INSPECTION POINTS SCHEDULE:

TEST BENCH CONTROL

Rev: 24-02/21
No. INSPECTION POINTS ANNOTATION
1.1 Check the oil and coolant levels.
1.2 Remove the CP, CM enclosure covers and remove documentation from within the genset.
1.3 Remove the AVR cover and check that the terminals are correctly connected. Only if there is a reconnection or an optional
1.4 Remove the alternator cover and check that the terminals are correctly connected. Mandatory for power ≥ 250 kW
1.5 Remove the G.A.C. cover and check that the terminals are correctly connected. Only if there is G.A.C.
1.6 Check the data of the genset and all the optionals against the order header.
1.7 Check that the genset is in concordance with the external control panel: Note down the code on the order and the cabinet sticker Only if there is A.C. or C.C.
1.8 Check if you need any material such as a cover for the controller or a programming timer, and install them. Operation 30 and Comments
1.9 Adjust the circuit breaker, the differential and any other switches that require adjustment.
1.10 Check that the mono block has been correctly aligned: The fan is centred in its casing.
1.11 Check that all the bolts and clamps of the genset are properly secured.
1.12 Check that all the terminals of the control panels are correctly connected and secured.
2.1 Connect power wiring and any other needed auxiliary wiring. Wiring edge contact free
2.2 Connect the battery charger and check that the voltage is correct (12 or 24 V). Only if there is a battery charger
2.3 Activate emergency stop and connect the negative terminal of the battery.
2.4 Update the version of the control unit and load-modify the configuration of the control unit.
2.5 Enter the data of the Genset into the Sigma-Crestchic program.
IF GAS UNIT GO TO ANEX III
2.6 Load diesel oil and purge the system.
2.7 Start the genset up at no load and check the emergency stop and the normal stop.
2.8 Check the absence of any fluid loss and make sure the parameters of the control unit are correct.
IF FRECUENCY VARIATOR TAKE PICTURE
3.1 Adjust overspeed. Only for M1 and M6 control units
3.2 Adjust the engine speed until you achieve the desired frequency indicated on the order. (Mechanical governor or GAC) Margin of acceptance: +/-0.5 Hz
3.3 Regulate the voltage on the AVR potentiometer until you achieve the desired voltage indicated on the order. Margin of acceptance: +/-4 V
3.4 Check the direction of the rotation of the phases.
3.5 Check protection elements, alarms and J1939. Use ground effect meter (differential test)
IF RENTAL UK , MODIFY PARAMETERS AND EARTH LEAK RELAY TIMES
3.6 Check the external start-up and the disablement of the external start-up.
3.7 Adjust the current transformers to 0. Only for CEM and CEA control units
3.8 Enter load jumps and check margins of acceptance at 100% load. Check readings: KW, A, V, HZ, fp… Perform according to Annex 1
3.9 Readjust the frequency until you achieve rated values under 100% load. Only for mechanical governor
3.10 Check optionals: Distribution box, fuel transfer pump etc. fill auxiliar PPI if it needed
3.11 Check manual and automatic switching to mains failure. Check mains readings Mains failure: Mains and individual phase drop
3.12 IF Synchronism GO TO ANEX IV
3.13 Perform Test Perform according to Annex 2
4.1 Clear the history of alarms from the control unit and the ECU, reset the counters to zero and schedule maintenance.
4.2 Save the configuration of the control unit in the database with the serial number of the genset - cabinet.
4.3/4.3A Set the language of the control unit. (Leave negative battery disconnected)
4.4 Check that CAN-BUS remains at 60 ohms. (Add resistance or adjust switches in the control unit, as per the diagram) Check with PC disconnected
4.5 Attach whatever seals are necessary and close-seal those manholes that have been opened. Check CP front cover reassembly
IF DIRECT CONECTION TO ALTERNATOR CONNECTION TERMINAL , TAKE PICTURE
 IF GAS UNIT GO TO ANEX III
4.6 Leave the 3-way valve in "A" position (internal tank) Only if there is a 3-way valve
4.7 Clean any coolant and diesel that may have been spilt during the test.
4.8 Check that all documentation remains inside the genset.
 INSPECTION POINTS SCHEDULE:
TEST BENCH CONTROL

No. APPENDIX I: LOAD JUMPS AND ACCEPTANCE MARGINS ANNOTATION

Recommended load jumps: 0->30->70->100% For all gensets
Mandatory load jumps: 0->60% and 0->40->100% Only for Meccalte alternators
Acceptance margins at 100% load: 0-25 kW (1 kW) 25-200 kW (2 kW) 200-500 kW (3 kW) 500-2000 kW (5 kW) Power generator (acceptable deviation)
No. APPENDIX II: MANDATORY LOAD TEST ANNOTATION
Mandatory standard test: - Check that when performing the load test, the values obtained in the TEST PROTOCOL are within the intervals that correspond to the power,
Scheduled test with automatic jumps: 0->25->50->75->100% the Genset model, the load percentage and the predefined times.
(15 min) - Open the data menu to add the numeric data (model and series) and the technical data of the machine being tested (RPM, kW, voltage).
- Once the Genset is running and having made the appropriate adjustments, we proceed to apply load manually, with the up and down cursor of
the load and accepting or rejecting using the 0 (red) and I (green) buttons, to check the power.
Margin of acceptance al 100%: Check against test values - Record the standard Himoinsa test (PLAY icon)
0-25 kW = 1 kW - Record/save and then print the test, once the 5 automatic load jumps have been completed, as predefined in said test.
25-200 kW = 2 kW - Attach it to the order.
200-500 kW = 3 kW
500-2000 kW = 5 kW

Optional test: Test performed at the customer's request. Special test

Nº ANEX III: GAS GENSETS ANNOTATION

Check the type of gas required by the genset, NG or LPG. Also check design pressure for tests.
Check if there is any leakage in the connection between the genset and the supply pipe. Check also for leakings in the gas train. To check leaks
please use soapy water, sprayed over the joints that must be checked. If bubbles are detected, all of manual valves (in genset and test bench) will
be closed immediatly. Once we are sure there is no gas in the line, leakage will be repaired.
If during the test there is any smell of gas, Emergency STOP button will be pulsed inmediatly. This button is situated besides the control
Connect the genset to the correct gas pipe depending of type computer. After that all personal will abandone the room inmediatly. When STOP button is pulsed, gas supply is immediatly stopped by an
2.9
of gas and supply pressure. automatic solenoid valve. Nobody will return to the test room until several minutes and only if gas smell has disappeared.
Once the conditions are OK, manual valves will be closed and after that leaking must be detected and repaired. Check de joints and the
manometers.
Automatic solenoid valve only will be opened again when we will be completely sure that the leakage has been detected and repaired or in case
we need pressure to detect the problem, we will test part by part safely, opening once a time the valve needed and not the whole instalation.
Engine will not be started up until all the leakings will be repaired.
 During genset start-up, check proper function of double solenoid valve (or single, if installed). Check also valve checking system if it is installed.
Check manometer reaction during opening of the double solenoid valve (or single, if installed) and once genset is on regime.
Check if inlet and outlet pressure of the gas train (read manometers) are as expected. If not, proceed to regulate the pressure in the primary
pressure regulator (the first one close to the manual shut-off valve).
2.9A Check proper function of gas train
Check if logic of function of the gas train is working properly. Double solenoid valve will open only after crankin the engine a few seconds and
then, in normal stop, it will close before sending stop signal to the engine. If two start attempts are done without success, IT IS MANDATORY TO
MAKE AN STARTING ATTEMP WITH MANUAL VALVE CLOSED IN ORDER TO BE SURE THAT ANY AMOUNT OF GAS IS VENT OUT OF THE GAS TRAIN
AND ENGINE.
 INSPECTION POINTS SCHEDULE:
TEST BENCH CONTROL

Nº ANEX IV: Synchronism ANNOTATION

49 Step 3 of the PPI.
We disconnected the performance on the AVR.
Step 5 of the PPI in case of motors with speed control card.
Step 15 of the PPI in case of motors with can regulation (ECU).
We disconnected the performance on the engine speed.
Step 30 of the PPI
We connect the performance on the engine speed and proceed to the settings according to central.
We connect the performance on the AVR and proceed to the settings according to central
Note: The settings of the plants will follow the specifications of each manufacturer, manuals or training courses.
Standard frequency settings: the parallel control units must be adjusted to be able to raise and lower the frequency of the group from the
nominal at 2Hz (2.5Hz for DSE plants) and in an interval between 8 and 15 seconds, and must be a response curve similar to the FIG.1 graph
(VERY IMPORTANT AVOID OSCILLATIONS).
Standard voltage settings: the parallel plants must be adjusted to be able to raise and lower the voltage of the group relative to the nominal in X
volts [see voltage table] and in an interval between 8 and 20 seconds, it must be a response curve similar to the FIG.1 graph (VERY IMPORTANT
TO AVOID OSCILLATIONS).

50 Control cheking "• Check that the power cables are properly connected according to the sequence or direction of rotation.
• Check that the control units are all communicated and identify each other through the Can Bus.
• Start up a single device and allow it to close its switch so that there is voltage on the Bus.
• Verify that the other units detect voltage on the Bus in your control unit.
• When the equipment that is started has its switch closed, then start another unit and previously prevent its switch from closing (disconnecting
the undervoltage coil or the closing operation)
• Check that when the control unit of the equipment that has its switch open and its closure has been prevented is synchronized and gives the
order to close, the voltage between phase “U” of its group and phase “U” of the Bus Bar, is lower than 50v the lower this voltage the better.
Carry out this process in "V" and "W" with their respective bus voltages.
• If we have more than 2 machines repeat this in the following.
• Once this process has been carried out, we will stop the machine that is not authorized to close its switch. We will connect the maneuver that
prevented this operation and proceed to start it. "