693KA8-24-R-00012 - Section J Attachment J.07 Site Acceptance Test (SAT).pdf

693KA8-24-R-00012

Section J Attachment J.07

Engine Generator System (EGS)

FAA Generator System Start-up and

On-site Orientation Procedures

Site Acceptance Test (SAT)

Document Revision History Date Revision Change Description Approval

New Initial document release.

A

B .

J.07 2 08/2023

Site/Installation Data Site Contract No.

Address City

State Contact

Phone No.

Generator Set Information

Generator Model Engine Model

Generator Spec No. Engine Serial No.

Generator Serial No. CLIN

Transfer Switch Information

Model Serial No.

Load Bank Information

Model Serial No.

Distributor Startup Representative Distributor Representative Name

Date Representative Signature

Subcontractor Startup Representative (if applicable)

Company Representative Name

Date Representative Signature

FAA Project Engineer or Designated FAA Representative (must be an FAA employee)

Authority Having Jurisdiction Name Office/Organization

Authority Having Jurisdiction Signature Date

Approved with the Following Exceptions (mark one box):

� None � Listed on Page 2

J.07 3 08/2023

Exceptions This table lists items that were not completed successfully. These exceptions must be resolved to complete the Start-up Procedures

Page Paragraph Number

Procedure Name

Description

J.07 4 08/2023

Safety Precautions and Instructions

Read and follow all safety precautions and instructions. SAVE THESE INSTRUCTIONS.

IMPORTANT SAFETY INSTRUCTIONS. Electromechanical equipment, including generator sets, transfer switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained.

To prevent accidents be aware of potential dangers and act safely. Read and follow all safety precautions and instructions.

SAVE THESE INSTRUCTIONS.

This manual has several types of safety precautions and instructions: Danger, Warning, Caution, and Notice.

DANGER

DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE

NOTICE is used to address practices not related to physical injury.

Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain how to act safely. The decals are shown throughout this publication to improve operator recognition. Replace missing or damaged decals.

Accidental Starting

WARNING Accidental starting.

Can cause severe injury or death.

Disconnect the battery cables before working on the generator set. Remove the negative (–) lead first when disconnecting the battery. Reconnect the negative (–) lead last when reconnecting the battery.

Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the generator set or equipment connected to the set, disable the generator set as follows: (1) Press the generator set off/reset button to shut down the generator set. (2) Disconnect the power to the battery charger, if equipped. (3) Remove the battery cables, negative (–) lead first. Reconnect the negative (–) lead last when reconnecting the battery. Follow these precautions to prevent the starting of the generator set by the remote start/stop switch.

J.07 5 08/2023

Battery

WARNING Sulfuric acid in batteries.

Wear protective goggles and clothing. Battery acid may cause blindness and burn skin.

WARNING Explosion.

Relays in the battery charger cause arcs or sparks.

Locate the battery in a well‐ventilated area. Isolate the battery charger from explosive fumes.

Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid can cause blindness and burn skin. Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery. Do not open a sealed battery or mutilate the battery case. If battery acid splashes in the eyes or on the skin, immediately flush the affected area for 15 minutes with large quantities of clean water. Seek immediate medical aid in the case of eye contact. Never add acid to a battery after placing the battery in service, as this may result in hazardous spattering of battery acid.

Battery acid cleanup. Battery acid can cause severe injury or death. Battery acid is electrically conductive and corrosive.

Add 500 g (1 lb.) of bicarbonate of soda (baking soda) to a container with 4 L (1 gal.) of water and mix the neutralizing solution.

Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction (foaming) has ceased. Flush the resulting liquid with water and dry the area.

Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging. Do not dispose of a battery in a fire. To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects.

Remove all jewelry before servicing the equipment. Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery. To avoid sparks, do not disturb the battery charger connections while the battery is charging. Always turn the battery charger off before disconnecting the battery connections. Ventilate the compartments containing batteries to prevent accumulation of explosive gases.

Battery short circuits. Explosion can cause severe injury or death. Short circuits can cause bodily injury and/or equipment damage. Disconnect the battery before generator set installation or maintenance. Remove all jewelry before servicing the equipment. Use tools with insulated handles. Remove the negative (–) lead first when disconnecting the battery. Reconnect the negative (–) lead last when reconnecting the battery. Never connect the negative (–) battery cable to the positive (+) connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together.

J.07 6 08/2023

Engine Backfire/Flash Fire

WARNING Risk of fire.

Do not smoke or permit flames or sparks near fuels or the fuel system.

Servicing the fuel system. A flash fire can cause severe injury or death. Do not smoke or permit flames or sparks near the fuel mixer, fuel line, fuel filter, or other potential sources of fuel vapors. When removing the fuel line or fuel system be aware that liquid propane can cause frostbite on contact.

(Gaseous-fueled Model)

Servicing the fuel system. A flash fire can cause severe injury or death. Do not smoke or permit flames or sparks near the fuel injection system, fuel line, fuel filter, fuel pump, or other potential sources of spilled fuels or fuel vapors. Catch fuels in an approved container when removing the fuel line or fuel system.

(Diesel-fueled Model)

Servicing the air cleaner. A sudden backfire can cause severe injury or death. Do not operate the generator set with the air cleaner removed.

Combustible materials. A fire can cause severe injury or death. Generator set engine fuels and fuel vapors are flammable and explosive. Handle these materials carefully to minimize the risk of fire or explosion. Equip the compartment or nearby area with a fully charged fire extinguisher. Select a fire extinguisher rated ABC or BC for electrical fires or as recommended by the local fire code or an authorized agency. Train all personnel on fire extinguisher operation and fire prevention procedures.

Exhaust System

WARNING Carbon monoxide.

Can cause severe nausea, fainting, or death.

The exhaust system must be leakproof and routinely inspected.

Generator set operation. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Avoid breathing exhaust fumes when working on or near the generator set. Never operate the generator set inside a building unless the exhaust gas is piped safely outside. Never operate the generator set where exhaust gas could accumulate and seep back inside a potentially occupied building.

Carbon monoxide symptoms. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is a poisonous gas present in exhaust gases. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Carbon monoxide poisoning symptoms include but are not limited to the following:

• Light-headedness, dizziness,

• Physical fatigue, weakness in joints and muscles,

• Sleepiness, mental fatigue, inability to concentrate or speak clearly, blurred vision,

• Stomachache, vomiting, nausea.

If experiencing any of these symptoms and carbon monoxide poisoning is possible, seek fresh air immediately and remain active.

Do not sit, lie down, or fall asleep. Alert others to the possibility of carbon monoxide poisoning. Seek medical attention if the condition of affected persons does not improve within minutes of breathing fresh air.

J.07 7 08/2023

Fuel System

WARNING Explosive fuel vapors.

Use extreme care when handling, storing, and using fuels.

WARNING Avoid high pressure fluids.

Do not work on high pressure fuel or hydraulic systems without protective equipment to protect hands, eyes, and body. Avoid the hazard by relieving pressure before disconnecting fuel injection pressure lines. Search for leaks using a piece of cardboard.

Always protect hands, eyes, and body from high pressure fluids. If an accident occurs, seek medical attention immediately.

The fuel system. Explosive fuel vapors can cause severe injury or death. Vaporized fuels are highly explosive. Use extreme care when handling and storing fuels. Store fuels in a well-ventilated area away from spark-producing equipment and out of the reach of children. Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks. Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors. Keep the fuel lines and connections tight and in good condition. Do not replace flexible fuel lines with rigid lines. Use flexible sections to avoid fuel line breakage caused by vibration. Do not operate the generator set in the presence of fuel leaks, fuel accumulation, or sparks.

Repair fuel systems before resuming generator set operation.

Explosive fuel vapors can cause severe injury or death. Take additional precautions when using the following fuels:

Gasoline—Store gasoline only in approved red containers clearly marked GASOLINE.

Propane (LPG)—Adequate ventilation is mandatory. Because propane is heavier than air, install propane gas detectors low in a room. Inspect the detectors per the manufacturer’s instructions.

Natural Gas—Adequate ventilation is mandatory. Because natural gas rises, install natural gas detectors high in a room. Inspect the detectors per the manufacturer’s instructions.

Fuel tanks. Explosive fuel vapors can cause severe injury or death. Gasoline and other volatile fuels stored in day tanks or subbase fuel tanks can cause an explosion. Store only diesel fuel in tanks.

Draining the fuel system. Explosive fuel vapors can cause severe injury or death. Spilled fuel can cause an explosion. Use a container to catch fuel when draining the fuel system. Wipe up spilled fuel after draining the system.

Gas fuel leaks. Explosive fuel vapors can cause severe injury or death. Fuel leakage can cause an explosion. Check the LPG vapor or natural gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to 6– 8 ounces per square inch (10–14 inches water column). Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation. A successful test depends on the ability of the solution to bubble.

LPG liquid withdrawal fuel leaks. Explosive fuel vapors can cause severe injury or death. Fuel leakage can cause an explosion. Check the LPG liquid withdrawal fuel system for leakage by using a soap and water solution with the fuel system test pressurized to at least 90 psi (621 kPa). Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation. A successful test depends on the ability of the solution to bubble.

J.07 8 08/2023

Hazardous Noise

CAUTION Hazardous noise.

Can cause hearing loss.

Never operate the generator set without a muffler or with a faulty exhaust system.

Engine noise. Hazardous noise can cause hearing loss. Generator sets not equipped with sound enclosures can produce noise levels greater than 105 dBA. Prolonged exposure to noise levels greater than 85 dBA can cause permanent hearing loss.

Wear hearing protection when near an operating generator set.

Hazardous Voltage/Moving Parts

DANGER Hazardous voltage.

Will cause severe injury or death.

Disconnect all power sources before opening the enclosure.

Only authorized personnel should open the enclosure.

DANGER Hazardous voltage. Moving parts.

Operate the generator set only when all guards and electrical enclosures are in place.

WARNING Hazardous voltage. Backfeed to the utility system.

Can cause property damage, severe injury, or death.

If the generator set is used for standby power, install an automatic transfer switch to prevent inadvertent interconnection of standby and normal sources of supply.

Servicing the generator set when it is operating. Exposed moving parts will cause severe injury or death. Keep hands, feet, hair, clothing, and test leads away from the belts and pulleys when the generator set is running. Replace guards, screens, and covers before operating the generator set.

Grounding electrical equipment. Hazardous voltage will cause severe injury or death. Electrocution is possible whenever electricity is present. Ensure you comply with all applicable codes and standards. Electrically ground the generator set and related equipment and electrical circuits. Turn off the main circuit breakers of all power sources before servicing the equipment.

Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution.

J.07 9 08/2023

Disconnect the electrical load. Hazardous voltage will cause severe injury or death. Disconnect the generator set from the load by turning off the line circuit breaker or by disconnecting the generator set output leads from the transfer switch and heavily taping the ends of the leads. High voltage transferred to the load during testing may cause personal injury and equipment damage. Do not use the safeguard circuit breaker in place of the line circuit breaker. The safeguard circuit breaker does not disconnect the generator set from the load.

Installing the battery charger. Hazardous voltage will cause severe injury or death. An ungrounded battery charger may cause electrical shock. Connect the battery charger enclosure to the ground of a permanent wiring system. As an alternative, install an equipment grounding conductor with circuit conductors and connect it to the equipment grounding terminal or the lead on the battery charger. Install the battery charger as prescribed in the equipment manual. Install the battery charger in compliance with local codes and ordinances.

Connecting the battery and the battery charger. Hazardous voltage will cause severe injury or death. Reconnect the battery correctly, positive to positive and negative to negative, to avoid electrical shock and damage to the battery charger and battery(ies). Have a qualified electrician install the battery(ies).

Servicing the day tank. Hazardous voltage will cause severe injury or death. Service the day tank electrical control module (ECM) as prescribed in the equipment manual. Disconnect the power to the day tank before servicing. Press the day tank ECM OFF pushbutton to disconnect the power. Notice that line voltage is still present within the ECM when the POWER ON light is lit. Ensure that the generator set and day tank are electrically grounded. Do not operate the day tank when standing in water or on wet ground because these conditions increase the risk of electrocution.

Short circuits. Hazardous voltage/current will cause severe injury or death. Short circuits can cause bodily injury and/or equipment damage. Do not contact electrical connections with tools or jewelry while making adjustments or repairs. Remove all jewelry before servicing the equipment.

Engine block heater. Hazardous voltage will cause severe injury or death. The engine block heater can cause electrical shock. Remove the engine block heater plug from the electrical outlet before working on the block heater electrical connections.

Electrical backfeed to the utility. Hazardous backfeed voltage can cause severe injury or death. Install a transfer switch in standby power installations to prevent the connection of standby and other sources of power. Electrical backfeed into a utility electrical system can cause severe injury or death to utility personnel working on power lines.

Installing accessories to the transfer switch transformer assembly. Hazardous voltage will cause severe injury or death.

To prevent electrical shock, deenergize all power sources and then disconnect the harness plug before installing accessories that will be connected to the transformer assembly primary terminals on microprocessor logic models. Terminals are at line voltage.

Testing live electrical circuits. Hazardous voltage or current will cause severe injury or death. Have trained and qualified personnel take diagnostic measurements of live circuits. Use adequately rated test equipment with electrically insulated probes and follow the instructions of the test equipment manufacturer when performing voltage tests. Observe the following precautions when performing voltage tests: (1) Remove all jewelry. (2) Stand on a dry, approved electrically insulated mat. (3) Do not touch the enclosure or components inside the enclosure. (4) Be prepared for the system to operate automatically. (600 volts and under)

CAUTION

Welding the generator set.

Can cause severe electrical equipment damage.

Welding on generator set will cause serious damage to engine electronic controls components. Disconnect all engine electronic control connections before welding.

Welding on the generator set. Can cause severe electrical equipment damage. Before welding on the generator set perform the following steps: (1) Remove the battery cables, negative (–) lead first. (2) Disconnect all engine electronic control module (ECM) connectors. (3) Disconnect all generator set controller and voltage regulator circuit board connectors. (4) Disconnect the engine battery-charging alternator connections. (5) Attach the weld ground connection close to the weld location.

J.07 10 08/2023

Heavy Equipment

WARNING Unbalanced weight.

Improper lifting can cause severe injury or death and equipment damage.

Do not use lifting eyes. Lift the generator set using lifting bars inserted through the lifting holes on the skid.

WARNING Lifting eye failure.

Improper lifting can cause severe injury or death and equipment damage.

Do not lift the generator set from the engine or alternator eyes. Never stand under a unit being lifted. Always maintain a safe distance from the unit being lifted.

See the lifting instructions in the installation manual that was provided with the unit.

Hot Parts

WARNING Hot coolant and steam.

Before removing the pressure cap, stop the generator set and allow it to cool. Then loosen the pressure cap to relieve pressure. Fill system before starting unit.

WARNING Hot engine and exhaust system.

Do not work on the generator set until it cools.

Servicing the exhaust system. Hot parts can cause severe injury or death. Do not touch hot engine parts. The engine and exhaust system components become extremely hot during operation.

Servicing the alternator. Hot parts can cause severe injury or death. Avoid touching the alternator field or exciter armature.

When shorted, the alternator field and exciter armature become hot enough to cause severe burns.

Servicing the engine heater. Hot parts can cause minor personal injury or property damage. Install the heater before connecting it to power. Operating the heater before installation can cause burns and component damage. Disconnect power to the heater and allow it to cool before servicing the heater or nearby parts.

J.07 11 08/2023

NOTICE

Voltage reconnection. Affix a notice to the generator set after reconnecting the set to a voltage different from the voltage on the nameplate. Order voltage reconnection decal from OEM representative.

NOTICE

Foreign material contamination. Cover the transfer switch during installation to keep dirt, grit, metal drill chips, and other debris out of the components. Cover the solenoid mechanism during installation. After installation, use the manual operating handle to cycle the contactor to verify that it operates freely. Do not use a screwdriver to force the contactor mechanism.

NOTICE

Improper manual operator handle usage. Use the manual operator handle on the transfer switch for maintenance purposes only. Return the transfer switch to the normal position. Remove the manual operator handle, if used, and store it in the place provided on the transfer switch when service is completed.

J.07 12 08/2023

Section 1. Procedure

1.1 Overview

This startup procedure is intended to satisfy the Engineering Support Services requirements of the contract pertaining to onsite:

• Startup warranty validation,

• Orientation training,

• Equipment maintenance training.

The equipment provided is in accordance with the bill of material (BOM) developed to meet the contract specifications.

This COTS equipment BOM may not meet nor is it intended to meet all the requirements of the previous FAA specifications and/or maintenance orders, i.e., Order 6980.11.

These tests are designed to be run and recorded using common diagnostic tools and meters. We do not require the use of recording meters or strip charts to capture performance parameters.

The following equipment and literature are required for a standard FAA warranty startup:

• Common hand tools,

• Multimeter,

• Two AC analog voltmeters (closed transition automatic transfer switches only),

• EG Controller Operation Manual,

• ATS Controller Operation Manual,

• Engine Operation Manual,

• Warranty Startup Procedure Requirements Service Bulletin SB-616,

• Startup and Onsite Test Procedure J.07.

1.2 Installation Contractor's Prestart Checklist

Complete the following checks before the startup date. See the engine operation/maintenance manuals for specifications and quantities of lubricants, coolants, etc.

These procedures are suitable for use with any engine generator controller purchased by the FAA on the national contract.

Note:

Due to differences in site equipment, some tests may not be applicable to all sites. Clearly indicate when a test cannot be completed because of equipment configuration.

If a remote audiovisual alarm is installed, check the indications at the remote station at the same time as checking the indications on the EG controller. Record any discrepancies for later correction.

1.2.1 Oil Level

Check that the engine oil level is at or near the FULL mark on dipstick but not over. Check the oil level in the long run oil system, if applicable; oil should be at or near full level. Check the engine operation/maintenance manual and, if applicable, long run oil system operation/maintenance manual for specific lubrication specifications.

J.07 13 08/2023

1.2.2 Fuel Level

Make sure there is an adequate fuel supply; keep tanks full to allow operation for extended periods.

1.2.3 Battery

Check the connections, check the electrolyte level (lead-acid batteries only), and charge the battery. Review Battery Activation Installation Instructions (Dry-Charged Batteries).

1.2.4 Air Cleaner

Check that the air cleaner is clean and properly installed to prevent unfiltered air from entering the engine.

1.2.5 Operating Area

Make sure there are no obstructions that could block the flow of cooling air. Make sure area is clean. Do not leave rags, tools, or debris on or near the generator set.

1.2.6 Coolant Level

Maintain coolant level at approximately 19–38 mm (3/4–1 1/2 in.) below the radiator fill neck seat when the engine is cold. If the generator set is equipped with a coolant recovery tank, coolant level in the tank should be between 1/3 full (cold) and 2/3 full (hot).

Refer to the engine manufacturer’s operation manual for specific engine coolant specifications.

Do not add coolant to an overheated engine; wait until the engine has cooled. Adding coolant to an extremely hot engine can cause a cracked block or cylinder head.

Note:

Do not turn on the block heater before filling cooling system. Before energizing a block heater, run the engine until warm and refill the radiator to purge air from the system. Block heater failure will result if the heater element is not immersed in water.

1.2.7 Exhaust System

The exhaust outlet must be clear; the silencer and piping must be tight and in good condition.

1.2.8 Electrical Interconnections

Connect all power and control electrical connections for the battery charger, block heater, ATS, day tank, fuel converter, etc., per installation drawings.

Note:

Balance the site load as close as possible on all phases.

J.07 14 08/2023

1.2.9 One Hour Emergency Power System Test

To ensure that the emergency power system operates properly and is thoroughly tested, the following one-hour load bank test is recommended prior to switching the facility over to the emergency power system.

Because the 1.5-hour facility load test, found later in this manual, is intended to simulate a cold start scenario, the 1-hour emergency power system test may need to be performed on the day prior to performing the facility load test due to time constraints. See the test procedure below.

1. Turn the generator set load sensing potentiometer to maximum.

Note:

The relay will be reset at the completion of this test.

2. Start the generator set and allow it to come up to rated voltage and frequency.

3. Using the load bank, add load up to simulated facility load level.

Note:

Not all readings will be available on single-phase sets.

4. Check and record the information in Figure 1 or Figure 3 at the listed intervals after startup.

5. Increase load bank load up to FAA nameplate rating. Continue the balance of the one-hour test at the maximum of the load bank rating. See Figure 2 or Figure 4

The load bank maximum rating should be 100% of the generator set nameplate rating.

Three-Phase Generator Set Load Test

Interval, min.

Volts

Amps

Frequency, Hz

Oil Pressure, kPa (psi)

Water Temperature, °C (°F)

Battery Charging Rate, Volts/Amps

Day Tank

Level

L1-L2 L1 L2-L3 L2 L3-L1 L3

L2-L3 L2

Figure 1 Load Bank 5–25 Minute Testing Results

J.07 15 08/2023

Water Temperature, °C (°F)

Battery

L2-L3 L2 L3-L1 L3

Figure 2 Load Bank 30–60 Minute Testing Results at the Maximum of the Load Bank Rating (The load bank maximum rating should be 100% of the generator set nameplate rating)

Single-Phase Generator Set Load Test

Water Temperature, °C (°F)

Battery

L1-L0 L1

L2-L0 L2 L1-L2

L2-L0 L2

Figure 3 Load Bank 5–25 Minute Testing Results

Water Temperature, °C (°F)

Battery

L2-L0 L2 L1-L2

Figure 4 Load Bank 30–60 Minute Testing Results at the Maximum of the Load Bank Rating (The load bank maximum rating should be 100% of the generator set nameplate rating)

J.07 16 08/2023

1.3 Typical Schedule of Events

• Review sequence of events with all parties,

• Installation inspection including connections, clearances, fluid levels, etc.,

• Emergency stop test,

• Operation and performance tests,

• ATS startup verification,

• One hour/load bank test,

• Governor test,

• Load bank operation test,

• Cold start test; see the following subsection, Optional Onsite Tests,

• Two-hour site load test,

• Load bank shed/share verification,

• ATS facility load transfer/bypass verification,

• Day tank verification,

• Remote monitoring system,

• Onsite orientation/maintenance training.

1.4 Installation Inspection

• Engine generator,

• Automatic transfer switch (ATS); see the following subsection, Visual and Mechanical Inspection, later in the manual,

• Load bank,

• Day tank or gas vaporizer.

1.5 Emergency Stop/No Load Test

1.5.1 Local Emergency Stop (E-Stop) Test

The following safety test verifies the generator set emergency stop function. Disconnect the generator set from load by opening the line circuit breaker.

1. Press the master control RUN button to start the generator set.

2. Allow the generator set to come up to rated voltage and frequency.

3. Push the generator set controller emergency stop switch to test the local emergency stop function. Does the generator set shut down immediately?

Yes No

4. Does “Emerg Stop Shutdown” appear on the controller display and does the generator set FAULT lamp show red?

Yes No

5. Reset the generator set controller by pulling the Emergency Stop button back out, pressing the OFF/RESET button, and then pressing the AUTO button.

Record Test Results: Pass Fail

J.07 17 08/2023

1.5.2 Remote Emergency Stop (E-Stop) Test

Note:

If activating the circuit breaker shunt-trip is applicable for this project, verify that the emergency stop activates the generator circuit breaker shunt trip.

1. Press the master control RUN button to start the generator set.

2. Allow the generator set to come up to rated voltage and frequency.

A. Reset the generator set controller by pressing the OFF/RESET button and then pressing the AUTO button.

Record Test Results: Pass Fail

4. Verify the remote emergency stop function by using one of the following methods.

A. Remove the glass piece and activate the remote emergency stop switch

1. Does the generator set immediately shut down?

Yes No

2. Does “Emerg Stop Shutdown” appear on the controller display and does the generator set FAULT lamp show red?

3. Deactivate the emergency stop switch and reinstall the glass piece.

4. Reset remote emergency stop switch.

B. Open the circuit of the remote emergency stop switch at the remote location.

1. Does the generator set immediately shut down?

2. Does “Emerg Stop Shutdown” appear on the controller display and does the generator set FAULT lamp show red?

3. Close the remote emergency stop switch circuit.

4. Reset remote emergency stop switch.

5. Reset the generator set controller by pressing the OFF/RESET button and then pressing the AUTO button.

J.07 18 08/2023

1.6 Generator Set Operational and Performance Checks

The following checks test the generator set startup and stopping from the generator set controller.

1. Lamp Test

Press and hold the ALARM SILENCE button. Do the annunciator lamps on the controller front panel illuminate and does the digital display light? Record results below.

OFF Yes No

AUTO Yes No

RUN Yes No

ALARM SILENCE Yes No

FAULT Yes No

2. Generator Set Start

With no load applied, press the master control RUN button. Does the generator set start and come up to rated voltage and frequency?

Yes No

3. Oil or Coolant Leaks

Allow the generator set to run for approximately 5 minutes. Is there any indication of lube oil, fuel oil, or coolant leaks from the generator set?

Yes No

4. Steady-State Operation

Does the generator set run smoothly during steady state operation? Watch that the frequency and voltage displays are steady with no load applied and with a fixed amount of load applied. Listen to verify that the unit is not hunting audibly.

Yes No

5. Stopping

Press the generator set master control OFF/RESET button. Does the generator set promptly stop?

Yes No

6. Not in Auto Fault

Does the FAULT yellow lamp illuminate and does the Not In Auto Warning appear on the controller display?

Yes No

1.7 System Fault Annunciation Tests

For the tests outlined in Sections 1.7.1 through 1.7.13, press the master control RUN button for starting. Press the master control OFF/RESET button to reset after each fault test. Refer to the wiring diagrams in the supplied manuals to locate the circuit wires.

Some engine fault switches do not function during the first 30 seconds after startup (inhibit time). These fault switches include:

• High coolant temperature warning and shutdown

• High oil temperature shutdown, if equipped

• Low coolant level shutdown

• Low oil pressure warning and shutdown

• Low coolant temperature warning

J.07 19 08/2023

1.7.1 Over-frequency

To test the over frequency fault:

1. Press the master control RUN button to start the generator set.

2. Select Frequency on the digital display from the Overview Menu.

3. Using the generator set controller, not the throttle actuator or the injector control rod, manually increase the engine speed to 1890 RPM until the generator set shuts down after a 10 second time delay. Record the frequency when the generator set shuts down.

Hz

Note:

If “Freq High Shutdwn” shutdown does not occur at 63 Hz, reset the “Freq High Shutdwn” fault to 63 Hz (105%).

4. Does “Freq High Shutdwn” appear on the controller display and does the generator set FAULT lamp show red when the frequency reaches 63 Hz (1890 rpm)?

Yes No

Record Test Results: Pass Fail

5. Press the master control OFF/RESET button to reset.

6. Press the master control RUN button to start the generator set.

7. Adjust the engine speed back to 1803 rpm ± 2 rpm (60.1 Hz ± 0.05 Hz).

8. Stop the generator set using the master control OFF/RESET button.

1.7.2 Under-frequency Test

To test the under-frequency fault protection:

1. Press the master control RUN button to start the generator set.

2. Select Frequency on the digital display from the Overview Menu.

3. Using the generator set controller, not the throttle actuator or the injector control rod, manually decrease the engine speed to 1710 RPM until the generator set shuts down after a 10 second time delay. Record the frequency when the generator set shuts down.

Hz

Note:

If “Frequency Low Shutdwn” shutdown does not occur at 57 Hz, reset the “Frequency Low Shutdwn” fault to 57 Hz (95%).

4. Does “Frequency Low Shutdwn” appear on the controller display and does the generator set FAULT lamp show red when the frequency reaches 57 Hz (1710 rpm)?

Yes No

Record Test Results: Pass Fail

5. Press the master control OFF/RESET button to reset.

6. Press the master control RUN button to start the generator set.

7. Adjust the engine speed back to 1803 rpm ± 2 rpm (60.1 Hz ± 0.05 Hz).

8. Stop the generator set using the master control OFF/RESET button.

J.07 20 08/2023

1.7.3 Overvoltage Test

To test the overvoltage fault protection:

Note:

Use a laptop and suitable OEM software to verify that the overvoltage parameter is set to drop out at 110%.

1. Press the master control RUN button to start the generator set.

a. FAA Rating 10- 300 kW. Select Volts Line-to-Line on the digital display from the Overview Menu. Manually increase the voltage using the adjust potentiometer on the controller front panel until the overvoltage fault protection activates and the generator set shuts down after a 2 second time delay.

Record the voltage level when the generator set shuts down. volts

b. FAA Rating 350- 1500 kW. Go to the Voltage Regulator Menu and select VR Volt Adj on the digital display. Then press and hold the pushbutton/rotary selector dial until the Editing Enabled popup appears. When VR Volt Adj appears again, turn the pushbutton/rotary dial to the desired value and push the pushbutton/rotary dial again to increase the voltage until the overvoltage fault protection activates and the generator set shuts down after a 2 second time delay.

Record the voltage level when the generator set shuts down. volts

2. Does Volts (L1-L2-L3 or L3-L1) “High Shutdwn” appear on the controller display and does the generator set FAULT lamp show red?

Yes No

Record Test Results: Pass Fail

3. Press the master control OFF/RESET button to reset.

4. Press the master control RUN button to start the generator set.

5. Adjust the generator set voltage to the correct nominal voltage for the generator set.

6. Stop the generator set using the master control OFF/RESET button.

Note:

There is no dedicated undervoltage shutdown or annunciation. The generator set is inherently protected. Use a laptop and suitable OEM software to verify that the Undervoltage parameter is set to pick up at 95%.

1.7.4 Information, Fault Tests in Sections 1.7.5 through 1.7.10

The fault tests outlined in Sections 1.7.5 through 1.7.10 can be performed by using the information found in SB-616.

1.7.5 Low Oil Pressure Warning Test

To test the low oil pressure warning fault protection:

1. Review SB-616 and set up the required test.

2. Press the master control RUN button to start the generator set.

3. Perform the test based on SB-616 instructions.

4. Does Oil Press Low Warning appear on the controller display and does the generator set FAULT lamp show red and does the generator set continue to run?

5. Stop the generator set using the master control OFF/RESET button, if still running.

6. Restore the generator set sensor and wiring to the original configuration.

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1.7.6 Low Oil Pressure Shutdown Test

To test the low oil pressure shutdown fault protection:

2. the master control RUN button to start the generator set.

3. Perform the test based on SB-616 instructions.

4. The generator set should shut down after a 5 second time delay.

5. Does “Oil Press Low Shutdwn” appear on the controller display and does the generator set FAULT lamp show red?

Yes___ No___

6. Does the generator set stop? Yes No

7. Stop the generator set using the master control OFF/RESET button, if still running.

8. Restore the generator set sensor and wiring to the original configuration.

1.7.7 High Coolant Temperature Warning Test

To test the high coolant temperature warning fault protection:

2. Press the master control RUN button to start the generator set.

3. Perform the test based on SB-616 instructions.

4. Does “Coolant Temp High Warning” appear on the controller display and does the generator set FAULT lamp show yellow?

Yes No

5. Does the generator set continue to run?

Yes No

Record Test Results: Pass Fail

6. Stop the generator set using the master control OFF/RESET button, if still running.

7. Restore the generator set sensor and wiring to the original configuration.

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1.7.8 High Coolant Temperature Shutdown Test

To test the high coolant temperature shutdown fault protection:

1. Review SB-616 and set up the required test.

2. Press the master control RUN button to start the generator set.

3. Perform the test based on SB-616 instructions.

4. The generator set should shut down after a 5 second time delay.

5. Does “Coolant Temp High Shutdwn” appear on the controller display and does the generator set FAULT lamp show red?

Yes No

6. Does the generator set stop? Yes No

Record Test Results: Pass Fail

7. Stop the generator set using the master control OFF/RESET button, if still running.

8. Restore the generator set sensor and wiring to the original configuration.

1.7.9 Low Coolant Temperature Warning Test

To test the low coolant temperature warning fault protection, use one of the following methods:

If the site temperature is 16°C (60°F) or below, the sender can also be checked by allowing the generator set room to cool overnight with the block heater unplugged and the generator set room heating disabled.

Does “Coolant Temp Low Warning” appear on the controller display and does the generator set FAULT lamp show yellow?

Yes No

Reconnect the block heater and enable the room heating system. Proceed to step 1.7.10.

OR

Use the following test regardless of site temperature:

1. Review SB-616 and set up the required test.

2. Press the master control AUTO button. The generator set should not start.

3. Perform the test based on SB-616 instructions.

4. Does “Coolant Temp Low Warning” appear on the controller display and does the generator set FAULT lamp show yellow?

Yes No

5. Verify that the generator set will start by pressing the RUN button. Does the generator set start and run?

Yes No

Record Test Results: Pass Fail

6. Stop the generator set using the master control OFF/RESET button, if still running.

7. Restore the generator set sensor and wiring to the original configuration.

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1.7.10 Low Coolant Level Shutdown Test

To test the low coolant level shutdown fault protection:

1. Simulate a low coolant level condition by using one of the following methods:

a. Drain the coolant level below the low coolant level sender.

b. Unplug the existing sender and connect a sender of the same part no. and leave it in the air so it detects no coolant.

2. Press the master control RUN button to start the generator set.

3. The generator set should shut down after a 5 second time delay.

4. Does Coolant Lvl Low Shutdwn appear on the controller display, does the generator set FAULT lamp show red, and does the generator set stop?

Yes No

Record Test Results: Pass Fail

5. Stop the generator set using the master control OFF/RESET button, if still running.

6. Restore the generator set coolant level to the original level, as needed. Restore the sensor and wiring to the original configuration, as needed.

1.7.11 Low Fuel Warning Test

These procedures can be used to test the Low Fuel Warning on a generator set with a natural gas, LP gas, or diesel fueled engine.

To test the low fuel warning fault protection:

Note:

This fault test can be performed by connecting a jumper wire from controller terminal P1- 2 to the engine block ground. This type of test is convenient especially for testing the low fuel warning where the actual sensor may be at a remote location. However, this type of test is less reliable since the wiring to the sensor is not part of the test circuit.

Note:

For a diesel fueled engine, the sender viability can be checked by deenergizing the day tank pump and drawing down the fuel level during test runs.

Note:

For a natural gas or LP gas fueled engine, the sender viability can be checked by slowly closing the fuel valve on the gas supply line.

1. For a natural gas or LP gas fueled engine, remove sensor lead 63 and ground the lead to the engine block ground system or connect a jumper wire from the sensor terminal to the engine block ground system.

For a diesel fueled engine, connect a jumper wire across the low fuel contact terminals (63C and N) on the day tank.

2. Does Fuel Level Low Warning appear on the controller display and does the generator set FAULT lamp show yellow?

Yes No

Record Test Results: Pass Fail

3. Restore the generator set sensor and wiring to the original configuration.

4. Restore the fuel system to automatic operation.

a. For natural gas or LP gas systems, open the fuel valve on the gas supply line.

b. For diesel systems, reenergize the day tank and observe that the pump fills the day tank to 100%.

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1.7.12 Battery Charger Fault Warning Test

Note:

Do not leave the battery charger deenergized for any length of time or Low Battery Warning may appear on the controller display during the overcrank test.

1. Deenergize the battery charger power supply.

2. Does Batt Chg Flt Warning appear on the controller display and does the generator set FAULT lamp show yellow?

Yes No

Record Test Results: Pass Fail

3. If the Low Battery Voltage Warning Test is required, leave the battery charger power supply deenergized until the Overcrank Shutdown Test and Low Battery Voltage Warning Test are complete.

If the Low Battery Voltage Warning Test is not required, reenergize the battery charger power supply.

1.7.13 Overcrank Shutdown Test and Low Battery Voltage Warning Test

To observe the Low Battery Voltage Warning Test, deenergize the battery charger power supply if not already done and conduct the Overcrank Shutdown Test. It may be necessary to conduct the Overcrank Shutdown Test several times to sufficiently discharge the generator set batteries where the monitoring circuits can detect a low battery voltage condition. There is no external sensor circuit for the Low Battery Voltage Warning Test.

Note:

When performing the Overcrank Shutdown Test several times to observe a Low Battery Voltage Warning, allow 10- 15 minutes between each overcrank test to allow the starter motors to cool and help prevent overheating damage.

Overcrank Shutdown Test

1. Disable the fuel system to prevent engine starting. Diesel models: Disconnect the fuel injection harness.

Gas models: Close the fuel supply valve or disconnect the fuel solenoid wiring.

2. Press the master control RUN button. The default engine cranking cycle is shown following.

Cyclic Cranking with:

15 Seconds Crank

15 Seconds Rest

15 Seconds Crank

15 Seconds Rest

15 Seconds Crank

3. When the engine fails to start after the third 15-second cranking attempt, does Over Crank Shutdwn appear on the controller display and does the generator set FAULT lamp show red?

Yes No

Does the generator set suspend further engine cranking attempts?

Yes No

Record Test Results: Pass Fail Note:

Low Battery Warning may display on the controller during the overcrank test.

4. Reset the generator set controller by pressing the generator set master control OFF/RESET button.

5. If the Low Battery Voltage Warning Test is required, go to step 6.

If the Low Battery Voltage Warning Test is not required, go to the next test.

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6. If Low Battery Warning display does appear on the controller, go to step 7.

If Low Battery Warning display does not appear on the controller, repeat steps 2 through 4 to sufficiently discharge the generator set batteries.

When performing the Overcrank Shutdown Test several times to observe a Low Battery Voltage Warning, allow 10- 15 minutes between each overcrank test to allow the starter motors to cool and help prevent overheating damage.

Low Battery Voltage Warning Test

7. Does Low Battery Warning appear on the controller display and does the generator set FAULT lamp show yellow?

Yes No

Record Test Results: Pass Fail

8. Enable the fuel system that was previously disabled in step 1.

9. Go to Section 1.7.14, Battery Charger Test.

1.7.14 Battery Charger Test

Section 1.7.13, Overcrank Shutdown Test and Low Battery Voltage Warning Test, verifies the battery charger alarm system.

1. After performing the Overcrank Shutdown Test and Low Battery Voltage Warning Test, reenergize the battery charger power supply.

2. Does the battery charger indicate an increased charge rate after performing the overcrank shutdown test and then reenergizing the power supply?

Yes No

3. Press the master control OFF/RESET button, then the AUTO button. Does the Low Battery Warning message disappear on the controller display and does the generator set FAULT yellow lamp go out?

Yes No

Does the Over Crank Shutdwn message disappear on the controller display and does the generator set FAULT lamp go out?

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1.7.15 Generator Set Master Switch Not in Auto Mode Test

To test the generator set master switch not in auto mode protection: Press the generator set master control OFF/RESET button.

1. Does Not In Auto Warning appear on the controller display, does the generator set FAULT yellow lamp illuminate, and does the audible alarm sound?

Yes No

2. Press the master control RUN button.

3. Does Not In Auto Warning appear on the controller display, does the generator set FAULT yellow lamp illuminate, and does the audible alarm sound?

Yes No

Record Test Results: Pass Fail

4. Press the master control AUTO button.

5. Does Not In Auto Warning disappear on the controller display, does the generator set FAULT yellow lamp go out, and does the audible alarm stop?

Yes No

1.7.16 Overspeed Shutdown Test

Does this EG have an Engine Control Module (ECM) that prevents manual overspeeding?

If YES, this test cannot be performed. Go to the next test.

If NO, proceed with this test.

To test the overspeed shutdown fault protection:

1. Press the master control RUN button to start the generator set.

2. Manually increase the engine speed on units so equipped with throttle linkage.

3. The generator set should shut down after a 0 second time delay.

4. Does Eng Speed High Shutdwn appear on the controller display and does the generator set FAULT lamp show red?

Yes No

Record Test Results: Pass Fail

5. Restore the generator set to the original speed configuration.

6. Stop the generator set using the master control OFF/RESET button after restoring the original speed configuration.

1.8 Controller Calibration and Settings

The EG controller requires calibration if the system voltage is changed or the main logic control board is replaced. Refer to the OEM maintenance manual for EG controller calibration.

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1.9 Optional Onsite Tests

The following checks may be accomplished by the local maintenance organization. These checks are not required for successful Startup and may be impractical at many sites.

Verification of sender operation for:

• Low oil pressure shutdown,

• Low oil pressure warning,

• High coolant temperature shutdown,

• High coolant temperature warning,

• Low coolant level shutdown,

• Cold start, overnight cooldown with block heater functioning,

• Low coolant temperature warning.

Note:

The OEM verifies the operation of these sender units at the factory.

Any wiring to activate the circuit breaker shunt-trip is not provided by the OEM.

1.10 Relay to Shunt-Trip Load Bank Circuit Breaker Check

This check confirms the function controlling the load bank circuit breaker when ATS transfers to emergency, and to activate when sensing just above 100% load bank load.

Note:

Only qualified personnel should attempt these procedures.

The following check can only be performed with a portable load bank, typically used with 100 kW generator sets and below. The check cannot be performed with a stationary (permanent) load bank, typically used with larger generator sets, (above 100 kW).

Does the generator set use a portable load bank?

Yes No

If YES, proceed with this test.

If NO, this test cannot be performed. Go to the next test.

Note:

A portable load bank shunt trips the load bank breaker. With a permanently installed load bank, the load bank controller looks to the ATS Aux contact and will automatically dump the load when it transfers to standby power.

Note:

If activating the circuit breaker shunt-trip is applicable for this project, verify that…