property of american airlines maintenance · 2018-12-03 · hitzinger-acon which can be only...

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Maintenance

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2. MAINTENANCE

CONTENTS

2.1 SERVICING ............................................................................................................................. 3 2.1.1 Safety instructions .......................................................................................................... 3 2.1.2 Servicing operation ......................................................................................................... 4

2.1.2.1 Elements for servicing on operation panel ............................................................ 4 2.1.2.1.1 Display-Menu „Enter password“........................................................................ 4 2.1.2.1.2 Display-Menu „TEST“ ....................................................................................... 5 2.1.2.1.3 Display-Menu „STACK Detail“ .......................................................................... 7 2.1.2.1.4 Display-Menu „SETUP“..................................................................................... 8

2.1.3 Device settings ............................................................................................................... 9 2.1.3.1 Voltage regulator 200/115V 400Hz adjustment..................................................... 9 2.1.3.2 Thermal relay adjustment ...................................................................................... 9 2.1.3.3 Speed / Frequency adjustment.............................................................................. 9 2.1.3.4 Adjustments for 50Hz frequency converter (Option) ............................................. 9

2.1.4 Servicing schedule........................................................................................................ 10 2.1.4.1 Non-periodic maintenance works for new or overhauled engines....................... 10 2.1.4.2 Periodic maintenance works................................................................................ 10

2.1.5 SERVICING WORKS.................................................................................................... 11 2.1.5.1 Check fuel level ................................................................................................... 11 2.1.5.2 Check oil level of reservoir (Option) .................................................................... 11 2.1.5.3 Check coolant level ............................................................................................. 11 2.1.5.4 Check cooling system.......................................................................................... 12 2.1.5.5 Clean Cooler........................................................................................................ 12 2.1.5.6 Renew engine oil with oil drain valve................................................................... 13 2.1.5.7 Drain coolant ....................................................................................................... 14 2.1.5.8 Load run at continuous low load operation.......................................................... 14 2.1.5.9 Lubricate trailer.................................................................................................... 14 2.1.5.10 Lubricate canopy ................................................................................................. 15 2.1.5.11 Check canopy...................................................................................................... 15 2.1.5.12 Check screws on trailer ....................................................................................... 15 2.1.5.13 Check adjustment of brakes and readjust if necessary ....................................... 16 2.1.5.14 Check exhaust system ........................................................................................ 16 2.1.5.15 Check elastic mounting of genset........................................................................ 16 2.1.5.16 Check hoses and clamps on air intake side ........................................................ 16 2.1.5.17 Check battery connections .................................................................................. 17 2.1.5.18 Visual inspection of switch panel......................................................................... 17 2.1.5.19 Check output cables and plugs ........................................................................... 17 2.1.5.20 Check LED’s........................................................................................................ 17 2.1.5.21 Check measuring unit of Hitzinger-ACON ........................................................... 17 2.1.5.22 4kV Insulation test (IT)......................................................................................... 18

2.1.5.22.1 General preparations..................................................................................... 18 2.1.5.22.2 Testing operation........................................................................................... 18

2.1.5.22.2.1 Testing procedure.................................................................................. 18 2.1.5.22.2.2 Measuring points ................................................................................... 19

2.1.5.22.3 Evaluation and test determination ................................................................. 19 2.1.5.23 Check complete function ..................................................................................... 20

2.1.5.23.1 Preparation.................................................................................................... 20 2.1.5.23.2 Operation....................................................................................................... 20 2.1.5.23.3 Alarm and trip simulation............................................................................... 22

2.1.5.23.3.1 Common control + auxiliaries failures.................................................... 22 2.1.5.23.3.2 Diesel engine + genset failures ............................................................. 23 2.1.5.23.3.3 400Hz alternator failures........................................................................ 26 2.1.5.23.3.4 28VDC (option) failures ......................................................................... 31

D POWER1 Edition 01 - Page 1 / 43

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2.2 TROUBLESHOOTING ........................................................................................................... 33 2.2.1 FAILURES .................................................................................................................... 33

2.2.1.1 Common control + auxiliaries failures ................................................................. 33 2.2.1.2 Diesel-engine + genset failures ........................................................................... 35 2.2.1.3 400Hz alternator failures ..................................................................................... 39 2.2.1.4 28VDC (option) failures ....................................................................................... 42

2.2.2 RESISTANCE MEASURING POINTS AND NOMINAL VALUES................................. 43


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2. MAINTENANCE

2.1 SERVICING

2.1.1 Safety instructions

WARNING

Only persons which are special trained are allowed to carry out service and trouble shooting works.

WARNING

Before inspecting or servicing electrically-powered equipment, take the following precautions: 1. Switch off battery main switch. 2. Disconnect all output cables. 3. Do not remove covers before switch off battery main switch.

WARNING

If troubleshooting must be done with the unit energised, have another person present who is trained in turning off the unit and providing or calling for first aid.

WARNING

Serious injury can result from contact with fans inside some equipment. Shut down and disconnect minus of such equipment for inspection and routine maintenance. When equipment is in operation use extreme care in performing necessary trouble-shooting and adjustment. Don’t remove guards, while equipment is operating.

WARNING

Care must be taken to avoid scalding by escaping vapour when removing the filler cap from the pressurised radiator on a hot engine.

To avoid scald let engine cool down before opening Diesel engine water cooler.

CAUTION

Batteries can explode or give off flammable hydrogen gas. Acid (if no gel batteries are used) and arcing from a ruptured battery can cause and additional failures. While servicing, don’t smoke, cause sparks or use open flame in the surroundings of the battery.

WARNING !

Use ears protection when maintenance flaps are opened!


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2. MAINTENANCE

2.1.2 Servicing operation

2.1.2.1 Elements for servicing on operation panel

NOTE!

This chapter describes the operation elements necessary for service operation.

The Display-Menu „TEST“ and „ STACK Detail” and also the “RESET” of service working hours in Display-Menu „Measurement DIESEL“ are password protected (access only for authorized trained personal).

2.1.2.1.1 Display-Menu „Enter password“

NOTE!

You receive the password from our customer service.

(Warning will be displayed only when changing to display-menu „TEST“)


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2.1.2.1.2 Display-Menu „TEST“

(access via Display-Menu „Measurement”)

1 Button "Ignition on/off" For programming of speed controller at standstill. Ignition off = stop of GPU (diesel engine)

2 Lamp "Ignition on" Green LED continuous light in case of ignition on.

3 Button "Motor Start" Start of GPU (Diesel engine)

4 Combined button+signal lamp "Automatic oil-refill" (Option) Yellow signal lamp: "oil level check" for signalling the operation status of automatic oil-refill. Button: Button for test operation and reset button for failures of automatic oil-refill.

5 Signalling "Failure message available" By pushing on this signal, the screen changes to Display-Menu „Messages“.

6 Button "400Hz voltage test on/off " Switching on and off of manual voltage adjustment (400Hz). Switching off - the voltage is automatically regulated by ACON to the preset nominal value.

7 Lamp "400Hz voltage test on" Green LED continuous light in case of voltage test on.

8 Display "400Hz voltage and frequency"

9 Combined button+display "400Hz voltage input field and display of nominal value" By pushing the input field is open. Select a nominal value and press enter to save.

10 Button "SET 400Hz voltage" By pushing button “SET” the voltage is automatically regulated to the selected value.

11 Button "SETUP“ Change to Display-Menu „SETUP“

12 Lamp "Bypass 400Hz 1 on" LED continuous light in case of Bypass 400Hz 1 on.

13 Button "Bypass 400Hz 1 on/off " Manually release of 400Hz 1 output contactor, without closing EF-contact.

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14 Lamp "Bypass 400Hz 2 on" LED continuous light in case of Bypass 400Hz 2 on.

15 Button "Bypass 400Hz 2 on/off" Manually release of 400Hz 2 output contactor, without closing EF-contact.

WARNING !

Switch on of the Bypass-switch is only allowed for servicing works. Because during handling of the cables the existence of dangerous voltage on the 400Hz aircraft plug may be possible!

In case of activated 400Hz by-pass switch (message "BY-PASS ON") and alternator voltage available the outputs can be switched on at any time (protection on plugs bridged). " This condition is not allowed for normal air side operation!

16 Button "DPF regeneration on/off" (Option) Switching on and off of diesel particle filter regeneration (only DPF system with passive regeneration).

17 Button "Speed test on/off" Switching on and off of manual speed adjustment. Switching off - the speed is automatically regulated by ACON to the preset nominal value.

18 Lamp "Speed test on" Green LED continuous light in case of diesel engine speed test.

19 Display "Speed"

20 Combined button+display "Speed input field and display of nominal value" By pushing the input field is open. Select a nominal value and press enter to save.

21 Button "SET speed" By pushing button “SET” the speed is automatically regulated to the selected value.

22 Button "STACK Detail" Change to Display-Menu “STACK Detail” (Password protected!).

23 Button "28VDC voltage test on/off" Switching on and off of manual voltage adjustment (28VDC). Switching off - the voltage is automatically regulated by ACON to the preset nominal value.

24 Lamp "28VDC voltage test on" Green LED continuous light in case of voltage test on.

25 Display "28VDC voltage"

26 Combined button+display "28VDC voltage input field and display of nominal value" By pushing the input field is open. Select a nominal value and press enter to save.

27 Button "SET 28VDC voltage" By pushing button “SET” the voltage is automatically regulated to the selected value.

28 Button "HOME" Change to Display-Menu „HOME“.

29 Button "28 VDC" Change to Display-Menu „Measurement 28VDC“.

30 Button "DIESEL" Change to Display-Menu „Measurement Diesel“.

31 Button "400Hz" Change to Display-Menu „Measurement 400Hz“.


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2.1.2.1.3 Display-Menu „STACK Detail“

1 Button "Module on/off“ Switching on and off of individual modules.

WARNING !

Switch on of the 28VDC Modules is only allowed for servicing works, because immediately there is a dangerous voltage on the 28VDC aircraft plug!

This condition is not allowed for normal air side operation!

2 Display "Module-Temperature"

3 Display "Modul-Current"

4 Display "Group 1 Voltage" (Option) Only with 2 x 28VDC outputs aktivated – 28VDC voltage on output 1.

5 Display "STACK Voltage" If only one 28VDC output is available - 28VDC voltage at the output.

6 Display "Group 2 Voltage" (Option) Only with 2 x 28VDC outputs aktivated – 28VDC voltage on output 2.

7 Button "TEST" Change to Display-Menu “TEST“

8 Button "HOME“ Change to Display-Menu “HOME“.

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2.1.2.1.4 Display-Menu „SETUP“

(access via Display-Menu „Home”)

1 Display "System data" Information about Type, Order no., ACON Version, TSwin Version and IP address can be found.

2 Combined button+display "Script Execution" (Option) Default with "0". Possibility of performing additional startup scripts (Option). By pushing the input field is open. Select and press enter to save.

3 Combined button+display "LCD Background" By pushing the input field is open. Select background brightness / contrast of the display and press enter to save.

4 Combined button+display "Date" By pushing the input field is open. Select date and press enter to save.

5 Combined button+display "Time" By pushing the input field is open. Select time and press enter to save.

6 Button "SET Date/Time" By pushing button “SET” the selected date and time are taken as new setpoints.

7 Button "Language" Select language by pushing buttons marked with the national colors.

8 Button "HOME" Change to Display-Menu „HOME“

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2.1.3 Device settings

Voltage regulator 200/115V 400Hz

Thermo-Relais 400Hz Hitzinger-ACON Engine – diagnostic regulator connection

2.1.3.1 Voltage regulator 200/115V 400Hz adjustment

Adjustment of nominal voltage and voltage droop are software settings (parameter) in the Hitzinger-ACON which can be only changed by using a programming device (PC).

Only for servicing the voltage can be changed temporary (see Display-Menu „TEST“). T21: Turn both potentiometers fully clockwise and then back to vertical position.

Do not turn to minimum or maximum position. AVC63: Potentiometer „DRP“ (Line Drop Compensation) turn fully counterclockwise.

Potentiometer „STB“ (Stability) turn to 8 o’clock. Remove connections 2 and 3, short terminals 2 and 3, adjust potentiometer „VLT ADJ“ (voltage adjust) at no load to nominal voltage 115 V (L-N) and finally reconnect terminals 2 and 3.

2.1.3.2 Thermal relay adjustment

Adjust 400Hz thermal relays to nominal current (refer to wiring diagrams)

2.1.3.3 Speed / Frequency adjustment

These are software settings and can be changed only by using engine programming device (Engine – diagnostic regulator connection).

Only for servicing the speed can be changed temporary (see Display-Menu „TEST“).

2.1.3.4 Adjustments for 50Hz frequency converter (Option)

Adjustment of 50Hz frequency converter is factory made (software) and must not be readjusted manually.


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2.1.4 Servicing schedule

2.1.4.1 Non-periodic maintenance works for new or overhauled engines

Description of action Interval (h) Description see

Check engine for leakage’s 50 - 150 Engine manual

Check engine oil 50 - 150 Engine manual

Check fuel prefilter 50 - 150 Engine manual

Check fuel system 50 - 150 Engine manual

Check engine mounts 50 - 150 Engine manual

Check coolant, additive-concentration 50 - 150 Engine manual

Check v-belts (retension if necessary) 50 - 150 Engine manual

Check screws on trailer Before first putting into operation 2.1.5.12

Check screws on trailer After 1 and 4 week operation 2.1.5.12

2.1.4.2 Periodic maintenance works

Description of action Interval (h) Description see

Check oil level in the sump daily Engine manual

Check fuel level daily 2.1.5.1

Check oil level of reservoir (Option) daily 2.1.5.2

Check air filter daily Engine manual

Check coolant level daily 2.1.5.3

Check cooling system 125 2.1.5.4

Clean Cooler If necessary 2.1.5.5

Drain water separator acc. Maintenance plan Engine manual

Check coolant, additive-concentration acc. Maintenance plan Engine manual

Renew engine oil acc. Maintenance plan Engine manual + 2.1.5.6

Renew oil filter cartridge acc. Maintenance plan Engine manual

Renew fuel filter cartridge acc. Maintenance plan Engine manual

Check v-belts (retension if necessary) acc. Maintenance plan Engine manual

Check fuel prefilter acc. Maintenance plan Engine manual

Check glow plugs acc. Maintenance plan Engine manual

Check hoses/clamps on air intake side acc. Maintenance plan Engine manual

Check valve clearance and rocker arm clearance (readjust if necessary)

acc. Maintenance plan Engine manual

Check fuel system (leakage line, change defective lines) acc. Maintenance plan Engine manual

Renew coolant acc. Maintenance plan Engine manual + 2.1.5.7

Load run in case of permanent low-load operation 500 - 1000 2.1.5.8

Lubricate trailer annual 2.1.5.9

Lubricate canopy annual 2.1.5.10

Check canopy annual 2.1.5.11

Check screws on trailer annual 2.1.5.12

Check adjustment of brakes and readjust if necessary annual 2.1.5.13

Check exhaust system annual 2.1.5.14

Check elastic mounting of genset annual 2.1.5.15

Check hoses and clamps on air intake side annual 2.1.5.16

Check battery connections annual 2.1.5.17

Visual inspection of switch panel annual 2.1.5.18

Check output cables and plugs annual 2.1.5.19

Check bulbs and LED’s annual 2.1.5.20

Check measuring unit of Hitzinger-ACON annual 2.1.5.21

4kV insulation test (Option) annual 2.1.5.22

Check complete function annual 2.1.5.23

Check adjustments annual 2.1.3


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2. MAINTENANCE

2.1.5 SERVICING WORKS

2.1.5.1 Check fuel level

Check fuel on gauge nearby filling socket. Refill fuel according chapter fuel of engine operation manual if necessary.

WARNING

Care must be taken to avoid breathe in toxical fumes. Keep enough distance during replenishing.

2.1.5.2 Check oil level of reservoir (Option)

The oil level must be within the MIN and MAX markings. Refill lubrication oil if necessary.

2.1.5.3 Check coolant level

The water level must be above middle of the lower inspection glass – refill if necessary (coolant acc. chapter operating materials of engine operation manual).

WARNING !

Care must be taken to avoid scalding by escaping vapour when removing the filler cap from the pressurised radiator on a hot engine.

To avoid scald let engine cool down before opening Diesel engine water cooler.


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2.1.5.4 Check cooling system

Check tightness of the cooling system (if necessary tighten hose clamps or replace hoses).

Check the cooler, when it is dirty, clean it.

2.1.5.5 Clean Cooler

If the cooler is dirty (GPU deliver not enough power), you have to clean the cooler with a damp streamer (low pressure)

ATTENTION!

Engine with DEUTZ Diesel particle filter - DPF-System (Option)

The insolation of the exhaust line must not be damaged! Do not wash the engine!

Loosen locking device of air outlet duct on the bottom left and right. Remove air outlet duct through two persons by lifting up (~40mm) and carefully move

forward.

NOTE !

Lower air outlet duct carefully on a prepared soft padded surface (for example foam or cardboard) to avoid scratch of glass-fibre-surface.

Clean cooler with damp streamer (low pressure). Blow out cooler and cooling fins always from exhaust side to fresh air side.

Warm up engine and cooler that water residues evaporate. Mount air outlet duct carefully. Snap in locking device of air outlet duct on the bottom left and right.


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2.1.5.6 Renew engine oil with oil drain valve

,,

Check that GPU is on a level surface. Allow engine to warm up (lube oil temperature

approx. 80°C, approx. 2 minutes). Shut down engine. Place oil tray under oil drainage. Unscrew drain plug (1). Open cock (2). Drain oil. Close cock (2) Fit oil drain plug (1). Refill lube oil in oil filling socket (3) according chapter quality grade and viscosity of engine

operation manual (oil quantity see technical data).

ATTENTION !

Engine with DEUTZ Diesel particle filter - DPF-System (Option)

Use only the lubricating oil Quality Class DQC III LA (low ash oil)!

Pull oil dip stick and clean it with clean and fibre free rag. Put in oil dip stick until stop and pull it again.

Check oil level (must be underneath the ‘’MAX’’ mark) and refill if necessary.

WARNING !

Be careful when draining hot oil - danger of scalds! Do not let used oil run into the soil but catch in a container ready for proper disposal.

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2.1.5.7 Drain coolant

Place tray under drainage, Unscrew

drain plug and open cock.

Engine with DPF-System (Option) –- when filling with coolant vent cooler of exhaust gas recirculation (EGR).

2.1.5.8 Load run at continuous low load operation

When the engine is operated continuously with low load (load profile can be read on the controller), i.e. load at 90% of the time is below 30%, then soot deposits in the exhaust system increase the exhaust back pressure, which will cause damage to the engine. In this case it is necessary to operate the engine every 500h during servicing on the load bank with 100% load, so that the soot is burned by the higher exhaust temperature. Maximum allowable back pressure in the exhaust system (except particulate filter):

Deutz engines ~ 75 mbar Cummins engines ~ 100mbar.

NOTE!

100% shock load only possible after appr. 5 min. warm up of engine.

2.1.5.9 Lubricate trailer

DPF (Option):

Grease trailer on marked points until new grease leaves (grease quality K3K according to DIN 51825).

Grease sliding surface of drawbar Clean trailer of surplus grease.


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2.1.5.10 Lubricate canopy

Grease hinges, locks, guide rods with grease of quality K3K according to DIN 51825.

2.1.5.11 Check canopy

Check door sealing. Check function of gas springs. check function of locks. Check function of hinges.

2.1.5.12 Check screws on trailer

Check all screws on trailer for tight seat. Retighten wheel screws (M12x1,5) with 90Nm.

NOTE !

The wheel screws of the trailer have to be retighten before fist putting into operation, after 1 week operation, after 4 weeks operation, and then regularly once a year!


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2.1.5.13 Check adjustment of brakes and readjust if necessary

Check that brake cable starts to become tight about 10cm (measured on towing eye) before vertical and horizontal stop position. Touch the cable by hand to feel the beginning tightening.

Readjustment:

10cmStop Position

10cm

Stop Position

1. Lift up drawbar about 10cm from horizontal stop. 2. Adjust screw for horizontal adjusting until brake cable becomes tight. 3. Lower drawbar about 10cm from vertical lock. 4. Adjust screw for vertical adjusting until brake cable becomes tight.

2.1.5.14 Check exhaust system

Remove air outlet duct according item 2.1.5.5 Check and retighten mounting screws of silencer. Check and retighten clamps. Check tightness. Check condition of heat insulation inside the canopy. Mount air outlet duct according item 2.1.5.5

2.1.5.15 Check elastic mounting of genset

Check and retighten screws. Check condition and clearance of vibration dampers.

2.1.5.16 Check hoses and clamps on air intake side

Check tube between Engine and Airfilter (change it, if necessary) Retighten all clamps. Check low pressure switch.


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2.1.5.17 Check battery connections

WARNING

Take care that the battery poles are not short circuited!

Remove battery cover and pole covers Loosen battery clamps. Clean battery poles as well as clamps and lubricate them with an acid-free and

acid-resistant grease. During assembly pay attention that battery is not short circuited. Mount pole covers over connections and battery cover.

2.1.5.18 Visual inspection of switch panel

Check all components on perfect fit and clean them with compressed air and vacuum cleaner.

Check operation- and indication elements. Check all electric connections, retighten them, if necessary. Check cables on isolation damage.

2.1.5.19 Check output cables and plugs

Check cable isolation. Check plugs for damages and corrosion.

2.1.5.20 Check LED’s

Switch on control voltage via push button "Power". Push button "Options" (option) Switch on and of parking lights, spot light and revolving light and check function.

2.1.5.21 Check measuring unit of Hitzinger-ACON

Start Diesel engine. Load one 400Hz output with full load (maximum 90kVA cos 0,8). Compare voltage, current, frequency, cos and power measurements of Hitzinger-ACON

with measurements of external instruments (accuracy class at least 1%). Switch off checked output. Load second 400Hz output with full load (maximum 90kVA cos 0,8). Compare voltage, current, frequency, cos and power measurements of Hitzinger-ACON

with measurements of external instruments (accuracy class at least 1%). Switch off checked output. Load both 400Hz outputs with load (in summary nominal power of GPU) (cos 0,8). Compare voltage, current, frequency, cos and power measurements of Hitzinger-ACON

with measurements of external instruments (accuracy class at least 1%). Switch off checked outputs Load 28VDC output with nominal load (Option). Compare voltage, current and power measurements of Hitzinger-ACON with

measurements of external instruments (accuracy class at least 1%). The difference of Hitzinger-ACON measuring to instrument measuring must be less than

2%.


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2. MAINTENANCE

2.1.5.22 4kV Insulation test (IT)

(Only for ground power units with modified protective separation of 400Hz alternator from ground /earth according to DFS400)

2.1.5.22.1 General preparations

The GPU must be completely loaded (all electronic devices remain connected).

28VDC Power Stack (Option): disconnect supply cable (white) in 400Hz switch panel (U1/V1/W1)

No load may be hooked up to the output (400Hz cable). The parts to be tested must be free of dirt and moisture.

WARNING !

Safety precautions: Contact with energized parts is life threatening. Cordon off the entire test area, or employ one person who prevents unauthorized people from coming into proximity of the test object (minimum distance 1400mm).

2.1.5.22.2 Testing operation

2.1.5.22.2.1 Testing procedure

WARNING !

The test with 4000V (proof of modified separation in accordance with DFS 400) is carried out exclusively during inspection of rewinding: All additional repeat tests are carried out at a testing voltage of at most 2000V (risk of equipment damage).

Testing is always conducted to earth:

Testing voltage 50Hz Test time Notes

Stator winding 400Hz

2000V (Repeat testing) 1 min

Tested on the neutral point of the winding

Output (400Hz - cable)

2000V (Repeat testing)

1 min Each phase is tested to earth

The testing voltage must be increased slowly and continuously until reaching full value. Simultaneously, the discharge current must be observed in order to avoid damage to the

equipment, the test will be aborted in case of a disconnection (breakdown). Warning: After testing, the stator winding must be discharged (risk of equipment damage

and personal injury). Pinpoint the fault location, check for dirt and moisture, remedy the fault (clean or dry, if

necessary) before the test can be repeated.<


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2.1.5.22.2.2 Measuring points

Test each of the three phases L1 / L2 / L3 (1) to earth (3). Test the neutral point of the stator winding (2) to earth (3).

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2.1.5.22.3 Evaluation and test determination

During the test, no breakdown may occur.

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2.1.5.23 Check complete function

2.1.5.23.1 Preparation

WARNING

Only persons which are special trained are allowed to carry out service and trouble shooting works with opened switchboard flap.

WARNING

If troubleshooting must be done with the unit energised, have another person present who is trained in turning off the unit and providing or calling for first aid.

2.1.5.23.2 Operation

Action / simulation Checks Display

Switch on battery main switch. (right cable tray, on back side of switch panel - reachable from outside)

Activate the control unit via push button “Power”.

Wait 20 minutes without starting the Diesel engine. (during this 20 minutes there must be no error)

Check that control is automatically switching off after 20 minutes.

Press button “Motor start”

Start Diesel engine. Lamp "Automatic oil-refill" (option) on display menu “TEST” must illuminate for a few seconds and then extinguish.

At low temperatures the preglowing unit must operate.

Pre-heating in operation

Engine must start. Motor start-up

Engine must run up. Motor run up (15 sec.)

Engine must run stable. Plant in operation (standby)

If load resistances with EF-control circuit are available, connect them to the available outputs. Otherwise push button “Bypass 400Hz.1 and/or 400Hz.2” on display-menu “TEST”.

Lamp “Bypass 400Hz 1 on” and/or “Bypass 400Hz 2 on” on display menu “TEST” are illuminated.

Switch on 400Hz output 1. Check that voltage (200/115V, 400Hz) is available on output 1.

Plant in operation (output active)

Switch on 400Hz output 2 (option). Check that voltage (200/115V, 400Hz) is available on output 2.

Switch on 28VDC output (in case of 28VDC simultaneously operating the output is switched on together with all available 400Hz outputs (option).

Check that voltage (28VDC) is available on 28VDC output.

Start Diesel engine and wait for 20 minutes without switching on any output.

Engine must shut down automatically after 20 min.

Automatic engine stop

Switch on several bypass switches on display-menu “TEST”

Warning message that one or more Bypass switches are on.

Bypass 400Hz 1 on

Bypass 400Hz 2 on (option)

Bypass 400Hz 1 + 2 on (option)

Start Diesel engine.


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2. MAINTENANCE


Switch on one or more outputs without load for 20 minutes.

Engine must shut down automatically after 20 min.

Automatic engine stop (I<<)

Automatic engine stop

Stop Diesel engine.

Push button ignition on display-menu “TEST”.

EMR programming (only during standstill) is activated.

!! Test run Ignition on !!.

For reset of EMR programming push button ignition on display-menu “TEST” again.

EMR programming is deactivated.


Switch on 400Hz output.

Release 400Hz voltage test by pushing red button “400Hz voltage test” on display menu “TEST”.

Green lamp “400Hz voltage test on” on display menu “TEST” is illuminated.

!! Test run voltage 400Hz !!

Enter the desired value of the 400Hz voltage and confirm with button “SET 400Hz voltage” on display menu “TEST”.

After confirmation the 400Hz voltage is regulated to the desired value.

To end the 400Hz voltage test push red button “400Hz voltage test” on display menu “TEST“ again.


Switch on 28VDC output (option).

Release 28VDC voltage test by pushing red button “28VDC voltage test” on display menu “TEST”.

Green lamp “28VDC voltage test on” on display menu “TEST” is illuminated.

!! Test run voltage 28VDC !!

Enter the desired value of the 28VDC voltage and confirm with button “SET 28VDC voltage” on display menu “TEST”.

After confirmation the 28VDC voltage is regulated to the desired value.

To end the 28VDC voltage test push red button “28VDC voltage test” on display menu “TEST“ again.


Release engine speed test by pushing red button “Speed test” on display menu “TEST”.

Green lamp “Speed test on” on display menu “TEST” is illuminated.

!! Test run speed test !!

Enter the desired value of rpm and confirm with button “SET speed” on display menu “TEST”.

After confirmation the speed of the Diesel engine is regulated to the desired value.

To end the engine speed test push red button “Speed test” on display menu “TEST“ again.

Option for pulled GPU with sensor on drawbar

Check if plugs are stored correct in the provided holders.

Switch on Hitzinger-ACON control unit.

Take out the cable-plugs from the provided holders.

Plug not stored correct (option)

Move draw bar into horizontal position An implemented sensor detects the position of the draw bar.

Acoustic signal (horn) and/or light signal appears (option).

Option for pulled GPU with sensor on wheel


Swich on Hitzinger-ACON.


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Move GPU a short distance (quarter turn of wheel).


Reset warning signal by storing the plug correct in the provided holder or pushing button "Reset" on Hitzinger-ACON on display-menu “Messages”.


Option for self driven (SKID mounted etc.) GPU´s with ignition or gear control.


Swich on Hitzinger-ACON.

Take away cable plug from the provided holder.


Try to move GPU Ignition is locked or vehicle engine stops running when engaging a gear


Reset warning signal by storing the plug correct in the provided holder or pushing button "Reset" on Hitzinger-ACON on display-menu “Messages”.

Switch on Hitzinger-ACON.

Switch on Bypass switch on display menu “TEST”.

Switch on Bypass Bypass 400Hz 1 on

Bypass 400Hz 2 on (option)

Bypass 400Hz 1 + 2 on (option)

2.1.5.23.3 Alarm and trip simulation

2.1.5.23.3.1 Common control + auxiliaries failures

Action / simulation Checks Display (Menu “Messages”)


Push button "Emergency stop". Diesel engine must shut down. Emergency stop pushed

Reset emergency stop push button by pulling out.

Switch off mini CB(s) for 50Hz supply.

Switch on mini CB(s) for 50Hz supply.

Warning message is shown 50Hz line safety switch tripped

Switch on Hitzinger-ACON.

Remove one of the ACON-modules (except CPU-module)

Warning message is shown (when removing an optional module).

CAN-Modul 50Hz error -128A1 (as an example)

Shut down failure (when removing of a main module).

CAN-Modul Tableau error (shut down) -121A1 (as an example)

Refit CAN-module.


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2. MAINTENANCE

2.1.5.23.3.2 Diesel engine + genset failures



Disconnect (for example) coolant-water temperature sensor.

Shut down error. Diesel Error (shut down)

Redo wiring.


Disconnect any sensor of the Diesel engine.

Warning error. Diesel Error (warning)

Redo wiring.

Can not be simulated. Shut down error. Oil pressure error (shut down)

Can not be simulated. Shut down error. Coolant water temperature too high (shut down)


Jumper coolant water level sensor (terminals -452XS1)

Shut down error. Coolant water level (shut down)

Redo wiring.

Can not be simulated. Shut down error. Overspeed (shut down)

Can not be simulated. Shut down error. Fuel temperature error (shut down)

Can not be simulated. Shut down error. Fuel pressure error (shut down)

Can not be simulated. Shut down error. Turbo boost pressure error (shut down)

Can not be simulated. Shut down error. Charge air temperature error (shut down)

Can not be simulated. Shut down error. Ambient pressure error (shut down)

Can not be simulated. Shut down error. Ambient temperature error (shut down)

Can not be simulated. Warning error. Battery error (warning)

Can not be simulated. Shut down error. Start failure (shut down) (too many starts necessary)

Can not be simulated. Warning error. Fuel shortage

Can not be simulated. Warning error. Fuel shortage (warning)


Jumper oil shortage signal (terminal -468XS1.7) to ground (0V DC bus-bar)

Warning error. Oil-refill failure

Redo wiring.


Slowly reduce air inlet area of air filter. Warning error. Inlet air filter dirty (warning)

Can not be simulated. Warning error. Sensor failure – oil pressure

Can not be simulated. Warning error. Oil pressure error (warning)


Disconnect coolant temperature sensor from Diesel engine during operation.

Warning error. Sensor failure – coolant water temperature

Can not be simulated. Warning error. Coolant water temperature high (warning)

Can not be simulated. Warning error. Sensor failure – coolant water level


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Jumper coolant water level sensor (terminals -452XS1)

Warning error. Coolant water level (warning)

Can not be simulated. Warning error. Sensor failure - speed

Can not be simulated. Warning error. Overspeed (warning)

Can not be simulated. Warning error. Sensor failure – air inlet temperature

Can not be simulated. Warning error. Air inlet temperature (warning)

Can not be simulated. Warning error. Air inlet temperature too high (warning)

Can not be simulated. Warning error. Sensor failure – fuel temperature

Can not be simulated. Warning error. Fuel temperature (warning)

Can not be simulated. Warning error. Sensor failure – fuel pressure

Can not be simulated. Warning error. Fuel pressure (warning)

Can not be simulated. Warning error. Sensor failure – turbo boost pressure

Can not be simulated. Warning error. Turbo boost pressure (warning)

Can not be simulated. Warning error. Sensor failure – charge air temperature

Can not be simulated. Warning error. Charge air temperature (warning)

Can not be simulated. Warning error. Sensor failure – ambient pressure

Can not be simulated. Warning error. Ambient pressure (warning)

Can not be simulated. Warning error. Sensor failure – ambient temperature

Can not be simulated. Warning error. Ambient temperature (warning)

Can not be simulated. Warning error. Feedback rack position failure (warning)

Can not be simulated. Warning error. Throttle position undefined (warning)

Can not be simulated. Warning error. Sensor failure – Water in Fuel

Can not be simulated. Warning error. Water in fuel (warning)

Can not be simulated. Warning error. Sensor failure – Oil level low

Can not be simulated. Warning error. Oil level low (warning)

Can not be simulated. Warning error. Sensor failure – Oil temperature

Can not be simulated. Warning error. Oil temperature high (warning)

Can not be simulated. Warning error. Sensor failure – crankcase pressure

Can not be simulated. Warning error. Crankcase pressure (warning)

Can not be simulated. Warning error. Sensor failure – camshaft position

Can not be simulated. Warning error. Sensor failure – flywheel position and speed

Can not be simulated. Warning error. Sensor failure – piston cooling pressure

Can not be simulated. Warning error. Piston cooling pressure (warning)

Can not be simulated. Warning error. Starter relay (warning)

Can not be simulated. Warning error. Sensor failure – flue gas temperature


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Can not be simulated. Warning error. Flue gas temperature (warning)

Can not be simulated. Warning error. Flue gas temperature too high (warning)

Can not be simulated. Warning error. Sensor failure - Flue gas valve

No scope of supply. Warning error. Sensor failure – inlet air filter monitoring

No scope of supply. Warning error. Engage inlet air filter dirty (warning)

Can not be simulated. Warning error. Sensor failure – flue gas differential pressure

Can not be simulated. Warning error. Flue gas differential pressure (warning)

Can not be simulated. Warning error. Flue gas temperature upstream (warning)

Can not be simulated. Warning error. Flue gas temperature downstream (warning)

Can not be simulated. Warning error. J1939 Communication error


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2.1.5.23.3.3 400Hz alternator failures



Short the respective thermistors (PT-100, L1/L2/L3) on the plug -401XP1.

Warning error.

All outputs are switched off.

Alternator temperature sensor error Phase L1 below min limit



Redo shortening.


Disconnect plug -401XP1. Warning error.

All outputs are switched off.

Alternator temperature sensor error Phase L1 maximum exceeded



Reconnect plug.


Switch on 400Hz output 1 and 2 (option) and adjust load to 110%.

Diesel engine must shut down (Delay time 1 hour).

Alternator overcurrent L1 (110%)




Diesel engine must shut down (Delay time 5 minutes).





Diesel engine must shut down (Delay time 5 seconds).





Load output 1 with 120% nominal power of output 1

Output 1 must switch off within 10 minutes.

400Hz output 1 overcurrent


Load output 2 with 120% nominal power of output 2

Output 2 must switch off within 10 minutes.

400Hz output 2 overcurrent (option)

Disconnect and isolate wires from terminal 14 and 6 of 400Hz voltage regulator (-401E1).

Start Diesel engine. Diesel engine must run up and shut down just after. (Delay: 0,3 sec.)

Alternator undervoltage (<70V)


Switch on 400Hz output 1 or output 2 (option)


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Go to display-menu “TEST” (password recommended)

Push red button “400Hz voltage Test” to switch on 400Hz voltage test. (Note! The set-point of the test-voltage has to be within the permissible limits (115V). Otherwise the GPU is turned off prematurely with voltage error.)

The green lamp “400Hz voltage test” on display menu “TEST” is illuminated.

Enter a new set-point (eg 100V) in the combined button + display “400Hz voltage input field and display of nominal value” (numeric keypad is displayed) and press ENTER to save.

The new defined voltage value for test is stored and displayed.

Push button “SET 400Hz voltage”. Now the new defined voltage set-point is used for voltage regulation during test.

Diesel engine must shut down at 104V 1% (Delay: 2 sec.)


The measured 400Hz voltage is displayed in display „400Hz voltage and frequency”.

By entering a value at low 400Hz voltage, it can be checked whether the Diesel engine is stopped properly in case of undervoltage.

After end of voltage test the set-point of the 400Hz test voltage should be brought back to 115V.

Push red button “400Hz voltage test” to switch off voltage test. The nominal value of the 400Hz voltage is regulated to 200/115V. (This preference for regular operation can not be changed).

The green lamp “400Hz voltage test” on display menu “TEST” is dark.




Push red button “400Hz voltage Test” to switch on 400Hz voltage test. (Note! The set-point of the test-voltage has to be within the permissible limits (115V). Otherwise the GPU is turned off prematurely with voltage error.)

The green lamp “400Hz voltage test” on display menu “TEST” is illuminated.

Enter a new set-point (eg 130V) in the combined button + display “400Hz voltage input field and display of nominal value” (numeric keypad is displayed) and press ENTER to save.


Push button “SET 400Hz voltage”. Now new defined voltage set-point is used for voltage regulation during test.

Diesel engine must shut down at 124V 1% (Delay: 0,5 sec.)

Alternator overvoltage (>124V)

The measured 400Hz voltage is displayed in display „400Hz voltage and frequency”.

By entering an excessive 400Hz voltage value, it can be checked whether the Diesel engine is stopped properly in case of overvoltage.

After end of voltage test the set-point of the 400Hz test voltage should be brought back to 115V.


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Push red button “400Hz voltage test” to switch off voltage test. The nominal value of the 400Hz voltage is regulated to 200/115V. (This preference for regular operation can not be changed).

The green lamp “400Hz voltage test” on display menu “TEST” is dark.

Can not be simulated. Alternator overvoltage (>150V)




Push red button “Speed test” to switch on speed test. (Note! The set-point of the test-speed has to be within the permissible limits (1500rpm). Otherwise the GPU is turned off prematurely with frequency error.)

The green lamp “Speed test” on display menu “TEST” is illuminated.

Enter a new set-point (eg 1280rpm) in the combined button + display “Speed input field and display of nominal value” (numeric keypad is displayed) and press ENTER to save.

The new defined speed value for test is stored and displayed.

Push button “SET speed”. Now the new defined speed set-point is used for speed regulation during test.

Diesel engine must shut down at approx. 345Hz (Delay: 0,5 sec)

Alt. underfrequency (<345Hz)

The measured speed is displayed in display „Speed”.

By entering a value at low engine speed, it can be checked whether the Diesel engine is stopped properly in case of underfrequency.

After end of speed test the set-point of the engine speed should be brought back to 1500rpm.

Push red button “Speed test” to switch off speed test. The nominal value of the Diesel engine is regulated to 1500rpm. (This preference for regular operation can not be changed).

The green lamp “Speed test” on display menu “TEST” is dark.









Diesel engine must shut down at approx 380Hz (Delay: 4sec)

Alt. underfrequency (<380Hz)


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2. MAINTENANCE



By entering a value at low engine speed, it can be checked whether the Diesel engine is stopped properly in case of underfrequency.












Diesel engine must shut down at approx 420Hz (Delay: 4sec)

Alt. overfrequency (>420Hz)


By entering an excessive speed value, it can be checked whether the Diesel engine is stopped properly in case of overfrequency.










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Diesel engine must shut down at approx. 435Hz. (Delay: 0,5 sec)

Alt. overfrequency (>435Hz)


By entering an excessive speed value, it can be checked whether the Diesel engine is stopped properly in case of overfrequency.





Switch on output 400Hz 1 without connecting cable and not switching on bypass switch.

Warning failure must be displayed on Hitzinger-ACON.

400Hz output1 not accepted


Switch on output 400Hz 2 without connecting cable and not switching on bypass switch.


400Hz output 2 not accepted (option)

Switch off mini CB(s) for 400Hz socket supply.


MCB 400Hz socket off (option)

Produce low earth failure current (via resistor 500-1000Ω) between phase and PE.

Earth failure supervision by summary current relay.

Diesel engine must shut down 2 sec. delayed.

Alternator earth failure (option)


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2. MAINTENANCE

2.1.5.23.3.4 28VDC (option) failures



Switch on 28VDC output 1 and/or output 2 (option)


Push red button “28VDC voltage Test” to switch on 28VDC voltage test. (Note! The set-point of the test-voltage has to be within the permissible limits (28V). Otherwise the GPU is turned off prematurely with voltage error.)

The green lamp “28VDC voltage test” on display menu “TEST” is illuminated.

Enter a new set-point (eg 20V) in the combined button + display “28VDC voltage input field and display of nominal value” (numeric keypad is displayed) and press ENTER to save.


Push button “SET 28VDC voltage”. Now the new defined voltage set-point is used for voltage regulation during test.

28VDC output must switch off at approx. 20V DC. (Delay: <10sec)

28VDC undervoltage output 1

28VDC undervoltage output 2 (option)

The measured 28VDC voltage is displayed in display „28VDC voltage”.

By entering a value at low DC voltage, it can be checked whether all DC outputs are switched off properly in case of undervoltage.

After end of voltage test the set-point of the DC test voltage should be brought back to 28VDC.

Push red button “28VDC voltage test” to switch off voltage test. The nominal value of the DC voltage is regulated to 28VDC. (This preference for regular operation can not be changed).

The green lamp “28VDC voltage test” on display menu “TEST” is dark.


Switch on 28VDC output 1 and/or output 2 (option)


Push red button “28VDC voltage Test” to switch on 28VDC voltage test. (Note! The set-point of the test-voltage has to be within the permissible limits (28V). Otherwise the GPU is turned off prematurely with voltage error.)

The green lamp “28VDC voltage test” on display menu “TEST” is illuminated.

Enter a new set-point (eg 32V) in the combined button + display “28VDC voltage input field and display of nominal value” (numeric keypad is displayed) and press ENTER to save.


Push button “SET 28VDC voltage”. Now the new defined voltage set-point is used for voltage regulation during test.

28VDC output must switch off at approx. 32V DC. (Delay: <10sec)

28VDC overvoltage output 1

28VDC overvoltage output 2 (option)

The measured 28VDC voltage is displayed in display „28VDC voltage”.


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By entering an excessive VDC voltage value, it can be checked whether all DC outputs are switched off properly in case of overvoltage.

After end of voltage test the set-point of the DC test voltage should be brought back to 28VDC.

Push red button “28VDC voltage test” to switch off voltage test. The nominal value of the DC voltage is regulated to 28VDC. (This preference for regular operation can not be changed).

The green lamp “28VDC voltage test” on display menu “TEST” is dark.

Can not be simulated. 28VDC outputs must switch off. 28VDC overtemperatur module 01

28VDC overtemperatur module 02






Switch on output 1

Disconnect plug -22XP1 28VDC output 1 must switch off. 28VDC cable broken group 01


Switch on output 2 (option)

Disconnect plug -24XP1 28VDC output 2 must switch off. 28VDC cable broken group 02


Switch on 28VDC output 1 without connecting output cable. (Function only available if a splitted pilot contact on the plug is present)

28VDC output 1 must switch off. (Delay 1s)

28VDC output 1 not accepted


Switch on 28VDC output 2 without connecting output cable. (Function only available if a splitted pilot contact on the plug is present)

28VDC output 2 must switch off. (Delay 1s)

28VDC output 2 not accepted (option)


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2.2 TROUBLESHOOTING

2.2.1 FAILURES

2.2.1.1 Common control + auxiliaries failures

Kind of failure Possible causes Remedy

Emergency stop pushed Push button „Emergency stop“ has been pushed.

Reset emergency stop push button by pulling out.

Broken wire in emergency stop circuit.

Check for failure in emergency stop circuit.

Service required Number of working hours for service have been reached.

Carry out service works and reset service working hours.

50Hz frequency failure Converter not adjusted correct Adjust converter according to converter-manual.

Converter fault. Replace converter.

50Hz converter failure Failure message from converter. Correct failure according to converter-manual.

50Hz contactor failure Contactor fault. Replace contactor.

50Hz transformer overtemperature

50Hz load too high. Reduce load.

Excessive pollution of transformer. Clean transformer windings.

50Hz line safety switch tripped

Mini CB has been switched off or has tripped.

Switch on mini CB´s.

Short circuit on output. Carry out and repair short circuit.

CAN-Modul 400Hz Measurement (shut down) -113A1

ACON module is defective. Replace ACON module.

Terminating resistor is missing or defective.

Check for correct value (120Ω) or reconnect resistor. Replace defective resistor if necessary.

CAN-Bus is disconnected. Check connection and replace cable-tree if necessary.

CAN-Modul 400Hz Tableau (shut down) -121A1





CAN-Modul 400Hz Control (shut down) -121A2





CAN-Modul Diesel Control (shut down) -123A1





CAN-Modul Diesel J1939 (shut down) -151A1



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CAN-Modul Drive-Away-Warning (shut down) -123A2





CAN-Modul Remote Control (shut down) -125A1





CAN-Modul MIL Control (shut down) -125A2





CAN-Modul TGPU Control IN (shut down) -121A1





CAN-Modul TGPU Contorl OUT (shut down) -131A1





CAN-Modul 400Hz PWM error -140A1





CAN-Modul Analog IN error -141A1





CAN-Modul 28VDC Master 1 error -122A1



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CAN-Modul 28VDC Master 2 error -122A2





CAN-Modul External signalisation error -124A1





CAN-Modul 50Hz error -124A2





Plug not stored correct GPU is moved and cable plug(s) are not stored in the provided holders.

Position switch(es) defective.

Check for correct storage before moving GPU.

Check for correct function of position switch(es).

2.2.1.2 Diesel-engine + genset failures


Diesel error (shut down) Problem with switches or sensors directly wired from Diesel engine to speed controller.

Check switches and sensors for correct function. Replace defective parts.

Speed controller defective. Check speed controller EMR for correct function. Replace defective regulator.

Diesel error (warning) Problem with switches or sensors directly wired from Diesel engine to speed controller.

Check switches and sensors for correct function. Replace defective parts.

Speed controller defective. Check speed controller EMR for correct function. Replace defective regulator.

Oil pressure error (shut down)

Oil level too low. Check oil level and refill, if necessary.

Oil Pressure Error (warning)

Oil system is not tight. Check engine and oil draining tube for visual leakage and repair, if possible.

Oil pressure sensor defective. Check oil pressure switch.

Oil system of diesel engine defective or wear of engine too significant.

Checking and repair by Deutz.

Sensor failure - oil pressure

Oil pressure sensor defective. Check oil pressure sensor (refer to Deutz Diesel-engine trouble shooting manual) and replace if necessary.

Coolant water temperature too high (shut down)

Cooling water temperature sensor is defective.

Check cooling water temperature switch.


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Coolant Water Temperature high (warning)

Air in- or outlet openings are blocked. Check air in- and outlet openings.

Cooler is polluted too much. Clean cooler.

Excessive ambient temperature. Reduce load or ambient temperature.

Excessive alternator load. Reduce load.

Failure at Diesel engine cooling system.

Refer to Deutz Diesel-engine trouble shooting manual.

Sensor failure - coolant water temperature

Cooling water temperature sensor is defective.

Check coolant water temperature sensor (refer to Deutz Diesel-engine trouble shooting manual) and replace if necessary.

Coolant water level (shut down)

Cooling water level has reached minimum.

Cooling water refill necessary.

Coolant water level (warning)

Cooling water circuit is leaky. Check for porosity or leaky hoses and valves.

Cooling water shortage sensor defective.

Check for correct function. Exchange sensor or switch if necessary.

Sensor failure - coolant water level

Cooling water shortage sensor defective.

Check coolant water level sensor (refer to Deutz Diesel-engine trouble shooting manual) and replace if necessary.

Overspeed (shut down) Speed of engine too high. Readjust speed (EMR interface).

Overspeed (warning) Speed controller defective. Refer to EMR speed controller trouble shooting manual.

Speed sensor failure Speed sensor defective. Check sensor (refer to Deutz Diesel-engine trouble shooting manual) and replace if necessary.

Fuel temperature error (shut down)

Fuel temperature too high. Check fuel temperature sensor.

Fuel temperature (warning)

Excessive fuel temperature. Reduce fuel temperature (cooling).

Excessive ambient temperature. Reduce ambient temperature.

Sensor failure - fuel temperature

Fuel temperature sensor is defective.

Check sensor (Refer to Deutz Diesel-engine trouble shooting manual) and replace if necessary.

Fuel pressure error (shut down)

Fuel pressure sensor is defective. Check sensor (Refer to Deutz Diesel-engine trouble shooting manual) and replace if necessary.

Fuel pressure (warning) Loss of pressure in fuel lines. Check for fuel loss on engine (not tight).

Engine fuel compression pump defective.

Check fuel pump (Refer to Deutz Diesel-engine trouble shooting manual).

Sensor failure - fuel pressure

Fuel pressure sensor is defective. Check sensor (Refer to Deutz Diesel-engine trouble shooting manual) and replace if necessary.

Turbo boost pressure (shut down)

Turbo pressure sensor is defective. Check sensor (Refer to Deutz Diesel-engine trouble shooting manual) and replace if necessary.

Turbo boost pressure (warning)

Loss of pressure in lines. Check for loss of pressure on engine.

Sensor failure - turbo boost pressure

Turbo pressure sensor is defective. Check sensor (Refer to Deutz Diesel-engine trouble shooting manual) and replace if necessary.

Charge air temperature error (shut down)

Charge air temperature sensor is defective.

Check and replace sensor if necessary.

Air in- or outlet openings are blocked. Check air in- and outlet openings.

Charge air temperature (warning)

Excessive ambient temperature or alternator load.

Reduce load or ambient temperature


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Sensor failure - charge air temperature

Charge air temperature sensor is defective.


Ambient pressure error (shut down)

Ambient pressure sensor is defective. Check and replace sensor if necessary.

Ambient pressure (warning)

Altitude of site for Diesel engine too high.


Failure at Diesel engine control system.

Sensor failure - ambient pressure

Ambient pressure sensor defective. Check sensor (Refer to Deutz Diesel-engine trouble shooting manual) and replace if necessary.

Ambient temperature (warning)

Temperature sensor is defective. Check and replace sensor if necessary.




Sensor failure - ambient temperature

Ambient pressure sensor defective. Check sensor (Refer to Deutz Diesel-engine trouble shooting manual) and replace if necessary.

Feedback rack position failure (warning)

Rack defective. Check rack position (Refer to Deutz Diesel-engine trouble shooting manual) and repair or replace if necessary.

Throttle position undefined (warning)

Throttle defective. Check throttle position (Refer to Deutz Diesel-engine trouble shooting manual) and repair or replace if necessary.

Air inlet temperature too high (warning)

Air inlet temperature sensor is defective.

Check and replace sensor if necessary.

Air inlet temperature (warning)

Excessive ambient temperature. Reduce ambient temperature.

Sensor failure - air inlet temperature

Air inlet temperature sensor is defective.


Water in fuel (warning) Water in fuel sensor is defective. Check and replace sensor if necessary.

Water has come into fuel. Refer to Deutz Diesel-engine trouble shooting manual.

Sensor failure - Water in fuel

Water in fuel sensor is defective. Check sensor (Refer to Deutz Diesel-engine trouble shooting manual) and replace if necessary.

Oil level low (warning) Oil level in engines oil sump is too low.

Check oil level, refill oil in sump.

Oilsystem is leaky. Check lubrication system for visual leakages and repair, if possible.

Oil shortage sensor is defective. Check oil level sensor.

Diesel engine lubrication system is defective or engine wear is too large.

Check and repair by engine manufacturer necessary.

Sensor failure - Oil level low

Oil shortage sensor is defective. Check sensor (Refer to Deutz Diesel-engine trouble shooting manual) and replace if necessary.

Oil temperature high (warning)

Oil temperature sensor is defective. Check oil temperature sensor.

Ambient temperature is too high. Reduce load or ambient temperature.

Load is too high. Reduce load.

Diesel engine cooling system is defective.



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Sensor failure - oil temperature

Oil temperature sensor is defective. Check sensor (Refer to Deutz Diesel-engine trouble shooting manual) and replace if necessary.

Crankcase pressure (warning)

Crankcase pressure sensor is defective.

Check crankcase pressure sensor.

Pressure in crankcase is too high. Refer to Deutz Diesel-engine trouble shooting manual.

Diesel engine control system is defective.


Sensor failure - crankcase pressure

Crankcase pressure sensor is defective.


Sensor failure - camshaft position

Camshaft position sensor is defective.


Sensor failure - flywheel position and speed

Flywheel position and speed sensor is defective.


Piston cooling pressure (warning)

Piston cooling pressure sensor is defective.


Piston cooling pressure failure. Refer to Deutz Diesel-engine trouble shooting manual.

Sensor failure - piston cooling pressure

Piston cooling pressure sensor is defective.


Starter relais (warning) Starter relay is defective. Refer to Deutz Diesel-engine trouble shooting manual

Flue gas temperature too high (warning)

Flue gas temperature sensor is defective.


Flue gas temperature (warning)

Flue gas temperature too high. Check sensor (Refer to Deutz Diesel-engine trouble shooting manual) and replace if necessary.

Sensor failure - flue gas temperature

Flue gas temperature sensor is defective.


Sensor failure - Flue gas valve

Flue gas valve sensor is defective. Check sensor (Refer to Deutz Diesel-engine trouble shooting manual) and replace if necessary.

Sensor failure inlet air filter monitoring

Inlet air filter monitoring sensor is defective.


Flue gas differential pressure (warning)

Differential pressure in particle-filter too high.

Operate GPU under full load.


Sensor failure - flue gas differential pressure

Flue gas differential pressure sensor isdefective.


Flue gas temperature upstream (warning)

Flue gas temperature upstream sensor is defective.


Flue gas temperature downstream (warning)

Flue gas temperature downstream sensor is defective.


J1939 Communication error

J1939 module is defective. Check J1939module. Replace if necessary.

CAN bus connection between J1939 module and EMR broken.

Ceck CAN bus connection. Repair if necessary.


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Speed controller (EMR) is defective. Check speed controller and replace if necessary.

Inlet air filter dirty (warning) Air filter is dirty or blocked. Clean or exchange filter, remove blockage, exchange air-filter cartridge.

Intake silencer for combustion air is blocked.

Visual inspection of air inlet ducts and tubes. Remove blockage or dirt.

Switch for under-pressure detection is defective.

Replace under-pressure-switch if necessary.

Battery error (shut down) Charging generator is defective. Check and repair charging generator or replace if necessary..

Batteries are defective. Check batteries and replace them if necessary.

Start failure (shut down) Batteries are defective or empty. Check charging generator.

Charge batteries or replace them if necessary.

Starter is defective. Check Starter and control for start up.

Alternator is blocked. Check bearings. Check air gap between rotor and stator for pollution.

Diesel engine is blocked Refer to Deutz Diesel-engine trouble shooting manual.

Fuel shortage Fuel level below minimum level. Fill tank.

Fuel shortage (warning) Fuel shortage sensor is defective. Check sensor and replace if necessary.

Oil refill failure (option)

Oil level in engines oil sump and / or oilmaster reservoir is too low.

Check oil level, refill oil in sump and oilmaster reservoir.

Oilsystem is leaky. Check oilsystem for visual leakages and repair, if possible.

Switch for oil shortage is defective. Check oil shortage switch.

Oil refill unit is defective. Check oil-refill unit (oilmaster).

Speed of Diesel engine is unstable

Speed controller is defective. Refer to manual trouble shooting of speed controller (EMR).

Speed governor is not set correctly. Set speed controller correctly (EMR interface).

Inadmissible Vibrations of Unit

Mounting of genset is loose. Check fastening screws of intermediate flange, coupling and feet.

Bearing is defective. Check bearing noise, carry out SPM measurement, replace bearing.

Vibrations of Diesel engine are too high.


Bearing Noise Bearing is defective (by transport damage).

Disassemble bearing and order a detailed check.

Bearing is running dry. Replace defective bearing.

2.2.1.3 400Hz alternator failures


Alternator temperature warning Phase L1

Excessive alternator load.

Excessive ambient temperature.

Reduce load.

Reduce ambient temperature.


Air in- or outlet openings blocked.

Alternator windings polluted too much.

Check air in- and outlets.

Clean windings.


Alternator over-temperature PTC (shut down)



Reduce load.



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2. MAINTENANCE





Clean windings.

Temperature detection device defective.

Replace defective control unit (TÜS100).

Alternator over-temperature phase L1 (shut down)



Reduce load.






Clean windings.


Alternator temperature sensor defective.

Check sensor. Defective sensor can not be replaced.


Alternator temperature sensor (PT-100) L1 is short circuited.









Alternator temperature sensor (PT-100) L1 wire broken.









Rotating rectifiers defective. Disconnect and measure rectifier.


Overvoltage suppressor defective. Replace overvoltage suppressor.

Exciter rotor defective. Measure and check winding resistance at all three phases and to ground (resistance >5MΩ).

Failure in pole wheel or connection to rectifiers defective.

Disconnect pole wheel from rectifier, measure and check winding resistance Measure insulation resistance to ground. (resistance >5MΩ).

Auxiliary winding or wiring interrupted.

Disconnect wires of auxiliary winding in switch board, measure and check resistance. Measure insulation resistance against ground and stator winding (resistance >5MΩ).

Exciter field or wiring defective. Disconnect wires of exciter stator in switch board, measure and check resistance. Measure insulation resistance to ground (resistance >5MΩ).

Voltage adjustment out of limit. Readjust voltage.

Voltage regulator defective. Repair or replace regulator.


Interruption in sensing circuit. Measure alt. voltage on regulator terminals (30/32), repair interruption.


Static line droop faulty. Check wiring, current transformers and adjustment.

Voltage adjustment out of limit. Readjust voltage to nominal value.


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400Hz Voltage regulator defective. Repair or replace 400Hz regulator.

Alt. underfreq. (<345Hz) Speed of engine too low. Readjust speed.

Alt. underfreq. (<380Hz) Speed controller defective. Refer to trouble shooting manual of speed controller (EMR).

Active load too high. Reduce load.

Pick up defective. Check pick up.

Alt. overfreq. (>420Hz) Speed of engine too high. Readjust speed.

Alt. overfreq. (>435Hz) Speed controller defective. Refer to manual trouble shooting of speed controller (EMR).


Excessive alternator load (110%). Reduce load.

















400Hz output 1 overcurrent Excessive load of output 1 400Hz. Reduce load.

Wrong adjust of thermal overcurrent relay.

Adjust thermal overcurrent relay to nominal value (refer to wiring diagrams).

400Hz output 2 overcurrent (option)

Excessive load of output 2 400Hz. Reduce load.

Wrong adjust of thermal overcurrent relay.

Adjust thermal overcurrent relay to nominal value (refer to wiring diagrams).

400Hz outp. 1 not accepted

The cable between GPU and aircraft has been disconnected during feeding.

Connect cable and start feeding again.

Output voltage and / or frequency not accepted by aircraft.

Check tolerances of the GPU-output. Check voltage- and speed settings.

An error has occurred in the aircraft. Check for errors in the aircraft.

400Hz outp. 2 not accepted (option)

The cable between GPU and aircraft has been disconnected during feeding.

Connect cable and start feeding again.


Check tolerances of the GPU-output. Check voltage- and speed settings.


Alternator earth failure (option)

Earth failure on power cable or consumer (aircraft).

Check cables to consumer.

Check consumer current (aircraft).

MCB 400Hz socket off (option)

Short circuit .

Mini CB switched off.

Check for short circuit .

Switch on mini CB(s) for 400Hz socket.


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2. MAINTENANCE

2.2.1.4 28VDC (option) failures


28VDC communication error

CAN bus connection to stack has been interrupted.

Check wiring and cable. Replace if necessary.

Connuication error with stack Check cable for communication on stack.


Alternator or 400Hz regulator defective.

Refer to point alternator over- and undervoltage of this documentation.

Both sensing lines broken. Replace defective cables.


28VDC stack defective. Replace 28VDC stack.




(option) Both sensing lines broken. Replace defective cables.










(option) 28VDC stack defective. Replace 28VDC stack.


The cable between GPU and aircraft has been disconnected during feeding.(Function only possible if a splitted contact in the 28VDC plug is available)

Switch off output. Connect cable and start feeding again.


Check tolerances of the GPU-output. Check voltage-settings.



The cable between GPU and aircraft has been disconnected during feeding.(Function only possible if a splitted contact in the 28VDC plug is available)

Switch off output. Connect cable and start feeding again.


Check tolerances of the GPU-output. Check voltage-settings.


28VDC overtemperature module 01

Excessive 28VDC load. Reduce load.




Air in- or outlet openings blocked. Check air in- and outlets.




28VDC cable broken group 01

Cable for 28VDC output defective. Repair or replace cable and switch on output.

28VDC cable broken group 02


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2. MAINTENANCE


2.2.2 RESISTANCE MEASURING POINTS AND NOMINAL VALUES

Connection must be disconnected

Schematic diagram for resistance measuring

Exc

iter

sta

tor

Exciterrotor

Ro

tatin

g r

eci

fiers

Pol

ew

hee

l

Sta

tor

Aux

illia

ry w

ind

ing

6

7

8

9

10

11

12

21 3 4 5

Tolerance Description Equipment Destination Measuring points

90 – 120 kVA 140 – 180 kVA

Stator L1 / L2 / L3

-315K1 1 / 3 / 5

1-2 / 1-3 / 2-3 0,014 - 0,018 0,0088 - 0,011

Auxiliary winding -401XS1 1 / 2 4-5 0,32 - 0,54 0,3 - 0,5

Exciter stator -401XS1 3 / 4 6-7 4,5 – 7,5 4,5 – 7,5

Exciter rotor -- 8-9 / 8-10 / 9-10 0,13 - 0,19 0,13 - 0,19

Pole wheel -- 11-12 0,85 - 1,05 1,14 - 1,4

Note: use a suitable measuring instrument!!

7

5

6

2

3

4

8 9 10

11 12

1

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