STANDARD FACTORY TEST

1. Standard Conditions
 Ambient temperature on test bench: <40°C (depending on actual outside ambient
temperature).
 Generator Sets with air-to-air charge air cooled engines will be tested incl. the standard
set mounted mechanical radiator cooler.
 Generator sets with air-to-water charge air cooling will be tested without optional cooling
equipment. The generator set will be connected to the cooling equipment of the test
bench.
 The generator set will be filled with fluids and lubricants according to the engine
manufacturers fluids and lubricants specification.
 The generator set will be operated with fuel according to the engine manufacturers fluids
and lubricants specification.

2. Preparation for test run

Visual Check (conducted at setup station outside of test bench)
Mechanical Components
 Fan belt
 Check for visible damages and leakages
 Check if components are mounted properly (Control cabinet, Water jacket heating, …)
Electrical components
 Cabeling for engine, generator, batteries, circuit breaker and additional auxiliary drives
(of installed)
 Starter motor
 Protective earth (PE) conductor (fully and continuous connected) incl. resistance
measuring.

MTU Onsite Energy Systems GmbH

Rotthofer Straße 8, 94099 Ruhstorf / Germany / T +49 8531 9782-0 / www.mtu-online.com
Geschäftsführung / Board of Management Peter Kappes (CEO) Sitz der Gesellschaft / Domicile Ruhstorf
Handelsregister / Register Court Passau HRB 8570 USt-Ident-Nr. / V.A.T No. DE 249818731
QM zertifiziert nach / QM certified ISO 9001:2008

A Rolls-Royce Power Systems Company

Blank_27.01.2014

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Control Cabinet & Software
 Parameterization of control panel.
 Setting up and testing communication between engine controller and genset controller.
 Checking and adjusting all control cabinet mounted components.

3. Test Run
Pre-Testing
Testing/ checking of (actual scope of testing depends on generator set configuration):
 Manual start/stop
 Emergency stop
 Lube oil level
 Coolant level
 Alarms for low coolant level
 Voltage adjustment via control panel
 Speed adjustment via control panel

Idle Run
Testing of alarm & emergency shutoff in case of:
 Low oil pressure
 High engine temperature
 Over frequency

MTU Onsite Energy Systems GmbH

Rotthofer Straße 8, 94099 Ruhstorf / Germany / T +49 8531 9782-0 / www.mtu-online.com
Geschäftsführung / Board of Management Peter Kappes (CEO) Sitz der Gesellschaft / Domicile Ruhstorf
Handelsregister / Register Court Passau HRB 8570 USt-Ident-Nr. / V.A.T No. DE 249818731
QM zertifiziert nach / QM certified ISO 9001:2008

A Rolls-Royce Power Systems Company

OER-DV-0003
Load Run
Procedure

Load factor Running Time Power Factor (cos phi)

0 - 100% 5 min 1,0
100% 15 min 1,0
110% 2 min (valid only for prime power units) 1,0

Protocolled Data
Measurement of the protocolled data will be carried out at the end of each operating period.
 Frequency
 Voltage
 Current (3 phases)
 Power factor
 Active power
 Fuel consumption
 Lube oil pressure
 Lube oil temperature
 Coolant temperature
 Air intake temperature before engine
 Water temperature before charge air cooler
 Intake air temperature before cylinder
 Intake air pressure before cylinder
 Engine speed
 Requested torque

MTU Onsite Energy Systems GmbH

Rotthofer Straße 8, 94099 Ruhstorf / Germany / T +49 8531 9782-0 / www.mtu-online.com
Geschäftsführung / Board of Management Peter Kappes (CEO) Sitz der Gesellschaft / Domicile Ruhstorf
Handelsregister / Register Court Passau HRB 8570 USt-Ident-Nr. / V.A.T No. DE 249818731
QM zertifiziert nach / QM certified ISO 9001:2008

A Rolls-Royce Power Systems Company

OER-DV-0003
Step Load Testing
Step load testing according to ISO 8528 performance class G3

Load step Time after start signal

0 - 50% 9 sec
50 - 75% 12 sec
75 - 100% 15 sec
100 - 0% ~ 30 sec

4. Final Inspection
Check for the following items:
 Automatic circuit breakers are tripped
 Battery is disconnected
 All covers are attached
 Name plates are attached
 Generator set is cleaned

Factory test procedure and specification are subject to change without notice.

MTU Onsite Energy Systems GmbH

Rotthofer Straße 8, 94099 Ruhstorf / Germany / T +49 8531 9782-0 / www.mtu-online.com
Geschäftsführung / Board of Management Peter Kappes (CEO) Sitz der Gesellschaft / Domicile Ruhstorf
Handelsregister / Register Court Passau HRB 8570 USt-Ident-Nr. / V.A.T No. DE 249818731
QM zertifiziert nach / QM certified ISO 9001:2008

A Rolls-Royce Power Systems Company

OER-DV-0003