Adveco TOTEM 10 User manual

PRODUCT MANUAL
TR400057
TOTEM
Cogeneration (CHP) Range
PRACTICAL, EFFICIENT & SUSTAINABLE
BUILDING SERVICES SOLUTIONS
TOTEM 10 -TOTEM 20 -TOTEM 25 MICROCOGENERATORS
Service Manual

Important Notes
No tampering and/or changes of any kind to the product are permitted, including
replacement of components with non-genuine spare parts and/or any alternation
to original product conformity unless expressly approved by O EM ENERGY.
Any changes to the casing or components inside the product will cause suspension
and/or exclusion of the product warranty.
By way of non-exhaustive example, the following are not permitted in any manner
before or after commissioning the product:
•Piercing the casing, the structure or the components inside the product.
•Welding or gluing system parts or components to the casing or to the devices
inside the product.
•Changes to the electrical system and to the devices inside the product.
•ransporting and positioning the product in manner different from the
transportation instructions illustrated in this manual.
•Non-conforming grounding.
•Non-conforming product storage.
•Alteration or tampering with the software or control parameters.
•Electrical powering of the product not conforming with the specifications
illustrated in this manual.
PRACTICAL, EFFICIENT & SUSTAINABLE BUILDING SERVICES SOLUTIONS
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Index
01. Safety nstructions ......................................................................................................6
02. Safety ...................................................................................................................... 12
03. Safety Line Checking Procedures ................................................................................. 14
04. nspections and Checks ............................................................................................. 17
05. Panel and Upright dentification .................................................................................. 19
06. Side Panel Removal- nstallation (Removal)................................................................... 21
07. Upper Panel Removal- nstallation (Removal) ................................................................ 22
08. Casing Upright Removal- nstallation (Removal) ............................................................ 24
09. Automatic Engine Oil Change (Removal) ...................................................................... 34
10. Manual Engine Oil Change (Removal) .......................................................................... 37
11. Level Switch Holder Replacement (Removal) ................................................................ 42
12. Coolant Check and Top-Up ......................................................................................... 46
13. Coolant Change (Removal) ......................................................................................... 47
14. TOTEM Module Battery Check ..................................................................................... 51
15. TOTEM Module Battery Replacement ........................................................................... 52
16. Electronic Control Unit Replacement (Removal) ............................................................ 53
17. Gateway Replacement (Removal) ................................................................................ 56
18. Electrical Panel Component Replacement (Removal) ..................................................... 58
19. Electrical Panel Replacement (Removal) ....................................................................... 70
20. Lambda Sensor Replacement (Removal) ...................................................................... 76
21. PT200 Sensor Replacement (Removal) ........................................................................ 80
22. Flow Switch Replacement (Removal) ........................................................................... 82
23. Engine Water Sensor Replacement (Removal) .............................................................. 84
24. Solenoid Valve Replacement, Electrical Part (Removal) .................................................. 86
25. Solenoid Valve Replacement, Mechanical Part (Removal) ............................................... 88
26. NTC Sensor Replacement (Removal) ........................................................................... 95
27. Deaerator Replacement (Removal) .............................................................................. 97
28. DUNGS Valve Replacement (Removal) ......................................................................... 99
29. Primary Air Cleaner Replacement (Removal) ............................................................... 103
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30. Secondary Air Cleaner Replacement ( nstallation) ....................................................... 105
31. Secondary Air Cleaner Assembly Replacement (Removal) ............................................ 107
32. Engine Oil Filter Replacement (Removal) ................................................................... 111
33. Plate Heat Exchanger Replacement (Removal)............................................................ 113
34. Coaxial Replacement (Removal) ................................................................................ 117
35. Tube Bundle Heat Exchanger Replacement (Removal) ................................................. 121
36. gnition Coil Replacement (Removal) ......................................................................... 125
37. Spark Plug Wire Replacement (Removal) ................................................................... 127
38. Spark Plug Replacement (Removal) ........................................................................... 129
39. Timing Upper Cover Replacement (Removal) .............................................................. 131
40. Timing Lower Cover Replacement (Removal) .............................................................. 133
41. Timing Belt Replacement (Removal) .......................................................................... 135
42. Tappet Cover Replacement (Removal) ....................................................................... 139
43. Valve Clearance Check/Restore ................................................................................. 143
44. Front Support Replacement (Removal) ...................................................................... 145
45. Exhaust Manifold Replacement (Removal) .................................................................. 147
46. Catalytic Converter Replacement (Removal) ............................................................... 151
47. Cylinder Head Replacement (Removal) ...................................................................... 153
48. Camshaft Replacement (Removal)............................................................................. 157
49. Cylinder Compression Pressure Check ........................................................................ 161
50. Engine Unit Replacement (Removal) .......................................................................... 163
51. Starter Motor Replacement (Removal) ....................................................................... 171
52. Generator Unit Replacement (Removal) ..................................................................... 175
53. Electrical Engine Water Pump Replacement (Removal) ................................................ 185
54. Mechanical Engine Water Pump Replacement (Removal) ............................................. 188
55. Engine Wiring Replacement (Removal) ...................................................................... 190
56. Vibration Damping Replacement (Removal) ................................................................ 192
57. Fan Replacement (Removal) ..................................................................................... 195
58. Blow-by Line ........................................................................................................... 199
59. nsulation ............................................................................................................... 200
60. ndications for Cleaning ........................................................................................... 205
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61. Tube Bundle Cleaning ( nstallation) ........................................................................... 206
62. Gas Detector Cleaning ( nstallation) .......................................................................... 210
63. nstruments ............................................................................................................ 212
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01. Safety nstructions
Secure the TOTEM module as described in CHAPTER 02 before starting any maintenance
operations.
Some internal components of the TOTEM, such as the endothermic engine, the heat recovery
devices (heat exchangers), the pumps, the engine water and service water pipes, the exhaust pipes
and the exhaust muffler, become very hot during normal use (some even hotter than 700°C). Some
components remain hot for many hours after having switched the TOTEM off.
The entire machine must normally operate in safe conditions with the casing panels installed to
prevent direct access to hot parts. Where possible, the internal components are heat-insulated to
ensure protection for the operator if panels need to be removed for troubleshooting or servicing.
However, some zones remain accessible and may be freely touched.
These activities must be performed by technically qualified personnel trained for performing the
operations using appropriate PPE.
Remember that high temperatures may cause fires in presence of potentially flammable
substances.
The TOTEM module contains chemical substances which are essential for its operation.
n particular, it contains substances such as battery acid, new and used lubricating oil and water
and glycol mixture.
t is very important to avoid direct contact of these substances with the eyes and skin and to
respect safety regulations for their storage and disposal. Refer to the safety datasheets of the
lubricants.
After contact with the chemical substances, wash the concerned body parts with plenty of water. f
needed, call a doctor and take the product datasheet with you. These substances may be very hot
and cause burns.
Furthermore, the TOTEM module produces a constant flow of exhaust gas containing CO, CO2 and
NOX during operation.
Electrical damage may occur if the safety protections are removed from the system, the control
panel or the ignition system if required for troubleshooting, servicing or commissioning (e.g.
functional test).
These activities must be performed by technically qualified personnel trained for performing the
operations using appropriate PPE. Always cut off the master switch of the machine and the
interface device (DD ) before starting any servicing operation.
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A. Symbols used
[Danger]
This indicates operative procedures which may cause injury or death if not performed correctly.
[Warning]
This indicates operative procedures which may cause severe damage to the device.
[Information]
This indicates important information related to use of the device.
B. Glossary and definitions
Operator: person without specific skills capable of performing only simple tasks, i.e. operating the
machine by means of the controls provided for the operator, checking operation and reporting any
faults to service.
Qualified technician: a professional with specific skills in the areas of heating and hot water
production systems, electrical systems and electricity generators, systems running on fuel gas and
devices equipped with Otto or Miller cycle endothermic engines. This person must be enabled
according to the law in force where the system is installed.
Service technician: a qualified technician having acknowledge professional systems trained and
authorized by TOTEM ENERGY to perform maintenance operations on the TOTEM® modules.
Personal protection equipment (PPE): including:
•ear protection (ear muffs or ear plugs) for protecting the hearing of workers operating with
the soundproofing panel removed and with the TOTEM® microcogenerator running (for
troubleshooting and servicing only);
•gloves and protective eyewear for working with battery acid, glycol and engine lubricant;
•safety footwear;
•dielectric insulating screen and gloves for operations on live components.
The PPE must be worn by service technicians during installation, starting and servicing operations
on the TOTEM®.
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C. Safety instructions
If you smell gas:
•Close the gas valve.
•Ventilate the room.
•Evacuate the room.
•Do not operate any electrical devices, including the telephone.
•Promptly call a professionally qualified technician or the gas company from another room.
Call the fire department if this is not possible or if emergency intervention is needed.
•Report the active safety system fault if the room is provided with a gas leakage detection
system.
If you smell exhaust fumes:
•Switch the device off.
•Ventilate the room.
•Evacuate the room.
•Call a qualified technician.
•Report the active safety system fault if the room is provided with a fume and CO detection
system.
If you see leakages of water, glycol, oil or other fluids on the floor near the O EM®:
•Switch the device off.
•Call a professionally qualified technician.
•Cut off services, such as the water or gas line.
nstallation, calibration or changes to the gas feeding system must be performed by a qualified
technician according to national and local laws and to the instructions provided in the installation
manual.
nstallation, calibration or changes to the electrical power system must be performed by a qualified
technician according to national and local laws and to the instructions provided in the installation
manual.
nstallation, calibration or changes to the water supply system must be performed by a qualified
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technician according to national and local laws and to the instructions provided in the installation
manual.
The exhaust gas evacuation line from the device must be connected to a fume evacuation pipe
compliant with the regulations in force at the place where the TOTEM® module is installed. Failure
to respect this instruction implies severe risks for the safety of humans and animals.
The user, in accordance with instructions for use, shall keep the installation in good conditions and
guarantee reliable and safe operation of the microcogenerator and of the systems connected to it
by entrusting the operations to qualified technical personnel.
The user shall have the device serviced according to the instructions contained in this manual in
compliance with national and local regulations by a qualified technician. ncorrect installation or
poor servicing may cause damage or injury to humans, animals or property for which TOTEM
ENERGY will not be liable.
Make sure all panels and screens are correct installed before starting. Risks for personnel safety
exist.
Do not obstruct the intake and exhaust pipe terminals, even partially.
Do not store materials which could be dangerous, such as explosive, combustible or flammable
material, in the same room as the microcogenerator. Do not stay in the utility room while the
microcogenerator is operating.
Do not tamper with, modify or alter the microcogenerator, its accessory components, the systems
needed for its operation (gas, water, electricity, cut-off devices, fire-fighting devices, detectors,
panels, electrical panels, parts of the utility room where the TOTEM® is installed, etc.) for any
reason to prevent even very severe accidents to humans, animals or property.
This manual is an integral and essential part of the microcogenerator and must be kept with care
by the user. Always make sure that this manual is given to the new owner if the microcogenerator
is transferred or if the property of the building in which it is installed changes hands.
The information contained in this manual is up-to-date and referred to the date of
publishing except for changes and technical updates. Minor differences may be present in images,
process descriptions and technical data as the result of continual product updates. Please contact
us to receive the most recent version of the documentation or in case of suggestions for
improvement or if inaccuracies are found.
The microcogenerator must be used only for the purpose for which it was expressly designed, e.g.
for the contextual production of:
•hot water for closed circuits for residential or industrial purposes
•low voltage electricity (400 Volts) for use on site, supplying to the grid or for self-
consumption.
TOTEM ENERGY shall not be liable in contractual or extra-contractual terms for damage caused by
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errors in installation or use and in all case for failure to respect the instructions provided by the
manufacturers or to respect applicable national and local laws.
D. Potential safety risks
Mechanical risks
Mechanical injury or damage may occur when safety protections are removed (panels or casing
protecting moving parts of the microcogenerator). These activities must be performed exclusively
by maintenance technicians trained for performing the operations using appropriate PPE.
Electrical risks
Electrical injury or damage may occur when safety protections are removed in the system or in the
control panel or the ignition system. Furthermore, changes to the existing electrical system may
cause even severe dangers if performed by personnel who is not enabled. These activities must be
performed exclusively by maintenance technicians trained for performing the operations using
appropriate PPE.
Heat risks
Some components inside the TOTEM® may become very hot during normal operation. The entire
machine must normally operate in safe conditions with the casing panels installed to prevent direct
access to hot parts. The panels may be opened by maintenance technicians only.
Noise risks
The entire TOTEM® module must normally operate in safe conditions with the casing panels
installed to abate the sound emission of the module.
Vibration risks
The TOTEM® unit is provided with appropriately dimensioned vibration damping feet to contain
vibrations to structures and the system connected to them. The vibration damping joints on the
connections to the gas line, fume exhaust line and heat system must not be removed.
Radiation/electromagnetic risks
The TOTEM® complies with Directive 2004/108/EC in the matter of electromagnetic compatibility.
n all cases, the magnetic fields generated by the asynchronous generator may cause temporary
malfunctioning of electro-medical devices (pacemakers, hearing aids, etc.) in the immediate
proximity.
Risk of injury due to contact with dangerous materials and substances
The TOTEM® module contains chemical substances essential for its operation. n particular, it
contains substances such as battery acid, new and used lubricating oil and water and glycol
mixture. Direct contact with these substances in case of spillage outside the TOTEM® module must
be absolutely avoided. After contact with the chemical substances, wash the concerned body parts
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with plenty of water. f needed, call a doctor and take the product datasheet with you. These
substances may be very hot and cause burns. Furthermore, the TOTEM® module during operation
produces a constant flow of exhaust gas. n case of release or stagnation of exhaust gas from the
fume evacuation system leave the area immediately and stop operation of the module, if possible.
nstallation of a CO/CH4 sensor in the room may be required by the regulations of the place where
the product is installed. The TOTEM® module is equipped with a CH4 leakage detection sensor.
Contact the Technical Service to have the device periodically checked and calibrated.
Risk of slipping, tripping and falling
Leakages of lubricant oil, glycol water or battery acids may occur following a fault or
malfunction of the module making surfaces slippery and causing the risk of falling.
Spillage must be promptly contained and disposed of according to the regulation in
force if possible.
Emergency stopping/shutdown risk
The TOTEM® is set to stop immediate if one or more safety device outside the TOTEM® and
connected to it trip.
Blackout risk
The TOTEM® is set to be shutdown immediately in safe conditions in case of electrical grid
blackout. The presence of an interface protection device (not supplied by TOTEM ENERGY) suited
and approved by the laws in force in the place of installation, guarantees interruption of the
connection to the electrical mains if the requirements stated in standards are not satisfied.
Control panel failure risk
The TOTEM® is set to be shutdown immediately in safe conditions in case of control panel failure.
Fault-related risks during normal operation
The TOTEM® is ready to operate in manner which is safe for operators, users and connected
systems providing it is intact, employed according to the expected destination of use and technical
parameters envisaged by TOTEM ENERGY and correctly serviced.
Risk deriving from use in environments with risk of explosion/fire (Ex)
The TOTEM® is not designed to work in environments with risk of explosion/fire (Ex). Do not keep
materials which may increase the risk of explosion or fire in the rooms where the TOTEM® is
installed.
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02. Safety
Note: Read CHAP ER 01 carefully before securing the O EM module.
Description:
Close the system gas cut-off valve (external to
the TOTEM module).
Turn the main switch on the panel of the module
to the "OFF" position.
Switch the battery disconnector off as described in CHAPTER 15.
Deactivate the service water circulation pump and cut off the circuit, where possible, by closing the
valves. (External to the module).
Select the interface device (DD ) (external to the TOTEM device).
Emergency Stop
Main Switch
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Safety
Safety instruction: Perform this operation in safe conditions with all casing panels
installed. If the panels need to be removed during troubleshooting or for specific
service activities, these activities may be performed exclusively by technically qualified
personnel trained for performing the operations using the specific PPE.
Description:
Reset the interface device (DD ) (external to the TOTEM device).
Turn the main switch on the panel of the module
to the "ON" position
Release the emergency stop button on the
module panel.
Switch the battery disconnector on as described in CHAPTER 15.
Restore service water circulation in the circuit by opening the valves and reactivating the service
water circulation pump. (External to the module).
Open the system gas cut-off valve (external to the TOTEM module)
Main Switch
Emergency Stop
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03. Safety Line Checking Procedures
Note: Read CHAPTER 01 carefully before securing the TOTEM module.The safety line of the
machine is designed to trip and secure the machine if the temperature inside the box is over 65°C
and in case of leakage of natural gas in the box. The parameters are detected by two sensors fitted
inside the box in zones suited to detect the faults.
Methane sensor check
The gas sensor is provided with a specific kit for calibrating and testing it. The kit consists of a
canister containing a mixture of methane equal to 50%LEL (2.2%CH4 in air), an adapted for the
detector head and a pre-calibrated flow adjustment valve.
Description:
Open the side panel P6 as described in CHAPTER 06.
Disconnect the connector of the 20%LEL signal directed to the PLC and jump it.
Apply the adapter to the sensor head.
Fit the flow adjuster to the calibr
ation canister.
Connect the flexible pipe with quick connector to the head and to the cylinder.
Slowly open the valve to obtain a constant gas flow slower than 0.5 l/min. The valve is pre-
calibrated to obtain the required flow when opened.
Check that the safety functions are actuated:
•The machine switches off (if it was running).
•The two LEDs on the safety relay switch off.
•The “Emergency line alarm” signal appears on the operator panel.
•Machine restart is inhibited (after switch-off or if the machine was not running).
•Fan is activated (if the machine is off).
•Sending of a signal to the system fan which can be verified with a tester.
n order to restart the machine it is necessary to eliminate the presence of methane so that the
sensor can resume normal operating conditions. f sensor is automatically rearmed when the
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presence of methane is no longer detected and LED 1 appears again on the safety relay. Press the
manual rearm button on the panel flat safety line (LED 2 on the safety relay will light up) and reset
the alarm on the operator panel.
Safety thermostat check
The temperature safety function may be checked by increasing the air temperature near the
thermostat and checking that the safety functions are actuated. The sensor is set by the
manufacturer to 65°C. Another temperature sensor connected to the PLC is present in the machine.
The PLC is set to switch the machine off over 60°C. n this way the safety line will only trip in case
of fault to the machine control system.
Temperature increase may be simulated using an industrial heat gun. The heat gun may be
adjusted by setting the air temperature to the required value.
1. Open the panel at the thermostat.
1. Set the gun to a temperature of 65°C.
1. Send the hot air flow onto the thermostat bulb,
2. Check that the safety functions are actuated:
•The machine is switched off.
•The two LEDs on the safety relay switch off.
•The “Emergency line alarm” signal appears on the operator panel.
•Machine restart is inhibited (after switch-off).
To be able to restart the machine, it is necessary to manually rearm the thermostat, the LED 1 on
the safety relay lights up, press the manual rearming button for the safety line on the panel door
(LED 2 on the safety relay will light up) and reset the alarm on the operator panel.
Emergency stop button check
The emergency stop button can be checked by pressing it during machine operation and checking
that the safety functions are actuated.
•The machine is switched off.
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•The two LEDs on the safety relay switch off.
•The fan and the water circulating pump is also switched off.
•Machine restart is inhibited (after switch-off).
To be able to restart the machine, it is necessary to rearm the button, press the manual rearming
button for the safety line on the panel door and reset the alarm on the operator panel.
Refit the side panel P6 as described in CHAPTER 06.
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04. nspections and Checks
Safety instruction: Carry out the " O EM module securing" operation or make sure that
it was previously performed in correct manner as described in CHAP ER 02.
Safety instruction: Do not perform the "Restoring otem for normal operation"
procedure and do not attempt to operate or start the otem module before having
completed the "Inspections and checks" operation and in all cases before refitting all
the components, including the panels.
Safety instruction: Carry out the machine inspection and checking operation with the
interior parts closed.
Safety instruction: Risk of contact with engine oil or coolant.
Description:
Secure the TOTEM module as described in CHAPTER 02.
Remove all the panels from the TOTEM module as described in CHAPTER 06.
Visually check all the internal parts of the TOTEM module. Check that:
•All components are intact and operative.
•There are no residues of liquid, such as engine oil or mixture of water and glycol on the
module base.
•All electrical connections and contacts are well positioned and well connected.
•The wirings inside the module are intact and not tripped or broken along the path.
•All plastic or metal pipe connections are tight on the respective connections.
•There are no interferences between wiring and rotating parts.
Open the front panel of the electrical panel of the TOTEM module and visually check that:
•All electrical connections are well positioned and correctly connected in the respective
housings.
•The wire insulation is not stripped in any points.
•There are no burns near the terminal.
•All terminal boards are correctly closed on the respective terminals (with a suitable
screwdriver).
•There are no traces of humidity or liquid residues in the electrical panel.
•All fuses are still intact.
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Using a specific torque wrench check the
tightening torques of all tube bundle interfaces
(see example in photo).
IGH ENING ORQUE: 50 ± 2.5 Nm
Check the tightening of the electrical components
in the module (see example in photo).
nstall all the panels from the TOTEM module as described in CHAPTER 06.
Restart the TOTEM module as described in CHAPTER 02.
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05. Panel and Upright dentification
UPRIGHT A
UPRIGHT
B
UPRIGHT
C
UPRIGHT
D
PANEL 3
PANEL 4
PANEL
2
PANEL 1
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UPRIGHT G
UPRIGHT F
UPRIGHT E
UPRIGHT D
UPRIGHT H
PANEL 8
PANEL 7
PANEL
6
PANEL
5
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