476B, Lab 5 Manual, TurboGen

TurboGenTM
Gas Turbine Electrical Generation System
Operator’s Manual
Turbine Technologies Ltd.
Revision 5/12
THIS MANUAL MUST BE KEPT WITH THE SYSTEM

AND AVAILABLE AT ALL TIMES
Model TG-501
GENERAL INFORMATION
Copyright 2012 Turbine Technologies, LTD.
Service Publications
410 Phillips Street
Chetek, WI 54728
All rights reserved. No part of this manual may be reproduced, stored in a retrieval system or
transmitted by any means, electronic, mechanical, photocopying, recording or otherwise—without
written permission of Turbine Technologies, ltd., except for the explicit and inclusion in a course of
academic study utilizing the Turbine Technologies, Ltd. TurboGenTM Gas Turbine Electrical Generation
System.
Many of the designations used by manufacturers to distinguish their products are claimed as trademarks
or service marks. Every attempt has been made to supply trademark information about manufacturers
and their products mentioned in this manual. A list of trademark or service mark designations and their
owners appear on this page under Trademark Notices.
Every effort has been made to make this manual as complete and accurate as possible. The purchaser
shall be responsible for determining the suitability of the information contained herein. Please see
Suitability on this page.
TRADEMARK NOTICES
TurboGenTM is a trademark of Turbine Technologies, Ltd.
Microsoft, Windows are registered trademarks of Microsoft Corporation
USB 6218 and LabView are registered trademarks of National Instruments, Incorporated.
SUITABILITY
The Turbine Technologies, Ltd. TurboGenTM is not offered as and shall not be construed by the purchaser
to be “Consumer Products” within the common definition of the United States Federal Trade
Commission. All Turbine Technologies, Ltd. products are represented to be, and offered as,
EXPERIMENTAL TECHNOLOGY, subject to the limitations in safety and performance inherent to
equipment so classified. PURCHASER SHALL BE SOLELY RESPONSIBLE for determining, prior to
purchase, at acceptance and for all subsequent usage, the suitability for any purpose(s) intended of
equipment, instructions, procedures or materials offered or supplied by Turbine Technologies, Ltd. for
use in any educational, laboratory or industrial setting.
V811 Page i TurboGen Operators Manual

TABLE OF CONTENTS
Contents
Section 1 - General Information
1.1 Introduction ……………………………………………………………………………………………………..…………….. 1
1.2 SAFETY ………………………………………………………………………………………………………..………………….. 2
1.3 Specifications …………………………………………………………………………..……………………………………… 3
1.3.1 Dimensions …………………………………………………………………………………………………………….. 3
1.3.2 Operational Requirements ……………………………………………………………………………………… 3
1.3.3 Operational Controls (Operator Panel) …………………………………………………………………… 4
1.3.4 Digital and Analog Operator Display ………………………………………………………….………..…. 4
1.3.5 Operational and Data Acquisition Instrumentation …………………………………….………….. 5
1.4 Uncrating and Set-Up …..…………………………………………………………..……………………………………… 7
1.4.1 Uncrating ………………………………………………………………………………………...……………………. 7
1.4.2 Set-up ……………………..…………………………………………………………………………………..………… 10
A. Facilities …………………………………………………………………………………………………..………… 10
B. Utilities ……………………………………………………………..……………………………………………….. 11
C. Operating Fluids ………………………………………………………………..………………..…………….. 11
1.4.3 Hush Kit Installation ………………………………………………………………………...………………..….. 11
Section 2 – Limitations
2.1 SR-30 Turbojet Engine …………………………………………………………………………………………………… 13
2.2 TG-2000 Electrical Generator ………………………………………………………..………….…..……………... 13
Section 3 – Abnormal Procedures

3.1 System Shut Down Using Auto Start System ……………………………………..………………….……….. 14
3.2 Engine Throttle/Generator Excitation Load Lever Quadrant ………………………………..….…….. 15
Section 4 – Normal Procedures

4.1 Abbreviated Normal Procedures ……………………………………………………………..…………….………. 16
4.1.1 Pre-Start .………………………………………………………………………………………….……..…….. 18
4.1.2 Start, Operation and Shutdown ……………………………………………………………….…….. 19
4.1.3 Data Collection ………………………………..……………………………………………………….……. 20
4.2 Expanded Normal Procedures …………………………………………………..……………………………....….. 21
4.2.1 Pre-start ………………………………………………………………………………..…….…….…..………. 22
4.2.2 Start, Operation and Shutdown ………………………………………………………….…..…...... 24
4.2.3 Data Collection ……………………………………………………………………………..……..…………. 26
4.3 General Guidelines ………………………………………………………………………………………………..……….. 31
Section 5 – Systems
5.1 SR-30 Gas Turbine Engine …………………………………………………..………….…….……………..…………. 32
5.1.1 Inlet ……………………………………………………………………………………………………...………… 33
5.1.2 Centrifugal Flow Compressor ………………………….……………………….……………...……… 33
5.1.3 Diffuser …………………………………………………………………………………………………………… 34
5.1.4 Annular Combustor …………………………………………………………………..……………………. 34
5.1.5 Fuel Atomization Nozzle ……………………………………………………………………..………….. 35
5.1.6 Fuel Controller ……………………………………………………….…………………………….……..... 35
5.1.7 Transition Liner …………………………………………………………………………….………………... 35
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TABLE OF CONTENTS CONTINUED
5.1.8 Vane Guide Ring ………………………………………………………………………………………….….. 36

5.1.9 Axial Flow Turbine ………………………………………………………………….…………………….…. 36
5.1.10 Thrust Nozzle ………………………………………………………………….…………………………….. 36
5.1.11 Miscellaneous ………………………………………………………………………………..…..…..….… 36
5.2 TG-2500 Turbine Powered Electrical Generator …………………………………………….………..………. 37

5.2.1 Exhaust Thrust Transition Liner/Cone …………………………………………….…….….………. 37
5.2.2 Free Turbine ………………………………………………………………………………….…….………….. 37
5.2.3 Liquid-Cooled Alternator …………………………………………………………………………….….. 37
5.2.4 Generator Load Control System …………………………………………………………….……….. 37
5.3 Gas Turbine Engine Accessories ………………………………………………………………………………..…… 39

5.3.1 Fuel …………………………………………………………………………………………………………….….. 39
5.3.2 Oil …………………………..…………………………………………………….…………………………..……. 39
5.3.3 Ignition …………………………………………………………………………………………..………..…….. 39
5.3.4 Starting Air ……………………………………………………………………………..…………..………….. 39
5.4 Cabinetry ………………………………………………………….…………………………………………………………… 40

5.4.1 Test Section ………………………………………………………………………………………....…….….. 40
5.4.2 Operator Panel ………………………………………………………………………………..……………… 40
5.4.3 One Touch Gas Turbine Auto Start System …………………………..……………….…..…... 41
5.4.4 Air Clearing Procedure ………………………………………………………………………..……..…… 43
5.4.5 Chassis …………………………………………………………………………………………….…..………... 45
5.4.6 Electrical Service …………………………………………………………………….………………………. 45
5.4.7 Casters ……………………………………………………………………………………………………..….... 45
5.4.8 Opening View Shield ………………………………………………………………………………...……. 45
5.4.9 Removing View Shield Compartment ………………………………………………………….….. 46
5.5 Data Acquisition System …………………………………………………………………………………………….….. 46

5.5.1 Computer ………………………………….……….……………………………………………………….…. 46
5.5.2 DAQ Module …………………..…………………………………………………………….……………….. 47
5.5.3 Sensors ……………………..…………………………………………………………………………..…….... 47
5.5.4 Software …………………..…………………………………………………………………….……………… 53
Section 6 – Service and Maintenance

6.1 General Maintenance ………………………………………………………………..……………………………..……. 54
6.1.1 Oil and Fuel Fill …………………………………………………………….………………………………... 54
6.1.2 Oil and Fuel Filter Replacement …………………………………………..……………………….… 55
6.1.3 Cleaning …………………………………………………………………………..…………………………….. 57
6.1.4 Condition Inspection ………………………………………………………..………………………….… 57
6.1.5 Service Schedule …………………………………………………………….…………………….……..... 58
6.2 Troubleshooting……………………………………………………………………………………..……………….…….. 59
6.3 Factory Service ………………………………………………………………………………………..……………………. 60
Appendix A –Operational Limits of TurboGen Throttle/Load Lever System ..…….…………..….. 61

Appendix B – Loading Data Acquisition Software ……………………………………………………………… 63
Appendix C – WARRANTY INFORMATION …………………………………………………………………………. 67
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LIST OF FIGURES
List of Figures
1.1 System Control/Display Panel ……………………………………………………………………………………………. 4
1.2 Virtual Instrument Display Panel ……………………………………………………………………………………….. 5
1.3 TurboGen as shipped …………………………………………………………………………………………………………. 7
1.4 Hushkit Installation Orientation ……………………………………………………………………………….………. 10
1.5 Hushkit Mating with SR-30 ………………………………………………………………….………………………….… 10
3.1 System Panel Mounted Start/Stop Buttons …………………….……………………………………………..... 15
3.2 Throttle/Load Lever Quadrant Detail …………………………………………………………………………….…. 16
4.1 Abbreviated Data Acquisition Software Controls ……………………………………………………………... 20
4.2 TurboGen Launch Icon ……………………………………………………………………………………………………… 26
4.3 Measurement and Automation Launch Icon …………………………………………………….………………. 26
4.4 Software Controls Overview …………………………………………………………………………………………….. 27
4.5 Data Logging/Data Display ……………………………………………………………………………………………….. 28
4.6 Sampling Rates ……………………………………………………………………………………………….…………..…... 29
4.7 Screen Image Export/Sensor Calibration ………………………………………………………………………….. 30
5.1 SR-30 Turbojet Engine Components ………………………………………………………………………….……… 33
5.2 TG-2000 Generator Components .……………………………………………..……..……..………………………. 37
5.3 Generator Base Load Resistive Cell …………………………………………………………….……………………. 37
5.4 Load Lever/Pinned Stop …………………………………………………………………………………………………… 38
5.5 Generator RPM Caution ………………………………………………………..…………………………………………. 38
5.6 Hold Down Bolt ……………………………………………………………………………………..……………..……...…. 45
5.7 Lower Prop Rod Hole …………………………………………………………………………………….…………………. 45
5.8 View Shield Prop Rod Hole ………………………………………………………………………………………………. 45
5.9 View Shield Open …………………………………………………………………………………………………………….. 45
5.10 Remove Hinge Pins ………………………………………………………………………………………………………... 46
5.11 Carefully Remove Shield Compartment …………………………………………………………………………. 46
5.12 National Instruments 6218 USB DAQ Module ……………………………………………………………….. 47
5.13 TurboGen Sensor Locations …………………………………………………………………………………………… 52
6.1 Fuel and Oil Filter Location ………………………………………………………………………………………………. 54
6.2 Typical Fluid Filter Installation-Oil Filter …………………………………………………………………………… 55
6.3 TurboGen General (No Displays with Power Key On) ………………………………………………………. 59
Appendix B Loading TurboGen Software Steps ……………………………………………………………………… 62
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LIST OF TABLES
List of Tables
5.1 Shipping Container Inventory List ……………………………………….………………………….……………… 6
5.2 OneTouch System CAUTION Flags ……………………………………………………..………….………….…. 43
5.3 One Touch System WARNING Flags …………………………………………………..…….….….…….…….. 44
5.4 Sensor Locations-DAQ Module ………………………………………………………………..….………………. 48
5.5 DAQ Channel Assignments and Sensor Details …………………………………………….………………. 50
6.1 No displays with Power Key On ………………………………………………….……..….………….…………. 59
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SECTION 1 GENERAL INFORMATION
Section 1
General Information
1.1 Introduction
The Turbine Technologies,Ltd. TurboGen Gas Turbine
Electrical Generation System is a complete, self-
contained jet engine electrical generation laboratory
featuring the SR-30 Jet Engine and TG-2000 Electric
Generator. Designed expressly for engineering
education and research purposes, the TurboGen
allows all aspects of gas turbine theory and electrical
generation principles be easily demonstrated and
readily explored.
A pure turbojet, the SR-30 is representative of all straight jet engines in which combustion results in an
expanding gas that is sufficiently capable of producing useful work and propulsive thrust. Consisting of a
centrifugal flow compressor, annular combustor and axial flow power turbine, the SR-30 Engine is
typical of the basic engine core found in turbofan, turboprop and turboshaft gas turbine engines. These
types of engines are used for aircraft, defense systems and maritime propulsion as well as stationary
and industrial power generation.
A free-turbine driven electrical generator, the TG-2000 is representive of most any electrical generation
station where a prime mover spins an alternator to generate electricity. In the case of TurboGen, the
thrust from the SR-30 Jet Engine is ducted to a second stage axial flow turbine wheel, turning that
turbine by thrust force only (no directly-connected shaft). That second stage turbine wheel is directly
connected by a shaft to the electric alternor, causing it to spin and generate electricity. The TurboGen
thus acts like a typical Auxilliary Power Unit (APU) (seen powering aircraft accessories while the main
engines are shut down), or like an Electric Generation Peaking Plant (which are used to supplement base
load electric generation plants on days where demand exceeds supply).
All engine and generator systems are integrated into the TurboGen cabinetry. Aside from fuel and oil,
standard electrical service and compressed air are all that is necessary to run the SR-30 engine of the
TurboGen. No facility modifications or dedicated test cells are required. The TurboGen is easily rolled
to any convenient location that offers suitable ventilation such as an exterior overhead doorway. The
time between uncrating and first run is measured in minutes.
The TurboGen provides an ideal platform for the study of gas turbine power systems and gas turbine
electrical generation systems. Students can start by learning first hand about the gas turbine cycle
(known as the Brayton Cycle). They can then carry that knowledge to the study of gas turbine driven
electric power generation. Students can see, hear and feel the basic principles discussed in lectures and
read about in text books. Theoretical predictions can be measured by actual hardware utilizing the
included data acquisition system and interactive virtual instrumentation panel. Sensors located along
the gas flow path and in critical data areas allow accurate, real time measurements of the operating
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V811 Page 1 TurboGen Operator’s Manual
conditions of these points. Explaining the differences and accountiing for the real world results presents
limitless educational opportunities.*
The TurboGen can serve as a foundation for various research programs, including; biofuels, combustion
processes, high temperature metallurgy, emissions control and their related condition factors to electric
power generation.
Equipped with the OneTouch Gas Turbine Auto Start System, virtually anyone can operate TurboGen.
Start sequencing is completely automatic with all critical engine parameters monitored during
operation. In the unlikely event of an engine fault, the OneTouch system will safely stop the engine and
alert the operator to the problem. No specialized training is requirred to operate the TurboGen
equipped with this system.
*Reasonable expectations regarding experimental results must be made when operating TurboGen or any other similar
equipment where scale effects and sensor errors are present. Efficiency, power output and overall system performance will
naturally be different than that for the same process on a larger scale. Temperature and pressure in a turbine engine can vary
by an order of magnitude within the width of a sensor tip. In whole, TurboGen provides an excellent foundation for exploring
the shortcomings (and pitfalls) of applying textbook formulas and ideal data to a problem without considering all aspects of the
overall system. The challenge to the student is in the analysis of experimental run-time data and determining the reasons that
results may differ from analytical expectations. This is the true benefit of hands-on, laboratory and experimental engineering.
Rest assured, no Laws of Thermodynamics are broken during the operation of TurboGen.
1.2 SAFETY
As with any piece of of laboratory equipment, basic safety precautions must be followed at all times.
Protective eyewear and hearing protection must be worn whenever the equipment is in operation.
Complete familiarization with all aspects of the TurboGen Gas Turbine Electrcial Generation System and
its operation is necessary prior to usage.
The TurboGen hinged cover and safety shield must be down and secured while the system is in
operation. The operator and all observers shall remain clear of the engine inlet and exit at all times. At
no time shall the system be operated with any loose items in the proximity of the inlet or exit. Because
of the mass flow rate, any loose object in the vacinity of the inlet is subject to ingestion. Due to the
considerable energy of the rotating assembly and the turbine engine’s critical balance requirements, any
object ingested into the engine could lead to catastrophioc failure of the engine/generator system with
disastorous results including loss of life or limb.
The TurboGen will be of a temperature sufficient to cause severe burns during operation and for an
extended period of time after shutdown.
DO NOT ATTEMPT TO MAKE ANY ADJUSTMENTS TO OR BYPASS SAFETY DEVICES AND/OR CONTROLS TO
FORCE OPERATIONS OUTSIDE OF PUBLISHED LIMITATIONS. DO NOT EXCEED, UNDER ANY
CIRCUMSTANCES, THE PUBLISHED MAXIMUM OPERATING RPM OR TEMPERATURE.
If any limitation is exceeded, operation of the system should be suspended until a determination is
made of the cause of the out of limit condition and suitability for continued operation.
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The TurboGen is considered to be in “operation” WHENEVER an air source is connected to the cabinet,
the master switch is on or the engine internal assembly is rotating.
FAILURE TO FOLLOW THE LIMITATIONS AND USAGE AS SET FORTH IN

THIS OPERATOR’S MANUAL MAY CAUSE SERIOUS INJURY OR DEATH.
1.3 Specifications
1.3.1 DIMENSIONS – Gas Turbine Electrical Generation System

- LENGTH ……………………………………………………………………….. 42.0 inches (107 cm)
- WIDTH …………………………………………………………………………. 40.0 inches (102 cm)
- HEIGHT ………………………………………………………………………… 62.0 inches (158 cm)
- WEIGHT (operational) …………………………………………………………. 520lbs (236 kg)
1.3.2 Operational Requirements – Gas Turbine Electrical Generation System

- ELECTRICAL SERVICE: 120/240 VAC, Single Phase, 50/60 Hz, 20 Amps Breaker Protected.
- COMPRESSED AIR: Air Pressure 100 – 120 psi (690 – 830 kPa) sustained. Minimum internal
line diameter 0.25 inch (0.64 cm)
- FUEL: Jet A, A-1, B; JP-4, 5, 8; Kerosene, Diesel, Fuel Oil #1 or #2
- OIL: MIL-PRF-23699F-STD (aeroshell 500, BP/Exxon 2380)
- ADEQUATE VENTILATION: Air Intake, Exit and Combustion Gases
- ADEQUATE CLEARANCE to allow operator access to all four sides of unit, RECOMMENDED
60 inches (152 cm) on all sides. Existing Fire and Safety Codes may prevail.
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1.3.3 OPERATIONAL CONTROLS –TurboGen Operator Panel

1. MASTER SWITCH, KEYED: Secured control of access and engine operation
2. GREEN START BUTTON: Automated Engine Start, Multiple Functions
3. RED STOP BUTTON: Immediate EngineStop, Multiple Functions
4. T-HANDLED POWER LEVER: Engine RPM/Thrust Control, Forward Increases
5. EXCITATION LOAD LEVER (Blue Handle): Controls Excitation Loading on Electric Alternator
6. AUTOSTART LCD DISPLAY: Real Time System Status Automatically Shuts Off Unit if
Parameters Exceeded.
1.3.4 DIGITAL and ANALOG OPERATOR DISPLAY: Direct visual indication of

the following:
7. Digital Turbine Inlet Temperature (TIT)
8. Digital Engine Rotational Speed (RPM)
9. Digital Generator Turbine Rotational Speed (RPM)
10. Analog Oil Pressure
11. Analog Engine Pressure (P3)
12. Analog Fuel Pressure
13. Analog Starting Air Pressure
14. Excitation Voltage Indicator
15. Generator Overspeed Warning
7 8 9 6
15
14
1 2 3 10 11 12 13 5
4
Figure 1.1: System Control/Display Panel
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1.3.5 OPERATIONAL and DATA ACQUISITION INSTRUMENTATION

- DIGITAL DATA ACQUISITION SYSTEM: USB to computer output of the following:
 Compressor Inlet Temperature and Pressure (T1/P1)
 Compressor Exit Temperature and Pressure (T2/P2)
 Engine Turbine Stage Inlet Temperature and Pressure (T3/P3)
 Engine Turbine Stage Exit/Generator Turbine Inlet Temperature and Pressure (T4/P4)
 Generator Turbine Exit Temperature and Pressure (T5/P5)
 Fuel Flow
 Engine Rotational Speed (N1)
 Generator Rotational Speed (N2)
 Voltage
 Current
 Power
Figure 1.2: Virtual Instrument Display Panel
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ITEM
NUMBER DESCRIPTION QTY LOCATION
1 SHIPPING CONTAINER 1
2 TurboGen System 1 SHIPPING CONTAINER
3 Master Keys 2 TurboGen Throttle Lever
4 Important Documents 1 SHIPPING CONTAINER
5 Operator's Manual 2 Important Documents
6 Computer Software various Important Documents
7 Box 1 1 SHIPPING CONTAINER
8 Caster Kit 1 Box 1
9 Brackets, Casters, Hardware 4 each Box 1
10 Box 2 1 SHIPPING CONTAINER
11 Computer Equipment 1 Box 2
12 Computer as ordered Box 2
13 Power Cable, Computer as ordered Box 2
14 Power Cable, TurboGen 1 Box 2
15 USB Cable 1 Box 2
16 Software, Computer Vendor various Box 2
17 Box 3 if ordered SHIPPING CONTAINER
18 SR-30 Cutaway Engine 1 Box 3
19 Box 4 if ordered SHIPPING CONTAINER
20 HushKit Assembly 1 Box 4
Note any irregularities immediately
Table 1.1: Shipping Container Inventory List
Figure 1.3: TurboGen As Shipped
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1.4 Uncrating and Set-up
1.4.1 Uncrating
The TurboGen is shipped in a custom container (see Figure 1.1) for maximum protection against damage
during delivery. It is recommended that a thorough inspection of the container’s exterior be made prior
to acceptance from the shipper. If any damage or discrepancy is noted, it should be brought to the
attention of the shipping agent immediately and prior to any further disassembly of the shipping
container.+
When unloading or moving the shipping container, DO NOT apply pressure or force to the
container sides. Doing so may puncture the container and damage the contents inside.
The steps necessary to uncrate the TurboGen are outlined in the following section. NOTE: DO NOT
discard ANY material within the shipping container until a complete inventory has been made of the
included contents.
+
Turbine Technologies, Ltd. is not responsible for damage due to shipping. It is the recipient’s responsibility to inspect the
shipping container for obvious external damage and to make the appropriate claims with the shipping agent prior to accepting
the contents or opening the shipping container.
1. Clip Shipping Bands Securing Top and Sides of Crate to Pallet Base (CAUTION: Bands are in
tension and may release with an abrupt snapping motion). The container and its contents will
appear as in figure 1.3.
2. Remove Top of Crate and Set Aside
3. Carefully Remove Cardboard Sidewalls and Set Aside
4. Remove Packaged Contents Boxes. Various items are separately boxed and/or located around
the TurboGen cabinet (Note: Depending on the product ordered, various boxes may be attached
to the top of the TurboGen Shipping Container. Remove these boxes as soon as practical. Every
effort has been made to include all boxes in the main shipping container. ). The following items
are typically included:
(a) System Keys: TurboGen system keys are affixed to the power lever located on the right side
of the operator panel. Two keys are provided. One should be immediately secured in a safe
location while the other is inserted into the Master Switch until a specific key storage
location and usage policy can be determined
(b) Important Documents: All documents essential to the operation of the TurboGen (including
backup software disks and sensor calibration data). Included are two copies of the
TurboGen Gas Turbine Electrical Generation System Operator’s Manual. One copy should
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be removed at this time and used for the remainder of the setup process and all subsequent
operation. The other copy should be set aside for safe keeping. A set of Quick Check
operator checklists are included for the convenient reference and efficient operation of the
TurboGen.
(c) Box 1 – Caster Kit: The four mounting brackets, casters and attachment hardware are
located in this box. These four casters mount to the base of the TurboGen cabinet, allowing
it to be conveniently moved about.
(d) Box 2 – Computer Equipment: All computer equipment and accessories ordered with the
system will be found in this box. All software required to operate the data acquisition
system is preloaded on this computer. Power cables, power adapters and USB cable are
also found in this box.
(e) Box 3 – SR-30 Cutaway Engine: If ordered, the SR-30 Cutaway Engine is separately boxed.
This box may be attached to the top of the main shipping container.
(f) Box 4 – HushKit Inlet Assembly: If ordered, the HushKit Inlet Assembly is found in this box.
(g) Bubble-Wrapped Prop Rod: This is the prop rod used to hold open the engine
compartment viewing shield if any engine/generator maintenance is required. Two attach
clips are included which customer can choose to mount to system if prop rod is desired to
be with system at all times. Otherwise, prop rod should be stored in an easily located place.
(h) Bubble-Wrapped Inlet Screen: This is the air inlet screen for the engine air inlet hole on the
engine compartment viewing shield. It can be easily inserted into the 3 mount clips
fastened around the inlet hole. The screen can easily be pulled out the of mount clips in the
event a Hush Kit is being installed through the hole (see Section 1.4.3 on Page 12 for Hush
Kit Installation).
5. Remove Cardboard Shelf
6. Remove Hold Down Boards: Two hold down boards secure the TurboGen to the shipping
container pallet base. These boards pass through the forklift openings in the base of the
TurboGen and are individually screwed to the pallet base. Remove all screw fasteners so that
both down boards may be removed.
7. Lift the TurboGen Clear of Pallet: With adequate assistance and equipment, the TurboGen may
now be lifted clear of the container pallet and set on the floor. To avoid damaging the unit, only
lift at the provided forklift openings in the base of the TurboGen. DO NOT lift by hoisting on any
components making up the operator panel or test cell. If the casters are to be mounted in step
8, the TurboGen should be set on wooden blocks or temporary structure to allow the fastening
of the casters.
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8. Remove Protective Packing Material: A large piece of plastic will be draped over the entire
TurboGen. Bubble-wrap type material will be wrapped around the entire system. Remove all of
this material from the TurboGen.
9. Mount Caster Wheels: The four mounting brackets, casters and attachment hardware are
supplied ready to be mounted to the TurboGen cabinet sides. Once the four casters are
mounted, the TurboGen may be lifted clear of any support materials and set upon the floor.
10. Inventory/General Condition Assessment/Cleaning: Using Table 1.1 as a guide, inventory all
received contents and verify their general condition. Separate Packing and Inventory lists will be
found within the shipping container to further assist in this process. If any item is found to be
missing or damaged, contact Turbine Technologies, Ltd. immediately. With a soft cloth, wipe
any dust or dirt from the system cabinetry and accessories.
11. Retain Shipping Container/Materials: With the TurboGen components accounted for in Step
10, the shipping container may be removed for storage. All packing material should be placed
with the container materials. While the container may be disposed of at this time, it is
recommended that the container and packing materials be retained for future use should the
need arise to move the TurboGen over any appreciable distance, store for an extended period of
time or to return the TurboGen to the factory for service or upgrade.
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1.4.2 Set-Up
With the TurboGen free of its shipping container and with the caster wheels securely attached, the
TurboGen may now be prepared for its initial run.
A. Facilities
The TurboGen represents an entirely self-contained gas turbine based electrical generation system. For
occasional usage, the TurboGen may be conveniently rolled outdoors or to an overhead door opening
typically found in a university lab setting. More permanent installations may take advantage of existing
facility ventilation systems.
Any ventilation system or ducting that is attached directly to the TurboGen cabinetry must meet the
following guidelines:
1. Flow Direction: Air flows through the TurboGen’s SR-30 Engine/TG-2000 Generator System in a
“left to right” direction as viewed by the operator standing facing the control panel.
2. Mass Flow Rate: The TurboGen’s SR-30 Engine consumes in excess of 0.5 kilograms of air (and
fuel) a second. Since fuel is a small portion of the overall mass flow, an estimate of overall air
consumption can be based on the 0.5 value. This translates to approximately 850 cubic feet
(24,000 liters) per minute. All ducting must be designed to handle this amount of flow.
Conservatively, the inlet should be designed to handle a minimum of 1,000 cubic feet (28,300
liters) per minute while the exit duct should be sized for 1,500 cubic feet (42,500 liters) per
minute. All duct runs should be as straight and direct as possible. Avoid sharp bends, air
handling equipment (fans) and filters in both the inlet and exit flow paths. The best ducting is
straight flow paths from the building exterior to the TurboGen Cabinet.
3. Flow Velocity: Exhaust gasses leaving the exit manifold of the TurboGen’s SR-30 Engine/TG-
2000 Generator System can be traveling in excess of 800 feet (243 meters) per second. Access
to the exhaust exit must be limited either through ducting or physical barriers that prohibit
observers from entering the exhaust flow path. The exhaust exit also houses a spinning exhaust
fan of which contact should be avoided.
4. Noise: The TurboGen’s SR-30 Engine has a noise signature typical of any straight, turbojet
engine. Engine compressor inlet and exhaust noise through the generator exhaust manifold is
such that personal hearing protection is required for anyone within the immediate vicinity of the
engine during operation. An optionally available HushKit helps suppress engine noise and is
particularly suited for installations in an academic environment.
TM
B. Utilities
The TurboGen requires only external electricity and air for operation.
1. Electrical Service: Electrical service is required for the AutoStart system as well as the integral
fuel and oil pumps. A keyed master switch controls the flow of all electricity to the unit.
Standard laboratory electrical service capable of supplying 120 VAC, 60 Hz @ 20 Amps is
sufficient to power the TurboGen. The TurboGen is capable of operation on 220 VAC, 50 Hz
upon request.
2. Compressed Air: To simplify TurboGen operation, compressed air is utilized to start the
TurboGen’s SR-30 Engine. The compressed air is delivered tangentially to the compressor,
causing it to rotate. Once a suitable rotation speed is achieved, fuel is introduced and the
engine starts. Typical laboratory shop air is used for starting. Supply air pressure must be 100-
120 psi (690 – 830 kPa) with a sustainable pressure of 100 psi (687 kPa). Minimum air line
internal diameter is 0.375 inch (0.95 cm). As the supplied air is ingested by the engine, the air
source must supply clean, dry air at all times. Severe engine damage may result if the source
contains any amount of condensed water.
C. Operating Fluids
Like any turbine engine, the SR-30 Engine depends on a supply of suitable heavy fuel for operation and
the proper turbine oil for engine lubrication. Aviation grade jet fuel and turbine oil are readily available
at any nearby airport where commercial or business jets operate. Diesel fuel available from any service
station is also an acceptable fuel. Refer to Section 1.3 for a complete list of acceptable fuel and oil
types. Under no circumstances should automotive or aviation type gasoline be used in the SR-30
engine. Severe engine damage will result. The OneTouch Auto Start System monitors fuel and oil
levels continuously and will indicate a CAUTION flag should the volume of either fluid fall below an
acceptable level.
1.4.3 HushKit Installation

The HushKit Gas Turbine Sound Suppressor System is an optional silencer assembly available for
installation on the TurboGen. The HushKit is designed to significantly reduce compressor noise
emanating for the SR-30 Engine. The TG-2500 generator absorbs a great deal of the combustion noise
associated with the SR-30 Engine. Combined with the Hush Kit, SR-30 sound signature is greatly
reduced.
The HushKit System is composed of an engine intake suppressor unit. This aircraft style, nacelle shaped
intake suppressor housing is designed to reduce acoustic energy associated with compressor intake
flow. Molded from aerospace quality fiberglass, the intake suppressor mounts to the SR-30 Engine with
a pneumatic friction seal system. This seal permits rapid installation and removal of the suppressor
allowing full access to the engine inlet and compressor face for teaching and instructional purposes. The
Hush Kit does not interfere with engine operation.
TM
To install a HushKit, follow these steps:
The intake suppressor assembly is shaped like an engine nacelle and molded in white fiberglass.
Like the engine, the intake suppressor has an intake and exit end and must be properly oriented
with the SR-30 Engine in order to function. The intake end of the suppressor is identified by the
two baffle plates spaced approximately 6 inches (15 cm) from one another. These plates have a
number of holes cut in them and are covered with a thin, foam-like material. The exit end of the
suppressor is equipped with a mesh screen that fills the entire exit area (see Figure 1.2). This
screen is mounted to a much thicker baffle plate that also serves to support the inflatable seal.
This exit end of the suppressor is the side that mates with the SR-30 Engine. Make sure the
inflatable seal is completely deflated by opening the air valve on the squeeze bulb located on
the end of the seal inflation line. Pass the exit end of the suppressor through the TurboGen
cabinet test cell inlet opening towards the engine inlet. The thick metal baffle on this end of the
suppressor is designed to mate squarely with the intake bell of the engine. With these two parts
touching, verify that the inflatable seal is free and not pinched between the baffle plate and
inlet bell. Make sure the suppressor assembly is axially centered on the engine inlet bell (see
Figure 1.3). Close the air valve on the squeeze bulb and, while supporting the inlet end of the
suppressor, begin inflating the seal by pumping the squeeze bulb. As the seal inflates, it should
fill the space around the engine’s inlet bell and provide enough pressure to support the inlet
suppressor assembly. Continue inflating the seal until the intake suppressor is fully supported.
As ambient temperature and pressure changes, it may be necessary to periodically add more air
to the seal to maintain support of the intake suppressor assembly.
Figure 1.4: HushKIt Inlet Suppressor Properly Figure 1.5: HushKit Inlet Suppressor Mated
Oriented to SR-30 Engine Inlet with SR-30 Engine Inlet Bell. The seal can
now be inflated
TM
SECTION 2 LIMITATIONS
Section 2
LIMITATIONS
The TurboGen is designed to be operated within the following limitations. Under no circumstances
should these limitations be exceeded by any margin. Operator safety and efficient operation of the
TurboGen is contingent upon these limitations being followed. Should a parameter fall outside of the
listed limitations, contact the factory prior to further operation.
2.1 SR-30 Turbojet Engine

MAXIMUM RPM (actual) …………………………………………. 82,000 RPM
MAXIMUM RPM ………………………………………………………….….. 106.1%
MAXIMUM TURBINE INLET TEMPERATURE (TIT) ………………………………………………………………….. 870 oC
MAXIMUM EXHAUST GAS TEMPERATURE ……………………………………………………………………………. 720 oC
MINIMUM FUEL PRESSURE …………………………………………………………………………..…… 150 PSI (1034 kPa)
MAXIMUM OIL PRESSURE ……………………………………………………………………………………… 30 PSI (207 kPa)
MINIMUM OIL PRESSURE ………………………………………………………………………………………… 10 PSI (70 kPa)
MAXIMUM AIR PRESSURE ………………………………………………………………………………… 160 PSI (1,103 kPa)
MINIMUM AIR PRESSURE ……………………………………………………………………………………. 100 PSI (690 kPa)
MAXIMUM AMBIENT AIR TEMPERATURE ………………………………………………………………………………. 41 oC
MINIMUM AMBIENT AIR TEMPERATURE..…………………………………………………………………………………. 0 oC
2.2 TG-2000 Generator

MAXIMUM OPERATING RPM………………………………………… 8,000 RPM
AUTOMATIC SAFETY SHUTOFF RPM………………………….…….10,000 RPM
IMPORTANT: See Operational Limitations

Appendix A
TM
SECTION 3 ABNORMAL PROCEDURES
Section 3
ABNORMAL PROCEDURES
3.1 System Shut Off Using Auto Start System

The TurboGen Gas Turbine Electrical Generation System is designed with the highest regard to operator
safety. Equipped with the OneTouch Gas Turbine Auto Start System, the TurboGen is virtually fool proof
in operation. All critical SR-30 Engine parameters are monitored by the OneTouch System. Should any
engine limitation be exceeded, the OneTouch System will command an immediate and safe shutdown of
the engine. In the unlikely event the engine is stopped by the OneTouch Auto Start System, the LCD
display will reflect the reason for the stoppage. Refer to Section 5.4.3 and Tables 5.1 and 5.2 for more
information. As explained in Section 5.4.4, there may be occasion to use the air test or clearing
procedure to assist in rectifying a shutdown problem. All operators should be familiar with the air
clearing procedure in Section 5.4.4. (also covered in Abbreviated Normal Procedure, Section 4.1.2).
If any abnormal situation is encountered that the OneTouch System does not manage, remembering
“RED and OFF”, will get the TurboGen System into a safe state so that a further investigation may be
made.
1. RED – Press the RED stop button.

2. OFF – Turn OFF the keyed master switch.
“RED and OFF”
Figure 3.1: System Panel Mounted Start/Stop Buttons
TM
SECTION 3 ABNORMAL PROCEDURES
3.2 ENGINE THROTTLE/GENERATOR EXCITATION LOAD LEVER QUADRANT

The TG-2000 Turbine Generator also has
operational limitations for safety. To RPM Alert Light
avoid an over-speed condition on the
generator, two features have been
Light
incorporated into the generator loading
Excitation
system. An Excitation Load Lever is Voltage
Throttle
located on the panel next to the throttle. Indicator
If desired, this Load Lever gives the
operator the capability to direct a
variable excitation current to the
alternator to provide variable loading on
Retractable
the generator system. The Load Lever
NORMAL POSITION is in the midrange Pinned Stop
location being held by the pinned
Load Lever
position stop. This maintains a good
excitation load setting on the generator, Excitation Load Lever Tension Knob
yet allows good starts. The system can
be run over the full throttle range of the
jet engine, with the load lever “pinned” Figure 3.2: Throttle/Load Lever Quadrant Detail
at a specific excitation current. With
this lever pinned in place, a limit is placed on how low the loading should be allowed to go, eliminating a
no load condition (with the jet engine at high throttle setting) that could over-speed the generator. If
the operator would like to explore various levels of load addition or reduction, the set pin in the position
stop can be pulled away from the lever, allowing the lever to travel within the travel constraints
provided. Pulling the Load Lever back toward the operator adds excitation load, while pushing it
forward away from the operator reduces excitation load. An excitation level display is located right
above the load lever. This can be used as a reference to allow repeatability when running comparative
tests. NOTE: This indicator setting is not recorded by the data acquisition system. Any changes should
be marked down in lab test notes.
Changes in excitation loading should be performed slowly and smoothly, with no abrupt changes!
The generator monitoring sensor lights a red panel warning light if 8,000 RPM is reached by the
generator. If speed is allowed to continue to climb, the TurboGen Unit will automatically shut down
upon reaching 10,000 RPM on the generator. This is done for safety to mitigate over-speed, which
could cause damage to the generator. (This information is repeated and expanded upon in Section
5.2.4 on page 38, and related Operational Limits information is covered in Appendix A.
TM
SECTION 4 NORMAL PROCEDURES
Section 4
NORMAL PROCEDURES
The TurboGen Gas Turbine Electrical Generation System is designed with simplicity and operator
convenience in mind. Inexperienced operators will quickly gain familiarity and confidence with the
system permitting the collection of meaningful data from the very first run. No special knowledge or
skills are required to use the TurboGen, thereby allowing its usage in even the most basic of science and
engineering courses. The purpose designed OneTouch Gas Turbine Auto Start System greatly facilitates
TurboGen ease of usage.
This section provides a set of standard procedures to follow while operating the TurboGen. The steps
and the order in which they appear represent the most efficient and safe procedure to initiate operation
of the TurboGen and to collect run-time data for use in a typical academic setting. Operational runs can
be as short or long as necessary. Properly supervised, virtually anyone can operate the TurboGen with
no specific training required.
Summary operating checklists are provided in the Abbreviated Normal Procedures Section (4.1).
Detailed procedures for the same steps are described in the Expanded Procedures Section (4.2).
Familiarity with these procedures MUST be made prior to operating the TurboGen for the first time.
Experienced operators should continue to use the checklist for each operational run to eliminate the
possibility of overlooking or inadvertently eliminating a necessary step. With power removed from the
system (electrical service removed), the START and STOP buttons and the throttle lever may be
manipulated without harm to the system. This permits the ability to use the checklists in a “dry run” or
rehearsal fashion prior to operating the TurboGen under power.
BEFORE PLANNING TO OPERATE SYSTEM:
The TurboGen is shipped with an electronic SAFETY LOCK in place. Please contact Turbine
Technologies, Ltd., directly, to review your TurboGen set-up and for instructions on removing
the safety lock.
TM
4.1 ABBREVIATED NORMAL PROCEDURES

Abbreviated Normal Procedures consist of a series of easy to follow summary operating checklists for
the safe and efficient operation of the TurboGen.
These checklists are presented in order of usage. Each item should be completed before proceeding to
the next item. Each section must be completed before proceeding to the next section. It is
recommended that one operator read the checklist while another performs the task.
Three separate checklists are provided as follows:
1. Section 4.1.1 Pre-Start – Prepares the TurboGen for operation.

2. Section 4.1.2 Start, Operation and Shutdown – All aspects of system operation.
3. Section 4.1.3 Data Collection – Uses the data acquisition system to display and record system
operational parameters.
WARNING
Do Not Permit Unattended Operation of the TurboGen
TM
4.1.1 PRE-START
A. AREA CHECK ……………………………………………….…………….. VERIFY SUITABILITY FOR OPERATION
B. PERSONAL PROTECTION EQUIPMENT ………….……………………………………. AVAILABLE and USED
C. FIRE EXTINGUISHER …………………………………….…… LOCATE and FAMILIARIZE with OPERATION
D. CASTER WHEELS ……………………………………………….………….……………………………………….. LOCKED
E. KEYED MASTER SWITCH ………………………………………….………………………………….……………….. OFF
F. THROTTLE LEVER ……………………………………….………... MINIMUM POWER, FULL AFT POSITION
G. LOAD LEVER …………………………………………….………………. PINNED POSITION, LOAD LEVER STOP
H. VISUAL INSPECTION
I. VIEWING SHIELD ……………………………………………………………………………..…………..... CHECKED
J. INLET DUCTING …………………………………………………………………..………..……………….. CHECKED
K. EXHAUST FAN FREE ……………………………………………………………….………………….……..CHECKED
L. EXIT DUCTING ………………………………………………………………………….………..…….……. CHECKED
M. ENGINE MONITORING ……………………………………………………….………………...…....…. CHECKED
N. ENGINE FLUID LINES …………………………………………………………….………..…..…...………CHECKED
O. ENGINE/GENERATOR SENSOR LINES …………………….……………….………….………….. CHECKED
P. ENGINE INLET BELL ………………………………………………………………..…………….………… CHECKED
Q. ENGINE COMPRESSOR ……………………………………………………………..……….………….. CHECKED
R. ENGINE INLET AREA …………………………………………………………………..…………...…….. CHECKED
S. EXHAUST MANIFOLD EXIT AREA ……………………………………………..……….……………. CHECKED
T. CABINET INTERNALS ……………………………………………………………..………….…………... CHECKED
1. FUEL QUANTITY …………………………………………………………………………………………………… CHECKED
2. OIL QUANTITY …………………………………………………………………………………………………………. VERIFY
3. TURBOGEN ELECTRICAL SERVICE ………………………………………………………………………… CONNECT
4. TURBOGEN AIR SERVICE …………………………………………………………………..………………… CONNECT
5. AIR PRESSURE ………………………………………………………………………….. APPROX. 120 PSI (827 kPa)
6. COMPUTER DAQ SYSTEM 1 ……………………………………………………………… CONNECT USB CABLE
7. COMPUTER DAQ SYSTEM 2 ……………………………………………………………..………... COMPUTER ON
8. OBSERVERS …………………………………………………………………………………..………………………. BRIEFED
9. FINAL CHECK ……………………………………………………………………………….……………………. COMPLETE
TM
4.1.2 START, OPERATION and SHUTDOWN

1. KEYED MASTER SWITCH………………………………………………………………..………………….…………………ON
2. TURBINE INLET TEMPERATURE PANEL METER (TIT)……..………….………………………….…VERIFY ON
3. ENGINE RPM PANEL METER (ENGINE RPM) ……..……………………..…………………………… VERIFY ON
4. GENERATOR RPM PANEL METER (GENERATOR RPM)…………….……………………………...VERIFY ON
5. ENGINE THROTTLE LEVER………...….…MINIMUM POWER, FULL AFT POSITION (DETENT CLICK)
6. LCD DISPLAY……………………………………..………….….VERIFY THROT POSITION FLAG ILLUMINATES
7. GENERATOR LOAD LEVER…………………..……….. PINNED MID LOAD SETTING, LOAD LEVER STOP
8. LCD DISPLAY……………………………………………….………………………………..….RDY – READY DISPLAYED
9. ENGINE START……………………………………………….……………………………………GREEN START BUTTON
9. ENGINE RUN……………………………………………..….……..…..….. .Engine Will Start Within 20 Seconds
10. LCD DISPLAY…………………………………………..…….…..…….……..……….…….… RUN – RUN DISPLAYED
11. OPERATE ENGINE AS REQUIRED………………..………….………FULL RANGE OF POWER AVAILABLE
12. ENGINE STOP………………………………………………….………………………………..……..RED STOP BUTTON
13 Engine is ready for restart when RDY (ready) is displayed on LCD Panel
AIR CLEARING PROCEDURE
The following procedure is used to clear the engine when certain WARNING flags warrant.
See Section 5.3.3 for applicability.
a. ENGINE…………………………………………………………………………………………………..……………………….OFF
b. POWER LEVER……………………………………………..…………………………..…………..….MIDDLE POSITION
c. LCD DISPLAY……………………………………..……………VERIFY THROT POSITION FLAG ILLUMINATES
d. RED STOP BUTTON………………………………………..……………………………………………………………...PUSH
e. GREEN START BUTTON…………………………………………………………………………………………………..PUSH
Air will cycle for 5 seconds. Repeat as necessary.
TM
4.1.3 DATA COLLECTION

NOTE: The following steps assume the use of the standard TurboGen Data Acquisition Program and
default setting as supplied with the TurboGen. Use of non-default setting or other software may
necessitate alternative methods of procedures for data collection. Consult the LabView/National
Instruments software specific information as required.
1. OPEN DAQ SOFTWARE……………..………………………………………….……Click on TurboGen Desktop Icon

2. MONITOR DATA.…………………………….………………………………………….…..……Click Start Arrow (item 1)
3. DISPLAY DATA……………………………………………………………………………….………………………….…Running VI
4. LOG DATA TO FILE………………………………………………………………Click Log Data to File Button (Item 3)
5. VIEW REAL TIME DATA PLOTS..……………………………………..……………..Click Plot Data Button (Item 4)
NOTE: Computer must be connected to the TurboGen USB port prior to opening TurboGen Software.
Launch from Desktop Icon
Figure 4.1: Abbreviated Data Acquisition Software Controls
TM
4.2 EXPANDED NORMAL PROCEDURES
Expanded Normal Procedures consist of a series of descriptive steps detailing each summary operating
checklist item necessary for the safe and efficient operation of the TurboGen.
These steps are presented in order of usage. Each item should be completed before proceeding to the
next item. Each section must be completed before proceeding to the next section. It is recommended
that one operator read the steps aloud while another performs the task.
Three separate sections are provided as follows:
1. Section 4.2.1 Pre-Start – Prepares the TurboGen for operation.
2. Section 4.2.2 Start, Operation and Shutdown – Start the TurboGen and establishes a steady
state system.
3. Section 4.2.3 Data Collection – Uses the data acquisition system to display and record system
operational parameters.
TM
4.2.1 PRE-START
The PRE-START checklist must be completed prior to operating the TurboGen. The checklist establishes
that all systems are ready for operation and that the SR-30 Engine can be safely started and operated
within its entire performance range.
1. The AREA CHECK is a general assessment to VERIFY SUITABILITY FOR OPERATION. This includes
a suitability determination of safety and facilities factors, additional equipment requirement and
the presence of responsible, knowledgeable operators familiar with the contents of this manual.
All operators and personnel in the immediate area should be familiar with existing safety
policies and procedures, emergency escape routes, and emergency services telephone
numbers/points of contact. If run indoors, the facility must be capable of supplying adequate
intake air flow and accommodating the corresponding exit exhaust flow. All operators must be
thoroughly familiar with the contents of the manual prior to operating the TurboGen. It is
strongly encouraged that two or more individuals operate the TurboGen as a team to enhance
safety and ensure that all checklist items are completed.
2. PERSONAL PROTECTION EQUIPMENT such as hearing protection and safety glasses are
REQUIRED and must be AVAILABLE and USED for all individuals within the operating area of the
TurboGen.
3. A FIRE EXTINGUISHER should be available. A responsible individual should LOCATE and

FAMILIARIZE themselves with OPERATION of the fire extinguisher. It is highly unlikely that any
operation of the TurboGen will necessitate usage of a fire extinguisher. Normal STARTING
operation of the SR-30 Engine may sometimes result in the presence of a flame from the exit of
the exhaust manifold located right above the generator. If any flame appears, it may briefly
have a “blowtorch” type appearance and does now require any specific action on the operator’s
part. As the engine comes up to speed, this flame will recede back into the engine exhaust
manifold. Usually, light gray or white “whispy” smoke will exit the exhaust manifold for a brief
instant upon engine startup. Normal SHUTDOWN operation will sometimes result in this same
light gray or white “whispy” smoke. This smoke does not require any specific action on the
operator’s part. Should a persistent yellow or orange colored “lazy” flame be encountered that
lacks definition (like a candle flame), or heavy black or sooty smoke is experienced, a fire
requiring attention is occurring. Press the RED STOP button, turn the keyed MASTER SWITCH to
OFF and extinguish the flame as required.
4. CASTER WHEELS must be in the LOCKED position prior to operation, preventing movement that
may pose a safety hazard.
5. KEYED MASTER SWITCH to the OFF position puts the system into a known, safe condition from
which it can be properly started. The MASTER SWITCH controls electrical power distribution to
the entire system. With the MASTER SWITCH OFF, no electricity can flow to the air start system,
ignition system or fuel pumps thereby preventing any chance for engine start prior to the
system being ready.
TM
6. Moving the ENGINE THROTTLE to the MINIMUM POWER, FULL AFT POSITION puts the system
into a known, safe condition from which it can be properly started. Verify LOAD LEVER is in the
PINNED POSITION with respect to LOAD LEVER STOP.
7. A general VISUAL INSPECTION is required to verify the condition of the entire TurboGen System
prior to operation. Any deficiencies MUST be addressed prior to further operation of the
TurboGen. Items to be CHECKED include:
(a) VIEWING SHIELD – Check that it is in place, intact and clean. No scratches or cracks are
permissible in the viewing shield.
(b) INLET DUCTING – Check that the inlet opening to the TurboGen test cell is free from
obstruction and that there are NO loose items in the vicinity of the inlet that could be
ingested. Any existing, facility-specific ducting must be secure, intact, clean and free from
debris or obstruction.
(c) EXIT DUCTING – Check that the exit opening from the TurboGen test cell is free from
obstruction and that there are NO loose items in the vicinity that could be accelerated due
to high speed exhaust gasses/exhaust fan air flow. Any existing, facility-specific ducting
must be secure, intact, clean and free from debris or obstruction.
(d) ENGINE/GENERATOR MOUNTING – Check that the engine and generator are securely
attached to the shock absorbing spring mounted support platform. ENGINE FLUID LINES –
Check the air, oil and fuel fluid lines that pass through the text cell floor and attaché to the
engine for security of attachment, cleanliness and general condition (drops of fluid on the
line may indicate leaking connection).
(e) ENGINE/GENERATOR SENSOR LINES – Check the various hard lines (tubing) and wires that
pass through the test cell floor and mate to sensor locations around the engine/generator
for security of attachment, cleanliness and general condition.
(f) ENGINE INLET BELL – Check the inlet bell for security of attachment to the engine,
cleanliness and general condition.
(g) ENGINE COMPRESSOR – Check the compressor, visible through the engine inlet bell for
freedom of rotation, cleanliness and general condition. Pay particular attention to the
smoothness of engine rotation and the appearance of the individual blades. Rotation
should be smooth with no discernible drag resulting from contamination of the bearings.
Compressor blades should appear sharp and bright with no obvious discontinuities in their
shape.
(h) INLET AREA – Check the area through the test cell inlet opening (left side) up to and
including the inlet bell for any obstructions or loose materials. Any non-secured items in
this area have the potential to be sucked into the engine.
(i) EXIT AREA – Check the area from the exhaust ducts through the test cell exit opening (right
side) for any obstructions or loose materials. Any non-secured items in this area have the
potential to be expelled through the test cell exit opening and through the exhaust fan at
high speed.
(j) CABINET INTERNALS – Check the area within the test cell for cleanliness and general
condition. Verify that the two test cell view area hold down bolds, located on the front
inside corners nearest the operator panel are secured with the appropriate fastener nuts.
8. FUEL QUANTITY should be CHECKED for amount sufficient to conduct the intended run.
TM
9. OIL QUANTITY should be CHECKED to verify that the proper level of oil is present in the tank. As
some room is required for circulating, return oil flow, the oil tank should not be completely full.
An amount approximately 1 inch (2.5 cm) from bottom of the filler neck is adequate.
10. CONNECT suitable ELECTRICAL SERVICE to the TurboGen. Verify that the service to be
connected is the correct service for your particular TurboGen. Improper electrical service may
damage the TurboGen systems.
11. CONNECT suitable AIR SERVICE to the TurboGen air fitting at the back of the cabinet.
12. AIR PRESSURE should indicate a minimum of 120 psi (827 kPa) on the operator panel gauge.
13. The COMPUTER DAQ SYSTEM USB CABLE should now be CONNECTED to the DAQ system
receptacle on the left side panel of the TurboGen. A computer with the appropriate data
acquisition software should be connected to the opposite end of the cable. Make sure the
computer is OFF prior to connecting the cable or the DAQ Module hardware/software may not
properly initialize.
14. The COMPUTER DAQ SYSTEM (data acquisition computer) should be turned ON. This allows the
computer adequate time to initialize prior to data collection. Make sure the computer is
connected via USB cable to the DAQ system receptacle on the left side panel of the TurboGen
prior to turning the computer ON or the DAQ Module hardware/software may not properly
initialize.
15. All OBSERVERS must be BRIEFED and aware of the safety requirements of being in the proximity
of an operating jet engine. This includes awareness of intake and exit hazards as well as the
need for proper hearing and eye protection.
16. Ensure that a FINAL CHECK of all items in COMPLETE. Verify that each checklist item has been
covered.
4.2.2 START, OPERATION and SHUTDOWN

The START and OPERATION checklists details the steps necessary to get the TurboGen running in the
most safe and efficient manner possible. Usage of the ONETOUCH AUTOSTART System greatly simplifies
operation. The following steps must be followed to ensure the ONETOUCH functions correctly.
1. The KEYED MASTER SWITCH should be turned ON. This switch provides power to the entire TurboGen
unit including the OneTouch System.
2. VERIFY that the TURBINE INLET TEMPERATURE PANEL METER marked TIT powers ON. Meter power
will be indicated by the illumination of the meter display LEDs. The meter will go through a short self-
test and then display the current ambient temperature (providing this is the first operation of the
TurboGen for the day). If the temperature indicated on the meter does not seem reasonable
considering recent TurboGen usage, stop the checklist and determine the problem with the meter (or
associated thermocouple).
TM
3. VERIFY that the ENGINE RPM PANEL METER powers ON. Meter power will be indicated by the
illumination of the meter display LEDs. The meter will go through a short self-test and then display the
current engine RPM. With the engine off and not rotating, the displayed RPM should be zero (0000). If
any numbers other than zero are displayed, stop the checklist and determine the problem with the
meter.
4. VERIFY that the GENERATOR RPM PANEL METER powers ON. Meter power will be indicated by the
illumination of the meter display LEDs. The meter will go through a short self-test and then display the
current Generator RPM. With the engine off and not driving the generator, the displayed RPM should be
zero (0000). If any numbers other than zero are displayed, stop the checklist and determine the
problem with the meter.
5. The engine THROTTLE LEVER should be moved to the MAXIMUM POWER, FULL FORWARD POSITION
to verify freedom of movement throughout the full range of throttle operation.
6. GENERATOR LOAD LEVER should be in PINNED POSITION, LOAD LEVER LEVEL display should be on.
7. With the THROTTLE LEVER FULL FORWARD as in the previous step, VERIFY that the THROT POSITION
FLAG ILLUMINATES on the LCD DISPLAY.
8. The engine THROTTLE LEVER may now be returned to the MINIMUM POWER, FULL AFT POSITION.
As with an earlier step, this verifies that the throttle functions correctly throughout the full range of
motion.
9. With the Engine THROTTLE and Generator LOAD Lever in the PINNED POSITION, the LCD DISPLAY
should display RDY which indicates the TurboGen is READY for engine start.
10. ENGINE START may now be initiated by pressing the GREEN START BUTTON.
11. Once the GREEN START BUTTON has been pressed, the OneTouch System will initiate the engine
start sequence. High pressure air is directed into the engine to cause rotation. The high voltage ignition
system is also turned on that produces an electric arc in the burner can. When the proper RPM is
reached, fuel is introduced to the engine and sprayed into the combustion chamber. The arc ignites the
fuel and combustion begins. Expanding combustion gasses further the start process. While the start is
progressing, the OneTouch System monitors a variety of system parameters to ensure a safe and
efficient start. A normal start will take approximately 25 seconds to complete. An abnormal start will
result in the immediate shutdown of the start sequence.
12. Once the engine is running at idle, the LCD DISPLAY will display RUN indicating that the engine is
properly running and ready for data collection or demonstration.
13. The FULL RANGE OF engine POWER is now AVAILABLE allowing the engine to be operated as
required. Advancing the power lever away from the operator towards the test cell allows more fuel into
the engine, increasing RPM, power and thrust produced. Moving the power lever towards the operator
reduces the amount of fuel flowing to the engine, decreasing RPM, power and thrust. The engine may
be operated at any power setting for any amount of time. All power lever movements should be
smooth and deliberate. Avoid rapid or jerky movements of the power lever.
TM
14. The ENGINE may be STOPPED at any time by pressing the RED STOP BUTTON. After the engine has
spooled down, RDY will once again be displayed on the LCD DISPLAY indicating that the engine is ready
for another start.
If it is determined that the air clearing procedure as outlined in Section 5.3.3 (or through the
WARNING flag displays in Table 5.3) is required, complete the following steps:
(a) Verify that the ENGINE is OFF.

(b) Position the THROTTLE LEVER into the MIDDLE POSITION.
(c) Verify that the THROT POSITION FLAG ILLUMINATES on the LCD DISPLAY.
(d) PUSH the RED STOP BUTTON once to arm the air clearing function.
(e) PUSH the GREEN START BUTTON to activate the air clearing function. Normal starting air will flow
into the engine for five (5) seconds. Repeat as necessary. Table 5.3 should serve as guidance in using
the air clearing function. When id doubt, contact the factory for further information.
4.2.3 DATA COLLECTION

NOTE: The following steps assume the use of the standard TurboGen Software and default settings as
supplied with the TurboGen. Use of non-default setting or other software may necessitate alternative
methods or procedures for data collection. Consult the LabView/National Instruments software specific
information as required.
From Windows, OPEN the TurboGen Software by double-clicking on the

TurboGen 1.0 shortcut icon located on the Windows Desktop. TurboGen
1.0 will start with the Main Display/Control and Channel Configuration
Window displayed.
NOTE: The computer must be connected to the TurboGen USB port

prior to opening the TurboGen software.
The TurboGen configuration software is dependent upon the specific Figure 4.2: TurboGen Launch Icon
DAQ Module serial number as installed in the TurboGen and will not
function properly if the DAQ Module cannot be found. If this was done
incorrectly, exit the program, attach the USB cable and start over.
To verify that the software is communicating with the DAQ Module,

open Measurement and Automation from desktop. In menu tree, click
on Devices and Interfaces, then, click on NI DAQ 6218. This provides
and verifies the proper serial number for the on board DAQ system and
also verifies that a proper connection to that device is being made.
Figure 4.3: Measurement and Automation

Launch Icon
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Figure 4.4: Software Controls Overview
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Figure 4.5: Data Logging/Plot Display
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Figure 4.6: Sampling Rates
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Figure 4.7: Screen Image Export/Sensor Calibration
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4.3 GENERAL GUIDELINES

The following GENERAL GUIDELINES are offered as quick reminders of items requiring particular
attention.
Read and become familiar with the TurboGen Operator’s Manual

Use the provided checklists during every operation.
Mandate the appropriate personal safety equipment for all operators and observers.
Know the facility safety policies, emergency contact numbers and location of fire
extinguishers.
Consider all surfaces to be HOT during and for a significant time after operation.
Check the TurboGen fuel and oil level before and after every use. Add fuel and oil if
necessary.
Lock all four caster wheels during operation.
Use only in a well ventilated area.
Continually monitor all system parameters and be attentive for out of limit readings.
Immediately stop operation if anything is questionable.
Remember, turbojet engines require a large volume of air that is ultimately exhausted at
high temperature and velocity.
DO NOT operate the TurboGen without first becoming familiar with the Operator’s Manual.
DO NOT operate the system unattended.
DO NOT stand or allow others in the general proximity of the TurboGen intake or exhaust.
DO NOT move the system while operating.
DO NOT exceed scale readings/limitations on any instrument or gauge.
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Section 5
Systems
The TurboGen Gas Turbine Electrical Power Generation System is comprised of a turbojet engine tied to
a secondary turbine powered electrical generator, and various support equipment that enables
engine/generator operation. The engine is similar in design to power plants typical of aircraft, marine
and rail propulsion systems. It is also comparable to industrial and power generation type gas turbine
gensets. The only significant difference from these examples is size. Because of this small size, some of
the systems normally found on the engine itself have been relocated to the system cabinetry for
convenience and ease of operation. The following sections briefly describe the principle of components
of the TurboGen, their function and operation.
5.1 Gas Turbine
The SR-30 Turbojet Engine is designed and manufactured by Turbine Technologies, LTD specifically for
the Turbogen Gas Turbine Electrical Power Generation System. The SR-30 Turbojet Engine Cutaway in
Figure 5.6 is the same engine as installed in the TurboGen with proportions of selected components
removed to reveal the inner workings of the engine.
A pure turbojet, the SR-30 Engine is representative of all straight jet engines in which combustion
results in an expanding gas that is sufficiently capable of producing useful work and propulsive thrust.
Consisting of a centrifugal flow compressor, annular combustor and axial flow compressor turbine, the
SR-30 Engine is typical of the gas generator core found in turboprop and turboshaft engines.
Following the gas flow path is the easiest way to understand the relatively simple working of a jet
engine. Each major component of the engine is investigated in turn with consideration given to how the
individual parts contribute to the overall function of the engine. Showcasing the internal configuration
of the basic turbojet, the SR-30 Cutaway image in Figure 5.1 facilitates a qualitative understanding of gas
turbine fundamentals and establishes a foundation for more advanced theoretical study or experimental
exploration of the operating SR-30 Engine itself installed in the TurboGen Gas Turbine Electrical Power
Generation System.
The following sections provide a brief introduction to each of the principal engine components.
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SECTION 5 SYSTEMS
5.1.1 Inlet
The inlet is the first engine component to encounter the gaseous working fluid (atmospheric air)
necessary for the operation of the gas turbine engine. Not to be confused with the external inlet and
ducting installed on the TurboGen cabinetry (or the aerodynamic inlet on the nacelle of a jet transport
aircraft, for example) the engine inlet performs the final conditioning or treatment of the inlet air prior
to its entering the interior of the engine. The inlet bell of the SR-30 Engine is illustrative of a typical
subsonic inlet duct in which ambient air is directly routed to the face of the compressor. A purely
aerodynamic device, the inlet is not subject to temperature extremes. In the case of the SR-30 Engine,
the inlet is investment cast from aerospace quality aluminum, machined to mate with the rest of the
engine and polished on the interior surface to promote the smooth flow of air through the inlet.
Figure 5.1: SR-30 Engine Components Cutaway
5.1.2 Centrifugal Flow Compressor
The compressor (rotor), along with the axial flow turbine, makes up the rotating assembly of the
turbojet engine. The SR-30 Engine utilizes a centrifugal (radial flow) compressor, with the flow path
being referenced to the rotation axis of the compressor itself. As viewed from the front of the engine
looking aft, the engine rotates in a counter-clockwise direction to properly function. Through this
mechanical rotation, energy is imparted to the inlet air. The compressor, also known as an impeller,
typically rotates anywhere from 50,000 to 90,000 revolutions per minute (RPM) depending upon the
amount of load the engine thrust is experiencing. This high rotational speed device takes inlet air at the
impeller hub and centrifugally accelerates it in a radial direction toward the outer circumference of the
impeller where it is discharged through the diffuser. The compressor blade geometry and the
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corresponding aerodynamic and fluid forces resulting from the rotation effect a useful change in the
velocity and pressure of the working fluid. At 90,000 RPM, the tip speed of the compressor is at its
greatest radius and therefore the approximate velocity of the air leaving the compressor 1550 ft/s (473
m/s). Aside from aerodynamic requirements, the compressor must be mechanically designed to endure
the stress encountered while rotating at operating RPM’s. Either aluminum or steel alloys are used in
the manufacture of the compressor.
5.1.3 Diffuser
The diffuser (stator) works in conjunction with the compressor to further process the working fluid. The
compressor discharge air is directed through the diffuser where the fluid velocity is decreased and the
static pressure increased. The SR-30 Engine has a maximum pressure ratio of approximately 3, meaning
the pressure of the air exiting the diffuser is 3 times that of atmospheric. At sea level on a standard day
this would result in a total pressure of 44 psi (303 kPa). This discharge air also undergoes a 90 degree
change in direction, transitioning from a radial to axial flow (oriented along the length of the engine).
The compressor and diffuser working together comprise the compressor stage of the engine. Like the
inlet, the diffuser is investment cast from aluminum and finish machined.
5.1.4 Annular Combustor
High pressure air leaving the diffuser now enters the combustion chamber or combustor. The purpose of
the combustor is to further increase the potential energy content of the working fluid through
combustion of a gaseous fuel and air mixture. The SR-30 Engine features an annular type combustor
composed of two perforated tubes fixed in a concentric relation to one another. The combustor is
oriented in a reverse flow arrangement with the inlet of the combustor situated at the rear of the
engine. This arrangement allows for the most physically compact engine. Only a small fraction of the
available compressor air is necessary to support combustion. Mixed at the inlet end of the combustor,
this primary air and fuel is ignited during engine start by a high voltage spark type igniter plug. Once the
engine is started, the igniter is no longer necessary as the combustion process becomes self-sustaining.
Air in excess of that needed for combustion, termed secondary air, enters through the larger combustor
holes and helps to both stabilize and position the combustion flame within the combustor walls and to
cool the combustion gases to a value suitable for engine operation (limited by component material
properties). Typical combustion temperature ranges from 400C to 800C. Because of these higher
temperatures, the annular combustor is manufactured from Inconel sheet, rolled into the proper shape
and welded. The individual primary and secondary air holes are laser cut.
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5.1.5 Fuel Atomization Nozzle
Fuel enters the combustion inlet through six equally spaced fuel atomization nozzles located at the
extreme rear of the engine (mounted so as to protrude into the inlet of the reverse flow annular
combustor). The nozzles are designed to fully atomize the fuel as it exits the nozzle. Atomization aids in
the efficient, clean and thorough combustion of the fuel and air mixture. Combustion is further
enhanced by the introduction of turbulence within the fuel nozzle to combustor mounting assembly.
The advanced nozzle design permits a wide range of heavy type fuels (diesel, kerosene) to be used in the
engine without the need for preheating or other forms of fuel conditioning. The amount of fuel
necessary to operate the engine varies with the desired power output. A common measure of fuel usage
is Specific Fuel Consumption (SFC) which relates the amount of fuel per unit of thrust per unit of time.
The SR-30 Engine has an SFC of approximately .80 at high RPM (high thrust).
5.1.6 Fuel Controller
Fuel is provided to the atomization nozzles via the fuel controller. The engine speed is regulated by
controlling the amount of fuel entering the combustor through the fuel atomization nozzles. Fuel is
delivered to the controller at constant pressure. The controller then regulates the amount of fuel
reaching the atomization nozzles through a high pressure, return flow throttling technique. At low
engine speeds, the majority of fuel entering the fuel controller is allowed to return to the fuel source.
When higher engine speeds are desired, the fuel controller return line is restricted causing more fuel to
reach the nozzles.
The engine is fully throttleable over the entire performance envelope from idle to maximum power.
There is no restriction on the speed or rate at which the fuel controller may be moved. The fuel
controller movement causes a nearly instantaneous response in engine power.
5.1.7 Transition Liner
Hot combustion gases leaving the annular combustor are turned back 180 degrees by the transition
liner. While combustor gases move in the reverse direction, the transition liner returns the flow path to
the normal front to back direction.
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5.1.8 Vane Guide Ring
The vane guide ring (stator) is the first component in the turbine stage and permits the turbine to
extract useful work from the combustion process. This ring consists of a shrouded series of small airfoil
blades each facing into the oncoming combustion gas flow as directed by the transition liner. As the flow
path narrows between the individual blades, the hot, high pressure combustion gases are accelerated to
a high velocity, high energy flow. The vane guide ring further directs this accelerating gas in such a
manner as to produce the most effective reaction against the turbine blades.
Like the combustor components, the vane guide ring is manufactured from Inconel 718 alloy.
5.1.9 Axial Flow Turbine
The turbine (rotor) absorbs energy from the accelerating gas flow and converts it into usable
mechanical power. Further acceleration of the expanding flow takes place through the turbine blades.
Much like blades of the vane guide ring, the individual turbine blades are also airfoil shaped. A
combination of aerodynamic and reaction forces cause the turbine to rotate. Coupled to the
compressor, the sole job of the turbine is to effect a rotation of the compressor to perpetuate the
engine flow process. Only the power necessary to drive the compressor is extracted from the flow as it
expands through the turbine blades. The remaining energy is available and utilized for the generation of
propulsive thrust.
The turbine wheel is designed as an integrally bladed disk commonly called a blisk. The turbine wheel
blisk is precision vacuum investment cast from CMR 247 Super Alloy.
5.1.10 Thrust Nozzle
A convergent tube of gradually decreasing cross-section, the thrust nozzle converts the remaining
combustion heat energy into kinetic energy. The gas accelerates through the nozzle at high velocity
resulting in propulsive thrust at the nozzle exit. The thrust nozzle also serves as a turbine wheel
containment ring in the vent the turbine wheel were to come apart while the engine is running.
5.1.11 Miscellaneous
Numerous other components such as bearings, seals, fittings, galley ways and fasteners are found
throughout the engine.
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5.2 Turbine Powered Electrical Generator.
EXHAUST THRUST TRANSITION

LINER/CONE
THRUST POWERED
FREE TURBINE
LIQUID COOLED ALTERNATOR
Figure 5.2: TG-2000 Generator Components Cutaway
5.2.1 Exhaust Thrust Transition Liner/Cone
The regular SR-30 Gas Turbine Engine expels thrust out the back. The new TurboGen TG-2000
Generator Section is mated to this thrust section to take advantage of the energy in the thrust stream.
Exhaust gases travel at high speed through a diverging liner with divergence cone to direct the rapidly
moving gases into a turbine wheel, known as a free turbine.
5.2.2 Free Turbine

A free turbine is identified as a turbine that is not directly linked to a power source by a drive shaft, but
rather is driven thermodynamically by hot rushing gases through the system. The TG-2000 generator
utilizes a single axial-bladed turbine wheel for this purpose.
5.2.3 Liquid-Cooled Alternator

The free turbine spins a Liquid-Cooled Alternator to generate
electricity.
5.2.4 Generator Load/Control System

The TG-2000 generator is base-loaded by a cabinet mounted
fixed value resistive load cell.
Figure 5.3: Generator Base Load Resistive Cell
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SECTION 5 SYSTEMS
An Excitation Load Lever is located on the panel next to the throttle. If desired, this Load Lever gives the
operator the capability to direct a variable excitation current to the generator to provide variable
loading on the generator system. The Load Lever
NORMAL POSITION is in a midrange location being Increasing Engine Throttle
held by the pinned position stop. This maintains a
good excitation load setting on the generator, yet Decrease
allows good starts. The system can be run over the
full throttle range, with the load lever “pinned” at a
specific excitation current. If the operator would like
to explore various levels of load addition or
reduction, the set pin in the position stop can be
pulled away from the lever using the knurled knob, Increase
allowing the lever to travel within the constraint
settings provided. Pulling the lever back toward the
operator adds excitation load, while pushing it
Pinned Stop (retractable)
forward away from the operator reduces excitation Generator Excitation Load Lever
load. Changes in excitation loading should be
performed slowly and smoothly, with no abrupt changes; Figure 5.4: Load Lever/Pinned Stop
See CAUTION in next paragraph!
CAUTION!!! Unpinning Load Lever from position stop

enables it to be repositioned to either increase or
decrease excitation current to the generator. It is
especially important to know that if excitation current
is reduced too much, too quickly, the possibility of
generator over-speed could occur, which could cause
generator structural damage. Excitation “Load”
should be reduced very slowly and deliberately,
allowing generator RPM to stabilize with each
reduction before going further. Generator RPM
should not be allowed to exceed 8,000 RPM. If 8,000
RPM is reached, a red light positioned above the Load
Lever will light up and the N2 VI Panel Meter will turn
red. If attention is diverted and RPM continues to
Figure 5.5: Generator RPM Caution
climb, the whole system will automatically shut itself
off at 10,000 RPM.
Important Note: Please see Appendix A:

Operational Limits of TurboGen Throttle/Load Lever. Please follow
recommendations closely to avoid possible damage to your system.
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5.3 SR-30 Gas Turbine Engine Accessories
For simplicity and ease of operation, all engine ancillary accessories are located separate from the
engine itself.
5.3.1 Fuel
The TurboGen fuel system is comprised of a fuel reservoir, fuel pump and fuel delivery lines. The
stainless steel fuel reservoir, accessed from the rear of the TurboGen cabinet, holds 7 gallons (26.5 ltrs)
of fuel. Fuel is pumped from the reservoir by an electrically driven fuel pump, passed through a fuel
filter and sent through the fuel lines to the fuel controller. Fuel in excess of that needed by the fuel
controller is routed back to the fuel reservoir.
5.3.2 Oil
The TurboGen features a fully recirculating oil system. The oil system is comprised of an oil reservoir, oil
pump and oil delivery lines. The stainless steel oil reservoir, accessed from the rear of the TurboGen
cabinet, holds 1 gallon (3.8 ltrs.) of oil. Oil is pumped from the reservoir by an electrically driven oil
pump, passed through an oil filter and sent through the oil delivery lines to the engine. Oil flows
through oil galley-ways in the engine that directs oil to the main bearings upon which the compressor
and turbine ride. The oil is used to cool and lubricate these bearing. After the oil flows through the
bearings, it is returned to the oil reservoir.
5.3.3 Ignition
A dedicated exciter box provides high voltage to the single spark igniter used to initiate combustion.
Combustion is self sustaining once the engine starts. The exciter box is shut off and the igniter ceases to
spark.
5.3.4 Starting Air
Compressed air is used to start the engine. A standard air fitting is provided on the back of the
TurboGen cabinet for the connection of standard shop air. A solenoid valve controls the flow of air from
this fitting to the engine via an air line. The air line attaches to the engine and is oriented to direct air
tangentially against the engine compressor. This air rotates the compressor up to a speed sufficient to
start the engine.
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5.4 Cabinetry
5.4.1 Test Section
The TurboGen features a fully integrated test cell mounted atop the system cabinetry. Front and rear
viewing shields allow observation of the engine/generator during operation while providing a safety
barrier between the engine/generator and observers. Access to the engine/generator is gained by
opening the test cell about its side hinged connection. All engine fluid, electrical and sensor lines pass
through the floor of the test cell into the cabinet below.
5.4.2 Operator Panel

Various controls and indicators are provided to assist the operator in using the TurboGen.
1. Keyed Master Switch: The key lockable system master switch controls the supply of electrical
power to the main bus that powers all TurboGen System components. When selected ON, power is
available to the TurboGen. When selected OFF, no power is available to any system component,
thereby preventing the engine from running. In all cases, removing TurboGen electrical power by
selecting this switch to OFF will cause the engine to stop running.
2. Green Start Button: The start button’s primary function is to initiate the automatic engine start
sequence through the OneTouch Gas Turbine Auto Start System. This button controls a number of
the OneTouch system functions depending upon the current system state. See Section 5.3.3 for
more information.
3. Red Stop Button: The stop button’s primary function is to command the OneTouch System to stop
or shutdown a running engine. Pressing this button will immediately cause the engine to stop
operating. If, for any reason, this button fails to stop the engine, the Keyed Master Switch can be
used as a backup to stop the engine. This button controls a number of other OneTouch System
functions depending upon the current system state. See Section 5.3.3 for more information.
4. Oil Pressure Gauge: The oil pressure gauge provides a direct indication of oil pressure available to
the engine for cooling and lubrication. The oil pressure setting is established at the factory prior to
shipment and should fall in the range specified in Section 2.
5. P3 Gauge: The P3 gauge indicates gauge pressure in the combustion can of the engine. This value
provides a relative measurement of engine power.
6. Fuel Pressure Gauge: The fuel pressure gauge provides a direct indication of fuel pressure directed
to the engine fuel control unit. The fuel pressure setting is established at the factory prior to
shipment and should fall in the range specified in Section 2.
7. Air Pressure Gauge: The air pressure gauge provides a direct indication of air pressure available for
engine starting. The indicated air pressure must fall in the range specified in Section 2 for proper
engine starting.
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8. Turbine Inlet Temperature – TIT – Panel Meter: The TIT panel meter indicates the temperature of
the combustion gases just prior to entering the compressor turbine. Maximum TIT is specified in
Section 2.
9. Engine Rotational Speed – RPM – Panel Meter: The RPM panel meter indicates the rotational
speed of the compressor and turbine (also know and n1 speed) of the SR-30 Engine. The higher the
RPM, the greater the flow through the engine and the higher the indicated thrust. Maximum RPM
is specified in Section 2.
10. Electrical Generator Rotational Speed-RPM-Panel Meter: The GEN RPM panel meter indicates the
rotational speed of the electrical generator and its driving turbine wheel.
11. OneTouch LCD Display Panel: All OneTouch System indications are presented on the LCD Display
Panel. This panel is backlit for low light settings.
12. Power Lever (Throttle): The T-Handled Power Lever controls the amount of thrust the engine
produces by throttling the amount of fuel allowed to flow into the fuel nozzles (via the fuel
controller). The power lever is set up in the conventional way: full power is away from the
operator, idle power is towards the operator. The power lever also controls a number of OneTouch
functions depending upon the current system state. See Section 5.3.3 for more information.
13. Generator Load Lever: The smaller adjustable lever mounted next to the Power Lever (Throttle)
which is used to control excitation current levels to the alternator, which in turn loads the electric
generation system during operation.
5.4.3 OneTouch Gas Turbine Auto Start System
The OneTouch Gas Turbine Auto Start System simplifies operation of the TurboGen through the
automation of the engine start sequence. It further assists the operator by continuously monitoring
critical engine temperatures and RPM as well as verifying an adequate supply of fuel and oil during
operation.
The OneTouch System utilizes a dedicated computer and purpose designed controller board to provide
the automation functions. The computer and controller, along with a dedicated power supply and LCD
Display are packaged into the OneTouch box and mounted beneath the TurboGen operator panel.
Operation of the TurboGen equipped with the OneTouch System is both intuitive and straightforward.
The keyed master switch limits TurboGen operation to those that are authorized to do so. With the
keyed switch on, power is immediately applied to the OneTouch System computer. During system
initialization, several screens are displayed that provide basic TurboGen information such as unit serial
number, registered owner and cumulative system time displayed as engine run-time and total engine
start/stop cycles. The availability of this information is particularly helpful when making operational or
service inquiries to the factory.
Two buttons and the traditional T-handled power lever located on the TurboGen operator panel are all
that is necessary to operate the TurboGen through the OneTouch System. A backlit LCD display panel
integral to the operator panel severs as the primary user interface. During normal operation, the LCD
display indicates all monitored engine parameters and provides a simple indication of system state.
Should the OneTouch System command an engine shutdown, the cause for the shutdown will be
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displayed. Additional diagnostic functions are available through a combinatorial selection of the two
buttons and power lever.
Following initialization, the OneTouch System will display the normal operation screen and indicate the
engine is ready to start through the RDY or ready flag. The throttle lever needs to be in the full aft
position to arm the START button. If the throttle is in any other position, an indication on the display
screen will flag the operator to reset the throttle. Pressing the green START button commences the
Auto Start sequence. The RDY flag will change to STR indicating the staring sequence in underway.
Engine rotation begins through the introduction of starting air. Rotational speed is displayed as a
percentage of the maximum engine RPM limit as indicated by the N1% value. As N1 increases, fuel is
introduced at the appropriate time and ignited thereby starting the combustion process. The displayed
Turbine Inlet Temperature (TIT) values will show an immediate temperature rise indicating positive
combustion. As N1 continues to increase, the P3 pressure value relating total engine pressure to
ambient will also increase. Starting air remains on until the engine achieves a stable idle RPM and the
TIT has cooled to an acceptable lever. Once the starting air is shut off, the display will show the RUN
flag to indicate the starting sequence was successful.
The engine is now running and may be operated as desired. For reference purposes, an elapsed run-
time counter displays the time since engine start. Stopping the engine is as easy as pressing the red
STOP button. The OneTouch System continues monitoring the engine through the entire shutdown. The
RUN flag will now change to AIR to let the operator know the engine is spooling down and only air is
passing through it. Once N1 and TIT values are within safe start limits, the OneTouch System enables
the engine for an immediate restart by indicating RDY once again. Through the OneTouch System, the
engine may be repeatedly started and stopped without any adverse affect to the engine or the
TurboGen system.
During start and operation, should any critical engine value be exceeded or a problem found with any
TurboGen system, the OneTouch System will command an engine shutdown and alert the operator to
the problem. Faults are segregated between CAUTION and WARNING depending upon the severity of
the problem and the operator intervention required to rectify the fault. A CAUTION is indicative of a
minor problem that can be immediately fixed. Low fuel or oil levels are examples of CAUTIONs that are
fixed simply by adding the appropriate fluid. A WARNING suggests the potential for a more serious
problem that must be investigated before the engine can be run again. See Table 5.2 and Table 5.3 for a
complete listing of CAUTION and WARNING flags.
The air solenoid and the engine ignition system can be operated independently of the auto start
sequence for diagnostic and test purposes. To do so, and with engine off, move the throttle lever out of
the aft position so that the CAUTION – THROT POSITION screen is displayed. With this screen displayed,
push the red STOP button. A new screen will display indicating that the AIR & IGNITION are OFF.
Pressing the green START button will close the air relay for five seconds. Pressing the red STOP button
will close the ignition relay for five seconds. The display will indicate whether the air or ignition is on or
off. A working air relay will make a “snapping” sound if the air is not hooked up and the usual
compressor whine if air is connected to the TurboGen. A working ignition system will emit a low volume
”hissing” or static like sound from the engine while the ignition is on. It is not necessary to test these
functions during normal TurboGen usage. Certain WARNING flags may require the air test function if
they are encountered, See the CAUTION and WARNING flag descriptions that follow, Tables 5.2 and 5.3
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(note: If air is connected to the TurboGen when testing the air function, the SR-30 Engine will spool up
just as it would during a start sequence. Although no fuel will be introduced, the engine should be
considered in operation requiring all operators and observers to remain clear of the test cell inlet and
exit, and that appropriate eye and hearing protection be worn.)
CAUTION FLAG
Indication Cause Remedy
THROTTLE POSITION The throttle lever is not in the Pull the throttle all the way aft (towards the
low power or most aft setting. operator, away from the test cell). A microswitch
located under the operator panel detects when
the throttle lever is in the proper position.
FUEL LEVEL Inadequate fuel supply in the Add fuel to the fuel tank. Tank capacity is
fuel tank. approximately 7 gallons (26.5 liters), however
a certain volume should be left for expansion
and fuel return. For this reason, there should not
be more than 5 gallons (18.9 liters) of fuel in the
tank when full. Fuel level is detected via a float
switch on the bottom of the fuel
tank.
OIL LEVEL Inadequate oil supply in the oil Add oil to the oil tank. Tank capacity is
tank. approximately 4 quarts (3.8 liters). The oil level
should always be full to assist in engine cooling.
Oil level is detected via a float switch on the
bottom of the oil
tank.
TABLE 5.1:-- One Touch Caution Flags
5.4.4. Air Clearing Procedure
AIR CLEARING PROCEDURE

1. Engine Power Off
2. Throttle Moved to Mid Range Setting
3. Push the red STOP button to enable air
4. Push the green START button to activate air
5. Repeat as Necessary
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WARNING FLAG
Indication Cause Remedy
LOW START PRESSURE Insufficient air pressure to enable Air supply pressure must be at least 120 psi
engine start. (828 kPa) (100 psi (690 kPa sustained) to start
the engine. 120 ps1 (828 kPa) is ideal and
results in relaible starts (with the proper
sized air line).
FALSE START Engine did not start successfully. Contact the factory for further instructions.
HUNG START Engine isn't accelerating Verify that fuel pressure is approximately
sufficiently to sustain idle RPM. 150 psi (1035 kPa) as indicated on the panel
guage. If the fuel pressure is above or below
this value, contact the factory for adjustment
procedures. If there is no fuel pressure
indication, make sure there are no kinked or
bent fuel lines and that the fuel pump is run-
ning during the start sequence. If the problem
persists, contact the factory for further
instructions. If excessive fuel is dripping
from the engine, follow the air cleaning
procedure (air test function) in this section.
Activate air several times to fully clear all fuel.
OIL PRESSURE Low Oil Pressure Verify that oil pressure is between 10 and 30
psi (70 and 207 kPa) on the panel guage. If the
oil pressure is outside this range, contact the
the factory for adjustment procedures. If there
is no oil pressure indication on the panel
guage, make sure there are no kinked or bent
oil lines and that the oil pump is running
during the start sequence. If the problem
persists, contact the factory for further
instructions.
OVER SPEED The engine rotational speed has The upper throttle setting has likely
exceeded the maximum RPM been changed from factory setting.
limit. Contact the factory for further instructions.
OVER TEMP The maximum Turbine Inlet Follow the air clearing procedure (air test
Temperature (TIT) has been function) in this section. Activate the air
exceeded. several times to fully cool the internal engine
components. Contact the factory for further
instructions. All engine operation must be
discontinued until the cause of the overtemp
can be determined and the condition of the
internal engine components verified.
TABLE 5.2-- One Touch System Warning Flags
TM
SECTION 5 SYSTEMS
5.4.5 Chassis
The TurboGen chassis is purpose built, laser cut for precision and powder coated for long lasting
durability.
5.4.6 Electrical Service
Standard outlet service of 120 VAC, 60 Hz (220 VAC, 50 Hz) is the only electrical service necessary to
operate the TurboGen. Data Acquisition System electrical requirement are served internally. No
additional external electrical service is required. Computer equipment or additional operator provided
sensors, meters or instrumentation will necessarily require their own electrical service as appropriate to
the specific equipment used.
5.4.7 Casters
The TurboGen cabinetry is fitted with lockable caster wheels to facilitate movement of the system for
use and storage.
5.4.8 Opening Viewing Shield

: Because of the configuration of the
Turbine Genset, the Cabinet Viewing
aShield Compartment opens on two
hinges mounted at the exhaust end of
the cabinet. Opening Viewing Shield
should be done with two people.
Step 1: If Viewing Shield compartment

still has shipping hold-down bolt applied, Figure 5.6: Hold Down Bolt Figure 5.7: Lower Prop Rod Hole
please remove it by removing cabinet
side panel and reaching through intake
to allow tools to be used.
Step 2: With two people, tilt view shield

compartment around hinges.
Step 3: Place one end of prop rod into

lower prop rod hole below resistor bank.
Figure 5.8: View Shield Prop Figure 5.9: View Shield Open
Step 4: Positon and insert free end of
prop rod into view shield compartment Rod Hole
hole. Prop rod holds the view shield
open as shown.
TM
SECTION 5 SYSTEMS
5.4.9 Removing View Shield Compartment
The Viewing Shield Compartment can also be removed for better

access to the turbine genset in the event some testing or
maintenance is required.
Step One: Remove hinge pins by depressing spring loaded security

pin and pushing each pin out of the hinge.
Step 2: Two people should grasp the View Shield Compartment and
carefully lift straight up to clear the turbine genset. Then it should
be carefully set aside on a soft material such as a mat or carpet. Figure 5.10: Remove Hinge Pins
Step 3: Secure the Hinge Pins back in the hinge to keep track of
them.
Step 4: To return the View Shield Compartment to operational

status, please reverse the previous steps.
Figure 5.11: Carefully Remove Shield Compartment

5.5 Data Acquisition System
The TurboGen comes equipped with a National InstrumentsTM precision data acquisition system
permitting a full range of system parameter measurement. This system, comprising a suite of sensors,
excitation power sources, signal conditioners, data acquisition hardware and user interfaces software,
when used in conjunction with an appropriate computer, allows actual run-time data to be displayed
and recorded for later analysis. Off the shelf hardware, industry standard software and factory setup
and calibration of the data acquisition system makes data collection a trivial event allowing the
educational emphasis to be placed on system operation and analysis.
Additional information can be obtained from the respective manufacturer’s equipment and software
manuals contained in the three-ring binder included with the TurboGen. In the unlikely event that data
acquisition system software settings or sensor calibration is lost, all factory settings are provided on CD-
ROM for quick data restoration. Additional information regarding default system settings can be found
in subsequent sections of this chapter.
5.5.1 Computer
The TurboGen is typically provided with a Microsoft Windows-based laptop computer for portability and
system security. Final factory sensor settings are saved to this computer as well as a standard user
TM
SECTION 5 SYSTEMS
interface display for initial system familiarization and data collection runs. The computer is equipped
with a writable CD-ROM and Ethernet interface to facilitate run-time data dissemination.
For maximum flexibility, the system is designed to work with any Windows-based computer equipped
with a standard Universal Serial Bus (USB).
5.5.2 DAQ Module
The TurboGen Digital Data Acquisition System utilizes a

National Instruments 6218 USB Data Acquisition
Module. The unit features a 22-bit analog to digital
conversion capability. Multiple voltage channels,
thermocouples, pulse, frequency and digital I/O can be
measured and controlled. This is accomplished through
32 single-ended or 16 differential analog (up to +-10V
full scale) or thermocouple input channels, 16
programmable ranges, 500V optical isolation, 16 digital
I/O lines and four frequency/pulse channels. The
integrated USB connection allows a single cable
interface of up to 16 feet (5 meters) between the
TurboGen and the data acquisition computer. This
distance is easily increased up to 98 feet (30 meters)
through the use of powered USB hubs (serving as data
repeaters). The USB’s high-speed data transfer rate (up
to 250Ks/s) allows for a real-time display of acquired
data, while eliminating the need for buffer memory in
the data acquisition system itself.
Figure 5.12: National Instruments 6218
Unused data channels are available for operator use. USB DAQ Module
With sensors or transducers appropriate to the variables
of interests, interface to the DAQ Module is accomplished through convenient, removable screw-
terminal input connections.
5.5.3 Sensors
Fifteen (15) system parameters are sensor measured with the stock TurboGen configuration. Some data
acquisition channels are utilized in single-ended mode while others are used in differential mode.
The basic sensor package includes pressure, temperature, RPM and flow sensors (calibrated) measuring
parameters common to Brayton Cycle type analysis. The following list details the measured system
parameters and their corresponding physical DAQ Module channels. Table 5.3 provides more detailed
information concerning channel assignments, installed sensor or transducer type and a listing of all open
and available DAQ Module channels. Figure 5.6 shows the location of the temperature and pressure
TM
SECTION 5 SYSTEMS
sensors with their corresponding subscripted location number. Engine and Generator RPM, Fuel Flow
and Generator Output Elements are also shown.
Table 5.3 Sensor Locations-DAQ Module (Page 1 of 2)
TM
SECTION 5 SYSTEMS
Six (6) K-Type thermal couples are used to measure the stock
TurboGen configuration. A small thermal couple is attached
directly to channel Al 16 – Al 24 to provide cold junction
compensation for the DAQ software.
Table 5.3: Sensor Locations-DAQ Module (Page 2 of 2)
TM
SECTION 5 SYSTEMS
Physical Terminal System Sensor Physical Sensor

Channel Number Parameter Type Range Output
PFI 0/P0.0 (in) 1 Open
D GRD 5 Open
PFI 4/P1.0
(out) 6 Open
PFI 5/P1.1
(out) 7 Open
PFI 6/P1.2
(out) 8 Open
PFI 7/P1.4
(out) 9 Open
+5 V 10 Open
D GRD 11 Open
AO 0 12 Open
AO 1 13 Open
AO GRD 14 Open
Al 0 15 P1 - Compressor Inlet + Setra Differential 0 - 25" WC 0.0 - 5.0 Volts
Al 8 16 P1 - Compressor Inlet -
Al 1 17 P2 - Compressor Exit + Setra Model 209 0 - 50 (psig) 0.5 - 5.5 Volts
Al 9 18 P2 - Compressor Exit -
Al 2 19 P3 - Turbine Inlet + Setra Model 209 0 - 50 (psig) 0.5 - 5.5 Volts
Al10 20 P3 - Turbine Inlet -
Al 3 21 P4 - Turbine exit and Generator Inlet + Setra Model 209 0 - 5 (psig) 0.5 - 5.5 Volts
Al 11 22 P4 - Turbine exit and Generator Inlet -
Al SENSE 23
Al 4 24 P5 - Free turbine Exit + Setra Model 209 0 - 5 (psig) 0.5 - 5.5 Volts
Al 12 25 P5 - Free turbine Exit -
Al 5 26 Fuel Flow + Setra Model 209 0 - 200 (psig) 0.5 - 5.5 Volts
Al 13 27 Fuel Flow -
Al GRD 28
0 ≈ 100,000
Al 6 29 Gas Turbine RPM (N1) + Pulse Counting RPM
Al 14 30 Gas Turbine RPM (N1) -
Al 7 31 Free Turbine Generator RPM (n2) + Pulse Counting 0 ≈ 10,000 RPM
Al 15 32 Free Turbine Generator RPM (n2) -
Table 5.4: DAQ Chanel Assignments and Sensor Details

Continued on Next Page
TM
SECTION 5 SYSTEMS

PFI 10/P0.6
(in) 35 Open
PFI 11/P0.7
(in) 36 Open
D GRD 37 Open
PFI 12/P1.4
(out) 38 Open
PFI 13/P1.5
(out) 39 Open
PFI 14/P1.6
(out) 40 Open
PFI 15/P1.7
(out) 41 Open
+5 V 42 Open
D GRD 43 Open
NC 44 Open
NC 45 Open
Al GRD 46 Open
Al 16 47 Cold Junction Compensation + K - type Thermocouple Max 1375°C
Al 24 48 Cold Junction Compensation -
Al 17 49 T1 - Compressor Inlet + K - type Thermocouple Max 1375°C
Al 25 50 T1 - Compressor Inlet -
Al 18 51 T2 - Compressor Exit + K - type Thermocouple Max 1375°C
Al 26 52 T2 - Compressor Exit -
Al 19 53 T3 - Turbine Inlet + K - type Thermocouple Max 1375°C
Al 27 54 T3 - Turbine Inlet -
Al GRD 55 Open
Al 20 56 T4 - Turbine exit and Generator Inlet + K - type Thermocouple Max 1375°C
Al 28 57 T4 - Turbine exit and Generator Inlet -
Al 21 58 T5 - Free turbine Exit + K - type Thermocouple Max 1375°C
Al 29 59 T5 - Free turbine Exit -
Al GRD 60 Open
Al 22 61 Generator Amperage +
Al 30 62 Generator Amperage -
Al 23 63
Al 31 64
Table 5.4 Continued
TM
SECTION 5 SYSTEMS
T1: Compressor Inlet Temperature

Engine/Generator Sensor Locations
T4: Turbine1 Exit
Temperature
ENGINE T3: Turbine1 Inlet T2: Compressor T5: Turbine2 Exit
Turbine2 Inlet
RPM Temperature Exit Temperature Temperature
Temperature
P2: Compressor P4: Turbine1 P5: Turbine Exit
Exit Pressure Exit Pressure Pressure
Turbine2 Inlet
Pressure
P3: Turbine1
Inlet Pressure
P1: Compressor VOLTAGE

Inlet Pressure CURRENT
Fuel Flow Rate
T1: Compressor Inlet POWER
Temperature GEN RPM
Figure 5.13: TurboGen Sensor Locations
TM
SECTION 5 SYSTEMS
5.5.4 Software
The data acquisition system utilizes National Instrument’s LabView software for outstanding
graphical data acquisition. This software provides an easy-to-use yet powerful data acquisition
application that allows inexperienced users to test, display and record data within minutes of
power-up while requiring no programming. The software works seamlessly with the National
Instruments 6218 USB Data Acquisition Module installed in the TurboGen. Individual channel
configuration is accomplished through a spreadsheet type interface. Each channel can be
enabled, configured and labeled independently of all other channels. Sensor output is
converted into physical, engineering terms by applying Scale and Offset values in an mX + b
operation. The software allows the creation of customized real-time displays using built-in
display options including charts, graphs and meters. Each display option can be independently
configured by channel to show instantaneous values, peak hold and trends. All displayed data is
easily recorded for later play-back and follow-on analysis. Post-acquisition software is also
included to facilitate time-domain data viewing of multiple channels. Additional software to
enable real-time data acquisition from within Microsoft Excel is also available.
The LabView Virtual Instrument Environment lends itself to expansion and modification to meet
individual display needs, especially those who are doing advanced research in fuels, controls and
emissions. Since TurboGen does mimic a full-sized Gas Turbine Powered Electrical Generation
Plant, the unit can be configured to simulate full-sized system operation for facility operator
training purposes.
Software comes preloaded with all systems that are ordered with a data acquisition/display
computer. For those that are ordered without a computer, the data acquisition software is
provided. Step by step installation instructions are provided in Appendix B of this document.
TM
SECTION 6 SERVICE AND MAINTENANCE
Section 6
Service and Maintenance
6.1 General Maintenance
The TurboGen Gas Turbine Power System is designed for continuous educational and research use
requiring only a minimal amount of service or maintenance. This section provides information regarding
operator conducted routine service procedures.
The TurboGen Gas Turbine Power System in general and the SR-30 Turbojet Engine in particu-
lar contains no user serviceable parts or components. Under no circumstances should any operator
attempt to disassemble, modify or alter any part or component in any way. When any component
requires service other than that outlined in this section, contact Turbine Technologies, LTD for addi-
tional assistance.
6.1.1 Oil and Fuel Fill
Figure 6.1: Fuel (left) and Oil (right) Fill Location at the Rear of the TurboGenTM.
The combined oil and fuel location is located on the rear of the TurboGen cabinet. Opening the
access door exposes the ports for the two fluids. The fuel port is on the left and the oil port
is on the right. To avoid confusion and the potential to intermix fluids, the oil cap is labeled “OIL."
The two caps are sized differently making it impossible to inadvertently place the cap onto the wrong
tank. The larger fuel tank cap is made of hard plastic and screws into place while the smaller oil tank
cap is made of soft rubber and snaps into place.
Fuel and oil levels should be checked prior to and at the conclusion of each day's operation. Proper
oil level is particularly important as the tank is sized to provide proper engine cooling capacity. Each
TM
tank should be filled to within a 1.0 inch (2.54 cm) of the bottom of the filler neck. This allows enough
remaining space in the tank to accommodate return flow and fluid expansion.
Failure to maintain proper oil level WILL result in damage to the engine.
6.1.2 Oil and Fuel Filter Replacement

TurboGen oil and fuel lines are equipped with standard
industrial-type, full flow filters to remove potentially
damaging contaminants from the operating fluids.
Filter replacement intervals depend largely on the
frequency and duration of usage as well as the fuel
type being used. For a unit that receives light to
moderate usage (5 to 25 hours per year), an annual
filter change is sufficient. Before beginning the filter
change procedure, make sure all parts and equipment
necessary for the job are at hand. The procedure
should be completed as quickly as possible so as to
minimize the potential for introducing contaminants
into the individual fluid systems. During the filter
change, some fluid will leak or spill out of the filter
mounting bosses. This is normal and should be cleaned
up as quickly as possible. Before installing new filters,
each filter is to be “primed" with an amount of
the fluid appropriate to the filter being changed. This
minimizes the introduction of air into the fluid
systems and ensures that fluid is available immediately
when the pumps start. It is recommended Figure 6.2: Typical Fluid Filter Installation
that each filter be removed and replaced in turn. This Oil Filter Shown
prevents placing a primed filter onto the wrong
boss with the result of cross-fluid contamination.
The filters themselves are simply threaded onto the boss. Rotate counter-clockwise to loosen and
remove, clockwise to replace and tighten. To help ensure a tight seal and prevent leakage, the large
rubber o-ring seal at the top of the filter should be lubricated with the same fluid used to prime that
particular filter.
Replace the filters as follows:
1. Obtain replacement filters, an adequate amount of the appropriate fluid for that filter to “prime"
or fill the replacement filter and a suitable container to dispose of the used filter.
2. Disconnect all electrical service to the TurboGen.
3. Remove the TurboGen front panel (aft sloping panel below the operator's panel).
4. Locate the two filters - oil to the left, fuel to the right.
5. Remove filters - the filter will be FULL of the fluid applicable to that filter. Take care not to
TM
spill this fluid into the TurboGen cabinet.
6. Prime each filter with an amount of clean fluid appropriate to the filter being changed. Lubricate
the filter o-ring seal.
7. Replace the filters onto their respective mounting bosses.
8. Clean up any additional fluid that may have spilled into the TurboGen cabinet.
9. With ALL tools and equipment clear of the TurboGen interior, reconnect electrical service.
10. Briefly operate the TurboGen. Verify proper fuel and oil pressure readings per Section 2.0.
11. Disconnect all electrical service to the TurboGen.
12. Inspect both filter locations for leaks. Rectify any and all leaks prior to proceeding.
13. Replace the TurboGen front panel.
The removed filters and the fluid contained within them should be inspected prior to disposal.
The presence of anything unusual such as metal fragments, carbon deposits, water, etc. should be
brought to the attention of the factory prior to further operation.
Providing the required oil reservoir level is maintained and the oil filter is regularly changed, it is
NOT necessary to completely change the oil in the reservoir at any interval. The fuel and oil tanks are
equipped with bottom drains should they need to be flushed out. With proper care and normal
operation, this should not be required.
TM
6.1.3 Cleaning
Keeping the TurboGen clean and free from dirt, fuel and oil accumulation is the best way to maximize
the usefulness and efficiency of the system. Typical household, non-flammable and non-abrasive
cleaners may be used where appropriate. Non-toxic, biodegradable, “green" or “citrus" type
concentrated cleaners are particularly well suited for cleaning the TurboGen where fuel or oil buildup
may occur.
SR-30 Turbojet Engine: An occasional wipe down with a dry cloth is all that is necessary.
Cabinetry: All cabinet surfaces are electrostatically powder coated for maximum surface durability. Mild
soap and water should be sufficient for most cleaning needs.
Viewing Shield: The viewing shield should be cleaned periodically with a household glass cleaner.
Care should be taken to not scratch the clear surfaces.
6.1.4 Condition Inspection

The prudent operator will make a cursory condition check prior to each and every start up, operation
and shutdown cycle of the TurboGen. At regular intervals, particularly after long term storage or after
extended running periods, it is advisable to conduct a more thorough inspection of the entire system
to insure safety and reliability.
The following points provide a minimal checklist for a periodic Condition Inspection:
1. Cleanliness: Keeping the system clean and free from dust, dirt, fuel and oil accumulation will
help in readily identifying problems. A regular cleaning helps the operator become more familiar
with the general arrangement of components and aware when things aren't as they should be.
Pay particular attention to large accumulations of fuel and oil. The presence of very small
amounts of fluid on the underside of the engine are normal, especially at engine startup (there
is a small vent hole on the underside of the engine). Most of these fluids will “burn off" during
engine operation. If significant amounts are present following operation, contact the factory.
2. Security of Fittings: Ensuring all nuts, bolts and other areas where two components are
physically attached are tight and secure will prevent future problems stemming from leakage
or wear. All electrical wires and signal lines within the test cell should also be inspected for
looseness or wear.
3. Proper Operation: Simply monitoring the TurboGen for operation consistent with the manual will
assist in determining if greater problems are imminent. High operating TIT and low operating oil
and fuel pressures are of particular concern. If any value is outside of the limitations in Section 2.0,
the factory should be consulted prior to further operation.
4. General Condition: Always be observant of the TurboGen's general condition. Light damage
such as paint chips, scratches or dents may appear minor, but could be hiding more extensive
damage resulting in poor or improper operation of the TurboGen as a whole.
5. Presence of Foreign Objects: Always be aware of the presence of foreign objects within the
TM
test cell or the potential for foreign objects to enter the test cell. With the large volume of
air required for engine operation, it is very easy for objects to get sucked into the engine inlet.
Considering the rotational speeds of the engine components, even the smallest object will cause
considerable and potentially catastrophic damage to the engine which may result in injury to
those in the vicinity. Pay particular attention to the quality and condition of external ducting.
Exercising common sense is the best action to follow. If something doesn't “look" or “act" right,
there may be a problem. Usage should be delayed until the potential problem can be investigated
and rectified. Always err on the side of caution. This protects the user as well as the machine. The
TurboGen should be afforded the same respect in operation, maintenance and overall care given to
any piece of laboratory grade equipment.
6.1.5 Service Schedule
The design of the TurboGen eliminates all periodic or reoccurring maintenance outside of that
specifically listed in the entirety of Section 6. Engines operated with exotic or unusual fuels may
require more thorough inspections. Consult the factory for more information.
TM
6.2 Troubleshooting
Troubleshooting information is provided to identify and provide solutions to common operator
problems. These problems usually arise from not following the Normal Procedures in their proper
order. Use of the included checklists will eliminate the possibility that a necessary step is overlooked or
executed out of sequence (see Section 4 - Normal Procedures). Review the checklist steps prior
to consulting the Troubleshooting tables.
The OneTouch Autostart System monitors most system parameters and will indicate the fault on
the LCD Display Panel. Review Section 5.3.3 and Tables 5.2 and 5.3 for more information. This
section also provides a method to test the air start solenoid valve and the engine ignition exciter box
and spark igniter. Testing these two items also provides a way to test the START and STOP buttons
and indirectly the OneTouch Autostart System itself.
Problems that relate directly to TurboGen hardware, such as a failed or damaged component, should
be directed to the factory for immediate attention. Readily diagnosed problems arising from loose
or broken electrical wires, loose fluid fittings and no or low air pressure are generally deferred to the
operator for troubleshooting and repair.
Data acquisition hardware and software usage and troubleshooting is covered in greater detail within
the provided users information resources. Refer to National Instruments USB 6218 DAQ System Device
Documentation CD and LabVIEW Virtual Instrument Panel help menu.
No Displays with Power Key On

TROUBLE PROBABLE CAUSE REMEDY
No panel meter / LCD display panel No electrical service to the Verify the TurboGen is plugged
Indication with Keyed Master TurboGen into an outlet that is OK
Switch in the ON Position (no tripped facility breakers). Reset
the circuit breaker on the rear of
the TurboGen by the power cord.
Table 6.1: No Displays with Power Key On
TM
6.3 Factory Service

Turbine Technologies, LTD Factory Service Department is available to perform any service required on
the TurboGen. Factory trained technicians using only approved parts and the latest product information
will clean, service and test your system. Our full parts inventory, production tooling and engineering
department are available to insure that your TurboGen is returned in the same condition as originally
delivered.
Before sending any Turbine Technologies, LTD product to the factory for service, first e-mail Prod-
uct Technical Support (service@turbinetechnologies.com) to verify that there is a true problem
with the system requiring factory service. In many cases, service issues can be handled by the operator
through factory direction, eliminating the downtime associated with a factory return.
If it is determined that factory service is required, a service information form will be sent for
completion by the operator. Please include this service information form with the system when it is
returned to the factory. Any information that may be beneficial in servicing the system should be
included on the service information form.
To facilitate safe transportation of the system to the factory, ship it in its original factory shipping
container. If the original container is no longer available, other crating may be used provided the
system is securely packed. Damage caused by poor or inappropriate crating will not be covered
under warranty. Do not send product documentation, cables, computers, support equipment (beakers,
hoses, funnels, etc.) or any user add-ons not specifically part of the service concern. Under certain
circumstances, only the actual part or system requiring service needs to be returned.
TM
APPENDEX A-OPERATIONAL LIMITS
Operational Limits of TurboGen Throttle/Load Lever System

Because of the high operational speed of gas turbine equipment, TurboGen TM has some
operational limits that must be followed. The generator is driven by a free turbine, propelled
by the jet engine thrust. A high jet thrust setting combined with low system loading can cause
the free turbine to spin faster than the generator can allow. Consequently, operational
limitations have been set to avoid generator over speed.
Condition 1: With Load Lever in pinned position, engine is started and run up to idle RPM.
51,400 210
Engine and Generator RPM based on Throttle/Load

Throttle: Set at Idle
Lever settings shown (approximate numbers shown). Load Lever: Pinned
Condition 2: With Load Lever pinned, slowly advance engine throttle to full throttle, then
return to idle position.
73,000 840
Engine and Generator RPM based on Throttle/Load

Throttle: Moved to full position
Lever settings shown (Approximate numbers shown).
Load Lever: Pinned
.
NOTE: There is some capacity to add additional excitation load by unpinning load lever and
pulling back toward operator. Care must be used, especially when the engine is at idle, as the
generator can be stalled if too much excitation load is applied. Stalling the generator should
be avoided.
TM
APPENDEX A-OPERATIONAL LIMITS
Condition 3: With Throttle at Idle, remove Load Lever from pinned position and slowly advance
it fully forward to reduce excitation current on generator rotor. Slowly return to pinned
position. If Generator RPM starts rapidly climbing to 8,000 RPM (over-speed warning limit),
RPM can be readily reduced by pulling back on Load Lever.
51,400 8,000
Throttle: Idle
Approximate Engine and Generator RPM (Max). Load Lever: Unpinned, moved
Generator RPM over speed warning light will full forward/returned to pin.
come on if 8,000 RPM is reached.
Condition 4: With throttle set at 65,000 RPM (maximum engine speed for Load Lever
operation), unpin Load Lever and slowly advance it forward to reduce excitation current on
generator rotor. Slowly return to pinned position. If Generator RPM starts rapidly climbing to
8,000 RPM (over-speed warning limit), RPM can be reduced by pulling back load lever.
Generator RPM is more sensitive with this higher throttle setting, so care must be taken when
making adjustments to Load Lever. IF GENERATOR RPM is allowed to reach 10,000 RPM, unit
will automatically shut down due to over-speed protection limit being reached.*
65,000 7,999
Approximate Engine and Generator RPM (Max).

Throttle: Set at 65,000 RPM
Generator RPM over speed warning light will stay off
Load Lever: Unpinned and
until 8,000 RPM is reached.
carefully moved forward.
*If system is automatically shut down by over-speed protection, operator must wait 10 minutes
for restart to allow any excess fuel in combustion chamber (from system shutdown), to drain and
clear. Starting with excess fuel in system will cause smoking and can cause engine/component
damage.
TM
APPENDEX B-LOADING DATA ACQUISITION SOFTWARE
TM
TM
TM
TM
APPENDEX C-WARRANTY INFORMATION
TURBOGEN WARRANTY INFORMATION

Two Year Warranty
Turbine Technologies, LTD warrants each TurboGen Gas Turbine Electric Generation System (which
includes the SR-30 Turbojet Engine), of its manufacture, to be free of defects in materials and
workmanship at time of shipment and to remain in serviceable condition for a period of two years (24
calendar months) following date of shipment. In the event of malfunction or failure, purchaser may, at
its expense, return the TurboGen to Turbine Technologies, LTD for inspection. If, in the sole discretion
of Turbine Technologies, LTD, the malfunction or failure resulted from a defect in materials or
workmanship, Turbine Technologies, LTD will repair or replace any defective component or assembly.
Specific Exceptions
Specific exceptions to the above section include:
1. This warranty will become void if any person has made an attempt, regardless of extent, to
repair or modify the TurboGen without express written authorization by Turbine Technologies,
LTD.
2. This warranty does not apply to any damage resulting from operation outside the published
operating limitations found in the Operator's Manual.
3. The TurboGen is not offered as and shall not be construed by purchaser, or any agent thereof, as a
“Consumer Product" (within the common definition or definitions of the United States Federal
Trade Commission).
4. The TurboGen is represented to be, and is offered as, experimental technology, subject to the
Limitations in performance and safety risks inherent to equipment so classified.
5. The Purchaser and agents thereof shall be solely responsible for determining, prior to purchase,
the suitability for any purpose or purposes intended of equipment, services or information offered
or supplied by Turbine Technologies, LTD.
6. This Limited Warranty, as written, constitutes the entire warranty offered or intended, expressed
or implied, and is offered in lieu of all other warranties.
7. The Limited Warranty does not apply to “on-board" hardware or software items that are covered by
other OEM warranties.
TM

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TurboGenTM

Gas Turbine Electrical Generation System

THIS MANUAL MUST BE KEPT WITH THE SYSTEM

Copyright 2012 Turbine Technologies, LTD.

V811 Page i TurboGen Operators Manual

Section 3 – Abnormal Procedures

Section 4 – Normal Procedures

V811 Page ii TurboGen Operators Manual

5.1.8 Vane Guide Ring ………………………………………………………………………………………….….. 36

5.2 TG-2500 Turbine Powered Electrical Generator …………………………………………….………..………. 37

5.3 Gas Turbine Engine Accessories ………………………………………………………………………………..…… 39

5.4 Cabinetry ………………………………………………………….…………………………………………………………… 40

5.5 Data Acquisition System …………………………………………………………………………………………….….. 46

Section 6 – Service and Maintenance

Appendix A –Operational Limits of TurboGen Throttle/Load Lever System ..…….…………..….. 61

V811 Page iv TurboGen Operators Manual

V811 Page v TurboGen Operators Manual

FAILURE TO FOLLOW THE LIMITATIONS AND USAGE AS SET FORTH IN

1.3.1 DIMENSIONS – Gas Turbine Electrical Generation System

1.3.2 Operational Requirements – Gas Turbine Electrical Generation System

1.3.3 OPERATIONAL CONTROLS –TurboGen Operator Panel

1.3.4 DIGITAL and ANALOG OPERATOR DISPLAY: Direct visual indication of

Figure 1.1: System Control/Display Panel

1.3.5 OPERATIONAL and DATA ACQUISITION INSTRUMENTATION

Figure 1.2: Virtual Instrument Display Panel

Note any irregularities immediately

Table 1.1: Shipping Container Inventory List

Figure 1.3: TurboGen As Shipped

1.4 Uncrating and Set-up

2. Remove Top of Crate and Set Aside

3. Carefully Remove Cardboard Sidewalls and Set Aside

5. Remove Cardboard Shelf

1.4.3 HushKit Installation

To install a HushKit, follow these steps:

2.1 SR-30 Turbojet Engine

MAXIMUM RPM ………………………………………………………….….. 106.1%

MAXIMUM TURBINE INLET TEMPERATURE (TIT) ………………………………………………………………….. 870 oC

MAXIMUM EXHAUST GAS TEMPERATURE ……………………………………………………………………………. 720 oC

MINIMUM FUEL PRESSURE …………………………………………………………………………..…… 150 PSI (1034 kPa)

MAXIMUM OIL PRESSURE ……………………………………………………………………………………… 30 PSI (207 kPa)

MINIMUM OIL PRESSURE ………………………………………………………………………………………… 10 PSI (70 kPa)

MAXIMUM AIR PRESSURE ………………………………………………………………………………… 160 PSI (1,103 kPa)

MINIMUM AIR PRESSURE ……………………………………………………………………………………. 100 PSI (690 kPa)

MAXIMUM AMBIENT AIR TEMPERATURE ………………………………………………………………………………. 41 oC

MINIMUM AMBIENT AIR TEMPERATURE..…………………………………………………………………………………. 0 oC

2.2 TG-2000 Generator

AUTOMATIC SAFETY SHUTOFF RPM………………………….…….10,000 RPM

IMPORTANT: See Operational Limitations

3.1 System Shut Off Using Auto Start System

1. RED – Press the RED stop button.

“RED and OFF”

Figure 3.1: System Panel Mounted Start/Stop Buttons

3.2 ENGINE THROTTLE/GENERATOR EXCITATION LOAD LEVER QUADRANT

BEFORE PLANNING TO OPERATE SYSTEM:

4.1 ABBREVIATED NORMAL PROCEDURES

Three separate checklists are provided as follows:

1. Section 4.1.1 Pre-Start – Prepares the TurboGen for operation.

4.1.2 START, OPERATION and SHUTDOWN

AIR CLEARING PROCEDURE

4.1.3 DATA COLLECTION

1. OPEN DAQ SOFTWARE……………..………………………………………….……Click on TurboGen Desktop Icon

Launch from Desktop Icon

Figure 4.1: Abbreviated Data Acquisition Software Controls

4.2 EXPANDED NORMAL PROCEDURES