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LWX Genset Operators Handbook
LWX Genset Operators Handbook
LWX Genset Operators Handbook
P027-10623
Abbreviations
The following are the abbreviations used in Lister Petter Power Systems operators' handbooks.
Statement of Indemnity
The information, specifications, illustrations, is based upon results obtained from tests
instructions and statements contained carried out at the place of manufacture. This
within this publication are given with our Company does not guarantee that the same
best intentions and are believed to be results will be obtained elsewhere under
correct at the time of going to press. different conditions.
Our policy is one of continued development Parts that have not been approved by the
and we reserve the right to amend any Lister Petter Power Systems organisation
technical information with or without prior cannot be relied upon for correct material,
notice. dimensions or finish. The Company cannot
Whilst every effort is made to ensure the therefore be held responsible for any
accuracy of the particulars contained within damage arising from the use of such parts,
this publication, neither the Manufacturer, and the guarantee will be invalidated.
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 P027-10623
and Sale; is for the assistance of users; and Copyright © Lister Petter Power Systems
2
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
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Alpha SERIES LWA/LWX genset operators' handbook
Model designation
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
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Alpha SERIES LWA/LWX genset operators' handbook
1. Alpha series LWA/LWX generating sets: acoustic set (left) and open set (right).
5
ALPHA
Alpha SERIES
SERIES LWA/LWX
LWA/LWX GENSET
genset OPERATORS'
operators' HANDBOOK
handbook
1.2. The1.2.
ISOThe ISO
8999 8999 symbols
symbols used byused
ListerbyPetter
ListerPower
PetterSystems
1.2
1.2 SAFETY
Safety SYMBOLS
Symbols WARNING
Take note of,
Take note of,and
andbebe familiar
familiar with,
with, the A
Awarning
warning with
with this
this type
type of
of text
text draws
draws
the ISO 8999 symbols used by Lister
ISO 8999 symbols used by Lister Petter attention
attention to
to special
special instructions
instructions oror
Petter,
Power shown in fishown
Systems, gure 1.2.
in figure 1.2. procedures
procedures which,
which, if if not
not correctly
correctly
followed,
followed, can
can result
result inin personal
personal
1.3
1.3 CAUTIONS
Cautions AND
and WARNINGS
Warnings injury.
injury.
When
When aa diesel
diesel engine
engine is is being
being
serviced
serviced there
there are
are risks
risks that
that must
must bebe
WARNING
avoided. A
A WARNING
WARNING SYMBOL
SYMBOL WITH
WITH THIS
THIS
avoided. IfIf you
you do
do not
not take
take proper
proper TYPE
safety TYPE OF
OF TEXT
TEXT DRAWS
DRAWS ATTENTION
ATTENTION
safety precautions
precautions you
you may
may bebe injured
injured TO
or TO SPECIAL
SPECIAL INSTRUCTIONS
INSTRUCTIONS OR OR
or killed,
killed, oror the
the product
product maymay be be PROCE
PROCEDURES
D URES WHICH,
WHICH, IF IF NOT
NOT
damaged.
damaged. Warning
Warning messages
messages are are CORRECTLY
correctly FOLLOWED,
followed, CAN can
used
used throughout
throughout this
this publication
publication to
to alert
alert RESULT
RESULT ININ SEVERE
SEVERE PERSONAL
PERSONAL
you,
you, as
as follows:
follows: INJURY,
INJURY, OR
OR LOSS
LOSS OF
OF LIFE.
LIFE.
CAUTION 1.4
1.4 GENERAL
General PRECAUTIONS
Precautions
This
This caution
caution draws
draws attention
attention to
to
special
special instructions
instructions oror procedures
procedures WARNING
which,
which, ifif not
not correctly
correctly followed,
followed, can
can Before
Before your
your generating
generating set
set can
can be
be
result
result in
in damage
damage to,
to, or
or destruction
destruction used
used itit must
must be
be correctly
correctly installed
installed by
by
of,
of, equipment.
equipment. qualifi ed engineers.
qualified engineers. See
See Appendix:
Appendix:
Installation
Installation and
and Commissioning.
Commissioning.
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Alpha SERIES LWA/LWX genset operators' handbook
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Alpha SERIES LWA/LWX genset operators' handbook
1. Tropical rates apply to those countries or areas where the average temperature of any
month of the year exceeds 27°C (80°F).
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Alpha SERIES LWA/LWX genset operators' handbook
The control module is used to start and It monitors various engine and
stop the engine, either manually or generator parameters. Under out
automatically and to indicate operational of limit conditions it will either show
status and fault conditions. a warning alarm or shut the engine
Front panel mounted push buttons down, indicated by a LCD symbol or
provide Automatic, Manual, Start, Stop/ LED display.
Reset, Lamp Test and Display Scroll
facilities.
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Alpha SERIES LWA/LWX genset operators' handbook
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Alpha SERIES LWA/LWX genset operators' handbook
The LED display shows the selected parameter code and function as indicated
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 Configurable 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
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Alpha SERIES LWA/LWX genset operators' handbook
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.
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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 configured and fitted 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)
Menu navigation
Used for navigating the instrumentation, event log and configuration screens.
For further details, please see the more detailed description of these items
elsewhere in this manual.
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Alpha SERIES LWA/LWX genset operators' handbook
Auto Appears when the engine is at rest and the unit is in auto mode.
Appears when the engine is at rest and the unit is in manual
Manual
mode.
Timer
Appears when a timer is active, for example cranking time, crank rest etc.
Animation
Appears when the engine is running, and all timers have expired,
Running
either on or off load. The animation rate is reduced when running
Animation
in idle mode.
Front Panel
Appears when the unit is in the front panel editor.
Editor
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Alpha SERIES LWA/LWX genset operators' handbook
Scheduled run
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Alpha SERIES LWA/LWX genset operators' handbook
2.6 PROTECTIONS
When an alarm is present the LCD will display the appropriate icon. If a
display will jump from the ‘Information shutdown then occurs, the module
page’ to display the Alarm Page. In will again display the appropriate icon,
the event of a warning alarm, the LCD flashing.
Display Reason
The DC supply has risen above the high volts
Battery High Voltage setting level for the duration of the high battery volts
timer.
The DC supply has fallen below the low volts setting
Battery Low Voltage
level for the duration of the low battery volts timer
The auxiliary charge alternator voltage is low as
Charge Alternator Failure
measured from the W/L terminal.
Auxiliary Digital inputs can be user configured as
Digital Input A-D
Digital inputs and will display the relevant icon.
Auxiliary Analogue inputs can be user configured as
Analogue Input A-C
Digital inputs and will display the relevant icon.
The module has detected a condition that indicates
that the engine is running when it has been
instructed to stop.
Fail to Stop NOTE:
‘Fail to Stop’ could indicate a faulty oil pressure
sensor - If engine is at rest check oil sensor wiring
and configuration.
Generator High Voltage The generator output voltage has risen above the
Warning pre-set prealarm setting.
The generator output voltage has fallen below the
Generator Low Voltage
pre-set prealarm setting after the Safety On timer
Warning
has expired.
The module detects that the engine coolant
High Coolant Temperature temperature has exceeded the high engine
Warning temperature pre-alarm setting level after the Safety
On timer has expired
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Alpha SERIES LWA/LWX genset operators' handbook
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Alpha SERIES LWA/LWX genset operators' handbook
Low Oil Pressure The engine oil pressure has fallen below the low oil pressure
Shutdown trip setting level after the Safety On timer has expired.
The module detects that the fuel level is below the configured
Low Fuel Level
setting.
Over Frequency
The generator output frequency has risen above the preset level.
Shutdown
Over Speed Shutdown The engine speed has exceeded the pre-set trip.
Under Frequency
The generator output frequency has fallen below the preset level.
Shutdown
The engine speed has fallen below the pre-set trip after the
Under Speed Shutdown
Safety On timer has expired.
Temperature Sensor
Temperature sensor has been detected as being open circuit.
Open Circuit
Oil Pressure Sensor
Oil pressure sensor has been detected as being open circuit.
Open Circuit
Flexible Sensor The flexible sensor warning alarm has been triggered.
Note:
When the fault condition has been rectified press the stop/reset button to reset the module.
18
ALPHA SERIES LWA/LWX GENSET
ALPHA SERIES OPERATORS'
GENSET operators' HANDBOOK
OPERATORS' handbook
HANDBOOK
Alpha LWA/LWX genset
3. THE
3. The CONTROL
THE Control SYSTEM
CONTROL System
SYSTEM
CONTROL MODULE EMERGENCY STOP BUTTON AC CIRCUIT BREAKER
CONTROL MODULE EMERGENCY STOP
(OPEN SETS BUTTON
ONLY) AC CIRCUIT BREAKER
(OPEN SETS ONLY)
The generating
The generating set
set is
is governed
governed byby the
the 3.1 Control
3.1 CONTROL SYSTEM
CONTROL System
SYSTEM
control panel (Figure 3.1), the operation FEATURES
control panel (Figure 3.1), the operation FEATURES
Features
of which is described in 4. Electric Start
of which is described in 4. Electric Start The set-mounted control system
and 5.
Sets and 5. Automatic
Automatic Mains
Mains Failure
Failure The set-mounted control system
Sets features:
Sets. Automatic mains failure sets have features:
Sets. Automatic mains failure sets have •• Automatic
Automatic engine
engine control
control module
module
an additional wall-mounted automatic
an additional wall-mounted automatic • Emergency stop button (open sets
transfer cubicle. • Emergency stop button (open sets
transfer cubicle. only)
The only)
The principal
principal element
element inin the
the control
control
system is the control module (Figure •• DC
DC control
control switch
switch
system is the control module (Figure
2.1 or 2.2).
2.1 or 2.2).
19
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Alpha SERIES LWA/LWX genset operators' handbook
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Alpha SERIES LWA/LWX genset operators' handbook
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Alpha SERIES LWA/LWX genset operators' handbook
4.3.4 Alarm and Fault 4.When the set is ready, the generator
Conditions available LED illuminates and the
During the running period the engine 12V DC signal becomes available at
control module monitors the set for the B7 and B8. At this point the load can
alarm and shutdown faults detailed in be connected to the generating set.
2.6 Protections.
A 12V DC signal for remote indication 4.4.2 Monitoring
of an alarm can be taken across Electrical outputs and engine conditions
terminals B3(+) and B4(-). can be monitored on the control module
display by successive operation of
4.3.5 AC Circuit Breaker Trip the scroll button; refer to Figure 2.1
If the AC circuit breaker trips, investigate Control Module.
and rectify the cause, then wait two
minutes before re-closing it. The set 4.4.3 Stopping
will continue to run. 1.Disconnect the load from the
generating set.
4.4 Automatic Control 2.Open the remote contact.
3.After a one-minute cooling-down
This section describes the automatic
period the engine will shut down and
control and operation of the standard
come to rest.
generating set.
4.If the generating set is not going to
A remote switch or contact has to be
be used again for more than eight
connected across terminals B5 and
hours it is recommended that the
B6. The contact is arranged to close
DC control switch is turned to the
to start and run the set, and to open
off position.
to stop it.
A 12v DC signal for remote indication
of plant available (load transfer) can
4.4.4 Alarm and Fault
be taken across terminals B7(+) and Conditions
B8(-). During the running period the engine
control module monitors the set for the
alarm and shutdown faults detailed in
4.4.1 Starting 2.6 Protections.
1.Turn the DC control switch to the
A 12v DC signal for remote indication of
on position.
an alarm can be taken across terminals
2.Press the automatic mode button
B3(+) and B4(-).
on the control module. An LED
indicator by the side of the button
will illuminate. 4.4.5 AC Circuit Breaker Trip
3.On closure of the remote contact If the AC circuit breaker trips, investigate
and after a short delay, plus a further and rectify the cause, then wait two
ten-second pre-heat period (LPWT4 minutes before re-closing it. The set
only), the set will start and run up to will continue to run.
speed and voltage.
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Alpha SERIES LWA/LWX genset operators' handbook
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Alpha SERIES LWA/LWX genset operators' handbook
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Alpha SERIES LWA/LWX genset operators' handbook
6. Dummy Load
The Dummy load comprises of a when the dummy load is required. If the
number of resistive elements, to load level is below the 'trip' setting for
suit the configuration of the genset, the duration of the 'trip delay' (initially
mounted in front of the radiator and set to 10 minutes) then the dummy load
a control system to turn the load on control is activated.
and off. The control system is via the If the load level rises above the 'return'
control module fitted in the genset setting for the duration of the 'return
control panel. delay' (initially set to 1 second) then
When the genset is started, the Control the dummy load is deactivated and the
module will monitor the load and control timer is reset.
25
Alpha SERIES LWA/LWX genset operators' handbook
ALPHA SERIES LWA/LWX GENSET OPERATORS' HANDBOOK
7.
7. Long
LONG Run
RUN Sets
SETS
726 EXHAUST
UEL FILTER
7 AIR
CLEANER FUEL CONTROL
RADIATOR
EXPANSION BOTTLE SOLENOID LUB OIL
AUXILIARY FILTER
CUBICLE
(E ECTRIC START O ENSET)
990
ANTI-VIBRATION MOUNTS
1400
7.1
7.1 Features
FEATURES •• Heavy
Heavy duty
Duty fuel
oil fiagglomerator
lter
Long •• Heavy
7” Air Cleaner filter
Duty oil
Long run run sets
sets have
have thethe following
following •• 7” Air Performance
Cleaner
standard features:
standard features: High Oil bypass filter
•• Available •• High Performance Oil bypass filter
Available in in either
either Electric
Electric start
start and
and Radiator
•• Radiator
with expansion
with expansion
tank bottle
tank bottle
AMF control systems.
AMF control systems. Bulk Head fittings for “external” fuel
•• Fabricated •supply
Bulk Head fittings for “external” fuel
Fabricated steelsteel base
base frame
frame with
with anti
anti supply
vibration
vibration mountings
mountings
•• Lister
ListerPetter
Petterwater
Power Systems
cooled enginewater
close 7.2 LONG RUN SETS
cooled 7.2 Long Run Sets
coupled to a brushless alternator to a
engine close coupled COMMISIONING
brushless alternator Commisioning
• 55 litre steel fabricated lube oil tank To be read in conjunction with
•(in55place
litre steel fabricated
of standard fuel lube
tank)oil tank To be read1inofconjunction
Appendix with
this handbook
(in place of standard
• Starter battery and leads fuel tank) Appendix 1 of this handbook
•• Starter
12 volt battery and leads
starter motor and solenoid 7.2.1
•• 12 volt starter motor
12 volt charging alternatorand solenoid 7.2.1
Ensure the 55 litre lube tank contains
•• Inspection
12 volt charging alternator Ensure
cover for lube tank for ease 20 litresthe 55 litre lube
of running oil. tank contains
•ofInspection cover
access and cleaning for lube tank for ease 20 litres of running oil.
Generator sets manufactured at Lister
of accessdutyandfuel
cleaning Generator
• Heavy agglomerator Petter will sets
come manufactured
as standard at Lister
with 20
26
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Alpha SERIES LWA/LWX genset operators' handbook
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Alpha SERIES LWA/LWX genset operators' handbook
8. Routine Maintenance
WARNING 8.2 Diesel Engine
Only qualified engineers should Refer to the Engine Operators'
attempt any maintenance or Handbook, P027-08270, supplied
adjustments. Refer to 1.2 Safety with the set, for details of routine
Symbols, 1.4 Safety Precautions maintenance to be carried out after
and the equivalent sections of your prescribed periods.
engine Operators' Handbook.
8.3 Alternator
WARNING No routine maintenance by the user is
Do not work on the set before required, nor should it be attempted.
disconnecting the starter battery.
The alternator manufacturer's manual
Always disconnect the negative
is provided for use only by specialised
terminal first, reconnect the negative
terminal last and use insulated tools. personnel employed to undertake
maintenance work on the alternator.
8.1 General
On a regular basis, check and 8.4 Battery
replenish if necessary: To keep terminals and connections free
• The fuel level; from corrosion, coat with petroleum
• The lubricating oil level; jelly or other suitable protective.
• The coolant level. Also refer to 1.5 Preparing the Battery.
WARNING
Do not check the coolant level when WARNING
the engine is hot, or running. Battery electrolyte is corrosive and
must not be splashed on your skin.
Refer to the engine Operators' Batteries must be handled with care,
Handbook, P027-08270, supplied and protective clothing should be
with the set, for capacities and worn.
specifications.
9. Troubleshooting
9.2 Alternator
WARNING The alternator manual supplied with
Fault finding and rectification should the set suggests possible causes
be undertaken only by competent for the most common faults, for the
professional engineers.
guidance of specialised electrical
9.1 Diesel Engine engineers.
The engine Operators' Handbook
supplied with the set suggests possible
9.3 Electrical System
In the case of a suspected fault employ
causes for the most common faults,
a qualified professional electrical
for the guidance of specialised diesel
engineer to resolve the fault.
engine maintenance engineers.
The wiring diagrams supplied with this
manual are for use only by specialised
electrical engineers.
28
Alpha SERIES LWA/LWX genset operators' handbook
Production Facility
Lister Petter Power Systems Limited
Units 13-15 Quadrant Distribution
Centre, Hardwicke, Gloucester
GL2 2RN
sales@listerpetter.com
www.listerpetter.com
29
Alpha SERIES LWA/LWX genset operators' handbook
Appendix 1
Installation and Commissioning
30
Alpha SERIES LWA/LWX genset operators' handbook
1.It is the responsibility of the installer oil (see the Engine Operators'
to ensure that the generating set Handbook).
is adequately earthed to a low- 3.Ensure that the battery connections
resistance earthing rod or earth are secure. Make the final battery
plate. connection only when everything is
2.Ensure that the battery is fully ready for the first start, connecting
charged and serviceable, that the the negative battery terminal last.
engine coolant level is correct and 4.Before starting read the safety
that the engine has the correct section in the Engine Operators'
quantity of the correct lubricating Handbook.
31
Alpha SERIES LWA/LWX genset operators' handbook
Appendix 2:
List of Drawings
Electric Start Sets
LPW/LWX 2,3,4 (open) ����������������������������������������������������������������������� 084-27396
LPW/LWX 2,3,4 (acoustic) ������������������������������������������������������������������ 084-27397
LPW/LWX 2,3,4 + dummy load (open) ����������������������������������������������� 084-27398
LPW/LWX 2,3,4 + dummy load (acoustic)������������������������������������������� 084-27399
LPW/LWX 2,3,4 + battery charger (open) ������������������������������������������ 084-27400
LPW/LWX 2,3,4 + battery charger (acoustic)�������������������������������������� 084-27401
LPW/LWX 2,3,4 + battery charger + dummy load (open)�������������������� 084-27402
LPW/LWX 2,3,4 + battery charger + dummy load (acoustic)��������������� 084-27403
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Alpha SERIES LWA/LWX genset operators' handbook
33
34
35
California Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known to the State
of California to cause cancer, birth defects, and other reproductive harm.
Head Office
Lister Petter Power Systems Limited
Unit 14 Estuary Court, Broadmeadow Industrial Estate
Teignmouth, TQ14 9FA
T: +44 (0) 1285 702211
Production Facility
Lister Petter Power Systems Limited
Units 13-15 Quadrant Distribution Centre
Hardwicke, Gloucester, GL2 2RN
sales@listerpetter.com
www.listerpetter.com