Chicago Pneumatic CPG 90-120 JD Instruction Manual
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Chicago Pneumatic CPG 90-120 JD Instruction Manual

Chicago Pneumatic CPG 90-120 JD Instruction Manual

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Instruction Manual
for AC Generators
English
CPG 90-120 JD

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Summary of Contents for Chicago Pneumatic CPG 90-120 JD

  • Page 1 Instruction Manual for AC Generators English CPG 90-120 JD...
  • Page 3 CPG 90-120 JD Instruction Manual for AC Generators Instruction manual .................. 5 Circuit diagrams ..................47 Printed matter N° 1310 3012 23 CHICAGO PNEUMATIC - PORTABLE AIR DIVISION 04/2010 www.cp.com...
  • Page 4 The manufacturer does not accept any liability for any damage arising for modifications, addi- tions or conversions made without the manufacturer's approval in writing. Copyright 2010, Chicago Pneumatic. Any unauthorized use or copying of the contents or any part thereof is prohibited.

  • Page 5: Table Of Contents

    While every effort has been made to ensure that the information in this manual is correct, Chicago Pneumatic does not assume responsibility for possible errors. Chicago Pneumatic reserves the right to make changes without prior notice.

  • Page 6: Safety Precautions For Portable Generators

    An operator is trained in all aspects of operating the unit The policy of Chicago Pneumatic is to provide the users mainly applicable to Chicago Pneumatic equipment. with the push-buttons, and is trained to know the safety of their equipment with safe, reliable and efficient aspects.
  • Page 7 General safety precautions Pressure and temperature gauges shall be checked Safety during transport and installation regularly with regard to their accuracy. They shall The owner is responsible for maintaining the unit in To lift a unit, all loose or pivoting parts, e.g. doors and be replaced whenever outside acceptable tolerances.
  • Page 8 Never refill fuel while the unit is running, unless device must be applied and kept in good order. floor is not level or can vary in inclination, consult otherwise stated in the Chicago Pneumatic Chicago Pneumatic. To lift heavy parts, a hoist of ample capacity, tested Instruction Book (AIB).
  • Page 9 - below 70 dB(A): no action needs to be taken, direct an air or gas stream at people. Never use it to 22 Whenever an abnormal condition arises, e.g. - above 70 dB(A): noise-protective devices should clean dirt from your clothes. excessive vibration, noise, odour, etc., switch the be provided for people continuously being circuit breakers to OFF and stop the engine.
  • Page 10 13 Use only lubricating oils and greases recommended by insulating caps. cartridge is used and that its useful service life is not or approved by Chicago Pneumatic or the machine On electrically driven units the main switch shall be surpassed.
  • Page 11 Tool applications safety When connecting an auxiliary battery (AB) in parallel to the unit battery (CB) with booster cables: Apply the proper tool for each job. With the knowledge connect the + pole of AB to the + pole of CB, then of correct tool use and knowing the limitations of tools, connect the - pole of CB to the mass of the unit.

  • Page 12: Leading Particulars

    Leading particulars General description The CPG 90-120 John Deere is an AC generator, built for continuous running at sites where no electricity is available or as stand-by in cases of interruption of the mains. The generator can run in 3 different modes: 60 Hz, 480 V - 3 phase, 60 Hz, 208 V - 3 phase lower voltage and 60 Hz, 240 V - 1 phase. The CPG 90-120 John Deere generator is driven by a water-cooled diesel engine, manufactured by John Deere.

  • Page 13: Bodywork

    Bodywork Indicates that these parts can become Indicates that the alternator should not very hot during operation (e.g. engine, The alternator, the engine, the cooling system, etc. are be cleaned with high pressurised cooler, etc.). Always make sure that enclosed in a sound-insulated bodywork that can be water.

  • Page 14: Drain Plugs And Filler Caps

    A1 ..Qc1002™ display Drain plugs and filler caps Control and indicator panel Qc1002™ F10 ..Fuse The drain holes for the engine oil, the coolant and the General description Qc1002™ control plug for the fuel, are located and labelled on the frame panel The fuse activates when the current from the at the service side.
  • Page 15 Qc1002™ Module Following LEDs are used on the Qc1002™ UP: Is used to scroll through the display information and to adjust parameter value upwards. DOWN: Is used to scroll through the display information and to adjust parameter value downwards. BACK: Is used to leave the Alarm pop-up window, to leave the Parameter list and to leave menu's Power...
  • Page 16 Qc1002™ Menu Overview Controller type and version display LOG list display At Qc1002™, the LCD will show following information: LOG List Qc1002 CAN – in Normal condition (scroll through the v1.00.0 information using UP and DOWN): • Status (eg: preheat, crank, cooldown, extended stop time, …) (pop-up: this display is only This view shows the controller type and the ASW This view shows the alarm memory and gives access...
  • Page 17 Battery Voltage display Fuel level display Qc1002™ Menu Description Status Display (pop-up window) Battery 13.2 V Fuel 00168.1h 00168.1h This view shows the Battery voltage and the running This view shows the Fuel level and the running hours. hours. Voltage - frequency - running hours In case special statuses are entered, a pop-up window Coolant temperature display display...
  • Page 18 – Service Timer 2 reset – Generator Undervoltage: failclass, enable, delay, setpoint – Service Timer 1 reset DIAGNOSTIC – Generator Overvoltage: failclass, enable, delay, These menus are used to reset the service timers. setpoint When a service timer alarm occurs and is acknowledged, the service timer will be reset –...
  • Page 19 This is the described menu flow for changing the unit type: - 19 -...
  • Page 20 Alarm Display (pop-up window) Following general groups of Alarms exist: – Warning: Alarm LED lights up + Alarm pop-up LOW FUEL LEVEL appears on the display + Alarm relay is empowered (if configured) – Trip of GB: ‘Warning’ actions + Generator Contactor opens LOW COOLANT In case an Alarm occurs, a pop-up window will...
  • Page 21 LOG list Remote start operation The unit will keep an event log of the latest 30 events. Installation wirings: SERVICE TIMER Events are: – X25.1 & X25.2 to be wired for the remote start switch. – shutdowns – X25.3 & X25.4 to be wired for the remote –...

  • Page 22: Output Terminal Board

    X4 ..Single phase GFCI outlet socket Q3 ..Circuit breaker for X3 Output terminal board (120V). Socket rated to 20A. Interrupts the power supply to X3 when a The output terminal board is situated below the short-circuit occurs at the load side, or when X5 ..

  • Page 23: Triple Voltage (3V)

    Q1.1 ..Circuit breaker for low voltage, high Triple voltage (3V) Depending on which mode the generator is running current in, circuit breaker Q1.1 or Q1.2 will be operational. The generator can run in three different modes: Interrupts the low voltage power supply Circuit breakers Q1.1 and Q1.2 cannot be switched on –...

  • Page 24: Spillage Free Skid

    Spillage free skid Operating instructions cooling air is not recirculated. If necessary, consult Chicago Pneumatic. A spillage free skid with forklift slots allows the In your own interest, always strictly – Leave enough space for operation, inspection and customer to transport the generator easily with a...
  • Page 25 For safety reasons, it is necessary to ray equipment, audio amplifiers and elevators. provide an isolating switch or circuit Consult Chicago Pneumatic for measures against the breaker in each load circuit. Local The lowest acceptable wire section and the adverse influence of non-linear loads.

  • Page 26: Before Starting

    Before starting Operating Qc1002™ – Switch on circuit breaker Q1.1/Q1.2 . – Put the remote start/stop switch in position start. – With the generator standing level, check the Starting Qc1002™ engine oil level and top up if necessary. The oil –...
  • Page 27 To stop the unit when the Qc1002™ If circuit breakers are activated during operation, module is in position , proceed as switch off the load and stop the generator. Check and, follows: if necessary, decrease the load. – Switch off the load. The generator’s doors may only remain opened for short periods –...

  • Page 28: Maintenance

    1310 3004 46 For the most important subassemblies, Chicago Pneumatic has developed service kits that combine all wear parts. These service kits offer you the benefits of genuine parts, save on administration costs and are offered at reduced price, compared to the loose components. Refer to the parts list for more information on the contents of the service kits.
  • Page 29 Generators in standby application have to be tested on a regular basis. At least once a month the engine should run for Inspection by Chicago Pneumatic Service technician minimum 30 minutes at a high load ( 50% - 70% ) that the engine reaches its operating temperature.

  • Page 30: Engine Maintenance

    Refer to the engine’s operator manual for full Specifications GENOIL maintenance schedule. GENOIL from Chicago Pneumatic is the ONLY oil tested and approved for use in all engines built into Chicago Pneumatic compressors and generators. Extensive laboratory and field endurance tests on Chicago Pneumatic equipment have proven GENOIL to match all lubrication demands in varied conditions.

  • Page 31: Engine Oil Level Check

    GENOIL 15W40 is a Synthetic ultra high manufacturer's directions. performance diesel engine oil with a high viscosity- index. Chicago Pneumatic GENOIL 15W40 is Never mix different coolants and designed to provide excellent lubrication from start- mix the coolant components outside...

  • Page 32: Coolant Check

    GENCOOL EG is the only coolant that has been number Monitoring coolant condition tested and approved by all engine manufacturers currently in use in Chicago Pneumatic compressors 0.175 1626 2255 00 In order to guarantee the lifetime and quality of the and generators.

  • Page 33: Storage Of The Generator

    – Store the generator in a dry, frost-free room which Topping up of coolant is well ventilated. – From the Chicago Pneumatic Instruction book, – Verify if the engine cooling system is in a good determine the amount of GENCOOL EG required –...

  • Page 34: Preparing For Operation After Storage

    Preparing for operation after storage Checks and trouble shooting Checking voltmeter P4 Before operating the generator again, remove the – Put a voltmeter in parallel with voltmeter P4 on Never perform a test run with wrapping, VCI paper and silica gel bags and check the the control panel.

  • Page 35: Alternator Troubleshooting

    Alternator troubleshooting Symptom Possible cause Corrective action Alternator gives 0 Volt Blown fuse. Replace fuse. No residual voltage. Excite the alternator by applying a 12V battery voltage with a 30 W resistor in series on the + and - terminals of the electronic regulator, respecting the polarities.

  • Page 36: Technical Specifications For Cpg 90-120 John Deere

    Technical specifications for CPG 90 John Deere Readings on gauges Gauge Reading Unit Ammeter L1-3 (P1-3) Below max. rating Voltmeter (P4) Depends upon selector switch Settings of switches Switch Function Activates at (US) Activates at (Metric) Engine oil pressure Shut down 7.25 psi 0.5 bar Engine coolant temperature...
  • Page 37 Technical specifications for CPG 90 John Deere Metric Rated PRP power (PRP) 3ph 90 kVA 90 kVA Rated PRP power (PRP)1ph 60 kVA 60 kVA Rated voltage 3ph. line to line 480 V 480 V Rated voltage 3ph. line to line lower voltage 208 V 208 V Rated voltage 1ph.
  • Page 38 Technical specifications for CPG 90 John Deere Metric Design data 4) Standard IEC 34-1 IEC 34-1 Alternator ISO 8528-3 ISO 8528-3 Make NEWAGE NEWAGE Model UCI 224 G1 UCI 224 G1 Rated output, class H temp. rise 90 kVA 90 kVA Rating type acc.
  • Page 39 Technical specifications for CPG 90 John Deere Metric Power circuit Circuit-breaker, 3 phase Number of poles Thermal release It 125A 125 A Magnetic release Im 3.5xIn 3.5xIn Circuit-breaker, 3 phase, lower voltage (208 V) Number of poles Thermal release It 250 A 250 A Magnetic release Im...
  • Page 40 Technical specifications for CPG 120 John Deere Readings on gauges Gauge Reading Unit Ammeter L1-3 (P1-3) Below max. rating Voltmeter (P4) Depends upon selector switch Settings of switches Switch Function Activates at (US) Activates at (Metric) Engine oil pressure Shut down 7.25 psi 0.5 bar Engine coolant temperature...
  • Page 41 Technical specifications for CPG 120 John Deere Metric Rated PRP power (PRP) 3ph 120 kVA 120 kVA Rated PRP power (PRP)1ph 72 kVA 72 kVA Rated voltage 3ph. line to line 480 V 480 V Rated voltage 3ph. line to line lower voltage 208 V 208 V Rated voltage 1ph.
  • Page 42 Technical specifications for CPG 120 John Deere Metric Design data 4) Standard IEC 34-1 IEC 34-1 Alternator ISO 8528-3 ISO 8528-3 Make NEWAGE NEWAGE Model UCI 274 C UCI 274 C Rated output, class H temp. rise 125 kVA 125 kVA Rating type acc.
  • Page 43 Technical specifications for CPG 120 John Deere Metric Power circuit Circuit-breaker, 3 phase Number of poles Thermal release It 150A 150 A Magnetic release Im 3.5xIn 3.5xIn Circuit-breaker, 3 phase, lower voltage (208 V) Number of poles Thermal release It 333 A 333 A Magnetic release Im...
  • Page 44 Notes Reference conditions for engine performance to ISO 3046-1. See derating diagram or consult the factory for other conditions. At reference conditions unless otherwise stated. Rating definition (ISO 8528-1): LTP: Limited Time Power is the maximum electrical power which a generating set is capable of delivering (at variable load), in the event of a utility power failure (for up to 500 hours per year of which a maximum of 300 hours is continuous running).
  • Page 45 4000 When nominal power is lower then 33kVA => 30kVA, the derating factor is different! temperature (°C) derating factor % 1000 1500 2000 2500 3000 3500 4000 For use of generator outside theseconditions, please contact Chicago Pneumatic. - 45 -...

  • Page 46: Conversion List Of Si Units Into British Units

    Conversion list of SI units into British Dataplate units 1 bar 14.504 psi 0.035 oz 1 kg 2.205 lb 1 km/h 0.621 mile/h 1 kW 1.341 hp (UK and US) 0.264 US gal 0.220 lmp gal (UK) 0.035 cu.ft 3.281 ft 1 mm 0.039 in 1 m³/min...
  • Page 47 Circuit diagrams - 47 -...
  • Page 48 1310 3200 01/00 Applicable for CPG 90-120 John Deere - Power circuit - 48 -...
  • Page 49 - 49 -...
  • Page 50 Mark Name F1,,5 Fuse 4A Alternator Aux, relay (lower volt,) Aux, relay (higher volt,) Contactor Automatic Voltage Regulator Optional Equipment Q1,1 Circuit breaker 3pole Q1,2 Circuit breaker 3pole Circuit breaker 1pole Circuit breaker 1pole Circuit breaker 2pole Circuit breaker 2pole Coolant Heater Voltage Adjustnent Potmeter Emergency stop (S2a see Engine Circ.)
  • Page 51 - 51 -...
  • Page 52 1310 3200 00/00 Applicable for CPG 90-120 John Deere - Engine circuit Qc1002 - 52 -...
  • Page 53 - 53 -...
  • Page 54 Mark Grid Name Control Module Fuel Level Sensor Engine controller Fuse Fuse Battery 12V Panel Light e1-f5 Engine connector Starter Relay Starter Motor P1-3 c9-10 A-Meters V-meter Resistor 120 ohm Emergency Stop Button (S2b: see Power Circuit) Voltmeter change-over switch Coolant Level Switch Low Fuel Level Switch Low Fuel Level Switch, Warning...
  • Page 55 - 55 -...
  • Page 56 www.cp.com...

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