Operation and Maintenance Manual Power

GHP/QSB5-G9 TIER 4i 100kW US STD & OFFSHORE

REVISION HISTORY
Rev.
Rev. Date Details of Changes Prepared By Reviewed By Approved By
No.
Updated A05/G08 and D20
G 11/08/2016 G. Rabone R. Maguire W. Telfer
added to manual.

August 2016 M02000537-G Page 1 of 103

1.0 SAFETY .............................................................................................................................5
1.1. General Information ......................................................................................................................... 5
1.2. Electrical Power ............................................................................................................................... 5
1.3. Materials ........................................................................................................................................... 5
1.4. Operational Precautions .................................................................................................................. 6
1.5. Safety Labels ................................................................................................................................... 7
2.0 NOISE EMISSION ..............................................................................................................8
2.1. Noise Control Prohibited Acts .......................................................................................................... 8
2.2. Generator Noise Emission Control Information ............................................................................... 8
3.0 HANDLING .........................................................................................................................9
3.1. Lifting / Handling .............................................................................................................................. 9
3.2. Storage / Transport .......................................................................................................................... 9
4.0 INSTALLATION ................................................................................................................ 10
4.1. Unpacking ......................................................................................................................................10
4.2. Location of the Plant ......................................................................................................................10
4.3. Commissioning...............................................................................................................................10
4.4. Prior to Starting ..............................................................................................................................10
4.5. Electrical Connection .....................................................................................................................10
4.6. Earthing ..........................................................................................................................................11
4.7. Remote Fuelling .............................................................................................................................11
5.0 GENERAL DATA .............................................................................................................. 11
5.1. General Operation .........................................................................................................................11
5.2. Design Load Capacity ....................................................................................................................11
5.3. Design Temperatures ....................................................................................................................12
5.4. Canopy & Base Frame ...................................................................................................................12
5.5. Diesel Engine .................................................................................................................................12
5.6. Engine Lubrication System ............................................................................................................12
5.7. Engine Cooling System ..................................................................................................................12
5.8. Engine Fuel System .......................................................................................................................13
5.9. Exhaust System .............................................................................................................................13
5.10. Engine Control System ..................................................................................................................13
5.11. Generator .......................................................................................................................................14
5.12. Main Circuit Breaker ......................................................................................................................14
5.13. Voltage Selector Switch .................................................................................................................14
5.14. Aggreko Remote Monitoring ..........................................................................................................17
5.15. Operating Controls and Instruments ..............................................................................................18
5.15.1. Control Panel ..................................................................................................... 18
5.15.2. Control Module ................................................................................................... 20
5.15.3. Display Pages .................................................................................................... 21

August 2016 M02000537-G Page 2 of 103

 5.16. Operating procedure ......................................................................................................................22
5.16.1. Manual Operation ............................................................................................... 22
5.16.2. Remote/standby operation ................................................................................. 23
5.17. Modes of operation ........................................................................................................................23
5.17.1. Single set operation ............................................................................................ 23
5.17.2. Loadsharing with another 5510 controller ........................................................... 23
5.17.3. Baseload operation ............................................................................................ 24
5.17.4. Loadsharing with a GENerator set fitted with analogue parallel lines .................. 25
5.18. Alarm functions ..............................................................................................................................25
5.19. Changing Parameters ....................................................................................................................26
5.19.1. General .............................................................................................................. 26
5.19.2. Parameter Adjustment For Alternative Alternator Configurations ........................ 28
6.0 MAINTENANCE ............................................................................................................... 29
6.1. General ..........................................................................................................................................29
6.2. Maintenance Schedule ..................................................................................................................30
6.2.1. Inspection Criteria .................................................................................................. 30
6.2.2. Service Criteria ...................................................................................................... 31
6.3. Daily Maintenance .........................................................................................................................32
6.3.1. Check The Engine Oil Level: .................................................................................. 32
6.3.2. Check The Fuel Tank Level ................................................................................... 32
6.3.3. Check That All Meters And Gauges Function Correctly.......................................... 32
6.3.4. Check The Air Filter ............................................................................................... 33
6.3.5. Check The Battery ................................................................................................. 33
6.3.6. Check For Leaks .................................................................................................... 33
6.4. Weekly Maintenance ......................................................................................................................33
6.4.1. Check The Water/Antifreeze Level ......................................................................... 33
6.4.2. Carry Out A Visual Check Of The Drive Belts. ....................................................... 34
7.0 LUBRICATION ................................................................................................................. 35
7.1. General Information .......................................................................................................................35
7.2. Generator Oil Change ....................................................................................................................35
7.3. Oil specification ..............................................................................................................................35
Trouble Shooting ......................................................................................................................... 36
7.4. Introduction ....................................................................................................................................36
7.5. Action Plan .....................................................................................................................................36
7.6. Trouble Shooting Chart ..................................................................................................................37
APPENDIX A - MATERIAL SAFETY DATA SHEETS ................................................................. 39
APPENDIX B – EQUIPMENT DATA SHEET .............................................................................. 77

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APPENDIX C – INSTALLATION OUTLINE DRAWING ............................................................... 82
APPENDIX D – CONTROL PANEL LAYOUT ............................................................................. 84
APPENDIX E – ALTERNATOR & AVR SCHEMATIC DIAGRAM ................................................ 86
APPENDIX F – MAIN LOAD & METERING SCHEMATIC DIAGRAM ......................................... 88
APPENDIX G – DC CONTROL SYSTEM SCHEMATIC DIAGRAM ............................................ 90
APPENDIX H – ECM 2250 INTERCONNECTIONS ........................................................................ 92
APPENDIX I – TERMINAL LAYOUT & ENGINE WIRING ........................................................... 94
APPENDIX J – LIVERY LAYOUT DRAWING ............................................................................. 96
APPENDIX K – MANUFACTURERS COMPONENT DATA ........................................................ 98
APPENDIX L – LIFTING BEAM CERTIFICATE ........................................................................ 100
APPENDIX M – DNV SPARK ARRESTOR CERTIFICATE ....................................................... 102

August 2016 M02000537-G Page 4 of 103

1.0 SAFETY

1.1. General Information

Ensure that the operator reads and understands the decals and consults the manuals before maintenance
or operation.

Ensure that the Operation and Maintenance manual, and the manual holder, are not removed permanently
from the machine.

Ensure that maintenance personnel are adequately trained, competent and have read the Maintenance
Manuals.

Make sure that all protective covers are in place and that the canopy/doors are closed during operation.

The specification of this machine is such that the machine is not suitable for use in flammable gas risk
areas. WARNING: NO ATTEMPT SHOULD BE MADE TO OPERATE IN SUCH AREAS WITHOUT
THE EXPRESS AUTHORITY FROM AGGREKO.

Installation of this generator must be in accordance with recognised electrical codes and any local Health
and Safety Codes.

1.2. Electrical Power

Prior to installation of the generating set you should check that the electrical load to be applied is within the
rated output of the machine at the site ambient conditions.

Before carrying out any maintenance or repairs to the Engine/Alternator assembly disconnect the starting
battery and isolate the alternator from the switchboard.

Before carrying out any maintenance repair to the AC and DC circuits, isolate these from external control
panel and power supplies.

Ensure that the generator set and the load it is connected to are properly earthed.

The generating set should be connected to the load only by a qualified electrician and in accordance with
the applicable regulations.

1.3. Materials
The following substances are used in the manufacture of this machine and may be hazardous to health if
used incorrectly:

Antifreeze

Engine Lubricating Oil

Preservative Grease

Rust Preventative

Diesel Fuel

Battery Electrolyte.

August 2016 M02000537-G Page 5 of 103

 AVOID INGESTION, SKIN CONTACT AND INHALATION OF FUMES.
When handling fuel, lubricating oil, cooling fluid and battery electrolyte, wear appropriate personal
protection equipment.

For further information, consult Material Safety Data Sheet contained in this manual.

Avoid build-up of Engine Exhaust Fumes in confined spaces.

Avoid breathing Exhaust Fumes.

1.4. Operational Precautions

Never operate unit without first observing all safety warnings and carefully reading the operation and
maintenance manual shipped from the factory with this machine.

IF IN DOUBT CONTACT AGGREKO.

Never operate the engine of this machine inside a building without adequate ventilation. Avoid breathing
exhaust fumes when working on or near the machine. Do not alter or modify this machine.

A battery contains sulphuric acid and can give off gases, which are corrosive and potentially explosive.
Avoid contact with skin, eyes and clothing. In case of contact, flush area immediately with water.

Exercise extreme caution when using booster battery. To jump battery, connect ends of one booster cable
to the positive (+) terminal of each battery. Connect one end of other cable to the negative (-) terminal of
the booster battery and other end to a ground connection away from dead battery (to avoid a spark
occurring near any explosive gases that may be present). After starting unit, always disconnect cables in
reverse order.

Never operate unit without first observing all safety warnings and carefully reading the operation manual.

This machine may include such materials as oil, diesel fuel, antifreeze, oil/air filters and batteries which
may require proper disposal when performing maintenance and service tasks. Contact local authorities for
proper disposal of these materials.

This machine produces loud noise with the doors open. Extended exposure to loud noise can cause
hearing loss. Always wear hearing protection when doors are open.

Never inspect or service unit without first disconnecting battery cable(s) or using the battery isolator switch
to prevent accidental starting.

Do not remove the pressure cap from a HOT radiator. Allow radiator to cool down before removing
pressure cap.

Do not use petroleum products (solvents or fuels) under high pressure as this can penetrate the skin and
result in serious illness. Wear eye protection while cleaning unit with compressed air to prevent debris from
injuring eye(s).

Hot pressurized fluid can cause serious burns. Do not open radiator while hot.

Rotating fan blade can cause serious injury. Do not operate without guard in place.

Use care to avoid contacting hot surfaces (engine exhaust manifold and piping, etc.).

Never operate unit with guards, covers or screens removed. Keep hands, hair, clothing, tools, etc. well
away from moving parts.

August 2016 M02000537-G Page 6 of 103

 1.5. Safety Labels
Look for these signs on machine, which point out potential hazards to the safety of you and others. Read and
understand thoroughly. Heed warnings and follow instructions.

DANGER
FIRE RISK

RISK OF
ELECTRIC SHOCK

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

CAUTION
Hot

DISCONNECT STARTING
BATTERY AND ISOLATE
LOAD BEFORE WORKING
ON ENGINE /
ALTERNATOR ASSEMBLY

(for stackable containers only)

August 2016 M02000537-G Page 7 of 103

2.0 NOISE EMISSION

2.1. Noise Control Prohibited Acts

WARNING
Tampering with noise control system prohibited
The following acts or misuse of the unit are prohibited:
1) The removal or rendering inoperative by any persons, other than for purposes of maintenance, repair, or
replacement, of any device or element of design incorporated into any new generator for the purpose of noise
control prior to its sale or delivery to the ultimate purchaser or while it is in use
Or
2) The use of the generator after such device or element of design has been removed or rendered inoperative by
any person.
Among those acts included in the prohibition against tampering are these:
Removal or rendering inoperative any of the following:
a) The engine exhaust system or parts thereof.
b) The air intake system or parts thereof.
c) Enclosure or parts thereof.
Removal of any of the following:
 Fan shroud
 Vibration mounts
 Sound absorption material
Operation of the generator with any of the enclosure doors open.

2.2. Generator Noise Emission Control Information

A. The removal or rendering inoperative, other than for the purpose of maintenance, repair, or
replacement of any noise control device or element of design incorporated into this generator in
compliance with the noise control act;

B. The use of this generator after such device or element of design has been removed or rendered
inoperative.

THIS GENERATOR HAS BEEN SPECIFICALLY DESIGNED WITH A SOUND ATTENUATING

ENCLOSURE. THE CANOPY DOORS SHOULD REMAIN LOCKED SHUT UNDER NORMAL
OPERATING CONDITIONS. UNDER ANY OTHER CONDITIONS EXCESSIVE NOISE LEVELS CAN BE
PRODUCED AND PROLONGED EXPOSURE IS HAZARDOUS TO HEARING.

FOR SAFETY, EAR PROTECTION SHOULD ALWAYS BE

WORN WHEN WORKING IN THE VICINITY OF AN
OPERATING GENERATOR SET.

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3.0 HANDLING

3.1. Lifting / Handling

The generator set includes 1 lifting beam and forklift pockets. There is the option for a two-point lift
configuration suitable for offshore service.

All lifting and handling equipment must be adequately rated for applicable weights.

During all lifting and handling operations the following weights must be considered.

Complete Package Max. Fuel 6920 lbs (3139 kgs)

Complete Package Without Fuel 5816 lbs (2638 kgs)

Bolt on steel plate buffers are located at the front and rear of the base to protect the body of the generator.

Where 2 point lifting is provided, ensure that the correct length of strop / wire rope is used on each lifting
beam to ensure a level lift. Also ensure that the included angle does not exceed 90°.

CAUTION: THE GENERATOR SET SHOULD NOT BE LIFTED OR DRAGGED BY THE END
BUFFERS.

3.2. Storage / Transport

Carry out the following points before transporting the generator or preparing the generator for storage.

Empty the fuel tank (in case of overseas transport).

Disconnect the battery terminals (in case of overseas transport).

Close all fuel valves.

Seal the remote fuel connection with a blind stop.

Ensure that the radiator cap is fitted securely and the exhaust rain cap is closed.

Close all doors.

All units are to be loaded flat onto transport and properly secured.

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4.0 INSTALLATION

4.1. Unpacking
Ensure that the correct fork lift truck slots or marked lifting / tie down points are used whenever the
machine is lifted or transported.

4.2. Location of the Plant

The generator can be installed on any solid, flat and level surface capable of supporting the full operating
load of the package. A dry, well-ventilated area where the atmosphere is as clean as possible is
recommended. Ensure that the machine is positioned securely and on a stable foundation.

CAUTION: A minimum of 1 metre (3 ft) all round the generator is recommended. Hot air will exit
from the roof outlet. It is important that this hot air does not re-circulate to the package inlet.

The generator must be allowed sufficient space all round and above, to enable the effective removal of the
cooling air which, in turn, will reduce the risk of re–circulating the cooling air back through the generator.
Adequate clearance needs to be allowed around and above the machine to permit safe access for
specified maintenance tasks. Hard surfaces may reflect noise with an apparent increase in the decibel
level. It is recommended that provision be made for lifting heavy components during major overhaul.
NOTE: When operating at elevated altitude please refer to engine manufacturer’s guidelines for
power deration.

4.3. Commissioning
Upon receipt of the unit, and prior to putting it into service, it is important to adhere strictly to the
instructions given below in section 4.4 PRIOR TO STARTING.

Ensure all persons concerned are suitably competent with generator installations.

Ensure that the operator reads and understands the decals and consults the manuals before maintenance
or operation.

Ensure that the position of the emergency stop device is known and recognised by its markings. Ensure
that it is functioning correctly and that the method of operation is known.

4.4. Prior to Starting

Ensure that the unit is clean, free from debris and fluids. All connections, joints, seals must be correctly
fitted and tightened. All filters, louvers and air inlets are free and open.

Ensure that there is a safe working procedure which has been issued by supervisory personnel, and that all
persons concerned with the operation of the generator understand it.

Ensure that the safety procedure to be applied is based on the appropriate national and local regulations.

Ensure that the safety procedure is followed at all times.

4.5. Electrical Connection

A suitably trained electrician should carry out all electrical connections.

Ensure the generator main isolator is off and that the power cables are in good condition.

Ensure that the phases are correct after the cables have been connected.

Ensure all safety covers are back in place after electrical connection is complete.

August 2016 M02000537-G Page 10 of 103

 4.6. Earthing
An external earthing boss is fitted onto the base frame at the control panel end of the set. This allows a
dedicated earthing connection if required.

4.7. Remote Fuelling

External fuel tank supply can be connected to the generator set.

One ½” BSP Adaptor (Supply)

One ½” BSP Adaptor (Return)

There is an access hole in the base frame to allow access to the internal fuel connections.

5.0 GENERAL DATA

NOTE: Each generator of this type is uniquely identified by a Plant Number and Serial Number indicated
on the identification plate affixed to the outside of the control panel. This information is required when
ordering spare parts. Major component serial numbers are contained within the manual.

The technical data defining the generator and the limits on its operating environment are tabulated in the
Equipment Data Sheet. A copy of the Equipment Data Sheet has been included in the manual.

In order to assist in the operation and maintenance of the generator, a full set of electrical and installation
drawings has been included in the manual.

5.1. General Operation

The generator is a diesel engine driven alternator with control electronics, mounted on a bedplate with
internal fuel tank. The standard package is composed of the following:

Alternator and engine assembly

Pressurised oil system with cooler

Automated control system

Instrumentation

Safety provisions

Engine cooler pack

Spark arrestor / Silencer

Internal fuel tank

The engine and alternator are integrally mounted. This assembly is isolated from the base by rubber
isolation mounts.

5.2. Design Load Capacity

The GHP/QSB5-G9 (106kVA @ 50 Hz PRP) generator set can be run up to a maximum of 122 kVA @ 60
Hz at prime power rating. It is strongly advised that this set should not be run for extended periods of time
on less than 30% load.

August 2016 M02000537-G Page 11 of 103

 5.3. Design Temperatures
The GHP/QSB5-G9 (100kW) generator set can operate through an ambient temperature range of:
-10°C (14°F) to 45°C (100°F)
5.4. Canopy & Base Frame
The overall dimensions for the generator set are 3430 X 1200 X 2088 mm.

The canopy is manufactured from welded Galvatite and has access to the inside of the generator through
lockable doors.

The base frame has 120% capacity of the fuel tank to prevent fuel leaking out of the generator set in the
event of a fuel leakage inside the generator. A level switch is fitted inside the bund for spillage indication.

This will shut down the engine when activated.

5.5. Diesel Engine

The generator set uses a Cummins Diesel Engine, which is capable for either 50 Hz or 60 Hz. Details of
the engine are outlined below.

4 cylinder inline turbo charged and charge

Type:
air cooled
Model: Cummins QSB5-G9
RPM: 1500 / 1800
Nominal Engine Output @ 1500rpm: 85kWm @ Prime Power
Governor: CM2250 (Engine Management System)
Starting System: 12V battery system
Fuel Consumption @ Continuous
25 L/Hr @ 100% Prime Power
1500rpm:

5.6. Engine Lubrication System

The engine oil lubrication system includes pump, strainer and sump all fitted internally within the engine
block. Oil filtration is fitted to the side of the engine block for ease of access and maintenance.

Total Oil Capacity: 12.1 Ltrs

The Lube oil specification is as per API CJ4 / CES20081

The sump can be drained using the K1 pump via a Ball valve.

Refer to manufacturers data for all filter information.

5.7. Engine Cooling System

The engine cooling consists of a pump, thermostat, heater and radiator assembly.

Cooling fluid is from the radiator, through the pump, which is belt driven from the engine pulley. The
thermostat controls the flow to the radiator. The radiator assembly is mounted at the front of the engine,
with the fan mounted on the front of the engine.

Cooling air enters the generator through the canopy end louvers and noise attenuation baffles. This air
then passes into the canopy space then across the radiator assembly.

The cooling air exits through the roof of the package.

August 2016 M02000537-G Page 12 of 103

The coolant is factory filled with Valvoline HD Extended Life RTU coolant, providing protection to –37°C.
Please consult Aggreko if filling is required.

There is a radiator expansion tank fitted to this unit that should be checked, prior to starting the unit.

5.8. Engine Fuel System

CAUTION: This engine utilises a High Pressure Common Rail fuel system and the Cummins
engine manual must be consulted before carrying out maintenance on any part of this
system.

The engine fuel system consists of an internal fuel tank, Racor filter (see Figure 5.2), fine fuel filter, fuel
pump, injection pump and nozzles.

Fuel can be taken from either an external or the internal fuel tank. A manual selection valve is used to
select the fuel supply direction. Fuel is then pumped through the Racor filter to the fine fuel filters and then
passed to the injectors and then to the injection nozzles.

The internal fuel tank has a fuel capacity of 686 Litres. Low warning and low shut-off sensors are fitted in
the internal fuel tank. The fuel tank fill point is internal. There are 2 cleaning ports on the fuel tank that are
all accessible through the canopy doors.

External fuel supply can be connected to the package using the ½” BSP Adaptors. Internal supply and
return fittings/valves must be re-configured to ensure that the engine fuel is not drawn from the onboard
supply.

The use of ASTM No. 2D Ultra Low Sulphur Diesel (15 PPM) fuel is mandatory for optimum engine
performance. At operating temperatures below 0°C, acceptable performance can be obtained using blends
of No. 1 and No. 2D. The viscosity of fuels must be kept above 1.3 cSt to provide adequate lubrication.

When changing the secondary (fine) fuel filter it is a Cummins recommendation to fit this filter dry
and then prime via the manual priming pump, set the pump to “pump” prior to priming the filter.
Ensure the priming pump is set to “run” after priming the filter.

Refer to manufacturers data for all filter information.

5.9. Exhaust System

The exhaust system consists of the exhaust ducting, exhaust silencer complete with DOC and rain cap
assembly. The exhaust gases exit the engine and are passed through the exhaust ducting and exhaust,
out the top of the canopy through the rain cap assembly. Insulation and heat shields are fitted to the
exhaust ducting to prevent user contact with high temperature surfaces.

Exhaust Manufacturer: IMS

DOC Manufacturer: Cummins

5.10. Engine Control System

An Engine Management System (CM2250) controls the engine output.

A Deep Sea Electronic 5510 control module is used to monitor the safety circuits and set the operation
mode of the generator. See section 6.1.2 Control Module for more detail.

August 2016 M02000537-G Page 13 of 103

 5.11. Generator
Manufacturer: Newage Stamford
Type: UC1274E
50Hz: 380-415 Volts
Voltage Range
60Hz: 416-480 Volts

Voltage Regulator within 1% from no load to full load AS440

1 Phase configurable on Alternator TB & A voltage selector which is fitted

5.12. Main Circuit Breaker

Manufacturer: Schneider
Type: NLG400-3P

5.13. Voltage Selector Switch

Manufacturer: UK Solenoid.
Type: C315GBM607*01ER.
This switch allows the unit to have various alternator wiring configurations to be selected.

1. Series Star.
2. Parallel Star
3. Parallel Zig Zag

August 2016 M02000537-G Page 14 of 103

 Oil Pressure
Gauge

Priming Pump

Fuel Selector
Valve

AMOT Valve
(Offshore)
K1 Oil Pump

Vent Valve
Battery Switch

Figure 5.2 – 100 kW Generator Part Locations

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 VOLTAGE
SELECTOR
SWITCH

Figure 5.3 - 100 kW Generator Part Locations

August 2016 M02000537-G Page 16 of 103

 5.14. Aggreko Remote Monitoring
The Aggreko Remote Monitoring (ARM) system is the corporate telemetry solution developed by
Aggreko Manufacturing in conjunction with Telemisis Ltd and Aggreko Technology services(ATS),
based on Telemisis proprietary SiteWatch product offering.

ARM is designed to provide a fully featured remote asset management system. ARM monitors all
aspects of the equipment, no matter how remote, continually checking for any signs that could lead to
equipment failure alerting designated users by email or text message as required.

The telemetry module used on this generator is the ATT1 rugged cellular module.

Manufacturer: Telemisis
Type: ATT1

For information on system administration, general operation and installation refer to the OEM product
literature.

Literature available from ARM v4 help tab:

For comprehensive detail on ATT1 configuration please refer to the OEM literature.

The ATT1 is now hosted on V4 ARM server, access to this portal is available from the URL below,

https://arm.aggreko.biz/

The website can be accessed from any internet portal (see your system administrator to obtain a
system account), on successful login you will be granted access to the ARM system level in
accordance to your individual user privileges and customer settings.

August 2016 M02000537-G Page 17 of 103

OPERATING INSTRUCTIONS

5.15. Operating Controls and Instruments

5.15.1. Control Panel

The operating controls and instruments are arranged on the control panel as shown in
figures 6.1 and 6.2. A description of each panel device is given in the key below.

Figure 6.1 – Control Panel Exterior

1 5510 controller 2 Power ON/OFF

Key for figure 6.1

August 2016 M02000537-G Page 18 of 103

 16 17 1 6 15

18

10

12

4
2

11

12

3
9

14
13
Figure 6.2 – Control Panel Interior

1 AVR 10 MCB1 (DC Control Supply)

2 400/5A CT,s 11 Diodes V1-V3

3 Schneider NLG400-3P 12 Relays R1 (Run Relay)

R2 & R3 MCCB Open/Close
Relays
Base-load Switch & Diagnostics
4 MCB7 (For Diagnostics) 13
Plug
Current Limiter Device Busbar-
5 MCB6 (ECM supply) 14
in
6 MCB5 (Water Heater) 15 Earth Bar
7 MCB4 (Breaker Controls) 16 Deep Sea 5510 Controller
MCB3 (Generator Sensing
8 17 Telemetry ATT1 unit
Volts)
9 MCB2 (Generator Bus Volts) 18 Telemetry 1A Fuses F1 & F2
Key for figure 6.2

August 2016 M02000537-G Page 19 of 103

 5.15.2. Control Module

The control module used on this generator set is the 5510 control module by Deep Sea.
Figure 6.3 below shows the front panel layout of the 5510 control module.

12
1

2 11

3
10

4 9

5 6 7 8
5
Figure 6.3 – 5510 Generator controller

1. Auto select
1 Display scroll buttons 7
2. Accept setpoint value
2 CB open button 8 Mute alarm/lamp test
3 CB indication 9 Manual start
Generator available
4 Stop button/alarm accept 10
indication
1. Manual select
5 2. Scroll down/reduce 11 CB close button
1. – s
6 2. Scroll up/increase 12
Status LEDse
setpoint t
1 – in normal mode p
2 – in configuration mode o
i
Key for figure 6.3 n
t
The 5510 generator control module is an automatic engine control module. It has all the features of the
5310 control module but with synchronising and loadsharing/baseload capability. In addition, the 5510
control module is equipped with integrated push buttons for circuit breaker control. The features of the
5510 controller include:
 Text based LCD (supporting multiple languages)
 Comprehensive metering of electrical parameters (voltage, current, power)
 Engine parameter monitoring
 Manual and remote/standby operation
 Synchronising capability with displayed synchroscope
 Loadsharing capability between two 5510 controllers via CANBUS connection (see
“modes of operation” for further details)

August 2016 M02000537-G Page 20 of 103

  Loadsharing capability between 5510 and older units with conventional parallel
loadsharing lines (see “modes of operation” for further details)
 Baseload or parallel to mains operation (see “modes of operation” for further details)
 Comprehensive range of alarms
 Compatible with different alternator configurations
 Support of electronic engines via J1939 CANBUS interface
 On Aggreko canopy sets, binary inputs on the 5510 controller are configured for
remote start input, circuit breaker status and alarms, e.g. Low fuel level or fuel
spillage.
 Analogue inputs are typically configured for low oil pressure, high water temperature
(either senders or discrete switches) and fuel gauge (where fitted).
 Binary outputs are configured for circuit breaker open and close and, where fitted,
for Air flap closed (on offshore sets). In addition, one output is dedicated to provide
a common alarm output which provides a positive DC signal in the event of any
alarm.

5.15.3. Display Pages

The 5510 module displays the following pages on the LCD. Pressing the green Info button
will scroll between these pages. Pressing the Up or Down arrow buttons will scroll between
instrumentation parameters. If no parameters are selected, then autoscroll through the
parameters with begin.
i. Status page
This shows the current status of the generator; e.g. generator at rest, manual mode, auto
mode. When the generator is running, generator parameters are also shown (as
displayed in figure 6.3).
ii. Engine instrumentation
Displays information related to the engine such as engine speed, battery voltage and run
time. If connected to an electronic engine, a range of additional engine parameters are
displayed which is dependent upon the engine type. These include parameters such as
inlet temperature, turbo pressure and fuel consumption.
iii. Gen instrumentation
Displays electrical parameters relating to the engine. These include:
- Generator phase voltages
- Generator line voltages
- Frequency
- Generator currents
- Generator real power and apparent power
- Power factor and reactive power
- kWh
- Phase sequence
- Synchroscope
iv. Bus instrumentation
As the 5510 controller is capable of synchronising, bus information is displayed
separately to generator information. This includes:
- Generator phase voltages

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 - Generator line voltages
- Frequency
- Phase sequence
v. Current alarm page
Displays the current alarms in clear text.

Front Panel LEDs

The following LEDs are provided.
 Green LED to indicate circuit breaker closed [symbol 3 in figure 6.3]
 Green LED to indicate Generator available (lit after starting timers have expired) [symbol 10 in
figure 6.3]
 Red LEDs for stop, manual and auto indication
 Status LEDs to indicate:
- Remote start input signal present.
- Alternative voltage selected. When alternative voltage is selected, under and overvoltage
protection is halved. In addition, overcurrent protection is doubled. Alternative voltage is
intended for use when the generator set alternator windings are configured in parallel, as
opposed to series configuration.
- Alternative frequency selected. For US generator sets, normal frequency is 60Hz and
alternative frequency is 50Hz. For European and AI generator sets, normal frequency is
50Hz and alternative frequency is 60Hz. When alternative frequency is selected protection
settings for over/under frequency and over/under speed are moved accordingly.
- Common alarm indication. This LED is lit if any alarm condition is detected.

5.16. Operating procedure

CAUTION: - Always open the battery isolator switch to avoid unauthorised starting during
transport and maintenance.
This section describes the basic operation of the generator set. For more details on the different
modes of operation, see section 6.3 Modes of operation below.
5.16.1. Manual Operation

To start generator:
1. Prior to starting, exercise daily maintenance. See section 7.1.
2. Turn on DC power.
3. Check that no alarms are present. If a shutdown condition is present, the generator set will not be
allowed to start.
4. Ensure that the baseload switch inside the panel is OFF.
5. Press the manual select button. The display will read “Generator at rest” and “Waiting in
Manual”.
6. Press the manual start button.
7. Once the generator has run-up to speed, check the frequency and voltage. Voltage can be
adjusted via the AVR or potentiometer. Frequency can only be adjusted on non-electronic
engines.
8. Walk around the engine and check for any leakages.
9. After the start up timers have expired, close the circuit breaker by pressing the CB close push
button. Once the circuit breaker is closed, the 5510 will regulate the voltage and frequency to its

August 2016 M02000537-G Page 22 of 103

 nominal values. These can be adjusted from the front panel display. See section 6.5 Changing
parameters for details on how to adjust these parameters.
To stop generator:
1. Open circuit breaker by pressing the CB open push button.
2. Allow the engine to cool down for at least 5 minutes, especially when the set has been running
with a high load.
3. Press engine stop.

5.16.2. Remote/standby operation

CAUTION: In remote operation, motorised breakers will close automatically. The 5510
controller will close onto a dead bus or synchronise onto a live bus after the start-up timers
have expired.

1. Turn on DC power
2. Check for alarms
3. Ensure that the busload switch inside the panel is OFF
4. Press Auto select. The display will read “Generator at rest” and “Auto mode”
5. The generator set can be started by providing a connection between terminals 2 and 3.
6. Generator set can be stopped by removing the connection between terminals 2 and 3.
7. A test run should be carried out at least once a week.

5.17. Modes of operation

Please read section 6.2 Operating procedure for details on the basic operation of the 5510 controller.
For 50 or 60 Hz operation (the vast majority of operating conditions) it will not be necessary to
manually adjust the nominal frequency as this is automatically changed when alternative frequency is
selected. For more details, see section 6.5 Changing parameters.

5.17.1. Single set operation

When used as a standalone generator, the 5510 will regulate to its internal voltage and frequency
nominal settings as soon as the breaker is closed. If any adjustment to frequency or voltage is made
when the breaker is closed, the controller will regulate back to its nominal setpoints.

5.17.2. Loadsharing with another 5510 controller

Loadsharing between 2 or more 5510 controllers is achieved via the Multiset Communications (MSC)
CANBUS link.
Communications link
The connection is made using 2 core screened cable. See diagram 6.4 below.

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 Figure 6.4 – MSC CANBUS connection between 5510 control modules

Notes:
a. The Multiset Communications link terminals are only to be connected to other
Deep Sea controllers and not to any other device.
b. Do not connect the MSC cable screen (SCR) to earth at any point. Protection
from interference is provided within the module and may be compromised by
earthing the MSC cable screen.
c. The maximum total length of the MSC link is 250 m.
d. A 120Ω resistor must be placed on the first and last devices on the
communications bus.
e. Up to 16 Deep Sea controllers can be connected via the MSC link.
The features of the MSC link include:
f. Determining which set closes onto a dead bus, eliminating the chance that two
sets close onto a dead bus at the same time.
g. Active and reactive loadsharing (equivalent to analogue loadsharing lines).
h. Identifying when sets should start or stop when used in automatic start/stop on
load demand mode. A digital input requires to be configured for this mode in
order to use this feature.

5.17.3. Baseload operation

Baseload mode is used to export a fixed power and PF from a generator set. It is normally
used when in parallel with the mains. The toggle switch located within the generator control
panel is used to select baseload mode.
The power and PF that the unit will operate at are set in the configuration menu, as shown in
figure 6.5, and are termed “load parallel power” and “load power factor” respectively. Refer
to section 6.5 Changing parameters for details on how to set parameters.

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 Figure 6.5 – Configuration menu pages which are required to be set for baseload operation

When setting the power levels shown in figure 6.5 for baseload operation, take care not to
set the value above the load that is available. This can result in other generation
experiencing reverse power conditions.

5.17.4. Loadsharing with a GENerator set fitted with analogue parallel lines

The normal loadsharing mode of operation of the 5510 controller is to loadshare with other
5510 devices via the MSC link. However, it is possible to loadshare with sets possessing
conventional analogue parallel
lines using a Deep Sea P123
interface available separately
from Deep Sea. Figure 6.6
shows a photograph of this
module. One P123 is required
for each 5510 controller and
connects between the MSC
CANBUS connection and the
analogue line. Please note that
advanced CANBUS features
such as 1 set closure onto a
dead bus and automatic
start/stop on load demand are
not available when analogue Figure 6.6 – P123 loadsharing interface module
parallel lines are used.

5.18. Alarm functions

When an alarm condition has been detected, the alarm page will be displayed automatically.
Depending upon the severity of the alarm, the 5510 control module will take one of the
following courses of action.

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 1. Warning
- Display the alarm in clear
text and sound an audible
alarm

2. Shutdown
- Display the alarm in clear
text and sound an audible
alarm
- Trip the circuit breaker
- Shutdown the generator set

3. Controlled shutdown Figure 6.7 – Alarm page display

- Display the alarm in clear
text and sound an audible
alarm
- Trip the circuit breaker
- Cooldown the generator set for the cooldown period and shutdown the machine

 The audible alarm can be muted using the mute alarm button [symbol 8 in figure 6.3].
 Warnings will be automatically removed when the relevant parameter has returned to
within its normal operating range.
 Shutdowns require to be acknowledged using the stop button. If the shutdown condition
is still present, the shutdown will continue to be displayed.
 When a shutdown condition is still present after the machine has shutdown, e.g.
Emergency stop or Air flap closed, the module will prevent the generator set from
cranking and starting until the condition has been removed and the shutdown has been
acknowledged. “Generator at rest and locked out” will be displayed on the LCD.
 In the event of an alarm, the Common alarm LED will light
 A common alarm output is provided, which will turn high (+12v DC) when any alarm is
detected. See the wiring diagrams for the terminal number.
 Up to the last 25 shutdown conditions will be displayed in the event log.

5.19. Changing Parameters

5.19.1. General

For most applications, required parameter changes can be undertaken from the front fascia.
Full configuration can be undertaken using the configuration software.
To access the front panel editor
Press the Stop/Reset and Info buttons simultaneously.
Enter PIN Number
With the limited access pin number, the following can be adjusted:
Language

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 Alternative Frequency – Enable/Disable
Alternative Voltage – Enable/Disable
AC System
Generator Full Load
Droop – Enable/Disable (electronic engines only)
Droop percentage (electronic engines only)
Contrast
Date and Time
Generator Run Priority (for automatic start/stop on load demand mode)
Auto Scroll Time
Generator CT Primary Rating
Generator CT Secondary Rating
Generator Control Full kW Rating
Generator Control Full kVAr Rating
Load Ramp Rate
Load Level for more sets (for automatic start/stop on load demand mode)
Load Level for less sets (for automatic start/stop on load demand mode)
Load Parallel Power (for baseload mode)
Load Power Factor (for baseload mode)
With the full access pin number, in addition to the above, the full range of alarm setpoints
and timers can also be adjusted. Pressing the + and - buttons will scroll up and down
through the parameters.
To adjust a parameter
Scroll to the desired parameter using the + and - buttons
Press the tick button and the parameter will start to flash
Press the + or - button to adjust the parameter to the desired value
Press the tick button to save the value
To select another parameter to edit, press the + or – button
To exit the front panel configuration editor at any time, press the Stop/Reset button
When adjusting the date and time, the Up and Down arrows are used to scroll between
seconds, minutes, hours, day, month and year
Alternative frequency and alternative voltage
When alternative frequency is selected within the configuration menu, the generator set
changes from its primary frequency setting to its alternative frequency setting, i.e. from 50 to
60 Hz or vice versa. In Europe and AI, 50 Hz is the primary setting, whereas in the US, 60
Hz is the primary setting. The status LED labelled “alterative freq” will light to indicate that
alternative frequency is selected.
All alarm set points for frequency and speed within the 5510 controller will be adjusted
accordingly when alternative frequency is selected. In addition, the nominal frequency will
also be moved. For certain electronic engines, such as the Scania DC12/16, the 5510
controller will automatically adjust the engine speed between 50 and 60 Hz. For non-
electronic engines, the speed must be adjusted separately via the governor.

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 Alternative voltage may be required when changing the alternator configuration, e.g. from
series star to parallel star. When alternative voltage is selected, all alarm setpoints for
voltage and the nominal voltage are halved.

5.19.2. Parameter Adjustment For Alternative Alternator Configurations

The Deep Sea 5510 module is designed to be used with different alternator configurations. When
changing the alternator configuration, it may be necessary to adjust the AC System and/or Alternative
Voltage within the Deep Sea module, depending upon how the alternator is being configured. The table
below outlines the most common alternator configurations and the corresponding Deep Sea set up.

Alternator Deep Sea set-up

configuration AC System Alternative Voltage
Series star 3 phase, 4 wire Disable
Parallel star 3 phase, 4 wire Enable
Enable for 120V Ph-N
1 phase, 2 wire or 2 phase, 3 wire
Parallel zig-zag Disable for 220-240V
depending upon output configuration
Ph-N
Enable for 120V Ph-N
1 phase, 2 wire or 2 phase, 3 wire
Double delta Disable for 220-240V
depending upon output configuration
Ph-N
1 phase, 2 wire or 2 phase, 3 wire
Series zig-zag Disable
depending upon output configuration
Series Delta 3 phase, 3 wire Disable

Table 0-1 Deep Sea controller set up for different alternator configurations

By selecting alternative voltage the voltage protection is halved. The actual output voltage
value is adjusted separately via the AVR.
When 1 phase 2 wire or 2 phase 3 wire ac systems are selected on the Deep Sea 5510
controller, the number of phase voltage and current readings which are displayed changes
to 1 or 2 respectively. When 3 phase 3 wire ac system is selected, only line voltages are
displayed. This configuration can be used with a mid-winding or floating neutral.

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6.0 MAINTENANCE

6.1. General
The Cummins QSB5-G9 engine is supplied with an after treatment package which is required to
achieve emissions compliance. This package is part of the “certified system” which includes all
components from air intake to DOC (see pg. 26 for DOC maintenance details) outlet.

There are strict guidelines for the modification of any of these components by OEM or end user which need
to be adhered to in order to maintain certification. If there is any doubt please refer back to Aggreko
Manufacturing for advice prior to carrying out any modifications / repairs.
In addition to periodic inspections, many of the components in these units require periodic servicing to
provide maximum output and performance. Servicing may consist of pre-operation and post-operation
procedures to be performed by the operating or maintenance personnel. The primary function of preventive
maintenance is to prevent failure, and consequently, the need for repair. Preventive maintenance is the
easiest and the least expensive type of maintenance. Maintaining your unit and keeping it clean at all times
will facilitate servicing.

Ensure that maintenance personnel are adequately trained, competent and have read the Maintenance
Manuals.

Prior to attempting any maintenance work, be aware of the following:

 Any unauthorized modification or failure to maintain this equipment may make it unsafe and out of
factory warranty.
 Use extreme care to avoid contacting hot surfaces (engine exhaust manifold and piping, etc.).
 Never operate this machine with any guards removed.
 Imperial and Metric hardware was used in the design and assembly of this unit. Consult the parts
manual for clarification of usage.
 The machine cannot be started accidentally or otherwise, by posting warning signs and/or fitting
appropriate anti–start devices.
 All residual electrical power sources (mains and battery) are isolated.

Prior to opening or removing panels or covers to work inside a machine, ensure that:

 Anyone entering the machine is aware of the reduced level of protection and the additional
hazards, including hot surfaces and intermittently moving parts.
 The machine cannot be started accidentally or otherwise, by posting warning signs and/or fitting
appropriate anti–start devices.

Prior to attempting any maintenance work on a running machine, ensure that:

 The work carried out is limited to only those tasks which require the machine to run.
 The work carried out with safety protection devices disabled or removed is limited to only those
tasks which require the machine to be running with safety protection devices disabled or removed.
 All hazards present are known (e.g. pressurised components, electrically live components,
removed panels, covers and guards, extreme temperatures, inflow and outflow of air, intermittently
moving parts, safety valve discharge etc.).
 Appropriate personal protective equipment is worn.
 Loose clothing, jewellery, long hair etc. is made safe.
 Warning signs indicating that Maintenance Work is in Progress are posted in a position that can be
clearly seen.

Upon completion of maintenance tasks and prior to returning the machine into service, ensure that:

 The machine is suitably tested.

 All guards and safety protection devices are refitted.

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  All panels are replaced, canopy and doors closed.
 Hazardous materials are effectively contained and disposed of.

To assist with ordering spare parts and other service activities, a short form list of Component
Manufacturers data has been included in this manual.

Prior to engine starting, check the oil and coolant levels.

Carry out a visual check of the following:

 Leaks.
 Loose or damage parts.
 Worn or damaged belts, change in engine appearance.

Refer to the Maintenance Schedule for quick reference.

Report unusual noise/vibration and/or exhaust smoke and ensure the generator set is kept clean, both
inside and out.

6.2. Maintenance Schedule

6.2.1. Inspection Criteria

3 Months / 6 Months / 12 Months

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

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 6.2.2. Service Criteria

3 Months / 6 Months / 5 years /

Daily Weekly Monthly
400 Hrs* 1000 Hrs 4800 hrs
Engine Oil & Filters R
Air Filter Element R
Fuel / Water Separator
R
Element
Fine Fuel Element R
Engine Coolant R
R=replace
Refer to manufacturers operating and maintenance instructions for additional information and all other
maintenance.
* This figure should be in line with current service best practise.
DOC Operation: - If operation is at low load and low ambient then DOC has a potential to block. Too
clear DOC then run at 80% for 2 hrs. Please refer to graph below for more details.

QSB5 T4i Operating Guidance

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 6.3. Daily Maintenance
6.3.1. Check The Engine Oil Level:

A. Stop the engine and wait 5 minutes to allow the oil to drain to the oil pan.
B. Remove the dipstick and check the oil level.
C. Replenish if necessary using a recommended grade of engine oil (see section 8).
CAUTION: Never operate the engine with the oil level below the ‘L’ mark or above the ‘H’

mark. See FIG. 7.1 below.

Figure 7.1 - Engine Oil Level Check

6.3.2. Check The Fuel Tank Level

Check the fuel level gauge on the control panel.

Replenish as necessary using clean, good quality, diesel/Derv/Gas Oil that conforms to ISO or equivalent.
Always ensure that the filler cap is replaced after replenishment.

6.3.3. Check That All Meters And Gauges Function Correctly

Start the generator and inspect the following items:

- Oil pressure gauge is between 85 & 95psi.

- After 5 minutes check that the cooling water temperature gauge reads between 45 & 55°C.
- The voltage and frequency gauges are within specification.
- Fuel gauge indicates the tank is not empty.

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 - Engine hours display increases after 10 minutes.
- Safety module has no alarm indicators on.
- Press the “LAMP TEST” button on the control panel and confirm that all indicator lamps are
working.

6.3.4. Check The Air Filter

NOTE: In dusty conditions clean the primary filters regularly.

Check the air filter restriction indicator next to the air filter above the engine. If this has changed to the
restricted position, then the filter will need replaced.

6.3.5. Check The Battery

Check that the battery connections are properly installed and that the electrolyte level in each cell covers
the top plates. If necessary, top up with clean distilled water.

6.3.6. Check For Leaks

There are several fluids used inside the generator, e.g. diesel, oil, coolant. Look for signs of leakage all
around the engine.

Any source of leak should be checked and fixed. Clean up any fluid lying inside the generator and dispose
of according to the appropriate local regulations.

Recurring leaks should be reported to AGGREKO.

6.4. Weekly Maintenance

6.4.1. Check The Water/Antifreeze Level

Stop the engine and wait for the temperature to cool before checking the coolant level.

Remove the pressure cap slowly to relieve the pressure of the cooling system. Failure to do so could result
in personal injury from heated coolant spray (See Figure 7.2).
Check the coolant level. Replenish with the correct coolant fluid as necessary (see section 8).

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 Figure 7.2 - Coolant Level Check

6.4.2. Carry Out A Visual Check Of The Drive Belts.

The cooling pump, alternator and radiator fan are driven by a single belt arrangement from the engine
pulley. Check the belts for signs of wear. Check the belt tension.

NOTE: Do not remove guards.

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7.0 LUBRICATION

7.1. General Information

Lubrication is an essential part of preventive maintenance, affecting to a great extent the useful life of the
unit. Different lubricants are needed and some components in the unit require more frequent lubrication
than others. Therefore, it is important that the instructions regarding types of lubricants and the frequency
of their application be explicitly followed. Periodic lubrication of the moving parts reduces to a minimum the
possibility of mechanical failures.

The Preventive Maintenance Schedule shows those items requiring regular service and the interval in
which they should be performed. A regular service program should be developed to include all items and
fluids. These intervals are based on average operating conditions. In the event of extremely severe (hot,
cold, dusty or wet) operating conditions, more frequent lubrication than specified may be necessary. Details
concerning lubrication of the running gear are in Maintenance Section.

7.2. Generator Oil Change

These units are normally furnished with an initial supply of oil sufficient to allow operation of the unit for
approximately 6 months or 400 hours, although this should be in line with the current service best practise.
The unit will however need to be topped up with oil during this period. If a unit has been completely drained
of all oil, it must be refilled with new oil before it is placed in operation. Refer to specifications in Lubrication
Table.
NOTICE: Some oil types are incompatible when mixed and result in the formation of varnishes,
shellacs, or lacquers that may be insoluble. Such deposits can cause serious problems including clogging
of the filters. Where possible, do NOT mix oils of different types and avoid mixing different brands. A type
or brand change is best made at the time of a complete oil drain and refill.

If the unit has been operated for the time/ hours mentioned above, it should be completely drained of oil. If
the unit has been operated under adverse conditions, or after long periods in storage, an earlier change
period may be necessary as oil deteriorates with time as well as by operating conditions.

An oil change is good insurance against the accumulation of dirt, sludge, or oxidized oil products.

Completely drain the reservoir, piping. If the oil is drained immediately after the unit has been run for some
time, most of the sediment will be in suspension and, therefore, will drain more readily. However, the fluid
will be hot and care must be taken to avoid contact with the skin or eyes.

After the unit has been completely drained of all old fluid, close the drain valve. Add oil in the specified
quantity at the filler plug. Tighten the filler plug and run the machine to circulate the oil. Check the oil level
when unit is warm and not running. If not near the middle of the dipstick, stop the unit and make
corrections. DO NOT OVERFILL.

7.3. Oil specification

The oil required for this engine is:
Manufacturer: Fuchs
Product Name: Titan Cargo 15W-40
Relative Density @ 15°C: 0.876 g/cm³
Viscosity @ 40°C 115.3 mm²/s
Viscosity @ 100°C 15.1 mm²/s
Viscosity Index 136
Flash Point (COC) 248 °C
Pour Point -45 °C
Sulphated Ash: 1.0%

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Trouble Shooting

7.4. Introduction
Trouble shooting for a generator set is an organized study of a particular problem or series of problems and
a planned method of procedure for investigation and correction. The trouble-shooting chart that follows in
Section 9.3 includes some of the problems that an operator may encounter during the operation of a
generator set.

The chart does not attempt to list all of the troubles that may occur, nor does it attempt to give all of the
answers for correction of the problems. The chart does give those problems that are most probable to
occur. To use the trouble shooting chart:

1) Find the problem being experienced in the Symptom column on the far left.

2) Proceed to work through the possible causes in the next column, instigating the appropriate
corrective action where required from the next column.

7.5. Action Plan

Think Before Acting: Study the problem thoroughly and ask yourself these questions:

1) What were the warning signals that preceded the trouble?

2) Has a similar trouble occurred before?
3) What previous maintenance work has been done?

If the generator will still operate, is it safe to continue operating it to make further checks?

Do The Simplest Things First: Most problems are simple and easily corrected. Always check the easiest
and most obvious things first, following this simple rule will save time and trouble.

Note: For trouble shooting electrical problems, refer to the Wiring Diagram Schematic found in
Appendix D.

Double Check Before Disassembly: The source of most generator troubles can be traced not to one
component alone, but to the relationship of one component with another. Too often, a generator can be
partially disassembled in search of the cause of a certain trouble and all evidence is destroyed during
disassembly. Check again to be sure an easy solution to the problem has not been overlooked.

Find And Correct Basic Cause: After a mechanical failure has been corrected, be sure to locate and
correct the cause of the trouble so the same failure will not be repeated. A complaint of "premature
breakdown" may be corrected by repairing any improper wiring connections, but something caused the
defective wiring. The cause may be excessive vibration.

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 7.6. Trouble Shooting Chart
SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION

Battery isolator switch not

Close battery isolator switch.
closed.
Batteries flat or bad. Read
ENGINE DOES NOT CRANK value on battery voltage meter Replace or charge batteries.
WITH 12V/24V ELECTRIC (must be 12V/24V or more).
MOTOR Mini circuit breaker of 10A in
Reset.
terminal box is open.
Start relay at cranking motor Measure the voltage over the
defective. start relay.
Fuel tank empty. Fill up fuel tank.
Check system for leaks. Bleed
Air in the fuel system.
the fuel system.
Dirty fuel filters. Replace fuel filters.
ENGINE CRANKS BUT DOES Check voltage (12V/24V) over
NOT START Call for AGGREKO support.
fuel shut-off valve during crank.
Optional air shutdown valve
Open air shutdown valve.
closed.
Overspeed protection is Put key back to 0 and try to
activated. start the engine again.
Check system for leaks. Bleed
Air in the fuel system.
the fuel system.
Dirty fuel filters. Replace fuel filters.
ENGINE STARTS UP BUT Overspeed during acceleration. Decrease frequency setting.
STOPS AFTERWARDS
Check safeties:
Oil pressure – Water
Shutdown after 6 seconds.
temperature – Water pressure –
Oil temperature (option)
Adjust frequency to the correct
Frequency too high.
level.
Connection between governor
ENGINE OVERSPEEDS Repair connection.
and fuel pump interrupted.
Check system for leaks. Bleed
Air in the fuel system.
the fuel system.
Wait until engine has reached
Engine not yet at operating
the normal operating
temperature.
temperature of 80-90ºC.
ENGINE SPEED NOT
STABLE Dirty fuel filters. Replace fuel filters.
Wear in ball eyes, linkage
Replace ball eyes.
governor / fuel pump.
Dirty air filters. Replace air filters.

ENGINE SHOWS EXCESS Dirty fuel filters. Replace fuel filters.

SMOKE AND / OR LACK OF Check system for leaks. Bleed
POWER Air in the fuel system.
the fuel system.
Overload. Check load.

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 SYMPTOM POSSIBLE CAUSE
Voltmeter defective.
ALTERNATOR DOESN’T
GENERATE VOLTAGE Voltage regulator defective.
Air in the fuel system.
Speed frequency too high /
low.
ALTERNATOR VOLTAGE
TOO HIGH / LOW Incorrect voltage setting.
No identifiable cause.
Engine speed not stable.
ALTERNATOR VOLTAGE
NOT STABLE
Incorrect stability adjustment.
Circuit breaker control switch
(Figure 6.1) set remote control.
Circuit breaker tripped.
MAIN CIRCUIT BREAKER
WILL NOT CLOSE Circuit breaker not charged,
motor mechanism broken.
Lamp ‘CIRCUIT BREAKER
CLOSED’ defective.
MAIN CIRCUIT BREAKER Switch on overload or short
CLOSES BUT TRIPS AGAIN circuit.
August 2016 M02000537-G
CORRECTIVE ACTION
Measure voltage at outlet
terminals of alternator. If voltage
measured replace voltmeter.
Replace voltage regulator,
Check system for leaks. Bleed
the fuel system.
Check frequency meter and
adjust if required.
Adjust voltage regulator.
Consult AGGREKO.
Check stability of engine speed.
Adjust stability on the voltage
regulator.
Select local position.
Reset circuit breaker.
Charge motor mechanism
manually, inform AGGREKO.
Replace lamp.
Remove load.
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 APPENDIX A - MATERIAL SAFETY DATA SHEETS

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 APPENDIX B – EQUIPMENT DATA SHEET

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 APPENDIX C – INSTALLATION OUTLINE DRAWING

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 APPENDIX D – CONTROL PANEL LAYOUT

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APPENDIX E – ALTERNATOR & AVR SCHEMATIC DIAGRAM

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 APPENDIX F – MAIN LOAD & METERING SCHEMATIC
DIAGRAM

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 APPENDIX G – DC CONTROL SYSTEM SCHEMATIC
DIAGRAM

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 APPENDIX H – ECM 2250 INTERCONNECTIONS

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 APPENDIX I – TERMINAL LAYOUT & ENGINE WIRING

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 APPENDIX J – LIVERY LAYOUT DRAWING

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 APPENDIX K – MANUFACTURERS COMPONENT DATA

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 APPENDIX L – LIFTING BEAM CERTIFICATE

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 APPENDIX M – DNV SPARK ARRESTOR CERTIFICATE

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