Dr. Alchhorn HITZINGER D POWER 90-180M User manual

Property of American Airlines
Maintenance

2. MAINTENANCE
CONTENTS
2.1 SERVICING .............................................................................................................................3
2.1.1 Safety instructions ..........................................................................................................3
2.1.2 Servicing operation.........................................................................................................4
2.1.2.1 Elements for servicing on operation panel ............................................................4
2.1.2.1.1 Display-Menu „Enter password“........................................................................4
2.1.2.1.2 Display-Menu „TEST“ .......................................................................................5
2.1.2.1.3 Display-Menu „STACK Detail“ ..........................................................................7
2.1.2.1.4 Display-Menu „SETUP“.....................................................................................8
2.1.3 Device settings ...............................................................................................................9
2.1.3.1 Voltage regulator 200/115V 400Hz adjustment.....................................................9
2.1.3.2 Thermal relay adjustment......................................................................................9
2.1.3.3 Speed / Frequency adjustment..............................................................................9
2.1.3.4 Adjustments for 50Hz frequency converter (Option) .............................................9
2.1.4 Servicing schedule........................................................................................................10
2.1.4.1 Non-periodic maintenance works for new or overhauled engines.......................10
2.1.4.2 Periodic maintenance works................................................................................10
2.1.5 SERVICING WORKS....................................................................................................11
2.1.5.1 Check fuel level...................................................................................................11
2.1.5.2 Check oil level of reservoir (Option) ....................................................................11
2.1.5.3 Check coolant level .............................................................................................11
2.1.5.4 Check cooling system..........................................................................................12
2.1.5.5 Clean Cooler........................................................................................................12
2.1.5.6 Renew engine oil with oil drain valve...................................................................13
2.1.5.7 Drain coolant .......................................................................................................14
2.1.5.8 Load run at continuous low load operation..........................................................14
2.1.5.9 Lubricate trailer....................................................................................................14
2.1.5.10 Lubricate canopy.................................................................................................15
2.1.5.11 Check canopy......................................................................................................15
2.1.5.12 Check screws on trailer.......................................................................................15
2.1.5.13 Check adjustment of brakes and readjust if necessary.......................................16
2.1.5.14 Check exhaust system ........................................................................................16
2.1.5.15 Check elastic mounting of genset........................................................................16
2.1.5.16 Check hoses and clamps on air intake side........................................................16
2.1.5.17 Check battery connections..................................................................................17
2.1.5.18 Visual inspection of switch panel.........................................................................17
2.1.5.19 Check output cables and plugs ...........................................................................17
2.1.5.20 Check LED’s........................................................................................................17
2.1.5.21 Check measuring unit of Hitzinger-ACON...........................................................17
2.1.5.22 4kV Insulation test (IT).........................................................................................18
2.1.5.22.1 General preparations.....................................................................................18
2.1.5.22.2 Testing operation...........................................................................................18
2.1.5.22.2.1 Testing procedure..................................................................................18
2.1.5.22.2.2 Measuring points ...................................................................................19
2.1.5.22.3 Evaluation and test determination.................................................................19
2.1.5.23 Check complete function.....................................................................................20
2.1.5.23.1 Preparation....................................................................................................20
2.1.5.23.2 Operation.......................................................................................................20
2.1.5.23.3 Alarm and trip simulation...............................................................................22
2.1.5.23.3.1 Common control + auxiliaries failures....................................................22
2.1.5.23.3.2 Diesel engine + genset failures .............................................................23
2.1.5.23.3.3 400Hz alternator failures........................................................................26
2.1.5.23.3.4 28VDC (option) failures .........................................................................31
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2. MAINTENANCE
2.2 TROUBLESHOOTING...........................................................................................................33
2.2.1 FAILURES....................................................................................................................33
2.2.1.1 Common control + auxiliaries failures .................................................................33
2.2.1.2 Diesel-engine + genset failures...........................................................................35
2.2.1.3 400Hz alternator failures .....................................................................................39
2.2.1.4 28VDC (option) failures.......................................................................................42
2.2.2 RESISTANCE MEASURING POINTS AND NOMINAL VALUES.................................43
D POWER1 Edition 01 - Page 2 / 43
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2. MAINTENANCE
2.1 SERVICING
2.1.1 Safety instructions
WARNING
Only persons which are special trained are allowed to carry out service and
trouble shooting works.
WARNING
Before inspecting or servicing electrically-powered equipment, take the
following precautions:
1. Switch off battery main switch.
2. Disconnect all output cables.
3. Do not remove covers before switch off battery main switch.
WARNING
If troubleshooting must be done with the unit energised, have another
person present who is trained in turning off the unit and providing or calling
for first aid.
WARNING
Serious injury can result from contact with fans inside some equipment.
Shut down and disconnect minus of such equipment for inspection and
routine maintenance.
When equipment is in operation use extreme care in performing necessary
trouble-shooting and adjustment.
Don’t remove guards, while equipment is operating.
WARNING
Care must be taken to avoid scalding by escaping vapour when removing
the filler cap from the pressurised radiator on a hot engine.
To avoid scald let engine cool down before opening Diesel engine water
cooler.
CAUTION
Batteries can explode or give off flammable hydrogen gas. Acid (if no gel
batteries are used) and arcing from a ruptured battery can cause and
additional failures. While servicing, don’t smoke, cause sparks or use open
flame in the surroundings of the battery.
WARNING !
Use ears protection when maintenance flaps are opened!
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2. MAINTENANCE
2.1.2 Servicing operation
2.1.2.1Elements for servicing on operation panel
NOTE!
This chapter describes the operation elements necessary for service
operation.
The Display-Menu „TEST“ and „ STACK Detail” and also the “RESET” of
service working hours in Display-Menu „Measurement DIESEL“ are
password protected (access only for authorized trained personal).
2.1.2.1.1 Display-Menu „Enter password“
NOTE!
You receive the password from our customer service.
(Warning will be displayed only
when changing to display-menu
„TEST“)
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2. MAINTENANCE
2.1.2.1.2 Display-Menu „TEST“
(access via Display-Menu „Measurement”)
1Button "Ignition on/off"
For programming of speed controller at standstill.
Ignition off = stop of GPU (diesel engine)
2Lamp "Ignition on"
Green LED continuous light in case of ignition on.
3 Button "Motor Start"
Start of GPU (Diesel engine)
4Combined button+signal lamp "Automatic oil-refill" (Option)
Yellow signal lamp: "oil level check" for signalling the operation status of automatic oil-refill.
Button: Button for test operation and reset button for failures of automatic oil-refill.
5Signalling "Failure message available"
By pushing on this signal, the screen changes to Display-Menu „Messages“.
6Button "400Hz voltage test on/off "
Switching on and off of manual voltage adjustment (400Hz).
Switching off - the voltage is automatically regulated by ACON to the preset nominal value.
7Lamp "400Hz voltage test on"
Green LED continuous light in case of voltage test on.
8Display "400Hz voltage and frequency"
9Combined button+display "400Hz voltage input field and display of nominal value"
By pushing the input field is open. Select a nominal value and press enter to save.
10 Button "SET 400Hz voltage"
By pushing button “SET” the voltage is automatically regulated to the selected value.
11 Button "SETUP“
Change to Display-Menu „SETUP“
12 Lamp "Bypass 400Hz 1 on"
LED continuous light in case of Bypass 400Hz 1 on.
13 Button "Bypass 400Hz 1 on/off "
Manually release of 400Hz 1 output contactor, without closing EF-contact.
28 31
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2. MAINTENANCE
14 Lamp "Bypass 400Hz 2 on"
LED continuous light in case of Bypass 400Hz 2 on.
15 Button "Bypass 400Hz 2 on/off"
Manually release of 400Hz 2 output contactor, without closing EF-contact.
WARNING !
Switch on of the Bypass-switch is only allowed for servicing works. Because
during handling of the cables the existence of dangerous voltage on the
400Hz aircraft plug may be possible!
In case of activated 400Hz by-pass switch (message "BY-PASS ON") and
alternator voltage available the outputs can be switched on at any time
(protection on plugs bridged).
"
This condition is not allowed for normal air side operation!
16 Button "DPF regeneration on/off" (Option)
Switching on and off of diesel particle filter regeneration (only DPF system with passive
regeneration).
17 Button "Speed test on/off"
Switching on and off of manual speed adjustment.
Switching off - the speed is automatically regulated by ACON to the preset nominal value.
18 Lamp "Speed test on"
Green LED continuous light in case of diesel engine speed test.
19 Display "Speed"
20 Combined button+display "Speed input field and display of nominal value"
By pushing the input field is open. Select a nominal value and press enter to save.
21 Button "SET speed"
By pushing button “SET” the speed is automatically regulated to the selected value.
22 Button "STACK Detail"
Change to Display-Menu “STACK Detail” (Password protected!).
23 Button "28VDC voltage test on/off"
Switching on and off of manual voltage adjustment (28VDC).
Switching off - the voltage is automatically regulated by ACON to the preset nominal value.
24 Lamp "28VDC voltage test on"
Green LED continuous light in case of voltage test on.
25 Display "28VDC voltage"
26 Combined button+display "28VDC voltage input field and display of nominal value"
By pushing the input field is open. Select a nominal value and press enter to save.
27 Button "SET 28VDC voltage"
By pushing button “SET” the voltage is automatically regulated to the selected value.
28 Button "HOME"
Change to Display-Menu „HOME“.
29 Button "28 VDC"
Change to Display-Menu „Measurement 28VDC“.
30 Button "DIESEL"
Change to Display-Menu „Measurement Diesel“.
31 Button "400Hz"
Change to Display-Menu „Measurement 400Hz“.
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2. MAINTENANCE
2.1.2.1.3 Display-Menu „STACK Detail“
1Button "Module on/off“
Switching on and off of individual modules.
WARNING !
Switch on of the 28VDC Modules is only allowed for servicing works,
because immediately there is a dangerous voltage on the 28VDC aircraft
plug!
This condition is not allowed for normal air side operation!
2Display "Module-Temperature"
3Display "Modul-Current"
4Display "Group 1 Voltage" (Option)
Only with 2 x 28VDC outputs aktivated – 28VDC voltage on output 1.
5Display "STACK Voltage"
If only one 28VDC output is available - 28VDC voltage at the output.
6Display "Group 2 Voltage" (Option)
Only with 2 x 28VDC outputs aktivated – 28VDC voltage on output 2.
7Button "TEST"
Change to Display-Menu “TEST“
8Button "HOME“
Change to Display-Menu “HOME“.
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2. MAINTENANCE
2.1.2.1.4 Display-Menu „SETUP“
(access via Display-Menu „Home”)
1Display "System data"
Information about Type, Order no., ACON Version, TSwin Version and IP address can be found.
2Combined button+display "Script Execution" (Option)
Default with "0". Possibility of performing additional startup scripts (Option).
By pushing the input field is open. Select and press enter to save.
3Combined button+display "LCD Background"
By pushing the input field is open. Select background brightness / contrast of the display and press
enter to save.
4Combined button+display "Date"
By pushing the input field is open. Select date and press enter to save.
5Combined button+display "Time"
By pushing the input field is open. Select time and press enter to save.
6Button "SET Date/Time"
By pushing button “SET” the selected date and time are taken as new setpoints.
7Button "Language"
Select language by pushing buttons marked with the national colors.
8 Button "HOME"
Change to Display-Menu „HOME“
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2. MAINTENANCE
2.1.3 Device settings
Voltage regulator
200/115V 400Hz Thermo-Relais 400Hz Hitzinger-ACON Engine – diagnostic regulator connection
2.1.3.1Voltage regulator 200/115V 400Hz adjustment
Adjustment of nominal voltage and voltage droop are software settings (parameter) in the
Hitzinger-ACON which can be only changed by using a programming device (PC).
Only for servicing the voltage can be changed temporary (see Display-Menu „TEST“).
T21: Turn both potentiometers fully clockwise and then back to vertical position.
Do not turn to minimum or maximum position.
AVC63: Potentiometer „DRP“ (Line Drop Compensation) turn fully counterclockwise.
Potentiometer „STB“ (Stability) turn to 8 o’clock.
Remove connections 2 and 3, short terminals 2 and 3, adjust potentiometer „VLT ADJ“
(voltage adjust) at no load to nominal voltage 115 V (L-N) and finally reconnect terminals 2
and 3.
2.1.3.2Thermal relay adjustment
Adjust 400Hz thermal relays to nominal current (refer to wiring diagrams)
2.1.3.3Speed / Frequency adjustment
These are software settings and can be changed only by using engine programming device
(Engine – diagnostic regulator connection).
Only for servicing the speed can be changed temporary (see Display-Menu „TEST“).
2.1.3.4Adjustments for 50Hz frequency converter (Option)
Adjustment of 50Hz frequency converter is factory made (software) and must not be
readjusted manually.
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2. MAINTENANCE
2.1.4 Servicing schedule
2.1.4.1Non-periodic maintenance works for new or overhauled engines
Description of action Interval (h) Description see
Check engine for leakage’s 50 - 150 Engine manual
Check engine oil 50 - 150 Engine manual
Check fuel prefilter 50 - 150 Engine manual
Check fuel system 50 - 150 Engine manual
Check engine mounts 50 - 150 Engine manual
Check coolant, additive-concentration 50 - 150 Engine manual
Check v-belts (retension if necessary) 50 - 150 Engine manual
Check screws on trailer Before first putting into operation 2.1.5.12
Check screws on trailer After 1 and 4 week operation 2.1.5.12
2.1.4.2Periodic maintenance works
Description of action Interval (h) Description see
Check oil level in the sump daily Engine manual
Check fuel level daily 2.1.5.1
Check oil level of reservoir (Option) daily 2.1.5.2
Check air filter daily Engine manual
Check coolant level daily 2.1.5.3
Check cooling system 125 2.1.5.4
Clean Cooler If necessary 2.1.5.5
Drain water separator acc. Maintenance plan Engine manual
Check coolant, additive-concentration acc. Maintenance plan Engine manual
Renew engine oil acc. Maintenance plan Engine manual + 2.1.5.6
Renew oil filter cartridge acc. Maintenance plan Engine manual
Renew fuel filter cartridge acc. Maintenance plan Engine manual
Check v-belts (retension if necessary) acc. Maintenance plan Engine manual
Check fuel prefilter acc. Maintenance plan Engine manual
Check glow plugs acc. Maintenance plan Engine manual
Check hoses/clamps on air intake side acc. Maintenance plan Engine manual
Check valve clearance and rocker arm clearance
(readjust if necessary) acc. Maintenance plan Engine manual
Check fuel system (leakage line, change defective lines) acc. Maintenance plan Engine manual
Renew coolant acc. Maintenance plan Engine manual + 2.1.5.7
Load run in case of permanent low-load operation 500 - 1000 2.1.5.8
Lubricate trailer annual 2.1.5.9
Lubricate canopy annual 2.1.5.10
Check canopy annual 2.1.5.11
Check screws on trailer annual 2.1.5.12
Check adjustment of brakes and readjust if necessary annual 2.1.5.13
Check exhaust system annual 2.1.5.14
Check elastic mounting of genset annual 2.1.5.15
Check hoses and clamps on air intake side annual 2.1.5.16
Check battery connections annual 2.1.5.17
Visual inspection of switch panel annual 2.1.5.18
Check output cables and plugs annual 2.1.5.19
Check bulbs and LED’s annual 2.1.5.20
Check measuring unit of Hitzinger-ACON annual 2.1.5.21
4kV insulation test (Option) annual 2.1.5.22
Check complete function annual 2.1.5.23
Check adjustments annual 2.1.3
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2. MAINTENANCE
2.1.5 SERVICING WORKS
2.1.5.1Check fuel level
Check fuel on gauge nearby filling socket.
Refill fuel according chapter fuel of engine operation manual if necessary.
WARNING
Care must be taken to avoid breathe in toxical fumes.
Keep enough distance during replenishing.
2.1.5.2Check oil level of reservoir (Option)
The oil level must be within the MIN and MAX markings.
Refill lubrication oil if necessary.
2.1.5.3Check coolant level
The water level must be above middle of the lower inspection glass – refill if necessary
(coolant acc. chapter operating materials of engine operation manual).
WARNING !
Care must be taken to avoid scalding by escaping vapour when
removing the filler cap from the pressurised radiator on a hot engine.
To avoid scald let engine cool down before opening Diesel engine water
cooler.
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2. MAINTENANCE
2.1.5.4Check cooling system
Check tightness of the cooling system
(if necessary tighten hose clamps or replace hoses).
Check the cooler, when it is dirty, clean it.
2.1.5.5Clean Cooler
If the cooler is dirty (GPU deliver not enough power), you have to clean the cooler with a
damp streamer (low pressure)
ATTENTION!
Engine with DEUTZ Diesel particle filter - DPF-System (Option)
The insolation of the exhaust line must not be damaged!
Do not wash the engine!
Loosen locking device of air outlet duct on the bottom left and right.
Remove air outlet duct through two persons by lifting up (~40mm) and carefully move
forward.
NOTE !
Lower air outlet duct carefully on a prepared soft padded surface (for
example foam or cardboard) to avoid scratch of glass-fibre-surface.
Clean cooler with damp streamer (low pressure). Blow out cooler and cooling fins always
from exhaust side to fresh air side.
Warm up engine and cooler that water residues evaporate.
Mount air outlet duct carefully.
Snap in locking device of air outlet duct on the bottom left and right.
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2. MAINTENANCE
2.1.5.6Renew engine oil with oil drain valve
,,
Check that GPU is on a level surface.
Allow engine to warm up (lube oil temperature
approx. 80°C, approx. 2 minutes).
Shut down engine.
Place oil tray under oil drainage.
Unscrew drain plug (1).
Open cock (2).
Drain oil.
Close cock (2)
Fit oil drain plug (1).
Refill lube oil in oil filling socket (3) according chapter quality grade and viscosity of engine
operation manual (oil quantity see technical data).
ATTENTION !
Engine with DEUTZ Diesel particle filter - DPF-System (Option)
Use only the lubricating oil Quality Class DQC III LA (low ash oil)!
Pull oil dip stick and clean it with clean and fibre free rag.
Put in oil dip stick until stop and pull it again.
Check oil level (must be underneath the ‘’MAX’’ mark) and refill if necessary.
WARNING !
Be careful when draining hot oil - danger of scalds!
Do not let used oil run into the soil but catch in a container ready for
proper disposal.
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2. MAINTENANCE
2.1.5.7Drain coolant
Place tray under drainage, Unscrew
drain plug and open cock.
Engine with DPF-System (Option) –-
when filling with coolant vent cooler of
exhaust gas recirculation (EGR).
2.1.5.8Load run at continuous low load operation
When the engine is operated continuously with low load (load profile can be read on the
controller), i.e. load at 90% of the time is below 30%, then soot deposits in the exhaust
system increase the exhaust back pressure, which will cause damage to the engine.
In this case it is necessary to operate the engine every 500h during servicing on the load
bank with 100% load, so that the soot is burned by the higher exhaust temperature.
Maximum allowable back pressure in the exhaust system (except particulate filter):
Deutz engines ~ 75 mbar
Cummins engines ~ 100mbar.
NOTE!
100% shock load only possible after appr. 5 min. warm up of engine.
2.1.5.9Lubricate trailer
DPF (Option):
Grease trailer on marked points until new grease leaves
(grease quality K3K according to DIN 51825).
Grease sliding surface of drawbar
Clean trailer of surplus grease.
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2. MAINTENANCE
2.1.5.10 Lubricate canopy
Grease hinges, locks, guide rods with grease of quality K3K according to DIN 51825.
2.1.5.11 Check canopy
Check door sealing.
Check function of gas springs.
check function of locks.
Check function of hinges.
2.1.5.12 Check screws on trailer
Check all screws on trailer for tight seat.
Retighten wheel screws (M12x1,5) with 90Nm.
NOTE !
The wheel screws of the trailer have to be retighten before fist putting
into operation, after 1 week operation, after 4 weeks operation, and
then regularly once a year!
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2. MAINTENANCE
2.1.5.13 Check adjustment of brakes and readjust if necessary
Check that brake cable starts to become tight about 10cm (measured on towing eye)
before vertical and horizontal stop position. Touch the cable by hand to feel the beginning
tightening.
Readjustment:
10cm
Stop Position
10cm
Stop Position
1. Lift up drawbar about 10cm from horizontal stop.
2. Adjust screw for horizontal adjusting until brake cable becomes tight.
3. Lower drawbar about 10cm from vertical lock.
4. Adjust screw for vertical adjusting until brake cable becomes tight.
2.1.5.14 Check exhaust system
Remove air outlet duct according item 2.1.5.5
Check and retighten mounting screws of silencer.
Check and retighten clamps.
Check tightness.
Check condition of heat insulation inside the canopy.
Mount air outlet duct according item 2.1.5.5
2.1.5.15 Check elastic mounting of genset
Check and retighten screws.
Check condition and clearance of vibration dampers.
2.1.5.16 Check hoses and clamps on air intake side
Check tube between Engine and Airfilter (change it, if necessary)
Retighten all clamps.
Check low pressure switch.
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2. MAINTENANCE
2.1.5.17 Check battery connections
WARNING
Take care that the battery poles are not short circuited!
Remove battery cover and pole covers
Loosen battery clamps.
Clean battery poles as well as clamps and lubricate them with an acid-free and
acid-resistant grease.
During assembly pay attention that battery is not short circuited.
Mount pole covers over connections and battery cover.
2.1.5.18 Visual inspection of switch panel
Check all components on perfect fit and clean them with compressed air and vacuum
cleaner.
Check operation- and indication elements.
Check all electric connections, retighten them, if necessary.
Check cables on isolation damage.
2.1.5.19 Check output cables and plugs
Check cable isolation.
Check plugs for damages and corrosion.
2.1.5.20 Check LED’s
Switch on control voltage via push button "Power".
Push button "Options" (option)
Switch on and of parking lights, spot light and revolving light and check function.
2.1.5.21 Check measuring unit of Hitzinger-ACON
Start Diesel engine.
Load one 400Hz output with full load (maximum 90kVA cos 0,8).
Compare voltage, current, frequency, cos and power measurements of Hitzinger-ACON
with measurements of external instruments (accuracy class at least 1%).
Switch off checked output.
Load second 400Hz output with full load (maximum 90kVA cos 0,8).
Compare voltage, current, frequency, cos and power measurements of Hitzinger-ACON
with measurements of external instruments (accuracy class at least 1%).
Switch off checked output.
Load both 400Hz outputs with load (in summary nominal power of GPU) (cos 0,8).
Compare voltage, current, frequency, cos and power measurements of Hitzinger-ACON
with measurements of external instruments (accuracy class at least 1%).
Switch off checked outputs
Load 28VDC output with nominal load (Option).
Compare voltage, current and power measurements of Hitzinger-ACON with
measurements of external instruments (accuracy class at least 1%).
The difference of Hitzinger-ACON measuring to instrument measuring must be less than
2%.
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2. MAINTENANCE
2.1.5.22 4kV Insulation test (IT)
(Only for ground power units with modified protective separation of 400Hz alternator from
ground /earth according to DFS400)
2.1.5.22.1 General preparations
The GPU must be completely loaded (all electronic devices remain connected).
28VDC Power Stack (Option):
disconnect supply cable (white) in
400Hz switch panel (U1/V1/W1)
No load may be hooked up to the output (400Hz cable).
The parts to be tested must be free of dirt and moisture.
WARNING !
Safety precautions:
Contact with energized parts is life threatening.
Cordon off the entire test area, or employ one person who prevents
unauthorized people from coming into proximity of the test object
(minimum distance 1400mm).
2.1.5.22.2 Testing operation
2.1.5.22.2.1 Testing procedure
WARNING !
The test with 4000V (proof of modified separation in accordance with
DFS 400) is carried out exclusively during inspection of rewinding:
All additional repeat tests are carried out at a testing voltage of at most
2000V (risk of equipment damage).
Testing is always conducted to earth:
Testing voltage 50Hz Test time Notes
Stator winding
400Hz 2000V
(Repeat testing) 1 min Tested on the neutral point of the
winding
Output
(400Hz - cable) 2000V
(Repeat testing) 1 min Each phase is tested to earth
The testing voltage must be increased slowly and continuously until reaching full value.
Simultaneously, the discharge current must be observed in order to avoid damage to the
equipment, the test will be aborted in case of a disconnection (breakdown).
Warning: After testing, the stator winding must be discharged (risk of equipment damage
and personal injury).
Pinpoint the fault location, check for dirt and moisture, remedy the fault (clean or dry, if
necessary) before the test can be repeated.<
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2. MAINTENANCE
2.1.5.22.2.2 Measuring points
Test each of the three phases L1 / L2 / L3 (1) to earth (3).
Test the neutral point of the stator winding (2) to earth (3).
1
2.1.5.22.3 Evaluation and test determination
During the test, no breakdown may occur.
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