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: M020252
Revision: D
Date: 25/01/2010
Created by: J.McKell
Approved by: S.Doherty
USER MANUAL
FOR
NEF45 60kVA (AI & AUS)
Document M02.0252
Document No.: M020252
Revision: D
Date: 25/01/2010
Created by: J.McKell
Approved by: S.Doherty
TABLE OF CONTENTS
1.0 SAFETY
1.1. GENERAL INFORMATION .....................................................................................................1
1.2. ELECTRICAL POWER ...........................................................................................................1
1.3. MATERIALS ............................................................................................................................1
1.4. OPERATIONAL PRECAUTIONS ...........................................................................................1
1.5. SAFETY LABELS ...................................................................................................................2
3.0 HANDLING
3.1. LIFTING / HANDLING .............................................................................................................5
3.2. STORAGE / TRANSPORT .....................................................................................................5
4.0 INSTALLATION
4.1. UNPACKING ...........................................................................................................................6
4.2. LOCATION OF THE PLANT ...................................................................................................6
4.3. COMMISSIONING ...................................................................................................................6
4.4. PRIOR TO STARTING ............................................................................................................6
4.5. ELECTRICAL CONNECTION .................................................................................................6
4.6. EARTHING ..............................................................................................................................6
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Document No.: M020252
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7.0 MAINTENANCE
7.1. GENERAL .............................................................................................................................18
7.2. MAINTENANCE SCHEDULE ...............................................................................................19
7.3. WEEKLY MAINTENANCE ....................................................................................................21
8.0 LUBRICATION
8.1. GENERAL INFORMATION ...................................................................................................22
8.2. GENERATOR OIL CHANGE ................................................................................................22
8.3. OIL SPECIFICATION ............................................................................................................22
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Document No.: M020252
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Document No.: M020252
Revision: D
Date: 25/01/2010
Created by: J.McKell
Approved by: S.Doherty
1.0 SAFETY
1.1. GENERAL INFORMATION
Ensure that the operator reads and understands the decals and consults the manuals before
maintenance or operation.
Ensure that the Operation and Maintenance manual, and the manual holder, are not removed
permanently from the machine.
Ensure that maintenance personnel are adequately trained, competent and have read the Maintenance
Manuals.
Make sure that all protective covers are in place and that the canopy/doors are closed during operation.
The specification of this machine is such that the machine is not suitable for use in flammable gas risk
areas. WARNING: NO ATTEMPT SHOULD BE MADE TO OPERATE IN SUCH AREAS
WITHOUT THE EXPRESS AUTHORITY FROM AGGREKO.
Installation of this generator must be in accordance with recognised electrical codes and any local Health
and Safety Codes.
1.2. ELECTRICAL POWER
Prior to installation of the generating set you should check that the electrical load to be applied is within
the rated output of the machine at the site ambient conditions.
Before carrying out any maintenance or repairs to the Engine/Alternator assembly disconnect the starting
battery and isolate the alternator from the switchboard.
Before carrying out any maintenance repair to the AC and DC circuits, isolate these from external control
panel and power supplies.
Ensure that the generator set and the load it is connected to are properly earthed.
The generating set should be connected to the load only by a qualified electrician and in accordance with
the applicable regulations.
1.3. MATERIALS
The following substances are used in the manufacture of this machine and may be hazardous to
health if used incorrectly:
Antifreeze
Engine Lubricating Oil
Preservative Grease
Rust Preventative
Diesel Fuel
Battery Electrolyte.
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Document No.: M020252
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A battery contains sulphuric acid and can give off gases, which are corrosive and potentially
explosive. Avoid contact with skin, eyes and clothing. In case of contact, flush area immediately with
water.
Exercise extreme caution when using booster battery. To jump battery, connect ends of one booster
cable to the positive (+) terminal of each battery. Connect one end of other cable to the negative (-)
terminal of the booster battery and other end to a ground connection away from dead battery (to
avoid a spark occurring near any explosive gases that may be present). After starting unit, always
disconnect cables in reverse order.
Never operate unit without first observing all safety warnings and carefully reading the operation
manual.
This machine may include such materials as oil, diesel fuel, antifreeze, oil/air filters and batteries
which may require proper disposal when performing maintenance and service tasks. Contact local
authorities for proper disposal of these materials.
This machine produces loud noise with the doors open. Extended exposure to loud noise can cause
hearing loss. Always wear hearing protection when doors are open.
Never inspect or service unit without first disconnecting battery cable(s) or using the battery isolator
switch to prevent accidental starting.
Do not remove the pressure cap from a HOT radiator. Allow radiator to cool down before removing
pressure cap.
Do not use petroleum products (solvents or fuels) under high pressure as this can penetrate the skin
and result in serious illness. Wear eye protection while cleaning unit with compressed air to prevent
debris from injuring eye(s).
Hot pressurized fluid can cause serious burns. Do not open radiator while hot.
Rotating fan blade can cause serious injury. Do not operate without guard in place.
Use care to avoid contacting hot surfaces (engine exhaust manifold and piping, etc.).
Never operate unit with guards, covers or screens removed. Keep hands, hair, clothing, tools, etc.
well away from moving parts.
1.5. SAFETY LABELS
Look for these signs on machine, which point out potential hazards to the safety of you and others.
Read and understand thoroughly. Heed warnings and follow instructions.
DANGER
FIRE RISK
Risk of Electric
Shock
)
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CAUTION
Hot
DISCONNECT STARTING
BATTERY AND ISOLATE LOAD
BEFORE WORKING ON ENGINE
/ ALTERNATOR ASSEMBLY
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WARNING
Tampering with noise control system prohibited
The following acts or misuse of the unit are prohibited:
1) The removal or rendering inoperative by any persons, other than for purposes of maintenance,
repair, or replacement, of any device or element of design incorporated into any new generator
for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is
in use
Or
2) The use of the generator after such device or element of design has been removed or rendered
inoperative by any person.
Among those acts included in the prohibition against tampering are these:
Removal or rendering inoperative any of the following:
a) The engine exhaust system or parts thereof.
b) The air intake system or parts thereof.
c) Enclosure or parts thereof.
Removal of any of the following:
a) Fan shroud
b) Vibration mounts
c) Sound absorption material
Operation of the generator with any of the enclosure doors open.
2.2. GENERATOR NOISE EMISSION CONTROL INFORMATION
A. The removal or rendering inoperative, other than for the purpose of maintenance, repair, or
replacement of any noise control device or element of design incorporated into this generator in
compliance with the noise control act;
B. The use of this generator after such device or element of design has been removed or rendered
inoperative.
THIS GENERATOR HAS BEEN SPECIFICALLY DESIGNED WITH A SOUND ATTENUATING
ENCLOSURE. THE CANOPY DOORS SHOULD REMAIN LOCKED SHUT UNDER NORMAL
OPERATING CONDITIONS. UNDER ANY OTHER CONDITIONS EXCESSIVE NOISE LEVELS
CAN BE PRODUCED AND PROLONGED EXPOSURE IS HAZARDOUS TO
HEARING.
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3.0 HANDLING
3.1. LIFTING / HANDLING
The generator set includes 1 lifting beam and forklift pockets.
All lifting and handling equipment must be adequately rated for applicable weights.
During all lifting and handling operations the following weights must be considered.
Bolt on steel plate buffers are located at the front and rear of the base to protect the body of the
generator.
Where 2 point lifting is provided, ensure that the correct length of strap / wire rope is used on each lifting
beam to ensure a level lift. Also ensure that the included angle does not exceed 90°.
CAUTION: THE GENERATOR SET SHOULD NOT BE LIFTED OR DRAGGED BY THE END
BUFFERS.
3.2. STORAGE / TRANSPORT
Carry out the following points before transporting the generator or preparing the generator for storage.
Empty the fuel tank (in case of overseas transport).
Disconnect the battery terminals (in case of overseas transport).
Ensure that the radiator cap is fitted securely and the exhaust rain cap is closed.
Close all doors.
All units are to be loaded flat onto transport and properly secured.
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4.0 INSTALLATION
4.1. UNPACKING
Ensure that the correct fork lift truck slots or marked lifting / tie down points are used whenever the
machine is lifted or transported.
4.2. LOCATION OF THE PLANT
The generator can be installed on any solid, flat and level surface capable of supporting the full
operating load of the package. A dry, well-ventilated area where the atmosphere is as clean as
possible is recommended. Ensure that the machine is positioned securely and on a stable
foundation.
CAUTION: A minimum of 1 metre (3 ft) all round the generator is recommended. Hot air
will exit from the roof outlet. It is important that this hot air does not re-circulate to the
package inlet.
The generator must be allowed sufficient space all round and above, to enable the effective removal
of the cooling air which, in turn, will reduce the risk of re–circulating the cooling air back through the
generator. Adequate clearance needs to be allowed around and above the machine to permit safe
access for specified maintenance tasks. Hard surfaces may reflect noise with an apparent increase
in the decibel level. It is recommended that provision be made for lifting heavy components during
major overhaul.
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Sump Pump
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2 3
2 DC on/off switch
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2
1
4
9
5
7
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1 10
2 9
3 8
4 5 6 7
5
Figure 6.3 – 5310 Generator controller
1. Auto select
1 Display scroll buttons 6
2. Accept setpoint value
1 – in normal mode
2 – in configuration mode
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Document No.: M020252
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On Aggreko canopy sets, binary inputs are configured for remote start input, circuit breaker status
and alarms, e.g. Low fuel level or Air flap closed. Where a motorised breaker is fitted, 2 binary
inputs are configured for circuit breaker open and circuit breaker close.
Analogue inputs are configured for low oil pressure, high water temperature (either senders or
discrete switches) and fuel gauge (where fitted).
Binary outputs are configured for Air flap closed (on offshore sets) and, where a motorised breaker
is fitted, for circuit breaker open and close outputs. In addition, one output is dedicated to provide a
common alarm output which provides a positive DC signal in the event of any alarm.
6.2.2. DISPLAY PAGES
The 5310 module displays the following pages on the LCD. Pressing the green info button will
scroll between these pages.
1. Status page
This shows the current status of the generator; e.g. stop mode, waiting in manual, running in
manual. When the generator is running, generator parameters are also shown (as displayed in
figure 6.3).
2. Parameter pages
The following parameters are displayed via the parameter pages. Pressing the Down arrow button
will scroll between the parameter pages. Holding down the Down arrow button for 2 seconds will
start auto-scroll through the parameter pages.
RPM
Frequency
Engine run time
Battery voltage
Generator phase voltages
Generator line voltages
Generator currents
Generator real power/apparent power and power factor
Number of starts
Oil pressure (if sensor fitted)
Coolant temperature (if sensor fitted)
If used in conjunction with an electronic engine (e.g. Cummins QSM11 or Scania DC12), a range of
engine parameters are also displayed.
3. Current alarm page
Displays the current alarms in clear text. Shutdowns which have not been acknowledged are
displayed as flashing text. Shutdowns which have been acknowledged and warnings are displayed
as constantly lit text.
4. Alarm log page
Stores the last 15 shutdown conditions. Pressing the Down arrow button will scroll through the
shutdown log.
6.2.3. FRONT PANEL LEDS
The following LEDs are provided.
- Green LED to indicate circuit breaker closed [symbol 2 in figure 6.3]
- Green LED to indicate Generator available (lit after warm-up timer has expired) [symbol 9 in
figure 6.3]
- Red LEDs for stop, manual and auto indication
- Status LEDs to indicate:
Remote start input signal present.
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Document No.: M020252
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CAUTION: - Always open the battery isolator switch to avoid unauthorised starting
during transport and maintenance.
6.3.1. MANUAL OPERATION
To start generator:
a. Prior to starting, exercise daily maintenance. See section 7.1.
b. Turn on DC power.
c. Check that no alarms are present. If a shutdown condition is present, the generator set will not
be allowed to start.
d. Press the manual select button. The display will read “Waiting in Manual”
e. Press the manual start button.
f. Once the generator has run-up to speed, check the frequency and voltage and adjust if
necessary, either using the potentiometers or the Governor/AVR adjustment.
g. Walk around the engine and check for any leakages.
h. After the warm-up timer has expired, close the circuit breaker.
To stop generator:
1. Open circuit breaker.
2. Allow the engine to cool down for at least 5 minutes, especially when the set has been running
with a high load.
3. Press engine stop.
6.3.2. REMOTE/STANDBY OPERATION
1. Turn on DC power
2. Check for alarms
3. Press Auto select. The display will read “Waiting in Auto”
4. The generator set can be started by providing a connection between terminals 2 and 3.
5. Generator set can be stopped by removing the connection between terminals 2 and 3.
6. A test run should be carried out at least once a week.
NOTE: When setting up for remote operation with a manual breaker, the generator set
should be started with the breaker closed. Remove the link between terminals 18 and 19 so
that the breaker can be closed when the generator set is stopped.
CAUTION: In remote operation, motorised breakers will close automatically after the
warm-up period. The 5310 controller is for single set use only and no synchronising facility is
provided. When synchronising capability is required, POWERLINK, or an alternative system,
must be used.
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2. Shutdown
- Display the alarm in clear text
and sound an audible alarm
- Trip the circuit breaker
- Shutdown the generator set
3. Controlled shutdown
- Display the alarm in clear text
and sound an audible alarm
- Trip the circuit breaker Figure 6.4 – Alarm page display
- Cooldown the generator set
for the cooldown period and
shutdown the machine
Shutdowns which have not been acknowledged are displayed as flashing text. Shutdowns which
have been acknowledged and warnings are displayed as constantly lit text.
The audible alarm can be muted using the mute alarm button [symbol 7 in figure 6.3].
Warnings will be automatically removed when the relevant parameter has returned to within its
normal operating range.
Shutdowns require to be acknowledged using the stop button. If the shutdown condition is still
present, the shutdown will continue to be displayed.
When a shutdown condition is still present after the machine has shutdown, e.g. Emergency stop
or Air flap closed, the module will prevent the generator set from cranking and starting until the
condition has been removed and the shutdown has been acknowledged. “Generator Locked-out”
will be displayed on the LCD.
In the event of an alarm, the Common alarm LED will light
A common alarm output, terminal 8, is provided, which will turn high (+12v DC or +24V DC) when
any alarm is detected.
The last 15 shutdown conditions will be stored in the shutdown log.
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Document No.: M020252
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With the limited access pin number, the following can be adjusted:
Language
Alternative Frequency – Enable/Disable
Alternative Voltage – Enable/Disable
AC System
Droop – Enable/Disable (electronic engines only)
Droop percentage (electronic engines only)
Contrast
Date and Time
With the full access pin number, in addition to the above, the full range of alarm setpoints and timers
can also be adjusted. Pressing the + and - buttons will scroll up and down through the parameters.
To adjust a parameter
Scroll to the desired parameter using the + and - buttons
Press the tick button and the parameter will start to flash
Press the + or - button to adjust the parameter to the desired value
Press the tick button to save the value
To select another parameter to edit, press the + or – button
To exit the front panel configuration editor at any time, press the Stop/Reset button
When adjusting the date and time, the Down arrow is used to scroll between minutes, hours, day,
month and year
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Document No.: M020252
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7.0 MAINTENANCE
7.1. GENERAL
In addition to periodic inspections, many of the components in these units require periodic servicing
to provide maximum output and performance. Servicing may consist of pre-operation and post-
operation procedures to be performed by the operating or maintenance personnel. The primary
function of preventive maintenance is to prevent failure, and consequently, the need for repair.
Preventive maintenance is the easiest and the least expensive type of maintenance. Maintaining your
unit and keeping it clean at all times will facilitate servicing.
Ensure that maintenance personnel are adequately trained, competent and have read the
Maintenance Manuals.
Prior to attempting any maintenance work, be aware of the following:
Any unauthorized modification or failure to maintain this equipment may make it unsafe and
out of factory warranty.
Use extreme care to avoid contacting hot surfaces (engine exhaust manifold and piping, etc.).
Never operate this machine with any guards removed.
Imperial and Metric hardware was used in the design and assembly of this unit. Consult the
parts manual for clarification of usage.
The machine cannot be started accidentally or otherwise, by posting warning signs and/or
fitting appropriate anti–start devices.
All residual electrical power sources (mains and battery) are isolated.
Prior to opening or removing panels or covers to work inside a machine, ensure that:
Anyone entering the machine is aware of the reduced level of protection and the additional
hazards, including hot surfaces and intermittently moving parts.
The machine cannot be started accidentally or otherwise, by posting warning signs and/or
fitting appropriate anti–start devices.
Prior to attempting any maintenance work on a running machine, ensure that:
The work carried out is limited to only those tasks which require the machine to run.
The work carried out with safety protection devices disabled or removed is limited to only those
tasks which require the machine to be running with safety protection devices disabled or
removed.
All hazards present are known (e.g. pressurised components, electrically live components,
removed panels, covers and guards, extreme temperatures, inflow and outflow of air,
intermittently moving parts, safety valve discharge etc.).
Appropriate personal protective equipment is worn.
Loose clothing, jewellery, long hair etc. is made safe.
Warning signs indicating that Maintenance Work is in Progress are posted in a position that
can be clearly seen.
Upon completion of maintenance tasks and prior to returning the machine into service, ensure that:
The machine is suitably tested.
All guards and safety protection devices are refitted.
All panels are replaced, canopy and doors closed.
Hazardous materials are effectively contained and disposed of.
To assist with ordering spare parts and other service activities, a short form list of Component
Manufacturers data has been included in this manual.
Prior to engine starting, check the oil and coolant levels.
Carry out a visual check of the following:
Leaks.
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CAUTION: Never operate the engine with the oil level below the ‘L’ mark or above the ‘H’
mark. See FIG. 7.1 below.
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Check that the battery connections are properly installed and that the electrolyte level in each cell
covers the top plates. If necessary, top up with clean distilled water.
7.2.8. CHECK FOR LEAKS.
There are several fluids used inside the generator, e.g. diesel, oil, coolant. Look for signs of leakage
all around the engine.
Any source of leak should be checked and fixed. Clean up any fluid lying inside the generator and
dispose of according to the appropriate local regulations.
Recurring leaks should be reported to AGGREKO.
7.3. WEEKLY MAINTENANCE
7.3.1. CHECK THE WATER/ANTIFREEZE LEVEL.
Stop the engine and wait for the temperature to cool before checking the coolant level.
Remove the pressure cap slowly to relieve the pressure of the cooling system. Failure to do so could
result in personal injury from heated coolant spray (See Figure 7.2).
Check the coolant level. Replenish with the correct coolant fluid as necessary (see section 8).
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8.0 LUBRICATION
8.1. GENERAL INFORMATION
Lubrication is an essential part of preventive maintenance, affecting to a great extent the useful life of
the unit. Different lubricants are needed and some components in the unit require more frequent
lubrication than others. Therefore, it is important that the instructions regarding types of lubricants
and the frequency of their application be explicitly followed. Periodic lubrication of the moving parts
reduces to a minimum the possibility of mechanical failures.
The Preventive Maintenance Schedule shows those items requiring regular service and the interval
in which they should be performed. A regular service program should be developed to include all
items and fluids. These intervals are based on average operating conditions. In the event of
extremely severe (hot, cold, dusty or wet) operating conditions, more frequent lubrication than
specified may be necessary. Details concerning lubrication of the running gear are in Maintenance
Section.
8.2. GENERATOR OIL CHANGE
These units are normally furnished with an initial supply of oil sufficient to allow operation of the unit
for approximately 3 months or up to 400 hours in line with current service recommendations,
whichever comes first. The unit will however need to be topped up with oil during this period. If a unit
has been completely drained of all oil, it must be refilled with new oil before it is placed in operation.
Refer to specifications in Lubrication Table.
NOTICE: Some oil types are incompatible when mixed and result in the formation of varnishes,
shellacs, or lacquers that may be insoluble. Such deposits can cause serious problems including
clogging of the filters. Where possible, do NOT mix oils of different types and avoid mixing different
brands. A type or brand change is best made at the time of a complete oil drain and refill.
If the unit has been operated for the time/ hours mentioned above, it should be completely drained of
oil. If the unit has been operated under adverse conditions, or after long periods in storage, an earlier
change period may be necessary as oil deteriorates with time as well as by operating conditions.
An oil change is good insurance against the accumulation of dirt, sludge, or oxidized oil products.
Completely drain the reservoir and piping. If the oil is drained immediately after the unit has been run
for some time, most of the sediment will be in suspension and, therefore, will drain more readily.
However, the fluid will be hot and care must be taken to avoid contact with the skin or eyes.
After the unit has been completely drained of all old fluid, close the drain valve. Add oil in the
specified quantity at the filler plug. Tighten the filler plug and run the machine to circulate the oil.
Check the oil level when unit is warm and not running. If not near the middle of the dipstick, stop the
unit and make corrections. DO NOT OVERFILL.
8.3. OIL SPECIFICATION
The oil required for this engine is:
Manufacturer: Castrol
Product Name: Tection T 15W-40 (Formerly RX Super Plus)
Relative Density @ 25°C 0.89 g/cm³
Viscosity @ 40°C 110 mm²/s
Viscosity @ 100°C 14.5 mm²/s
Viscosity Index 135
CCS –20ºC 6450 mPA.s
Total Base Number (TBN) 11.6 mgKOH/g
Flash Point (COC) 228 °C
Pour Point -36 °C
Sulphated Ash 1.5 %m
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APPENDIX A
MATERIAL SAFETY DATA SHEETS
Appendix A - i
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Appendix A - ii
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Appendix A - iii
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Appendix A - iv
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Appendix A - v
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The handling and proper use of lead-acid batteries is not hazardous provided sensible precautions are observed and
that Operatives having been trained in their use are adequately supervised.
Eye Contact Immediately irrigate eyes for at least 10 minutes with clean
water.
Swallowing Make the victim drink volumes of water, milk or milk of
magnesia.
DO NOT GIVE EMETIC
In all cases seek medical attention. Speed of action is vital.
[Spillages]
Small spillages can be swilled away with volumes of water.
[Disposal]
See Section 5.
2. ELECTRICAL ENERGY
[The Hazards]
The accidental connection of battery terminals by conductive objects, e.g. metal tools or metal personal jewellery etc.,
may generate sufficient heat to cause burns, create arcing or cause molten metal to splash.
Appendix A - vi
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[PAGE TWO].
[Precautions]
Always ensure correct installation. The positive cable must be attached to the terminal marked [+] and the negative
to the terminal marked [-]. Cables and terminals should be kept clean and securely fitted.
Before using metallic tools on a battery remove metallic objects from hands and wrists.
Before working on a vehicle electrical system disconnect the Battery, disconnecting the earth strap first and
reconnecting last. Do not place tools on top of batteries.
[Emergency Action]
3. EMISSION OF GASES
A mixture of oxygen and hydrogen is emitted during charging and may be emitted if a battery is moved or shaken.
[The Hazards]
An explosive atmosphere exists if the concentration of hydrogen exceeds 4%.
[Precautions]
Always charge in a well ventilated environment.
No naked flames NO SMOKING
Be certain that current is switched off before making breaking connection. Always remove earth strap first and re-
connect last.
[Emergency Action]
Explosion: Seek medical advice remembering that acid may have been sprayed.
4. WEIGHT
In general terms batteries are heavy and awkward to handle. Care should be taken and correct lifting techniques
employed.
5. DISPOSAL
Batteries, Battery Acid, Lead and Lead compounds must be disposed of in accordance with:
[a] The deposit of Poisonous Waste Act 1972
[b] The Control of Pollution Act 1974
[c] Consumer Protection Act 1987
If in doubt, consult the Environmental Department of your Local Authority.
For further information refer to:- BRITISH STANDARD BS 6604; 1985
SAFE OPERATION OF STARTER BATTERIES.
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Appendix A - ix
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Appendix A - x
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Appendix A - xiii
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APPENDIX B
EQUIPMENT DATA SHEET
Appendix B - i
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Appendix B - ii
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11 Running Hours
100% Prime Power Hours 24.1 21.3
75% 32.4 28.2
50% 47.1 40.2
12 Exhaust Emissions
Measurement Method TA-Luft EPA-MOH/CARB
Specific Load 100% Load 2% IS0 8178D2
NOx - Oxides of Nitrogen 1908 mg/m3 5,69 gr/kWh
5,73 gr/kWh
PM - Particulate Matter 11,5 mg/m3 0,25 gr/kWh
0,145 gr/kWh
CO - Carbon Monoxide 82 mg/m3 2,1 gr/kWh
0,69 gr/kWh
HC - Unburnt Hydrocarbons 0,51 gr/kWh 0,25 gr/kWh
13 Exhaust Silencer
Make & Type IMS
Certificate DNV M-10084
Permissible back pressure mm (ins) Hg 12.7 (0.5)
14 Noise
Sound Pressure at 1 metre dBA 76 79
Sound Pressure at 7 metre dBA 68 71
15 Engine
Make & Type Iveco
NEF45SM1.A001
Cylinders & Form 4 in Line
Aspiration Turbocharged and Charge Air Cooled
Fuel Pump Stanadyne
Governor Type Electronic
Make & Model GAC ESD 5500
Steady State frequency % ±0.5
Battery Voltage Volts 12
16 Overall Dimensions
- Length Metres (feet) – AI 2.660(8’7”)
Aus 3.034(10’)
- Width Metres (feet) – AI 1.0 (3’3”)
Aus 1.0 (3’3”)
- Height Metres (feet) – AI 1.775 (5’8”)
Aus 1.775 (5’8”)
17 Weight
- Without fuel Kg (lbs) 1600 (3528)
- With fuel Kg (lbs) 1881 (4147)
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18 Capacities
- Fuel gross Litres (US gall) 367 (97)
Usable 330 (87)
- Lub oil total 12.8 (6.8)
pan 11.5 (3.0)
- Coolant 18.5 (4.9)
19 External fuel supply
- maximum above base Metres (feet) 1.5 (5’0”)
- maximum below base Metres (feet) 0.3 (1’0”)
Appendix B - iv
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APPENDIX C
INSTALLATION OUTLINE DRAWING
Appendix C - i
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Appendix C - ii
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APPENDIX D
CONTROL PANEL LAYOUT
Appendix D - i
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Appendix D - ii
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APPENDIX E
ALTERNATOR & AVR SCHEMATIC DIAGRAM
Appendix E - i
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Appendix E - ii
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APPENDIX F
MAIN LOAD & METERING SCHEMATIC DIAGRAM
Appendix F - i
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Appendix F - ii
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APPENDIX G
DC CONTROL SYSTEM SCHEMATIC DIAGRAM
Appendix G - i
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Appendix G - ii
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APPENDIX H
TERMINAL LAYOUT & ENGINE WIRING
Appendix H - i
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Appendix H - ii
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APPENDIX J
LIVERY LAYOUT DRAWING
Appendix J - i
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Appendix J - ii
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Appendix J - iii
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APPENDIX K
MANUFACTURERS COMPONENT DATA
Appendix K - i
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SUPPLIER / AGGREKO
DESCRIPTION QTY SUPPLIER PART No.
MANUFACTURER PART No.
Radiator 1 Iveco 8048895 N/A
Radiator Fan 1 Iveco 504005039 N/A
Coupling, Disc 2 Newage 45-0759 N/A
Charging Belt / Fan Belt 1 Iveco 504013617 N/A
Starter Motor 1 Iveco 504031929 N/A
Battery Charging Alternator 1 Iveco 504010576 N/A
Deep Sea
Engine Protection Module 1 5310 5310
Electronics
Circuit Breaker
4P NS250N with Trip Unit
(STRE22SE) 250A 1 Merlin Gerin Refer to Description 11-0011364
(31780) (31480) (31480) (29382)
(29450) (29322) (29315)
CB Aux (29450) 1 Merlin Gerin Refer to Description 29450
Current Transformer 250/5A 3-in-1 1 Hobut CT353 11-0012706
ELRV 30/289 12~60V
Earth Leakage Relay 1 Broyce ELRV-30/Z89
DC
Water Temperature Switch 1 Iveco 8030937 N/A
Oil Pressure Switch 1 Iveco 8104140 N/A
Lube Oil Filter 1 Iveco 2992242 N/A
Combustion Air Filter 1 Iveco 8041642 N/A
Secondary Fuel Filter 1 Iveco 504107584 N/A
Primary Fuel Filter for 500FGS/S 1 Racor 2010-PM N/A
Appendix K - ii
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APPENDIX L
LIFTING BEAM CERTIFICATE
Appendix L - i
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Appendix L - ii
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APPENDIX M
DNV SPARK ARRESTOR CERTIFICATE
Appendix M - i
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Appendix M - ii
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Appendix M - iii
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APPENDIX N
INTERNATIONAL CONTACT INFORMATION
Appendix N - i
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Approved by: S.Doherty
In case of emergencies please contact the nearest service department of AGGREKO. They can be reached 24 hours
a day and are operational at any place in the world
BELGIUM FRANCE GREAT BRITAIN
Aggreko N.V. Aggreko S.a.r.l. Aggreko Generators Ltd.
Smallandlaan 7 1 Chemin de l’Ancien Parc Overburn Avenue
2660 Hoboken 91220 Bretigny Sur Orge DUMBARTON
Belgium France G82 2RL
Tel: (+32) 03 825 02 71 Tel: +33 (0)825 008007 Tel: (+44) 1389 767821
Fax: (+32) 03 825 11 81 Fax: +33 (0)1 69 737119 Fax: (+44) 1389 761577
NETHERLANDS NORWAY SPAIN
Aggreko International (Ned) Aggreko Norway A.S. Aggreko Iberia S.A.
B.V. Sorlandsveien 318 Avda. Torre Mateu, 35-37
Ketelweg 77 Postboks 543 Polg. Industrial Can Salvatella
3356 LD Papendrecht EGERSUND 08210 Barbera del Valles
EUROPE Netherlands N-4379 BARCELONA
Tel: (+31) 078 64 41 441 Norway Tel: (+34) 93 747 93 90
Fax: (+31) 078 642 80 83 Tel: (+47) 810 00 333 Fax: (+34) 93 729 02 83
Fax: (+47) 051 46 45 90
GERMANY GERMANY ITALY
Frankfurt Mulheim Aggreko Italia srl
(Central Europe South East) (Central Europe North) Via Copernico, 60
Aggreko Deutschland GmbH Aggreko Deutschland GmbH 20090 Trezzano sul Naviglio
Darmstadter Straße 66-68 Ruhrorter Straße 112 (Milano)
64572 Büttelborn 45478 Mülheim/Ruhr Italy
Germany Germany Tel: +39 02 4846 3024
Tel: +49 (0)61 52 93 93 0 Tel: +49 (0)208 58 09 70 Fax: +39 02 4451 243
Fax: +49 (0)61 52 93 93 99 Fax: +49 (0)208 58 09 798
CANADA U.S.A.
Aggreko Inc. Aggreko LLC
300 Clarence Street 4607 W Admiral Doyle Drive
NORTH Brampton, PO Box 10004
AMERICA ONTARIO NEW IBERIA, LA 70562-0004
L6W 1T5 Tel: (+1) 337 365 5479
Tel: (+1) 905 459 3321 Fax: (+1) 337 367 0870
Fax: (+1) 905 459 3392
REPUBLIC OF
SINGAPORE
Aggreko Singapore Pte Ltd
10 Pioneer Sector 1
ASIA
SINGAPORE
62844
Tel: (+65) 6862 1501
Fax: (+65) 6862 0182
UNITED ARAB EMIRATES
Aggreko Inc.
PO Box 17576
MIDDLE
Jebel Ali
EAST
DUBAI
Tel: (+971) 04 834059
Fax: (+971) 04 834145
AUSTRALIA/PACIFIC
Aggreko Generator Rentals
Pty Ltd
101 Woodlands Drive
AUSTRALIA /
Braeside Victoria
PACIFIC
3195
MELBOURNE
Tel: (+61) 03 586 5050
Fax: (+61) 03 586 50514
Appendix N - ii