Enclosure (1) Operator Manual model 450-480VAC Navy Specification.pdf

COMPACT SERIES PORTABLE GENERATOR

Operator Manual Model 450-480VAC Navy Specification

Read and Save these Instructions

Revision Date: August 2022

This page intentionally left blank

Compact Series

Model 450Vac-480Vac Portable Generator

Operator Manual

© Turbine Marine Inc.

1940 NW 32nd St.

Pompano Beach, FL 33064 Phone 953.984.9110 • Fax 954.984.8110

Change Log

Recommended Changes

Please forward any recommended improvements or changes to this technical manual to:

John Arruda

Turbine Marine Inc.

TurbinePowerSolutions.com

1940 NW 32nd street

Pompano Beach Florida

33064

Office Line 954 979-4409

Direct Line 954 415-7218

Fax Line 954 984-8110 jarruda@turbinemarine.com

REVISIONS

REV DESCRIPTION BY DATE APPROVED

Table of Contents Foreword

2.1 Safety Messages

2.2 Skill Requirements and Training of Personnel

2.3 Personal Protective Equipment (PPE)

2.4 Noise

2.5 Electrical Equipment

2.6 Radiological

2.7 Lockout/Tagout

2.8 Spill Prevention, Control, and Countermeasure (SPCC) Requirements

Generator Power Output and Deratings

2.9 Fuel Types, Limitations, and Deratings

Starting and Stopping the Generator

3.1 Engine Start Pre-Operation Check

NOTE: See Appendices for Pre-Operation check sheet

3.1.1 Make sure the generator is on firm level terrain and the wheels are chocked

3.1.2 Insulation Resistance (IR) / Megger Checks

3.1.3 Generator and Cable Shield Grounding Point

3.1.4 Output Leads Connection

3.1.5 Communication Port

3.1.6 Emergency STOP Button

3.1.7 Fuel Line Connection and Priming

3.1.8 Priming the Day Tank Fuel Line System

3.1.9 Priming the Auxiliary (AUX) Tank Fuel Supply Lines

3.1.10 Priming the Auxiliary (AUX) Tank Fuel Supply Lines Without Priming Pump

3.1.11 Switching from Day Tank Fuel Supply to Auxiliary Fuel Supply

3.1.12 Main Battery On/Off Switch

3.1.13 Main Power supply circuit (ANL fuse)

3.1.14 Exhaust Rain lid

3.1.15 Engine Oil

3.2 Starting the Engine

3.2.1 Pre-Start Visual Inspection

3.2.2 Starting the Engine

3.2.3 Performing a Service/Manual Start

3.2.4 Failed Start

3.3 During Operation

3.3.1 Operating Visual Inspection

3.3.2 Operational/Standby Procedure

3.4 Stopping the Engine

3.5 Post Operation

Load Sharing

4.1 General Information

4.2 Multi-Master Principal

4.3 Device Number

4.4 Parameter Alignment

4.5 Missing Members

4.6 120 Ohms Impedance Resistor

4.7 Maximum CAN bus Length

4.8 Bus Shielding

4.9 Troubleshooting

4.10 Creating a Load Sharing Network

4.10.1 Password

4.10.2 Assign Unique Device Number

4.10.3 System Update

4.10.4 Visualize units on the network

4.11 Adding Generators to an Active Load Sharing Network

4.11.1 Configuring Additional Generators

Control Panel Overview AND Quick Function Reference

5.1 AUTO-MASKIN MARINE PRO. DCU 410E Display Dash

5.1.1 DCU 410 Display

5.2 WOODWARD EasyGen 3400XT

5.2.1 WOODWARD EasyGen 3400XT

5.3 Volt Meter

5.4 Battery Voltage/Generator Voltage switch

5.5 Manual Engine Functions

5.5.1 Manual Mode

5.5.2 Engine Run/Stop

5.5.3 Engine Igniters

5.5.4 Engine Fuel Pump

5.6 Lighting

5.6.1 Interior

5.6.2 Exterior

5.7 Temp Control

5.7.1 Engine Anti-Ice

5.7.2 Engine Oil Cooling Fans Override

5.8 Engine Warnings

5.8.1 Engine Alarm

5.8.2 Oil Tank Level

5.8.3 Metal in Oil Contamination

5.8.4 Voltage Regulator Fault

Generator Electronics

6.1 DCU 410E Display

6.1.1 Understanding the DCU 410E Display

6.1.2 Engine N1 and Engine N2

6.1.3 Normal Operational Values

6.1.4 DCU Alarms

6.1.5 Clearing DCU Alarms

6.2 EasyGen 3400XT/3500XT

6.2.1 Understanding EasyGen Display Screen

6.2.2 Understanding the EasyGen 3500

6.2.3 Alarm Conditions

6.2.4 Maintenance Days Exceeded

6.2.5 Alarm Warning and Shutdown Setpoints

6.3 Digital Voltage Regulator

6.3.1 Digital Voltage Regulator

6.3.2 Alarm Codes

6.3.3 Fault Codes

6.3.4 Clearing DVR Alarms and Faults

6.3.5 Programmed Settings

6.4 24Vdc Battery Tender

6.5 Generator Circuit Breaker (GCB)

6.5.1 Single Wire Open/Close

6.5.2 Running with a Disconnected GCB

Generator Relay Shelf

7.1 Electrical Components

7.1.1 24V Voltage Regulator

7.1.2 24V Buffer (Power Supply)

7.1.3 4-20mA Signal Conditioner

7.1.4 Woodward DPG

7.1.5 Fan Relays

7.1.6 Electrical System Breakers

7.1.7 Rio 412

7.1.8 Terminal Blocks

7.1.9 Electrical System Relays

7.1.10 Ground Terminals

7.1.11 Speed Switch

Shipping Container/ Storm Shelter

8.1 Container Overview

8.2 Preparing To Run ETG In Container

8.3 Container Electronics Overview

Remote Operation

9.1 Remote Control Box Overview

9.2 Remote Control Setup

Supplemental Load Bank

10.1 Load Bank

Maintenance

11.1 Enclosure

11.1.1 Drop T Handle Locks

11.1.2 Piano Hinges on Doors

11.2 Woodward

11.3 Auto-Maskin

11.4 T-53 Turbine Engine

11.4.1 Exhaust

11.4.2 Engine

11.4.3 Engine Oil Change

11.4.4 Oil Filter Change

11.5 Air Filter Cleaning

11.5.1 Removing the Air Filter Element

11.5.2 Washing/ Oiling the Air Filter Element

11.5.3

11.5.4

11.5.5 Dry Filter

11.5.6 Lubricate Filter

11.6 Fuel Filter Change

11.7 Return Fuel Reservoir

11.8 Marathon 741/742/743 Frame Alternator (Generator) Maintenance

11.9 Day Tank

Transporting

12.1 Emergency Deployment

12.2 Road Transport

12.2.1 Wheel Bearing Oil Level

12.2.2 Tire Pressure

12.2.3 Tow Hook

12.2.4 Lights and Brake Lines

12.3 Helicopter Transport

12.4 Reducing Generator Weight for Air Transport

12.4.1 Removing GCB

12.4.2 Removing Day Tank

12.5 On-Site Staging

Storage

13.1 Long Term Maintenance Recommendation

13.1.1 General

13.1.2 Engine/Alternator Couplings

13.1.3 Batteries

Troubleshooting

14.1 Measuring electrical insulation resistance

14.2 Soft Start Actuator Fuse

Appendix A: List of Acronyms

Appendix B: Pre-start Inspection Checklist

Appendix C: Automatic Startup Checklist

Appendix D: While-Operating Checklist

Appendix E: Shutdown Checklist

Appendix F: List of Recommended On-Hand Repair Parts

Engine Specialty Tools

Lifting Sketch

Changing EasyGen Voltage Settings Via Soft Keys

Changing EasyGen Voltage Settings Via PC

Foreword Turbine Marine generators are designed to provide safe and dependable service when operated and maintained according to these instructions. This manual contains instructions for safely operating, servicing and maintaining your generator.

Before operating the generator, read this manual and make sure that any personnel who operate, service or maintain the equipment have access to the manual and all additional documentation provided. Misuse and/or failure to follow these instructions, and the use of non-approved parts, may invalidate the product warranty, and lead to potential malfunctions of the generator.

This manual is an essential part of safe and efficient operation of the Compact Series Generator. It should be available to all users throughout the life of the generator.

This manual contains step-by-step operating instructions for inspecting, starting, running, and synchronizing multiple generator units, and performing load share operations to a live bus. It also contains set points and alarm thresholds of the generator for quick reference.

Important Safety Information

2.1 Safety Messages

Safety Messages are provided throughout the manual to help prevent personal injury and equipment or property damage. All safety messages contain a signal word to indicate the level of hazard. Notice panels emphasize important or critical information.

This symbol indicates a hazardous situation that, if not avoided, can result in death.

This symbol indicates a hazardous situation that, if not avoided, could result in death or serious injury.

This symbol indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.

This symbol indicates information considered important but not hazardous that, if not avoided, could result in damage to the generator.

2.2 Skill Requirements and Training of Personnel

Operation and maintenance procedures must only be carried out by trained and qualified personnel who have training by Turbine Marine Inc, or qualified Navy personnel. Turbine Marine offers a product training class which includes generator operation procedures and equipment maintenance.

This training is provided by Turbine Marine’s staff for any customer who wishes to learn more about operating its equipment.

2.3 Personal Protective Equipment (PPE)

All persons operating, servicing, maintaining or working with the generator must wear appropriate Personal Protective Equipment (PPE).

Recommended PPE includes;

• Ear and eye protection

• Head and face protection

• Safety footwear

• Clothing that protects lower arms and legs

2.4 Noise

When operating generator, wear appropriate ear protection to prevent ear drum injury or hearing loss. Double hearing protection may be required.

Turbine generators produce a high level of noise emissions when operating. Wear adequate ear protection to avoid hearing loss.

2.5 Electrical Equipment

This generator produces a substantial amount of electrical power, enough to cause serious injury or electrocution if misused. Work that requires access to electrical conductors must be performed with the unit turned OFF. Also, operators must comply with all applicable local and national safety procedures for voltages involved. Always use genuine branded replacement parts.

Performing operation, service or maintenance on the generator in wet conditions could result in electrocutions.

Never touch bare wires or receptacles.

Use extreme caution when servicing or operating the generator. Make sure the generator is off, and disconnect battery switch and breakers to avoid electrical shock or damage to the unit.

2.6 Radiological

Radiological Caution: A PHNSY&IMF C/105 radiological inspection performed on 28APR2021 found zero radiation emission from any part of the ETG. The ETG Ignition System Ignition Unit 1-300-245- 02J and Ignitor Part #: 40404, may contain very small amounts of radioactive material (cesium-barium 137). Under normal operation, no special handling requirements exist. If ignitor damage is suspected, do not attempt to repair. Contact the local Radiation Safety Office/Officer for additional handling and disposal instructions.

2.7 Lockout/Tagout

Lockout/Tagout of the ETG is accomplished by first isolating the ETG output bussing from other electrical components and then securing the battery disconnect switch in the OFF position using an approved method (e.g. Lock out Tags Plus (LOTP)). See section titled, “Main Battery On/Off Switch” for further details.

2.8 Spill Prevention, Control, and Countermeasure (SPCC) Requirements Combined Federal Regulations (40 CFR part 112) require facilities with aggregate aboveground oil storage capacity greater than 1,320 U.S. gallons and with a reasonable expectation of an oil discharge into or upon navigable waters of the U.S. or adjoining shorelines to prevent oil spills and develop and implement an SPCC plan. In addition to understanding the SPCC plan applicable to the ETG usage location, operators must ensure appropriate catchment/containment is provided.

Provision of an appropriate spill kit with sorbent materials, drip pans, etc. is the operator’s responsibility.

2.9 Generator Power Output and Deratings

All engines, including turbines, are rated at ISO 59F°. There is a 0.5% power derating per 1F° above 59F°. Turbine Marine has configured the compact series portable generator to allow for transient power draw above these derating limits for very limited time. For continuous operation, however, electrical load must be adjusted to match the derated power output. Prolonged High ETG will result in a overtemperature condition resulting in an Class F alarm, GCB opening, and loss of electrical power to the attached load.

The following list contains the conditions necessary for each of the derate alarms to become active.

Derate below 900Kw – Intake temperature of 80°F and Load above 900Kw

Derate below 850Kw – Intake temperature of 90°F and Load above 850Kw

Derate below 800Kw – Intake temperature of 100°F and Load above 800Kw

Derate below 750Kw – Intake temperature of 110°F and Load above 750Kw

Derate below 700Kw – Intake temperature of 120°F and Load above 700Kw

Note: There are two alarms Reduce load 1 and Reduce load 2 that will be active depending on the Derate below alarm active. They are used to enable the remote screen to display the overload alarms. Reduce load 1 will be active if Derate below 900Kw or 850Kw is active. Reduce load 2 will be active if Derate below 800Kw,750Kw,700Kw.

1000KW980KW 960KW 940KW 920KW 900KW 880KW 860KW 840KW 820KW 800KW 780KW 760KW

0%

20%

40%

60%

80%

100%

120%

59° F 63° F 67° F 71° F 75° F 79° F 83° F 87° F 91° F 95° F 99° F 103° F 107° F

Ra te d Po w er

KW

Ambient Temperature

Engine Ambient Air Intake Derating Chart Vs. KW Output.

Generator Derating Chart

2.10 Fuel Types, Limitations, and Deratings

Though Turbine Marine has operated Compat Turbine Generators on fuels ranging from diesel, to soy bean oil, to compressed natural gas (CNG), generator operational capabilities vary depending upon the type of fuel used.

JP8 is always preferred over Diesel when it can be used. JP 5 and JP 8 are both kerosene’s. The JP 5 has a 60° C higher flash point than JP 8 and therefore more care has to be taken in storing and refueling with JP 8. JP 4 is 65% kerosene and 35% gasoline which gives it a higher heating value and about 2% more energy than JP 5.

A turbine engine can be started on JP 4 down to - 65 degrees F. The more viscous JP 5 reaches 12 centistokes at - 25 degrees F to -32 degrees F. Turbine engines usually will not start when the viscosity gets above 12 centistokes. The JP 8 is a slightly less viscous than JP 5 and the flash point is lower. The viscosity varies more as a result of where the crude came from. Crude oil from the middle eastern countries is less viscous than the crude from North America. JP 5 is used where vapors and heating of the fuel can occur like on aircraft carriers. Since the flash point of JP 8 is 60° C lower, more care has to be taken while handling and storage in above ground tanks.

In short, unless there is fear of the vapors or storage temperature, JP 8 is preferable.

One must evaluate the heating value of the fuel used. All Jet fuels are required to have a minimum of 18300 BTUs per pound. The aircraft owners pay a premium for fuel that has a heating value of 18700 BTUs per pound or higher. The fuel that is below 18700 BTU per pound is sold to the unsuspecting public. A difference of plus 400 BTUs per pound means that the engine will burn

70.5

121.5

20% 40% 60% 80% 100%

Fu el

F lo w (G

PH

Rated Power %

Diesle Fuel Flow Chart at 80°F

Fuel Flow Chart

2.165 % less fuel. An engine running at 700 #/hr for 1000 hours will burn 152895 pounds less fuel when using 18700 BTUs compare to using 18300 BTUs per pound. That is 1493 gallons less fuel. “

CAUTION: Some hot weather diesel fuel blends contain paraffin which can cause clogging of turbine engine start fuel nozzles if left in fuel lines for prolonged periods. If the generator is operated using high paraffin content fuels, running the engine for approximately 5 minutes on a paraffin-free fuel is advised prior to engine shutdown.

Starting and Stopping the Generator

3.1 Engine Start Pre-Operation Check

NOTE: See Appendices for Pre-Operation check sheet.

3.1.1 Make sure the generator is on firm level terrain and the wheels are chocked.

3.1.2 Insulation Resistance (IR) / Megger Checks

See “Troubleshooting” section “Measure Insulation Resistance” should pre-installation/pre-operation Insulation Resistance readings be required/desired.

3.1.3 Generator and Cable Shield Grounding Point

Generator Ground Attachment points

Generator and Cable Shield Ground attachment points are provided behind the driver side rear fender of the unit. Use these terminals to ground the Cable Shields to plant ground or directly to earth.

NOTE: The ground stud is equipped on all generators delivered in 2022 and After.

3.1.4 Output Leads Connection

Connect all load cables to GCB and ensure the connections are securely bolted in place. Follow all color codes on connections and ensure proper phase rotation for plant systems.

480V Standard Phase Rotation Line Phase 1 Black Line Phase 2 White Line Phase 3 Red

Neutral White (Unused for ungrounded power applications such as Emergency Shore Power replacement)

DO NOT stretch load cables to the point where the weight of the cable rests on the connection point! Decoupling of the load cables may cause serious injury or death due to electrical shock.

3.1.5 Communication Port

The generator’s communication connectors are located on the driver side of the unit, towards the rear of the enclosure inside the electrical compartment. The Communication Panel (or COMM Panel) contains all of the connection ports required for generator-to-generator communications, remote, and auxiliary functions.

• Generator Input: CAN high and Low, for generator-to-generator communications, for load-sharing.

• Generator Output: CAN high and low for generator-to-generator communications, for load-haring. (Termination 120-Ohms resistor cap).

• Remote Control: Communications for the remote screen.

• Load Bank Control: Communication for the supplemental minimum load. (Load-bank)

• Resistor CT: NGR CT COMM connection. (Disconnected from Manufacturer)

• Remote Screen Ethernet Port: Remote screen communication.

For more information on Load Sharing, please see the topic “Load Sharing”.

3.1.6 Emergency STOP Button

The generator contains two (2) Emergency Stop buttons, one on each side of the generator. Using either of these buttons during operation will immediately open the GCB and shut the engine down. It will also trigger alarm strobe lights and a siren. Prior to starting the generator confirm both the Emergency Stop Buttons are in the off position by pulling the buttons until a pop is heard. If the emergency stop is active, the generator will remain in STOP mode with the alarm strobe lights and siren active until the Emergency Stop Alarm is cleared on the EasyGen controller. The generator will not start if any Emergency stop is active. Refer to Alarm Conditions for more information on clearing alarms.

3.1.7 Fuel Line Connection and Priming

The main fuel intake valve is located on the passenger side of the generator. There are two valves one for the on-board day tank and one for main fuel as pictured above. When connecting a fuel line confirm the safety locks on the fuel coupling are properly locked before the fuel valve is opened and fuel is primed into the line.

3.1.8 Priming the Day Tank Fuel Line System

• Before connecting the fuel line, open the fuel line valve into an approved container and allow the air in the line to escape.

• Once air has cleared the line, and fuel is available, close the dry break coupling and reconnect the fuel line to the generator.

• Once connected ensure the fuel valve is in the open position.

• Power on the ETG, and wait for the control system to boot.

• After ETG has booted switch the unit into manual mode.

• Turn on the engine fuel pump switch, and check for proper fuel pressure on the DCU engine monitoring system or on mechanical gauge located on fuel boost pump. Proper fuel pressure is between 70-80 psi.

• Once pressure is verified the fuel pump can be turned off.

• Switch the ETG back into automatic mode, the fuel line is primed.

3.1.9 Priming the Auxiliary (AUX) Tank Fuel Supply Lines

• Attach a fuel-priming pump to the aux fuel tank.

• Connect the aux fuel line to the output of the fuel-priming pump.

• Ensure the fuel pump is in the PUMP position.

• Insert the male fuel connector into the female fuel connector on the end of the fuel line opposite the fuel pump.

• While holding over a suitable fuel spill container, open the valve on this end of the aux fuel line. Set the valve into an appropriate fuel spill container.

• At the aux tank, pump the priming pump several times until fuel flows freely into the spill container.

• Close the aux fuel line output valve in the spill container and remove the male connector.

• After priming the fuel line and closing the female side of the fuel line, remove the priming pump.

• Reattach the primed fuel line to the aux fuel tank. See the Turbine Marine Video on aux fuel line priming for additional information.

Failure to remove the aux fuel pump from the fuel line will limit fuel delivery to the ETG resulting in engine shutdown at higher loads due to low fuel pressure.

3.1.10 Priming the Auxiliary (AUX) Tank Fuel Supply Lines Without Priming Pump

• Make sure the day tank has sufficient fuel to run the ETG and the fuel line is connected with both valves in the open position.

• Attach the auxiliary tank fuel line to the ETG with the valve in the off position.

• Run the ETG off the day tank fuel supply.

• While the generator is running slowly open the auxiliary fuel line valve allowing the line to start priming.

• While opening the auxiliary fuel line valve monitor the fuel pressure and N2% on the DCU if either parameter starts to drop in pressure or speed close the aux fuel valve. This will allow the ETG to stabilize.

• Once the fuel pressure and generator speed have stabilized repeat the previous two steps until no fluctuation is noticed at this point the aux fuel line is primed.

The preferred method of priming the auxiliary tank fuel line is with the hand priming pump. The above method is only recommended if the priming pump is not available or if the auxiliary fuel line isn’t completely void of fuel.

3.1.11 Switching from Day Tank Fuel Supply to Auxiliary Fuel Supply

• Prime the Day Tank and aux Tank fuel supply lines as detailed above

• Remove the External Tank Fuel Input cap.

• Connect the Dry-Break valve to the External Fuel Tank Input.

• Start the generator using the generator day tank fuel supply.

• After the unit reaches normal operating speed, slowly open the aux fuel line valve. The transition between tanks should be seamless.

• If fuel pressure dips too low, or a decrease in engine RPM is heard, shut the aux fuel line valve handle and let the day tank fuel supply take over again.

• Once the engine N1 RPM has recovered, attempt the transition from day tank to aux tank again, opening the aux valve more slowly.

• Once the aux tank fuel line is primed and the aux valve is fully open, slowly close the Day Tank fuel valve.

Failure to close the Generator Day-Tank dry-break fuel line valve (One or both) after transitioning to an aux tank will result in emptying of the Day Tank. Air will get drawn into the system resulting in engine shutdown.

DO NOT use cracked or damaged fuel lines, with damaged couplings, or with missing or damaged coupling locks. Poor engine performance may result. Fire hazard is also possible!

3.1.12 Main Battery On/Off Switch

The 24Vdc main battery disconnect switch is located inside the front of the enclosure on the driver side of the generator.

The switch may be secured with a padlock in the event a battery lockout is required.

3.1.13 Main Power supply circuit (ANL fuse)

The main 24Vdc 60Amp ALN fuse, is located directly next to the battery switch. In the event there is no power to the unit’s electrical system with the battery switch in the “ON” position, the operator should check the fuse to ensure that it is still intact.

To inspect, squeeze the cover on both sides simultaneously and pull on the plastic cover. Removal of the cover will expose the fuse for inspection. Ensure that the cover is reapplied after inspection or replacement of the fuse prior to generator operation.

3.1.14 Exhaust Rain lid

The generator is equipped with an automated exhaust lid. Upon the generator receiving a start command the lid will automatically open prior to the start of the turbine engine. The automated lid system is outfitted with a switch to allow the controller to verify the lid is open prior to starting the turbine.

The operator should visually verify the exhaust lid is opens before the generator has fully started.

NOTE: For maintenance or extended cooling of the exhaust system. The unit can be placed in “Service Mode” while unit is NOT running to open exhaust lid. Revert back to “Auto Mode” to close lid. No other action is needed to perform this operation

NEVER allow the turbine to start if the exhaust lid is closed. Press the E-stop Immediately if this scenario is observed.

3.1.15 Engine Oil

Before running the generator, it is important to perform a visual inspection on the oil reservoir lines and fittings for any leaks.

When in long term storage, the oil in the reservoir may back flow in to the engine, therefore, the oil top level indicator on the oil reservoir will not show an oil level. This is normal and the oil level returns to indicator when the engine is running. There should always be oil in the bottom sight glass.

If before or during operation the “Oil Level” warning LIGHT illuminates, oil NEEDS to be added to the system immediately.

Always use Eastman Turbo 2380 oil that meets or exceeds the MIL- PRF-23699F-STD specifications. Always check the API service label on the oil container to be sure it meets or exceeds those specifications. Note: (If possible, do not mix oil brands).

3.2 Starting the Engine

3.2.1 Pre-Start Visual Inspection

Before starting the generator, perform a visual inspection on the items below:

• Generator is on firm level terrain.

• Fuel coupling is securely locked, fuel valve is open, and fuel system is primed.

• Oil is visible in the bottom sight glass minimally.

• Verify no oil/fuel leaks are present inside the enclosure

• Load Sharing cables are securely fastened and locked (When applicable).

• All Input/output leads are securely fastened and no person is holding, or has contact with electrical cables.

• Load cables are securely fastened, and phases are in proper orientation, and rotation.

• No active alarms on EasyGen or DCU displays

3.2.2 Starting the Engine

Switch the generator ignition toggle switch to the “ON” position. The control panel components will power on and cycle through their initial sequence.

Check to make sure that the EasyGen 3500XT is displaying the “AUTO” icon, and not the “STOP” icon.

Press the (Green) “START” button located on the DCU display then release this will bring up a confirmation screen asking if you are sure you want to start. Press the lower left soft-key to confirm the generator will begin its start sequence.

Monitor the engine speed until the turbine has reached its warm up speed, ~80% N2. If N1 speed does not go over 20% in the 25 seconds, DO NOT CONTINUE, as a Failed Start has occurred. Proceed to next topic titled “Failed Start” before proceeding.

The generator will now go through an automated start sequence, upon completing the start sequence the generator will go through a warm up cycle for approximately 90 seconds. After completing the warm up sequence, the generator will ramp up to operational frequency and close the GCB and wait for load to be applied.

3.2.3 Performing a Service/Manual Start

It is recommended that the operator does not perform service starts unless actually performing service or maintenance on the unit, or if troubleshooting a problem. However, if a service start is required, perform the following steps

• Set generator to Service Mode by placing the Service toggle switch in the up position.

• Activate toggle switches for Run/Stop, Igniters, and Fuel Pump.

• Lift and firmly hold Ignition switch for approximately 40 seconds or until N1 speed reaches 40%, whichever occurs first, then release. If N1 Speed does not go over 20% in the 25 seconds, DO NOT CONTINUE, a Failed Start has occurred. Proceed to next topic titled “Failed Start” before proceeding.

• Once the N1 speed has reached 80% or greater, set the Service Switch to the Automatic position by closing the “Red” safety cover.

• Wait approximately 60-90 seconds for engine warm up, before engaging the operational switch to put the unit in operational mode that will bring the unit to 60 Hz.

• Ensure generator N1 speed has reached 80% or greater before returning Run/Stop, Ignitors, and Fuel Pump Toggle switches to the OFF position.

WHEN SERVICE MODE IS ACTIVE (TOGGLE SWITCH IN UP POSITION). ALL ALARMS AND

SAFETY FEATURES MONITORED BY THE WOODWARD EASYGEN 3400 ARE DISABLED. THE

GENERATOR “WILL NOT” ACTIVATE ANY CLASS F (ENGINE KILL / BREAKER OPEN) ALARM If

DETECTED.

DO NOT OPERATE THE GENERATOR IN “SERVICE MODE” AFTER AN EMERGANCY START FOR

ANY EXTENDED TIME THAT IS NOT CRITICAL.

NOTE:

INDEPENDENT FROM THE EASYGEN 3400 SAFETY SETTING SYSTEMS. A COUPLING OVER-

SPEED SWITCH MONITORING SYSTEM IS IN PLACE TO STOP “KILL” THE ENGINE AT ANY

SPEEDS OVER 113%-N2 ENGINE SPEED, OR 2034RPM GENERATOR COUPLING SPEED.

3.2.4 Failed Start

The start sequence will maintain the starter motor engaged for approximately +/- 25 seconds.

During this time, monitor the engine speed until the turbine has reached a N1 speed of 40% N1 or greater. If the N1 speed does not reach 40% or greater, and the start sequence has timed out, switch the generator ignition toggle switch to the “OFF” position and attempt the start sequence a second time after checking for a probable cause listed below. Let the starter cool down for 3-5 min between start attempts. Contact support personnel for assistance, if the problem persists for more than 3 starts. Turbine Marine should be contacted for remote trouble shooting (call or Text 1 954 415-7218)

The most frequent reasons for a timed out start sequence.

1. Low Battery:

Under 24.5Vdc Static. Under 17Vdc while engine is spooling up on starter.

Run / Stop fuel valve not operational. (Check Breaker)

E-Stop Active

2. No Fuel to engine

Air in NEW or newly installed fuel line after transport.

Check fuel tank for fuel

Fuel hose fittings are NOT tight (Air Leak)

Check and make sure fuel line is not kinked

Priming pump installed in-line with fuel line, is not in the run position.

Low fuel pressure 70 - 80PSI (Boost Pump is capable of 15 PSI of air pressure with no fuel).

Vacuum leak from faulty fuel Filter installation or loose fuel line.

Quick disconnect dry-break fuel connection not in the OPEN position, or not connected or locked in place correctly to the Generator.

Independent Over Speed System Fuel Valve Active or Not Re-Set.

3.3 During Operation

3.3.1 Operating Visual Inspection

After starting the generator, or during prolonged periods of operation, perform a visual inspection on the items below. In parenthesis is the typical range for each parameter during normal operation.

• Check for warnings on EasyGen 3400XT display.

• Verify voltage and frequency are within operating range.

• Verify Oil Pressure is within operating range of (75-100psi).

• Verify EGT is within operating range of (450-650˚C MAX).

• (Reference Engine Ambient Intake Air Temperature De-Rating Chart Page 16).

Reference Engine Air - Intake Temperature from AUOTOMASKING Engine Display Page #2. “Air Intake Temperature”.

• Verify Oil Temp within operating range of (Ambient-190˚F MAX).

• Verify Fuel Pressure is within operating range (70-80psi)

• Check oil/fuel lines and fittings for leaks.

• Check to make sure Anti-Ice is OFF, unless frost is observed around the intake of the engine.

3.3.2 Operational/Standby Procedure

After starting the generator, the unit will automatically go through a warm up cycle (Approximately 90sec). Upon completion of the warm up, the unit will ramp up to operating frequency and initiate the necessary systems to come online. Once the generator is at operating frequency the GCB will close and await its load.

The unit will run for 2 minutes to apply load, or the generator will automatically go back to idle to avoid running for prolonged periods of time at 60Hz not loaded.

If load is applied during those 2 minutes the generator will continue to run until a shutdown command is issued.

If the operator wishes to apply load after the generator goes back into idle mode, they will need to hold the Operational/Standby switch (Located on the bottom right of the control dash) in the operational position for approximately 5sec this will signal the generator to ramp back up to frequency and close the GCB allowing load to be applied.

If the generator sits in Idle mode for 10+ minutes if will go into cool down mode and shutoff automatically. If this occurs the operator will have to restart the generator in order to apply load again.

3.4 Stopping the Engine

Press the Red Stop button located on the DCU410 front panel upon doing so a confirmation screen will appear asking if the stop engine command is intended. Confirm with the lower left button on the DCU410. The generator will now begin its power down sequence by opening the breaker and going into its cool down period. Upon completion of the cool down period (Approximately 120 seconds) the engine will completely shut off.

3.5 Post Operation

Switch the ignition toggle switch and main battery switch to the “OFF” position when not in use.

Load Sharing

4.1 General Information

Turbine Marine Compact Series Portable Generators utilize the Woodward 3400XT and 3500XT Series Generator Controller, which is designed to synchronize and load share with up to 32 units providing the units are equipped with the same EasyGen XT Series controller. Information between generators is transmitted through the CAN bus cables connected at the COMM port on each unit. The CAN bus communication cable consists of two (2) 22g wires which connect at the “Gen Output” plug from one generator to the “Gen Input” plug on the other, which is located on the generator COMM Ports. (3400XT, is Bulkhead mounted / 3500XT is Panel mounted

4.2 Multi-Master Principal

It is important to understand that the load share functionality is subject to a multi-master principal.

This means that there is no dedicated master and slave function. Each generator decides for itself how it has to behave based on the information published on the network. The benefit is that there is no master generator, which may cause load-sharing failure in case the master generator fails.

4.3 Device Number

Generators must be assigned a generator specific identification number, ranging from 01 to 32. That number will enable all generators to monitor each other’s status, such as load, breaker position, running mode etc. If multiple generators share the same number, they will not be included in the logical network despite being physically connected to the network.

4.4 Parameter Alignment

The multi-unit parameter alignment functionality requires that the relevant parameters in the software are all configured identically on all participating units. All relevant parameters must be identical in order for proper unit load sharing. A warning alarm will be displayed, “Parameter Alignment”, when a difference is detected. For additional information on this topic, refer to Chapter “Multi-Unit Parameter Alignment”, of the EasyGen 3400XT User Manual.

4.5 Missing Members

The missing member functionality displays an error message “Missing Members” if there is/are generators which should be, but are no longer, on the network. This occurs in the case where the control panel of a unit on the network has been shut off, a CAN bus cable has been disconnected or cut, or the impedance resistor has been removed from the first and last generator on the chain.

4.6 120 Ohms Impedance Resistor The CAN bus must be terminated with a resistor, which corresponds to the impedance of the cable at both ends. This resistor can be located directly on the CAN bus connection on the back of the device, or through a plug (supplied) on the output of the COMM port. 2 CAN bus resistors are required: one located on the first unit; and the other located at the very last unit of the daisy chain.

4.7 Maximum CAN bus Length

The maximum length of the communication bus wiring is dependent on the configured baud rate.

The slower baud rate, the longer the distance may be. Turbine Marine has supplied the correct cable length for optimal performance. Consult a Woodward Load Sharing Professional, or contact Turbine Marine Inc., before changing the cable length.

4.8 Bus Shielding

All bus connections of the EasyGen 3500XT are internally grounded via an RC element. Therefore, they may either be grounded directly or also via an RC element on the opposite bus connection.

4.9 Troubleshooting

If a unit is connected but does not appear on the network, or there is no data transmission on the CAN bus, check for the following common CAN bus communication problems:

- A T-structure bus is utilized

- CAN-L and CAN-H are switched

- Not all devices on the bus are using identical baud rates

- Termination resistor/s are missing

- The configured baud rate is too high for the wiring length

- The CAN bus cables is routed in close proximity with power cables.

- A unit CAN bus cable is unplugged.

4.10 Creating a Load Sharing Network

In this section are the steps needed to add a generator to a network for load sharing to occur between two (2) generators. The same steps will be performed on every unit, up to 32 units.

4.10.1 Password

The first step in configuring the generator for Load Sharing is to assign the generator its unique device number. The device number functions as an IP address for the generator on the network.

To access the Password page select the “parameter” soft key.

Next, select the “Enter Password" Soft key.

Insert the Global Administrator Numerical Password. Without this password, the Operator will not have access to any parameters. Contact Administrative Personnel for the password.

With this password, personnel, including unauthorized personnel, will be granted access to privileged menus and allowed to make changes to critical generator settings which, if changed, may cause undesired operations, or may render the generator inoperable. Exercise caution when making changes to the factory programmed settings.

4.10.2 Assign Unique Device Number

After the password has been input, return to the home page and, again, select the “Parameter” soft key.

Proceed by selecting the “System Management” soft key.

From the menu, select “Device Number” ranging from 01-32. It is recommended that the numbers assigned flow in sequential order. If, for example, Four (4) units will be participating, the units should be numbered; 1, 2, 3, and 4.

We do not recommend skipping numbers in the sequence, for example, 1, 4, 9, 11. By numbering the units in this manner, the units will not all be displayed in the same unit visualization page, requiring the Operator to navigate to multiple pages to view each generator’s status.

4.10.3 System Update

Once you have assigned each unit its unique device number, it will be required to perform a system update, this function monitors all members on the load share bus and will teach all members the current constellation of members. From the homepage select the “Next Page” soft key.

Select the “Multi-unit” Soft key.

Proceed to select the “Diagnostic devices” soft key.

Once on the Diagnostic devices page select the “System Update” function.

Once the system update function is active it will take approximately 30 seconds for it to complete.

Upon completion the status of the all EasyGen’s will be displayed on the Diagnostic devices page. If all units trying to load share are configured correctly and communicating each will be displayed according to their device number with a green dot and an OK symbol pictured above. All units to be load shared need to have the green dot and OK status in order to successfully load share. If you are experiencing issues having units successfully communicate refer to our troubleshooting guide in the beginning of the Load Share section of this manual or 4.5.6.17.2 section in the EasyGen 3400 manual.

4.10.4 Visualize units on the network

Once you have assigned each generator its unique device number, and configured the number of generators that will be included in the Load Sharing network, the Administrator may check to ensure that all units are actively on the network. No password from an Administrator is required to view this information, and we encourage all personnel to visualize this information periodically.

To do this, follow the steps below;

From the home page, select the “Next Page” soft key

Proceed to select the “Multi-Unit” soft key.

Select the “States EasyGen” soft key.

Every unit currently on the load sharing network will be displayed in the following screen.

Operators will see the current operational status of every generator on the network: breaker position, the unit number, and (in black) the segment of which the generator is currently a part (if applicable). This information can be seen on any of the units on the network.

4.11 Adding Generators to an Active Load Sharing Network

Adding a generator or generators to an active Load Sharing network without disrupting the load is possible, however, it is important that the operator clearly understands the steps, and completes them in the exact order, to successfully add supporting generators to an active load sharing network.

4.11.1 Configuring Additional Generators

Assign Consecutive Device Numbers

The first step would be to configure all the additional supporting generators to the new network.

Follow the steps outlined in the topic above titled “Assign Unique Device Number” and assign each generator being added to the network its unique device number, continuing in sequential order from the units that are already actively load sharing. For instance, two units are currently Load Sharing, and their assigned device number is 1 and 2. The additional unit added to the network should have its device number configured to 3, and so on.

Configure Total Number of Units on Network Follow the steps outlined in the topic above titled “Number of Units” and configure the total number of units which will be communicating in the new network on all supporting units. In our example, we are adding a 3rd unit to a load share network containing two (2) units. The “number of generators communicating” on the supporting generator will be set to three (3).

Prepare Active Units for the Additional Supporting Units On the currently active generators, proceed to the “Number of Generators Communicating” screen on the EasyGen 3500 Controller. Begin to edit the “Number of Generators Communicating” to three (3), however, DO NOT press ENTER at this time.

DO NOT change the “Number of Generators Communicating” on the currently active load sharing generators at this time! In seconds, load imbalance conditions will occur resulting in “Reverse Power” and forcing one (1) or multiple units to malfunction and shut down.

Connect all COMM Cables Stage the additional supporting units in the desired locations and proceed to connect all additional generators to each other using the supplied COMM cables. Connect the COMM cable from the additional supporting generator to the last currently active load sharing generator.

When staging the additional supporting units, remain close enough to the active load sharing units to share the same length COMM cable. Different cable lengths require different Baud Rates, and it is important to retain the same configured Baud Rate throughout every unit. The Baud Rate is a parameter which must remain the same on all controllers to prevent a controller from transmitting data packets at the same time as another controller and causing network congestion or possible loss of data.

120 Ohms Termination Resistor Quickly relocate the 120 Ohms termination resistor from the last currently active Load Sharing generator to the last additional supporting generator.

Set Number of Generators Communicating on Active Load Sharing Units Once the COMM cables are in place, and the 120 Ohms termination resistor has been relocated to the last additional supporting unit, you may proceed to the actively Load Sharing units and press ENTER on the screens to submit the new number of generators communicating to three (3).

Visualize Units on the Network At this time, you may confirm all additional supporting units are on the network by proceeding to the “States EasyGen’s” screen and visualize all the current generators currently on the network.

Control Panel Overview AND Quick Function Reference

ENGINE DATA

MONITORING

AND AUTO

START STOP

MODE

BUTTONS

EASYGEN

3400XT

450-480VAC

LOAD

MONITORING

AND SAFETY

SYSTEMS

GENERATOR

SYSTEM

WARNING

LIGHTS

24 VDC

BATTERY AND

ENGINE

CHARGING

SYSTEM METER

AND SELECTOR

SWITCH

ENGINE

MANUAL

STARTING

SELECTOR

MODE SWITCH

AND SYSTEM

OPERATION

FUNCTION

SWITCHES

OIL COOLER

FAN OVERIDE

(ON) SWITCH

(RIGHT)

HOT AIR

ENGINE DE-ICE

SWITCH

GENERATOR

OPERATION MODE

MOMENTARY SWITCH.

UP 3 SECONDS FOR

60HZ OPERATION

GFROM IDLE MODE

ENCLOSURE

LIGHT

SWITCHES

ENGINE IGNITION (FIRST

POSSITION UP)

MANUAL START SWITCH

SECONG MOMENTERY POSITION

UP

5.1 AUTO-MASKIN MARINE PRO. DCU 410E Display Dash

5.1.1 DCU 410 Display

The Turbine Marine 480V Portable Series Generator utilizes the DCU 410 Digital Display as its main engine monitoring component.

The DCU is programmed to display the following engine parameters:

• Engine N1 (Engine RPM)

• Engine N2 (Output Shaft RPM)

• Exhaust Gas Temperature (EGT)

• Oil Temperature

• Oil Pressure

• Fuel Pressure

• Intake Temperature

• Fuel Level

• 24VDC Battery Voltage

5.2 WOODWARD EasyGen 3400XT

5.2.1 WOODWARD EasyGen 3400XT

The Turbine Marine 450Vac - 480V Portable Series Generator utilizes the EasyGen 3400XT/3500XT series control panel for generator power management and automatic operating functions.

Generators equipped with “remote screen option”, have the EasyGen 3400XT and remote touch screen installed which also contains context-sensitive touch keys to navigate through the menus, as well as displays all measured values, modes of operation, hour meter, and alarms.

5.3 Volt Meter

The Volt Meter displays the voltage from the battery and from the 24Vdc charging system. The voltage display can be toggled between battery and charging system by making the selection using the “24V System” toggle switch.

5.4 Battery Voltage/Generator Voltage switch

This toggle switch will have the voltage meter display current voltage levels based on what option is selected. In the “Battery” position, the voltage meter will display the current battery voltage. (24-27Vdc)

In the “Generator” position, the voltage meter will display the current voltage generated by the turbine’s starter/generator (24-29 Vdc) The LED illuminates when at 24Vdc.

The small center button on the voltage meter itself, is the gauge light dimming switch.

5.5 Manual Engine Functions

5.5.1 Manual Mode

The Manual Mode switch is used by maintenance personnel during service. When activated, all automatic features are disabled, and attempts to start the generator through the Start/Stop buttons will be ignored. Any active alarms or alarms that become active while running in Manual Mode will be ignored. It is not recommended to operate the generator in Manual Mode for prolonged periods of time past 60 seconds, as the generator controller will not be able to shut down the unit in case of a class F alarm. (Shut Down Alarm)

5.5.2 Engine Run/Stop

During maintenance or service, this toggle switch is used by personnel to operate and test the Engine Run/Stop Valve, or other systems without allowing the engine to star. Under normal operation, this valve is operated automatically, and the toggle switch input is ignored. The Run/Stop solenoid valve is what allows main fuel to flow into the engines fuel system. The generator will not run with this valve off.

5.5.3 Engine Igniters

During maintenance or service, this toggle switch is used by personnel to operate and test the Engine Igniter system or other systems without allowing the engine to start. Under normal operation, the Igniter’s are operated automatically. With this switch in the on position the ignitors will fire when the starter is active.

5.5.4 Engine Fuel Pump

This toggle switch is used to activate the main fuel boost pump, and the fuel priming pump. Under normal operation, this is controlled automatically. However, this toggle switch remains functional to assist in priming the fuel system or verifying fuel pressure settings.

5.6 Lighting

5.6.1 Interior

Interior light toggle switch activates the bright L.E.D.’s located in the following locations;

• Engine Compartment

• Electrical Compartment

5.6.2 Exterior

Exterior light toggle switch activates the bright L.E.D.’s located in the following locations;

• Oil Sight Glass

• Dash Switch Panel

5.7 Temp Control

5.7.1 Engine Anti-Ice

This user-controlled toggle switch will activate the “Engine Anti-Ice” solenoid valve, which opens a solenoid valve located on the hot side of the engine, and allows hot air to be bleed into the engine air intake. This hot air serves to prevent ice buildup in the intake during prolonged operations in subzero environmental temperatures, and should only be used when frost buildup is observed on the intake or engine. Engine anti-ice is an automated function in the control system on the generator however this switch can be used to by-pass the automated control if the operator sees fit. It will automatically turn on when the intake temperature is below freezing (32°F - 0°C)

Anti-Ice is used to prevent ice build-up in the Engine’s air intake when operating in environments where freezing may occur. Use only in the event frost buildup on the intake is observed, as to not decrease engine performance.

5.7.2 Engine Oil Cooling Fans Override

Cooling fans automatically activate at an oil temperature of 130°F, however, in case they fail to activate automatically, this manual override switch is available.

5.8 Engine Warnings

5.8.1 Engine Alarm

Engine related alarms received from the control system will illuminate this alarm light. If this light is illuminated the generator will go into a cool-down and shutdown automatically to prevent engine damage. To be able to turn off an alarm light, the alarm must be no longer active, and it will need to be acknowledged and cleared from the DCU or EasyGen display.

Note: An example of one condition that would turn this light on is a high EGT event.

5.8.2 Oil Tank Level

Oil tank level light illuminates when low oil level is detected in the oil tank. If this light is illuminated, the control system will automatically put the engine in a cool-down sequence and shut off. In order to re-set this light, the oil will need to be added to the oil sump.

5.8.3 Metal in Oil Contamination

A magnetic oil plug is located in the engine oil sump, which collects metallic debris. If enough metallic debris is collected, they will close a circuit illuminating this light on the dashboard. When this occurs, it will trigger an automatic cooldown and shutdown to prevent engine damage.