Operation & Maintenance MT80CHP. Micro Turbine CHP. Models: TP /03

Transcription

1 Operation & Maintenance Micro Turbine CHP Models: MT80CHP TP /03

2 California Proposition 65 WARNING Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Product Identification Information Product identification numbers determine service parts. Record the product identification numbers in the spaces below immediately after unpacking the products so that the numbers are readily available for future reference. Record field-installed kit numbers after installing the kits. Micro Turbine Identification Numbers Record the product identification numbers from the micro turbine s nameplate(s). Model Designation Specification Number Serial Number Accessory Number Accessory Description

3 Table of Contents Product Identification Information... Inside front cover Safety Precautions and Instructions... I Introduction... i Service Assistance... i Section 1 General Information Introduction Safety Maintenance Policy Overall Description Variants Dimensions and Weights... 2 Section 2 Technical Description Control and Power Electronics Bay Start and Normal Operation Stop and Emergency Stop Operation Engine and Heat Recovery Bays Gas Turbine and Alternator Oil System Fuel System Aspiration Air System Battery Charger and Oil Pump Section 3 Operating Instructions Safety General Precautions Natural Gas Exhaust Controls and Indications Power Controls Control Panel Operating Procedures Preliminary System Status System Operating Mode Selection Local Mode Operation Local Test Mode Operation Remote Mode Operation Modbus Remote Mode Section 4 Scheduled Maintenance Service Schedule Safety Fault Finding Common Faults Power Faults Gas System Faults Cooling System Faults Exhaust Gas Temperature High Fault TP /03 Table of Contents

4 Table of Contents, continued 4.4 Servicing Control and Power Electronics Gas Turbine and Alternator Oil System Gas Fuel System Air System Recuperator Engine Igniter Oil Cooler Oil Coalescer Filter Repair Control and Power Electronics Gas Turbine and Alternator Heat Recovery Appendix A Abbreviations... A-1 Appendix B Glossary of Micro Turbine Terms... A-3 Table of Contents TP /03

5 Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS. Electromechanical equipment, including generator sets, transfer switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained. To prevent accidents be aware of potential dangers and act safely. Read and follow all safety precautions and instructions. SAVE THESE INSTRUCTIONS. This manual has several types of safety precautions and instructions: Danger, Warning, Caution, and Notice. DANGER Danger indicates the presence of a hazard that will cause severe personal injury, death,orsubstantial property damage. WARNING Warning indicates the presence of a hazard that can cause severe personal injury, death, or substantial property damage. CAUTION Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage. NOTICE Notice communicates installation, operation, or maintenance information that is safety related but not hazard related. Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain how to act safely. The decals are shown throughout this publication to improve operator recognition. Replace missing or damaged decals. Accidental Starting WARNING Accidental starting. Can cause severe injury or death. Disconnect the battery cables before working on the generator set. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery. Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the generator set or connected equipment, disable the generator set as follows: (1) Move the generator set master switch to the OFF position. (2) Disconnect the power to the battery charger. (3) Remove the battery cables, negative (--) lead first. Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent starting of the generator set by an automatic transfer switch, remote start/stop switch, or engine start command from a remote computer. Battery WARNING Sulfuric acid in batteries. Can cause severe injury or death. Wear protective goggles and clothing. Battery acid may cause blindness and burn skin. WARNING Explosion. Can cause severe injury or death. Relays in the battery charger cause arcs or sparks. Locate the battery in a well-ventilated area. Isolate the battery charger from explosive fumes. Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid can cause blindness and burn skin. Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery. Do not open a sealed battery or mutilate the battery case. If battery acid splashes in the eyes or on the skin, immediately flush the affected area for 15 minutes with large quantities of clean water. Seek immediate medical aid in the case of eye contact. Never add acid to a battery after placing the battery in service, as this may result in hazardous spattering of battery acid. Battery acid cleanup. Battery acid can cause severe injury or death. Battery acid is electrically conductive and corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking soda) to a containerwith4l(1gal.)ofwaterand mix the neutralizing solution. Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction (foaming) has ceased. Flush the resulting liquid with water and dry the area. TP /03 Safety Precautions and Instructions I

6 Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging. Do not dispose of a battery in a fire. To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects. Remove all jewelry before servicing the equipment. Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery. To avoid sparks, do not disturb the battery charger connections while the battery is charging. Always turn the battery charger off before disconnecting the battery connections. Ventilate the compartments containing batteries to prevent accumulation of explosive gases. Battery short circuits. Explosion can cause severe injury or death. Short circuits can cause bodily injury and/or equipment damage. Disconnect the battery before generator set installation or maintenance. Remove all jewelry before servicing the equipment. Use tools with insulated handles. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery. Never connect the negative (--) battery cable to the positive (+) connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together. Engine Backfire/Flash Fire WARNING Fire. Can cause severe injury or death. Do not smoke or permit flames or sparks near fuels or the fuel system. Servicing the fuel system. A flash fire can cause severe injury or death. Do not smoke or permit flames or sparks near the carburetor, fuel line, fuel filter, fuel pump, or other potential sources of spilled fuels or fuel vapors. Catch fuels in an approved container when removing the fuel line or carburetor. Servicing the air cleaner. A sudden backfire can cause severe injury or death. Do not operate the generator set with the air cleaner removed. Combustible materials. A fire can cause severe injury or death. Generator set engine fuels and fuel vapors are flammable and explosive. Handle these materials carefully to minimize the risk of fire or explosion. Equip the compartment or nearby area with a fully charged fire extinguisher. Select a fire extinguisher rated ABC or BC for electrical fires or as recommended by the local fire code or an authorized agency. Train all personnel on fire extinguisher operation and fire prevention procedures. Exhaust System WARNING Carbon monoxide. Can cause severe nausea, fainting, or death. The exhaust system must be leakproof and routinely inspected. Generator set operation. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Avoid breathing exhaust fumes when working on or near the generator set. Never operate the generator set inside a building unless the exhaust gas is piped safely outside. Never operate the generator set where exhaust gas could accumulate and seep back inside a potentially occupied building. Carbon monoxide symptoms. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is a poisonous gas present in exhaust gases. Carbon monoxide poisoning symptoms include but are not limited to the following: Light-headedness, dizziness Physical fatigue, weakness in joints and muscles Sleepiness, mental fatigue, inability to concentrate or speak clearly, blurred vision Stomachache, vomiting, nausea If experiencing any of these symptoms and carbon monoxide poisoning is possible, seek fresh air immediately and remain active. Do not sit, lie down, or fall asleep. Alert others to the possibility of carbon monoxide poisoning. Seek medical attention if the condition of affected persons does not improve within minutes of breathing fresh air. Copper tubing exhaust systems. Carbon monoxide can cause severe nausea, fainting, or death. Do not use copper tubing in diesel exhaust systems. Sulfur in diesel exhaust causes rapid deterioration of copper tubing exhaust systems, resulting in exhaust leakage. Fuel System WARNING Explosive fuel vapors. Can cause severe injury or death. Use extreme care when handling, storing, and using fuels. The fuel system. Explosive fuel vapors can cause severe injury or death. Vaporized fuels are highly explosive. Use extreme care when handling and storing fuels. Store fuels in a well-ventilated area away from spark-producing equipment and out of the reach of children. Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks. Do not smoke or permit flames or sparks to occur near sources of spilled II Safety Precautions and Instructions TP /03

7 fuel or fuel vapors. Keep the fuel lines and connections tight and in good condition. Do not replace flexible fuel lines with rigid lines. Use flexible sections to avoid fuel line breakage caused by vibration. Do not operate the generator set in the presence of fuel leaks, fuel accumulation, or sparks. Repair fuel systems before resuming generator set operation. Explosive fuel vapors can cause severe injury or death. Take additional precautions when using the following fuels: Natural Gas Adequate ventilation is mandatory. Because natural gas rises, install natural gas detectors high in a room. Inspect the detectors per the manufacturer s instructions. Gas fuel leaks. Explosive fuel vapors can cause severe injury or death. Fuel leakage can cause an explosion. Check the LP vapor gas or natural gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to 6--8 ounces per square inch ( inches water column). Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation. A successful test depends on the ability of the solution to bubble. Hazardous Noise CAUTION Hazardous noise. Can cause hearing loss. Never operate the generator set without a muffler or with a faulty exhaust system. Engine noise. Hazardous noise can cause hearing loss. Generator sets not equipped with sound enclosures can produce noise levels greater than 105 dba. Prolonged exposure to noise levels greater than 85 dba can cause permanent hearing loss. Wear hearing protection when near an operating generator set. Hazardous Voltage/ Electrical Shock DANGER Hazardous voltage. Will cause severe injury or death. Disconnect all power sources before opening the enclosure. WARNING Hazardous voltage. Moving rotor. Can cause severe injury or death. Operate the generator set only when all guards and electrical enclosures areinplace. WARNING Hazardous voltage. Backfeed to the utility system can cause property damage, severe injury, or death. If the generator set is used for standby power, install an automatic transfer switch to prevent inadvertent interconnection of standby and normal sources of supply. Grounding electrical equipment. Hazardous voltage can cause severe injury or death. Electrocution is possible whenever electricity is present. Open the main circuit breakers of all power sources before servicing the equipment. Configure the installation to electrically ground the generator set, transfer switch, and related equipment and electrical circuits to comply with applicable codes and standards. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution. Installing the battery charger. Hazardous voltage can cause severe injury or death. An ungrounded battery charger may cause electrical shock. Connect the battery charger enclosure to the ground of a permanent wiring system. As an alternative, install an equipment grounding conductor with circuit conductors and connect it to the equipment grounding terminal or the lead on the battery charger. Install the battery charger as prescribed in the equipment manual. Install the battery charger in compliance with local codes and ordinances. TP /03 Safety Precautions and Instructions III

8 Connecting the battery and the battery charger. Hazardous voltage can cause severe injury or death. Reconnect the battery correctly, positive to positive and negative to negative, to avoid electrical shock and damage to the battery charger and battery(ies). Have a qualified electrician install the battery(ies). Short circuits. Hazardous voltage/current can cause severe injury or death. Short circuits can cause bodily injury and/or equipment damage. Do not contact electrical connections with tools or jewelry while making adjustments or repairs. Remove all jewelry before servicing the equipment. Electrical backfeed to the utility. Hazardous backfeed voltage can cause severe injury or death. Install a transfer switch in standby power installations to prevent the connection of standby and other sources of power. Electrical backfeed into a utility electrical system can cause severe injury or death to utility personnel working on power lines. Testing live electrical circuits. Hazardous voltage or current can cause severe injury or death. Have trained and qualified personnel take diagnostic measurements of live circuits. Use adequately rated test equipment with electrically insulated probes and follow the instructions of the test equipment manufacturer when performing voltage tests. Observe the following precautions when performing voltage tests: (1) Remove all jewelry. (2) Stand on a dry, approved electrically insulated mat. (3) Do not touch the enclosure or components inside the enclosure. (4) Be prepared for the system to operate automatically. (600 volts and under) Heavy Equipment WARNING Unbalanced weight. Improper lifting can cause severe injury or death and equipment damage. Do not use lifting eyes. Lift the generator set using lifting bars inserted through the lifting holes on the skid. Hot Parts WARNING Hot coolant and steam. Can cause severe injury or death. Before removing the pressure cap, stop the generator set and allow it to cool. Then loosen the pressure cap to relieve pressure. WARNING Hot engine and exhaust system. Can cause severe injury or death. Do not work on the generator set until it cools. Servicing the generator. Hot parts can cause severe injury or death. Avoid touching the generator set field or exciter armature. When shorted, the generator set field and exciter armature become hot enough to cause severe burns. Checking the coolant level. Hot coolant can cause severe injury or death. Allow the engine to cool. Release pressure from the cooling system before removing the pressure cap. To release pressure, cover the pressure cap with a thick cloth and then slowly turn the cap counterclockwise to the first stop. Remove the cap after pressure has been completely released and the engine has cooled. Check the coolant level at the tank if the generator set has a coolant recovery tank. Servicing the exhaust system. Hot parts can cause severe injury or death. Do not touch hot engine parts. The engine and exhaust system components become extremely hot during operation. Moving Parts WARNING Hazardous voltage. Moving rotor. Can cause severe injury or death. Operate the generator set only when all guards and electrical enclosures areinplace. WARNING Rotating parts. Can cause severe injury or death. Operate the generator set only when all guards, screens, and covers are in place. IV Safety Precautions and Instructions TP /03

9 WARNING Airborne particles. Can cause severe injury or blindness. Wear protective goggles and clothing when using power tools, hand tools, or compressed air. Tightening the hardware. Flying projectiles can cause severe injury or death. Loose hardware can cause the hardware or pulley to release from the generator set engine and can cause personal injury. Retorque all crankshaft and rotor hardware after servicing. Do not loosen the crankshaft hardware or rotor thrubolt when making adjustments or servicing the generator set. Rotate the crankshaft manually in a clockwise direction only. Turning the crankshaft bolt or rotor thrubolt counterclockwise can loosen the hardware. Servicing the generator set when it is operating. Exposed moving parts can cause severe injury or death. Keep hands, feet, hair, clothing, and test leads away from the belts and pulleys when the generator set is running. Replace guards, screens, and covers before operating the generator set. Notice NOTICE This generator set has been rewired from its nameplate voltage to NOTICE Voltage reconnection. Affix a notice to the generator set after reconnecting the set to a voltage different from the voltage on the nameplate. Order voltage reconnection decal from an authorized service distributor/dealer. NOTICE Hardware damage. The engine and generator set may use both American Standard and metric hardware. Use the correct size tools to prevent rounding of the bolt heads and nuts. NOTICE When replacing hardware, do not substitute with inferior grade hardware. Screws and nuts are available in different hardness ratings. To indicate hardness, American Standard hardware uses a series of markings, and metric hardware uses a numeric system. Check the markings on the bolt heads and nuts for identification. NOTICE Canadian installations only. For standby service connect the output of the generator set to a suitably rated transfer switch in accordance with Canadian Electrical Code, Part 1. TP /03 Safety Precautions and Instructions V

10 Notes VI Safety Precautions and Instructions TP /03

11 Introduction MT80CHP Micro Turbines are compact natural gasfired power generators for distributed power generation applications. The prime mover is a micro gas turbine and the power generation is derived from a high speed alternator via a power conversion stage. The systems can be configured either with or without exhaust gas heat recovery systems integrated within the system enclosure. Where the exhaust gas heat recovery system is integrated within the system enclosure, it is identified as a cogeneration system. This is equipped with a recuperator which heats the combustion air utilizing exhaust gas heat. Where the exhaust gas heat is made available for use elsewhere, it is identified as a simple cycle system that is supplied with neither a recuperator nor heat recovery system. Perform all required installation and startup (commissioning) checks before operating the micro turbine. Information in this publication represents data available at the time of print. Kohler Co. reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever. Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury. Read and follow the Safety Precautions and Instructions section at the beginning of this manual. Keep this manual with the equipment for future reference. Service Assistance For professional advice on generator power requirements and conscientious service, please contact your nearest Kohler distributor or dealer. Consult the Yellow Pages under the heading Generators Electric Visit the Kohler Power Systems website at KohlerPowerSystems.com Look at the labels and stickers on your Kohler product or review the appropriate literature or documents included with the product Call toll free in the US and Canada Outside the US and Canada, call the nearest regional office Africa, Europe, Middle East London Regional Office Langley, Slough, England Phone: (44) Fax: (44) Asia Pacific Power Systems Asia Pacific Regional Office Singapore, Republic of Singapore Phone: (65) Fax: (65) China North China Regional Office, Beijing Phone: (86) (86) (86) Fax: (86) East China Regional Office, Shanghai Phone: (86) Fax: (86) India, Bangladesh, Sri Lanka India Regional Office Bangalore, India Phone: (91) (91) Fax: (91) Japan, Korea North Asia Regional Office Tokyo, Japan Phone: (813) Fax: (813) Latin America Latin America Regional Office Lakeland, Florida, USA Phone: (863) Fax: (863) X:in:008:001a TP /03 Introduction i

12 Notes ii Introduction TP /03

13 Section 1 General Information 1.1 Introduction The weights of main components within the MT80CHP Micro Turbine system are shown in Figure 1-1. Component Weight, kg (lb.) Heat exchanger (assembled) 220 (485) Recuperator 170 (375) Engine (assembled) 130 (287) Power converter 57 (126) Rear panel (heat exchanger) 46 (101) Enclosure door 43 (95) Side panel (heat exchanger) 41 (90) Silencer and foam 32 (71) Heat exchanger transition duct 24 (53) Extract fan (assembled) 21 (46) Figure 1-1 MT80CHP System Weights 1.2 Safety A list of all warnings and precautions contained in this manual is provided in the Safety Precautions and Instructions section of this manual. Applicable warnings and cautions are also included wherever necessary. Always keep the following warnings in mind when operating or maintaining the Micro Turbine: Gas is extremely flammable and explosive under certain conditions. Do not smoke or allow flames or sparks in working area. Lethal voltages and currents exist within the Micro Turbine. Take all normal precautions with electrical connections when any side panel is removed or side door is opened. High temperatures exist within the Micro Turbine. Take normal precautions when any side panel is removed or side door is opened. If the engine must be run during testing/maintenance with the side panels removed, wear ear protection Figure 1-2 Micro Turbine General View TP /03 Section 1 General Information 1

14 1.3 Maintenance Policy This manual covers operator and first-line maintenance only. The operator/maintainer should not attempt to perform any maintenance action beyond the scope of this manual. Service Rules Use parts and lubricants recommended in manual. See the appropriate sections for recommendations. Install new gaskets, O-rings, lock plates, etc., when reassembling. When tightening bolts or nuts, begin with larger diameter or inner bolts first unless a particular sequence is specified. Clean parts in cleaning solution upon dismantling and lubricate any sliding surfaces before reassembling. After reassembling, check all parts for proper installation and operation. Ensure that all cables are run within cable tracks provided or cable tied together. 1.4 Overall Description The Micro Turbine has three main functional areas: control and power electronics, engine, and heat recovery. The three areas are contained within three main compartments as shown in Figure The control and power electronics bay contains the local operator interface (control panel) and electrical interfaces for the 3-phase power output, auxiliary power input, and remote control. It monitors and controls the Micro Turbine and provides conditioning and switching of the output power supply. 2. The engine bay contains a combined Micro Turbine and alternator, together with all associated systems. These systems provide the fuel supply, air supply, and lubrication/cooling (oil) for the turbine and alternator. 3. The heat recovery bay contains the engine components that provide the CHP heat transfer facilities and enable the Micro Turbine to obtain high operating efficiency. In maximum configuration, these components are a recuperator, waste heat recovery unit, and an oil cooler. See Section 1.5 for a description of variants. Refer to Section 3, Operating Instructions, for a more detailed description. 1.5 Variants There are three basic variants of the Micro Turbine: Fully recuperated system configuration as listed above. Recuperator bypass system configuration. This valve forms part of the air system and, when installed, adjusts proportion of air routed through recuperator, thus controlling the exhaust entry temperature to the water heat exchanger. A simple cycle configuration, which does not have the recuperator or boiler installed. This variant requires an external or air blast oil cooler. 1.6 Dimensions and Weights Parameter Recuperated Simple Cycle Length, overall, mm (in.) 3100 (122.1) 2185 (86.0) Width, overall, mm (in.) 876 (34.49) Height, overall, mm (in.) 1955 (76.97) Net weight, wet, kg (lb.) 1751 (3860) 1225 (2700) Engine weight, kg (lb.) 80 (176) Oil capacity, L (gal.) 15 (3.96) Oil type MIL-L Figure 1-3 Dimensions and Weights 2 Section 1 General Information TP /03

15 Figure 1-4 Micro Turbine Side View/Functional Block Diagram TP /03 Section 1 General Information 3

16 Notes 4 Section 1 General Information TP /03

17 Section 2 Technical Description As described previously and shown in Figure 2-1, the Micro Turbine comprises the following compartments and major functional systems: Control and power electronics bay. Engine bay, containing: Gas turbine and alternator Oil system Fuel system Air system Recuperator Heat recovery bay, containing (dependent on configuration): Heat recovery unit Oil cooler These compartments and the systems/functions within them are described in Section 2.1 and Section 2.2. C&M -- Control and Monitoring Figure 2-1 Micro Turbine Functional Block Diagram TP /03 Section 2 Technical Description 5

18 2.1 Control and Power Electronics Bay Figure 2-2 is a simplified block diagram of the control and power electronics. It comprises three main areas: Control electronics including the operator local and remote control interfaces, central processor, and optional facilities. Power electronics including a power conditioning unit (PCU) and output switching circuits with internal and external interlock/emergency off controls provided for personnel and equipment safety. Auxiliary power supply and battery power supply circuits including battery charging, battery start, and oil pump motor supply circuits Start and Normal Operation Fully automatic control and protection of the gas turbine starting/stopping, synchronizing, and power output control (including thermal modulation for the Micro Turbine) is provided in the package. A 24-volt battery, together with an integral battery charger, provides the running power for system electronics. In addition, the system is designed for parallel operation with the public electric utility. The start circuit takes power from the 3-phase import/ export cable to drive the alternator as a motor to start the gas turbine and control the start sequence. When the gas turbine is running, the PCU switches to its main function of driving the output load using power from the alternator. The start sequence includes a purge timer to ensure the recuperator, boiler, and exhaust is cleared of gas prior to ignition. A heat demand signal (not shown in Figure 2-2) should be supplied by an external building management system to control the heat transfer provided by the boiler. This is normally a ma signal Stop and Emergency Stop Operation Internal and external interlock connections are provided to enable the Micro Turbine to be stopped automatically under specified conditions. C&M -- Control and Monitoring Figure 2-2 Control and Power Electronics Overall Block Diagram 6 Section 2 Technical Description TP /03

19 2.2 Engine and Heat Recovery Bays The following external interfaces are provided: 1. Fuel (gas) supply. Gas is supplied via an external gas train, which is controlled and monitored by the control electronics. A gas compressor will be required if the supply pressure is below 5.5 bar. 2. Aspiration air intake. Air is drawn into the engine compartment via a prefilter and main filter. This air is then drawn into the turbine compressor. 3. Cooling air intake. Air is drawn into the engine bay via the electronics cabinet, which is equipped with an intake filter. 4. Air outlet. Cooling air is expelled from the engine compartment. This warm air, 50 C (122 F), should be ducted from the plant room. 5. Exhaust. Waste gases from the gas turbine are exhausted through the recuperator and waste heat recovery unit (if equipped). 6. Electrical. Electrical power output and control and monitoring (C&M) connections to the control and power electronics bay. 7. Water inlet and outlet. Used (in maximum configuration) for oil cooling and recovery of heat from the exhaust via the waste heat recovery unit. The Micro Turbine generator is a combined gas turbine and alternator with single rotor shaft comprising a turbine, compressor, and permanent magnet rotor. During normal running, air is drawn in from outside via a 2-stage filtration system through the radial compressor and preheated in the recuperator before entering the turbine burner (or combustor) stage, together with the fuel gas. The combusted gas powers the turbine, compressor, and alternator. The electrical power output from the alternator is fed to the power conditioner and switchgear circuits in the control and power electronics bay. During startup, the alternator acts as a starter motor, driven by a single-phase utility feed in the control and electronics bay. The oil pump, control valves, cooling fans, and monitoring devices are also powered from the control and power electronic bay. The cooling fans within the engine bay circulate the cooling air around the engine and other components. Cooling air is drawn in and discharged via ducts at the top of the enclosure. C&M -- Control and Monitoring Figure 2-3 Engine and Heat Recovery Overall Block Diagram TP /03 Section 2 Technical Description 7

20 2.2.1 Gas Turbine and Alternator The engine is a recuperated cycle single shaft turbine rotating at 68,000 rpm. It has a single stage radial compressor, annular combustor (burner), and single radial turbine. The turbine/compressor/alternator rotor shaft is supported on forward and aft bearings within the alternator housing. These bearings are lubricated and the alternator is cooled by oil from the oil system. Air for gas combustion is routed from the compressor to the recuperator and then to the burner. The fuel system controls the supply of gas, which is combusted in the burner to drive the turbine. See Figure Oil System Oil is used for both bearing lubrication and cooling. The alternator oil pump, driven by a DC motor, supplies oil to the alternator bearings and cooling jacket. The oil temperature is controlled at 76 C (169 F) by a 3-way directional control valve. The system is also fitted with a 3-micron simplex filter and pressure switch. The system is filled using a 21 L (5.55 gal.) oil tank that incorporates an oil heater with thermostat set to heat the oil to a maximum of 30 C (86 F) and a sight level gauge. Oil pressure is monitored with a pressure switch, set at 3.2 bar, and transducer. The transducer output is fed to the central processor where output is monitored and the shutdown pressure is set at 3.2 bar. Control and monitoring connections are from/to control and power electronics bay. See Figure 2-5. C&M -- Control and Monitoring Figure 2-4 Gas Turbine and Alternator Simplified Block Diagram C&M -- Control and Monitoring Figure 2-5 Oil System Simplified Schematic Diagram 8 Section 2 Technical Description TP /03

21 2.2.3 Fuel System The fuel system comprises a gas train, which is external to the Micro Turbine cabinet, and an internal fuel system that provides fine control of the gas fed to the burners. See Figure 2-6. This internal fuel system has safety devices with the following functions: Gas guard pressure switch. Monitors gas pressure and, if the control valve goes to the full open position, shuts the unit down thereby preventing an overgasing situation. Pressure transducer (optional). Used for monitoring purposes and for the setting to work. Control and monitoring connections are from/to control and power electronics bay. External Gas Train The gas train comprises a manual isolation valve, filter, and pressure-regulating valve (optional). The pressureregulating valve maintains gas pressure at a constant pressure if the supply pressure is not sufficiently regulated. High and low pressure switches ensure that the system shuts down if the pressure falls below 4.8 bar or exceeds 7 bar. Two block valves maintain positive shutoff to the engine in normal and emergency shutdown procedures. Internal Fuel System Gas from the gas train is filtered and fed to the turbine via the gas control valve, which is accurately controlled by the control electronics. The control electronics also drive the start sequencer, which provides an interface to control the output from the gas train. The gas train performs a fuel safety function to ensure that fuel is supplied to the unit within the correct pressure range. It also ensures a positive gas supply shutoff. C&M = Control and Monitoring Figure 2-6 Fuel System Simplified Block Diagram TP /03 Section 2 Technical Description 9

22 2.2.4 Aspiration Air System As described previously, the aspiration air system routes air to the compressor and, via the recuperator, to the burner. The recuperator transfers heat from the exhaust gas to the compressed air to improve turbine efficiency. See Figure Battery Charger and Oil Pump The battery charger and oil pump assembly provide two functions that are completely independent of each other. The battery charger maintains a 24-volt battery charge and powers the low voltage control electronics. The oil pump driver controls a 24-volt brushless DC motor/ pump. C&M = Control and Monitoring Figure 2-7 Aspiration Air System Simplified Block Diagram 10 Section 2 Technical Description TP /03

23 Section 3 Operating Instructions All operating information presented in this section assumes that the Micro Turbine has been properly installed and commissioned by qualified personnel. Refer to Section 4, Installation, for a summary of activities that should have been completed during installation and commissioning. Operation of the Micro Turbine is possible from: The local controls. A building management system (BMS). A remote computer terminal connected via an RS-232 or RS-485 serial communications link. Remotely located emergency stop and other interlocking devices may be connected to the Micro Turbine in addition to the local emergency stop and internal interlocks. 3.1 Safety Refer to the Safety Precautions and Instructions section at the beginning of this manual prior to operating the Micro Turbine under normal or maintenance conditions General Precautions The following is a list of general precautions to observe when operating the Micro Turbine: Keep ABC-rated fire extinguishers handy. Allow only qualified personnel access inside the enclosure. Obey all warning labels. other sources of ignition well away from areas where natural gas is present and from areas sharing ventilation. If you smell natural gas, immediately cease operation of the equipment and locate and repair the source of the leak Exhaust Exhaust gases contain small amounts of carbon monoxide. Carbon monoxide can be lethal in fairly low concentrations. If a leak of exhaust gases is suspected, cease operation of the equipment and locate and repair the source of the leak. The exhaust stream and exhaust piping are hot enough to cause personal injury and fires. Keep people, equipment, structures, trees, etc., well away from the exhausts. Vent the exhaust outside in accordance with local regulations. 3.2 Controls and Indications Power Controls Emergency Stop Button Pressing the emergency stop button stops power generation and shuts down the engine. The button incorporates a latching mechanism that holds the button in the stopped condition. The button is reset by rotating the button clockwise until it springs back to the operating position. An emergency stop may also be initiated by a remote emergency stop button (or interlock) if connected. See Figure 3-1. Keep equipment clean. Do not allow any flammable materials to remain inside the enclosure. Follow all applicable local, state, and federal codes and regulations. Use extreme caution when working on electrical equipment. Remove all jewelry. Make sure clothing and shoes are dry. Stand on an insulated platform on the ground or floor Natural Gas Keep flames, cigarettes, sparks, pilot lights, electrical arc producing equipment, switches or tools, and all Figure 3-1 Power Controls TP /03 Section 3 Operating Instructions 11

24 Utility Isolator The utility isolator switches the Micro Turbine 3-phase power supply output ON (I) or OFF (O). Note: Isolate the batteries within unit if unit is shut down for periods longer than 48 hours Control Panel The control panel, shown in Figure 3-2, comprises: Power ON/OFF switch Status LEDs LCD status display Keypad comprising ESC, DOWN, UP, ENTER, START (I), and STOP (O) buttons. Power ON/OFF Switch Enable control and power electronics by moving power ON/OFF switch to ON and disable by moving the switch to OFF. If the unit is not in the Idle state and the voltage on the DC link is greater than 35 volts, the electronics remainoneveniftheswitchismovedtooff. The electronics turn off only when the unit returns to the Idle state and the DC link falls to less than 35 volts Figure 3-2 Control Panel Status LEDs Refer to Figure 3-3 for status LED descriptions. LED Remote Enable Generating Fault Auxiliary Supply OK 24V OK Figure 3-3 Fault Clear Description Indicates operating mode has been set to either Remote or Modbus Remote. Indicates when the unit is generating in current or voltage mode. Indicates software has detected a fault condition. The type of fault is indicated by a message on the bottom line of LCD. The buzzer sounds if this LED is on. Indicates Auxiliary Supply is connected to unit. Indicates internal 24V supply is greater than 20V. Status LED Descriptions During an alarm, the unit shuts down, the fault LED lights, a buzzer sounds, and a fault message displays on the lower line of the display. Press the ESC key on the Modbus is a registered trademark of Schneider Electric. 12 Section 3 Operating Instructions local panel to clear the fault in the local mode. Toggle the remote start relay to clear the fault in the remote start. To clear a Modbus remote fault, toggle it clear on the PC screen. LCD Status Display LCD can display four lines of information. Bottom line of the display always shows the present status of the unit or any faults present. The top three lines display further information depending on which screen is selected. At power up, the software version screen is displayed. During power up, self test routines are performed and a sequence of Test n messages displays indicating that testing is in progress. On completion of the tests, the display momentarily shows an End of Test message before changing to the Voltage, Current, Power screen. Use the DOWN, UP, ESC, and ENTER buttons to navigate through all available screens. Operator level menu structure is shown in Figure 3-6. Pressing the ESC button while displaying these screens causes a return to the Voltage, Current, Power screen. TP /03

25 Use the DOWN and UP buttons to cycle around the display screens as follows: Voltage, Current, Power Utilization Factor kva Total Power, Output Frequency, DC Link Voltage EGT1 (Exhaust Gas Temperature), EGT2, Oil Temperature Engine Speed, Battery Voltage, Cranking Voltage Boiler Air Temp., Required Temp., Recuperation (only displayed when the CHP option is enabled) Active Power, Reactive Power (this is hidden and is only displayed if the load following option is enabled) Starts Log, Run Hours, kw Hours Action Log Pressing ENTER while displaying the Action Log screen allows viewing of further screens showing the times and details of the last 100 events. Example events are changes of state and the reason for the generator stopping. Cycle around the events using the DOWN and UP buttons. Pressing the ESC button causes a return to the Action Log screen. The Action Log is stored in non-volatile memory (EEPROM); therefore, its contents are retained even if the electronics have been turned off. Date/Time User Settings (seven associated screens are available from this screen, see Figure 3-4) Pressing ENTER while displaying the User Settings screen allows viewing of further screens. The screens shown in Figure 3-4 can be accessed using the UP and DOWN buttons. Pressing ENTER while displaying screens shown in Figure 3-4 allows parameter adjustment. Pressing ENTER while displaying the BEMAPOS Software Version screen allows access to further menus of parameters (see BEMAPOS Software Version screen). These parameters are set as part of the manufacture and installation process; they cannot be changed by the operator and are security protected. At any position within the menu structure, press the ESC button to return to a higher level screen. Repeated pressing eventually causes return to the Voltage, Current, Power screen (see Figure 3-6). Screen Description 1 Set Operating Mode 2 Set Power* 3 Set Power Factor* 4 Set Power Factor Sign* 5 Set Time 6 Set Date 7 BEMAPOS Software Version * These apply only to systems configured for utility connection. They have no effect for voltage generation systems. Figure 3-4 Gas Supply System User Settings Screen A manual control valve forms part of the gas supply train as shown in Figure 3-5. Use this valve to open or close the gas supply to the Micro Turbine. The supply to the gas boost compressor or plant room should also be fitted with a slam shut valve (not supplied). Link this valve to the BMS or fire detection system Figure 3-5 External Gas Train TP /03 Section 3 Operating Instructions 13

26 Figure 3-6 Menu Structure 14 Section 3 Operating Instructions TP /03

27 3.3 Operating Procedures Preliminary System Status 1. Perform all required installation and startup (commissioning) checks. 2. Before a start is attempted, ensure that the Micro Turbine is ready for normal operation after any maintenance activity or installation. 3. Ensure that the power controls (Figure 3-1) are in the following states: a. Utility isolator closed (I). b. Emergency stop not latched. c. Ensure that the power switch on the control panel is in the OFF position. 4. Open the manual gas control valve to provide the gas supply to the gas train (Figure 3-5). 5. Move power switch to the ON position (Figure 3-2). 6. The power ON sequence is as follows: a. When electronics have been powered up, four control panel LEDs (Remote Enable, Generating, Aux. Supply OK, and 24V OK) turn on. b. The processor then executes a self-test and configuration routine. The LCD display shows a sequence of Test n messages. c. On completion of the tests, display momentarily shows an End of Test message before changing to Voltage, Current, Power screen. d. The LCD backlight turns on. e. The Generating LED is extinguished. f. The 24V OK and Aux. Supply OK LEDs show status of the supplies. g. The Remote Enable LED shows control status. 7. View or select the System Operating Mode as described in Section 3.3.2, System Operating Mode Selection System Operating Mode Selection The operating mode can be selected using the keypad and LCD display (see Figure 3-2): 1. From the Voltage, Current, Power screen, press UP or DOWN to display the User Settings screen. 2. Press ENTER to display the Set Operating Mode screen. The operating mode is shown on the third line of the display; it can be one of the following: Local Mode Local Test Mode Remote Mode Modbus Remote Mode 3. Provided the system is in the Idle state (indicated on bottom line of the display), change the mode by pressing ENTER, UP or DOWN to choose the required mode, and ENTER to set the new mode. Pressing ENTER to change mode when system is not in the Idle state results in an Access Denied fault message. 4. Press ESC to return to the User Settings screen. The operating mode cannot be changed using the Modbus remote control interface Local Mode Operation After power has been applied, unit is started by pressing START (I) and stopped at any time by pressing STOP (O). To START the unit in Local Mode, proceed as follows: 1. Select the local mode of operation as described in Section 3.3.2, System Operating Mode Selection. 2. Press START (I), which causes the unit to go through the following states of a normal start. These states are indicated by status messages on the bottom line of the LCD: Start -- Heat Oil Start -- Pump Oil Start -- Precharge Start -- Power Start -- Configure Start -- Sensor Train Start -- Purge Start -- Ignite Speed Start --Electric Accelerate Start -- Chemical Accelerate Running -- Off Line Running -- Raise DC Utility Generation or Voltage Generation Modbus is a registered trademark of Schneider Electric. TP /03 Section 3 Operating Instructions 15

28 3. The unit remains in the Utility Generation state until the STOP button is pressed. To stop, press STOP (O), which causes the unit to go through the following states as indicated on the bottom line of the LCD. Rundown -- Spooldown Rundown -- Discharge Rundown -- Precharge Rundown -- Power Rundown -- Configure Rundown -- Purge Rundown -- Halting Idle Local Test Mode Operation This mode is used to prove the operation of the Micro Turbine during installation, after maintenance, or as part of fault finding or test routines. To start the unit in Local Test Mode, proceed as follows: 1. Select local test mode of operation as described in Section 3.3.2, System Operating Mode Selection. 2. Press START (I), which causes unit to go through the following states. These states are indicated by status messages on the bottom line of the LCD. Start -- Heat Oil Start -- Pump Oil Start -- Precharge Start -- Power Start -- Configure Start -- Sensor Train Start -- Purge 3. The unit remains in the Start -- Purge state until the STOP button is pressed. To stop, press STOP (O), which causes the unit to go through the following states: Rundown -- Halting Idle Remote Mode Operation This mode can be used only if equipped with the remote control option. The remote control inputs and outputs available for connection by the user to a BMS are listed below: Remote Alarm Clear input -- relay coil (voltage specified by user), energize relay to clear alarm. Remote Alarm Input -- relay coil (voltage specified by user), energize for no alarm. Remote Alarm Output -- voltage free contacts, closed for no alarm, open for alarm or system off. Control procedures are not included, but remote control inputs and outputs are described as follows: 1. Select remote mode of operation as described in Section 3.3.2, System Operating Mode Selection. 2. Starting unit in remote mode requires a transition from inactive to active on the Remote Start Input. This initiates a normal engine start sequence (as described for local mode in Section 3.3.3, Local Mode Operating Procedure). Pressing the START button on the control panel has no effect other than causing an Operating Mode Wrong warning if the system is in the idle state. 3. Stopping unit in remote mode requires a transition from active to inactive on the Remote Start Input. This initiates a rundown sequence (as described for local mode in Section 3.3.3, Local Mode Operating Procedure. The STOP button on the control panel may also be pressed. 4. For normal operation, the Remote Alarm Input should be held active to indicate no alarm. If the input is set inactive, it causes a Remote Alarm fault. This fault shuts down the engine when enabled. 5. Pressing local START (I) causes an Operating Mode Wrong warning if the unit is in the Idle state; otherwise it is ignored. 6. Pressing local STOP (O) initiates a rundown sequence. 7. Faults display an error message on the LCD and sound the local buzzer. The Remote Alarm Output activates. The fault shuts down the engine. 8. A transition from inactive to active on the Remote Alarm Clear Input clears the local buzzer and the Remote Alarm Output. 9. Pressing the local ESC button clears the local buzzer and the Remote Alarm Output. 10. Modbus remote control signals will be ignored. Remote Start Input -- relay coil (voltage specified by user), energize relay to start. Modbus is a registered trademark of Schneider Electric. 16 Section 3 Operating Instructions TP /03

29 3.3.6 Modbus Remote Mode Use this mode only if equipped with Modbus remote control option. 1. A transition from 0 to 1 written to the Modbus Start register initiates a normal engine start sequence. 2. Setting the Modbus Start register to 0 initiates an engine shutdown sequence and sets a Remote Stop fault. 3. Local START causes an Operating Mode Wrong fault if pressed during Idle state; otherwise it is ignored. 4. Local STOP initiates a shutdown sequence. 5. Faults display an error message on the LCD and sound the local buzzer. The Remote Alarm Output, if equipped, activates. The fault shuts down the engine. 6. A transition from 0 to 1 written to the Modbus Alarm Clear Register clears the local buzzer and the Remote Alarm Output. 7. Local ESCAPE clears the local buzzer and the Remote Alarm Output. 8. Monitor faults remotely by reading the Fault Code Modbus register. A zero value represents no fault and a non-zero value indicates a fault. If a fault is indicated, clear it using the Modbus Alarm Clear register (unless it is cleared by local ESCAPE). 9. A watchdog timer is implemented requiring the PC or Modbus controller to reset a counter within the time period set by System Settings, Modbus Timeout. A transition from 0 to 1 written to the Modbus Watchdog Reset register resets timer. If the PC or Modbus controller fails to reset counter within the time period, a Modbus Timeout fault is set and the engine shuts down. If System Settings, Modbus Timeout is set to 0, the watchdog is disabled. The Modbus System Settings, Modbus Timeout is set as part of the installation procedure and cannot be modified by the operator. 10. Remote control inputs will be ignored. Modbus Protocol The Modbus protocol is specified in a separate publication that will be supplied if the user selects this option. Modbus is a registered trademark of Schneider Electric. TP /03 Section 3 Operating Instructions 17

30 Notes 18 Section 3 Operating Instructions TP /03

31 Section 4 Scheduled Maintenance The Micro Turbine is designed for low maintenance. Operator maintenance is limited to fault identification using the control panel indicators, servicing in accordance with the service schedule in Section 4.1, and simple repairs. 4.1 Service Schedule Frequency Item Monthly Every6Monthsor 4500 Hours Yearly Every 5 Years Fuel Lines I Gas Filter I Igniter* I R Lube Oil Check Level R Lube Oil Filter R Cooling System Hoses and Connectors I Nuts, Bolts, and Fasteners I Oil Pump I Oil Cooler Repaired or replaced as needed. Electronic and Combustion Cooling Air Filter I R Combustion Main Filter I R Engine Combustor I I Recuperator Oil Coalescer Filter I R Batteries Door Seals/Hardware A Adjust C Clean I Inspect, clean or lubricate, and replace as required L Lubricate R Replace T Test * Change the igniter after 500 starts or as detailed above Renew air intake filter if unit load falls or shuts down 10,000 hours maximum Check battery voltage I T I Every 10 Years 4.2 Safety Refer to the Safety Precautions and Instructions section at the beginning of this manual prior to operating the Micro Turbine under normal or maintenance conditions. 4.3 Fault Finding Common Faults The common fault messages shown in Figure 4-1 can arise during normal operation and do not usually indicate faulty operation of the unit. If faults cannot be cleared, report the fault to your authorized service distributor Power Faults Utility Generation The utility grid failing or going outside of specified limits causes power faults. Attempting to connect to the utility with output power set to 0 kw causes power faults. If the Micro Turbine output power begins to drop off and the exhaust gas temperature (EGT) remains constant, the intake filters may be choking and need cleaning or replacement. If the utility grid is not at fault and the output power is not set to 0 kw, report the fault to your authorized service distributor. TP /03 Section 4 Scheduled Maintenance 19

32 Dual Mode Operation (Voltage Generation) Power faults can be caused by application of a load outside specified range. If the applied load is within the specification, report the fault to your authorized service distributor. Confirm that the applied load matches the setting within the Micro Turbine system, i.e. voltage and frequency. Power fault messages are listed in Figure 4-2. Fault Message Access Denied V Supply Low V Auxiliary Fault DC Link Low DC Link High Safety Loop Fault Operating Mode Wrong Oil Level Low Oil Level Low Fault Remote Alarm Oil Pressure Figure 4-1 Meaning Attempting to change setting or calibration without entering security code. 24V supply is less than the setpoint (20V). Caused by batteries becoming discharged, possibly due to operating electronics without the auxiliary supply connected. Auxiliary supply is not present. DC link voltage is below expected value for the present state. Can be caused by Auxiliary supply voltage being too low. If Auxiliary supply is correct, report fault to your authorized service distributor. DC link voltage is above expected value for the present state. Can occur after system has been stopped when in Local Test Mode. The fault clears when the DC link voltage has decayed below 200V. Emergency stop button pressed or external circuit has broken the safety loop. The vibration sensor may have tripped. If not cleared by correcting these causes then check oil pressure switch, loop wiring and processor enable on output board. Local Start button has been pressed when the system is set to a remote operating mode. Oil level below warning level. Oil should be added (warning message only, no alarm will sound). Oil level below fault level, oil should be added. Remote Alarm input is signalling a fault. May occur momentarily (warning message only, no alarm will sound) when system returns to Idle state after running as oil pump continues to run briefly after engine stops rotating. If an Oil Pressure fault occurs at any other time, contact your authorized service distributor. Common Faults Fault Message Phase Error Blue Vrms High Yellow Irms Wrong Frequency High Red Vrms Low Blue Irms Wrong Frequency Low Yellow Vrms Low Red UF Wrong Red Vpeak High Blue Vrms Low Yellow UF Wrong Yellow Vpeak Red VDCO High Blue UF Wrong High Blue Vpeak High Yellow VDCO DC Link Fault High Red Vrms High Blue VDCO High DC Link High Yellow Vrms High Red Irms Wrong Figure 4-2 Power Fault Messages Gas System Faults Gas system faults as shown in Figure 4-3 can occur if gas supply or gas safety train is faulty. If the gas supply and gas safety train are not at fault and the fault message persists, report fault to your authorized service distributor. Fault Message Low Gas Pressure High Gas Pressure Gas Valve Open Gas Valve Closed Ignition Failure RPM Low EGT Low Speed Drop Fault EGT Drop, Flame Out Gas Load Fault Figure 4-3 Meaning Low gas pressure switch open. No gas supply. High gas pressure switch open. No gas supply. Gas shut off valve proving switch is indicating that valve is open when system has set it to be closed. Gas shut off valve proving switch is indicating that valve is closed when system has set it to be open. No EGT rise detected during Ignition State. Remove clean or replace. RPM has fallen below minimum value. EGT has fallen below minimum value. During chemical acceleration or normal running the engine speed has dropped for more than 1 second. This is probably due to the flame extinguishing. During electrical acceleration the EGT has fallen for more than EGT Drop Time. This is probably due to the flame extinguishing. High gas pressure detected before ignition, or low gas pressure detected when at running speed. Gas System Faults 20 Section 4 Scheduled Maintenance TP /03

33 4.3.4 Cooling System Faults Cooling system faults can occur when: The cooling system is faulty Air intakes are obstructed If the cooling system is not at fault and the fault message persists, report fault to authorized service distributor. Oil Level Check Procedure Check the level as described below: 1. If performing this check with unit running, use ear protection before opening inspection door. Shut system down before adding oil to the storage tank. 2. Do not allow the oil level to drop below the 3/4 mark on the sight glass. Fault Message Oil Temp High Oil Temp Low IGBT Heat Sink Hot Boiler Too Hot Figure 4-4 Meaning Oil temperature is greater than Oil Temp Max setting 90 C (194 F). Oil temperature is less than Oil Temp Min setting (can occur if oil is so cold that the heaters fail to raise the oil temperature within 20 minutes of starting). Power converter too hot 80 C (176 F). Boiler overtemperature switch open 95 C (203 F). Cooling System Faults Oil Change Procedure Change oil with the engine shut down and the oil at normal operating temperature. 1. Remove the filler cap from the storage tank. See Figure Exhaust Gas Temperature (EGT) High Fault EGT high fault can occur when total electrical demand exceeds system capability at ambient temperature. If total demand is within system specification, report fault to your authorized service distributor. See Figure 4-5. Fault Message EGT High Figure 4-5 Meaning EGT has risen above maximum value. EGT High Fault 4.4 Servicing Control and Power Electronics In event of a problem or failure, consult your authorized service distributor Gas Turbine and Alternator In event of a problem or failure, consult your authorized service distributor Oil System Allow oil system to cool before starting maintenance. If the engine must be run during testing/maintenance with the side panels removed, wear ear protection. When removing oil hoses, blank off disconnected ends to prevent contamination. Figure 4-6 Location of Oil Filter and Filler Cap 2. Pump out the used oil Change the oil filter using lube oil filter replacement procedure. 4. Refill storage tank to the 3/4 mark on sight glass. 5. Run engine purge cycle in Local Test mode. Do not exceed 15 minutes of operation in this mode; otherwise the battery will be discharged. 6. Top off the storage tank if necessary. TP /03 Section 4 Scheduled Maintenance 21