Engine

DETAILED ENGINEERING
DOCUMENT
ORDER
DATE
Nov-2012
ENGINEERING VEC001101
INDEX

CUSTOMER
ROYAL GK PTE LTD

- CONTENT -
1 GENERATOR SETS INSTALLATION MANUAL GUASCOR VEC001110
2 LIST OF PLANS
3 LIST OF MATERIALS

INSTALLATION
MANUAL

Equipment: SFGM560/4
Order: VEC001110
Customer: ROYAL GK PTE LTD

2.9.1. Generator sets instalation manual
Guascor VEC001110

Documentacin
Documentation

INSTALLATION
MANUAL

Order: VEC001110

INSTALLATION
MANUAL

Order: VEC001110

EQUIPMENT
SFGM560/4
ORDER

VEC001110
CUSTOMER
ROYAL GK PTE LTD

DATE
2012-11

INDEX A
CONSISTENTS WITH OUR CONTINUAL PRODUCT IMPROVEMENT POLICY, GUASCOR RESERVES THE RIGHT TO CHANGE ANY SPECIFICATION WITHOUT PRIOR NOTICE 1/2

INSTALLATION MANUAL INDEX

DENOMINATION REFERENCE
REVIEW OF COMPLIANCE WITH EUROPEAN MACHINERY SAFETY
REGULATIONS AND "CE" MARK
IC-G-D-60-003e
SAFETY PRECAUTIONS FOR GUASCOR GAS ENGINES IC-G-D-60-002e
POWER GENERATING SET (GENERAL DIMENSIONS) IT-O-A-2-001110-01e
NORMS FOR CORRECT HANDLING OF GAS GENSETS GUASCOR IT-G-A-70-003e
FIXING OF LAND - BASED SETS IT-C-A-70-004e
CHECK FOR ALIGNMENT OF FLANGED SETS IT-C-A-70-010e
ELASTIC SUSPENSION Ref. 76.82.450 IT-C-A-70-009e
VENTILATION IT-C-A-35-001e
BLOWBY GASES EXHAUSTING GUASCOR ENGINES IT-C-A-25-001e
BASES FOR USE OF PRE-LUBRICATION AND OIL AND WATER PREHEATING IC-C-D-00-008e
AUTOMATIC ENGINE OIL LEVEL CONTROLLER IT-C-A-25-002e
LUBE OIL LEVEL INDICATOR IT-C-A-25-009e
GUASCOR MOTOROIL 3040 PLUS LUBE OIL FOR NATURAL GAS-FUELLED AND
ETHANOL ENGINES
IC-G-D-25-003e
REMOTE PRELUBING WITH 300Lt. (79,25 gal) OIL TANK 360/480/560 SERIES
ENGINES
IT-C-A-25-008e
INSTALLATION OF EXHAUST PIPELINE IT-C-A-40-001e
EXHAUST FLEXIBLE REF. 16.40.040 IT-C-A-40-002e
GUASCOR EXHAUST SILENCER GENERAL DESCRIPTION IC-C-D-40-002e
EXHAUST SILENCER 30 dB(A) DN300 REF. 76.81.229 IT-O-A-2-001110-05e
SFGM 560 ENGINES EXHAUST CONNECTION IT-O-A-2-001110-02e
COOLING WATER QUALITY AND TREATMENT IO-C-M-20-001e
COOLING SYSTEM (GENERAL INFORMATION) IT-C-A-20-003e
METHOD FOR CALCULATION OF HEAD LOSSES AND FLOWRATES IT-C-A-20-001e
EXPANSION TANK ADAPTATION 80L. REF. 40.20.450 & 50 L. REF. 40.20.460 IT-O-A-2-001110-07e
ELECTRIC PUMPS IN GENSET BEDPLATE 40.20.E80
INSTALLING THE IN-LINE ELECTRIC WATER PUMP IT-C-A-20-011e
MAIN CIRCUIT WATER ELECTRO-PUMP REF. 76.28.287 IC-G-D-20-067e
AUXILIARY CIRCUIT WATER ELECTRO-PUMP REF. 76.28.285 IC-G-D-20-066e
FLEXIBLES JOINTS REF. 38.20.510 (DN80(3) REF. 76.14.305 & DN50 (1) REF.
76.14.303)
IT-C-A-20-014e

EQUIPMENT
SFGM560/4
ORDER

VEC001110
CUSTOMER
ROYAL GK PTE LTD

DATE
2012-11

INDEX A
CONSISTENTS WITH OUR CONTINUAL PRODUCT IMPROVEMENT POLICY, GUASCOR RESERVES THE RIGHT TO CHANGE ANY SPECIFICATION WITHOUT PRIOR NOTICE 2/2

DENOMINATION
REFERENCE
AIRCOOLER
INSTALLING AN AIRCOOLERS IT-C-A-20-016e
AIRCOOLER DRAWING 76.73.625
USER AND INSTALALTION MANUAL STANDARD AIRCOOLERS IT-G-A-20-020e
GAS RAMP
INSTALLING GAS VALVE TRAINS IT-G-A-30-015e
GAS INLET FLEXIBLE 38.30.250 IT-G-A-30-011e
GAS RAMP 2.000553.040
24 Vdc. WIRING BOX 2.001110.120
400Vac WIRING BOX 2.001110.130
ALTERNATOR INFORMATION LSAC50.2 L8
GENERAL RECOMMENDATIONS
76.26.453 INSTALLATION AND MAINTENANCE MANUAL
R450 REGULATOR
POWER & CONTROL CABINET
POWER & CONTROL CABINET 2.001110.020
GENSET ELECTRIC CABINET POWER MODULE IO-C-M-AP-001e
GAS GENSET STANDARD CONTROL CABINET HMI OPERATORS MANUAL

IO-G-M-AC-001e

SAFETY AND PRECAUTIONS
PRODUCT INFORMATION

INDEX

DATE
Dept. 2
IC-G-D-60-003e C
August 2012:
REVIEW OF COMPLIANCE WITH EUROPEAN MACHINERY
SAFETY REGULATIONS AND "CE" MARK

1/7

1. INTRODUCTION

This document describes all the design and operative features of our engines and their applications (generating
sets or others) as well as the technical solutions that we have implemented in order to comply with the current
machinery safety regulations. These include the Royal Decree 1435/1992 and subsequent amendments, the
European Directive 2006/42/CE, and the harmonised standards UNE-EN ISO 12100-1 and UNE-EN ISO 12100-
2. Compliance with them is mandatory in order to be able to issue the Declaration of Conformity with the
European Regulations and to use the "CE" mark.

2. ENGINE DESIGN

The check for compliance with the European Regulations on Machine Safety described in this document applies
to GUASCOR POWER GAS and ETHANOL engines.

Those engines are developments of their DIESEL counterparts whose design has passed technical audits by
renowned Certification Agencies - LLOYDS REGISTER, BUREAU VERITAS, GERMANISCHER LLOYDS,
RINA, DET NORSKE VERITAS, HELLENIC REGISTER OF SHIPPING, and others - for approval in marine
applications and has been awarded the TYPE APPROVAL' certificate that guarantees the suitability of the basic
engineering design.

In designing and manufacturing the engines, GUASCOR POWER follows risk suppression or reduction criteria,
implementing adequate solutions and adopting the necessary protective measures when it is not possible to
eliminate said risks. In this event, GUASCOR POWER informs users of any residual hazards due to incomplete
effectiveness of the protective measures, advising them that they must have specific training and use personal
protective equipment where necessary.

Similarly, in designing and manufacturing the machine as well as in writing the product information, GUASCOR
POWER bears in mind not only the normal use, but also any reasonably expectable use of the machine.

3. ENGINE ROOM

The engine room or the area surrounding the engine or generating set cannot be rated as a danger zone under
the prevailing regulations, since the running of the engine will under no circumstances give rise to the release of
solids, liquids or heat in the same, which could affect the operators' safety.

Notwithstanding this, given that the engine operation, service or control while running does not require anybody to
be very close to it, we recommend that operators should stay at an adequate safety distance to prevent the
effects of any fatal, unforeseeable failure, if it ever occurs.

Adjustment and fine-tuning operations (valve timing, oil and water level control, etc.) are to be performed with the
engine off. Only qualified and trained personnel must carry out carburetion adjustments with the engine on
according to the established procedures, without putting any of the operators in danger.

4. RISK ANALYSIS

In designing the engines, we adopted technical options or solutions that avoid intrinsic and specific engine
operation hazards.

Nevertheless, due to the very concept of the machine and its operation, there still exist various unavoidable,
though limited hazard features, representing a risk for the operator.

PRODUCT INFORMATION

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This section reviews the design solutions implemented in order to overcome possible machine-specific risks and
the preventive measures established against unavoidable risks.

Guascor Power shall not be liable for any injury or damage arising from any use of the engine other than that
described in the instruction manual. Operating the engine beyond its nominal conditions (e.g. in terms of power,
advance ignition, mixture strength - carburetion, etc.) can have serious consequences for the user, or even put
the user's life at risk and cause extensive material damage.

4.1. Materials and Products

The materials and products used for the construction and operation of the machine do not involve any health or
safety hazard, on condition that operators abide by the user instructions and prevailing regulations.

4.2. Drives of the Equipment

The drive systems are safe and reliable, with clearly identified and visible controls, including adequate alarms as
well as normal and emergency stop devices.

4.3. Mechanical Hazards

The equipment supplied has been designed and built to offer sufficient stability under the planned operating
conditions. Their components are designed for appropriate resistance in operation. Product Information sheets
specify the necessary inspection and maintenance programmes for safetys sake.

We design and manufacture the moving parts of the engine to avoid any risk. Therefore, they incorporate guards
or protective systems impeding physical contact that would cause injuries or accidents. Driving components
(pulleys, belts, gears, etc.) have covers that can be fixed or movable depending on the frequency of servicing
tasks. All protective devices are made solidly and resistant.

4.4. Electrical Hazards

The engines design, construction and equipment prevent or ensure possible prevention of all electrical hazards.
Refer to section Electrical Installation. Moreover, the engines have static elimination systems.

4.5. Fire, Explosion or High Temperature Hazards

We have taken precautionary measures to avoid injuries caused by hot parts or materials through physical
contact or remotely. Moreover, we addressed the risk of flying hot matters and avoided fire and overheating
hazards originating in the engine.

Different types of fluids of varying characteristics circulate through the engine at variable temperatures.

4.5.1. Cooling Water

By design, all the connections in the water circuit are fitted with mechanical seals and/or bushed systems with
ethylene propylene O-rings, suitable for the high temperature of the engine coolant in the main system (120C)
and in the auxiliary circuit (90C). Therefore, no rubber couplings are used.

4.5.2. Lubricating Oil

The oil circuit has been designed fully integrated into the engine; in this way, the only outgoing pipes are those to
and from the oil cooler. Sealing of all the tubes is through mechanical seals or bushed systems with Viton O-rings,
avoiding the use of rubber couplings by all means.

PRODUCT INFORMATION

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4.5.3. Forced Induction

In the supercharging circuit (downstream of the turbocharger), sealing of the different components is by means of
mechanical seals with Viton O-rings. Rubber sleeves and other materials have been totally discarded.

4.5.4. Manifolds and Exhaust Pipe

To limit leak risks, the engine exhaust manifolds are mechanically sealed by means of special metal-reinforced
joints.

For the purposes of protecting the operators in case of accidental contact, we have designed a refrigerated
exhaust manifold with the engine cooling water circulating outside and around the exhaust manifold; in this way,
the temperature on the exhaust manifold surface, otherwise 400 to 500 C, falls to the coolant temperature levels
of 80 to 90 C.

As for the turbocharger, the turbine casing (exhaust side), that is also very hot and cannot be refrigerated, is
protected with a heat-insulating blanket (or jacket) limiting the surface temperature to less than 90 C. This
solution also applies where the engine application requires the use of hot (uncooled) exhaust manifolds.

A similar type of protection covers that portion of the exhaust elbow or pipe extending to the connecting flange on
the hose for connection to the external exhaust pipe. The installation project shall provide for the protection of this
exhaust pipe. When supplying the installation, we check for possible contact with this piping and, where
appropriate or for exhaust heat recovery if desired, we protect the pipe with a stainless steel lined heat-insulating
blanket.

4.6. Vibration

Engine vibrations do not affect operator safety, although they could be transmitted through the engine mounting
to other machines or to the building, resulting in a nuisance for people in the neighbourhood. Engines for
applications where structure-borne vibrations are likely to occur will be isolated from their support by means of
elastic vibration absorbers.

Additionally, we use flexible elements to connect all the utilities (water, fuel, oil, etc.) to the outside of the engine.

4.7. Noise

Noise generation is inherent to the engine and is in general inevitable, although design approval is conditioned to
a sustainable sound level when adequate and necessary means of protection are used.

Ear protection is necessary for all the people present in the engine room when the engines are running.
Therefore, at the entrance to the engine room, there must be a clear and visible warning of the obligation for the
operators to wear ear protection.

No type of ear protection is specified, as the certified personal protective equipment usually available on the
market is deemed appropriate.
As regards noise outside the engine room (environmental noise pollution), it is necessary to install and we do
install in all cases adequate exhaust silencers to meet the local or environmental rules and regulations in force
where the engines operate.

4.8. Electrical Installation

The electrical installation of the engine just consists of one terminal box for the connection of 24VDC and 220V
devices, including sensors, contacts, etc. This terminal box and wiring of the said devices comply with the low
voltage wiring regulations and Directive 73/23/EEC as amended by Directive 93/68/EEC. On the front of the
aforementioned box, there is a switch for immediate stopping of the engine in case of an emergency.

PRODUCT INFORMATION

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4.9. Fuel System

GAS

The gas system design always conforms to the applicable regulations in force (UNE 60.620) and comprises the
following elements:

ERM. Gauge and meter panel built to the applicable standard for this type of engine in order to ensure gas supply
under the established pressure conditions.

VALVE TRAIN. Set of elements comprising a hand-operated shut-off valve, gas filters, a control pressure gauge,
a double normally-closed solenoid valve to stop the gas flow to the engine, a venting line for leakage control, all
consistent with the standard specifications.

CONNECTIONS TO THE ENGINE, by means of DIN flanges and homologated hoses in all cases.

ENGINE-MOUNTED PRE-CARBURATION PIPING designed with a minimum of development and connections.
In any case, the pipes are made to the installer's standards and checked for leaks during the engine tests.

POST-CARBURATION AIR/GAS MIXTURE PIPING. The whole circuit has been mechanically-sealed with Viton
O-rings (all the rubber or silicone couplings have been suppressed).

ETHANOL

The ethanol fuel system includes the following:

ERM. Gauge and meter panel built to the applicable standard for this type of engine in order to ensure ethanol
supply under the established pressure conditions.

VALVES Set of elements comprising a hand-operated shut-off valve, ethanol filters, a control pressure gauge, a
double normally-closed solenoid valve to stop the ethanol flow to the engine, all in accordance with the
specifications as required by regulation.

CONNECTIONS TO THE ENGINE in all cases by means of DIN flanges, NPT couplings and authorised hoses.

ENGINE-MOUNTED PIPING designed with a minimum of development and connections. In any case, the pipes
are made in accordance with standards and checked for leaks during the engine test phase. To ensure sealing
and avoid any incident, the solution adopted includes double layer hoses using a stainless braid without any type
of elastomer that deteriorates on contact with ethanol.

Both fuel systems (gas and ethanol) come equipped with the following additional safeguards:

"BACKFIRING" or "DETONATION" PROTECTION. In a gas engine, backfiring may happen when burning of the
fuel mixture takes place in the intake manifold because damaged valves do not seal the combustion chamber
hermetically. Detonation occurs if the mixture strength varies out of control or when the mixture autoignites in
contact with hot surfaces.

As a direct protection against these phenomena, two forms of protection or safeguards have been adopted. The
mechanical resistance of the equipment (as regards intake manifold joints, ribs, etc.) has been increased with
respect to the normal design specification (diesel type) and two pressure-relief valves have been installed in the
intake manifold to permit pressure leak while preventing any overload of the manifolds.

Indirect protection is provided by the engine's own control and regulating systems which have been designed to
protect the engine against erratic or abnormal operation.

PRODUCT INFORMATION

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4.10. Blowby Gases

Because it is impossible to have the combustion chamber completely sealed, combustion gases always
accumulate in the crankcase and can give rise to oil splashing outside due to overpressure in the crankcase. As
prevention against this occurrence, all the engines come complete with an explosion relief valve for the expulsion
of those gases that are fed back, after filtering, into the engine intake system on environmental protection
grounds.

4.11. Exhaust Gases

The emission of exhaust gas is intrinsic to the engine function and, thus, inevitable. There are clear and specific
instructions for installing exhaust gas piping that eliminate the risk of contaminating the engine room.

Those instructions specify the requisites for the exhaust piping layout, how to calculate the pipe diameters, norms
for the placement of expansion joints, etc.

4.12. Maintenance

Maintenance tasks must be done with the machine idle. The maintenance, adjustment, lubrication and
upkeep points lie outside dangerous areas. Staff can work safely and at ease, and the reasons for their
intervention are limited.

4.13. Information

Product information necessary for using the equipment is clear, concise and easy to understand. The machines
include alarm systems that report any malfunction of the machine and warn exposed persons of possible risks.
There are signalling devices (dial gauges, control panels, etc.) on the equipment, as well as warning signs
informing of potential non-evident persistent hazards through pictograms everybody understands.

All engines are delivered with a minimum of safety devices and operational controls, and although their primary
function may not be to protect operators, they do protect them indirectly by preventing malfunctions or inadequate
operation.

The following information is legibly and indelibly available on each machine: nameplate (manufacturer's name
and address, model, serial number, year of manufacture, power, fuel gas quality and pressure requirements), and
specific CE mark tag. Moreover, product information contains all the necessary instructions for safe operation
of the machine.

On the non-moving parts of the engine there are strong lugs for safe handling of the engine with conventional
lifting equipment. Additionally, product information clearly states the engine weights necessary to arrange for
adequate transport of same.
4.14. Installation, Operation and Maintenance Instruction Manuals

Each machine has its instruction manual containing a reminder of the data required for the marking, except the
serial number, as well as the instructions for easy maintenance, conditions of intended use, instructions for safe
commissioning, operation, handling (including information about the machine weight), installation, assembly,
disassembly, adjustment, maintenance (preventive and corrective), and counter-indications.

GUASCOR has prepared an instruction manual in Spanish, English, French, German and Italian. This manual
must be close to the machine, when put into service. The mechanic's handbook, intended for specialist staff who
source from the manufacturer, is available in English or Spanish. According to the standing regulations, in order
to use the CE mark, it is compulsory to have the engine instruction manuals available in the official language of
the member state where the engine operates. Fulfilment of these regulations will be achieved by translating the
current Installation, Operation and Maintenance Instruction Manuals in pace with the sales of our engines to the
different countries of the European Union.

PRODUCT INFORMATION

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The instruction manuals include all necessary drawings and diagrams to install, operate, maintain, inspect the
machine and check it for correct operation, and make any repair, if needed, in addition to other relevant
recommendations, especially in relation to safety issues. GUASCOR POWER has drawn up the following
manuals in compliance with the Machinery Safety Directive:

- Installation Manual (installation and start-up)

- Operation and Maintenance Manual (maintenance, inspection, safety and correct operation testing)

- Spare Parts Manual (list of spare parts for the equipment)

- The Mechanic's Manual (specialist inspection and repair of the equipment)

Catalogues and other documents used to present the machine are consistent with the instruction manuals as
regards safety. The Installation Manual provides assembly and installation recommendations in order to reduce
noise and vibration (dampers, foundation, etc.). Data on the machine airborne noise appear in the Instruction
Manuals.

Engines are installed according to an installation manual specific for each application. In this manual, we will find:

- Engine general dimensions diagram.

- Engine peripherals diagram (it includes necessary information for installing all the necessary peripherals for
engine operation: water, oil, fuel, exhaust)

- Specific installation instructions for each peripheral.

- Specific instructions for engine complements or optional and additional devices (not mandatory).

The operation and maintenance manuals for each engine are written so the operator has readily available
information for:

- Identification of the machine and its components.

- Instructions for proper adjustment and start-up.

- Operational instructions.

- Maintenance instructions: (frequency of maintenance operations). are of major importance as a direct safety
element to insure proper engine condition and operation.

5. SAFEGUARDING AGAINST MALFUNCTION

The monitoring and safety systems, that verify the engine operating condition through the measurement of its
major parameters, activate PREVENTIVE warning signals when actual values exceed the predetermined
setpoints or immediately STOP THE ENGINE if the alarm threshold is reached.

In any event, in prevision of any potential monitoring system failure, all gas engines are fitted with a
communication and junction box connected to the electric control panels. This box placed ON THE ENGINE
includes an EMERGENCY STOP SWITCH for deliberate and immediate stoppage of the engine.

Moreover and in all cases, there is an engine-mounted EMERGENCY STOP LEVER available, which, once
operated MANUALLY and deliberately, blocks the air/gas charge to the engine immediately, causing the engine
to stop at once.

PRODUCT INFORMATION

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6. SAFETY PRECAUTIONS

In all instances, together with the engine operation and maintenance documentation, we deliver Product
Information IC-G-D-60-002e regarding GUASCOR GAS ENGINE SAFETY PRECAUTIONS, which indicates
preventive measures for handling our engines and their environment.

7. CONCLUSION

The preceding review allows us to conclude that GUASCOR POWER GAS engines have been designed in full
awareness of and in compliance with the machinery safety regulations requirements, as specified in
Directive 2006/42/EC and the harmonised standards UNE-EN ISO 12100-1 and UNE-EN ISO 12100-2.
Consequently, it is right to issue the relevant Declaration of Conformity and to use the "CE" mark that guarantees
the same.

Related product information:

- IC-G-D-00-040, "GAS ENGINES GENERAL DESCRIPTION OF CONSTRUCTION.
- IC-L-D-00-001, "ETHANOL ENGINES GENERAL DESCRIPTION OF CONSTRUCTION".
- IC-G-D-60-002, "SAFETY PRECAUTIONS FOR ENGINES".

NOTE

All certifications that support the statements and conclusions in this report have been documented and submitted
to external auditing.
PRODUCT INFORMACTION

INDEX

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SAFETY PRECAUTIONS FOR GUASCOR GAS ENGINES

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1. INTRODUCTION

All GUASCOR engines have been designed in accordance with European Machinery Safety Regulations,
European Directive 2006/42/EC and the harmonised standards UNE-EN ISO 12100-1 and UNE-EN ISO 12100-2.
Accordingly, we supply them with the EC Declaration of Conformity and CE mark.

The intention has been to supply an intrinsically-safe engine, although the nature of this machine does not rule
out the possibility of potential risks, for which it is necessary to adopt certain safety precautions.

The aim of this document is to inform the users of GUASCOR equipment on the safety precautions which are
required for handling and operating it adequately.

Engine installations and specially fuel-powered engines must be adapted in all cases to the local regulations.

2. PRELIMINARY OBSERVATIONS

We recommend you to read these safety precaution instructions on receiving your GUASCOR engine. They are
part of the engine operation and maintenance manual we supply with each engine.

Therefore, we recommend that the manual be kept in perfect condition and readily available to the operator and
those responsible for engine maintenance.

Our Network of Repair Shops is at your disposal to carry out revisions and repairs under the best conditions and
in accordance with the standards established by GUASCOR.

The use of original spare parts ensures high performance over long periods of operation. These parts have been
manufactured with the same strict quality controls, which were used for the manufacture of the original
equipment.

3. BODILY PROTECTION

Wear approved bodily, sight, hearing and respiratory protection. Never wear loose clothing, jewellery or long hair
around the engine.

CAUTION

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4. EXHAUST GASES

IC engine exhaust products are toxic and may cause injury or death if inhaled. All engine installations must have
an exhaust discharge pipe so that the exhaust gases are delivered into the outside air. A closed building or
shelter must be adequately vented to provide a steady supply of fresh air.

5. ENGINE FUELS

If a gas engine has been cranked excessively without starting, shut off the gas fuel supply and continue cranking
the engine to purge the cylinders and exhaust system of accumulated, unburned gas. If you fail to do this, a spark
plug could ignite and cause an explosion.

Engine fuels may ignite or explode. These must be delivered to the engine with proper piping, free from leaks and
designed to resist breakage from vibration.

6. POSITIVE FUEL SHUT-OFF

Some means of positive fuel shut-off should be provided for emergency use.

Pressurised fuels such as natural gas, landfill or digester gas should have another positive shut off valve (manual,
automatic or valve train), other than those in the carburettor or gas pressure regulation equipment.

It is the final responsibility of the user to ensure that the installation is free from fuel or exhaust leakage and such
installation meets all applicable codes.

7. SAFETY GUARDS

IC engines must be provided with guards to protect persons or structures from rotating or heated parts. It is the
responsibility of the engine owner to fit such protection.

CAUTION
CAUTION
CAUTION
CAUTION

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8. CRANKCASE GASES

All the engines incorporate a crankcase gases vent to relieve pressure that builds up inside as a portion of the
combustion gases flow in through the piston rings (blow by). Make sure the vent pipe is correctly fitted, allowing
free passage of the gases.

9. COOLING SYSTEM PRESSURE CAPS AND CONNECTIONS

Do not remove the pressure caps while the engine is operating or while coolant is hot. The cooling system is
under pressure and severe burns could result from the hot coolant spewing out when the cap is removed. Wait
until the engine and coolants have cooled down before removing caps from the intercooler, thermostat box,
radiator or surge tank. Always replace the weak hoses, lines and fittings.

10. IGNITION SYSTEM

Ignition systems can cause electric shocks. Avoid contacting ignition units and wiring.

A spark plug will fire if the storage capacitor in the electronic ignition module is connected. This may even happen
when the cable is disconnected. When this cable is connected the capacitor will discharge and fire the spark plug
which will ignite any gas which has accumulated in that cylinder. The crankshaft and driven equipment may
rotate, possibly causing personal injury or damage to equipment. Gas which has accumulated In the exhaust
system may also be ignited.

Before reconnecting the cabling of the electronic ignition module, shut off the supply of current.

Protect spark plugs, wires and coils from the rain and snow.

CAUTION
CAUTION
WARNING

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11. GENERATOR SETS

The voltage produced by generator sets is dangerous for anyone who touches a part of the electrical system
while this is working. Severe, possibly fatal shock may result from contact. Make sure the generator set is
grounded before operation. Be extremely careful when the unit or surrounding area in damp or wet. When
servicing any part of the electrical system or making any connections, make sure that the main power switch is
off. Clean or service generator only when engine is shut down.

In case of an accident from electrical shock, shut down the generator set at once. If it cannot be shut down, free
the victim from the live conductor.

Avoid direct contact with the victim. Use a dry board, dry rope or any non-conducting implement to free the victim.
If the victim is unconscious, apply artificial respiration and get medical help.

Do not operate the generator set with the ammeter circuit open. Voltage, dangerous to both equipment and
personnel, can be generated in an open secondary circuit of a current transformer.

If the generator set is stopped by operation of safety devices, do not attempt or operate until the cause has been
eliminated.

When the generator set is shut down after operation, disconnect all line switches to all external power load and
parallel circuits.

12. TIDINESS AND CLEANLINESS

Tidiness and cleanliness are essential to endure a safe workplace. A tidy workspace with clean catwalks and
well-ordered equipment and tools, allows one to do the job better and is an important factor in accident
prevention.

13. ENGINE AND EQUIPMENT; REPAIR AND SERVICE

Always stop the engine before cleaning, servicing or repairing the engine or driven equipment. Place all controls
in the off position to prevent accidental restarting. If possible, lock all controls in the off position and take the key.
Put a sign on the instrument panel warning that the engine is being serviced. Before restarting, make sure that all
tools and other material are removed from the engine and equipment.

Proper service and repair is important to the safe, reliable operation of the engine and related equipment. The
procedures recommended by GUASCOR in this manual are effective methods for performing service and repair
operations. Some of these procedures require the use of specially-designed tools. Special tools should be used
when and as recommended. Anyone who uses a service, repair or installation procedure not recommended by
GUASCOR must first satisfy themselves thoroughly that their safety will not be jeopardised by the service
methods they selected.

DANGER
WARNING
CAUTION

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DATE
Dep. 1
IC-G-D-60-002e A
June 2010

5/9

14. ENGINE FAN BLADES

- Do not operate the engine with the fan bent, broken, modified or damaged in any way.

- Do not operate the engine if the fan contacts or strikes any engine accessory or the radiator shroud or core.

- Do not try to rebalance the fan. Contact the supplier if rebalancing is required.

- Ensure that all bolts attaching the fan are securely installed to a torque specified by the engine, vehicle or boat
manufacturer.

- Install the fan so that it is directed correctly towards the radiator.

- Perform all required maintenance on the drive system, as described in this manual.

- Do not modify or substitute any parts of the engine without the approval of the Service Department of
GUASCOR. Take special care not to make modifications which will increase the operating speed of the fan.

- Install the fan only if the engine has been approved for fan installation. Likewise, install a drive system defined
by GUASCOR.

- If the fan or drive contains any plastic or rubber component, have the fan and drive inspected by a qualified
mechanic after operation or exposure to excessively high temperatures (air temperature of over 120C).

- Replace the fan if indications of excessive corrosion or erosion appear in the fan.

- For reversible or adjustable pitch fans, make sure the blades are correctly locked in the proper position prior to
operation. Also, inspect the fan prior to operation to ensure that ice and dirt have not accumulated on the fan
to cause potential imbalance of the fan.

- Be sure that all fans, fan drives and belts are properly shielded.

CAUTION

INDEX

DATE
Dep. 1
IC-G-D-60-002e A
June 2010

6/9

15. TURBOCHARGERS

Turbochargers are designed specifically for each application. Turbochargers operate at high temperatures,
therefore all inflammable material must be kept away from them. Engines must be shut down and at room
temperature before working on turbochargers or burns will result.

16. ENGINE STORAGE CHEMICALS

Protective oils contain a petroleum distillation, which is harmful or fatal if swallowed. Avoid contact with skin, eyes
and clothes. Vapour is harmful and causes irritation of eyes, nose, throat and skin. Use only with adequate
ventilation. Avoid breathing of vapour. Do not take internally. Keep container closed and away from heat. Always
read and observe the <<CAUTION>> labels on the containers. Do not destroy the labels on the containers.

In general, protective compounds should not be heated over 90C. To heat at this temperature, the containers
must be placed in a vessel with hot water. The cover must be removed and a hole must be made in the container
to reduce the danger of explosion. Heating or direct heat is an unnecessary fire risk.

17. FIRE PROTECTION

Locate fire extinguishers so that they are easily accessible if a fire start. Carefully maintain records of extinguisher
inspection and recharging to ensure the fire extinguishing capabilities when required. Consult your fire
extinguisher supplier or insurance engineering for recommendations required for the engine installation. It is also
recommended to have well-identified fire emergency escape routes in all engine installations, in accordance with
regulations.

18. CLEANING SOLVENT

Use approved cleaning solvents in a well ventilated area. Do not breathe fumes as some vapours can be fatal.
Keep away from open flames or sparks. Do not use gasoline or paint thinners or other highly volatile fluids for
cleaning. Always read and observe the <<CAUTION>> labels of containers. Do not destroy the labels on the
containers. Cleaning solvents can cause various kinds of skin irritations.

CAUTION
DANGER
WARNING
CAUTION

INDEX

DATE
Dep. 1
IC-G-D-60-002e A
June 2010

7/9

19. WELDING EQUIPMENT

Welding gas cylinders can explode if damaged. Cylinders must be stored in accordance with manufacturers
specifications and applicable safety requirements.

When using acetylene, check valves should be installed between the regulators and hoses to prevent flashback
into the regulators and supply tanks. Flashback could cause the regulators and supply tanks to explode.

Oily and greasy materials must be kept away from oxygen valves, hoses, etc. Oxygen, if combined with such
materials, will cause and explosive reaction.

Always wear protective eyes shields when welding, cutting or watching welding operations. Protective clothing
must be worn. Do not weld or cut near combustible materials.

20. GROUNDING PRECAUTIONS WHEN WELDING

When using an electrical welder on an engine, clip the ground lead as close to the welding site as possible.
Putting the ground lead too far from the welding site may result in arching across the main bearings and fusing
these to the crankshaft.

21. ELECTRICAL TOOLS

Make sure that electrical tools are properly grounded. Wear proper eye protection. Do not work in wet or damp
conditions. Be sure that the tool is in good condition and safety guards are in position. An electric trouble light
must also be grounded. Do not carry electric power tools by the cord. Do not yank the cord when removing from
an outlet. Instead, grasp the plug to remove it from an outlet.

22. BATTERIES

Always disconnect the battery ground connection from batteries before performing any work on the engine or
equipment. This will prevent sparks or burns when accidentally shorting an electrical connection.
CAUTION
CAUTION
CAUTION
CAUTION

INDEX

DATE
Dep. 1
IC-G-D-60-002e A
June 2010

8/9

Never expose batteries to open flame or electric spark. The chemical action of the battery produces hydrogenous
gas which is inflammable and explosive. Do not allow the battery fluid to contact skin, eyes, clothes or painted
surfaces. The electrolyte is a sulphuric acid solution, which could cause serious burns or damage equipment.
Wear eye protection when working with batteries.

23. PRECAUTIONS WHEN USING BOOSTER BATTERIES AND CABLES

Do not attempt to jump start an engine having a frozen battery. The battery may rupture or explode. Before
starting, examine all fill vents on the battery. If ice can be seen, or if the electrolyte fluid cannot be seen, do not
attempt to start with jump cables. Batteries, charged and discharged, should be treated carefully when using
jumper cables.

The following procedures assist in reducing sparks and explosion hazards always present in both batteries when
connecting charged batteries to discharges batteries:

- Turn off all electrical loads. Remove vent caps and lay damp cloth over open vent well of each battery. The
charged booster battery or batteries must have the same voltage capacity as the discharged battery or
batteries.

- The positive post is identified by a <<+>>, pos. and red colour and is larger in diameter than the negative post.

- The negative post is identified by a <<->> neg, and natural lead colour (grey).

24. COMPRESSED AIR

Compressed air or gases should never be used to clean clothing or your body. Compressed air can pierce the
skin and cause severe and very painful injury.

Never use your hand to check air, gas, or liquid flow rates, or check for leaks. Do not engage in <<horseplay>>
with air, gas or liquid hoses. Observe all applicable regulations as related to compressed gases.

25. INTOXICANTS AND NARCOTICS

Anybody under the influence of intoxicants and/or narcotics is hazard to themselves and other employees.

26. SAFETY PRACTICES FOR HANDLING ACIDS

Cleaning with acid for certain castings and pieces of equipment is frequent. In handling them, follow these
recommendations:

- Avoid contact with skin, clothing and eyes.

- Descaling operations should be performed away from all fire, spark or other ignition sources.

- Keep acid off of concrete floors because it attacks the lime in the concrete. If solution does get on concrete
surfaces, apply an alkaline solution to neutralise.
CAUTION

INDEX

DATE
Dep. 1
IC-G-D-60-002e A
June 2010

9/9

- Acids can react with metals to form various gases. Generally, acid solutions on lime scale and rust result in the
formation of harmless carbon dioxide. However, when acids contact aluminium, zinc, cadmium, tin, sulphur,
arsenic or cyanide, poisonous and explosive gases may be generated. When descaling is done in closed
equipment, install proper ventilation to carry the gases away.

- Always store containers closed, placing these in their normal position.

- Be sure that there are no leaks in the vessel being descaled, which will permit solution to leak into opposite
side of equipment. Good practice is to fill the opposite side of the equipment being descaled with water to level
higher than the acid solution.

- Use an acid-proof pump, or an inexpensive, throw-away pump.

- Do not agitate acid solutions with compressed air.

- Applications of acid should be followed by thorough rising, then neutralising with an alkaline solution to remove
all acidic residue, to prevent further action.

- Store acid solutions in either an acid-proof wooden or synthetic rubber lined steel container.

- Check steel equipment to be treated with acid solution for copper or brass fittings or fusible metal plugs. If
possible, dissimilar metals should be removed prior to descaling to prevent electrolytic action which might
interfere with the inhibiting action of acid solution. Do not use acid to descale equipment constructed of
aluminium.

27. ENGINE LIFTING AND HANDLING

- The use of cloth slings is recommended to avoid damaging the equipment with rough movements.

- Assure that the slings do not come into contact with sensitive parts of the equipment.

- Correctly inspect all anchor points so that there is no defective welding, loose screws, etc. that might
jeopardize the lifting of the equipment.

- Verify that all pertinent structures have been inspected, are in good condition, and can support at least the
weight of the equipment plus 10%. If you are not sure, weigh the equipment prior to lifting it.

- Prior to lifting it, be sure to balance the equipment to the maximum, using slings of different lengths if
necessary.

- Keep all personnel away when the unit is in the air.

- Do not lift the equipment further than necessary.


INDEX

DATE
Dep. 8
IT-G-A-70-003e A
February 2010

NORMS FOR CORRECT HANDLING
OF GAS GENSETS GUASCOR

1/5

1. INTRODUCTION

The purpose of this product information sheet is to provide the general standards for the correct lifting of gas
genset GUASCOR as well as the points where the genset must be lifted.

2. GENERAL STANDARDS

- Always be careful when the lifting the genset or its components.

- Keep all the personnel away and do not walk under or around the genset when is lifted.

- Inspect all anchoring points to make sure that there are no faulty welds, loose bolts, etc., which could make
the lifting of the genset dangerous.

- Be sure that the apparatus used for the lifting has been inspected, that it is in good condition and that it can
bear the weight of the genset plus 10%. If you are not sure, weight the genset before raising it.

GAS GENSETS GUASCOR ORIENTATIVE WEIGHT TABLE

MODEL WEIGHT (KG) WEIGHT (LB)
F/SFGLD/SFGM180 4004 8827
F/SFGLD/SFGM240 4937 10884
F/SFGLD/SFGM360 7230 15939
F/SFGLD/SFGM480 9225 20338
F/SFGLD/SFGM560 10005 22057
HGM560 11735 25871

- The use of cloth slings is recommended in order to prevent damage to the genset with sharp movements.

- Ensure that the slings do not make contact with sensitive parts of the genset.

- Before raising the genset, make sure that it is a balanced as possible. If necessary, use slings of different
lengths.

- Do not raise the genset higher than necessary (Move it to the ground).


INDEX

DATE
Dep. 8
IT-G-A-70-003e A
February 2010


2/5

3. LIFTING OF UNITS IN GENERAL

The in-line gas genset are raised at three points, one at the front of the engine and two on the rear of the genset.
(See Fig.1)

Fig. 1 - Lifting of FG/FGLD/SFGLD180/240/HGM240

1
5
0
0

(
M
i
n
.
)
[
5
9
.
0
6

(
M
i
n
.
)
]


INDEX

DATE
Dep. 8
IT-G-A-70-003e A
February 2010


3/5

The V gas genset are lifted at 4 points, two in the front of the engine block and two on the rear of the genset.
(See Fig.2)

To make its lifting it is necessary to use a perch.

Fig. 2 - Lifting of FGLD/SFGLD360/FGLD480

[70.87]
1800
1
5
0
0

(
M
i
n
.
)
[
5
9
.
0
6
]

(
M
i
n
.
)


INDEX

DATE
Dep. 8
IT-G-A-70-003e A
February 2010


4/5

In gensets SFGLD/SFGM480/560 to carry a single inlet filter must introduce the two slings back
through holes in the filter holder as shown in Fig.3

Fig. 3 - Lifting of SFGLD480/SFGLD/SFGM/560

[
9
4
.
7
8
]
2
4
0
7
[70.08]
W
[27.56]
700
1780
[
5
9
.
0
6
]
1
5
0
0
[42.52]
1080

Top view

INDEX

DATE
Dep. 8
IT-G-A-70-003e A
February 2010


5/5

For elevation HGM560 genset is needed on a perch or rocker different than that used for lifting other
gas gensets in "V".(See Fig.4)

Fig. 4 - Lifting of HGM560

[
7
5
.
2
9
]
1
9
1
2
1300
[51.18]

[
1
1
4
.
9
6
]
2
9
2
0
CERTIFIED CLASS I, GROUP D, DIV.2T4 ALTRONIC,INC YOUNGSTOWN,OHIO
PART NO. U.S. PATENT NO.5.623.209
R
S/N
R
[
9
3
.
3
0
]
2
3
7
0


INDEX

DATE
Dep. 8
IT-C-A-70-004e
April 2004

FIXING OF LAND BASED SETS

1/5

1. DEFINITION
A land-based set is a unit made up by a engine and a driven equipment normally supported by a rigid metal
bedframe.
In given applications, auxiliary or complementary equipment (radiator, etc.) may be installed on the bedframe
2. OBJECT
The object of this specification is to define the method of fixing the set to its emplacement in order to:
- Guarantee its correct anchorage.
- To isolate the environment from the natural vibrations generated by the alternative combustion engine
3. SET FOUNDATIONS
3.1. PREPARATION
For its seating, the set requires a concrete foundation (acting as a seismic mass) that provides vibration isolation.
The recommended dimensions of the concrete slab are as follows:
WIDTH (A) - The width shall be at least 30 cm. wider than the set base.
LENGTH (L) - .The length shall be at least 30 cm. wider than the set base.
HEIGHT (H) - The height of the concrete foundation shall be such that the weight of the same is at least 1.5 times
the weight of the whole set.

Fig. 1 Concrete Block
(H) Is calculate by using the following equation:

Where:
H ......... Height of concrete block in metres. H Height of concrete block in feet.
1,5 ....... Minimum constant for diesel engines. 1,5 Minimum constant for diesel engines.
P .......... Weight of whole set in Kg. P Weight of whole set in lb.
A ......... Width of concrete block in metres. A Width of concrete block in feet.
A ......... Width of concrete block in metres. A Width of concrete block in feet.
2162 .... Concrete density in Kg./m3. 134,97 Concrete density in lb/ft
3
.
1,5 x P
H = ------------------- = (m.)
L x A x 2162
A
L
H

1,5 x P
H = ------------------- = (ft.)
L x A x 2162

INDEX

DATE
Dep. 8
IT-C-A-70-004e
April 2004


2/5

3.2. CALCULATION OF SPECIFIC FLOOR LOAD "C"
Specific floor load "C" is determined from the equation bellow:
2,5 ( P + F ) 2,5 ( P + F )
C = ---------------------- = (Kg./m2) C = ---------------------- = (lb/ft
2
)
A x L A x L
Where:
2,5 Safety factor. 2,5 Safety factor
P .......... Set weight in kg. P Set weight in lb.
F .......... Weight of concret block ( A x L x H x 2162) F Weight of concret block ( A x L x H x 134,97)
A ......... Width of concrete block (m.) A Width of concrete block (ft.)
L .......... Length of concrete block (m.) L Length of concrete block (m.)
The calculated specific floor load must then be checked against the emplacement soil bearing capacity.
Table N 1 shows the approximate values of bearing capacities that will usefully serve as a basis for comparison
in each case of application.
Should the specific floor load exceeds the soil bearing capacity, then it would be necessary to increase the
supporting area in order to reduce the specific load to admissible values (see Figure 2).

TYPE OF SOIL BEARING CAPACITY (Kg/cm2)
Hard Rock, etc. 240.000-980.000
Medium-Hard Rock, Slate, etc. 100.000-150.000
Mixed Hard Layers 80.000-100.000
Loose Rock 50.000-100.000
Densely-Packed Sand and Gravel 50.000-60.000
Flint Clay 40.000-50.000
Coarse Sand and Gravel 40.000-50.000
Coarse-Grained Light Soil 30.000-40.000
Medium to Coarse Sand 30.000-40.000
Close Sand 30.000-40.000
Medium Clay 20.000-40.000
Loose Fine Sand 10.000-20.000
Loose Clay 15.000
Table -1

Fig. 2- Normal and Meagre Soils.

FOOT

INDEX

DATE
Dep. 8
IT-C-A-70-004e
April 2004


3/5

3.3. PREPARING THE FOUNDATION FOR SET ANCHORAGE
For set anchorage into the foundation, it is essential that two steel sections are laid in the concrete mass itself, as
they will allow fixing the metal bedframe of the set later on.
If such sections are properly aligned both lengthwise and crosswise, and if they are perfectly flat, they provide
optimum bearing surfaces with a maximum misalignment varying from 2 to 4 mm. (see Figure 3).
3.4. LEVELING OF THE BEDFRAME
The levelling of the bedframe refers to the operation by which the same is adjusted for perfect flatness and equal
load distribution on the foundation, so that any defect of the floor or the seat of the bedframe is corrected. (The
levelling of the bedframe is sometimes referred to as the alignment of the bedframe and this must not be
mistaken for the set alignment).

Fig. 3 Preparing of the Foundation.

4. TYPES OF FIXINGS
4.1. RIGID FIXING
- This fixing system (the simplest one) applies where isolating the set from its environment is not absolutely
necessary
- In this arrangement, the set bedframe is anchored into the concret-embedded sleepers, with insertion of
supporting blocks (see Figure 4)

Fig.4 Rigid Fixing
SLEEPER
FOUNDATION
BLOCK
LOCK SCREW
BEADFRAME
SUPPORTING
BLOCK
LEVELLING
SCREW
ADJUSTING

SURFACE TO
BE ALIGNED
STEEL
SECTION
CONCRETE
FOUNDATION

INDEX

DATE
Dep. 8
IT-C-A-70-004e
April 2004


4/5

- Levelling of the bedframe is performed by means of levelling screws that are driven through the bedframe
and butt against the sleepers, allowing the bedframe to be levelled at 6 or 8 positions.
- Once this operation is completed, height or gap "adjusting block" should be inserted between the
bedframe and the supporting block. Next, the bedframe can be secured onto the blocks by means of
locks crews.
4.2 FLEXIBLE ATTACHMENT
- This attachment is recommended where the location of the set requires some vibration isolation of the
same.
- In this fixing system, there are elastic components and vibration dampers inserted between the set
bedframe and the concrete foundation (see Figure 5).
- DETERMINING THE ELASTIC SUSPENSION IS ALWAYS SUBJECT TO AN INDIVIDUAL PROJECT
FOR THE INSTALLATION AND ITS APPLICATION IS MADE AS PER DRAWINGS.
- The project is so designed that the position of the flexible supports ensures an (almost) even load
distribution on the same.
- By no means should the position of the elastic components be modified.
- Levelling or aligning the bedframe is achieved by placing the same on the levelling blocks inserted under
the levelling screws passing through the bedframe.
- This operation requires a distance (A) to be allowed for, which permits installing the elastic suspension
under the bedframe.
- The next operation is levelling the bedframe by means of the levelling screws.
- Install the spring components under the bedframe and fill the gap under the bedframe, if any, with
adjusting shims or washers.

Fig. 5 Flexible Attachment

- Thereafter, back off the levelling screws, so that the bedframe rests on the elastic components and check
all the springs for a balanced (similar) compression.
- Finally, secure the suspension elements onto the bedframe by means of the lock screws.
- For some installations, other types of flexible attachments may be engineered (see Figure 6).
- In these events, fixing is carried out as described for the flexible attachment.

BEADFRAME
LOCK SCREW
WASHERS
ADJUSTING
SUPPORTING
BLOCK
LEVELLING
SCREW
A
LEVELLING
BLOCK
SLEEPER ON
FOUNDATION


INDEX

DATE
Dep. 8
IT-C-A-70-004e
April 2004


5/5

Fig. 6 Alternative Flexible Attachment

4.3. FIXING THROUGH SET DEADWEIGHT
In this type of arrangement, the set simply rests on the base from which it is separated by a few flat elements
made of non-skid elastic material (see Figure 7).
This method is exclusively used for emergency sets due that they operate for very short periods of time.

Fig. 7 Fixing Through Set Deadweight

10 - 20 mm.
[0,393-0,787 inches]
10 - 20 mm.
[0,393-0,787 inches]

PRODUCT INFORMATION

INDEX

DATE
Dep. 8
IT-C-A-70-010e
June 2009

CHECK FOR ALIGNMENT OF FLANGED SETS

1/4

1. AIM

This procedure aims to ensure that the factory alignment of the set remains unchanged at the final operating site.

2. DEFINITION

Flanged sets refer to items of equipment where the engine and the alternator / gearbox / machine, etc. are
mutually joined together, thus forming a single unit, namely by assembling the engine flywheel cover (flywheel
housing) to the coupling cover of the alternator / gearbox etc., through a separator or frame.

3. CHECK

After installing the set complete with its mounting at its operating site, fix it to the ground and do the following:
3.1. Undo the fixing screws from the engine cover (flywheel housing) and the alternator cover (see Fig. 1).
3.2. Put a 0.05mm thickness gauge through the gap between both covers.

Fig. 1 General Layout

19.30.205
bar 1
0
2
3 80
7 40
6
4 5
60
120 C
110
100
Digital Tachometer MT-90

TOP
UNDO THE SCREWS
PUT GAUGE THROUGH
PUT GAUGE THROUGH
BOTTOM
PRODUCT INFORMATION

INDEX

DATE
Dep. 8
IT-C-A-70-010e
June 2009


2/4

Fig. 2 Gap at the top of flanged joint

- 3.2.1. If the gap is wider at the TOP (Fig. 2), raise the front supports of the engine until the gap width is
homogeneous from top to bottom. It might happen that you have to lower the rear supports a little.

Fig. 3 Gap at the bottom of the flanged joint

- 3.2.2. If the gap is wider at the BOTTOM (Fig. 3), raise the rear supports of the engine until the gap width is
homogeneous from top to bottom. It might happen that you have to lower the front supports a little.

0.05MM THICKNESS
GAUGE
TOP

0.05mm THICKNESS
GAUGE
BOTTOM
PRODUCT INFORMATION

INDEX

DATE
Dep. 8
IT-C-A-70-010e
June 2009


3/4

3.3. Act on the anchorage of the engine supports in order to RAISE them with adjustable wedges (see Fig. 4)

1 CLAMPING OR FIXING SCREW
2 JACKSCREW
3 ADJUSTABLE WEDGES
4 OPENING TO TURN THE ADJUSTABLE WEDGES
5 C-SPANNER TO DRIVE THE ADJUSTABLE WEDGES

Fig. 4 Layout of Support and Adjustable Wedges

- 3.3.1. Loosen the fixing screw (1).
- 3.3.2. Drive the jackscrew (2) in to a stop (just tighten it).
- 3.3.3. Turn the jackscrew (2) alternately at both supports until the gap between the covers is uniform.
- 3.3.4. Raise the adjustable wedges (3) unscrewing them with the spanner (5) until they touch the seats of the
engine supports.
- 3.3.5. Remove the jackscrew (2).
- 3.3.6. Tighten the clamping or fixing screw (1) with a torque wrench to the applicable torque as specified in the
enclosed table.
- 3.3.7. Tighten the fixing screws into the engine frame and alternator cover with a torque wrench, applying the
torque specified in the enclosed table for this type of screw.

1
4
4
3
2

PRODUCT INFORMATION

INDEX

DATE
Dep. 8
IT-C-A-70-010e
June 2009


4/4

3.4. Act on the anchorage of the engine supports in order to LOWER them with adjustable wedges (see Fig. 5)

1 CLAMPING OR FIXING SCREW
2 JACKSCREW
3 ADJUSTABLE WEDGES
4 OPENING TO TURN THE ADJUSTABLE WEDGES
5 C-SPANNER TO DRIVE THE ADJUSTABLE WEDGES

Fig. 5 Layout of Support and Adjustable Wedges

- 3.4.1. Loosen the fixing screw (1).
- 3.4.2. Drive the jackscrew (2) in to a stop (just tighten it).
- 3.4.3. Lower the adjustable wedges (3) screwing them with the spanner (5) until they clear the seats of the
engine supports.
- 3.4.4. Lower both supports with the jack screw (2) until the gap between the covers is uniform.
- 3.4.5. Raise the adjustable wedges (3) unscrewing them with the spanner (5) until they touch the seats of the
engine supports.
- 3.4.6. Remove the jackscrew (2).
- 3.4.7. Tighten the clamping or fixing screw (1) with a torque wrench to the applicable torque as specified in the
enclosed table.
- 3.4.8. Tighten the fixing screws into the engine frame and alternator cover with a torque wrench, applying the
torque specified in the table below for this type of screw.

THREAD
GRADE
THREAD
GRADE
8G / 8.8 10K / 10.9 12K / 12.9 8G / 8.8 10K / 10.9 12K / 12.9
Kgm Kgm
M.5 0.6 0.9 1.1 M.18 25.0 36.0 43.0
M.6 1.1 1.5 1.8 M.20 33.0 47.0 56.0
M.8 2.5 3.4 4.3 M.22 43.0 60.0 72.0
M.10 4.7 6.5 8.3 M.24 56.0 79.0 95.0
M.12 7.8 11.3 14.0 M.27 71.0 106.0 118.0
M.14 12.0 17.5 21.0 M.33 111.0 154.0 173.0
M.16 18.0 26.0 31.0
Screw Tightening Torque Table
1
4
4
3
2

PRODUCT INFORMATION

INDEX

DATE
Dep. 8
IT-C-A-70-009e A
July 2008
ELASTIC SUSPENSION - BSB 160 Type
Ref. 76.82.450 / Ref. 76.82.480

1/2

Fig. 1 Application Sample

M.12
(7.1)
(5.2)
132
180
(
7
.
1
)
1
8
0
(
5
.
2
)
1
3
2
(6.14)
156
M.16
(
2
.
3
2
)
2
5
(
0
.
9
8
)
5
9
(
3
.
3
1
)
8
4

Fig. 2 General Dimensions

Dimensions: Millimetres and (Inches)

PRODUCT INFORMATION

INDEX

DATE
Dep. 8
IT-C-A-70-009e A
July 2008
ELASTIC SUSPENSION - BSB 160 Type
Ref. 76.82.450 / Ref. 76.82.480

2/2

Fig. 3 Characteristic Curves

TYPE AMC CODE 50 Sh WEIGHT [Kg.]
BSB 160 Chart [Kg.] 1200 1,818

7 6
100
150
200
Natural Frequency Hz
12 11 10 9 8 20 18 16 14
C
h
a
r
t

[
K
g
]
250
300
400
500
800
600
700
1000
2000
1500
NATURAL FREQUENCY
5 1,5 1
100
150
200
4 3 2
Arrow [mm]
10 8 7 6
C
h
a
r
t

[
K
g
]
250
300
400
500
800
600
700
1000
2000
1500
ARROW RATING CHART

INDEX

DATE
Dep. 8
IT-C-A-35-001e C
February 2010
VENTILATION

1/3

1. ENGINE ROOM VENTILATION

The ventilation of the engine room should satisfy two fundamental functions:

- Guarantee the environmental conditions, which permit the optimum performance level of the engine annd
equipment.
- Provide the most comfortable environmental conditions possible for the people who have to work in the engine
room.

In designing a ventilation system, the same importance should be given to the necessary volume of air as to the
flow direction.

The ventilation system must be able to provide sufficient combustion air and to remove radiation heat from the
rest of the facility.

For an estimated thermal difference of 5C (9F) between inlet and outlet air temperatures, the air inflow must be
in the region of 70 m
3
/h per 1kW installed power. (Refer to Table 1)

Generally, the air flow direction in an engine room will match the following pattern

- The entry of air in the engine room should be from the area furthest away from any sources of heat.
- The fresh air should be able to flow freely from the point of entry to the sources of heat, in its circulation
towards the point of exit.
- The expulsion of hot air should be at a point directly above the most important sources of heat, avoiding the
intake of the exhaust gas.
- Where the temperature of the engine room or, in particular, of the crankcase gases return lines to the intake
manifold is too low, the said lines must be heat-insulated so as to prevent condensation in the said piping
section.

In all cases, the hot air should be forced out of the engine room by means of an outlet duct, without allowing it to
mix wit the fresh ventilation air.

2. VENTILATION SYSTEMS

2.1. FORCED VENTILATION (EXHAUST FAN & PUSHER FAN)

We recommend this ventilation system for all machine rooms in general. The exhaust fan must be less powerful
than the pusher fan, since the engine consumes part of the air inflow.
Both air inlet and outlet depend on the location of the air filters and alternator, as the following picture shows:

AIR
INLET
FAN
AIR FILTER
FAN
1 9. 3 0 .2 0 5
Di gi tal Tachometer
0 bar 76 5 4 3 21 120
100
C
80 6040 110
MT-90
OUTLET
HOT AIR

INDEX

DATE
Dep. 8
IT-C-A-35-001e C
February 2010
VENTILATION

2/3

2.2. LAYOUT OF ENGINE ROOM WITH RADIATOR

When the engine comes complete with a radiator, it is necessary to remove hot air to the outside of the room
through a properly sized duct that could also be conditioned to dampen the engine noise.
Likewise, the pusher fan discharging air into the room for the combustion and engine cooling processes can be
soundproofed.

3. INSTALLATION OF AIR FILTERS

- The filters should be installed in every case in the most optimum place according to the layout of the engine
room.

- A sufficient quantity of combustion air should be guaranteed.

- In case of an external air inlet, avoid any risk of water entering into the filter.

- To make the air intake tube or duct and the filter protector, the following criteria apply:

- The minimum cross section area (S) of air flow through the filter protector derives from the following equation:

S = S1 x 2
(where S1 = developed area of the filter)

- The air duct between the filter and the engine should be made of metal with a circular or rectangular section.

- Determining the air duct section may be made approximately, by using the following recommendation:

P
installation
= Leq*hf +P
filter
L*1.2*hf+P
filter

hf (pressure drop by unit)

The maximum admissible pressure drop in the air intake duct after filter should not be bigger than 381
mm.w.c. relative to external atmosphere. It is recommended to keep approximately 81 mm.w.c. in reserve,
that is to say that with clean filter the maximum pressure drop shouldnt exceed 300 mm.w.c.

- The fitting of the air intake duct should be studied by the installer and should eliminate all the abnormal forces
due to the sheer weight of the air intake duct and all the vibrations which could be produced, as both these
factors could result in problems for the correct functioning of the engine.

INLET
AIR
AIR FILTER
SILENCER
SILENCER
120
100
1 9. 30 .2 0 5
0 bar 7 6 5 4 3 21 C
80 6 040
Di gi tal Tachometer MT-90
110
OUTLET
HOT AIR
CONDUCTION
RADIATOR

INDEX

DATE
Dep. 8
IT-C-A-35-001e C
February 2010
VENTILATION

3/3

- The air intake duct connection to engine should be made by means of a flexible rubber hose.

- Fit a drain cock at the lowest point of the air intake duct. This point is generally as near as possible to the
turbochargers. It is important and necessary that, if the air intake duct were over hot parts it would be well
isolated. (See fig.1)

In any case, the air temperature for combustion should not exceed in general 25C (77F) at the filter entry point,
otherwise it will be necessary to reduce the engine power. For more detail see Product Information
IC-G-B-00-001 for the Series FG/FGLD/SFGLD/SFGM/HGM and IC-C-D-00-007 for the Series E/F/SF.

The following table shows the necessary airflow for the air intake of the engine and for the ventilation of the
engine room.

ENGINE TYPE EXHAUST MANIFOLD
AIR FLOW RATE
AIR INTAKE
ENGINE
ENGINE ROOM
VENTILATION
TOTAL
m
3
/hCV m
3
/hkW m
3
/hCV m
3
/hkW m
3
/hCV m
3
/hkW
NATURALLY
ASPIRATED
WATER-COOLED 3 4 44 60 47 64
DRY 3 4 44 60 47 64
TURBOCHARGED
WATER-
COOLED
EXTERNAL FILTER 0 0 44 60 44 60
INTERNAL FILTER 7 10 44 60 51 70
DRY
EXTERNAL FILTER 0 0 44 60 44 60
INTERNAL FILTER 7 10 44 60 51 70

Table 1 Air flow rates

TURBOCHARGER
INLET
AIR
AIR FILTER
DRAIN COCK
0 b ar
4 3 21 80 6040 7 6 5
C 120 1 10 100
Di g it a l Ta ch ome te r MT-90
OUTLET
HOT AIR

INDEX

DATE
Dep. 2
IT-C-A-25-001e G
July 2012

BLOW BY GASES EXHAUSTING GUASCOR POWER ENGINES

1/5

1. PURPOSE

The purpose of this Product Information Sheet is to specify the conditions in which the blow by gases exhaust
installation must be made.

2. DEFINITION

"Blow by gases" refers to the portion of fire gases that enters the engine oil casing through the combustion
chamber sealing segments, building a pressure in excess of the atmospheric pressure, and has to be removed
outside the engine room in order to avoid:

- A clogged of the intake filters.
- The risks of explosion and fire.
- A polluted atmosphere in the engine room, which would be unhealthy for the maintenance staff.
For this reason, blow by gases of continuous duty engines must be removed to the outside through an
appropriate system. As an exception, exhaust of blow by gases into the engine room may be allowed for
emergency engines. In this event, please contact GUASCOR POWER.

1 Filtering element
2 Inspection door
3 Lube oil sump
4 Gas outlet
5 Oil blowdown

Fig. 1 Detail of blow by gases breather

3. INSTALLATION

The engine gas exit is achieved through the so-called "blow by gases breather" that is connected through an
inspection door of the unit, always above the engine oil level.
The breather comprises an expansion chamber filled with a gas-borne oil absorbing material intended to retain
the oil.
The gas must be conveyed to the open air through the ad hoc piping, while the segregated oil must flow back
through an oil blow down situated in the lowest part.
The diameter of the exhaust pipe shall be as specified in Table 1.
The initial blow by pressure in a new engine will fluctuate during the operation early hours, until all the
components are settled. As a general rule, 10 mm H
2
O pressure is considered the maximum pressure for a new
engine. Higher values may indicate problems in the design of the pipe evacuation outside.
3
2
4
1
5


INDEX

DATE
Dep. 2
IT-C-A-25-001e G
July 2012


2/5

The blow by pressure will increase during the engine life, due to the wear of the components. This increase is
explained in IC-C-D-25-007 information.

Engine
Pipe mm (inch)
(Up To A Length 10 m, 393 inch)
Engine
Pipe mm (inch)
(Up To A Length 10 m, 393 inch)
F/SF180 60,3 [2] FG/FGLD/SFGLD/SFGM/SFE240
60,3 [2]
F/SF240 FG/FGLD/SFGLD/SFGM/SFE240
F/SF360
76,1 [2
1
/
2
]
HGM240
76,1 [2
1
/
2
]
FGLD/SFGLD/SFGM/SFE360
F/SF480
FGLD/SFGLD/SFGM/SFE480
SFGLD/SFGM 560 / HGM560
Table 1 Gas exhaust pipe diameter

The oil vapour outlet of the exhaust pipe shall be visible so as to enable a control of both the blowing of the
casing and the oil vapour exhaust. It must be constructed so as to prevent entry of rain water and the like. (Refer
to Fig. 2, 3 & 4).

The piping shall always be laid upwards to impede oil "deposits" due to gas condensation. Set an oil blow dawn in
the lowest parto f that pipe (See Fig. 1)
The blow-by conduction to the outside must not be made in one piece. This conduction must be divided in 2
section joined with a flexible element. In this way we will avoid vibration troubles.
If are some engines, the gas outlet pipe installation will must be independent.


INDEX

DATE
Dep. 2
IT-C-A-25-001e G
July 2012


3/5

Fig. 2 F/SF180/240 & FG/FGLD/SFGLD/SFGM/SFE180/240 engines blow by gases exhausting disposition
ELEMENTO FLEXIBLE
60,3 [2 "]

Fig. 3 HGM240 engine blow by gases exhausting disposition
FLEXIBLE ELEMENT
60,3 [2"]

76,1 [2
1/2
]

INDEX

DATE
Dep. 2
IT-C-A-25-001e G
July 2012


4/5

Fig. 4 F/SF360/480 engines blow by gases exhausting disposition

Fig. 5 FGLD/SFGLD/SFGM/SFE360/480 y SFGLD/SFGM560 engines blow by gases exhausting disposition
76,1 [2" ]
1/2
FLEXIBLE ELEMENT


INDEX

DATE
Dep. 2
IT-C-A-25-001e G
July 2012


5/5

Fig. 6 HGM560 engines blow by gases exhausting disposition

PRODUCT INFORMATION

INDEX

DATE
Dep. 8
IC-C-D-00-008e C
September 2011
CRITERIA FOR APPLICATION OF PRE-LUBRICATION, POST-
LUBRICATION AND OIL AND WATER PRE-HEATING

1/3

1. APPLICATION OF OIL PRE-HEATING

PRE-HEATING oil is intended to raise the oil temperature, before starting the engine, up to the appropriate
minimum value (approx. 40C) required to ensure adequate oil viscosity for the engine's rise in power.

Application criteria. Pre-heating shall apply in the following cases:
Stand-by emergency sets expected to develop full power as soon as they receive the start signal.
Power generation or cogeneration applications with programmed starting, that are also expected to be
operating at full power within a short time (less than 5 minutes) after their starting.
Power generation or cogeneration applications with programmed starting, driven by GAS-engines (that are
more difficult to start), where correct automatic (unattended) starting must be guaranteed.
Applications where the engine room temperature is less than 5C for diesel engines and 15 for gas engines
and where there is a risk of high oil viscosity.

2. OIL PRE-HEATING PROCESS

The oil PRE-HEATING process must be automatic and thermostat-controlled so that the heating resistors turn
on at an oil temperature of about 35C and off at 40C.

For electrical energy generation or cogeneration applications, timing the automatic process must be such that its
activation starts 3 hours prior to the expected starting time of the generating set.

3. APPLICATION OF WATER PRE-HEATING

PRE-HEATING water aims to ensure the engine as a whole and more particularly the area of the combustion
chamber are at an adequate temperature for the engine's rise in power.

Application criteria. Pre-heating shall apply in the following cases:
Power generation or cogeneration applications with programmed starting that are also expected to be
Power generation or cogeneration applications with programmed starting, driven by GAS-engines (that are
more difficult to start), where correct automatic (unattended) starting must be guaranteed.
Applications where the cooling system is at risk of freezing. Engine room temperature below 5C.
Applications driven by GAS engines fitted with pre-chamber spark plugs.

4. WATER PRE-HEATING PROCESS

The water pre-heating process must be automatic and thermostat-controlled so that the heating resistors turn on
at an oil temperature of about 35C and off at 40C.

For electrical energy generation or cogeneration applications, timing the automatic process must be such that its
activation starts 3 hours prior to the expected starting time of the generating set.
PRODUCT INFORMATION

INDEX

DATE
Dep. 8
IC-C-D-00-008e C
September 2011

2/3

5. APPLICATION OF ENGINE PRE-LUBRICATION

Engine pre-lubrication aims to ensure oil is available in all the lubricating circuits of the engine, so that oil
pressure quickly builds up to a sufficient level for correct operation in those applications where the engine is
expected to develop its full power after the start command.

Application criteria

Engine pre-lubrication must be used in the following applications:


Power generation or cogeneration applications with programmed starting that are also expected to be

Applications where restarting must take place fifteen (15) minutes after any programmed or emergency
shutdown of the engine.

In those applications, both GAS and DIESEL engines need pre-lubrication.

6. PRE-LUBRICATION PROCESS

The pre-lubrication process must be automatic and timed.

In plants with emergency stand-by generating sets, we recommend pre-lubrication cycles of 5 minutes every
1/4 hour.

For electrical energy generation or cogeneration plants where oil is cold, we recommend a single pre-
lubrication process of 5 minutes for DIESEL engines and of 10 minutes for GAS engines, just before enabling
the engine start command.

For power generation or cogeneration applications with forced lubrication cylinder head engines, the pre-
lubrication process only takes place when the starting and loading process is to be immediate. Said process
will last for 10 minutes immediately before engine start. This process may not take place when the engine
start is not required.

NOTE

Pre-heating and pre-lubrication services are not necessary for emergency sets where the starting and loading
process is manual or automatic but not immediate, i.e. can take more than ten minutes. It is essential to
differentiate effective emergency sets from (low cost) normative emergency sets.

PRODUCT INFORMATION

INDEX

DATE
Dep. 8
IC-C-D-00-008e C
September 2011

3/3

7. APPLICATION OF ENGINE POST-LUBRICATION

Engine post-lubrication aims to reduce and balance the temperatures of different engine components.
Components like turbochargers reach very high temperatures during the operation of the engine. Therefore, we
recommend a shutdown protocol that allows these components to cool down progressively in order to avoid oil
coking.

A programmed shutdown of both diesel and gas engines consists of a sequence of operations that leads to a
lowering of the engine temperature: progressive decrease in load and idling for a 5-10 minute period. However, a
number of applications require, in addition, a post-lubrication process.

Engine post-lubrication is necessary in the following applications:

At a programmed or emergency shutdown:

Applications including engines with a dry exhaust manifold where very high exhaust temperatures can be
expected.

Applications with an HGM-560 engine, because this engine has critical components for which this process is
obligatorily specified.

8. POST-LUBRICATION PROCESS

The post-lubrication process must be automatic and timed.

For programmed shutdowns:

In applications including engines with a dry exhaust manifold, it is necessary to post-lubricate the engine
during 20 minutes after shutdown.

Applications in which an HGM-560 is running require 20-minute post-lubrication after each shutdown.

For electrical generation or co-generation applications with forced lubrication cylinder head engines, post-
lubrication must be limited to 10 minutes at most.

For alarm shutdowns:

In applications including engines with a dry exhaust manifold, it is necessary to post-lubricate the engine
during 20 minutes after shutdown.

Applications in which an HGM-560 is running require 20-minute post-lubrication after each shutdown.

For electrical generation or co-generation applications with forced lubrication cylinder head engines, post-
lubrication must be limited to 20 minutes at most.


INDEX

DATE
Dep. 2
IT-C-A-25-002e D
September 2012
AUTOMATIC ENGINE OIL LEVEL CONTROLLER

1/3

1. INTRODUCTION
If engine-driven equipment is intended for 24-hour operation or similar, it is recommended that the engine
should be fitted with an oil level controller.

Fig. 1 General Layout over engines series 180/240

Fig. 2 General Layout over generating sets series 180/240


INDEX

DATE
Dep. 2
IT-C-A-25-002e D
September 2012

2/3

6
MT-90 DigitalTachometer
bar
3
1
2
0
4 5
6
7
60
40
80 100
120 C
110
3 4 1 5 2

Fig. 3 General Layout over engines/generating sets series 360/480/560

1 Automatic oil level controller
2 Oil tank
3 Fillinghose
4 Oil sump to level controller hose
5 Ventighose
6 Lube oil level indicator (See IT-C-A-25-009e)


INDEX

DATE
Dep. 2
IT-C-A-25-002e D
September 2012

3/3

Fig.4 Automatic Oil Level Controller.

3 Fillinghose
4 Oil sump to level controller hose
5 Ventighose

2. DESCRIPTION
The oil level controller is a mechanical actuator placed on the oil sump at the bottom of the engine. It includes a
floater inside a small reservoir which opens or closes the oil flow into the engine crankcase.
Connection to the external circuit is via a hose (supplied) suitable for 12mm (0.47 inches) pipes.

3
5
4

INDEX

DATE
Dep. 2
IT-C-A-25-009e F
February 2012

LUBE OIL LEVEL INDICATOR

1/2

Fig. 1 Main Drawing

1 Lube oil level indicator
2 High level indicator
3 High level adjust
4 Low level indicator
5 Low level adjust
6 Float
7 Two-way valve
8 Lube oil pan
9 Conn rods inspection door

Table 1 Elements Specification

B
A
4
1
MAX.
MIN.
8
6
2
3
5 9
7

INDEX

DATE
Dep. 2
IT-C-A-25-009e F
February 2012

LUBE OIL LEVEL INDICATOR

2/2

Engine Ref.
A
mm (inch)
B
mm (inch)
Capacity Lube Oil
Pan Litres (gal)
F180
31.60.360
180 (7.086) 205 (8,070) 40 (10.5)
F180T 145 (5.708) 174 (6.850) 55 (14.5)
F180TB
85 (3.34) 142 (5.59)
70 (18.4)
F180TA/TAB
F240TA/TAB 95 (25)
F360TA
31.60.540 47 (1,85) 107 (4.212)
150 (39.6)
F480TA 195 (51.5)
SF180TA
31.60.360 85 (3.34) 142 (5.59)
70 (18.4)
SF240TA 95 (25)
SF360TA
31.60.540 47 (1,85) 107 (4.212)
150 (39.6)
SF480TA 195 (51.5)

FG/FGLD180
31.60.360 85 (3.34) 142 (5.59)
70 (18.4)
FG/FGLD240 95 (25)
FGLD360
31.60.540 47 (1,85) 107 (4.212)
150 (39.6)
FGLD480 196 (51.7)
SFGLD/SFGM180
31.60.360 85 (3.34) 142 (5.59)
70 (18.4)
SFGLD/SFGM240 95 (25)
HGM240 170 (44.9)
SFGLD/SFGM360
31.60.540 47 (1,85) 107 (4.212)
150 (39.6)
SFGLD/SFGM480 196 (51.7)
HGM560 427 (112.8)
SFGLD/SFGM560 31.60.540 16 (0,62) 62 (2,44) 232 (61.3)

SFE180
31.60.360 85 142
70
SFE240 95
SFE360
31.60.540 47 107
150
SFE480 196

Table 2 General Characteristics

B High (Black)
C Low (Red)
D Common (White)

Fig. 2 Electric Diagram

PRODUCT INFORMATION

INDEX

DATE
Dept. 2
IC-G-D-25-003e B
October 2012
GUASCOR MOTOROIL 3040 PLUS LUBE OIL FOR NATURAL
GAS-FUELLED AND ETHANOL ENGINES

1/2

1. INTRODUCTION

There are currently no standard procedures for classifying lube oils to be used in gas-fuelled and ethanol-fuelled
engines. It is therefore necessary to perform exhaustive field tests in order to approve a suitable lubricant. Along
with the ash content, there are several other parameters to bear in mind. These include phosphorus content,
resistance to oxidation and nitration (often produced by the high working temperatures), neutralising capacity and
corrosion inhibition (particularly in the presence of aggressive gases).

2. DESCRIPTION

GUASCOR MOTOROIL 3040 PLUS is a lubricant designed by GUASCOR R&D division in collaboration with the
most prestigious lubricant manufacturers. It has been specially formulated for use in GUASCOR engines that
operate on gas or ethanol. See documents IP IC-G-D-30-002, IC-G-D-30-013, IC-L-D-30-001.

GUASCOR MOTOROIL 3040 PLUS is a high-performance oil with a medium ash content. It is formulated with
prime quality paraffin bases that provide it with exceptional oxidation and nitration stability, great thermal
resistance, and a very low tendency to carbon deposit and residue build-up. Maintaining excellent performance
after a long period of operation is thus ensured. Additionally, this oil has a low foam-forming tendency, good
emulsibility and corrosion protection for cylinders and bearings, while considerably reducing wear on piston rings,
liners and valve seats. All this means the oil has a long service life and filters withstand extended maintenance
intervals.

Given its advanced formulation, GUASCOR MOTOROIL 3040 PLUS is specially suitable for modern four-stroke
engines with low oil consumption. It has been specially developed to ensure extended intervals between oil
changes in engines whose usability is limited by the oil lifespan.

Its detergency and dispersancy system controls the build-up of carbon deposits and sludge, which results in
cleaner engines, longer lasting oils and lower filter costs.

This oil has also been designed to provide exceptional protection against piston abrasion and wear of cylinder
liners and piston rings.

3. APPLICATIONS

GUASCOR MOTOROIL 3040 PLUS has been specially designed and is recommended for providing the highest
performance in GUASCOR engines that operate on natural gas and ethanol. It can however be used in all kinds
of naturally-aspirated or supercharged four-stroke engines, whether high or medium rated, that require a lubricant
having a medium ash content. It is designed to ensure optimum engine life and lower maintenance costs. Its
scope of application encompasses stoichiometric combustion and lean-burn engines as well, ensuring low oil
consumption in both cases.

Given its low zinc and phosphorus content, this lube oil can be used in engines fitted with a catalytic converter,
which require lube oil having a medium ash content.

Its advanced technology means any wear on the valve train components can be monitored as well as reducing
the risk of abrasion, scoring and accelerated wear of pistons and piston rings. The end result means lower engine
operating and maintenance costs.
PRODUCT INFORMATION

INDEX

DATE
Dept. 2
IC-G-D-25-003e B
October 2012
GUASCOR MOTOROIL 3040 PLUS LUBE OIL FOR NATURAL
GAS-FUELLED AND ETHANOL ENGINES

2/2

4. ADVANTAGES AND BENEFITS

- Excellent resistance in the presence of oxidation and nitration.

- Very high protection of cylinder head valve seats and guides.

- Excellent protection against piston scoring and liner surface wear.

- Excellent engine cleanliness.

- Minimum deposit build-up.

- High foam-forming and corrosion resistance.

- Excellent performance of the alkaline reserve.

- Longer oil and filter life.

- Lower maintenance costs.

5. HEALTH AND SAFETY

No special precautions are required for its use, except good personal hygiene and avoiding contact with the skin
for extended periods of time. There is a Safety Data Sheet available on request.

TYPICAL CHARACTERISTICS

PROPERTY ASTM GUASCOR MOTOROIL 3040 PLUS
Viscosity, SAE grade 40
Flashpoint, Open Cup method,
o
C D-92 240
Freezing point,
o
C D-97 -21
Density @ 15
o
C, g/cc D-4052 0.895
Viscosity, cSt @ 100 oC D-445 13.6
Viscosity, cSt @ 40 oC D-445 124.3
TBN, mg KOH/gr D-2896 9.0

The values of typical properties shown in the table are mean values given for information purposes only. They do
not constitute any guarantee These values are subject to change without prior notice.
_________________________________________________________________________________________________________________
PRODUCT INFORMATION

INDEX

DATE
Dep. 1
IT-C-A-25-008e E
December 2009

REMOTE PRELUBING WITH 300Lt. (79,25 gal) OIL TANK
360/480/560 SERIES ENGINES

1/1

Fig. 1 General Disposition Engine With 300 Lt. (79,25 gal) Oil Tank.

Fig. 2 Detail, oil sump outlet closed valve.

A Lube oil tank filling 1 Filling flexible connection REF. 31.25.106
B Engine pre-lubing & lube oil filling 2 Drain flexible connection REF. 31.25.180
C Automatic oil level control 3 Automatic oil level control flexible connection REF. 30.30.069
D Oil sump drain
FILLING AND DRAIN FLEXIBLES ASSEMBLY REF. 31.25.900
E Oil drain

OIL
SUMP
RIGHT SIDE VIEW
OIL
TANK
LEFT SIDE VIEW

INDEX

DATE
Dep. 8
IT-C-A-40-001e C
February 2010
INSTALLATION OF EXHAUST PIPELINE

1/6

1. INTRODUCTION

The purpose of this Product Information Sheet is to establish the procedure for the laying of the gas exhaust
pipeline through to the outside of the engine room in order to ensure the proper operation of the engines.

Non-compliance with this specification may generate various troubles such as difficulty in scavenging the
combustion chamber, rise in exhaust gas temperature, increase in fuel consumption, increase in smoke point,
and, generally, low performance of the engine, which may indirectly make the proper operation of the engine
impossible.

IMPORTANTE

IN ANY CASE, THE BACKPRESSURE AT THE OUTLET OF THE ENGINE GASES SHOULD NOT EXCEED
VALUES SPECIFIED IN THE FOLLOWING TABLE

2. EXHAUST PIPELINE

The exhaust pipeline shall be made up of as few bends as possible and no unnecessary pipe lengths, in order to
reduce pressure losses to a minimum.

Below are some aspects to be borne in mind when designing the installation:

- Insert the appropriate number of expansion joints into the exhaust pipeline, as will enable free expansion and
contraction of the pipes under temperature changes.

- The rigid fixing of the exhaust pipes to the engine room structure usually is a source of noise and vibrations.
Additionally, it may be the cause for exhaust pipeline breakage.

DIESEL ENGINES GAS ENGINES
E318/F180 Naturally Aspirated Engines Naturally Aspirated Engines
250 mm wc EXHAUST BACKPRESSURE 250 mm wc EXHAUST BACKPRESSURE
E318/F180/240/360/480 Supercharged Engines 90C (194 F) Jacket Water Temperature - Supercharged Engines
250 mm wc EXHAUST BACKPRESSURE
FGLD 180/240
FGLD 360/480
250 mm wc EXHAUST BACKPRESSURE (*)
SF180/240/360/480 Supercharged Engines 450 mm wc EXHAUST BACKPRESSURE (*)
450 mm wc EXHAUST BACKPRESSURE 120C (248 F)Jacket Water Temperature - Supercharged Engines
H33/44/66 Naturally Aspirated Engines FGLD 180/240
450 m .wc EXHAUST BACKPRESSURE
250 mm wc EXHAUST BACKPRESSURE FGLD 360/480/560
H33/44/66/74/84 Supercharged Engines
SFGLD-SFGM180/240/360/480/560 & HGM560 Supercharged
Engines
450 mm wc EXHAUST BACKPRESSURE 450 mm wc EXHAUST BACKPRESSURE
(*) There are two different FGLD gas engine families. The first family is composed of the FGLD180/240/360/480 engines designed for a
maximum admissible backpressure of 250 mm wc, and the second family is composed of the same engines, but designed for a maximum
admissible backpressure of 450 mm wc.


INDEX

DATE
Dep. 8
IT-C-A-40-001e C
February 2010

2/6

A Inner Diameter See Table 1
B Exhaust Flexible Diameter
C 20 mm (0.78 inch)
D 10 mm (0.39 inch)
E 30 (86F)
n A
Fig. 1 V Engine Installation of Exhaust Pipeline
ALTERNATIVES TO PREVENT
WATER INFILTRATIONS
SILENCER
FLEXIBLE
SLIDING FIXING
POINT
FLEXIBLE
FLEXIBLE
DIAMETER AS PER TABLE 1
CONDENSATE
TRAP
DRAINING VALVE

INDEX

DATE
Dep. 8
IT-C-A-40-001e C
February 2010

3/6

- The exhaust pipeline shall be secured by means of collars through which it can slide and properly distributed
fixed anchorage points.
- The exhaust pipeline and silencer shall be protected and heat-insulated to avoid big heat radiations into the
engine room and the subsequent reduction in the engine performance.
- The exhaust pipeline must be laid for each engine individually. Never put together the gas outlets of various
engines in a single collector.
- For completion of the exhaust pipeline, there must be a condensate trap installed at the lower end of the last
vertical run of exhaust pipe as well as one draining valve (see Figure 1).

3. DETERMINING THE EXHAUST PIPE DIAMETER

The recommended exhaust pipe diameter can be obtained from Table 1 taking into account the engine power and
the effective pipeline length.

ENGINE
POWER
(HP)
Recommended Nominal Diameter of Exhaust
Pipeline Depending on Effective Length L
ENGINE
POWER
(HP)
Recommended Nominal Diameter of Exhaust
Pipeline Depending on Effective Length L
PIPE LENGTH IN METRES (FEET) PIPE LENGTH IN METRES (FEET)
10 (32) 15 (49) 20 (65) 25 (82) 30 (98) 10 (32) 15 (49) 20 (65) 25 (82) 30 (98)
PIPE DIAMETERIN MILLIMETRES (INCHES) PIPE DIAMETERIN MILLIMETRES (INCHES)
40
70
(2.75)
75
(2.95)
80
(3.14)
85
(3.34)
90
(3.54)
700
230
(9.05)
250
(9.84)
265
(10.43)
275
(10.82)
290
(11.41)
60
80
(3.14)
85
(3.34)
90
(3.54)
95
(3.74)
100
(3.93)
750
240
(9.44)
260
(10.23)
270
(10.62)
285
(11.22)
295
(11.61)
75
100
(3.93)
110
(4.33)
110
(4.33)
115
(4.52)
120
(4.72)
800
245
(9.64)
265
(10.43)
280
(11.02)
290
(11.41)
305
(12)
100
110
(4.33)
115
(4.52)
125
(4.92)
125
(4.92)
130
(5.11)
850
250
(9.84)
270
(10.62)
290
(11.41)
300
(11.81)
310
(12.2)
150
125
(4.92)
130
(5.11)
145
(5.7)
150
(5.9)
155
(6.1)
900
260
(10.23)
280
(11.02)
295
(11.61)
310
(12.2)
320
(12.59)
200
140
(5.51)
150
(5.9)
160
(6.29)
165
(6.49)
170
(6.69)
950
265
(10.43)
285
(11.22)
300
(11.81)
315
(12.4)
325
(12.79)
250
150
(5.9)
165
(6.49)
170
(6.69)
185
(7.28)
190
(7.48)
1000
270
(10.62)
290
(11.41)
310
(12.2)
320
(12.59)
330
(12.99)
300
165
(6.49)
180
(7.08)
190
(7.48)
200
(7.87)
205
(8.07)
1050
275
(10.82)
295
(11.61)
315
(12.4)
325
(12.79)
335
(13.18)
350
175
(6.88)
180
(7.08)
205
(8.07)
210
(8.26)
220
(8.62)
1100
280
(11.02)
300
(11.81)
320
(12.59)
330
(12.99)
340
(13.38)
400
190
(7.48)
205
(8.07)
220
(8.62)
230
(9.05)
240
(9.44)
1150
285
(11.22)
305
(12)
325
(12.79)
335
(13.18)
345
(13.58)
450
195
(7.67)
210
(8.26)
230
(9.05)
235
(9.25)
245
(9.64)
1200
290
(11.41)
310
(12.2)
330
(12.99)
340
(13.38)
350
(13.77)
500
205
(8.07)
220
(8.62)
235
(9.25)
245
(9.64)
250
(9.84)
1250
295
(11.61)
315
(12.4)
335
(13.18)
345
(13.58)
355
(13.97)
550
215
(8.64)
220
(8.62)
245
(9.64)
250
(9.84)
260
(10.23)
1300
300
(11.81)
320
(12.59)
340
(13.38)
350
(13.77)
360
(17.17)
600
220
(8.62)
240
(9.44)
250
(9.84)
265
(10.43)
270
(10.62)
1350
305
(12)
325
(12.79)
345
(13.58)
355
(13.97)
365
(14.37)
650
225
(8.85)
245
(9.64)
255
(10.03)
270
(10.62)
280
(11.02)
1400-1700
310
(12.2)
330
(12.99)
350
(13.77)
360
(17.17)
370
(14.56)
Table 1 Nominal Based on Effective Length L

INDEX

DATE
Dep. 8
IT-C-A-40-001e C
February 2010

4/6

4. CALCULATION OF EFFECTIVE LENGTH

The exhaust pipeline effective length can be calculated as indicated below:

Effective "L" = geometrical "L" + bend equivalent "L" + silencer equivalent "L"

- The geometrical "L" depends on the total length of the pipeline.

- The bend equivalent "L" is given in Table 2 for various pipe diameters and different types of bends.

- The silencer equivalent "L" is derived from the curve shown on Fig. 2, in relation to the silencer diameter.

Once the effective "L" is known, with reference to Table 1 -Exhaust Pipe Diameter , the recommended inside
diameter can be determined according to the engine power and the effective pipe length, for the specific
application concerned.

Equivalent Pipe Length Based on Pipe Diameter and Type of Bend
PIPE mm (inch) 90 BEND 120 BEND PIPE mm (inch) 90 BEND 120 BEND
0-100 (0-3.93) 1,3 1 180-210 (7.08-8.26) 2,8 2,4
100-120 (3.93-4.72) 1,55 1,25 210-240 (8.26-9.44) 3,4 3
120-150 (4.72-5.9) 1,95 1,65 240-270 (9.44-10.62) 3,8 3,4
150-180 (5.9-7.08) 2,4 2 270-300 (10.62-11.81) 4,2 3,7

Table 2 Equivalent Pipe Length.

The use of this curve is valid for standard GUASCOR silencers type "SM15" (refer to sheet "IT-F-A-40-001"). For
special silencers, contact GUASCOR Application Engineering Dept.

INSIDE OF SILENCER INLET (mm)
E
Q
U
I
V
A
L
E
N
T

P
I
P
E

L
3

(
m
)

E
Q
U
I
V
A
L
E
N
T

P
I
P
E

L
3

(
f
e
e
t
)

INSIDE OF SILENCER INLET (inch)

INDEX

DATE
Dep. 8
IT-C-A-40-001e C
February 2010

5/6

SHIFT
NOMINAL DIAMETER mm (inch)
65 (2.55) 80 (3.14) 100 (3.93) 125 (4.92) 150 (5.9) 175 (6.88) 200 (7.87) 300(11.79)
A 15 (0.59) 20 (0.78) 25 (0.98) 30 (1.18) 35 (1.37) 40 (1.57)
B 2 (0.07) 4 (0.15)

Table 3 Shift in Relation to Nominal Diameter

5. EXPANSION JOINTS

Although there is no problem for installing expansion joints or flexible exhaust pipes, the following should be taken
into consideration:

- The expansion joints are basically designed to make good any longitudinal extension of the exhaust pipes.
- To prevent exhaust pipes from moving crosswise, the pipes should be guided and attached to the engine room
structure in such a way that their longitudinal movement only is permitted to avoid damage to the expansion
joints.
- The expansion joints have one single assembly position in accordance with the direction of the exhaust gas.
- The number of joints to be installed is determined by the length and layout of the exhaust pipeline.
- To determine the expansion of an exhaust pipeline, refer to the curves attached as Figure 5 allowing to
calculate the same and to find out the number of joints necessary.

Figures 3 and 4 show the admissible axial shift and cross travel as well as the direction of exhaust gas escape for
standard GUASCOR flexible pipes.

A Max. (mm)
B Max. (mm)
DIRECTION OF
EXHAUS GAS
INNER
LINING
Fig. 3 Axial Shift (Compression) Fig. 4 Cross Travel

INDEX

DATE
Dep. 8
IT-C-A-40-001e C
February 2010

6/6

Example
The expansion of a 30-m long pipeline subject to exhaust gas temperatures as high as 375(C and a room
temperature of 20(C will be 145 mm (See Fig. 5).

EXPANSION IN CENTIMETERS
E
X
H
A
U
S
T

G
A
S

T
E
M
P
E
R
A
T
U
R
E

(
F
)

E
X
H
A
U
S
T

G
A
S

T
E
M
P
E
R
A
T
U
R
E

(
C
)

EXPANSION IN INCHES
PRODUCT INFORMATION

INDEX

DATE
Dep. 8
IT-C-A-40-002e C
April 2011

EXHAUST FLEXIBLE

1/1

ENGINE DN S/DIN REF. A mm B mm C mm d mm e mm F mm mm n
E212 / E318 -- -- 15.40.120 196 300 100 25 25 169,6 13 4
E318T/T2/TA/TA2 200 2573 15.45.240 320 300 220 18 18 280 18 8
F180 125 2573 16.40.030 240 275 131,7 18 18 200 18 4
F180T/TB
150 2573 16.40.040 265 275 159,3 18 18 225 18 8
F180TA/TAB/TAC
F240TA/TAB
F360TA/TAC
F480TA
SF180TA/240TA
SF360TA/480TA
FG/FGLD180/240
FGLD360/480
SFGLD180/240
SFGM180/240
SFGLD360/480/560
SFGM360/480/560
HGM 240 150 2576 19.40.133 285 275 170,5 22 22 240 22 8
HGM 560 300 2573 19.40.073 440 300 296 24 24 395 23 12


INDEX

DATE
Dep. 8
IC-C-D-40-002e
October 2005

GUASCOR EXHAUST SILENCER
GENERAL DESCRIPTION

1/1

1. OBJECT

The scope of this Product Information is resume the technical and constructive characteristics of the GUASCOR
exhaust silencer.

2. CLASSIFICATION

The GUASCOR exhaust silencers are sorted in two principal groups according to their constructive characteristics
and the exhaust gases sound level attenuation type.

Absorption type: The exhaust gas goes through a conduct with high efficiency phono-absorber coating internal
core, protected with perforated metal plate. The attenuation level should be 15 or 30 dB(A).

Mixed type: The exhaust gas through a expansion double chamber with venturi type coupling device, afterwards
it flows through the absorption chamber. The attenuation level is 40 dB(A).

The two exhaust silencer types should be equipped with or without spark arrester.

For another attenuation type, please ask to GUASCOR.

3. TECHNICAL CARACTHERISTICS

All the exhaust silencer , with or without spark arrester, are made of full metal plate, perforated metal plate and
foul-smelling backs of carbon steel S 235 JR. The connection flanges are made of carbon steel ST 37,
according to DIN 2576.

The used plate thickness depends of the exhaust silencer diameter. This thickness should be between 1.5 and 3
millimeter normally.

There is two types of external coating for the exhaust silencer according to the place to be installed.

Indoor installation: The exhaust silencer external surface is made of two heat resistant 35 40 micron printing
coat (600 C). The internal surface is painting with heat resistant black painting (600C).

Outdoor installation: The exhaust silencer external surface is sand blasted to SA3 and 120 micron thickness
zinc metallization. The external finish is made of one coat of aluminium of 30 - 35 micron thickness. The internal
surface is painting with heat resistant black painting (600C).

4. INSTALLATION

The exhaust silencer should be mounted in the exhaust pipeline taking in mind the flow direction.

5. MAINTENANCE

The GUASCOR exhaust silencers do not require any maintenance, except the external painting. It should be
necessary to paint the silencer with a 20 micron anticaloric painting (600C) ever 5 years.

INDEX

DATE
Dep. 8
IT-O-A-2-001110-05e B
June 2012

EXHAUST SILENCER GENERAL DIMENSIONS

1/1

EXHAUST SILENCER 30 dB(A) WITHOUT SPARK ARRESTER (Outdoor)

Straight through

Exhaust silencer reference and general dimensions in millimeter

Reference DN L T D E WEIGHT
76.81.229 400 3380 708 406 377 KG

BODY LENGHT (L T)
FLOW DIRECTION

D

DIN 2576 FLANGES


INDEX

DATE
Dep. 8
IT-O-A-2-001110-02e
November 2012

SFGM 560 ENGINES
EXHAUST CONNECTION

1/2

Fig. 1 General Disposition

ENGINE REFERENCE
A B
milimeter inches milimeter inches
SFGM560 38.40.007 2072 81,575 2047 80,590

R
B
A

PRODUCT INFORMATION

INDEX

DATE
Dep. 2
IO-C-M-20-001e B
July 2011

COOLING WATER QUALITY AND TREATMENT

1/6

1. GENERAL

In developing the engine set-up equipment, one point to bear in mind is the quality of the cooling water that will be
used, in order to prevent heat transfer problems.
Any water treatment programme mainly aims at protecting the cooling system from corrosion, deposit or scale which
might impair the continuous flow of the coolant.
The most typical problems with an engine cooling system arise from corrosion, cavitation, microbiological growth,
deposits and scale.

Corrosion
This is a metal degrading process arising from oxygen-triggered chemical or electrochemical reactions. As for cooling
systems, the reactive medium is water that attacks the metallic materials of piping and heat exchangers.
Corrosion is knowingly dependent upon the effect of temperature, high salinity (especially of chlorides), high water
velocity, alkalinity or acidity, dissolved solids, dissolved gas traces, microbial growth and pollution by manufacturing
process waste. The major negative effect of corrosion is a decrease in the engine components fatigue strength.

The following are the most frequently occurring types of corrosion:

- Electrochemical: Bonding of metals of varying electrochemical properties.
- Chemical: pH and salinity
- Physical: Abrasion and cavitation
- Differential aeration: Low deposits
- Bacterial: Sulphate-reducing bacteria, ferrobacteria, nitrifying bacteria, denitrifying bacteria.

Cavitation
Cavitation is the creation of bubbles within a liquid when it passes through a high pressure area at high speed
and increases when the pressure is low in the cooling system and/or when there are leaks. In addition, as the
vibration increases, so the number of bubbles in the coolant also increases. These bubbles cause erosive
corrosion of the cylinder wall and frequently lead to pitting of cylinder walls.
To solve cavitation problems, purge the cooling circuit thoroughly and, for applications requiring high temperature,
keep the circuit under pressure. Also add coolant additives that will cover the metal surfaces and limit cavitation-
induced erosion and pinholes.

Scale
This is the crystallisation and deposition in their solid form of different combined ions present in water, due to
oversaturation of the solution at a given temperature. It usually appears as compact, hard and adhering deposits
of predominantly inorganic matters, but may occasionally take soft, non-adhesive forms and be a mixture of
organic and inorganic components.
The major compositions of scale include, but are not limited to: calcium carbonate, calcium sulphate, calcium
phosphate, magnesian salts, silica, and iron and manganese compounds. Scale forming depends on multiple factors
such as: temperature, salt concentration, pH and alkalinity, dissolved solids content, fluid-dynamic and thermostatic
conditions of the system, etc.
PRODUCT INFORMATION

INDEX

DATE
Dep. 2
IO-C-M-20-001e B
July 2011


2/6

One of the most typical reactions is:

Ca (HCO
3
)
2
+ heat CO
2
+ H
2
O + Ca CO
3

Calcium bicarbonate Carbon dioxide Calcium carbonate
highly soluble (760 mg/l. approx.) (hardly soluble: only 30 mg/l. approx.)

The presence of scale has a significant impact on the performance and operation of the equipment, since some of its
effects are:

- Reduction in heat transfer
- Non-scheduled outages
- Maintenance costs
- Deterioration and overheating of exchangers
- Decrease in the quantity of circulating water

Microbiological growth
This basically originates in algae, fungi, bacteria and other micro-organisms to a lower extent, all of which avail
themselves of light, heat, sludge and contamination by the manufacturing process or otherwise, nutrients and pH to
keep growing. Special consideration is to be given to autotrophic bacteria (ferrobacteria and sulphate-reducing
bacteria) which can give rise to localised corrosion.
A product of this activity is sludge that builds up in the system, reducing its efficiency in addition to limiting the water
passage and decreasing the flow rate, which in turn results in an increase in temperature. Both observing the colour,
feel and smell of sludge and analysing it will provide information about its origin.

2. COOLING WATER QUALITY

In general, an engine coolant consists of water, additives and antifreeze.
There are several basic parameters that ensure optimum coolant quality and, thus, a trouble-free operation of the
equipment.
This is why, it is strongly advisable to have cooling water analysed at the planning stage or before commissioning, so
that should results fail to match the values in Table 1, the user can contact a water treatment specialist in order to
take the necessary actions to ensure compliance with those specifications.
According to information provided by the equipment and the available water analysis results, it is essential to
determine the optimum concentration and any appropriate external and internal treatment which will maintain the
above issues under control and ensure the lowest possible water consumption.

These are the most usual chemical treatments:

- Sludge dispersants or conditioners.
- Scale inhibitors.
- Corrosion inhibitors.
- Algicides
- Microbicides/biocides
- Biodispersants

In the market, there exist combined products suitable for treating different problems simultaneously.
PRODUCT INFORMATION

INDEX

DATE
Dep. 2
IO-C-M-20-001e B
July 2011


3/6

Minimum coolant requirements.

PARAMETERS VALUE UNITS
Aspect and odour Transparent, neutral odour, free from sediments
pH value @ 25C 7-9
Total hardness 35-170 / 2-9.5 ppm CO
3
Ca / dH
Sulphates SO
4
-2
Max 100 ppm or mg/l
Chlorides Cl
-
Max 40 ppm or mg/l
Nitrates Max 10 ppm or mg/l
Total dissolved solids (TDS) Max 300 ppm or mg/l
Conductivity @ 25C Max 400 S/cm
Total alkalinity Max 150 ppm CO
3
Ca
TABLE 1

Aspect and Odour: Water-borne chemical compounds like phenols, several hydrocarbons, chlorine, organic matters
in any state of decomposition or the products of outgassing algae and fungi can give water a very strong odour and
taste, even if said compounds exist only in very small concentrations. Salts or minerals give water a salty or metallic
taste, but not always an odour.
Particles such as clay and silt, a.o., although not dissolved, are transported by water in either of two ways: as a
colloidal solution or in a dissolved condition that only persists while these particles are carried away by the flow of
water. Colloids will settle only if undergoing coagulation or flocculation (clumping of particles).
pH: The pH value expresses the acidity or alkalinity of an aqueous system. To be precise, it is the measurement of
the hydrogen ion "activity" in a given sample; in practical terms, it is a measure of the hydrogen ion concentration in a
sample. Since the pH scale is logarithmic and inverse, any increase in pH by one unit corresponds to a tenfold
decrease in the hydrogen ion molar concentration. The lower end of the scale (pH = 0) defines the acidity equivalent
to a solution of 1.0 M HCl whereas the upper end of the scale (pH = 14) represents the alkalinity equivalent to a
solution of NaOH 1.0 M.
Total hardness: The sum of temporary and permanent hardness. This is the sum of water dissolved metallic
ions. It is always stated in mg /l CO
3
Ca
Temporary hardness caused by acid calcium or magnesium carbonate. These bicarbonates precipitate, as water
warms up, to form insoluble carbonates.
Permanent hardness: due to the contents of sulphates, nitrates and calcium, magnesium, sodium and iron
chlorides. These salts do not precipitate as solutions.
Sulphates: Salts that dissociate in an aqueous solution and form ions which combine with calcium and magnesium.
These compounds combine with hydrogen to form acids which turn water corrosive.
Chlorides: The amount of chloride ions present in the system enhances the conductivity of water and affects the
protective film on the metallic surface, creating a favourable atmosphere for corrosion.
Nitrates: Salts that, in an aqueous solution, combine with hydrogen to form aggressive corrosive acids that may
damage the cooling system.
PRODUCT INFORMATION

INDEX

DATE
Dep. 2
IO-C-M-20-001e B
July 2011


4/6

Total alkalinity: Water alkalinity may be defined either as the water capacity to neutralise acids, react with
hydrogen ions, or accept protons or as a measure of the water total contents of alkaline substances (OH-).
Determining total alkalinity and different forms of alkalinity is important in chemical coagulation, softening and
corrosion control processes.
Natural water alkalinity generally derives from the presence of three types of ions: bicarbonates, carbonates and
hydroxides.
Some waters will contain other compounds (borates, silicates, phosphates, etc.) which contribute to their
alkalinity; but, in practice, the effect of these compounds is insignificant and can be disregarded.
Total dissolved solids: Solid substances appear in most waters as suspended materials or colloidal solutions.
They are measured in laboratory by the filtration method. Fine solids generate turbidity (NTU and JTU). Turbidity
is measured by the effect of light on these particles.
Conductivity: Electrical conductivity is the capacity of inorganic salts in solution (electrolytes) to conduct
electricity. Pure water hardly conducts electricity which is however conducted by water containing dissolved salts.
Positively and negatively charged ions are the elements that conduct electricity; the amount of conduction
depends on the number of existing ions and their mobility.
The use of distilled or de-ionised water increases the risk of corrosion and it is therefore necessary to add corrosion
inhibitors. Such additives can be rust-preventive products used alone or diluted in the antifreeze.

Additives. Antifreeze

The best way of avoiding problems due to corrosion, oxidation, scale, deposits, etc. in the cooling system is to treat
water with adequate additives which will protect the metallic surfaces of the system. These products form a rust-
proofing film on the surfaces of the cooling system, preventing corrosion and inhibiting settlements.
Thus, engine corrosion and rust can be fought with different types of anticorrosion additives.

Additive Protection / Purpose Inconvenient
Phosphates
(PO4)
Steel, iron, aluminium Unstable, fast wearing, deposits (caused by hard water).
Borates (BO4) Iron Corrode aluminium at high temperature.
Tolytriazol (TT) Copper
Nitrites NO2 Iron (cavitation ) and steel
Fast wearing. They expand welds. Dangerous if combined with
amines.
Silicates SiO3
Aluminium, Iron, general, relative
neutralisation
Fast wearing. Form films and, if excessive, they produce a "green
paste" that impairs heat transfer.
Carboxylic acids
Aluminium, general, stable,
neutralisers

Additionally, in order to prevent cooling water from freezing, it is recommended to add good quality commercial
antifreeze, even in hot climate areas, because such product raises the boiling point of cooling water, which impedes
that water boils and evaporates.
Antifreeze products are glycol-based water-soluble liquids (e.g. ethylene glycol, propylene glycol), which generally
contain the above mentioned additives whose object is to prevent the effects of corrosion, deposits, foam, etc.
An inadequate concentration will not only reduce frost protection or the boiling risk, but also increase cooling water
corrosiveness.
The effectiveness of a cooler-based cooling system decreases by ca. 2% per every 10% antifreeze added to the
coolant.
PRODUCT INFORMATION

INDEX

DATE
Dep. 2
IO-C-M-20-001e B
July 2011


5/6

The antifreeze-coolant ratio depends on the ambient temperature at the place of installation of the engine and it is the
antifreeze supplier who should state the concentration based on its product specifications and take responsibility for
any secondary effects. As a rule, GUASCOR recommends to add, at most, a 30% of glycol in water, since higher
concentrations can lead to a reduction of the coolant's heat transfer capacity.

Glycol Concentration, % weight

3. COOLANT TREATMENT
Maintaining cooling water in good condition will avoid troubles with and failures of the cooling system, as commented
earlier, as well as help us to detect a possible malfunction of the engine.
For instance, a decrease of the pH value together with an increase in the sulphate contents may be symptomatic of
water pollution by exhaust gases. On the other hand, a rise in chloride contents may be due to contamination by
seawater, and in this event, it would be advisable to inspect the engine and look for the source of the leak.
In closed circuits, where fluid refilling is infrequent, a complete corrective treatment can be applied initially, while
cooling water properties can be checked subsequently on refilling large amounts of water, but at least once a year.
In open systems that operate on large volumes of water, water treatment is very expensive. Input treatments are
usual practice or, if the installation allows, chemical cleaning will be undertaken periodically. For this type of system,
water tests are required to be made at least once a month, both at the cooling tower and in the water circuit to the
engine.
Companies specialising in water analysis and treatment possess test kits that enable users to check the cooling
system periodically.
If the results of periodic checks fail to match the values shown in Table 1, the customer must contact the water
treatment specialist, who has to participate actively in preparing and in defining the protection method most
suitable for the installation concerned.
Antifreeze decomposes into corrosive acids due to the cooling system's temperature cycles; contamination can build
up in the system and the corrosion inhibitors will eventually get exhausted. It is therefore recommended that the
antifreeze concentration in the system should be checked with a refractometer or hydrometer when testing the water
PRODUCT INFORMATION

INDEX

DATE
Dep. 2
IO-C-M-20-001e B
July 2011


6/6

quality. This will aid to ensure that the glycol concentration remains within adequate limits. By measuring the coolant
density as shown below, you can determine whether the antifreeze concentration is correct:

Glycol Concentration % weight Coolant density @ 20C Freezing point of coolant
10% 1,020 g/l -4C
20% 1,030 g/l -9.5C
30% 1,045 g/l -16.5C

PRODUCT INFORMATION

INDEX

DATE
Dep. 2
IT-C-A-20-003e B
February 2011
COOLING SYSTEM FOR GUASCOR ENGINES

1/4

1. INTRODUCTION

GUASCOR engines require a cooling system able to dissipate the thermal energy they generate when in
operation.

In order to cool the engine, water is used as the coolant fluid, after being treated to ensure optimum heat transfer
and the non-appearance of problems related to the lowquality of the same.

When cooling the system, there may be one or two independent cooling circuits, depending on the application
and the engine in question:

Single cooling circuit. All engine components, including the air/mixture cooler are cooled by a single
circuit.

Double cooling circuit. This consists of a main high temperature circuit responsable for cooling most
engine components and a secondary circuit used to cool the air or air/fuel mixture cooler and the oil
cooler. The air cooler and/or oil cooler may sometimes be dealt with by the main engine circuit.

2. COOLING CIRCUIT DIAGRAM

Below we have an example of a cooling system of an engine with a double cooling circuit, showing all its
components: (Fig. 1)

Fig. 1 Engine with double cooling circuit

PRODUCT INFORMATION

INDEX

DATE
Dep. 2
IT-C-A-20-003e B
February 2011

2/4

1. Main circuit water impeller pump
2. Main circuit oil cooler
3. Engine block. Linings and cylinder heads
4. Turbocharger bearing body
5. Main circuit temperature regulator
6. Cooling system external to the engine of the main circuit
7. Main circuit expansion tank
8. Venting piping at the highest point of the engine of the main circuit and engine water vent
9. Venting piping at the main circuit pump inlet
10. Venting piping at the highest point of cooling system external to the engine of the main circuit
11. Auxiliary water preheating pump
12. Water preheating resistor
13. Auxiliary circuit water impeller pump
14. Air or air/fuel mixture cooler
15. Auxiliary circuit temperature regulator
16. Cooling system external to the engine of the main circuit
17. Auxiliary circuit expansion tank
18. Venting piping at the highest point of the engine of the auxiliary circuit and engine water vent
19. Venting piping at the auxiliary circuit pump inlet
20. Venting piping at the highest point of cooling system external to the engine of the auxiliary circuit
PRODUCT INFORMATION

INDEX

DATE
Dep. 2
IT-C-A-20-003e B
February 2011

3/4

3. COOLING SYSTEM COMPONENTS
3.1 . IMPELLER PUMP
Responsable for passing the right amount and pressure of cooling water past all elements of the engine. It can be
operated mechanically by the engine itself or electrically from outside the engine.
3.2. OIL COOLER
Lubrication and cooling oil cooling system.
3.3. ENGINE BLOCK
Distributes water to the engine block to cool the liners and then the cylinder heads.
3.4. AIR OR AIR/FUEL INLET COOLER
This is the component of turbocharged engines that cooles the air or air/fuel inlet mixture, which is heated by
compression in the turbocharger, before it enters the combustion chamber.
3.5. TURBOCHARGER BEARING BODY
When the engine has a water-cooled turbocharger bearing body, part of the cooling system water is sent to this
component to cool it.

3.6. WATER PREHEATING SYSTEM
This is an auxilary system that allows the engine cooling water to be at the optimum temperature when the engine
starts from cold. This system consists of a heating element that heats up the water and, occasionally, an auxiliary
water pump that distributes the water throughout the engine.
3.7. WATER TEMPERATURE REGULATOR
The temperature of the water in the circuit needs to be controlled in order to stay at the right temperature. This
can be done by means of thermostatic valves that are installed in a thermostat box or by electronic regulation
using 3-way valves.
Temperature regulation using thermostatic valves is generally used for cases where precise temperature control
is needed, as they control ranges from 8 to 10C. Electronic regulation is used for cases where precise
temperature control is needed, in heat recovery applications for example.
3.8. VENT
An element that purges any possible air pockets from the circuit while the cooling circuit is being filled.
3.9. EXPANSION TANK

Due to the incresed volume of heated water, a tank has to be installed to control said increases in volume.

The expansion tank has to be installed at the highest point of the cooling circuit.

A pipe must run from the expansion tank to the circuit water pump inlet.

Alll venting pipes on the circuit must lead to the expansion tank below water level.

The expansion tank mst be fitted with a low water level sensor that does not allow the water level to fall below a
minimum level and a safety valve that allows air to enter the circuit at negative pressure and water, steam or air to
leave at positive overpressure.

PRODUCT INFORMATION

INDEX

DATE
Dep. 2
IT-C-A-20-003e B
February 2011

4/4

The expansion tank must have a capacity of at least 15% of the total volume of water in the cooling circuit.

Pressurised expansion tanks must be used in those cases where the minimum pressure requirement of the
cooling circuit cannot be reached with cooling systems using unpressurised expansion tanks or where engine
temperature exceeds 100C.

3.10. VENTING PIPES

This is a system of pipes that avoid air from collecting in the cooling system.
At least the following venting pipes should be installed, leading to the expansion tank, always below the water
level in the tank:
From the circuit water pump inlet to the expansion tank
From the highest point of the cooling circuit in the engine to the expansion tank
From the highest point of the external cooling circuit to the expansion tank

3.11. EXTERNAL COOLING SYSTEM

This par tof the cooling circuit is responsable for cooling the heat produced by the engine.
These ystems may be of different types, depending on the requirements and application in question.

4. REQUIREMENTS OF THE ENGINE COOLING SYSTEM

The cooling system must be able to dissipate all the heat generated by the engine and keep the same at the
correct in all possible operating conditions.

The heat generated and the cooling temperture are reflected in the thermal balances of each engine.
The heat generated by the engine and shown on the thermal balance sheet is a value determined under
specific operating parameters and standard conditions, meaning that in real conditions the heat generated by
the engine may vary, depending on its operating conditions and on environmental conditions. The cooling
circuit should be sized taking into account these variations, as well as taking into account the fact that the
cooling system may well get dirty. GUASCOR recommends having a reserve capacity of 15%.

The cooling liquid must satisfy the requirements listed in product information IO-C-M-20-001. The cooling
circuit must be designed to take into account the fact that using antifreeze in the coolant reduces heat transfer
by 3% for each 10% of antifreeze added to the coolant.

The cooling circuit pressure must always be positive throughout the circuit and comply with all minimum
requirements laid down for each engine in product information sheets IO-G-M-60-002, IO-G-M-60-006, IO-F-
M-60-002 and IO-D-M-60-001.

The cooling circuit must have a certain flow rate, defined in product information sheets IT-G-A-20-007 and IT-
F-A-20-005.

PRODUCT INFORMATION

INDEX

DATE
Dep. 2
IT-C-A-20-001e
February 2004

METHOD FOR
CALCULATION OF HEAD LOSSES AND FLOWRATES

1/2

According to the arrangement of the components in the cooling circuit, there are series components and parallel
components.

1. SERIES COMPONENTS

These are components connected to each other in tandem. For head loss calculations, thermostat boxes are
deemed to be installed this way.

K = K1 + K2 +

To determine the total head loss of the system (K), add the K constants of the different components.

2. PARALLEL COMPONENTS

To calculate the total head loss, first add the K constants of the different series components and apply the
following equation (based on the figure above):

4 3
1
2 1
1 1
K K K K K

A 20% safety margin is provided, to account for the restrictions of the components linking pipes and elbows as
well as for dirt building up in the circuit between successive cleaning operations as specified in the maintenance
guidelines. This safety margin is already included in the table of the components.

3. CALCULATING THE FLOWRATE IN THE CIRCUIT

To calculate the flowrate, identify the intersecting point of the pump curve, at the required rotational speed (1200,
1500, 1800 rpm), with the circuit characteristic that is given by the equation deltaP = K
circuit
*Q
2
. Measuring units
are [bar] for pressure drop (deltaP) and [m3/h] for flowrate (Q). If other units are used, constant K will change.

1 l/min = 0.06 m
3
/h
1 m
3
/h = 16.67 l/min
1 barmin
2
/l
2
= 277.4629 barh
2
/m
6

1 barh
2
/m
6
= 0.003604 barmin
2
/l
2

K1 K2
K1 K2
K3 K4
PRODUCT INFORMATION

INDEX

DATE
Dep. 2
IT-C-A-20-001e
February 2004

METHOD FOR
CALCULATION OF HEAD LOSSES AND FLOWRATES

2/2

Here is an example, based on the SFGLD360 engines auxiliary circuit comprising a power pump (19.20.860),
GEA intercooler (76.73.441), oilcooler (76.73.469-A) and 4-thermostat box (19.31.750). Adding the restrictions of
each individual component gives K = (K
GEA
+K
Oil
+K
ThermBox
) = 1.53610
-3

Draw the pump curves (they will be found in Product Information Sheet Group 20) as well as the circuit
restriction curve, which is deltaP = 1,53610
-3
Q
2
.

This graph will enable you to find out that the flowrate is 20m
3
/h at 1200rpm, 25m
3
/h at 1500rpm and 28m
3
/h at
1800 rpm.
In the event a water-to-water plate cooler were fitted into the circuit, it would be necessary to increase the circuit
restriction K by the K constant for the part of said cooler that is on the engine auxiliary circuits side. As a result,
the curve would change, rising more sharply, and the flowrate would decrease.

4. OTHER POINTS TO BE TAKEN INTO CONSIDERATION

The more components there are in a circuit, the lower the flowrate will be. Likewise, the greater the restriction of
one single component, the lower the flowrate will be. Therefore, components with the smaller possible restriction
should always be used in order to improve cooling.
Elbows as well as long and narrow pipe lengths also affect the flowrate negatively. This point must be borne in
mind when making the installation.
It may occur that the minimum flowrate specified for an engine according to the thermal balance sheets cannot be
reached with a defined power pump-based circuit. In this case, the power pump must be replaced by an electric
pump capable of ensuring a greater flowrate.

Pump Curve
1200 rpm
Pump Curve
1500 rpm
Pump Curve
1800 rpm
Auxiliary
Circuit Curve

INDEX

DATE
Dep. 1
IT-O-A-2-001110-07e
June 2010

EXPANSION TANK ADAPTATION

1/2

Fig. 1 General Disposition

REF. CAPACITY dm3 (gal) H mm (inch) D mm (inch)
40.20.440 50 (13.2) 630 (24.8) 360 (14.17)
40.20.450 80 (21.13) 590 (23.22) 485 (19.09)

Table 1 General Characteristics

Fig. 2 Water Circulation / Hydraulic Circuit

A
B B

H
D
R-G.3/4"

COLLECTING
DISCHARGE
WATER COOLER
ENGINE
PURGE
WATER
PUMP

WATER PUMP
PUMP INLET
PURGE VALVE


INDEX

DATE
Dep. 1
IT-O-A-2-001110-07e
June 2010

EXPANSION TANK ADAPTATION

2/2

In the up mid way points, where exist possibility to form air pocket, it is essential to install air automatic purges.
With those automatic purgers we have warranted the purge of all air pocket in every points of the installation.

Fig. 5 Security Valve. Tare: 3,5 kg/cm
2
(49.7 psi)
28
R-G.1"

R-G.1/2"

WATER
PUMP
Fig. 3 Detail A Engine Water Inlet
Fig. 4 Detail B Air Automatic Purger
Install in all up mid way points of the circuit
ENGINE WATER
OUTLET
DISCHARGE
PRODUCT INFORMATION

INDEX

DATE
Dep. 3
IT-C-A-20-011e
B MAY 2012

INSTALLATION MANUAL ELECTRIC PUMPS

1/6

1. INTRODUCTION

This document describes how to install the electric water pumps used by Guascor to circulate water through
Guascor engine cooling circuits and cooling tower water circuits.

The following points should be borne in mind before installing the pumps:

Ensure that all pipe welding work and cleaning has finished and the pipes are free of foreign bodies,
particles and dirt. Particles can damage the pumps and other parts of the installation, this is why Guascor
recommends that filters be installed at pump inlets. The filter baskets can be removed after a time in use,
when they have eliminated all foreign bodies and dirt.
The pumps are supplied correctly lubricated, with covers protecting the inlets and outlets. The covers
should be left in place for as long as possible during installation in order to prevent foreign bodies from
getting into the pumps.
The pumps should be installed in an area free of any risk of explosion that is well-ventilated, dust-free-
free and protected from the wind and frost. The maximum recommended ambient temperature is 40C.
The pumps should be easy to access for maintenance work. A minimum distance of 15 cm should be left
between the engine fan grille and the nearest wall.

2. INSTALLATION

Guascor supplies two kinds of standard pumps inline pumps that are fitted directly to the piping, and base plate
pumps that are used to pump water in circuits with cooling towers. Among the inline pumps, which can be fitted to
the piping or installed on a base, we find the split shaft pumps that used to be standard and the extended shaft
pumps supplied now. The latter are much easier to install, as they are supplied with the shaft already aligned,
meaning that you neither have to align them nor check their alignment on site.

Use authorised lifting apparatus when handling the pumps. They should be lifted using the connection flanges
and, when necessary, the outside of the motor. The lifting eyes can be used as a guide but should never be used
to transport the complete pump, as they are only used for raising motor engine during maintenance operations.

All installation positions are allowed, except for the motor facing downwards, as long as the connection box is not
facing downwards. If this is the case, unscrew the hex head screws and carefully rotate the motor or motor block
so as not to damage the housing O-ring. Inline P7.5 KW pumps can be fitted directly to the piping with no base
to secure them, although 5.5 KW should be installed on a solid base.
PRODUCT INFORMATION

INDEX

DATE
Dep. 3
IT-C-A-20-011e
B MAY 2012


2/6

In all cases, the pumps should be installed where they can be easily accesses for maintenance operations, and
the maximum axial distance between the closest wall and the fan cover should be more than 200mm+.

Although the pipes can be routed as you wish, GUASCOR recommends following the CEN TR 13932 guidelines,
where a straight sections without valves or filters and at least 5 times the diameter of the piping should be
installed between the last elbow before the inlet and the inlet connection or bushing. The filter should also be at a
distance of at least six times the diameter of the piping before the inlet.

2.1. INSTALLING INLINE PUMPS

Inline pumps are fitted directly to the piping.

When installing the pump on a base, it must be flat, with enough space to support the frame correctly and respect
the anchoring points. A minimum axial distance of 250mm+ fan cover between the pump and the wall, so that the
latter does not hinder installation and removal of the engine. A minimum distance of 15 cm must be left between
the motor fan grille and the closest wall.

WARNING! If the pipes are insulated, the pump volute casing can be insulated, but not the motor!

WARNING! The purge valve must always point upwards.
The pumps should be connected to the pumps in such a way that there is no stress between them and the pump,
and the pipes should be supported so that the pump does not have to bear their weight. The size of the
connection flanges should not be used to determine the size of the pipes if in doubt, check with IT-G-A-20-019
or the Guascor Engineering Applications Department. You should fit dampers and cut-off valves on both sides of
the pump to avoid transmitting vibration and make it possible to carry out easy pump installation and removal
operations without having to empty the circuit. If there is danger of backflow, a non-return valve must be fitted.

Inline extended shaft pumps (IPL): Nowadays, the standard Guascor pumps are inline and extended
shaft. The extended shaft makes installation easier, as it is supplied aligned and the alignment of the
pump shaft does not need to be checked. The following is an exploded view of an extended shaft pump.

Inline split shaft pumps (IL): Guascor used to supply inline split shaft pumps for fitting to piping. The
only difference with the extended shaft pumps is that the alignment of the shafts has to be checked. To
do so, check that the gap between the lantern and the coupling is 5mm all round the circumference with
the mounting yoke or a 5mm gauge.

Drain
valve
PRODUCT INFORMATION

INDEX

DATE
Dep. 3
IT-C-A-20-011e
B MAY 2012


3/6

2.2. INSTALLING BASE PLATE PUMPS

The precautions to be taken when installing base plate pumps are similar to those for inline pumps. The main
difference between the two kinds of pumps is the volute, how the connections are arranged and how they are
installed. The BL series base plate pumps are installed on foundations or suitable consoles. The motor is coupled
in similar fashion to extended shaft pumps.

The BL base plate pumps are also split shaft, meaning that their shaft alignment must be checked after
installation, just as with inline split shaft pumps. The pump is supplied with a 5mm mounting yoke for this purpose,
or a 5mm thick gauge can also be used.

As regards the stresses on the connections of base plate pumps, the maximum acceptable stresses and torques
are shown on the table below. These limits must never be exceeded.

DN Inlet/Outlet Flanges
Stresses [kN]
Torques [kNm]
M
tmax

F
Vmax
F
Hmax

65/40
2.4 1.7 0.55
2.4 1.7 0.52
2.4 1.7 0.50
2.4 1.8 0.62

Mounting
yoke
PRODUCT INFORMATION

INDEX

DATE
Dep. 3
IT-C-A-20-011e
B MAY 2012


4/6

3. ELECTRICAL CONNECTION

The electrical connection must be carried out by a qualified electrician and observe the regulations in force at the
installation site. The electrical connection of the pump must be made in all cases using solid wiring with a plug or
switch for all poles, with a gap of at least 3mm, as per German standard VDE 0730, Part1.

In order to ensure that the installation is protected against dripping water and stuffing box strain relief, wires with
an appropriate external diameter must be used. The wires must also be folded near the stuffing box to create a
run-off loop for dripping water.

WARNING! When pumps are installed in facilities where the water temperature exceeds 90 C, a heat-resistant
power supply cable must be used.

The electric power supply cable must be fitted so that it never comes into contact with the piping or the pump and
motor housing. Check the type of current and network voltage, respecting the information on the motor
specifications plate.

Protection using fuses: depending on the rated current of the motor.

The pump and the installation must be earthed in accordance with the regulations in force. The electrical
connection diagram is found on the cover of the connection box and on the pump data sheet. The motor should
be protected against overload with a circuit breaker:

Direct start-up: Adjustment to the rated current of the motor as per the data on the motor specifications
plate.

Star/delta start-up: if the circuit breaker is connected with the input cable of the star/delta starter, the
adjustment is made as with direct start-up. If the motor safety switch is connected to a phase of the
engine input cable (U1/V1/W1 or U2/V2/ W2), the circuit breaker must be adjusted to a value of 0.58 x the
rated current of the motor.

In certain circumstances, the motor can be fitted with a PTC thermistor. Connect the PTC to a trip relay.

WARNING! At the terminals, the PTC can only be subject to a maximum voltage of 7.5 V, as a higher voltage
would damage the thermistor.

PRODUCT INFORMATION

INDEX

DATE
Dep. 3
IT-C-A-20-011e
B MAY 2012


5/6

The connection to the network from the terminal strip is carried out according to motor power P2, network voltage
and connection type. The configuration required the terminal bridges for 50Hz networks is shown in the following
table:

Connection type
Motor output
P2 3 kW P2 4 kW
Network voltage
3 ~230 V 3 ~ 400 V 3 ~ 400 V
Direct Connection delta (3a) star Y (3b) delta (3a)
Star (Y)/() delta start-up Remove bridges (3c) Impossible Remove bridges (3c)

With 60Hz networks, the connection diagram and their configuration depend on the network voltage and can be
checked on the data sheet of the pump in question and/or on the cover of the motor connection box. If in doubt,
contact the Guascor Engineering Applications Department.

PRODUCT INFORMATION

INDEX

DATE
Dep. 3
IT-C-A-20-011e
B MAY 2012


6/6

4. START-UP

WARNING! Before testing the pump, the pipes and the pump must be filled and purged correctly by loosening the
purge screw. The pump must never operate dry.

To avoid cavitation, ensure that the inlet pipe pressure is higher than the NPSH required.

WARNING! Take care with the purge screw, if it is left fully open hot water or pressurised steam can leak out, with
the consequent danger to equipment and people.

Start up briefly to check that the pump rotates in the same way as the arrow on the motor. If not, proceed as
follows:

Direct start-up: Invert two phases on the motor terminal strip (e.g. L1 to L2).

Star/delta start-up: Invert the start and end of two coils on the motor terminal strip (e.g. V1 to V2 and W1
to W2).

In continuous operation, the minimum flow rate must not be less than 10% of the rated flow rate.

WARNING! The pump must never operate empty or without flow (Q=0 m
3
/h).

Check that the absorbed current does not exceed the rated current stated on the motor specifications plate. You
can also check the pump head with a differential pressure gauge connected to the pump inlet and outlet pressure
connections.

WARNING! Depending on the operating conditions, the pump may run very hot, so you should keep away from it
and never touch it while it is in operation.

WARNING! The pump must be checked to ensure that it is supplying the flow stated in the fact file once it has
started up and is operating at continuous rating. To do this, use a differential pressure gauge to check that the
head provided by the pump corresponds with that stated on the technical data sheet. If the head reading is
lower, generate an artificial loss of head in the cooling circuit downstream of the pump until the required
differential pressure value is reached and the operating point is corrected.
REFERENCE

INDEX

DATE
Dep. 3
IC-G-D-20-067e
October 2011

7628287 TECHNICAL COMMERCIAL INFORMATION SHEET
STANDARD ELECTRICAL PUMP

1/1

1. DESCRIPCIN
Electric cooling water pump that guarantees the minimum flow needed for correct cooling group offered. To
calculate the head losses of the motor and its components, consult documents IT-C-A-20-001 and IT-C-A-20-002.
As regards installation, the steps to be taken are described in IT-C-A-20-011, while the maintenance guidelines
are described in IO-C-M-20-003.

The impeller pumps used by GUASCOR for the cooling circuits of its engines are 3-phase inline centrifugal dry
rotor pumps. They operate at 2.900 rpm with 50 Hz networks. Mechanical seal with forced cooling independent of
the direction of rotation. Flanges with R1/8 connections to measure differential pressure.

2. OVERALL DIMENSIONS AND TECHNICAL DETAILS

Connections
Inlet side DN 80 / PN10
Outlet side DN 80 / PN10
Weight 85 kg

Motor details
Rated power P2 5.5 kw
Rated speed 2900 1/min
Rated voltage 3 400 V, 50 Hz
Max. absorbed current 10,5 A
Protection rating IP 55

Pumping height
REFERENCE

INDEX

DATE
Dep. 3
IC-G-D-20-066e
October 2011

7628285 TECHNICAL COMMERCIAL INFORMATION SHEET
STANDARD ELECTRICAL PUMP

1/1

1. DESCRIPTION
Electric cooling water pump that guarantees the minimum flow needed for correct cooling group offered. To
calculate the head losses of the motor and its components, consult documents IT-C-A-20-001 and IT-C-A-20-002.
As regards installation, the steps to be taken are described in IT-C-A-20-011, while the maintenance guidelines
are described in IO-C-M-20-003.

The impeller pumps used by GUASCOR for the cooling circuits of its engines are 3-phase inline centrifugal dry
rotor pumps. They operate at 2900 rpm with 50 Hz networks. Mechanical seal with forced cooling independent of
the direction of rotation. Flanges with R1/8 connections to measure differential pressure.

2. OVERALL DIMENSIONS AND TECHNICAL DETAILS

Connections
Inlet side DN 40 /PN10
Outlet side DN 40 /PN10
Weight 32 kg

Motor details
Rated power P2 2.2 kw
Rated speed 2900 1/min
Rated voltage 3 400 V, 50 Hz
Max. absorbed current 4.6 A
Protection rating IP 55

Pumping height

INDEX

DATE
Dep. 8
IT-C-A-20-014e
October 2005

TECHNICAL INFORMATION OF
STANDARD FLEXIBLES JOINTS

NR 1/2

APLICATION
Flexibles joints for water circuit below 100C.

CHARACTERISTIC
NOMINAL 32 a 300 350 a 500
WORKIN PRESSURE 15 kg/cm
2
8 kg/cm
2

BREAK PRESSURE 60 kg/cm
2
24 kg/cm
2

VACUUM 750 mm. Hg
TEMPERATURE -10C a 115C

NOMINAL

REFERENCE D1 d1 d2 L M T N d3
32 76.14.301 140 100 69 95 22 16 4 18
40 76.14.302 150 110 69 95 22 16 4 18
50 76.14.303 165 125 86 105 22 16 4 18
65 76.14.304 185 145 106 115 25 18 4 18
80 76.14.305 200 160 116 130 25 18 8 18
100 76.14.306 220 180 150 135 25 18 8 18
125 76.14.307 250 210 180 170 28 20 8 18
150 76.14.308 285 240 209 180 30 22 8 23
200 76.14.309 340 295 260 205 33 22 8 23
250 76.14.311 395 350 320 240 35 24 12 23
300 76.14.312 445 400 367 260 35 24 12 23
350 76.14.313 505 460 408 265 44 32 16 23
400 76.14.314 565 515 472 265 46 34 16 27
500 76.14.316 670 620 522 265 50 38 20 27
Table 1 General Dimensions

Clamps: DIN 2501 - PN-10

INDEX

DATE
Dep. 8
IT-C-A-20-014e
October 2005

TECHNICAL INFORMATION OF
STANDARD FLEXIBLES JOINTS

NR 2/2

NOMINAL
OFFSET (mm)
ANGULAR
DEFLECTION (D+E)
AXIAL
RADIAL
(C)
COMPRESSION
(A)
EXTENSION
(B)
32 8 4 8 15
40 8 4 8 15
50 8 5 8 15
65 12 6 10 15
80 12 6 10 15
100 18 10 12 15
125 18 10 12 15
150 18 10 12 15
200 25 14 22 15
250 25 14 22 15
300 25 14 22 15
350 25 16 22 15
400 25 16 22 15
500 25 16 22 15
Table 2 Offset

RADIAL OFFSET

ANGULAR DEFLECTION

NORMAL POSITION

COMPRESSED

EXTENDED

PRODUCT INFORMATION

INDEX

DATE
Dept. 3
IT-C-A-20-016e
A September 2012
INSTALLATION AND USER MANUAL FOR GUASCOR
STANDARD DRY-COOLERS

1/5

1. INTRODUCTION

This document describes the requirements to be met when installing dry-coolers in GUASCOR engine cooling
circuits.

For further information on installing and connecting water circuits, refer to document IT-GA-20-019.

It is imperative to operate the Dry-cooler under the conditions outlined the initial study (flow rate, temperature,
pressure, etc ...). Adhering to the installation instructions and preventive maintenance will mean proper operation
of the equipment.

1.1. REMINDER OF OPERATING CONDITIONS

The function of the Dry-cooler is to cool the water in the cooling circuits with external air by means of a monoblock
heat exchanger made of tubes and continuous vanes; air is propelled between continuous vanes and by fans.
These fans can be arranged either above the appliance, using induced ventilation draught, or under the dry-
cooler, using a forced ventilation draught. This arrangement depends on the thermal characteristics of the
installation as established during the study. The installer and user must ensure that the fluid used is fully
compatible with the copper in the pipes and the material in the vanes.

Any request for additional information, spare parts, etc. must specify the serial number of the device.

2. DESCRIPTION

The Dry-cooler consists of a vaned tubular bundle of copper tubes and aluminium vanes protected with an
anticorrosive coating. This assembly is supported by means of perforated sheets and the apparatus frame. The
tubular bundle is powered via PN16 flanges, which are connected to the copper distribution manifolds. These
manifolds have a vent at the top and a drain plug at the bottom. The main components are:

One or several motorised fan units: Each unit is composed of a single voltage three-phase electric
engine (380V to 415V for supply at 50Hz and 440 for 60Hz) with IP55 protection level and an axial
propeller mounted on the end of the shaft, statically and dynamically balanced. A protective grid on the
propeller is installed at the bottom (forced draught) or at the top (induced draught) of the latter. These
units are designed for exterior use and conform to the CE standard.

Air intake chamber: It is made of galvanized steel sheets, assembled with bolts or rivets, which the unit is
built into. The intake chamber rests on several supporting brackets. All these plates may have been
treated for corrosion as per the Sorabond process. Interior partitions allow each fan to operate
separately.

Junction box: This box is fixed to the front of the apparatus, above the manifolds. It is airtight, IP65. The
standard version contains a strip on which all electric motors are connected. The plate which is fitted with
a stuffing box must be perforated by the installer depending on the cables to be used. The engines must
be grounded. Similarly, protection against overcurrent and short circuits must be carried out by the
installer in accordance with sound engineering practice and local regulations in force.

NOTE: All installations must have a system to absorb the expansion of the fluid in the circuit.
PRODUCT INFORMATION

INDEX

DATE
Dept. 3
IT-C-A-20-016e
A September 2012

2/5

3. INSTALLATION

When installing the equipment, the following norms apply:

The dry-cooler must be installed outside.

No adjacent wall should obstruct the air intake or outlet of hot air(The fans are not designed to withstand
additional head losses).

The dry-cooler should be far enough away from all kinds of air discharge, smokestack or adjacent
equipment, to prevent polluted or warmed-up air from being sucked in the system. Also, check that no
hot or polluted air will be driven to the air intake by the action of dominant winds.

The equipment must be fitted maintaining a minimum of 2 metres between the dry-cooler and any vertical
wall; under no circumstances shall any such wall exceed 1.5 metres in relation to the installation plane of
the equipment.

All support components of the apparatus (supporting brackets, fixing plates ...) should rest over the entire
surface, on a rigid plinth. The apparatus installation plane should be set to hold the weight of the
apparatus loaded. It should be perfectly flat to ensure the apparatus empties correctly. When using
shock mounts (external supply), these must comply with the conditions listed above.

When installing several units on the same site, we recommend fitting them next to each other spaced
apart by a few centimetres. Raising the height of the apparatus should be provided for. Please refer to
GUASCOR.

Pipes shall be laid in such a way as to prevent air pockets from building up by installing an upstream
circuit and automatic bleeders etc. To do this properly, refer to document IT-GA-20-019 regarding the
design of hydraulic circuits.

Fig. 2 Minimum distance between equipment

PRODUCT INFORMATION

INDEX

DATE
Dept. 3
IT-C-A-20-016e
A September 2012

3/5

4. HANDLING

There are four lifting lugs at the top of the appliance. For 1,2 or 3-fan machines these lugs can be replaced by
lateral holes in the four corners of the appliance.

Always use a crane or similar equipment for handling the dry-cooler. Ensure the following sling angles are strictly
adhered to:

90 in length

from 50 to 70 width

Use a spreader beam if necessary.

It is vital any manipulation of the unit is performed with the aid of a forklift for a horizontal, induced draught
apparatus with one row of fans and whose length does not exceed 2 to 3 times the base of the forks. Moreover,
the length of the forks must be greater than the width of the unit so as not to damage the vanes. In this case, try
to protect the side of the unit to avoid any damage to the box and its covering. In all other cases, use a crane or
similar equipment.

Under no circumstances shall the operator climb on the device or use the piping or equipment that may be
attached (expansion tank, electrical cabinet etc.) to handle or move it.

Fig. 1 - Lifting the dry-cooler

PRODUCT INFORMATION

INDEX

DATE
Dept. 3
IT-C-A-20-016e
A September 2012

4/5

5. ASSEMBLY/MECHANICAL CONNECTION

To avoid any malfunction of the system, the appliance must be perfectly level. Shims of different thicknesses are
provided for this purpose.

For the structural design of construction work and anchor bolts, bear in mind the weight of the fully-loaded
apparatus, complete with all its accessories, expansion tank and supporting structure (refer to the general
documentation or assembly drawing). If the air injector is to be installed in a particularly exposed area, anchorage
shall be defined according to the dominant winds and, where appropriate, the height of the supporting structure.

The appliance is supplied fully assembled. In some cases, the supporting legs are delivered unmounted (for
transport reasons) and will have to be assembled by an installer. See assembly drawing to locate exact position
where the unit is to be fitted. In the case where the apparatus is provided with a supporting structure, refer to the
specific drawing.

Fix the apparatus on its installation plane. Use shims if required. Carefully check the unit has been levelled off,
and then make the fluid connections.

Remove the sealing caps. Connect the flanges of the device to the circuit piping after cleaning and rinsing the
latter. Make sure no welding or other waste get into the apparatus. Gaskets and bolts are not supplied. No stress
should be transmitted by the pipework due to expansion or assembly tolerances. We recommend installing
flexible joints(in this case bridged by grounding braid).

The pipework should ensure a counterflow between the water stream and the air current.

In order to verify operation, the system will be equipped with pressure and temperature readings at the points
provided therein. These clocks can be installed in the pipes with suitable couplings, if necessary. Specified points
on the dry-cooler will be used to install automatic air bleeders.

For easy servicing and maintenance of the system, fly-nut valves should be installed on the 4 connections, flush
with the diameter of the pipework.

VERY IMPORTANT Never use the dry-cooler frame as a ground for welding the supply piping. Otherwise, the
electric arcs would perforate the tubes of the perforated plates. Select a ground on the pipes of the circuit, as near
the working area as possible. Failure to adhere to the above recommendations will invalidate the warranty.

6. POWER WIRING

The power supply line must be fitted with an automatic differential magnetothermal circuit breaker with effective
earth contact, in accordance with the safety regulations in force.

Always check that the power supply rating, number of phases, voltage and frequency coincide with the
specifications on the fan nameplate. The section of the leads must be suitable for the current to be carried and
the distance over which current has to be transported.

Earthing is required by law. The installer shall connect the earth wire from the ground connection plates to an
earthing point on the appliance (e.g. supporting leg).

To ensure maintenance staff's safety, it is advisable to equip the system with an emergency line breaker.

PRODUCT INFORMATION

INDEX

DATE
Dept. 3
IT-C-A-20-016e
A September 2012

5/5

7. ADJUSTMENT

The modular design of these devices allows fans to operate separately. This makes it possible to adapt the
heating capacity of the unit depending on the conditions of use: reduced heat load, low temperature, either by
varying the number of fans in operation (regulation by stages "all or nothing"), either the speed of all fans with the
help of a variable speed drive. Adjustment setpoint is generally the water outlet temperature. The measurement
probe should be placed as close as possible to the apparatus so as to avoid instability. The adjustment system
chosen must necessarily meet the following conditions:

Adjustment in stages: The number of stages is determined by the number of fans in the apparatus, with a
recommended maximum of four stages. Adjustments of the gap between contacts and differential will be
done so as not to exceed the 6 fan starts per hour with an equal operating and stopping time, whatever
the operating conditions.

Frequency variation: Only appliances equipped with 1000 rpm or 750 rpm engines can accept this type
of adjustment. It is imperative the drive type is adapted to ventilation or "quadratic mode. Failure to
enforce this would mean destruction of the engines in the short-term. The drive the installer chooses must
be approved by the service department. Any other type of variable speed drive via varying voltage or
system that has an effect on the current sinusoid is prohibited.

8. SYSTEM OPERATION

Before start-up, ensure that:

All protective packaging fitted on the apparatus for safety reasons during transport have been removed.

Condensate drain plugs on ventilation motors have been removed at the bottom and are in place at the
top.

The suction area of the apparatus is free from foreign bodies that could be aspirated by air flow.

All pipes are perfectly clean and contain no waste or other residue.

The fans turn freely by hand; no evidence of "standstills".

The screws are correctly fitted (connecting flanges, electrical connections, mounts for mechanical parts.)

Once finished checking these points, proceed to the effective start-up for use:

Remove the venting plugs on the inlet manifold.

Fill the whole circuit preferably at a low point of the installation using the fluid under contract, until it
comes out through the vent. The addition of glycol is imperative where there is a risk of frost. For the
right amount of glycol to be used, refer to document IO-CM-20-001 A.

Close the circuit, controlling leak-tightness.

Start the circulation pump(s) to expel air pockets contained in the circuit. A very noisy fluid flow signals
the presence of air in the circuit.

After completely expelling air pockets, check the fluid level. Fill if necessary.

Stop the fluid feed.

76.73.625
PRODUCT INFORMATION

INDEX

DATE
Dep. 3
IT-G-A-20-020e
October 2011

USER AND INSTALALTION MANUAL STANDARD
AIRCOOLERS TYPE RGR-RGF-TGR-TGF-MGR

1/4

1. INTRODUCTION

These are the user and installation instructions for standard aircoolers type RGR - RGF-TGR -TGF and MGR.

For the installation and connection of the water circuits see document IT-G-A-20-019e.

The Aircooler must operate according to the initial study conditions (Flow, temperatures, pressure, etc.).
Respecting the installation and maintenance rules will ensure that the equipment operates correctly.

1.1. SUMMARY OF THE CONDITIONS OF USE

The function of the Aircooler is to cool the cooling circuit water with atmospheric air by means of monoblock heat
exchanger with continuous pipes and fins, the air being moved between the fins by fans. The fans may either be
on top of the apparatus for induced draft (RGR- TGR - MGR) or below the apparatus for forced draft" (RGF -
TGF). The arrangement depends on the thermal characteristics of the installation that have been laid down in the
study. Installers and users must ensure that the fluid used is fully compatible with the copper pipes and the
material of the fins.

All requests for further information, spare parts, etc. must state the Serial N of the apparatus.

2. DESCRIPTION

The aircooler consists of a finned tube bundle made from copper tubes and aluminium fins protected with an anti-
corrosion coating. The unit is held up by perforated plates and the frame of the apparatus. The tube bundle is fed
through copper PN16 flanges connected to the distribution manifolds. The manifolds have air vents at the top and
drain plugs at the bottom. The main components are:

1 or more motor fan units: these consist of a 3-phase monotension electric motor (380V to 415V for
powering at 50Hz and 440 at 60Hz) IP 55 protection and axial blades fitted to the end of the shaft and
balanced statically and dynamically. A grille to protect the blades is fitted at the bottom (Forced draft) or
the top (Induced draft) of the latter. These units have been designed for outdoor operation and comply
with CE standards.

Air box: This is made from galvanised steel sheet assembled with rivets or bolts, and containing the unit.
The box rests on support feet. The plates may have been treated against corrosion using the Sorabond
procedure. Internal partitions allow each fan to operate separately.

Connection box: The box is attached to the front of the apparatus, above the manifolds. It is hermetic,
with IP 65 protection. It normally has a connection strip to which all the electric motors are connected.
The plate with a gland must be perforated by the installer according to the cables to be used. The motors
must be earthed. Overvoltage and short-circuit protection must be installed by the installer as per
common practice and local regulations.

NOTE: All installations must have a system for absorbing the expansion of fluid in the circuit.

PRODUCT INFORMATION

INDEX

DATE
Dep. 3
IT-G-A-20-020e
October 2011


2/4

3. INSTALLATION

The apparatus must be chosen bearing in mind the following rules:

The Aircooler must be installed outdoors.

No neighbouring wall should obstruct the cooling air intake or the hot air outlet (The fans are not designed
to withstand supplementary static pressure).

The apparatus must be far enough away from all air outlets, chimneys and neighbouring equipment to
ensure that the equipment does not suck in contaminated or reheated air. You should also ensure that
the prevailing winds do not funnel hot or contaminated air to the air inlet.

The apparatus must be sited at least 2 metres from any vertical wall and in no case should said wall be
1.5 metres high with regard to the installation of the apparatus.

The whole surface area of all support elements of the apparatus (Support feet, fixing plates, etc.) should
rest firmly on a rigid base. The installation must sustain the weight of the loaded apparatus and be
perfectly level to ensure that it can be emptied correctly. If vibration dampers are used (Not in supply),
they should be designed to satisfy the conditions described above.

When several units are installed at the same location, we recommend that they be placed side by side,
several centimetres apart. The apparatus may have to be raised. Check with GUASCOR.

The pipes should be laid so that air pockets, rising circuits, the installation of automatic purge valves, etc.
are avoided. To do this correctly, see document IT-G-A-20-019, dealing with the design of hydraulic
circuits.

4. HANDLING

There are four lifting eyes on top of the apparatus. With 1, 2 and 3 fan units, these lifting eyes may be replaced by
holes at the four corners of the apparatus.

The apparatus should always be handled with a crane or similar. You must respect the following sling angles:

90 length

from 50 to 70 width

Use a loading beam if necessary.

In exceptional circumstances, the apparatus can be handled with a forklift truck, but only for an induced draft unit
with 1 row of fans, whose length does not exceed 2 to 3 times the base of the blades. The blades must also be
longer than the width of the apparatus so as not to damage the fins. In this case, protect the side of the apparatus
to avoid damaging the box and its lining. In all other cases use a crane or equivalent.

Never climb on to the apparatus, handle or move it by the pipes or any possible associated equipment (expansion
tank, electric cabinet, etc.)
PRODUCT INFORMATION

INDEX

DATE
Dep. 3
IT-G-A-20-020e
October 2011


3/4

5. INSTALALTION/CONNECTION

To avoid incorrect operation, the installer should have wedges of different sizes to ensure that the apparatus is
perfectly level.

When sizing the preparatory work and anchor bolts, take into account the weight of the full apparatus with all
possible accessories, expansion tank, possible support structure (consult the general documentation or the plan
of the unit). If the site is particularly exposed, the anchor bolts must be sized according to the prevailing winds
and the height of the support structure.

The apparatus is supplied completely assembled. In some cases the support feet may be delivered unfitted for
transport reasons and have to be fitted by the installer. See the plan of the unit to locate their exact positions.
When the apparatus is supplied with its support structure, check the specific plan.

Install the apparatus in its position using wedges if necessary. Carefully check that the apparatus is level and then
make the fluid connections.

Remove the plugs. Connect the flanges of the apparatus to the piping of the circuit after cleaning and rinsing the
latter. No foreign bodies should enter the apparatus. The gaskets and bolts are not supplied. The pipes should
not transmit any stress due to expansion or assembly tolerances. You should use flexible joints (In this case,
bridge to earth with braided wire).

VERY IMPORTANT: Never carry out welding work on the piping using the frame as earth. This would perforate
the tubes of the unit in the perforated sheets, due to the striking of electric arcs. Earth must be made on the piping
of the circuit, as close as possible to the work area. The guarantee is void is these conditions are not respected.

6. ADJUSTMENT

The modular nature of the apparatus means that the fans can operate separately. This makes it possible to adapt
the thermal power of the apparatus to the conditions of use: reduced thermal load, low ambient temperature, by
varying either the number of fans in service (Stepped adjustment "all or nothing") or the speed of all the fans with
the help of a variable speed drive. The rated value of the adjustment is normally the outlet temperature of the
water. The measurement probe should be fitted as close as possible to the apparatus to avoid instability
problems. The adjustment system chosen should satisfy the following conditions:

Stepped adjustment: the number of steps is determined by the number of fans in the apparatus, with a
maximum of four steps being recommended. The adjustment of the separation between contacts and the
differential should ensure that there are no more than 6 start-ups for each fan in any one hour, with an
equal operating time and shut-down, whichever are the operating conditions.

Frequency inverter: only units with 1,000 rpm or 750 rpm motors can adopt this kind of control. The type
of inverter must be adapted to the ventilation or "quadratic mode". Non-compliance with this requirement
will lead to the destruction of the motors in a short period. The technical service of the manufacturer must
approve the inverter chosen by the installer. Any other kind of frequency inverter using voltage variation,
or system that affects the sinusoidal shape of the current is prohibited.
PRODUCT INFORMATION

INDEX

DATE
Dep. 3
IT-G-A-20-020e
October 2011


4/4

7. START-UP

Before start-up, ensure that:

All protections attached to the apparatus for transport have been removed.

The condensate drain plugs on the fan motors have been removed from the bottom and inserted at the
top.

The suction area of the apparatus is free of foreign bodies that could be sucked in with the air.

All the pipes are perfectly clean and free of any foreign bodies or residues.

The fans rotate freely by hand, with no "sticky points".

All screws have been tightened correctly (Connection flanges, electrical connections, and brackets for
mechanical parts).

After checking the above points, proceed with the start-up:

Remove the air vent plugs from the inlet manifold.

Fill the circuit, preferably from a low point of the installation, using the contracted fluid until it starts coming
out of the air vent. Glycol must be added in case of frost. Consult the documentation to identify the
correct amount of glycol.

Close the circuit and check that it is hermetic.

Start the pumps to evacuate air pockets in the circuit. Noisy fluid circulation is a sign that air is present in
the circuit.

After driving out all the air pockets, check the fluid level and top up if necessary.

Stop the fluid circulating.


INDEX

DATE
Dep. 3
IT-G-A-30-015e
A November 2011

INSTALLING GAS VALVE TRAINS

1/4

1. INTRODUCTION

This document aims to define the requirements to be met when installing gas valve trains in the supply line to
GUASCOR gas engines.

"Gas valve train" means a set of devices arranged so as to supply, control and cut off the gas flow to a receiving
installation, namely a GUASCOR engine.

The design of valve trains conforms to the specifications of UNE 60620-88 - "Gas Receiving Installations".

2. DESCRIPTION

A valve train comprises the following principal components arranged from left to right in the gas flow direction:

1 Manual shutoff valve 3 Pressure regulator (optional)
2 Gas filter 4 - Double solenoid valve

A pressure regulator is incorporated into the valve train when the gas supply pressure exceeds 150mbrar; its type
will vary according as the gas supply pressure limit is 500mbar or 4 bar.
Inside the solenoid valve chest, there is the electronic leak control, which checks the leak-tightness of the double
solenoid valve as per EN 1643.
In the double solenoid valve chest there are also two high and low pressure switches that will either protect the
components of the valve train if pressure exceeds the maximum permissible limit or cut off the gas supply in case
the pressure does not reach the minimum level specified for fuelling the engine.
Both the double solenoid valve and the electronic leak detector must be powered to operate.


INDEX

DATE
Dep. 3
IT-G-A-30-015e
A November 2011


2/4

3. HANDLING

We supply the valve train mounted in a frame for easier handling and installation. In any case, adequate means
must be used to handle the valve train, having regard to its weight: fork lift truck, crane, pulley or similar
equipment. Never take hold of the valve train by its connecting flanges on shutoff valve and solenoid valve sides.

4. INSTALLATION

In selecting the location of the valve train, bear in mind two important factors: proximity to the engine and easy
access to the valve train for its operation and maintenance.

The valve train frame can be bolted or welded directly in place, at the selected location. It can be fixed to a wall, if
there is one nearby, or directly into the ground. For installation above the floor, make sure the fixing system used
is strong enough to support the weight of the complete valve train and frame assembly.

Clean and flush the pipes of the gas circuit, remove the protection plugs from the flanged connections and fix the
valve train flanges to the pipes. These pipes must suit the diameters of the valve train connections, both at inlet
and outlet. Make sure no weld residue or other impurity enters the valve train. Gaskets and fixing bolts are not
supplied.

It is important that no stress is transmitted to the valve train due to the tolerances and weights of the equipment
piping.

Never use the valve train frame as a ground for welding the mains pipes. Damage to the electric components of
the valve trains could ensue. Select a ground on the pipes of the circuit, as near the working area as possible.

5. POWER WIRING

The power supply line must be fitted with an automatic differential magnetothermal circuit breaker with effective
earth contact, in accordance with the safety regulations in force.

The voltage supplied to the electric components making up the valve train is 24Vcc. The section of the leads must
be suitable for the current to be carried and the distance over which current has to be transported.

Earthing is required by law. Electrical continuity must be provided between the gas supply line and the valve train
by electrically interconnecting the external flanges of the valve train and those of the pipeline.


INDEX

DATE
Dep. 3
IT-G-A-30-015e
A November 2011


3/4

Below are the wiring diagrams for the electric components of the valve train.

Fig. 1 Double solenoid valve

Fig. 2 Pressure switches


INDEX

DATE
Dep. 3
IT-G-A-30-015e
A November 2011


4/4

Fig. 3 LGV bypass valve

Fig. 4 VPS leak detector

tight
leaking
Fig. 5 Pressure switches

PRODUCT INFORMATION

INDEX

DATE
Dep. 8
IT-G-A-30-011e
October 2005

DN80/DIN 2576 (3) GAS INLET FLEXIBLE - Ref. 38.30.250

1/1

Fig. 1 General Disposition.

Fig. 2 General Dimensions.
DIMENSIONS = millimeters (mm) & inches

[39,370]
[40,335]
1024,5
DN 80/DIN 2576
[,709]
8-18
1000
DN 80
DIN 2576
1
6
0
[3
,5
0
0
]
2
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[7
,8
7
4
]
8
8
,9
[
6
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2
9
9
]
DIN 2576
DN 80
[,965]
24,5

CONTROL & POWER
CABINET
Order: VEC001110
Customer ROYAL GK PTE LTD

CONSISTENTS WITH OUR CONTINUAL PRODUCT IMPROVEMENT POLICY, GUASCOR POWER RESERVES THE RIGHT TO CHANGE ANY SPECIFICATION WITHOUT PRIOR NOTICE. 1/1

EQUIPMENT ORDER
DATE
11-2012
SFGM560/4 VEC001110
INDEX
CUSTOMER
ROYAL GK PTE LTD
CONTROL & POWER CABINET

POWER & CONTROL CABINET 2.001110.020
GENSET ELECTRIC CABINET POWER MODULE IO-C-M-AP-001e
GAS GENSET STANDARD CONTROL CABINET HMI OPERATORS MANUAL IO-G-M-AC-001e

1 2
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Page Page Page Page A3 A3 A3 A3
Scale Scale Scale Scale 1 : 1 : 1 : 1 : REv. REv. REv. REv. DRAWN DRAWN DRAWN DRAWN APPROvED APPROvED APPROvED APPROvED DATE DATE DATE DATE
Cf Leonardo Da vinci (Parque Tecnolgico), 12 Cf Leonardo Da vinci (Parque Tecnolgico), 12 Cf Leonardo Da vinci (Parque Tecnolgico), 12 Cf Leonardo Da vinci (Parque Tecnolgico), 12
01S10 vitoria - Gasteiz - Spain 01S10 vitoria - Gasteiz - Spain 01S10 vitoria - Gasteiz - Spain 01S10 vitoria - Gasteiz - Spain
COvER PAGE
Power 8 Control Cabinet
B
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f 11+111+8
09f10f2012
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DATE DATE DATE DATE
DRAWN DRAWN DRAWN DRAWN
CHECKED CHECKED CHECKED CHECKED
APPROvED APPROvED APPROvED APPROvED
Guascor !ngenieria S.A. Guascor !ngenieria S.A. Guascor !ngenieria S.A. Guascor !ngenieria S.A. REF. REF. REF. REF.
GUASCOR: GUASCOR: GUASCOR: GUASCOR: 2.001110.020 2.001110.020 2.001110.020 2.001110.020
Project description Power 8 Control Cabinet
Number of pages
vEC106S1072 f 11101119 f 11+111+8
SFGNS60 12S0kvA +00vcafS0Hz SFGNS60 12S0kvA +00vcafS0Hz SFGNS60 12S0kvA +00vcafS0Hz SFGNS60 12S0kvA +00vcafS0Hz
Poject number
78
Application
Company
Customer Royal GK Pte.Ltd (Nyanmar)
Dresser - Rand Dresser - Rand Dresser - Rand Dresser - Rand
Guascor Guascor Guascor Guascor
Barrio de Oikia, ++
207S9 Zumaia (Guipuzcoa)
www.guascor.com
Dresser - Rand Dresser - Rand Dresser - Rand Dresser - Rand
Guascor Guascor Guascor Guascor
REF. REF. REF. REF.
GUASCOR GUASCOR GUASCOR GUASCOR
2.001110.020 2.001110.020 2.001110.020 2.001110.020
1 2
A
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PAGE !NDEX
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f 11+111+8
09f10f2012
AGA
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1111
3 + S 6 7 8
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DATE DATE DATE DATE
REv!S!ON
PAGE !NDEX
DENON!NAT!ON PAGE DRAWN
COvER PAGE 09f10f2012 AGA =0000AfA
PAGE !NDEX 09f10f2012 AGA =0000AfB
PAGE !NDEX =0000AfC
S!NGLE L!NE D!AGRANS 09f10f2012 AGA =0000A+00DA00f1
NA!NS vOLTAGE 09f10f2012 AGA =0000A+00DA00f2
GENERATOR vOLTAGE 09f10f2012 AGA =0000A+00DA00f3
GENERATOR NA!N C.B CONTROL 09f10f2012 AGA =0000A+00DA00fS
BATTERY CHARGER GENERATOR 09f10f2012 AGA =0000A+00DA00f6
ENERGENCY STOP 8 GAS RANP GENERATOR 09f10f2012 AGA =0000A+00DA00f7
ELECTRON!C !GN!T!ON 09f10f2012 AGA =0000A+00DA00f8
SPEED CONTROL NODULE CONTROL 09f10f2012 AGA =0000A+00DA00f9
SPEED CONTROL NODULE CONTROL 09f10f2012 AGA =0000A+00DA00f10
GENERATOR AUX!L!ARY SERv!CES 09f10f2012 AGA =0000A+00DA00f11
GENERATOR AUX!L!ARY SERv!CES 09f10f2012 AGA =0000A+00DA00f12
BUSBARS vOLTAGE 09f10f2012 AGA =0000A+00DA00f13
GPU CONTROLLER 09f10f2012 AGA =0000A+00DA00f1+
CONTROLLER SUPPLY GENERATOR 8 PLC 09f10f2012 AGA =0000A+00DA00f1S
GPU CONTROLLER 09f10f2012 AGA =0000A+00DA00f16
PLC NODULES POS!T!ON 09f10f2012 AGA =0000A+00DA00f20
PLC POWER SUPPLY 8 CPU NODULE 09f10f2012 AGA =0000A+00DA00f21
PLC D!G!TAL !NPUTS 09f10f2012 AGA =0000A+00DA00f22
PLC D!G!TAL !NPUTS 09f10f2012 AGA =0000A+00DA00f2+
PLC D!G!TAL !NPUTS 09f10f2012 AGA =0000A+00DA00f2S
PLC D!G!TAL OUTPUTS 09f10f2012 AGA =0000A+00DA00f30
PLC ANALOG !NPUTSfOUTPUTS 09f10f2012 AGA =0000A+00DA00f38
PLC ANALOG !NPUTSfOUTPUTS 09f10f2012 AGA =0000A+00DA00f39
PLC D!G!TAL !NPUTSfOUTPUTS 09f10f2012 AGA =0000A+00DA00f+0
PLC D!G!TAL !NPUTSfOUTPUTS 09f10f2012 AGA =0000A+00DA00f+1
POTENT!AL FREE CONTACTS SPARE 09f10f2012 AGA =0000A+00DA00fS0
NA!NS C.B. S2-L 09f10f2012 AGA =0000A+00DA00fSS
vOLTAGE REFERENCES SELECT!ON 09f10f2012 AGA =0000A+00DA00fS6
AERO GENERATOR 09f10f2012 AGA =0000A+00DA00f60
AERO GENERATOR 09f10f2012 AGA =0000A+00DA00f61
WATER PUNPS GENERATOR 09f10f2012 AGA =0000A+00DA00f62
AERO ROON FAN 09f10f2012 AGA =0000A+00DA00f6S
CONTROL PANEL L!GHTS AND FAN 09f10f2012 AGA =0000A+00DA00f70
vOLTAGE REFERENCES AND SERv!CES AUX. C.B 09f10f2012 AGA =0000A+00DA00f7S
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PAGE !NDEX
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DATE DATE DATE DATE
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vOLTAGE REFERENCES AND SERv!CES AUX. C.B 09f10f2012 AGA =0000A+00DA00f76
CanOpen 8 ETHERNET CONNUN!CAT!ON 09f10f2012 AGA =0000A+00DA00f80
D!G!TAL !NPUTS OvERv!EW 09f10f2012 AGA =0000A+00DA00f8S
D!G!TAL OUTPUTS OvERv!EW 09f10f2012 AGA =0000A+00DA00f87
ANALOG !NPUTSfOUTPUTS OvERv!EW 09f10f2012 AGA =0000A+00DA00f88
D!G!TAL !NPUTSfOUTPUTS OvERv!EW 09f10f2012 AGA =0000A+00DA00f89
GPU OvERv!EW 09f10f2012 AGA =0000A+00DA00f9+
CAB!NET CARACTER!ST!CS 09f10f2012 AGA =0000A+00DA00f9S
ELECTR!C CAB!NET 09f10f2012 AGA =0000A+00DA00f100
ELECTR!C CAB!NET 09f10f2012 AGA =0000A+00DA00f300
ELECTR!C CAB!NET 09f10f2012 AGA =0000A+00DA00f300A
ELECTR!C CAB!NET DR!LL!NGS 09f10f2012 AGA =0000A+00DA00fS00
ELECTR!C CAB!NET DR!LL!NGS 09f10f2012 AGA =0000A+00DA00fS01
ELECTR!C CAB!NET DR!LL!NGS 09f10f2012 AGA =0000A+00DA00fSS0
ELECTR!C CAB!NET DR!LL!NGS 09f10f2012 AGA =0000A+00DA00fSS1
B!LL OF NATER!ALS 09f10f2012 AGA =0000A+00DA00f600
B!LL OF NATER!ALS 09f10f2012 AGA =0000A+00DA00f60+
B!LL OF NATER!ALS =0000A+00DA00f60S
B!LL OF NATER!ALS =0000A+00DA00f606
TOTAL L!ST =0000A+00DA00f6S0
TERN!NAL STR!P =0000A+00DA00f700
TERN!NAL STR!P 09f10f2012 AGA =0000A+00DA00f701
TERN!NAL STR!P =0000A+00DA00f702
09f10f2012 AGA
09f10f2012 AGA
09f10f2012 AGA
09f10f2012 AGA
09f10f2012 AGA
09f10f2012 AGA
09f10f2012 AGA
!NTERNAL v!EW
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DATE DATE DATE DATE
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BUS +00vac S0Hz NA!N vOLTAGE
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1
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DATE DATE DATE DATE
BUS +00vac S0Hz GENERATOR vOLTAGE BUS +00vac S0Hz GENERATOR vOLTAGE
230vac AUX!L!ARY SERv!CES
103 10+
ALTERNATOR
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DATE DATE DATE DATE
BUS 230vac NA!N CB CONTROL
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DATE DATE DATE DATE
N
GENERATOR GENERATOR GENERATOR GENERATOR
BATTER!ES BATTER!ES BATTER!ES BATTER!ES
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FEEEDER FEEEDER FEEEDER FEEEDER
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DETCON DETCON DETCON DETCON
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DATE DATE DATE DATE
ENERGENCY ENERGENCY ENERGENCY ENERGENCY
PUSH-BUTTON PUSH-BUTTON PUSH-BUTTON PUSH-BUTTON
SPARE SPARE SPARE SPARE
K2 K2 K2 K2
K1 K1 K1 K1
SER!ES vALvES
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BEARAGE vALvE
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CONTROL POWER
SUPPLY
GAS LEAK
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ENERGENCY
STOP
SAFETY RELAY
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137 017
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GAS RANP
GENERATOR
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ENERGENCY
STOP
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1+7
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0S7
067
BR!DGE
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ENERGENCY STOP
SAFETY RELAY
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Q0.2.30
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DATE DATE DATE DATE
ENG!NE
BOX
ELECTRON!C !GN!T!ON ELECTRON!C !GN!T!ON ELECTRON!C !GN!T!ON ELECTRON!C !GN!T!ON
!GN!T!ON - CPU9S !GN!T!ON - CPU9S !GN!T!ON - CPU9S !GN!T!ON - CPU9S L
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SPEED CONTROL
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09f10f2012
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DATE DATE DATE DATE
EGS-02 CONTROL AfF EGS-02 CONTROL AfF EGS-02 CONTROL AfF EGS-02 CONTROL AfF
8888
SPEED - POWER CONTROL SPEED - POWER CONTROL SPEED - POWER CONTROL SPEED - POWER CONTROL
2+vdc
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ENG!NE
BOX
PROACT PROACT PROACT PROACT
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DATE DATE DATE DATE
EGS-02 CONTROL AfF EGS-02 CONTROL AfF EGS-02 CONTROL AfF EGS-02 CONTROL AfF
8888
SPEED - POWER CONTROL SPEED - POWER CONTROL SPEED - POWER CONTROL SPEED - POWER CONTROL
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ENG!NE
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DATE DATE DATE DATE
230vac AUX!L!ARY SERv!CES 230vac AUX!L!ARY SERv!CES
ENG!NE
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ENG!NE
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DATE DATE DATE DATE
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DATE DATE DATE DATE
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DATE DATE DATE DATE
DE!F GPU 3 DE!F GPU 3 DE!F GPU 3 DE!F GPU 3
GENERATOR !NTENS!T!ES GENERATOR !NTENS!T!ES GENERATOR !NTENS!T!ES GENERATOR !NTENS!T!ES
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DATE DATE DATE DATE
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GPU CONTROLLER
17
16 vEC106S1072 f 11101119
f 11+111+8
09f10f2012
AGA
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DATE DATE DATE DATE
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GPU CONTROLLER
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17 vEC106S1072 f 11101119
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DATE DATE DATE DATE
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GPU CONTROLLER
20
18 vEC106S1072 f 11101119
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DATE DATE DATE DATE
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DATE DATE DATE DATE
POWER SUPPLY
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DATE DATE DATE DATE
6+ Df! NODULE PART 1 OF 8
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DATE DATE DATE DATE
BUS 2+vdc
GAS
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PLC D!G!TAL !NPUTS
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DATE DATE DATE DATE
BUS 2+vdc
ENG!NE
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CONECTOR A
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GENERATOR
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!0.1.22 !0.1.21 !0.1.20 !0.1.19 !0.1.18 !0.1.17 !0.1.16
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+L+
+L-
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!0.1.22 !0.1.21 !0.1.20 !0.1.19 !0.1.18 !0.1.17 !0.1.16 -X
-22A1
B0122 f 2S.2 B0122 f 23.3
+L+ f 22.3
+L- f 22.3
+L+ f 26.2
+L- f 26.2
1 2
2+
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PLC D!G!TAL !NPUTS
26
2S vEC106S1072 f 11101119
f 11+111+8
09f10f2012
AGA
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1111
3 + S 6 7 8
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DATE DATE DATE DATE
6+ Df! NODULE PART + OF 8
BUS 2+vdc
ENG!NE
BOX
RACK 0 POS.1
CONECTOR A
P P CPU 9S
f22.2
-22A1
!23
!0.1.23
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WATER LOW PRESSURE
!2+
!0.1.2+
AUX. C!RC.
EXPANS!ON TANK
WATER LOW PRESSURE
!2S
!0.1.2S
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(CPU-9S)
ALARN
GENERATOR
!26
!0.1.26
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!GN!T!ON
(CPU-9S)
FA!LURE
GENERATOR
!27
!0.1.27
H!GH LEvEL
300L TANK
!28
!0.1.28
LOW LEvEL
300L TANK
!29
!0.1.29
AUX!L!ARY
SERv!CES
PROTECT!ON
TR!PPED
!30
!0.1.30
CONTROL
vOLTAGE
PROTECC.
TR!PPED
f2+.2
-2+A1
107 108 109 110 111 112 113 11+
0122
0122
!0.1.23 !0.1.30
!31
!0.1.31
START FRON
ZERO
OFF
!0.1.31
11S
!0.1.28 !0.1.27 !0.1.26 !0.1.2S !0.1.2+ !0.1.29
11 -X 9S 10 97
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11
1+
-76Q3
f76.3
f76.S
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SERv!CES
PROTECT!ON
TR!PPED
12
11
1+
-76FS
f76.6
CONTROL
vOLTAGE
PROTECC.
TR!PPED
BR!DGE BR!DGE BR!DGE BR!DGE BR!DGE BR!DGE
0122 -X 0122 0122 0122 0122 0122 0122
!0.1.23 -X !0.1.31 !0.1.28 !0.1.27 !0.1.26 !0.1.2S !0.1.2+
-22A1
B0122 f 2+.7
0122 f 26.3
B0122 f 2S.7
0122 f 23.7
B0122 f 2S.6 B0122 f 28.3
1 2
2S
Sh
PLC D!G!TAL !NPUTS
27
26 vEC106S1072 f 11101119
f 11+111+8
09f10f2012
AGA
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1111
3 + S 6 7 8
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DATE DATE DATE DATE
6+ Df! NODULE PART S OF 8
BUS 2+vdc
RACK 0 POS.1
CONECTOR B
f22.2
-22A1
!33
!0.1.33
NA!N C!RC.
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PROTECT!ON TR!PPED
GENERATOR
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!N SERv!CE
!36
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AERO FAN 182
PROTECT!ON
TR!PPED
!37
!0.1.37
AERO FAN 182
!N SERv!CE
f27.2
-26A1
100 101 102 103 10+ 10S
!32
!0.1.32
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WATER PUNP
PROTECT!ON TR!PPED
GENERATOR
-1SD1
2+vdc
+L+ +L-
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AERO FAN 38+
PROTECT!ON
TR!PPED
106
0122 0122 0122
0122
0122 0122
0122
!0.1.38 !0.1.37 !0.1.36 !0.1.3S !0.1.3+ !0.1.33 !0.1.32
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PROTECT!ON
TR!PPED
GENERATOR
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NA!N C!RC.
WATER PUNP
!N SERv!CE
21
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f62.+
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WATER PUNP
PROTECT!ON TR!PPED
GENERATOR
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1+
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AUX.C!RC
WATER PUNP
!N SERv!CE
21
22
-60Q1
f60.2
AERO FAN 1
PROTECT!ON
TR!PPED
21
22
-60Q2
f60.3
AERO FAN 2
PROTECT!ON
TR!PPED
!0.1.36
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13
1+
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f60.+
AERO FAN 182
!N SERv!CE
21
22
-60Q3
f60.S
AERO FAN 3
PROTECT!ON
TR!PPED
21
22
-60Q+
f60.6
AERO FAN +
PROTECT!ON
TR!PPED
!0.1.38
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+2+ 0v 0v +2+
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+L+
+L-
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-22A1
0122 f 27.2 0122 f 2S.7
+L+ f 2+.2
+L- f 2+.2
+L+ f 28.2
+L- f 28.2
1 2
26
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PLC D!G!TAL !NPUTS
28
27 vEC106S1072 f 11101119
f 11+111+8
09f10f2012
AGA
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1111
3 + S 6 7 8
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DATE DATE DATE DATE
BUS 2+vdc
RACK 0 POS.1
CONECTOR B
f22.2
-22A1
!39
!0.1.39
AERO FAN 38+
!N SERv!CE
!+0
!0.1.+0
AERO FAN S86
PROTECT!ON
TR!PPED
!+1
!0.1.+1
AERO FAN S86
!N SERv!CE
!+2
!0.1.+2
WATER
PREHEAT!NG PUNP
PROTECT!ON
TR!PPED
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!0.1.+3
WATER
PREHEAT!NG
RES!STANCES
PROTECT!ON
TR!PPED
!++
!0.1.++
WATER
PREHEAT!NG PUNP
!N SERv!CE
!+S
!0.1.+S
O!L PREHEAT!NG
PROTECT!ON
TR!PPED
!+6
!0.1.+6
O!L PREHEAT!NG
!N SERv!CE
f26.2
-26A1
107 108 109 110 111 112 113 11+
0122 0122 0122
0122
0122 0122 0122
!0.1.39 !0.1.+6
0122
!+7
!0.1.+7
NEASURENENT
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TR!PPED
BUSBAR
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11S
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2+
-11FS
f11.6
WATER
PREHEAT!NG
RES!STANCES
PROTECT!ON
TR!PPED
13
1+
-60K2
f60.7
AERO FAN 38+
!N SERv!CE
21
22
-61Q1
f61.2
AERO FAN S
PROTECT!ON
TR!PPED
21
22
-61Q2
f61.3
AERO FAN 6
PROTECT!ON
TR!PPED
!0.1.+0
0122
13
1+
-61K1
f61.+
AERO FAN S86
!N SERv!CE
21
22
-12Q1
f12.2
WATER
PREHEAT!NG PUNP
PROTECT!ON
TR!PPED
13
1+
-11K3
f11.7
WATER
PREHEAT!NG
!N SERv!CE
13
1+
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f11.8
WATER
PREHEAT!NG
PUNP
!N SERv!CE
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21
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-11F3
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PROTECT!ON
TR!PPED
13
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-11K2
f11.S
O!L PREHEAT!NG
!N SERv!CE
12
11
1+
-13F1
f13.2
NEASURENENT
PROTECT!ON
TR!PPED
BUSBAR
-22A1
0122 f 26.7 0122 f 29.6
1 2
27
Sh
PLC D!G!TAL !NPUTS
29
28 vEC106S1072 f 11101119
f 11+111+8
09f10f2012
AGA
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1111
3 + S 6 7 8
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DATE DATE DATE DATE
BUS 2+vdc
RACK 0 POS.1
CONECTOR B
f22.2
-22A1
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!S0
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ANY OTHER
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NA!NS C.B.
S2-L TR!PPED
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!0.1.S3
SPARE
f29.2
-28A1
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EXTERNAL START
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-1SD1
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BR!DGE BR!DGE BR!DGE BR!DGE BR!DGE BR!DGE BR!DGE BR!DGE
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-22A1
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+L+ f 26.2
+L- f 26.2
+L+ f 30.1
+L- f 30.1
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28
Sh
PLC D!G!TAL !NPUTS
30
29 vEC106S1072 f 11101119
f 11+111+8
09f10f2012
AGA
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1111
3 + S 6 7 8
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DATE DATE DATE DATE
6+ Df! NODULE PART 8 OF 8 BNX DD! 6+02K
!NPUT !NTERFACE ABE 7H3+E300 PART 2 OF 2
BUS 2+vdc
RACK 0 POS.1
CONECTOR B
f22.2
-22A1
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SPARE
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SPARE
!S7
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SPARE
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SELECT!ON
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vOLTAGE TO DE!F
f28.2
-28A1
107 108 109 110 111 112 113 11+
0122 0122
!63
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BUSBARS vOLTAGE
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AS NA!NS
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0122
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-22A1
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0122
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BR!DGE BR!DGE
B0122 f 28.7
0122 f 38.2
B0122 f +0.+
0122 f 27.8
1 2
29
Sh
PLC D!G!TAL OUTPUTS
31
30 vEC106S1072 f 11101119
f 11+111+8
09f10f2012
AGA
ZEL
1111
3 + S 6 7 8
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DATE DATE DATE DATE
32 DfO NODULE PART 1 OF 6
OUTPUT !NTERFACE RELAY PART 1 OF 3
300
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101
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fS0.3
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+07 308
208
108
f7.3
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+08 309
209
109
f9.+
609
S09
+09 310
210
110
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610
S10
+10
RACK 0 POS.2
CONECTOR A
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START
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-30A1
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QS
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GAS RANP
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-30A1
+L+ f 28.2
+L- f 28.2
+L+ f 32.1
+L- f 32.1
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30
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PLC D!G!TAL OUTPUTS
32
31 vEC106S1072 f 11101119
f 11+111+8
09f10f2012
AGA
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1111
3 + S 6 7 8
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DATE DATE DATE DATE
311
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-30A1
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GENERATOR C.B
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GENERATOR !N
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+11 S11 611 111 211 311 +12 S12 612 112 212 312 +13 S13 613 113 213 313 +1+ S1+ 61+ 11+ 21+ 31+ +1S S1S 61S 11S 21S 31S
-30A1
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PLC D!G!TAL OUTPUTS
33
32 vEC106S1072 f 11101119
f 11+111+8
09f10f2012
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DATE DATE DATE DATE
32 DfO NODULE PART + OF 6
32 DfO NODULE PART S OF 6
300
200
100
fS0.1
600
S00
+00 301
201
101
f11.3
601
S01
+01 302
202
102
f60.+
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203
103
f60.7
603
S03
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20+
10+
f61.+
60+
S0+
+0+
30S
20S
10S
f62.3
60S
S0S
+0S 306
206
106
f62.S
606
S06
+06 307
207
107
f11.S
607
S07
+07 308
208
108
f11.7
608
S08
+08 309
209
109
fSS.2
609
S09
+09 310
210
110
fSS.2
610
S10
+10
RACK 0 POS.2
CONECTOR A
Q20
Q0.2.20
START
AERO FAN S86
f30.1
-30A1
Q16
Q0.2.16
GENERATOR
RUNN!NG
Q17
Q0.2.17
START
LUBE O!L PUNP
GENERATOR
Q18
Q0.2.18
START
AERO FAN 182
Q19
Q0.2.19
START
AERO FAN 38+
PPS2- PPS2- PPS2+ PPS2+
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f32.1
f33.1
-32A1
0v
0
0v
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-30A1
Q22
Q0.2.22
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-32A1
Q21
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-1SD1
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+L-
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+0S S0S 60S 10S 20S 30S +06 S06 606 106 206 306 +07 S07 607 107 207 307 +08 S08 608 108 208 308 +09 S09 609 109 209 309 +10 S10 610 110 210 310
-30A1
+L+ f 30.2
+L- f 30.2
+L+ f 38.1
+L- f 38.1
1 2
32
Sh
PLC D!G!TAL OUTPUTS
38
33 vEC106S1072 f 11101119
f 11+111+8
09f10f2012
AGA
ZEL
1111
3 + S 6 7 8
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1
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DATE DATE DATE DATE
311
211
111
fSS.2
611
S11
+11 312
212
112
fS.S
612
S12
+12
fSS.6
313
213
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CONECTOR A
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-30A1
Q28
Q0.2.28
NA!NS PROTECT!ON
D!SABLED !N
GENSET AND ENABLED
!N NA!N NA!NS
C.B. S2-L
Q29
Q0.2.29
NA!NS-GENSET
CBS
STATUS TO GPU
Q30
Q0.2.30
HORN
Q31
Q0.2.31
SPARE
f32.1
-32A1
Q27
Q0.2.27
NA!NS C.B
TR!P S2-L
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-30A1
1 2
33
Sh
PLC ANALOG !NPUTSfOUTPUTS
39
38 vEC106S1072 f 11101119
f 11+111+8
09f10f2012
AGA
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1111
3 + S 6 7 8
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1
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DATE DATE DATE DATE
+ ANALOGf! + 2 ANALOGfO NODULE PART 1 OF 2
BUS 2+vdc
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BOX +6 -S
++
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++
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RACK 0 POS.3
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f38.3
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-38A1
2
!W0.3.0
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EXHAUST TENPERATURE
GENERATOR
LEFT BANK
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0138
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7
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13
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11
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+L- f 39.1
1 2
38
Sh
PLC ANALOG !NPUTSfOUTPUTS
+0
39 vEC106S1072 f 11101119
f 11+111+8
09f10f2012
AGA
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1111
3 + S 6 7 8
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0
1
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DATE DATE DATE DATE
BUS 2+vdc
ENG!NE
BOX
RACK 0 POS.+
PE
ALTERNATOR R+S0
3PH
1K Ohm
S1 S2
f39.1
f39.3
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1 2
39
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PLC D!G!TAL !NPUTSfOUTPUTS
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f 11+111+8
09f10f2012
AGA
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3 + S 6 7 8
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1
6
DATE DATE DATE DATE
8 D!G!TALf! + 8 D!G!TALfO NODULE PART 1 OF 2
BUS 2+vdc
SPEED
!NCREASE
SPEED
DECREASE
f+1.1
f89.1
-+0A1
2
!0.S.1
BUSBARS vOLTAGE
SELECT!ON
AS GENERATOR
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SPARE
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SPARE
S
!0.S.+
ROON FAN
PROTECT!ONS
TR!PPED
6
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ROON FAN
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1
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GENSET vOLTAGE
SELECT!ON
AS GENERATOR
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7
!0.S.6
SPEED
!NCREASE
8
!0.S.7
SPEED
DECREASE
10
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9
0v
-1SD1
2+vdc
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S+
-S6K3
f1+.+
GENSET vOLTAGE
SELECT!ON
AS GENERATOR
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S+
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BUSBARS vOLTAGE
SELECT!ON
AS GENERATOR
vOLTAGE TO DE!F
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!0.S.2 -X
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0122
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!0.S.3
21
22
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ROON FAN
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BR!DGE BR!DGE
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BR!DGE BR!DGE
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12
11
1+
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ROON FAN
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DATE DATE DATE DATE
LOAD
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GENERATOR C.B
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GENERATOR C.B
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DATE DATE DATE DATE
BUS 2+vdc
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1
6
DATE DATE DATE DATE
BUS 2+vdc
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6A
Curve C
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S 6 f1+.7
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1 2 f1+.7
3 + f1+.8
S 6 f1+.8
1+ 13 f29.7
22 21 fS6.2
21
22
-S6K1
fS6.2
07S6
21
22
-S6K2
fS6.2
12
11
1+
-+1K1
f+1.3
NA!N vOLTAGE
SELECT!ON
AS NA!NS
vOLTAGE TO DE!F
02S6
12
11
1+
-+1K2
f+1.+
BUSBARS vOLTAGE
SELECT!ON
AS NA!NS
vOLTAGE TO DE!F
03S6
01S6
06S6
01S6
A1
A2
-S6K3
9A
2+vdc
NA!NS vOLTAGE
SELECT!ON
1 2 f1+.+
3 + f1+.+
S 6 f1+.+
1+ 13 f1+.S
S+ S3 f+0.3
6+ 63
22 21 fS6.+
2L-
2L-
A1
A2
-S6K+
9A
2+vdc
1 2 f1+.S
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S 6 f1+.S
1+ 13 f1+.6
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6+ 63
22 21 fS6.3
21
22
-S6K3
f1+.+
09S6
21
22
-S6K+
f1+.S
12
11
1+
-+1K3
f+1.+
GENSET vOLTAGE
SELECT!ON
AS GENERATOR
vOLTAGE TO DE!F
0+S6
12
11
1+
-+1K+
f+1.S
BUSBARS vOLTAGE
SELECT!ON
AS GENERATOR
vOLTAGE TO DE!F
0SS6
01S6
08S6
2L-
01SS
6v1+ f SS.2
2L+ f SS.2
2L- f SS.2
1 2
S6
Sh
AERO GENERATOR
61
60 vEC106S1072 f 11101119
f 11+111+8
09f10f2012
AGA
ZEL
1111
3 + S 6 7 8
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1
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0
1
6
DATE DATE DATE DATE
230vac AUX!L!ARY SERv!CES 230vac AUX!L!ARY SERv!CES
0L1
0L2
0L3
1
2
-60K1
f60.+
12A
3
+
S
6
1
2
3
+
S
6
-60Q1
!n:6,3A
!t:+6,3A
!m:78A
!> !> !>
13
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+
21
22
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6
.
6
0360
0+60 0S60
1
2
3
+
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6
-60Q2
!n:6,3A
!t:+6,3A
!m:78A
!> !> !>
13
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+
21
22
f
2
6
.
6
0360
0+60
0S60
0960
1060
1160
1260
1360
1+60
PE
U -X W PE
Pn=1.8Kw
Un=+00vac
!n=+A
AERO
FAN 1
U
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W
PE
3~
N
v
PE
U -X W PE
Pn=1.8Kw
Un=+00vac
!n=+A
AERO
FAN 2
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W
PE
3~
N
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1
2
-60F1
6A
Curve C
1L1 1L2
A1
A2
-60K1
12A AC3
230vac
AERO FAN 182
CONTROL
1 2 f60.2
3 + f60.2
S 6 f60.2
1+ 13 f26.6
22 21
0160
13
1+
-60Q1
f60.2
13
1+
-60Q2
f60.3
0160
0L1 0L2 0L3
1
2
-60K2
f60.7
12A
3
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S
6
1
2
3
+
S
6
-60Q3
!n:6,3A
!t:+6,3A
!m:78A
!> !> !>
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f
6
0
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7
21
22
f
2
6
.
7
0660
0760
0860
1
2
3
+
S
6
-60Q+
!n:6,3A
!t:+6,3A
!m:78A
!> !> !>
13
1+
f
6
0
.
8
21
22
f
2
6
.
7
0660
0760
0860
1S60
1660
1760
1860
1960
2060
PE
U -X W PE
Pn=1.8Kw
Un=+00vac
!n=+A
AERO
FAN 3
U
v
W
PE
3~
N
v
PE
U -X W PE
Pn=1.8Kw
Un=+00vac
!n=+A
AERO
FAN +
U
v
W
PE
3~
N
v
1
2
-60F2
6A
Curve C
1L1
A1
A2
-60K2
12A AC3
230vac
AERO FAN 38+
CONTROL
1 2 f60.S
3 + f60.S
S 6 f60.S
1+ 13 f27.3
22 21
0260
13
1+
-60Q3
f60.S
13
1+
-60Q+
f60.6
0260
-76D1
+00vac
-76D2
f76.6
230vac
-76D2
f76.6
230vac
-76D1
+00vac
0L1
0L2
0L3
0L1
0L2
0L3
1L1 1L1
1L2
1L2
302
202
102
-32A1
Q0.2.18
f32.S
303
203
103
-32A1
Q0.2.19
f32.6
0960 -X 1060 1160 1260 1360 1+60 1S60 1660 1760 1860 1960 2060
2160
2160
2360
2260
2260
2+60
0L1 f 60.S
0L2 f 60.S
0L3 f 60.S
0N f 60.S
0L1 f 12.2
0L2 f 12.2
0L3 f 12.2
0N f 12.2
0L1 f 61.2
0L2 f 61.2
0L3 f 61.2
0N f 61.2
0L1 f 60.2
0L2 f 60.2
0L3 f 60.2
0N f 60.2
1L1 f 12.3
1L2 f 12.3
1L1 f 60.7
1L2 f 60.7
1L1 f 60.+
1L2 f 60.+
1L1 f 61.+
1L2 f 61.+
60K2 f 60.7 60K2 f 60.+
1 2
60
Sh
AERO GENERATOR
62
61 vEC106S1072 f 11101119
f 11+111+8
09f10f2012
AGA
ZEL
1111
3 + S 6 7 8
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1
6
0
1
6
DATE DATE DATE DATE
0L1
0L2
0L3
1
2
-61K1
f61.+
12A
3
+
S
6
1
2
3
+
S
6
-61Q1
!n:6,3A
!t:+6,3A
!m:78A
!> !> !>
13
1+
f
6
1
.
+
21
22
f
2
7
.
3
0261
0361
0+61
1
2
3
+
S
6
-61Q2
!n:6,3A
!t:+6,3A
!m:78A
!> !> !>
13
1+
f
6
1
.
+
21
22
f
2
7
.
3
0261
0361
0+61
0S61
0661
0761
0861
0961
1061
PE
U -X W PE
Pn=1.8Kw
Un=+00vac
!n=+A
AERO
FAN S
U
v
W
PE
3~
N
v
PE
U -X W PE
Pn=1.8Kw
Un=+00vac
!n=+A
AERO
FAN 6
U
v
W
PE
3~
N
v
1
2
-61F1
6A
Curve C
1L1 1L2
A1
A2
-61K1
12A AC3
230vac
AERO FAN S86
CONTROL
1 2 f61.2
3 + f61.2
S 6 f61.2
1+ 13 f27.+
22 21
13
1+
-61Q1
f61.2
13
1+
-61Q2
f61.3
-76D1
+00vac
-76D2
f76.6
230vac
1L1
1L2
0L1
0L2
0L3
0S61 -X 0661 0761 0861 0961 1061
30+
20+
10+
-32A1
Q0.2.20
f32.7
2261
2261
2361
2361
2+61
1L1 f 60.8
1L2 f 60.8
1L1 f 62.3
1L2 f 62.3
0L1 f 62.2
0L2 f 62.2
0L3 f 62.2
0N f 62.2
0L1 f 60.6
0L2 f 60.6
0L3 f 60.6
0N f 60.6
1 2
61
Sh
WATER PUNPS
GENERATOR
6S
62 vEC106S1072 f 11101119
f 11+111+8
09f10f2012
AGA
ZEL
1111
3 + S 6 7 8
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1
6
0
1
6
DATE DATE DATE DATE
0L1
0L2
0L3
1
2
-62K1
f62.3
18A
3
+
S
6
1
2
3
+
S
6
-62Q1
!n:1+A
!t:91+A
!m:170A
!> !> !>
13
1+
f
6
2
.
3
21
22
f
2
6
.
3
0362
0+62
0S62
0962
1062
1162
PE
U -X W PE
Pn=S.SKw
Un=+00vac
!n=11A
NA!N C!RC.
WATER PUNP
U
v
W
PE
3~
N
v
1
2
-62F1
6A
Curve C
1L1 1L2
A1
A2
-62K1
18A AC3
32A AC1
230vac
NA!N C!RC.
WATER PUNP
CONTROL
1 2 f62.2
3 + f62.2
S 6 f62.2
1+ 13 f26.+
22 21
0162
13
1+
-62Q1
f62.2
0L1
0L2
0L3
1
2
-62K2
f62.S
9A
3
+
S
6
1
2
3
+
S
6
-62Q2
!n:6,3A
!t:+6,3A
!m:78A
!> !> !>
13
1+
f
6
2
.
S
21
22
f
2
6
.
+
0662
0762
0862
1262
1362
1+62
PE
U -X W PE
Pn=2.2Kw
Un=+00vac
!n=+.8A
AUX C!RC.
WATER PUNP
U
v
W
PE
3~
N
v
1
2
-62F2
6A
Curve C
1L1
A1
A2
-62K2
9A AC3
2SA AC1
230vac
AUX C!RC.
WATER PUNP
CONTROL
1 2 f62.+
3 + f62.+
S 6 f62.+
1+ 13 f26.S
22 21
0262
13
1+
-62Q2
f62.+
-76D1
+00vac
-76D2
f76.6
230vac
-76D1
+00vac
-76D2
f76.6
230vac
0L1
0L2
0L3
0L1
0L2
0L3
1L1
1L2
1L1
1L2
30S
20S
10S
-32A1
Q0.2.21
f32.2
306
206
106
-32A1
Q0.2.22
f32.3
0962 -X 1062 1162 1262 1362 1+62
1S62
1762
1662
1862
0L1 f 6S.1
0L2 f 6S.1
0L3 f 6S.1
0N f 6S.1
0L1 f 62.2
0L2 f 62.2
0L3 f 62.2
0N f 62.2
0L1 f 62.+
0L2 f 62.+
0L3 f 62.+
0N f 62.+
0L1 f 61.2
0L2 f 61.2
0L3 f 61.2
0N f 61.2
1L1 f 61.S
1L2 f 61.S
1L1 f 62.S
1L2 f 62.S
1L1 f 62.3
1L2 f 62.3
1L1 f 6S.3
1L2 f 6S.3
62K2 f 62.S 62K2 f 62.3
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DATE DATE DATE DATE
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AERO ROON
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CONTROL PANEL
L!GHTS AND FAN
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3 + S 6 7 8
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DATE DATE DATE DATE
CONTROL
PANEL L!GTHS
CONTROL
PANEL FAN
CONTROL
PANEL SOCKET
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6A
Curve C
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230vac
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1L1 f 76.6
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1 2
70
Sh
vOLTAGE REFERENCES
AND SERv!CES AUX. C.B
76
7S vEC106S1072 f 11101119
f 11+111+8
09f10f2012
AGA
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1111
3 + S 6 7 8
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DATE DATE DATE DATE
G
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BUS 230vac NA!N CB CONTROL
BUS +00vac S0Hz GENERATOR vOLTAGE
GENERATOR
NA!N C.B
CONTROL
GENERATOR
vOLTAGE
REFERENCES
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N1
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Curve C
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1LU1 f 1+.2
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vOLTAGE REFERENCES
AND SERv!CES AUX. C.B
80
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09f10f2012
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1
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DATE DATE DATE DATE
N
+00vac S0Hz
+00vac S0Hz
BUSBARS
+00vac S0Hz BUS BAR vOLTAGE
-76T2
1 - 2 2.1
1.1
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3.1
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R1
S1
T1
N1
R1
2x(80x10) mm
ALUN!N!UN
S1
2x(80x10) mm
ALUN!N!UN
T1
2x(80x10) mm
ALUN!N!UN
N1
80x10 mm
ALUN!N!UN
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2x(80x10) mm
ALUN!N!UN
S
2x(80x10) mm
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T
2x(80x10) mm
ALUN!N!UN
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80x10 mm
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R
S
T
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3
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7
8
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AUX!LARY
SERv!CES
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C2
C1
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6
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SA
TA
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0L2
0L3
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2
3
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RA SA
0176
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1
2
3
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Curve C
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PE
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A1 A2
T1
T2
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1276
C2
C1
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1376
0876
0776
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1
2
3
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0L1 0L3
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PE
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2
3
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Curve C
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11
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S
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RL3
RL2
RL1
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R
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0L3
1L2
1L1
0L1
0L2
0L3
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BR!DGE
BR!DGE
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R1 f 7S.8
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ETHERNET CONUN!CAT!ON
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DETCON
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DATE DATE DATE DATE
Fuse Fuse
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LUBE O!L PUNP !N SERv!CE
f23.6
!13
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!0.1.13
LUBE O!L PUNP PROTECT!ON
TR!PPED
f23.S
!12
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!0.1.12
EGS02 ALARN
f23.+
!11
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!0.1.11
ALTERNATOR HEAT!NG
PROTECT!ON TR!PED
f23.6
!1+
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!0.1.1+
ALTERNATOR W!ND!NG T
PROTECT!ON TR!PPED
f23.7
!1S
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!0.1.1S
START FRON ZERO OFF
f2S.7
!31
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!0.1.31
SPS1+
SPS1-
AUX. C!RC. EXPANS!ON TANK
WATER LOW PRESSURE
f2S.3
!2+
A
!0.1.2+
NA!N C!RC. EXPANS!ON TANK
WATER LOW PRESSURE
f2S.3
!23
A
!0.1.23
SPARE
f2+.6
!21
A
!0.1.21
O!L H!GH LEvEL GENERATOR
f2+.7
!22
A
!0.1.22
-22A1
f22.2
WATER H!GH TENPERATURE
GENERATOR
f2+.3
!16
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!0.1.16
SPS2+
SPS2-
O!L H!GH TENPERATURE
GENERATOR
f2+.6
!20
A
!0.1.20
H!GH !NTAKE NAN!FOLD
TENPERATURE GENERATOR
f2+.S
!19
A
!0.1.19
O!L LOW LEvEL GENERATOR
f2+.+
!18
A
!0.1.18
O!L LOW PRESSURE
GENERATOR
f2+.+
!17
A
!0.1.17
EGS02 FA!LURE
f23.+
!10
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!0.1.10
DETCON SUPPLY PROTECT!ON
TR!PPED
f23.3
!9
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!0.1.9
LOW GAS PRESSURE
GENERATOR
f23.3
!8
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!0.1.8
H!GH GAS PRESSURE
GENERATOR
f22.7
!7
A
!0.1.7
GAS LEAK !N RANP
f22.7
!6
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!0.1.6
STATUS PROTECT!ON RELAY
GPU OK
f22.6
!S
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!0.1.S
NEASURENENT PROTECT!ON
TR!PPED GENERATOR
f22.6
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ELECTRON!C !GN!T!ON
(CPU-9S) ALARN GENERATOR
f2S.+
!2S
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!0.1.2S
ELECTRON!C !GN!T!ON
(CPU-9S) FA!LURE GENERATOR
f2S.+
!26
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!0.1.26
H!GH LEvEL 300L TANK
f2S.S
!27
A
!0.1.27
LOW LEvEL 300L TANK
f2S.6
!28
A
!0.1.28
AUX!L!ARY SERv!CES
PROTECT!ON TR!PPED
f2S.6
!29
A
!0.1.29
CONTROL vOLTAGE PROTECC.
TR!PPED
f2S.7
!30
A
!0.1.30
TR!PPED NA!NS
f22.S
!3
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!0.1.3
ENERGENCY PUSH-BUTTON
f22.+
!2
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!0.1.2
GENERATOR C.B TR!PPED
f22.+
!1
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!0.1.1
GENERATOR C.B CLOSED
f22.3
!0
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!0.1.0
SPS2+
SPS1+
SPS1- SPS2-
O!L PREHEAT!NG
PROTECT!ON TR!PPED
f27.6
!+S
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!0.1.+S
WATER PREHEAT!NG PUNP !N
SERv!CE
f27.6
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!0.1.++
WATER PREHEAT!NG
RES!STANCES PROTECT!ON
TR!PPED
f27.S
!+3
A
!0.1.+3
O!L PREHEAT!NG !N SERv!CE
f27.7
!+6
A
!0.1.+6
TR!PPED BUSBAR
f27.7
!+7
A
!0.1.+7
BUSBARS vOLTAGE
SELECT!ON AS NA!NS
vOLTAGE TO DE!F
f29.7
!63
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!0.1.63
SPS3+
SPS3-
SPARE
f29.3
!S6
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!0.1.S6
SPARE
f29.3
!SS
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!0.1.SS
SPARE
f28.6
!S3
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!0.1.S3
SPARE
f28.7
!S+
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!0.1.S+
-22A1
f22.2
EXTERNAL START ORDER
f28.3
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!0.1.+8
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NA!NS C.B. S2-L TR!PPED
f28.6
!S2
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!0.1.S2
NA!NS C.B. S2-L CLOSED
f28.S
!S1
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!0.1.S1
ANY OTHER GENSET !N LOAD
f28.+
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!0.1.S0
FACTORY ENERGENCY STOP
f28.+
!+9
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!0.1.+9
WATER PREHEAT!NG PUNP
PROTECT!ON TR!PPED
f27.+
!+2
A
!0.1.+2
AERO FAN S86 !N SERv!CE
f27.+
!+1
A
!0.1.+1
AERO FAN S86 PROTECT!ON
TR!PPED
f27.3
!+0
A
!0.1.+0
AERO FAN 38+ !N SERv!CE
f27.3
!39
A
!0.1.39
AERO FAN 38+ PROTECT!ON
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f26.7
!38
A
!0.1.38
AERO FAN 182 !N SERv!CE
f26.6
!37
A
!0.1.37
AERO FAN 182 PROTECT!ON
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f26.6
!36
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!0.1.36
SPARE
f29.+
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A
!0.1.S7
SPARE
f29.+
!S8
A
!0.1.S8
SPARE
f29.S
!S9
A
!0.1.S9
SPARE
f29.6
!60
A
!0.1.60
SPARE
f29.6
!61
A
!0.1.61
NA!NS vOLTAGE SELECT!ON
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f29.7
!62
A
!0.1.62
AUX.C!RC WATER PUNP !N
SERv!CE
f26.S
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!0.1.3S
AUX.C!RC WATER PUNP
PROTECT!ON TR!PPED
GENERATOR
f26.+
!3+
A
!0.1.3+
NA!N C!RC. WATER PUNP !N
SERv!CE
f26.+
!33
A
!0.1.33
NA!N C!RC. WATER PUNP
PROTECT!ON TR!PPED
GENERATOR
f26.3
!32
A
!0.1.32
SPS++
SPS3+
SPS3- SPS+-
1 2
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D!G!TAL OUTPUTS
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DATE DATE DATE DATE
Fuse Fuse
+
-
+
-
+ +
SPARE
f31.+
Q13
A
Q0.2.13
ALARN RESET
f31.3
Q12
A
Q0.2.12
GENERATOR !N PARARELL
W!TH NA!NS
f31.2
Q11
A
Q0.2.11
GENERATOR C.B
f31.S
Q1+
A
Q0.2.1+
DROOP !SOCRONO
f31.6
Q1S
A
Q0.2.1S
SPARE
f33.6
Q31
A
Q0.2.31
17 PPS1+
18 PPS1-
WATER PREHEAT!NG
f32.S
Q2+
A
Q0.2.2+
O!L PREHEAT!NG
f32.+
Q23
A
Q0.2.23
HEAT RECOvERY NA!N C!RC.
WATER PUNP
f32.2
Q21
A
Q0.2.21
HEAT RECOvERY AUX. C!RC.
WATER PUNP
f32.3
Q22
A
Q0.2.22
-30A1
f30.1
GENERATOR RUNN!NG
f32.3
Q16
A
Q0.2.16
39 PPS2+
38 PPS2-
START AERO FAN S86
f32.7
Q20
A
Q0.2.20
START AERO FAN 38+
f32.6
Q19
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Q0.2.19
START AERO FAN 182
f32.S
Q18
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Q0.2.18
START LUBE O!L PUNP
GENERATOR
f32.+
Q17
A
Q0.2.17
RATED SPEED (!DLE)
GENERATOR
f30.7
Q10
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Q0.2.10
EGS02 ONfOFF
f30.6
Q9
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Q0.2.9
ENERGENCY STOP SAFETY
RELAY RESET GENERATOR
f30.S
Q8
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Q0.2.8
ALARN GENERATOR
f30.+
Q7
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Q0.2.7
ELECTRON!C !GN!T!ON
D!SABLE GENERATOR
f30.3
Q6
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Q0.2.6
GAS RANP GENERATOR
f30.2
QS
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Q0.2.S
START GENERATOR
f30.7
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NA!NS C.B CLOS!NG W!TH
S!NYNCHRON!ZER S2-L
f32.6
Q2S
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Q0.2.2S
NA!NS C.B CLOS!NG W!THOUT
S!NYNCHRON!ZER S2-L
f32.7
Q26
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Q0.2.26
NA!NS C.B TR!P S2-L
f33.2
Q27
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Q0.2.27
NA!NS PROTECT!ON D!SABLED !N GENSET
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DATE DATE DATE DATE
ORANGE ORANGE ORANGE ORANGE
GREEN-YELLOW GREEN-YELLOW GREEN-YELLOW GREEN-YELLOW GROUND GROUND GROUND GROUND
!EC 6020+-1 !EC 6020+-1 !EC 6020+-1 !EC 6020+-1
EN 6020+-1 EN 6020+-1 EN 6020+-1 EN 6020+-1
GROUND GROUND GROUND GROUND GREEN-YELLOW GREEN-YELLOW GREEN-YELLOW GREEN-YELLOW
ORANGE ORANGE ORANGE ORANGE EXTERNAL FEEDERS EXTERNAL FEEDERS EXTERNAL FEEDERS EXTERNAL FEEDERS
BLUE BLUE BLUE BLUE CONTROL C!RCU!TS C.C CONTROL C!RCU!TS C.C CONTROL C!RCU!TS C.C CONTROL C!RCU!TS C.C
RED RED RED RED CONTROL C!RCU!TS C.A CONTROL C!RCU!TS C.A CONTROL C!RCU!TS C.A CONTROL C!RCU!TS C.A
BLACK BLACK BLACK BLACK POWER C!RCU!TS C.A 8 C.C POWER C!RCU!TS C.A 8 C.C POWER C!RCU!TS C.A 8 C.C POWER C!RCU!TS C.A 8 C.C
POWER C!RCU!TS BARS POWER C!RCU!TS BARS POWER C!RCU!TS BARS POWER C!RCU!TS BARS
EXTERNAL FEEDERS EXTERNAL FEEDERS EXTERNAL FEEDERS EXTERNAL FEEDERS
BLUE BLUE BLUE BLUE CONTROL C!RCU!TS C.C CONTROL C!RCU!TS C.C CONTROL C!RCU!TS C.C CONTROL C!RCU!TS C.C
RED RED RED RED
BLACK BLACK BLACK BLACK POWER C!RCU!TS C.A 8 C.C POWER C!RCU!TS C.A 8 C.C POWER C!RCU!TS C.A 8 C.C POWER C!RCU!TS C.A 8 C.C
PHASE (-): BLUE (L-) PHASE (-): BLUE (L-) PHASE (-): BLUE (L-) PHASE (-): BLUE (L-)
PHASE (+): RED (L+) PHASE (+): RED (L+) PHASE (+): RED (L+) PHASE (+): RED (L+)
BUS L1fL2fL3 BUS L1fL2fL3 BUS L1fL2fL3 BUS L1fL2fL3
+00vac +00vac +00vac +00vac
BUS L+fL- BUS L+fL- BUS L+fL- BUS L+fL-
S7Svdc S7Svdc S7Svdc S7Svdc
!NTERNAL W!RE !NTERNAL W!RE !NTERNAL W!RE !NTERNAL W!RE
NEASSURENENT C!RCU!T NEASSURENENT C!RCU!T NEASSURENENT C!RCU!T NEASSURENENT C!RCU!T BLACK BLACK BLACK BLACK
!EC 60++6 !EC 60++6 !EC 60++6 !EC 60++6
PHASE R: BROWN (L1) PHASE R: BROWN (L1) PHASE R: BROWN (L1) PHASE R: BROWN (L1)
PHASE S: BLACK (L2) PHASE S: BLACK (L2) PHASE S: BLACK (L2) PHASE S: BLACK (L2)
PHASE T: GREY (L3) PHASE T: GREY (L3) PHASE T: GREY (L3) PHASE T: GREY (L3)
-6D1 -6D1 -6D1 -6D1
BUS 2+ vdc BUS 2+ vdc BUS 2+ vdc BUS 2+ vdc
-6D2 -6D2 -6D2 -6D2
-9D1 -9D1 -9D1 -9D1
-76D2 -76D2 -76D2 -76D2
BUS 230 vac BUS 230 vac BUS 230 vac BUS 230 vac
AUX. SERv!CES AUX. SERv!CES AUX. SERv!CES AUX. SERv!CES
-76D1 -76D1 -76D1 -76D1
BUS +00 vac BUS +00 vac BUS +00 vac BUS +00 vac
AUX. SERv!CES AUX. SERv!CES AUX. SERv!CES AUX. SERv!CES
-1SD1 -1SD1 -1SD1 -1SD1
PHASE N: BLUE (N) PHASE N: BLUE (N) PHASE N: BLUE (N) PHASE N: BLUE (N)
1 2
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-X:RRN
-X:083
-X:083
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-X:019
-X:129
-X:139
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-X:1310
-X:1310
-X:1311
-X:1S11
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-X:1611
-X:1611
-X:1711
-X:1711
-X:1711
-X:1811
-X:1811
-X:1911
-X:1911
-X:1911
-X:2111
-X:2111
-X:0612
-X:0712
-X:0812
-X:0812
-X:0112
-X:0112
-X:!0.1.7
-X:!0.1.8
-X:!0.1.16
-X:!0.1.17
-X:!0.1.18
-X:!0.1.19
-X:!0.1.20
-X:!0.1.21
-X:!0.1.22
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-X:!0.1.S0
-X:!0.1.S1
-X:!0.1.S2
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-X:!0.1.S6
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-X:0138
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-X:0238
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-X:!0.S.6
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-X:11S0
-X:13S0
-X:1SS0
-X:17S0
-X:19S0
-X:21S0
-X:23S0
-X:2SS0
-X:27S0
-X:29S0
-X:31S0
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-X:06SS
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-X:106S
-X:116S
-X:116S
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72 71 6970 68 67 6S66 6263 S96061 S8 S6S7 SS S3S+6+ S2 S1 S0 +9 +7 +6 ++ +3+S+8 +1 +0 38 3739+2
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ELECTR!C CAB!NET
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DATE DATE DATE DATE
Bill of materials
Designation Page Qt. Designation Description Reference Nanufacturer
-6A1 f6.2 1 BATTERY CHARGER
-7A1 f7.1 1 HORN 2+vdc
-7A1 f7.1 1 BUTTONS SUPPORT D!N RA!L 3Smm
-9A1 f9.1 1 SPEED CONTROL AND LOAD CONTROL
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-1SA1 f1S.1 1 GPU D!SPLAY
-21A1 f21.2 1 POWER SUPPLY
-21A2 f21.S 1 CPU ETHERNET+Can Open
-21A2 f21.S 1 CONNECTOR CAN
-21A3 f21.S 1 TOUCH CONTROL SCREEN
-22A1 f22.2 1 6+ D!G!TAL !NPUTS NODULE
-22A2 f22.2 1 !NPUT !NTERFACE
-2+A1 f2+.2 1 !NPUT !NTERFACE
-26A1 f26.2 1 !NPUT !NTERFACE
-28A1 f28.2 1 !NPUT !NTERFACE 2+vdc 3m Screw Terminal
-30A1 f30.1 1 32 D!G!TAL OUTPUTS NODULE 2+vdc
3x+00f+80vac f 2+vdc f 20A
2+vdc Suministro GUASCOR
2+vdc 3m Screw Terminal
-30A1 f30.1 1 PREASSENBLED CORDSETS For Nodicon Telefast ABE 7 sub-bases
-30A2 f30.1 1 !NTERFACE 16 DfO RELAY 2NONC volt Free
-32A1 f32.1 1 !NTERFACE 16 DfO RELAY 2NONC volt Free
-38A1 f38.2 1 + ANALOG !NPUT + 2 ANALOG OUTPUTS NODULE
-38A1 f38.2 1 TERN!NAL CONECTOR
-39A1 f39.2 1 + ANALOG !NPUT + 2 ANALOG OUTPUTS NODULE
-39A1 f39.2 1 TERN!NAL CONECTOR
-+0A1 f+0.2 1 8 D!G!TAL !NPUT + 8 D!G!TAL OUTPUTS NODULE 2+vdc
-+0A1 f+0.2 1 TERN!NAL CONECTOR FOR BNX AN! 0+10;ANO 0210;ANO 0+10;ANO 0802;ANN 0600
-100CAB!NET f20.S 1 Power 8 Control Cabinet 800mm+1000mm
-100CAB!NET f20.S 1 Label Kit Power and Control
-100CAB!NET f20.S 1 STANDARD CABLES 1800mm
-6D1 f6.2 1 BUS !! 100 A
-6D2 f6.6 1 BUS !! 12SA
-9D1 f9.1 1 BUS !! 12SA
-1SD1 f1S.3 1 BUS !!
-76D1 f76.3 1 BUS !v
-76D2 f76.6 1 BUS !!
-2F1 f2.1 1 FUSE HOLDER !!!
-2F1 f2.1 3 FUSE CARTR!DGE
-2F2 f2.2 1 C!RCU!T BREAKER !!!
12SA
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FOR BNX AN! 0+10;ANO 0210;ANO 0+10;ANO 0802;ANN 0600
FOR BNX AN! 0+10;ANO 0210;ANO 0+10;ANO 0802;ANN 0600
12SA
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32A Size 10x38
Type aN 16AfS00vac 10x38
6A,Curve C,C60N
1 2
600
Sh
B!LL OF NATER!ALS
602
601 vEC106S1072 f 11101119
f 11+111+8
09f10f2012
AGA
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1111
3 + S 6 7 8
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DATE DATE DATE DATE
Bill of materials
-2F2 f2.2 1 AUX!L!ARY CONTACT (OF)
-3F1 f3.2 1 AUX!L!ARY CONTACT (OF)
-SF1 fS.S 1 FUSE HOLDER !
-SF1 fS.S 1 FUSE CARTR!DGE
-6F2 f6.2 1 C!RCU!T BREAKER !
-6F+ f6.3 1 C!RCU!T BREAKER !
-6FS f6.3 1
-6F6 f6.+ 1 C!RCU!T BREAKER !!
-6F7 f6.S 1 C!RCU!T BREAKER !! 2A,Curve C,C60N
-6F7 f6.S 1 AUX!L!ARY CONTACT (OF) 1NANC
-6F8 f6.6 1 C!RCU!T BREAKER !! 16A,Curve C,C60N
-8F1 f8.3 1 FUSE HOLDER !! 32A Size 10x38
-8F1 f8.3 2 FUSE CARTR!DGE Type aN 10AfS00vac 10x38
-9F1 f9.1 1 C!RCU!T BREAKER ! 6A,Curve C,C60N
-11F1 f11.2 1 C!RCU!T BREAKER !! 2SA,Curve C,C60N
-11F1 f11.2 1 AUX!L!ARY CONTACT (OF) 1NANC
-11F3 f11.+ 1 C!RCU!T BREAKER !! 10A,Curve C,C60N
-11F3 f11.+ 2 AUX!L!ARY CONTACT (OF) 1NANC
-11F+ f11.S 1 C!RCU!T BREAKER ! 6A,Curve C,C60N
-11FS f11.6 1 C!RCU!T BREAKER !! 16A,Curve C,C60N
-11FS f11.6 2 AUX!L!ARY CONTACT (OF) 1NANC
-13F1 f13.2 1 C!RCU!T BREAKER !!! 6A,Curve C,C60N
-1SF1 f1S.3 1 C!RCU!T BREAKER !! 10A,Curve C,C60N
-1SF2 f1S.+ 1 FUSE HOLDER ! 32A Size 10x38
-1SF2 f1S.+ 1 FUSE CARTR!DGE Type aN 1AfS00vac 10x38
-1SF3 f1S.S 1 C!RCU!T BREAKER ! 6A,Curve C,C60N
C!RCU!T BREAKER !!
10A,Curve C,C60N
1NANC
6A,Curve C,C60N
1NANC
32A Size 10x38
Type aN +AfS00vac 10x38
6A,Curve C,C60N
2SA,Curve C,C60N
2SA,Curve C,C60N
2SA,Curve C,C60N
1 2
601
Sh
B!LL OF NATER!ALS
603
602 vEC106S1072 f 11101119
f 11+111+8
09f10f2012
AGA
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1111
3 + S 6 7 8
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DATE DATE DATE DATE
Bill of materials
-SSF1 fSS.2 1 C!RCU!T BREAKER ! 6A,Curve C,C60N
-S6F1 fS6.2 1 C!RCU!T BREAKER ! 6A,Curve C,C60N
-60F1 f60.+ 1 C!RCU!T BREAKER ! 6A,Curve C,C60N
-62F2 f62.S 1 C!RCU!T BREAKER ! 6A,Curve C,C60N
-6SF1 f6S.3 1 C!RCU!T BREAKER ! 6A,Curve C,C60N
-7SF1 f7S.+ 1 FUSE HOLDER !! 32A Size 10x38
-7SF1 f7S.+ 2 FUSE CARTR!DGE Type aN 2AfS00vac 10x38
-7SF2 f7S.+ 1 C!RCU!T BREAKER !! 1A,Curve C,C60N
-7SF3 f7S.S 1 FUSE HOLDER !!!+N 32A Size 10x38
-7SF3 f7S.S 3 FUSE CARTR!DGE Type aN 16AfS00vac 10x38
-76F1 f76.S 1 FUSE HOLDER !! 32A Size 10x38
-76F1 f76.S 2 FUSE CARTR!DGE Type aN 2AfS00vac 10x38
-76F2 f76.S 1 C!RCU!T BREAKER !! 1A,Curve C,C60N
-76F3 f76.+ 1 D!FERENT!AL PROTECT!ON RELAY RH99N 30mAf2SA 230vca
-76F+ f76.6 1 FUSE HOLDER !! 32A Size 10x38
-76F+ f76.6 2 FUSE CARTR!DGE Type aN 10AfS00vac 10x38
-76FS f76.6 1 C!RCU!T BREAKER !! 10A,Curve C,C60N
-76FS f76.6 1 AUX!L!ARY CONTACT (OF) 1NANC
-76F6 f76.6 1 FUSE HOLDER !!!+N 32A Size 10x38
-76F6 f76.6 3 FUSE CARTR!DGE Type aN 16AfS00vac 10x38
-1SG1 f1S.2 2 AUX!L!ARY BATTER!ES 12vdc 7Ah
-70H1 f70.2 1 SW!TCH LANP FOR CAB!NET 230vac 8W S0f60Hz
-3K2 f3.+ 1 PROTECT!ON RELAY 1NO+1NC 11S230vac S0f60Hz
-SK1 fS.2 1 CONTROL RELAY 3NO+2NC 230vac S0f60Hz
-SK2 fS.6 1 CONTROL RELAY
-7K1 f7.3 1 CONTROL RELAY
-7K2 f7.+ 1 CONTROL RELAY 3NO+2NC 2+vdc
-7K3 f7.2 1 SAFETY RELAY 2+vdc 2NO
-7K+ f7.7 1 AUX!L!ARY RELAY
-7K+ f7.7 1 AUX!L!ARY RELAY SOCKET
-7K+ f7.7 1 PLAST!C RETA!N!NG CL!P
3NO+2NC 230vac S0f60Hz
3NO+2NC 2+vdc
Push !n Connection
2+vdc, + contact
1 2
602
Sh
B!LL OF NATER!ALS
60+
603 vEC106S1072 f 11101119
f 11+111+8
09f10f2012
AGA
ZEL
1111
3 + S 6 7 8
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DATE DATE DATE DATE
Bill of materials
-8K1 f8.S 1 AUX!L!ARY RELAY
-9K1 f9.+ 1 AUX!L!ARY RELAY
-9K1 f9.+ 1 AUX!L!ARY RELAY SOCKET
-9K1 f9.+ 1 PLAST!C RETA!N!NG CL!P
-9K2 f9.S 1 AUX!L!ARY RELAY
-9K2 f9.S 1 AUX!L!ARY RELAY SOCKET
-9K2 f9.S 1 PLAST!C RETA!N!NG CL!P
-11K1 f11.3 1 CONTACTOR !!!
-11K2 f11.S 1 CONTACTOR !!!
-11K+ f11.8 1 CONTACTOR !!!
-16K1 f16.3 1 AUX!L!ARY RELAY
-16K1 f16.3 1 AUX!L!ARY RELAY SOCKET
-16K1 f16.3 1 PLAST!C RETA!N!NG CL!P
-18K1A f18.+ 1 AUX!L!ARY RELAY
-18K1A f18.+ 1 AUX!L!ARY RELAY SOCKET
-18K1A f18.+ 1 PLAST!C RETA!N!NG CL!P
-18K2A f18.S 1 AUX!L!ARY RELAY
-18K2A f18.S 1 AUX!L!ARY RELAY SOCKET
-18K2A f18.S 1 PLAST!C RETA!N!NG CL!P
-+1K1 f+1.3 1 AUX!L!ARY RELAY
-+1K1 f+1.3 1 AUX!L!ARY RELAY SOCKET
-+1K1 f+1.3 1 PLAST!C RETA!N!NG CL!P
-+1K2 f+1.+ 1 AUX!L!ARY RELAY
-+1K2 f+1.+ 1 AUX!L!ARY RELAY SOCKET
-+1K2 f+1.+ 1 PLAST!C RETA!N!NG CL!P
-+1K3 f+1.+ 1 AUX!L!ARY RELAY
-+1K3 f+1.+ 1 AUX!L!ARY RELAY SOCKET
Push !n Connection
2+vdc, 1NO+1NC
Push !n Connection
2SA AC3 1NA+1NC 2+vdc (Low consumption)
Push !n Connection
9A AC3 1NA+1NC 230vac S0f60Hz
Push !n Connection
Push !n Connection
Push !n Connection
Push !n Connection
Push !n Connection
Push !n Connection
Push !n Connection
Push !n Connection
2+vdc, + contact
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2+vdc, + contact
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2+vdc, + contact
2+vdc, + contact
1 2
603
Sh
B!LL OF NATER!ALS
60S
60+ vEC106S1072 f 11101119
f 11+111+8
09f10f2012
AGA
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1111
3 + S 6 7 8
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DATE DATE DATE DATE
Bill of materials
-+1K3 f+1.+ 1 PLAST!C RETA!N!NG CL!P
-+1K+ f+1.S 1 AUX!L!ARY RELAY
-+1K+ f+1.S 1 AUX!L!ARY RELAY SOCKET
-+1K+ f+1.S 1 PLAST!C RETA!N!NG CL!P
-+1KS f+1.S 1 AUX!L!ARY RELAY
-+1KS f+1.S 1 AUX!L!ARY RELAY SOCKET
-+1KS f+1.S 1 PLAST!C RETA!N!NG CL!P
-SSK1 fSS.2 1 CONTROL RELAY
-SSK2 fSS.2 1 CONTROL RELAY
-S6K1 fS6.2 1 CONTACTOR !!!
-S6K3 fS6.3 1 CONTACTOR !!!
-S6K3 fS6.3 1 AUX!LARY CONTACTS
-S6K+ fS6.+ 1 AUX!LARY CONTACTS
-60K1 f60.+ 1 CONTACTOR !!!
-61K1 f61.+ 1 CONTACTOR !!!
-62K2 f62.S 1 CONTACTOR !!!
-6SK1 f6S.3 1 CONTACTOR !!!
-70N1 f70.3 1 EXTRACTOR
-6P1 f6.2 1 ANNETER
-12Q1 f12.2 1 NAGNETOTHERN!C C!RCU!T BREAKER !!!
-12Q1 f12.2 1 AUX!LARY CONTACTS 1NO+1NC FRONT
-60Q1 f60.2 1 NAGNETOTHERN!C C!RCU!T BREAKER !!! !n:6,3A; !t:+6,3A; !m:78A
Ent:02SAcc , Esc:02SA (72x72 90)
!n:1,6A; !t:11,6A; !m:22,SA
-60Q2 f60.3 1 NAGNETOTHERN!C C!RCU!T BREAKER !!! !n:6,3A; !t:+6,3A; !m:78A
-60Q3 f60.S 1 NAGNETOTHERN!C C!RCU!T BREAKER !!! !n:6,3A; !t:+6,3A; !m:78A
Push !n Connection
Push !n Connection
Push !n Connection
Push !n Connection
Push !n Connection
3NO+2NC 2+vdc
2NO
230vac,S0f60Hz 300f3S0m3fh RAL 703S !PS+
3NO+2NC 2+vdc
9A AC3 1NA+1NC 2+vdc (Low consumption)
9A AC3 1NA+1NC 2+vdc (Low consumption)
2NO
2+vdc, + contact
2+vdc, + contact
2+vdc, + contact
2+vdc, + contact
2+vdc, + contact
1 2
60+
Sh
B!LL OF NATER!ALS
606
60S vEC106S1072 f 11101119
f 11+111+8
09f10f2012
AGA
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3 + S 6 7 8
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1
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DATE DATE DATE DATE
Bill of materials
-60Q3 f60.S 1 AUX!LARY CONTACTS 1NO+1NC FRONT
-60Q+ f60.6 1 NAGNETOTHERN!C C!RCU!T BREAKER !!! !n:6,3A; !t:+6,3A; !m:78A
-60Q+ f60.6 1 AUX!LARY CONTACTS
-61Q1 f61.2 1 AUX!LARY CONTACTS
-62Q1 f62.2 1 NAGNETOTHERN!C C!RCU!T BREAKER !!! !n:1+A; !t:91+A; !m:170A
1NO+1NC FRONT
1NO+1NC FRONT
!n:6,3A; !t:+6,3A; !m:78A
!n:6,3A; !t:+6,3A; !m:78A
-62Q2 f62.+ 1 NAGNETOTHERN!C C!RCU!T BREAKER !!! !n:6,3A; !t:+6,3A; !m:78A
-62Q2 f62.+ 1 AUX!LARY CONTACTS 1NO+1NC FRONT
-6SQ1 f6S.2 1 NAGNETOTHERN!C C!RCU!T BREAKER !!! !n:10A; !t:610A; !m:138A
-6SQ1 f6S.2 1 AUX!LARY CONTACTS 1NO+1NC FRONT
-76Q1 f76.1 1 SW!TCH 1-0-2
-76Q1 f76.1 1 D!RECT HANDLE BLACK
-76Q1 f76.1 2 TERN!NAL COvER
-76Q2 f76.+ 1 C!RCU!T BREAKER !v Nasterpack NW20 2000A, 6SkA
-76Q2 f76.+ 1 XF CLOSE CO!L 2002S0v, AC S0f60Hz, For NASTERPACT NTfNW
-76Q2 f76.+ 1 N!N!NUN CO!L 2002S0v, AC S0f60Hz, For NASTERPACT NTfNW
-76Q2 f76.+ + ADD!T!ONAL BLOCK ONfOFF (6A-2+0v) NW
-76Q2 f76.+ 1 GEAR NOTOR NCH 2002+0v, AC S0f60Hz, For NASTERPACT NW
-76Q2 f76.+ 1 ADD!T!ONAL BLOCK 1 CONTACT SDE (SA-2+0v) NW
-76Q2 f76.+ 1 DOORFRANE NASTERPACT NW08-NW63
-76Q2 f76.+ 1 ALUN!NUN PLATE 2x80x10mm
-76Q3 f76.3 1 NAGNETOTHERN!C C!RCU!T BREAKER !v Compact NSX160H TND12SD +P +R 70kA 380+1Svac , 6SkA ++0vca
-76Q3 f76.3 1 AUX. CONTACT For Compact NSX100f160f2S0f+00f630
-76Q3 f76.3 1 OPEN RELAY
-76Q3 f76.3 2 SHORT TERN!NAL COvER
-10R1 f10.6 1 RES!STANCE 120 Ohm
-10R2 f10.7 1 RES!STANCE
-7S1 f7.2 1 RED NUSHROON HEAD +0mm, Unlatching by turning to the left
-7S1 f7.2 1 SOCKET + CONTACTS BLOCK
-7S1 f7.2 1 NETAL GUARDS
-70S1 f70.2 1 L!N!T SW!TCH
-70S2 f70.2 1 L!N!T SW!TCH 1NC+1NO
120 Ohm
1NC
-70S3 f70.3 1 THERNOSTAT (NA)-vENT, 0f+60C
-7ST1 f7S.1 1 CURRENT TRANSFORNER TUC80 2000fSA SP10
1NC+1NO
For Compact NSX100f160f2S0 !v
For Compact NSX100f160f2S0f+00f630, 220-2+0vac S0f60Hz
12SA 3P+N
1 2
60S
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B!LL OF NATER!ALS
6S0
606 vEC106S1072 f 11101119
f 11+111+8
09f10f2012
AGA
ZEL
1111
3 + S 6 7 8
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1
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DATE DATE DATE DATE
Bill of materials
-7ST+ f7S.+ 1 TRANSFORNER !!
-76T1 f76.S 1 TRANSFORNER !! 380-+00-++0-+80f230vac +0vA S0f60Hz
-76T2 f76.+ 1 TORO!DAL PA S0mm
-76T3 f76.6 1 TRANSFORNER !!
-20U1 f20.6 1 RACK 8 POS!T!ONS
-6v1 f6.7 1 D!ODE
380-+00-++0-+80f230vac 2KvA S0f60Hz
2+vdc 6A
380-+00-++0-+80f230vac 2S0vA S0f60Hz
-6v2 f6.7 1 RECT!F!ER JUNPER 3SA S00v
-70X1 f70.+ 1 SOCKET 16A
1 2
606
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TOTAL L!ST
6S1
6S0 vEC106S1072 f 11101119
f 11+111+8
09f10f2012
AGA
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1111
3 + S 6 7 8
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1
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1
6
DATE DATE DATE DATE
Nanufacturer Reference Description Designation Quantity
Total list
1
2x80x10mm ALUN!NUN PLATE 1
BATTERY CHARGER 1
GPU GENERATOR CONTROLLER 1
GPU D!SPLAY 1
380-+00-++0-+80f230vac 2S0vA S0f60Hz TRANSFORNER !! 1
380-+00-++0-+80f230vac +0vA S0f60Hz TRANSFORNER !! 1
380-+00-++0-+80f230vac 2KvA S0f60Hz TRANSFORNER !! 1
3SA S00v RECT!F!ER JUNPER 1
2+vdc, 1NO+1NC AUX!L!ARY RELAY 1
2+vdc 2NO SAFETY RELAY 1
Label Kit 1
ANNETER 1
CURRENT TRANSFORNER 3
HORN 1
BUTTONS SUPPORT 1
POWER SUPPLY 1
CPU ETHERNET+Can Open 1
CONNECTOR CAN 1
TOUCH CONTROL SCREEN 1
6+ D!G!TAL !NPUTS NODULE 1
!NPUT !NTERFACE +
32 D!G!TAL OUTPUTS NODULE 1
PREASSENBLED CORDSETS 1
!NTERFACE 16 DfO RELAY 2
+ ANALOG !NPUT + 2 ANALOG OUTPUTS NODULE 2
FOR BNX AN! 0+10;ANO 0210;ANO 0+10;ANO 0802;ANN 0600 TERN!NAL CONECTOR 3
8 D!G!TAL !NPUT + 8 D!G!TAL OUTPUTS NODULE 1
Power 8 Control Cabinet 1
BUS !! 1
BUS !! +
BUS !v 1
FUSE HOLDER !!! 1
FUSE CARTR!DGE 9
C!RCU!T BREAKER !!! +
AUX!L!ARY CONTACT (OF) 10
FUSE HOLDER ! 2
FUSE CARTR!DGE 1
STANDARD CABLES 1800mm
2+vdc
2+vdc
2NONC volt Free
800mm+1000mm
Power and Control
2+vdc
3x+00f+80vac f 2+vdc f 20A
Ent:02SAcc , Esc:02SA (72x72 90)
TUC80 2000fSA SP10
2+vdc
2+vdc
100 A
12SA
12SA
32A Size 10x38
6A,Curve C,C60N
1NANC
32A Size 10x38
Type aN +AfS00vac 10x38
2+vdc
D!N RA!L 3Smm
2+vdc
For Nodicon Telefast ABE 7 sub-bases
1 2
6S0
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TOTAL L!ST
6S2
6S1 vEC106S1072 f 11101119
f 11+111+8
09f10f2012
AGA
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1111
3 + S 6 7 8
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1
6
0
1
6
DATE DATE DATE DATE
Total list
C!RCU!T BREAKER ! 2
C!RCU!T BREAKER !! 2
C!RCU!T BREAKER !! +
FUSE HOLDER !! +
FUSE CARTR!DGE +
C!RCU!T BREAKER ! 17
1NANC AUX!L!ARY CONTACT (OF) 1
1NANC AUX!L!ARY CONTACT (OF) 1
6A,Curve C,C60N C!RCU!T BREAKER !! 1
Type aN 1AfS00vac 10x38 FUSE CARTR!DGE 1
Type aN 2AfS00vac 10x38 FUSE CARTR!DGE +
1A,Curve C,C60N C!RCU!T BREAKER !! 2
32A Size 10x38 FUSE HOLDER !!!+N 2
RH99N 30mAf2SA 230vca D!FERENT!AL PROTECT!ON RELAY 1
230vac 8W S0f60Hz SW!TCH LANP FOR CAB!NET 1
1NO+1NC 11S230vac S0f60Hz PROTECT!ON RELAY 1
3NO+2NC 230vac S0f60Hz CONTROL RELAY 2
3NO+2NC 2+vdc CONTROL RELAY +
2SA AC3 1NA+1NC 2+vdc (Low consumption) CONTACTOR !!! 1
12A AC3 1NA+1NC 230vac S0f60Hz CONTACTOR !!! +
18A AC3 1NA+1NC 230vac S0f60Hz CONTACTOR !!! 2
9A AC3 1NA+1NC 230vac S0f60Hz CONTACTOR !!! 3
9A AC3 1NA+1NC 2+vdc (Low consumption) CONTACTOR !!! 2
2NO AUX!LARY CONTACTS 2
230vac,S0f60Hz 300f3S0m3fh RAL 703S !PS+ EXTRACTOR 1
!n:1,6A; !t:11,6A; !m:22,SA NAGNETOTHERN!C C!RCU!T BREAKER !!! 1
1NO+1NC FRONT AUX!LARY CONTACTS 10
!n:6,3A; !t:+6,3A; !m:78A NAGNETOTHERN!C C!RCU!T BREAKER !!! 7
!n:1+A; !t:91+A; !m:170A NAGNETOTHERN!C C!RCU!T BREAKER !!! 1
!n:10A; !t:610A; !m:138A NAGNETOTHERN!C C!RCU!T BREAKER !!! 1
Nasterpack NW20 2000A, 6SkA C!RCU!T BREAKER !v 1
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2002S0v, AC S0f60Hz, For NASTERPACT NTfNW N!N!NUN CO!L 1
ONfOFF (6A-2+0v) NW ADD!T!ONAL BLOCK +
2002+0v, AC S0f60Hz, For NASTERPACT NW GEAR NOTOR NCH 1
SDE (SA-2+0v) NW ADD!T!ONAL BLOCK 1 CONTACT 1
16A,Curve C,C60N
32A Size 10x38
6A,Curve C,C60N
2A,Curve C,C60N
2SA,Curve C,C60N
2SA,Curve C,C60N
10A,Curve C,C60N
1 2
6S1
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TOTAL L!ST
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6S2 vEC106S1072 f 11101119
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09f10f2012
AGA
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Total list
NASTERPACT NW08-NW63 DOORFRANE 1
Compact NSX160H TND12SD +P +R 70kA 380+1Svac , 6SkA ++0vca NAGNETOTHERN!C C!RCU!T BREAKER !v 1
For Compact NSX100f160f2S0f+00f630 AUX. CONTACT 1
For Compact NSX100f160f2S0f+00f630, 220-2+0vac S0f60Hz OPEN RELAY 1
For Compact NSX100f160f2S0 !v SHORT TERN!NAL COvER 2
+0mm, Unlatching by turning to the left RED NUSHROON HEAD 1
SOCKET + CONTACTS BLOCK 1
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THERNOSTAT 1
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RACK 8 POS!T!ONS 1
SOCKET 1
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TERN!NAL COvER 2
AUX!L!ARY RELAY 17
AUX!L!ARY RELAY SOCKET 17
PLAST!C RETA!N!NG CL!P 17
SPEED CONTROL AND LOAD CONTROL 1
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16A
120 Ohm RES!STANCE 2
2+vdc 6A D!ODE 1
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(NA)-vENT, 0f+60C
BLACK
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12vdc 7Ah AUX!L!ARY BATTER!ES 2
1 2
6S2
Sh
TERN!NAL STR!P
701
700 vEC106S1072 f 11101119
f 11+111+8
09f10f2012
AGA
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1111
3 + S 6 7 8
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PART 1 OF 1
1 2
700
Sh
TERN!NAL STR!P
702
701 vEC106S1072 f 11101119
f 11+111+8
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AGA
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1111
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PART 1 OF 3
PART 2 OF 3
1 2
701
Sh
TERN!NAL STR!P
800
702 vEC106S1072 f 11101119
f 11+111+8
09f10f2012
AGA
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1111
3 + S 6 7 8
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PART 3 OF 3
1 2
702
Sh
TERN!NAL L!NE LEvEL
801
800 vEC106S1072 f 11101119
f 11+111+8
09f10f2012
AGA
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1111
3 + S 6 7 8
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DATE DATE DATE DATE
Terminal line-up diagram
Component Terminal Stage Bridge Component Terminal Stage Bridge Component Terminal Stage Bridge Component Terminal Stage Bridge Component Terminal Stage Bridge
=0000A+00DA00-9A1X =0000A+00DA00-9A1X =0000A+00DA00-9A1X =0000A+00DA00-9A1X =0000A+00DA00-9A1X
J1A2 1 Tope 10
J1AS 2
Tope 10
J1A6 1 Borne Doble 2.S
J1A7 2
J1A10 2
J1A13 2
J1A1+ 1 Borne Doble 2.S
J1A16 2
J1A19 2
J1A2+ 2
J1A2S 1 Borne Doble 2.S
J1A26 2
J1A29 2
Placa separacin
Doble
J1B1 1 Borne Doble 2.S
J1B9 2
J1B10 2
J1B1+ 2
J1B1S 1 Borne Doble 2.S
J1B20 2
J1B22 2
J1B23 2
J1B2+ 1 Borne Doble 2.S
SH 1 Borne Doble 2.S
SH 2
Placa separacin
Doble
J1C1 1 Borne Doble 2.S
J1C2 2
J1C+ 2
J1CS 1 Borne Doble 2.S
J1C6 2
J1C10 2
J1C1S 1 Borne Doble 2.S
J1C17 2
J1C18 2
SH 1 Borne Doble 2.S
Placa separacin
Doble
J2A1S 1 Borne Doble 2.S
J2A16 2
J2A19 2
J2A2+ 2
Placa separacin
Doble
J2BS 1 Borne Doble 2.S
J2B9 2
J2B1S 2
J2B21 2
Placa separacin
Doble
Tope 10
1 2
800
Sh
TERN!NAL L!NE LEvEL
802
801 vEC106S1072 f 11101119
f 11+111+8
09f10f2012
AGA
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1111
3 + S 6 7 8
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DATE DATE DATE DATE
=0000A+00DA00-X =0000A+00DA00-X =0000A+00DA00-X =0000A+00DA00-X =0000A+00DA00-X
R00 Tope 10
Tope 10
S00 Borne +
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RRN Borne +
Placa separacin
083 1 Borne Doble 2.S
093 2
Placa separacin
Doble
1+6 Borne 6
Placa separacin
1L+ Borne 6
Placa separacin
1L- Borne 6
Placa separacin
136 2
Placa separacin
Doble
097 2
097 2
2L- 2
2L- 2
0+7 1 Borne Doble 2.S
2L- 2
0S7 1 Borne Doble 2.S
067 2
Placa separacin
Doble
038 2
2L- 2
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L+ 1 Borne Doble 2.S
L- 2
PE 1 Borne Doble 2.S
088 2
Placa separacin
Doble
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Placa separacin
029 2
3L- 2
3L- 2
Placa separacin
Doble
3L- 2
P 2
3L- 2
P 2
0610 2
P 2
3L- 2
3L- 2
1010 2
P 1 Borne Doble 2.S
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P2- 2
H 1 Borne Doble 2.S
C 2
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C 2
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L 2
1+10 2
Placa separacin
Doble
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Placa separacin
1611 Borne +
1611 Borne +
1711 Borne +
1711 Borne +
Placa separacin
1811 Borne +
1811 Borne +
1911 Borne +
1911 Borne +
Placa separacin
1L2 2
Placa separacin
Doble
0612 Borne +
0712 Borne +
0812 Borne +
Placa separacin
0212 2
Placa separacin
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0122 2
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0122 2
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0122 2
0122 2
0122 2
0122 2
0122 2
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0122 2
0122 2
0122 2
0122 2
0122 2
!0.1.+8 1 Borne Doble 2.S
0122 2
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0122 2
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0122 2
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0122 2
0122 2
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0122 2
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0122 2
0122 2
0122 2
+L- 2
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+L- 2
0338 2
0+38 2
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Doble
0139 2
0239 2
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+L- 2
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Doble
0639 2
Placa separacin
Doble
!0.S.2 1 Borne Doble 2.S
0122 2
0122 2
0122 2
0122 2
Placa separacin
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02S0 2
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06S0 2
08S0 2
10S0 2
12S0 2
1+S0 2
16S0 2
18S0 2
20S0 2
22S0 2
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1 2
801
Sh
TERN!NAL L!NE LEvEL
802 vEC106S1072 f 11101119
f 11+111+8
09f10f2012
AGA
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1111
3 + S 6 7 8
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DATE DATE DATE DATE
=0000A+00DA00-X =0000A+00DA00-X =0000A+00DA00-X =0000A+00DA00-X =0000A+00DA00-X
26S0 2
28S0 2
30S0 2
32S0 2
3+S0 2
36S0 2
Placa separacin
Doble
06SS 1 Borne Doble 2.S
03SS 2
0+SS 2
0SSS 2
0SSS 2
0SSS 2
0SSS 2
Placa separacin
Doble
0960 Borne +
1060 Borne +
1160 Borne +
Placa separacin
1260 Borne +
1360 Borne +
1+60 Borne +
Placa separacin
1S60 Borne +
1660 Borne +
1760 Borne +
Placa separacin
1860 Borne +
1960 Borne +
2060 Borne +
Placa separacin
0S61 Borne +
0661 Borne +
0761 Borne +
Placa separacin
0861 Borne +
0961 Borne +
1061 Borne +
Placa separacin
0962 Borne +
1062 Borne +
1162 Borne +
Placa separacin
1262 Borne +
1362 Borne +
1+62 Borne +
Placa separacin
096S Borne +
106S Borne +
116S Borne +
Placa separacin
Tope 10
PRODUCT INFORMATION INDEX DATE
Dep. 3
IO-C-M-AP-001e A
May 2012
GENSET ELECTRIC CABINET POWER MODULE

1/9

1. INTRODUCTION
Each Guascor genset is supplied with an electric cabinet which main purpose is to connect the synchronous
generator to the electrical grid through an automatic circuit breaker.
This cabinet is supplied either as a stand-alone cabinet called as power cabinet, or as a module in a bigger
cabinet with power and control modules joined together. The latter implies that are installed all the equipment
needed to carry out all the control and power protection functions needed by the genset and its auxiliary
services in the same cabinet.
For detailed information on the electrical wiring and construction details of the cabinet please refer to the
electrical wiring diagrams supplied.
CAUTION: manipulation of the internal part of the cabinet represents an electric hazard and
must be carried out by experienced and trained personnel only. SEVERE RISK of fatal injuries.
2. MAIN DEVICES INSTALLED IN THE POWER MODULE
2.1. GENERATOR AUTOMATIC CIRCUIT BREAKER
The synchronous generator connection to the electrical grid of the plant where is installed the genset is
controlled by an automatic circuit breaker with the characteristics and rating suitable for the application.
The functions of the circuit breaker are:
Connect and disconnect in a normal way the machine to the electrical grid.
Keep the machine disconnected safely from the electrical grid (safe isolation switch function), so no
electrical danger downwards (between the breaker and the generator) is expected.
Disconnect the machine when electrical abnormal conditions are detected, being capable of opening
without damage the maximum short circuit currents expected.
The circuit breaker is supplied with the following accesories:
- An opening undervoltage release coil which makes the circuit breaker to open when the operating
voltage which feeds the coil drops below a value between 35 % and 70 % of its rated voltage. It is the
element used by the control system to open the breaker instantaneously. The circuit breaker can only
close if the voltage to this coil is over the 85% of its rated value.
- A closing release coil which makes when energized the circuit breaker to close (only if the voltage
feeding the undervoltage release coil is over the 85% of its rated value, this safety feature prevents the
breaker to be closed unsafely even manually with its mechanical pushbutton).
- A gear motor to charge the operating spring mechanism. The electric motor automatically charges and
recharges the spring mechanism when the circuit breaker is closed.
- Electric status indication changeover contacts to signal the status of the circuit breaker to the control
system.
- An electronic protection unit that carries overcurrent protection functions that trip the breaker. The
measurements used by this unit are internal within the circuit breaker.
The voltage for maneuver of the circuit breaker is taken between the circuit breaker and the synchronous
generator, so when the genset is stopped (and the circuit breaker is so open) there is no voltage in this circuit
and the circuit breaker cannot be closed because it is not with voltage the undervoltage release.
This is the desired safe operation because a connection of the machine to the electrical grid in an inappropriate
moment is very dangerous and can damage seriously the generator.
Dep. 3
IO-C-M-AP-001e A
May 2012

2/9

Only the Genset control PLC (Programmable Logic Controller) enables the closing of the circuit breaker by the
feeding of the undervoltage release.
The circuit breaker has a front side that is shown through a gap on the cabinet module frontal door. On this
front the circuit breaker has all of the status indications and controls to be checked and operated.
CAUTION: IT IS NOT RECOMMENDED TO OPERATE THE CIRCUIT BREAKER DIRECTLY WITH THE
COMPONENTS ON ITS FRONT.

Below are described all of the elements that can be seen on the circuit breaker front (describing them
clockwise):
Reset pushbutton: is one of the most important element on the circuit breaker. When it has happened a
trip of the circuit breaker by its built-in electronic protection unit the pushbutton protrudes out of the
front, showing that there has been a trip. At this status the breaker cannot be closed by any means
until the pushbutton is pressed to reset the circuit breaker.
Opening pushbutton: pressing this button makes to open the circuit breaker immediately. It is a
mechanical device so opens the circuit breaker in any circumstance (supposing no failure of the
breaker).
Closing pushbutton: this pushbutton is intended only for disconnected checks and must not be
operated in normal operation. CAUTION: DO NOT USE THIS PUSHBUTTON FOR AN ELECTRICAL
LIVE GRID WHEN THE MACHINE IS STILL NOT COUPLED (RUNNING before its circuit breaker is
closed as coupled to the grid).
Springs charging handle: it is a handle not to be used in a normal situation. By pushing it down
repeatedly charges the internal spring mechanism (this mechanism closes and opens the breaker).
Springs
charging
handle
Rating
Plate
Electronic
Protection
Unit
Protection
Unit
Display
Reset
pushbutton
Opening
pushbutton
Closing
pushbutton
Open/closed
Status window
Spring Mechanism & closing
readiness Status window
Dep. 3
IO-C-M-AP-001e A
May 2012

3/9

Rating plate: it is an informative plate where the most important information of the breaker is shown.
Spring mechanism and closing readiness status window: it is an indication window where are shown
the status of the spring mechanism to open the breaker and the readiness of the breaker to be closed.
There are 2 spring mechanisms, one to close and the other to open the breaker. It is necessary the
springs to be loaded to be able to close the breaker but it is a necessary but not sufficient condition.
The other indication status (OK or OK) indicates if the breaker is ready to be closed.

Open/closed status window: it is a status window where the open/closed status of the breaker is
indicated.
Electronic protection unit: it is the unit that carries out the protective functions of the breaker. These all
are overcurrent functions. The unit processes the internal current measurements of the breaker and
trips it in case of an overcurrent above the settings. The unit has several adjustment dials to set the
protective functions parameters. With the current measurements the unit also displays the current
values at each phase and the neutral if present. The normal displaying of the unit is the current at each
phase or the neutral (if present). The phase displayed can be changed by pressing the button with a
right side pointing arrow on the unit.
CAUTION: DO NOT CHANGE THE PROTECTIVE PARAMETER SETTINGS. It can led to a lack of
protection of the machine or either a spurious and not desired tripping of the breaker.
When the circuit breaker opens with a high current as for example the one in a short circuit, there will be an arc
between the power contacts, and as it is an air circuit breaker (the arc extinguish medium is the air), the
chambers where the arc is extinguished have openings to the exterior. To reduce the arc flash these openings
have metallic meshes to chute the flash. On the following photograph are shown the arc chutes of a typical
breaker (placed on its top face):

CAUTION: DO NOT LAY ANYTHING ON THE ARC CHUTES. Potential fire hazard. Do not allow any liquid or
powdery substance to fall over them.
DANGER : Arc flash hazard in case of short circuit.

Dep. 3
IO-C-M-AP-001e A
May 2012

4/9

2.2. AUXILIARY SERVICES CHANGEOVER SWITCH
It is installed a changeover switch to change the feeding for the cabinet AC circuits and the auxiliary services of
the genset between the grid side or the generator side of the busbars the circuit breaker is attached to.

When the genset has the blackout starting capability (optional feature) and it is going to be carried out a
blackout start the changeover switch must be switched to get the voltage from the generator side.
CAUTION: A blackout start can only be carried out with the mains circuit breaker open.
2.3. AUXILIARY SERVICES CIRCUIT BREAKER
It is installed a smaller circuit breaker to protect the feeder circuits of the rest of the electrical equipment of the
genset as well as its auxiliary services.
The breaker has an appearance and the main characteristics and element as follows:
Dep. 3
IO-C-M-AP-001e A
May 2012

5/9

On the rating plate are reflected the circuit breaker model, ratings and standards compliance.
The toggle switch lever shows the circuit breaker status. When facing upwards the circuit breaker is closed.
When facing downwards are 2 possibilities: if it is on the full down position the breaker is open, if it is on a
middle downward position the breaker has tripped. In order to be able to close the breaker, it must be reset
by pushing the lever down to its lower position.
If the breaker has tripped, all of the circuits protected by the device must be checked to find out the failure that
has caused the breaker action, and remove the failure or isolate it.
A trip can be caused by 2 reasons:
An overcurrent detected by the built-in overcurrent protection unit
A trip command issued by the residual current relay by the circuit breaker opening release.
Rating Plate
Trip
pushbutton
Toggle switch lever
Toroidal residual
current transformer
Overcurrent
protection unit
Dep. 3
IO-C-M-AP-001e A
May 2012

6/9

The overcurrent protection unit is the electronic unit that watches the current levels and if necessary trips the
breaker according with its settings.
CAUTION : The settings left by the Guascor personnel must not be changed, doing so can cause
inappropriate tripping or feeder circuit or lack of adequate protection. This can represent an electric hazard.
Any change in the setting must be done by experienced and trained personnel only.
The toroidal residual current transformer is the measuring device to measure the residual current of the feeder
circuit of the cabinet devices and auxiliary systems.
The residual current transformer has the aim of detect a current derivation from a system phase that can led to
a dangerous voltage for the personnel. It has a safety function in a TT installation. All of the cables for the
circuit phases and (if present) the neutral must pass through the toroid. The secondary of the transformer is
connected to the residual current relay installed in the cabinet.
Trip pushbutton is a testing element that can be used to make the breaker trip to verify its operation. It is
recommended to make one testing trip once a year.
WARNING: a testing trip should be done with the genset stopped.
2.4. RESIDUAL CURRENT RELAY
The feeder circuit for all of the cabinet systems and the genset auxiliary systems has a protective system
against electric shocks which comply the IEC standards.
To ensure the protection against electric shocks in a TT system, it is installed a residual current relay which
makes trip the auxiliary services feeder circuit breaker when detects a residual overcurrent above its settings.
The relay would have the appearance as in the following photograph (the particular model can be different but
with similar features). To identify the relay, please refer to the electrical wiring diagrams where can be checked
the designation reference code that identifies each device on the diagrams and on the cabinet. Each device
has a yellow label stuck on the device with the designation reference marked on it.

Designation reference
label with the same
identification code as in
the electrical diagrams
Dep. 3
IO-C-M-AP-001e A
May 2012

7/9

CAUTION, IMPORTANT SAFETY INFORMATION: the safety of personnel relies totally on this
device in a TT system. It must be made sure that the device is connected and operating. It has a green lamp
with the label on on its right side that must be lit if the device is operating. DO NOT CHANGE relay settings
left by the Guascor personnel. When the device trips means an insulation failure in some place of the circuits
fed. The tripping is indicated by the red light with the label fault on its right side. It must be located the place
of the failure and isolated from the rest of the system. When a trip has happened, after the isolation of the
failing part, it is necessary to reset the relay by pressing its Reset button before the circuit breaker can be
closed again. It is necessary to carry out periodic testing of the relay by pressing the Test button.
For more information please refer to the relay manufacturer users manual.
3. ELECTRIC SAFETY
The design and construction of the cabinet is made in accordance with the IEC safety standards.
Manipulation of the internal part of the cabinet represents an electric hazard and must be carried out by
experienced and trained personnel only. There is SEVERE RISK of fatal injuries for personnel who do not
comply with these conditions. Any work to be done inside the cabinet must be done switching off the external
power infeed to it and making sure that no person can switch on the power until the works have been
completed (by blocking the external feeding breaker and signaling with the appropriate sign that works are
being carried out).
When must be carry out works inside the cabinet, the personnel making them must be equipped with all the
equipment necessary to ensure the working safety.
The correct operation of the protective system against electric shocks largely relies on the correct status of
the electrical earthing wiring system of the genset and their cabinets. It must be checked periodically (at
least once a year) the correct status of the earthing cabling bondings and the continuity of all conductive non-
live parts to the earthing system as per IEC 61439-1.
It must be also checked that the earthing busbars of the cabinet are wired to the plant earthing system. It
must be also ensured that the earth resistance value is below that which ensures the personnel safety (when
the plant has a TT system) by the operation of the residual current relay.
The module has 3 window-type current transformers to measure the current at the generator busbars, each of
their secondaries are cabled to terminals in this module. In the following photograph are shown the
transformers.
Dep. 3
IO-C-M-AP-001e A
May 2012

8/9

These terminals in turn are connected to the GPU-3 generator protection unit placed in the control module
(which is the device that measures the currents):

ELECTRIC HAZARD: with the genset working (generator coupled to the plant grid), NEVER
disconnect any wire connection in the current measurement circuits. That is to say NEVER open any of the
current measurement loops. Danger of injuries or even death.
It must be ensured periodically (at least once a year) that the wiring connections in the current measurement
loops are tight enough.
Current
measurements
input terminals
of the
protection unit
Dep. 3
IO-C-M-AP-001e A
May 2012

9/9

4. THERMAL MANAGEMENT
All the electric cabinets have means to remove the heat produced inside them.
It is important to make sure that the openings and means to carry out this function are enough clean and in
good conditions to remove the heat adequately.
This is more important when the control module for the genset is installed in the cabinet.
PRODUCT INFORMATION

INDEX

DATE

Dep. 3
IO-G-M-AC-001e
May 2012

GAS GENSET STANDARD CONTROL CABINET
HMI OPERATORS MANUAL

1/71

1. INTRODUCTION
The electrical control cabinet for a gas generator set is supplied with all the equipment needed to protect and
drive the electric devices needed to make the generator set work. The cabinet is set up with all the control
devices needed to control the generator set and its auxiliary equipment.
The control cabinet can be supplied either as a separate cabinet, or as a part in a bigger cabinet with a power
part or module and a control module joined as a whole.
On the right side door of the cabinet are installed the devices needed to interact with the operator.
In the following photograph is shown the cabinet door where the HMI and other devices seen by the operator are
installed:

The main device of this type is an operator dialogue panel. The operator uses it to display the status of the
genset and its auxiliary equipment, and to take control of all its elements. It is a graphical touch screen placed in
the cabinet door that works as a human-machine interface (HMI) for the genset.
Additionally on the same door, it is placed the terminal of the generator protection unit. It is a device that
includes all of the electrical functions needed for the synchronous generator protection, displays the main
electrical parameters of its electrical connection and is able to carry out the genset synchronization.
Another interacting device that is installed on this door, it is an ammeter in the top part that displays the current
measurement of the DC output of the rectifier-battery charger installed inside the cabinet that generates the DC
voltage and current needed by all the devices fed with this type of voltage.
To complete the interacting devices installed on this door, there is an emergency stop pushbutton that allows to
stop immediately the genset.
This manual describes the equipment and functions of this type of cabinet.
Operator dialogue
interface
HMI
Generator protection and
measurement unit GPU3
Emergency
stop
pushbutton
Ammeter for the DC ouput
current of the rectifier
battery charger
PRODUCT INFORMATION

INDEX

DATE

Dep. 3
IO-G-M-AC-001e
May 2012


2/71

1.1. GENERATOR SET OPERATION
A Guascor generator set can be configured either as a master or slave on a plant.
The actual status of the genset (master or slave) is displayed on the upper right corner of the HMI screen.
When there is only one genset in a plant, it must be always configured as a master.
A master genset must be always set when there is more than one GUASCOR genset in a plant and there is NO
plant control cabinet (it is mandatory to have one plant control cabinet when there are more than 3 GUASCOR
gensets within a plant, in which case all of the gensets have to be set as slaves).
The master genset has several tasks to carry out:
To control the generated active and reactive power by a particular working genset when islanding
(islanding operation is an optional feature of the Guascor supply).
To control the generated active power by a particular working genset when it is enabled and working the
control of the power exchanged with the mains (imported or exported) (the control of the power
exchanged is an optional feature of the Guascor supply).
To decide the gensets to be working on the economode operation and set the power to be generated by
each of them (economode operation is an optional feature of the Guascor supply).
1.1.1. Generator Set start and stop
The generator set has always 2 operation modes automatic and manual. To select any of them must be used
the operation mode selector located in one of the screens of the graphical human interface (touch screen) HMI.
* Automatic mode option: set the selector in the AUT position. The genset will start and stop automatically
by the PLC at the moments programmed with the HMI.
* Manual mode option: set the selector in the MAN position. The genset will start and stop using
START/STOP pushbuttons located in a screen of the HMI.
To start on manual mode, press the green pushbutton START until the green light with the label GENSET
RUNNING is on. The PLC disables the start button once the genset begins to start until the genset comes back
to a stop status.
To get a normal stop, push the STOP screen-button. If the generator is running unloaded it will stop
immediately. If the generator is working with load, pressing the button will start a stop sequence controlled by the
PLC.
Optionally, it is possible if the supply has this option to start and stop the genset from an external command from
other control system, either supplied by Guascor (plant control cabinet) or supplied by the client.
When this option is available, the genset can be set on remote operating mode to be commanded externally or
on local operating mode to be operated by its control cabinet.
When is to be used the Economode algorithm (optional) the gensets must be set on remote operating mode.
Economode is an algorithm to optimize the number of gensets working for a given amount of power to be
generated.
When the option to start from black out is available (optional), the genset can be set to be enabled black out
starts. When enabled, the operator can start the genset manually when there is a black out and the mains circuit
breaker is open, provided that the engine is pre-lubricated and there are no active alarms. To ensure the engine
pre-lubrication it is necessary to enable and configure the periodic pre-lubrications of the engine, to guarantee it
is always pre-lubricated and ready to a black start. For details on the configuration of periodic pre-lubrications
see section 3.1.10.1 on page 37.
To display more clearly the different operating modes, it is shown below a flowchart of the generator set
operation when there is voltage in the electrical grid of the plant.
PRODUCT INFORMATION

INDEX

DATE

Dep. 3
IO-G-M-AC-001e
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GENSET at Stand by
with grid voltage OK
Local or
Remote?
Manual or
Automatic?
Is there any Plant
Control Cabinet or
external starting
control?
Within a programmed and
enabled daily operating band
and no alarms?
External starting
command and no
alarms?
Manual starting command
and no alarms?
PRE-LUBRICATING
PRE- START
CHECKOUT
SYNCHRONIZATION
ON LOAD
Coupled within
specified time?
Lubricated?
START
OK?
STOP
NO
YES
Remote
Local
Automatic
Manual
YES
NO
NO
YES
NO
YES
NO
YES
NO
NO
YES
YES

When black out start is an available option and is enabled, and there is no voltage on the electrical grid with the
mains circuit breaker open, then it is possible to start the genset with a manual operator command by the
following operative sequence:
PRODUCT INFORMATION

INDEX

DATE

Dep. 3
IO-G-M-AC-001e
May 2012


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Genset at Stand by
and no voltage on
plant electrical grid
and black out starting
available
Enabled black out
starting?
Electrical conditions
OK and start manual
command (HMI)?
PRE-START CHECKOUT
STABILIZING
ON LOAD
(Islanding)
Voltage and frequency
within acceptable band?
Pre-lubricated
START
OK?
STOP
NO
YES
NO
YES
NO
NO
NO
YES
YES
YES
YES
Mains circuit
breaker open?
YES

A more complete and detailed list of possible states that would be displayed by the HMI is shown on page 10.
1.1.2. Generator circuit breaker operation
In a similar way that was described in the previous section, the generator circuit breaker allows 2 operation
modes to get its opening and closing manually or automatically.
* Automatic closing/opening: To carry out an automatic closing/opening of the breaker in the starting and
stopping sequences of the genset, the selector must be placed in the AUTO position. The maneuvers will be
PRODUCT INFORMATION

INDEX

DATE

Dep. 3
IO-G-M-AC-001e
May 2012


5/71

controlled by the PLC. The signals to close/open the breaker will be set automatically at the appropriate
moments by the appropriate devices.
* Manual closing/opening: When the selector is set at the MANUAL position, the breaker only closes or opens
when the operator press the corresponding button, provided that the genset is ready to carry out that operations.
The PLC checks for the conditions and only enables the buttons when the conditions are fullfilled.
It is necessary to point out that the closing of the breaker always is done after checking voltage in the network
side power connection. There are 2 possibilities:
There is voltage so the PLC asks for an automatic synchronization to the protection unit.
There is no voltage, so the closing of the breaker is controlled by the PLC and takes place only if the
generator is at its nominal voltage and frequency. This only could happen if blackout starts (optional)
are enabled (supposing the genset is prepared for this type of start and it is enabled by using the
appropriate objects in the respective screen of the HMI to enable this feature).
The closing is always carried out and supervised by the PLC, and after a synchronization when needed. It is only
carried out if the genset is enabled to be at load by the operator (paramater set in the HMI). The opening is
always done immediately and the genset goes to a no-load state running at nominal speed after the opening.
The genset remains in that state for a limit period of time, waiting again for a closing command. If this command
does not happen in the period available, the genset stops.
1.1.3. Emergency stop system
There is an emergency stop system for the generator set included in the cabinet. The emergency stop is
activated when one of the emergency stop pushbuttons is pressed.
By pressing one of the emergency stop devices, it is carried out an instantaneous stop and disconnection of the
generator, and an alarm is visualized in the HMI, making the horn noise. It is necessary to reset the alarm in
order to get the genset ready to start again.
2. GENERATOR MEASUREMENT AND PROTECTION UNIT GPU3
Every generator set control cabinet will be equipped with a protection and control unit for the synchronous
generator. This unit will receive voltage and current measurements to carry out the generator protection and its
synchronization.
As it has available the electrical measurements of the generator, they can be displayed in its terminal display.
Different electrical measurements both from the generator side and the network side of the circuit breaker are
available in different terminal menus.
The unit carries out the synchronization of the genset (the only appropriate way of coupling the machine to the
electrical grid, both in parallel to mains or on islanding when there are more gensets working). The unit changes
the speed of the engine to get the voltage of the generator match the voltage of the grid within some margins.
CAUTION : DO NOT change the parameters set in the unit during the commissioning. Changing the
parameters can led to serious damage to the machine. In case of being necessary to change any parameter,
please consult to the Guascor technical assistance service.
For more detailed information please refer to the unit users manual.
PRODUCT INFORMATION

INDEX

DATE

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3. OPERATOR DIALOGUE TERMINAL
The operator terminal unit it is a touch panel used as the human-machine interface (HMI) by the operator to
display the genset operation and select the operation modes and adjustable parameters.
It is communicated with the PLC, the device that carry out the control of the system.
It has a STN 5.7 colour display with analogue sensitive touching capability of resolution 1024 x 1024.
3.1. OPERATOR DIALOGUE TERMINAL SCREENS OPERATION
In this chapter are described the screens available in the HMI with their functionalities.
It is possible that the specific screens programmed in a particular supply would differ slightly from those showed
in this document but the changes will be slight and the functionalities would be basically the same.
3.1.1. Launch screen
This is the screen shown when the HMI is switched on or when it is pushed the house icon in any other screen.
Touching in any place of the screen makes the main menu screen to be displayed.

3.1.2. Conventions for the screen use
There are basically 3 types of controls to change the screen parameters, based on the type of the parameter:

Boolean parameters (only 2 states possible): normally this type of parameters is usually changed by a
toggle type pushbutton that toggles the status of the related variable. The actual status of the variable is
usually displayed within the button frame by text and usually also by the color which is filled up with.
Normally the pushbuttons are represented by an embossed box with shaded edges that mark the
sensation of relief or with an embossed edge. Consecutive pressing of the pushbutton toggles the status
of the variable and also toggles the appearance and the text within the button to display the alternating
values of the controlled variable. An example is shown below, where the enable control for the
import/export feature is set by a toggle pushbutton, and in the figure below the variable is off (the control
is disabled):

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In this status if the pushbutton is pressed once its appearance changes to the following figure:

and the variable has changed its value to on (control enabled). Consecutive pressings on the button will
alternate between the 2 status and visualizations.
For the control of a boolean parameter sometimes is also used a 2 position-selector type control,

Discrete parameters with more of 2 states: when a discrete variable has more than 2 states, usually is
used a selector type control to change its status among them with as many positions as states the
variable has. The selector is switched among its positions by pressing it and using a keypad that
appears then. The keypad has the keys Esc, up arrow, down arrow and Enter. The Esc key
makes the keypad to disappear without changing neither the selector nor the variable. The arrows
switches the selector through its positions and the Enter key saves the changes.

Numerical parameters: there are many parameters that are numerical values modifiable by the operator.
Usually they are within a textbox and usually the box is filled in blue. Pressing the box makes to appear
a numerical keypad to change the value as explained on the next section.
3.1.3. Numerical value insertion
When a box has a numerical value that can be changed by the operator, pressing the box makes to appear a
keypad in the screen like the one shown below:
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Pressing the Esc box makes the keypad to close without changing the related value in the original screen.
Pressing the left oriented arrow right below the value edition rectangle, clears one left value from the cursor
position. Pressing Clr clears all of the edition rectangle. Pressing Enter closes the keypad substituting in the
origin screen the original value by the inserted value.
In some cases right under the edition rectangle it is shown the value range allowed to be inserted by the
application, as below:

3.1.4. Main menu
On all screens except for the launch one, there is an upper part of the screen where there are a number of
elements fixed and a menu bar with buttons to access sub-menus. These sub-menus have their corresponding
pushbuttons to access the corresponding screens.
The fixed elements are the Guascor Power logo, a house icon which makes to get displayed the launch screen,
2 arrow icons that allow to change the buttons of the menu bar, the hour and date and the master/slave status of
the genset. The main menu area is shown in the figure below.

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When in a button there is a padlock on its left side that means the related submenu or screen is access
restricted and it will be displayed a screen for password insertion.
On next sections are described the menus and screens related with each button of the menu.
3.1.5. Generator menu
Pressing on the GENERATOR button in the main menu bar brings on a pull-down menu that is shown below:

Pressing on any of the buttons in the menu makes to be displayed the corresponding screen. The available
screens are described in the next sections.

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3.1.5.1. GEN 1 screen
When the button GEN 1 is pressed, the following screen is shown:

This is an informative screen where a number of parameters can be displayed.
The first objects shown in the upper part of the screen are two black fixed text boxes, the left one displays Auto
mode to indicate that below there are 2 text status displaying boxes when the working is set in automatic, and
the right one displays the text Genset Status, meaning that below the black box is another box which displays a
text that specifies the state of the genset.
Below the left side label with the text Auto Mode when this mode is set, are 2 state rectangle boxes. The one is
just below the referred label shows either if the genset is in one of the time bands established for automatic
starting or not and in the bottom one it is displayed an indication if there is or not external starting command
(when this command is possible).
The possible states of the genset displayed below the textbox with the label Genset Status are the
following ones:
- DAMAGE: the genset is stopped because of a severe alarm that hasnt been fixed and/or acknowledge.
- STANDBY: the genset is stopped, no stopping alarm active and ready to start.
- PRELUBING: it is being carried out an engine lubrication before its start.
- CRANKING: the genset is started by the cranking motor until the normal firing of the cylinders and the idle
speed is reached.
- IDLE SPEED: the engine is at idle speed (there is a threshold speed specified to evaluate if it is at idle
speed).
- IN NOMINAL RPM: the genset raises it speed to get it within an interval around the nominal speed.
- STABILIZING: the genset is at nominal speed and must stay within specified limits of voltage and frequency.
- SYNCHRONIZING: the genset has stabilized and the synchronizer is working in order to close the circuit
breaker when the needed conditions are fulfilled.
- ON LOAD: the generator breaker is closed, the genset is connected to the power grid and generating power.
- TRIPPING: the genset is reducing the power until it reaches a specified value and then the circuit breaker
opens.
- UNLOAD: Genset is disconnected from the grid and and keeping its speed with its breaker open.
- STOPPING: the genset is disconnected from the grid and reducing its speed to get a total stop state
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- TIME BETWEEN CRANKS: a wait time after a failed crank attempt before a new attempt is made.
- SYNCHRO FAILURE: when it is carried out a synchronization maneuver and the time specified to be done is
elapsed, the genset goes to this state.
The other parameters that can be checked in this screen in the blue background area are described below
(identified by their labels in underlined italics):
Genset C.B. status which is the label for a text box that displays the status (open or closed) of the
generator circuit breaker
Working Mode: in this box is displayed either ISLAND or PARALLEL TO MAINS depending on the
state of the mains circuit breaker. Allows to know if the plant is connected to mains while the genset is
working (if it can work in island mode).
Genset Running: if the genset is working the squared box next to the right of the label is in green color
and the next box displays the rpm value of the genset.
Power Set point: in the box next to the label is displayed the genset power set point in kW.
Power Generator: in this box is displayed the actual power generated by the genset in kW.
Partial Hours: in this box is displayed the number of hours with the genset working (running above a
specified speed) elapsed since the last time this counter was reset.
Total Hours: the total number of hours the genset has been working since its installation.
Generated Energy total value of the energy in kWh generated by the genset since its installation.
Finally in this screen there is a rectangle with white background where can be checked the state of the variables
described below identified by their screen labels (in underlined italics). These are on/off variables and when they
are active (true) the squared box at their right is filled with red color. When they are not active are colored as
shown in the above figure. Now the description of the variables (the first four ones are alarms and the last two
are state-indicative):
Fast Stop Al. it activates when the genset has disconnected and stopped immediately because of a severe
alarm.
Genset Al. it activates when the genset has any type of alarm. When the Fast Stop Al hasnt been activated
the alarm is not severe (a warning).
Mains Al. it activates when there is an alarm with the connection of the plant to the mains.
EGS Al. it activates when the engine control unit activates an alarm digital output. This can happen either by a
major (shutdown) alarm or a minor alarm. A major alarm will make the genset to immediately stop. In the HMI
there will be an especific alarm message when the EGS activates its major alarm output.
Last 2 status boxes are displaying if there is any genset power derating (reduction) due to an excessive cooling
water temperature or intake air temperature. When there is no regulation (no derating) the box is white, and
when the regulation is working (power derating) the box is red.
Water Reg. it activates when the genset is derating due to an excesive cooling water temperature.
Intake Reg. it activates when the genset is derating due to an excesive air intake temperature.
3.1.5.2. START/STOP screen
From this screen the operator sets the genset operating mode for its start and stop, manual or automatic and in
manual the operator can start and stop the genset.
3.1.5.2.1 Genset with no remote start/stop capability and NOT Economode operation available
When there is no remote start/stop possibility (for example by a signal from Plant Control Cabinet or when it is
supplied and working the Economode mode of operation (both optional)), the start and stop requests are
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given by the genset own control system exclusively. The screen for the manual start/stop requests or the
start/stop configuration is shown below:

Two labels identify the maneuvers for the genset and for the genset circuit breaker (Genset C.B.)
When the selector buttons are in MANUAL mode the START/STOP and OPEN/CLOSE pushbuttons are
operative.
Pressing the OPEN button makes the circuit breaker open and the genset goes to the unload state (if its speed
does not increase over the stopping limit). At the unload state, pressing the CLOSE button makes the genset to
do a synchronization. The unload state lasts a limited period of time (see UNLOADED TIME on pag. 23), after
which the genset stops.
If it has been carried out a genset starting and the genset is at nominal rpm, the CLOSE button can be pressed
to carry out a synchronization.
It is also possible to close the circuit breaker if there is a blackout, the blackout start (optional feature) is
enabled and the electrical nominal conditions are fulfilled.
It is highly recommended to set the operating mode of the circuit breaker in the automatic position (displaying
AUTO).
Pressing both pushbuttons they toggle to the automatic mode:

Right below the manual operation buttons there is a row of numerical boxes to display some numerical values,
the 2 first ones are optional:
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Gas Pres. [mbar] (if this measurement is available): optionally when the genset consumes a biogas or
a synthesis gas, it can be supplied with a fuel gas pressure measurement in mbar which is displayed in
this box.
%CH4: similarly if in the Guascor supply is included a fuel gas analyzer that includes the measurement
of CH4 concentration, then the % of this compound in the gas is displayed in this box.
RPM: in this box is displayed the measurement of the engine speed in Revolutions Per Minute.
Below the row of numerical parameter boxes there is a text display box which shows the genset state.
On the right side of the previous text box there is a display of the prelubed status of the genset (YES or NO)
with the text label Gen. prelubed.
NOTE: Only a prelubed engine can be started in manual mode.
3.1.5.2.2 Genset with remote start/stop capability or with Economode operation available
When there is remote start/stop possibility (for example by a signal from Plant Control Cabinet), this screen has
another additional selector pushbutton. This selector allows to select between local configuration/operation and
remote (by a remote controller through a signal or communication variable from that controller).
The start and stop requests are given by the genset own control system when the midpoint selector pushbutton
is set in LOCAL position, and by an external signal when is in REMOTE position. Pressing the button toggles
the selector state. The screen for the manual start/stop requests or the start/stop configuration is shown below.

When the selected mode is LOCAL, the screen is the same as in the previous section.
When the selected mode is REMOTE, the screen toggles to the format shown below:
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And the genset start/stop and the control of its circuit breaker are fully controlled by the remote signals.
When the generation plant supplied by Guascor is supplied with the Economode (optional) operation mode, it
will be displayed on this screen an additional pushbutton that makes to be displayed a screen to configure this
operation mode as follows:

The pushbutton is the squared one on the bottom right corner of the screen, with the text ECO inside.
The screen to display or modify the status of this mode of operation is described on section 3.1.5.6 on page 18.
3.1.5.3. Genset instrumentation screen (Instrument.)
Pressing in this pushbutton an informative screen is shown where are displayed several parameters of the
genset instrumentation, most of them engine temperatures and pressures. It can also be displayed the voltage of
the batteries.
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OPTIONALLY there could be other tabs, depending on the Guascor specific supply:
When it is supplied a temperature sensor kit (optional) to measure the cylinders exhaust gas outlet
temperature, there will be a tab with the label CYLINDERS which when pressed makes to be displayed
the following screen (the actual number of cylinders will depend on the specific engine model).

When it is supplied a temperature sensor kit to measure the temperature at the stator coils of the
synchronous generator (optional), there will be a tab with the label ALTERNATOR which when
pressed makes to be displayed the following screen.
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Optionally if the genset is supplied with a gas analyzer (optional), there will be another tab with the label
GAS which will give access to another screen where will be displayed the percentage concentrations
of some compounds in the gas.

3.1.5.4. Instrumentation trending screens (Inst. Trends and Gas Trends the latter one optional)
Pressing the button Inst. Trends shows a screen with several tabs, each of them makes to be shown a
graphical screen with the trending evolution of some instrument measurement described in the previous section.

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As in the previous section, if it is supplied the optional compound measurements with a gas analyzer, there will
be another pushbutton with the label Gas Trends which shows another screen with its corresponding tabs, one
for each of the compounds. Below it is shown the appearance of these screens.

3.1.5.5. CAN communication
The last pushbutton of the GENERATOR menu has the label CAN communication. Pressing this element
makes the HMI show a screen displaying the status error of the nodes of the CANopen bus.
It displays 2 columns, the left one with the title DEVICE shows the name of the device connected to the
CANopen bus, the right one with the title NODE displays the number of the node in the bus and if the node is
OK or not (with its color).
In red color are displayed nodes in error and in green color nodes communicating correctly.

In the above figure there is an error in the communication with node 5, PT-KIT C1-8 (device that collects the
signals from the temperature sensors of the engine cylinders from 1 to 8).
NOTE: depending on the actual network configuration and the existing devices the number of nodes displayed
may be different and it is possible that would not appear some of the devices displayed on the figure above.
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3.1.5.6. Economode screen (optional feature)
When the plant gensets are supplied with the Economode mode of operation included, there will be another
screen on this sub-menu named as Economode and it can also be displayed by pressing the respective button
on the sub-menu or by pressing the icon on the START/STOP screen (see page 14).
This mode of operation can be supplied when there is more than 1 Guascor genset working in the same plant,
and it can be configured in one of the gensets (the one configured as master) when it is not included a plant
control cabinet in the Guascor supply. Its aim is to optimize the working of the gensets when there is a restriction
in the overall amount of power to be generated by the plant:
When islanding because generated power must match consumed one.
If it is demanded the control of the amount of power exchanged with the external electrical distribution
grid, both exported or imported.
The algorithm makes work only the gensets needed to generate the amount of power demanded by the
electrical loads and if it is controlled the exportation or importation of power, the setpoint of power exchanged
with the mains stated by the operator. The working gensets generate the same amount of power, i.e. share
equally the required load. The gensets are started in a working hours basis, so first is started the genset with
less working hours.
Only gensets with REMOTE mode of operation can participate in this mode, see section 3.1.5.2.2 on page 13.
NOTE: this mode of operation is only meaningful when all of the gensets are enabled to participate and so
configured with the REMOTE mode of operation.
There are 2 different possibilities, the genset configured as SLAVE or as the MASTER.
The screen in case of the genset to be a SLAVE is the following one:

On this screen there is no object to make commands and are displayed on the upper part only several boolean
(on/off) status pilots of the operation mode:
EXPORT CONTROL: a pilot that indicates the control of active power exported algorithm is working
(when green). To enable this operation mode (only in the MASTER genset HMI) see section 3.1.7.1 on
page 25.
IMPORT CONTROL: a pilot that indicates the control of active power imported algorithm is working
(when green). To enable this operation mode (only in the MASTER genset HMI) see section 3.1.7.1 on
page 25.
ISLAND OPERATION: a pilot that indicates the Economode algorithm is working and the plant is on
islanding operation (when green).
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RUN COMMAND: a pilot that indicates the Economode algorithm is working and the genset is being
commanded (when green) to generate power.
The screen in case of the genset to be the MASTER and ECONOMODE is not enabled is the following one:

To enable the algorithm to work (only if the genset is the MASTER) the toggle pushbutton with the labels
ECONOMODE OFF/ECONOMODE ON must be pressed to get displayed the text ECONOMODE ON on it.
When the operation mode is enabled it is displayed the following screen:

On this screen are displayed the same pilots as in the previous case and additionally are displayed other several
objects described below.
Below the toggle pushbutton, in first place, there is a row of changeable parameters inside blue blackground
boxes with its labels on black background boxes on their left side:
SP %: it is the setpoint of the active power in % of their nominal to start a additional genset. When the
working gensets have to generate more active power than the set on this parameter, an additional
stopped and available genset is started to generate power.
Hist. %: it is the amount of active power in % of their nominal of the band that make no changes in the
number of gensets generating power. The band is between (SP Hist.) (lower limit) and SP (upper limit).
When the working gensets have to generate less power than SP Hist. during the time set in the TIME
TO STOP parameter, one of the gensets (the one that has more working hours) is stopped.
TIME TO STOP: it is the time in minutes that the working gensets must be generating active power

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Then there is a column of non-changeable parameters (not on this screen) with the following meaning:
IMPORT/EXPORT SP: it is the setpoint for the whole plant active power import or export control. The
type of control is displayed with the pilots in the top part of the screen. The import or export control mode
can be set on the MASTER genset on the screen (restricted access) described on section 3.1.7.1 on
page 25.
STOP SP: it is the amount of active power in kW that if the active power generated by each genset is
below it during more time than the specified in TIME TO STOP, makes stop one of the gensets.
RUN SP: it is the amount of active power in kW that if the active power generated by each genset is
above it, makes to start another genset.
ACTUAL POWER: it is the active power generated in kW by all working gensets in the plant.
MAINS POWER: it is the active power exchanged with the mains in kW. When it is exported has the
minus sign.
3.1.6. MAINS menu
It is access by pressing MAINS pushbutton in the main menu button bar. This menu has 2 screens that are
described in the succeeding sections.

3.1.6.1. Mains screen
In this screen is shown a very simplified one line diagram of the electrical network of the plant, displaying
basically the most significant circuit breakers of the network and the power generated by the genset. Breakers
closed are displayed in red color and open in green color.
There is an icon in this screen that shows if there is voltage in the network which the genset is connected to.

Voltage presence icon
Case of no voltage
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3.1.6.2. Loss of mains
In this screen is displayed a list with a series of last occurrence of a loss of mains event. In the right side there is
a counter which displays the total number of this type of events since the genset commissioning.
This type of electrical phenomena is a mains event detected by the generator protection unit which is potentially
dangerous to the generator if it is kept connected to the mains. It cannot be done nothing to avoid it, and the
proper action is to immediately disconnect the genset or the plant from the mains, as it is done by the control
system.

3.1.7. General Parameter menu
This menu is restricted to authorized personnel only and its access is password protected. This is because in
these screens several important genset parameters can be changed.
When the pushbutton with the label GENER. P. in the main menu button bar is pressed it is showed the
password insertion screen below:
Voltage presence icon
Case of voltage OK
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To insert the password, it must be pressed the square box with 3 asterisks inside. A numerical keypad is shown
to insert the password (after insert the number, it must be pressed enter). Then it is displayed a pushbutton with
the label Continue and when pressed the complete menu is shown as below:

- General Parameters.
- Island selection
- Rpm/voltage/reactive power regulations
- Power regulation
- Daily Running permission
- Date/hour change
- Start from zero
- Authorized Personnel (restricted access)

On the following sections are described the sub-menus listed above.
3.1.7.1. General Parameters (Gen. P. 1 pushbutton)
When pressed the button with the label Gen. P. 1 is showed the first screen of a group of 3, labelled as
GENERAL PAR. 1, GENERAL PAR. 2 and GENERAL PAR. 3. The user can toggle among the screens by
pressing the green arrow icons on the right side of the screen.
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In these 3 screens the following parameters can be changed by pressing the blue box at its right to insert a
numerical value in it (and then press enter).
GENERAL PAR. 1 tab:
Stand by time: the time in seconds that the genset must be at a standstill after a normal stop, until it is
allowed to be started again.
CRANKING TIME : it is the time in seconds that the PLC remains to check out that the genset is
already started (by checking the genset speed) after the PLC begins to start the genset. When this time
has elapsed without a successful start. The PLC waits until trying again to start the genset. The PLC
only tries to start 3 straight times and if it is not successful in doing it, gives up and sets an alarm.
TIMINING BET. CRANKS: when the genset fails to start, the PLC waits this time (in seconds) until it
tries to start the genset again. The PLC only has 3 attempts to start the genset. If they are used up, an
alarm will be shown.
IDLE SPEED TIME: after the genset is already started, it is kept at idle speed the time set in this box in
minutes.
STABILISATION TIME: it is the time that the genset is allowed to carry out a synchronization or a
controlled closing of the circuit breaker if it is being performed a black out start.
UNLOADED TIME: is the time in minutes (despite the text shown on the screen) that the genset is at
nominal speed with its circuit breaker open (unloaded) in order to let its temperatures to get down in a
softer way. This is the state called UNLOAD.
GENERAL PAR. 2 tab:
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Stop time: it is the time in seconds that the genset takes to go from the unloaded status to a
completely stop.
Loads Trip Time Island: it is the time in seconds that the genset waits before tripping a load switch or
breaker when it is at island status, it is necessary and has the signals needed to make the trips. When it
is able to trip more than one switch or breaker is also the time between consecutive trips.
Load speed: it is the rate of generating power increase in kW/s that the genset will make after getting
on load or after a change in the power set point, only when is in parallel to the mains.
Gen power Decrease. with normal alarm : it is the rate of power decrease when a warning alarm is on.
Gen power Decrease. with normal stop : it is the rate of power decrease when a normal stop sequence
its active.
GENERAL PAR. 3 tab:
When there is a plant control cabinet or the genset is set as a slave, the screen shown in this tab is the one
below:

Reduced power maximum time: it is the time in minutes that the genset is allowed to generate less
power than the specified in the next parameter Reduced power [kW]. It is only taken into account when
connected to the mains. When it is below this power more time than it is set, the genset goes to a
normal stop by the alarm.
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Reduced power: when the genset is generating less active power than this value (in kW) during more
time than the specified on the previous parameter, an alarm is set and the genset makes an ordinary
stop.
Manual load set point: it is the power set point in kW the genset must generate, either in parallel with
the mains (see Power Setpoint on page 11) or at base load mode being in island (see Baseload
mode on page 27).
Active power: it is NOT a changeable parameter, it is the actual active power generated by the genset
at that time.
When there is NO plant control cabinet and the genset is set as MASTER, if it is included in the Guascor
supply the control of the power interchanged with mains, there will be another 3 more controls on this screen as
shown below:

It will be displayed a 3-state selector with the states OFF,IMPORT and EXPORT that allow to set if it is
going to be carried out an import or export active power control algorithm. Those algorithms let the operator to
choose either generate with the genset the active power set in the Manual load setpoint (at the OFF position)
or to control the active power imported from mains (IMPORT position) or the active power exported to the
mains (EXPORT position).
The parameter Import Power is the power the plant must import from the mains, and the working gensets
control the active power they are generating to achieve this goal dividing equally among them the power to be
generated. This is the way of working and the setpoint active when the selector is at IMPORT position.
In a similar way, Export Power is the power the plant must export to the mains, and the working gensets control
the active power they are generating to achieve this goal dividing equally among them the power to be
generated. This is the way of working and the setpoint active when the selector is at EXPORT position.
3.1.7.2. Island operation / Load sharing mode (only for supplies with this optional feature)
In these set of 2 screens it is configured the way of working when there is an alarm related to a fault or a
disturbance detected in the mains connection.
There are 2 possibilities:
1. it is not supplied a plant control cabinet and the genset is set as a master:
Then it appears the screen below, with 4 label boxes, ISLAND SELECT, Mains C.B., WORKING MODE,
FORCE PARALLEL which identifies the function of the elements they are referred to.
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ISLAND SELECT: identifies a selector object that allows to select between island mode enabled or not. When
the selection is YES any alarm from the protection unit related with a problem with the mains connection
(mains alarm) trips the mains circuit breaker. When the selection is NO trips the generator circuit breaker.
When the selector is set in YES position and the mains circuit breaker trips, the genset generates only the
power necessary by the demand of the plant.
Mains C.B. (optional, only if it is included in the supply islanding of the plant, and it is available the control of
the mains circuit breaker to the MASTER genset): identifies 3 toggle pushbuttons below the box. The one
labelled as MANUAL or AUTO right below the box, allows to toggle between both modes. When in AUTO
the genset carries out a synchronization automatically with the mains circuit breaker when islands are enabled.
This is done when the circuit breaker has opened and after that there are no mains alarms active. When in
MANUAL the genset carries out a synchronization only when the close button is pressed (again it is required
the absence of mains alarms). When the plant is in parallel with the mains and the island mode is enabled,
pressing the OPEN button opens the circuit breaker.
FORCE PARALLEL MODE: this is an optional control and not always is displayed. With this toggle pushbutton
in PARALLEL the genset control system behaves as if all the chain of circuit breakers from the genset to the
mains were closed (ignoring the actual status of the signals). This let the genset to synchronize and work without
checking out the actual status of the circuit breakers apart from that of the genset. It is assumed that there is
voltage upwards of the generator circuit breaker. This mode is planned to use only for commissioning and
checks of the system.
WORKING MODE: is the label for a pushbutton with a green arrow inside it that makes to be displayed a
screen described next in this section, in which it is possible to set the regulation modes when islanding.
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2. it is supplied a plant control cabinet or the genset is set as a slave:
When the genset is a slave or there is a plant control cabinet, the screen displayed is as below:

And only are accessible the WORKING MODE pushbutton and optionally if it is enabled the FORCE
PARALLEL MODE toggle button.
When pressing the button with the label WORKING MODE and the green arrow in the left bottom part of the
screen, it is displayed the screen below:

This screen is entitled WORK MODE SELECTION ISLAND, and has 2 selectors with 3 positions each.
The left one with the label ACTIVE POWER lets to select the active power regulation mode of the genset when
working in island and there is more than 1 genset working. It has 3 positions:
0- Isochronous load sharing: the load power of the plant is equally shared among the gensets working at
that moment also in this mode.
1- Baseload (Power setting): the genset tries to generate always the same power set in the GENERAL
PAR. 3 tab. There must be at least another genset in mode isochronous. When this setting is used,
the genset will generate the reactive power set on the screen REACTIVE REG. described on page 28.
2- Frequency Droop: the genset lowers or raises its generated power depending on the changes in
frequency. More the frequency lower the power and vice versa There must be at least another genset in
mode isochronous.
The selector on the right side with the label REACTIVE POWER lets to select the reactive power regulation
mode of the genset when working in island and there is more than 1 genset working. It has 3 positions:
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0- Reactive load sharing: the reactive power load of the plant is equally shared among the gensets working
at that moment also in this mode.
1- Cosphi setting: the genset tries to generate always the power with the same power factor as set in the
middle tab with REACTIVE REG. label of the set of screens accessible by the PID V/kVAr/rpm
pushbutton (see cos fi parameter on page 29). There must be at least another genset in Reactive load
sharing mode.
2- Voltage Droop: the generator lowers or raises its excitation depending on the changes in voltage. More
the voltage lower the excitation and vice versa. There must be at least another genset in mode
isochronous.
3.1.7.3. Voltage/reactive power/rpm PIDs (PID V/kVAr/rpm)
When pressing the button with the label PID V/kVAr/rpm it is displayed the following screen:

It can be accessed a set of 3 screens by mean of 3 tabs. Each screen is for the configuration of each of the 3
following PID regulations: Voltage, reactive power and active power.
In each of the screens can be changed the PID parameters SP, Kp, Ti and Td as explained on section 3.3 on
page 71. Also in every screen is displayed the actual current status of the regulation (working (YES) or not
(NO)) on the right side of a text label within a white filled box on the bottom part of the screen.
Next are described each of the screens:
VOLTAGE REG.: in this screen can be set the parameters for a PID working over the time slot
previous to the generator circuit breaker closing or in islanding. This PID regulates the voltage given by
the generator and the numerical parameters in the blue boxes can be changed as in a standard PID of a
PLC. This PID regulates the reactive power generated by the generator in islanding situation actuating
on the signal given to the automatic voltage regulator of the generator.
REACTIVE REG.
When pressing the tab it is displayed the next screen:
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In this screen the numerical values of a standard PID can be changed. This PID regulates the reactive power
generated by the generator in parallel to the mains, actuating in the signal given to the automatic voltage
regulator of the generator.
The Island Mode button lets to go to the WORK MODE SELECTION ISLAND screen described on page 27
where the working modes on islanding can be changed.
The MAN/AUTO pushbutton makes to be displayed the following screen:

The MANUAL/AUTOMATIC pushbutton toggles the regulation between both modes. When in MANUAL as
in the figure the set point for the regulation is the one set in the blue box with the label cos fi at the top of the
screen. The number must be between 0.8 and 1 as it is a power factor value. The pushbutton on the right with
the IND. (or CAP. toggling between them) label toggles the value in the blue box to be inductive or capacitive
power factor for the power generated by the genset. When the power factor is inductive, the generator gives
reactive power to the grid and the output current lags the voltage. When the power factor is capacitive, the
generator takes reactive power from the grid and the output current leads the voltage. Since there is a stability
limit for a synchronous generator when it is taking reactive power from the grid, the control system limits the
capacitive power factor to a minimum of 0.96 to avoid the genset to enter in unstabiltity.
In the bottom part of the screen there is a white lined box with the label AUTOMATIC where the paramaters for
the AUTOMATIC mode can be changed. These parameters are arranged in a table manner. The rows of the
table indicate the time band (TB) of the day in which the data is used. There are 3 time bands, and it can be set
the start and end time of each band in the first 2 columns. In the third column it can be set the set point value of
the power factor for each band. And in the latter column there are pushbuttons to toggle the value between
inductive and capacitive with the same meaning as stated above.
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The PID button lets to come back to the previous screen where the PID parameters can be set.
REG. rpm tab:
When pressing the tab it is displayed the next screen:

On this screen can be set the parameters of the PID that regulates the active power generated by the genset on
islanding when there is at least another genset working. The boxes in the column on the left side are only to
display the actual values used by the PID. The blue boxes in the column on the right let to change the PID
parameter values Kp, Ti and Td. Again, there is an Island Mode button that lets to go to the WORK MODE
SELECTION ISLAND screen described on page 27 where the working modes on islanding can be changed.
3.1.7.4. Power derating screens (OPTIONAL, Power Regulations button)
When it is included in the supply a power derating (optional) by cooling water temperature or air intake
temperature there will be a screen like this in the HMI.
This button get access to 2 screens, WATER REG. and INTAKE REG. accessible by 2 tabs as is shown
below:

In these screens there are several configurable parameters.
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WATER REG. screen:
In this screen the operator can enable and configure a genset power derating because a too high temperature of
the outlet water of the engine cooling circuit.
The controls of the screen are described next.
water regulation: it is the label of a push button that toggles between YES or NO. When YES is
displayed, the regulation is enabled. Pressing the button the regulation is disabled and so forth.
Gen. Exit Water Temp: in the white box is displayed the actual value of the outlet cooling water
temperature, measured from the circuit. It is only a visualization value not changeable.
Set Point: in the blue box on the right can be set the temperature over which the regulation starts and
works until it is stopped.
Histeresys: it can be set the differential temperature band below the set point in which the regulation
still works. When the temperature goes down below the value resulting of subtract hysteresis from the
set point value, the regulation stops until the temperature would go again over the set point.
Time between impulse sheddings: here the operator can set the value in seconds for the time elapsed
between derating pulses. In each pulse the genset decreases its generated power in 1 kW.
Working: on the right of the label there is a box that displays the working status of the regulation cycle.
If it is working the box is red and displays YES, and if not is green and displays NO. To be working
means that in that moment engine power control is receiving derating pulses with the elapsing time
described in the previous parameter.
INTAKE REG. screen:
In this screen the operator can enable and configure a genset power derating because a too high temperature of
the inlet air to the engine, at the outlet of the air filter.

The controls of this screen are described next.
Filter Temp. regulation: it is a push button that toggles between YES or NO. When YES is
displayed, the regulation is enabled. Pressing the button the regulation is disabled and so forth.
Filter Temp.: in the white box is displayed the actual value of the air temperature, measured from the
filter outlet. It is only a visualization value not changeable.
Set Point: in the blue box on the right can be set the temperature over which the regulation starts and
works until the temperature drops under this value.
% Derating C: here the operator can set the value in % of the engine power set point that the set point
for the power regulation control is decreased for each 1C the actual temperature is over the set point.
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Working: on the right of the label there is a box that displays the working status of the regulation cycle.
If it is working the box is red and displays YES, and if not is green and displays NO. To be working
means that in that moment the regulation is enabled and the actual air temperature is over the set point,
so the engine power control is receiving a derated set point under the one set by the operator.
3.1.7.5. Daily scheduled working (Running perm. button)
In this screen can be scheduled the daily automatic working of the genset.

This scheduling works only when the automatic start mode of the genset is enabled (see START/STOP screen
on section 3.1.5.2.1 Genset with no remote start/stop capability on page 11).
There is a toggle pushbutton for each day of the week, that lets to enable (YES) or disable (NO) the
automatic start and stop of the genset on that day.
On every day the automatic operation is enabled, 2 time bands (TB1 and TB2) can be set for the working
timetable of the genset, although it can be used only one of them.
For each of the 2 bands, the start and stop hours can be set, typing the values in the blue boxes.
3.1.7.6. Date/hour change screen (Change hour button)
In this screen the date/hour of both the screen and the PLC can be changed. Also the values that the PLC has
for date and hour can be checked (to check if they are different from that of the screen).

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To change the values in the white boxes, the only thing to do is pressing the box and then type the value.
3.1.7.7. Start from a blackout (OPTIONAL)
In this screen the genset can be enabled to start from a blackout if the genset is supplied with this feature
(optional).

Pressing the selector icon the selector toggles is position. If it is set in YES then in case of a blankout the
genset will accept a starting command with the busbar to which is connected without voltage. The starting
command can be made in the START/STOP screen.
3.1.7.8. Authorized personnel screens
The access to these set of screens is password protected since is for authorized personnel only.

This pushbutton let to access a restricted access screens, and makes to be displayed the respective password
insertion message. These screens let change parameters that only can be changed by trained Guascor
personnel and its modification by non skilled personnel can led to serious damage to the engine so its access is
not allowed.
3.1.8. Alarm management
Pressing the button ALARMS in the main menu, it is displayed a pull-down submenu with 2 buttons, Alarms
and Historic.

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3.1.8.1. Alarms screen
Pressing the Alarms button makes to be displayed a screen with a listing with the active alarmas and 3 buttons
to reset (acknowledge) different types of alarms.

In the white box in the upper left part of the screen with a pointing downwards arrow grey box on its right side is
displayed and can be selected the type of alarms that are displayed in the list. The selection can be made
pressing the downwards pointing arrow icon, that makes to pull-down a white box where are displayed the text of
the respective selection of the different alarm types.
It can be displayed all type of alarms but also can be displayed specifically alarms generated by the EGS
(EGS_ALARMS), by any part of the genset system (Gen Alarms) or specifically alarms generated by the
detection of electric problems related with the electric connection with the mains (Mains Alarms). And finally
can be displayed all type of alarms that can be generated by the control system (*All Alarms).

Alarm type
selection box
Alarm type list
pulldown button
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With the pushbuttons on the right side of the alarm type selection box, the operator can reset (acknowledge) the
alarms generate by the genset or by the electric connection with mains, and can stop the horn making noise.
Pressing on the arrows on the right side of the screen pointing upwards and downwards the operator can move
through the listing.
3.1.8.2. Alarms log screen
With the Historic pushbutton can be displayed a screen with the list log of alarms ocurred in the system with
the same screen format as the previous case but without the reset buttons. In white background are displayed
those alarms still active and in grey background those that not.

The log has a limited amount of memory and when it is exceeded the oldest alarms are cleaned as the new ones
are logged.
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3.1.9. Partial hours configuration (PARTIAL HOURS button in the main menu)
When pressing the button with the label PARTIAL HOURS in the main menu it is displayed a password
insertion screen since this is a restricted access screen.

When the correct password is typed it is displayed the following screen:

In this screen there are 4 parameter objects and 1 pushbutton. Next it is the description of each of them. The
parameters are described next:
The first parameter is for displaying only and has the label Total hours. It shows the total number of
hours that the genset has been working since its installation.
Partial hours: the number of hours the genset has been working since the last time a reset of this
quantity was made (by the pushbutton in the lower part of the screen).
Alarm working hours: it is a configurable parameter pressing in the blue box. It is the number of hours
the partial hours counter has to reach to set the related alarm. This alarm will stop the genset.
Warning working hours: it is a display-only value and it is the number of hours since the last reset, i.e.
the partial hours number that when exceeded the control system will display a warning of that condition.
With the RESET pushbutton, the partial hours counter will be reset to zero.
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3.1.10. Auxiliary services (AUX. SERV. button)
Pressing the button AUX. SERV. in the main menu, it is displayed a pull-down submenu with several buttons,
that give access to screens where can be configured the auxiliary services of the engine.

Not all of the buttons shown will be available in every application, that will depend on the specific supply and if it
is included that auxiliary service in it.
Next are described all of the screens accessible from this menu:
3.1.10.1. Prelube pump
In this screen can be configured the working of the prelube pump of the engine.

The selector on the left side of the screen lets to set the pump working in manual or in automatic mode.
With the selector at 0 position, the pump remains stopped.
With the selector at MAN position, the pump is started and left working continuosly unless the genset start, in
which case stops, changing automatically the selector to the AUTO position.
With the selector at AUTO position, the pump will start and work during a period of time previously to an engine
automatic start (by time bands in daily schedule, see section 3.1.7.5 on page 32). When the engine starts the
pump will stop.
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If the CICLIC OFF/CICLIC ON toggle pushbutton is in on position (in green color), the pump will start and
stop automatically during scheduled time periods when the genset is stopped and the selector set in AUTO.
Then in the white boxes with the label above them REMAINING TIME TO START, it will be displayed the time
remaining to the next pump start.
In the text boxes with the labels Status and Prot. will be displayed respectively the working status of the pump
(YES and green color if working and NO and red color if stopped) and the status of the electric protections of
the pump (NO if protections OK and YES if tripped).
3.1.10.2. Cooling circuit pumps (optional, Circ. water pump button)
This screen allows to set the manual or automatic operation of the water pumps of the engine cooling circuits.

The selector object on the left side of the screen controls the operation of the main cooling circuit pump and the
selector on the right side controls the operation of the auxiliary cooling circuit pump.
With the selector at 0 position, the pump remains stopped.
With the selector at MAN position, the pump starts and remains working until the selector is set in another
position. With the selector at AUTO position the pump will start automatically when the genset is going to start
and will stop automatically some time after the genset stop.
For each pump are displayed 2 objects with the working status of the pump and the electric protections of its
feeding, as in the previous screen.
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3.1.10.3. Aerocooler fans (optional, Aero Fan button)
When aerocoolers are supplied (optional supply) with the genset to extract the heat from the cooling circuits, the
control of their fans can be configured in these screens. The control of the fans will be doing in pairs, each pair
will have their own controls.
For the 2 first pairs there will be a button that will give access to their configuration screen (labeled as Aero fan
1, 2, 3, 4):

This screen will be divided in 2 halves, the left one with the label Aero Fan 1&2 and the right one with the label
Aero Fan 3&4. Each part has the controls for their fans.
The left one controls the two first fans with a 3 position status selector, with the positions MAN, 0 and
AUTO. In manual position, the fans will be started and kept working until the selector will be changed of
position. In 0 position fans will remain stopped. In AUTO position the start and stop control of the fans will be
done by the control system following its programmed logic.
Below the selector there will be 2 status objects to display the working status of the apparatus and the status of
the electric protections.
For the Aero fan 3&4 the controls are the same as the previous case but there are 2 additional numeric
parameters to adjust. These parameters are SP and HIS, and there are two pairs, one for the main cooling
circuit and the other for the auxiliary cooling circuit. The parameters are arranged in a table on the right side of
the screen. The first column is for the parameters of the main cooling circuit and the second for the auxliary.
These parameters apply only for the automatic mode (AUTO).
PV: In the first row, it is displayed in a white box the parameter PV that is the actual process value of
the temperature measured in the cooling circuit that is the reference for the regulation.
SP: In the second row, it can be changed the set point value for the regulation, which has the label
SP, by pressing the respective blue box. When the process temperature exceeds the SP value, the
pair of fans are started.
HIS: in the third row, it can be changed the value for the hysteresis. Once the SP has been exceeded
and the fans started, they will be stopped only when the actual temperature will decrease below the SP
value minus the HIS value.
When there are more than 4 fans, there will be an additional screen for the fans 5 and 6, with controls identical
to those of the fans 3 and 4.

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3.1.10.4. Engine circuit preheatings (optional, Preheating button)
The genset can be supplied optionally with preheatings for the cooling water and lube oil circuits.

This screen allows to configure the controls for the maneuvers of the electric circuits for this systems.
In the upper part of the screen there are 2 labels, Water Preheating and Oil Preheating and under them are
the controls for each maneuver.
Each control has a 2 position selector. The 0 position remains the preheating not working. The 1 position
remains the preheating working. This means that with the genset stopped the pump and resistor for the
maneuver are connected. The resistor is disconnected and connected alternatively by a thermostat which
measures the liquid temperature.
Below each selector, there are status displaying boxes to show the status (on-off) of the maneuver and the
status of the electric protections.
Below the water preheating selector, in the status box labeled Resist. Prot. is displayed the status of the
protections of the feeding circuit of the resistor and in the status box Pump Prot. is displayed the respective
one of the pump of this preheating.
3.1.10.5. Room ventilation (optional, Room fan button)
Optionally the genset can supply and control a fan for the room in which it is installed.
The fan can be controlled by a thermostat installed in the room.

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In the screen accessed by this button there is a selector with 3 positions. As usual in MAN the fan is connected
and remains working until the position of the selector is changed. In 0 the fan remains disconnected and in
AUTO the fan is started and stopped by the thermostat signal.
As usual also there are 2 status indicators, one for the working status and the other for the electrical protection
status.
3.1.10.6. Heat recovery pump (optional)
In the case it is supplied the control a pump (optional supply) for a heat recovery circuit, the control of this pump
can be set in the screen shown below:

The screen has a 3 position selector as in the previous case, with the same functioning but in AUTO the pump
will be started when the genset is going to start and stopped at certain time after the genset stop.
As in the previous case there would be 2 indicators of the working status and the electric protection status.
3.1.11. Ignition unit
One of the main menu bar buttons displays an initial screen that give access to a set of screens that display
information about the ignition system of the engine. The access is gained by pressing the respective pushbutton
in the column on the right.

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In this initial screen are also displayed 4 numerical values of the operating status of the ignition system:
Speed: at its right it is displayed the numerical value of the rpm of the engine measured by the unit
through a pickup sensor.
Timing: it is the firing retard angle value in degrees before the top dead centre (Btdc) that is being
applied to firing of the cylinders of the engine (the spark will be produced earlier in time before top dead
centre when this value is greater).
Energy it is the Level of energy being applied to the spark plugs for the spark generation. There are 3
Levels, being 3 the top energy Level.
mA: it is the value in mA of the analogue signal input for firing angle retard control of the ignition unit
(the spark will be produced earlier in time before top dead centre with greater values of current). This
signal is controlled by the engine antidetonation system and therefore must be equal than the parameter
displayed in the respective detonation system parameters screen (see page 4742).
In the following sections are described some of the screens accesible by the buttons on the right side of this
initial screen (only those without restricted access by password):
3.1.11.1. Overview screen
When pressing the first button it is displayed the following screen:

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For each cylinder there is a graphic object with a label in its top part that begins by C and follows by the cylinder
number. In the bottom part of the cylinder it is displayed a number that is the spark energy average value for that
cylinder.
In the upper part of the screen are displayed the same values of the ignition unit initial screen.
Pressing the button labeled with MENU makes to go back to the initial screen.
3.1.11.2. Energy
When the button with the inscription ENERGY is pressed it is displayed the following screen:

For each cylinder there is a graphic object with a label in its top part that begins by C and follows by the cylinder
number. In the bottom part of the cylinder it is displayed a number that is the energy needed for generating the
spark in that cylinder.
In the upper part of the screen is displayed the energy level selected for the generation of the sparks of the
ignition unit.
In the upper right corner of the screen there is an icon with an arrow oriented at 45 angle. Pressing that icon
makes to return to the ignition unit initial screen.
3.1.11.3. Warnings
With this button can be displayed a screen that shows the list of the last warnings generated by the ignition unit.

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For each warning it is shown its time and date and a description of the warning.
There are 2 pushbuttons above the warning table.
The button labeled with RESET makes to clear the list if the cause of the alarms is not still active.
The button labeled with WARNING RECORDING makes to be displayed a new screen with a table of warnings
saved in memory.

Pressing the icon with the arrow in both cases makes to go back to the previous screen.
3.1.12. Engine carburetion and load control system (EGS 02 pushbutton)
There is a button in the main menu bar to access 2 screens that display the current settings of the engine
carburetion and load control system, designated as EGS.
These screens are only for displaying and they have no changeable parameter. Both screens can be displayed
by pressing its respective tab.
For more details see the operating manuals of the EGS and TECJET units.
The screen displayed when pressing the button is shown below (with the tab labeled as LECT EGS):

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This screen displays the following parameters (see EGS 02 manual for more details) given by the EGS through
CAN communication:
Desired Power: it is the power set point in kW read by the unit.
Measured Power: it is the active power generated in kW calculated by the genset control system from
the electric measurements of the GPU unit.
Intake manifold Temp: it is the measurement of the intake air temperature in C at the filter outlet.
MAP1: it is the absolute pressure measurement at the right side cylinder band intake manifold in kPa.
MAP2: it is the absolute pressure measurement at the left side cylinder band intake manifold in kPa
Closed Loop: correction factor calculated by the EGS from the difference between the calculated load
and the actual load gives a correction factor. With this value the EGS modifies the gas intake opening
when in GQCL mode (Gas Quality Closed Loop control).
Throttle position: it is the value in (degrees) of the angular opening position of the throttle valve that
controls the fuel gas intake, from the closed position (0).
R.P.M.: engine speed in revolutions per minute calculated by EGS with the pulse signal from the
pickup sensor.
Unstability: value of the variation of the engine speed in rpm per second, a mesurement of the engine
unstability.
Thermal power calculated: fuel gas power consumed by the engine calculated by the EGS.
Pressing the tab with the label TECJET is displayed, the following screen with other variables read from the
EGS related to the intake fuel gas actuator and flow rate meter named as TECJECT, device that controls the
intake fuel gas to the engine.

Position: is the % of opening position of the TECJET.
Delta P over tecjet: is the differential pressure in kPa measured by the TECJET (venturi type) to
calculate the flow rate intake to the engine.
Absolute inlet gas pressure: absolute fuel gas intake pressure in kPa measured by the TECJET.
Fuel Temperature: fuel gas intake temperature in C measured by the TECJET.
In the bottom part of the screen are displayed boolean parameters for on/off status variables given by the EGS
through discrete inputs/outputs. When the variables are ON the circle on the left of the label is in red color. Next
are described these parameters:
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Fuel on: status of a discrete input to the EGS that makes the EGS to start the engine. If this signal is
not active the engine cannot work. When the signal is on the circle on the left of the label is in red color.
Idle on: status of a discrete input to the EGS that makes the engine to work at idle speed.
Gen Breaker closed: status of a discrete input to the EGS with the the generator circuit breaker
position. When the circle is red the signal is on and the EGS is assuming the circuit breaker is closed
and so the genset is coupled to the plant electrical grid.
Ut. Breaker closed: status of a discrete input to the EGS of the mains circuit breaker position. When
the circle is red the signal is on and the EGS is assuming the mains circuit breaker is closed and so the
plant is parallel to the mains. When the circle is in grey color the EGS assumes that if the genset is
coupled, it is on islanding operation.
Reset: status of a discrete input to the EGS to reset its alarms. When the circle is red the signal is on
and the EGS will reset its alarm if the alarm conditions have disappeared.
Gas select. on: status of a discrete input to the EGS that makes it to use a gas composition
prearranged in the EGS. Normally this input is always on (the circle on the left is red).
Droop on: status of a discrete input to the EGS that when set makes the EGS to use a droop control for
the engine speed on islanding operation.
Raise: status of a discrete input to the EGS that makes it to raise the engine speed when
synchronizing.
Lower: status of a discrete input to the EGS that makes it to lower the engine speed when
synchronizing.
Major relay: status of a discrete output from the EGS to indicate to the PLC a severe alarm, that will
stop the genset immediately.
Minor relay: status of a discrete output from the EGS to indicate to the PLC a warning alarm, that will
not stop the genset.
GQCL on: the EGS is working in GQCL mode. This status is received by the PLC through CAN
communication, not a discrete signal.
For more details see EGS and TECJET unit manuals.
3.1.13. Antidetonation system (OPTIONAL, ANTIDETO. button)
When it is supplied an antidetonation system with the genset (optional), pressing the button ANTIDETO. in the
main menu, it is displayed a pull-down submenu with several buttons, that give access to screens where can be
displayed and configured parameters of the antidetonation system of the engine.

In the sections following below is the description of each of these screens.
3.1.13.1. Events
Pressing this button makes to be displayed a screen of a group of 3 accessible by the green arrow icon on the
bottom right side. The parameters displayed in these screens are for visualization only and cannot be changed.
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The screen has 4 parameters described below:
N TRIP STOPS: in the white box is displayed the total number of the counter of trip stops of the
genset made by the antidetonation system. This counter can be reset from another screen with
restricted access.
LOAD REDUCTIONS: in the white box is displayed the total number of the counter of genset power
reductions made by the antidetonation system. This counter can be reset from another screen with
restricted access.
N OF INCREASES: here is displayed the total number of the counter of genset firing retards increases
carried out by the antidetonation system. This counter can be reset from another screen with restricted
access.
4-20 mA (actual): in the white box is displayed the 4-20mA current loop mA value set by the detonation
system to the ignition unit, to control the firing angle retard of the cylinders ignition (the spark will be
produced earlier in time before top dead centre with greater values of current). This value has to be
equal than the value displayed in the ignition unit system initial screen (see page 42).
Pressing the green arrow icon on the bottom left side of the screen makes to be displayed the following screen
in which are listed the last 8 events related with the antidetonation system. There are 3 different types of events
(alarms) caused by the antidenotation system: Detonation which makes the unit to modify the ignition timing,
load reduction when detonation is continuing to happen and the ignition timing modification has reached its
limit, and stop when the antidetonation system has measured knocking energy greater than an adjusted limit
and gives the trip command to the control system that makes a full immediate stop.

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The parameters in this screen are described as follows:
HOUR: the hour of the event.
DATE: date of the event.
mA MX.: the maximum value of the analogue firing angle retard signal in mA (from 4 to 20)
reached during the event.
kW GEN: the generated power in kW by the genset at the moment of the beginning of the event.
DETON.: counter for events that cause the analogue firing angle retard signal to be increased
because the knocking energy has exceeded a pre-established limit. Each time there is an event that
causes this action the counter increases in a unit.
LOAD REDUC.: counter for events that cause the load reduction variable to be set because the
knocking energy has not decreased under the pre-established limit of the previous parameter and
the analogue signal has reached its limit (20mA). Each time there is an event that causes this action
the counter increases in a unit.
STOP: counter for events that cause the genset to stop. Each time there is an event that causes
this action the counter increases in a unit.
Pressing the green arrow icon in the bottom right side of the screen, it is displayed an identical screen that has
been described but for the following 7 events in time, to add up to 15 total detonation events.

Pressing the green arrow icon in the bottom right side of this screen, it is displayed again the first screen of this
group.
3.1.13.2. CAN events
Pressing CAN events button makes to be displayed the following screen:
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In this screen are displayed several parameters of the antidetonation unit read through CAN communication.
On the left half of the screen are displayed so many square objects with round dials inside as cylinders has the
engine. Each dial has a white label beginning with C and followed by the cylinder number. When there is a
knocking energy measurement for the cylinder the pointer of the dial spins through it proportionally and in the
bottom right side of the square box is displayed the number of the knocking intensity (it is the percentage from 0
to full scale of the knocking sensors).
On the right half of the screen are displayed several parameters explained as follows:
mA: it is the value in mA of the analogue output of the firing angle retard signal of the antidetonation
unit that uses the ignition unit as an input to adjust the spark timing (as explained in the previous page
and also see section 3.1.11 Ignition unit on page 42.
Ignition reduction limit: it is the knocking intensity that when exceeded makes the knocking alarm to be
set and makes the analogue output of the firing angle retard to increase in ramp with time, while the limit
remains exceeded.
Below the previous 2 parameters are 3 labels of alarms which status is represented in the circle on their right
side. When the alarm is active the circle is red and when not is green. The description of each alarm is as
follows:
Knocking: is the status of the knocking alarm (there is at least one cylinder which knocking intensity
exceeds the preestablished limit).
Load reduction: when the analogue output has reached its full scale value (20mA) and the knocking
alarm is still active, the antidetonation unit sets this variable to decrease the genset generated power.
Trip: is the status of the trip alarm. When the knocking intensity of at least one cylinder exceeds a
preestablished limit, antidetonation unit sets this alarm that makes an immediate stop of the genset
(severe alarm).
Finally the label sensor is above a matrix of boxes with the identification of the cylinder on its right, that display
the correct or failure status of the knocking sensor of that cylinder. When the sensor is OK the box is green and
when not turns to white. So a white box represents a failing sensor.
3.1.13.3. Restricted access screens
Pushbuttons Parameters and Reset Events give access to a restricted access screens and makes to be
displayed the respective password insertion screen. These screens let change parameters that only can be
changed by trained Guascor personnel and its modification by non-skilled personnel can led to serious damage
to the engine so its access is not allowed.
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3.1.14. SCAT
This pushbutton let to access a restricted access menu, and makes to be displayed the respective password
insertion screen. These screens allow to change parameters that only can be changed by trained Guascor
personnel and its modification by non-skilled personnel can led to serious damage to the engine so its access is
not allowed.
3.1.15. Valve control screens (OPTIONAL , VALVES pushbutton)
When the supply includes the control of optional valves such that of the exhaust gases from the engine or the
engine cooling circuits, there will be a pushbutton in the main menu bar that will give access to the screens for
the control and parameter displaying of that devices, as shown below.

The pushbutton will display a pulldown menu with pushbuttons for the access to the available screens (the
screens available will depend on the supply).
The description made in the following sections for these screens is for a generic installation details and the
supplied with a specific genset will differ depending on the details of the supply.
3.1.15.1. Exhaust valve control screen (Optional, Exhaust button)
In some cases the supply of the genset includes a recovery system for the exhaust gas heat. The recovery
system usually consists of a 3-way damper valve that can send the gases to a heat exchanger or to the
atmosphere (normal position). In the secondary side of the heat exchanger usually flows water. The regulation
system it is completed with the temperature measurement of the water at the output of the exchanger.
When in the genset supply is included the control of an exhaust gas valve, it will be a pushbutton in the pulldown
menu that will give access to a screen for configure and display the parameters of the valve control, as follows:
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The screen shown above is displayed when the control mode of the valve is automatic. The selection of the
control mode, manual or automatic is done with the toggle pushbutton in the upper left part of the screen. In the
screen shown is displaying the text AUTO VALVE and is filled with white color. If the pushbutton is pressed
toggles to red color and displays the text MANUAL VALVE.
When in auto mode, in the top right part of the screen it is displayed the valve position in percentage being 0%
fully open to the atmosphere, and an increasing percentage represents an increasing opening to heat recovery
system.
Right under this parameter it is a pushbutton to display a screen for the configuration of the PID of the
regulation.
Apart from the selector being in AUTO mode there are 3 more conditions that must be fulfilled to allow the
regulation to work. The rectangular boxes on the right side of the screen display the fulfillment or not of the 3
conditions.
When the box is red, the respective condition is NOT fulfilled and when is green then it is fulfilled.
The conditions are described as follows.
1. The first condition is about the genset generated active power.
On the right of the label ACTIVE POWER it is displayed the actual genset generated active power in kW. It is a
display only value. Below this text box there are 2 blue boxes where parameters can be changed.
The label SP identifies the set point for enable the regulation in kW. When the genset active power exceeds
this set point, this regulation condition is fulfilled until the active power decreases below the SP value minus the
Hysteresis value inserted in the blue box on the right.
2. The second condition is for the minimum temperature of the water at the outlet of the heat exchanger.
On the right of the label EXHAUST RECUP. OUTLET WATER TEMP. is displayed the actual process value of
this temperature in C.
The parameter SP MIN. is the temperature that when exceeded the regulation condition is fulfilled and remains
in this condition while the water temperature does not decrease under the value of the SP MIN. parameter
minus its hysteresis. Its hysteresis can be changed at the blue box on its right.
This condition avoids exhaust gases to flow through the exchanger if the secondary water flowing is too cold.
3. The third condition is for the maximum water temperature at the outlet of the heat exchanger.
When this temperature is over the value set in the blue box with the label SP MAX. the condition is NOT
fulfilled. When it is under that value then it is fulfilled.
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The regulation can only work when all of the 3 conditions explained are fulfilled simultaneously. If any of them is
not fulfilled, the regulation is disabled and the valve position is set at 0% (to atmosphere).
If the pushbutton PID ADJUST is pressed, the following screen is displayed:

Again, on the right of the label EXHAUST RECUP. OUTLET WATER TEMP. is displayed the actual process
value of the heat exchanger water outlet temperature in C.
As in any PID of the engine control system, in this screen can be set 4 parameters for this regulation: the set
point, EXHAUST RECUP. OUTLET SP which is the desired water temperature at the heat exchanger outlet,
and the PID parameters Kp, Ti and Td.
Pressing the white icon with the left oriented arrows at the left bottom corner of the screen, it is displayed again
the origin screen.
When the toggle pushbutton AUTO/MANUAL is set in MANUAL VALVE, the regulation of the valve position
is disabled and it is displayed the following screen:

In this screen with the label VALVE POSITION is displayed the actual percentage of valve opening value to
heat recovery and below can be set the desired percentage.
3.1.15.2. Engine cooling circuits valves (OPTIONAL, Water button)
The type and control of 3-way valves of the engine cooling circuits will depend on the specific plant supply (heat
recovery or not, etc.) and it is an optional feature.
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There could be at most 2 different types of 3-way valves in each circuit with positioner which are able to do an
automatic regulation:
1. a 3-way valve that can by-pass the rest of the circuit connecting the outlet and inlet of the engine cooling
circuit, and
2. a 3-way valve to regulate the percentage of water flow that is derived to aero coolers when there is a
heat exchanger for heat recovery, and this exchanger could not be able to cool the water in the needed
amount. This type of valve when is for the main cooling circuit is normally referred as an emergency
valve, as in the screen below:

For each valve of the system there will be a tab to access its configuration and status screen.
In the screen shown above, there are the following objects:
MAIN CIRC. WATER TEMP.: here it is displayed the process reference temperature, in this case the
engine water outlet temperature. It is the process variable that is wanted to be regulated.
AUTO VALVE / MANUAL VALVE: it is a toggle pushbutton that toggles between automatic and
manual mode. It is set in automatic mode when the button is in white color and with the text AUTO
VALVE and it is set in manual when in red color and with the text MANUAL VALVE.
MAIN CIRC. SP: it is the desired temperature set point value given to the PID controller.
PID Kp, PID Ti and PID Td are the regular PID parameters of the PLC PID control function.
VALVE POSITION: is the percentage of opening of the valve to the aero coolers.
When the valve control is set in MANUAL mode the screen displayed is as follows:
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In this mode the only parameter that can be changed is the position of the valve in percentage at the blue box.
That will be the percentage the valve opens to aero coolers.
The first type of control valve (a valve that can by-pass the rest of the circuit connecting the outlet and inlet of the
engine cooling circuit) is regulated by the engine control system and its parameters are for displaying only. An
example of screen for this type of valve is shown below:

3.1.15.3. Optional thermal diagram
Optionally, when there is a heat recovery system in the plant for the engines wasted otherwise heat energy,
sometimes is included a screen with a schematic diagram of the heat recovery system that displays the most
important temperature measurements.
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3.1.16. Booster (OPTIONAL)
Depending on the specific supply, optionally there would be a fuel gas blower to supply the genset and this
blower is normally driven by a variable or adjustable speed drive (ASD).
In this case the control of this blower can be done optionally by the genset control system and there would be a
screen for its configuration accessible by a pushbutton with the label BOOSTER in the main menu bar.
By pressing this button is displayed a screen as follows:

It can work in 2 modes automatic and manual. The mode is selected by a toggle pushbutton that also displays
the actual mode of the control. The button has the label MANUAL OPERATION BOOSTER above it and can
display OFF and be red-filled when the regulation is in automatic mode, and ON and green-filled when the
regulation is in manual mode.
In manual mode, the set point to the ASD is set in the green box below the toggle button and with the text Hz
on its right.
The circle on the left bottom corner of the screen displays the working status of the booster. When in dark green
is not working and when in light green is working.
In a red lined box on the right half of the screen, there are several parameters changeable when automatic
operation.
GAS PRESSURE: is the actual measured pressure of the booster outlet in mbar.
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SET POINT: is the desired set point for the previous pressure, and the set point for the PID controller.
Kp, Ti and Td: are the PID changeable parameters.
BOOSTER: is the actual speed set point value given to the ASD device.
Cranking Delay time: is the value in seconds between 5 and 15, that the genset will wait until begin to
crank when the pressure has exceeded the setpoint value.
Pressing the trend graphical icon at the right bottom corner of the screen makes to be displayed a trend screen
where the GAS PRESSURE, SETPOINT and BOOSTER [Hz] variable trends are displayed.
3.2. ALARM DESCRIPTION
The operator terminal is in charge of displaying system alarms and make their management.
There are 2 main types of alarms, those that makes the genset to stop and those that not.
In the tables shown in the next sections the alarms are categorized in the column TYPE depending on the
actions taken as follows:
SEVERE: Trips the generator circuit breaker and brings it a full stop immediately.
MINOR: if ramp power decrease is enabled the genset decreases its power in this way and then
opens the breaker and makes a normal stop, with an unloaded running operation during the
preestablished time.
ITUS: immediate trip of the generator breaker and unloaded running operation during its
preestablished time before the complete stop.
WARNING: Alarm for its displaying in the HMI only.
DS: Alarm that disables the engine start.
When an alarm leads to different actions depending on the genset status if in parallel to the mains or on
islanding, both categories are shown in the last column, first the category when in parallel to mains and then the
category when on islanding.
3.2.1. General type alarms
In the following table is a list of the general type of alarms.

NUM. ALARM DESCRIPTION TYPE
1.
Generator CB tripped
SEVERE
2.
Overspeed
SEVERE
3.
Emergency stop
SEVERE
4.
Gen measurement tripped
SEVERE
5.
Status DEIF no OK
SEVERE
6.
Gas Leak In Ramp
SEVERE
7.
Fire detection in container
SEVERE
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8.
Fire detection sensor not OK
SEVERE
9.
High Gas Pressure
SEVERE
10.
Low gas pressure
SEVERE
11.
Detcon Supply Tripped
MINOR/ITUS
12.
EGS Failure
SEVERE
13.
EGS Alarms
WARNING
14.
Main water Circ High Temp (digital)
SEVERE
15.
Oil Low Pressure (digital)
SEVERE
16.
Oil Low Level (digital)
SEVERE
17.
High intake manifold temp (digital)
MINOR/ITUS
18.
Oil High Temp (digital)
MINOR/ITUS
19.
Oil High Pressure (digital)
MINOR/ITUS
20.
Oil High Level (digital)
MINOR/ITUS
21.
Electronic Ignition Alarm
WARNING
22.
Electronic Ignition Fault
SEVERE
23.
Prelube pump tripped
DS
24.
Prelube pump out of order
DS
25.
Alternator Heating Prot. Tripped
WARNING
26.
Aero Fan 1&2 Prot Tripped
WARNING
27.
Aero Fan 1&2 Out of order
WARNING
28.
Aero Fan 3&4 Prot.Tripped
WARNING
29.
Aero Fan 3&4 Out of order
WARNING
30.
Aero Fan 5&6 Prot.Tripped
WARNING
31.
Aero Fan 5&6 Out Of Order
WARNING
32.
Gas Leak In Room
SEVERE
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33.
Main Water Circ.Pump Prot.Tripped
SEVERE
34.
Aux.Water Circ.Pump Prot.Tripped
SEVERE
35.
Main Water Circ.Pump Out Of Order
SEVERE
36.
Aux.Water Circ.Pump Out Of Order
SEVERE
37.
Main Circuit Water Low Level
MINOR/ITUS
38.
Aux. Circuit Water Low Level
MINOR/ITUS
39.
Control Voltage Trafo Prot.Tripped
SEVERE
40.
Factory Emergency Stop
SEVERE
41.
Auxiliar Services Prot. Tripped
SEVERE
42.
No run permission
MINOR
43.
300L Tank Oil High Level
WARNING
44.
300L Tank Oil Low Level
WARNING
45.
Can Open Fault (EGS)
WARNING
46.
Main Circuit Water Low Pressure
MINOR/ITUS
47.
Aux. Circuit Water Low Pressure
MINOR/ITUS
48.
Can Open Fault (Deif)
SEVERE
49.
Can Open Fault (Detcon)
SEVERE
50.
High increase oil temp Alarm
SEVERE
51.
High increase oil temp Warning
WARNING
52.
Maximum frequency Gen tripped (PLC)
SEVERE
53.
Maximun voltage Gen tripped (PLC)
SEVERE
54.
Detcon: Engine Knocking
WARNING
55.
Detcon: Sensor Fault
WARNING
56.
Detcon: Endoscopic Revision
SEVERE
57.
Detcon: Trip
SEVERE
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58.
Detcon: Maximum numbers of shed exceed
SEVERE
59.
Detcon: Power shedding working
WARNING
60.
Alternator Winding Protec. Tripped
WARNING
61.
Main Water Circ temp regulating
WARNING
62.
Intake manifold temp regulating (EGS)
WARNING
63.
Aux.Water Temp. sensor failure
WARNING
64.
Oil low pressure warning (Analogic)
WARNING
65.
High water temperature warning (Analogic)
WARNING
66.
Engine stopped tacometric relay failure
SEVERE
67.
Synchronisation disabled (by touch-screen)
WARNING
68.
Engine crancking fault
SEVERE
69.
Engine sincronization failure
SEVERE
70.
Working hours maintenance warnning
WARNING
71.
Working hours maintenance alarm
MINOR/ITUS
72.
Comunication CAN DEIF fault (PDO)
ITUS
73.
Gen Prelube Fault
MINOR
74.
Minimum Generator Power
MINOR
75.
Generator as Slave Mode
WARNING
76.
Low gas pressure in biogas tank
MINOR/ITUS
77.
Right exhaust temp sensor failure
WARNING
78.
Left exhaust temp sensor failure
WARNING
79.
Oil temp sensor failure
WARNING
80.
Oil Pressurer sensor failure
WARNING
81.
water temp. sensor failure
WARNING
82.
Filter temp. sensor failure
WARNING
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83.
Booster: Out of order
SEVERE
84.
High gas pressure before regulator
SEVERE
85.
Booster C.B. Prot.Tripped
SEVERE
86.
Booster: Fault variable speed controller
SEVERE
87.
No master Selected
WARNING
88.
%CH4 out of range
SEVERE
89.
%SH2 out of range
MINOR/ITUS
90.
%CH4 variation alarm
SEVERE
91.
Posible failure AVR alternator
MINOR/ITUS
92.
Warnning AVR checking
WARNING
93.
Gas pressure sensor failure
WARNING
94.
%CH4 sensor failure
WARNING
95.
H2S sensor failure
WARNING
96.
Oil Preheating Prot. Tripped
WARNING
97.
Water Preheating Pump Prot.Tripped
WARNING
98.
Water Preheating Prot. Tripped
WARNING
99.
Left Bank Air Intake Filter Clogged
WARNING
100.
Bank Air Intake Filter Clogged
WARNING
101.
Heat recovery pump protections tripped
WARNING
102.
Heat recovery pump Out of order
WARNING
103.
Master-slave Ethernet failure (warning)
WARNING
104.
Ethernet comunication failure
SEVERE
105.
Right exhaust high temp.
MINOR/ITUS
106.
Left exhaust high temp.
MINOR/ITUS
107.
Diference temp between exhaust
MINOR/ITUS
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108.
Mechanic over load (PLC)
ITUS
109.
Master PLC: Genset stop Alarm
ITUS
110.
Master PLC: Tripping
SEVERE
111.
Master PLC: C.B.Tripped
MINOR
112.
Room Fan Protection Tripped
MINOR/ITUS
113.
Room Fan Out of Order
MINOR/ITUS
114.
Gas Analyzer: CH4 Alarm
WARNING
115.
Gas Analyzer: H2S Alarm
WARNING
116.
Gas Analyzer: CO2 Alarm
WARNING
117.
Gas Analyzer: O2 Alarm
WARNING
118.
Measurement Prot.Tripped in Busbars
SEVERE
119.
Stator Winding Temperature 1 >=155C
WARNING
120.
WARNING
121.
WARNING
122.
WARNING
123.
WARNING
124.
WARNING
125.
Front Anti Friction Bearing Temperature >=90C
WARNING
126.
Back Anti Friction Bearing Temperature >=90C
WARNING
127.
ITUS
128.
ITUS
129.
ITUS
130.
ITUS
131.
ITUS
132.
ITUS
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133.
Front Anti Friction Bearing Temperature >=95C
ITUS
134.
Back Anti Friction Bearing Temperature >=95C
ITUS

3.2.2. Generator protection unit (GPU3) alarms
The alarms shown in the following table are generated by the generator protection and measurement unit (also
known as GPU3) when problems in the electrical connection of the generator with the rest of the grid are
detected by this unit.

1 GPU: 1010 G-P>2 ITUS
2 GPU: 1030 G I>1 ITUS
3 GPU: 1030 G I>2 ITUS
4 GPU: 1090 G I>inv. ITUS
5 GPU: 1110 G Iv> ITUS
6 GPU: 1130 G I>>1 ITUS
7 GPU: 1140 G I>>2 ITUS
8 GPU: 1150 G U>1 ITUS
9 GPU: 1160 G U>2 ITUS
10 GPU: 1170 G U<1 ITUS
11 GPU: 1180 G U<2 ITUS
12 GPU: 1210 G f>1 ITUS
13 GPU: 1220 G f>2 ITUS
14 GPU: 1240 G f<1 ITUS
15 GPU: 1240 G f<2 ITUS
16 GPU: 1450 G P>1 ITUS
17 GPU: 1460 G P>2 ITUS
18 GPU: 1500 G Unbalance I ITUS
19 GPU: 1510 G Unbalance U ITUS
20 GPU: 1520 G -Q> ITUS
21 GPU: 1530 G Q> ITUS
22 GPU: 1540 G neg. seq. I ITUS
23 GPU: 1550 G neg. seq. U ITUS
24 GPU: 1570 G zero seq. I ITUS
25 GPU: 1580 G zero seq. U ITUS
26 GPU: 2130 GB sync. failure ITUS
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27 GPU: 2150 Phase sequence error ITUS
28 GPU: 2160 GB open failure ITUS
29 GPU: 2170 GB close failure STOP
30 GPU: 2180 GB position failure ITUS
31 GPU: 2190 Vector mismatch ITUS
32 GPU: 2560 Governor regulation fail ITUS
33 GPU: 2630 Deload error ITUS
34 GPU: 2680 AVR regulation fail. ITUS
35 GPU: 4960 U<aux. term. WARNING
36 GPU: 4970 U>aux. term. WARNING
37 GPU: 6370 Not in remote. ITUS

3.2.3. Mains connection alarms
This alarms are generated by problems or anomalies in the plant-mains electrical connection. These alarms will
produce different effects depending on the islanding condition.
When in parallel to the mains, if islanding operation is enabled, then the mains circuit breaker trips and the
genset tries to work on islanding condition. If islanding operation is not enabled, then the generator circuit
breaker trips and the genset is running at no load until the alarm are reset and the problem has dissapeared.
This type of operation when in parallel is designated by ISLorITUW
When the alarm arises on islanding condition, the alarm will be managed as a warning.

Num. ALARM DESCRIPTION TYPE
1
Mains measurement protec. tripped
ISLorITUW / WARNING
2
Loss of mains df/dt (ROCOF)
ISLorITUW / WARNING
3
Loss of mains vector jump
ISLorITUW / WARNING
4
Mains under frequency
ISLorITUW / WARNING
5
Mains over frequency
ISLorITUW / WARNING
6
Mains under voltage
ISLorITUW / WARNING
7
Mains over voltage
ISLorITUW / WARNING
8
Mains CB 52L Tripped - Normal
ISLorITUW / WARNING
9
Mains Line not Ready
ISLorITUW / WARNING

PRODUCT INFORMATION

INDEX

DATE

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3.2.4. Engine carburetion and load control system alarms
Every alarm generated by the engine carburetion system control unit (EGS 02) is read by the PLC through CAN
communication. The EGS 02 unit can generate 2 types of alarm, SEVERE (immediate stop) and WARNING. In
its own terminology, it calls Minor Relay alarms to those of the warning level and Major Relay to those of the
sever level. Additionally it has 2 discrete voltage free outputs to indicate that an alarm of each type has been set.

1 AL 80 - Engine Overspped SEVERE
2
AL 440 - Engine Overload WARNING
3
AL 370 - Misfire detected Alarm WARNING
4
AL 380 - Misfire detected SD SEVERE
5
AL 1 - System lean (bank_1) WARNING
6
AL 10 - System rich (bank_1) WARNING
7
AL 150 - ECT Sensor voltage Low WARNING
8
AL 160 - ECT Sensor voltage High WARNING
9
AL 20 - MAP sensor_1 low signal SEVERE
10
AL 30 - MAP sensor_1 High signal SEVERE
11
AL 210 - TPS (Trhottle Position) input voltage low WARNING
12
AL 220 - TPS (Trhottle Position) input voltage high WARNING
13
AL 40 - MAP sensor_2 low signal SEVERE
14
AL 50 - MAP sensor_2 High signal SEVERE
15
AL 390 - Potmeter inpit voltage low WARNING
16
AL 400 - Potmeter inpit voltage low High WARNING
17
AL 60 - Map diff. out of range WARNING
18
Al 70 - No RPM signal SEVERE
19
AL 90 - Power sensor low signal SEVERE
20
AL 100 - Power sensor high signal SEVERE
21
AL 110 - UEGO sensor_1 low signal WARNING
22
AL 120 - UEGO sensor_1 high signal WARNING
PRODUCT INFORMATION

INDEX

DATE

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23
AL 410 - PTP_1 sensor voltage low WARNING
24
AL 420 - PTP_1 sensor voltage high WARNING
25
AL 430 - Mixture throttle not OK WARNING
26
AL 130 - MAT_1 Volt low WARNING
27
AL 140 - MAT_1 Volt high WARNING
28
AL 170 - CH4 sensor low signal WARNING
29
AL 180 - CH4 sensor high signal WARNING
30
AL 230 - 5V Supply XDRP_A low WARNING
31
AL 240 - 5V Supply XDRP_A high WARNING
32
AL 250 - 5V Supply XDRP_B low WARNING
33
AL 260 - 5V Supply XDRP_B high WARNING
34
AL 270 - Lambda Close Loop Closed loop corr_1 > max. WARNING
35
AL 280 - Lambda Close Loop Closed loop corr_1 < min. WARNING
36
AL 290 - GQCL Closed loop corr_2 >max. WARNING
37
AL 300 - GQCL Closed loop corr_2 <min. WARNING
38
AL 310 - CAN 1 controller Error status SEVERE
39
AL 320 - CAN 1 controller bus off status SEVERE
40
AL 311 - CAN 2 controller Error status WARNING
41
AL 321 - CAN 2 controller bus off status WARNING
42
AL 330 - Main Supply voltage low SEVERE
43
AL 340 - Main Supply voltage high SEVERE
44
AL 190 - Remote input low signal WARNING
45
AL 200 - Remote input high signal WARNING
46
AL 350 - Speed bias input low signal WARNING
47
AL 360 - Speed bias input high signal WARNING
48
AL 460 - Firefly CAN data watchdog timeout WARNING
PRODUCT INFORMATION

INDEX

DATE

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IO-G-M-AC-001e
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49
AL 470 - IC-920 Ignition CAN data Watchdog timeout WARNING
50
AL 450 - SHUTDOWN Tecjet_1 CAN data watchdog timeout WARNING
51
AL 500 - Tecjet_1 high electrical temperature WARNING
52
AL 501 - Tecjet_1 electronics temp fail high WARNING
53
AL 502 - Tecjet_1 fuel gas Temp fail high WARNING
54
AL 503 - Tecjet_1 fuel gas Press fail high WARNING
55
AL 504 - Tecjet_1 coil current fail high WARNING
56
AL 505 - Tectet_1 electronic temp fail low WARNING
57
AL 506 - Tecjet_1 fuel gas Temp fail low WARNING
58
AL 507 - Tecjet_1 fuel gas Press fail low WARNING
59
AL 508 - Tecjet_1 coil current fail low WARNING
60
AL 509 - battery voltage low error WARNING
61
AL 510 - Tecjet_1 fuel gas Temp low limit error WARNING
62
AL 511 - Tecjet_1dp low limit error WARNING
63
AL 512 - Tecjet_1 fuel gas Press low limit error WARNING
64
AL 513 - Tecjet_1 battery voltage high error WARNING
65
AL 514 - Tecjet_1 fuel gas Temp high limit error WARNING
66
AL 515 - Tecjet_1dp high limit error WARNING
67
AL 516 - Tecjet_1 fuel gas Press high limit error WARNING
68
AL 517 - Tecjet_1 CAN flow demand failed WARNING
69
AL 518 - Tecjet_1 CAN port fault WARNING
70
AL 600 - SHUTDOWN Tecjet_1 Valve position error SEVERE
71
AL 601 - SHUTDOWN Tecjet_1 dp FAIL high SEVERE
72
AL 602 - SHUTDOWN Tecjet_1 Valve position Fail high SEVERE
73
AL 603 - SHUTDOWN Tecjet_1 dp FAIL low SEVERE
74
AL 604 - SHUTDOWN Tecjet_1 Valve position Fail low SEVERE
PRODUCT INFORMATION

INDEX

DATE

Dep. 3
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75
AL 605 - SHUTDOWN Tecjet_1 SHUTDOWN SEVERE
76
AL 606 - SHUTDOWN Tecjet_1 internal fault SEVERE
77
AL 607 - SHUTDOWN Tecjet_1 parameter error SEVERE
78
AL 608 - SHUTDOWN Tecjet_1 parameter version error SEVERE
79
AL 609 - SHUTDOWN Tecjet_1 Main EEprom Read Fail SEVERE
80
AL 610 - SHUTDOWN Tecjet_1 Main EEprom Write Fail SEVERE
81
AL 611 - SHUTDOWN Tecjet_1 SPA A/D converter error SEVERE
82
AL 612 - SHUTDOWN Tecjet_1 Sensen 5 Volt error SEVERE
83
84
85
AL 615 - SHUTDOWN Tecjet_1 A/D converter error SEVERE
86
AL 616 - SHUTDOWN Tecjet_1 exception error SEVERE
87
AL 617 - SHUTDOWN Tecjet_1 factory calibration error SEVERE
88
AL 618 - Tecjet_1 Zero Pressure Detected SEVERE
89
AL 700 - SHUTDOWN PCMHD Rategroup SLIP SEVERE
90
AL 701 - SHUTDOWN PCMHD High temperature SEVERE
91
AL 702 - SHUTDOWN PCMHD EEPROM Primary Fault SEVERE
92
AL 703 - SHUTDOWN PCMHD EEPROM Primary Fault SEVERE
93
AL 519 - Tecjet Flow Not Reached WARNING
94
AL 113 - UEGO 1 LSU Sensor not Ready WARNING
95
AL 114 - Bosch Uego sensor Fault WARNING
96
AL 121 - UEGO 1 LSU Heater Voltage Hi WARNING
97
AL 141 - MAT Temperature Hi WARNING
98
AL 142 - MAT Temperature HiHi (SD) WARNING
99
AL 151 - Lube oil pressure voltage Lo WARNING
100
AL 152 - Lube oil pressure voltage Hi WARNING
PRODUCT INFORMATION

INDEX

DATE

Dep. 3
IO-G-M-AC-001e
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101
AL 161 - ECT Temperature Hi WARNING
102
AL 162 - ECT Temperature HiHi (SD) WARNING
103
AL 261 - 14 Volt Supply Lo WARNING
104
AL 262 - 14 Volt Supply Hi WARNING
105
AL 485 - Lube oil Pressure Lo WARNING
106
AL 486 - Lube oil Pressure LoLo WARNING
107
Al 490 - Lube oil Level Lo WARNING
108
Al 495 - Coolant Level Lo WARNING
109
AL 1050 - Proact Shutdown WARNING
110
AL 1051 - Primary Demannd Fault WARNING
111
AL 1052 - Backup Demand Fault WARNING
112
AL 1053 - Position error WARNING
113
AL 1054 - High Temperature WARNING
114
AL 1055 - Temp Limiting Active WARNING
115
AL 1056 - High Battery Supply Voltage WARNING
116
AL 1057 - Low Battery Supply Voltage WARNING
117
AL 475 - Proact Watchdog Timeout (SD) WARNING
118
AL 900 - Firefly_1: Knock sensor FireFly#1 fault WARNING
119
120
121
122
123
124
125
126
AL 908 - Firefly_1: FireFly speed sensor fault WARNING
PRODUCT INFORMATION

INDEX

DATE

Dep. 3
IO-G-M-AC-001e
May 2012


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127
AL 909 - Firefly_1: FireFly phase sensor fault WARNING
128
AL 910 - Firefly_1: FireFly load sensor fault WARNING
129
AL 911 - Firefly_1: Engine severity limit reached FireFly#1 SEVERE
130
AL 912 - Firefly_1: FireFly cilinder severity limit reached WARNING
131
AL 913 - Firefly_1: FireFly cilinder commications fault WARNING
132
AL 1032 - C9xx: warning Missing Ring Gear Signal WARNING
133
AL 1033 - Warning Missing Reset Signal WARNING
134
AL 1034 - C9xx: Warning Missing Camshaft Signal WARNING
135
AL 1035 - C9xx: Odd Energy Level out of Range WARNING
136
AL 1036 - C9xx: Even Energy Level out of Range WARNING
137
AL 1037 - C9xx: SCR fault Odd SEVERE
138
AL 1038 - C9xx: SCR fault Even SEVERE
139
AL 451 - Tecjet_2 CAN data watchdog timeout WARNING
140
AL 520 - Tecjet_2 High electrical temperature WARNING
141
AL 521 - Tecjet_2 electronics temp fail high WARNING
142
AL 522 - Tecjet_2 fuel gas Temp fail high WARNING
143
AL 523 - Tecjet_2 fuel gas Press fail high WARNING
144
AL 524 - Tecjet_2 coil current fail high WARNING
145
AL 525 - Tecjet_2 electronics temp fail low WARNING
146
AL 526 - Tecjet_2 fuel gas temp fail low WARNING
147
AL 527 - Tecjet_2 fuel gas press fail low WARNING
148
AL 528 - Tecjet_2 coil current fail low WARNING
149
AL 529 - Tecjet_2 battery voltage low error WARNING
150
AL 530 - Tecjet_2 fuel gas Temp lo limit error WARNING
151
AL 531 - Tecjet_2 dp Low limit error WARNING
152
AL 532 - Tecjet_2 fuel gas Press low limit error WARNING
PRODUCT INFORMATION

INDEX

DATE

Dep. 3
IO-G-M-AC-001e
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153
AL 533 - Tecjet_2 battery voltage high error WARNING
154
AL 534 - Tecjet_2 fuel gas Temp high limit error WARNING
155
AL 535 - Tecjet_2 dp High limit error WARNING
156
AL 536 - Tecjet_2 fuel gas Press high limit error WARNING
157
AL 537 - Tecjet_2 CAN flow demand failed WARNING
158
AL 538 - Tecjet_2 CAN port fault WARNING
159
AL 620 - SHUTDOWN Tecjet_2 Valve position error SEVERE
160
AL 621 - SHUTDOWN Tecjet_2 dp FAIL High SEVERE
161
AL 622 - SHUTDOWN Tecjet_2 Valve position Fail high SEVERE
162
AL 623 - SHUTDOWN Tecjet_2 dp FAIL Low SEVERE
163
AL 624 - SHUTDOWN Tecjet_2 Valve position Fail low SEVERE
164
AL 625 - SHUTDOWN Tecjet_2 SHUTDOWN SEVERE
165
AL 626 - SHUTDOWN Tecjet_2 internal fault SEVERE
166
AL 627 - SHUTDOWN Tecjet_2 parameter error SEVERE
167
AL 628 - SHUTDOWN Tecjet_2 parameter Version error SEVERE
168
AL 629 - SHUTDOWN Tecjet_2 Main EEPROM Read Fail SEVERE
169
AL 630 - SHUTDOWN Tecjet_2 Main EEPROM Write Fail SEVERE
170
AL 631 - SHUTDOWN Tecjet_2 SPA A/D converter error SEVERE
171
AL 632 - SHUTDOWN Tecjet_2 Sense 5 Volt error SEVERE
172
173
174
AL 635 - SHUTDOWN Tecjet_2 A/D converter error SEVERE
175
AL 636 - SHUTDOWN Tecjet_2 exception error SEVERE
176
AL 637 - SHUTDOWN Tecjet_2 Factory calibration error SEVERE
177
AL 638 - Tecjet_2 Zero Pressure Detected SEVERE
178
Al 539 - Tecjet_2 Flow Not Reached SEVERE

PRODUCT INFORMATION

INDEX

DATE

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3.3. PLC PID CONTROL FUNCTION
In this section is described the standard PID function used by the PLC to carry out this type of regulations. When
in one of the screens of the HMI a set of parameters for a PID can be set, these parameters are those described
as follows in this section.
When a control system is using this function to carry out a regulation, in the respective screen of the HMI can be
changed the respective parameters: Kp, Ti y Td.
These parameters have the following properties:
Kp: proportional gain without units. The value used by the function is the hundredth of the actual
parameter set by the operator in the screen. It can be specified with its sign and the operator can type
any number in the following range (-10.000<KP<+10.000). The sign establishes the direction of the PID
action (positive: direct, negative: reversing). A direct PID action means that when the error (deviation)
increases with positive value the output of the PID also increases and when error (deviation) increases
with a negative value, the output of the PID decreases. A reversing PID action means the opposite,
when the error increases with positive value the output of the PID decreases. Depending on the process
variable to be controlled, the action must be chosen in either one of the previous ways.
Ti: integral time, an unsigned integer value from 0 to 20000 and its unit is 0.1 seconds.
Td: differential time, an unsigned integer value from 0 to 10000 and its unit is 0.1 seconds.
The SET POINT value (also identified as SP in the HMI screens) when it is no mention to its variables, is a
normalized (without units) unsigned integer value ranging from 0 to 10.000 and those are the values that the
operator can insert.
The output of the PID function of the PLC, is a normalized value ranging from 0 to 10.000, calculated by the PLC
in 2 different ways, depending on the established Ti value:
If Ti=0 the calculus output is added to a bias of 5000.
if Ti>0, the algorithm is turned to incremental type and the result of the calculus is added to the result of
the previous calculus carried out.

ALTERNATOR
INFORMATION
Reference: 76.26.453
Order: VEC001110

CONSISTENTS WITH OUR CONTINUAL PRODUCT IMPROVEMENT POLICY, GUASCOR POWER RESERVES THE RIGHT TO CHANGE ANY SPECIFICATION WITHOUT PRIOR NOTICE. 1/1

EQUIPMENT ORDER
DATE
11-2012
SFGM560/4 VEC001110
INDEX
CUSTOMER
ROYAL GK PTE LTD
ALTERNATOR INDEX

GENERAL RECOMMENDATIONS
76.26.453 INSTALLATION AND MAINTENANCE MANUAL
R450 REGULATOR

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Recommandations gnrales
pour stockage et mise en service des alternateurs
General recommendations
for storing and installing alternators
fr-en-de-es-it-pt-nl-sv-da--no-el-cs-et-hu-lt-lv-pl-ru-sk-sl-ar-tr-zh-ja-ko
Recommendations for
storing and installing
alternators
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Before using your alternator you should read carefully this sheet of recommendations, and the installation
and maintenance manual provided with the machine. All operations carried out on the alternator should be
performed by a person qualied and trained in installation, servicing and maintenance of electrical and mechanical
units.
CAUTION !
This document does not replace the installation and maintenance instructions.
RECEIPT
- Check the state of the alternator. If the alternator or even the packaging has been damaged, notify your haulage
contractor.
- Check that the correct alternator has been delivered (power, voltage, mounting arrangement, information on nameplate).
STORAGE
- Place the equipment in a clean dry area, protected from impacts, vibrations, temperature extremes and in an environment
with relative humidity less than 90%.
- Do not remove the rotor blocking device in the stator for single bearing alternators.
- When storing for longer than six months, consult the maintenance manual.
BEFORE INSTALLATION
- Check the insulation resistance of the windings (phase/earth R greater than 1 M). If this resistance is lower, dry the
machine as indicated in the maintenance manual.
- During this check or if you are going to carry out a dielectric test on the alternator you must disconnect the regulator in order
to be covered by the guarantee.
- Check that the bearings are working correctly if the alternator has been stored longer than 6 months.
- Drain any condensation water.
MECHANICAL INSTALLATION
- Install the alternator in the same type of environment (Temperature, Relative humidity, Altitude) as specied in the order.
- Lifting the alternator : use the lifting rings to handle the alternator, whilst taking care not to damage the terminal box. With
single bearing alternators the machine must be kept horizontal in order to prevent the rotor falling out of the machine.
- Before coupling the alternator to its drive motor, check their compatibility by means of a torsional analysis of the shaft line
and a dimensional inspection of the coupling modules.
- Mount the alternator in its anticipated position, on a support able to withstand the distortions and vibrations which occur
when the generator is running.
- Ensure that the xing screws (coupling disks, foot or ange) are tightened to the correct torque. The screw diameter must
t the xing holes.
- Ensure that alignment of the mechanical shafts and mounting of the coupling or pulley are carried out correctly.
- Check that the loads applied to the alternator shaft (belt tension) comply with the maximum values stated in the maintenance
manual.
- Do not knock the shaft or the coupling when mounting.
- Make sure that the machine is properly cooled. The air inlets and outlets must be clear; if the unit has a cover, take steps to
ensure that the air is not constantly recycled.
- Check that the protective grilles and housing have been reassembled correctly.
- Protected alternators (IP21, 23) must be installed under cover.
en
ELECTRICAL CONNECTION
- Mistakes made when connecting, installing or handling electrical appliances can cause serious or even
fatal accidents.
You should therefore check that: :
- a differential circuit-breaking device complying with standards in the country of use
has been tted to the alternators power output,
- that the machine is connected to the supply with the spade terminals on top of one
another (see diagram) and that the nuts are screwed tight,
- that connections and couplings comply with the diagram in the maintenance manual,
- that earthing is carried out in compliance with current national standards,
- that there are no short-circuits between phases or phase/neutral between the alternator output terminals and the generator
control cabinet.
- Do not connect the alternator if you do not understand the wiring diagram or if it is missing: please consult LEROY-
SOMER.
COMMISSIONING
- Check that the regulators connections comply with the diagram in the maintenance manual, check the position of the
frequency selection strap and the voltage reference wires. The regulator is preset at the factory: to obtain different settings,
please consult the maintenance manual.
- Ensure that the various protections are tted properly.
- Check that the protective panels and the terminal box cover have been replaced properly.
- The alternator is designed to operate at the speeds listed on the nameplate (do not exceed the maximum speeds listed in
our technical catalogue.
- Comply with the voltage and frequency indicated on the nameplate.
- Do not use the alternator at a higher power than indicated on the nameplate.
MAINTENANCE
- All maintenance operations apart from greasing the bearings must be carried out with the generator switched off and
electrical safety devices activated.
- Ensure that the recommendations concerning mechanical and electrical installation continue to be adhered to.
- Refer to the nameplate for the frequency of greasing the bearings and the type of grease to be used. If no details are given,
the bearings are greased for life.
WARNING

These specications, instructions and descriptions concern standard operation. They do not take account of any
variations in construction or special adaptations.
If these recommendations are not respected, the alternator may deteriorate prematurely and manufacturer guaran-
tee may not apply.
These guarantee conditions feature in the manufacturers general conditions of sale, available to customers on
request.
LEROY-SOMER can be contacted for technical, commercial and service advice via its worldwide network.
33
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ALTERNATORS
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Valeurs excit / Excit. values
en charge / full load
vide / at no load M
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2 - TECHNICAL CHARACTERISTICS
2.1 - EIectricaI characteristics
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3 - INSTALLATION
PersonneI undertaking the various
operations discussed in this section
must wear the appropriate personaI
protective equipment for mechanicaI
and eIectricaI hazards.
3.1 - AssembIy
AII mechanicaI handIing operations
must be undertaken using approved
equipment and the aIternator must be
horizontaI. Check how much the
aIternator weighs (see 4.8.3) before
choosing the Iifting tooI.
3.1.1 - HandIing
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During this operation, do not aIIow
anyone to stand under the Ioad.
3.1.2 - CoupIing
3.1.2.1 - SingIe bearing aIternator
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WARNING
When coupIing the aIternator to the
prime mover, the hoIes of the coupIing
discs shouId be aIigned with the ywheeI
hoIes by rotating the engine ywheeI.
Do not use the fan to turn the aIternator
rotor.
Make sure the aIternator is secureIy
bedded in position during coupIing.
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3.1.2.2 - Two-bearing aIternator
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with a 1/2 key.
3.1.3 - Location
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3.2 - Inspection prior to rst use
3.2.1 - EIectricaI checks
Under no circumstances shouId an
aIternator, new or otherwise, be operated
if the insuIation is Iess than 1 megohm
for the stator and 100,000 ohms for the
other windings.
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WARNING
Ensure that the aIternator has the degree
of protection matching the dened
environmentaI conditions.
3.2.2 - MechanicaI checks
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3.3 - TerminaI connection diagrams
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Any intervention on the aIternator
terminaIs during reconnection or checks
shouId be performed with the machine
stopped.
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LSA 50.2 - 4 POLES
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3.3.1 - Standard terminaI connection : 6-wire
Connection code L.L voltage Factory connection
3-phase
N
T1
T4
T3
T6
T5
T2
L1(U)
L3(W) L2(V)
D
L1(U)
L3(W)
T1
T4 T3
T6
T5 T2
L2(V)
F
3-phase
(
*
)
Winding
60 Hz 50 Hz
380 - 415 380 - 480
440
380 - 416
-
-
-
6S
7S
8S
Winding
60 Hz 50 Hz
R 450 voltage sensing:
0 => (T3) / 220 V => (T2)
9S
600
220 - 240
220 - 240
220 - 277
240 - 254 -
-
6S
7S
8S
With winding 9: R 450 + transfo voltage sensing (Diagram on request)
NDE
L1(U)
L2(V)
L3(W)
T4
T6
T5
T1
T2
T3
N
If the alternator is reconnected, check that the AVR is sensing the voltage!
As an option, the factory can provide special connector bars to make these connections (*).
R 450 voltage sensing:
0 => (T3) / 380 V => (T2)

NDE
L1(U)
L2(V)
L3(W)
T4
T6
T5
T1
T2
T3
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LSA 50.2 - 4 POLES
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3.3.2 - Option connection diagram
R791 T interference suppression kit (standard for CE marking) External voltage potentiometer
Black
Black
Black
Blue
White
Connections
D F
T1 T1
T2 T2
T3 T3
N
Voltage adjustment via remote
potentiometer
ST4
1000 ohms
Connection of current transformer Space heater PTC stator sensors
Shield PT100 White
Neutral link
White
Red
Red
6 wires
- PH 1
In/4 Secondary 1 A
D connection
P1
P2
T4
T4
Ph1
Ph2
Ph3
101
102
103
104
130 C
blue wire
150 C
black wire
180 C
red/white
wire
500W - 220 V
121
122
122
White
Red
Red
123
124
124
DE
NDE
122
122
124
124
123
121 103
104
104
105
106
106
107
108
108
White
Red Red Red
Red Red Red
103
104
104
PH 1
White
105
106
106
PH 2
White
107
108
108
PH 3
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LSA 50.2 - 4 POLES
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3.3.3 - Connection checks
EIectricaI instaIIations must compIy with
the current IegisIation in force in the
country of use.
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3.4 - Commissioning
The aIternator can onIy be started up and
used if the instaIIation is in accordance
with the reguIations and instructions
dened in this manuaI.
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3.5 - Settings
The various adjustments during tests
must be made by a quaIied engineer.
Ensure that the drive speed specied on
the namepIate is reached before
commencing adjustment.
After operationaI testing, repIace aII
access paneIs or covers.
The AVR is used to make any adjust-
ments to the machine.
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LSA 50.2 - 4 POLES
ALTERNATORS
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4 - SERVICING - MAINTENANCE
4.1 - Safety measures
Servicing or troubIeshooting must be
carried out strictIy in accordance with
instructions so as to avoid the risk of
accidents and to maintain the machine in
its originaI state.
AII such operations performed on the
aIternator shouId be undertaken by
personneI trained in the commissioning,
servicing and maintenance of eIectricaI
and mechanicaI components, who must
wear personaI protective equipment
appropriate for mechanicaI and eIectricaI
hazards.
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4.2 - ReguIar maintenance
4.2.1 - Checks after start-up
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4.2.3 - EIectricaI servicing
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Do not use: trichIorethyIene, perchIo-
rethyIene, trichIoroethane or any aIkaIine
products.
These operations must be performed at a
cIeaning station, equipped with a
vacuum system that coIIects and ushes
out the products used.
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4.2.4 - MechanicaI servicing
CIeaning the machine using water or a
highpressure washer is strictIy prohi-
bited. Any probIems arising from such
treatment are not covered by our
warranty.
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WARNING
WARNING
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4.4 - MechanicaI defects
Fau|l Poss|o|e causes
8ear|r
Excess|ve over|eal|r ol ore or ool|
oear|rs (lerperalure > 80C or l|e
oear|r rela|rers W|l| or W|l|oul
aororra| ro|se)
- Erd s||e|ds |rcorrecl|y a||red (lares rol proper|y llled).
- ll l|e oear|r |as lurred o|ue or |l l|e rease |as lurred o|ac|, c|are l|e oear|r.
Aororra|
lerperalure
Excess|ve over|eal|r ol a|lerralor
|ous|r (rore l|ar 10 C aoove l|e
aro|erl lerperalure)
- A|r loW (|rla|e-oul|el) parl|a||y c|oed or |ol a|r |s oe|r recyc|ed lror
l|e a|lerralor or er|re
- A|lerralor operal|r al loo ||| a vo|lae (> 105 ol ur or |oad)
- A|lerralor over|oaded
v|oral|or
Excess|ve v|oral|or
- V|sa||rrerl (coup||r)
- 0elecl|ve rourl|r or p|ay |r coup||r
- Rolor oa|arc|r lau|l
Excess|ve v|oral|or ard |urr|r ro|se
cor|r lror l|e a|lerralor
- A|lerralor operal|r |r s|r|e-p|ase rode (s|r|e-p|ase |oad or lau|ly corlaclor or
|rsla||al|or lau|l)
- 3lalor s|orl-c|rcu|l
Aororra|
ro|se
A|lerralor daraed oy a s|r|lcarl
|rpacl, lo||oWed oy |urr|r ard
v|oral|or
- 3ysler s|orl-c|rcu|l
- V|s-para||e||r
Poss|o|e corsequerces
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- 8ro|er or oerl s|all erd.
- 3||ll|r ard s|orl-c|rcu|l ol ra|r le|d W|rd|r
- Far lraclured or cor|r |oose or s|all
- lrreparao|e darae lo rolal|r d|odes or AvR.
4.5 - EIectricaI fauIts
Fau|l Acl|or Ellecl C|ec|/Cause
No vo|lae
al ro |oad
or slarl-up
Correcl a reW oallery
ol 1 lo 12 vo|ls lo
lerr|ra|s E- ard E,
respecl|r l|e po|ar|ly,
lor 2 lo 3 secords
T|e a|lerralor ou||ds up ard |ls vo|lae
|s sl||| correcl W|er l|e oallery |s
reroved.
- Lac| ol res|dua| rarel|sr
T|e a|lerralor ou||ds up oul |ls
vo|lae does rol reac| l|e raled
va|ue W|er l|e oallery |s reroved.
- C|ec| l|e correcl|or ol l|e vo|lae relererce lo l|e AvR
- Fau|ly d|odes
- Arralure s|orl-c|rcu|l
T|e a|lerralor ou||ds up oul |ls
vo|lae d|sappears W|er l|e oallery
|s reroved
- Fau|ly AvR
- F|e|d W|rd|rs d|scorrecled
- Va|r le|d W|rd|r oper c|rcu|l - c|ec| l|e res|slarce
vo|lae loo
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C|ec| l|e dr|ve speed
Correcl speed
C|ec| l|e AvR correcl|ors (AvR ray oe lau|ly)
- F|e|d W|rd|rs s|orl-c|rcu|led
- Rolal|r d|odes ourrl oul
- Va|r le|d W|rd|r s|orl-c|rcu|led - C|ec| l|e res|slarce
3peed loo |oW
lrcrease l|e dr|ve speed
(0o rol louc| l|e AvR vo|lae pol. (P2) oelore rurr|r al l|e
correcl speed.)
vo|lae loo
|||
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polerl|oreler
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vo|lae
osc|||al|ors
Adjusl AvR slao|||ly
polerl|oreler
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EIectricPowerGenerationDivision

DecIarationofCEcompIianceandincorporation
ThisDeclarationappliestothegeneratorsdesignedtobeincorporatedinto4achinesco4pl?ing>iththe
Machiner?DirectiveNr4CEdated17Ma?
MTEU"#LE"Y#ME" ML#HLCE#TL#" MTEU"#LE"Y#ME"

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Lo>VoltageDirectiveNr95CEdated1Dece4ber
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3

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8

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R
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$
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V
/
L
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0
R
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L
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V
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L
8
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|

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P
P
H
C
2J
0 1
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9
8 7
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1
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380V 220 110 0V E- E+ Z2 X1 Z1 X2
2012.03 / e
T
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R 450
AVRs
4531 en -
2
2012.03 / e
LEROY-SOMER nstallation and maintenance
R 450
AVRs
4531 en -
SAFETY MEASURES
Before using your machine for the frst time,
it is important to read the whole of this
installation and maintenance manual.
All necessary operations and interventions
on this machine must be performed by a
qualifed technician.
Our technical support service will be pleased
to provide any additional information you
may require.
The various interventions described in
this manual are accompanied by
recommendations or symbols to alert the
user to potential risks of accidents. t is vital
that you understand and take notice of the
various warning symbols used.
Warning symboI for an operation capabIe
of damaging or destroying the machine
or surrounding equipment.
Warning symboI for generaI danger to
personneI.
Warning symboI for eIectricaI danger to
personneI.
Note: LEROY-SOMER reserves the right to
modify the characteristics of its products
at any time in order to incorporate the
latest technological developments. The
information contained in this document may
therefore be changed without notice.
WARNING
This manuaI concerns the aIternator AVR which you have just purchased.
We wish to draw your attention to the contents of this maintenance manuaI. By foIIowing
certain important points during instaIIation, use and servicing of your AVR, you can Iook
forward to many years of troubIe-free operation.
2012.03 / e
LEROY-SOMER
3
nstallation and maintenance
R 450
AVRs
4531 en -
CONTENTS
1 - GENERAL INFORMATION ............................................................................................... 4
1.1 - Description ................................................................................................................... 4
1.2 - Characteristic ............................................................................................................... 4
2 - POWER SUPPLY ............................................................................................................... 5
2.1 - AREP excitation system ............................................................................................... 5
2.2 - PMG excitation system ................................................................................................. 6
2.3 - SHUNT or separate excitation system .......................................................................... 7
3 - TECHNICAL CHARACTERISTICS .................................................................................... 8
3.1 - Electrical characteristics ............................................................................................... 8
3.2 - Confgurations .............................................................................................................. 8
3.3 - U/F and LAM functions ............................................................................................... 12
3.4 - Typical effects of the LAM with a diesel engine with or without a LAM (U/F only) ........ 12
3.5 - AVR options ............................................................................................................... 13
4 - INSTALLATION - COMMISSIONING ............................................................................... 14
4.1 - Electrical checks on the AVR ...................................................................................... 14
4.2 - Setting up ................................................................................................................... 14
4.3 - Electrical faults ........................................................................................................... 17
5 - SPARE PARTS ................................................................................................................. 18
5.1 - Designation ................................................................................................................ 18
5.2 - Technical support service ........................................................................................... 18

AII servicing or repair operations performed on the AVR shouId be undertaken by
personneI trained in the commissioning, servicing and maintenance of eIectricaI and
mechanicaI components.
Copyright 2005: LEROY-SOMER MOTORS
This document is the property of:
LEROY-SOMER
t may not be reproduced in any form without prior authorization.
All brands and models have been registered and patents applied for.
4
2012.03 / e
R 450
AVRs
4531 en -
1 - GENERAL INFORMATION
1.1 - Description
The R450 AVR is supplied in a casing
designed to be mounted on a panel with
dampers.
- Operating temperature: - 30C to + 65 C.
- Storage temperature: - 55C to + 85C.
- Shocks on the base: 9 g depending on the
3 axes.
- Vibrations: less than 10 Hz, 2 mm
half-peak amplitude 10 Hz to 100 Hz: 100
mm/s, above 100 Hz: 8 g.
WARNING
The AVR is IP00, it must be incorporated
in an environment which ensures it a
IP20 protection.
1.2 - Characteristic
The connection is realised by Faston
connectors and the voltage sensing is
single - phase.
R 450
V
0
|
R

N
0
T
|
6
E
3
E
E

h
0
7
/
C
E
V
O
L
T
.

S
T
A
B
.

I

E
X
C

S
T
A
T
.
F
U
S
I
B
L
E
S

/

F
U
S
E
S

1
k
3
P
H
.
S
1

S
2
50 Hz
60 Hz
EXT FREQ
SETTING
7
L
A
H
0
F
F
L
A
H
0
N
0
N
L
Y
F
0
R
8
P
E
6
|A
L
6
0
N
F
|C
.
K
N
E
E
L
A
Y
0
F
F
5
h
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L
A
H
0
F
F
L
A
H
H
0
0
E
2
L
A
H
H
0
0
E
1

L
A
H
0
F
F
L
A
H
H
0
0
E
2
L
A
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H
0
0
E
1

5
0
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.
F
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.
S
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.
0 5
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9
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1
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/
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L
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/
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0
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A
L
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8
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|

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R
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P
P
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C
2J
0 1
0
9
8 7
6
5
4
32
1 0
3
2
1
140 mm
L
E
D
S

P1 Voltage
P2
Stability
P3
Excitation
Overrun
indications
Fuses 10A
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115 mm
380V 220 110 0V E- E+ Z2 X1 Z1 X2
2
0
0

m
m

Rotating switch
- Lam and U/F
- Voltage
- Excitation
4 holes 6.5 mm
1
7
5

m
m
50 Hz
60 Hz
3
E
R
/E
3
L
8
A
4
9
.1
|
5
0
.2
7
0
0
0
|
8
0
0
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3
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R
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3
L
8
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4
9
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|
5
0
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7
0
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0
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3
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3
L
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4
.2
|
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7
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0
0
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3
L
8
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4
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4
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5
0
0
0
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0
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1

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h
A
8
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8
E
N
8
|
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3

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A
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8
E
8

8
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N
8
|
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C
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0 1
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1
P4
Quad
droop
2012.03 / e
LEROY-SOMER
5
R 450
AVRs
4531 en -
2 - POWER SUPPLY
Both the SHUNT/AREP & PMG excitation
systems are controlled by the AVR.
2.1 - AREP excitation system
With AREP excitation, the electronic AVR is
powered by two auxiliary windings which
are independent of the voltage sensing
circuit.
The frst winding has a voltage proportional
to the alternator main voltage (Shunt
characteristic), the second one has a
voltage proportional to the stator current
(compound characteristic : Booster effect).
The power supply voltage is rectifed and
fltered before being used by the AVR
monitoring transistor.
This system provides the machine with a
short-circuit current capacity of 3 N for 10 s.
The rotating switch should be in the AREP
position (see 3.2.3).
AREP SYSTEM
Field
Armature
T1 T2 T3
T4 T5 T6
V
a
r
i
s
t
o
r
5+ 6-
T7 T8 T9
T10 T11 T12
according to voltage
Aux. windings
1
0

Y
e
l
l
o
w
1
1

R
e
d
9

G
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e
n
1
2

B
l
a
c
k
10 Yellow
11 Red
9 Green
12 Black
STATOR : 6 wires ( T1 to T6)

MAN FELD
R 450
V
0
|
R

N
0
T
|
6
E
3
E
E

h
0
7
/
C
E
V
O
L
T
.

S
T
A
B
.

I

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X
C

S
T
A
T
.
F
U
S
I
B
L
E
S

/

F
U
S
E
S

1
k
3
P
H
.
S
1

S
2
50 Hz
60 Hz
EXT FREQ
SETTING
7
L
A
H
0
F
F
L
A
H
0
N
0
N
L
Y
F
0
R
8
P
E
6
|A
L
6
0
N
F
|C
.
K
N
E
E
L
A
Y
0
F
F
5
h
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L
A
H
0
F
F
L
A
H
H
0
0
E
2
L
A
H
H
0
0
E
1

L
A
H
0
F
F
L
A
H
H
0
0
E
2
L
A
H
H
0
0
E
1

5
0
H
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E
X
T
.
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.
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.
6
0
H
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0 5
6
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1
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R
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3
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4
9
.1
|
5
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7
0
0
0
|
8
0
0
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R
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3
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4
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.1
|
5
0
.2
7
0
0
0
|
8
0
0
0
3
E
R
/E
3
L
8
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4
.2
|
4
7
.2
5
0
0
0
|
0
0
0
3
E
R
/E
3
L
8
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4
.2
|
4
7
.2
5
0
0
0
|
0
0
0
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R
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R
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P
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380V 220 110 0V E- E+ Z2 X1 Z1 X2
1

P
h
A
8
E

8
E
N
8
|
N
C
3

P
A
h
A
8
E
8

8
E
N
8
|
N
C
6
2012.03 / e
R 450
AVRs
4531 en -
2.2 - PMG excitation system
With PMG excitation, a permanent magnet
generator (PMG) added to the alternator
supplies the AVR with voltage which is
independent of the main alternator winding.
This system provides the machine with a
short-circuit current capacity of 3 N for 10 s.
The AVR monitors the alternator output
voltage by adjusting the excitation current.
The rotating switch should be in the PMG
position (see 3.2.3).
PMG SYSTEM
PMG
T1 T2 T3
T4 T5 T6
V
a
r
i
s
t
o
r
5+ 6-
14
14
15
15
16
16
T7 T8 T9
T10 T11 T12

according to voltage
Field
Armature
MAN FELD
R 450
V
0
|
R

N
0
T
|
6
E
3
E
E

h
0
7
/
C
E
V
O
L
T
.

S
T
A
B
.

I

E
X
C

S
T
A
T
.
F
U
S
I
B
L
E
S

/

F
U
S
E
S

1
k
3
P
H
.
S
1

S
2
50 Hz
60 Hz
EXT FREQ
SETTING
7
L
A
H
0
F
F
L
A
H
0
N
0
N
L
Y
F
0
R
8
P
E
6
|A
L
6
0
N
F
|C
.
K
N
E
E
L
A
Y
0
F
F
5
h
z
L
A
H
0
F
F
L
A
H
H
0
0
E
2
L
A
H
H
0
0
E
1

L
A
H
0
F
F
L
A
H
H
0
0
E
2
L
A
H
H
0
0
E
1

5
0
H
z
E
X
T
.
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R
E
Q
.
S
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T
.
6
0
H
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0 5
6
9
8
1
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R
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3
L
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4
9
.1
|
5
0
.2
7
0
0
0
|
8
0
0
0
3
E
R
/E
3
L
8
A
4
9
.1
|
5
0
.2
7
0
0
0
|
8
0
0
0
3
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R
/E
3
L
8
A
4
.2
|
4
7
.2
5
0
0
0
|
0
0
0
3
E
R
/E
3
L
8
A
4
.2
|
4
7
.2
5
0
0
0
|
0
0
0
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0 1
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|0
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|0
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P
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380V 220 110 0V E- E+ Z2 X1 Z1 X2
1

P
h
A
8
E

8
E
N
8
|
N
C
3

P
A
h
A
8
E
8

8
E
N
8
|
N
C
2012.03 / e
LEROY-SOMER
7
R 450
AVRs
4531 en -
2.3 - SHUNT or separate excitation
system
With SHUNT excitation, the AVR is powered
by the main winding (100V to 140V -
50/60 Hz ) by using X1, X2 on the AVR.
The rotating switch should be in the SHUNT/
AREP position (see 3.2.3).
SHUNT SYSTEM
T1 T2 T3
T4 T5 T6
V
a
r
i
s
t
o
r
5+ 6-
T7 T8
T9
T10 T11
T12

X2
X1
Field
Armature
MAN FELD
R 450
V
0
|
R

N
0
T
|
6
E
3
E
E

h
0
7
/
C
E
V
O
L
T
.

S
T
A
B
.

I

E
X
C

S
T
A
T
.
F
U
S
I
B
L
E
S

/

F
U
S
E
S

1
k
3
P
H
.
S
1

S
2
50 Hz
60 Hz
EXT FREQ
SETTING
7
L
A
H
0
F
F
L
A
H
0
N
0
N
L
Y
F
0
R
8
P
E
6
|A
L
6
0
N
F
|C
.
K
N
E
E
L
A
Y
0
F
F
5
h
z
L
A
H
0
F
F
L
A
H
H
0
0
E
2
L
A
H
H
0
0
E
1

L
A
H
0
F
F
L
A
H
H
0
0
E
2
L
A
H
H
0
0
E
1

5
0
H
z
E
X
T
.
F
R
E
Q
.
S
E
T
.
6
0
H
z
0 5
6
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8
1
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3
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R
/E
3
L
8
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4
9
.1
|
5
0
.2
7
0
0
0
|
8
0
0
0
3
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R
/E
3
L
8
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4
9
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|
5
0
.2
7
0
0
0
|
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0
0
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3
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R
/E
3
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8
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4
.2
|
4
7
.2
5
0
0
0
|
0
0
0
3
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R
/E
3
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4
.2
|
4
7
.2
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0
0
|
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0
0
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|0
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|0
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P
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C
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380V 220 110 0V E- E+ Z2 X1 Z1 X2
1

P
h
A
8
E

8
E
N
8
|
N
C
3

P
A
h
A
8
E
8

8
E
N
8
|
N
C
8
2012.03 / e
R 450
AVRs
4531 en -
3 - TECHNICAL CHARACTERISTICS
3.1 - EIectricaI characteristics
- maximum power supply: 150V - 50/60 Hz
- Rated overload current: 10 A - 10 s
- Electronic protection:
- n the case of a short-circuit, the excitation
current is reduced to a value less than 1A
after 10 s
- n the event of loss of voltage reference,
the excitation current is reduced to a value
less than 1A after 1s for AREP/SHUNT, 10 s
for PMG.
- n the event of overexcitation, the current
is reduced as indicated in the next diagram
(see 3.2.1.4).
- Fuses: F1 on X1 and F2 on Z2 10A, 250V.
- Voltage sensing
0-110 V terminals = 95 to 140 V
For other voltages, a transformer should be
used.
- Voltage regulation: 0.5%.
- Current sensing: (parallel operation): input
S1, S2 intended for 1 C.T. < 2.5 VA cl1,
secondary 1 A or 5 A.
3.2 - Congurations:
3.2.1 - Settings
3.2.1.1 - VoItage
Voltage adjustment via potentiometer P1 in
the ranges described in the table below:
For 50 and 60 Hz Max.
High range 320V < Un > 530 V
Low range 80 V > Un > 320 V
WARNING
The aIIowed adjustment range is 5%;
when the setting exceeds these Iimits,
pIease check that it is conform with the
power tabIe.
3.2.1.2 - Quadrature droop:
Quadrature droop adjustment via
potentiometer P4 within a range :
- from 0 to 8% with a PF=0.8 for 400V
applications.
- From 0 to 14% with a PF=0.8 for 240V
applications.
- From 0 to 8% for 110V applications with a
step-up transformer (ratio of 4) placed on
the voltage reference.
The potentiometer P4 has a non linear
response. Then, when a 1A secondary CT is
connected the effective range starts from
the the second 1/3 of P4 range and in the
case of a 5A secondary CT the effective
range starts from the frst 1/3.
When a 5A CT is used, the adjustment range
is higher, so P4 must be set to the frst 1/4
(anti-clockwise) and then progressively
increase it.
WARNING
The CT must be connected.
3.2.1.3 - StabiIity:
Stability adjustment via potentiometer P2.
Selection of rotating switch according to the
machine type and the response time as
indicated in paragraph 3.2.3.
3.2.1.4 - Excitation Iimitation:
Excitation limitation adjustment via
potentiometer P3 as described below.
The excitation current limitation threshold in
steady state is set by a potentiometer at
110% of the rated value. The adjustment is
made by the operator during the on-load test
at rated power by tuning the potentiometer.
When the excitation current exceeds this
value, a counter is activated at the speed of
one record per second for 90 s. When this
time is elapsed, the current is reduced to the
value of the rated excitation current. f in the
meantime the excitation current drops
below the threshold value, the counter
counts down at the same speed.
2012.03 / e
LEROY-SOMER
9
R 450
AVRs
4531 en -
WARNING
The Iimitation threshoId must be
adjustabIe between 1 and 5.5 A. The
genset breaker must be open during the
short circuit. If the genset is restarted in
short circuit, there is a excitation buiId
up during 10s again at the maximum
vaIue.

Operation between 3 and 6 In when
short-circuited:
The excitation current ceiling during a
short-circuit equals 2.9 times the fxed
threshold when setting the permitted
excitation ceiling in continuous operation.
When the threshold is exceeded for a period
= 10 s the current is reduced to a value
between 0.5 and 0.7 A (shutdown).
n all operating conditions the maximum
excitation current must be limited to
9 A 0.5 A.
Overrun indications:
One green LED:
- Lights up when the excitation current is
below the continuous operation threshold
t signals the AVR normal operation.
- Turns off when the excitation current ceiling
used to obtain short-circuit operation is
reached and when the excitation current is
reduced to the shutdown value.
- Flashes when the over excitation counter
is decrementing.
NB: After an obvious short-circuit, the
voltage is limited to 70% of the rated voltage.
This avoids overvoltages on machines
whose no-load excitation current is below
the lower current threshold (only in AREP).
P3
Diagram 1
9.5
exc(A)
(Maximum current exc)
Decrease of
90 s tempo.
Activation of
90 s tempo.
Activation of
90 s tempo.
Red led
Green led
Activation of
10 s tempo. 10s tempo. elapsed :
shutdown apllication
t(s)
2.9x threshold
(max. 9.5 A)
threshold
(1...5.5A)
Shutdown
0.5 ~ 0.7
10
2012.03 / e
R 450
AVRs
4531 en -
One red LED:
- Lights up simultaneously with the green led
when the continuous operation threshold is
reached for more than 90 s and the excitation
current is reduced to the continuous
operation threshold. t is used to set the
excitation current ceiling
- Turns off when the excitation current is less
than the setting value (< 110% n)
- Flashes when the excitation current is
above the continuous operation threshold
during less than 90 s.
Green LED stays on,
- fashes when the excitation current has
reached the ceiling in < 10s with PMG
excitation.
- ftays on if exc = Shutdown.

WARNING
If the overIoad protection is activated, a
voItage drop possibIy exceeding 10% of
the reference voItage wiII be observed.
The AVR does not provide undervoItage
protection. The customer wiII need to
make sure that their instaIIation is
correctIy protected against under-
voItages.
During Ioad shedding, an overvoItage is
observed, which wiII disappear in a few
seconds.
P3
Diagram 2
9.5
exc(A)
t(s)
(Maximum current exc)
Activation of
90 s. tempo
Red led
Green led
90 s. tempo elapsed : application
of permanent limitation
2.9x threshold
(max. 9.5 A)
threshold
(1...5.5A)
Shutdown
0.5 ~ 0.7
2012.03 / e
LEROY-SOMER
11
R 450
AVRs
4531 en -
3.2.2 - Rotating switch seIection: LAM
and U/F
7
LAH
0FF
LAH
0N
0NLY F0R
8PE6|AL
60NF|C.
KNEE
LAY 0FF
5hz
LAH
0FF
LAH
H00E 2
LAH
H00E 1
LAH
0FF
LAH
H00E 2
LAH
H00E 1
50Hz
EXT.FREQ.
SET.
60Hz
0
5
6
9
8
1
2
J
4
0
9
8
7
65
4
3
2
1

- Pos 0: Change in the voltage according to
the U/F ratio, knee-point position at 48 Hz.
the 2U/F, knee-point position at 48 Hz.
the self auto-adaptating LAM combined with
2U/F, knee-point position at 48 Hz.
the U/F ratio, knee-point position at 58 Hz
the 2U/F, knee-point position at 58 Hz.
the self auto-adaptating LAM combined with
2U/F, knee-point position at 58 Hz.
the U/F ratio, knee-point position at 65 Hz
(Tractelec application and variable speed
above 1800 rpm).
- Pos 7: Special (not used).
the U/F ratio, knee-point position at 48 Hz or
58 Hz according to selection of the frequency
by an external contact.
LAM 1, knee-point position at 48 Hz or 58 Hz
according to selection of the frequency by
an external contact
WARNING
For Pavers and hydrauIic appIications,
seIect positions 0 (50 Hz) or 3 (60 Hz).
3.2.3 Rotating switch: excitation type
and time response
RAP|0E
F/$T
RAP|0E
F/$T
N0RHAL
hDPV/L
N0RHAL
hDPV/L
AREP
PHC
2
J 0
1
0
3
2
1
0: AREP excitation and normal time
response.
3: AREP excitation and fast time response.
1: PMG excitation and normal time response.
2: PMG excitation and fast time response.
For SHUNT appIications, AREP excitation
must be seIected.
3.2.4 Rotating switch: voItage sensing
3ER/E3
L8A49.1| 50.2
7000| 8000
3ER/E3
L8A49.1| 50.2
7000| 8000
3ER/E3
L8A4.2| 47.2
5000| 000
3ER/E3
L8A4.2| 47.2
5000| 000
1 PhA8E 8EN8|NC
0hLY w/7h
EX7ERhAL R7J1 Y00JLE
3 PhA8E8 8EN8|NC
2
J 0
1
0
3
2
1
0: Single phase sensing
- LSA46.2/47.2 series.
3: Single phase sensing

1: Three-phase sensing with optional
module R731
2: Three-phase sensing with optional
module R731

12
2012.03 / e
R 450
AVRs
4531 en -
3.3 - U/F and LAM function
3.3.1 - Frequency variation compared
with voItage (without LAM)
100 %
50 Hz 60 Hz
Hz
50 Hz
48 Hz
57.5 Hz
60 Hz
Voltage
Bend
U/UN
Frequency
3.3.2 - LAM (Load Acceptance ModuIe)
characteristics
3.3.2.1 - VoItage drop
The LAM system is integrated in the AVR. As
standard it is active.
Role of the LAM:
On application of a load, the genset rotation
speed decreases. When it falls below the
preset frequency threshold, the LAM causes
the voltage to drop proportionately to the
frequency (LAM1) or to the active power
(LAM2) depending the the rotating switch
position. This reduces the active load scale
applied until the speed returns to its rated
value.
Hence the LAM can be used either to reduce
the speed variation (frequency) and its
duration for a given applied load, or to
increase the applied load possible for one
speed variation (turbo-charged engine).
To avoid voltage oscillations, the trip
threshold for the LAM function should be set
approximately 2 Hz below the rated
frequency.
LAM
UN
0
48 or 58 Hz
0,85 UN
Voltage
Voltage
U/f
50 or 60 Hz
fC fN
ST3
3.3.2.2 - Soft voItage recovery function
During load impacts, the function helps the
genset to return to its rated speed faster with
a gradual increase in voltage according to
the principle:
- f the speed drops between 46 and 50 Hz
(in 50Hz operation), the rated voltage is
recovered by following a fast gradient.
- f the speed drops below 46 Hz, since the
engine needs more help, the voltage follows
a slow gradient as it returns to the reference
value.
0
Time

Drop N 46 Hz

U

Drop N > 46 Hz

3.4 - TypicaI effects of the LAM with
a dieseI engine with or without a
LAM (U/F onIy)
3.4.1 - VoItage
3.4.2 - Frequency
UN
0
0,9
0,8
(U/f)
with
LAM
Tim
without LAM
1 s 2 s 3 s
Transient voItage drop
0,9
0,8
fN
Max. speed drop
0
with
LAM
Time
without
LAM
1 s 2 s 3 s
2012.03 / e
LEROY-SOMER
13
R 450
AVRs
4531 en -
3.4.3 - Power
3.5 - AVR options
- Current transformer for parallel opera-
tion of....../1 A or 5 A according to the po-
tentiometer P4 position.
- VoItage transformer (adaptation)
- Remote voItage adjustment potentio-
meter.
For a range of variation:
5% : 470 C
10% : 1 kC
the power of the potentiometer can be
0.5 W, 2 W or 3 W.

The potentiometer input must be
isoIated. Do not connect it to the ground.
- R 731 moduIe: 3-phase voltage sensing
200 to 500 V, compatible with parallel
operation in balanced installations.
- R 734 moduIe: 3-phase current and
voltage sensing for parallel operation on
unbalanced installations (unbalance >
15%).
- R 726 moduIe: regulation system
changed to 4 - function (see the
maintenance manual and connection
diagram).
PF regulation (2F) .
Equalization of voltages before
paralleling (3 F).
Possibility of coupling to the mains of
alternators already running in parallel (4F).
- R729 moduIe: same as R726 with
additional functions.
Detection of a diode fault.
4-20 mA input.
Possibility of kVAR regulation.
- VoItage controI: with an isoIated
D.C. current source applied to the terminals
used for the external potentiometer:
nternal impedance 1.5 kC.
A variation of 0.5 V corresponds to a
voltage adjustment of 10%.
0 1 s 2 s 3 s
Time

LAM
Variation in the Ioad

L
o
a
d

o
n

t
h
e
s
h
a
f
t

(
k
W
)
Load shedding due to LAM
14
2012.03 / e
R 450
AVRs
4531 en -
4 - INSTALLATION - COMMISSIONING
4.1 - EIectricaI checks on the AVR
- Check that all connections have been
made properly as shown in the attached
wiring diagram.
- Check the rotating switches selections
- frequency,
- type of alternator,
- normal position (response time),
- external potentiometer,
- rated voltage,
- secondary current of the CT used,
- type of excitation.
- R450 optional operating modes
4.2 - Setting up
The various adjustments during tests
must be made by a quaIied engineer. It
is essentiaI that the drive speed
specied on the namepIate is reached
before commencing adjustment. After
operationaI testing, repIace aII access
paneIs or covers.
The AVR is used to make any
adjustments to the machine.
4.2.1 - Setting up the R450
Before using the AVR, make sure that
the rotating switches have been
correctIy congured with AREP/SHUNT
or PMG excitation
a) nitial potentiometer settings (see table
below)
Action Factory setting Pot.
P1
P2
P3
P4
10 A
maximum
400 V - 50 Hz
Not set
(centre position)
Not set
(fully
anti-clockwise)
Excitation ceiling
- Factory-sealed
Voltage quadrature droop
(// operation with C.T.)
- 0 quadrature droop fully
anti-clockwise
Voltage
minimum fully
anti-clockwise
Stability
StabiIity adjustments in standaIone
operation
b) nstall a D.C. analogue voltmeter (needle
dial) cal. 100 V on terminals F+, F- and an
A.C. voltmeter cal. 300 - 500 or 1000 V on
the alternator output terminals.
c) Check the rotating switch selection.
d) Voltage potentiometer P1 at minimum,
fully anti-clockwise.

e) Stability potentiometer P2 around 1/3 in
from the anti-clockwise stop.
f) Start the engine and set its speed to a
frequency of 48 Hz for 50 Hz, or 58 for
60 Hz.
g) Set the output voltage to the desired
value using P1.
- Rated voltage U
N
for solo operation
(eg. 400 V)
- Or U
N
+ 2 to 4% for parallel operation with
C.T. (eg. 410 V -)
f the voltage oscillates, use P2 to make
adjustments (try both directions), observing
the voltage between F+ and F- (approx.
10 V D.C.). The best response time is
obtained at the limit of the instability. f no
stable position can be obtained, try selecting
the fast position.
h) Check LAM operation: depending on the
rotating switch selection.
2012.03 / e
LEROY-SOMER
15
R 450
AVRs
4531 en -
i) Vary the frequency (speed) around 48 or
58 Hz according to the operating frequency,
and check the change in voltage from that
observed previously (~ 15%).
j) Readjust the speed of the genset to its
rated no-load value.
Adjustments in parallel operation
Before starting work on the alternator, make
sure that the speed droop is identical for all
engines.
k) Preset for parallel operation (with C.T.
connected to S1, S2)
- Potentiometer P4 (quadrature droop) in
1/4 position in the case of 5A CT and at 1/2
position in the case of 1A CT.
Apply the rated load (PF = 0.8 inductive).
The voltage should drop by 2 to 3% (400 V).
f it increases, check that neither V and W
nor S1 and S2 have been reversed.
I) The no-load voltages should be identical
for all the alternators intended to run in
parallel.
- Couple the machines in parallel.
- By adjusting the speed, try to obtain 0 kW
power exchange.
- By altering the voltage setting P1 on one of
the machines, try to cancel (or minimise) the
current circulating between the machines.
- From now on, do not touch the voltage
settings.
m) Apply the available load (the setting is
only correct if a reactive load is available)
- By altering the speed, match the kW (or
divide the rated power of the units
proportionally)
- By altering the quadrature droop
potentiometer P4, match or divide the
currents.
4.2.2 - Max. excitation adjustment
(excitation ceiIing)
n standard setting, the potentiometer P3 is
in maximum position.
However, for applications requiring an
overload protection (see 3.2.1.4), the
excitation ceiling must be adjusted by using
the following procedures in AREP and PMG.
Method 1 :
-Connect the AVR to the alternator
-apply load to 110% of rated machine rated
at PF=0.8, the green led is on and the red
one is off.
-record the excitation current value
-adjust P3 until obtaining the red led fashing,
the green one is always on.
-decrease the load to 100% and make sure
that the red led is off.
- ncrease the load at 115%, check that the
red LED fashes during 90 seconds and that
the excitation current is brought back to the
above adjusted value (
ex adjusted
).
Method 2 :
The rated excitation current (see machine
plate) must be multiplied by 1.1 and the
obtained value is used to set the
potentiometer P3 at the right position.
The following table must be used.
Position of
P3
exc (A)
8h 1
9h 1.55
10h 1.95
11h 2.5
12h 3.15
13h 3.65
14h 4.25
15h 4.7
16h 5.15

P3
8H
12H
16H
NB: n the case of a permanent short-circuit,
the excitation current must reach 2.9 x
ex

adjusted (limited to 9.5A), during 1 second
in AREP or 10 seconds in PMG and shuts
down to a value less than 1A.
16
2012.03 / e
R 450
AVRs
4531 en -

When the excitation current is set to the
rated vaIue, a voItage dip is observed in
excitation current Iimit when the
Iimitation is activated and the current
Iimit is reached.
4.2.3 - SpeciaI type of use

WARNING

The excitation circuit F+, F- must not be
Ieft open when the machine is running:
this wiII irreparabIy damage the AVR.
4.2.3.1 - R450 (SHUNT) eId weakening
X2
Z1
X1
Z2
E+
E-
The exciter is switched off by disconnecting
the AVR power supply (1 wire - X1 or X2)
Contact rating: 16 A - 250 V A.C.
4.2.3.2 - R450 (AREP/PMG) eId
weakening
X2
Z1
X1
Z2
E+
E-
The exciter is switched off by disconnecting
the AVR power supply (1 wire on each
auxiliary winding) - contact rating 16 A -
250 V A.C.
Connection is identical for resetting the AVR
internal protection.

If eId weakening is used, provide eId
forcing.
4.2.3.3 - R450 eId forcing
AppIications B VoIt Time t
Guaranteed voltage build-up 12 (1A) 1 - 2 s
Parallel operation, de-energized 12 (1A) 1 - 2 s
Parallel operation, at standstill 12 (1A) 5 - 10 s
Frequency starting 12 (1A) 5 - 10 s
Sustained voltage on overload 12 (1A) 5 - 10 s
X2
Z1
X1
Z2
E+
E-
Battery (B Volt)
+ - t
(400V - 10A)
Exciter field winding
Diode
t
B Volt
Field forcing
Time
2012.03 / e
LEROY-SOMER
17
R 450
AVRs
4531 en -
4.3 - EIectricaI fauIts
Fault Action Measurements Check/Cause
No voltage at
no load on
start-up
Connect a new battery
of 4 to 12 V to terminals
F- and F+, respecting
the polarity, for 2 to 3
seconds
The alternator builds up and its
voltage is still correct when the
battery is removed
- Lack of residual magnetism
The alternator builds up but its
voltage does not reach the rated
value when the battery is removed
- Check the connection of the voltage
reference to the AVR
- Faulty diodes
- Armature short-circuit
The alternator builds up but its
voltage disappears when the
battery is removed
- Faulty AVR
- Field windings disconnected
- Revolving feld coil open circuit. Check the
resistance
Voltage too
low
Check the drive speed
Correct speed
- Check the AVR connections and settings
(AVR faulty)
- Field windings short-circuited
- Rotating diodes burnt out
- Revolving feld coil short-circuited
- Check the resistance
Speed too low
ncrease the drive speed
(Do not touch the AVR voltage pot. (P1)
before running at the correct speed)
Voltage too
high
Adjust AVR voltage
potentiometer
Adjustment ineffective - Faulty AVR
- 1 faulty diode
Voltage
oscillations
Adjust AVR stability
potentiometer
f no effect: try normal/fast
recovery modes
- Check the speed: possibility of cyclic
irregularity
- Loose connections
- Faulty AVR
- Speed too low when on load
(or U/F knee-point set too high)
Voltage
correct at no
load and too
low when on
load (*)
Run at no load and
check the voltage
between F+ and F- on
the AVR
Voltage between F+ and F-
AREP/PMG < 10 V
- Check the speed
(or U/F knee-point set too high)
Voltage between F+ and F-
AREP/PMG > 15 V
- Faulty rotating diodes
- Short-circuit in the revolving feld coil.
Check the resistance
- Faulty exciter armature
(*) Caution: For single-phase operation, check that the sensing wires coming from the AVR are correctly connected to
the operating terminals.
Voltage
disappears
during
operation (**)
Check the AVR, the
surge suppressor, the
rotating diodes, and
replace any defective
components
The voltage does not return to the
rated value
- Exciter winding open circuit
- Faulty exciter armature
- Faulty AVR
- Revolving feld coil open circuit or
short-circuited
- Overload (see LED)
(**) Caution: nternal protection may be activated (overload, open circuit, short-circuit)
Caution: After operationaI testing or
troubIeshooting, repIace aII access
paneIs or covers.
18
2012.03 / e
R 450
AVRs
4531 en -
5 - SPARE PARTS
5.1 - Designation
Description Type Code
Voltage regulator
(AVR)
R 450 AEM 110 RE 031
5.2 - TechnicaI support service
Our technical support service will be pleased to
provide any additional information you may
require.
When ordering spare parts, you should indicate
the AVR type and code number.
Address your enquiry to your usual contact.
Our extensive network of service centres can
dispatch the necessary parts without delay.
To ensure correct operation and the safety of our
machines, we recommend the use of original
manufacturer spare parts.
n the event of failure to comply with this advice,
the manufacturer cannot be held responsible for
any damage.
2012.03 / e
LEROY-SOMER
19
R 450
AVRs
4531 en -
www.leroy-somer.com

LIST OF PLANS

Equipment: DETAILED ENGINEERING
Order: VEC001101

DOCUMENT ORDER
DATE
Nov-2012
List of plans VEC001101
INDEX

CUSTOMER
ROYAL GK PTE LTD

CONSISTENTS WITH OUR CONTINUAL PRODUCT IMPROVEMENT POLICY, GUASCOR POWER RESERVES THE RIGHT TO CHANGE ANY SPECIFICATION WITHOUT PRIOR NOTICE. i

- CONTENTS -
1 SITUATION AND LOCATION .......................................................................... 1
2 PROCESS DIAGRAMS AND P&IDS ............................................................... 2
3 ELECTRICAL SINGLE LINE DIAGRAMS ....................................................... 3
4 LAY-OUT .......................................................................................................... 4
5 CIVIL ENGINEERING....................................................................................... 5
6 STRUCTURE .................................................................................................... 6
7 PIPING AND DUCTING .................................................................................... 7
8 SECURITY AND HEALTH ............................................................................... 8

DOCUMENT ORDER
DATE
Nov-2012
INDEX

CUSTOMER
ROYAL GK PTE LTD

CONSISTENTS WITH OUR CONTINUAL PRODUCT IMPROVEMENT POLICY, GUASCOR POWER RESERVES THE RIGHT TO CHANGE ANY SPECIFICATION WITHOUT PRIOR NOTICE. 1

1 SITUATION AND LOCATION
Code TITLE SIZE Revision

DOCUMENT ORDER
DATE
Nov-2012
INDEX

CUSTOMER
ROYAL GK PTE LTD


2 PROCESS DIAGRAMS AND P&IDS
12-01 Genset flow diagram A3 0
13-01 Engine cooling system P&Id diagram A3 0
13-02 Lube oil P & ID diagram A3 0
13-03 Natural gas P&Id diagram A2 0
13-04 Engine Exhaust Gas P&Id diagram A3 0

ENGINE EXHAUST GAS

P&Id DIAGRAM

DOCUMENT ORDER
DATE
Nov-2012
INDEX

CUSTOMER
ROYAL GK PTE LTD


3 ELECTRICAL SINGLE LINE DIAGRAMS
21-01 MT Single line diagram - Power plant A1 0
21-02
MT Single line diagram - Detail of head protection
cells
A2 0
21-03 MT Single line diagram - Typical Genset A2 0
22-01
BT Single line diagram. General switchboard of
power plant aux services
A3 0
22-02 BT Single line diagram. Engine rooms switchboards A3 0
22-03
BT Single line diagram. Workshop switchboard and
power socket
A3 0
24-01 Diagram of buried grounding grid distribution A1 0
24-02 Grounding grid. Details 0
25-01 Lights and lighting rods location A1 0
26-01 Power and lighting installation A1 0
29-01 Lighting rods protection area A1 0

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DATE
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INDEX

CUSTOMER
ROYAL GK PTE LTD


4 LAY-OUT
31-01 General Lay-out A1 0
31-11 Lay-out genset n-1 A3 0
31-12 Lay-out genset n-2-13 A3 0
31-13 Lay-out genset n-14 A3 0
31-14 Lay-out genset n-15-26 A3 0
35-01 Fire-Gas Detection & Extintion System Layout A3 0
39-01 General Lay-out. Actual and future A0 0

Scale: 1:50
LAY-OUT GENSET N1
1
Scale: 1:500
LAY-OUT GENERAL
1
Scale: 1:50
LAY-OUT GENSET N2-13
2
Scale: 1:500
LAY-OUT GENERAL
1
Scale: 1:50
LAY-OUT GENSET N1+
14
Scale: 1:500
LAY-OUT GENERAL
1
Scale: 1:50
LAY-OUT GENSET N15-26
2
Scale: 1:500
LAY-OUT GENERAL
1

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DATE
Nov-2012
INDEX

CUSTOMER
ROYAL GK PTE LTD


5 CIVIL ENGINEERING
41-01 URBANIZATION. STAKEOUT BENCHMARK +0.00 0
41-02
URBANIZATION. FOUNDATION IN
UNDERGROUND INSTALLATIONS
0
41-03 URBANIZATION. GENERAL SECTIONS 0
41-04 URBANIZATION. TRENCH AND DETAILS. 0
41-05
FOUNDATION. TRANSFORMERS, GENSETS
AND DETAILS
0
41-06
FOUNDATION. WALLS, RMS, CELLS CABINET
AND DETAILS
0
42-01
ENGINE ROOM 1. PLANTA, PLANTA DE
CUBIERTA Y CUADRO DE CARPINTERIA
0
42-02 ENGINE ROOM 1. FRONT VIEW AND SECTION 0
42-03
ENGINE ROOM 1. FOUNDATION AND
STRUCTURE (BENCHMARK+1.00)
0
42-04
ENGINE ROOM 1 STRUCTURE (BENCHMARK
+4.00) AND COVER STRUCTURE
0
42-05
ENGINE ROOM 1 STRUCTURE FRONT VIEW
AND SECTION
0
42-06
ENGINE ROOM 2. TOP VIEW, COVER TOP VIEW
AND CARPENTRY FRAME
0
42-07 ENGINE ROOM 2. FRONT VIEW AND SECTION 0
42-08
ENGINE ROOM 2. FOUNDATION AND
STRUCTURE (BENCHMARK+1.00)
0
42-09
ENGINE ROOM 2 STRUCTURE (BENCHMARK
+4.00) AND COVER STRUCTURE
0
42-10
ENGINE ROOM 2 STRUCTURE FRONT VIEW
AND SECTION
0
42-11
ENGINE ROOMS 1 Y 2. FOUNDATION DETAILS
AND STRUCTURE
0
42-12
ENGINE ROOMS 1 Y 2. CONSTRUCTIVE
SECTIONS
0
42-17
AUXILIARY SERVICES BUILDING. FOUNDATION
DETAILS AND STRUCTURE
0

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DATE
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ROYAL GK PTE LTD


6 STRUCTURE

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7 PIPING AND DUCTING
65-01 Natural gas. General connection 0
61-02 Lay-out natural gas 0

Scale: 1:100
LAY OUT NATURAL GAS
1

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DATE
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ROYAL GK PTE LTD


8 SECURITY AND HEALTH


LIST OF MATERIALS

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ORDER
DATE
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LIST OF MATERIALS VEC001101
INDEX

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LINE MATERIAL LIST

LIST OF ELECTRICAL AND CONTROL MEASUREMENTS

LINE MATERIAL LIST
Order: VEC001101

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DATE
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Line material list VEC001101
INDEX

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ROYAL GK PTE LTD


- CONTENIDO -
1 NATURAL GAS .................................................................................................. 1

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DATE
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1 NATURAL GAS
Short Description Long Description (Size) Spec Size (")
Pressure
Class (bar) Cant Cut Length
Ball valve
Threaded ball valve, two piece, full bore Thr-F PN64,
DN15 A10 1/2

1

4

Total Ball valve

Butterfly valve Butterfly valve ND 200-PN 16, C, L=60.0 A10 8 10 4
Total Butterfly
valve

Cap Cap EN 10253-1 A10 8 ( 2 (
Total Cap

Elbow Elbow EN 10253-1; 90; 3D A10 2 1/2

52

3

78

8

14

Total Elbow

Flange Flange SW EN 1092-1, tipo 01, cara A PN10 A10 2 1/2 10 130

3 10 104

8 10 30

Total Flange

Flange adaptor Flange adaptor PE100 SRD11 PE1 8 ( 4 (
Total Flange
adaptor

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Short Description Long Description (Size) Spec Size (")
Pressure
Class (bar) Cant Cut Length
FLEXIBLE HOSE FLEXIBLE HOSE, FL 1000mm A10 8

4

FLEXIBLE HOSE, FL 500mm A10 2 1/2

26

3

26
Total FLEXIBLE
HOSE

Pipe Pipe polyetilen SDR11 PE1 8

25m

Seamless Pipe EN 10255 medium series M A10 1/2

6m

2 1/2

10m

8

200m
Total Pipe

LIST OF ELECTRICAL AND CONTROL
MEASUREMENTS

POWER CABLE LIST OF
LOW VOLTAGE
Order: VEC001101

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DATE
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Power Cable list of Low Voltage VEC001101
INDEX

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ROYAL GK PTE LTD


- CONTENIDO -
1 MEASUREMENT TABLES ................................................................................ 1

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DATE
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1 MEASUREMENT TABLES
POS
DESCRIPTION

Unit AMOUNT AMOUNT AMOUNT Terminal AMOUNT
Batch Stretches Total Batch
POWER TERMINAL AND CABLE OF LOW
VOLTAGE

30
Single-pole cable of 0,6/1 kV isolation, with flexible
copper conductor, class 5, isolation of crosslinked
polyethylene (R) and PVC cover (V), for the
following sections:

30.a 1 x 240 mm2 m 53 52 10.344
Low voltage
terminal 0,6/1kV
for copper
conductor of 240.
1.248
30.a1
Stretch from Generator to genset power switchboard
3(4(1x240)) RV-K 0,6/1kV
m 17 26 5.304 UD 624
30.a2
Stretch from each genset power switchboard to
Transformers 3(4(1x240)) RV-K 0,6/1kV
m 16 25 4.800 UD 600
30.a3
Strecht from genset 13 power switchboard to T13
transformer 3(4(1x240)) RV-K 0,6/1kV
m 20 1 240 UD 24

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POS
DESCRIPTION

Unit AMOUNT AMOUNT AMOUNT Terminal AMOUNT
Batch Stretches Total Batch
POWER TERMINAL AND CABLE OF LOW
VOLTAGE

30.b 1 x 120 mm2 m 46 1 184
Low voltage
terminal 0,6/1kV
for copper
conductor of 120.
8
30.b1
Strecht from power switchboard of power plant
auxiliary services to auxiliary services T14
Transformer 4(1(1x120)) RV-K 0,6/1kV
m 46 1 184 UD 8

MEDIUM VOLTAGE
CABLE LIST
Order: VEC001101

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DATE
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Medium Voltage Cable List VEC001101
INDEX

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ROYAL GK PTE LTD


- CONTENIDO -
1 MEASUREMENT TABLES ................................................................................ 1

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DATE
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1 MEASUREMENT TABLES

DESCRIPTION

POS Unit AMOUNT AMOUNT Terminal AMOUNT
actual Batch Total Batch

POWER TERMINAL AND CABLE OF
MEDIUM VOLTAGE

15
Medium voltage cable, single-pole, of flexible copper,
class 2, with 26/45 kV isolation, type HMA (with
frame of aluminum wire) (AWA), for the following
sections:

15.a 1 x 240 mm2 m 280 1.680
Thermo-retactable
terminal for outside
location of 240
26/45kV, for copper
conductor with
frame of aluminum
wire.
24
15.a1
From T15 protection cell to T15 transformer (35
MVA) and from transformer to cell cabinet (cell C15)
3(2(1x240))
m 140 840 UD 12
15.a2
From T16 protection cell to T16 transformer (35
MVA) and from transformer to cell cabinet (cell C16)
3(2(1x240))
m 140 840 UD 12

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DESCRIPTION

15.b 1 x 95 mm2 m 618 1.854
Thermo-retactable
terminal for outside
location of
9526/45kV, for
copper conductor
with frame of
aluminum wire
84
15.b1
From T1 transformer (2,5 MVA) to C1 protection
cell 3(1x95))
m 52 156 UD 6
15.b2
cell 3(1x95))
m 43 129 UD 6
15.b3
cell 3(1x95))
m 34 102 UD 6
15.b4
cell 3(1x95))
m 32 96 UD 6
15.b5
cell 3(1x95))
m 41 123 UD 6
15.b6
cell 3(1x95))
m 50 150 UD 6
15.b7
cell 3(1x95))
m 52 156 UD 6
15.b8
cell 3(1x95))
m 43 129 UD 6

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DESCRIPTION

15.b9
cell 3(1x95))
m 34 102 UD 6
15.b10
cell 3(1x95))
m 32 96 UD 6
15.b11
cell 3(1x95))
m 41 123 UD 6
15.b12
cell 3(1x95))
m 50 150 UD 6
15.b13
cell 3(1x95))
m 57 171 UD 6
15.b14
cell 3(1x95))
m 57 171 UD 6

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DETAILED ENGINEERING

Checking the windings and

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4.7 - InstaIIation and maintenance of

MTEU"#LE"Y#ME" ML#HLCE#TL#" MTEU"#LE"Y#ME"

ENGINE EXHAUST GAS

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