Lister Petter alpha Series Service manual

P027-10623
lWA/lWX GenerAtinG Set
OperAtOrS' HAndbOOk
ORIGINAL INSTRUCTIONS
ALPHA SERIES

2
Statement of Indemnity
The information, specications, illustrations,
instructions and statements contained
within this publication are given with our
best intentions and are believed to be
correct at the time of going to press.
Our policy is one of continued development
and we reserve the right to amend any
tech nical information with or without prior
notice.
Whilst every effort is made to ensure the
accuracy of the particulars contained within
this publication, neither the Manufacturer,
the Distributor nor the Dealer shall in
any circumstances be held liable for any
inaccuracy or the consequences thereof.
The information given is subject to the
Company’s current Conditions of Tender
and Sale; is for the assistance of users; and
P027-10623
Copyright © Lister Petter Power Systems
Abbreviations
The following are the abbreviations used in Lister Petter Power Systems operators' handbooks.
is based upon results obtained from tests
carried out at the place of manufacture. This
Company does not guarantee that the same
results will be obtained elsewhere under
different conditions.
Parts that have not been approved by the
Lister Petter Power Systems organisation
cannot be relied upon for correct material,
dimensions or nish. The Company cannot
therefore be held responsible for any
damage arising from the use of such parts,
and the guarantee will be invalidated.
AC alternating current
AL battery-charge alternator
ASU automatic control module
BC battery charger
CCR charge circuit relay
CT1 current transformers
DC direct current
DCCB DC circuit breaker
DCS DC control switch
EPB emergency stop pushbutton
ETX engine temperature sender
F1 fuses
FCS fuel control solenoid
HP1 heater plug
HR heater relay
LED light-emitting diode
MC mains contactor
MCB AC circuit breaker
MOL mains-on-load lamp
OPS oil pressure switch
OPX oil pressure sender
PC plant contactor
POL plant-on-load lamp
SB starter battery
SM starter motor
SS starter solenoid

3
CONTENTS
Model designation ....................................................................... 4
1. Introduction and Precautions ................................................... 5
2. The Control Module ................................................................. 9
3. The Control System ............................................................... 19
4. Standard Electric Start Sets .................................................. 21
5. Automatic Mains Failure Sets ................................................ 23
6. Dummy Load ......................................................................... 25
7. Long Run Sets ....................................................................... 26
8. Routine Maintenance............................................................. 28
9. Troubleshooting ..................................................................... 28
10. Replacement Parts .............................................................. 29
Appendix 1. Installation and Commissioning ............................. 30
Appendix 2. List of Drawings ..................................................... 32

4
ALPHA SERIES LWA/LWX GENSET OPERATORS' HANDBOOK
Model Engine type r/min
LWA 10 LPW2 1500/1800
LWA 15 LPW3 1500/1800
LWA 20 LPW4 1500/1800
LWA 27 LPWT4 1500/1800
LWA 14 LPW2 3000/3600
LWA 22 LPW3 3000/3600
LWA 30 LPW4 3000/3600
LWA 41 LPWT4 3000
LWX 13 LPWX2 1500/1800
LWX 20 LPWX3 1500/1800
LWX 27 LPWX4 1500/1800
LWX 30 LPWXT4 1500/1800
MODEL DESIGNATION

5
ALPHA SERIES LWA/LWX GENSET OPERATORS' HANDBOOK
1. INTRODUCTION AND PRECAUTIONS
This handbook covers the operation and
routine maintenance of LWA generating
sets powered by Lister Petter Power
Systems Alpha LPW series engines in
the following versions:




There is a separate handbook for the
engine.
Some features and facilities of the
     
models, as indicated in the text. To
determine the version of generating
set that you are using refer to the serial
number stamped on the nameplate and
read section 1.1 Nameplates.
1.1 NAMEPLATES
There are nameplates on the generating
set, engine and alternator. They tell you
what each item or equipment can do.

the performance of the complete
generating set and its limits.
An example of a generating set serial
number is:
11 12345 G LPW4 22 6
which is interpreted as follows:
11...............Year of manufacture code
12345.............Consecutive number of
genset
G...............Lister Petter Power Systems
diesel genset




6......................Lister Petter Power
Systems alternator

serial number in the box below.
The engine nameplate defines the
capabilities of the engine.

maximum capabilities of the alternator

frequency, connection arrangement,
ambient temperature and conditions
shown.
Where there are differences between
the   
nameplate data should be used.
1. Alpha series LWA/LWX generating sets: acoustic set (left) and open set (right).

6
ALPHA SERIES LWA/LWX GENSET OPERATORS' HANDBOOK
1.2 SAFETY SYMBOLS
Take note of, and be familiar with, the
ISO 8999 symbols used by Lister Petter

1.3 CAUTIONS AND WARNINGS
When a diesel engine is being
serviced there are risks that must be
avoided. If you do not take proper
safety precautions you may be injured
or killed, or the product may be
damaged. Warning messages are
used throughout this publication to alert
you, as follows:
CAUTION
This caution draws attention to
special instructions or procedures
which, if not correctly followed, can
result in damage to, or destruction
of, equipment.
WARNING
A warning with this type of text draws
attention to special instructions or
procedures which, if not correctly
followed, can result in personal
injury.
WARNING
A WARNING SYMBOL WITH THIS
TYPE OF TEXT DRAWS ATTENTION
TO SPECIAL INSTRUCTIONS OR
PROCEDURES WHICH, IF NOT
CORRECTLY FOLLOWED, CAN
RESULT IN SEVERE PERSONAL
INJURY, OR LOSS OF LIFE.
1.4 GENERAL PRECAUTIONS
WARNING
Before your generating set can be
used it must be correctly installed by
qualied engineers. See Appendix:
Installation and Commissioning.
1.2. The ISO 8999 symbols used by Lister Petter Power Systems
6
ALPHA SERIES LWA/LWX GENSET OPERATORS' HANDBOOK
1.2 SAFETY SYMBOLS
Take note of, and be familiar with,
the ISO 8999 symbols used by Lister
Petter, shown in fi gure 1.2.
1.3 CAUTIONS AND WARNINGS
When a diesel engine is being
serviced there are risks that must be
avoided. If you do not take proper
safety precautions you may be injured
or killed, or the product may be
damaged. Warning messages are
used throughout this publication to alert
you, as follows:
CAUTION
This caution draws attention to
special instructions or procedures
which, if not correctly followed, can
result in damage to, or destruction
of, equipment.
1.2. The ISO 8999 symbols used by Lister Petter
WARNING
A warning with this type of text draws
attention to special instructions or
procedures which, if not correctly
followed, can result in personal
injury.
WARNING
A WARNING SYMBOL WITH THIS
TYPE OF TEXT DRAWS ATTENTION
TO SPECIAL INSTRUCTIONS OR
PROCEDURES WHICH, IF NOT
CORRECTLY FOLLOWED, CAN
RESULT IN SEVERE PERSONAL
INJURY, OR LOSS OF LIFE.
1.4 GENERAL PRECAUTIONS
WARNING
Before your generating set can be
used it must be correctly installed by
qualifi ed engineers. See Appendix:
Installation and Commissioning.

7
ALPHA SERIES LWA/LWX GENSET OPERATORS' HANDBOOK
WARNING
Untrained people must not start or
operate any diesel generating set.
It is dangerous. Operators must
read and follow the instructions
contained in this manual as well as
the engine and alternator handbooks
supplied.
      
intervals, check the fuel, lubricating
  
refer to the Engine Operators'
Handbook.
When the Set is Running
 
  not touch any electrical
connections.
 not run the set with any covers
or guards removed or damaged.
 not smoke near the generating
set.
  not touch any part of the
exhaust system.
 not breathe exhaust fumes.
When the Set is at Rest
 not touch the exhaust system
immediately after the engine has
stopped. It will still be very hot.
  not attempt any maintenance
or adjustments unless you have the

See 7. Routine Maintenance and read
the precautions in this chapter.
  not work on the set before
disconnecting the starter battery.
Always disconnect the negative
    
terminal last and use insulated tools.
    
control or contactor cubicles they
must
supplies.
1.5 PREPARING THE BATTERY
If batteries are supplied they can be
    
     
charged batteries can normally be used
     
acid without initial charging.
WARNING
Battery electrolyte is corrosive.
Batteries must be handled with care,
and protective clothing should be
worn.
Preparing a Dry-Charged Battery
The following procedure should be

sealed charge.
1.Remove the vent plugs.

with sulphuric acid in accordance

1up
to the maximum acid level mark, or
15 mm above upper edge of plates.
The temperature of the battery and


      
minutes, tilt slightly several times
and top up with acid to correct level
if required.
4.Clean and dry the outside of the
battery. Thinly coat the terminals

plugs.
5.Clean the plant connections, thinly
coat with petroleum jelly and connect
the battery, making sure that the
positive cable is connected to the
positive terminal and the negative
terminal cable to the negative
terminal.
If the battery does not provide an

8
ALPHA SERIES LWA/LWX GENSET OPERATORS' HANDBOOK
adequate starting performance then it
must be charged.
Charging a Battery
1.Use a charge rate of approximately
  

battery is fully charged when the acid
density and charging voltage have
stopped rising for two hours.
2.After charging check the acid level
and if required top up with distilled
water to the maximum acid level
mark, or 15 mm above the upper
edge of the separators.
3.The battery should be checked within
      
gravity is uniform throughout the

   1. If this is
not the case then the battery must
be recharged as in steps 1 and 2
above.
Care of Batteries
 
long periods in the discharged state.
Always recharge the battery promptly.
      
acid at regular intervals and adjust by

CAUTION
Do not use impure water or so-called
'improving agents'.
    
and dry. Inspect the terminals, and if
necessary clean them and coat them
with petroleum jelly.
 
circuit the cells. Take special care when
using spanners near a battery.
WARNING
Never allow battery cells to become
short-circuited by metal objects.
Severe burns and electric shock
can result.
1.6 USING THIS HANDBOOK


It is recommended that the individual
steps contained in the various
maintenance or repair operations are
followed in the sequence in which they
appear.
When a diesel engine is operating or
being overhauled there are a number
of associated practices which may
lead to personal injury or product
damage. Your attention is drawn to the
caution and warning messages used
   

Work should be carried out only if the
necessary hand and service tools
are available. When the user has

to carry out adjustments, maintenance
or repairs, this work should not be
attempted.
Where accurate measurements
or torque values are required they
can only be made using calibrated
instruments.
WARNING
Under no circumstances should
makeshift tools or equipment be
used as their use may adversely
affect safe working procedures and
operation.
1. Tropical rates apply to those countries or areas where the average temperature of any


9
ALPHA SERIES LWA/LWX GENSET OPERATORS' HANDBOOK
2. THE CONTROL MODULE
2.1 THE CONTROL MODULE
The control module is used to start and
stop the engine, either manually or
automatically and to indicate operational
status and fault conditions.
    

     
facilities.
It monitors various engine and
generator parameters. Under out
of limit conditions it will either show
a warning alarm or shut the engine
   

Figure 2.1 Typical Control Module

10
ALPHA SERIES LWA/LWX GENSET OPERATORS' HANDBOOK
2.2 CONTROLS AND INDICATORS
Figure 2.1 Electric Start Control Module
Figure 2.2 Typical AMF Control Module

11
ALPHA SERIES LWA/LWX GENSET OPERATORS' HANDBOOK

by the icon.
Code Function
1 Automatic mode selection
2 Manual mode selection
3 Start under manual control
4 Stop/Reset - this will clear any alarm condition or stop the engine if it is running
5 Alarm mute/Lamp test button
6 Display scroll buttons - used to step through measured parameters
7 Generator available LED
8 Connect to load LED
9 Main Status LCD display
10 Congurable alarms indicators
11 Transfer to generator button
12 Open generator button (ES), transfer to mains (AMF)
13 Connect to mains (LED)
14 Test mode button
15 Mains available LED
2.3 VIEWING THE
INSTRUMENTS
At power up, the display will show
the software version and then show
the default screen, which will display
Generator Voltage.
It is possible to scroll to display the
different pages of information by

page buttons .
The contents of each information page
is shown below.
Once selected the page will remain on

a different page, or after an extended
period of inactivity, the module will
revert to the status display.


Oil Pressure
Coolant Temperature

Run Time




Generator Current
Generator Load

12
ALPHA SERIES LWA/LWX GENSET OPERATORS' HANDBOOK
Generator kVA



Generator Phase Sequence




Not all parameters are available on all
of the control modules.
2.4 EVENT LOG
Press the left or right scroll button to
gain access. Pressing the down
button on this display will move to the
previous event, the event log entry at
position 1 being the most recent. On
moving from the instrumentation to
the event log the unit will display the
most recent entry. A number in the
bottom left indicates the event log entry
currently displayed.
The number of event log entries varies
on control modules. When the event
log is displayed the icon in the alarm
icon area indicates the alarm type at
that position of the event log. The
hours run at the time of the alarm
shows in the instrumentation area. The
bottom right icon indicates the current
mode as normal.

     
may vary depending on control
module.
Controls
Stop / Reset
This button places the module into its Stop/Reset mode. This will clear any alarm
conditions for which the triggering criteria have been removed. If the engine is
running and the module is in Stop mode, the module will automatically instruct
the changeover device to unload the generator ('Close Generator' becomes
inactive (if used)). The fuel supply de-energises and the engine comes to a
standstill. Should a remote start signal be present while operating in this
mode, a remote start will not occur.
Figure 2.4 Example of Auxiliary Input Shutdown Alarm

13
ALPHA SERIES LWA/LWX GENSET OPERATORS' HANDBOOK
Manual
This mode allows manual control of the generator functions. Once in Manual
mode the module will respond to the start button, start the engine, and run off
load. If the engine is running off-load in the Manual mode and a remote start
signal becomes present, the module will automatically instruct the changeover
device to place the generator on load ('Close Generator' becomes active (if
used)). Upon removal of the remote start signal, the generator remains on
load until either selection of the 'STOP/RESET' or 'AUTO' modes.
Auto
This button places the module into its 'Automatic' mode. This mode allows
the module to control the function of the generator automatically. The module will
monitor the remote start input and mains supply status and once a start request is
made, the set will be automatically started and placed on load.
Upon removal of the starting signal, the module will automatically transfer the
load from the generator and shut the set down observing the stop delay timer and
cooling timer as necessary. The module will then await the next start event.
2.4.1 TEST (DSE7x20 only)
This button places the module into its 'Test' mode. This allows an on load test
of the generator. Once in Test mode the module will respond to the start
button, start the engine, and run on load.
2.4.2 START
This button is only active in STOP/RESET or MANUAL mode. Pressing
this button in manual or test mode will start the engine and run off load (manual)
or on load (test).
Pressing this button in STOP/RESET mode will turn on the CAN engine ECU
(when correctly congured and tted to a compatible engine ECU)
Mute / Lamp Test
This button silences the audible alarm if it is sounding and illuminates all of the
LEDs as a lamp test feature.
Transfer to generator
Allows the operator to transfer the load to the generator (when in Manual mode only)
Open generator (DSE7x20 only)
Allows the operator to open the generator (when in Manual mode only)
Transfer to mains (DSE7x20 only)
Allows the operator to transfer the load to the mains (when in Manual mode only)
Menu navigation
Used for navigating the instrumentation, event log and conguration screens.
For further details, please see the more detailed description of these items
elsewhere in this manual.

14
ALPHA SERIES LWA/LWX GENSET OPERATORS' HANDBOOK
Icon Graphic Details
Stopped Appears when the engine is at rest and the unit is in stop mode.
Auto Appears when the engine is at rest and the unit is in auto mode.
Manual Appears when the engine is at rest and the unit is in manual
mode.
Timer
Animation Appearswhenatimerisactive,forexamplecrankingtime,crankrestetc.
Running
Animation
Appears when the engine is running, and all timers have expired,
either on or off load. The animation rate is reduced when running
in idle mode.
Front Panel
Editor Appears when the unit is in the front panel editor.
2.5 MODULE DISPLAY
The display is segmented into areas for instrumentation, units, alarm icons and
various other icons.
Inst. Icon Instrumentation Units Alarm
Icon
Active
cong
event
index
Instrumentation Units
Mode
Icon
Instrumentation Units
2.5.1 Display Example
This example shows Generator Volts as shown by the Generator symbol.
Figure 2.5.1 Display Example
2.5.2 Mode Icon
An icon is displayed in the mode icon area of the display to indicate what mode
the unit is currently in.

15
ALPHA SERIES LWA/LWX GENSET OPERATORS' HANDBOOK
2.5.3 Auto Run Icon
When the engine is running in AUTO mode, an icon is displayed to indicate the
reason for the set being run.
Auto Run Reason Icon
Remote Start Input ►
Low battery run
Scheduled run
Mains failure (7x20 only)
2.5.4 Instrumentation Icons
When displaying instrumentation a small icon is displayed in the instrumentation
icon area to indicate what value is currently being displayed.
Icon Graphic Details
Generator Used for generator voltage and generator
frequency
Mains Used for mains voltages and mains frequency
Engine Speed Engine speed instrumentation screen
Hours Run Hours run instrumentation screen
Battery Voltage Battery voltage instrumentation screen
Engine Temperature Coolant temperature instrumentation screen
Oil Pressure Oil pressure instrumentation screen
Flexible sensor Flexible sensor instrumentation screen
Event Log Appears when the event log is being displayed
Unit time Current time held in the unit
Scheduler setting The current value of the scheduler run time and
duration
Generator Current Generator current instrumentation screen

16
ALPHA SERIES LWA/LWX GENSET OPERATORS' HANDBOOK
2.6 PROTECTIONS
      
display will jump from the ‘Information
page’ to display the Alarm Page. In

will display the appropriate icon. If a
shutdown then occurs, the module
will again display the appropriate icon,

2.7 WARNING ALARMS
   
conditions and do not affect the
operation of the generator system, they
serve to draw the operators attention
to an undesirable condition.
       
will jump to the alarms page, and
scroll through all active warnings and
shutdowns.

the fault condition is removed.
Display Reason
Battery High Voltage
The DC supply has risen above the high volts
setting level for the duration of the high battery volts
timer.
Battery Low Voltage The DC supply has fallen below the low volts setting
level for the duration of the low battery volts timer
Charge Alternator Failure The auxiliary charge alternator voltage is low as
measured from the W/L terminal.
Digital Input A-D Auxiliary Digital inputs can be user congured as
Digital inputs and will display the relevant icon.
Analogue Input A-C Auxiliary Analogue inputs can be user congured as
Digital inputs and will display the relevant icon.
Fail to Stop
The module has detected a condition that indicates
that the engine is running when it has been
instructed to stop.
NOTE:
‘Fail to Stop’ could indicate a faulty oil pressure
sensor - If engine is at rest check oil sensor wiring
and conguration.
Generator High Voltage
Warning
The generator output voltage has risen above the
pre-set prealarm setting.
Generator Low Voltage
Warning
The generator output voltage has fallen below the
pre-set prealarm setting after the Safety On timer
has expired.
High Coolant Temperature
Warning
The module detects that the engine coolant
temperature has exceeded the high engine
temperature pre-alarm setting level after the Safety
On timer has expired

17
ALPHA SERIES LWA/LWX GENSET OPERATORS' HANDBOOK
Low Oil Pressure Warning
The module detects that the engine oil pressure has
fallen below the low oil pressure pre-alarm setting
level after the Safety On timer has expired.
Low Fuel Level The module detects that the fuel level is below the
congured setting.
Over Frequency Warning The generator output frequency has risen above the
pre-set prealarm setting.
Over Speed Warning The engine speed has risen above the overspeed
pre alarm setting.
Under Frequency Warning
The generator output frequency has fallen below the
pre-set prealarm setting after the Safety On timer
has expired.
Under Speed Warning The engine speed has fallen below the underspeed
pre alarm setting.
Flexible Sensor The exible sensor warning alarm has been
triggered.
2.8 SHUTDOWN ALARMS
Shutdowns are latching alarms and stop the Generator. Clear the alarm and
 to reset the module.
Display Reason
Digital Input A-D Auxiliary Digital inputs can be user congured as Digital
inputs and will display the relevant icon.
Analogue Input A-C Auxiliary Analogue inputs can be user congured as Digital
inputs and will display the relevant icon.
Emergency Stop
The emergency stop button has been depressed. This is a
failsafe (normally closed to battery negative) input and will
immediately stop the set should the signal be removed.
NOTE:
The Emergency Stop Negative signal must be present
otherwise the unit will shutdown.
Fail to Start The engine has not red after the preset number of start
attempts.
Generator High Voltage
Shutdown The generator output voltage has risen above the preset level.
Generator Low Voltage
Shutdown The generator output voltage has fallen below the preset level.
High Coolant
Temperature Shutdown
The module detects that the engine coolant temperature has
exceeded the high engine temperature shutdown setting after
the Safety On timer has expired.

18
ALPHA SERIES LWA/LWX GENSET OPERATORS' HANDBOOK
Low Oil Pressure
Shutdown
The engine oil pressure has fallen below the low oil pressure
trip setting level after the Safety On timer has expired.
Low Fuel Level The module detects that the fuel level is below the congured
setting.
Over Frequency
Shutdown Thegeneratoroutputfrequency hasrisen abovethepresetlevel.
Over Speed Shutdown The engine speed has exceeded the pre-set trip.
Under Frequency
Shutdown Thegeneratoroutputfrequencyhasfallenbelowthepresetlevel.
Under Speed Shutdown The engine speed has fallen below the pre-set trip after the
Safety On timer has expired.
Temperature Sensor
Open Circuit Temperature sensor has been detected as being open circuit.
Oil Pressure Sensor
Open Circuit Oil pressure sensor has been detected as being open circuit.
Flexible Sensor The exible sensor warning alarm has been triggered.
Note:
When the fault condition has been rectied press the stop/reset button to reset the module.

19
ALPHA SERIES LWA/LWX GENSET OPERATORS' HANDBOOK
3. THE CONTROL SYSTEM
The generating set is governed by the
Figure 3.1
of which is described in 4. Electric Start
Sets and 5. Automatic Mains Failure
Sets. Automatic mains failure sets have

transfer cubicle.
The principal element in the control
system is the Figure
2.1 or 2.2
3.1 CONTROL SYSTEM
FEATURES
   
features:

     


Figure 3.2 AMF Control Cubicle
19
ALPHA SERIES LWA/LWX GENSET OPERATORS' HANDBOOK
3. THE CONTROL SYSTEM
The generating set is governed by the
control panel (Figure 3.1), the operation
of which is described in 4. Electric Start
Sets and 5. Automatic Mains Failure
Sets. Automatic mains failure sets have
an additional wall-mounted automatic
transfer cubicle.
The principal element in the control
system is the control module (Figure
2.1 or 2.2).
3.1 CONTROL SYSTEM
FEATURES
The set-mounted control system
features:
• Automatic engine control module
• Emergency stop button (open sets
only)
• DC control switch
EMERGENCY STOP BUTTON
(OPEN SETS ONLY)
CONTROL MODULE AC CIRCUIT BREAKER
DC CONTROL SWITCH DC CIRCUIT BREAKER
Figure 3.1 Control Cubicle
Figure 3.2 AMF Control Cubicle
EMERGENCY STOP BUTTON
(OPEN SETS ONLY) INDICATOR LAMPS
Figure 3.1 Control Cubicle
19
ALPHA SERIES LWA/LWX GENSET OPERATORS' HANDBOOK
3. THE CONTROL SYSTEM
The generating set is governed by the
control panel (Figure 3.1), the operation
of which is described in 4. Electric Start
Sets and 5. Automatic Mains Failure
Sets. Automatic mains failure sets have
an additional wall-mounted automatic
transfer cubicle.
The principal element in the control
system is the control module (Figure
2.1 or 2.2).
3.1 CONTROL SYSTEM
FEATURES
The set-mounted control system
features:
• Automatic engine control module
• Emergency stop button (open sets
only)
• DC control switch
EMERGENCY STOP BUTTON
(OPEN SETS ONLY)
CONTROL MODULE AC CIRCUIT BREAKER
DC CONTROL SWITCH DC CIRCUIT BREAKER
Figure 3.1 Control Cubicle
Figure 3.2 AMF Control Cubicle
EMERGENCY STOP BUTTON
(OPEN SETS ONLY) INDICATOR LAMPS

20
ALPHA SERIES LWA/LWX GENSET OPERATORS' HANDBOOK

AC circuit breaker
fuses
transformers
     
following remote input and output
circuits:
Emergency stop
Common alarm
Control contact input
Load transfer signal
• 
optional on electric start.
3.2 THE CONTROL MODULE
The control module is used to start
and stop the engine, either manually
or automatically, and to indicate
operational status and fault conditions.
  
given in the following two chapters.
3.2.1 Controls and Indicators
The controls and indicators are
illustrated and labelled in Figure 3.1 and
3.2. In both electric start and automatic
mains failure sets there is a choice
between manual mode and automatic
mode      