Attachment No. 17 - Generator Set Startup and Onsite Orientation Procedures Form.pdf

TP-6224 3/05 1

Kohler-FAA Generator Set Startup and Onsite Orientation Procedures for Decision-Maker� 550 Controller

Site/Installation Data

Site Contract No.

Address City

State Zip 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

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Exceptions

This table lists items that were not completed successfully. These exceptions must be resolved to complete the Startup

Procedures.

Page Paragraph Number Procedure Name Description

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Safety Precautions and Instructions

IMPORTANT SAFETY INSTRUCTIONS.

Electromechanical equipment, including generator sets, transfer switches,switchgear, andaccessories, 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.

Thismanual hasseveral typesofsafety precautions and instructions: Danger, Warning, Caution, and Notice.

DANGER

Danger indicates the presence of a hazard that will cause severe personal injury,death, orsubstantial property damage.

WARNING

Warning indicates the presence of a hazard that can cause severe personal injury,death,orsubstantial property damage.

CAUTION

Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage.

NOTICE

Notice communicates installation, operation, or maintenance information that is safety related but not hazard related.

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

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.

WARNING

Disabling the generator set.

Accidental starting can cause severe injury or death. Before working on the generator set or connected equipment, disable the generator set as follows: (1) Move the generator set master switch to theOFF position. (2) Disconnect the power to the battery charger. (3) Remove the battery cables, negative (--) lead first.

Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent starting of the generator set by an automatic transfer switch, remote start/stop switch, or engine start command froma remote computer.

Battery

Sulfuric acid in batteries.

Can cause severe injury or death.

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

WARNING

Explosion.

Can cause severe injury or death.

Relays in the battery charger cause arcs or sparks.

Locate the battery in awell-ventilated area. Isolate thebattery charger from explosive fumes.

WARNING

Battery electrolyte is a diluted sulfuric acid. Batteryacidcancause 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 immediatemedical aid in thecase of eye contact. Never add acid to a battery after placing the battery in service, as thismay result inhazardous 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.

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Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke orpermit flamesor sparks to occurnear 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.

Removeall jewelrybefore servicing the equipment. Discharge static electricity from your body before touching batteries by first touching a grounded metal surfaceaway from thebattery. 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.

Engine Backfire/Flash Fire

Fire.

Can cause severe injury or death.

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

WARNING

Servicing the fuel system. A flash firecancausesevere injuryordeath.

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.

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

Carbon monoxide.

Can cause severe nausea, fainting, or death.

The exhaust system must be leakproof and routinely inspected.

WARNING

Generator set operation. Carbon monoxidecancauseseverenausea, fainting, or death. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Avoid breathingexhaust fumeswhenworking 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 couldaccumulateandseepback inside a potentially occupied building.

Carbon monoxide symptoms.

Carbonmonoxide can cause severe nausea, fainting, or death. Carbon monoxide isapoisonousgaspresent in exhaust gases. 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 improvewithinminutes of breathing fresh air.

Copper tubing exhaust systems.

Carbonmonoxide can cause severe nausea, fainting, or death. Do not use copper tubing in diesel exhaust systems. Sulfur in diesel exhaust causes rapid deterioration of copper tubing exhaust systems, resulting in exhaust leakage.

Fuel System

Explosive fuel vapors.

Can cause severe injury or death.

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

WARNING

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

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condition. Do not replace flexible fuel lines with rigid lines. Use flexible sections to avoid fuel line breakage causedbyvibration. Donotoperate 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:

Propane (LP)—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. Useacontainer to catch fuel whendraining the fuel system. Wipeup 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 LP vapor gas 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 preventbubble formation. Asuccessful test depends on the ability of the solution to bubble.

LP liquid withdrawal fuel leaks.

Explosive fuel vapors can cause severe injury or death. Fuel leakage can cause an explosion. Check the LP liquid withdrawal gas 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.

Hazardous Noise

Hazardous noise.

Can cause hearing loss.

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

CAUTION

Engine noise. Hazardous noise can cause hearing loss. Generator sets not equipped with sound enclosures can produce noise levels greater than 105 dBA. Prolongedexposure tonoise levels greater than 85 dBA can cause permanent hearing loss. Wear hearing protection when near an operating generator set.

Hazardous Voltage/ Electrical Shock

Hazardous voltage.

Will cause severe injury or death.

Disconnect all power sources before opening the enclosure.

DANGER

Hazardous voltage.

Can cause severe injury or death.

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

Moving rotor.

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.

WARNING

Welding the generator set.

Can cause severe electrical equipment damage.

Never weld components of the generator set without first disconnecting the battery, controller wiringharness, andengineelectronic control module (ECM).

CAUTION

Grounding electrical equipment.

Hazardous voltage can cause severe injury or death. Electrocution is possible whenever electricity is present. Open the main circuit breakers of all power sources before servicing theequipment. Configure the installation to electrically ground the generator set, transfer switch, and related equipment and electrical circuits to complywithapplicablecodes and standards. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution.

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Disconnecting the electrical load.

Hazardous voltage can cause severe injury or death. Disconnect the generator set from the load by opening 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.

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.

Installing the battery charger.

Hazardous voltage can cause severe injury or death. An ungrounded battery charger may cause electrical shock. Connect the batterychargerenclosure to theground 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 can 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 can cause severe injury or death. Service the day tank electrical control module (ECM) as prescribed in the equipmentmanual. 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 can 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.

Removeall jewelrybefore servicing the equipment.

Engine block heater. Hazardous voltage can 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.

Handling the capacitor. Hazardous voltage can cause severe injury or death. Electrical shock results from touching the charged capacitor terminals. Discharge the capacitor by shorting the terminals together.

(Capacitor-excited models only)

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.

Installingaccessories to the transfer switch transformer assembly.

Hazardous voltage can 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.

Making line or auxiliary connections. Hazardous voltage can cause severe injury or death. To preventelectrical shockdeenergize the normal power source before making any line or auxiliary connections.

Servicing the transfer switch.

Hazardous voltage can cause severe injuryordeath. Deenergizeall power sources before servicing. Open the main circuit breakers of all transfer switch power sources and disable all generator sets as follows: (1) Move all generator set master controller switches to the OFF position. (2) Disconnect power to all battery chargers. (3) Disconnect all battery cables, negative (--) leads first.

Reconnectnegative (--) leads lastwhen reconnecting the battery cables after servicing. Follow these precautions to prevent the starting of generator sets byanautomatic transfer switch, remote start/stop switch, or engine start command from a remote computer.

Before servicing any components inside the enclosure: (1) Remove all jewelry. (2) Stand on a dry, approved electrically insulated mat. (3) Test circuits with a voltmeter to verify that they are deenergized.

Servicing the transfer switch controls and accessories within the enclosure. Hazardous voltage can cause severe injury or death.

Disconnect the transfer switch controls at the inline connector to deenergize the circuit boards and logic circuitry but allow the transfer switch to continue to supply power to the load. Disconnect all power sources to accessories that are mounted within the enclosure but are not wired through the controls and deenergized by inline connector separation. Test circuits with a voltmeter to verify that they are deenergized before servicing.

Testing live electrical circuits.

Hazardous voltage or current can cause severe injury or death. Have trained and qualified personnel take diagnostic measurements of live circuits. Use adequately rated test equipment with electrically insulated probesand follow the instructionsof the test equipment manufacturer when performing voltage tests. Observe the following precautions when performing voltage tests: (1) Remove all jewelry.

(2)Standonadry, approvedelectrically 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)

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Heavy Equipment

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

Unbalanced weight.

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

Use adequate lifting capacity.

Never leave the transfer switch standing upright unless it is securely bolted in place or stabilized.

WARNING

Hot Parts

Hot coolant and steam.

Can cause severe injury or death.

Before removing the pressure cap, stop the generator set and allow it to cool. Then loosen the pressure cap to relieve pressure.

WARNING

Hot engine and exhaust system.

Can cause severe injury or death.

Do not work on the generator set until it cools.

WARNING

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.

Checking the coolant level. Hot coolant can cause severe injury or death. Allow the engine to cool.

Release pressure from the cooling system before removing the pressure cap. To release pressure, cover the pressure capwith a thick cloth and then slowly turn the cap counterclockwise to the first stop. Remove the cap after pressure has been completely released and the engine has cooled.

Check the coolant level at the tank if the generator set has a coolant recovery tank.

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.

Moving Parts

Hazardous voltage.

Can cause severe injury or death.

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

Moving rotor.

WARNING

Rotating parts.

Can cause severe injury or death.

Operate the generator set only when all guards, screens, and covers are in place.

WARNING

Tightening the hardware. Flying projectiles can cause severe injury or death. Loose hardware can cause the hardware or pulley to release from thegeneratorsetengineandcancause personal injury. Retorque all crankshaft and rotor hardware after servicing. Donot loosen thecrankshaft hardwareor rotor thrubolt whenmaking adjustments or servicing the generator set. Rotate the crankshaft manually in a clockwise direction only. Turning the crankshaft bolt or rotor thrubolt counterclockwise can loosen the hardware.

Servicing the generator set when it is operating. Exposedmoving parts can 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. Replaceguards, screens,and covers before operating the generator set.

Notice

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 246242 from an authorized service distributor/dealer.

NOTICE

Hardware damage. The engine and generator set may use both American Standard and metric hardware. Use the correct size tools to prevent rounding of the bolt heads and nuts.

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NOTICE

Hardware damage. The transfer switch may use both American Standard and metric hardware. Use the correct size tools to prevent rounding of the bolt heads and nuts.

NOTICE

When replacing hardware, do not substitute with inferior grade hardware. Screws and nuts are available in different hardness ratings.

To indicate hardness, American Standard hardware uses a series of markings, and metric hardware uses a numeric system. Check the markings on the bolt heads and nuts for identification.

NOTICE

Improper operator handle usage.

Use themanual 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.

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.

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Section 1 Procedure

1.1 Overview

This startup procedure was jointly developed by Kohler

Power Systems and the FAA Program office for

Generator Replacement Contracts D-95049 and

D-06602. It 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 andmeters. Wedo not require the use of recording meters or strip charts to capture performance parameters.

The following equipment is required for a standard FAA warranty startup:

� Common hand tools

� Multimeter

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

� Decision-Maker� 550 Operation Manual, TP-6200

� Engine Operation Manual

� Warranty Startup Procedure Requirements Service Bulletin SB-616

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 Kohler generator set system with a Decision-Maker� 550 controller purchased by the FAA on the national contract.

Note: Due to difference 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 EC controller. Record any discrepancies for later correction.

1.2.1 Oil Level

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

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, and charge the battery. See TT-796, 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 flowof 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).

See the safety precautions before filling the radiator.

Typically, use a coolant solution of 50% ethylene glycol and 50% clean, softened water to inhibit rust/corrosion.

Follow the engine manufacturer’s recommendations for coolant type if different than stated previously.

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A coolant solution of 50% ethylene glycol provides freezing protection to --37°C (--34°F) and overheating protection to 129°C (265°F). A coolant solution with more than 50% ethylene glycol can cause damage to the engine and components. Do not use alcohol or methanol antifreeze or mix them with the specified coolant. Consult 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 outletmust 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.

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 Section 1.8, 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 Section 1.14.1., Visual and Mechanical Inspection

� Load bank

� Day tank or gas vaporizer

1.5 Emergency Stop/No Load Test

1.5.1 Local Emergency 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. Move the generator set master switch (RUN-OFF/ RESET-AUTO) to the RUN position 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.

Generator sets with the Decision-Maker�550 controllers include an emergency stop switch.

Does the generator set shut down immediately?

Yes No

4. Does EMERGENCY STOP appear on the controller display and does the generator set System Shutdown lamp illuminate?

Yes No

5. Reset the generator set controller by moving the generator set master switch to the OFF/RESET position.

Note: Recheck oil level. Oil level should be at or near the FULL mark on the dipstick.

Record Test Results: Pass Fail

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1.5.2 Remote Emergency Stop Test

1. Move the generator set master switch to the RUN position to start the generator set.

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

3. 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 and go to step 6.

b. Open the circuit of the remote emergency stop switch at the remote location and go to step 6.

c. Use the following procedure to simulate a remote emergency stop. Go to step 4.

4. Remove the controller cover.

5. Disconnect wire 1 or 1A on terminal strip TB1 to check the remote emergency stop circuit.

6. Does the generator set immediately shut down?

Yes No

7. Does EMERGENCY STOP appear on the controller display and does the generator set System Shutdown lamp illuminate?

Yes No

8. If method c was selected, reconnect wires 1 and 1A to terminal strip TB1 in the controller.

9. Reset the generator set controller by moving the generator set master switch to the OFF/RESET position.

Record Test Results: Pass Fail

1.6 Generator Set Operational and

Performance Checks

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

1. Lamp Test

a. Move the generator set master switch to the OFF/RESET position.

b. Press the RESET MENU key.

c. Press the LAMP-TEST key. Do the alarm lamps on the controller front panel illuminate and does the digital display light? Record results below.

System Ready Yes No

Not In Auto Yes No

Programming Mode Yes No

System Warning Yes No

System Shutdown Yes No

Digital Display Yes No

2. Generator Set Start

With no load applied, move the generator set master switch to the RUN position. 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?

Yes No

5. Stopping

Return the generator set master switch to the

OFF/RESET position. Does the generator set promptly stop?

Yes No

6. Not in Auto Fault

Does theNot in Auto lamp illuminate and doesNOT

IN AUTO appear on the controller display?

Yes No

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1.7 System Fault Annunciation

Tests

Note: For the tests outlined in Sections 1.7.1 through 1.7.14, move the generator set master switch to theRUNposition for starting. Move the generator set master switch to the OFF/RESET position 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

1.7.1 Overspeed Protection Test

Does this model generator set have a computer-controlled engine control module (ECM) engine with engine controller logic that prevents manual control of the engine speed?

Yes No

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

If NO, proceed with this test.

Note: Complete the test within the first 10 seconds after engine startup or the generator set may shut down on overfrequency (normally set at 63 Hz).

To test the overspeed fault protection:

1. Move the generator set master switch to the RUN position to start the generator set.

2. Select FREQUENCY on the digital display in Menu 7, Generator System.

3. Using the generator set controller, not the throttle actuator or the injector control rod, manually increase the engine speed until the generator set shuts down.

Does OVERSPEED appear on the controller display and does the generator set System

Shutdown lamp illuminate when the frequency reaches 70 Hz (2100 rpm)?

Yes No

Note: If engine speed adjustment does not advance to 70 Hz, reset overspeed setting to 65 Hz and repeat test to check circuit operation. Follow the instructions in the respective generator set service manual.

Reset system overspeed to 70 Hz when this test is complete.

4. Move the generator set master switch to the OFF/ RESET position.

Record Test Results: Pass Fail

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

1.7.2 Overfrequency Test

Does this model generator set have a computer-controlled engine control module (ECM) engine with engine controller logic that prevents manual control of the engine speed?

Yes No

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

If NO, proceed with this test.

To test the overfrequency fault protection:

1. Move the generator set master switch to the RUN position to start the generator set.

2. Select FREQUENCY on the digital display in Menu 7, Generator System.

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

_________Hz

Note: If OVERFREQUENCY shutdown does not occur at 63Hz, reset theOVERFREQUENCY fault to 63 Hz (105%).

4. Does OVERFREQUENCY appear on the controller display and does the generator set System Shutdown lamp illuminate when the frequency reaches 63 Hz (1890 rpm)?

Yes No

Record Test Results: Pass Fail

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

TP-6224 3/05 13

1.7.3 Underfrequency Test

Does this model generator set have a computer-controlled engine control module (ECM) engine with engine controller logic that prevents manual control of the engine speed?

Yes No

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

If NO, proceed with this test.

To test the underfrequency fault protection:

1. Move the generator set master switch to the RUN position to start the generator set.

2. Select FREQUENCY on the digital display in Menu 7, Generator System.

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

_________Hz

Note: If UNDERFREQUENCY shutdown does not occur at 57 Hz, reset the UNDERFREQUENCY fault to 57 Hz (95%).

4. Does UNDERFREQUENCY appear on the controller display and does the generator set System Shutdown lamp illuminate when the frequency reaches 63 Hz (1890 rpm)?

Yes No

Record Test Results: Pass Fail

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

1.7.4 Overvoltage Test

To test the overvoltage fault protection:

1. Move the generator set master switch to the RUN position to start the generator set.

a. CLINS 421--452, FAA Rating 10--250 kW.

Select L1-L2 VOLTS on the digital display in Menu 1, Generator Monitoring. Manually increase the voltage using the adjust potentiometer on the controller front panel until the generator set shuts down after a 2--10 second time delay.

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

b. CLINS 453--466, FAA Rating 300--900 kW.

Go toMenu 14, ProgrammingMode, and select local programming if not already done. Go to Menu 1, Generator Monitoring, and select the L1-L2 VOLTS/INCREASE VOLTAGE on the digital display. Use the YES key to increase the voltage until the generator set shuts down after a 2--10 second time delay.

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

2. Does OVERVOLTAGE appear on the controller display and does the generator set System

Shutdown lamp illuminate?

Yes No

Record Test Results: Pass Fail

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

Note: There is no dedicated undervoltage shutdown or annunciation. The generator set is inherently protected.

TP-6224 3/0514

1.7.5 Information, Fault Tests in

Sections 1.7.6 through 1.7.12

The fault tests outlined in Sections 1.7.6 through 1.7.12 can be performed by connecting a jumper wire from the appropriate controller terminal to the engine block ground. Remove the controller cover if this test system is used.

1.7.6 Low Oil Pressure Warning Test

Does this model generator set have a computer-controlled engine control module (ECM) engine with engine controller logic that prevents testing the low oil pressure warning?

Yes No

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

If NO, proceed with this test.

To test the low oil pressure warning fault protection:

1. Move the generator set master switch to the RUN position to start the generator set.

2. Remove sensor lead 41A and ground the lead to the engine block or connect a jumper wire from the sensor terminal to the engine block.

3. Does LOWOIL PRESSUREWARNING appear on the controller display and does the generator set System Warning lamp illuminate?

Yes No

Does the generator set continue to run?

Yes No

Record Test Results: Pass Fail

4. Remove jumper wire and reconnect the sensor lead.

1.7.7 Low Oil Pressure Shutdown Test

Does this model generator set have a computer-controlled engine control module (ECM) engine with engine controller logic that prevents testing the low oil pressure shutdown?

Yes No

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

If NO, proceed with this test.

To test the low oil pressure shutdown fault protection:

1. Move the generator set master switch to the RUN position to start the generator set, if not already running.

2. Remove sensor lead 13 and ground the lead to the engine block or connect a jumper wire from the sensor terminal to the engine block. The generator set should shut down after a 5 second time delay.

3. DoesOILPRESSURESHUTDOWNappear on the controller display and does the generator set System Shutdown lamp illuminate?

Yes No

Does the generator set stop?

Yes No

Record Test Results: Pass Fail

4. Remove jumper wire and reconnect the sensor lead.

1.7.8 High Coolant Temperature

Warning Test

Does this model generator set have a computer-controlled engine control module (ECM) engine with engine controller logic that prevents testing the high coolant temperature warning?

Yes No

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

If NO, proceed with this test.

TP-6224 3/05 15

To test the high coolant temperature warning fault protection:

1. Move the generator set master switch to the RUN position to start the generator set.

2. Remove sensor lead 40A and ground the lead to the engine block or connect a jumper wire from the sensor terminal to the engine block.

3. Does HI COOL TEMP WARNING appear on the controller display and does the generator set System Warning lamp illuminate?

Yes No

Does the generator set continue to run?

Yes No

Record Test Results: Pass Fail

4. Remove jumper wire and reconnect the sensor lead.

1.7.9 High Coolant Temperature

Shutdown Test

Does this model generator set have a computer-controlled engine control module (ECM) engine with engine controller logic that prevents testing high coolant temperature shutdown?

Yes No

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

If NO, proceed with this test.

To test the high coolant temperature shutdown fault protection:

1. Move the generator set master switch to the RUN position to start the generator set, if not already running.

2. Remove sensor lead 34 and ground the lead to the engine block or connect a jumper wire from the sensor terminal to the engine block. The generator set should shut down after a 5 second time delay.

3. Does HI COOL TEMP SHUTDOWN appear on the controller display and does the generator set System Shutdown lamp illuminate?

Yes No

Does the generator set stop?

Yes No

Record Test Results: Pass Fail

4. Remove jumper wire and reconnect the sensor lead.

1.7.10 Low Coolant Temperature

Warning Test

Does this model generator set have a computer-controlled engine control module (ECM) engine with engine controller logic that prevents testing the low coolant temperature warning?

Yes No

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

If NO, proceed with this test.

To test the low coolant temperature warning fault protection:

Note: 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.

1. Move the generator set master switch to the AUTO position. The generator set should not start.

2. Remove sensor lead 35A and ground the lead to the engine block or connect a jumper wire from the sensor terminal to the engine block.

3. Does LOW COOLANT TEMP appear on the controller display and does the generator set System Warning lamp illuminate?

Yes No

Does the generator set continue to run?

Yes No

Record Test Results: Pass Fail

4. Remove jumper wire and reconnect the sensor lead.

TP-6224 3/0516

1.7.11 Low Coolant Level Shutdown Test

Does this model generator set have a computer-controlled engine control module (ECM) engine with engine controller logic that prevents testing the low coolant level shutdown?

Yes No

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

If NO, proceed with this test.

To test the low coolant level shutdown fault protection:

1. Move the generator set master switch to the RUN position to start the generator set, if not already running.

2. Remove sensor lead 31A and ground the lead to the engine block or connect a jumper wire from the sensor terminal to the engine block. The generator set should shut down after a 5 second time delay.

3. Does LOW COOLANT LEVEL appear on the controller display and does the generator set System Shutdown lamp illuminate?

Yes No

Does the generator set stop?

Yes No

Record Test Results: Pass Fail

4. Remove jumper wire and reconnect the sensor lead.

1.7.12 Low Fuel Warning Test

Note: 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 TB4-2 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 thewiring to the sensor is not part of the test circuit. Remove the controller cover if this test system is used.

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 on the day tank.

2. Does LOW FUEL appear on the controller display and does the generator set System Warning lamp illuminate?

Yes No

Does the generator set continue to run?

Yes No

Record Test Results: Pass Fail

3. Remove jumper wire and reconnect the sensor lead.

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%.

TP-6224 3/05 17

1.7.13 Battery Charger Fault Warning

Test

To test the battery charger fault warning protection:

Note: Do not leave the battery charger deenergized for any length of time or LOW BATTERY VOLTAGE may appear on the controller display during the overcrank test.

1. Deenergize the battery charger power supply.

2. Does BATTERY CHARGER FAULT appear on the controller display and does the generator set System Warning lamp illuminate?

Yes No

Does the generator set continue to run?

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.

1.7.14 Overcrank Shutdown Test and

Low Battery Voltage Warning Test

Note: 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 themonitoring circuits can detect a low battery voltage condition. There is no external sensor circuit for the Low Battery Voltage Warning Test.

Overcrank Shutdown Test

1. Disable the fuel system to prevent engine starting.

2. Move the generator set master switch to the RUN position. The default engine cranking cycle is shown below.

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 OVERCRANK appear on the controller display and does the generator set System Shutdown light illuminate?

Yes No

Does the generator set suspend further engine cranking attempts?

Yes No

Record Test Results: Pass Fail

Note: LOW BATTERY VOLTAGE may display on the controller during the overcrank test.

4. Reset the generator set controller by moving the generator set master switch to the OFF/RESET position.

5. If the LowBattery VoltageWarning Test is required, go to step 6 .

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

6. If LOW BATTERY VOLTAGE display does appear on the controller, go to step 7.

If LOW BATTERY VOLTAGE display does not appear on the controller, repeat steps 2 through 4 to sufficiently discharge the generator set batteries.

Low Battery Voltage Warning Test

7. Does LOW BATTERY VOLTAGE appear on the controller display and does the generator set System Warning lamp illuminate?

Yes No

Does the generator set continue to run.

Yes No

8. Go to Section 1.7.15, Battery Charger Test.

TP-6224 3/0518

1.7.15 Battery Charger Test

Section 1.7.14, Overcrank Shutdown Test and Low

Battery Voltage Warning Test, verify 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. Move the generator set master switch to the OFF/ RESET position, then to the AUTO position. Does the LOW BATTERY VOLTAGE message disappear on the controller display and does the generator set System Warning lamp go out?

Yes No

Does the OVERCRANK message disappear on the controller display and does the generator set System Shutdown lamp go out?

Yes No

Record Test Results: Pass Fail

1.7.16 Generator Set Master Switch Not

in Auto Position Test

To test the generator set master switch not in auto position fault protection:

1. Move the generator set master switch to the OFF/ RESET position.

2. Does NOT IN AUTO appear on the controller display, does the generator set Not in Auto lamp illuminate, and does the audible alarm sound?

Yes No

3. Move the generator set master switch to the RUN position.

4. Does NOT IN AUTO appear on the controller display, does the generator set Not in Auto lamp illuminate, and does the audible alarm sound?

Yes No

Record Test Results: Pass Fail

5. Move the generator set master switch to the AUTO position.

6. Does NOT IN AUTO disappear on the controller display, does the generator setNot in Auto lamp go out, and does the audible alarm stop?

Yes No

Record…