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5.5.3.3 DISTRIBUTION AND CONTROL CABLING

DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET ISOPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN ASOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SETIS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULTFROM FAILURE TO OBSERVE THIS WARNING.

HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACTDURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTIONAND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHENLOAD CABLES ARE HANDLED.

VERIFY THAT CONNECTION POINTS ARE DE-ENERGIZED BEFORE MAKING ANYCONNECTIONS. FAILURE TO CHECK THAT CONNECTORS ARE DE-ENERGIZEDMAY RESULT IN INJURY OR DEATH.

a. Lay out and park the load cables for each phase (A, B, & C) between the PU Tie Output parkingstations and the Primary Switching Center (PSC).

b. Connect each phase cable to the appropriate phase connection on the Primary Switching Center(PSC).

NOTE 1: For complete set-up of the Primary Switching Center (PSC), refer to Radian Inc. CommercialTechnical Manual CTM 01646.1R1260, Chapter 2.6.

NOTE 2: For Unit Isolation Procedure (any unit) - Plant with PSC, and Unit Re-InstallationProcedure Plant with PSC, refer to Chapter 5.9, Sections 5.9.6.15 and 5.9.6.16.

c. Connect each load cables drain wire to the grounding grid.

d. Open the Tie Output connector loadbreak covers on the first PU.

e. Connect the Tie Output Cables to the appropriate phase connectors; ensure there are no cross-phase connections.

f. Close and lock the Tie Output connector covers.

g. Repeat steps a through f on each remaining PU.

h. Connect the first (A) (B) communication cable to B receptacle on first PU.

i. Route the first (A) (B) communication cable to second PU.

j. Connect the first (A) (B) communication cable to A receptacle on second PU.

WARNING

WARNING

WARNING
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k. Connect the second (A) (B) communication cable to B receptacle on second PU.

l. Route the second (A) (B) communication cable to second PU.

m. Connect the second (A) (B) communication cable to A receptacle on third PU.

n. Connect third (A) (B) communication cable to B receptacle on third PU.

o. Route the third (A) (B) communication cable to fourth PU.

p. Connect the third (A) (B) communication cable to A receptacle on fourth PU.

q. Connect the fourth (A) (B) communication cable to B receptacle on fourth PU.

r. Leave the loose end of the fourth cable loose and capped.

5.5.3.4 SETPOINT VERIFICATION

a. Turn on PU DC control power by pushing in on the DC Control Power breaker.

b. On each of the five overcurrent relays, verify the settings:

(1) Press the [] key to get to the top-level menu 1 REPORT STATUS.

(2) Press the [] key 5 times to display 6 GENERAL SETTINGS.

(3) Press the [] key to display 6.1 COM SETTINGS.

(4) Press the [] key 2 times to display 6.3 POWER SYSTEM SETTINGS.

(5) Press the [] key to display 6.3.1 CT RATIO.

(6) Verify the P and N values match Chapter 5.1 Table 5.1.3.4-1 CT Ratio Settings.


(8) Press the [] key to display 5 PROTECTION LOGIC USER.

(9) Press the [] key 3 times to display 5.1.1.1 50TP.

(10) Verify the 50TP PU and TD settings in Chapter 5.1 Table 5.1.3.4-2 Instantaneous TripSettings. In order to edit values, Press the Edit key. Select correct value, and pressEdit again to save changes. Ensure light is off otherwise you can accidentally changevalue again.

(11) Press the [] key to display 5.1.1.2 50TN.

(12) Verify the 50TN settings.

(13) Press the [] key to display 5.1.1.3.

(14) Verify the 50TQ settings.

(15) Press the [] key to display 5.1.1 50T SETTINGS.
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(16) Press the [] key to display 5.1.2 51 SETTINGS.

(17) Press the [] key to display 5.1.2.1 51P.

(18) Verify the 51P PU, TD, and C settings in Chapter 5.1 Table 5.1.3.4-3 TimeOvercurrent Settings.

19) Press the [] key to display 5.1.2.2 51N.

(20) Verify the 51N settings.

(21) Press the [] key 3 times to display 5 PROTECTION LOGIC USER.

c. Use the following procedure to verify the Generator 1 and Generator 2 GSC+ settings:

NOTE: Refer to the EMCPII+ Reference Chart, located on the interior Generator Control PanelDoor (Look-up)

(1) PlaceECS in the COOLDOWN/STOP position.

(2) PressSERVICE MODE key to enter service mode. OP1 is showing on the lower display.

(3) PressSCROLL UP key until OP3 is showing.

(4) PressSELECT key. PE - with the first dash flashing is showing.

(5) PressSCROLL RIGHT key. PE 1 - with the second dash flashing is showing.

(6) PressSCROLL DOWN key. PE 13 with the third dash flashing is showing.

(7) PressSCROLL UP key. PE 132 with the fourth dash flashing is showing.

(8) PressSCROLL DOWN key. PE 1323 with the fifth dash flashing is showing.

(9) PressSCROLL RIGHT key. PE13231 with all digits not flashing is showing.

(10) PressENTER key. PE PASS is showing.

(11) PressEXIT key. OP4 is showing.

(12) PressSCROLL UP key until OP5-0 is showing on the lower display.

(13) PressSELECT key. POO1 followed with the value of the setpoint is showing.

(14) PressSCROLL UP orSCROLL DOWN key. The next setpoint with its value is showing.Use Chapter 5.1 Table 5.1.3.4-4 OP5 Settings for the parameter values to be verified.

Repeat until the desired setpoints are verified.

(15) PressEXIT key. OP5-0 is showing on the lower display.

(16) PressSCROLL UP key until OP5-1 is showing.

(17) PressSELECT key.

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(18) Press SCROLL UP orSCROLL DOWN key. The next setpoint with its value is showing.Use Chapter 5.1 Table 5.1.3.4-5 OP5-1 Settings for the parameter values to be verified.Repeat until the desired setpoints are verified.

(19) Press EXIT key. OP5-1 is showing.

(20) Press SCROLL UP key. OP6 is showing.

(21) Press SELECT key.

(22) PressSCROLL UP orSCROLL DOWN key. The next setpoint with its value is showing.Use Chapter 5.1 Table 5.1.3.4-6 OP6 Settings for the parameter values to be verified.Repeat until the desired setpoints are verified.

(23) Press EXIT key twice. The display returns to normal.

NOTE: If an incorrect setpoint value is displayed, the value must be changed to match the DPGDSsetpoint value as follows:

(a) With the setpoint with the incorrect value showing on the display, press the

SELECT key. The incorrect value flashes on the display.

(b) Press SCROLL UP or SCROLL DOWN key until the correct value appearsflashing on the display.

(c) PressENTER. The correct value stops flashing on the display.

(d) Press SCROLL UP or SCROLL DOWN key to continue to verify the remainingparameter values.

d. ReturnECS1 and ECS2 to the OFF/RESET position.

NOTE: Use up or down keys to change values.

e. At the AVR verify the operation settings using Chapter 5.1 Table 5.1.3.4-7 AVRParameter/Setpoints:

(1) Open the GCPG1 cabinet door.

(2) Press the [] key to display parameter 90.

(3) Press the [] key to display the current value.

(4) Press the [] key to change the value to 0015. Enables parameter editing.

(5) Press the [] key to accept change and display the parameter number.

(6) Press the [] key to the next parameter needed to change.


(8) Press the [] or [] key to change the value.


(10) Repeat steps 5 through 9 for the each parameter needing to be changed.
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(11) When complete, press the [] to display parameter 01.

NOTE: Parameters 20, 21, 22, 36, 37, and 38 are displayed but not used.

NOTE: Parameters 23 to 29, 39 to 49, 59 and 61 to 89 are not displayed and not used.



(14) Press the [] key to change the value to 0009. Disables DVR parameter editing.


(16) Press the [] key to change to display parameter 01.

(17) Close the GCPG1 cabinet door.

(18) Repeat steps 1 through 16 for Generator 2.

5.5.3.5 PRE-OPERATION CHECKS

Starting from the left rear of the PU and working around the PU in a clockwise direction, perform thechecks identified in Chapter 5.1 Table 5.1.3.5-1 Pre-Operation Checklist. (Gen. 1 is on the left and Gen. 2is on the right):

5.5.3.6 PRE-OPERATION RUN

ENSURE ALL PERSONNEL ARE CLEAR AND THE PU DOORS ARE CLOSEDPRIOR TO STARTING A GENERATOR.

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED ANDENFORCED.NOISE LEVELS IN EXCESS OF 85 DB EXIST WITHIN AN 88-FOOT RADIUS OF ANOPERATING DPGDS. PERSONNEL MUST WEAR SINGLE HEARING PROTECTIONWITHIN 88 FEET OF AN OPERATING DPGDS.

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED ANDENFORCED.DURING MAINTENANCE ACTIVITIES WITH THE SIDEDOORS OPEN, NOISELEVELS IN EXCESS OF 113 DB EXIST WITHIN A 12-FOOT RADIUS OF ANOPERATING DPGDS. PERSONNEL MUST WEAR DOUBLE HEARING PROTECTIONWITHIN 12 FEET OF AN OPERATING DPGDS. EXPOSURE MUST BE LIMITED TOUNDER 2.5 HOURS.

WARNING

WARNING

WARNING
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BY CLOSING THE FEEDER OR TIE BREAKER, HIGH VOLTAGE WILL BE PRESENTON THE LOAD CABLES. ENSURE ALL PERSONNEL ARE CLEAR OF ALL LOADCABLES PRIOR TO CLOSING FEEDER OR TIE BREAKERS.

TABLE 5.5.3.6-1 PRE-OPERATION RUN INSTRUCTION SEQUENCE(Perform on each PU in the power plant)

STEP --60HZ OPERATIONS -- --50HZ OPERATIONS --

1 Verify System Mode Switch (SMS) is in MANUAL

2 Verify DC Control Power is on

3 Verify Emergency Stop is pulled out

4

Verify the 60Hz light is on

Verify the 50Hz light is on

5 Start engine 1 by placing ECS1 in MANUAL

6 Verify the engine accelerates to 1800RPM Verify the engine accelerates to 1500RPM

7 Adjust the generator frequency to 60Hzusing the Frequency Adjust Rheostat (FAR)

Adjust the generator frequency to 50Hz usingthe Frequency Adjust Rheostat (FAR)

8 Adjust the generator voltage to 4295VACusing the Voltage Adjust Rheostat (VAR)

Adjust the generator voltage to 3915VACusing the Voltage Adjust Rheostat (VAR)

9 Close BCS-G1, toggle the Phase Rotation Test Light switch, verify that light ABC lights,open BCSG1

10 Shutdown engine 1 by placing ECS1 in OFF/RESET









If the wrong frequency light is on, open the Master Control Door and change the FrequencySelector Switch (FSS) to the desired frequency.

WARNING

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5.5.3.7 ORT SETUP

a. Remove the ORT from its case and set it up on a flat and level surface.

b. Remove the mouse from the case and plug it into the mouse (PS2) port on the back of the ORT.

c. If 120VAC power is available, connect the ORT power supply cord to the 120VAC power. TheORT can operate up to three hours on its batteries.

d. Connect one end of the 150-foot patch cable to the ORT networking port on the PU.

e. Route the cable from the ORT to the PU and connect the cable to the ORT port.

f. Turn on the ORT.

g. Observe that the ORT boots to the operators Overview screen.

h. Select the EquipID pop-up screen and enter the necessary information for the units. Thisincludes the Trailer ID number, the Engine ID number, and the Generator ID number for each

PU.

i. Select the Oneline pop-up screen and enter the descriptor for the main load connected to thefeeders.

h. Return to the Overview pop-up screen.

5.5.3.8 CONTROLS SETUP

Complete the switch arrangements according to the following Table, and verify the lampindicators:

NOTE: Ignore settings for Power Units not being used.

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TABLE 5.5.3.8-1 CONTROL SWITCH SETUP

PANEL SWITCH 1ST

PU 2ND

PU 3RD

PU 4TH

PU

DC PowerPushed In

(ON)Pushed In

(ON)Pushed In

(ON)Pushed In

(ON)

SMS OFF OFF OFF OFF

GMS PRIMEPOWER

PRIMEPOWER

PRIMEPOWER

PRIMEPOWER

AVRSPRIME

POWERPRIME

POWERPRIME

POWERPRIME

POWER

60Hz Light ON ON ON ONUSS A B C DBSS NORMAL NORMAL NORMAL NORMAL

SSS OFF OFF OFF OFF

MASTERCONTROL PANEL

MCP

SSL All OFF All OFF All OFF All OFF

INSIDE MCP FSS 50/60 Hertz 50/60 Hertz 50/60 Hertz 50/60 HertzEmergency

StopPulled-Out Pulled-Out Pulled-Out Pulled-Out

GENERATORCONTROL PANEL

GCPG1 ECS OFF OFF OFF OFFEmergency



GCPG2 ECS OFF OFF OFF OFF

With the SMS in the OFF position, the 50/60Hz lights indicate the position of the FrequencySelector Switch (FSS). If the wrong light is on, open the door and change the switch position.

No more than one switch can be in the same position in any multi-PU line-up. With the SMS inOFF, none of the USI lights will be on and any previously set address on the PU is cleared.

5.5.3.9 PSC RELAY SETTING VERIFICATION

a. Turn on the ORT and log in as administrator using the procedures of PSC Manual (Table 3.3.2-1DPGDS ORT ADMINISTRATOR LOG-IN PROCEDURE).

b. Click on Windows Start button.

c. Select Programs then Accessories then HyperTerminal.

d. Double Click on Vista.ht

NOTE: if vista.ht does not appear on the menu, refer to the windows 98 procedure contained in

APPENDIX C of S&C instruction sheet 681-515 to create it.

NOTE: Use Com 1 communications port on the ORT.

e. Click on Connect.

NOTE: Do Not Connect the communication cable before completing step e. Otherwise Windows NTwill search for a new device on the ORT COM port.

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f. Connect the communication cable between the ORT to the left (Ways 3 and 4) OvercurrentRelay (OCR).

g. Press Enter on the ORT.

NOTE: The overcurrent relay main menu should appear.

h. Select View Menu 1, WAY 3.

i. Select View relay settings.

j. Verify relay settings according to Table 5.5.3.9-1

NOTE: Refer to S&C Instruction Sheet 681-515 page 14, PROGRAMMING to change settings.

k. Repeat steps g through I for WAY 4.

l. Return to the main menu and test the Trip Function of each interrupter using the Test TripMenu.

m. Return to the Main Menu and Disconnect using Windows HyperTerminal when desiredprogramming action is complete.

n. Disconnect the OCR end of the communication cable.

o. Repeat steps e. through l, for the right OCR (Ways 5 and 6).

p. Repeat steps e. though m. for each PSC in use.

q. Exit Windows HyperTerminal.

r. Shut-down the ORT.

TABLE 5.5.3.9-1 PSC RELAY SETTINGS

PSCWAY

FUNCTIONCABLE

SIZECURVE

MIN.PICKUP(AMPS)

INST.PICKUP(KAMPS)

TIMEDELAY(SEC.)

3,4, or 5 Feeder 1/0 TAP 200 1 Off

3,4, or 5 Feeder Ground 1/0 TAP 50 0 Off

3,4, or 5 Single Output 500 KCM MAIN 600 1 Off

3,4, or 5 Single Output Ground 500 KCM MAIN 100 0 Off

6 PSC Interconnect 4/0 TAP 400 0 C (64ms)

6PSC InterconnectGround

4/0 TAP 80 0 C (64ms)

5.5.4 PLANT STARTUP

ALWAYS PAD LOCK THE PSC INTERCONNECT SWITCHES. FAILURE TO DO SOCOULD RESULT IN PERSONAL INJURY. OR DAMAGE TO EQUIPMENT. IFATTEMPTING TO RECLOSE WAY, REFER TO SECTION 5.9.5.3.

WARNING

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Starting up a Multi-PU Prime Power Plant in Manual Mode

a. At the external switchgear, close the associated connection for each PU supplying power to theswitchgear and close and pad lock the PSC interconnect switches when using more than oneprimary switch.

b. At the external switchgear, close the connections between the external switchgears.

c. At the external switchgear, open all connections of loads to the switchgear.

NOTE: 1: For complete set-up of the Primary Switching Center (PSC), refer to USAF TO 35F14-1-1and USA TM9-6115-725-14&P.

NOTE: 2: For Unit Isolation Procedure (any unit) - Plant with PSC, and Unit Re-InstallationProcedure Plant with PSC, refer to Section 5.9, Section 5.9.6.15, and Section 5.9.6.16.

d. Complete the switch arrangements according to the following Table, and verify the lampindicators:

TABLE 5.5.4-1 SWITCH SETUP MANUAL MODE

PANEL SWITCH 1ST

PU 2ND

PU 3RD

PU 4TH

PU

BCS-T Green Target Green Target Green Target Green Target

SMS MANUAL MANUAL MANUAL MANUAL

MSES Enable Enable Enable EnableMASTER CONTROL

PANEL MCP

USI A, B, C, D,BCS-G1 Green Target Green Target Green Target Green Target

BCS-F1 Green Target Green Target Green Target Green TargetGENERATOR

CONTROL PANEL 1GCPG1 ECS-1 OFF OFF OFF OFF

BCS-G2 Green Target Green Target Green Target Green Target

BCS-F2 Green Target Green Target Green Target Green TargetGENERATOR

CONTROL PANEL 2

GCPG2 ECS-2 OFF OFF OFF OFF

Hold the MSES in an ENABLE position until the selected USI indicator energizes. The switchreturns to the center position when released. This sets the PU networking address and enablesthe control and monitoring.

No more than one of each indicator can be on for multi-PU operations. The light on should matchUSS position. The USI light will de-energize after the SMS has been in OFF for 3 seconds.

e. At A-unit GCPG1 place the Engine Control Switch (ECS) in MANUAL.

f. Observe the generator starts and accelerates to operating voltage and frequency.

g. At the A-unit MCP, place the Sync Source Switch (SSS) in the GEN 1 position.

h. Close Generator 1 breaker by cycling BCS-G1 to the CLOSE position.

i. Observe that BCSG1 breaker closes.

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j. Place the SSS in the TIE position

k. Close the BCST by cycling BCST to the CLOSE position.

l. Return the SSS to the OFF position.

m. At A-unit GCPG2 place the Engine Control Switch (ECS) in MANUAL.

n. Observe the engine starts and accelerates to operating voltage and frequency.

o. At the A-unit MCP, place the Sync Source Switch (SSS) in the GEN 2 position.

p. Close BCSG2 when the two green triangular LEDs at 12 oclock on the Synchroscope areenergized by cycling BCSG2 to the CLOSE position. For detailed instructions on manualsynchronizing refer to Chapter 5.9 Section 5.9.6.14.

q. Observe that the BCSG2 closes.

r. Return the SSS to the OFF position.

s. At B-unit MCP, place the SSS in the TIE position.

t. Close the BCST by cycling BCST to the CLOSE position.

u. Return the SSS to the OFF position.

v. At B-unit GCPG1, place the Engine Control Switch (ECS) in MANUAL.

w. Observe the generator starts and accelerates to operating voltage and frequency.

x. At the B-unit MCP, place the Sync Source Switch (SSS) in the GEN 1 position.

y. Close BCSG1 when the two green triangular LEDs at 12 oclock on the Synchroscope areenergized by cycling BCSG1 to the CLOSE position. For detailed instructions on manualsynchronizing refer to Chapter 5.9 Section 5.9.6.14.

z. At B-unit GCPG2, place the Engine Control Switch (ECS) in MANUAL.

aa. Observe the generator starts and accelerates to operating voltage and frequency.

bb. At the B-unit MCP, place the Sync Source Switch (SSS) in the GEN 2 position.

cc. Close BCSG2 when the two green triangular LEDs at 12 oclock on the Synchroscope areenergized by cycling BCSG2 to the CLOSE position. For detailed instructions on manualsynchronizing refer to Chapter 5.9 Section 5.9.6.14.

dd. Return the SSS to the OFF position.

ee. At the C-unit, if installed, repeat steps s through dd.

ff. At the D-unit, if installed, repeat steps s through dd.

gg. At the external switchgear, close the connections of loads to the switchgear.
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hh. Ensure generators have assumed load.

ii. Observe the KW, PF and KVAR of each generator at the LCP.

Note: If adjustment is needed for KVAR balance, start with the generator that is the furthest from the average

KVAR (either too low or too high). Make minor adjustments of the Voltage Adjust Rheostat (VAR) until the

KVAR sharing between generators are within +/ 10% of the average plant KVAR load. This adjustment willtypically be required only once during initial power plant setup and is intended to compensate for meter

variations among generators.

CAUTION

Improper adjustment of the VAR can cause a reverse KVAR shutdown of a generator. 5.5.5 PLANT OPERATIONS

Refer to Chapter 5.9 for specific operating procedures.

In this mode of operation the ORT provides no remote operation capability. It will provide monitoring of

the generator parameters.

5.5.6 POWER PLANT TEARDOWN

5.5.6.1 SHUTDOWN GENERATORS

a. Unload all generators by opening all feeder breakers. This must be done locally from the LCP orORT.

b. Open each BCST locally at the respective MCP.

c. Place all generators in cooldown by placing all SMS switches in OFF.

d. Observe all generator breakers open.

e. Open all the switchgear generator supply disconnect switches.

f. Allow all engines to completely cooldown and shutdown (5 minutes).

g. Place all ECS switches in OFF/RESET.

h. Pull out the DC Control Power breaker on all PUs.

5.5.6.2 DISCONNECT CABLES

NEVER REMOVE POWER CABLES BY HAND, USE HOT STICK AND HIGHVOLTAGE GLOVES. NEVER TOUCH A HIGH VOLTAGE LEAD OR TERMINAL UNTILIT HAS BEEN DISCHARGED TO GROUND. FAILURE TO OBSERVE THE WARNINGMAY RESULT IN DEATH BY ELECTROCUTION.

WARNING
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CAUTION

ALLOW ALL OPERATING ENGINES TO SHUT DOWN AND COOL DOWNCOMPLETELY.

a. Disconnect the (A)(B) communication cables from between the PUs, Reinstall thecommunication cable receptacle covers, and store inside the PUs (one per unit).

b. Disconnect the ORT cable and store it in the ORT case.

c. Close and latch the ORT port on the PU.

d. Disconnect all load cables used in operation of the PUs.

5.5.6.3 DISCONNECT FUEL LINES

a. Turn all fuel system valves to the off position.

b. Disconnect the fuel hose from the PU fuel connection and the fuel supply.

c. Drain any fuel from the hoses into an auxiliary fuel supply and store the hoses.

5.5.6.4 DISCONNECT GROUNDING

a. Remove ground connections from the PU and store with the ground rod.

b. Disconnect the parking stations from the ground grid.

c. Remove the parking stations from their operating positions and reinstall them in theirtransportation locations on the inside of the PU rear side access doors.

5.5.6.5 PREPARE PU FOR TRANSPORTATION

a. Reinstall the four radiator splashguards (PU-810B only).

b. Verify DC Control power is off.

c. Close and lock the LCP access doors.

d. Close and lock all PU side doors.

5.5.6.6 FUEL, OIL, AND COOLANT DRAINAGE

The Power Unit may be safely shipped with oil, fuel, and coolant at maximum capacities or less. Drainingfluids is not required unless federal, state, or local regulations prohibit shipment with fluids present. Referto Section 14.3.1.1, Section 13.4.5.5 and Section 6.5.3 for procedures for draining the oil, coolant and fuelliquids respectively.
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CHAPTER 5.6OPERATING INSTRUCTIONS

SINGLE OR MULTIPLE PU, PRIME POWER, EXTERNAL SWITCH,AUTOMATIC MODE

TABLE OF CONTENTSSECTION TITLE PAGE

5.6 SINGLE/ MULTIPLE PU, PRIME POWER, EXTERNALSWITCH, AUTOMATIC MODE ................................................................................111

5.6.1 SAFETY PROCEDURES .........................................................................................111

5.6.2 POSITIONING THE PU ............................................................................................111

5.6.3 INITIAL PLANT SETUP ...........................................................................................112

5.6.3.1 GROUNDING............................................................................................................112

5.6.3.2 FUEL MANIFOLD.....................................................................................................113

5.6.3.3 DISTRIBUTION AND CONTROL CABLING ...........................................................114

5.6.3.4 SETPOINT VERIFICATION......................................................................................115

5.6.3.5 PRE-OPERATION CHECKS....................................................................................119

5.6.3.6 PRE-OPERATION RUN ...........................................................................................119

5.6.3.7 ORT SETUP..............................................................................................................121

5.6.3.8 CONTROLS SETUP.................................................................................................122

5.6.3.9 PSC RELAY SETTING VERIFICATION ..................................................................122

5.6.4 PLANT STARTUP ....................................................................................................124

5.6.5 PLANT OPERATIONS (AUTOMATIC MODE) ........................................................126

5.6.5.1 PRECAUTIONS AND WARNINGS ..........................................................................126

5.6.5.2 DESCRIPTION..........................................................................................................127

5.6.5.3 DEFAULT OPERATING SEQUENCE......................................................................127

5.6.6 POWER PLANT TEARDOWN .................................................................................128

5.6.6.1 SHUT DOWN GENERATORS .................................................................................128

5.6.6.2 DISCONNECT CABLES ..........................................................................................128

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5.6.6.3 DISCONNECT FUEL LINES ....................................................................................129

5.6.6.4 DISCONNECT GROUNDING...................................................................................129

5.6.6.5 PREPARE PU FOR TRANSPORTATION ...............................................................129

5.6.6.6 FUEL, OIL, AND COOLANT DRAINAGE................................................................129

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LIST OF FIGURES

FIGURE TITLE PAGE

FIGURE 5.6.3.1-1

MEP-PU-810A GROUND POINTS 112

FIGURE 5.6.3.1-2 MEP-PU-810B GROUND POINTS 113

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LIST OF TABLES

TABLE TITLE PAGE

TABLE 5.6.3.6-1

PRE-OPERATION RUN INSTRUCTION SEQUENCE 120

TABLE 5.6.3.8-1 PDC CONTROL SWITCH SETUP 122

TABLE 5.6.3.9-1 PSC RELAY SETTINGS 124

TABLE 5.6.4-1 SWITCH SETUP AUTOMATIC MODE 125

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5.6 SINGLE/ MULTIPLE PU, PRIME POWER, EXTERNAL SWITCH, AUTOMATIC MODE

5.6.1 SAFETY PROCEDURES

a. Safety precautions must be observed while operating or maintaining the PU. Safetyprecautions must be observed to ensure that the operator/technician cannot have contact with thefollowing:

Hot engine parts

Hot engine fluids

Medium Voltage AC electricity

Low Voltage AC electricity

Low Voltage DC electricity

Rotating Parts

High noise levels

b. Minor Troubleshooting can be performed while both engines are running as long as safety

precautions are taken. Refer to the appropriate troubleshooting section for recommendations.

5.6.2 POSITIONING THE PU

a. Position the PU in such a way as to allow the plant operator to have full vision of the operatorcontrol panels on the unit.

b. Level the MEP-PU-810B front to rear with the trailer leveling hand crank.

c. Position the PU to provide a minimum of 10 feet of clearance for maintenance access on allsides of each unit. Ensure that there are no overhead obstructions around the exhaust outlets.

FUEL SPILLAGE CAN OCCUR IF THE POWER UNIT LEVEL IS GREATER THAN + 5DEGREES.

d. Ensure that the ground is capable of supporting the weight of the PU. The site surface should beas level as possible (+ 5 degrees).

WARNING

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5.6.3 INITIAL PLANT SETUP

5.6.3.1 GROUNDING

THERE CAN ONLY BE ONE GROUNDING POINT FOR THE PU.

a. Drive an 8-foot ground rod into the earth and should be within 6 feet of the PU and at a locationthat minimizes the tripping hazard, until only 6 inches (15 cm) protrudes above the surface.

b. Repeat step a for each PU being used.

c. Connect all of the grounding rods together with a #2 AWG copper conductor creating a centralground grid.

d. Using a #2 AWG copper conductor, secure one end of a ground cable to one of the slottedground studs on the PU, see Figure 5.6.3.1-1 or Figure 5.6.3.1-3. Secure the other end of the

ground cable to the ground rod.

e. Repeat step d for every PU.

f. Test Ground Resistance using Ground Resistance Test Equipment. Resistance must be 25 orless. Refer to Annex H for special equipment required for this task.

g. Remove parking stand plates from their transportation positions inside each rear, side PU doorand slide them into their respective operating positions on the sides of the PDC.

h. Connect the parking stand ground wires to either of the two chassis ground lugs on the PU.

FIGURE 5.6.3.1-1 MEP-PU-810A GROUND POINTS

NOTE: Connect only one ground point to the ground grid.

WARNING

GROUND POINTGROUND POINT

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FIGURE 5.6.3.1-2 MEP-PU-810B GROUND POINTS


5.6.3.2 FUEL MANIFOLD

ENSURE THAT THE FUEL LINES ARE PROTECTED FROM ALL ELECTRICALCABLES AND ARE ROUTED TO MINIMIZE THE POTENTIAL FOR PHYSICALDAMAGE OR CAUSING A TRIPPING HAZARD.

a. Lay out the fuel hoses between the PU, the fuel manifold, and the fuel bladders to establish thefuel supply system. See Chapter 5.1 Figure 5.1.3.2-1 External Fuel Supply.

b. Install the external fuel hose for the PU to the Fuel Transfer Pump at the Tow end of the PU.

c. Connect the other end of the fuel hose to the fuel manifold outlets.

d. Connect the 3 hose, with quick-disconnect hose ends, from the fuel manifold to the fuelbladders.

e. Connect the fuel manifold ground wire to the ground grid.

f. Open only the appropriate fuel manifold valves (once connected to the PU) to supply fuel to thepower units and check for leaks.

WARNING

GROUND POINT GROUND POINT
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VERIFY THAT CONNECTION POINTS ARE DE-ENERGIZED BEFORE MAKING ANYCONNECTIONS. FAILURE TO CHECK THAT CONNECTORS ARE DE-ENERGIZEDMAY RESULT IN INJURY OR DEATH.

a. Lay out and park the load cables for each phase (A, B, & C) between the PU Tie Output parkingstations and the Primary Switching Center (PSC).








g. Repeat steps a through f on each remaining PU.




WARNING

WARNING

WARNING

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l. Route the second (A) (B) communication cable to third PU.


n. Connect the third (A) (B) communication cable to B receptacle on third PU.




r. Leave the loose end of fourth cable loose and capped.


a. Turn on PU DC control power by pushing in on the DC Control Power breaker.







(6) Verify the P and N values match Chapter 5.1 Table 5.1.3.4-1 CT Ratio Settings.




(10) Verify the 50TP PU and TD settings in Chapter 5.1 Table 5.1.3.4-2 Instantaneous TripSettings. In order to edit values, Press the Edit key. Select correct value, and pressEdit again to save changes. Ensure light is off otherwise you can accidentally changevalue again.


(12) Verify the 50TN settings.


(14) Verify the 50TQ settings.



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(18) Verify the 51P PU, TD, and C settings in Chapter 5.1 Table 5.1.3.4-3 TimeOvercurrent Settings.

19) Press the [] key to display 5.1.2.2 51N.

(20) Verify the 51N settings.


c. Use the following procedure to verify the Generator 1 and Generator 2 GSC+ settings:



















(18) Press SCROLL UP orSCROLL DOWN key. The next setpoint with its value is showing.Use Chapter 5.1 Table 5.1.3.4-5 OP5-1 Settings for the parameter values to be verified.Repeat until the desired setpoints are verified.
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(20) Press SCROLL UP key. OP6 is showing.

(21) Press SELECT key.


(23) Press EXIT key twice. The display returns to normal.


(a) With the setpoint with the incorrect value showing on the display, press theSELECT key. The incorrect value flashes on the display.

(b) Press SCROLL UP or SCROLL DOWN key until the correct value appears

flashing on the display.


(d) Press SCROLL UP or SCROLL DOWN key to continue to verify the remainingparameter values.

d. ReturnECS1 and ECS2 to the OFF/RESET position.

NOTE: Use up or down keys to change values.

e. At the AVR verify the operation settings using Chapter 5.1 Table 5.1.3.4-7 AVRParameter/Setpoints:

(1) Open the GCPG1 cabinet door.

(2) Press the [] key to display parameter 90.


(4) Press the [] key to change the value to 0015. Enables parameter editing.


(6) Press the [] key to the next parameter needed to change.


(8) Press the [] or [] key to change the value.


(10) Repeat steps 5 through 9 for the each parameter needing to be changed.


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NOTE: Parameters 20, 21, 22, 36, 37, and 38 are displayed but not used.

NOTE: Parameters 23 to 29, 39 to 49, 59 and 61 to 89 are not displayed and not used.



(14) Press the [] key to change the value to 0009. Disables DVR parameter editing.


(16) Press the [] key to change to display parameter 01.

(17) Close the GCPG1 cabinet door.

(18) Repeat steps 1 through 16 for Generator 2.

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5.6.3.5 PRE-OPERATION CHECKS

Starting from the left rear of the PU and working around the PU in a clockwise direction, perform thechecks identified in Chapter 5.1 Table 5.1.3.5-1 Pre-Operation Checklist. (Gen. 1 is on the left and Gen. 2is on the right):

5.6.3.6 PRE-OPERATION RUN

ENSURE ALL PERSONNEL ARE CLEAR AND THE PU DOORS ARE CLOSEDPRIOR TO STARTING A GENERATOR.

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED ANDENFORCED.NOISE LEVELS IN EXCESS OF 85 DB EXIST WITHIN AN 88-FOOT RADIUS OF AN

OPERATING DPGDS. PERSONNEL MUST WEAR SINGLE HEARING PROTECTIONWITHIN 88 FEET OF AN OPERATING DPGDS.

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED ANDENFORCED.DURING MAINTENANCE ACTIVITIES WITH THE SIDEDOORS OPEN, NOISELEVELS IN EXCESS OF 113 DB EXIST WITHIN A 12-FOOT RADIUS OF ANOPERATING DPGDS. PERSONNEL MUST WEAR DOUBLE HEARING PROTECTIONWITHIN 12 FEET OF AN OPERATING DPGDS. EXPOSURE MUST BE LIMITED TOUNDER 2.5 HOURS.

BY CLOSING THE FEEDER OR TIE BREAKER, HIGH VOLTAGE WILL BE PRESENTON THE LOAD CABLES. ENSURE ALL PERSONNEL ARE CLEAR OF ALL LOADCABLES PRIOR TO CLOSING FEEDER OR TIE BREAKERS.

WARNING

WARNING

WARNING

WARNING
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TABLE 5.6.3.6-1 PRE-OPERATION RUN INSTRUCTION SEQUENCE(Perform on each PU in the power plant)

STEP --60HZ OPERATIONS -- --50HZ OPERATIONS --

1 Verify System Mode Switch (SMS) is in MANUAL

2 Verify DC Control Power is on

3 Verify Emergency Stop is pulled out

4 Verify the 60Hz light is on Verify the 50Hz light is on



7 Adjust the generator frequency to 60Hz

using the Frequency Adjust Rheostat (FAR)

Adjust the generator frequency to 50Hz using

the Frequency Adjust Rheostat (FAR)













If the wrong frequency light is on, open the Master Control Door and change the FrequencySelector Switch (FSS) to the desired frequency.

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5.6.3.7 ORT SETUP

a. Remove the ORT from its case and set it up on a flat and level surface.

b. Remove the mouse from the case and plug it into the mouse (PS2) port on the back of the ORT.

c. If 120VAC power is available, connect the ORT power supply cord to the 120VAC power. TheORT can operate up to three hours on its batteries.

d. Connect one end of the 150-foot patch cable to the ORT networking port on the PU.

e. Route the cable from the ORT to the PU and connect the cable to the ORT port.

f. Turn on the ORT.

g. Observe that the ORT boots to the operators Overview screen.

h. Select the EquipID pop-up screen and enter the necessary information for the units. Thisincludes the Trailer ID number, the Engine ID number, and the Generator ID number for each

PU.

i. Select the Oneline pop-up screen and enter the descriptor for the main load connected to thefeeders.

h. Return to the Overview pop-up screen.

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5.6.3.8 CONTROLS SETUP

Complete the switch arrangements according to the following Table, and verify the lampindicators:

NOTE: Ignore settings for Power Units not being used:

TABLE 5.6.3.8-1 PDC CONTROL SWITCH SETUP

PANEL SWITCH 1ST

PU 2ND

PU 3RD

PU 4TH

PU

DC PowerPushed In

(ON)Pushed In

(ON)Pushed In

(ON)Pushed In

(ON)

SMS OFF OFF OFF OFF

GMSPRIME

POWERPRIME

POWERPRIME

POWERPRIME

POWER

AVRSPRIME

POWERPRIME

POWERPRIME

POWERPRIME

POWER

60Hz Light ON ON ON ONUSS A B C DBSS NORMAL NORMAL NORMAL NORMALSSS OFF OFF OFF OFF

MASTER CONTROLPANEL MCP

SSL All OFF All OFF All OFF All OFF

INSIDE MCP FSS50/60

Hertz50/60

Hertz50/60

Hertz50/60

HertzEmergency



GCPG1 ECS OFF OFF OFF OFF

EmergencyStop

Pulled-Out Pulled-Out Pulled-Out Pulled-OutGENERATOR

CONTROL PANELGCPG2 ECS OFF OFF OFF OFF

With the SMS in the OFF position, the 50/60Hz lights indicate the position of the FrequencySelector Switch (FSS). If the wrong light is on, open the door and change the switch position.

No more than one switch can be in the same position in any multi-PU line-up. With the SMS inOFF, none of the USI lights will be on and any previously set address on the PU is cleared.

5.6.3.9 PSC RELAY SETTING VERIFICATION

a. Turn on the ORT and log in as administrator using the procedures of PSC Manual (Table 3.3.2-1DPGDS ORT ADMINISTRATOR LOG-IN PROCEDURE).

b. Click on Windows Start button.

c. Select Programs then Accessories then HyperTerminal.

d. Double Click on Vista.ht

NOTE: If vista.ht does not appear on the menu, refer to the Windows 98 procedure contained inAPPENDIX C of S&C instruction sheet 681-515 to create it.

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NOTE: Use Com 1 communications port on the ORT.

e. Click on Connect.

NOTE: Do Not Connect the communication cable before completing step e. Otherwise Windows NTwill search for a new device on the ORT COM port.

f. Connect the communication cable between the ORT to the left (Ways 3 and 4) OvercurrentRelay (OCR).

g. Press Enter on the ORT.

NOTE: The overcurrent relay main menu should appear.

h. Select View Menu 1, WAY 3.

i. Select View relay settings.

j. Verify relay settings according to Table 5.6.3.9-1

NOTE: Refer to S&C Instruction Sheet 681-515 page 14, PROGRAMMING to change settings.

k. Repeat steps g through I for WAY 4.

l. Return to the main menu and test the Trip Function of each interrupter using the Test TripMenu.

m. Return to the Main Menu and Disconnect using Windows HyperTerminal when desiredprogramming action is complete.

n. Disconnect the OCR end of the communication cable.

o. Repeat steps e. through l. for the right OCR (Ways 5 and 6).

p. Repeat steps e. though m. for each PSC in use.

q. Exit Windows HyperTerminal.

r. Shut-down the ORT.

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TABLE 5.6.3.9-1 PSC RELAY SETTINGS

PSC WAY FUNCTIONCABLE

SIZECURVE

MIN.PICKUP(AMPS)

INST.PICKUP(KAMPS)

TIMEDELAY(SEC.)

3,4, or 5 Feeder 1/0 TAP 200 1 Off

3,4, or 5FeederGround

1/0 TAP 50 0 Off

3,4, or 5SingleOutput

500 KCM MAIN 600 1 Off

3,4, or 5SingleOutputGround

500 KCM MAIN 100 0 Off

6PSCInterconnect

4/0 TAP 400 0 C (64ms)

6PSCInterconnectGround

4/0 TAP 80 0 C (64ms)

5.6.4 PLANT STARTUP

ONCE THE SYSTEM STATUS LIGHTS TURN GREEN AND THE MSES IS ENABLED,THE PU WILL START. ENSURE PERSONNEL ARE CLEAR OF THE PU.

ONLY ONE PU MAY BE SELECTED TO ANY ONE USS POSITION DURING MULTIPLE

PU OPERATIONS. OPERATING WITH MORE THAN ONE UNIT AT THE SAME IDCAUSE UNSAFE AND ERRATIC OPERATIONAL CONDITIONS.

ALWAYS PAD LOCK THE PSC INTERCONNECT SWITCHES. FAILURE TO DO SOCOULD RESULT IN PERSONAL INJURY OR DAMAGE TO EQUIPMENT

Starting up a Multi-PU Prime Power Plant in Automatic Mode

a. At the Primary Switching Center (PSC), close the associated connection for each PU supplyingpower to the switchgear and close and pad lock the PSC interconnect switches when using morethan one primary switch.

b. At the PSC, close the connections between the external switchgears.

c. At the PSC, open all the connections of loads to the PSC.

WARNING

WARNING

WARNING

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d. Complete the switch arrangements according to the following Table, and verify the lampindicators:

TABLE 5.6.4-1 SWITCH SETUP AUTOMATIC MODE

PANEL SWITCH 1ST

PU 2ND

PU 3RD

PU 4TH

PU

BCS-T Red Target Red Target Red Target Red Target

SMS AUTO AUTO AUTO AUTOMASTER CONTROLPANEL MCPUSS A B C D

BCS-G1 Red Target Red Target Red Target Red Target

BCS-F1 Red Target Red Target Red Target Red TargetGENERATOR

CONTROL PANEL 1GCPG1 ECS-1 AUTO AUTO AUTO AUTO

BCS-G2 Red Target Red Target Red Target Red Target

BCS-F2 Red Target Red Target Red Target Red Target

GENERATOR

CONTROL PANEL 2GCPG2 ECS-2 AUTO AUTO AUTO AUTO

MSES Enable Enable Enable EnableMASTER CONTROLPANEL MCP USI A, B, C, D,

Hold the MSES in an ENABLE position until the selected USI indicator energizes. The switchreturns to the center position when released. This sets the PU networking address and enablesthe control and monitoring.

No more than one of each indicator can be on for multi-PU operations. The light on should matchUSS position. The USI light will de-energize after the SMS has been in OFF for 3 seconds.

With the SMS in AUTO any generator started, manually or automatically, will automaticallyparallel to the bus. To prevent the generator from paralleling to the bus put the generatorsbreaker in the Pull-To-Lock position.

NOTE: The automatic economizing feature will shutdown one generator every 3 minutes until thesystem load is at or below the 360KW/450KVA per generator threshold.

e. At A-unit, observe Generator 1 automatically starts and accelerates to operating voltage andfrequency.

f. At A-unit, observe Generator 1 automatically closes to the system bus.

g. At A-unit, observe the Tie breaker automatically closes.

h. At B-unit, observe the Tie breaker automatically closes.

i. At C-unit, observe the Tie breaker automatically closes.

j. At D-unit,observe the Tie breaker automatically closes.

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k. At A-unit, observe Generator 2 automatically starts and accelerates to operating voltage andfrequency.

l. At A-unit, observe Generator 2 automatically parallels to the system bus.

m. At B-unit, observe Generator 1 automatically starts and accelerates to operating voltage andfrequency.

n. At B-unit, observe Generator 1 automatically parallels to the system bus.

o. At B-unit, observe Generator 2 automatically starts and accelerates to operating voltage andfrequency.

p. At B-unit, observe Generator 2 automatically parallels to the system bus.

q. At C-unit, observe Generator 1 automatically starts and accelerates to operating voltage andfrequency.

r. At C-unit, observe Generator 1 automatically parallels to the system bus.

s. At C-unit, observe Generator 2 automatically starts and accelerates to operating voltage andfrequency.

t. At C-unit, observe Generator 2 automatically parallels to the system bus.

u. At D-unit, observe Generator 1 automatically starts and accelerates to operating voltage andfrequency.

v. At D-unit, observe Generator 1 automatically parallels to the system bus.

w. At D-unit, observe Generator 2 automatically starts and accelerates to operating voltage andfrequency.

x. At D-unit, observe Generator 2 automatically parallels to the system bus.

y. At the external switchgear, close all switches/breakers connecting the external switchgear to theload (s).

z. Ensure generators have assumed load.

aa. Observe the KW, PF and KVAR of each generator at the LCP.

Note: If adjustment is needed for KVAR balance, start with the generator that is the furthest from the average

KVAR (either too low or too high). Make minor adjustments of the Voltage Adjust Rheostat (VAR) until theKVAR sharing between generators are within +/ 10% of the average plant KVAR load. This adjustment will

typically be required only once during initial power plant setup and is intended to compensate for meter

variations among generators.

CAUTION

Improper adjustment of the VAR can cause a reverse KVAR shutdown of a generator. 5.6.5 PLANT OPERATIONS (AUTOMATIC MODE)

5.6.5.1 PRECAUTIONS AND WARNINGS

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This mode of operation places control of all generator starting, stopping, synchronizing, and loadmanagement under the auspices of the Programmable Logic Controller (PLC) system. As long as theSMS is in AUTO, any generator started, manually or automatically, is automatically synchronized to thesystem bus. Care must be taken when starting a generator manually when the SMS is in AUTO. Eitherplace the associated BCS in Pull-To-Lock (prevent closing to the bus) or ensure it has the red targetvisible (allow paralleling to the bus) before starting the engine. The only exception is automatic operationof the feeder breakers. Auto Mode does not automatically close feeder breakers; it only enables remoteoperation of the feeder breakers from the ORT.

5.6.5.2 DESCRIPTION

The master controller (the designated A unit) will control all connected generators based on the totalsystem KW/KVA load. The controller shuts down one of the generators after 3 minutes should the systemload drop below a level where the remaining generator load would not exceed 85% (360kW) if agenerator is shutdown. If the load of the remaining generator exceeds 85% (360kW) for one minute, astandby generator is started and paralleled to the bus. A change of system load is recognized by thecontrol system and appropriate action is taken to maintain generator load in the 85% (360 KW/450 KVA)range. The system never automatically shuts down the final generator under normal operating conditions.

The shutdown of the final generator must be done following manual operating procedures. The defaultconfiguration is Economizing Mode on. The economizing mode can be turned off from the ORT. Throughthe ORT, the AUTO shut down is disabled but the AUTO start-up remains active to prevent overloadingthe online generator(s).

5.6.5.3 DEFAULT OPERATING SEQUENCE

Start-Up Sequence: The automatic controls will continuously monitor the system load. As load on thesystem increases, the controls automatically start and place additional units on line in the followingsequence at 1-minute intervals:

a. One generator from PU B based on lower engine runtime.

b. One generator from PU C based on lower engine runtime.

c. One generator from PU D based on lower engine runtime.

d. Remaining generator from PU A.

e. Remaining generator from PU B.

f. Remaining generator from PU C.

g. Remaining generator from PU D.

Shutdown Sequence: Based on the loading experienced, the controller shuts down generator sets thatare not needed. For the purpose of explanation, we will assume that all generator sets are on linefollowing an initial startup. Based on load, the controls shut down generator sets in the following

sequence at 3-minute intervals:

a. One generator from PU D based on higher engine runtime.

b. One generator from PU C based on higher engine runtime.

c. One generator from PU B based on higher engine runtime.

d. One generator from PU A based on higher engine runtime.

e. Remaining generator from PU D.

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f. Remaining generator from PU C.

g. Remaining generator from PU B.

5.6.6 POWER PLANT TEARDOWN

5.6.6.1 SHUT DOWN GENERATORS

a. Unload all generators by opening all feeder breakers. This must be done locally from the LCP orORT.

b. Open each BCST locally at the respective MCP.

c. Place all generators in cooldown by placing all SMS switches in OFF.

d. Observe all generator breakers open.

e. Open all the switchgear generator supply disconnect switches.

f. Allow all engines to completely cooldown and shutdown (5 minutes).

g. Place all ECS switches in OFF/RESET.

h. Pull out the DC Control Power breaker on all PUs.

5.6.6.2 DISCONNECT CABLES

NEVER REMOVE POWER CABLES BY HAND, USE HOT STICK AND HIGH VOLTAGE

GLOVES. NEVER TOUCH A HIGH VOLTAGE LEAD OR TERMINAL UNTIL IT HAS BEENDISCHARGED TO GROUND. FAILURE TO OBSERVE THE WARNING MAY RESULT INDEATH BY ELECTROCUTION.

CAUTION

ALLOW ALL OPERATING ENGINES TO SHUT DOWN AND COOL DOWN COMPLETELY.

a. Disconnect the (A)(B) communication cables from between the PUs, Reinstall thecommunication receptacle covers, and store inside the PUs (one per unit).

b. Disconnect the ORT cable and store it in the ORT case.

c. Close and latch the ORT port on the PU.

d. Disconnect all load cables used in operation of the PUs.

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5.6.6.3 DISCONNECT FUEL LINES

a. Turn all fuel system valves to the off position.

b. Disconnect the fuel hose from the PU fuel connection and the fuel supply.

c. Drain any fuel from the hoses into an auxiliary fuel supply and store the hoses.

5.6.6.4 DISCONNECT GROUNDING

a. Remove ground connections from the PU and store with the ground rod.

b. Disconnect the parking stations from the ground grid.

c. Remove the parking stations from their operating positions and reinstall them in theirtransportation locations on the inside of the PU rear side access doors.

5.6.6.5 PREPARE PU FOR TRANSPORTATION

a. Reinstall the four radiator splashguards (PU-810B only).

b. Verify DC Control power is off.

c. Close and lock the LCP access doors.

d. Close and lock all PU side doors.

5.6.6.6 FUEL, OIL, AND COOLANT DRAINAGE

The Power Unit may be safely shipped with oil, fuel, and coolant at maximum capacities or less. Drainingfluids is not required unless federal, state, or local regulations prohibit shipment with fluids present. Referto Section 14.3.1.1, Section 13.4.5.5 and Section 6.5.3 for procedures for draining the oil, coolant and fuelliquids respectively.
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CHAPTER 5.7OPERATING INSTRUCTIONS

MEP-PU-810 AND MEP-012 PARALLEL OPERATIONS, MANUAL ANDAUTOMATIC MODE

TABLE OF CONTENTS

SECTION TITLE PAGE

5.7 MEP-PU-810 & MEP-012 PARALLEL OPERATIONS, MANUAL ANDAUTOMATIC MODE 135

5.7.1 SAFETY PROCEDURES 135

5.7.2 MEP-PU-810 AND MEP-012 PARALLEL OPERATION DESCRIPTION 135

5.7.3 POSITIONING THE PU 136

5.7.4 INITIAL PLANT SETUP 137

5.7.4.1 GROUNDING 137

5.7.4.2 FUEL MANIFOLD 139

5.7.4.3 DISTRIBUTION AND CONTROL CABLING 140

5.7.4.4 SETPOINT VERIFICATION 142

5.7.4.5 PRE-OPERATION CHECKS 155

5.7.4.6 PRE-OPERATION RUN 157

5.7.4.7 ORT SETUP 159

5.7.4.8 CONTROLS SETUP 160

5.7.5 PLANT STARTUP 161

5.7.5.1 MANUAL MODE 161

5.7.5.1.1 STARTING UP SINGLE OR MULTIPLE PUS IN MANUAL MODE WITH AMEP-012 POWER PLANT 161

5.7.5.1.2 STARTING UP SINGLE OR MULTIPLE MEP-012S WITH A MEP-PU-810POWER PLANT IN MANUAL MODE 164

5.7.5.2 AUTOMATIC MODE 165

5.7.5.2.1 STARTING UP SINGLE OR MULTIPLE PUS IN AUTOMATIC MODE WITH AMEP-012 POWER PLANT 165

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5.7.5.2.2 STARTING UP SINGLE OR MULTIPLE MEP-012S WITH A PU POWERPLANT IN AUTOMATIC MODE 167

5.7.6 PLANT OPERATIONS 168

5.7.7 POWER PLANT TEARDOWN 168

5.7.7.1 SHUT DOWN GENERATORS 168

5.7.7.2 DISCONNECT CABLES 168

5.7.7.3 DISCONNECT FUEL LINES 169

5.7.7.4 DISCONNECT GROUNDING 169

5.7.7.5 PREPARE PU FOR TRANSPORTATION 169

5.7.7.6

FUEL, OIL, AND COOLANT DRAINAGE 169

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LIST OF FIGURES

FIGURE TITLE PAGE

FIGURE 5.7.4.1-1 MEP-PU-810A GROUND POINTS 138

FIGURE 5.7.4.1-2 MEP-PU-810B GROUND POINTS 138

FIGURE 5.7.4.2-1 EXTERNAL FUEL SUPPLY 139

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LIST OF TABLES

TABLE TITLE PAGE

TABLE 5.7.4.4-1 CT RATIO SETTINGS 142

TABLE 5.7.4.4-2 INSTANTANEOUS TRIP SETTINGS 142

TABLE 5.7.4.4-3 TIME OVERCURRENT TRIP SETTINGS 143

TABLE 5.7.4.4-4 OP5-0 SETPOINTS 145

TABLE 5.7.4.4-4 OP5-0 SETPOINTS (CONTINUED) 146

TABLE 5.7.4.4-5 OP5-1 SETPOINTS 148



TABLE 5.7.4.4-6 OP6 SETPOINTS 151

TABLE 5.7.4.4-6 OP6 SETPOINTS (CONTINUED) 152

TABLE 5.7.4.4-7 AVR PARAMETERS/SETPOINTS 153

TABLE 5.7.4.4-7 AVR PARAMETERS/SETPOINTS (CONTINUED) 154

TABLE 5.1.3.5-1 PRE-OPERATION CHECKLIST 155

TABLE 5.1.3.5-1 PRE-OPERATION CHECKLIST (CONTINUED) 156

TABLE 5.7.4.6-1 PRE-OPERATION RUN INSTRUCTION SEQUENCE 158

TABLE 5.7.4.8-1 CONTROL SWITCH SETUP 160

TABLE 5.7.5.1-1 SWITCH SETUP MANUAL MODE 162

TABLE 5.7.5.1-2 GENERATOR CAPACITIES 163

TABLE 5.7.5.2.1-1 SWITCH SETUP AUTOMATIC MODE 166
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5.7 MEP-PU-810 & MEP-012 PARALLEL OPERATIONS, MANUAL AND AUTOMATICMODE

5.7.1 SAFETY PROCEDURES

a. Safety precautions must be observed while operating or maintaining the PU. Safetyprecautions must be observed to ensure that the operator/technician cannot have contact with thefollowing:

Hot engine parts

Hot engine fluids

Medium Voltage AC electricity

Low Voltage AC electricity

Low Voltage DC electricity

Rotating Parts

High noise levels

b. Minor Troubleshooting can be performed while both engines are running as long as safetyprecautions are taken. Refer to the appropriate troubleshooting section for recommendations.

5.7.2 MEP-PU-810ANDMEP-012PARALLELOPERATIONDESCRIPTION

TheMEP-PU-810 generator is an isochronous generator. It operates at 50 or 60 Hertz for itscomplete load range of 0-420KW. By design, a single isochronous generator will assume theload on the bus up to its full capacity. To allow multiple isochronous generators to work in parallelLoad Share Modules (LSM) are used. Each generator has its own LSM and these areinterconnected by load share lines. The LSMs of online generators put a voltage on the loadshare lines that is sensed by all other LSMs. Each LSM then compares the load share linevoltage to its internal load voltage and develops an error signal. This error is then used to raiseor lower the KW load carried by that generator until all online generators are sharing the loadequally (no error signal). With this type of operation no adjustment to the generator frequency isrequired to distribute load equally among the generators. This also allows multiple generators,even ones of different capacity, to operate in parallel under all conditions from no-load to full-load.

The MEP-012 will be operated as a droop generator. As it is loaded from 0-750KW, its frequencydroops by a set ratio. The generators frequency adjust potentiometer is then raised to maintainthe desired frequency. Operating multiple droop generators together requires the operator toadjust generator frequency potentiometers to distribute the load proportionally among generators.Additionally, the operator must constantly adjust generator frequencies to maintain the requiredfrequency whenever loads are added or shed.

Both kinds of generators may be operated together; however, close attention must be paid to thesystem load and the droop units frequency. The isochronous generator will set system

frequency and try to assume its full capacity. This requires the operator to lower the droop unitfrequency to transfer the load to the isochronous generator. That unit carries load increases upto the capacity of the droop unit. Additional load above the total capacity of both generators willobviously require an additional generator. Load decreases below the full capacity rating of justthe isochronous unit will require the operator to shutdown the droop unit.

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The recommended method of operating MEP-PU-810s and MEP-012s together is to place theMEP-PU-810 generators on the bus and allow them to carry the normal load. When the systemload approaches the rated capacity of the MEP-PU-810 generator(s), add MEP-012 generatorsas required to provide the necessary capacity. As the load drops off, shutdown the MEP-012generator(s).

CAUTION

THE MEP-PU-810 WILL TRY TO ASSUME ITS RATED LOAD WHEN PARALLELEDWITH ANOTHER GENERATOR THAT IS OPERATING IN DROOP. VOLTAGE ANDFREQUENCY ADJUSTMENTS ON THE DROOP PLANT MUST BE USED TOCONTROL THE LOAD SHARING BETWEEN THE PLANT AND THE MEP-PU-810 .

There may be situations where the recommended method of operation is not ideal. In thesesituations, understanding the way isochronous and droop generators work and operationalexperience are useful in achieving a line-up that is best for the application.

5.7.3 POSITIONING THE PU

a. Position the PU in such a way as to allow the plant operator to have full vision of the operatorcontrol panels on the unit.

b. Level the MEP-PU-810B front to rear with the trailer leveling hand crank.

c. Position the PU to provide a minimum of 10 feet of clearance for maintenance access on allsides of each unit. Ensure that there are no overhead obstructions around the exhaust outlets.

FUEL SPILLAGE CAN OCCUR IF THE POWER UNIT LEVEL IS GREATER THAN + 5

DEGREES.

d. Ensure that the ground is capable of supporting the weight of the PU. The site surface should beas level as possible (+ 5 degrees).

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5.7.4 INITIAL PLANT SETUP

5.7.4.1 GROUNDING

THERE CAN ONLY BE ONE GROUNDING POINT FOR THE PU. WHEN USING ANEUTRAL GROUND RESISTER (NGR), IT MUST USE THE PU GROUND ROD TOAVOID CREATING A GROUND LOOP.

a. Drive an 8-foot ground rod into the earth and should be within 6 feet of the PU and at a locationthat minimizes the tripping hazard, until only 6 inches (15 cm) protrudes above the surface.

b. Repeat step a for each PU being used.

c. Connect all of the grounding rods together with a #2 AWG copper conductor creating a centralground grid.

d. Using a #2 AWG copper conductor, secure one end of a ground cable to one of the slottedground studs on the PU, see Figure 5.7.4.1-1 or Figure 5.7.4.1-3. Secure the other end of theground cable to the ground rod.

e. Repeat step d for every PU.

f. Test Ground Resistance using Ground Resistance Test Equipment. Resistance must be 25 orless. Refer to Annex H for special equipment required for this task.

g. Remove parking stand plates from their transportation positions inside each rear, side PU doorand slide them into their respective operating positions on the sides of the PDC.

h. Connect the parking stand ground wires to either of the two chassis ground lugs on the PU.

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FIGURE 5.7.4.1-1 MEP-PU-810A GROUND POINTS


FIGURE 5.7.4.1-2 MEP-PU-810B GROUND POINTS




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5.7.4.2 FUEL MANIFOLD

ENSURE THAT THE FUEL LINES ARE PROTECTED FROM ALL ELECTRICALCABLES AND ARE ROUTED TO MINIMIZE THE POTENTIAL FOR PHYSICALDAMAGE OR CAUSING A TRIPPING HAZARD.

a. Lay out the fuel hoses between the PU, the fuel manifold, and the fuel bladders to establish thefuel supply system see Figure 5.7.4.2-1.

b. Install the external fuel hose for the PU to the Fuel Transfer Pump at the Tow end of the PU.

c. Connect the other end of the fuel hose to the fuel manifold outlets.

d. Connect the 3 hose, with quick-disconnect hose ends, from the fuel manifold to the fuelbladders.

e. Connect the fuel manifold ground wire to the ground grid.

f. Open only the appropriate fuel manifold valves (once connected to the PU) to supply fuel to thepower units and check for leaks.

FIGURE 5.7.4.2-1 EXTERNAL FUEL SUPPLY

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VERIFY THAT CONNECTION POINTS ARE DE-ENERGIZED BEFORE MAKING ANYCONNECTIONS. FAILURE TO CHECK CONNECTORS DE-ENERGIZED MAYRESULT IN INJURY OR DEATH.

a. Lay out and park the load cables for each phase (A, B, & C) between the PU Tie Output parkingstations and the load.








g. Repeat steps b through f on each remaining PU.


WARNING

WARNING

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l. Route the second (A) (B) communication cable to second PU.


n. Connect the third (A) (B) communication cable to B receptacle on third PU.




r. Leave the loose end of fourth cable loose and capped.

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a. Turn on the control power by pushing in the DC Control Power breaker.







(6) Verify the P and N values match the following table:

TABLE 5.7.4.4-1 CT RATIO SETTINGS

BREAKER RELAY CT RATIO P VALUE N VALUE

GENERATOR 100:5 20 20

FEEDER 200:5 40 40

TIE 200:5 40 40




(10) Verify the 50TP PU and TD settings in Table 5.7.4.4-2. In order to edit values, Pressthe Edit key. Select correct value, and pressEdit again to save changes. Ensure

light is off otherwise you can accidentally change value again.

TABLE 5.7.4.4-2 INSTANTANEOUS TRIP SETTINGS

PHASEINSTANTANEOUS

TRIP50TP

NEUTRALINSTANTANEOUS

TRIP 50TN

NEGATIVE SEQUENCETRIP50 TQ

BREAKER RELAY

PU TD PU TD PU TD

GENERATOR 0.0 0m 3.0 0m 3.0 0m

FEEDER 7.5 84m 1.25 84m 0 0m

TIE 0.0 0m 0 0m 0.0 0m


(12) Verify the 50TN settings in Table 5.7.4.4-2.


(14) Verify the 50TQ settings



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(18) Verify the 51P PU, TD, and C settings in Table 5.7.4.4-3.

TABLE 5.7.4.4-3 TIME OVERCURRENT TRIP SETTINGS

PHASE TIME OVERCURRENTTRIP 51P NEUTRAL TIME OVERCURRENTTRIP 51NBREAKER RELAY

PU TD C PU TD C

GENERATOR 4.50 0.5 VV2 1.25 0.5 VV2

FEEDER 2.50 1.0 VV2 1.00 1.0 VV2

TIE 5.00 2.0 VV2 1.50 2.0 VV2

(19) Press the [] key to display 5.1.2.2 51N.

(20) Verify the 51N settings in Table 5.7.4.4-3.


c. Use the following procedure to verify the Generator 1 and Generator 2 GSC+ settings in step d:















(14) PressSCROLL UP orSCROLL DOWN key. The next setpoint with its value is showing.Use Table 5.7.4.4-4 for the parameter values to be verified. Repeat until the desiredsetpoints are verified.


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(18) Press SCROLL UP orSCROLL DOWN key. The next setpoint with its value is showing.Use Table 5.7.4.4-5 for the parameter values to be verified. Repeat until the desiredsetpoints are verified.


(20) Press SCROLL UP key until OP6 is showing.


(22) Press SCROLL UP orSCROLL DOWN key. The next setpoint with its value is showing.Use Table 5.7.4.4-6 OP6 Setpoints for the parameter values to be verified. Repeat until thedesired setpoints are verified.

(23) PressEXIT Key twice. The display returns to normal.


(a) With the setpoint with the incorrect value showing on the display, press theSELECT key. The incorrect value flashes on the display.

(b) Press SCROLL UP or SCROLL DOWN key until the correct value appearsflashing on the display.


(d) Press SCROLL UP or SCROLL DOWN key to continue to verify the remaining

parameter values.d. At GSCG1 and GSCG2, verify the operation settings using the following table:

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TABLE 5.7.4.4-4 OP5-0 SETPOINTS

SETPOINTS OP5-0 ENGINE/GENERATOR PROGRAMMINGSETPOINT-NAME-DESCRIPTIONS RANGE OF VALUES

FACTORY

DEFAULT

DPGDSSETPOINT

P001 - Fuel Solenoid Type: type of fuel system solenoid

used on the genset.

0- ETR fuel solenoid

1- ETS fuel solenoid

0 0

P002 - Units Shown: type of measurement units shownon the GSC+ display.

0-for English units (PSI, F)

1-for metric units (kPa, C).0 0

P003 - Shutdown Override For Engine Fault: GSC+response to a low engine oil pressure or high coolanttemperature fault.

0-for engine shutdown

1-for alarm only (shutdown override, noengine shutdown).

0 0

P004 - Shutdown Override For Sensor Fault: GSC+response to a diagnostic fault with the engine oil pressuresensor, coolant temperature sensor, oil temperaturesensor, sensor power supply or coolant loss sensor.

0-for alarm only shutdown override, noengine shutdown).

1-for engine shutdown.

0 0

P005 - Coolant Loss Sensor Installed: tells whether ornot the optional engine coolant loss sensor is installed onthe genset.

0-for gensets without a coolant loss sensor

1-for gensets with coolant loss sensor0 1

P006 - Shutdown Override For Coolant Loss Fault:

GSC+ response to an engine coolant loss fault.

0-for engine shutdown.

1-for alarm only (shutdown override, noengine shutdown). 0 0

P007 - System Voltage, 24 Or 32 Volts: system voltage(battery voltage) of the genset.

24 or 32. 24 24

P008 - This setpoint is not currently being used by theGSC+ and cannot be programmed.

N/A N/A N/A

P009 - Number Of Ring Gear Teeth: number of teeth onthe ring gear of the engine. Used by the GSC+ todetermine engine speed.

95 to 350 teeth in increments of one tooth. 136 teeth 136 teeth

P010 - Engine Overspeed: engine speed used by theGSC+ to declare that an engine overspeed fault exists.The engine overspeed setpoint (for all 60 Hz applications)is 1.18 times the rated speed.

500 to 4330 rpm in increments of 10 rpm. 2120 rpm 2120 rpm

P011 - Crank Terminate Speed: engine speed used bythe GSC+ to disengage the starting motor during enginecranking.


P012 - Oil Step Speed: engine speed used by the GSC+for distinguishing between rated speed and idle speedwhen a low oil pressure fault exists.


P013 - Low Oil Pressure Shutdown At Rated Speed:oil pressure used by the GSC+ to declare that a low oilpressure shutdown fault exists with engine at rated speed(the engine speed must have exceeded the oil step speedfor nine seconds).

5 to 61PSI (34 to 420kPa) in increments of 130 PSI

(205 kPa)

30 PSI

(205 kPa)

P014 - Low Oil Pressure Shutdown At Idle Speed:oil pressure used by the GSC+ to declare that a low oilpressure shutdown fault exists with the engine at idlespeed (the

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