SDMO R570U User And Maintenance Manual
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SDMO R570U User And Maintenance Manual

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User and maintenance manual
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R570U
33504081501NE_1_1

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Summary of Contents for SDMO R570U

  • Page 1 User and maintenance manual for generating sets R570U 33504081501NE_1_1...
  • Page 2 CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. If this product contains a gasoline engine WARNING The engine from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm...

  • Page 3: Table Of Contents

    1. Preface ........................................3 1.1. General recommendations ............................... 3 1.2. Pictograms and their meanings ..............................4 1.3. Instructions and safety regulations ............................8 1.3.1 General advice ..................................8 1.3.2 Risks related to exhaust gases and fuels ..........................9 1.3.3 Risks related to toxic products ............................... 10 1.3.4 Risk of fire, burns and explosion ............................
  • Page 4 6.3. Generator set with KERYS control panel ..........................53 6.3.1 Presentation of the KERYS..............................53 6.3.1.1. Operating conditions ..............................53 6.3.1.2. Conformity to legal and regulatory requirements ...................... 54 6.3.2 Description of the KERYS ..............................55 6.3.2.1. Identification of the hardware components ....................... 55 6.3.2.2.

  • Page 5: Preface

    1. Preface 1.1. General recommendations Thank you for choosing an electrical generating set from our company. This manual has been designed to help you operate and maintain your electrical generating set correctly. The information contained in this manual is taken from technical data available at the time of print. In line with our policy of continually improving the quality of our products, this information may be amended without warning.

  • Page 6: Pictograms And Their Meanings

    1.2. Pictograms and their meanings Safety notices are clearly mounted on the equipment to draw the operator's or maintenance technician's attention to the potential dangers and explain the action to be taken in the interest of safety. These notices are reproduced in this publication for ease of identification by the operator.
  • Page 7 WARNING: DANGER This symbol warns of a safety hazard. The presence of this symbol indicates a risk of injury. Observe the safety instructions and precautions for use. Important: Carefully read the instructions supplied with the generating set before using or servicing the equipment.
  • Page 8 WARNING: DANGER  Hot coolant can cause serious burns.  Switch off the engine. Do not remove the filler cap until it is completely cold. Do not open the radiator when it is hot.  DANGER  Rotating parts can cause serious injury. Do not operate the generating set with the doors open.
  • Page 9 WARNING: DANGER A poor earth connection can lead to serious injuries or death.   Always connect the earth terminal of the generating set to an external earth terminal. WARNING Voltage selector This function should be used by qualified persons only. WARNING Adjust the output voltage correctly before connecting a load.

  • Page 10: Instructions And Safety Regulations

    1.3. Instructions and safety regulations THESE SAFETY GUIDELINES ARE IMPORTANT If you do not understand or have any questions about any point in this manual, contact your dealer who will explain it to you or give you a demonstration. A list of risks and precautionary measures to take follows. You should also refer to any local and national regulations that apply in accordance with your own jurisdiction.

  • Page 11: Risks Related To Exhaust Gases And Fuels

    Environment  The operator must take the necessary measures to comply with the aesthetics of the site of use. The whole site must be maintained in a good state of cleanliness.  The premises must be kept clean, and be regularly cleaned so as to avoid accumulation of dangerous materials or pollutants and dust, which could ignite or cause an explosion.

  • Page 12: Risks Related To Toxic Products

    1.3.3 Risks related to toxic products Glycol is a toxic product and dangerous if absorbed. The corrosion inhibitor contains alkali. Avoid all contact with the skin and eyes. Read the Do not swallow it. instructions on the packaging. This substance should not come into contact with the eyes.

  • Page 13: Risks Related To Electrical Networks

    1.3.5 Risks related to electrical networks  The electrical equipment supplied with the generating set complies with standard NF C15.100 (France), or with the standards of the countries in question.  The earth connection must be installed in accordance with the standards in force in each country in question, and with the neutral system sold.

  • Page 14: Identifying Sets

    1.4. Identifying sets Generating sets and their components are identified by means of identification plates. The precise rules for identifying each major component (engine, alternator etc.) are set out in each manufacturer's documents contained in this manual. Examples of identification plates Generating set Engines Figure 1.2 : Examples of identification plates...
  • Page 15 Alternator Cabinet Figure 1.3 : Examples of identification plates 13/297...

  • Page 16: General Description

    2. General description 2.1. Description Overview Control unit Protective grilles External emergency stop Chassis Expansion bottle Circuit breakers Figure 2.1 : General description of the generating set 14/297...
  • Page 17 Battery charge alternator Main circuit breaker Starter batteries Connection termination box Figure 2.1 (continued): General description of the generating set Filling with fuel External fuel supply combined tap (optional) Oil filters Circuit breaker Figure 2.1 (continued): General description of the generating set 15/297...
  • Page 18 Sockets ( voltage 208/120V ) 16/297...

  • Page 19: Technical Specifications

    2.2. Technical specifications RENTAL POWER / R570U Range / Generating set type Weights and Dimensions Dimensions with standard tank Dimensions l x w x h: 5031 mm x 1560 mm x 2695 mm Weight: 4870 kg dry weight 5410 kg in operating configuration...
  • Page 20 Fuel Fuel type Diesel Standard fuel tank 500 L High autonomy fuel tank 1770 L Lubrication Oil capacity with filter 48 L Min. Oil pressure 0.7 bar Nominal oil pressure 6.5 bar Oil consumption (100 % load) 0,11 L/h Oil sump capacity 42 L Type of lubricant Genlub...

  • Page 21: Fuel And Consumables

    2.3. Fuel and consumables All specifications (product features) are given in the motor and alternator maintenance manuals attached to this manual. In addition, we recommend the consumables to be used in the "specifications" section. 2.3.1 Specifications 2.3.1.1. Oil grades Engine Make Type Make...

  • Page 22: Specifications Of Coolants

    2.3.1.2. Specifications of coolants Engine Coolants Make Type Make Type John Deere GenPARTS GENCOOL PC -26°C Mitsubishi MITSUBISHI GenPARTS GENCOOL PC -26°C Volvo GenPARTS GENCOOL PC -26°C GenCOOL PC -26 High-protection coolant, approved by manufacturers. GenCOOL PC -26 is a ready-to-use, highly protective coolant which is produced from an antifreeze recommended by the majority of European manufacturers.

  • Page 23: Installation

    RECOMMENDATIONS FOR USE:  Compatible with the original fluid. It is recommended that the cooling system is completely drained when replacing the fluid.  TRIAL SPECIFICATIONS UNITS SPECIFIED VALUES METHODS kg/m 3 R 15-602-1 Density at 20°C 1,059 +/- 3 NF T 78-103 7.5 to 8.5 NF T 78-101...

  • Page 24: Fork Lift Truck

    3.1.2.2. Fork lift truck  Position the forklift arms under the base frame (except with generating sets fitted with "forklift pockets", in which case position the forklift arms in these pockets), making sure that only its cross-members are resting on the arms. ...
  • Page 25 Figure 3.3: Offset fluid retention container underneath the generating set chassis. Figure 3.4: Offset fluid retention container integrated into the chassis and tank. Generating sets fitted with the offset tank option (DW) above also have a high level indicator in the retention container. In all cases, the retention containers must be regularly checked to ensure they contain no fluid (fuel, oil and coolant, or rainwater or condensation).

  • Page 26: Choice Of Location

    3.3. Choice of location It should be determined on the basis of use. There are no specific rules governing the choice of location, other than proximity to the electric distribution panel and disturbances caused by the noise. However, fuel supply, burnt gas evacuation, and the direction of these gases and the noises emitted should be taken into account.

  • Page 27: Electricity

    3.4. Electricity a) Connections - general information As with low voltage electrical installations, use and maintenance is governed by standard NFC 15.100 (France) or by the standards in the relevant country, based on international standard IEC 60364-6-61. They must also adhere to the regulations in the NFC 15.401 application guide (France) or to the regulations and standards in the relevant country.

  • Page 28: Special Arrangements

    d) Safety guidelines References: NFC 15-100:2002 (France) - IEC: 60364-5-54 In order to protect personnel against electric shocks, this generating set is equipped with a differential residual current protector "factory" set to trigger instantly, with a sensitivity of 30 mA. Any modification to this setting could endanger personnel.

  • Page 29: Trailer

    4. Trailer 4.1. Trailer linkage Before attaching the trailer, check the trailer hook on the tow vehicle; it should fit the trailer ring perfectly. Trying to tow a trailer with a non-matching device (bar, wires, cords, etc.) could lead to serious accidents.

  • Page 30: Operation

    4.3. Operation "On-site" trailer These trailers are not fitted with a main brake, and so cannot be braked in motion; the tyres allow for a maximum speed of 27 km/h. So it is absolutely prohibited to exceed this speed. Nor are these trailers fitted with signalling lights. On-road use is prohibited. "On-road"...

  • Page 31: Implementation For Installation

    4.5. Implementation for installation Operations to be carried out:  Ensure that the ground is strong enough for the assembly not to sink into it.  Unhitch the trailer.  Immobilise the trailer by placing chocks under the wheels.  Fully engage the parking brake (if fitted).
  • Page 32 Figure 4.3: Braking transmission Figure 4.4: Cross bar fitting Figure 4.5: Tandem bearing fitting 30/297...

  • Page 33: Faults And Repairs

    4.7. Faults and repairs Fault observed Origin Solutions Erratic braking of trailer - Faulty shock absorber Replace the shock absorber - Jaws worn Replace the jaws - Jaws not run in Fault will disappear only after running in - Incorrect linkage setting Adjust the setting Braking too weak - Significant friction on the slide...

  • Page 34: Electrical Connection Diagram

    4.8. Electrical connection diagram Figure 4.6 : Electrical connection diagram 4.9. Complete wheels technical information COMPLETE TYRES WHEELS Cross section Radius under Load Pressure Dimensions Indices Diameter (mm) (mm) load (mm) (Kg) (bar) 135 R 13 70 T 145 R 13 75 T 155 R 13 79 T...

  • Page 35: Preparation Before Operating The Set

    5. Preparation before operating the set The inspections referred to in this section enable the electrical generator set to operate. Specific skills are required to carry out these operations. They must only be entrusted to personnel with the necessary skills. Failure to follow these instructions in any way could result in malfunction or very serious accidents.
  • Page 36 • Oil level, check and top up  Check the oil level every day before the first start-up.  Check that it is between the MAX and MIN marks on the oil dipstick.  If necessary, top up the oil through the filler opening, on the left-hand side of the engine.

  • Page 37: Generator Set With Telys Control Panel

    6.2. Generator set with TELYS control panel 6.2.1 Control panel presentation 6.2.1.1. View of the front panel Figure 6.4 : View of the front panel Emergency stop button (AU) for switching off the generating set in the event of a fault which could endanger personnel or damage equipment.
  • Page 38 Figure 6.5 : Description of the LEDs A lit LED indicates: Alarm activated (flashing yellow). Fault found (flashing red). Module on (green, on continuously). Figure 6.6: Close-up of USB ports USB key connection (HOST): file transfer between USB key and TELYS and vice versa. Connection for microcomputer (DEVICE): ...

  • Page 39: Description Of The Screen

    6.2.1.2. Description of the screen The screen is backlit and requires no contrast adjustments. This screen is divided into 4 zones.    SERIAL No.: 08030010000 SOFTWARE: 5.3.5 NOMINAL VOLTAGE: 400V FREQUENCY: 50Hz NOMINAL KW: 320kW EARTH SYSTEM: TNS ...

  • Page 40: Description Of The Pictograms In Zone 1

    6.2.1.3. Description of the pictograms in zone 1 Pictograms in zone 1 Pictograms Display Activation conditions Fixed TELYS in manual mode (MANU) For 5 seconds when switching from AUTO Flashing mode to MANU mode "MANU" Mode Fixed TELYS in automatic mode (AUTO) For 5 seconds when switching from MANU Flashing mode to AUTO mode...

  • Page 41: Description Of The Pictograms In Zone 3

    6.2.1.4. Description of the pictograms in zone 2 Alarm and fault pictograms in zone 2 All the pictograms in this zone are activated when TELYS is initialised. Data displayed Fuel level indicator Alarm / Fault Alarm / Fault low fuel level high fuel level Coolant level / temperature indicator Alarm...
  • Page 42 6.2.1.5. Description of the pictograms in zone 3 Pictograms in zone 3 All the pictograms in these zones are activated when TELYS is initialised. The pictograms below are given as examples. Generating set stopped Screen no. Pictograms Data displayed Fuel Level Indicator Indication of Temperature of High Temperature coolant (HT) (units according to settings menu) Indication of Battery Voltage...
  • Page 43 Generating set started Screen no. Pictograms Data displayed Fuel Level Indicator Alternator composite Voltage Indicator Default screen in Total Active Power Indicator operation Alternator Frequency Indicator U12 Alternator composite Voltage Indicator U23 Alternator composite Voltage Indicator U31 Alternator composite Voltage Indicator Alternator Frequency Indicator V1 Alternator single Voltage Indicator V2 Alternator single Voltage Indicator...
  • Page 44 Screen no. Pictograms Data displayed Single phase Alternator current indicator Two phase Alternator current indicator Three phase Alternator current indicator Neutral Alternator current indicator Total Active Power Indicator Total Reactive Power Indicator Total Effective Power Indicator Total Power Factor Indicator (lagging or leading) Fuel Level Indicator Indication of Battery Voltage Indication of Battery Amps...

  • Page 45: Display Of Messages In Zone 4

    6.2.1.6. Display of messages in zone 4 The display (zone 4), among other things, displays messages relating to the operation of the generating set. The messages are as follows: Initialisation of TELYS Screen no. Screen Data displayed Initialisation of TELYS when the power is switched on and/or when loading a configuration Generating set serial no.
  • Page 46 Generating set stopped Screen no. Screen Data displayed OPERATION MANUAL Operating mode - generating set in Manual Mode ready to Press START start to start Date and time (depending on settings) 24/08/2005 13:12 OPERATION AUTO Operating mode - generating set in Auto Mode ready to WARNING start START-UP POSSIBLE...
  • Page 47 Generating set started Screen no. Screen Data displayed AVAILABLE POWER Operating phase – generating set in operation – stable voltage and frequency Default Available power screen Date and time (depending on settings) 24/08/2005 13:12 AUTOMATIC STOP Operating mode - operation in Auto Mode IN PROGRESS Opening of power supply device (motorised circuit breaker or source changeover switch controlled by TELYS)
  • Page 48 Operating mode changeover (switching from Manual Mode to Auto Mode following auto start demand) Screen no. Screen Data displayed Start Demand AUTO Do you wish to change to Auto Mode? Operating mode - operation in Manual Mode G 12 WARNING AUTOMATIC start demand Immediate start Generating set stop request due to fault or by pressing STOP in Auto Mode...

  • Page 49: Starting

    6.2.2 Starting Check that the generating set circuit breaker has triggered. Danger  Connect the generating set battery  Turn the key switch to the ON position (without forcing it to the ON position), the ON lamp will light up (if the lamp does not light up, check and replace the fuse if necessary) ...

  • Page 50: Switching Off

    6.2.3 Switching off  Open the circuit breaker  manually  by selecting menu 12 "CONTROL LOAD" The following display will disappear (supply stopped)  Press the STOP button  The following screen is displayed and the generating set will stop IN PROGRESS 24/08/2005 13:12...

  • Page 51: Activation Of An Alarm Or Fault

    In conjunction with this LED:  a flashing pictogram appears on the LCD screen  message on graphic display (example) representing the circuit affected by the fault and the FAULT associated indicator, if present (example) FAULT Oil Pressure 25/12/05 15:30 OK=HELP Faults have priority over alarms.

  • Page 52: Activation Of An Alarm And A Fault

    6.2.4.3. Activation of an alarm and a fault The appearance of an alarm and a fault causes:  The yellow and red LEDs to flash  the related screen to be displayed (example below) FAULTS 1/2 FAULT Emergency Stop If several faults are present, the number of faults is displayed at 25/12/05 15:30 the top of the screen.

  • Page 53: Engine Fault Codes Display

    6.2.4.4. Engine fault codes display Certain alarms and engine faults generate specific fault codes. These codes are standardised according to the J1939 and/or J1587 standards, except for MTU engines that have a specific transmission protocol (see appendix, if applicable). Terminology used by the SAE CAN J1939 standard SPN: Suspect Parameter This represents the system or component at fault, for example: SPN 100, Number...

  • Page 54: Horn Reset

    In the event of a fault, the screen will display the following message: FAULT Engine fault code. ALARM Pressing OK will display fault finding information. In addition, appendix D indicate the meaning of the code. The ENGINE GENERAL 110 18 checking and maintenance operations to carry out in order to 25/12/2005 15:30...

  • Page 55: Generator Set With Kerys Control Panel

    6.3. Generator set with KERYS control panel 6.3.1 Presentation of the KERYS The MICS Kerys system consists of a set of electronic modules in which each module performs a specific function.. These modules are interconnected according to a very precise architecture and exchange data to allow the following: the command, control, regulation and protection of one or more generating sets according to multiple configurations.

  • Page 56: Conformity To Legal And Regulatory Requirements

    6.3.1.2. Conformity to legal and regulatory requirements The various components of the system comply with the following standards:  Requirements specific to programmable controllers: (Functional characteristics, immunity, robustness, safety, etc.)  EN 61131-1/2/3 (IEC 1131-2, IEC 664), EN61326,  CSA 22-2, ...

  • Page 57: Description Of The Kerys

    6.3.2 Description of the KERYS 6.3.2.1. Identification of the hardware components KERYS Tactil MMI module MMI Module Module item reference P/N: 31613391001 D346000: manufacturer product reference D346000/B1 B1: module hardware upgrade index 1800: serial number “not related” with a batch number S/N: 1800 (1800 = the 1800 module manufactured since the start)
  • Page 58 Regulation module Regulation module Module item reference 31613391501 A44Z1: manufacturer product reference A44Z1-G G: “main” module hardware upgrade index 04: week of manufacture (week 4) 08: year of manufacture (year 2008) A: “secondary” module hardware upgrade index 0408A519 519: serial number “related” with a batch number (*) (519 = the 519 module manufactured in week 04 of the year 2008)
  • Page 59 Logical inputs and outputs module Logical inputs and outputs module (ESTOR – Binary inputs and outputs) P/N : Module item reference 31613391201 D341000: manufacturer product reference D341000/B1 B1: module hardware upgrade index 0250: serial number “not related” with a batch number S/N: 0250 (0250 = le 250 module manufactured since the start)

  • Page 60: Identification Of The Software Components

    6.3.2.2. Identification of the software components Only the components base module, MMI module, regulation module and protection module have embedded software. ”Software version” is referred to in order to identify a program implemented in one of the components. V: as software version 1.05 : is the revision, which is a combination of 3 digits V1.05c1 c : main revision index...

  • Page 61: Description Of The Man Machine Interface (Ihm/Mmi)

    6.3.3 Description of the Man Machine Interface (IHM/MMI) 6.3.3.1. The Man Machine Interface Signalling control Operating buttons of the keys generating set Navigation keys Alphanumeric keypad Backlit display with touch-sensitive keypad M.M.I. operation LED (flashing) Display The display has the following specifications: ...
  • Page 62 The generating set operational keys Manual mode selection. The illuminated led indicates that the mode is active Selecting stop mode. The illuminated led indicates that the mode is active Automatic mode selection. The illuminated led indicates that the mode is active Test in progress LED.
  • Page 63 The navigation keys It is also possible to navigate through the menus using the keypad. Return to upper level or escape for the dialogue boxes Move up Move to the right Move to the left Move down Confirm function of selected key It is possible to gain direct access to a menu by pressing the numerical key corresponding to its name.

  • Page 64: Navigation In The Screens

    6.3.3.2. Navigation in the screens There are three types:  the home screen,  the navigation screens,  the operation and configuration screens. Home screen This screen is the entry point to the system. It enables the main functions of the navigation to be accessed. 15/10/03 19:10 :00 GS 1...
  • Page 65 The operating and configuration screens These screens bring up the information and commands relating to the active menu. They are divided into three zones:  an upper band common to all types of screens. the central section in which the specific information on the selected menu appears. ...
  • Page 66 Controls Access to the “Alarms and Faults” screen Access to the regional parameters screen Access to the “Alarms and Faults” screen Access to the “Drive” or “TOR variables” screen Access to the regional parameters screen 15/07/09 19:10 :00 GS 1 Welcome Auto Faults...
  • Page 67 Entry of a text Text to be modified or created Name of the modified function Inserts a space to the left of the cursor Title configuration CDE AERO Insert Copy Paste Valid Delete title Delete a character Esc. Deletes the letter shown by the cursor Deletes the entire text Closes the menu without saving the changes Saves the changes and closes the dialogue box...
  • Page 68 Selecting from a list The box heading indicates the parameter which will be assigned from your selection. Arrows for moving the cursor List indicating possible selections Type of fault (6000) Whithout General Alarm Valid Esc. Active selection Arrows only visible if the number of choices does not fit on the screen (enables you to go to the next page on the list Saving changes...

  • Page 69: Configurations

    6.3.4 Configurations 6.3.4.1. Operating principle The operational modes are as follows: Note: Without coupling: the switch is equipped with electrical and mechanical interlocking. With coupling: the switch is not equipped with an electrical and mechanical interlock. 6.3.4.2. Legends Electrically controlled circuit breaker Exchange of information from A to B and from B to A Transmission of information from A to B only 3 PH...

  • Page 70: Configuration In Solo Generating Set

    6.3.4.3. Configuration in solo generating set Without Normal/Emergency inverter (A612) This configuration is designed to provide: The generation of electricity for an installation from an external starting command (dry contact).   The generation of electricity for an installation in forced operation. Regulation module 3PH + N...
  • Page 71 Temporary coupling to the grid (A651) This configuration is designed to provide:  Emergency electricity supply to an installation following a grid loss. Return to the grid is achieved by a temporary coupling with transfer of the generating set load to the grid. ...
  • Page 72 FORCED OPERATION (Kerys in “AUTO” mode) (temporary outward and return coupling) Start of FORCED OPERATION • Generating set start request. • The generating set voltage and speed increase. • When the generating set is stabilised in speed and voltage, synchronisation of the generating set to the grid is requested. •...

  • Page 73: Power Plant Configuration (Several Generating Sets In Parallel)

    6.3.4.4. Power plant configuration (Several generating sets in parallel) Without common part and without Normal/Emergency inverter (A632) This configuration is designed to provide: Emergency electricity supply to an installation following a grid loss (The grid loss is not controlled by Kerys). Return to the grid ...
  • Page 74 Principle of coupling in normal operation Coupling in normal operation enables all the generating sets to be coupled (in voltage and frequency) to a busbar supplied by a generating set designed as master at the output. A number (1 to 15) is assigned to each Kerys. This number serves solely to establish the IP address of each Kerys for communication by Ethernet and loading the programs.
  • Page 75 The second GS thus coupled initiates its power on ramp (adjustable delay) and the distribution of power among the two generating sets takes place. Each generating set will then take 50% of the required power, i.e. 225 kW. When the power required for the application reaches 75% of the power of the two generating sets in operation (GSs at priority 01 and 02), i.e.
  • Page 76 The Kerys PLCs remain in “AUTO” mode The installation is supplied by the generating sets End of FORCED OPERATION • Generating set power units switched on. • Cooling delay. • Generating sets stopped and set to standby. The Kerys PLCs remain in “AUTO” mode The installation is supplied by the grid Manual power plant operation This mode of operation is selected with the “MANU”...
  • Page 77 Principle of coupling in normal operation Coupling in normal operation enables all the generating sets to be coupled (in voltage and frequency) to a busbar supplied by a generating set designed as master at the output. A number (1 to 15) is assigned to each Kerys. This number serves solely to establish the IP address of each Kerys for communication by Ethernet and loading the programs.
  • Page 78 When the power required for the application reaches 75% of the power of the two generating sets in operation (GSs at priority 01 and 02), i.e. 900 kW, the third GS (at priority 03) is then started and is synchronised with GS1 and GS2. Its flow is then closed. The third GS thus coupled initiates its power on ramp (adjustable delay), and the distribution of power among the three generating sets takes place.Each generating set will then take 33.33% of the required power, i.e.
  • Page 79 FORCED OPERATION Start of FORCED OPERATION • Generating set power units switched off. • Generating set start request. • The generating sets increase in speed. • Speed stabilisation delay. • Order of excitation for each generating set at nominal speed; the voltage is then quickly established on the busbar. •...

  • Page 80: Connections Of The Generating Sets

    6.3.5 Connections of the generating sets 6.3.5.1. Recommendations before the connections Disconnect the battery cables before carrying out any work on the generating set. To disconnect the battery disconnect the negative cable (-) first. Warning 6.3.5.2. Connections according to the configurations Ground connection Ground connection box Facility power outlet...

  • Page 81: Earthing System (Standard Only)

    6.3.5.3. Earthing system (Standard only) • The ground of the generating set must be connected to earth. To do so, use a copper cable (Green / Yellow), 25 mm² minimum for a bare cable and 16 mm² for an insulated cable, connected to the earth of the generating set, and to a ground rod of galvanised steel pushed vertically into the ground.
  • Page 82 Earthing system: TNS Neutral connected to grounds Interconnection bar between genset grounds CIRCUIT DISJONCTEUR Current BREAKER transformer Ground Ground rod Earthing system: TT Active differential circuit breaker Interconnection Neutral bar between genset grounds CIRCUIT DISJONCTEUR BREAKER Current transformer Ground Ground rod Type of earthing system: EDF application (On rental generating set only) Active differential circuit breaker Interconnection...
  • Page 83 Power plant Connection of the generating sets to the box Genset 1 Genset 2 Genset x Neutral 1 current transformer per GS Earth junction Ground rod Genset 1 Genset 2 Genset x One ground rod for one generating set power plant Important 81/297...
  • Page 84 Earthing system: IT Isolated neutral CIRCUIT DISJONCTEUR BREAKER Current transformer Ground Ground rod Earthing system: TNS Neutral connected to grounds CIRCUIT DISJONCTEUR BREAKER Current transformer Ground Ground rod Earthing system: TT Neutral CIRCUIT DISJONCTEUR BREAKER Current transformer Ground If equipped Ground rod Junction box 82/297...

  • Page 85: Facility Power Outlet

    Connection of generating sets to client terminal boards Junction box Remove shunts terminals 45-48 and 46-47 Reinsert the shunts of terminals 45 and 46 after having disconnected the current transformer from the junction box. Important 6.3.5.4. Facility power outlet The facility power outlet (if fitted) provides the emergency supply to the generating set from an external electrical source. It enables the different units (preheating, desk, etc.) to be powered without using their batteries.

  • Page 86: Connecting Cable Between The Generating Sets (Power Plant)

    6.3.5.5. Connecting cable between the generating sets (power plant) 2 generating sets Generating set 1 Generating set 2 019x04 019x12 019x04 019x12 3 or more generating sets Generating set 1 Generating set 2 Generating set 3 Generating set x 019x04 019x12 019x04 019x04...

  • Page 87: Power

    6.3.5.6. Power 1. Pass the power cables through the access hatch to the power box of the generating set (AIPR or console, depending on the generating set). 2. Connect the power cables to the busbars. 3. Connect the power cables to the application. GENERATING SET APPLICATION Check that the direction of rotation of the phases between the generating set and the application is the...

  • Page 88: Operation And Setting Menus

    6.3.6 Operation and setting menus 6.3.6.1. Layout of the menus The diagram below shows the layout of the main menus. - 0 - Home - 3 - - 1 - - 2 - - 4 - - 5 - - 6 - Archiving Operation Fault finding...

  • Page 89: Setting Of Regional Parameters

    6.3.6.2. Setting of regional parameters Without an input access code this screen allows:  input of the display language  setting of date and time Navigation reference: 6.1 15/07/09 19 :10 :00 GS 1 Regional parameters Stop Faults Alarms Language Français English Espanol...
  • Page 90 In this case the transmission of a signal to the bus, enabling the different real time clocks to be reset, is defined by the synchronisation time. Pressing the “KOHLER home logo” key alters the appearance of the home screen by replacing the KOHLER logo with the SDMO logo as default. The home screen then looks like this:...

  • Page 91: Information On The Kerys

    Information on the KERYS Indication of the application Navigation reference: 6.2 This screen enables SDMO to identify the project. This information is required for queries sent to SDMO’s customer service, so that the associated file can be consulted. Identification 15/07/09 19 :10 :00...
  • Page 92 Software version Navigation reference: 6.3 The information relating to the software versions installed in the different modules is accessible from this menu. Only the lines corresponding to the installed equipment appear 15/07/09 19 :10 :00 GS 1 Software versions Stop Faults Alarms Module...

  • Page 93: Operating Menus

    6.3.6.4. Operating menus Operation This main screen displays all the main electrical parameters of the generating set. It is the general operating and monitoring screen for the generating set. This screen can also be displayed by pressing the indicator displaying the operation mode of the generating set. The frequency, U23 voltage, active and reactive power indicators, can be displayed in analog or digital form.
  • Page 94 Alarms and faults This menu can also be called directly by pressing the flashing “Alarms ” and “Faults ” keys on the upper band. This screen allows the user to view the list of faults present on the installation. The first two columns give details of the date and time that the fault appeared. The “Status ”...

  • Page 95: Rental Configurations

    6.3.7 Rental configurations 6.3.7.1. Choice of application configuration Solo generating set Without inverter (A612) 1. Turn off the battery isolator switch. 2. Check that the emergency stop buttons are activated. 3. Press the “STOP” button on the KERYS. 4. Turn the changeover switch to position 1: SOLO GENERATING SET WITHOUT GRID COUPLING APPLICATION: A612 2: PRODUCTION POWER PLANT WITHOUT GRID COUPLING...
  • Page 96 5. Select the configuration of the mains detection of the generating set by clicking directly on the touch screen.  For a mains detection by means of the regulation card you must select the configuration “Mains supply detection using the adjustment card” and connect the voltage reference to the terminals Xcbc1 - 1-2-3 . ...
  • Page 97 Back-up to perform GS 1 Rental application Stop Faults Alarms A612: Single Genset without N/E Mains supply detection using the adjustment card Saving in flash … Validation Mains supply detection using an external contact 7. The KERYS saves your new configuration. 8.
  • Page 98 Solo generating set, CRF coupling (A651) 1. Turn off the battery isolator switch. 2. Check that the emergency stop buttons are activated. 3. Press the “STOP” button of the KERYS. 4. Turn the changeover switch to position 1: SOLO GENERATING SET WITHOUT GRID COUPLING APPLICATION: A612 2: PRODUCTION POWER PLANT WITHOUT GRID COUPLING APPLICATION: A632 / A633...
  • Page 99 15/07/09 19:10 :00 GS 1 Rental application Stop Faults Alarms A651: Temporary power grid single Genset coupling Validation Grid CT ratio 20.0 7. Press the “Validation” button on the touch screen. 15/07/09 19:10 :00 GS 1 Rental application Stop Faults Alarms A651: Temporary power grid single Genset coupling...
  • Page 100 9. After return to the KERYS home screen, The configuration will only be taken into account if the following operations are carried out:  Turn on the battery isolator switch.  Wait 5 seconds.  Turn off the battery isolator switch. Important Power plant Without common part and without inverter (A632-A633) 1.
  • Page 101 Back-up to perform GS 1 Rental application Stop Faults Alarms A633: Power plant without shared switching unit without Normal/Emergency Digital Bus Number of gen sets in power plant Genset number Validation 6. Press the generating set number on the touch screen. Back-up to perform GS 1 Rental application...
  • Page 102 Back-up to perform GS 1 Rental application Stop Faults Alarms A633: Power plant without shared switching unit without Normal/Emergency Digital Bus Number of gen sets in power plant Genset number Validation 9. Press the generating set number on the touch screen. Back-up to perform GS 1 Rental application...
  • Page 103 Back-up to perform GS 1 Rental application Stop Faults Alarms A633: Power plant without shared switching unit without Normal/Emergency Digital Bus Number of gen sets in power plant Genset number Validation 12. Press “Validation" on the touch screen. Back-up to perform GS 1 Rental application Stop...

  • Page 104: Use

    14. After returning to the Kerys home screen, The configuration will only be taken into account if the following operations are carried out:  Turn on the battery isolator switch.  Wait 5 seconds.  Turn off the battery isolator switch. Important Operations to be carried out on each generating set of the power plant.
  • Page 105 15/07/09 19:10 :00 GS 1 Welcome Stop Faults Alarms - 0 - Welcome - 1 - Operation - 2 - - 7 - Function keys User adjustments - 3 - - 6 - Synchro. column Alarms & Faults - 4 - - 5 - Central unit measure.
  • Page 106 User parameters 15/07/09 19:10 :00 GS 1 Stop Faults Alarms (1/2) Power return No load test time delay Without Confirmation request (sec) : Power 1 Power loss time delay (sec) : Power return time delay (sec) : Inversion in non-coupl. Whithout In emergency mode Inversion in non-coupl.
  • Page 107 Generating set 15/07/09 19:10 :00 GS 1 Stop Faults Alarms priority Modification Priority GS select. select Return to the previous Valid priorities Display General parameters Thresholds Press the selection arrows on the touch screen to select the priority of the generating set selected. Generating set 15/07/09 19:10 :00...
  • Page 108 Generating set Back-up to perform GS 1 Stop Faults Alarms priority Modification Priority GS select. select Return to the previous Valid priorities Display General parameters Thresholds Press “Save" on the touch screen. Generating set Back-up to perform GS 1 Stop Faults Alarms priority...
  • Page 109 Generating set Back-up to perform GS 1 Stop Faults Alarms priority Modification Priority GS select. select Return to the previous Valid priorities Saving in flash … Display General parameters Thresholds 10. The Kerys saves your new configuration. Generating set 15/07/09 19:10 :00 GS 1 Stop...

  • Page 110: Starting, Tests And Stop

    6.3.8.2. Starting, tests and stop In manual mode Starting Check there are no faults: grey: no fault. red: fault present. grey: no alarm. orange: alarm present. If faults are present, the fault management screen can be accessed by pressing Reset . Refer to the section “Alarms and Faults”...
  • Page 111 The manual start-up phase will begin once key 1 in the test keypad is pressed. The start-up request is maintained until the generating set starts (it is not necessary to keep key 1 pressed). This method may not, under any circumstances, be used to turn the engine over manually.
  • Page 112 Pressing 1 on the test keypad brings up the following window for selecting the test type. 15/07/09 19 : 10 :00 GS 1 Operation Manu Faults Alarms I1(A) 2701 0,9 L Test selected Select the test to be carried out Under load No load Q (kVAr)
  • Page 113 At any time the generating set may be stopped by pressing Stop or by pressing 0 on the test keypad. Pressing Stop may interrupt the power supply, depending on its status when the key is pressed (e.g. isolated grid operation). The generating set will stop after a cooling delay (180 seconds by default).
  • Page 114 In automatic mode Starting Check there are no faults: grey: no fault. red: fault present. grey: no alarm. orange: alarm present. If faults are present, the fault management screen can be accessed by pressing Reset. Refer to the section “Alarms and Faults” in the Operating menus” to eliminate the faults.
  • Page 115 Tests If no faults are present, automatic mode can be activated by pressing Auto. The test starting phase is then initiated after pressing 1 on the test keypad. Pressing 1 on the test keypad brings up the following window for selecting the test type. 15/07/09 19 : 10 :00 GS 1...
  • Page 116 After validation of the test, the orange LED on the test keypad lights up steady. During the start-up phase, and until the alternator voltage and generating set speed stabilise, the green LED underneath the symbol for the generating set flashes and becomes steady at the end of this phase.

  • Page 117: Rental Options

    Switching off The generating set may be stopped at any time by pressing 0 on the test keypad. Pressing Stop may cause an interruption in the power supply depending on its status when the button is pressed (e.g. isolated grid operation). The generating set will stop after the cooling delay (180 seconds by default).
  • Page 118 Air preheating (Optional) Turn the switch to “ON” to initiate preheating of the generating set. AIR PREHEATING In the case of a power plant, the position of the air preheating switches must NECESSARILY be the same on all the switches of the generating sets in the power plant. Important Bi-frequency (Optional) Turn the switch to the desired frequency and voltage.

  • Page 119: Maintenance Schedule

    7. Maintenance schedule 7.1. Reminder of use The maintenance interval frequency and the operations to be carried out are outlined in the maintenance schedule, given as a guideline. N.B. the environment in which the generating set is operating determines this schedule. If the generating set is used in extreme conditions, shorter intervals between maintenance procedures should be observed These maintenance intervals only apply to generating sets running on fuel, oil and coolant which conform to the specifications given in this manual.

  • Page 120: Alternator

    At least every Every 4 000 hours (month) Belt tensioner  Drive belt  Coolant (green)  At least every Every 8 000 hours (month) Coolant VCS (yellow)  7.3. Alternator  After 20 hours in operation, check the tightness of all the mounting bolts, the general condition of the machine and the various electrical connections of the installation.

  • Page 121: Battery

    8. Battery Fit the battery so that it is properly ventilated. Maintenance should only be carried out by qualified personnel. If replacing the batteries, use the same type of batteries. Do not throw the old battery in the fire. Only use insulated tools (the operator should not be wearing a watch, chain or any metal object). Never use sulphuric acid or acid water to top up the electrolyte level.

  • Page 122: Battery Setting Into Service

    8.2. Battery setting into service  Batteries filled with acid have a density of 1.28 g/ml and are charged.  In the case of dry batteries, fill each battery cell with acid up to the maximum level mark or to 15 mm above the plates. Let the battery rest for 20 minutes.

  • Page 123: Load Preconization

    8.4. Load preconization  Highly discharged or sulphated batteries (formation of whitish lead sulphate deposit on the plates, which becomes hard and insoluble to acid; this deposit reduce the active surface of the plates, and increases their internal resistance) can no longer regenerate or be charged in a generating set.

  • Page 124: Faults And Remedies

    8.5. Faults and remedies Fault observed Probable origin Measures or observations The acid heats up when a new battery is - Incorrect composition - Cool filled - Incorrect storage - Charge - Prolonged storage in a damp place - Check the acid density The acid escapes through the filler holes - Battery overflow during filling - Reduce the battery fluid level...

  • Page 125: Appendix

    9. Appendix 9.1. Appendix A – Engine user and maintenance manual 123/297...
  • Page 126 124/297...
  • Page 127 User guide and maintenance manual 7748681 33522064501_3_1 01/12/2011 125/297...
  • Page 128 126/297...
  • Page 129 OPERATOR’S MANUAL Generating set and industrial engines 16 liter (EMS 2) 127/297...
  • Page 130 This Operator’s Manual may be ordered in a diffe- Denne instruktionsbog kan bestilles gratis på et an- rent language free of charge up to 12 months after delivery, det sprog via Internettet i op til 12 måneder efter leveringen. via internet. http://vppneuapps.volvo.com/manual/coupon/ http://vppneuapps.volvo.com/manual/coupon/ Hvis det ikke er muligt at bestille via Internettet, bedes du...
  • Page 131 Content Foreword ...................... 2 Safety Information ..................3 Introduction ....................7 Presentation ....................9 Instruments and Controls ................ 11 Starting ...................... 22 Operation ....................26 Engine Shutdown ..................27 Fault Handling ................... 30 Fault Code Register .................. 36 Maintenance Schedule ................49 Maintenance ....................

  • Page 132: Foreword

    Foreword Volvo Penta engines are used all over the world. They are used in all possible operating conditions. This is not a coincidence. After 100 years as an engine manufacturer the Volvo Penta name has become a symbol of reliability, technical innovation, top of the range performance and long service life.

  • Page 133: Safety Information

    Safety Information Read the Operators Manual through very carefully before you start the engine or do any maintenance or service. It has to do with your safety, an incorrect operation can lead to personal injury and damage to products or property. This chapter describes how safety precaution is presented in the Operators Manual and on the product.
  • Page 134 Safety Information Safety rules for operation and maintenance Daily checks Starting lock Make it a habit to give the engine and engine bay a If the instrument panel does not have a key switch, visual check before starting (before the engine is the engine room must be lockable, to prevent unau- started) and after operation (once the engine has thorized persons from starting the engine.
  • Page 135 Safety Information Care and maintenance Knowledge Before starting The Operators Manual contains instructions for doing Re-install all guards which have been removed during the most common service and maintenance tasks in service work, before re-starting the engine. Make sure a safe and correct manner. Read them carefully that there are no tools or other objects left behind on before starting work.
  • Page 136 Safety Information Electrical System Disconnect the power Batteries Before any work is done on the electrical system, the Batteries contain a highly corrosive electrolyte. Pro- engine must be stopped and the power removed by tect your eyes, skin and clothes during charging and switching off the main switch(es).

  • Page 137: Introduction

    Introduction The Operator's Manual contains the information required for the correct, safe operation and maintenance of your Volvo Penta engine. We recommend therefore that you read the manual carefully and learn to handle the engine and other equipment in a safe manner before starting the engine. The Operator's Manual describes the engine and equipment sold by Volvo Penta.
  • Page 138 Introduction Environmental care Certified engines All of us like to live in a clean, healthy environment, If you own an emission-certified engine used in an where we can breathe clean air, see healthy trees, area where exhaust emissions are regulated by have clean water in lakes and seas, and enjoy sun- law, it is important to be aware of the following: light without fearing for our health.

  • Page 139: Presentation

    Presentation Engines This Operator's Manual contains industrial engines TAD1640GE, TAD1641GE, TAD1642GE, TWD1643GE, TAD1650GE, TAD1651GE, TAD1641VE, TAD1642VE, TAD1643VE and TAD1650VE. TAD1650GE and TAD1651GE have internal EGR (Exhaust Gas Recirculation). These are in-line, directly injected, 6-cylinder industrial diesel engines. All engines are equipped with elec- tronically controlled fuel management (EMS), turbo- charger, charge air cooler, thermostatically controlled cooling systems and electronic speed control.
  • Page 140 Presentation EMS (Engine Management System) EMS (Engine Management System) is an electronic system with CAN communication (Controller Area Network) for diesel engine control. The system has been developed by Volvo Penta and includes fuel control and diagnostic function. Input signals Output signals The control module receives input signals about the Based on the input signals the control module controls...

  • Page 141: Instruments And Controls

    Instruments and Controls DCU (Display Control Unit) The DCU (Diesel Control System) control panel is available as an optional accessory for the EMS (Engine Management System) electronic control sys- tem. The DCU is a digital instrument panel which commu- nicates with the engine control unit. The DCU has sev- eral functions, such as engine control, monitoring, diagnostics, and parameter setting.
  • Page 142 Instruments and Controls Menus There are several sub-menus under each main menu. There is not space for all the menu choices on the dis- play. To scroll through the menus, use the 7 and 9 but- tons on the display. Press the SEL button 8 to make a selection.
  • Page 143 Instruments and Controls Preheat manual activation of pre-heating. When it is activated, the EMS system senses at start-up if pre-heating is needed. For automatic pre-heating, refer to the Setup / Preheat on ignition menu. NOTICE! Must be activated with temperatures below 0°C (32°F).
  • Page 144 Instruments and Controls Setup parameter setting in the engine's control systems. Dif- ferent menus appear under Customer parameter, depending on whether Versatile or Gen set has been selected from Set application. See below. The parameters that can be set/selected (choice is made with the SEL button) are: •...
  • Page 145 Instruments and Controls Customer parameter / Gen set • Primary engine speed - selection of engine rpm, 1500 or 1800 rpm. • Preheat on ignition - activation of automatic pre- heating. The engine control system senses if pre- heating is needed and activates it directly at switch- •...
  • Page 146 Instruments and Controls Display setting settings for the display. Adjustment is made with the 7 and 9 buttons; see DCU panel illustration. • Set contrast (%) - contrast setting. • Set backlight time (sec) - time setting (in seconds) for display backlighting on, lighting is then shut off if the panel is not used.
  • Page 147 Instruments and Controls DU (Display Unit) The DU is an computerized instrument panel which shows engine working values on an LCD screen. In the display it is possible to show multiple windows with dif- ferent information, i. g. engine rpm, coolant tempera- ture, fuel consumption and fault messages.
  • Page 148 Instruments and Controls Engine Rpm and coolant temperature is shown in the upper part of the display. In the lower part it will show trip computer and a fuel level indicator, if these function are installed. Multi In the multi mode, button 2, the information can be shown in four windows,analogue or digital.
  • Page 149 Instruments and Controls Graph The information is shown as graphs. Press button 4 repeatedly to choose what information will be shown. The time interval is set in the Configuration menu. If the connection is broken there will be a straight line in the display.
  • Page 150 Instruments and Controls Alarm Status List of active alarms, refer to Fault Han- dling page 33 Settings - LANGUAGE; setting of what language is to be used in the display. - BLEEP; On/Off, setting if pressing the instrument buttons will be followed by a beep or not. - DISPLAY;...
  • Page 151 Instruments and Controls CIU (Control Interface Unit) The CIU is a "translator" between the control unit (EMS) and the customer's own control panel. The CIU has two serial communication links, one fast and one slow. The fast one is a so-called CAN link. All data related to instruments, indication lamps, connectors and poten- tiometers is controlled by this link.

  • Page 152: Starting

    Starting Make it a habit of giving the engine and engine room a visual check before starting. This will help you to discover quickly if anything abnormal has happened, or is about to happen. Also check that instruments and warning displays show normal values after you have started the engine. WARNING! Never use start spray or similar products as starting aid.
  • Page 153 Starting Starting the Engine EMS (Engine Management System) The pre-heating time is adjusted to suit the engine temperature, and can last for up to 50 seconds both before and after starting. The starter motor connection time is maximized to 20 seconds.
  • Page 154 Starting Starting in Extreme Cold Certain preparations must be made to facilitate engine starting, and in some cases to make starting possible at all: • Use a winter grade fuel (of a well-known make) which has been approved for the relevant tempera- ture.
  • Page 155 Starting Starting Using Auxiliary Batteries WARNING! Explosion hazard. Batteries contain and give off an explosive gas which is highly flammable and explosive. A short circuit, open flame or spark could cause a vio- lent explosion. Ventilate well. 1 Check that the auxiliary batteries are connected (series or parallel) so that the rated voltage corre- sponds to the engine system voltage.

  • Page 156: Operation

    Operation Correct operating technique is very important for both fuel economy and engine life. Always let the engine warm up to normal operating temperature before operating at full power. Avoid sudden throttle openings and operation at high engine rpm. Reading the Instruments Check all instruments directly after starting, and then regularly during operation.

  • Page 157: Engine Shutdown

    Engine Shutdown During longer breaks in operation, the engine must be warmed up at least once every two weeks. This prevents corrosion in the engine. If you expect the engine to remain unused for two months or more, it must be laid up: Refer to the chapter Storage page 78.
  • Page 158 Engine Shutdown Extra Stop For location of the extra stop, please refer to Location of Sensors page 55. WARNING! Working with or going close to a running engine is a safety risk. Watch out for rotating components and hot surfaces. 7748681 12-2011 156/297...
  • Page 159 157/297...
  • Page 160 Fault Handling Fault Tracing A number of symptoms and possible causes of engine malfunctions are described in the table below. Always contact your Volvo Penta dealer if any problems occur which you can not solve by yourself. IMPORTANT! Read through the safety advice for care and mainte- nance work in the chapter Safety precautions for boat operation before you start work.

  • Page 161: Fault Handling

    Fault Handling 1 Discharged batteries 2 Poor contact/open circuit in electrical wiring 3 Main switch turned off 4 Main fuse faulty 5 Faulty ignition lock 6 Faulty main relay 7 Faulty starter motor/-solenoid 8 No fuel: – fuel cocks closed –...
  • Page 162 Fault Handling Diagnostic Function The diagnostic function monitors and controls the engine. The diagnostic function has the following tasks: • detecting and locating disturbances • reporting detection of disturbances providing guidance when fault tracing • A fault message in the form of a fault code is always generated when a disturbance is the detected by the diagnostic function.
  • Page 163 Fault Handling If the diagnostics button is pressed after the fault has been rectified and the fault codes have been erased, code 1.1 “No fault” will be displayed. DU (Display Unit) 1 When the system detects a fault, a pop-up is shown on the display.
  • Page 164 Fault Handling Display Control unit (DCU) 1 When a fault is detected the following text is dis- played: !! ENGINE WARNING !! alternating with Press SEL for information. 2 Reduce engine speed to idle or shut down the engine. 3 Press the SEL button to get to the fault list. The fault list shows: –...
  • Page 165 Fault Handling Erasing fault codes The memory of the diagnostic function is reset when the power to the engine is disconnected. When the power is switched on again the diagnostic function will check if there are any malfunctions in the system.

  • Page 166: Fault Code Register

    Fault Code Register No fault (Code 1.1) Cause Reaction Remedy There are no active faults. Preheating Relay (Code 5.4, PID 45/SPN 626) Cause Reaction Remedy • Short circuit to positive (+) or • Preheating can not be acti- • Check that the relay input earth (ground) (–).
  • Page 167 Fault Code Register Oil Level Sensor (Code 5.9, PID/SPN 98) Cause Reaction Remedy • Shorted to plus (+) or minus • None • Check that the cable harness to the oil level sensor has not been damaged • Break • Check the oil level sensor function Oil Pressure Sensor (Code 3.1, PID/SPN 100)
  • Page 168 Fault Code Register Boost Pressure Sensor (Code 3.4, PID/SPN 102/106) Cause Reaction Remedy • Short circuit to positive (+) or • Engine smokes more than • Check that the boost pressure earth (ground) (–) normally during acceleration/ sensor connector is correctly load increase installed •...
  • Page 169 Fault Code Register Coolant Temperature Sensor (Code 3.3, PID/SPN 110) Cause Reaction Remedy • Short circuit to positive (+) or • Preheating is also activated • Check that the coolant tem- earth (ground) (–) when the engine is hot perature sensor connector is correctly installed •...
  • Page 170 Fault Code Register Crankcase Ventilation Pressure Sensor (Code 7.8, PID/SPN 153) Cause Reaction Remedy • Shorted to plus (+) or minus • None • Check that the crankcase ventilation pressure sensor contact is correctly installed • Break • Check that the cable harness to the crankcase ventilation pressure sensor has not been damaged...
  • Page 171 Fault Code Register TWD1643GE Exhaust Temperature (Code 1.9, PID 173/SPN 1184) Cause Reaction Remedy • Exhaust temperature to high • Warning lamp lights up • Insufficient air supply • Engine is shutdown • Low coolant level • Air in the coolant system •...
  • Page 172 Fault Code Register Engine Speed (Code 2.6, PID/SPN 190) Cause Reaction Remedy • Engine speed too high • None • After the engine has stopped, look for the reason for the high speed Starter Input CIU (Code 5.2, PPID 4/SPN 520194) Cause Reaction Remedy...
  • Page 173 Fault Code Register Piston Cooling Pressure Sensor (Code 6.8, PPID 8/SPN 520192) Cause Reaction Remedy • Shorted to plus (+) or minus • None • Check that the piston cooling pressure sensor contact is correctly installed • Break • Check that the cable harness to the piston cooling pressure sensor has not been dam- aged...
  • Page 174 Fault Code Register Injector, Cylinder #2 (Code 7.2, SID 2/SPN 652) Cause Reaction Remedy • Electrical fault • Engine runs on 5 cylinders • Check that the injector cables are not damaged • Faulty compression or injec- • Abnormal sound •...
  • Page 175 Fault Code Register Injector, Cylinder #6 (Code 7.6, SID 6/SPN 656) Cause Reaction Remedy • Electrical fault • Engine runs on 5 cylinders • Check that the injector cables are not damaged • Faulty compression or injec- • Abnormal sound •...
  • Page 176 Fault Code Register TAD1650VE, TWD1643GE Preheating Sensor (Code 8.6, SID 70/SPN 729) Cause Reaction Remedy • Fault in cable harness • Preheating can not be acti- • Check the cable harness vated • Fault in preheating relay • Check the preheating relay Data Link (CAN), CIU (Code 6.4, SID 231/SPN 639) Cause Reaction...
  • Page 177 Fault Code Register Power Supply Sensor (Code 9.3, SID 232/SPN 620) Cause Reaction Remedy • Shortcut • Faulty values in oil pressure • Check that the cable harness and boost pressure sensors to oil pressure and boost • Fault in sensor pressure sensor has not been •...
  • Page 178 Fault Code Register TAD1650VE, TWD1643GE Fan actuator (SID 33/SPN 975) Cause Reaction Remedy • Short circuit to positive (+) or • Warning lamp lights up • Check that the fan actuator is negative (-) properly mounted • Open circuit • Check that the wiring to the fan actuator is not damaged •...

  • Page 179: Maintenance Schedule

    Maintenance Schedule Your Volvo Penta engine and its equipment are designed for high reliability and long life. It is built so as to have minimal environmental impact. If given preventive maintenance, according to the maintenance schedule, and if Volvo Penta original spares are used, these properties are retained and unnecessary malfunctions can be avoided.
  • Page 180 Maintenance Schedule Every 500 hours At least every (month) Fuel Tank (sludge trap), Drain ● Inspection with VODIA (Diagnostic Tool) ● Fuel pre-filter, draining condensed water ● Air Filter Inserts (Indicator), Engine ● Radiator ● Drive Belts ● Batteries, electrolyte level ●...

  • Page 181: Maintenance

    Maintenance This chapter describes the most common maintenance items, see Service program for service intervals. NOTICE! Service points which are not described here must be performed by authorized Volvo Penta workshop. CAUTION! Read the chapter on Maintenance before starting work. It contains instructions on how to carry out maintenance and service operations in a safe and correct manner.
  • Page 182 Maintenance Orientation TAD1640GE, TAD1641GE, TAD1641VE, TAD1642GE, TAD1642VE, TAD1650GE, TAD1651GE 1 AC generator 2 Control unit EMS 2 3 Air Filter 4 Oil dipstick 5 Fuel filter, with fuel pressure monitor 6 Fuel prefilter with water monitor 7 Expansion tank 8 Charge air cooler (TAD) 9 Starter motor 10 Oil Filter 7748681 12-2011...
  • Page 183 Maintenance TWD1643GE 1 Control unit, EMS 2 Charge air cooler, HP-turbo 3 Oil filler 4 Oil dipstick 5 Fuel filter with fuel pressure monitor 6 Fuel pre-filter with water monitor 7 Air filter 8 HP-turbo 9 LP-turbo 10 Expansion tank 11 Starter motor, located behind charge air cooler 12 Charge air cooler, LP-turbo 13 Oil filter...
  • Page 184 Maintenance TAD1650VE 1 Control unit, EMS 2 Oil filler 3 Oil dipstick 4 Fuel filter, to be installed separately 5 Fuel pre-filter with water monitor, to be installed separately 6 Starter motor 7748681 12-2011 182/297...
  • Page 185 Maintenance Location of Sensors TAD1640GE, TAD1641GE, TAD1641VE, TAD1642GE, TAD1642VE, TAD1643VE, TAD1650GE, TAD1651GE 1 Coolant level sensor, in expansion tank 8 Water in fuel sensor 2 Charge air pressure and temperature sensor 9 Oil level and temperature sensor 3 Air filter indicator 10 Fuel pressure sensor 4 Flywheel position and engine speed sensor 11 Crankhouse pressure sensor...
  • Page 186 Maintenance Location of Sensors TWD1643GE P0002059 1 Coolant level sensor, in expansion tank 9 Oil level and temperature sensor 2 Charge air pressure and temperature 10 Crankhouse pressure sensor sensor 3 Oil pressure sensor 11 Coolant temperature sensor 4 Airfilter indicator 12 Exhaust temperature sensor 5 Aux stop 13 Piston cooling pressure sensor...
  • Page 187 Maintenance Location of Sensors TAD1650VE 1 Crankhouse pressure sensor 7 Oil level and temperature sensor 2 Charge air pressure and temperature sensor 8 Water in fuel sensor 3 Flywheel position and engine speed sensor 9 Fuel pressure sensor 4 Fuse 10 Coolant temperature sensor 5 Aux stop 11 Piston cooling pressure sensor...
  • Page 188 Maintenance Engine, General General inspection Make it a habit to give the engine and engine bay a visual inspection before starting the engine and after operation once the engine has stopped. This will help you to discover quickly if anything abnormal has hap- pened, or is about to happen.
  • Page 189 Maintenance Charge Air Pipe, Leakage Check Inspect the condition of the charge air hoses, hose unions and clamp condition for cracks and other dam- age. Change as necessary. IMPORTANT! Clamps must be tightened using a torque wrench to 9 ±2 Nm (6.6 ±1.5 lbf.ft.). P0002083 7748681 12-2011 187/297...
  • Page 190 Maintenance Drive Belt and Alternator Belt, Inspection Inspections must be carried out after operations, while the belts are hot. You should be able to depress the alternator belt and the drive belt about 3-4 mm between the pulleys. The alternator belts and drive belts have automatic belt tensioners and do not need to be adjusted.
  • Page 191 Maintenance Drive Belt, Change 1 Disconnect the main switch(es) and check that the engine is not connected to system voltage. 2 Remove the fan guard and fan ring round the cool- ing fan. 3 Remove the belt guard. 4 Insert a 1/2” square wrench in the belt tensioner (1). Lift the wrench and remove the drive belt.
  • Page 192 Maintenance Lubrication System Oil change intervalls may vary according to the lubri- cation oil grade and fuel sulfur content. Refer to Tech- nical data, Lubrication system. NOTICE! Oil change intervals must never exceed a period of 12 months. If longer oil change intervals than those given in Tech- nical data are required, the condition of the oil must be checked by the oil manufacturer via regular oil tests.
  • Page 193 Maintenance Engine Oil, Change WARNING! Hot oil and hot surfaces can cause burns. Oil changes must be done when the engine is warm. 1 Connect the drain hose to the oil drain pump and check that no leakage can occur. 2 Pump the oil out (or remove the bottom drain plug and drain the oil).
  • Page 194 Maintenance Fuel System WARNING! Fire hazard. When carrying out work on the fuel system make sure the engine is cold. A fuel spill onto a hot surface or an electrical component can cause a fire. Store fuel soaked rags so that they can not cause fire. Only use the grades of fuel recommended in the fuel specification below, please refer to Technical Data page 83.
  • Page 195 Maintenance Fuel Pre-filter, Change 1 Undo the cable from the water trap sensor. 2 Remove the water trap filter from the filter housing. Collect any spilled fuel in a container. 3 Remove the lower part of the water trap from the filter.
  • Page 196 Maintenance Cooling System The engine's internal cooling system makes sure the engine works at the right temperature. It is a closed system that must always be filled with a mixture of concentrated coolant and water in order to protect the engine against internal corrosion, cavitation and bursts due to freezing.
  • Page 197 Maintenance Ready Mixed Ready mixed coolant contains 40% Volvo Penta Cool- ant / Volvo Penta Coolant VCS and 60% water. This mixture protects the engine against internal corrosion, cavitation and bursts due to freezing down to –28°C (– 18 F). Coolant, Mixing The concentrated coolant must be mixed with pure water (distilled or de-ionized water) according to spec-...
  • Page 198 Maintenance Coolant Level, Checking and Topping Up WARNING! Do not open the coolant filler cap when the engine is warm, except in emergencies, this could cause serious personal injury. Steam or hot fluid could spray out. IMPORTANT! Filling of coolant must be performed with the engine stopped.
  • Page 199 Maintenance Filling a completely empty system NOTICE! Mix the correct amount of coolant in advance, to ensure that the cooling system is com- pletely filled. Refer to Technical Data page 84 for the correct coolant volume. NOTICE! Do not start the engine until the system is purged and completely filled.
  • Page 200 Maintenance Coolant, Draining WARNING! Do not open the coolant filler cap when the engine is warm, except in emergencies, this could cause serious personal injury. Steam or hot fluid could spray out. IMPORTANT! On engines which are to be put in storage, the engine cooling system should not be drained.
  • Page 201 Maintenance Coolant Filter, Change NOTICE! Only applies to engines using Volvo Penta Coolant (green). Engines using Volvo Penta Coolant VCS are not fitted with coolant filters. 1 Turn the tap (1) 90° to stop the flow through the Open Closed coolant filter.
  • Page 202 Maintenance 5 Drain the coolant after 1-2 days of operation. Remove the filler cap and possibly the lower radia- tor hose to increase the speed of emptying. To prevent suspended material from settling back in the system, emptying should be done rapidly, within the space of 10 minutes, when the engine has not been standing still for a long time.
  • Page 203 Maintenance Cooling air filter WARNING! Stop the engine before doing any maintenance work. A newly-installed cooling air filter reduces cooling per- formance by 4 %. Installation 1 Slide one half of the filter over the fan cover (as in fig.1). 2 Turn the half filter until it is able to hang loosely on the fan cover (see fig.
  • Page 204 Maintenance Electrical System The engine is equipped with a 2-pole electrical system and an alternator. System voltage is 12V or 24V. WARNING! Always stop the engine and break the current using the main switches before working on the engine. Main switch IMPORTANT! Never disconnect the current with the main switches when the engine is running, the alternator and elec-...
  • Page 205 Maintenance Battery, Maintenance WARNING! Risk of fire and explosion. Never allow an open flame or electric sparks near the battery or batteries. WARNING! P0002107 Never confuse the positive and negative poles on the batteries. Risk of arcing and explosion. WARNING! The battery electrolyte contains extremely corrosive sulfuric acid.
  • Page 206 Maintenance Filling The electrolyte level should be 5–10 mm (0.2– 0.4”) above the cell plates in the battery. Top up with distilled water as required. After filling, the battery should be charged for at least 30 minutes by running the engine at idle. Some maintenance-free batteries have special instructions, which must be followed.
  • Page 207 Maintenance • Charge batteries if they have become discharged. During charging, unscrew the cell plugs but leave them in the plug holes. Ventilate well, especially if the batteries are charged in an enclosed space. • If the engine is not used for a longer period of time, the batteries should be fully charged, then possibly trickle charged (please refer to the battery manu- facturer’s recommendations).

  • Page 208: Storage

    Storage The engine and other equipment must be laid up to prevent damage if they are not used for two months or more. It is important that this is done in the correct manner, and nothing is forgotten. For this reason, we have compiled a check list of the most important points.
  • Page 209 Storage Bringing out of storage • Remove any covers from the engine, air filter • Close the drain taps and install any drainplugs. and exhaust pipe. • Check the coolant level. Top up as necessary. • Put the correct grade of oil into the engine, if •...

  • Page 210: Technical Data

    Technical Data Engines Type designation TAD1640GE TAD1641GE TAD1642GE TWD1643GE Power, prime/stand-by Refer to the sales literature Torque, Prime/Standby Refer to the sales literature No. of cylinders Bore, mm (inch) 144 (5.67) 144 (5.67) 144 (5.67) 144 (5.67) Stroke, mm (inch) 165 (6.50) 165 (6.50) 165 (6.50)
  • Page 211 Technical Data Type designation TAD1641VE TAD1642VE TAD1650VE TAD1643VE Power, prime/stand-by Refer to the sales literature Torque, Prime/Standby Refer to the sales literature No. of cylinders Bore mm (inch) 144 (5.67) 144 (5.67) 144 (5.67) Stroke mm (inch) 165 (6.50) 165 (6.50) 165 (6.50) 16,12 (983.9) 16,12 (983.9)
  • Page 212 Technical Data Lubrication System Change volume, including filter change 48 liter (12.68 US gal) TAD1650VE 53 liter (14 US gal) Oil pressure, hot engine at operating speed 300-650 kPa (44–94 psi) TAD1650VE 400–650 kPa (58–94 psi) Oil filter Full flow filter By-pass filter Lube oil pump Type...
  • Page 213 Technical Data Fuel System Feed pump Feed pressure at 600 rpm min 100 kPa (14.5 psi) Feed pressure at 1200 rpm min 300 kPa (43,5 psi) Feed pressure at full load min 300 kPa (43,5 psi) Bypass valve Opening pressure 400-550 kPa (58–80 psi) Fuel specification The fuel must comply with national and international standards for commercially supplied fuels, such as:...
  • Page 214 Technical Data Cooling System Type Pressurized, sealed Pressure cap, max. opening pressure 75 kPa (10.88 PSI) Coolant quantity (engine): 33 liter (8.72 US gallon) Coolant quantity (engine, radiator and hoses): TAD1640–42GE, TAD1641–43VE, TAD1650VE, 60 liter (15.85 US gallon) TAD1650–51GE TWD1643GE 95 liter (25.1 US gallon) Thermostat, quantity 1 pc.
  • Page 215 Technical Data Electrical System System voltage Alternator voltage/max. current 28V/80A power app. 2200W Alternative generating equipment (optional) voltage/max. current 28V/110A power app. 2800W Battery capacity 2 pcs. series connected 12 V, max. 220 Ah Battery electrolyte density at +25°C ° fully charged battery 1,28 g/cm (1,24 g/cm...
  • Page 216 Technical Data Identification Numbers Chassis and serial number A Engine designation B Engine power, net, (without fan) C Max. engine speed D Main software E Dataset 1 F Dataset 2 P0002052 G Product number 1 Engine designation 2 Serial number 3 Specification number 7748681 12-2011 214/297...
  • Page 217 Declaration for the installation of partially-completed machinery in accordance with Machinery Directive 2006/42/EC Engine Manufacturer: AB Volvo Penta Gropegårdsgatan SE 405 08 Göteborg Sweden Description of engine: 4-cycle diesel engine Engine types covered by this declaration: TAD1660VE TAD1640GE TWD1643GE TAD1641VE TAD1641GE TWD1663GE TAD1642VE...
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  • Page 219: Alphabetical Index

    Alphabetical index After Engine Shutdown..........27 Reading the Instruments.......... 26 Air Filter, Check and Change........58 Alarms..............26 Service program............49 Alternator Belt, Change..........60 Starting in Extreme Cold.......... 24 Starting the Engine........... 23 Battery, Charging............. 76 Starting Using Auxiliary Batteries......25 Battery, Maintenance..........
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  • Page 221 © 2011 AB VOLVO PENTA Volvo reserves the right to make changes Printed on environmentally friendly paper 219/297...
  • Page 222 220/297...

  • Page 223: Appendix B - Alternator User And Maintenance Manual

    9.2. Appendix B - Alternator user and maintenance manual 221/297...
  • Page 224 222/297...
  • Page 225 User guide and maintenance manual & & 3742 g 33522060501_10_1 01/03/2011 223/297...
  • Page 226 224/297...
  • Page 227 3742 en - 2011.03 / g LSA 47.2 - 4 POLES ALTERNATORS Installation and maintenance 225/297...
  • Page 228 Installation and maintenance LEROY-SOMER 3742 en - 2011.03/ g LSA 47.2 - 4 POLES ALTERNATORS This manual concerns the alternator which you have just purchased. We wish to draw your attention to the contents of this maintenance manual. SAFETY MEASURES WARNING SYMBOLS Before using your machine for the first time, We wish to draw your attention to the...
  • Page 229 Installation and maintenance LEROY-SOMER 3742 en - 2011.03/ g LSA 47.2 - 4 POLES ALTERNATORS CONTENTS 1 - RECEIPT ..........................4 1.1 - Standards and safety measures ...................4 1.2 - Inspection ........................4 1.3 - Identification ......................... 4 1.4 - Storage ........................4 1.5 - Applications ........................

  • Page 230: Receipt

    Installation and maintenance LEROY-SOMER 3742 en - 2011.03/ g LSA 47.2 - 4 POLES ALTERNATORS 1 - RECEIPT • C : excitation system (C : AREP / J : SHUNT or PMG) 1.1 - Standards and safety • 6/4 : winding number / number of poles. measures 1.3.1 - Nameplate alternators...

  • Page 231: Technical Characteristics

    Installation and maintenance LEROY-SOMER 3742 en - 2011.03/ g LSA 47.2 - 4 POLES ALTERNATORS 2 - TECHNICAL CHARACTERISTICS 2.2 - Mechanical characteristics - Steel frame 1.1 - Electrical characteristics - Cast iron end shields The LSA 47.2 alternator is a machine - Protected ball bearings, greased for life without sliprings or revolving armature - Mounting arrangements:...

  • Page 232: Installation

    Installation and maintenance LEROY-SOMER 3742 en - 2011.03/ g LSA 47.2 - 4 POLES ALTERNATORS 3 - INSTALLATION 3.1.2 - Coupling Personnel undertaking various 3.1.2.1 - Single-bearing alternator operations indicated in this section must Before coupling the machines, check that wear personal protective equipment they are compatible by: appropriate for mechanical and electri-...

  • Page 233: Terminal Connection Diagrams

    Installation and maintenance LEROY-SOMER 3742 en - 2011.03/ g LSA 47.2 - 4 POLES ALTERNATORS 3.3.1 - Terminal connection: 12 wire There are 2 possible methods for restoring the above minimum values. The connection accessories are detailed in a) Dry out the machine for 24 hours in a section 5.3.3.
  • Page 234 Installation and maintenance LEROY-SOMER 3742 en - 2011.03/ g LSA 47.2 - 4 POLES ALTERNATORS Connection codes Voltage L.L Factory connection 50 Hz 60 Hz L1(U) Winding 190 - 208 190 - 240 3-phase L3(W) L2(V) 190 - 208 L1(U) R 250 voltage sensing: 0 =>...
  • Page 235 Installation and maintenance LEROY-SOMER 3742 en - 2011.03/ g LSA 47.2 - 4 POLES ALTERNATORS 3.3.2 - Terminal connection: 6 wire (not possible with the R 250) Connection codes Voltage L.L Factory connection 50 Hz 60 Hz L1(U) Winding 380 - 415 380 - 480 3-phase L3(W)

  • Page 236: Commissioning

    Installation and maintenance LEROY-SOMER 3742 en - 2011.03/ g LSA 47.2 - 4 POLES ALTERNATORS 3.4 - Commissioning 3.3.4 - Connection checks Electrical installations must comply with The machine can only be started up and the current legislation in force in the used if the installation is in accordance country of use.

  • Page 237: Servicing - Maintenance

    Installation and maintenance LEROY-SOMER 3742 en - 2011.03/ g LSA 47.2 - 4 POLES ALTERNATORS 4 - SERVICING - MAINTENANCE 4.2.3 - Electrical servicing 4.1 - Safety measures Commercially-available volatile degreasing Servicing or troubleshooting must be agents can be used. carried out strictly in accordance with instructions so as to avoid the risk of WARNING...

  • Page 238: Mechanical Defects

    Installation and maintenance LEROY-SOMER 3742 en - 2011.03/ g LSA 47.2 - 4 POLES ALTERNATORS 4.4 - Mechanical defects Fault Action Excessive temperature rise in one or - If the bearing has turned blue or if the grease has turned black, change the bearing both bearings (bearing temperature more - Bearing not fully locked (abnormal play in the bearing cage) Bearing...
  • Page 239 Installation and maintenance LEROY-SOMER 3742 en - 2011.03/ g LSA 47.2 - 4 POLES ALTERNATORS 4.5.1 - Checking the winding Assembly A: Connect a 12 V battery in series with a rheostat of approximately You can check the winding insulation by 50 ohms - 300 W and a diode on both exciter performing a high voltage test.

  • Page 240: Dismantling, Reassembly

    Installation and maintenance LEROY-SOMER 3742 en - 2011.03/ g LSA 47.2 - 4 POLES ALTERNATORS 4.6 - Dismantling, reassembly 4.6.4 - Access to connections and the (see sections 5.4.1. & 5.4.2.) regulation system Access directly by removing the top of the WARNING cover (48) or the AVR access door (466).
  • Page 241 Installation and maintenance LEROY-SOMER 3742 en - 2011.03/ g LSA 47.2 - 4 POLES ALTERNATORS - Slide the threaded rod into the shield hole - Slide the threaded rod into the shield hole to make it easier to assemble (see basic to make it easier to assemble (see basic diagram).

  • Page 242: Installation And Maintenance Of The Pmg

    Installation and maintenance LEROY-SOMER 3742 en - 2011.03/ g LSA 47.2 - 4 POLES ALTERNATORS If using a single-bearing or double-bearing To replace, follow the instructions in reverse machine with the regreasable bearing order. option: - Mount the new preloading (wavy) washer (79) + the new “O”...

  • Page 243: Table Of Characteristics

    Installation and maintenance LEROY-SOMER 3742 en - 2011.03/ g LSA 47.2 - 4 POLES ALTERNATORS 4.8 - Table of characteristics Field excitation current i exc (A) Symbols: “i exc”: excitation current of the Table of average values exciter field Alternator - 4 poles - 50 Hz - Standard winding No.

  • Page 244: Spare Parts

    Installation and maintenance LEROY-SOMER 3742 en - 2011.03/ g LSA 47.2 - 4 POLES ALTERNATORS 5 - SPARE PARTS In the event of failure to comply with this advice, the manufacturer cannot be held 5.1 - First maintenance parts responsible for any damage. Emergency repair kits are available as an option.

  • Page 245: Exploded Views, Parts List And Tightening Torque

    Installation and maintenance LEROY-SOMER 3742 en - 2011.03/ g LSA 47.2 - 4 POLES ALTERNATORS 5.4 - Exploded view, parts list and tightening torque 5.4.1 - LSA 47.2 single-bearing 243/297...
  • Page 246 Installation and maintenance LEROY-SOMER 3742 en - 2011.03/ g LSA 47.2 - 4 POLES ALTERNATORS 5.4.2 - LSA 47.2 double-bearing 244/297...
  • Page 247 Installation and maintenance LEROY-SOMER 3742 en - 2011.03/ g LSA 47.2 - 4 POLES ALTERNATORS Screw Torque Screw Torque Ref. Qty Description Ref. Qty Description Ø Ø Stator assembly Fixing screws Rotor assembly Inner bearing retainer Preloading (wavy) washer Lifting ring Exciter field Shaft extension key Fixing screws...
  • Page 248 Installation and maintenance LEROY-SOMER 3742 en - 2011.03/ g LSA 47.2 - 4 POLES ALTERNATORS Electric Power Generation Division Declaration of CE compliance and incorporation This Declaration applies to the generators designed to be incorporated into machines complying with the Machinery Directive Nr 2006/42/CE dated 17 May 2006.
  • Page 249 Installation and maintenance LEROY-SOMER 3742 en - 2011.03/ g LSA 47.2 - 4 POLES ALTERNATORS 247/297...
  • Page 250 www.leroy-somer.com 248/297...
  • Page 251 4067 en - 2009.05 / b STATOR : 12 wires (marking T1 to T12) MAIN FIELD SHUNT SYSTEM Induced Field 75 mm R 250 110 0V 4 x holes Ø 5.8 x 50 x 115 mm Slow fuse 250V 8 A Voltage 50Hz KNEE...
  • Page 252 LEROY-SOMER Installation and maintenance 4067 en - 2009.05 / b R250 A.V.R. This manual concerns the alternator A.V.R. which you have just purchased. We wish to draw your attention to the contents of this maintenance manual. By following certain important points during installation, use and servicing of your A.V.R., you can look forward to many years of trouble-free operation.
  • Page 253 LEROY-SOMER Installation and maintenance 4067 en - 2009.05 / b R250 A.V.R. SUMMARY 1 - SUPPLY ..........................4 1.1 - SHUNT excitation system ....................4 2 - R250 A.V.R.........................5 2.1 - Characteristics ......................5 2.2 - U/F fonction and LAM ....................5 2.3 - R250 A.V.R.

  • Page 254: Supply

    LEROY-SOMER Installation and maintenance 4067 en - 2009.05 / b R250 A.V.R. 1 - SUPPLY The regulator controls the excitation current according to the alternator’s output voltage. 1.1 - SHUNT excitation system With a very simple conception, the SHUNT The SHUNT excitation alternator is auto- excitation alternator does not have a short excited with a R 250 voltage regulator.

  • Page 255: R250 A.v.r

    LEROY-SOMER Installation and maintenance 4067 en - 2009.05 / b R250 A.V.R. 2 - R250 A.V.R. The threshhold position and LAM fonction settings are done with the jumper. 2.1 - Characteristics - Storage: -55°C; +85°C Operating at 50 Hz: (U/F gradient) - Operation: -40°C;...

  • Page 256: R250 A.v.r. Option

    LEROY-SOMER Installation and maintenance 4067 en - 2009.05 / b R250 A.V.R. 2.3 - R250 A.V.R. option It is advised to use the “LAM” at 25% for load impacts > at 70% of the genset rated power. Potentiometer for voltage setting, 1000 W / 0,5 W min: setting range ±...

  • Page 257: Typical Effects Of The Lam

    LEROY-SOMER Installation and maintenance 4067 en - 2009.05 / b R250 A.V.R. 2.5 - Typical effects of the LAM with a diesel engine or without a LAM (U/F only) 2.5.1 - Voltage Transient voltage drop (U/f) without LAM with Time 2.5.2 - Frequency Max speed drop with...

  • Page 258: Installation - Commisioning

    LEROY-SOMER Installation and maintenance 4067 en - 2009.05 / b R250 A.V.R. 3 - INSTALLATION - 3.2.2 - Special type of use COMMISSIONING 3.1 - Electrical checks on the AVR WARNING - Check that all connections have been Excitation circuit E+, E- must not be left made properly as shown in the attached open when the machine is running: wiring diagram.

  • Page 259: Electrical Faults

    LEROY-SOMER Installation and maintenance 4067 en - 2009.05 / b R250 A.V.R. 3.3 - Electrical faults Fault Action Effect Check/cause The alternator starts up and its voltage is still correct when the - Lack of residual magnetism battery is removed. Connect a new battery The alternator starts up but its - Check the connection of the voltage...

  • Page 260: Spare Parts

    LEROY-SOMER Installation and maintenance 4067 en - 2009.05 / b R250 A.V.R. 4 - SPARE PARTS 4.1 - Designation Description Type Code A.V.R. R 250 AEM 110 RE 019 4.2 - Technical support service Our technical support service will be pleased to help you with any information needed.
  • Page 261 LEROY-SOMER Installation and maintenance 4067 en - 2009.05 / b R250 A.V.R. 259/297...
  • Page 262 MOTEURS LEROY-SOMER 16015 ANGOULÊME CEDEX - FRANCE 338 567 258 RCS ANGOULÊME S.A. au capital de 62 779 000 ¤ www.leroy-somer.com 260/297...
  • Page 263 4531 en - 2012.03 / e R 450 50 Hz EXT FREQ 60 Hz SETTING 380V 220 110 0V E- E+ Z2 X1 Z1 X2 R 450 AVRs Installation and maintenance 261/297...
  • Page 264 LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs This manual concerns the alternator AVR which you have just purchased. We wish to draw your attention to the contents of this maintenance manual. By following certain important points during installation, use and servicing of your AVR, you can look forward to many years of trouble-free operation.
  • Page 265 LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs CONTENTS 1 - GENERAL INFORMATION ....................4 1.1 - Description ........................4 1.2 - Characteristic ....................... 4 2 - POWER SUPPLY ....................... 5 2.1 - AREP excitation system ....................5 2.2 - PMG excitation system ....................6 2.3 - SHUNT or separate excitation system ................7 3 - TECHNICAL CHARACTERISTICS ..................8...

  • Page 266: General Information

    LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs 1 - GENERAL INFORMATION 1.2 - Characteristic The connection is realised by “Faston” 1.1 - Description connectors and the voltage sensing is The R450 AVR is supplied in a casing single - phase.

  • Page 267: Power Supply

    LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs 2 - POWER SUPPLY characteristic), the second one has a voltage proportional to the stator current Both the SHUNT/AREP & PMG excitation (compound characteristic : Booster effect). systems are controlled by the AVR.

  • Page 268: Pmg Excitation System

    LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs 2.2 - PMG excitation system The AVR monitors the alternator output voltage by adjusting the excitation current. With PMG excitation, a permanent magnet The rotating switch should be in the PMG generator (PMG) added to the alternator position (see 3.2.3).

  • Page 269: Shunt Or Separate Excitation System

    LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs 2.3 - SHUNT or separate excitation system With SHUNT excitation, the AVR is powered by the main winding (100V to 140V - 50/60 Hz ) by using X1, X2 on the AVR. The rotating switch should be in the SHUNT/ AREP position (see 3.2.3).

  • Page 270: Technical Characteristics

    LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs 3 - TECHNICAL CHARACTERISTICS 3.2.1.2 - Quadrature droop: Quadrature droop adjustment 3.1 - Electrical characteristics potentiometer P4 within a range : - maximum power supply: 150V - 50/60 Hz - from 0 to 8% with a PF=0.8 for 400V - Rated overload current: 10 A - 10 s applications.
  • Page 271 LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs excitation current must be limited to WARNING 9 A ± 0.5 A. Overrun indications: limitation threshold must adjustable between 1 and 5.5 A. The One green LED: genset breaker must be open during the - Lights up when the excitation current is short circuit.
  • Page 272 LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs I exc(A) Diagram 2 2.9x I (Maximum current I exc) threshold (max. 9.5 A) threshold (1...5.5A) t(s) Shutdown Activation of 90 s. tempo elapsed : application 0.5 ~ 0.7 90 s.
  • Page 273 LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs 3.2.2 - Rotating switch selection: LAM 3.2.3 Rotating switch: excitation type and U/F and time response 50Hz EXT.FREQ. AREP SET. MODE 1 RAPIDE NORMAL FAST NORMAL MODE 2 ONLY FOR SPECIAL CONFIG.

  • Page 274: U/F And Lam Functions

    LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs 3.3 - U/F and LAM function 3.3.2.2 - Soft voltage recovery function During load impacts, the function helps the 3.3.1 - Frequency variation compared genset to return to its rated speed faster with with voltage (without LAM) a gradual increase in voltage according to the principle:...

  • Page 275: Avr Options

    LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs 3.4.3 - Power • Equalization voltages before paralleling (3 F). • Possibility of coupling to the mains of alternators already running in parallel (4F). - R729 module: same as R726 with Variation in the load additional functions.

  • Page 276: Installation - Commissioning

    LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs 4 - INSTALLATION - COMMISSIONING Action Factory setting Pot. 4.1 - Electrical checks on the AVR Voltage - Check that all connections have been minimum fully 400 V - 50 Hz anti-clockwise made properly as shown in the attached wiring diagram.
  • Page 277 LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs i) Vary the frequency (speed) around 48 or However, for applications requiring an 58 Hz according to the operating frequency, overload protection (see 3.2.1.4), the and check the change in voltage from that excitation ceiling must be adjusted by using observed previously (~ 15%).
  • Page 278 LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs The exciter is switched off by disconnecting the AVR power supply (1 wire on each auxiliary winding) - contact rating 16 A - 250 V A.C. When the excitation current is set to the Connection is identical for resetting the AVR rated value, a voltage dip is observed in internal protection.

  • Page 279: Electrical Faults

    LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs 4.3 - Electrical faults Fault Action Measurements Check/Cause The alternator builds up and its - Lack of residual magnetism voltage is still correct when the battery is removed No voltage at Connect a new battery The alternator builds up but its...

  • Page 280: Spare Parts

    LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs 5 - SPARE PARTS 5.1 - Designation Description Type Code Voltage regulator R 450 AEM 110 RE 031 (AVR) 5.2 - Technical support service Our technical support service will be pleased to provide any additional information you may require.
  • Page 281 LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs 279/297...
  • Page 282 www.leroy-somer.com 280/297...

  • Page 283: Appendix C - Common Spare Parts

    9.3. Appendix C - Common spare parts R570U Rental Power VOLVO TAD1641GE Fan belt 330052530 Charging alternator belt 330051537 Thermostat 330051545 Rocker cover seal 330051812 Water temperature sensor 330050189 Oil pressure sensor 330050188 Pressure/temperature 330052072 sensor Oil pressure/oil temperature 330052203...
  • Page 284 210 L 330910100 330560243 330570120 + 330570119 330560617 + 330510015 + 330510015 330560551 330560634 LEROY-SOMER LSA472M7 Direct diodes 330410032 Inverse diodes 330410033 Varistor 330410109 Note: For all technical assistance or spare part requests, contact your nearest SDMO agent. 282/297...

  • Page 285: Appendix D - List Of John Deere - Volvo And Perkins Fault Codes

    9.4. Appendix D - List of John Deere - Volvo and Perkins fault codes PPID Description Comment Throttle #3 Position Throttle Voltage high, short to V+ Short to V+ Throttle Voltage low, short to V- Short to V- Throttle #2 Position Throttle Voltage high, short to V+ Short to V+ Throttle Voltage low, short to V-...
  • Page 286 PPID Description Comment Oil pressure sensor Engine oil pressure extremely low Oil pressure sensor input voltage high Short to V+ Oil pressure sensor input voltage low Short to V- Oil pressure sensor open circuit Engine oil pressure low Engine oil pressure moderately low Oil pressure detected, motor stopped Manifold air pressure sensor Manifold air pressure above normal...
  • Page 287 PPID Description Comment Not use with EDC III and Barometric pressure sensor EMS2 Air pressure invalid High barometric pressure sensor short to high High barometric pressure sensor short to ECM option, sensor not High barometric pressure connected Coolant temperature sensor Coolant temperature extremely high Coolant temperature sensor input voltage high...
  • Page 288 PPID Description Comment Inlet temperature Ambient air temperature sensor sensor for PERKINS Ambient air temperature sensor input Inlet air temperature sensor voltage high input voltage high Ambient air temperature sensor input Inlet air temperature sensor voltage low input voltage low Ambient air temperature sensor open circuit High Inlet air temperature...
  • Page 289 PPID Description Comment Overspeed output status Overspeed output open/short to B+ Overspeed output short to ground Coolant temperature output status Coolant temperature lamp open/short to Coolant temperature lamp short ground Oil pressure output status Oil pressure output open/short to B+ Oil pressure output short to ground Oil pressure output open circuit Shutdown output status...
  • Page 290 PPID Description Comment Start enable device (intake heater and ether) Start enable device output short to B+ Not used, the control panel Start enable device output short to is in charge of managing the ground start enable device Start enable device output open circuit Power supply Injector supply voltage problem For 6125HF070 only...
  • Page 291 PPID Description Comment Communication status Bus Off error Passive bus error Data registers read back failure Loss of message error Bus CAN error Engine shutdown vehicle status Engine shutdown vehicle request invalid Engine shutdown vehicle request Status of the Turbo with variable geometry Supply voltage of the Turbo actuator low Error in communication between the ECU...
  • Page 292 PPID Description Comment Cylinder #3 injector status Recalibration of the injectors Injector outside the specifications required Recalibration of the injectors Injector outside the specifications required Short circuit high side to B+ Short circuit high side to low side or low side to B+ Short circuit high or low side to ground Cylinder #3 circuit open...
  • Page 293 PPID Description Comment Cylinder #6 injector status Recalibration of the injectors Injector outside the specifications required Recalibration of the injectors Injector outside the specifications required Short circuit high side to B+ Short circuit high side to low side or low side to B+ Short circuit high or low side to ground Cylinder #6 circuit open...
  • Page 294 PPID Description Comment 1069 Tire size status Tire size error Not possible with Genset Tire size invalid application Tire size error 1075 Feed pump of the fuel circuit High impedance at the terminals of the pump or open circuit Pump coil short to ground Pump defective 1076 Fuel Injection pump status...
  • Page 295 PPID Description Comment Input temperature 1172 compressor Input voltage of the temperature sensor Short to V+ high Input voltage of the temperature sensor Short to V- 1180 Input temperature of the TGV turbine Turbine temperature extremely high Short to V+ Turbine temperature moderately high Short to V- 1184...
  • Page 296 PPID Description Comment 2630 Air temperature at the air cooler outlet Air temperature extremely high Sensor input voltage high Short to V+ Sensor input voltage low Short to V- Air temperature high Air temperature moderately high 2659 Flow level of the EGR valve Calculated EGR flow not valid Calculated EGR flow rather high Calculated EGR flow rather low...
  • Page 297 SAE J1939-73 : March 2004 FMI and Description FMI=0—DATA VALID BUT ABOVE NORMAL OPERATIONAL RANGE - MOST SEVERE LEVEL The signal communicating information is within a defined acceptable and valid range, but the real world condition is above what would be considered normal as determined by the predefined most severe level limits for that particular measure of the real world condition ( Region e of the signal range definition) Broadcast of data values is continued as normal.
  • Page 298 FMI=11—ROOT CAUSE NOT KNOWN It has been detected that a failure has occurred in a particular subsystem but the exact nature of the fault is not known. Broadcast of data value is substituted with the “error indicator” value. FMI=12—BAD INTELLIGENT DEVICE OR COMPONENT Internal diagnostic procedures have determined that the failure is one which requires the replacement of the ECU, used here to mean the packaged unit that includes some microprocessor and its associated components and circuits.
  • Page 299 FMI=20-30—RESERVED FOR SAE ASSIGNMENT FMI=31—CONDITION EXISTS Used to indicate that the condition that is identified by the SPN exists when no more applicable FMI exists or in cases when the reported SPN name spells out the component and a non-standard failure mode. This type of fault may or may be directly associated with the value of general broadcast information.

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