Ruby Pwrhs O&M Manual

7/23/2019 Ruby Pwrhs O&M Manual

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RUBYPOWER PLANT UPGRADE

OPERATIONS &

MAINTENANCE

MANUAL


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INDEX

Introduction & Overview ......................................................................................Tab I

1.1 Introduction

1.2 Additional Resources

1.3 Power Plant Overview

Periodic Inspections & Maintenance .................................................................Tab II

2.1 Daily Inspection

2.2 Monthly Inspection

2.3 Six Month Inspection & Maintenance

2.4 Annual Inspection & Maintenance

2.5 Engine 250 Hour Service

2.6 Engine 1,000 Hour Service

2.7 Engine 2,000 Hour Service

2.8 Inspection & Service Logs

System Descriptions & Troubleshooting......................................................... Tab III

3.1 Switchgear

3.2 Engine-Generators

3.3 Fuel System

3.4 Cooling System

3.5 Heat Recovery System

3.6 Plant Heating & Ventilation

3.7 Station Service Electrical System

3.8 Fire Suppression System

Inspection & Service Log Forms.......................................................................Tab IV

Equipment Suppliers & Service Instructions ....................................................Tab V


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Tab I.Introduction &

Overview


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RUBY POWER PLANT INTRODUCTION &OVERVIEW

1.0 INTRODUCTION & OVERVIEW

1.1 Introduction:

This Operation and Maintenance (O&M) Manual has been prepared to provideguidance in the routine operation, inspection, and maintenance of the power plant.

Proper care of the power plant will ensure long life and reliable performance. It iscritical that thorough inspections be performed on a daily basis and that allrequired maintenance be performed at the specified time intervals.

This manual is divided into six sections. Tab I includes a list of additionalresources and a basic overview description of the power plant. Tab II containsdescriptions of periodic inspections and routine maintenance including appropriateintervals. Tab III includes detailed descriptions of each system along withtroubleshooting information. Tab IV has blank log forms for recording all

inspections and maintenance. Tab V has an index of equipment withmanufacturer, model, and vendor for each item. It also includes catalog literatureand maintenance instructions for many of the common service items. Tab VIincludes record drawings of the complete facility.

1.2 Additional Resources:

This manual covers all systems in the power plant in limited detail. For some ofthe more complicated items, such as the switchgear, a separate detailed O&M

Manual has been prepared to supplement this manual. Following is a list ofadditional material for this facility:

Switchgear Operation & Maintenance Manual

Engine Generator Service Manuals

Fire Suppression System Operation & Maintenance Manual

Bulk Fuel System Procedures & Maintenance Manual

Operators need to receive regular training to develop the skills required to properlyoperate and maintain the power plant. The Alaska Vocational Technical Center(AVTEC) provides training courses for power plant operators. AVTEC can becontacted at 1-800-478-5389.

For complex repairs that are beyond the expertise of the local operators,the Alaska Energy Authority (AEA) offers technical support through itsCircuit Rider Maintenance Program. AEA can be contacted at 1-888-300-8534.

AVTEC and the AEA have prepared a Supplemental Training Resource Guide.This guide contains most of the information in this manual in a video format on twoCD-ROMs. It is useful for both introductory training and as a refresher course. Itshould be viewed on a regular basis by all plant operators. There is also a similarCD-ROM video resource available for bulk fuel systems. Copies of the CD-ROMscan be obtained from AVTEC or the AEA.


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Power is generated at 277/480V three phase.Automatic paralleling switchgear located in thecontrol room provides control and monitoring of all

power generation functions. An individual section isprovided for each generator. The upper portion ofeach generator section contains all of the low voltage controlequipment while the lower portion contains the 480V circuitbreaker and contactor.

A master section provides overall system control and monitoring.The master section contains the programmable logic

controller (PLC), the operator interface unit (OIU), thepower meters, the annunciation panel, and othermaster control devices.

A separate section is provided for the communityfeeder. The lower portion contains the 480V circuitbreaker for the main feeder to the community and the

circuit breaker for the station service power. The upper

portion contains the variable frequency drives for thecharge air coolers and radiators (and main heat recoverypump).

Under normal operation the PLC monitors the load on the system and selects theappropriate generator to operate. As the load increases the PLC brings a largergenerator on line and takes the smaller unit off. As the load decreases the PLCbrings a smaller generator on line and takes the larger unit off. The systemautomatically parallels multiple generators to the bus for a smooth and seamless

transition of power from one unit to the next. Any combination of generators canbe operated in parallel to meet an extreme high peak demand. The system willautomatically share load between the generators. All control functions can be

monitored and many of the system settings can bechanged through the OIU.

A server (personal computer) provides access to thesame information displayed on the OIU. The server isconnected to the internet and allows the system to bemonitored and modified by another computer in a remotelocation. Password protection is included in the systemprogramming to limit access to critical settings and data.

Cameras are installed in the generation and control


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The piping systems in the power plant utilize color coded tags to identifythe product. Green indicates diesel fuel, pink indicates ethylene glycolcoolant, and gray indicates propylene glycol heat recovery. The tagsare installed on significant valves and describe the function. Othervalves are provided with small brass tags labeled N.O. for normally open

or N.C. for normally closed.

A 160 gallon day tank provides diesel fuel to all of the enginesthrough a piping manifold. The day tank is supplied from a 5,000gallon intermediate tank located across the street from the powerplant. The day tank fills automatically and is equipped withseveral redundant protective systems to prevent overfill orrunning the plant out of fuel.

All of the engines are connected to a common coolingpiping system that runs to a pair of remote radiators.Each engine is also provided with a charge air cooler toremove heat from the turbocharger. Each air cooler isdedicated to the associated engine. All of the radiators

and charge air coolers are controlled by variable frequencydrives in the switchgear that modulate the fan speed tomatch the cooling load.

Jacket water heat from the generators is captured andused to provide space heat through the heat recovery

system to the washetria/water plant and also to theadjacent water/sewer truck garage.

The control room is heated by a cabinet unit heater.Cooling and ventilation for the control room is provided

by an operable window. Cooling for the generationroom is provided by wall mounted exhaust fans.Combustion air for the generators and make up air forthe exhaust fans and the radiators is provided through ducted intakes that are

equipped with filters. All intake, exhaust,and radiator ducts are equipped withnormally closed motorized dampers that


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All AC power for the plant isprovided from the main busthrough the station service circuitbreaker. A dry-type transformerconverts the 277/480V power to

120/208V where it is distributedthrough circuit breakers in thethree phase station servicepanelboard SS.

The building is equipped with an automatic fire suppression system. Multipledetectors are installed in each room. Activation of a single detector anywhere inthe plant shuts the generators down, closes all of the duct dampers, and soundsan alarm. Activation of a second detector in the generation room will begin a 30second countdown to discharge. At the end of the 30 second period the systemwill begin to discharge and a second exterior strobe will flash to signal discharge.The system will discharge for at least 10 minutes filling the generation room with afog of water mist. Fire detection is provided in all rooms while fire suppression isonly provided for the generation room.


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Tab II.Periodic Inspection

&Maintenance


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RUBY POWER PLANT PERIODIC INSPECTIONS &MAINTENANCE

2.0 PERIODIC INSPECTIONS & MAINTENANCE

2.1 Daily Inspection:

The plant should be inspected a minimum of three times per day. At least one ofthe inspections needs to include a thorough check of all systems in the plant.The other inspections need to include at a minimum a walk-through visual checkof the plant plus recording meter readings.

A) When approaching the plant check the site security. Make sure the doorsand windows on the power plant are closed and locked. Look for anyevidence of vandalism or damage to the building.

B) Check the exhaust for the operating engine. A change in thecolor to black or blue could indicate an engine problem. Check

the charge air coolers for obstructions (snow drifts, leaves, etc).

C) Check the fuel level in the intermediate tank. If the level isbelow 50% the tank should be re-filled. Verify that all valves arein the normal position (open or closed as indicated by tags).Check for any leaks or signs of damage.

D) Enter the control room andcheck the switchgear forany alarms or faults. Verifythat all engines are in theauto position and availableto run. Check the VariableFrequency Drives (VFD)and verify that all are in the VFD position and that there are no alarms.

E) Get the daily inspection log. Record the date, time,temperature, site security, exhaust color, intermediate tanklevel, and other information from the exterior inspection.

Read the main (bus) meter and record the total kWhgenerated, running kW, frequency, voltage (for all 3 phases),and amperage (for all 3 phases). Read the station servicemeter and record the total kWh. Note that the meterdisplays actual ly read in MWh s o ign ore the decimalpoint to read kWh. Read the OIU and record the main (bus) peak kW thenpress the RESET button on the OIU screen to reset the peak reading.

F) Record which engine is on line and inspect the on-line generator. Verify that the battery charger isworking (no alarms). Check the air filter for alarms(indicated by red display). Look for signs of wear orleaks and wipe down as required. Record the totalengine hours, jacket water temperature, oil pressure,and battery voltage. The water temperature should be 180F-200F, the oilpressure should be 40 PSI 60 PSI, and the voltage should be 24V-28V.Ch k th i il l l th it N t th t if th l l t


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H) Check the day tank. Verify that the level is between 1/2 andfull. Check the panel to make sure the green power light ison and that there are no alarm lights. Check the filter bowlfor sediment and water. Drain bowl or replacefilter element as required. Check the piping for

leaks. Record the total gallons from the meter.

I) Verify proper operation of the crankcase ventilation fan EF-3.The fan should operate any time the plant is on. The gaugeshould show a vacuum of approximately 0.5. Wipe any oilseeps from the fan body and piping. Check the condensate drip

leg (clear pipe) and drain off water as required.

J) Check the cooling system. Verify that the coolant temperature is 180F-200Fin the discharge (upper) pipe and 10F-20F colder inthe suction (lower) pipe. Verify that the pressure inthe lower pipe is 3 PSI 5 PSI and that the glycollevel in the expansion tank is between 1/2 and 2/3.Check the radiators and piping for leaks. Verify that

the radiator discharge and intake dampers are openwhen the radiators are running.

K) Check the heat recovery system. Verify thatthe coolant temperature on the engine side ofthe heat exchanger is 180F-200F and thepressure is 3 PSI 5 PSI. Verify that thecoolant temperature on the heat recovery

(exterior) side of the heat exchanger is 170F-190F and the pressure is 30 PSI40 PSI.Verify that all pumps are on (red pilot lightswitches on) and operating. When the pumpsrun the pressure gauge on the downstreamside will be higher than on the upstream side.Proper operation can be verified by turning thepumps off momentarily and then back on and watching the pressure gauges.Check the heat exchanger, pumps, and piping for leaks.

L) Verify that all lights are working. Check room temperatures to make surethat heating and ventilation systems are operating properly. Verify that allred pilot light switches are on.

M) Check the fire suppression system. Verify that the nitrogen pressure is in thenormal range Check the panel to make sure there


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2.2 Monthly Inspection:

A thorough inspection of basic systems in the plant needs to be performed atleast one time per month. This is in addition to the daily inspections.

A) Check the annunciator lights on the switchgear.

On the master section press the LAMP TESTbutton. All lights on the master section and theengine sections should light up. Note that thelamps on the VFD section cannot be tested.Replace any lamps that do not work.

B) Check the function of the day tank control panel. Pressthe DAY TANK FILL PUMP P-DF1 PUSH TO TESTbutton and hold for approximately 5 seconds. Verifythat the pump runs, the PUMP RUN light turns on,and the ACTUATOR VALVE OPEN lamp turns on.Release the button and verify that the pump stops andthe lamps turn off. Note that theACTUATOR VALVE OPEN lamp may takeup to 10 seconds to turn off. Press thePUSH TO TEST ALARM HORN button andverify that the exterior alarm horn sounds

and the strobe flashes. Note that a second person may be

required to verify horn and strobe operation.C) Check the fluid levels in each cell of each battery. Re-fill as required. Use

only dist i l led w ater .

D) Inspect all of the fluorescent lights and replace any bulbs that are dim orburned out.

E) Verify that all emergency lights operate. This can be accomplished bypushing the press to test button on each emergency light or by shutting offthe circuit breakers for the normal lighting.

F) Verify proper operation of heating and ventilation equipment andthermostats. The cabinet unit heater should turn on when thethermostat is raised and turn off when it is lowered. The normalsetpoint is 70F. The exhaust fans should turn on when thethermostat is lowered and turn off when it is raised. The normalsetpoint is 80F. Verify that the motorized dampers on the fan andon the associated intake open when the fan starts and close when the fanstops. Note that the dampers may take up to one minute to open. Note also

that the combustion air damper should be open any time the plant isoperating.

2.3 Six Month Inspection and Maintenance:

Several systems require testing and maintenance at least two times per year.This is in addition to the monthly inspections.

A) Air intakes are located in the generation room on the


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C) Automatic air vents are installed in the heat recovery piping.They are located near the unit heaters, the heat exchanger, andany other high points in the system. The isolation valves arenormally left closed. Prior to venting air from the piping makesure the system is up to normal temperature and pressure.Open the isolation valves and remove the caps from the airvents. Cycle the pumps on and off several times in 30 secondintervals using the pump disconnect switches. After all air hasbeen vented replace the caps and close the isolation valves.Turn the pumps back on.

D) The engine cooling system is charged with a50% mix of Shell Rotella ELC ethylene glycol and

treated water. When the fluid level drops addonly pre-mixed solution identical to the originalfluid, do no t add water or other types of ant i -freeze. Every six months the glycol needs to betested for concentration and corrosion protection.The concentration can be checked with ahydrometer, spectrometer, or test strip. The level of corrosioninhibitors can be checked with a special test strip provided bythe supplier. Alternatively, a sample can be pulled and sent to the supplier

for testing.E) The heat recovery system is charged with a 50% mix of

Safe-T-Therm propylene glycol and treated water. Notethat this is different than the engine coolant. When thesystem pressure drops add only pre-mixed solutionidentical to the original fluid, do no t add water or othertyp es of anti- freeze. Every six months the glycol needsto be tested for concentration and corrosion protection.

The concentration can be checked with a hydrometer,spectrometer, or test strip. The level of corrosion inhibitors can only bechecked by the manufacturer. Pull a sample and send it to the supplier fortesting.

2.4 Annual Inspection and Maintenance:

In addition to the six month maintenance routine there are three additionalprocedures that need to be performed once each year.

A) The charge air coolers should be cleaned each fall prior tofreeze up to remove any dirt, leaves, bugs, or other debristhat may have accumulated over the summer. Note thatcharge air coolers can only be cleaned when the associatedengine is off. Using a pressure washer or hose and nozzle,spray the core from the front face, washing the debris towardsthe fan. Repeat for each cooler.


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C) The high voltage (bottom) section of the switchgearshould be inspected each year. This will require aplanned outage to take the plant completely off line.Inspect all of the cables, contactors, and circuitbreakers for any signs of wear or heat damage. Verify

that all lugs and cable connections are tight.

2.5 Engine 250 Hour Service:

Note that engine manufacturers have recent ly increased the interval for oi lchanges from 250 hou rs to 300 hou rs. The descr ipt ions below and theengine maintenance log forms al l say 250 hou rs. This service may beperformed at 300 hours instead.

The following tasks need to be performed on each engine after every 250 hours

of run time. If the required maintenance cannot be performed at the scheduledtime, take the engine out of service until all work has been completed.

A) Take the generator off line by placing the GCP in MAN mode.This will cause another unit to start. Once the other generatoris on line (contactor closed) press the blueSTOP button onthe GCP. Note that if the service time has been exceededthe GCP will automatically take the generator off line (as longas another generator is available) and will display a SERVICEDUE message.

B) Lock the unit out using the key switchbelow the GCP and tag out of service.

C) Change the engine oil. Open the oil drain valve near the front of the engineand drain the oil into a bucket. Remove the oil filter and drain. Install a new

oil filter. Close the oil drain valve. Add new oil and use the dipstick to verifyproper level.

D) Clean the dust trap (rubber boot) on the bottom of the air filter.

E) Check the water pump for any fluid seeps. Check the belts and hoses forwear and aging. Replace as required.

F) Remove the tag and turn the key switch back to the ON position. Press theblue MESSAGE button on the GCP to scroll through the display until theSERVICE DUE IN 000 HOURS message appears. Press and hold the blue

DISPLAY button until the hours reset to 300. Press and hold the blueRESET button to clear the alarms.

G) Press the blue TEST button on the GCP. The engine will automatically start.Verify the engine oil pressure is in the normal range and check the oil filterfor leaks. After the engine runs for one minute press the blueSTOP buttonon the GCP. Check the oil level using the dipstick and add oil as required.


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A) Take the engine off line as described in 2.5 A above.

B) Lock the unit out using the key switch below the GCP and tag out of service.

C) Perform all of the tasks for the 250 hour service.

D) Change the fuel filter. Close the fuel supply valve at the front of the enginewhich is marked NORMALLY OPEN, CLOSE ONLY FOR TEMPORARYMAINTENANCE OF ENGINE. Remove the fuel filter beingcareful to catch all drips. Note that some engines havemultiple filters. Change all filters at the same time. Placethe filter(s) in the basket on the used oil hopper to drain.Install new fuel filter(s). Open the fuel supply valve. Openthe air bleed fitting on the filter housing and prime thefilter(s) with the hand pump. Close the bleed fitting.

E) Change the glycol filter. Close both valves next to the glycolfilter. Remove the old filter and install a new one. Open bothvalves.

F) Check the air filter. Change if required.

G) Unlock the unit and reset the GCP as described in 2.5F above.

H) Test and check the engine as described in 2.5G above.

I) Place the GCP back in AUTO mode.

2.7 Engine 2,000 Hour Service:

Note that if the Engine 250 Hour Service (see Section 2.5) is performed at300 hour intervals, the Engine 2,000 Hour Service as described in thissect ion should be performed at 1,800 hour intervals (every sixth oi lchange).

The following tasks need to be performed on each engine after every 2,000hours of run time. If the required maintenance cannot be performed at the

scheduled time, take the engine out of service until all work has been completed.A) Take the engine off line as described in 2.5 A above.

B) Lock the unit out using the key switch below the GCP and tag out of service.

C) Perform all of the tasks for the 250 hour service and 1,000 hour service.

D) Change the air filter.

E) Adjust the valve tappets. See the engine service manual for procedure.

F) Inspect the wiring inside the generator enclosure. Look forany signs of wear. Verify that all lugs and cableconnections are tight.

G) Unlock the unit and reset the GCP as described in 2.5Fabove.

H) Test and check the engine as described in 2 5G above


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Tab III.System Description

&Troubleshooting


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RUBY POWER PLANT SYSTEM DESCRIPTIONS &TROUBLESHOOTING

3.0 SYSTEM DESCRIPTIONS & TROUBLESHOOTING

3.1 Switchgear:

The switchgear provides control and monitoring of all power

generation functions. It is set up for fully automatic operationbut can also be operated manually. It is capable of operatingany combination of generator sets in parallel. The switchgear iscomprised of five sections. There is a master section thatprovides overall system control and monitoring, a feeder sectionthat also contains variable frequency drives, plus an individualsection for each generator set.

The upper portion of each generator section contains all of thelow voltage control equipment including the Genset ControlPackage (GCP), the control switches, and the annunciationlamps. The lower portion of each generator section contains the480V wiring, the generator circuit breaker, and the contactorthat connects the generator to the bus. The master section contains the lowvoltage control equipment, the programmable logic controller (PLC), the operatorinterface unit (OIU), and the power meters. The lower portion of the feedersection contains the 480V circuit breaker for the main feeder to the communityand the circuit breaker for the station service power. The upper portion contains

the variable frequency drives for the radiators and charge air coolers.Under normal (automatic) operation the PLC monitors the load on the systemand selects the appropriate generator to operate. This operation is referred to asthe Demand Control. As the load increases the PLC brings a larger generator online and takes the smaller generator off. As the load decreases the PLC brings asmaller generator on line and takes the larger generator off. The systemautomatically parallels multiple generators to the bus for a smooth and seamlesstransition of power from one unit to the next. Any combination of generators canbe operated in parallel to meet an extreme high peak demand. The system will

automatically share load between the generators. These same functions canalso be performed manually by the plant operator.

All control functions can be monitored and many of the systemsettings can be changed through the OIU. A server (personalcomputer) provides access to the same information displayedon the OIU. The server is connected to the internet and allowsthe system to be monitored and modified by another computerin a remote location. Password protection is included in the

system programming to limit access to critical settings and data.A) SWITCHGEAR POWER SOURCE -

Primary control power for theswitchgear is provided by a 120V AC to24V DC converter located in the mastersection. This system operates any timethe station service power is on Power


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generator section the engine will not be able to start, the ENGINE ALARMand OVERCRANK lamps will illuminate, and a FAIL TO START banner willdisplay on the GCP. The most likely cause of this is a dead battery or atripped circuit breaker.

B) PROGRAMMABLE LOGIC CONTROLLER (PLC) -Under normal (automatic) operation the PLC runsthe Demand Control functions including starting andstopping generators, closes the main feeder breakerto the community, monitors all system functions, andcontrols all annunciation lamps.

C) OPERATOR INTERFACE UNIT (OIU) - The OIU is a touch screen withcolored graphic displays. It shows system operating status, alarm history,power generated, peak load, fuel consumption, and other data throughvarious screens. It also provides the operator access to the Demand Controlsettings and will display the current demand system operating status. Thedemand setpoints are stored in PLC memory and can bechanged using the OIU. The OIU communicates with thePLC via Ethernet communication. Additional information onthe OIU is included in the separate Operation andMaintenance Manual for the switchgear. All functionsperformed from the OIU can also be performed from the

server or a remote PC via the internet.D) MASTER CONTROL AUTO & MANUAL OPERATION - The Master Control

Switch (MCS) on the master section will enable the automatic DemandControl when in the AUTO position and will disable the automatic DemandControl when in the MAN position.

1) When the MCS is in the AUTO position the system willoperate automatically under the control of the PLC andwill select the appropriate size generator to match the

power demand. This is the normal mode of operation forthe system and is referred to as Demand Control.

2) The MCS should only be placed in the MAN position inthe event of a failure of the PLC. With the MCS in the MAN position thegenerator sets must be manually controlled. Each GCP must be set tothe MAN mode. The operator must select the appropriate generator forthe power demand, manually start the unit, and place it on line. SeeGCP section below for procedure.

E) DEMAND CONTROL - The automatic Demand Control system operateswhenever the MCS is in the AUTO position.

1) Generators are considered available for Demand Control only when theirGCP is in the AUTO mode and there are no alarms. See GCP and

Alarm sections below for additional descriptions. The Demand Controlsystem will utilize all available generators as required to meet the load onthe system The demand levels are shown in the table below The

R P P S D & T


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RAISE level for a pre-set time delay (usually 3 minutes) the DemandControl will switch to the next higher level of generating capacity. Whenthe load exceeds the OVERLOAD level the Demand Control willimmediately switch to the next higher level of generating capacity (notime delay). When the load drops below the LOWER level for a pre-settime delay (usually 5 minutes) the Demand Control will switch to the nextlower level of generating capacity. Following is a list of demand levelsfor each combination of generators at the time of the original plantcommissioning:

DEMANDLEVEL

GEN ON-LINEKW

RAISELEVEL

LOWERLEVEL

OVERLOADLEVEL

1 #2OR #3 120 110 0 120

2 #1 160 155 95 160

3 #2 240 215 145 240

4 #2OR #3

280 250 190 280

5 ALL 400 --- 230 ---

Note: Generator #2 has been equipped with a heat exchanger in theexhaust stack to provide additional heat recovery in the winter. On theOperator Interface Unit (OIU) select gen #2 as the lead unit forNovember through April. This will cause the PLC to preferentially runGen #2 when available. Select Gen #3 as the lead unit for May throughOctober to preferentially run Gen #3 when available.

F) GENSET CONTROL PACKAGE (GCP) Each engine

generator set is controlled by the GCP located on the frontpanel of the associated generator section in theswitchgear. The GCP has four operating modes whichare selected by the blue buttons: AUTO, MAN, TEST, andSTOP (off). The mode can be selected individually foreach generator. Under normal operating conditions allGCPs should be set to AUTOmode.

1) With the GCP in the AUTO mode the generator set is controlled by thePLC under the Demand Control system. On a start command from the

PLC the GCP will start the unit, synchronize it to the bus, and close thecontactor to place the unit on line. On a stop command from the PLC theGCP will shed the load off the unit, open the contactor to take the unit offline, run the engine through a cool down period, and then shut theengine off. Note that under normal automatic operation the PLC will nottake a unit off line until the next unit is on line. This provides for

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RUBY POWER PLANT SYSTEM DESCRIPTIONS & TROUBLESHOOTING


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require this unit to be on-line, the contactor will open and the enginewill shut off after a cool-down period

b) If the blueSTOP button is pressed while a unit is in MAN mode, theGCP will check to see if any other generators are on line. If there is

another unit on-line, the GCP will shed the load to the other unit,open the contactor, and shut off the engine after a cool-down period.If there is no other unit on-line, the contactor will open and theengine will shut off after a cool-down period.

c) If the redSTOP button is pressed while a unit is in MAN mode, thecontactor will open and the engine will shut off immediately withoutgoing through a cool-down period.

d) Pressing the contactor OFF button while the unit is operating in MAN

mode will open the contactor and take the unit off line. Pressing theredSTOP button will shut off the engine immediately without a cool-down period. The engine can be allowed to cool down by waitingtwo minutes prior to pressing the redSTOP button.

e) If a unit is left running in the manual mode with the contactor in theopen position for 5 minutes, it will shut down and a cool down/lockoutwill be indicated on the generator section. The unit will have to bereset to run again.

3) The TEST mode is only used to check an engine after performing repairsor routine maintenance such as oil changes. When the TEST button ispressed the engine will automatically start and run but the contactor willnot close. The unit will continue to run for 5 minutes or until taken out ofTEST mode. If the engine malfunctions or if testing is complete, shut theengine off by pressing the blue STOP button. If the engine performssatisfactorily, place the unit back in AUTO mode.

4) When the blue STOP button is pressed, the generator set is removed

from service and cannot be started. The PLC will remove this generatorset from use in the normal Demand Control as long as the GCP is inSTOP mode.

5) The GCP monitors the engine functions such as temperature and oillevel. The GCP will automatically shut a unit down in the event of aproblem. See the Generator Set Alarms and Faults Section below.

G) GENERATOR CONTACTOR CONTROLEach generator is provided with acontactor that is used to connect and disconnect the generator to the bus.

The contactor is controlled by the GCP. If the bus is energized(other generators on line) the GCP will adjust the engine speedand synchronize the generator to the bus before closing thecontactor. If the bus is dead (black start) the GCP will adjust theengine speed and close the contactor. A red light indicates thatthe contactor is closed and a green light indicates that thecontactor is open.



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the PLC. A control knob can be used to manually control the breaker. A redlight indicates that the breaker is closed and a green light indicates that thebreaker is open.

1) On a normal startup when the MCS is in the AUTO

position, the PLC will attempt to start all availablegenerator sets. This is to ensure that there is adequategenerating capacity on line prior to energizing thecommunity. The PLC will normally wait for a pre-set timedelay (usually 15 seconds) after the available generatorsare on line before closing the main feeder breaker.

2) When the MCS is in the AUTO position the main feederbreaker can be opened at any time by rotating the breakercontrol knob to the OPEN position. The PLC will thenstart all available generators and re-close the breakerfifteen seconds after the available generators are on line.

3) When the MCS is in the MAN position and the bus is live,the main feeder breaker can be operated manually.Rotate the control knob for the main feeder breaker to theCLOSE position. The breaker can be opened by rotatingthe knob to the OPEN position.

I) METERINGThe master section has a totalizing meter for the main bus anda meter for station service. Additional metering data is displayed on the OIU.

1) The main (bus) meter has multiple screens that can be viewed bypressing the buttons at the bottom. Pressing the POWER buttondisplays running kW load, pressing the V,I,Hz buttondisplays the frequency, pressing the VOLTS button displaysthe voltage for all three phases, and pressing the AMPSbutton displays the amperage for all three phases. Pressingthe ENERGY button displays the total kWh generated.

Note that this display actual ly reads in MWh so ignorethe decimal point to read kWh.

2) The station service meter is similar to the totalizing meter. Typically theonly display used is ENERGY to read the station service total kWh used.Note that this display also reads in MWh.

3) The OIU provides a display of much of the informationfrom the totalizing meter and station service meter. Inaddition, it provides a display of the main (bus) peak kW

load which can be reset after each reading by pressingthe RESET button on the screen. The total fuel pumpedinto the day tank and the overall plant fuel efficiency(kWH/gallon) are also displayed on the OIU. The fuel consumption forindividual engines can be read from the OIU. The heat recovery supplyand return temperatures, flow rate, system pressure, and total heatdelivered can also be read from the OIU



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K) PLANT FIRE ALARM - The plant fire alarm input signal will shutdown all running engines. The fire alarm shutdown must bereset by first clearing the fire alarm input signal at the fire systempanel, and then pushing the alarm reset button located on themaster section. The GCP for each generator must also be reset.

L) SYSTEM LOW WATER LEVEL - The system low water levelmonitors the system coolant level common to all the engines.Low water level detection will shut down all running engines.The low water level shutdown must be reset by first clearing thecause of the low water level signal (adding coolant) and thenpushing the alarm reset button located on the master section.The GCP for each generator must also be reset.

M) LOW FUEL LEVEL - The system monitors thediesel fuel level in the day tank. Low fuel leveldetection will sound an exterior alarm horn and willilluminate the alarm light on the master sectionafter the signal is received from the day tank. Theexterior alarm horn can be silenced by pressing theSILENCE button on the day tank control panel. If the low fuel level is notcorrected within 2 hours of the initial signal, all running engines will be shutdown. Pressing the alarm reset button on the master section any time duringthe initial 2 hour period will reset the 2 hour timer allowing the plant operatortime to add diesel fuel to the day tank without shutting down the generators.Pressing the alarm reset button after the plant has shut down will allow theplant to be re-started so that diesel fuel can be added to the day tank. TheGCP for each generator must also be reset prior to starting. To clear the daytank level alarm the cause of the day tank low fuel level must be correctedand the alarm reset button on the master section must be pressed again.

N) FEEDER BREAKER OVERCURRENT If the mainfeeder circuit breaker trips, the generator will continue to

operate but power to the step up transformer will be offand the FEEDER BREAKER OVERCURRENT lamp willilluminate. The cause of the breaker overload must becorrected, the breaker must be re-set, and the alarm resetbutton located on the master section must be pressed.

O) GENERATOR SET ALARMS AND FAULTS Each engine-generator is protected with warningalarms and shutdowns through its GCP.

Protection is provided for both engine problemssuch as low oil level, high jacket watertemperature, overspeed, etc. and for powerproblems such as over current, under frequency, reverse power, etc. Mostfaults will take the unit off line and run through a cool down cycle while somefaults will shut down the engine immediately. All faults are indicated by thelamps at the top of the generator control section and are also displayed on



22/380


P) HEAT RECOVERY ALARMS The master section monitors the heatrecovery system and has lights that illuminate to indicate loss of flow, loss ofpressure, and no load on heat recovery system. These alarms are only toindicate a potential problem and they do not shut down the generationsystem. The alarm lights go out when the problem is corrected.

3.2 Engine Generators:

A) MAINTENANCE & REPAIR - Separate service manuals are provided foreach engine-generator unit. Refer to the manufacturers manuals for specificmaintenance and repair instructions, parts lists, and other literature requiredfor service. Daily inspection of generators plus regular maintenance tasksand the appropriate time intervals are listed under Tab II PeriodicMaintenance and Inspections.

B) ALARMS - The generator sets areprovided with protective devices thatwill provide a warning or take the unitout of service in the event ofmechanical or electrical problems. Allof the alarm conditions are indicated by annunciation lights atthe top of each generator control section on the switchgear and a banner onthe face of the GCP. See additional description under Section 3.1 above.Note that the OIL LEVEL alarm may annunciate for either a high or low levelcondition. Check the dipstick to verify the cause of the alarm. In the event ofan alarm the cause must be determined, the condition corrected, and thenthe GCP must be cleared by first pressing the blue STOP button and thenpressing the RESET button. The unit can then be placed back in service.

C) AIR FILTER ALARMS The air filters are equipped with visualindicators for pressure drop. When the filter gets dirty and thepressure drop reaches a preset level the indicator will display red.The filter must be changed and the rubber button on the end of the

indicator must be pressed to clear the red alarm. In addition to thevisual indicator, the intake air manifold on these units are equippedwith a vacuum sensor that is connected to the switchgear. When thevacuum exceeds a preset limit the engine will be taken off line and a red AIRFILTER PLUGGED lamp will illuminate. The air filter must be replaced andthe GCP must be reset before the unit can be placed back in service.

D) FAILURE TO START / OVERCRANKThe GCP will make up to 4 attemptsto start an engine with a pre-set cranking time of 10 seconds and a 10second pause between each attempt. If the engine does not start after thefourth time the OVERCRANK and ENGINE ALARM lamps will illuminate anda FAIL TO START banner will appear on the GCP. If the engine does notcrank or cranks slow, check the battery voltage and fluid level. Verify that thebattery charger is operating. If the battery is good but the engine does notcrank check the starter solenoid. If the engine cranks but does not startcheck the fuel supply. Make sure the fuel valve is on, crack the bleed fitting



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provides a signal to the VFD. The VFD then adjusts the speed of the coolerfan to maintain a constant intake air temperature. See the MechanicalSpecifications Sequence of Operation in the Record Drawings under Tab VIfor normal setpoints. See the switchgear operation and maintenance manualfor additional detail on the sequence of operation. In the event of a VFDfailure or high temperature alarm the cooler can be operated full speed byselecting BYPASS mode on the VFD.

F) CRANKCASE VENTILATION This plant is equippedwith a system that provides positive ventilation for thecrankcase on each engine. A hose runs from the top ofeach engine to a black pipe located on the wall. Thepipe has drainage style fittings and slopes down to acondensate drip leg which is made of clear plastic and is

equipped with a normally closed drain valve. An in-lineexhaust fan, EF-3, is located above the drip leg. The fanvents the fumes out of the building near the exhaustpipes. The fan should operate any time the plant is on.

A vacuum gauge is mounted on the wall near the fan.The gauge should show a vacuum of approximately0.50. If the vacuum drops below 0.30 an alarm will beindicated at the switchgear. The mostlikely cause is a failed fan or a plugged

discharge pipe. Verify that the circuitbreaker and disconnect switch are on.Check the end of the pipe on the outside ofthe building for obstructions.

3.3 Fuel System:

The fuel system for this facility consists of a5,000 gallon intermediate tank locatedacross the street from the power plant. anda 160 gallon day tank that is located in thegeneration room. The intermediate tankneeds to be filled when it gets below the50% level. Filling the intermediate tank is amanually controlled operation. See the BulkFuel System Operation and MaintenanceManual and any placards for theintermediate tank filling procedure. The daytank is connected to all of the enginesthrough distribution piping along the wall with isolation valves at the branchconnection to each engine. The day tank fills automatically as fuel is used andhas several safety systems to prevent an overfill or running the engines out offuel. The following sections describe normal operation and troubleshooting of theday tank.

A) OVERVIEW Under normal operation the day tank will start a



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outlined under Tab IIPeriodic Maintenance and Inspections.

B) FILTER - A filter is located adjacent to the day tankupstream of the solenoid valves. The element should bechanged every six months or more frequently if significant

sediment is observed. Water can be drained from thebottom of the filter bowl through the drain valve on thebottom. To change the filter element, close valve labeled"NORMALLY OPEN, CLOSE ONLY FOR EMERGENCIES upstream ofthe filter. Drain fuel from bottom of filter bowl being careful to catch all drips.Unscrew bowl using special filter wrench and remove old element. Installnew 10 micron element equal to the original element and re-install bowl.Open valve labeled "NORMALLY OPEN, CLOSE ONLY. Check for leaks.

C) NORMAL OPERATION - When the fuel leveldrops to the pump start float switch, the normallyclosed day tank solenoid valve opens, the remoteactuator valve opens, the green "REMOTE

ACTUATOR VALVE OPEN lamp is illuminated, the pumpstarts, and the green "PUMP ON lamp is illuminated. Whenfuel level rises to the pump stop float switch the normally closed day tanksolenoid valve closes, the remote actuator valve closes, the green "REMOTE

ACTUATOR VALVE OPEN lamp turns off, the pump stops, and the green"PUMP ON lamp turns off. See Sequence of Operations on the RecordDrawings under Tab VI for more detailed information on the automatic fillsequence.

D) POWER FAILURE - If the green POWER ON lamp on the faceof the control panel is not on, verify that the disconnect switch onthe face of the panel is in the ON position. If the green lampdoes not turn on check the circuit breaker in the station servicepanel board.

E) PUMP TIME OUT ALARM - The day tank control panel includesa timer relay that is activated each time the pump is started andshuts the pump off after 10 minutes of operation. An alarmcondition occurs if the timer times-out prior to the fuel levelreaching the normal fill level (a normal fill cycle takesapproximately 5 minutes). The time out alarm is indicated by thealarm horn sounding and the red "PUMP TIME OUT ALARM"lamp on the day control tank panel illuminating. If a time-outalarm condition occurs the most likely cause is a low fuel level inthe intermediate tank. Other possible causes include: a closedvalve; a dirty day tank filter; a plugged, frozen or brokendistribution pipeline; loss of prime to the suction pump; a worn or failedsuction pump; an improperly set or failed pump timer relay; a failed solenoidvalve; or a stuck remote actuator valve. Pressing the "PUSH TO SILENCETIME-OUT & RESTART PUMP" button on the day tank control panel willsilence the time out alarm, turn off the alarm light, and start another fill cycle.



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"PUSH TO SILENCE OVERFILL/LOW LEVEL ALARM" button will silencethe alarm horn, turn off the alarm light, and reset the panel so another fillcycle can start when the fuel level drops to the pump start float switch.

G) LOW FUEL LEVEL ALARMAn alarm condition occurs if the day tank fuel

level reaches the low alarm float switch. The low level alarm is indicated bythe alarm horn sounding and the red "LOW FUEL LEVEL ALARM" lampilluminating. The low level alarm also starts a 2 hour timer in the switchgearthat will shut the generators down if the low level is not corrected. SeeSection 3.1 M for a more detailed description. If a low fuel level conditionoccurs the most likely cause is a low fuel level in the intermediate tank.Other possible causes include: a stuck or failed pump start float switch; aclosed valve; a dirty day tank filter; a plugged, frozen or broken distributionpipeline; loss of prime to the suction pump; a worn or failed suction pump; a

failed solenoid valve; or a stuck remote actuator valve. Pressing the "PUSHTO SILENCE OVERFILL/LOW LEVEL ALARM" button will silence the alarmhorn. Pressing the "PUSH TO SILENCE TIME-OUT & RESTART PUMP"button will start another fill cycle.

H) PUMP FAILURE - Under normal operation when the pump is started thegreen "PUMP ON" lamp will illuminate. When the lamp illuminates the pumpmotor starter (contactor) inside the control panel should close making a solid"click" sound. If this occurs and the pump motor does not run the problem ismost likely a failed pump or a fault in the wiring.

I) NO FLOW - If the pump runs but no fuel is flowingverify that the manual ball valves at the intermediatetank and the day tank are open. Verify that thenormally closed solenoid valve opens (the solenoidshould make a "click" sound when the pump starts).Verify that the actuator valve opens (the shaft of thevalve will rotate 90 degrees in approximately 10seconds and there is a position indicator on the base

of the actuator). If an actuator valve is stuck it can be manually operated(opened and closed) using a wrench for emergency operation. The actuatorvalve will need to be serviced or replaced.

J) PRESS TO TEST BUTTONS - Momentary contact buttons areprovided to test the pumps and alarm horn. Pressing day tankfill pump P-DF1 "PUSH TO TEST" button starts timer T1,momentarily opens the normally closed solenoid valve andactuated ball valve, energizes day tank fill pump P-DF1, andturns on the pump P-DF1 "ON" light. Pump P-DF1 is lockedout if the tank is at the overfill level. Pressing the "PUSH TO TEST DAYTANK ALARM" button momentarily energizes the alarm horn/strobe.

K) EMERGENCY MANUAL FILL - In the event of a failureof the pump or control system the day tank can bemanually filled using the hand priming pump. Turn offthe power to the day tank control panel Go out to the



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3.4 Cooling System:

All of the engines are connected into a common cooling piping manifold. Theupper pipe is the discharge (hot) pipe and the lower pipe is the suction (cold)pipe. The coolant runs through the discharge pipe to a pair of remote radiators

and then returns through the suction pipe to the engines. A variable frequencydrive (VFD) is provided for control of each radiator. Pressure gauges andthermometers have been installed in key locations to allow the system operationto be monitored.

A) NORMAL OPERATION - The coolant temperature should be 180F-200F inthe discharge pipe and 10F-20F colder in the suction pipe and the pressurein the suction pipe should be 3 PSI 5 PSI. The glycol level in theexpansion tank should be between 1/2 and 2/3. In theswitchgear, all of the radiator VFDs should be set to

VFD mode. In warm weather both radiators should beoperating between 10 Hz and 60 Hz. In colder weatherwhen the heat recovery system is operating the radiatorsmay cycle on and off or remain off. A running engineshould operate between 190F and 200F. The off lineengines should normally be at 120F-160F.

B) ENGINE CONNECTIONS Normally open ball valves areprovided at the branch piping connection to each engine.

The upper discharge hose connects to the enginethermostat. The discharge connection also includes a one-way check valve and a small vent valve that can be used tobleed air from an engine after service. A small hose runsparallel to the upper hose and connects from the enginethermostat to a 3/4 ball valve on the discharge piping main.This hose provides circulation of coolant to pre-heat theengine when it is not running. The lower suction hoseconnects to the engine water pump. The suction connection

also includes a normally closed drain valve. Note thatGenerator #2 includes an exhaust heat exchanger to

provide additional recovered heat.

C) RADIATORS The remote radiators areconnected in parallel so that one half of thecoolant flows through each one. Each radiator isprovided with isolation valves that can be closed toallow one radiator to be taken out of service while

the other one operates. Drain valves are installedon the radiator cores. On the radiator dischargeduct there is a normally closed damper that openswhenever the radiator fan runs. Above eachradiator is an air intake duct with a filter bank. The intake duct also has anormally closed damper that opens when the associated radiator fan runs.Note that the duct above radiator R1 also provides combustion air for the



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two radiators are typically set equal so that both radiators run together. Theradiator fans turn off when the temperature drops below the minimumsetpoint. See the Mechanical Specifications Sequence of Operation in theRecord Drawings under Tab VI for normal setpoints. See the switchgearoperation and maintenance manual for additional detail on the sequence of

operation. In the event of a VFD failure or high temperature alarm theradiator can be operated full speed by selecting BYPASS mode on the VFD.

E) EXPANSION TANK & GLYCOL MAKE-UP A 24 galloncapacity expansion tank provides room for expansion andcontraction of the coolant as the temperature varies. Theexpansion tank is equipped with a 2.5 PSI pressure cap to limitthe system pressure. The coolant level in the site gauge on theexpansion tank needs to be checked daily. The expansion tank

should be between 1/2 and 2/3 full at normal operatingtemperature. The system is charged with a 50% mix of ShellRotella ELC extended life ethylene glycol and treated water.When the fluid level drops add only pre-mixed solutionidentical to the original fluid, do n ot add water or othertyp es of anti- freeze. A hand pump is mounted near theexpansion tank for adding coolant. Place the hose in thedrum or pail of pre-mixed glycol solution. Open the valvelabeled NORMALLY CLOSED, OPEN ONLY FOR ADDING

COOLANT, ETHYLENE GLYCOL ONLY. Operate thehand pump until the expansion tank is 2/3 full. Close thevalve, remove the hose, and seal the drum or pail.

F) LOW COOLANT ALARMThe expansion tank is equipped witha low level switch. If the coolant level drops to the bottom of theexpansion tank, all engines will be shut down and the LOWCOOLANT ALARM lamp on the switchgear will illuminate.Check for leaks and use isolation valves to close off the affected

section. Add glycol to the system as described above. Resetthe alarm and place the plant back in service. Repair or replaceany failed piping or hoses.

G) HEAT EXCHANGER A brazed plate heat exchangerHX-1 is installed between the engines and the radiators.The heat exchanger is used to recover heat from theengines and transfer it to the heat recovery system. Theheat exchanger provides a separation between the enginecoolant and the heat recovery system. The heat

exchanger is equipped with isolation valves andthermometers on all 4 ports and pressure gauges, drainvalves, and pressure relief valves on both sides. Pump P-HR2 circulates hot engine coolant from the discharge pipethrough the hot side of the heat exchanger. Pump P-HR3circulates fluid through the cold side of the heat

f



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3.5 Heat Recovery System:

This plant is equipped with a system that captures jacket water heat from thediesel engines so that it can be used for heating other buildings referred to as theend user buildings. Pre-insulated arctic pipe is routed below grade from the

power plant up the hill to the washeteria.An additional pair of arctic pipes are alsorouted to the adjacent water/sewer truckgarage. At the time of plant commissioningthe system in the garage had not beenplaced in service. Heat exchanger HX-1separates the engine coolant from the fluidthat circulates through the arctic pipes andallows heat to transfer between the two

fluids. Pressure gauges and thermometershave been installed in key locations toallow the system operation to bemonitored.

A) NORMAL OPERATION - The heat recovery system is designed to reducethe amount of fuel consumed at the end user buildings and is not intended toserve as the primary heat source. The heating systems in the end userbuildings must be maintained and set to operate at appropriate temperaturesto allow the heat recovery system to function. The amount of heat available

for recovery varies with the electrical load on the generators. Pump P-HR2circulates hot engine coolant through the hot side of the heat exchangerand pump P-HR3 circulates heat recovery fluid through the cold side of theheat exchanger and arctic pipe. Both pumps should runcontinuously during the heating season. When the pumpsrun the pressure gauge on the downstream side will behigher than on the upstream side. Proper operation can beverified by turning the pumps off momentarily and thenback on and watching the pressure gauges. The hot fluidleaving the heat exchanger should be 170F-190F and thereturning fluid should be 10F-20F colder, depending uponthe heat load. The pressure in the arctic piping loopshould be 30 PSI 40 PSI when the system is at normaloperating temperature.

B) EXPANSION TANK & GLYCOL MAKE-UP The heat recovery system hasa separate expansion tank that provides room for expansion and contractionof the fluid as the temperature varies. The expansion tank is a sealed tank

that contains a bladder with an air pre-charge.There is no site level gauge on the sealed tank soproper operation must be monitored by observingthe system pressure. The heat recovery system ischarged with a 50% mix of Safe-T-Therm propyleneglycol and treated water. Note that this is differentthan the engine coolant When the system



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C) AIR VENTSAutomatic air vents are installed in the heat recoverypiping system. They are located near the heat exchangers andany other high points in the system. The isolation valves arenormally left closed to prevent leaking. Air must be vented fromthe system at least two times per year and whenever new fluid is

added. See Section 2.3 - Six Month Inspection and Maintenancefor procedure.

D) STRAINER A strainer is installed in the heat recoverypiping near HX-1. It is primarily used to remove debris fromthe piping during system startup. If the heat recovery flowrate slows down the strainer screen could be plugged.Turn off pump P-HR3 and close valves on both sides of thestrainer. Remove the plug and open the drain valve on the

bottom of the strainer being careful to catch all drips in abucket. Unscrew the bottom cover and remove the screen.Clean screen and re-install bottom cover and plug. Open valves and turnpump on. Check for leaks.

E) END USER BUILDINGS A heat exchanger,HX-2, is installed in the washeteria. The heatrecovery arctic piping loop from the power plantis connected to the hot side of the heatexchanger. The building heating system return

pipe is connected to the cold side of the heatexchanger. Under normal operation the heatexchanger pre-heats the fluid before returningto the boilers. When the amount of recoveredheat available is equal to or greater than theheat demand in the building, the heat recoverysystem will maintain the building temperatureand the boilers will not fire. When the heatdemand exceeds the amount of recovered heatavailable, the building heating piping temperature will gradually drop until theboilers fire. To ensure proper system operation the boilers should be set tofire at no lower than 160F and to shut off at no higher than 180F. Note thatinformation on the system connection in the water/sewer garage was notavailable but it is assumed to be similar.

F) ALARMS The master section of the switchgear has lamps that indicateproblems with the heat recovery system. If the flow rate in the heat recoverypiping drops below a pre-set level, a red LOSS OF FLOW lamp will

illuminate. The most likely causes are a closed valve or a failed pump. Thealarm will automatically clear once flow is started. If the pressure in the heatrecovery piping drops below a pre-set level, a red LOSS OF PRESSURElamp will illuminate. The most likely cause is a leak in the piping. The alarmwill automatically clear once the system is returned to normal pressure. If thetemperature in the heat recovery return pipe exceeds the temperature in theheat recovery supply pipe for a preset time interval (usually 1 hour) the



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G) ENERGY METER The heat recovery system isequipped with an energy meter to record the amount ofrecovered heat that is used. The energy meter consistsof a flow meter and temperature sensors for the supplyand return pipes. The flow meter and temperature

sensors are located in the power plant near HX-1 andmeasure the amount of heat leaving the power plant.

The PLC in the power plant switchgear calculates rate of heattransfer and records the total heat delivered. A display screenon the OIU shows the flow rate in gallons per minute (GPM), thepressure in PSI, the supply and return temperatures in degreesF, the heat transfer rate in BTU/hour, and the total heattransferred in BTU. Note that the units of the total heat transferdisplay are actually 100,000 BTU which is roughly equivalent tothe net heat in one gallon of diesel fuel.

3.6 Plant Heating & Ventilation:

The control room is heated by a cabinet unit heater. Cooling and ventilation forthe control room is provided by an operable window. The operating and off linegenerators reject more heat to the generation room than is required so exhaustfans with intake air ducts are installed to provide cooling.

A) UNIT HEATERS & PIPING Pump P-HR1circulates engine coolant from the piping mainsthrough the cabinet unit heater in the control room.The thermostat in the control room cycles the pumpand the heater fan on and off as required to maintaintemperature in the control room, usually 70F. Proper operation canbe verified by turning the thermostat up. If the system fails tomaintain temperature the most likely causes are a closed valve, afailed pump, a failed unit heater, or air in the piping. Verify thatcircuit breakers and disconnect switches are on.

B) EXHAUST FANS & INTAKE AIR There are two air intakes in thegeneration room ceiling near the back of the generators.The intakes are equipped with a motorized damper thatopens each time the associated exhaust fan runs. Thereare two exhaust fans located on the wall above the front ofthe generators. Each fan is equipped with a motorizeddamper that opens whenever the fan runs and a separatethermostat. The fans operate whenever the temperature

in the generation room is above the setting on thethermostat, usually 80F. Proper operation can be verifiedby turning the thermostat down. If the generation roomoverheats the most likely causes are dirty airfilters, stuck dampers on the intake or exhaustducts, or a failed exhaust fan. Verify that circuitb k d di t it h



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3.7 Station Service Electrical System:

The station service electrical system provides power for operation of everythingat the plant including interior and exterior lights, receptacles, battery chargers,fans, and pumps. It includes a transformer, a panelboard with circuit breakers,

lighting, devices, and associated wiring and raceways. The majority of thestation service wiring is run in wireway with surface mounted conduit for branchconnections to individual devices.

A) TRANSFORMER The station service transformer islocated in the generation room. It is a dry typetransformer that converts the 480V three phase power

from the switchgear bus to 120/208Vthree phase. Power is supplied to thetransformer through the station service

circuit breaker located in the mastersection of the switchgear.

B) PANELBOARD The 120/208V power from the station service transformeris distributed through the station service panelboard SSwhich is located adjacent to the transformer. Individualcircuit breakers are provided for each circuit. Single polebreakers provide 120V single phase power. Two polebreakers provide 208V single phase power. Three pole

breakers provide 208V three phase power. Ground faultinterrupter (GFI) circuit breakers are installed on thegeneration room receptacle circuits. Note that thecharge air coolers and radiators are powered direct lyfrom th e var iable frequency dr ives in the switch gearand are not c onn ected to the 120/208V port ion of thestat ion service system but the power is metered withthe other stat ion service.

C) LIGHTING & EMERGENCY LIGHTS The interior light fixtures are

fluorescent with high efficiency T8 style ballasts and 54W tubes. In additionthere are LED type night lights located in the control and generation rooms.The exterior light fixtures are LED type with photocell control. Whenreplacing tubes/lamps be sure to use the same type as the original. Theemergency lights have battery packs that provide up to 90 minutes ofoperation in the event of a loss of power on the main lighting circuit.Emergency lights can be tested by pushing the press to test button on eachfixture or by shutting off the circuit breakers for the main lighting.

D) PILOT LIGHT SWITCHESRed pilot light disconnect switches are installedon all devices that should normally have power. This includes unit heaters,fans, pumps, battery chargers, etc. These switches should only be turned offto work on a system or take a specific piece of equipment out of service.



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3.8 Fire Suppression System:

This building is equipped with a water mist fire suppression system. The systemincludes a pressurized nitrogen cylinder, water cylinders, piping, nozzles,detectors, alarms, a control panel, and associated wiring and raceways. Fire

detection and alarm is provided for both rooms. Fire suppression is onlyprovided for the generation room. In the event of a fire the system willautomatically discharge. This is indicated by an exterior alarmstrobe. Do not enter the space after a discharge. Thesystem will only work in a sealed space so all doors on theplant must be left closed. A separate Operation andMaintenance manual has been provided for the firesuppression system. Refer to it for more detailed descriptionsand data.

A) NITROGEN CYLINDER - The system uses medium pressure nitrogen topropel the water through the nozzles. The pressure in the nitrogen cylindershould normally be between 2,000 and 2,400 PSI. The pressure should bechecked daily and if it drops below 2,000 PSI the cylinder needs to be re-charged and the piping connections need to be checked for leaks.

B) WATER CYLINDERS - The system has threecylinders that are filled with water. Under normalconditions the water cylinders are not under

pressure. During a discharge the nitrogenpressurizes the water cylinders. The cylindersand piping connections should be checked forleaks periodically.

C) PIPING & NOZZLES The fire suppressionpiping runs directly from the water cylinders to thedischarge nozzles which are located on the ceiling. The piping is smalldiameter stainless steel tube.

D) DETECTORS The generation room has flame (optical)detectors and high temperature heat detectors. Thecontrol room has a normal temperature heat detector anda smoke (photoelectric) detector.

E) WIRING All wiring for the fire suppression system isrouted in dedicated conduit separate from the rest of the plant wiring. The

junction box covers are painted red on the fire system to distinguish it fromother wiring.

F) PANELThe fire system control panel is located in the controlroom. It has a front screen that displays the system status andany alarm or trouble conditions. It has a battery backup to allowoperation during a power outage.

G) SEQUENCE OF OPERATION (AUTOMATIC) Activation ofone detector in any zone will set off the alarm horns and shut



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H) SEQUENCE OF OPERATION (MANUAL) Manual pull stationsare located in the control room and the generation room.

Activation of a manual pull station will set off the alarm horns, shutdown the generators, and begin a 30 second countdown to agentrelease.

I) TROUBLE ALARMAny problems with the fire systemwill cause a trouble alarm at the control panel. This isindicated by a buzzer and a message on the paneldisplay screen. The most common trouble alarm is aloss of power which occurs any time there is a poweroutage. To stop the buzzer press the ALARM SILENCEbutton. Once the problem has been corrected press the

ACK button to acknowledge the alarm and the RESET

button to clear the alarm message. This will return thesystem to normal operating mode.

J) FALSE ALARM ABORT - A yellow abort button is locatednear the control panel. In the event of a false alarmcondition, pressing the abort button will restart the 30second countdown. This gives the operator time to attemptto reset the panel and clear the alarm prior to agent release.The abort button does not work if a manual pull station hasbeen activated.

K) SYSTEM FAILURE EMERGENCY OVERRIDEAnyfire alarm condition will automatically shut down thegenerators. The generators cannot be re-starteduntil the alarm is cleared. In the rare event of aproblem such as a control panel malfunction that willnot allow the system to clear, the fire alarm panelmay have to be disabled. Go to the station servicepanelboard and shut off the circuit breaker for the fire

system. Open the fire system control panel andremove the positive lead from the battery. The fire system will then bedisabled which will allow the generators to operate. The plant will no longerbe protected from fires so a technician will need to be contacted to repair andre-certify the system as soon as possible.

L) RE-CERTIFICATION - The fire suppression system needs to be tested andre-certified each year. See Section 2.4Annual Inspection & Maintenance.

Additional certification would also be required in the event of a systemdischarge or failure.


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Tab IV.Inspection & Service

Log Forms

POWER PLANT DAILY INSPECTION LOG Page 1 of 2 GENERAL PLANT STATUS


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Tim

eo

fDay

Ou

tside

Tempera

ture

Ins

ide

Tempera

ture

Pla

nt&Site

Secure

(fen

ce,

doors,windows)

Exhaus

tCo

lor

(C=

Clear,

BL=

Blue,

BK=B

lac

k)

Interme

diateTan

kSecure

(no

leaks,valvessecure,etc.)

Interme

diateTan

kLeve

l

(fee

t-inches)

Day

Tan

kNorma

l(power

on,no

alarms,

filterclear,noleaks,levelOK)

Day

Tan

kMe

ter

Rea

ding

(gallons)

Oil

Blen

der

Norma

l

(poweron,noalarms,noleaks)

Off

-Line

Genera

tor

Statu

s

(blo

ckwarm,noleaks,nofilteralarms,

oillevelOK,

batterychargeron)

Coo

ling

Sys

tem

Status

(exp.

tanklevel,temp&pressnormal)

Hea

tRecovery

Status

(pumpson,

temp&pressnor

mal)

Room

LightsWork

ing

Ceiling

&Ex

haus

tFans

Work

ing

RedPilotLightSw

itc

hes

On

Fire

Suppress

ion

Norma

l

(agentlevelingreen,noalarms)

Fire

Ex

tingu

ishers

(inplace&charged)

Monday

Date:

Tuesday

Date:

Wednesday

Date:

Thursday

Date:

FridayDate:

Saturday

Date:

Sunday

Date:

Note: Perform complete inspection at least one time per day and walk through with meter readings at least two times per day.

Operator:

Community:

POWER PLANT DAILY INSPECTION LOG Page 1 of 2 GENERAL PLANT STATUS

POWER PLANT DAILY INSPECTION LOG Pg 2 of 2 SWITCHGEAR & OPERATING GENERATOR


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InAu

toMo

de

&No

Alarms

AllGenera

tors

Ava

ilable

To

talkWHGenera

ted

Station

Serv

ice

kW

H

Runn

ing

kW

Load

Pea

kkW

Loa

d(res

etda

ily)

Frequency

(cyc

les)

Line

1Vo

ltage

Line

2Vo

ltage

Line

3Vo

ltage

Line

1Amps

Line

2Amps

Line

3Amps

Opera

ting

Generator

#

To

talEng

ine

Hours

Eng

ine

Wa

ter

Temp(norma

l)

Eng

ine

OilPressure(norma

l)

Eng

ine

OilLeve

l(norma

l)

Ba

ttery

Vo

ltage(norma

l)

Monday

Date:

Tuesday

Date:

Wednesday

Date:

Thursday

Date:

Friday

Date:

Saturday

Date:

Sunday

Date:

Note: Perform complete inspection at least one time per day and walk through with meter readings at least two times per day.

Operator:

Community

POWER PLANT DAILY INSPECTION LOG Pg 2 of 2 SWITCHGEAR & OPERATING GENERATOR


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POWER PLANT GENERAL INSPECTION & MAINTENANCE LOG COMMUNITY:


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Monthly Inspection

Date:

Monthly Inspection

Date:

Monthly Inspection

Date:

Monthly Inspection

Date:

Monthly Inspection

Date:

Monthly Inspection

Date:

6 Month Inspection

Date:

Note: Have certified technician test and recertify fire suppression system every year (coordinate with annual school inspection).

Emergency Lights (press to test): Thermostats (heat = 70F, ventilation = 80 F):

Comments:

Switchgear Lamp Test (master & engines):

Battery Fluid Levels (distilled water only):

Emergency Lights (press to test):

Day Tank Press to Test:

Flourescent Lights (check & replace):

Thermostats (heat = 70F, ventilation = 80 F):

















Battery Fluid Levels (distilled water only):Emergency Lights (press to test):







Flourescent Lights (check & replace):Thermostats (heat = 70F, ventilation = 80 F):



Wipe Down Lights & Paddle Fans:

Test Glycol (coolant & heat recovery):

Comments:

Intake Air Filters (check & replace):

Piping Air Vents (bleed then valve off):

POWER PLANT GENERAL INSPECTION & MAINTENANCE LOG COMMUNITY:


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Tab V.Equipment Suppliers

&Service Instructions

RUBY POWER PLANT INDEX OF MATERIALS, VENDORS, & SERVICE PROVIDERS


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SERVICE PROVIDERS

Alaska Diesel Electric (907) 562-2222 John Deere

Marsh Creek Technical Svcs (907) 258-0050 All Brands

Precision Power (907) 561-7797 All BrandsSWITCHGEAR

See separate O&M Manual for

additional information and all

product literature.

Serial # 7146Controlled Power

(425) 485-1778

ENGINE GENERATORS & ACCESSORIES

Engine-Generator Units - See

separate Service Manuals for

each individual unit for additional

information and all product

literature

Gen #1 (210kW)

John Deere 6081HF070 &

Marathon 432PSL6212

Gen #2 & #3 (120kW)

John Deere 4045HF485 &

Marathon 431PSL6204

Marsh Creek Technical Svcs

(907) 258-0050

Oil & Fuel Filters See Parts Manual for each engine

Air Filter See Actual Installed Filter on Unit

Glycol Filter Wix 24069 element

Oil Chevron Delo 400, SAE 30

Battery Size 8D Alaska Battery(907) 562-4949

Battery Charger SENS NRG24-20-RCLSMarsh Creek Technical Svcs

(907) 258-0050

FUEL SYSTEM

Actuator Ball Valve

(1", 120VAC, day tank fill)

Nutron T3-R10R01LZ-06 Ball Valve

RCS SXR-0897 Electric Actuator

DG Valve Systems

(780) 413-1760

Day Tank Control Panel See Panel Record Drawings - Tab VI See label on panel formanufacturer

Day Tank Float Switch Innovative Components LS-12-111/2

with minimum 60" long lead wires

Day Tank Level Gauge Rochester 8660 gauge with

side-view Dial #5025S00570

Day Tank Filter Goldenrod canister # 495 with

10 micron element # 470-5

Day Tank Meter Contoil Part #9226 with pulser

Day Tank Solenoid Valve Normally Closed - ASCO 8210G94Normally Open - ASCO 8210G34

Day Tank Fill Pump Oberdorfer C992M3E5QF50 (1/2")

Day Tank Hand Priming Pump GPI Model HP-100 (piston)

Fusible Valve Firomatic 200F (1/2")

Flanged Ball Valve Apollo

Ace Supply

(907) 277-4113

Inlet Petroleum

(907) 274-3835

RUBY POWER PLANT INDEX OF MATERIALS, VENDORS, & SERVICE PROVIDERS


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Charge Air Cooler CAC-1, 2, & 3 Diesel Radiator DR3491, 2 Hp

Radiator R1 & R-2 Diesel Radiator DR3489, 3 HpLow Coolant Level Alarm Murphy EL150K1

Coolant Shell Rotella ELC extended life

ethylene glycol, 50% pre-mix

Inlet Petroleum

(907) 274-3835

Threaded/Solder End Ball Valve Milwaukee (full port for 2" and smaller,

large port on valves over 2")

Threaded/Solder End Swing

Check Valve

Milwaukee

Hose End Drain Valve Watts B6000CC

Gauge Cock (Valve) Legend Valve Item #101-531 (1/4")or 101-532 (3/8")

Fluid Safe-T-Therm propylene glycol,

50% pre-mix

Inlet Petroleum

(907) 274-3835

Heat Exchanger HX-1: Ameridex X-10B-70

HX-2: Ameridex X-10B-70

Ameridex

(770) 386-7855

Pumps P-HR1: Grundfos UPS 15-58FC 115V

P-HR2: Grundfos UP 43-75F, 115VP-HR3: Grundfos UPS 50-80/2, 115V

Expansion Tank ET-2: Amtrol AX-80

Solder End Strainer Mueller #358 S

Pressure Relief Valve Watts 174A (3/4", 50 PSIG)

Automatic Air Vent Maid-O-Mist #71 (1/4")

Cabinet Unit Heater CUH-1 Beacon Morris FI-1050-02-29

Thermostat Honeywell T6051A1016

Flow Meter Body Siemens Sitrans FM Magflow MAG3100 with PTFE Liner & Hastelloy C

Electrodes for 210F Operation

Flow Meter Transmitter Siemens Sitrans FM Magflow MAG

5000, Code No. FDK:7ME6910,

Option 1AA10-1AA0

Expansion Tank Pressure Cap Cim-Tek 60001, 2-1/2 PSI pressure,

1-1/2 Oz. vacuum

Ace Supply

(907) 277-4113Site Gauge Lube Devices G607-09-A-1-4

Engine Coolant Hoses Parker 6221 Wire Reinforced

Corrugated Silicone Hose

Jackovich Industrial

(907) 277-1406

Marsh Creek Technical Svcs

(907) 258-0050

Frontier Plumbing Supply

(907) 334-3700

Frontier Plumbing Supply

(907) 334-3700

PIPING SPECIALTIES

HEAT RECOVERY & PLANT HEATING SYSTEM

COOLING SYSTEM

Unit Process

(907) 522-1010


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SENS EnerGenius Technical Manual


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Installation & Operation ManualNRG12-20: 12-Volt, 20-Amp Battery Charger

NRG24-20: 24-Volt, 20-Amp Battery Charger

NRG22-20: 12/24-Volt, 20-Amp Battery Charger



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IMPORTANT SAFETY INSTRUCTIONS FOR INSTALLER AND OPERATOR

1. SAVE THESE INSTRUCTIONS.

2. DO NOT EXPOSE CHARGER TO RAIN OR SNOW.3. Use of an attachment not recommended or sold by SENS may result in a risk of fire, electric shock,

or injury to persons.

4. ONLY TRAINED AND QUALIFIED PERSONNEL MAY INSTALL AND SERVICE THIS

UNIT.5. Do not operate charger if it has received a sharp blow, been dropped, or otherwise damaged in any way; shut

off power at the branch circuit protectors and have the unit serviced or replaced by qualified personnel.

6. To reduce risk of electric shock, disconnect the branch circuit feeding the charger before attempting any main-tenance or cleaning. Turning off controls will not reduce this risk.

WARNING:

RISK OF EXPLOSIVE

GASES.

A. WORKING IN THE VICINITY OF A LEAD-ACID OR NICKEL-CADMIUM BATTERY IS

DANGEROUS. STORAGE BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL

BATTERY OPERATION. FOR THIS REASON, IT IS OF UTMOST IMPORTANCE THAT EACH

TIME BEFORE USING YOUR CHARGER, YOU READ THIS MANUAL AND FOLLOW THE

INSTRUCTIONS EXACTLY.B. To reduce the risk battery explosion, follow these instructions and those published by the battery

manufacturer and the manufacturer of any equipment you intend to use in the vicinity of a battery. Reviewcautionary markings on these products and on the engine.

A. Someone should be within range of your voice or close enough to come to your aid when you work near astorage battery.

B. Have plenty of fresh water and soap nearby in case battery electrolyte contacts skin, clothing, or eyes.

C. Wear complete eye protection and clothing protection. Avoid touching eyes while working near a storagebattery.

D. If battery electrolyte contacts skin or clothing, wash immediately with soap and water. If electrolyte enterseye, immediately flood the eye with running cold water for at least 10 minutes and get medical attentionimmediately.

E. NEVERsmoke or allow a spark or flame in vicinity of battery or engine.

F. Be extra cautious to reduce risk of dropping a metal tool onto battery. It might spark or short circuit batteryor other electrical part that may cause explosion. Using insulated tools reduces this risk, but will noteliminate it.

G. Remove personal metal items such as rings, bracelets, necklaces, and watches when working with a storagebattery. A storage battery can produce a short circuit current high enough to weld a ring or the like to metal,causing a severe burn.

H U thi h f h i LEAD ACID LIQUID ELECTROLYTE NICKEL CADMIUM

7. PERSONAL PRECAUTIONS


MODEL NUMBER CONFIGURATION


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This manual contains important safety, installation and operating instructions for SENS battery charger modelNRG12-20 (configured for 12V,20A only), NRG24-20 (configured for 24V, 20A only) and NRG22-20 (field

configurable for 12V or 24V, 20A).

INSTALLATION INSTRUCTIONS

WARNING:

ONLY TRAINED AND QUALIFIED PERSONNEL

MAY INSTALL AND SERVICE THIS UNIT.

MODEL NUMBER CONFIGURATION

Model Number Breakout

NRG 22-20-

Model Output Output Input Voltage Alarm System Agency Category

Voltage Current Frequency Code Code Code

12: 12 volts 20: 20 Amps H: 120/208-240V, C: 5 Alarms L: UL, CUL Listed S: Standard

24: 24 volts 50/60 Hz R: Recognized

22: 12/24 volts R: 120/208-240V, Component

60 Hz

NOTE: Not all configurations are available on all models.Contact the factory for confirmation.**UL listed, CSA certified

*UL listed, CSA certified and CE marked

6 (150 mm) minimum

ventilation clearance

top and bottom



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1. PREPARING FOR USE:

A. INSTALLATION OF THE UNIT MUST COMPLY WITH LOCAL ELECTRICAL CODES

AND OTHER APPLICABLE INSTALLATION CODES.

B. INSTALLATION MUST BE MADE ACCORDING TO THE INSTALLATION

INSTRUCTIONS AND ALL APPLICABLE SAFETY REGULATIONS.

WARNING:

ONLY TRAINED AND QUALIFIEDPERSONNEL MAY INSTALL AND

SERVICE THIS UNIT.


NeutralTe

+Battery


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C. This unit is permanently connected to the AC circuit and to the battery. An external disconnect device with a minimum of

0.12(3 mm) pole separation must be located in the AC input to the charger.

Do not energize the AC supply circuit until ALLwiring is connected, internal controls are properly set, and the cover is

secured. Always shut the AC supply circuit off before installing or removing any wiring or opening the cover for anyreason.

Always observe proper polarity of the DC output leads.

Always connect the output leads in this order: ungrounded charger output first, then ungrounded battery terminal, then

grounded charger output, and grounded battery terminal last. If the battery must be disconnected for service, remove theoutput wiring in the reverse of the order given above.

D. Be sure battery terminals are clean and properly tightened. Be careful to keep corrosion from coming in contact with eyes.E. Add distilled water to each cell until the electrolyte reaches the level specifi

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