350 kVA, M020246A, Scania GHP-DC12 60 (XAVM) 18-06-2007

Document No.: M02.
0246
Document Title: USER MANUAL
GHP / DC12 60 (AI & AUS)
Issue: A
Date: 18/06/07
USER MANUAL
FOR
Document M02.0246
Document No.: M02.0246
Issue: A
Date: 18/06/07
TABLE OF CONTENTS
1.0 SAFETY
1.1. GENERAL INFORMATION.....................................................................................................1
1.2. ELECTRICAL POWER ...........................................................................................................1
1.3. MATERIALS............................................................................................................................1
1.4. OPERATIONAL PRECAUTIONS ...........................................................................................1
1.5. SAFETY LABELS ...................................................................................................................2
2.0 NOISE EMISSION

2.1. NOISE CONTROL PROHIBITED ACTS.................................................................................4
2.2. GENERATOR NOISE EMISSION CONTROL INFORMATION .............................................4
3.0 HANDLING
3.1. LIFTING / HANDLING.............................................................................................................5
3.2. STORAGE / TRANSPORT .....................................................................................................5
4.0 INSTALLATION
4.1. UNPACKING ...........................................................................................................................6
4.2. LOCATION OF THE PLANT...................................................................................................6
4.3. COMMISSIONING...................................................................................................................6
4.4. PRIOR TO STARTING ............................................................................................................6
4.5. ELECTRICAL CONNECTION.................................................................................................6
4.6. EARTHING ..............................................................................................................................6
4.7. REMOTE FUELLING ..............................................................................................................7
5.0 GENERAL DATA

5.1. GENERAL OPERATION.........................................................................................................8
5.2. DESIGN LOAD CAPACITY ....................................................................................................8
5.3. DESIGN TEMPERATURES ....................................................................................................8
5.4. CANOPY & BASE FRAME.....................................................................................................8
5.5. DIESEL ENGINE .....................................................................................................................9
5.6. ENGINE LUBRICATION SYSTEM .........................................................................................9
5.7. ENGINE COOLING SYSTEM .................................................................................................9
5.8. ENGINE FUEL SYSTEM.........................................................................................................9
5.9. EXHAUST SYSTEM..............................................................................................................10
5.10. ENGINE CONTROL SYSTEM ..............................................................................................10
5.11. GENERATOR........................................................................................................................10
5.12. MAIN CIRCUIT BREAKER ...................................................................................................10
6.0 OPERATING INSTRUCTIONS

6.1. OPERATING CONTROLS AND INSTRUMENTS ................................................................12
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6.2. OPERATING PROCEDURE .................................................................................................16

6.3. MODES OF OPERATION .....................................................................................................17
6.4. ALARM FUNCTIONS............................................................................................................19
6.5. CHANGING PARAMETERS.................................................................................................20
7.0 MAINTENANCE
7.1. GENERAL .............................................................................................................................23
7.2. MAINTENANCE SCHEDULE ...............................................................................................24
7.3. DAILY MAINTENANCE ........................................................................................................25
7.4. WEEKLY MAINTENANCE....................................................................................................26
8.0 LUBRICATION
8.1. GENERAL INFORMATION...................................................................................................27
8.2. GENERATOR OIL CHANGE ................................................................................................27
8.3. OIL SPECIFICATION ............................................................................................................27
9.0 TROUBLE SHOOTING

9.1. INTRODUCTION ...................................................................................................................28
9.2. ACTION PLAN ......................................................................................................................28
9.3. TROUBLE SHOOTING CHART ...........................................................................................29
APPENDIX A: Material Safety Data Sheets

APPENDIX B: Equipment Data Sheet
Document No. Rev.
G080311 SHT. 1 to 3 A
APPENDIX C: Installation Outline Drawing

Drawing No. Rev.
A050187 SHT. 1 of 1 A
APPENDIX D: Control Panel Layout

Drawing No. Rev.
D210666 SHT. 1 of 1 A
APPENDIX E: Electrical Schematics

Drawing No. Rev. Title
D080880 SHT. 1 of 4 A Alternator & AVR Schematic Diagram
D080880 SHT. 2 of 4 A Main Load & Metering Schematic Diagram
D080880 SHT. 3 of 4 A Deep Sea 5510 Controller
D080880 SHT. 4 of 4 A Engine Controller DC Control Schematic
D140223 SHT. 1 of 1 A Engine Wiring Plug and Terminal Layout
APPENDIX F: Livery Layout

Drawing No. Rev.
D200159 SHT. 1 of 1 B
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APPENDIX G: Manufacturers Component Data

Document No. Rev.
M040130 SHT. 1 of 1 A
APPENDIX H: Lifting Beam Certificate – 14700842/001

APPENDIX J: DNV Spark Arrestor Certificate – M-10651
APPENDIX K: International Contact Information
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1.0 SAFETY
1.1. GENERAL INFORMATION
Ensure that the operator reads and understands the decals and consults the manuals before
maintenance or operation.
Ensure that the Operation and Maintenance manual, and the manual holder, are not removed
permanently from the machine.
Ensure that maintenance personnel are adequately trained, competent and have read the
Maintenance Manuals.
Make sure that all protective covers are in place and that the canopy/doors are closed during
operation.
The specification of this machine is such that the machine is not suitable for use in flammable gas
risk areas. WARNING: NO ATTEMPT SHOULD BE MADE TO OPERATE IN SUCH AREAS
WITHOUT THE EXPRESS AUTHORITY FROM AGGREKO.
Installation of this generator must be in accordance with recognised electrical codes and any local
Health and Safety Codes.
1.2. ELECTRICAL POWER
Prior to installation of the generating set you should check that the electrical load to be applied is
within the rated output of the machine at the site ambient conditions.
Before carrying out any maintenance or repairs to the Engine/Alternator assembly disconnect the
starting battery and isolate the alternator from the switchboard.
Before carrying out any maintenance repair to the AC and DC circuits, isolate these from external
control panel and power supplies.
Ensure that the generator set and the load it is connected to are properly earthed.
The generating set should be connected to the load only by a qualified electrician and in accordance
with the applicable regulations.
1.3. MATERIALS
The following substances are used in the manufacture of this machine and may be hazardous to
health if used incorrectly:
Antifreeze
Engine Lubricating Oil
Preservative Grease
Rust Preventative
Diesel Fuel
Battery Electrolyte.
AVOID INGESTION, SKIN CONTACT AND INHALATION OF FUMES.

When handling fuel, lubricating oil, cooling fluid and battery electrolyte, wear appropriate personal
protection equipment.
For further information, consult Material Safety Data Sheet contained in this manual.
Avoid build-up of Engine Exhaust Fumes in confined spaces.
Avoid breathing Exhaust Fumes.
1.4. OPERATIONAL PRECAUTIONS
Never operate unit without first observing all safety warnings and carefully reading the operation and
maintenance manual shipped from the factory with this machine.
IF IN DOUBT CONTACT AGGREKO.

Never operate the engine of this machine inside a building without adequate ventilation. Avoid
breathing exhaust fumes when working on or near the machine. Do not alter or modify this machine.
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A battery contains sulphuric acid and can give off gases, which are corrosive and potentially
explosive. Avoid contact with skin, eyes and clothing. In case of contact, flush area immediately with
water.
Exercise extreme caution when using booster battery. To jump battery, connect ends of one booster
cable to the positive (+) terminal of each battery. Connect one end of other cable to the negative (-)
terminal of the booster battery and other end to a ground connection away from dead battery (to
avoid a spark occurring near any explosive gases that may be present). After starting unit, always
disconnect cables in reverse order.
Never operate unit without first observing all safety warnings and carefully reading the operation
manual.
This machine may include such materials as oil, diesel fuel, antifreeze, oil/air filters and batteries
which may require proper disposal when performing maintenance and service tasks. Contact local
authorities for proper disposal of these materials.
This machine produces loud noise with the doors open. Extended exposure to loud noise can cause
hearing loss. Always wear hearing protection when doors are open.
Never inspect or service unit without first disconnecting battery cable(s) or using the battery isolator
switch to prevent accidental starting.
Do not remove the pressure cap from a HOT radiator. Allow radiator to cool down before removing
pressure cap.
Do not use petroleum products (solvents or fuels) under high pressure as this can penetrate the skin
and result in serious illness. Wear eye protection while cleaning unit with compressed air to prevent
debris from injuring eye(s).
Hot pressurized fluid can cause serious burns. Do not open radiator while hot.
Rotating fan blade can cause serious injury. Do not operate without guard in place.
Use care to avoid contacting hot surfaces (engine exhaust manifold and piping, etc.).
Never operate unit with guards, covers or screens removed. Keep hands, hair, clothing, tools, etc.
well away from moving parts.
1.5. SAFETY LABELS
Look for these signs on machine, which point out potential hazards to the safety of you and others.
Read and understand thoroughly. Heed warnings and follow instructions.
DANGER
FIRE RISK
RISK OF
ELECTRIC SHOCK
DO NOT STAND IN FRONT

OF ALTERNATOR AIR
OUTLETS WHEN UNIT IS
RUNNING
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CAUTION
Hot
DISCONNECT STARTING
BATTERY AND ISOLATE
LOAD BEFORE WORKING
ON ENGINE / ALTERNATOR
ASSEMBLY
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2.0 NOISE EMISSION

2.1. NOISE CONTROL PROHIBITED ACTS
WARNING
Tampering with noise control system prohibited
The following acts or misuse of the unit are prohibited:
1) The removal or rendering inoperative by any persons, other than for purposes of maintenance,
repair, or replacement, of any device or element of design incorporated into any new generator
for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is
in use
Or
2) The use of the generator after such device or element of design has been removed or rendered
inoperative by any person.
Among those acts included in the prohibition against tampering are these:
Removal or rendering inoperative any of the following:
a) The engine exhaust system or parts thereof.
b) The air intake system or parts thereof.
c) Enclosure or parts thereof.
Removal of any of the following:
• Fan shroud
• Vibration mounts
• Sound absorption material
Operation of the generator with any of the enclosure doors open.
2.2. GENERATOR NOISE EMISSION CONTROL INFORMATION
A. The removal or rendering inoperative, other than for the purpose of maintenance, repair, or
replacement of any noise control device or element of design incorporated into this generator in
compliance with the noise control act;
B. The use of this generator after such device or element of design has been removed or rendered
inoperative.
THIS GENERATOR HAS BEEN SPECIFICALLY DESIGNED WITH A SOUND ATTENUATING
ENCLOSURE. THE CANOPY DOORS SHOULD REMAIN LOCKED SHUT UNDER NORMAL
OPERATING CONDITIONS. UNDER ANY OTHER CONDITIONS EXCESSIVE NOISE LEVELS
CAN BE PRODUCED AND PROLONGED EXPOSURE IS HAZARDOUS TO HEARING.
FOR SAFETY, EAR PROTECTION SHOULD ALWAYS BE

WORN WHEN WORKING IN THE VICINITY OF AN
OPERATING GENERATOR SET.
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3.0 HANDLING
3.1. LIFTING / HANDLING
The generator set includes 1 lifting beam and forklift pockets. There is the option for a two-point lift
configuration suitable for offshore service.
All lifting and handling equipment must be adequately rated for applicable weights.
During all lifting and handling operations the following weights must be considered.
Complete Package Max. Fuel 14528 lbs (6590 kgs)
Complete Package Without Fuel 12787 lbs (5800 kgs)
Bolt on steel plate buffers are located at the front and rear of the base to protect the body of the
generator.
Where 2 point lifting is provided, ensure that the correct length of strop / wire rope is used on each
lifting beam to ensure a level lift. Also ensure that the included angle does not exceed 90°.
CAUTION: THE GENERATOR SET SHOULD NOT BE LIFTED OR DRAGGED BY THE END
BUFFERS.
3.2. STORAGE / TRANSPORT
Carry out the following points before transporting the generator or preparing the generator for
storage.
Empty the fuel tank (in case of overseas transport).
Disconnect the battery terminals (in case of overseas transport).
Close all fuel valves.
Seal the remote fuel connection with a blind stop.
Ensure that the radiator cap is fitted securely and the exhaust rain cap is closed.
Close all doors.
All units are to be loaded flat onto transport and properly secured.
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4.0 INSTALLATION
4.1. UNPACKING
Ensure that the correct fork lift truck slots or marked lifting / tie down points are used whenever the
machine is lifted or transported.
4.2. LOCATION OF THE PLANT
The generator can be installed on any solid, flat and level surface capable of supporting the full
operating load of the package. A dry, well-ventilated area where the atmosphere is as clean as
possible is recommended. Ensure that the machine is positioned securely and on a stable
foundation.
CAUTION: A minimum of 1 metre (3 ft) all round the generator is recommended. Hot air
will exit from the roof outlet. It is important that this hot air does not re-circulate to the
package inlet.
The generator must be allowed sufficient space all round and above, to enable the effective removal
of the cooling air which, in turn, will reduce the risk of re–circulating the cooling air back through the
generator. Adequate clearance needs to be allowed around and above the machine to permit safe
access for specified maintenance tasks. Hard surfaces may reflect noise with an apparent increase
in the decibel level. It is recommended that provision be made for lifting heavy components during
major overhaul.
NOTE: When operating at elevated altitude please refer to engine manufacturer’s

guidelines for power deration.
4.3. COMMISSIONING
Upon receipt of the unit, and prior to putting it into service, it is important to adhere strictly to the
instructions given below in section 4.4 PRIOR TO STARTING.
Ensure all persons concerned are suitably competent with generator installations.
Ensure that the operator reads and understands the decals and consults the manuals before
maintenance or operation.
Ensure that the position of the emergency stop device is known and recognised by its markings.
Ensure that it is functioning correctly and that the method of operation is known.
4.4. PRIOR TO STARTING
Ensure that the unit is clean, free from debris and fluids. All connections, joints, seals must be
correctly fitted and tightened. All filters, louvers and air inlets are free and open.
Ensure that there is a safe working procedure which has been issued by supervisory personnel, and
that all persons concerned with the operation of the generator understand it.
Ensure that the safety procedure to be applied is based on the appropriate national and local
regulations.
Ensure that the safety procedure is followed at all times.
4.5. ELECTRICAL CONNECTION
A suitably trained electrician should carry out all electrical connections.
Ensure the generator main isolator is off and that the power cables are in good condition.
Ensure that the phases are correct after the cables have been connected.
Ensure all safety covers are back in place after electrical connection is complete.
4.6. EARTHING
An external earthing boss is fitted onto the base frame at the control panel end of the set. This allows
a dedicated earthing connection if required.
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4.7. REMOTE FUELLING

External fuel tank supply can be connected to the generator set.
One ½” BSP Adaptor (Supply)
One ½” BSP Adaptor (Return)
There is an access hole in the base frame to allow access to the internal fuel connections.
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5.0 GENERAL DATA

NOTE: Each generator of this type is uniquely identified by a Plant Number and Serial Number
indicated on the identification plate affixed to the outside of the control panel. This information is
required when ordering spare parts. Major component serial numbers are contained within the
manual.
The technical data defining the generator and the limits on its operating environment are tabulated in
the Equipment Data Sheet. A copy of the Equipment Data Sheet has been included in the manual.
In order to assist in the operation and maintenance of the generator, a full set of electrical and
installation drawings has been included in the manual.
5.1. GENERAL OPERATION
The generator is a diesel engine driven alternator with control electronics, mounted on a bedplate
with internal fuel tank. The standard package is composed of the following:
Alternator and engine assembly
Pressurised oil system with cooler
Automated control system
Instrumentation
Safety provisions
Engine cooler pack
Spark arrestor / Silencer
Internal fuel tank
The engine and alternator are integrally mounted. This assembly is isolated from the base by rubber
isolation mounts.
5.2. DESIGN LOAD CAPACITY
The GHP/DC12-60 (350kVA) generator set can be run up to a maximum of 350 kVA at prime power
rating.
5.3. DESIGN TEMPERATURES
The GHP/DC12-60 (350kVA) generator set can operate through an ambient temperature range of:
-10°C (14°F) to 38°C (100°F)
5.4. CANOPY & BASE FRAME
The overall dimensions for the generator set are 4640 X 1500 X 2565 mm.
The canopy is manufactured from welded Zintec and has access to the inside of the generator
through lockable doors.
The base frame has 120% capacity of the fuel tank to prevent fuel leaking out of the generator set in
the event of a fuel leakage inside the generator. A level switch is fitted inside the bund for spillage
indication. This will shut down the engine when activated.
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5.5. DIESEL ENGINE

The generator set uses a Scania DC12-60 diesel engine, which is capable for either 50 Hz or 60 Hz.
Details of the engine are outlined below.
Four Stroke, 6 Cylinder In-line, Water Cooled,
Type:
Turbo charged, C/A Aftercooler
Model: Scania DC12-60
RPM: 1500 / 1800
Nominal Engine Output @ 1500rpm: 283kW @ Prime Power
Governor: S6 EMS (Engine Management System)
Starting System: 24V Battery System with Fitted Isolator
Fuel Consumption @ Continuous 1500rpm: 64 L/Hr @ 100% Prime Power
5.6. ENGINE LUBRICATION SYSTEM

The engine oil lubrication system includes pump, strainer and sump all fitted internally within the
engine block. Oil filtration is fitted to the side of the engine block for ease of access and
maintenance.
Total Oil Capacity: 28 Litres
The Lube oil specification is as per API/ASTM/SAE/CD (equivalent to series MIL-L-415993).
Recommended oils are Castrol Tection T 15W-40 (previously called RX Super Plus), Shell Rimula
15W 40.
The sump can be drained using the K1 pump via a Ball valve.
Refer to manufacturers data for all filter information.
NOTE: The oil centrifuge will continue to rotate after the engine has been switched off. Care
should be taken that it has stopped rotating before any maintenance is carried out on it.
5.7. ENGINE COOLING SYSTEM
The engine cooling consists of a pump, thermostat, heater and radiator assembly.
Cooling fluid is from the radiator, through the pump, which is belt driven from the engine pulley. The
thermostat controls the flow to the radiator. The radiator assembly is mounted at the front of the
engine, with the fan mounted on the front of the engine.
Cooling air enters the generator through the canopy end louvers and noise attenuation baffles. This
air then passes into the canopy
space then across the radiator
assembly.
The cooling air exits through the
roof of the package.
The coolant is factory filled with
Shell anti-freeze and anti-corrosion
coolant, in 50-50 water-coolant
concentration, providing protection
to –32°C. Please consult Aggreko if
filling is required.
There is a radiator expansion tank
fitted to this unit that should be
checked, prior to starting the unit,
that it is filled between the ‘min’ and Figure 5.1 – Radiator Expansion Tank
‘max’ lines on the tank (see Figure
5.1).
5.8. ENGINE FUEL SYSTEM
The engine fuel system consists of an internal fuel tank, Racor filter (see Figure 5.2), fine fuel filter,
fuel pump, injection pump and nozzles.
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Fuel can be taken from either an external or the internal fuel tank. A manual selection valve is used
to select the fuel supply direction. Fuel is then pumped through the Racor filter to the fine fuel filters
and then passed to the injectors and then to the injection nozzles.
The internal fuel tank has a fuel capacity of 930 Litres. Low warning and low shut-off sensors are
fitted in the internal fuel tank. The fuel tank fill point is internal. There are 2 cleaning ports on the fuel
tank that are all accessible through the canopy doors.
External fuel supply can be connected to the package using the ½” BSP Adaptors. Internal supply
and return fittings/valves must be re-configured to ensure that the engine fuel is not drawn from the
onboard supply.
The use of ASTM No. 2D fuel is recommended for optimum engine performance. At operating
temperatures below 0°C, acceptable performance can be obtained using blends of No. 1 and No. 2D.
The use of lighter fuels can reduce economy. The viscosity of fuels must be kept above 1.3 cSt to
provide adequate lubrication.
Refer to manufacturers data for all filter information.
5.9. EXHAUST SYSTEM
The exhaust system consists of the exhaust ducting, exhaust silencer complete with spark arrestor
and rain cap assembly. The exhaust gases exit the engine and are passed through the exhaust
ducting and exhaust, out the top of the canopy through the rain cap assembly. Insulation and heat
shields are fitted to the exhaust ducting to prevent user contact with high temperature surfaces.
Manufacturer: DISCOM
Spark Arrestor: DNV Certificate No M-10651
5.10. ENGINE CONTROL SYSTEM

An Engine Management System (S6 Controller) controls the engine output.
A Deep Sea Electronic 5510 control module is used to monitor the safety circuits and set the
operation mode of the generator. See section 6.1.2 Control Module for more detail.
5.11. GENERATOR
Manufacturer: Newage Stamford
Type: HCI434F1
50Hz: 380-440 Volts
Voltage Range
60Hz: 416-480 Volts
Voltage Regulator within 1% from no load to full load MX341
1 Phase configurable on Alternator TB
5.12. MAIN CIRCUIT BREAKER
Manufacturer: Merlin Gerin
NS1250N 4P with Micrologic 5.0 Electronic
Type:
Overload Protection, Motor Mech
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TEMPERATURE
GAUGE
OIL CENTRIFUGE
K1 PUMP
RACOR FUEL
FILTER
* Canopy shown is Australian – AI set has two step ladders with handholds
Figure 5.2 - 350 kVA Generator Part Locations
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6.0 OPERATING INSTRUCTIONS

6.1. OPERATING CONTROLS AND INSTRUMENTS
6.1.1. CONTROL PANEL
The operating controls and instruments are arranged on the control panel as shown in figure 6.1. A
description of each panel device is given in the key below.
2 3
Figure 6.1 – Control Panel Exterior
Deep Sea 5510 Earth Leakage Off

1 3
Controller Reset / On
2 DC Power Off/On
Key for figure 6.1
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11 5 12 1
10
2
4
7 17
6 9 13 15 16 14
Figure 6.2 – Control Panel Interior
1 AVR 10 Relay R1 Relay
2
1200/5A CTs 11 Relay R3 & R4
3 Merlin Gerin 1250A 4P MCCB 12 Diodes D1 - 2
Earth Leakage Relay MCB 6 (Bus Sensing Volts)

4 13
5
MCB4 (S6 Controls) 14 Current Limiter
MCB5 (MCCB Controls) 15 Baseload

6
MCB1 (E-Stop Supply) 16 Earth bar

7
MCB2 (Generator Sensing

8 Terminals
Volts) 17
9 Excitation Switch
Key for figure 6.2
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6.1.2. CONTROL MODULE

The control module used on this generator set is the 5510 control module by Deep Sea. Figure 6.3
below shows the front panel layout of the 5510 control module.
12
1
2 11
3
10
4 9
5 6 7 8
Figure 6.3 – 5510 Generator controller
1. Auto select
Display scroll buttons 7
1 2. Accept setpoint value
2 CB open button 8 Mute alarm/lamp test
3 CB indication 9 Manual start

Generator available
4 Stop button/alarm accept 10
indication
1. Manual select
CB close button
5
2. Scroll down/reduce setpoint 11
1. –
12 Status LEDs
6
2. Scroll up/increase setpoint
1 – in normal mode
2 – in configuration mode
Key for figure 6.3
The 5510 generator control module is an automatic engine control module. It has all the features of
the 5310 control module but with synchronising and loadsharing/baseload capability. In addition, the
5510 control module is equipped with integrated push buttons for circuit breaker control. The
features of the 5510 controller include:
• Text based LCD (supporting multiple languages)
• Comprehensive metering of electrical parameters (voltage, current, power)
• Engine parameter monitoring
• Manual and remote/standby operation
• Synchronising capability with displayed synchroscope
• Loadsharing capability between two 5510 controllers via CANBUS connection (see “modes
of operation” for further details)
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• Loadsharing capability between 5510 and older unit with conventional parallel loadsharing
lines (see “modes of operation” for further details)
• Baseload or parallel to mains operation (see “modes of operation” for further details)
• Comprehensive range of alarms
• Compatible with different alternator configurations
• Support of electronic engines via J1939 CANBUS interface
• On Aggreko canopy sets, binary inputs on the 5510 controller are configured for remote
start input, circuit breaker status and alarms, e.g. Low fuel level or Earth leakage. Where
POWERLINK plugs are fitted, 3 further binary inputs are used.
• Analogue inputs are typically configured for low oil pressure, high water temperature (either
senders or discrete switches) and fuel gauge (where fitted). For Scania DC12/16 electronic
engines, the analogue input for water temperature is reconfigured as speed control from
POWERLINK where POWERLINK is specified. Please note that this input (and hence
external speed control) is only active when a POWERLINK panel is connected.
• Binary outputs are configured for circuit breaker open and close and, where fitted, for Air
flap closed (on offshore sets). In addition, one output is dedicated to provide a common
alarm output which provides a positive DC signal in the event of any alarm.
6.1.3. DISPLAY PAGES

The 5510 module displays the following pages on the LCD. Pressing the green info button will scroll
between these pages. Pressing the Up or Down arrow buttons will scroll between instrumentation
parameters. If no parameters are selected, then autoscroll through the parameters with begin.
1. Status page
This shows the current status of the generator; e.g. generator at rest, manual mode, auto mode.
When the generator is running, generator parameters are also shown (as displayed in figure 6.3).
2. Engine instrumentation
Displays information related to the engine such as engine speed, battery voltage and run time. If
connected to an electronic engine, a range of additional engine parameters are displayed which is
dependent upon the engine type. These include parameters such as inlet temperature, turbo
pressure and fuel consumption.
3. Gen instrumentation
Displays electrical parameters relating to the engine. These include:
- Generator phase voltages
- Generator line voltages
- Frequency
- Generator currents
- Generator real power and apparent power
- Power factor and reactive power
- kWh
- Phase sequence
- Synchroscope
4. Bus instrumentation
As the 5510 controller is capable of synchronising, bus information is displayed separately to
generator information. This includes:
- Generator phase voltages
- Generator line voltages
- Frequency
- Phase sequence
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5. Current alarm page

Displays the current alarms in clear text.
6. Event log page
Stores the last 25 shutdown conditions and CB operations. Pressing the Up or Down arrow
buttons will scroll through the event log.
6.1.4. FRONT PANEL LEDS

The following LEDs are provided.
• Green LED to indicate circuit breaker closed [symbol 3 in figure 6.3]
• Green LED to indicate Generator available (lit after starting timers have expired) [symbol 10
in figure 6.3]
• Red LEDs for stop, manual and auto indication
• Status LEDs to indicate:
- Remote start input signal present.
- Alternative voltage selected. When alternative voltage is selected, under and
overvoltage protection is halved. In addition, overcurrent protection is doubled.
Alternative voltage is intended for use when the generator set alternator windings are
configured in parallel, as opposed to series configuration.
- Alternative frequency selected. For US generator sets, normal frequency is 60Hz and
alternative frequency is 50Hz. For European and AI generator sets, normal frequency is
50Hz and alternative frequency is 60Hz. When alternative frequency is selected
protection settings for over/under frequency and over/under speed are moved
accordingly.
- Common alarm indication. This LED is lit if any alarm condition is detected.
6.2. OPERATING PROCEDURE
CAUTION:- Always open the battery isolator switch to avoid unauthorised starting
during transport and maintenance.
This section describes the basic operation of the generator set. For more details on the different
modes of operation, see section 6.3 Modes of operation below.
6.2.1. MANUAL OPERATION
To start generator:
1. Prior to starting, exercise daily maintenance. See section 7.1.
2. Turn on DC power.
3. Check that no alarms are present. If a shutdown condition is present, the generator set will not
be allowed to start.
4. Ensure that the busload switch inside the panel is OFF
5. Press the manual select button. The display will read “Generator at rest” and “Waiting in
Manual”
6. Press the manual start button.
7. Once the generator has run-up to speed, check the frequency and voltage. Voltage can be
adjusted via the AVR or potentiometer. Frequency can only be adjusted on non-electronic
engines.
8. Walk around the engine and check for any leakages.
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9. After the start up timers have expired, close the circuit breaker by pressing the CB close
push button. Once the circuit breaker is closed, the 5510 will regulate the voltage and
frequency to its nominal values. These can be adjusted from the front panel display. See
section 6.4 Changing parameters for details on how to adjust these parameters.
To stop generator:
1. Open circuit breaker by pressing the CB open push button.
2. Allow the engine to cool down for at least 5 minutes, especially when the set has been running
with a high load.
3. Press engine stop.
6.2.2. REMOTE/STANDBY OPERATION
CAUTION: In remote operation, motorised breakers will close automatically. The 5510
controller will close onto a dead bus or synchronise onto a live bus after the start-up timers
have expired.
1. Turn on DC power
2. Check for alarms
3. Ensure that the busload switch inside the panel is OFF
4. Press Auto select. The display will read “Generator at rest” and “Auto mode”
5. The generator set can be started by providing a connection between terminals 2 and 3.
6. Generator set can be stopped by removing the connection between terminals 2 and 3.
7. A test run should be carried out at least once a week.
6.3. MODES OF OPERATION

Please read section 6.2 Operating procedure for details on the basic operation of the 5510 controller.
For 50 or 60 Hz operation (the vast majority of operating conditions) it will not be necessary to
manually adjust the nominal frequency as this is automatically changed when alternative frequency is
selected. For more details, see section 6.5 Changing parameters.
6.3.1. SINGLE SET OPERATION

When used as a stand alone generator, the 5510 will regulate to its internal voltage and frequency
nominal settings as soon as the breaker is closed. Please note that manual mode is not available
with the 5510 controller, and if any adjustment to frequency or voltage is made when the breaker is
closed, the controller will regulate back to its nominal setpoints.
6.3.2. LOADSHARING WITH ANOTHER 5510 CONTROLLER

Loadsharing between 2 or more 5510 controllers is achieved via the Multiset Communications (MSC)
CANBUS link.
Communications link
The connection is made using 2 core screened cable. See diagram 6.4 below.
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Figure 6.4 – MSC CANBUS connection between 5510 control modules
Notes:
a. The Multiset Communications link terminals are only to be connected to other Deep
Sea controllers and not to any other device.
b. Do not connect the MSC cable screen (SCR) to earth at any point. Protection from
interference is provided within the module and may be compromised by earthing the
MSC cable screen.
c. The maximum total length of the MSC link is 250 m.
d. A 120Ω resistor must be placed on the first and last devices on the communications
bus.
e. Up to 16 Deep Sea controllers can be connected via the MSC link.
The features of the MSC link include:
f. Determining which set closes onto a dead bus, eliminating the chance that two sets
close onto a dead bus at the same time.
g. Active and reactive loadsharing (equivalent to analogue loadsharing lines).
h. Identifying when sets should start or stop when used in automatic start/stop on load
demand mode. A digital input requires to be configured for this mode in order to use
this feature.
6.3.3. BASELOAD OPERATION
CAUTION: The 5510 controller does not possess ROCOF or Vector Jump protection
functions. Check with the local electricity supply company to determine what protection is
required to connect to a mains grid.
Baseload mode is used to export a fixed power and PF from a generator set. It is normally used
when in parallel with the mains. The toggle switch located within the generator control panel is used
to select baseload mode.
The power and PF that the unit will operate at are set in the configuration menu, and are termed
“load parallel power” and “load power factor” respectively. See figure 6.5. Refer to section 6.5
Changing parameters for details on how to set parameters.
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Figure 6.5 – Configuration menu pages which are required for baseload operation
When setting the power levels shown in figure 6.5 for baseload operation, take care not to set the
value above the load that is available. This can result in other generation experiencing reverse
power conditions.
6.3.4. LOADSHARING WITH A GENERATOR SET FITTED WITH ANALOGUE PARALLEL

LINES
The normal loadsharing mode of operation of the 5510 controller is to loadshare with other 5510
devices via the MSC link. However, it is possible to loadshare with sets possessing conventional
analogue parallel lines using a
Deep Sea P0123 interface
available separately from Deep
Sea. Figure 6.6 shows a
photograph of this module. One
P0123 is required for each 5510
controller and connects between
the MSC CANBUS connection
and the analogue line. Please
note that advanced CANBUS
features such as 1 set closure
onto a dead bus and automatic
start/stop on load demand are not
available when analogue parallel
lines are used.
Figure 6.6 – P123 loadsharing interface module
6.3.5. POWERLINK OPERATION (WHERE FITTED)

Where specified, Aggreko canopy generator sets are fitted with POWERLINK sockets. When
POWERLINK is connected to a set containing a 5510 controller, synchronising and loadsharing
functionality is automatically disabled within the 5510 unit and breaker control is passed to the
POWERLINK device. Disconnecting POWERLINK automatically reinstates
synchronising/loadsharing capability and breaker control to the 5510.
Even with POWERLINK disabled, the 5510 retains all of its protection functions and will open the
circuit breaker or shut down the generator set should a fault be detected.
6.4. ALARM FUNCTIONS

When an alarm condition has been detected, the alarm page will be displayed automatically.
Depending upon the severity of the alarm, the 5510 control module will take one of the following
courses of action.
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1. Warning
- Display the alarm in clear text
and sound an audible alarm
2. Shutdown
- Trip the circuit breaker
- Shutdown the generator set
3. Controlled shutdown
Figure 6.7 – Alarm page display
- Trip the circuit breaker
- Cooldown the generator set
for the cooldown period and shutdown the machine
• The audible alarm can be muted using the mute alarm button [symbol 8 in figure 6.3].
• Warnings will be automatically removed when the relevant parameter has returned to within its
normal operating range.
• Shutdowns require to be acknowledged using the stop button. If the shutdown condition is still
present, the shutdown will continue to be displayed.
• When a shutdown condition is still present after the machine has shutdown, e.g. Emergency stop
or Air flap closed, the module will prevent the generator set from cranking and starting until the
condition has been removed and the shutdown has been acknowledged. “Generator at rest and
locked out” will be displayed on the LCD.
• In the event of an alarm, the Common alarm LED will light
• A common alarm output is provided, which will turn high (+12v DC or +24V DC) when any alarm
is detected. See the wiring diagrams for the terminal number.
• Up to the last 25 shutdown conditions will be displayed in the event log.
6.5. CHANGING PARAMETERS

6.5.1. GENERAL
For most applications, required parameter changes can be undertaken from the front fascia. Full
configuration can be undertaken using the configuration software.
To access the front panel editor

Press the Stop/Reset and Info buttons simultaneously.
Enter PIN Number
With the limited access pin number, the following can be adjusted:
Language
Alternative Frequency – Enable/Disable
Alternative Voltage – Enable/Disable
AC System
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Generator Full Load

Droop – Enable/Disable (electronic engines only)
Droop percentage (electronic engines only)
Contrast
Date and Time
Generator Run Priority (for automatic start/stop on load demand mode)
Auto Scroll Time
Generator CT Primary Rating
Generator CT Secondary Rating
Generator Control Full kW Rating
Generator Control Full kVAr Rating
Load Ramp Rate
Load Level for more sets (for automatic start/stop on load demand mode)
Load Level for less sets (for automatic start/stop on load demand mode)
Load Parallel Power (for baseload mode)
Load Power Factor (for baseload mode)
With the full access pin number, in addition to the above, the full range of alarm setpoints and timers
can also be adjusted. Pressing the + and - buttons will scroll up and down through the parameters.
To adjust a parameter
Scroll to the desired parameter using the + and - buttons
Press the tick button and the parameter will start to flash
Press the + or - button to adjust the parameter to the desired value
Press the tick button to save the value
To select another parameter to edit, press the + or – button
To exit the front panel configuration editor at any time, press the Stop/Reset button
When adjusting the date and time, the Down arrow is used to scroll between minutes, hours, day,
month and year
Alternative frequency and alternative voltage

When alternative frequency is selected within the configuration menu, the generator set changes
from its primary frequency setting to its alternative frequency setting, i.e. from 50 to 60 Hz or vice
versa. In Europe and AI, 50 Hz is the primary setting, whereas in the US, 60 Hz is the primary
setting. The status LED labelled “alterative freq” will light to indicate that alternative freq is selected.
All alarm set points for frequency and speed within the 5510 controller will be adjusted accordingly
when alternative frequency is selected. In addition, the nominal frequency will also be moved. For
certain electronic engines, such as the Scania DC12/16, the 5510 controller will automatically adjust
the engine speed between 50 and 60 Hz. For non-electronic engines, the speed must be adjusted
separately via the governor.
Alternative voltage may be required when changing the alternator configuration, e.g. from series star
to parallel star. When alternative voltage is selected, all alarm setpoints for voltage and the nominal
voltage are halved.
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6.5.2. PARAMETER ADJUSTMENT FOR ALTERNATIVE ALTERNATOR CONFIGURATIONS

The Deep Sea 5510 module is designed to be used with different alternator configurations. When
changing the alternator configuration, it may be necessary to adjust the AC System and/or
Alternative Voltage within the Deep Sea module, depending upon how the alternator is being
configured. The table below outlines the most common alternator configurations and the
corresponding Deep Sea set up.
Alternator Deep Sea set-up

configuration AC System Alternative Voltage
Series star 3 phase, 4 wire Disable
Parallel star 3 phase, 4 wire Enable
Enable for 120V Ph-N
1 phase, 2 wire or 2 phase, 3 wire
Parallel zig-zag Disable for 220-240V
depending upon output configuration
Ph-N
Enable for 120V Ph-N
Double delta Disable for 220-240V
Ph-N
Series zig-zag Disable
Series Delta 3 phase, 3 wire Disable
Table 6-1 Deep Sea controller set up for different alternator configurations
By selecting alternative voltage the voltage protection is halved. The actual output voltage value is
adjusted separately via the AVR.
When 1 phase 2 wire or 2 phase 3 wire ac systems are selected on the Deep Sea 5310 controller,
the number of phase voltage and current readings which are displayed changes to 1 or 2
respectively. When 3 phase 3 wire ac system is selected, only line voltages are displayed. This
configuration can be used with a mid-winding or floating neutral.
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7.0 MAINTENANCE
7.1. GENERAL
In addition to periodic inspections, many of the components in these units require periodic servicing
to provide maximum output and performance. Servicing may consist of pre-operation and post-
operation procedures to be performed by the operating or maintenance personnel. The primary
function of preventive maintenance is to prevent failure, and consequently, the need for repair.
Preventive maintenance is the easiest and the least expensive type of maintenance. Maintaining
your unit and keeping it clean at all times will facilitate servicing.
Ensure that maintenance personnel are adequately trained, competent and have read the
Maintenance Manuals.
Prior to attempting any maintenance work, be aware of the following:
Any unauthorized modification or failure to maintain this equipment may make it unsafe and out of
factory warranty.
Use extreme care to avoid contacting hot surfaces (engine exhaust manifold and piping, etc.).
Never operate this machine with any guards removed.
Imperial and Metric hardware was used in the design and assembly of this unit. Consult the parts
manual for clarification of usage.
The machine cannot be started accidentally or otherwise, by posting warning signs and/or fitting
appropriate anti–start devices.
All residual electrical power sources (mains and battery) are isolated.
Prior to opening or removing panels or covers to work inside a machine, ensure that:
Anyone entering the machine is aware of the reduced level of protection and the additional hazards,
including hot surfaces and intermittently moving parts.
The machine cannot be started accidentally or otherwise, by posting warning signs and/or fitting
appropriate anti–start devices.
Prior to attempting any maintenance work on a running machine, ensure that:
The work carried out is limited to only those tasks which require the machine to run.
The work carried out with safety protection devices disabled or removed is limited to only those tasks
which require the machine to be running with safety protection devices disabled or removed.
All hazards present are known (e.g. pressurised components, electrically live components, removed
panels, covers and guards, extreme temperatures, inflow and outflow of air, intermittently moving
parts, safety valve discharge etc.).
Appropriate personal protective equipment is worn.
Loose clothing, jewellery, long hair etc. is made safe.
Warning signs indicating that Maintenance Work is in Progress are posted in a position that can be
clearly seen.
Upon completion of maintenance tasks and prior to returning the machine into service, ensure that:
The machine is suitably tested.
All guards and safety protection devices are refitted.
All panels are replaced, canopy and doors closed.
Hazardous materials are effectively contained and disposed of.
To assist with ordering spare parts and other service activities, a short form list of Component
Manufacturers data has been included in this manual.
Prior to engine starting, check the oil and coolant levels.
Carry out a visual check of the following:
Leaks.
Loose or damage parts.
Worn or damaged belts, change in engine appearance.
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Refer to the Maintenance Schedule for quick reference.

Report unusual noise/vibration and/or exhaust smoke and ensure the generator set is kept clean,
both inside and out.
7.2. MAINTENANCE SCHEDULE
7.2.1. INSPECTION CRITERIA
3 Months / 6 Months / 12 Months

Daily Weekly Monthly
500 Hrs 1000 Hrs / 2000 hrs
Engine Oil Level C
Fuel Tank (Fill at end of
C
day)
Gauges / Lamps C
Air Filter C
Fuel / Water Separator
C
Drain
Battery Connections /
C
Electrolyte
Radiator Coolant Level C
Fan / Alternator Belts C
Hoses (oil, air, intake, etc.) C
Automatic Shutdown
C
System Visual
Fasteners / Guards C
Engine Coolant Test C
Shutdown Switch Settings
C
Test
C=check (adjust if necessary)
Refer to manufacturers operating and maintenance instructions for additional information and all
other maintenance.
7.2.2. SERVICE CRITERIA
3 Months / 6 Months / 12 Months

Daily Weekly Monthly
400 Hrs* 1000 Hrs / 2000 hrs
Engine Oil & Filters R
Air Filter Element R
Fuel / Water Separator
R
Element
Fine Fuel Element R
Engine Coolant R
R=replace
Refer to manufacturers operating and maintenance instructions for additional information and all
other maintenance.
* This figure should be in line with current service best practise.
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7.3. DAILY MAINTENANCE

7.3.1. CHECK THE ENGINE OIL LEVEL:
C. Stop the engine and wait 5 minutes to allow the oil to drain to the oil pan.
D. Remove the dipstick and check the oil level.
E. Replenish if necessary using a recommended grade of engine oil (see section 8).
CAUTION: Never operate the engine with the oil level below the ‘L’ mark or above the ‘H’
mark. See FIG. 7.1 below.
Figure 7.1 - Engine Oil Level Check
7.3.2. CHECK THE FUEL TANK LEVEL.

Check the fuel level gauge on the control panel.
Replenish as necessary using clean, good quality, diesel/Derv/Gas Oil that conforms to ISO or
equivalent. Always ensure that the filler cap is replaced after replenishment.
7.3.3. CHECK THAT ALL METERS AND GAUGES FUNCTION CORRECTLY.
Start the generator and inspect the following items:
Oil pressure gauge is between 85 & 95psi.
After 5 minutes check that the cooling water temperature gauge reads between 45 & 55°C.
The voltage and frequency gauges are within specification.
Fuel gauge indicates the tank is not empty.
Engine hours display increases after 10 minutes.
Safety module has no alarm indicators on.
Press the “LAMP TEST” button on the control panel and confirm that all indicator lamps are working.
7.3.4. CHECK THE AIR FILTER.
NOTE: In dusty conditions clean the primary filters regularly.

Check the air filter restriction indicator next to the air filter above the engine. If this has changed to
the restricted position, then the filter will need replaced.
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7.3.5. CHECK THE BATTERY.

Check that the battery connections are properly installed and that the electrolyte level in each cell
covers the top plates. If necessary, top up with clean distilled water.
7.3.6. CHECK FOR LEAKS.
There are several fluids used inside the generator, e.g. diesel, oil, coolant. Look for signs of leakage
all around the engine.
Any source of leak should be checked and fixed. Clean up any fluid lying inside the generator and
dispose of according to the appropriate local regulations.
Recurring leaks should be reported to AGGREKO.
7.4. WEEKLY MAINTENANCE
7.4.1. CHECK THE WATER/ANTIFREEZE LEVEL.
Stop the engine and wait for the temperature to cool before checking the coolant level.
Remove the pressure cap slowly to relieve the pressure of the cooling system. Failure to do so could
result in personal injury from heated coolant spray (See Figure 7.2).
Check the coolant level. Replenish with the correct coolant fluid as necessary (see section 8).
Figure 7.2 - Coolant Level Check
7.4.2. CARRY OUT A VISUAL CHECK OF THE DRIVE BELTS.

The cooling pump, alternator and radiator fan are driven by a single belt arrangement from the
engine pulley. Check the belts for signs of wear. Check the belt tension.
NOTE: Do not remove guards.
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8.0 LUBRICATION
8.1. GENERAL INFORMATION
Lubrication is an essential part of preventive maintenance, affecting to a great extent the useful life of
the unit. Different lubricants are needed and some components in the unit require more frequent
lubrication than others. Therefore, it is important that the instructions regarding types of lubricants
and the frequency of their application be explicitly followed. Periodic lubrication of the moving parts
reduces to a minimum the possibility of mechanical failures.
The Preventive Maintenance Schedule shows those items requiring regular service and the interval
in which they should be performed. A regular service program should be developed to include all
items and fluids. These intervals are based on average operating conditions. In the event of
extremely severe (hot, cold, dusty or wet) operating conditions, more frequent lubrication than
specified may be necessary. Details concerning lubrication of the running gear are in Maintenance
Section.
8.2. GENERATOR OIL CHANGE
These units are normally furnished with an initial supply of oil sufficient to allow operation of the unit
for approximately 6 months or 400 hours, although this should be in line with the current service best
practise. The unit will however need to be topped up with oil during this period. If a unit has been
completely drained of all oil, it must be refilled with new oil before it is placed in operation. Refer to
specifications in Lubrication Table.
NOTICE: Some oil types are incompatible when mixed and result in the formation of varnishes,
shellacs, or lacquers that may be insoluble. Such deposits can cause serious problems including
clogging of the filters. Where possible, do NOT mix oils of different types and avoid mixing different
brands. A type or brand change is best made at the time of a complete oil drain and refill.
If the unit has been operated for the time/ hours mentioned above, it should be completely drained of
oil. If the unit has been operated under adverse conditions, or after long periods in storage, an earlier
change period may be necessary as oil deteriorates with time as well as by operating conditions.
An oil change is good insurance against the accumulation of dirt, sludge, or oxidized oil products.
Completely drain the reservoir, piping, and Purafiner system. If the oil is drained immediately after
the unit has been run for some time, most of the sediment will be in suspension and, therefore, will
drain more readily. However, the fluid will be hot and care must be taken to avoid contact with the
skin or eyes.
After the unit has been completely drained of all old fluid, close the drain valve. Add oil in the
specified quantity at the filler plug. Tighten the filler plug and run the machine to circulate the oil.
Check the oil level when unit is warm and not running. If not near the middle of the dipstick, stop the
unit and make corrections. DO NOT OVERFILL.
8.3. OIL SPECIFICATION
The oil required for this engine is:
Manufacturer: Castrol
Product Name: Tection T 15W-40 (Formerly RX Super Plus)
Relative Density @ 25°C 0.89 g/cm³
Viscosity @ 40°C 110 mm²/s
Viscosity @ 100°C 14.5 mm²/s
Viscosity Index 135
CCS –20ºC 6450 mPA.s
Total Base Number (TBN) 11.6 mgKOH/g
Flash Point (COC) 228 °C
Pour Point -36 °C
Sulphated Ash 1.5 %m
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9.0 TROUBLE SHOOTING

9.1. INTRODUCTION
Trouble shooting for a generator set is an organized study of a particular problem or series of
problems and a planned method of procedure for investigation and correction. The trouble-shooting
chart that follows in Section 9.3 includes some of the problems that an operator may encounter
during the operation of a generator set.
The chart does not attempt to list all of the troubles that may occur, nor does it attempt to give all of
the answers for correction of the problems. The chart does give those problems that are most
probable to occur. To use the trouble shooting chart:
1) Find the problem being experienced in the Symptom column on the far left.
2) Proceed to work through the possible causes in the next column, instigating the appropriate
corrective action where required from the next column.
9.2. ACTION PLAN
1) Think Before Acting: Study the problem thoroughly and ask yourself these questions:
1) What were the warning signals that preceded the trouble?
2) Has a similar trouble occurred before?
3) What previous maintenance work has been done?
If the generator will still operate, is it safe to continue operating it to make further checks?
F. Do The Simplest Things First: Most problems are simple and easily corrected. Always check
the easiest and most obvious things first, following this simple rule will save time and trouble.
Note: For trouble shooting electrical problems, refer to the Wiring Diagram Schematic found
in Appendix D.
G. Double Check Before Disassembly: The source of most generator troubles can be traced not
to one component alone, but to the relationship of one component with another. Too often, a
generator can be partially disassembled in search of the cause of a certain trouble and all
evidence is destroyed during disassembly. Check again to be sure an easy solution to the
problem has not been overlooked.
H. Find And Correct Basic Cause: After a mechanical failure has been corrected, be sure to locate
and correct the cause of the trouble so the same failure will not be repeated. A complaint of
"premature breakdown" may be corrected by repairing any improper wiring connections, but
something caused the defective wiring. The cause may be excessive vibration.
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9.3. TROUBLE SHOOTING CHART

SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION
Battery isolator switch not
Close battery isolator switch.
closed.
Batteries flat or bad. Read
value on battery voltage meter Replace or charge batteries.
ENGINE DOES NOT CRANK (must be 24V or more).
WITH 24V ELECTRIC MOTOR
Mini circuit breaker of 10A in
Reset.
terminal box is open.
Start relay at cranking motor Measure the voltage over the
defective. start relay.
Fuel tank empty. Fill up fuel tank.
Check system for leaks. Bleed
Air in the fuel system.
the fuel system.
Dirty fuel filters. Replace fuel filters.
ENGINE CRANKS BUT DOES Check voltage (24V) over fuel
NOT START Call for AGGREKO support.
shut-off valve during crank.
Optional air shutdown valve
Open air shutdown valve.
closed.
Overspeed protection is Put key back to 0 and try to
activated. start the engine again.
the fuel system.
Dirty fuel filters. Replace fuel filters.
ENGINE STARTS UP BUT Overspeed during acceleration. Decrease frequency setting.
STOPS AFTERWARDS
Check safeties:
Oil pressure – Water
Shutdown after 6 seconds.
temperature – Water pressure –
Oil temperature (option)
Adjust frequency to the correct
Frequency too high.
level.
Connection between governor
ENGINE OVERSPEEDS Repair connection.
and fuel pump interrupted.
the fuel system.
Wait until engine has reached
Engine not yet at operating
the normal operating
temperature.
temperature of 80-90ºC.
ENGINE SPEED NOT
STABLE Dirty fuel filters. Replace fuel filters.
Wear in ball eyes, linkage
Replace ball eyes.
governor / fuel pump.
Dirty air filters. Replace air filters.
ENGINE SHOWS EXCESS Dirty fuel filters. Replace fuel filters.

SMOKE AND / OR LACK OF Check system for leaks. Bleed
POWER Air in the fuel system.
the fuel system.
Overload. Check load.
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SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION

Measure voltage at outlet
Voltmeter defective. terminals of alternator. If voltage
measured replace voltmeter.
ALTERNATOR DOESN’T
GENERATE VOLTAGE Voltage regulator defective. Replace voltage regulator,
the fuel system.
Speed frequency too high / Check frequency meter and
low. adjust if required.
ALTERNATOR VOLTAGE
TOO HIGH / LOW Incorrect voltage setting. Adjust voltage regulator.
No identifiable cause. Consult AGGREKO.
Engine speed not stable. Check stability of engine speed.
ALTERNATOR VOLTAGE
NOT STABLE Adjust stability on the voltage
Incorrect stability adjustment.
regulator.
Circuit breaker control switch
Select local position.
(Figure 6.1) set remote control.
Circuit breaker tripped. Reset circuit breaker.
MAIN CIRCUIT BREAKER
WILL NOT CLOSE Circuit breaker not charged, Charge motor mechanism
motor mechanism broken. manually, inform AGGREKO.
Lamp ‘CIRCUIT BREAKER
Replace lamp.
CLOSED’ defective.
MAIN CIRCUIT BREAKER Switch on overload or short
Remove load.
CLOSES BUT TRIPS AGAIN circuit.
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APPENDIX A
MATERIAL SAFETY DATA SHEETS
Appendix A - i
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CASTROL TECTION T 15W-40
Appendix A - ii
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Appendix A - iii
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Appendix A - iv
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Appendix A - v
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LEAD ACID BATTERIES
HEALTH & SAFETY

LEAD ACID BATTERIES
##################################
The handling and proper use of lead-acid batteries is not hazardous provided sensible precautions are observed and
that Operatives having been trained in their use are adequately supervised.
The purpose of this letter is threefold:-

[ i] to indicate potential hazards that may arise.
[ ii] to outline the precautions to be taken to minimise such hazards.
[iii] to indicate action to be taken in the event of an accident.
1. SULPHURIC ACID [S.G. 1.260 - 1.300]

Batteries contain sulphuric acid which may leak for a variety of reasons and may be given off as droplets and/or
spray during recharging.
[The Hazards]
Sulphuric Acid is a poisonous and corrosive clear liquid which can burn/irritate skin and eyes and could burn clothing.
[Precautions]
Always handle batteries with care
Always store upright
Never over-fill with acid
Always charge in a well ventilated area. Maximum voltage 15v per each 12v Battery.
Use eye protection and protective clothing if there is any risk of acid splashing.
[Emergency Action]
Skin Contact: Immediately wash the affected area with copious amounts of
clean water. Remove any contaminated clothing.
Eye Contact Immediately irrigate eyes for at least 10 minutes with clean
water.
Swallowing Make the victim drink volumes of water, milk or milk of
magnesia.
DO NOT GIVE EMETIC
In all cases seek medical attention. Speed of action is vital.
[Spillages]
Small spillages can be swilled away with volumes of water.
[Disposal]
See Section 5.
2. ELECTRICAL ENERGY
[The Hazards]
The accidental connection of battery terminals by conductive objects, e.g. metal tools or metal personal jewellery etc.,
may generate sufficient heat to cause burns, create arcing or cause molten metal to splash.
Appendix A - vi
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[PAGE TWO].
[Precautions]
Always ensure correct installation. The positive cable must be attached to the terminal marked [+] and the negative
to the terminal marked [-]. Cables and terminals should be kept clean and securely fitted.
Before using metallic tools on a battery remove metallic objects from hands and wrists.
Before working on a vehicle electrical system disconnect the Battery, disconnecting the earth strap first and
reconnecting last. Do not place tools on top of batteries.
[Emergency Action]
Burns: Apply sterile bandage.

Electric Shock: Approach victim with care. Switch off or otherwise break
current. If not possible, detach victim from contact by means
of insulating material [wood, rubber or plastic hosepipe, folded
newspaper etc]
Do not touch with bare hands.
In each case seek medical advice. Speed of action is vital.
3. EMISSION OF GASES
A mixture of oxygen and hydrogen is emitted during charging and may be emitted if a battery is moved or shaken.
[The Hazards]
An explosive atmosphere exists if the concentration of hydrogen exceeds 4%.
[Precautions]
Always charge in a well ventilated environment.
No naked flames NO SMOKING
Be certain that current is switched off before making breaking connection. Always remove earth strap first and re-
connect last.
[Emergency Action]
Explosion: Seek medical advice remembering that acid may have been sprayed.
4. WEIGHT
In general terms batteries are heavy and awkward to handle. Care should be taken and correct lifting techniques
employed.
5. DISPOSAL
Batteries, Battery Acid, Lead and Lead compounds must be disposed of in accordance with:
[a] The deposit of Poisonous Waste Act 1972
[b] The Control of Pollution Act 1974
[c] Consumer Protection Act 1987
If in doubt, consult the Environmental Department of your Local Authority.
For further information refer to:- BRITISH STANDARD BS 6604; 1985
SAFE OPERATION OF STARTER BATTERIES.
Appendix A - vii
Issue: A
Date: 18/06/07
SUPERCOLDMASTER ANTIFREEZE
Appendix A - viii
Issue: A
Date: 18/06/07
Appendix A - ix
Issue: A
Date: 18/06/07
Appendix A - x
Issue: A
Date: 18/06/07
APPENDIXCB
APPENDIX
EQUIPMENT DATA SHEET
Appendix B - i
Issue: A
Date: 18/06/07
EQUIPMENT DATA SHEET No. G08.0311

Rev. A
Manufacturing
Diesel Generating Set Date June 2007
Birch Road
Dumbarton, G82 2RF 50Hz 350kVA
Tel: 0044 (0)1389 742214
Fax: 0044 (0)1389 742554
60Hz 350kW Page 1 of 3
1 Model Ref GHP/DC12 60A AI & Aus
2 Part Number Ref 601238A & 601239A
3 Specification Ref G32.0040
4 Installation Drawing Ref A050187
5 Maximum Ambient °C (°F) 35 (95) 38 (100)
6 Electrical Output Hz 50 60
ISO 8528-1
- Continuous Power (COP) kW (kVA) 254 (317.5) 297 (370)
- Prime Power (PRP) kW (kVA) 283 (354) 304 (380)
- Permissible average of PRP % 70 70
ISO3046/1
- Fuel Stop Power/Standby kW (kVA) 312 (390) 325 (406)
Single Step load application % 65 65
7 Alternator
Class F Temp. Rise (105°C)
- Three phase kW (kVA) 280 (350) 324 (405)
- Single phase kW (kVA) 140 (175) 146 (183)
Ends Out 12
Make & Type Newage HCI434F1
AVR MX341
Regulation % +/- 1.0
8 Circuit Breaker
Make & Type Merlin Gerin NS630N
Number of poles 4
Rating Amps 630
Trip Unit Type STR23SE
Overload Protection Range Amps 252-630
Short Circuit Protection Range Amps 2520-6300
Technical Department – Dumbarton Approved by
Appendix B - ii
Issue: A
Date: 18/06/07

Rev. A
Manufacturing Diesel Generating Set Date June 2007
Birch Road
Tel: 0044 (0)1389 742214
Fax: 0044 (0)1389 742554 60Hz 350kW Page 2 of 3
9 Load Terminals
Type M12
10 Fuel Consumption
Standby/Fuel Stop lit/hr(US gal/hr) 71.6 (18.9) 75.4 (19.9)
100% Prime Power " " 64 (16.9) 69.8 (18.4)
75% " " 48.3 (12.7) 52.6 (13.9)
50% " " 33 (8.7) 36 (9.5)
11 Running Hours
100% Prime Power Hours 14.5 13.3
75% 19.25 17.7
50% 28 25.8
12 Exhaust Emissions
Measurement Method TA Luft EPA-MOH/CARB
Specific Load g/kWh 100% Load ± 2% ISO 8178D2
NOx - Oxides of Nitrogen 5.762 TBC
PM - Particulate Matter 0.06 TBC
CO - Carbon Monoxide 0.833 TBC
HC - Unburnt Hydrocarbons 0.234 TBC
13 Exhaust Silencer
Make & Type Discom
Certificate No DNV M-9801
Permissible back pressure mm (ins) Hg 12.7 (0.5) 12.7 (0.5)
14 Noise
Sound Pressure at 1 metre dBA 73 70
Sound Pressure at 7 metre dBA 75 70
Appendix B - iii
Issue: A
Date: 18/06/07

Rev. A
Manufacturing
Birch Road
Diesel Generating Set Date June 2007
Tel: 0044 (0)1389 742214
Fax: 0044 (0)1389 742554
60Hz 350kW Page 3 of 3
15 Engine
Make & Type Scania DC12-60A
Cylinders & Form 6 in Line
Aspiration Turbocharged & Charge Aircooled
Fuel Pump Scania 8000 series
Governor Type Scania (EMS)

Engine Management System
Make & Model S6
Steady State frequency % +/-0.5
Battery Voltage Volts 24
16 Overall Dimensions
- Length Metres (feet) 4.64 (15’ 3”)
- Width Metres (feet) 1.50 (4’ 11”)
- Height Metres (feet) 2.565 (8’ 5”)
17 Weight
- Without fuel Kg (lbs) 5800 (12787)
- With fuel Kg (lbs) 6590 (14528)
18 Capacities
- Fuel gross Litres (US gall) 1025 (271)
usable 930 (246)
- Lub oil (min/max) 28-33 (7.4-8.7)
- Coolant 24 (6.3)
19 External fuel supply
- maximum above base Metres (feet) 2.4 (7’ 10”)
- maximum below base Metres (feet) 1.5 (5 ‘ )
Appendix B - iv
Issue: A
Date: 18/06/07
APPENDIX C
INSTALLATION OUTLINE DRAWING
Appendix C - i
Issue: A
Date: 18/06/07
Appendix C - ii
Issue: A
Date: 18/06/07
APPENDIX D
CONTROL PANEL LAYOUT
Appendix D - i
Issue: A
Date: 18/06/07
Appendix D - ii
Issue: A
Date: 18/06/07
APPENDIX E
ELECTRICAL SCHEMATICS
Appendix E - i
Issue: A
Date: 18/06/07
Appendix E - ii
Issue: A
Date: 18/06/07
Appendix E - iii
Issue: A
Date: 18/06/07
Appendix E - iv
Issue: A
Date: 18/06/07
Appendix E - v
Issue: A
Date: 18/06/07
Appendix E - vi
Issue: A
Date: 18/06/07
APPENDIX F
LIVERY LAYOUT
Appendix F - i
Issue: A
Date: 18/06/07
Appendix F - ii
Issue: A
Date: 18/06/07
APPENDIX G
MANUFACTURERS COMPONENT DATA
Appendix H - i
Issue: A
Date: 18/06/07
Document No. M04.0130

Revision A Date 18/06/07
DC12-60A 350kVA Genset AI & AUS Spares List & Manufacturers Data
Description Quantity Supplier Suppliers Part Aggreko Part

Per Set No. No.
Radiator 1 Covrad CRDA1345-A1 067091SS
Radiator Fan 1 Scania / Multi-Wing 9128835SGB N/A
Coupling, Disc 3 Newage 350-11580 N/A
Charging Belt / Fan
1 Scania 1 389 037 N/A
Belt
Starter Motor 1 Scania 571 463 N/A
Battery Charging
1 Scania 571 498 N/A
Alternator
Circuit Breaker
N1250N 4P Refer to Description
Micrologic Electronic 1 Merlin Gerin (Complete Assembly 293418A
Protection Motor 33304)
Mech
Current Transformer
3 Raytec Refer to Description 273084A
1200/5A
Water Temperature
1 Scania 1 539 107 N/A
Switch
Oil Pressure Switch 1 Scania 1 356 751 N/A
Lube Oil Filter 2 Scania 1 117 285 N/A
Combustion Air Filter
Technical Filtration
(Element & Safety 1 FRG15-0097 N/A
Systems
Element)
Secondary Fuel Filter 2 Scania 1 763 776 N/A
Primary Fuel Filter for
1 Racor 2040PM-OR N/A
900FG
Fuel level alarm 1 Fozmula T/LL70/11841 269069A
Fuel level sender
Float arm type to 1 Datcon / Fozmula Refer to description 269065A
230mm
Battery 2 DB Wilson 324 339002A
Coolant Temperature
1 Scania 1117301 N/A
Switch
Oil Pressure Switch 1 Scania 1 535 521 N/A
Appendix H - ii
Issue: A
Date: 18/06/07
APPENDIX H
LIFTING BEAM CERTIFICATE
Appendix H - i
Issue: A
Date: 18/06/07
Appendix H - ii
Issue: A
Date: 18/06/07
APPENDIX J
DNV SPARK ARRESTOR CERTIFICATE
Appendix J - i
Issue: A
Date: 18/06/07
Appendix J - ii
Issue: A
Date: 18/06/07
Appendix J - iii
Issue: A
Date: 18/06/07
APPENDIX K
INTERNATIONAL CONTACT INFORMATION
Appendix K - i
Issue: A
Date: 18/06/07
In case of emergencies please contact the nearest service department of AGGREKO. They can be reached 24 hours
a day and are operational at any place in the world
BELGIUM FRANCE GREAT BRITAIN
Aggreko N.V. Aggreko S.a.r.l. Aggreko Generators Ltd.
Smallandlaan 7 1 Chemin de l’Ancien Parc Overburn Avenue
2660 Hoboken 91220 Bretigny Sur Orge DUMBARTON
Belgium France G82 2RL
Tel: (+32) 03 825 02 71 Tel: +33 (0)825 008007 Tel: (+44) 1389 767821
Fax: (+32) 03 825 11 81 Fax: +33 (0)1 69 737119 Fax: (+44) 1389 761577
NETHERLANDS NORWAY SPAIN
Aggreko International (Ned) Aggreko Norway A.S. Aggreko Iberia S.A.
B.V. Sorlandsveien 318 Avda. Torre Mateu, 35-37
Ketelweg 77 Postboks 543 Polg. Industrial Can Salvatella
3356 LD Papendrecht EGERSUND 08210 Barbera del Valles
EUROPE Netherlands N-4379 BARCELONA
Tel: (+31) 078 64 41 441 Norway Tel: (+34) 93 747 93 90
Fax: (+31) 078 642 80 83 Tel: (+47) 810 00 333 Fax: (+34) 93 729 02 83
Fax: (+47) 051 46 45 90
GERMANY GERMANY ITALY
Frankfurt Mulheim Aggreko Italia srl
(Central Europe South East) (Central Europe North) Via Copernico, 60
Aggreko Deutschland GmbH Aggreko Deutschland GmbH 20090 Trezzano sul Naviglio
Darmstadter Straße 66-68 Ruhrorter Straße 112 (Milano)
64572 Büttelborn 45478 Mülheim/Ruhr Italy
Germany Germany Tel: +39 02 4846 3024
Tel: +49 (0)61 52 93 93 0 Tel: +49 (0)208 58 09 70 Fax: +39 02 4451 243
Fax: +49 (0)61 52 93 93 99 Fax: +49 (0)208 58 09 798
CANADA U.S.A.
Aggreko Inc. Aggreko LLC
300 Clarence Street 4607 W Admiral Doyle Drive
NORTH Brampton, PO Box 10004
AMERICA ONTARIO NEW IBERIA, LA 70562-0004
L6W 1T5 Tel: (+1) 337 365 5479
Tel: (+1) 905 459 3321 Fax: (+1) 337 367 0870
Fax: (+1) 905 459 3392
REPUBLIC OF
SINGAPORE
Aggreko Singapore Pte Ltd
10 Pioneer Sector 1
ASIA
SINGAPORE
62844
Tel: (+65) 6862 1501
Fax: (+65) 6862 0182
UNITED ARAB EMIRATES
Aggreko Inc.
PO Box 17576
MIDDLE
Jebel Ali
EAST
DUBAI
Tel: (+971) 04 834059
Fax: (+971) 04 834145
AUSTRALIA/PACIFIC
Aggreko Generator Rentals
Pty Ltd
101 Woodlands Drive
AUSTRALIA /
Braeside Victoria
PACIFIC
3195
MELBOURNE
Tel: (+61) 03 586 5050
Fax: (+61) 03 586 50514
Appendix K - ii

350 kVA, M020246A, Scania GHP-DC12 60 (XAVM) 18-06-2007

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2.0 NOISE EMISSION

5.0 GENERAL DATA

6.0 OPERATING INSTRUCTIONS

6.2. OPERATING PROCEDURE .................................................................................................16

9.0 TROUBLE SHOOTING

APPENDIX A: Material Safety Data Sheets

APPENDIX C: Installation Outline Drawing

APPENDIX D: Control Panel Layout

APPENDIX E: Electrical Schematics

APPENDIX F: Livery Layout

APPENDIX G: Manufacturers Component Data

APPENDIX H: Lifting Beam Certificate – 14700842/001

AVOID INGESTION, SKIN CONTACT AND INHALATION OF FUMES.

IF IN DOUBT CONTACT AGGREKO.

DO NOT STAND IN FRONT

2.0 NOISE EMISSION

FOR SAFETY, EAR PROTECTION SHOULD ALWAYS BE

Complete Package Max. Fuel 14528 lbs (6590 kgs)

Complete Package Without Fuel 12787 lbs (5800 kgs)

NOTE: When operating at elevated altitude please refer to engine manufacturer’s

4.7. REMOTE FUELLING

5.0 GENERAL DATA

5.5. DIESEL ENGINE

5.6. ENGINE LUBRICATION SYSTEM

5.10. ENGINE CONTROL SYSTEM

Figure 5.2 - 350 kVA Generator Part Locations

6.0 OPERATING INSTRUCTIONS

Figure 6.1 – Control Panel Exterior

Deep Sea 5510 Earth Leakage Off

Key for figure 6.1

Figure 6.2 – Control Panel Interior

1 AVR 10 Relay R1 Relay

3 Merlin Gerin 1250A 4P MCCB 12 Diodes D1 - 2

Earth Leakage Relay MCB 6 (Bus Sensing Volts)

MCB5 (MCCB Controls) 15 Baseload

MCB1 (E-Stop Supply) 16 Earth bar

MCB2 (Generator Sensing

Key for figure 6.2

6.1.2. CONTROL MODULE

2 CB open button 8 Mute alarm/lamp test

3 CB indication 9 Manual start

6.1.3. DISPLAY PAGES

5. Current alarm page

6.1.4. FRONT PANEL LEDS

6.2. OPERATING PROCEDURE

6.2.2. REMOTE/STANDBY OPERATION

6.3. MODES OF OPERATION

6.3.1. SINGLE SET OPERATION

6.3.2. LOADSHARING WITH ANOTHER 5510 CONTROLLER

Figure 6.4 – MSC CANBUS connection between 5510 control modules

6.3.3. BASELOAD OPERATION

6.3.4. LOADSHARING WITH A GENERATOR SET FITTED WITH ANALOGUE PARALLEL

6.3.5. POWERLINK OPERATION (WHERE FITTED)

6.4. ALARM FUNCTIONS

6.5. CHANGING PARAMETERS

To access the front panel editor

Generator Full Load

Alternative frequency and alternative voltage

6.5.2. PARAMETER ADJUSTMENT FOR ALTERNATIVE ALTERNATOR CONFIGURATIONS

Alternator Deep Sea set-up

Refer to the Maintenance Schedule for quick reference.

3 Months / 6 Months / 12 Months