Troubleshooting & Preventive

Maintenance Manual
Project: 12kW DCG with Solar and Delta Rectifier

Document Reference: M02DG12D-NG-01 Date: 17-Apr-16

This document provides troubleshooting, operation and preventive maintenance instructions for Hybrid
Solar solution type: 12kW DCG + Delta Rectifier + Solar
1 Contents
2 Introduction ................................................................................................................................................. 3
2.1 System description: ................................................................................................................ 3
2.1.1 General Specifications: ................................................................................................................ 4
2.1.2 Components and Parts Identification .......................................................................................... 5
3 Troubleshooting .......................................................................................................................................... 8
3.1 Understand System Connection and Operation..................................................................... 8
3.1.1 System connection ...................................................................................................................... 8
3.1.2 System Operation ........................................................................................................................ 8
3.1.3 Function of Major Engine Components....................................................................................... 9
3.2 Trion Alarms Rectification .................................................................................................... 11
3.3 Engine Troubleshooting........................................................................................................ 14
3.3.1 Engine Troubleshooting Table ................................................................................................... 14
3.4 Power System Troubleshooting............................................................................................ 16
3.4.1 Standard troubleshooting procedure ........................................................................................ 16
3.4.2 System status indications .......................................................................................................... 16
3.4.3 Alarm definitions ....................................................................................................................... 17
3.4.4 Alarm tracing ............................................................................................................................. 17
3.4.5 Troubleshooting Modules ......................................................................................................... 18
3.5 Hybrid System Troubleshooting Table ................................................................................. 18
3.6 Actuator calibration .............................................................................................................. 20
4 Maintenance.............................................................................................................................................. 23
4.1 Maintenance Duties ............................................................................................................. 23
4.2 Engine Periodic Maintenance ............................................................................................... 25
4.2.1 Changing oil ............................................................................................................................... 25
4.2.2 Remove the engine oil filter as follows: .................................................................................... 25
4.2.3 Drain and Clean Fuel Filter/ Water Separator ........................................................................... 25
4.2.4 Check and Clean Radiator Fins .................................................................................................. 26
4.2.5 Clean Air Cleaner Element ......................................................................................................... 26
4.2.6 Replace Air Cleaner Element ..................................................................................................... 27
4.2.7 Replace Fuel Filter ..................................................................................................................... 27
4.2.8 Check and Adjust Cooling Fan V-Belt......................................................................................... 27

Troubleshooting & Preventive Maintenance Manual Ref: M02DG12D-NG-01 17-Apr-16 1

Troubleshooting & Preventive Maintenance Manual Ref: M02DG12D-NG-01 17-Apr-16 2
2 Introduction
This manual provides detailed information related to the solar system connected to DC generator. It includes
information about the system components and specifications, installation procedures, operation,
maintenance and troubleshooting

Note: This is not a troubleshooting manual for generator or alternator internal problems. For
details, contact Technical Support Department, or refer to specific manuals of engine and/or
alternator.

2.1 System description:

The system is a hybrid-solar solution to provide and insure continuous availability of electrical power for
telecom loads. It uses solar energy, advanced generator and batteries.

As shown in the drawing 1, System is composed by the following major items:

Diesel Generator DCG12kW with fuel tank
Solar PV system including panels and junction boxes
Power cabinet including batteries, rectifier, and ATS

Troubleshooting & Preventive Maintenance Manual Ref: M02DG12D-NG-01 17-Apr-16 3

2.1.1 General Specifications:
Parameter Value
System Voltage 48VDC
Maximum System Output 58VDC
Solar PV System
Total Solar Power (peak) 3000Wp/6000Wp/9000Wp
Panels 12/24/36

Engine
Model 3TNV88
Rating 12kW
Max Speed 2400RPM
No. of Cylinders 3
Oil Capacity 6.7 Liter
Min. Allowable Oil Pressure 0.6 kgf/cm2 on 2.8 Liter of Oil
Dry Weight 155Kg
Recommended Battery 12V 70Ah
Converter
Model DPS-4000
Power Units DPR-4000
Max Input Current 25A/Module
Output Voltage 54VDC
Output Max Rated Current 300A
Output Max Rated Power (PMG) 12kW
Output Max Rated Power (Solar) 3kW/6kW/9kW

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2.1.2 Components and Parts Identification

2.1.2.1 Engine

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 2.1.2.2 Cabinet

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 2.1.2.3 Rectifier

2.1.2.4 ATS

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3 Troubleshooting
This guide is a step-by-step recommendation of what to do if problems occur. If the first step of the
recommendation does not solve the problem continue to the next one. If the problem cannot be solved
please call your IPT PowerTech office for assistance.

System indicators, such as LEDs are described, as well as usage of key features provided by the Trion
controller that help facilitate troubleshooting.

The information in this document is based on default settings. The customer settings might differ from
default settings

3.1 Understand System Connection and Operation

3.1.1 System connection
The following functional diagram shows the connection between different parts of the system. It is essential
to understand the details of this diagram in order to make logic troubleshooting, and fix any occurred
problem.

3.1.2 System Operation

The system ensures continues supply of DC power to the load from different sources prioritized as follow:

Priority-1: Solar Energy from Solar PV panels

Priority-2: Grid (Nepa)
Priority-3: Batteries
Priority-4: Genset

System will operate as per the following sequence:

1. Solar Panels will charge the batteries and feed the load as long as there is sun power.
2. If Grid is available, it will work in parallel with the solar if needed to charge the batteries and feed
the load.
3. When theres no Grid and the solar is not enough for the load, the batteries start discharging till they
reach a certain value (minimum discharge state).
4. Delta Rectifier monitors the voltage of the batteries and sends a remote start signal to the Genset to
Start.
a. The Genset send the command to the ATS to energize to position 1.
b. Genset start charging the batteries and feeding the load (in parallel with solar panels if sun
power is available).
5. The generator continues charging the batteries until batteries reach the full charging state or if the
Grid is sensed by the TRION controller. In this case, Genset will stop and ATS will energize to position
2.

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3.1.3 Function of Major Engine Components

Components Functions

Air Cleaner The air cleaner prevents airborne contaminants from entering the engine. Since
the air cleaner is application specific, it must be carefully selected by an
application engineer. It is not part of the basic engine package as shipped from
the factory. Periodic replacement of the air cleaner filter element is necessary.
See the Periodic Maintenance Schedule on page 69 for the replacement
frequency.
Alternator The alternator is driven by a V-belt which is powered by the crankshaft V-pulley.
The alternator supplies electricity to the engine systems and charges the battery
while the engine is running.
Dipstick (Engine Oil) The engine oil dipstick is used to determine the amount of engine oil in the
crankcase.
Electric Fuel Pump The electric fuel pump makes sure there is a constant supply of diesel fuel to the
fuel injection pump. The electric fuel pump is electro-magnetic and runs on
12VDC. An electric fuel pump may be Electric Fuel Pump installed as an option
or as standard equipment. Standard equipment may vary based on engine
model and specification. If an electric fuel pump is installed, turn the key switch
to the ON position for 10 to 15 seconds to prime the fuel system.
Engine Oil Filter The engine oil filter removes contaminants and sediment from the Engine Oil
Filter engine oil. Periodic replacement of the engine oil filter is necessary.
Fuel Filter The fuel filter removes contaminants and sediments from the diesel fuel.
Periodic replacement of the fuel filter is necessary.
Fuel Filter / Water The fuel filter / water separator removes contaminants, sediment and water
Separator from diesel fuel going to the fuel filter. This is a required component of the fuel
system and is standard equipment with every engine. The separator is installed
between the fuel tank and the fuel pump. Periodically drain the water from the
fuel filter / water separator using the drain cock at the bottom of the separator.
Fuel Priming Lever If the unit has a mechanical fuel pump, a fuel priming lever on the mechanical
fuel pump primes the fuel system. The fuel system needs to be primed before
you start the engine for the first time, if you run out of fuel, or if fuel system
service is performed. To prime the fuel system, operate the fuel priming lever
until the cup in the fuel filter is full of fuel.
Fuel Tank The fuel tank is a reservoir that holds diesel fuel. When fuel leaves the fuel tank
it goes to the fuel filter / water separator. Next, fuel is pumped to the fuel filter
by the electric or mechanical fuel pump.
Next the fuel goes to the fuel injection pump. Since fuel is used to keep the fuel
injection pump cool and lubricated, more fuel than necessary enters the
injection pump. When the injection pump pressure reaches a preset value, a
relief valve allows excess fuel to be returned back to the fuel tank. The fuel tank
is a required engine component.
Mechanical Fuel Pump The mechanical fuel pump is a diaphragm-type of pump and is installed on the
fuel injection pump body. The mechanical fuel pump is driven by a cam on the
camshaft of the fuel injection pump.
An electric fuel pump is available as an option. The mechanical fuel pump is not
installed on the fuel injection pump if the electric fuel pump option is installed.

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Components Functions

Side and Top Filler Port You can fill the crankcase with engine oil from either the side or top filler port
(Engine Oil) depending upon which one is most convenient.
Starter Motor The starter motor is powered by the battery. When you turn the key switch in
the operator's console to the START position, the starter motor engages with
the ring gear installed on the flywheel and starts the flywheel in motion.
Cooling System The engine is liquid-cooled by means of a cooling system. The cooling system
consists of a radiator, radiator cap, engine cooling fan, engine coolant pump,
thermostat, and reserve tank.
Engine Cooling The engine cooling fan is driven by a V-belt which is powered by the crankshaft
Fan V-pulley. The purpose of the engine cooling fan is to circulate air through the
radiator.
Engine Coolant The engine coolant pump circulates the engine coolant through the cylinder
Pump block and cylinder head and returns the engine coolant to the radiator.
Radiator The radiator acts as a heat exchanger. As the engine coolant circulates through
the cylinder block it absorbs heat. The heat in the engine coolant is dissipated in
the radiator. As the engine cooling fan circulates air through the radiator, the
heat is transferred to the air.
Radiator Cap The radiator cap controls the cooling system pressure. The cooling system is
pressurized to raise the boiling point of the engine coolant. As the engine
coolant temperature rises, the system pressure and the coolant volume
increases. When the pressure reaches a preset value, the release valve in the
radiator cap opens and the excess engine coolant flows into the reserve tank. As
the engine coolant temperature is reduced, the system pressure and volume is
reduced and the vacuum valve in the radiator cap opens allowing engine
coolant to flow from the reserve tank back into the radiator.
Reserve Tank The reserve tank contains the overflow of engine coolant from the radiator. If
you need to add engine coolant to the system, add it to the reserve tank, not
the radiator.
Thermostat A thermostat is placed in the cooling system to prevent engine coolant from
circulating into the radiator until the engine coolant temperature reaches a
preset temperature. When the engine is cold, no engine coolant flows through
the radiator. Once the engine reaches its operating temperature the thermostat
opens and allows engine coolant to flow through the radiator. By letting the
engine warm up as quickly as possible, the thermostat reduces engine wear,
deposits and emissions.

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3.2 Trion Alarms Rectification
Use the following logical procedure to start the troubleshooting procedure if you have found any alarm or
malfunction:

1. Record the status of the load and ensure your actions will not affect it
2. If the system is off, dont try to start before identifying the problem.
3. Check the wiring and connection of different parts
4. Ensure not burned parts before starting up, and change every part where physical damage is clear.
5. Check system values and consumables and record them (battery voltage, fuel quantity, engine oil,..)
6. Check for any tripping breakers or burned fuses
7. Use the below table to identify the error when occurred on Trion controller screen:

# Symbol on Fault Name Possible causes and troubleshooting

Trion Screen
1 ! Fail to start This alarm appears when you try to start the generator for many
times without success.
1. Check the fuel system (pipes, injector, and filter) for any non-
functional parts.
2. Check the fuel line for any bubbles of air inside it.
3. Check the electrical cranking system:
a. Measure battery voltage. It should be above 12V. if
voltage < 12, see point 4.
b. Check connections between battery and starter
c. Check if the starter is working
2 ! Emergency stop This alarm appears when the emergency switch is turned on.
Check the switch and its connections and keep it off.
3 ! High Battery This alarm appears if the DG battery is over charged.
Check the output voltage from Dynamo.
4 ! Low Battery This alarm appears when the DG battery voltage is low.
1. Check if the Dynamo is charging the batteries
2. Check if the Charger is providing voltage at the output. If not,
confirm it is connected correctly to 48V batteries.
If everything is OK, charge the battery and try to run the
generator again.
If the battery remains at low voltage, check the Trion controller
for excitation problem.

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# Symbol on Fault Name Possible causes and troubleshooting
Trion Screen
5 High Engine Temp. High temperature symbol in engine may be caused by:
Injection pumps problem
Air filter problems
Low coolant level
Blocked thermostat
Radiator fins blocked by dirt
Radiator faulty
Cam shaft seal broken
Blocked air opening on inlet
Outlet of canopy
Low oil level
Overload
Bad servicing for engine
High ambient beyond accepted standards

For details refer to the engine troubleshooting table and engine

manual
6 ! High Oil Temp. occurs when the oil temperature switch is detected on .
Check the oil temperature cables if connected properly or have
dust.
Check the switch
Check the oil filter

7 Low Coolant Level occurs when the coolant switch is detected active
(N/A) Check the coolant cables if connected properly or have dust.
Check the switch
8 Low Oil Pressure occurs when the oil pressure switch is detected on or when the
analog oil pressure sensor reading goes below the Low Oil
Pressure Alarm value
Check the oil sensor cables if connected properly or have dust
Check the oil level
Check if diesel is available in the tank and if fuel line and is clean
and water separator maintained
9 Low Fuel Level occurs when the analog reading goes below the tank Empty value
(N/A) Check the diesel level.
Check the fuel sensor cables if connected properly or have dust.
10 Low Dynamo Volt Occurs when the dynamo voltage decreases below the dynamo
shutdown voltage.
Check if the Dynamo voltage during generator running, and the
Dynamo belt.
If the dynamo or battery low voltage alarm remains, check the
Trion controller for excitation problem.
Check DG battery charger if charging the cranking battery when
the DCG is off, measure the voltage which should be 13V

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# Symbol on Fault Name Possible causes and troubleshooting
Trion Screen
11 ! Genset This alarm appears if one of the three line to line voltages of the
Over-Voltage generator is high.
oVolt Check the engine speed. It should be within the normal limits
Check the actuator functionality, and confirm the engine is
responding and not having any malfunction
Check logic board firmware
12 ! Genset This alarm appears if one of the three line to line voltages of the
Under-Voltage generator is low.
uVolt Check the engine speed. It should be within the normal limits.
Check fuel system in case speed is OK.
Check the actuator functionality, and confirm the engine is
responding and not having any malfunction
Check logic board firmware
13 ! Genset occurs when the voltage on one of the lines falls or the voltage
Phase Failure difference between any two phases exceeds or the frequency
goes below 15Hz.
14 ! Genset Sequence occurs when the phases are reversed
Failure N/A Check the rotation of the 3 phases if it properly connected.
15 Genset Occurs when the engine speed is too high. If happened:
Over Speed Check the connection between controller and actuator
oSPEED Check actuator limit settings and wires
Check the logic board
Disconnect and test if the actuator is going up and down using +/-
12VDC.
16 Genset Occurs when the engine speed is too low. If happened:
Under Speed Check the connection between controller and actuator
uSPEED Check actuator limit settings and wires
Check the logic board
Disconnect and test if the actuator is going up and down using +/-
12VDC.

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3.3 Engine Troubleshooting
THE ENGINE MUST BE STOPPED IMMEDIATELY WHEN:

The engine rpms suddenly increase and decrease;

A sudden and unusual noise is heard;
The color of the exhaust fumes suddenly darkens;
The oil pressure indicator light turns on while running.

3.3.1 Engine Troubleshooting Table

The following table contains the possible causes of some failures which may occur during operation. Always
perform these simple checks before removing or replacing any part.

If a problem occurs, stop the engine immediately.

Refer to the SYMPTOM column in the Troubleshooting Chart to identify the problem.

SYMPTOM PROBABLE CAUSE ACTION

Indicator Turns On - Engine Running
Engine oil pressure indicator
Engine coolant indicator
Battery Indicator
Indicator Does Not Turn ON - Key Switch is Turned to ON (OFF~ ON) - Engine Not Running
Indicator Stays On - Key Switch is Turned from Start to ON (START ~ ON) - Engine Not Running
Engine oil pressure indicator
stays ON
Engine Does Not Start
Starter motor operates but
engine does not start
Low level of engine oil Check and adjust oil level
Too high an oil level as necessary
Clogged engine oil filter Replace engine oil filter
Low engine coolant level Add engine coolant
Dirty radiator fins Clean the radiator fins
Engine coolant leaking Call the office
V-belt loose or damaged Adjust V-belt or replace
Contaminated engine coolant Call the office
Faulty engine coolant pump Call the office
V-belt loose or damaged Adjust V-belt or replace
Battery failure Check battery condition
Faulty alternator Call the office
Faulty electrical wiring or faulty indicator Call the office
Faulty alternator Call the office
Faulty engine oil pressure switch Call the office
Check and adjust oil level
No or low level of engine oil
as necessary
Clogged engine oil filter Replace engine oil filter
Refuel and prime fuel
No diesel fuel
system

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SYMPTOM PROBABLE CAUSE ACTION
Air in fuel system Prime fuel system
Replace with
Improper diesel fuel recommended diesel
fuel
Clogged fuel filter Replace fuel filter
Poor fuel injection Call the office
Compressed air leakage from Call the office
intake / exhaust valves Faulty engine stop
Call the office
solenoid
Check electrolyte,
Battery needs charging
recharge
Starter motor does not operate Clean terminals,
or rotates too slowly (engine can Faulty cable connection at battery terminals
retighten
be turned manually)
Faulty starter switch Call the office
Faulty starter motor Call the office
Engine cannot be manually
Inner parts seized or damaged Call the office
turned
White or Black Exhaust Smoke
Engine overloaded Reduce load
Clogged air cleaner element Clean element or replace
Replace with
Improper diesel fuel recommended diesel
Black exhaust smoke fuel
Faulty spraying of fuel injection Call the office
Excessive intake / exhaust valve clearance Call the office
Faulty EGR valve Call the office
Replace with
Improper diesel fuel recommended diesel
fuel
White exhaust smoke Faulty spray pattern of fuel injection Call the office
Fuel injection timing delay Call the office
Engine burning oil Call the office

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3.4 Power System Troubleshooting
This guide is a step-by-step recommendation of what to do if problems occur. If the first step of the
recommendation does not solve the problem continue to the next one. If the problem cannot be solved
please call your IPT PowerTech office for assistance.

System indicators, such as LEDs are described, as well as usage of key features provided by the ORION
controller that help facilitate troubleshooting.

The information in this document is based on default settings. The customer settings might differ from
default settings.

3.4.1 Standard troubleshooting procedure

Troubleshooting is always initiated by an alarm. Alarms may be monitored remotely or locally. Relay alarms
trigger LEDs locally, but can be wired for remote monitoring as well. If SNMP is in use, alarm traps can be
delivered to remote monitoring systems, or viewed from the ORION / PSC 3 web interface. Use the following
procedure to identify and solve problems in Delta Energy Systems:

1. Check the ORION / PSC 3 web interface home page for active alarms.
2. Check all LEDs in the system.
3. If relay alarms are used, use UIM on site to check the alarm event.
4. Handle the problem according to the event type or alarm-specific instructions.

3.4.2 System status indications

ORION provides system status indicators through both the UIM/UIL and web user interfaces. These
indicators are highly configurable and can be assigned to any event.

The assignments for the system status indicators are configured through the web interface with the User
Interface dialogue (go to Configuration HW Setup User Interface).

The LEDs on the front panel of the ORION / PSC 3 are used to give an initial indication of the severity or type
of alarm raised. The normal assignments of the LEDs are shown in table below:

Event LED Symbol

S Urgent Alarm 1

S Non Urg Alarm 2

S Alarm suppr. 3
S Mainsfailure 4
Special mode 5

Troubleshooting & Preventive Maintenance Manual Ref: M02DG12D-NG-01 17-Apr-16 16

3.4.3 Alarm definitions
The following events are the default alarm classifications:

Urgent Alarm (UA)

Non-Urgent Alarm (NUA)
Mains failure Alarm (MF)

UA and NUA alarms can be set for any event with any given name. For more information, see section
Configuring alarms in the Configuration instructions of controller ORION.

The web interface provides detailed descriptions of each event, including the event name, the alarm type
and definition. The UIM only provides the alarm classification.

3.4.4 Alarm tracing

The Alarm Status dialogue of the web interface displays the alarm event types and the status. To view the
Alarm Cause Inspection dialogue, click Inspect.

The UIM/UIL interface displays active alarms in the menu ALARM ALARM LIST. To view the cause of the
alarm, select the event listed on the display. The UIM displays the state of the event causing the alarm as
True (active).

The event names are based on the general instructions for configuring the ORION. Default system events
have a fixed name and prefix S.

Table 1: Common conditions for the UA and NUA alarms

Event Alarm type Definition

S Mains failure MF Main input power failure.
S Ua low UA The system voltage is lower than the threshold value of the Ua min: event.
S Ua high UA The system voltage is higher than the threshold value of the Ua max: event.
S Urgent RFA UA Digital Rectifier: Adjustable, by default set if 2 or more rectifiers failed.
LoadFuse x UA Load Fuse alarm. The voltage measurement is higher than the threshold
value of the LoadFuse x event.
BattFuse x UA Battery Fuse alarm. The voltage measurement is higher than the threshold
value of the BattFuse x event.
S BattFail BT UA Event indicating that at least one battery test was failed.
S Non Urg RFA NUA Digital Rectifier: Adjustable, default set if 1 rectifier failed.
Psys high NUA The total system power, calculated by the ORION, is higher than the
threshold value of the Psys high event.
S Us low NUA The system voltage is lower than the threshold value of the Us min: event.
S Us high NUA The system voltage is higher than the threshold value of the Us max: event.
S HW Failure NUA Reason for HW Failure can be seen only in menu Log / Status / Default

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3.4.5 Troubleshooting Modules
Use the following troubleshooting table if there is a rectifier alarm to find out whether a rectifier is faulty, or
the failure is outside the rectifier module.

LED ok: OFF and an alarm signal active:

Event Definition
Mains voltage is missing Check main switch and mains fuses in the system and
main distribution panel
Overvoltage protection (OVP) is activated Reset OVP by pulling out the rectifier for approx. 2
seconds
Over temperature protection (OTP) is activated Check air flow at front, clean air filter
Fan failure, air flow blocked Check air flow at front, clean air filter, check fan and
replace the rectifier module if necessary
COM-LED off or blinking Communication failed. Check bus cable to ORION / PSC 3.
Check correct IMBUS termination
Rectifier is faulty Replace rectifier module
Note! Internal failures can only be repaired in Delta Energy Systems factory. A faulty rectifier module must
be replaced.

3.5 Hybrid System Troubleshooting Table

Alarm Event Possible causes Action to fix it
type
MF S Mains Main input power failure. Put on the breaker
failure All Rectifier modules defected Check the ATS
ATS on position 0 Check the modules
UA S Ua low The system voltage is lower than the
threshold value of the Ua min.
S Ua high The system voltage is higher than the Check alarm set value or output voltage.
threshold value of the Ua max.
S Urgent RFA More of 1 rectifier defected Replace the defected rectifier module.
LoadFuse x Load breaker disconnected. check any short circuit
The voltage measurement is higher than Put on the breaker.
the threshold value of the LoadFuse x
event.
BattFuse x Battery breaker disconnected. Put on the breaker.
The voltage measurement is higher than
the threshold value of the BattFuse x
event.
VDR rectifier Surge Arrester inside ATS defected. Replace the surge arrester.
VDR solar Surge Arrester inside combiner box Replace the surge arrester.
defected.
Surge arrester High voltage Replace Blown Plugged Cartouche.

Door open Close door

check switch contact.
Check connection.

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Alarm Event Possible causes Action to fix it
type
Smoke Fire inside cabinet Visit site and check for any fire
detector Breaker input on rectifier system is off Check smoke functionality and alarm
contact.
Put on breaker.
Event indicating that at least one battery
S BattFail BT test was failed.
NUA S Non Urg 1 rectifier defected. Replace the defected rectifier module.
RFA
Psys high The total load power, calculated by the Adding rectifier modules.
controller, is higher than the total
rectifier capacity.
S Us low The system voltage is lower than the Check the voltage of the system
threshold value of the Us min. Check the Us min in the Orion
S Us high The system voltage is higher than the Check the voltage of the system
threshold value of the Us max. Check the Us max in the Orion

Temperature of batteries High Check air condition cooling.

Temperature of battery low Check heater functionality and set

thermostat to 10C.
PLD [U] PLD contactor disconnected due to Check the voltage.
battery voltage reaches below 46V. Replace the contactor if defected.
HW Failure Temperature sensor disconnected Plug temperature sensor connector at
alarm related place on Orion.
SENSN Board disconnected Plug connector to SENSN board or to
Orion
Genset failure Generator not turned On Check the battery voltage of generator.
alarm Cable not connected between ATS panel
and generator controller.
Alarm on generator controller
Generator overloaded or not supporting
the Load
Air condition not working

generator output breaker is Off switch On generator breaker.

DC light not working Breaker on rectifier system is off Put on breaker 20A
Switch on lamp is Off Put switch on On position

Batteries not charging Battery breaker off Switch on battery breaker

LVD contactor disconnected Check LVD signal cable between driver

Not enough rectifier modules
board and Orion.
Replace LVD contactor or Driver board.
Check LVD configured value.
Plug more rectifier modules after sizing
the system capacity.

Troubleshooting & Preventive Maintenance Manual Ref: M02DG12D-NG-01 17-Apr-16 19

Alarm Event Possible causes Action to fix it
type
Mains failure alarm and Problem with communication cable Check connection of communication
rectifier modules are (disconnected, loose connection or cable between module shelf and Orion
working (led OK is green damaged) controller.
and led Com is off)
Mains voltage not available and batteries Check input power and turn on rectifier
No Display and All Alarms totally discharged or battery breaker system to power the load and recharge
On disconnected. batteries.
Orion Controller defected. Replace Orion controller and download
setup file.
Stars on the display at Short circuit on the system. Reboot Orion controller or download
place of measured values. setup file again.

3.6 Actuator calibration

To set the actuator in the generator to the right position, follow these instructions:

Step Instruction Photo

1 First make sure the battery is
connected and then close all the
fuses in the control panel and put off
the generator breaker

2 Now let the relay R7 be closed as in

figure 2.1. In this step the actuator
will be moving up to the end until it
stops. This position is the minimum
position for the actuator. See figure
2.2. After that disengage R7 and put
back the blue switch to its original
position.

Troubleshooting & Preventive Maintenance Manual Ref: M02DG12D-NG-01 17-Apr-16 20

Step Instruction Photo
3 Now push the actuator cable from
the throttle side and ensure that the
cable is stretched well like in figure
3.1 and tighten the lock screw shown
in figure 3.2

4 Now run on the generator and fix the

display reading on the Trion
controller to the RPM reading. Use
the screw shown in figure 4.1 to
regulate the minimum speed of the
actuator to 1150 rpm. See figure 4.2.
To regulate unscrew the nut first and
adjust the speed with the screw.
When you finish adjustment lock
back the nut.

5 5. Now increase manually the

speed using relay R8 as in figure 5.1.
Press the relay with your hand and
you watch on the Trion controller
that the speed is increasing. keep
increasing the speed till you see that
it reached 2600 rpm. At this stage
press the emergency stop. See figure
5.2. In this process we made sure
that the position of the actuator is
set to the desired speed which is
2600 rpm.
6 After pressing the emergency stop
we should fix the movement of the
actuator and ensure it will not go
down more than that position. To do
so you should tighten the 10 mm
screw on the actuator shown in
figure 6.1. To tighten unscrew the 13
mm locking nut and turn the 10 mm
screw clock wise until you see that it
cannot be turned anymore, then
when you finish tight back the 13 mm
locking nut.

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Step Instruction Photo
7 Now remove the emergency stop and
run on the generator.

Check now the minimum and

maximum speeds on the Trion. The
minimum should be 1150 rpm and
the maximum should be 2600 rpm.
Note that these speeds are set
without load.

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4 Maintenance

4.1 Maintenance Duties

Maintenance actions have to follow the below list of actions:

Action Required

A Engine
1 Make sure that Trion is set on Auto mode Every Visit
Record then reset any present alarms. If alarm remain, call for
2 Every Visit
support
3 Record DG Running Hours Every Visit
4 Clean the air filter Every Visit
5 Check the tension and condition of the drive belt Every Visit
6 Check the condition of the fan belt Every Visit
7 Test the alternator output Every Visit
8 Inspect the coolant hoses, air hoses and hose clips Every Visit
9 Check and clean Radiator and tighten any loose parts Every Visit
10 Top-up cooling water Every Visit
11 Check and clean Diesel line Every Visit
12 Clean the water Separator Every Visit
13 Change Fuel pre-filter 500 hrs operation
14 Check the level and concentration of the coolant Every Visit
15 Change lubricating oil Every Visit
16 Replace oil filter 500 hrs operation
17 Replace air filter 500 hrs operation
18 Check generator battery and measure its voltage Every Visit
19 Tighten all Exhaust connections Every Visit
20 Clean Control Panel Filters Every Visit
21 Check the Fans in control Panel Every Visit
22 Tighten all electrical connections Every Visit
Start the engine and observe the control panel to ensure that all
23 Every Visit
gauges are operating properly.
Check SPDs cartridges and change them if defected (green are ok,
24 Every Visit
red are faulty)
25 Check and record Fuel Quality and Color Every Visit
26 Record Fuel tank Diesel level Every Visit
27 Check and clean any leakage of water, oil, or fuel Every Visit
B Solar System
1 Check panels and structure for any damage or missing parts Every Visit
2 Clean Panels using clean water and clean rag Quarterly, or if very dirty
3 check grounding connections of panels, junction box, and structure Every Visit
4 Check Combiner box Breakers and surge arrestors Every Visit

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 Action Required

5 Check cables and tighten if needed Every Visit

6 Tighten structure screws and nuts Once a year
C Power Part
Check the power modules and logic boards for any physical
1 Every Visit
damages
2 Check the cables and connections Every Visit
3 Inspect if all fans are working properly Every Visit
4 Clean filters and fans Every Visit
5 Test voltage output of each panel Every Visit
6 Record any abnormal temperature of modules Every Visit
7 Check and place correctly the battery cage and covers Every Visit
8 Check and tighten battery connection screws Every Visit
9 Test and record battery voltages Every Visit
D General
1 Make sure all doors are well closed before leaving the site Every Visit

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4.2 Engine Periodic Maintenance
Notes:

When shutting the engine down, you allow the engine to idle, without load, for five minutes. This
will allow the engine components that operate at high temperatures, such as the turbocharger (if
equipped) and exhaust system, to cool slightly before the engine itself is shut down.

4.2.1 Changing oil

Drain the engine oil as follows:

1. Make sure the engine is level.

2. Start the engine and bring it up to operating temperature.
3. Stop the engine.
4. Remove one of the oil filler caps to vent the engine crankcase and allow the engine oil to drain more
easily.
5. Position a container under the engine to collect waste oil.
6. Remove the oil drain plug (1) from the engine oil pan. Allow oil to drain.
7. After all oil has been drained from the engine, reinstall the oil drain plug (1) and tighten to
8. Dispose of used oil properly.

4.2.2 Remove the engine oil filter as follows:

1. Turn the engine oil filter (2) counter-clockwise (3) using an oil filter
wrench.
2. Clean the engine oil filter mounting face.
3. Lightly coat the gasket on the new oil filter with engine oil.
4. Install the new engine oil filter manually by turning it clockwise (4)
until it contacts the mounting surface. Tighten one additional turn
using the oil filter wrench.
5. Add new engine oil to the engine through either of the oil filler ports.
6. Warm up the engine by running it for 5 minutes and check for any
engine oil leaks.
7. After engine is warm, shut it off and let it sit for 10 minutes.
8. Recheck the engine oil level.
9. Add engine oil to engine oil filler port as needed until the level is
between the upper and lower lines shown on the dipstick
10. Reinstall the oil filler cap. If any engine oil is spilled, wipe it away with a clean cloth.

4.2.3 Drain and Clean Fuel Filter/ Water Separator

The separator cup is made from semi-transparent material. In the cup is a red-
colored float ring. The float ring will rise to the surface of the water to show
how much needs to be drained.

Drain the fuel filter / water separator as follows:

1. Position an approved container under the fuel filter / water separator

(1) to collect the contaminants.

Troubleshooting & Preventive Maintenance Manual Ref: M02DG12D-NG-01 17-Apr-16 25

 2. Close (2) the fuel cock (3).
3. Loosen the drain cock (4) at the bottom of the fuel filter / water separator. Drain any water collected
inside.
4. Hand-tighten the drain cocks.
5. Open the fuel cock (3).

4.2.4 Check and Clean Radiator Fins

Dirt and dust adhering to the radiator fins reduce the cooling performance, causing overheating. Make it a
rule to check the radiator fins daily and clean as needed.

1. Blow off dirt and dust from fins and radiator with 28 psi or less of compressed air. Be careful not to
damage the fins with the compressed air.
2. If there is a large amount of contamination on the fins, apply detergent, thoroughly clean and rinse
with tap water.

4.2.5 Clean Air Cleaner Element

The engine performance is adversely affected when the air cleaner element is clogged with dust.

Be sure to clean the air filter element periodically.

1. Unlatch and remove the air cleaner cover (1)

2. Remove the element (2) (outer element if equipped with
two elements).
3. Blow air (3) through the element from the inside out
using 42-71 psi (compressed air to remove the
particulates. Use the lowest possible air pressure to
remove the dust without damaging the element.
4. If the air cleaner is equipped with a double element, only
remove and replace the inner element (7) if the engine
lacks power or the dust indicator actuates (if equipped).

Note: The inner element should not be removed when cleaning or replacing the outer element. The inner
element is used to prevent dust from entering the engine while servicing the outer element.

5. Replace the element with a new one if the element is

damaged, excessively dirty or oily.
6. Clean inside of the air cleaner cover.
7. Reinstall the element into the air cleaner case (4)

Note: If there is a red line (8) in the outer element, reinsert the
element until the overlap position of red line and end face of
the air cleaner case.

8. Reinstall the air cleaner cover making sure you match the
arrow (5) on the cover with the arrow on the case (6).
9. Latch the air cleaner cover to the case.

Troubleshooting & Preventive Maintenance Manual Ref: M02DG12D-NG-01 17-Apr-16 26

When the engine is operated in dusty conditions, clean the air cleaner element more frequently.

NEVER operate the engine with the air cleaner element(s) removed. This may allow foreign material to
enter the engine and damage it.

4.2.6 Replace Air Cleaner Element

Replace the air cleaner element (2) every 500 hours even if it is not damaged or dirty.

When replacing the element, clean the inside of the air cleaner case (4).

If the air cleaner is equipped with a double element, only remove and replace the inner element (1) if the
engine lacks power. This is in addition to replacing the outer element.

4.2.7 Replace Fuel Filter

Replace the fuel filter at specified intervals to prevent contaminants from adversely affecting the diesel fuel
flow.

1. Stop the engine and allow it to cool.

2. Close the fuel cock of the fuel filter I water
separator.
3. Remove the fuel filter using a filter wrench to turn
it to the left (1). When removing the fuel filter,
carefully hold it to prevent the fuel from spilling.
Wipe up all spilled fuel.
4. Clean the filter mounting surface and apply a small
amount of diesel fuel to the gasket of the new fuel
filter.
5. Install the new fuel filter. Hand-tighten it to the
right (2) until it comes in contact with the mounting
surface. Use a filter wrench and tighten one additional turn using the filter wrench.

4.2.8 Check and Adjust Cooling Fan V-Belt

The V-belt will slip if it does not have the proper tension. This will prevent the alternator from generating
sufficient power. Also, the engine will overheat due to the
engine coolant pump pulley slipping.

Check and adjust the V-belt tension (deflection) as follows:

1. Press the V-belt down with your thumb with a force of

approximately 22 ft-Ib (98 Nm, 10 kgf/m) to check the
deflection.

There are three positions to check for V-belt tension ( (A), (B)
and C).

You can check the tension at whichever position is the most

accessible. The proper deflection of a used V-belt at each

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position is:

2. If necessary, adjust the V-belt tension. Loosen the adjusting bolt and related bolts and/or nuts, then
move the alternator with a pry bar to tighten the V-belt to the desired tension. Then tighten the
adjusting bolts and/or nuts.
3. Tighten the V-belt to the proper tension. There must be clearance between the V-belt and the
bottom of the pulley groove. If there is no clearance between the V-belt and the bottom of the
pulley groove, replace the V-belt.
4. Check the V-belt for cracks, oil or wear. If any of these conditions exist, replace the V-belt.
5. Install the new V-belt. Refer to the table for proper tension.
6. After adjusting, run the engine for 5 minutes or more. Check the tension again using the
specifications for a used V-belt.

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