Overspeed

N/A

2120 rpm

3

High Coolant Temperature

N/A

225°F

4

Low Coolant Temperature

N/A

70°F

5

High Oil Temperature

N/A

225°F

C-1

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GENERATOR - GSC CONDITION Over Voltage: 6

10 Seconds at -

- 105%

3990 Volts

- 110%

4180 Volts



60Hz

- 105%

4368 Volts

- 110%

4576 Volts

10 Seconds at -

15 Seconds at -



50Hz

- 90%

3420 Volts

- 85%

3230 Volts



60Hz

- 90%

3744 Volts

- 85%

3536 Volts

10 Seconds at -

10 Seconds at -



50Hz

- 53Hz

- 55Hz



60Hz

- 63Hz

- 66Hz

Under Frequency: 9

10 Seconds at -

50Hz

Over Frequency: 8

SHUTDOWN POINT



Under Voltage: 7

ALARM POINT

10 Seconds at –

15 Seconds at –



50Hz

- 48 Hz

- 45 Hz



60Hz

- 57 Hz

- 54Hz

10

Reverse Power

10 Seconds at 10%

11

Phase Overcurrent

0 Seconds at 150%

10 Seconds at 150%

12

Total Overcurrent

0 Seconds at 150%

10 Seconds at 150%

C-2

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ANNEX D BASLER OVERCURRENT RELAY SETPOINTS, ALARM AND SHUTDOWN POINTS CT RATIO SETTINGS BREAKER RELAY GENERATOR FEEDER TIE

CT RATIO 100:5 200:5 200:5

INSTANTANEOUS TRIP SETTINGS PHASE INSTANTANEOUS BREAKER RELAY TRIP 50TP PU TD 0.0 0m GENERATOR 7.5 84m FEEDER 0.0 0m TIE

“P” VALUE 20 40 40

“N” VALUE 20 40 40

NEUTRAL INSTANTANEOUS TRIP 50TN PU TD 3.0 0m 1.25 84m 0 0m

NEGATIVE SEQUENCE TRIP 50 TQ PU TD 3.0 0m 0 0m 0.0 0m

TIME OVERCURRENT TRIP SETTINGS PHASE TIME OVERCURRENT BREAKER RELAY TRIP 51P PU TD C 4.50 0.5 VV2 GENERATOR 2.50 1.0 VV2 FEEDER 5.00 2.0 VV2 TIE

D-1

NEUTRAL TIME OVERCURRENT TRIP 51N PU TD C 1.25 0.5 VV2 1.00 1.0 VV2 1.50 2.0 VV2

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D-2

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ANNEX E AUTOMATIC VOLTAGE REGULATOR (AVR) SETPOINTS Step 1: Go to parameter 90 and set "DPGDS Setpoints" to 01. Setpoints can only be changed when parameter 90 is any number besides 0009. 0009 locks changes out. After all changes have been made to setpoints, return to parameter 90 and change back to 0009.

DPGDS SETPOINTS

DPGDS AVR PARAMETERS PARAMETER

TITLE

TYPE

UNITS

RANGE OF VALUES

DEFAULT VALUE

60HZ OPS

50HZ OPS

01

Generator Output Voltage

Program

Volts

0080-9999

480①

4160

3800

02

Ratio of Output Voltage To Sensing Voltage Generator Type Rated Generator Output Current CT Voltage At Rated Generator Current

Program

001.0-100.0

001.0

17.3

17.3

03 04 05②

Program Program Program

Amps Volts

0000-0004 0000-9999 01.00-05.00

0004 0600 05.00

4 80 4.00

4 73 3.66

06 07 08 09 10

Knee Frequency Decreasing Volts/Hz Slope I Decreasing Volts/Hz Slope 2 Minimum Voltage Under Frequency Point

Program Program Program Program Program

Hz Volts/Hz Volts/Hz % Hz

045.0-065.0 001.0-010.0 001.0-010.0 050.0-100.0 020.0-040.0

050.0 002.0 002.0 050.0 025.0

59.8 2.0 2.0 50.0 25.0

49.8 2.0 2.0 50.0 25.0

11 12 13 14 15

Program Program Program Program Program Program

% Seconds % Seconds %

16⑤

Overvoltage Trip Point Overvoltage Trip Time Under Voltage Trip Point Under Voltage Trip Time Voltage Gain (IR Compensation) Integral Gain

0105-0140 0002-0030 0060-0095 0030-0120 000.0-0 10.0 001.0-020.0

014.0 0002 0060 0030 0000 006.0

125.0 5 75 30 0 6.0

125.0 5 75 30 0 6.0

17⑥

Proportional Gain

Program

001.0-020.0

005.0

5.0

5.0

Program

0000,0001

0000

0000

0000

31③

Single Phase Sensing Select (0=three_phase,_1=single phase) Diode Monitor Trip Point Droop Percentage pf/kVAR Select (0=pf, 1=kVAR)

001.0-010.0 000.0-010.0 0000, 0001

002.0 0000 0000

2.0 3 0

2.0 3 0

32③

Pf Reference

Program

00.60-01.10

01.00

0.8

0.8

33③

KVAR Reference

Program

Per Unit

00.00-01.00

0000

.10

.10

34③

Reverse Power Trip Point

Program

%

000.0-020.0

010.0

15

15

35③

Reverse Power Trip Time

Program

Seconds

000.0-020.0

010.0

5

5

50 51 52 53

Generator Output Frequency Generator Output Voltage Generator Output Current Generator Reactive Output Current

View View View View

Hz Volts Amps Amps

54 55

Generator Real Current Exciter Field Current Three Phase Kilowatts (KB and later) Power Factor

View View View

Amps Amps KW

18 19 30

56③ 57③

Program Program Program

Amps %

View

E-1

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DPGDS SETPOINTS

DPGDS AVR PARAMETERS PARAMETER

TITLE

TYPE

58③,④

Three Phase kVAR (KE and later)

View

60 90 91 92

Hours Password Software ID Latest Fault

View Program View View

93 94 96

Previous Fault Fault Clear Shutdown Fault Reset

View View Switch

UNITS

RANGE OF VALUES

Hours

0000-9999

DEFAULT VALUE

60HZ OPS

50HZ OPS

0009

0009

0000

0000

0000

0000

0000

0000

① Default value for output voltage is different depending on regulator sensing voltage. If the regulator is designed for l20 volts sensing, then the default output voltage is 4l60 volts. All other sensing types have the default output voltage set to 480 volts. ② Digital Voltage Regulators with earlier software (KD and earlier) have I less digit to the right of the decimal point. ③ Optional feature. ④ New parameter on serial number prefix KE and later Digital Voltage Regulators. ⑤ Previous range of 0001-099.9 and default value of 002.0 ⑥ Previous range of 0001-099.9 and default value of 002.0 NOTE:

Parameters 20, 21, 22, 36, 37, and 38 are displayed but not used.

E-2

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ANNEX F 3456 EPG ADEM SETPOINTS

CAT ELECTRONIC TECHNICIAN ET3.0 (OCT99) ECM Summary 01/12/2000 2:36 PM 3456 EPG Engine (9BZ00002) Parameter

Value

Equipment ID Engine Serial Number use data plate value ECM Serial Number Personality Module Part Number Personality Module Release Date Personality Module Description

F-1

9BZ00002 08390151CG 1730820-00 May99 EPG 3456

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CAT ELECTRONIC TECHNICIAN ET3.0 (OCT99) Configuration 3456 EPG Engine (9BZ00002) Parameter

Value

Description

Value

Selected Engine Rating Rating Number Rated Power Rated Peak Torque Top Engine Speed Range Test Spec ECM Identification Parameters Equipment ID Engine Serial Number use data plate value ECM Serial Number Personality Module Part Number Personality Module Release Date Personality Module Description Security Access Parameters Total Tattletale Engine/Gear Parameters Rated Engine Speed Acceleration Delay Time Engine Accel. Rate Low Idle Speed Cooldown Speed Engine Cooldown Duration Crank Duration Maximum No of Crank Cycles Configuration Continued Crank Terminate Speed I/O Configuration Parameters Ether Control Configuration ContinuedParameter Description Fuel Pressure Sensor

TT

2 669 HP at 1800 RPM 2655 lb-ft at 1200 RPM 1500 - 1945 RPM 0K1501 0 0

9BZ00002 08390151CG 1730820-00 May99 EPG 3456 1 1800 0 250 1200 1800 0 0 0

RPM Sec RPM/s RPM RPM min Sec

400

RPM

Enabled

0 0 0 0 0 0 0 0 0

Value Value Not Installed

F-2

Unit

Unit

TT 0

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CAT ELECTRONIC TECHNICIAN ET3.0 (OCT99) (CONTINUED) Exhaust Temperature Sensor Installation Status Engine Oil Temperature Sensor Installation Status User Defined Switch Installation Status User Defined Switch Active State Configuration System Parameters FLS use data plate value FTS use data plate value System Gain

F-3

Not Installed Not Installed Not Installed Low

0 0 0 0

-28 22 0

0 0 0

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Value

Description

State

Trip Point

Delay Time

Low System Voltage Warn Operator

On

20 Volts

5 Sec

Low Engine Oil Pressure Warn Operator Engine Shutdown

On Off

None None

5 Sec 10 Sec

High Engine Coolant Temperature Warn Operator Engine Derate Engine Shutdown

On On Off

217 Deg F 221 Deg F 223 Deg F

5 Sec 5 Sec 20 Sec

Low Engine Coolant Temperature Warn Operator

On

167 Deg F

5 Sec

On Off

2200 RPM 2300 RPM

0 Sec 0 Sec

On

12.8 PSI

0 Sec

Warn Operator

On

172.4 Deg F

30 Sec

High Fuel Temperature Warn Operator

On

176 Deg F

30 Sec

Monitoring System Tool Continued Engine Overspeed Warn Operator Engine Shutdown Monitoring System Tool ContinuedAltitude (atmospheric pressure) Engine Derate High Engine Inlet Air Temperature

F-4

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CAT ELECTRONIC TECHNICIAN ET3.0 (OCT99) Current Totals 01/12/2000 2:44 PM 3456 EPG Engine (9BZ00002) Parameter

Value

Description

Value

Unit

Total Time Total Fuel Ether Usage

2 31 0

hours Gal Gal

CAT ELECTRONIC TECHNICIAN ET3.0 (OCT99) Injector Codes Calibration 01/12/2000 2:43 PM 3456 EPG Engine (9BZ00002) Parameter

Value

Injector use data from each individual engine and the injector Injector 1 engine specific value Injector 2 engine specific value Injector 3 engine specific value Injector 4 engine specific value Injector 5 engine specific value Injector 6 engine specific value

F-5

Code 8837 8922 4657 7827 5622 5867

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CAT ELECTRONIC TECHNICIAN ET3.0 (OCT99) Active Code 01/12/2000 2:42 PM 3456 EPG Engine (9BZ00002) Parameter

Value

Code

Description

No Active Codes

CAT ELECTRONIC TECHNICIAN ET3.0 (OCT99) Logged Diagnostic Codes 01/12/2000 2:42 PM 3456 EPG Engine (9BZ00002) Parameter

Value

Code

Description

Occur

First

Last

11

0

0

3456 EPG Engine (9BZ00002) Diagnostic Clock = 2 hours 91- 8

Throttle Position signal abnormal

F-6

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Cat Electronic Technician ET3.0 (OCT99) Event Code 01/12/2000 2:42 PM 3456 EPG Engine (9BZ00002) Parameter

Value

Code

Description

Occur

First

Last

1

2

2

2

0

0

3456 EPG Engine (9BZ00002) Diagnostic Clock = 2 hours E027 E043

High Inlet Air Temperature Warning Low System Voltage Warning

CAT ELECTRONIC TECHNICIAN ET3.0 (OCT99) Status Group 1 01/12/2000 2:39 PM 3456 EPG Engine (9BZ00002) Parameter

Value

Description

Value

Unit

0 400 0 74 0 50 30 0

RPM RPM PSI %

3456 EPG Engine (9BZ00002) : 3456 EPG Engine Group 1 Engine Speed Desired Engine Speed Boost Pressure Throttle Position Fuel Position Rated Fuel Limit FRC Fuel Limit Engine Speed Droop

F-7

%

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CAT ELECTRONIC TECHNICIAN ET3.0 (OCT99) Status Group 2 01/12/2000 2:40 PM 3456 EPG Engine (9BZ00002) Parameter

Value

Description

Value

Unit

66 66 66 0 14 14.5 15 Unavailable Parameter Unavailable Parameter

Deg F Deg F Deg F PSI PSI PSI PSI PSI PSI

3456 EPG Engine (9BZ00002) : 3456 EPG Engine Group 2 Engine Coolant Temperature Inlet Air Temperature Fuel Temperature Engine Oil Pressure Engine Oil Pressure (abs) Atmospheric Pressure Turbo Outlet Pressure (abs) Fuel Pressure Fuel Pressure (abs)

F-8

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CAT ELECTRONIC TECHNICIAN ET3.0 (OCT99) Status Group 3 01/12/2000 2:41 PM 3456 EPG Engine (9BZ00002) Parameter

Value

Description

Value

Unit

Unavailable Parameter Unavailable Parameter Unavailable Parameter Abnormal Signal

PSI PSI Deg F Deg F

3456 EPG Engine (9BZ00002) : 3456 EPG Engine Group 3 Fuel Pressure Fuel Pressure (abs) Engine Oil Temperature Exhaust Temperature

F-9

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Value

Description

Value

3456 EPG Engine (9BZ00002) : 3456 EPG Engine Group 4 Engine Control Switch Remote E-Stop Switch Startup Mode Overspeed Test Switch Ether Injection Remote Start

Unit

Stop Off Off Off Off Unavailable Parameter

CAT ELECTRONIC TECHNICIAN ET3.0 (OCT99) Status Group 5 01/12/2000 2:41 PM 3456 EPG Engine (9BZ00002) Parameter

Value

Description

Value

Unit

0 0 25 0 Off 0

GPH % Volts Sec

3456 EPG Engine (9BZ00002) : 3456 EPG Engine Group 5 Fuel Rate Engine Load Factor Battery Voltage Remaining Cooldown Time Shutdown Notify Status Engine Power Derate

F-10

%

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Value

Description

State

Trip Point

Delay Time

Low System Voltage Warn Operator

On

20 Volts

5 Sec

Low Engine Oil Pressure Warn Operator Engine Shutdown

On Off

None None

5 Sec 10 Sec

High Engine Coolant Temperature Warn Operator Engine Derate Engine Shutdown

On On Off

217 Deg F 221 Deg F 223 Deg F

5 Sec 5 Sec 20 Sec

Low Engine Coolant Temperature Warn Operator

On

167 Deg F

5 Sec

On Off

2200 RPM 2300 RPM

0 Sec 0 Sec

Altitude (atmospheric pressure) Engine Derate

On

12.8 PSI

0 Sec

High Engine Inlet Air Temperature Warn Operator

On

172.4 Deg F 30 Sec

High Fuel Temperature Warn Operator

On

176 Deg F

Monitoring System Tool Continued Engine Overspeed Warn Operator Engine Shutdown Monitoring System Tool Continued-

F-11

30 Sec

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F-12

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ANNEX G CONSUMABLE OPERATING AND MAINTENANCE SUPPLIES Table G-1 lists the consumable materials needed to operate, maintain, and store/preserve the MEP-PU810 A/B. The items are identified by Military Specification, National Stock Number (NSN) or Vendor Part Number. MEP-PU-810 CONSUMABLE MATERIALS MEP-PU-810 MAJOR COMPONENT

SUBSYSTEM

ITEM

NSN/ PART NUMBER

DESCRIPTION

Fuel Type 1

Fuel System

Fuel JP-8

Fuel Type 2 9140-00-286-5294 Primary Fuel Filter Secondary Fuel Filter

Regular Grade, DF2 VV-F-800 (+20 to+125°F; -6.6 to +51.6°C)

QUANTITY REQUIRED FOR INITIAL START-UP 120 gallons (454 liters) 120 gallons (454 liters)

129-0372

2

1R-0749

2 Diesel Engine Oil (SAE 30) -32 °F to 104 °F

3456 ENGINE

Diesel Engine Oil (SAE 10W-30) -4 °F to 104 °F

Oil Lubrication

36 Gallons

Diesel Engine Oil (SAE 15W-40) +5 °F to 122 °F See Note 1 Lube Oil Filter

1R-0716

2

NOTE 1: Oil used in the Caterpillar 3456 engine must meet SAE viscosity ratings. (SAE = Society of Automotive Engineers) Also Oil used in the Caterpillar 3456 EPG engine must meet the following API standards. (API = American Petroleum Institute) ♦

CF-4, API GRADE OIL (Minimum requirement for 3456 EPG)



CH-4, API GRADE OIL (Recommended lube for 3456 EPG)

G-1

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SUBSYSTEM

ITEM

NSN/ PART NUMBER

DESCRIPTION

QUANTITY REQUIRED FOR INITIAL START-UP

Extended Life Coolant(ELC) 101-2844

1 Gallon, pre-diluted 50/50, -34 ºF

101-2845

55 Gallon, pre-diluted 50/50, -34 ºF

Coolant

32 Gallons Commercial Antifreeze meeting ASTM D5345 Commercial Antifreeze meeting ASTM D4985

COOLING

119-5152

1 Quart, ELC Extender, (Quantity needed is listed on bottle)

119-5150

1 Gallon, ELC Extender, (Used for adjusting lower freeze protection requirements or for mixing with correct water by customer)

Ether

2910-00-2094997

Tank, Primer, Starting (Ether)

Air Filter

4N-0015

ELC Extender

3456 ENGINE

Ether Starting System Air Intake System

2 2

Mobil AERO HF (-65˚F to 45˚F

Hydraulic System

Mobile DTE 18M (48˚F to 125˚F)

Hydraulic Fluid M9150 01 461 1142 Hydraulic Filter

RE-409-10

G-2

36 Gallons

Mobil DTE 11M (-25˚F to 75˚F) 2

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1R0254 MEP-PU-810 CONSUMABLE MATERIALS (CONTINUED) QUANTITY MEP-PU-810 REQUIRED NSN/ PART MAJOR SUBSYSTEM ITEM DESCRIPTION NUMBER FOR INITIAL COMPONENT START-UP SR-4B GENERATOR

Bearings

2S-3230 Mobil grease HP. Ronex MP. Kendall L427. Grease:

Valvoline Val-plex EP Grease. Pennzoil Premium Wheel Bearing Grease 707L. Union MP Gear Lube – LS.

Wheel Bearings/ Slack Adjusters/ Spider and Support Bushings

1.8 to 2.0 oz Every 2000 Hours Thickener Type: Lithium complex Dropping Point: 446°F minimum Consistency: 2

NLGI No.

Additives: EP, Corrosion & Oxidation Inhibitors Base Oil: Solvent Refined Petroleum Oil

Exxon Gear Oil GX80W-90.

TRAILER

Oil

Mobilube SHC 75W-90. Pennzoil Multipurpose Gear Lubricant 4092 and 4096.

Surge Brake (MEP-PU810A only) Towing assembly Landing Leg assembly (MEP-PU810B only) 3456 ENGINE

Storage/ Preservation

Brake Fluid

Grease

DOT-3 or DOT-4

1 Pint

General purpose axle grease GAA

Preserving Fluids

4C-6794

VCI Oil

5 Gallons

6V-6068

Calibration Fluid

5 Gallons

G-3

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

THIS PAGE INTENTIONALLY BLANK

G-4

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

ANNEX H SPECIAL TOOLS AND EQUIPMENT The tools and equipment required for Organizational Level Maintenance of the MEP-PU-810 are listed in the following Table: SPECIAL TOOLS AND TEST EQUIPMENT CATERPILLAR TOOLS ITEMS Battery Load Tester Ammeter Coolant and Battery Tester Strap Wrench Assembly Oil Filter Cutter Pressure Gauge Pressurizing Pump Flow Checking Tool Group Engine Turning Tool Injector Height Setting Engine Pressure Group Thermistor Indicator Group Crimping tool Diagnostic Cables Diagnostic Cables Diagnostic Cables Diagnostic Cables Wire Removal Tools Wire Removal Tools 4mm Hex tool Deutsch DT Connecter Service Kit Dial Indicator Group

NSN/ REFERENCE NUMBER 4C-4911 8T0900 5P-3514

USE Test Battery Condition Test Battery Condition Tests Coolant Freezing Point and Battery Fluid Condition

2P-8250

Remove Oil Filter

4C-5084 9S-8138 9S-8140 9S-9082

Inspect used Oil Filters for Debris To perform the Water Pump Pressure Check Inspect/Trouble-Shoot Coolant System Troubleshooting Fuel system and Preserving Engine For turning engine for maintenance

9U-7227

Setting Injector Height

1U-5470

Fuel Pressure

8T-470 8S-2328 1U-5804 7x-1710 7x-6370 7x-1715 7x-1160 151-6320 1U-5805 125-2584

Cooling System Temperature Troubleshooting Reinstall generator to engine Repair of Deutsch connectors Test/Repair of Deutsch connectors Test/Repair of Deutsch connectors Test/Repair of Deutsch connectors Test/Repair of Deutsch connectors Test/Repair of Deutsch connectors Test/Repair of Deutsch connectors Test/Repair of Deutsch connectors

9U-7250

Repair of wiring harness

8T-5096

Used to check endplay clearance of the turbocharger Used to check endplay clearance of the turbocharger Used to check endplay clearance of the turbocharger Used to check endplay clearance of the turbocharger

1P-0540

Holding Rod

7H-1945

Holding Rod

7H-1645

Universal Attachment

7H-1940

Communication Adapter II Group (ET Tool)

171-4400

Engine Diagnostics

H-1

USAF TO 35C2-3-518-1 USA TM 9-6115-484-14 DRS RADIAN CTM: 01646.1R0253/1R0254 SPECIAL TOOLS AND TEST EQUIPMENT (CONTINUED) SPECIAL TOOLS OTHER THAN CATERPILLAR ITEMS HIPOTRONICS DC Hipot Tester BIDDLE Digital – Low - Resistance - Ohmmeter ELASTIMOLD Bushing Installer MULTI-AMP MS-2 Circuit Breaker Tester FLUKE 1520 Meg-Ohm-Meter FLUKE 87 III Digital Multimeter AC/DC Ammeter CRAFTSMAN 12 ton jack; 9 7/8 in. to 18 5/8 in. range JOHN DOW INDUSTRIES 12 ton jack stands HIPOTRONICS Vacuum Interrupter Tester SNAP-ON Torque Wrench ¼ Inch Drive; 0 to 30 inch pound range SNAP-ON Torque Wrench 3/8 Inch Drive; 0 to 50 foot-pound range SNAP-ON Torque Wrench 1/2 Inch Drive; 0 to 250 foot-pound range SNAP-ON Torque Wrench 3/4 Inch Drive; 0 to 600 foot-pound range AEMC (Optimum Energy Products)

4 Point Ground Tester

NSN/ REFERENCE NUMBER

USE

880PL

Checking Load Break Bushings, Load Break Elbows, Load Cables

247002

Checking Contact Resistance on Contactors

200AT

For installing the 200 Amp High Voltage Bushings

MS-2-115

Tests Circuit Breaker

1520 Or Equivalent 87 III Or Equivalent 8T-0900/ 6625-00-892-1497 00950284000

Testing Alternator Insulation Resistance Trouble-Shoot/test electrical continuity, voltage, and current less than 10 Amps Trouble-Shoot/test current over 10 Amps WHEEL AND BRAKE WORK

JS - 12

Wheel and brake work

7BT60A

Checking Vacuum Bottles

GTE3A

General Maintenance

GTE50FA

General Maintenance

GTE250

General Maintenance

GTE602

General Maintenance

4630

Testing grounds during plant setup

H-2

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ANNEX I POWER UNIT LOGIC FLOWCHART

I-1

Terminator

Decision

Predefined subprocess

Logic process

Data

Extract

Merge

Off-page connector

Connector

I-2

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Start - Power ON

Entry point when system is powered up

Is this the initial scan after power on?

Virtual

Initialize Variables (Page I-6)

Subroutine

PPU configuration (Page I-7)

Subroutine

Main Logic

Sets station ID & IP address for network (Page I-10)

Subroutine

Station ID

Unpacks data from Caterpillar components into RTU usable variables for each engine (Page I-15)

Subroutine

Calculates the baseload (Page I-19)

Subroutine

Controls engine (1 & 2) emergency stop button (Page I-20)

Subroutine

Controls Genset 86 lockouts (Page I-21)

Subroutine

INIT_SCN

False

True

Initialize Variables

Unpack Data

1 to 2

Calculate Baseload

Engine ESTOP Control

Lockout

Page I-4

Subprogram continues…

Note: Program runs as a continuous loop from power on until power off.

I-3

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-3

Frequency

PDC Status Unpack

LS Check Enabled

True

False

Load Share

GenSet Load Share Control

Controls 50/60Hz mode (Page I-23)

Subroutine

Unpacks PDC data into usable variables (Page I-25)

Subroutine

Is automated load sharing enabled?

Virtual

Automated load sharing control (Page I-27)

Subroutine

Unpacks Caterpillar GSC+ data into variables (Page I-29)

Subroutine

Alarm and fault summary (Page I-30)

Subroutine

Calculates total KW load, and number of generators needed for load (Page I-38)

Subroutine

Determines which genset to turn on/off if needed. (Page I-43)

Subroutine

1 to 2

Alarms

Genarator Count

Economy

Page I-5

I-4

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-4

Unit A

False

True

Operate PPU A

Operate PPU

Is PPU unit A?

DIM1-IN15

Logic Specific for operating unit A (Page I-61)

Subroutine

Logic Specific for operating units B, C & D (Page I-66)

Subroutine

Controls PDC status LEDs (Page I-70)

Subroutine

Logic to control DBC (Page I-73)

Subroutine

Controls engines, first iteration for engine 1, second for engine 2. (Page I-76)

Subroutine

Controls tie & feeder breakers (Page I-95)

Subroutine

Controls PPU buzzer. (Page I-102)

Subroutine

1 to 3

Status

DBC Control

Engine Control

1 to 2

Tie / Feeder Control

Announce

Page I-3

I-5

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Start - Initialize Variables

Entry point for initialize variables routine

IP Address

Sets the Versatrak IP address

Virtual

Set each genset condition to "Off"

Virtual

Engine Start

Set each engine start command to "Off"

Virtual

Breaker Control

Set each generator remote open/close toggle relay to "Off"

Virtual

Set each generator remote start/stop relay to "Off"

Virtual

Set engine economizing blocking to "Off"

Virtual

Set default baseload setpoint to 500

Virtual

Genset Condition

Remote Start/Stop

1 to 2

Engine Econ. Blocking

Baseload Setpoint

Return

End of subprogram.

I-6

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Start - Main Logic

SMS Not Auto

Entry point for main logic subprogram

True

SMS Not Manual

False

False

True

Time Delay 3 seconds

No SMS Change

RTU-IN1

System Mode Switch (SMS) not set to Manual

RTU-IN2

The 3 second delay allows the SMS to transition through OFF to MAN and AUTO positions without start.

Function

SMS is set to OFF and three second time delay has expired.

True

False

PDC Off

INIT_SCN

MSPB_TOG =F

System Mode Switch (SMS) not set to Auto

True

Set PDC state variable to "Off"

Virtual

Reset initial scan variable to "True". This restores the system to power-up state.

Virtual

Is Master System Enable Toggle bit set to "False"?

Virtual

Set genset initial startup lockout to "False".

Virtual

Check Gen. 1 & 2 Ready variables to see if both or only 1 are ready for Auto operation.

Virtual

Set Dual variable to "True" if both ready for Auto operation, otherwise "False".

Virtual

Set Single variable to "False" if both ready for Auto operation, otherwise "True".

Virtual

False Genset Initial Startup Lockout Reset

Genset Ready

True

False Dual Genset

Dual Genset

Single Genset

Single Genset

Page I-8

I-7

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-7

Are neither generator 1 nor generator 2 breakers closed?

DIM1-IN3 & DIM2-IN3

Set QTY_GEN_ON internal variable to 0.

Virtual

Is generator 1 breaker open and gen. 2 closed, or is gen. 1 breaker closed and gen. 2 open?

DIM1-IN3 & DIM2-IN3

Set QTY_GEN_ON internal variable to 1.

Virtual

Are both generator 1 and generator 2 breakers closed?

DIM1-IN3 & DIM2-IN3

Set QTY_GEN_ON internal variable to 2.

Virtual

Is the Generator Mode Switch in Prime Power position?

RTU-IN5

Is load sharing routine disabled?

Virtual

Is total system KW load for ORT > 50?

Virtual

Enable the load sharing routine.

Virtual

Sets the auxillary relay for generator breaker status to breaker open/close current status.

Virtual

Set auxillary tie breaker

Sets the auxillary relay for tie breaker status to current tie breaker status.

Virtual

Set auxillary system bus

Sets the auxillary relay for system bus status to current system bus status.

Virtual

Breakers not closed

True

Qty Generators On = 0

False

1 breaker closed

True

Qty Generators On = 1

False

2 breakers closed

True

Qty Generators On = 2

False

GMS Prime Power False

True

LS Check disabled False

True

Total KW > 50 False

True Enable LS Check

Set auxillary generator relays

1 to 2

Page I-9

I-8

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-8

Fuel transfer pump

Startup timer expired

True

DOM1-OUT11

Did 2500 ms pass since power on?

Virtual

Turn on the PCM (or keep it on).

DOM1-OUT16

Is the B designated unit online (connected to the ethernet network)?

Virtual

Set network value used by "A" unit to check for overcurrent on "B" unit to 0.

Virtual

Is the C designated unit online (connected to the ethernet network)?

Virtual

Set network value used by "A" unit to check for overcurrent on "C" unit to 0.

Virtual

Is the D designated unit online (connected to the ethernet network)?

Virtual

Set network value used by "A" unit to check for overcurrent on "D" unit to 0.

Virtual

PCM on

False

B RTU online

Enable / disable the fuel transfer pump if Fuel_Permissive relay is on / off.

True

False B_Status_Word =0

C RTU online

True

False C_Status_Word =0

D RTU online

True

False D_Status_Word =0

Return

End of subprogram.

I-9

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Start - Station ID

MSPB

Start of Station ID subprogram.

True

False System mode Off False

True

USS A

True

Station # =1

False

IP address =ip1

USS B

True

Station # =2

False

IP address =ip2

USS C

True

Station # =3

False

IP address =ip3

USS D False

True

Station # =4

IP address =ip4

Is the Master Start Enable Switch in either ENABLE position?

RTU-IN3

Is the System Mode Switch not in the OFF position (MAN or AUTO)?

Virtual

Unit Select Switch is in the A position.

DIM1-IN15

Set station # variable to 1.

Virtual

Set IP address to constant ip1.

Virtual

Unit Select Switch is in the B position.

DIM1-IN16

Set station # variable to 2.

Virtual

Set IP address to constant ip2.

Virtual

Unit Select Switch is in the C position.

DIM2-IN15

Set station # variable to 3.

Virtual

Set IP address to constant ip3.

Virtual

Unit Select Switch is in the D position.

DIM2-IN16

Set station # variable to 4.

Virtual

Set IP address to constant ip4.

Virtual

Page I-11

I-10

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-10

MSPB_TOG =F

True

SMS =Off

False

True

False

RTU_EN =T

RTU_ON =T

RTU_ON =T

True

False

RTU_EN =F

True

Is Master System Enable Toggle bit set to "False"?

Virtual

Is the PPU System Mode Switch in the 'Off' position?

Virtual

Local PPU configured and ready for operation, True or False.

Virtual

PPU station ID set and ready for operation, True or False.

Virtual

Is the local PPU configured and ready for operation?

Virtual

Is the PPU station ID not set and ready for operation?

Virtual

Is the local PPU not configured and ready for operation?

Virtual

Is the PPU station ID set and ready for operation?

Virtual

Set IP selection fault to T or F. This block of code is legacy code, and only used to flag a mismatch between these variables.

Virtual

Is the PPU station ID set and ready for operation?

Virtual

Is Master System Enable Toggle bit set to "False"?

Virtual

False

RTU_ON =F

True

False

RTU_EN =T

True

False

Select Fault = F

RTU_EN =F False

Select Fault = T

True

MSPB_TOG =F

True

False

Page I-12 A

Page I-12 B

I-11

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-11 A

Page I-11 B

Is there no IP selection fault?

Virtual

Set the Master System Enable Toggle bit to T.

Virtual

Is the PPU System Mode Switch in the 'OFF' position?

Virtual

Set the Master System Enable Toggle bit to F.

Virtual

RTU_ON =F

PPU station ID set and ready for operation, reset to False.

Virtual

RTU_EN =F

Local PPU configured and ready for operation, reset to False.

Virtual

Is local PPU configured and ready for operation, variable changing from T to F?

Virtual

If the input is changing from T to F and the timer has been reset, a 1 second timer will start. If the input changes from F to T while the timer is running, the timer will cancel and reset.

Virtual

Did the timer expire?

Virtual

Set the station number to 6. Having a station number of 6 means the PPU is locked out of automated load sharing.

Virtual

Set the IP address to the constant ip6.

Virtual

Set variable flagging if the station's IP address was reset, T or F.

Virtual

Select Flt =F False

SMS = Off

MSPB_TOG =T

True MSPB_TOG =F

False

RTU_EN to F

True

True

False Start or Maintain Off Timer

Timer expired False

Reset timer

True

Station # =6

Set IP Addr. to ip6

ip_reset = F

ip_reset = T

ip_reset = F

Page I-13

I-12

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-12

SMS = Off True

False

IP 1 was set

Is the PPU System Mode Switch in the 'OFF' position?

Internal

Was IP set as station 1?

Internal

Is the Unit Select Switch in the "A" position?

RTU-OUT1

PPU is configured as unit "A", T or F.

RTU-OUT1

Was IP set as station 2?

Internal

Is the Unit Select Switch in the "B" position?

RTU-OUT2

PPU is configured as unit "B", T or F.

RTU-OUT2

Was IP set as station 3?

Internal

Is the Unit Select Switch in the "C" position?

RTU-OUT3

PPU is configured as unit "C", T or F.

RTU-OUT3

True

False

USS =A

True

False USS A =F

USS A =F

IP 2 was set

USS A =T

True

False

USS =B

True

False USS B =F

USS B =F

IP 3 was set

USS B =T

True

False

USS =C

True

False USS C =F

USS C =F

Page I-14 A

Page I-14 B

USS C =T

I-13

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-14 A

Page I-14 B

IP 4 was set

Was IP set as station 4?

Internal

Is the Unit Select Switch in the "D" position?

RTU-OUT4

PPU is configured as unit "D", T or F.

RTU-OUT4

True

False

USS =D

True

False USS D =F

USS D =F

USS D =T

Return

End of subprogram.

I-14

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Start - Unpack Data

Entry point for unpack data routine

Gen. True breaker closed

Is the generator x breaker closed?

DIM1-IN3 or DIM2-IN3

Is the Engine Control Switch in the MAN position?

Virtual

Takes 16-bit analog from GSC and unpacks into 16 1-bit booleans.

Function

High coolant temperature alarm variable is false or the value from the Cat GSC.

Virtual

Low coolant temperature alarm variable is false or the value from the Cat GSC.

Virtual

Low oil pressure alarm variable is false or the value from the Cat GSC.

Virtual

Engine control switch alarm variable is false or the value from the Cat GSC.

Virtual

High oil temperature alarm variable is false or the value from the Cat GSC.

Virtual

ADEM unit control alarm variable is false or the value from the Cat GSC.

Virtual

Is the Engine Control Switch in the OFF RESET position?

Virtual

Set ESC_OFF boolean to T or F.

Virtual

False

ECS Manual

True

False

Unpack GSC Alarm Data

HCT Alarm =F

HCT Alarm =GSC T/F

LCT Alarm =F

LCT Alarm =GSC T/F

LOP Alarm =F

LOP Alarm =GSC T/F

ECS Alarm =F

ECS Alarm =GSC T/F

HOT Alarm =F

HOT Alarm =GSC T/F

Control Alarm =F

Control Alarm =GSC T/F

ECS Position =1

True

False ESC_OFF =F

ESC_OFF =T

Page I-16

I-15

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-15

ECS Position =2

True

Is the Engine Control Switch in the OFF RESET position?

Virtual

Set ESC_MAN boolean to T or F.

Virtual

Is the Engine Control Switch in the COOLDOWN position?

Virtual

Set ESC_STOP boolean to T or F.

Virtual

Is the Engine Control Switch in the AUTO position?

Virtual

Set ESC_AUTO boolean to T or F.

Virtual

Takes 16-bit analog from GSC and unpacks into 16 1-bit booleans.

Function

ADEM fault shutdown from Cat GSC, T or F.

Virtual

Emergency stop shutdown from Cat GSC, T or F.

Virtual

ORT immediate stop shutdown from Cat GSC, T or F.

Virtual

High coolant temperature shutdown from Cat GSC, T or F.

Virtual

False ESC_MAN =F

ECS Position =3

ESC_MAN =T

True

False ESC_STOP =F

ECS Position =4

ESC_STOP =T

True

False ESC_AUTO =F

ESC_AUTO =T

Unpack GSC Shutdown Data

CL Shdn =GSC T/F

EStop Shdn =GSC T/F

SF Shdn =GSC T/F

HCT Shdn =GSC T/F

Page I-17

I-16

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-16

Low oil pressure shutdown from Cat GSC, T or F. Virtual LOP Shdn =GSC T/F

Overcrank shutdown from Cat GSC, T or F.

Virtual

Overspeed shutdown from Cat GSC, T or F.

Virtual

Is the generator x breaker closed?

DIM1-IN3 or DIM2-IN3

Is the generator in cooldown status?

Virtual

Takes 16-bit analog from GSC and unpacks into 16 1-bit booleans.

Function

Generator underfrequency alarm variable is false or the value from the Cat GSC.

Virtual

Generator overfrequency alarm variable is false or the value from the Cat GSC.

Virtual

Generator undervoltage alarm variable is false or the value from the Cat GSC.

Virtual

Generator overvoltage alarm variable is false or the value from the Cat GSC.

Virtual

Generator frequency sensing alarm variable is false or the value from the Cat GSC.

Virtual

Generator reverse power alarm variable is false or the value from the Cat GSC.

Virtual

OC Shdn =GSC T/F

OSS Shdn =GSC T/F

Gen. True breaker closed

False Gen. In Cooldown False

True

Unpack Generator Alarms

Gen UnFreq =F

Gen UnFreq =GSC T/F

Gen OvFreq =F

Gen OvFreq =GSC T/F

Gen UnVolt =F

Gen UnVolt =GSC T/F

Gen OvVolt =F

Gen OvVolt =GSC T/F

Gen FreqSense =F

Gen FreqSense =GSC T/F

Gen RevPow =F

Gen RevPow =GSC T/F

Page I-18

I-17

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-17

Unpack Gen. Shutdown Data

Gen UnFreq =GSC T/F

Gen OvFreq =GSC T/F

Gen UnVolt =GSC T/F

Gen OvVolt =GSC T/F

Gen FreqSense =GSC T/F

Gen RevPow =GSC T/F

Gen. Run = Eng. Run

Return

Takes 16-bit analog from GSC and unpacks into 16 1-bit booleans.

Function

Generator underfrequency shutdown variable is set to the value from the Cat GSC.

Virtual

Generator overfrequency shutdown variable is set to the value from the Cat GSC.

Virtual

Generator undervoltage shutdown variable is set to the value from the Cat GSC.

Virtual

Generator overvoltage shutdown variable is set to the value from the Cat GSC.

Virtual

Generator frequency sensing shutdown variable is set to the value from the Cat GSC.

Virtual

Generator reverse power shutdown variable is set to the value from the Cat GSC.

Virtual

Generator running status variable = engine running status variable.

Virtual

End of subprogram.

I-18

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Start - Calculate Baseload

GMS Baseload

False

True

RTU Enabled

True

False Calculate BL_REF

Return

Is the Generator Mode Switch in the BASELOAD position?

RTU-IN5

Is the local PPU configured and ready for operation?

Virtual

Calculate Baseload Reference: take baseload setpoint (500 default), convert to KW, and limit between 500 and 9830.

Function, virtual

End of subprogram.

I-19

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Start - Engine Emg. Stops

ECS 1 to OFF

Did Engine Control Switch for engine 1 change positions to OFF RESET?

Virtual

Reset engine 1's remote emergency stop toggle to false.

Virtual

True

Is the emergency stop toggle true for engine 1?

Virtual

True

Is there a Neutral Ground Resister fault on gererator 1?

DIM1-IN7

Set Spare Immediate Shutdown to True or False for generator 1.

DOM2-OUT15

Did Engine Control Switch for engine 2 change positions to OFF RESET?

Virtual

Reset engine 2's remote emergency stop toggle to false.

Virtual

True

Is the emergency stop toggle true for engine 2?

Virtual

True

Is there a Neutral Ground Resister fault on gererator 2?

DIM2-IN7

Set Spare Immediate Shutdown to True or False for generator 2.

DOM2-OUT16

True

Reset Engine 1 Emerg. Stop

False

Eng. 1 Emerg. Stop

False NGR 1 Fault

False Spare Immediate Shutdown = F

ECS 2 to OFF

Spare Immediate Shutdown = T

True

Reset Engine 2 Emerg. Stop

False

Eng. 2 Emerg. Stop

False NGR 2 Fault

False Spare Immediate Shutdown = F

Spare Immediate Shutdown = T

Return

End of subprogram.

I-20

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Start - Lockout

Run for each genset (1 and 2) in local PPU.

Gen. OC Trip

True

Is there an overcurrent relay trip signal on generator x?

DIM1-IN5 or DIM2-IN5

True

Is there a Neutral Ground Resister fault on gererator x?

DIM1-IN7 or DIM2-IN7

True

Is engine x flagged to shutdown?

Virtual

True

Is generator x flagged to shutdown?

Virtual

True

Is the Master Start Enable Switch not in either ENABLE position?

RTU-IN3

Is generator x lockout control set to True?

Virtual

Set generator x lockout control to True or False.

Virtual

False

NGR Fault False

Eng. Shutdown False

Gen. Shutdown False

MSES Not enable False

Gen. Lockout

True

False

Gen. Lockout =F

Gen. Lockout =T

1 to 2

Page I-22

I-21

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-21

Tie OC Trip

True

Is there a tie overcurrent relay trip?

DIM1-IN13

True

Is the Master Start Enable Switch not in either ENABLE position?

RTU-IN3

Is tie lockout set to T?

Virtual

Set tie lockout to T or F.

Virtual

Is there a low fuel level in the PPU daytank?

DIM2-IN13

Is there a low fuel fault?

Virtual

Set flag to shutdown engine for low fuel.

Virtual

Is there NOT a low fuel level in the PPU daytank?

DIM2-IN13

Are the PPU engines flagged to shutdown due to low fuel?

Virtual

Reset flag to shutdown engine for low fuel.

Virtual

Pack OCR1, OCR2 and OCR3 into virtual word "stat_word".

DIM1-IN5, DIM2-IN5, & DIM1-IN13

False

MSES Not enable False

Tie lockout

True

False

Tie lockout =F

Low fuel in PPU day tank

Tie lockout =T

True

False Low fuel Fault

True

False

Not low fuel PPU day tank

Set low fuel engine shutdown =T

True

False Low fuel shutdown False

True

Set low fuel engine shutdown =F

Pack overcurrent signals into 16-bit word "stat_word"

Return

End of subroutine.

I-22

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Start - Frequency

FSS 50 Hz

Switch set for 50 Hz operation.

RTU-IN6

System mode switch is in the OFF position and parameters have been cleared.

Virtual

PLC output shows 60 Hz.

DOM1-OUT10

Set PLC output to 50 Hz.

DOM1-OUT10

Switch set for 60 Hz operation.

RTU-IN6

System mode switch is in the OFF position and parameters have been cleared.

Virtual

PLC output shows 50 Hz.

DOM1-OUT10 (ON)

Set PLC output to 60 Hz.

DOM1-OUT10 (OFF)

Is the Master system enable toggle set to True?

Virtual

Does PLC output show 60 Hz?

DOM1-OUT10 (OFF)

KVA Setpoint =489

Set KVA setpoint for loadsharing at 489.

Virtual

KW Setpoint =391

Set KW setpoint for loadsharing at 391

Virtual

Rating 60Hz =T

Current rating of 60Hz variable is T or F.

Virtual

True

False

SMS Off

True

False

PLC 60 Hz

True

False

FSS 60 Hz

True

False

SMS Off

True

False

PLC 50 Hz False

MSPB =T False

True

PLC 60 Hz

True

PLC 60 Hz False

Rating 60Hz =F

PLC 50 Hz

True

Page I-24

I-23

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-23

MSPB =T False

True

PLC 50 Hz False

Rating 50Hz =F

Is the Master system enable toggle set to True?

Virtual

Does PLC output show 50 Hz?

DOM1-OUT10 (ON)

KVA Setpoint =418

Set KVA setpoint for loadsharing at 418.

Virtual

KW Setpoint =334

Set KW setpoint for loadsharing at 334.

Virtual

Rating 50Hz =T

Current rating of 50Hz variable is T or F.

Virtual

True

Return

End of subprogram.

I-24

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Start - PDC Status

PPU A is on False

Page I-26 A

True

Is the PPU configured as A on?

RTU-OUT1

Break B Status from 16-bit word into 16 1-bit booleans. B status is the network value used by A PPU to check for overcurrents on B PPU.

Function

B PPU Gen. 1 overcurr. = T/F

Set overcurrent flag on B PPU generator 1 to T or F, as reported by B PPU.

Virtual

B PPU Gen. 2 overcurr. = T/F

Set overcurrent flag on B PPU generator 2 to T or F, as reported by B PPU.

Virtual

B PPU Tie overcurr. = T/F

Set overcurrent flag on B PPU tie connector to T or F, as reported by B PPU.

Virtual

Break C Status from 16-bit word into 16 1-bit booleans. C status is the network value used by A PPU to check for overcurrents on C PPU.

Function

Unpack C Status Data

C PPU Gen. 1 overcurr. = T/F

Set overcurrent flag on C PPU generator 1 to T or F, as reported by C PPU.

Virtual

C PPU Gen. 2 overcurr. = T/F

Set overcurrent flag on C PPU generator 2 to T or F, as reported by C PPU.

Virtual

C PPU Tie overcurr. = T/F

Set overcurrent flag on C PPU tie connector to T or F, as reported by C PPU.

Virtual

Break D Status from 16-bit word into 16 1-bit booleans. D status is the network value used by A PPU to check for overcurrents on D PPU.

Function

Unpack D Status Data

D PPU Gen. 1 overcurr. = T/F

Set overcurrent flag on D PPU generator 1 to T or F, as reported by D PPU.

Virtual

D PPU Gen. 2 overcurr. = T/F

Set overcurrent flag on D PPU generator 2 to T or F, as reported by D PPU.

Virtual

D PPU Tie overcurr. = T/F

Set overcurrent flag on D PPU tie connector to T or F, as reported by D PPU.

Virtual

Unpack B Status Data

Page I-26 B

I-25

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-25 A

Page I-25 B

Is the overcurrent flag set to T for the A PPU generator 1?

Virtual

True

Is the overcurrent flag set to T for the A PPU generator 2?

Virtual

True

Is the overcurrent flag set to T for the B PPU generator 1?

Virtual

True

Is the overcurrent flag set to T for the B PPU generator 2?

Virtual

True

Is the overcurrent flag set to T for the C PPU generator 1?

Virtual

True

Is the overcurrent flag set to T for the C PPU generator 2?

Virtual

True

Is the overcurrent flag set to T for the D PPU generator 1?

Virtual

True

True

Is the overcurrent flag set to T for the D PPU generator 2?

Virtual

D Gen. 2 Overcurr.

Genset lockout

True

Is the summary genset lockout boolean flag set to T?

Virtual

Is the Master Start Enable Switch not set to one of the ENABLE positions?

RTU-IN3

Set summary genset lockout boolean flag to T or F.

Virtual

A Gen. 1 Overcurr. False

A Gen. 2 Overcurr. False

B Gen. 1 Overcurr. False

B Gen. 2 Overcurr. False

C Gen. 1 Overcurr. False

C Gen. 2 Overcurr. False

D Gen. 1 Overcurr. False

False

Genset lockout =F

MSES =F False

True

Genset lockout =T

Return

End of subprogram.

I-26

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Start - Load Share

Load Share Enabled False

True

Set load per online generator

Gen. online=0

True

Is automated load sharing enabled?

Virtual

Calculate load per online generator, = total KW load ÷ the number of online generators. This value is then converted into a Real number.

Virtual

Does the number of online generators = 0?

Virtual

Set load sharing error control #1 to T or F.

Virtual

Calculate the maximum load per online generator, = load per online generator + 50.

Virtual

Set load sharing error control #2 to T or F.

Virtual

Calculate the minimum load per online generator, = load per online generator - 50.

Virtual

Set load sharing error control #3 to T or F.

Virtual

False per_gen_1 =F

per_gen_1 =T

Set maximum load per generator

per_gen_2 =F

per_gen_2 =T

Set minimum load per generator

per_gen_3 =F

per_gen_3 =T

Page I-28

Return

End of subprogram.

I-27

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-27

Total KW < 50

True

Is total load < 50 KW?

Virtual

True

Is the tie breaker open?

DIM1-IN12

True

Is the breaker for local PPU generator 1 open?

DIM1-IN3

Is the breaker for local PPU generator 2 open?

DIM2-IN3

Set load sharing error alarm control = F.

Virtual

Disable automated load sharing.

Virtual

False Tie not closed

False

Gen. 1 breaker not closed False

Gen. 2 breaker not closed

True

False Load sharing error alarm=F

Load sharing enable = F

Return

End of subprogram.

I-28

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Start - GenSet Load Share

Gen. breaker closed

This program runs twice on each PPU: once for generator 1 and once for generator 2.

True

Is the breaker closed for generator x (1 or 2, depending on which generator this subroutine is run for)?

DIM1-IN3 or DIM2-IN3

True

Is automated loadsharing enabled?

Virtual

True

Is the KW load on generator x (1 or 2) outside the limits Min and Max previously set for load sharing, including a 10 KW hysteresis?

Virtual

Is the value changing from F to T?

Function

Start timer to delay for 45 seconds.

Function

False

Load share enabled False

Gen. KW out of LS range False

Changing F to T False

Delay for 45 seconds

Load sharing error alarm = F

Load sharing error alarm = T

Set load sharing alarm variable to T or F.

Virtual

Gen. X load share delay = F

Gen. X load share delay = T

Set current value of load share time delay for generator x to T or F.

Virtual

Return

End of subroutine.

I-29

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Start - Alarms

High coolant temp

Is there a high coolant temperature alarm on generator 1 from the GSC?

GSC

Is there a low coolant temperature alarm on generator 1 from the GSC?

GSC

Is there a low oil ressure alarm on generator 1 from the GSC?

GSC

Is there a high oil ressure alarm on generator 1 from the GSC?

GSC

True

Is there a ADEM unit control alarm?

GSC

True

Is the battery low (3

True

False

Requires 2 gen.

True

False

Gen. online >2

True

False

Requires 1 gen. False

True

Gen. online >1

True

False

Page I-46A

Page I-46B

Page I-46C

I-45

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-45A

Page I-45C

Page I-45B

No load mgt. block

True

Is automated load management enabled?

Virtual

Set the Sub_Gen flag to T or F (flags logic to turn off a genset).

Virtual

Is flag set to turn off one genset?

Virtual

True

Does the A unit recognize the D unit?

Virtual

True

Does the D PPU have two gensets available?

Virtual

Does the A PPU have exactly one genset available?

Virtual

Does the A PPU have no gensets available?

Virtual

Does the B PPU have exactly one genset available?

Virtual

Does the B PPU have no gensets available?

Virtual

False

Sub_Gen =F

Sub-Gen

False

Sub_Gen =T

True

A unit sees D False

D unit dual on False

A unit single

True

False

A unit none

True

False

B unit single

True

False

B unit none

True

False

Page I-47A

Page I-47B

Page I-47C

I-46

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-47A

Page I-47B

C unit single

True

Does the C PPU have exactly one genset available?

Virtual

Does the C PPU have no gensets available?

Virtual

Is the logical value changing from F to T?

Function

Start or reset a 3 minute timer.

Function

Has the timer expired?

Function

Flag D PPU to shut off a genset, T or F.

Virtual

Is flag set to turn off one genset?

Virtual

True

Does the A unit recognize the C unit?

Virtual

True

Does the D PPU have two gensets available?

Virtual

True

Does the D PPU have exactly one genset available?

Virtual

True

Does the D PPU have no gensets available?

Virtual

D unit single

False

C unit none

Page I-47C

True

True

False

changing T to F

True

False

changing F to T

True

False

Reset timer

timer expired

3 minute timer

True

False

Subtract D Gen. =F

Sub-Gen

False

Subtract D Gen. =T

True

A unit sees C False

C unit dual on False

D unit single False

D unit none False

Page I-48A

Page I-48B

Page I-48C

I-47

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-47A

A unit single

Page I-47B

Page I-47C

True

Does the A PPU have exactly one genset available?

Virtual

Does the A PPU have no gensets available?

Virtual

Does the B PPU have exactly one genset available?

Virtual

Does the B PPU have no gensets available?

Virtual

Does the C PPU have exactly one genset available?

Virtual

True

Does the D PPU have no gensets available?

Virtual

True

Is the logical value changing from F to T?

Function

Start or reset a 3 minute timer.

Function

Has the timer expired?

Function

Flag C PPU to shut off a genset, T or F.

Virtual

Is flag set to turn off one genset?

Virtual

False A unit none

True

False

B unit single

True

False B unit none

True

False

C unit single False

True

D unit none False

changing T to F

True

False

changing F to T Reset timer

False

timer expired

Start 3 minute timer

True

False

Subtract C Gen. =F

Sub-Gen

Subtract C Gen. =T

True

False Page I-49A

Page I-49B

I-48

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-48A

Page I-48B

A unit sees B

True Does the A unit recognize the B unit?

Virtual

Does the B PPU have two gensets available?

Virtual

True

Does the C PPU have exactly one genset available?

Virtual

True

Does the C PPU have no gensets available?

Virtual

Does the D PPU have exactly one genset available?

Virtual

Does the D PPU have no gensets available?

Virtual

True

Does the A PPU have exactly one genset available?

Virtual

True

Does the A PPU have no gensets available?

Virtual

Does the B PPU have exactly one genset available?

Virtual

True

Does the C PPU have no gensets available?

Virtual

True

Does the D PPU have no gensets available?

Virtual

False

B unit dual on

True

False

C unit single False C unit none False

D unit single

True

False D unit none

True

False

A unit single False A unit none False

B unit single False

True

C unit none False

D unit none False

Page I-50A

Page I-50B

I-49

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-49A

changing T to F

Page I-49B

True

False

changing F to T False

Reset timer

timer expired

True

Start 3 minute timer

True

Is the logical value changing from F to T?

Function

Start or reset a 3 minute timer.

Function

Has the timer expired?

Function

Flag B PPU to shut off a genset, T or F.

Virtual

Is flag set to turn off one genset?

Virtual

Does the A PPU have both gensets available?

Virtual

Does the B PPU have exactly one genset available?

Virtual

Does the B PPU have no gensets available?

Virtual

Does the C PPU have exactly one genset available?

Virtual

Does the C PPU have no gensets available?

Virtual

False

Subtract B Gen. =F

Sub-Gen False

Subtract B Gen. =T

True

A unit dual

True

False

B unit single

True

False B unit none

True

False

C unit single

True

False C unit none

True

False

Page I-51A

Page I-51B

I-50

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-50A

Page I-50B

D unit single

True

Does the D PPU have exactly one genset available?

Virtual

Does the D PPU have no gensets available?

Virtual

Is the logical value changing from F to T?

Function

Start or reset a 3 minute timer.

Function

Has the timer expired?

Function

Flag A PPU to shut off a genset, T or F.

Virtual

Is flag set to turn on one genset?

Virtual

Is the local PPU the A unit, and it is configured and online?

Virtual

Does the local PPU have exactly one genset available?

Virtual

Does the local PPU have no gensets available?

Virtual

Does the local PPU not have both gensets online?

Virtual

False D unit none

True

False

changing T to F

True

False

changing F to T

True

False

Reset timer

timer expired

Start 3 minute timer

True

False

Subtract A Gen. =F

Add-Gen False

Subtract A Gen. =T

True

A PPU local False

True

local unit single

True

False local unit none

True

False

local unit not dual

True

False

Page I-52A

Page I-52B

Page I-52C

I-51

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-51A

Page I-51B

Page I-51C

local unit not single

True

Does the local PPU not have either genset online?

Virtual

Does the local PPU have exactly one genset online?

Virtual

Does the B PPU have exactly one genset available?

Virtual

Does the B PPU have both gensets available?

Virtual

Does the A unit not recognize the B unit?

Virtual

Does the C PPU have exactly one genset available?

Virtual

True

Does the C PPU have both gensets available?

Virtual

True

Does the A unit not recognize the C unit?

Virtual

Does the D PPU have exactly one genset available?

Virtual

True

Does the D PPU have both gensets available?

Virtual

True

Does the A unit not recognize the D unit?

Virtual

False

local unit single False

True

B unit single

True

False B unit dual

True

False A unit not see B False

True

C unit single

True

False C unit dual False A unit not see C False

D unit single

True

False D unit dual False A unit not see D False

Page I-53A

Page I-53B

I-52

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-52A

changing T to F

Page I-52B

True

False

changing F to T

True

False

Reset timer

timer expired

Start 1 minute timer

True

Is the logical value changing from F to T?

Function

Start or reset a 1 minute timer.

Function

Has the timer expired?

Function

Flag A PPU to start a genset, T or F.

Virtual

Is flag set to turn on one genset?

Virtual

Does the A unit recognize the B unit?

Virtual

Does the B PPU have exactly one genset available?

Virtual

Does the B PPU have both gensets available?

Virtual

Is the B PPU running neither genset?

Virtual

Does the local PPU have exactly one genset available?

Virtual

Does the A unit have neither genset online?

Virtual

False

Add A Gen. =F

Add-Gen False

Add A Gen. =T

True

A unit sees B False

True

B unit single

True

False B unit dual

True

False

B unit none

True

False

local unit single

True

False A unit none

True

False

Page I-54A

Page I-54B

Page I-54C

Page I-54D

I-53

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-53A

Page I-53B

Page I-53C

local unit not dual

Page I-53D

True

Does the local PPU not have both gensets available?

Virtual

Does the local PPU not have exactly one genset available?

Virtual

Does the local PPU have both gensets available?

Virtual

Does the local PPU have exactly one genset available?

Virtual

Does the B PPU have exactly one genset available?

Virtual

Does the B PPU have no gensets available?

Virtual

Does the C PPU have exactly one genset available?

Virtual

True

Does the C PPU have no gensets available?

Virtual

True

Does the A unit not recognize the C unit?

Virtual

Does the C PPU have exactly one genset available?

Virtual

True

Does the C PPU have no gensets available?

Virtual

True

Does the A unit not recognize the C unit?

Virtual

False

local unit not single

True

False

local unit dual

True

False local unit single False

True

B unit single

True

False B unit none False

True

C unit single

True

False C unit none False A unit not see C False

D unit single

True

False D unit none False A unit not see D False

Page I-54A

Page I-54B

I-54

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-54A

changing T to F

Page I-54B

True

False

changing F to T

True

False

Reset timer

timer expired

Start 1 minute timer

True

Is the logical value changing from F to T?

Function

Start or reset a 1 minute timer.

Function

Has the timer expired?

Function

Flag B PPU to start a genset, T or F.

Virtual

Is flag set to turn on one genset?

Virtual

Does the A unit recognize the C unit?

Virtual

Does the C PPU have exactly one genset available?

Virtual

Does the C PPU have both gensets available?

Virtual

Is the C PPU running neither genset?

Virtual

Does the local PPU have exactly one genset available?

Virtual

Does the local PPU have both gensets available?

Virtual

False

Add B Gen. =F

Add-Gen False

Add B Gen. =T

True

A unit sees C False

True

C unit single

True

False C unit dual

True

False

C unit none

True

False

local unit single

True

False local unit dual

True

False

Page I-56A

Page I-56B

Page I-56C

I-55

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-55A

Page I-55B

Page I-55C

B unit single

True

Does the B PPU have exactly one genset available?

Virtual

Does the B PPU have both gensets available?

Virtual

Does the local PPU have exactly one genset available?

Virtual

Does the local PPU have both gensets available?

Virtual

Does the B PPU have exactly one genset available?

Virtual

Does the B PPU have both gensets available?

Virtual

Does the C PPU have exactly one genset available?

Virtual

Does the C PPU have neither genset available?

Virtual

Does the D PPU have exactly one genset available?

Virtual

Does the D PPU have both gensets available?

Virtual

Does the A unit not recognize the D unit?

Virtual

False B unit dual

True

False

local unit single

True

False local unit dual False

True

B unit single

True

False B unit dual False

True

C unit single

True

False C unit none

True

False

D unit single

True

False D unit dual

True

False A unit not see D

True

False

Page I-57A

Page I-57B

I-56

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-56A

changing T to F

Page I-56B

True

False

changing F to T

True

False

Reset timer

timer expired

Start 1 minute timer

True

Is the logical value changing from F to T?

Function

Start or reset a 1 minute timer.

Function

Has the timer expired?

Function

Flag C PPU to start a genset, T or F.

Virtual

Is flag set to turn on one genset?

Virtual

Does the A unit recognize the D unit?

Virtual

Does the D PPU have exactly one genset available?

Virtual

Does the D PPU have both gensets available?

Virtual

Is the D PPU running neither genset?

Virtual

Does the local PPU have exactly one genset available?

Virtual

Does the local PPU have both gensets available?

Virtual

False

Add C Gen. =F

Add-Gen False

Add C Gen. =T

True

A unit sees D False

True

D unit single

True

False D unit dual

True

False

D unit none

True

False

local unit single

True

False local unit dual

True

False

Page I-58A

Page I-58B

Page I-58C

I-57

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-57A

Page I-57B

Page I-57C

B unit single

True

Does the B PPU have exactly one genset available?

Virtual

Does the B PPU have both gensets available?

Virtual

Does the C PPU have exactly one genset available?

Virtual

Does the B PPU have both gensets available?

Virtual

Does the local PPU have exactly one genset available?

Virtual

Does the local PPU have both gensets available?

Virtual

Does the B PPU have exactly one genset available?

Virtual

Does the B PPU have both gensets available?

Virtual

Does the C PPU have exactly one genset available?

Virtual

Does the C PPU have both gensets available?

Virtual

Does the D PPU have exactly one genset available?

Virtual

False B unit dual

True

False

C unit single

True

False C unit dual

True

False

local unit single

True

False local unit dual False

True

B unit single

True

False B unit dual False

True

C unit single

True

False C unit dual

True

False

D unit single

True

False

Page I-59A

Page I-59B

I-58

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-58A

changing T to F

Page I-58B

True

False

changing F to T

True

False

Reset timer

timer expired

Start 1 minute timer

True

Is the logical value changing from F to T?

Function

Start or reset a 1 minute timer.

Function

Has the timer expired?

Function

Flag D PPU to start a genset, T or F.

Virtual

Does the local PPU not have exactly one genset available?

Virtual

Does the local PPU not have both gensets available?

Virtual

A unit has no gensets available, T or F.

Virtual

Does the B PPU not have exactly one genset available?

Virtual

Does the B PPU not have both gensets available?

Virtual

Does the A unit recognize the B unit?

Virtual

B unit has no gensets available, T or F.

Virtual

False

Add D Gen. =F

local unit not single

Add D Gen. =T

True

False

local unit not dual

True

False

A_No_Gen =F

B unit not single

A_No_Gen =T

True

False

A unit not see B

B unit not dual False

True

A unit sees B

False

B_No_Gen =F

True

True

False

B_No_Gen =T

B_No_Gen =F

B_No_Gen =T

Page I-58A

I-59

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-58A

C unit not single

True

False

A unit not see C

C unit not dual

True

False

True

A unit sees C

False

C_No_Gen =T

C_No_Gen =F

D unit not dual

True

False

True

A unit sees D

False

D_No_Gen =F

C_No_Gen =T

True

False

A unit not see D

Virtual

Does the C PPU not have both gensets available?

Virtual

Does the A unit recognize the C unit?

Virtual

C unit has no gensets available, T or F.

Virtual

Does the D PPU not have exactly one genset available?

Virtual

Does the D PPU not have both gensets available?

Virtual

Does the A unit recognize the D unit?

Virtual

D unit has no gensets available, T or F.

Virtual

False

C_No_Gen =F

D unit not single

True

Does the C PPU not have exactly one genset available?

True

False

D_No_Gen =T

D_No_Gen =F

D_No_Gen =T

Return

End of subroutine.

I-60

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Start - Operate PPU A

Not A PPU

Start of subroutine of logic specific to PPU A.

True

False Not A PPU B PPU

True

True

False

Is the Unit Select Switch not in the "A" position?

DIM1-IN15

Is the PPU not configured as "A" for network?

Virtual

Is the PPU configured as "B" for network?

Virtual

Is the PPU configured as "C" for network?

Virtual

Is the PPU configured as "D" for network?

Virtual

False

C PPU

True

False

D PPU

True

False Return

local PPU enabled

Return

True

Exit Subroutine.

Is the local PPU configured and ready for operation?

Virtual

Set A PPU enabled variable, T or F.

Virtual

Is the local PPU station ID set and ready for operation?

Virtual

Set A PPU station ID set variable, T or F.

Virtual

Does the B PPU not have exactly one genset online?

Virtual

Does the B PPU not have both gensets online?

Virtual

False A_RTU_EN =F

station ready

A_RTU_EN =T

True

False A_RTU_ON =F

B unit not single

A_RTU_ON =T

True

False B unit not dual

True

False

Page I-62A

Page I-62B

I-61

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-61A

Page I-61B

B_Qty_On =0

B_0_Generators =T

B unit single

Set B PPU generator quantity online to 0.

Virtual

Set B 0 generators online variable, T or F.

Local

Does the B PPU have exactly one genset online?

Virtual

B_Qty_On =1

Set B PPU generator quantity online to 1.

Virtual

B_1_Generator =T

Set B 1 generator online variable, T or F.

Local

Does the B PPU have both genset online?

Virtual

B_Qty_On =2

Set B PPU generator quantity online to 2.

Virtual

B_2_Generators =T

Set B 2 generator online variable, T or F.

Local

Does the C PPU not have exactly one genset online?

Virtual

Does the C PPU not have both gensets online?

Virtual

B_0_Generators =F

True

False

B_1_Generator =F

B unit dual

True

False

B_2_Generators =F

C unit not single False

True

C unit not dual

True

False

Page I-63A

Page I-63B

I-62

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-62A

Page I-62B

C_Qty_On =0

C_0_Generators =T

C unit single

Set C PPU generator quantity online to 0.

Virtual

Set C 0 generators online variable, T or F.

Local

Does the C PPU have exactly one genset online?

Virtual

C_Qty_On =1

Set C PPU generator quantity online to 1.

Virtual

C_1_Generator =T

Set C 1 generator online variable, T or F.

Local

Does the C PPU have both genset online?

Virtual

C_Qty_On =2

Set C PPU generator quantity online to 2.

Virtual

C_2_Generators =T

Set C 2 generator online variable, T or F.

Local

Does the D PPU not have exactly one genset online?

Virtual

Does the D PPU not have both gensets online?

Virtual

C_0_Generators =F

True

False

C_1_Generator =F

C unit dual

True

False

C_2_Generators =F

D unit not single False

True

D unit not dual

True

False

Page I-64A

Page I-64B

I-63

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-63A

Page I-63B

D_Qty_On =0

D_0_Generators =T

D unit single

Set D PPU generator quantity online to 0.

Virtual

Set D 0 generators online variable, T or F.

Local

Does the D PPU have exactly one genset online?

Virtual

D_Qty_On =1

Set D PPU generator quantity online to 1.

Virtual

D_1_Generator =T

Set D 1 generator online variable, T or F.

Local

Does the C PPU have both genset online?

Virtual

D_Qty_On =2

Set D PPU generator quantity online to 2.

Virtual

D_2_Generators =T

Set D 2 generator online variable, T or F.

Local

Divide generator 1 total KW by 1000.

Function

Set generator 1 KW to calculated value.

Virtual

Divide generator 2 total KW by 1000.

Function

Set generator 2 KW to calculated value.

Virtual

D_0_Generators =F

True

False

D_1_Generator =F

D unit dual

True

False

D_2_Generators =F

Gen. 1 Total KW / 1000

Gen. 1 KW = Value

Gen. 2 Total KW / 1000

Gen. 2 KW = Value

Page I-65

I-64

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-64

Gen. 1 Total KVA / 1000

Divide generator 1 total KVA by 1000.

Function

Set generator 1 KVA to calculated value.

Virtual

Divide generator 2 total KVA by 1000.

Function

Gen. 2 KVA = Value

Set generator 2 KVA to calculated value.

Virtual

Gen. 1 Total KVAR / 1000

Divide generator 1 total KVAR by 1000.

Function

Set generator 1 KVAR to calculated value.

Virtual

Divide generator 2 total KVAR by 1000.

Function

Set generator 2 KVAR to calculated value.

Virtual

Gen. 1 KVA = Value

Gen. 2 Total KVA / 1000

Gen. 1 KVAR = Value

Gen. 2 Total KVAR / 1000

Gen. 2 KVAR = Value

Return

End of subprogram.

I-65

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Start - Operate PPU

USS not X

Start of subroutine of logic to operate PPU B, C, and D. This subroutine runs three times; once for each.

True

Is the Unit Select Switch not in the X position (B, C or D, depending on iteration)?

DIM1-IN16, o DIM2-IN15, o DIM2-IN16

Is the PPU not configured as X?

Virtual

True

Is the PPU configured as "A"?

Virtual

True

Is the PPU configured as Y (C if first iteration, B otherwise)?

Virtual

True

Is the PPU configured as Y (C if third iteration, D otherwise)?

Virtual

False

Unit not X

True

False

Unit is A False

Unit is Y False

Unit is Z False

Local PPU ready

Return True

False

SMS AUTO False

Exit subroutine.

PPU =X

True

Unit X DBC

True

False

Gen. 1 DBC

True

Is the local PPU configured and ready for operation?

Virtual

Set PPU variable to X (B if first iteration, C if second, D if third).

Virtual

Is the System Mode Switch in the AUTO position?

RTU-IN1

Is the network not telling PPU X that it has control of the dead bus permissive?

Virtual

Is generator 1 dead bus close permissive set?

Virtual

Is generator 1 auto sync run enabled?

Virtual

False

Gen. 1 auto sync.

True

False

Page I-67A

Page I-67B

I-66

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-66A

Page I-66B

Gen. 1 RB open

True

Is generator 1 remote breaker open?

Virtual

Close generator 1's breaker for PPU X.

Virtual

True

Is generator 1 remote breaker closed?

Virtual

True

Is generator 1 breaker open enabled?

DOM1-OUT6

True

Is engine 1 autorun enabled?

Virtual

Is the system mode switch in the AUTO position?

RTU-IN1

Is generator 1's breaker for PPU X closed?

Virtual

Open generator 1's breaker for PPU X.

Virtual

Is the System Mode Switch in the AUTO position?

RTU-IN1

Is the network not telling PPU X that it has control of the dead bus permissive?

Virtual

Is generator 2 dead bus close permissive set?

Virtual

Is generator 2 auto sync run enabled?

Virtual

Is generator 2 remote breaker open?

Virtual

Close generator 2's breaker for PPU X.

Virtual

False

Gen. 1 RB closed

Gen. 1 breaker = close

False

Gen. 1 B enabled False E1 Autorun enabled False

SMS AUTO

True

False

Gen. 1 B closed

True

False

SMS AUTO False

Gen. 1 breaker = open

True

Unit X DBC

True

False

Gen. 2 DBC

True

False

Gen. 2 auto sync. False

True

Gen. 2 RB open False

True Gen. 2 breaker = close

Page I-68

I-67

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-67

Gen. 2 RB closed

True

Is generator 2 remote breaker closed?

Virtual

True

Is generator 2 breaker open enabled?

DOM2-OUT6

True

Is engine 1 autorun enabled?

Virtual

Is the system mode switch in the AUTO position?

RTU-IN1

Is generator 2's breaker for PPU X closed?

Virtual

Open generator 2's breaker for PPU X.

Virtual

Divide generator 1 total KW by 1000.

Function

Set generator 1 KW to calculated value.

Virtual

Divide generator 2 total KW by 1000.

Function

Set generator 2 KW to calculated value.

Virtual

Divide generator 1 total KVA by 1000.

Function

Set generator 1 KVA to calculated value.

Virtual

False

Gen. 2 B enabled False

E2 Autorun enabled False

SMS AUTO False

True

Gen. 2 B closed False

True

Gen. 2 breaker = open

Gen. 1 Total KW / 1000

Gen. 1 KW = Value

Gen. 2 Total KW / 1000

Gen. 2 KW = Value

Gen. 1 Total KVA / 1000

Gen. 1 KVA = Value

Page I-69

I-68

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-68

Gen. 2 Total KVA / 1000

Divide generator 2 total KVA by 1000.

Function

Gen. 2 KVA = Value

Set generator 2 KVA to calculated value.

Virtual

Gen. 1 Total KVAR / 1000

Divide generator 1 total KVAR by 1000.

Function

Set generator 1 KVAR to calculated value.

Virtual

Divide generator 2 total KVAR by 1000.

Function

Gen. 2 KVAR = Value

Set generator 2 KVAR to calculated value.

Virtual

PPU X status word = 1

Set status word for PPU X to 1.

Virtual

Gen. 1 KVAR = Value

Gen. 2 Total KVAR / 1000

Return

End of subprogram.

I-69

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Start - Status

Eng. 1 alarm

Start of subroutine to control status LEDs.

True

Is there an alarm on engine 1?

Virtual

True

Is there an alarm on generator 1?

Virtual

True

Is there an alarm on engine 2?

Virtual

True

Is there an alarm on generator 2?

Virtual

Is the alarm buzzer energized

DOM1-OUT15

Blink output on/off, 1 second per state.

Function

Turn the amber system status light on/off.

DOM2-OUT14

True

Is generator 1 lockout set?

Virtual

True

Is generator 2 lockout set?

Virtual

True

Is tie contactor lockout set?

Virtual

False

Gen. 1 alarm False

Eng. 2 alarm False

Gen. 2 alarm False

Buzzer energized

True

False Blink

Amber SSL = Off

Gen. 1 lockout

Amber SSL = On

Amber SSL = On/Off

False Gen. 2 lockout False Tie lockout False

Page I-71A

Page I-71B

I-70

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-70A

Page I-70B

Buzzer energized

True

Is the alarm buzzer energized?

DOM1-OUT15

Blink

Blink output on/off, 1 second per state.

Function

Red SSL = On/Off

Turn the red system status light on/off.

DOM1-OUT14

Is generator 1 ready for automatic operation?

Virtual

Is the generator 1 breaker switch not in the Pull-to-Lock position?

Virtual

Is there no engine 1 alarm?

Virtual

Is there no generator 1 alarm?

Virtual

Is generator 1 lockout not set?

Virtual

True

Is there an engine 1 alarm?

Virtual

True

Is there a generator 1 alarm?

Virtual

True

Is generator 1 lockout set?

Virtual

False

Red SSL = Off

Gen. 1 ready

Red SSL = On

True

False

Gen. 1 Br. not PTL

True

False

No eng. 1 alarm False

True

No gen. 1 alarm

True

False

No gen. 1 lockout

True

False

Eng. 1 alarm False Gen. 1 alarm False Gen. 1 lockout False

Page I-72A

Page I-72B

Page I-72C

I-71

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-72A

Page I-72B

Page I-72C

Blink

Gen. 1 SSL = Off

Gen. 2 ready

Gen. 1 SSL = On/Off

Gen. 1 SSL = On

True

Blink output on/off, 500 millisecond per state.

Function

Turn the generator 1 status light on/off.

DOM1-OUT13

Is generator 2 ready for automatic operation? Virtual

False

Gen. 2 Br. not PTL

True

False

Is the generator 2 breaker switch not in the Pull-to-Lock position?

No eng. 2 alarm False

True

Virtual

Is there no engine 2 alarm? Virtual

No gen. 2 alarm

True

Is there no generator 2 alarm? Virtual

False

No gen. 2 lockout

True

Is generator 2 lockout not set? Virtual

False

Eng. 2 alarm

True

Is there an engine 2 alarm? Virtual

False

Gen. 2 alarm

True

Is there a generator 2 alarm? Virtual

False

Gen. 2 lockout False

Gen. 1 SSL = Off

True

Is generator 2 lockout set? Virtual

Blink

Gen. 1 SSL = On/Off

Gen. 1 SSL = On

Return

Blink output on/off, 500 millisecond per state.

Function

Turn the generator 2 status light on/off.

DOM2-OUT13

End of subprogram.

I-72

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Start - DBC Control

PPU not A

Subroutine to control DBC.

True

Is the PPU not configured as "A"?

False

Tie output not energ.

Return

Exit subroutine.

True

False B bus not energ.

True

False C bus not energ.

RTU-OUT1

True

False D bus not energ.

True

Is the tie output bus not energized?

DIM2-IN11

Is the B PPU system bus not energized?

Virtual

Is the C PPU system bus not energized?

Virtual

Is the D PPU system bus not energized?

Virtual

Blink output on/off, 2.5 seconds per state.

Function

Pulse On/Off to transfer dead bus close permissive between generators.

Virtual

Is the dead bus close permissive transfer pulse changing from Off to On?

Virtual

Increment a counter.

Function

Has the counter reached 4 (4 DBP pulses)?

Function

Reset the counter to 0.

Function

Set dbc current value variable to the counter.

Virtual

False

Blink

Counter of DBP = Off

DBP pulse Off to On

Counter of DBP = On/Off

True

False Increment counter

Counter =4

True

False Reset counter

DBC current value = counter

Page I-74

I-73

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-73

Tie output energ.

True

False B bus energ.

True

False C bus energ.

True

False D bus energ.

True

Is the tie output bus energized?

DIM2-IN11

Is the B PPU system bus energized?

Virtual

Is the C PPU system bus energized?

Virtual

Is the D PPU system bus energized?

Virtual

Reset the dbc counter to 0.

Function

Does the dbc current value = 0?

Virtual

Dead bus permissive set to "A" PPU, T or F.

Virtual

Does the dbc current value = 1?

Virtual

Dead bus permissive set to "B" PPU, T or F.

Virtual

Does the dbc current value = 2?

Virtual

Dead bus permissive set to "C" PPU, T or F.

Virtual

False

Reset counter

DBC curr. val. = 0

True

False A DBC =F

DBC curr. val. = 1

A DBC =T

True

False B DBC =F

DBC curr. val. = 2

B DBC =T

True

False C DBC =F

C DBC =T

Page I-75

I-74

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-74

DBC curr. val. = 3

True

Does the dbc current value = 3?

Virtual

Dead bus permissive set to "D" PPU, T or F.

Virtual

Set current DBC value to 0.

Virtual

False D DBC =F

D DBC =T

Current DBC value = 0

Return

End of subprogram.

I-75

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Start - Engine Control

MSPB_TOG =T

Subroutine to control engines. This subroutine runs twice, once for each engine (X = 1, 2).

True

False

Gen. X not ready

Is the master system enable toggle = T?

Virtual

True

Is generator X not available for auto operation?

Virtual

True

Is the system mode switch not in the AUTO position?

RTU-IN1

True

Is engine X flagged to start for initial power plant startup?

Virtual

Block engine X from starting on initial power plant startup.

Virtual

Is generator X not available for auto operation?

Virtual

Is engine X blocked from starting on initial power plant startup?

Virtual

False

SMS not AUTO False

Eng. X initial start False

Gen. X ready False

Eng. X block from start = T

True

Eng. X block not start False

True

X= genset 1

True

Does X = 1 (first iteration of this program)?

False

Eng. 1 running

True

Is engine 1 running?

Virtual

True

Is generator 1 not configured and ready for operation?

Virtual

False

Gen. 1 not ready False

X= genset 2

True

Does X = 2 (second iteration of this program)?

False

Gen. X start =F

Gen. X start =T

Flag generator X to start on initial power plant startup, T or F.

Virtual

Page I-77

I-76

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-76

Eng. X ECS AUTO

True

Is the engine control switch for engine X in the AUTO position?

Virtual

Is the system mode switch in the AUTO position?

RTU-IN1

Is there not a summary failuer on generator X?

Virtual

Is there not an overcurrent alarm on generator X?

Virtual

Is the generator X lockout control set to F?

Virtual

Does the generator X breaker have the red target visible (not green)?

DIM1-IN1 or DIM2-IN1

Is the summary genset lockout set to F?

Virtual

Generator X is available for auto operation, T or F.

Virtual

True

Is the system mode switch in the MAN position?

RTU-IN2

True

Is the engine control switch for engine X in the manual position?

Virtual

Is engine X running?

Virtual

False SMS AUTO

True

False No gen. X sum. fail.

True

False No gen. X overcurrent

True

False

Gen. X lockout = F

True

False Gen. X breaker red

True

False Genset lockout = F

True

False

Gen. X ready =F

SMS MAN

Gen. X ready =T

False

Eng. X MAN False

Eng. X running

True

False Changing F to T

True

Is the output changing from F to T?

False

Page I-78A

Page I-78B

Page I-78C

I-77

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-77A

Page I-77B

Page I-77C

Start 2 second Timer

Changing T to F

Start a 2 second timer.

True

Is the output changing from T to F?

False Reset Timer

Timer expire

Reset the timer.

True

Did the timer expire?

False

Gen. X SMS transfer = F

Eng. X ECS auto

Gen. X SMS transfer = T

True

False Gen. X breaker cl.

True

False USS A

True

False A sub. gen. F to T

True

System mode switch transfer between MAN and AUTO on generator X without affecting operation, T or F.

Virtual

Is the engine control switch for engine X in the auto position?

Virtual

Is the breaker closed on generator X (on = closed)?

DIM1-IN3 or DIM2-IN3

Is the unit select switch in the A position?

RTU-OUT1

Is the A PPU flag to shut down one genset changing from F to T?

Virtual

Is the unit select switch in the B position?

RTU-OUT2

Is the B PPU flag to shut down one genset changing from F to T?

Virtual

False

USS B

True

False B sub. gen. F to T

True

False

Page I-79A

Page I-79B

Page I-79C

I-78

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-78A

Page I-78B

USS C

Page I-78C

True

False C sub. gen. F to T

True

Is the unit select switch in the C position?

RTU-OUT3

Is the C PPU flag to shut down one genset changing from F to T?

Virtual

Is the unit select switch in the D position?

RTU-OUT4

Is the D PPU flag to shut down one genset changing from F to T?

Virtual

Is the breaker for generator X closed?

DIM1-IN3 or DIM2-IN3

False

USS D

True

False D sub. gen. F to T

True

False

Gen. X br. closed

True

False X=1

True

Is this the first iteration (run for genset 1)?

False En. 1 hm > eng. 2 hm

True

Is the hourmeter for engine 1 > hourmeter for engine 2?

Virtual

Is the hourmeter for engine 2 > hourmeter for engine 1?

Virtual

Set generator X auxillary stop 1 to T or F.

Virtual

True

Is the engine control switch for engine X in the OFF / RESET position?

Virtual

True

Is the system mode switch in the OFF position and parameters have cleared?

Virtual

En. 2 hm > eng. 1 hm

True

False

False

Gen. X Aux. stop 1 = F

Eng. X ECS OFF

Gen. X Aux. stop 1 = T

False

PDC OFF False Page I-80A

Page I-80B

I-79

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-79A

Gen. X lockout

Page I-79B

True

Is lockout set for generator X?

Virtual

True

Does the generator X breaker not have the red target visible (is green)?

DIM1-IN1 or DIM2-IN1

True

Is the summary genset lockout flag set to T?

Virtual

Set auxillary stop relay #2 for generator X to T or F.

Virtual

Is start/stop permissive for generator X = F?

Virtual

True

Is auxillary stop relay #1 for generator X from F to T?

Virtual

True

Is auxillary stop relay #1 for generator X from F to T?

Virtual

True

Is the engine control switch for engine X in the AUTO position?

Virtual

Is the remote start/stop for generator X changing from T to F?

Virtual

Gen. X SS Permissive = T

Set start/stop permissive for generator X to T.

Virtual

Gen. X RSS =F

Reset remote start/stop for generator X to F.

Virtual

False

Gen. X breaker grn. False

Genset lockout False

Gen. X Aux. Stop 2 = F

Gen. X start/stop

Gen. X Aux. Stop 2 = T

True

False Gen. X aux. stop 1 False

Gen. X aux. stop 2 False

Eng. X ECS AUTO False

Gen. X RSS

True

False

Page I-81

I-80

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-80

Eng. X ECS AUTO False

True

Is the engine control switch for engine X in the AUTO position?

Virtual

Is the master system enable toggle = T?

Virtual

True

Is engine X not running?

Virtual

True

Is generator X in cooldown?

Virtual

Is the summary failure set to F for generator X?

Virtual

Is the summary failure set to F for generator Y (the generator this iteration is not running for)?

Virtual

Is the master start eneable switch is changing to either of the two enable positions?

RTU-IN3

Is engine X running?

Virtual

Is the system mode switch transfering between AUTO and MAN?

Virtual

Is generator X flagged to run on initial power planr startup?

Virtual

Set auxillary stop relay #2 for generator X to T or F.

Virtual

MSPB_TOG True =T False Eng. X not running False

Gen. X cooldown False

Gen. X no failure

True

False

Gen. Y no failure

True

False MSES F to T

True

False

Eng. X running

True

False SMS trans. =T

True

False

Gen. X init. run

True

False

Gen. X Aux. Start 2 = F

Gen. X Aux. Start 2 = T

Page I-82

I-81

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-81

Eng. X ECS AUTO

True

False Gen. X brk. not closed

Is the engine control switch for engine X in the AUTO position?

Virtual

Is the breaker not closed for generator X?

DIM1-IN3 or DIM2-IN3

True

Is the breaker not closed for generator Y (the generator this iteration is not run for)?

DIM2-IN3 or DIM1-IN3

True

Is this the first iteration (run for genset 1)?

True

False Gen. Y brk. not closed False

X=1 False

En. 1 hm < eng. 2 hm

True

Is the hourmeter for engine 1 >= hourmeter for engine 2?

Virtual

Is the hourmeter for engine 2 < hourmeter for engine 1?

Virtual

Is generator Y not available for auto operation?

Virtual

Is generator X available for auto operation?

Virtual

True

Is the breaker for generator Y closed (the generator this iteration is not run for)?

DIM2-IN3 or DIM1-IN3

True

Is the PPU configured as "A"?

RTU-OUT1

Is the flag for the A PPU to add a genset changing from F to T?

Virtual

En. 2 hm < eng. 1 hm

True

False

False

Gen. Y not ready

True

False Gen. X ready

True

False

Gen. Y brk. Closed False

PPU A False

A add gen. F to T

True

False

Page I-83A

Page I-83B

Page I-83C

I-82

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-82A

Page I-82B

PPU B

Page I-82C

True

Is the PPU configured as "B"?

RTU-OUT2

Is the flag for the B PPU to add a genset changing from F to T?

Virtual

Is the PPU configured as "C"?

RTU-OUT2

Is the flag for the C PPU to add a genset changing from F to T?

Virtual

Is the PPU configured as "D"?

RTU-OUT2

Is the flag for the D PPU to add a genset changing from F to T?

Virtual

Set auxillary stop relay #1 for generator X to T or F.

Virtual

Is start/stop permissive for generator X = F?

Virtual

True

Is the auxillary stop relay #1 for generator X = T?

Virtual

True

Is the auxillary stop relay #2 for generator X changing from F to T?

Virtual

False B add gen. F to T

True

False

PPU C

True

False C add gen. F to T

True

False

PPU D

True

False D add gen. F to T

True

False

Gen. X Aux. Start 1 = F

Gen. X start/stop

Gen. X Aux. Start 1 = T

True

False Gen. X aux. start 1 = T False

Gen. X aux. start 2 F/T False

Page I-84A

Page I-84B

Page I-84C

I-83

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-83A

Page I-83B

Eng. X ECS AUTO

Page I-83C

True

Is the engine control switch for engine X in the AUTO position?

Virtual

Is the remote start/stop flag for generator X changing from F to T?

Virtual

Gen. X start/stop = F

Set start/stop permissive for generator X to F.

Virtual

Gen. X RSS =T

Set remote start/stop flag for generator X to T.

Virtual

Is the master system enable toggle = T?

Virtual

Is generator X available for auto operation?

Virtual

Is the start/stop permissive for generator X =F?

Virtual

True

Is the system mode switch transfering between AUTO and MAN?

Virtual

True

Is the system mode switch not in the OFF position and parameters cleared?

Virtual

False Gen. X RSS F to T

True

False

MSPB_TOG True =T False Gen. X ready =T

True

False Gen. X SS =F

True

False

SMS trans. =T False

PDC not OFF False

Changing F to T

True

Is the input changing from F to T?

False Start 250ms timer

Page I-85A

Start a 250 ms timer.

Function

Page I-85B

I-84

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-84A

Page I-84B

Changing T to F

True

False

Timer expired

Is the input changing from T to F?

Reset timer

Reset the timer.

True

Function

Has the 250 ms timer expired?

False

Eng. X autorun =F

Autostart gen. X

Eng. X autorun =T

Set engine X autorun, T or F.

Virtual

True

Is generator X flagged to autostart?

DOM1-OUT2 or DOM2-OUT2

True

Is the engine control switch for engine X in the MAN position?

Virtual

Is engine X running?

Virtual

Is the PPU set for 50 Hz?

Virtual

True

Is the average VRMS for generator X greater than 3610?

Virtual

True

Is the average VRMS for generator X less than 3990?

Virtual

False

Eng. X ECS MAN False

Eng. X running False

True

50 Hz mode False

True

VRMS avg. > 3610 False

VRMS avg. < 3990 False

Page I-86A

Page I-86B

Page I-86C

I-85

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-85A

Page I-85B

60 Hz mode

Page I-85C

True

False

VRMS avg. > 3952

True

Is the PPU set for 60 Hz?

Virtual

Is the average VRMS for generator X greater than 3952?

Virtual

Is the average VRMS for generator X less than 4368?

Virtual

False

VRMS avg. True < 4368 False

Changing F to T

True

False

Changing T to F

Start 3 second timer

True

False

Timer expired

Is the input changing from T to F?

Start a 3 second timer.

Function

Is the input changing from T to F?

Reset timer

True

Reset the timer.

Function

Has the 3 second timer expired?

False

Gen. X ready for load = F

Gen. X ready for load = T

Generator X is running and ready for load, T or F.

Virtual

Page I-87

I-86

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-86

Gen. X ready

True

False SMS AUTO

True

False Gen. X br. not PTL

True

False Tie output not energ.

True

Is generator X running and ready for load?

Virtual

Is the system mode switch in the AUTO position?

RTU-IN1

Is the breaker switch for generator X not in the Pull-To-Lock position?

DIM3-IN1 or DIM3-IN2

Is the tie output bus not energized?

DIM2-IN11

False

X=2

True

Does X = 2 (is this the second iteration of this program, run for genset 2)?

False Gen. 1 no DBC

True

Is the dead bus close permissive relay for generator 1 set to F?

Virtual

False Blink at 2.5 second cycle

Input is on

Function

True

Is the blink input on (in the on/off cycle)?

False PPU A

True

False A DBC =T

True

Is the PPU configured as "A"?

RTU-OUT1

Is the A PPU dead bus permissive close relay set to T?

Virtual

Is the PPU configured as "B"?

RTU-OUT2

Is the B PPU dead bus permissive close relay set to T?

Virtual

False

PPU B

True

False B DBC =T

True

False

Page I-88A

Page I-88B

Page I-88C

I-87

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-87A

Page I-87B

PPU C

Page I-87C

True

Is the PPU configured as "C"?

RTU-OUT3

Is the C PPU dead bus permissive close relay set to T?

Virtual

Is the PPU configured as "D"?

RTU-OUT3

Is the D PPU dead bus permissive close relay set to T?

Virtual

Generator X dead bus close permissive = T or F.

Virtual

Is engine X available for autorun?

Virtual

True

Is the PLC output to autostart genset Y set to F?

DOM1-OUT2 or DOM1-OUT2 or

True

Is the PLC output to autostart genset X set to T?

DOM1-OUT2 or DOM1-OUT2 or

True

Is generator X in cooldown?

Virtual

True

Is engine Y running?

Virtual

Is engine X not running?

Virtual

False

C DBC =T

True

False

PPU D

True

False

D DBC =T

True

False

Gen. X DBC =F

Eng. X autorun False

Gen. X DBC =T

True

Eng. Y no autostart False

Eng. X autostart False

Gen. X cooldown False Eng. Y running False

Eng. X not running

True

False

Page I-89A

Page I-89B

I-88

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-88A

Page I-88B

Autostart gen. X =F

Autostart gen. X =T

Gen. X RTL

True

False

SMS AUTO

True

False

Gen. X br. not PTL

True

False

Tie output energized

True

Autostart generator X, T or F.

DOM1-OUT2 or DOM2-OUT2

Is generator X running and ready for load?

Virtual

Is the system mode switch in the AUTO position?

RTU-IN1

Is the breaker switch for generator X not in the Pull-To-Lock position?

DIM3-IN1 or DIM3-IN2

Is the tie output bus energized?

DIM2-IN11

Is the breaker for generator X not closed?

DIM1-IN3 or DIM2-IN3

Autosync for generator X = T or F.

Virtual

Is generator X set to autosync?

Virtual

Is the rempte breaker control for generator X open?

Virtual

Is generator X available for auto operation?

Virtual

PLC output to enable autosync for generator X is T or F.

DOM1-OUT3 or DOM2-OUT3

False

Gen. X br. not closed

True

False

Gen. X autosync =F

Gen. X autosync False

Gen. X autosync =T

True

Gen. X rem. br. open False

True

Gen. X ready

True

False

Gen. X autosync output = F

Gen. X autosync output = T

Page I-90

I-89

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-89

Gen. X rem. br. open

True

Is the rempte breaker control for generator X open?

Virtual

Is generator X not set to autstart?

DOM1-OUT2 or DOM2-OUT2

Is the breaker open for generator X?

DIM1-IN3 or DIM2-IN3

Reset the generator X remote breaker control to F (breaker open).

Virtual

Is the rempte breaker control for generator X open?

Virtual

Is the local PPU configured and ready for operation?

Virtual

Is the engine control switch for generator X in the OFF position?

Virtual

Is the system mode switch in the AUTO position?

RTU-IN1

True

Is the engine control switch for generator X in the STOP position?

Virtual

True

Is generator X lockout set to T?

Virtual

True

Is the generator X breaker switch in the Pull-To-Lock position?

DIM3-IN1 or DIM3-IN2

True

Is engine X autorun not enabled?

Virtual

False

Gen. X no autostart

True

False

Gen. X br. open

True

False

Gen. X rem. br. open

Reset gen. X remote br. to F

True

False

Local PPU ready

True

False

Gen. X ECS OFF

True

False

SMS AUTO

True

False

Gen. X ECS STOP False

Gen. X lockout False

Gen. X br. PTL False Eng. X no autorun False

Page I-91A

Page I-91B

Page I-91C

I-90

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-90A

Page I-90B

Gen. X ECS AUTO

Page I-90C

True

Is the engine control switch for generator X in the AUTO position?

Virtual

Enable generator X's breaker to open, T or F.

DOM1-OUT6 or DOM2-OUT6

Is the rempte breaker control for generator X closed?

Virtual

True

Is the PLC output to enable autosync for generator X turned on?

DOM1-OUT3 or DOM2-OUT3

True

Is generator X dead bus close permissive set to T?

Virtual

Is the PLC output to enable generator X's breaker to open set to F?

DOM1-OUT6 or DOM2-OUT6

Does the generator X breaker have the red target visible (not green)?

DIM1-IN1 or DIM2-IN1

Is generator X's breaker closed?

DIM1-IN3 or DIM2-IN3

Enable generator X's breaker to close, T or F.

DOM1-OUT5 or DOM2-OUT5

Is the engine control switch for generator X in the AUTO position?

Virtual

False

Enable gen. X br. to open = F

Gen. X rem. br. closed

Enable gen. X br. to open = T

True

False

Gen. X autosync False

Gen. X DBC False

Gen. X br. open = F

True

False

Gen. X breaker red

True

False

Gen. X brkr open

True

False

Enable gen. X br. to close = F

Gen. X ECS AUTO

Enable gen. X br. to close = T

True

False

Page I-92A

Page I-92B

I-91

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-91A

Page I-91B

Gen. X no autostart

True

False

Eng. X running

True

Is the PLC output to autostart generator X set to F?

DOM1-OUT2 or DOM2-OUT2

Is engine X running?

Virtual

Is the engine control switch for engine X in the STOP position?

Virtual

Generator X is in cooldown, T or F.

Virtual

Is the automatic voltage regulator switch in the utility parallel position?

RTU-IN7

Is generator X's breaker closed?

DIM1-IN3 DIM2-IN3

Generator X utilty parallel mode = T or F.

DOM1-OUT9 or DOM2-OUT9

Is the master system enable toggle = T?

Virtual

Is engine X's rpm >= 800?

Virtual

Engine X is running, T or F.

Virtual

False

Eng. X ECS STOP

True

False

Gen. X cooldown =F

AVRS UP

Gen. X cooldown =T

True

False

Gen. X br. closed

True

False

Utility parallel =F

Utility parallel =T

MSPB_TOG True =T False

Eng. X rpm >=800

True

False

Eng. X running =F

Eng. X running =T

Page I-93

I-92

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-92

Eng. X autorun

True

False

Eng. X not running

True

False

Changing F to T

True

False

Changing T to F

Is engine X not running?

Virtual

Is the input changing from F to T?

Start 2 minute timer

Start a 2 minute timer.

Stop and reset timer

Stop and reset the 2 minute timer.

True

False

Gen. X autosync

Virtual

True

False

Timer expired

Is engine X available for autorun?

Has the 2 minute timer expired?

Page I-94C

True

Is the PLC output to autosyn generator X set to T?

DOM1-OUT3 or DOM2-OUT3

True

Is generator X dead bus close permissive set to T?

Virtual

Is the breaker for generator X not closed?

DIM1-IN3 or DIM2-IN3

False

Gen. X DBC False

Gen. X br. not closed False

True

Changing F to T False

Page I-94A

True

Start 1 minute timer

Start a 2 minute timer.

Page I-94B

I-93

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-93A

Page I-93B

Changing T to F

Page I-93C

True

False

Timer expired

Stop and reset timer

True

Stop and reset the 1 minute timer.

Has the 1 minute timer expired?

False

Gen. X fail

True

Is the summary failure for generator X set to T?

Virtual

True

Is the lockout for generator X set to T?

Virtual

Is the master start enable switch in either enable position?

RTU-IN3

Set the summary failure flag for generator X, T or F.

Virtual

False

Gen. X lockout False

MSES ENABLE

True

False

Gen. X summary failure = F

Gen. X summary failure = T

Return

End of subprogram.

I-94

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Start - Tie / Feeder Control

SMS AUTO

Controls tie & feeder breakers.

True

False Not last PPU

Is the system mode switch in the AUTO position?

RTU-IN1

Is the LS-NET casble plugged into the "B" connector?

RTU-IN8

True

Is the remote tie open/close toggle set for open?

Virtual

True

Is the tie output bus energized?

DIM2-IN11

Is the main system bus not energized?

DIM2-IN12

Is the tie output bus not energized?

DIM2-IN11

Is the main system bus energized?

DIM2-IN12

Is there no tie breaker overcurrent relay alarm?

DIM1-IN4

Is there no tie breaker overcurrent trip?

DIM1-IN13

Is the battleshort switch not in the NORMAL position?

RTU-IN4

Enable tie breaker to close, T or F.

Virtual

True

False Remote tie open False

Tie bus energized False

Main bus not ener.

True

False

Tie bus not ener.

True

False Main bus energized

True

False

No tie OC relay alm. False

True

No tie OC trip

True

False

Battleshort not normal

True

False

Enable tie close =F

Enable tie close =T

Page I-96

I-95

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-95

Tie close enable

True

False

Tie not closed

True

False

No tie open en.

True

False

Tie not PTL

True

Is the tie breaker enabled to close?

Virtual

Is the tie breaker not closed?

DIM1-IN12

Is the PLC output to enable the tie breaker to open set to F?

DOM2-OUT11

Is the tie breaker switch not in the Pull-To-Lock position?

DIM3-IN3

Is the tie breaker lockout set to F?

Virtual

Enable tie breaker to close, T or F.

DOM2-OUT10

Is the LS-NET cable not plugged into the "B" connector?

RTU-IN8

Is the generator mode switch not in the utility parallel position (is in the prime power position)?

RTU-IN5

Is the tie breaker remote open/close toggle set to close?

Virtual

Is the system mode switch in the AUTO position?

RTU-IN1

Is the tie breaker tripped due to overcurrent?

DIM1-IN13

Is the battleshort switch in the NORMAL position?

RTU-IN4

False

No tie lockout

True

False

Enable tie close =F

Last PPU

Enable tie close =T

True

False

GMS prime pow.

True

False

Tie remote closed

True

False

SMS AUTO

True

False

Tie OC trip False

True

Battleshort NORMAL

True

False

Page I-97A

Page I-97B

I-96

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-96A

Tie lockout

Page I-96B

True

Is the tie breaker lockout set to T?

Virtual

True

Is the tie breaker switch in the Pull-To-Lock position?

DIM3-IN3

Enable tie breaker to open, T or F.

DOM2-OUT11

Is the tie breaker remote open/close toggle set to close?

Virtual

Is the system mode switch changing from the AUTO position to a different position?

RTU-IN1

Reset tie breaker remote open/close to F (open).

Virtual

Is the system mode switch in the AUTO position?

RTU-IN1

Is the tie output bus energized?

DIM2-IN11

Is the feeder 1 breaker remote open/close toggle set to T (closed)?

Virtual

Is the local PPU configured and ready for operation?

Vitual

Is there not an overcurrent alarm on feeder 1?

DIM1-IN10

Is there no overcurrent trip on feeder 1?

DIM1-IN9

False

Tie PTL False

Enable tie open =F

Tie remote closed

Enable tie open =T

True

False

SMS AUTO T to F

True

False

SMS AUTO False

Tie remote close =F

True

Tie bus energized

True

False

Feeder 1 rem. close

True

False

PPU ready

True

False

No feeder 1 OC alarm False

True

No feeder 1 OC trip

True

False

Page I-98A

Page I-98B

Page I-98C

I-97

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-97A

Page I-97B

Battleshort not NORM.

Page I-97C

True

Is the battleshort switch not in the NORMAL position?

RTU-IN4

Enable feeder 1 breaker to close, T or F.

Virtual

True

Is the tie output bus not energized?

DIM2-IN11

True

Is the PLC output to enable feeder 1 breaker to open set to T?

DOM1-OUT8

True

Is the PLC output to enable feeder 1 breaker to close set to T?

Virtual

Is feeder 1 not closed (open)?

DIM1-IN8

False

Enable feeder 1 close = F

Tie bus not energ.

Enable feeder 1 close = T

False

Feeder 1 open en. False

Feeder 1 close en. False

Feeder 1 open False

True

Changing F to T

True

False

Changing T to F

Start 1 second timer

Start a 1 second timer.

Stop and reset timer

Stop and reset the 1 second timer.

True

False

Timer expired

Is the input changing from F to T?

True

Has the 1 second timer expired?

False

Page I-99A

Page I-99B

I-98

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-98A

Page I-98B

Feeder 1 rem. close

True

Is the remote open/close toggle for feeder 1 set to close?

Virtual

Set feeder 1 remote open/close toggle to F (open).

Virtual

Is the PLC output to enable feeder 1 breaker to close set to T?

Virtual

Does the feeder 1 breaker switch have the red target visible?

DIM3-IN6

Is feeder 1 not closed?

DIM1-IN8

Is the PLC output to enable feeder 1 breaker to open set to F?

DOM1-OUT8

PLC output to enable feeder 1 to close = T or F.

DOM1-OUT7

Is feeder 1 tripped because of overcurrent?

DIM1-IN9

Is the battleshort switch in the NORMAL position?

RTU-IN4

True

Is the toggle for remote open/close of feeder 1 changing from T to F?

Virtual

True

Is the breaker switch for feeder 1 in the Pull-ToLock position?

DIM3-IN4

PLC output to enable feeder 1 to open = T or F.

DOM1-OUT8

False

Feeder 1 close en.

Feeder 1 remote open/close = F

True

False

Feeder 1 br. red

True

False

Feeder 1 not closed False

True

Feeder 1 not True open en. False

Feeder 1 close enable = F

Feeder 1 OC trip

Feeder 1 close enable = T

True

False

Battleshort NORMAL

True

False

Feeder 1 rem. close False

Feeder 1 PTL False Feeder 1 open enable = F

Feeder 1 open enable = T

Page I-99

I-99

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-99

SMS AUTO

True

Is the system mode switch in the AUTO position?

RTU-IN1

Is the tie output bus energized?

DIM2-IN11

Is the feeder 2 breaker remote open/close toggle set to T (closed)?

Virtual

Is the local PPU configured and ready for operation?

Vitual

Is there not an overcurrent alarm on feeder 2?

DIM2-IN10

Is there no overcurrent trip on feeder 2?

DIM2-IN9

Is the battleshort switch not in the NORMAL position?

RTU-IN4

Enable feeder 2 breaker to close, T or F.

Virtual

True

Is the tie output bus not energized?

DIM2-IN11

True

Is the PLC output to enable feeder 2 breaker to open set to T?

DOM2-OUT8

False

Tie bus energized

True

False

Feeder 2 rem. close

True

False

PPU ready

True

False

No feeder 2 OC alarm

True

False

No feeder 2 OC trip

True

False

Battleshort not NORM.

True

False

Enable feeder 2 close = F

Tie bus not energ.

Enable feeder 2 close = T

False

Feeder 2 open en. False

Page I-100A

Page I-100B

I-100

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-99A

Feeder 2 close en.

Page I-99B

True

False Feeder 2 open

True

False Changing F to T

True

Is the PLC output to enable feeder 2 breaker to close set to T?

Virtual

Is feeder 2 not closed (open)?

DIM2-IN8

Is the input changing from F to T?

False

Changing T to F

Start 1 second timer

Start a 1 second timer.

Stop and reset timer

Stop and reset the 1 second timer.

True

False

Timer expired

True

Has the 1 second timer expired?

True

Is the remote open/close toggle for feeder 2 set to close?

Virtual

Set feeder 2 remote open/close toggle to F (open).

Virtual

Is the PLC output to enable feeder 2 breaker to close set to T?

Virtual

Does the feeder 2 breaker switch have the red target visible?

DIM3-IN7

Is feeder 2 not closed?

DIM2-IN8

False

Feeder 2 rem. close False

Feeder 2 remote open/close = F

Feeder 2 close en.

True

False Feeder 2 br. red

True

False Feeder 2 not closed

True

False

Page I-101A

Page I-101B

I-101

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-100A

Page I-100B

Feeder 2 not True open en.

Is the PLC output to enable feeder 2 breaker to open set to F?

DOM2-OUT8

False

Feeder 2 close enable = F

Feeder 2 OC trip

Feeder 2 close enable = T

True

PLC output to enable feeder 2 to close = T or F. DOM2-OUT7

Is feeder 2 tripped because of overcurrent?

DIM1-IN9

Is the battleshort switch in the NORMAL position?

RTU-IN4

True

Is the toggle for remote open/close of feeder 2 changing from T to F?

Virtual

True

Is the breaker switch for feeder 2 in the Pull-ToLock position?

DIM3-IN5

PLC output to enable feeder 1 to open = T or F.

DOM2-OUT8

False

Battleshort NORMAL

True

False

Feeder 2 rem. close False

Feeder 2 PTL False

Feeder 2 open enable = F

Feeder 2 open enable = T

Return

End of subprogram.

I-102

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Start - Announce

Eng. 1 running

Controls the PPU buzzer.

True

Is engine 1 running?

Virtual

True

Is the high coolant temperature alarm for engine 1 changing from F to T?

GSC

True

Is the low coolant temperature alarm for engine 1 changing from F to T?

GSC

True

Is the low oil pressure alarm for engine 1 changing from F to T?

GSC

True

Is the high oil temperature alarm for engine 1 changing from F to T?

GSC

Eng. 1 ADEM True F to T

Is the ADEM unit alarm for engine 1 changing from F to T?

GSC

Is the generator 1 underfrequency alarm changing from F to T?

GSC

Add 1 to the Alarm_Count variable.

Virtual

Set alarm1a variable to T.

Virtual

Is engine 1 running?

Virtual

True

Is the generator 1 overfrequency alarm changing from F to T?

GSC

True

Is the generator 1 undervoltage alarm changing from F to T?

GSC

False Eng. 1 HCT F to T False

Eng. 1 LCT F to T False

Eng. 1 LOP F to T False

Eng. 1 HOT F to T False

False

Gen. 1 UF F to T

True

False Add 1 to Alarm_Count

Alarm1a =T

Eng. 1 running

True

False Gen. 1 OF F to T False

Gen. 1 UV F to T False

Page I-103A

Page I-103B

Page I-103C

I-103

This Power Unit Logic Flowchart is provided with Government Purpose License Rights

Page I-102A

Page I-102B

Page I-102C

True

Is the generator 1 overvoltage alarm changing from F to T?

GSC

True

Is the generator 1 reverse power alarm changing from F to T?

GSC

True

Is the generator 1 frequency sensing alarm changing from F to T?

GSC

Is the engine control switch for engine 1 not in the OFF position?

Virtual

Is the engine 1 battery low (
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