Property of American Airlines Maintenance...(b) Using a refrigeration recovery system compatible with R134a, pump refrigerant from the system and dispose. (c) Replace drier if necessary,

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Maintenance

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Operating ManualGF10 COMBOV. August 2016 Confidential

95

CHAPTER 3

Maintenance

3.1 Servicing

3.1.1 Introduction

This section contains instructions for Servicing, Inspecting and Preventive Maintenance on the GF10COMBO air conditioning unit.

To ensure that the unit is kept in correct operation condition, it must be inspected and maintainedon a regular basis. Proper cleaning on the air filter at recommended intervals will help in preventingdamage or failure of the unit, and provide optimum performance.

Overhaul Intervals: Under normal operating conditions and with proper preventive maintenancepractices, the GF10 COMBO will provide years of excellent service. Typically 20.000 to 30.000 hours(depending upon local conditions).

3.1.2 Refrigeration system

Refrigeration section access

Access door for the refrigeration section is located at right side of the unit.

WARNING!

WHEN WORKING WITH REFRIGERANTS, GOGGLES SHOULDALWAYS BE WORN. CONTACT WITH REFRIGERANT MAY CAUSE

INJURY.

S.A. LEBRUN - 13, rue Gerard - 7020 NIMY (Belgium), Phone : +32 65 403030, Fax : +32 65 3460 17, e-mail : [email protected] - Bank account number : IBAN : BE54 3700 1714 0997 - BIC :

BBRUBEBB - TVA : BE421.297.922 - registration number : 421.297.922/08.27.12

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Cannopy disassemblyFor some inspection or repair, it may be necessary to remove the polyester canopy following below

instructions:

(a) Dismounting air outlet

Dismount the 12 screws inside the air outlet.

Figure 3.1: Dismounting air outlet.

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(b) Dismounting canopy fixation right side

Open the door and dismount the 4 bolts on the bottom of the canopy

Figure 3.2: Dismounting canopy fixation - right side.

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(c) Dismounting air inlet grid

Figure 3.3: Dismounting air inlet grid

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(d) Dismounting canopy fixation - left side

Once the air grids are removed, dismount the 4 bolts on the bottom of the canopy.

Figure 3.4: Dismounting canopy fixation - left side.

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(e) Mounting lifting beam

To avoid breaking the canopy when lifting it, you have to use a proper lifting beam, havinghanging point at the vertical of canopy lifting points (see figure 3.5)

Figure 3.5: Mounting lifting beam

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(f) Lifting canopy

Figure 3.6: Lifting canopy

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(g) Full access to unit

Once the canopy is removed, you have full acces to every components.

Figure 3.7: Full access to unit.

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Refrigerant Leak Testing

A leak free system assures trouble system operation and performance. Loss of refrigerant willbe accompanied by reduced system efficiency and capacity. It will also cause repeated activation ofsystem safety monitors, shutting down the unit. Leak testing should be accomplished at scheduledintervals, and after any work has been accomplished on the unit.

Check the liquid line glass in order to control the flow of refrigerant and the humidity in the coolingcircuit.

If a leak has occurred, it may spread refrigerant throughout the interior of the unit, making locatingthe leak difficult. The interior of the unit should be aired prior to testing. When a leak is detectedbut you are unable to pinpoint the location, use compressed air to blow the area free of vapour, thenimmediately retest before the leaking vapour spreads.

Utilize a draft free area when leak testing to prevent the loss of vapour from small leaks. Insurethat the testing area is free of compressor oil, which may contain dissolved refrigerant, giving falsetest indications.

The testing method used here is the Electronic Leak Detector. This is the easiest method for leakdetection. Electronic leak detectors can be used in areas where an open flame is not permitted. Adetecting probe is passed over the area of a suspected leak. If a leak is present, the detector sounds ahigh frequency alarm or signals by a flashing light, depending on the model used.

Refrigerant leak repair

(a) Locate leak as described above.

(b) Using a refrigeration recovery system compatible with R134a, pump refrigerant from the systemand dispose.

(c) Replace drier if necessary, see sight glass for moisture indication.

(d) Correct leak as described below.

(e) If no leaks are present, pump out system and then evacuate system to at least 270 [Pa], holdfor 30 minutes. Break vacuum with nitrogen and raise system pressure to 0 to 0.34 bars. Re-evacuate system to 270 [Pa]. Repeat this for a total of three times, then charge the system withR134a.

WARNING!

ENSURE ADEQUATE VENTILATION DURING REPAIRS.PHOGENE GAS, A DEADLY POISON, IS GENERATED WHEN

REFRIGERANT IS EXPOSED TO FLAME.

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(f) Leak repair procedure :

• Thoroughly clean paint, dirt and oil film from adjacent piping. Use a wire brush, sandclothor sandpaper.

• Wrap nearby parts with water-soaked cloths to protect them from heat damage duringrepairs.

• If a solder joint requires repair, disassemble the joint and clean away any refrigerant oilwhich may be present. Oil traces will not allow a leak-proof solder repair to be made.After cleaning, reassemble the parts and solder.

• Solder repairs the leak. For copper to copper piping, use Lastek 34 (30% silver) typeL-AG30CD.

• Reassemble and tighten any connections previously loosened.

• If the plumbing system has been opened for repair, evacuate the system previously open toa vacuum of 405 [Pa]. Add dry nitrogen to raise pressure to 10,3 [bar].

• Open all previously closed valves.

• Perform a pressure check for leaks with foam products.

• If all leaks are repaired, evacuate system to 270 [Pa] at least three times.

Refrigerant charging

Charge procedure method:

Prior to starting, weigh the bottle of refrigerant to be used for charging, and record its weight.

(a) Using a recovery/charging unit, add approximately 10 kg of R134a to the cooling section thatwas repaired.

(b) Check all valves are open.

(c) Start the unit (compressor running).

(d) Charge the remainder of the refrigerant through the suction port until the liquid sight glassshows clear.

WARNING!

USE ONLY R134A REFRIGERANT. IF ANY OTHER TYPE OFREFRIGERANT IS USED, THE UNIT WILL NOT FUNCTION

PROPERLY.

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Maintenance

Moisture in a refrigerant system. Evacuation of moisture

The strainer/drier in the system is designed to remove particles and small amounts of moisturewhich may enter the system during minor servicing or fault conditions. Major moisture intrusionthrough fault or contamination may require complete system evacuation for moisture removal.

Moisture in a refrigerant system is directly or indirectly the real cause of more problems andcomplaints than all other causes combined. Moisture in a system can be classified as visible andinvisible. Rarely is liquid water found in a system, normally all intrusive moisture will be in the formof vapour. A single drop of moisture in a system can cause ”freeze-ups”’. Moisture can be picked upby the refrigerant and be transported through the lines as a fine mist, causing ice crystals to format the point of expansion (expansion valve). These ice crystals will retard or stop the flow of therefrigerant, causing a reduction or complete loss of cooling. As the expansion valve warms due to thelack of refrigerant, the ice melts and passes through the expansion valve. The moisture will then cyclethrough the system until it again returns to the expansion valve, and the cycle is repeated. The resultis intermittent cooling. Moisture can also cause corrosion, which can present serious problems, oftennot apparent until severe damage has occurred. Moisture, combined with refrigerants, can create acidswhich in turn greatly increase the corrosion of metals and copper plating.

Refrigerant oil has an attraction for moisture and will absorb it rapidly if left open to the atmo-sphere. Water formed acids mix with refrigerant oil, the two forming a closely bonded mixture offine globules. The effect is called ”sludging”’ and greatly reduces the lubricating ability of the oil.The corrosion caused by the presence of this moisture in the form of ”sludge”’ can plug fine strainers,expansion valves and capillary tubes. Because it usually contains acids, sludge will corrode whateverit clings to, accelerating system damage. It is imperative that only fresh oil from unopened containersbe used. Previously opened oil provides too great a danger of system moisture intrusion.

The most effective means in removing moisture from a system is to utilize a high (deep) vacuumpump. A high vacuum pump is capable of removing all moisture from a hermetic system by reducinginternal system pressures to the boiling point of water at normal temperatures. The vacuum pumpdoes not ”suck out”’ the liquid moisture, but rather causes it to boil into a vapour state at which timeit can be harmlessly removed from the system and exhausted through the vacuum pump.

The ideal vacuum pump should evacuate the system to at least 500 microns, and must also becapable of holding that vacuum throughout the dehydration process. It must pull that vacuum onthe entire system and not simply at the intake of the pump. This pump is able to remove moistureat an ambient temperature of 26oC or over. The adequate pump to be used for this cooling system ismentioned in the Support Test Equipement section.

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3.1.3 Air handling system

Air Filter - Cleaning Instruction

Regularly, you have to clean the filters according to the instructions below.

(a) Dismounting the air inlet grid

Figure 3.8: Inlet grid Figure 3.9: Grid dismounted

Once the grid is removed you get access to the prefilters

Figure 3.10: Prefilters

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(b) Taking out the prefilters

• Unlock and open the hooks at the four corners of each filter

Figure 3.11: Unlocking hook Figure 3.12: Opening hook

• Pull the prefilter out of the frame, you get access to the filter behind

Figure 3.13: Pulling out prefilter Figure 3.14: Filter

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• Pull the filter out of the frame

Figure 3.15: Pulling out filter

• Repeat those operations for the other prefilters and filters

(c) Cleaning the filters.

• When the filters are dismounted, blow some compressed air through the filter in the oppositedirection of the air flow in operation

• Clean-up the remaining dusts on the air inlet face with a vacuum-cleaner.

3.2 Maintenance Schedule

3.2.1 Consumable Materials

The table below indicates the list of consumable materials requested to perform good servicing of theGF10 COMBO .

Drier filter

1 x 848CM. (ref: 2863950)

Air filters

2 x PreFiltres (1750011)2 x Filtres (1750010)

Table 3.1: Consumable material

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3.2.2 Support Test Equipment Required

The equipments listed below are required to perform an adequate maintenance and inspection of theGF10 COMBO :

Connection - PLC TELEMECANIQUE

(Automaton)Software SoMachine (Vers.3.1)Communication cable USB Type A to USB Mini

Connection - TELEMECANIQUE Display

Software Vijeo DesignerCommunication cable ETHERNET TCP/IP

Outils pour installation de refroidissement

Vacuum pump ITE MK 162DSManifold 4 V - ITE 2804 BC + connectionRatchet spanner TOTALINE 127 CVacuum meter REFCO DV-150Multimeter (current, voltage, frequency)Thermometer

Table 3.2: Support test equipments

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3.2.3 Inspection

The following pages are provided as guidance to establish a proper service schedule. This periodicpreventive maintenance inspection schedule should be established and maintained. The followingschedule meets the minimum requirements necessary to ensure safe reliable service under normaloperating conditions. It may be modified as required to meet varying operating and environmentalconditions.

WARNING!

EXTREME CAUTION MUST BE USED WHILE MAKING SERVICEINSPECTIONS WITHIN THE UNIT. NEVER SERVICE THE UNIT ALONE.

SWITCH OFF THE GROUND SWITCH BEFORE PERFORMING ANYMAINTENANCE OPERATION. FAILURE TO FOLLOW THIS PRECAUTION

COULD RESULT IN SERIOUS INJURY OR DEATH.

Contact the Guinault customer service to obtain the reference, products, replacement procedureor maintenance of pieces relating to :

• The general structure

• The control panel

• The alternator

Guinault customer service:

Tel : +33 2 38 63 84 00Fax : +33 2 38 76 97 64E-mail : [email protected]

Otherwise, contact Lebrun customer service:

Tel : +32 65 40 30 30Fax : +32 65 34 60 17E-mail : [email protected]

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Figure 3.16: Diesel Engine

Daily

• Diesel Engine

– Check and fill if necessary the lube oil (see 1 on figure 3.16)

– Check the coolant liquid level (see 2 on figure 3.16)

– Check for leaks

– Check the engine dry/suction air filter (see 3 on figure 3.16)

• Unit

– Check the general wear.

– Check drawbar handling, its braking and locking pedal.

– Check the no copper is visible on the cables.

– Check that the plug terminals are not damage or corroded

– Check that the indicator lights of the operating unit come on when the ignition is switchedon.

– Clean the reflectors

– About cooling liquid, consult the engine documentation.

After every 200 operating hours

Cleaning of the unit outdoor prefilters with compressed air and with a vacuum cleaner (see figure3.10 in chapter 3.1.3).

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• Check the temperatures and pressures against what reported on the machine history logbook.

• Check oil level of the compressor

• control bolts tightening

• Visual inspection if the status of cable insulation.

• The oil level in the compressors (while in operation) (see figure 3.17). If the level is low, checkingwill be made again 3 to 4 hours later.


The electrical safeguards should be checked every 500 hours.

• Cleaning or eventual replacement of unit outdoor filters (see figure 3.9 and chapter 3.1.3).

• Change the lube oil of the engine (see 1 on figure 3.16)

• Replace the oil filter cartridge of the engine (see 4 on figure 3.16)

• Inspection:

– The general aspect of the compressors (see figure 3.17) .

– The presence of refrigerant in the sightglass (after +/- 30 minutes of continuous operation).

– The lack of foam in the oil crankcase (see 1 on figure 3.17).

– The good state of the steelcasing, paint, hinges, door handles, wheels, etc...

– The presence of traces of unusual humidity under the unit.

– The cleanness of the condenser with eventual cleaning.

Figure 3.17: Compressor elements

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• Measure:

– The working temperatures (ambience, outlet of supplied air, inside the unit).

– The air pressure.

– The voltage on the terminal block of each battery with a multimeter. If voltages are lowerthan 10,6 V, replace them.

• Check:

– The working state of control and visual devices

– Check the air inlets and outputs on the rear bodywork, clean if necessary.

– Check the mechanical strength of the reflectors and beacons.

– Control panel:

∗ LEDs,

∗ Shut-off contactor,

∗ Refrigerating and ventilation test.

– The operation of the crankcase heater.

– The proper functionning of the drainage.

– Clean and grease the battery lugs (Open the battery cut-off switch for this operation).

– Check the V-belt of the motor (tighten or replace if necessary)

– Check the starter connections, battery charging alternator connections, the engine’s varioussensors connections.

– Check hose attachment.

– Check that the fuse holder terminal blocks, contactors and the rectifier are in good condi-tion, tighten the connections and fixations if necessary.

– Check that the bundles are correctly connected to the control panel

– Check the board connectors are properly connected.

– Check the 400Hz and 28VDC unit contactors when the generator is at rated speed.

• Electrical safeguards:

– Activate the start-up cycle.

– Place a multimeter on the 400 Hz plug output and turn on the power switch.

– Measure the voltage

– Move the RS525’s P9 potentiometer to trigger the 400 Hz over and under-voltage safeguards(reposition the potentiometer in its original position between each triggering operation).

– Adjust the voltage to its original value.

• Engine safeguards:

– Contact Guinault customer services

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CAUTION!

THE DISCHARGE OF CONDENSATES IS ONLY ALLOWED IF THE INNERPRESSURE IS ABOVE +/- 10 [mBAR].

After every 1000 operating hours or twice a year

• Diesel engine

– Replacement of the fuel filter and pre-filter cartridge (see 5 & 6 on figure 3.16)

– Cleaning of the radiator (drain lube oil/condensate)

– Check the flexible fuel leakage lines

– Check the battery and cable connections

– Check the preheating plug

– Check the monitoring, warning system

– Check the fixings, hose connections(renew if damaged)

– Check the cooling system bearings (rubber and retaining elements)

• Towbar

– Check the manoeuvrability. If necessary, apply 10g of grease to the drawbar axle, 10 to 20gon the cables and the parts that rub cables and on the Capstan joint.

– Check the braking system.

– To adjust: In the high and low position, release the lock-nuts and tighten the cable toobtain effective braking. After adjustment, check that the brake is free when 8 to 10 cmabove the stop in the low position.

• Alternator

– Check the alternator grilles are not blocked, clean with dry air.

– Check the installation of the terminal board and the electrical connections.

• Cooling system and accessories

– Dry clean the engine cooling system and its accessories.

• Current safeguards:

– Use a three-phase load bank and check the 400 Hz distribution cable’s permissible overload.

– Use a Resistive load bank and check different overload points (consult the monitoringcurves).


• Pump out and clean the fuel tank

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• Replacement of the oil and oil filter of the compressor

• Replacement of 400Hz alternator bearing

Once a year

• Performance tests of the unit in ”cooling”’ working modes.

• Tests and adjustments of the different safety devices on the unit.

– Refrigeration part:

∗ HP/BP pressostat (see PSL and PSH1 on figure 3.17),

– Aerodynamic part:

∗ Safety pressostat (see PSH3 on figure 3.17),

• Checking of the absorbed powers.

• Checking of the condenser’s fan.

• Checking of the capacity regulation valve working order.

• Checking of the cooling system of the engine

• Checking of the exhaust system of the engine

• Cleaning of the air filter of the engine

• Replacement of the battery

• Cleaning of the fuel filter and replacement if necessary

• Replacement of the dehydrator filter (see 6 on figure 3.17).

• Control the charge of refrigerant and adapt the complementary charge.

• Greasing of the steering axles at the front of the unit.

• Greasing of the brake system and checking of its good working order.

• General inspection of:

– The air handling unit (presence of humidity, air leakage, bad fixings, ...),

– The fixings of the refrigeration piping,

– The piping insulation,

– The correct fixings of temperature sensors,

– The fixings of side panels,

– The good state of the panels acoustic insulation,

– The detection of any trace of rust,

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– The eventual presence of refrigerant leakage,

– The cleaning of the electrical brushes,

– The eventual tightening of terminals.

CAUTION!

PRESENCE OF ANY MAGNETIC DEVICE NEAR THE PLC MUST BE AVOIDED.

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3.2.4 Electronic board replacement procedure

All board replacement operations are performed with the battery cut-off switch open.

RS678: Relay (Electrical cabinet)

• Make sure the battery cut-off switch is open (no voltage on B1)

• Replace the fuse(s) if the fault has been identified and put the unit into service.

• If the board must be replaced, unscrew the cable bundle mounted on the B1 terminal with aNo. 8 spanner.

• Check that the cables are clearly identified.

• Disconnect the boards by grasping the connector and not the cable bundle.

• Unscrew the 4 mounting screws.

• Remove then replace the board, taking care to use the dedicated screws and nuts.

• Reconnect the connectors, screw the cable to the B1. Fix tightly to ensure a good connection.

• Close the battery cut-off switch and return to service.

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RS525: 200V / 400Hz Regulator (Electrical cabinet)

• Make sure the battery cut-off switch is open.

• Disconnect the XB5 connector by grasping the connector, and not the cable bundle.

• Using a No. 8 spanner, unscrew the 3 mounting screws on the metal case.

• Remove and replace the board.

• Screw the board onto the cabinet.

• Reconnect the XB5 connector and return to service. Fix tightly to ensure a good connection.

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RS944 : Sequencer (Electrical cabinet)

handling

The RS944 digital board must be handled with care. It will be packaged in anantistatic bag. The operator must avoid touching the components. It is prohibited to

manipulate the board before being electrically discharged by touching a ground point.

• Make sure the battery cut-off switch is open.

• Disconnect all connectors by grasping the connector and not the cable bundle.

• Using a No. 8 spanner, unscrew the 3 mounting screws on the metal case.

• Remove and replace the board.

• Screw the board onto the cabinet.

• Reconnect all the connectors and return to service. Fix tightly to ensure a good connection.

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3.2.5 Maintenance Table of the cooling unit

We recommend you to maintain the unit according tothese guidelines and frequencies. The number of oper-ating hours refer to average market conditions. Otherfrequencies and hours may be applicable depending onenvironmental conditions and other market data. Inthis case, please contact Guinault-Lebrun .

Eve

ry200

hou

rsor

wee

kly

Eve

ry500

hou

rsor

twic

ea

year

Ev e

ry4000

hou

rsor

twic

ea

year

Ev e

ry8000

hou

rsor

on

cea

year

THE COMPRESSOR

Check the oil •Check the general aspect •Check the refrigerant charge •Check the operating data •Check the protection devices and all compressor moni-toring parts

•

Check electrical cable connections on tight fitting •Check the tightening torques •Perform a tightness test •Update date protocol •THE ELECTRICAL MOTORS

Initial Inspection (Only once) •Regreasing See lubricant plate

Permanent lubrication (with coupling output) •Cleaning Depending on degree of local fooling

Main inspection After the first 16000 h or after 2 years

GENERAL INSPECTION

Clean the outdoor prefilters •Clean the outdoor filters (replace if necessary) •The lack of foam in the oil crankcase •The air handling unit :- presence or trace of humidity •- air leakage, bad fixings, etc... •The cleanness of the condenser. Clean if necessary. •The good state (paint, trace of rust, fixing,...) of the sideand acoustic insulation panels, the steelcasing, the doorhandels, the hinges, the wheels, etc...

• •

The tightening of terminals if necessary •The replacement of the safeguard battery in the PLC •The cleaning of the 3 electrical panels •

continued on next page

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continued from previous page

Eve

ry200

hou

rsor

wee

kly

Eve

ry500

hou

rsor

twic

ea

year

Ev e

ry4000

hou

rsor

twic

ea

year

Eve

ry8000

hou

rsor

on

cea

year

Greasing of the steering axles at the front of the unit andof the brake system + checking of its good working order

•

Fixings and insulations of the piping •Presence of refrigerant leakage •The correct fixing of temperature sensors •Replacement of the dehydrator filter •TESTS

The working state of control and visual devices •Checking of the condenser’s 2 fans •Checking of the control panel :- Shut-off contactor •- Refrigerating and ventilation test •- Leds •Measuring of the working temperatures (ambiance, outletof supplied air, inside the unit)

•

Measuring of the number of operating hours •Measuring of the air pressure •Checking of the correct working of the water discharge •Checking of the good working of the crankcase resistance •Tests and adjustments of the different safety devices onthe unit- Refrigeration part: HP/BP pressure switch •- Aerolic part: Safety pressure switch •Performance tests of the unit in ”cooling” working modes •Checking of the absorbed powers •

Table 3.3: Cooling unit maintenance planning

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3.2.6 Maintenance Table of the internal generator

For maintenance and inspection of the engine, it is necessary to refer to instruction manual of theengine prevailing on following tables. The general maintenance of the unit consist to execute periodicoperations on substantive bodies. Operations to execute are defined according to the hours of operationand are summarized in tables below.

ALL INTERVENTION on the engine beam, open cover, spinningmotor, is prohibited to any person not qualified.

INTERNAL WASHING OF THE GROUP WITH A PRESSUREWASHER IS NOT ALLOWED.

Please find here after the maintenance operationsto be carried out on the engine. It is necessary torefer to the engine manufacturer maintenance man-ual,supplied with the ACU. The following panels,issued by Guinault-Lebrun , can not replace theengine manuals.

Eve

ry10

hou

rsor

dai

ly

Eve

ry50

0h

ours

Eve

ry10

00h

ours

orye

arly

Eve

ry20

00h

ours

orev

ery

two

yea

rs

Eve

ry45

00h

ours

Dep

end

son

nee

ds

THE ENGINE

Check engine oil level •Check coolant liquid level •Check fuel filter •Replace engine oil and oil filter •Replace fuel filter •Check crankcase vent filter •Check Radiator support & engine shock absorbers(to be replaced if deteriorated) •Check electrical wiring •Replace air filter •Check the belt tension (1) •Check the cooling circuit •Check the engine intake system •Replace crankcase vent filter •Check the crankshaft damper •Check the engine speed •Replace the coolant liquid •Check the valve clearance •Replace the crankshaft vibration damper •Clean or replace air filter cartridge (2) •

continued on next page

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continued from previous page

Eve

ry10

hou

rsor

dail

y

Eve

ry500

hou

rs

Eve

ry1000

hou

rsor

yearl

y

Eve

ry2000

hou

rsor

ever

ytw

oyea

r

Eve

ry4500

hou

rs

Dep

end

son

nee

ds

Replace fan or alternator belt •Check the injectors •Check the exhaust pipe •Check the preheating resistance •Visual control of engine leak • •Control the water hose fixation •Test bench at rated load during 1h •Clean the turbocharger •Adjusting of rocker arms play •Draining water from the fuel prefilter •Draining water from the fuel tank •Clean the radiator • •

Table 3.4: Internal generator maintenance planning

Note:

• (1): During the running in period (first 50 hours), check daily the tension of the belts.

• (2): Air filter replacement depends on surrounding conditions (dust, ...)

• After first 100 hours, replace engine oil and oil filter.

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3.3 Troubleshooting

3.3.1 General

This section contains troubleshooting information to assist, to locate and to correct operating troubleswhich may develop in the unit. Each malfunction for an individual component, unit or system isfollowed by a list of tests or inspections which will help the technician to determine probable causesand corrective action to take.

The test/inspections and corrective actions should be performed in the order listed. Troubleshoot-ing is a logical and systematic process of determining and correcting the cause of a malfunction. Theprocess begins with verification of the malfunction. This may often involve an operational check-outof the unit. After the trouble has been verified, identify all components in the circuit whose failurecould cause the symptoms observed during the operational check-out. The technician should start bychecking those items which are highest in probability of causing the problem. Inspect and test eachcomponent, until the exact cause of the problem is determined and corrected.

WARNING!

USE EXTREME CARE TO AVOID CONTACT WITH HIGH VOLTAGELEADS AT ALL TIMES. REMOVE ALL JEWELRY, SUCH AS RINGS,

WATCHES, CHAINS, ETC..., THAT COULD COME INTO CONTACT WITHEXPOSED LEADS AND WIRES. FAILURE TO COMPLY MAY RESULT IN

SEVIER ELECTRICAL SHOCK OR DEATH, AND/OR CAUSE DAMAGE TOEQUIPMENT.

WARNING!

EAR PROTECTION DEVICES MUST BE WORN WHEN IN THEIMMEDIATE VICINITY OF THIS UNIT DURING OPERATION. REPEATEDEXPOSURE TO HAZARDOUS NOISE CAN CAUSE PERMANENT HEARING

LOSS.

WARNING!

REFRIGERANTS, OILS AND OTHER PRODUCTS CAN READILY BEABSORBED THROUGH THE SKIN AND INTO THE BLOOD STREAM.

WASH IMMEDIATELY AFTER COMING INTO CONTACT WITH THESEPRODUCTS.

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Maintenance

3.3.2 Fault Indication

Fault display

• At the time of the occurrence of a GPU or engine fault, the following symbol flashes:

• Press this symbol to access the fault history:

Figure 3.18: GPU fault screen display

The color advise on the fault status:

RED = Fault active (ongoing)ORANGE = Warning active (ongoing)GREEN = fault/warning non-active

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• In the case of engine faults, pressing on the error message allows access to the next screen inorder to get the SPN/FMI code:

Figure 3.19: SPN / FMI code

• Below the main faults, their consequences and the required actions for recommissioning:

400Hz DISTRIBUTION

Fault descriptionon the display

Faultwarn-inglight

Generatorstatus

Action

400 Hz over-voltagefault

Solid Enginestopped

Press Reset, restart the start-up cycle,

400 Hz under-voltagefault

Check the voltage on the display

400 Hz over-frequency fault

Solid Enginestopped

Press Reset, restart the start-up cycle,

400 Hz under-frequency fault

Check the frequency on the display

400 Hz over-amperage

Solid Engine notstopped

Press Reset, activate distribution

By-pass active EF Flashing X

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Maintenance

28VDC DISTRIBUTION

Fault description onthe display

Start-Resetindi-catorlight

Generatorstatus

Action

28VDC over-voltagefault



28VDC under-voltagefault

28VDC over-amperagefault



28VDC rectifier fault Solid Engine notstopped

Wait 10 minutes, press Reset, acti-vate distribution

By-pass active EF Flashing X

OTHER:



Generatorstatus

Action

Start-up failure Solid Enginestopped

Press Reset, restart the start-up cy-cle After several attempts, contactSAV Guinault

Fuses input rectifier600V

Solid Enginestopped

Check the condition of the fuses Q1and Q2. Press Reset, restart thestart-up cycle.

Low fuel level (enginestopped)

Solid Enginestopped

Fill the tank > 50%. Restart thestart-up cycle

Low fuel level Solid Engine notstopped

Stop the engine as soon as possible.Top up fuel. Restart the start-upcycle

Rectifier overheating600V (engine stopped)

Solid Enginestopped

Wait for the cooling of the 600V rec-tifier. Press Reset, restart the start-up cycle

Rectifier overheating600V (PCA stopped)


Wait for the cooling of the 600V rec-tifier. Press Reset, restart air con-ditioning

Engine overheating(400Hz/28VDC OFF)


Wait for the engine to cool. PressReset Restart the 400Hz or 28Vdcgeneration.

Engine overheating(PCA OFF)


Wait for the engine to cool. PressReset Restart the air conditioning.

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Maintenance

Contact the engine manufacturer for all SPN/IMF codes

MOTOR



Generatorstatus

Action

Oil pressure Solid Enginestopped

Check the oil level, check for leaks,check the condition of the oil circuit,press Reset, restart the start-up cy-cle

Engine temperature Solid Enginestopped

Let cool, check water level, checkfor leaks, check the coolant circuit,restart the start-up cycle

Low water level Solid Enginestopped

Let cool, check the coolant circuit,top up the water, restart the start-up cycle

Clogged air filter Solid Enginestoppedr

Check the condition of the filter,restart the start-up cycle

Oil level Solid Enginestopped

Check oil level, check for leaks, pressReset, restart the start-up cycle

Presence of water in fuel Solid Enginestopped

Remove the water using a diesel pre-filter

SPN Unknown Solid Enginestopped

Press the message to access theSPN/FMI. Correct the problem.Press Reset, restart the start-up cy-cle

1st low fuel level thresh-old (20%)

Solid Fuel levelalert light

None, the group can continue to op-erate

2nd low fuel levelthreshold (5%)

Solid Fuel levelalert light,Enginestopped

Restart is prevented. Add morethan 50% of the fuel capacity.Restart the start-up cycle

The total disconnection of the ignition may sometimes be necessary to allow the resetting of afaulty engine:

– Switch off the ignition

– Switch on the ignition

– Press Reset

– Restart the start-up cycle

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Maintenance

ELECTRIC



Generatorstatus

Action

Battery charging alter-nator fault

Solid Enginestopped

Press Reset, restart the start-up cy-cle

Help diagrams

5 possible types of malfunction are explained below:

• SITUATION 1 : Power-up faultSTOP-ON-START switch in the ON position: nothing happens.

• SITUATION 2 : Starting faultThe message ”Waiting for start” is displayed. After having put the STOP-ON-START switchin the START position, the engine does not start.

• SITUATION 3 : Engine faultThe unit is operating. Problem: the generator stops, the FAULT indicator comes on, an enginefault is indicated on the display

• SITUATION 4 : 400Hz distribution faultThe unit is operating. Problem: the unit stops or continues to operate, the FAULT indicatorcomes on, a 400Hz distribution fault is shown on the display. Do not rearm.

• SITUATION 5 : 28V distribution faultUnit generating 28V Problem: the FAULT indicator illuminates, the 28V contactor opens, a28V distribution fault is shown on the display, the engine continues to run.

RECOMMENDATIONS

Please contact GUINAULT Customer Service for all repair work. Ensure that these problems arenot caused by an engine fault (please refer to the engine owner’s manual supplied with the unit). Ifan electronic card needs to be changed, please contact Guinault Customer Service for its testing orrepair. In case of engine failure (loss of power, malfunction), refer to the engine operating manual.Whatever the problem, it must be addressed by a highly skilled technician.

ALL REPAIR WORK on the engine beam, open body, runningengine, is prohibited for all non-qualified people.

Materials needed:

• Set of mechanic tools

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Maintenance

• Universal multimeter

• Set of electrical tools

Take all necessary precautions, and locate the various elements before performing any maintenanceon the group.

BEFORE STARTING ANY WORK ON THE UNIT; DISCONNECTTHE BATTERIES.

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Maintenance

SITUATION 1 : Power-up faultSTOP / ON / START switch at the ON position: Nothing happens

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Maintenance

SITUATION 2 : The engine will not startThe STOP-ON-START warning light is switched on after the voltage is switched on, the display

indicates ”Waiting for start”. Once the switch is in the START position, the engine does not start.

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Maintenance

SITUATION 3 : Engine faultThe unit is operating.Problem: The unit stops, an engine fault appears on the screen (type SPN/FMI)

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Maintenance

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Maintenance

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Maintenance

SITUATION 4 : 400Hz faultThe unit has started, its no-load voltage is 200V (P/P)/400Hz, 400Hz distribution is active.

Problem: The 400Hz distribution stops and the unit stops (1) or the unit works (2)

Under and over-voltage faults can occur during operating cycles.

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Maintenance

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Maintenance

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Maintenance

SITUATION 5 : 28V distribution faultUnit generating 28V Problem: Opening of the switch 28V, the distribution indicator is turned off,

the ”default” indicator illuminates.

Under and over voltage faults can occur during the authorisedoperating cycles (strong load impact (under voltage) orload shedding

(over voltage)). Check the condition of the 28V current limiter.

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Maintenance

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Maintenance

3.3.3 Troubleshooting chart

Default on the MRS16 display

When a default occurs with the engine, the ”ENGINE FAILURE” red lamp of the operating stationlights on. In order to identify the code corresponding to the current problem, the user must consultthe alarm menu of the MRS 16 display (figure 3.20). If a ”Wrn ECu Alarm” occurs on the alarm list,the user must consult the ECU Alarm list menu.

Figure 3.20: MRS 16 Engine Monitoring System

Based on the code, the user must go to the corresponding board in the troubleshooting chart. Onevery board, information is presented in three categories:

• Cause

• Type

• Solution

When it is appropriate, the solution is presented through a tree. When the problem is solved, resetthe MRS 16 (reset button on the electrical cabinetof the engine).

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Maintenance

Table 3.5: Troubleshooting chart for engine failure

Eng Cool Temp Wrn

CAUSE: High water temperature, engine too hot

TYPE: Engine default causing a stop

SOLUTION: - Turn off the general start button.- Wait for the refreshing of the engine.- Control the level of cooling liquid in the tank.- Retry to start.- Check if the fan of the radiator is working.

Oil Press Wrn

CAUSE: Oil pressure is smaller than Wrn Oil press setpoint.

TYPE: Warning

SOLUTION: - Control the oil level.- Control the pressostat.- If necessary, reload oil.

Oil Press Sd

CAUSE: Oil pressure is smaller than Sd Oil press setpoint.


SOLUTION: See Oil Press Wrn.

Eng Cool Temp Sd

CAUSE: Water temperature is greater than Sd Water temp.

TYPE: Engine default causing a stop.

SOLUTION: - Turn off the general start button.- Wait for the refreshing of the engine.- Control the level of liquid cooling in the tank.- Retry to start.- Check if the fan of the radiator is working.

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Maintenance

Fuel level Wrn

CAUSE: Fuel level is smaller than Wrn fuel level setpoint (25%).

TYPE: Warning

SOLUTION: Refill the tank if necessary.

Fuel level Sd

CAUSE: Fuel level is smaller than Sd fuel level setpoint (10%).

TYPE: Shutdown

SOLUTION: Refill the tank if necessary.

Battery voltage <,>

CAUSE: Battery voltage is out of limits given by Batt overvolt and Batt un-dervolt setpoints.

TYPE: Warning

SOLUTION: - Check the alternator of the engine.- Check the main features of the battery.- Reload if necessary.- Retry to start.

Battery flat Sd

CAUSE: If the controller switches off during starting sequence due to badbattery condition, it doesn’t try to start again and activates thisprotection.


SOLUTION: See Battery voltage

Start failed

CAUSE: Gen-set start failed.


SOLUTION: Check the alternator.

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Maintenance

EmergencyStop Sd

CAUSE: If the input Emergency stop is opened, shutdown is immediately ac-tivated.


SOLUTION: - Turn off the general start button.- Control all the securities before disengaging emergency button.- Retry yo start and check all the unit.

ChrgAlternFail Wrn

CAUSE: Failure of the alternator for charging the battery.

TYPE: Warning

SOLUTION: - Check the alternator.- Check the battery.- Check the wires.

Air Filter Sd

CAUSE: The air pressostat of the engine filter switched on.


SOLUTION: - Remove filter for cleaning or replacement.- Check the wires.

Water in Fuel

CAUSE: Water presence in fuel filter.


SOLUTION: - Drain the fuel filter.- Check the wires.

Coolant Level

CAUSE: The coolant level sensor switched on.


SOLUTION: - Control the level liquid in the radiator and reload.- Check the wires.

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Maintenance

Default on the PLC display

This section presents the required solutions when the ”AIR SUPPLY FAILURE” lamp lights on. Onevery board of the table 3.6, information is presented through three categories:

• Cause

• Type

• Solution

When it is appropriate, the solution is presented through a tree. When the problem is solved, resetthe PLC (Reset/Maintenance button).

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Maintenance

Table 3.6: Troubleshooting chart for unit failures

D001

CAUSE: Failure comes from the speed controller of the blower SC1

TYPE: Stop of the unit in all mode

SOLUTION: look at the alarme on the speed controller by the PLC display (SeeChapter 2)

.

D002

CAUSE: Failure comes from the PTC probe


SOLUTION: - Wait until the temperature inside the unit goes down.- Restart the unit.- If the default occurs again, contact Guinault-Lebrun

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Maintenance

D003

CAUSE: The air pressure switch (PSH3) switched on


SOLUTION:

Is the air pressureswitch activated onthe speed controllerscreen on the PLC ?

The default is fixed. Reset thePLC with the maintenancebutton and reboot the unitin the selected mode. Checkif the default occurs again

and in which condition.

YES

Is cable 53 well connectedaccording to the Guinault-

Lebrun drawing andis it in a good state?

Check the wiring atthe terminal number

12 and 18 of the speedcontroller SC 1. If the

problem goes on, contactGuinault-Lebrun .

YE

S

Connect the ca-ble correctly and

replace it, if needed.

NO

NO

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Maintenance

D004

CAUSE: The circuit breaker QD1 switched off (blower protection device).


SOLUTION:

Did the circuit breakerQD1 switched off?

Reset the circuit breaker.Reset thePLC. Restart the group measuring

the current value consumed bythe frequency driver (after thecircuit breaker).If the problem

goes on, contact Guinault-Lebrun .

YES

Is the auxiliary contact on the circuitbreaker QD1 working properly? (mea-

sure with a ohm-meter, off power)

Check the wiringof the PLC card

DM72F0, terminal11. If the problemgoes on, contact

Guinault-Lebrun .

YE

S

Replace theauxiliary

contact of thecircuit breaker.

NO

NO

D005

CAUSE: The PLC did not receive the information that the speed controllerSC1 started even though it asked for it.


SOLUTION:

Is speed controller under power?

Start the unit in ventilationmode. Check the proper work-

ing of CAN communication BUS(contact Guinault-Lebrun )

YES

Check the circuit breakerQD1. If the problem goes on,

contact Guinault-Lebrun .

NO

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Maintenance

D009

CAUSE: The PLC detected a default on the Danfoss regulator (AKCC750).

TYPE: Stop of the unit in cooling mode

SOLUTION:

Is light n°5 of thefirst DM72FO card

of the PLC on?

The default disappeared.Reset the PLC with the

maintenance buttonand restart the unit

in the selection mode.Check if the default

comes back and underwhich circumstances.

YES

Check if the contacton the terminals 39

and 41 of the regulatorAKCC750 is openen.

Default of theAKCC750.

Check the pres-sure sensor PT3.

Check for over heating.Check the expansionvalves EV5, 6 and 7(adjust if necessary).

YE

S

Check the wiringbetween the PLCand the AKCC750

regulator at theterminals 39 and 41of the regulator. Is

there a problem there?

Correctthe wiring.

YE

S


DM72FO. Ifthe problem

goes on, contactGuinault-Lebrun .

NO

NO

NO

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Maintenance

D010

CAUSE: One of the circuit breaker QM2A or QM2B switched off (compressorprotection device).


SOLUTION:

Did the circuitbreaker QM2A or

QM2B switched off?

Reset the circuit breaker.Reset the PLC.

Restart the group measur-ing the current value con-

sumed by the frequency driver(after the circuit breaker).

If the problem goes on, con-tact Guinault-Lebrun .

YES

Is the auxiliary contact on thecircuit breaker QM2A or QM2B

working properly? (measurewith a ohm-meter, off power)


DM72F0, terminal21. If the problemgoes on, contact

Guinault-Lebrun .

YE

S

Replace the aux-iliary contact of

the circuit breaker.

NO

NO

D011

CAUSE: The PLC detected a shortage of compressor oil.


SOLUTION: - Reset the unit.- Check the auxiliary contacts of the contactors.- Control the oil level through the sightglass on the compressor.- Fill up if necessary.

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Maintenance

D012

CAUSE: The PLC did not receive the information that the compressor con-tactors started even though it commanded it.


SOLUTION:

Check the KM2A and KM2B contactors.Check the auxiliary contacts of the con-tactors. Is there a problem with these?

Replace the defective part

YES

Reset the PLC and restart in coolingmode. Do the contactors turn on? Both?

Problem in the commandof the wiring. Check

the wiring between thecontactor wiring and theexit card of the contactorand the PLC exit card.If the problem goes on,

contact Guinault-Lebrun

YE

S

Is light 0 of thesecond card DI12DEduring the 5 secondsbefore the default?

Problem of infor-mation return ofthe PLC. Check

the wiring betweenthe auxiliary con-tact and the PLC.

If the problemgoes on, contactGuinault-Lebrun

YE

S

Problemwith the

PLC.ContactGuinault-Lebrun

NO

NO

NO

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Maintenance

D013

CAUSE: The PLC detected a default on the Danfoss economizer regulator(AKCC550)


SOLUTION:

Is light 6 on the on theDM72FO card of the PLC on?

Check if the contact on theterminals 7 and 9 of the

regulator AKCC550 is open.

Check the wiringbetween the OTB andthe AKCC550 regu-lator at terminals 7

and 9 of the regulator.If problem goes on con-tact Guinault-Lebrun ?

YE

S

Default of theAKCC550.

Send the code dis-played on the screenof the AKCC550 toGuinault-Lebrun .

NO

YES

The default disappeared. Reset thePLC with the maintenance button

and restart the unit with the selectionmode. Check if the default occurs

again and under which circumstances.

NO

D014

CAUSE: The PLC reduced the capacity of the compressor to limit the currentconsumption.

TYPE: Information

SOLUTION: This is no default. The PLC limits the use of the unit under thenormal working conditions.

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Maintenance

D015

CAUSE: Failure comes from the speed controller of the condenser SC3


SOLUTION: look at the alarm on the speed controller by the PLC display (SeeChapter 2)

.

D016

CAUSE: The QD3 circuit breaker switched off.


SOLUTION:

Did the QD3 circuitbreaker switch off?

Restart the QD3 circuit breaker.Reset the PLC.

Restart the group measuring thevalue of the current consumed by

the frequency driver SC3 (after thecircuit breaker). If the problemgoes, contact Guinault-Lebrun .

YES

Does the auxiliary contactQD3 work well? (measure

with a ohm-meter off power)

Check the wiringat the PLC card

DM72F0 terminal12. If the problemgoes on, contact

Guinault-Lebrun .

YE

S

Replace the QD3auxiliary contact.

NO

NO

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Maintenance

D019

CAUSE: The number of successive start of the compressor is larger than 6 inan hour.


SOLUTION: - Reset the unit.- Restart the unit.- Check the low pressure.- Check that there is no leak in the cooling circuit.- If the problem goes on, contact Guinault-Lebrun .

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Maintenance

D020

CAUSE: The PLC detected a default with the internal protection of the com-pressor (Kriwan).

TYPE: Stop of the unit in cooling mode.

SOLUTION:

Is light 9 of the first card(DI12DE) of the PLC on?

The default is no morethere. Reset and check

the compressor working.If the problem goees on,contact Guinault-Lebrun

YES

Cut the current with theIs1 for 10 seconds. Reset

the Is1 and the PLC.Is the default still there

Check the wiringsbetween second cardDI12DE and connec-tions x3-1 and x3-2

Check cable LEB36. Ifthe problem goes on,


YE

S

The default is no morethere. Reset and check

the compressor working.If the problem goes on,


NO

NO

D021

CAUSE: The PLC detected a default with the high pressure pressure swtitch.

TYPE: Stop of the unit in cooling mode.

SOLUTION: - Reset the HP pressure switch (black button).- Reset the PLC.- Restart the unit → Check the operating pressure values.- Identify when the default occurs again.- Contact Guinault-Lebrun .

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Maintenance

Cooling Mode

That section presents a non-exhaustive list of problems that can occur when the unit is in coolingmode and their solution.

Cooling compressor fails to start (red lamp is off).

Is the fan in operation

Check the circuitbreaker for the opera-tion of the PLC QD10

YES

Is there a partial or com-plete loss of refrigerant charge.

Check the pressure onthe manometers PI1

and PI2. This pressuremust be up to 2,5 Bar topermit the operation ofthe compressor.Repair

leak and recharge system.

YE

S

Is there a defaulton the pressure

sensor PT4?

Check the valueof the PT4 onthe PLC and

compare with themanometer PI2.

YE

S

See nextPage.

NO

NO

NO

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Maintenance

Suction pressuretoo low (internalpressure switch).

Automatic restartof the compressorwhen the pressureis up to 1,5 bar.

YES

Waiting for short delay?Automatic restartof the compressorafter 2 minutes.

NO

Noisy compressor.

Is one or more expansionvalve in ”open” position (in-

dicated by abnormallycold suction line)?).

Check superheat.Adjust or replacevalve. Control the

operation of the directexpansion regulator.

YES

If electrical repair has beenmade to unit, check compres-sor electrical power 3-phase

for proper phase connections.

NO

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Maintenance

System cooling output poor.

Is there flash gas inliquid refrigerant line(indicated by a foamyor bubbly sight glass)?

Locate and repair leakin refrigerant system.Recharge refrigerant

to proper levels.

YES

Is the electronic expansionvalve not running correctly?

Control the opera-tion of the direct

expansion regulator.

YE

S

Is the drier/strainerclogged (feels cool

to the touch)?

Replacedrier/strainer

YE

S

See nextPage.

NO

NO

NO

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Maintenance

Is the evaporator coil dirty?

Clean coil.

YES

High ambient temperature(more than 40oC)

and/or air flow too high.

NO

Discharge pressure too high.

Is the condenserair flow too low?

Check speed controllerof the condenser.

chack fan operation.clean coil if required

YES

Is there air or any other non-condensable gas in system?

Evacuate system andrecharge. Install

new drier/strainer.

YE

S

If there is an over-charge of refrigerant,

purge or removeexcess from highside of system.

NO

NO

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Maintenance

Discharge pressure too low.

Is there a Lack of refrigerant (in-dicated by bubbles in sight glass)?

Repair leak and recharge system.

YE

S

Suction pressure too high.

Is the expansion valve not running correctly?

Repair or replace valve, if necessary.Controlthe operation of the direct expansion regulator.

YE

S

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Maintenance

Suction pressure too low.

Is there a lack of refrigerant(flash gas in liquid refrigerant

line indicated by a foamyor bubbly sight glass)?

Repair leakand recharge.

YES

Is the drier/strainer clogged(feels cool to the touch)?

Replacedrier/strainer.

YE

S

Is the expansionvalve not running

correctly?

Replace valveif necessary.Control theoperation ofthe directexpansionregulator.

YE

S

Is the Air sideof coil dirty?

Cleancoil.

YE

S

If the air flowis too low,

check the airflow at theunit outlet.

NO

NO

NO

NO

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Maintenance

Ventilation mode

The fan is running but the operation is not correct :- Air flow too low- Vibrations- Abnormal noise

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Maintenance

Operating modes starting

Engine is running and voltage is good but it is impossible to start the unit’s operatingmodes (cooling or ventilation).

Is the circuitbreaker of the

PLC off (QD10)?

Engage thecircuit breaker ofthe PLC. Check

the intensity.

YES

Are the fuses ofthe current trans-

former burnt?

Replace by new fuses (4AaM). Check the intensity.

YE

S

Is the circuitbreaker 220

V off (QD4)?

Engagethe circuit

breaker220 V.

Check theintensity.

YE

S

If the PLC isfaulty (red lamp inthe PLC), then :- Cut the circuit

breaker of the PLC.- Retry to engage

this circuit breaker.- If the PLC is

always in default, itmust be replaced.

NO

NO

NO

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Property of American Airlines Maintenance...(b) Using a refrigeration recovery system compatible with R134a, pump refrigerant from the system and dispose. (c) Replace drier if necessary,

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