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Jenbacher

4.1 Checklist for alarm messages

Documentation

-

General: When the installation is operational, the engine management system DIANE will not only control the engine but will also perform engine-failure management. The engine-failure management system checks all relevant system variables and will issue a warning or switch off the installation if certain set values are exceeded or underrun.

Remedying and resetting failures: When a failure results in the installation being switched off, the cause of the failure should be remedied first before the installation is started again. When a failure results in a warning being issued, the cause of the failure should be remedied first before the failure is reset. Turn off the engine according to Technical Instruction No. 1100-0105 and secure against unauthorized restart. It is forbidden simply to reset a failure and then start the engine again!

Keyword:

ENI Pakistan 1-10

Unit no.:

J F516/ J F662 - J F670

Module no.: ------

Module type :

JGS 312 GS-N.L.

Version:

C01

Engine no.: ------

Issued:

Doku./Pichler:

EN

4_1___B_DianeXT_EN.doc

Date: 2009-01 Page - No.: 1 / 104

Jenbacher

4.1 Checklist for alarm messages

Documentation

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Index 10 11 12 13 20 30 40 50 51 52 53 54 55 56 57 60 70 90 100 101 102 103 104 105 110 120 1017 1018 1019 1021 1023 1026 1027 1028 1031 1036 1037 1038 1039 1040 1041

START CONDITIONS MISSING OF MOTOR OF AGGREGATE OF THE UNIT MOTOR WON'T START MOTOR SAWING IN IDLE RUN (can't be synchronized) MOTOR DOES NOT REACH FULL LOAD (while maintaining the guaranteed pollutant emissions) MOTOR OR SYSTEM MOTOR/GENERATOR RUNS IRREGULARLY OR UNSTABLE WITH LOAD MOTOR VIBRATES STRONGLY MOTOR SHAKES (quick load fluctuations or great current and voltage fluctuations with little change of motor output) ENGINE ROCKING GENERATOR MOTOR ESCALATES (great current and voltage fluctuations at only little change in motor output) MOTOR ARCHIEVES NOT STABLE CONDITION (output swings slowly up and down) ENGINE STOPS (individual cylinders) OR HAS AN EXHAUST GAS TEMPERATURE DEVIATING FROM THE CENTRAL VALUE PERIODIC FLUCTUATIONS IN PERFORMANCE MOTOR KNOCKING MISFIRING DETECTION RESPONDS, OR AT BR6 DEVIATION OF CYLINDER FLUE GAS TEMPERATURE TOO GREAT OIL CONSUMPTION TOO HIGH TURBOCHARGER DEFECT COMPACTOR THROWING OIL TURBINE THROWING OIL TURBOCHARGER EFFICIENCY NOT OKAY (flue gas turbocharger no longer archieves required load pressure) COMPACTOR OR TURBINE WHEEL TOUCHED THE HOUSING TURBOCHARGER VIBRATING WATER IN LUBRICATION OIL THE CONTRACTUALLY AGREED DEGREE OF EFFICIENCY IS NOT REACHED IN SPITE OF THE SALES TOLERANCE OIL PRESSURE LOW ENGINE OIL LEVEL LOW JACKET WATER PRESSURE LOW JACKET WATER TEMPERATURE HIGH START UP FAILURE SHUTDOWN FAILURE FAILURE GAS TRAIN 1 GAS PRESSURE LOW IN GAS TRAIN 1 EMERGENCY STOP/SAFETY LOOP GENERATOR OVERLOAD/SHORT CIRCUIT GENERATOR WINDING TEMPERATURE HIGH GENERATOR REVERSE POWER SYNCHRONIZING FAILURE FUEL MIXTURE TEMPERATURE HIGH POWER SIGNAL MISSING

Keyword:

ENI Pakistan 1-10

Unit no.:

J F516/ J F662 - J F670

Module no.: ------

Module type :

JGS 312 GS-N.L.

Version:

C01

Engine no.: ------

Issued:

Doku./Pichler:

EN

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4.1 Checklist for alarm messages

Documentation

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1042 1043 1048 1050 1051 1052 1053 1054 1056 1057 1059 1061 1064 1078 1080 1081 1083 1105 1109 1110 1111 1112 1113 1114 1120 1126 1127 1129 1134 1135 1140 1143 1144 1145 1148 1167 1168 1177 1185 1186 1189 1192 1193 1194 1195 1196 1216 1217 1218 1219

POWER SIGNAL OVERLOAD ENGINE OIL TEMPERATURE HIGH KNOCKING FAILURE JACKET WATER PRESSURE HIGH ENGINE OIL LEVEL HIGH GAS PRE-ALARM GAS ALARM FIRE ALARM FAIL SAFE LOOP TRIPPED HIGH GAS PRESSURE IN GAS TRAIN 1 OIL FILTER DIFFERENTIAL PRESSURE HIGH IGNITION SYSTEM FAILURE OVERSPEED (RPS-CONTROL SYSTEM) BOOST PRESSURE MEASURING SIGNAL FAILURE LEANOX CONTROL ALLOWED DEVIATION EXCEEDED KNOCK SENSOR MEASURING SIGNAL FAILURE CONTROL CARBURATOR DEFECTIVE SPEED OF TEMPERATURE CHANGE MIXTURE TEMPERATURE MAXIMUM GENERATOR LOSS OF EXCITATION GENERATOR FREQUENCY TOO LOW GENERATOR FREQUENCY TOO HIGH NEUTRAL CURRENT MAXIMUM GENERATOR POWER MEASURING SIGNAL FAILURE FUEL MIXTURE TEMPERATURE MEASURING SIGNAL FAILURE SPEED MEASURING SIGNAL FAILURE GENERATOR VOLTAGE LOW GENERATOR VOLTAGE HIGH FAILURE WITH AUXILIARIES GROUND FAILURE ROOM TEMPERATURE HIGH MODULE INTERFACE PANEL CIRCUIT BREAKER TRIPPED VOLTAGE NEGATIVE SEQUENCE CURRENT NEGATIVE SEQUENCE JACKET WATER TEMPERATURE LOW STARTER BATTERY VOLTAGE LOW HEATING WATER RETURN TEMPERATURE HIGH REQUEST FOR MAINTENANCE ENGINE ROOM AIR PRESSURE MEASURING SIGNAL FAILURE GENERATOR WINDING TEMPERATURE HIGH HEATING WATER RETURN TEMPERATURE MEASURING SIGNAL FAILURE RELEASE FROM SYNCHRONIZING MISSING ACTUATOR FAILURE LOAD BANK FAN IS NOT RUNNING LOAD BANK COMMON ALARM LOAD BANK CONTACTOR FAILURE LOAD BANK CB OVERLOAD/SHORT CIRCUIT BUS BAR VOLTAGE SENSOR FAILURE GENERATOR CB STATUS SIGNAL FAILURE GENERATOR CB OPENING FAILURE GENERATOR CB CLOSING FAILURE

Keyword:

ENI Pakistan 1-10

Unit no.:

J F516/ J F662 - J F670

Module no.: ------

Module type :

JGS 312 GS-N.L.

Version:

C01

Engine no.: ------

Issued:

Doku./Pichler:

EN

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Jenbacher

4.1 Checklist for alarm messages

Documentation

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1220 1221 2082 2083 2084 2086 2097 2101 2102 2103 2104 2105 2111 2116 2117 2118 2120 3003 3025 3026 3027 3028 3029 3030 3031 3052 3216 3217 3218 3219 3220 3221 3223 3224 3310 3311 3402 3406 3411 3497 3506 3507 3515 3516 3517 3518

GENERATOR CB O-SIGNAL FAILURE GENERATOR CB 1-SIGNAL FAILURE PARAMETER(S) MISSING RPS (CONTROL SYSTEM) BATTERY FAILURE LEANOX ALGORITHM FAILURE CARBURATOR POSITION MEASURING SIGNAL FAILURE DEVIATION POWER SETPOINT TO POWER PRESENT VALUE MAXIMUM JACKET WATER TEMPERATURE MEASURING SIGNAL FAILURE ENGINE OIL TEMPERATURE MEASURING SIGNAL FAILURE JACKET WATER PRESSURE MEASURING SIGNAL FAILURE JACKET WATER PRESSURE MEASURING SIGNAL FAILURE GENERATOR WINDING TEMPERATURE MEASURING SIGNAL FAILURE KNOCK SENSOR MEASURING SIGNAL FAILURE DUMP RADIATOR FAILURE INTERCOOLER WATER PRESSURE LOW MIXTURE COOLING WATER PUMP FAILURE ENGINE ROOM VENTILATION FAILURE MEASURING SIGNAL FAILURE IGNITION TRIGGER PICKUP MISSING IGNITION RESET PICKUP MISSING IGNITION CAM PICKUP MISSING IGNITION SHUTOFF OVERSPEED IGNITION CPU FAILURE IGNITION PARAMETER FAILURE Faulty ignition/CAN coupling WRONG TYPE OF IGNITION SYSTEM ENGINE OIL TEMPERATURE HIGH MISFIRING FAILURE OIL PRESSURE LOW EXCITATION VOLTAGE LOW JACKET WATER TEMPERATURE HIGH GAS PRESSURE LOW IN GAS TRAIN 1 INTAKE AIR TEMPERATURE HIGH INTAKE AIR TEMPERATURE MEASURING SIGNAL FAILURE IGNITION OUTPUT MONITORING CYLINDER IN/OUT CHANNEL FAILURE JACKET WATER PRESSURE LOW JACKET WATER PRESSURE HIGH FUEL MIXTURE TEMPERATURE HIGH Failure in the safety loop POWER REDUCTION IN ISOLATED OPERATION OIL PRESSURE HIGH AIRCONDITIONING UNIT FAILURE IN MODULE INTERFACE CABINET JACKET WATER TEMPERATURE HIGH COMMUNICATION TO DIA.NE WIN SERVER FAILED DATA REGISTRATION IN DIA.NE WIN SERVER FAILED

Keyword:

ENI Pakistan 1-10

Unit no.:

J F516/ J F662 - J F670

Module no.: ------

Module type :

JGS 312 GS-N.L.

Version:

C01

Engine no.: ------

Issued:

Doku./Pichler:

EN

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4.1 Checklist for alarm messages

Documentation

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Index 10 10

START CONDITIONS MISSING

11

OF MOTOR There is a defect as e.g. min. or max. oil level. The current loop (safety loop) is open

12

13

20

OF AGGREGATE e.g. min. gas pressure closed current loop not released

OF THE UNIT no release through auxiliary operation

MOTOR WON'T START gas pressure too low or too high or gas pressure fluctuations

throttle flap won't open

Ignition defective Ignition spark missing

remove indicated cause remove loose contact or wire breakage, or replace defective monit. device.

remove cause or complain at trader;remove loose contact or wire breakage, or replace defect monitoring device

check which auxiliary operation is not running, e.g. HW-circulation pump or throughflow indicator and machine room vent flap open, gas warning installation etc.

gas pressure prior to gas pressure controller line does not correspond to listings in techn. scheme. check whether supply of the Heinzmann actuator driver is okay (amber LED in actuator be lit) the Heinzmann actuator driver is defective (red LED in driver lit) due to low voltage ( 90°C); the pickup or the wiring from the pickup to the actuator or DIANE is defective; check whether the throttle flap or the control systems are stuck or do not properly function. check following points (partly with stroboscope).mains supply of DISN-unit (relay

TI 10000300

Keyword:

ENI Pakistan 1-10

Unit no.:

J F516/ J F662 - J F670

Module no.: ------

Module type :

JGS 312 GS-N.L.

Version:

C01

Engine no.: ------

Issued:

Doku./Pichler:

EN

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Jenbacher

4.1 Checklist for alarm messages

Documentation

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electrode distance too smallat all spark plugs

start or idle run position of mixer or gas or air bypass flap incorrect

Unsuitable Impco or Jenbacher mixer

gas pressure in front of zero-pressure controller too high

wrong mixer adjustment membrane of gas pressure controller

defective or bad contact) pickup distance pickup connection defect at relay for the G-line DISN-unit defective wrong.One or several magnets with too little residual magnetism or magnet broken out when changing plugs by sets to non - JENBACHER tested models, electrode distance is often too small, needs greater distance. unsuited gas pressure controller causing gas pressure fluctuations,must be replaced, correction of programmed values to experimental values, or to an inflammable mixture via pollutant measuring kit; check whether the servo motor, the gas or air bypass flap is okay, or check drive for the feedback pot. mixer cone on Impco does not correspond to the current gas type;check whether the air slot at Jenbacher-mixer corresponds to used type of gas. 1) higher values lead to excessive enriching of motor at start; 2) following adjustment of gas adm. pressure: adjust zero pressure controller so that after start of motor there is not speed breakdown (motor in this case too rich); if motor does not increase speed or increases too slow it is too lean; if motor is too rich, gradually turn zero pressure spindle out by 1 rot; if motors is too lean gradually turn spindle in by 1 rot. check programming of start opening check membrane for ruptures

see maintenance

TI 10000300

Keyword:

ENI Pakistan 1-10

Unit no.:

J F516/ J F662 - J F670

Module no.: ------

Module type :

JGS 312 GS-N.L.

Version:

C01

Engine no.: ------

Issued:

Doku./Pichler:

EN

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Jenbacher

4.1 Checklist for alarm messages

Documentation

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defective gas pressure controller stuck gas magnet valve is defective no inflammable mixture forms

throttle flap opens and closes quickly during start procedure

30

check for easy movement check whether gas magnet valves open check whether the slot at the mixer cone at the Jenbachermixer corresponds to the %oposition programmed at the DIANE; check whether the mixer cone moves, whether in the drive the spring for the catching is missing or the servo motor is defective (wire breakage or pot-drive) cwrong pick-up adjustment and quite often must be positioned closer to toothed wheel of starter according to adjustment instructions

MOTOR SAWING IN IDLE RUN (can't be synchronized) Heinzmann actuator defective replace (damaged) unsuited mixer mixer cones at Impco do not correspond to gas type or the air slot on Jenbacher-mixer, e.g., for depot gas, is too high, i.e., replace mixer cone, or reduce air slot (replace mixer or reduce shims under mixer head with new Jenbacher mixers) ignition defective (cylinder missing) replace Ignition coildefective replace as a result of a pulsating draught in the fit flap with a solenoid valve at exhaust flue while still warm the foot of the flue. speed controller not optimally adjusted Gas-pressure fluctuations use manometer or water Check the control rods (ball heads worn columnto measure where the / sluggish) gas pressure fluctuations Mixture too lean / too rich appear, i.e., upstream of mixer, upstream of gas Check speed controller setting pressure controller or downstream of customergas admission controller; if controller unsuited, replace it, or call supplier (of admission pressure controller). damaged joint cones of control line replace joint cones

see

Keyword:

ENI Pakistan 1-10

Unit no.:

J F516/ J F662 - J F670

Module no.: ------

Module type :

JGS 312 GS-N.L.

Version:

C01

Engine no.: ------

Issued:

Doku./Pichler:

EN

4_1___B_DianeXT_EN.doc

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Jenbacher

4.1 Checklist for alarm messages

Documentation

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maintenance the control linkage adjusted too progressively in idle run throttle flap slightly bent following detonation in intake line and does not fully close anymore (idle speed partially too high) sluggish control lines, or throttle flap

Heinzmann actuator driver not optimally adjusted idle run position at gas or air bypass valve not optimally adjusted or no optimal programming in DIANE 40

correct adjustment and make sure that the flap can fully close. remove throttle flap and align, check for easy functioning

relube the joints, or disassemble the throttle flap bearing and replace; replace bearing bushing. check the 0% position of the actuator better adjust idle run position by trial or program differently

see maintenance

see maintenance

MOTOR DOES NOT REACH FULL LOAD (while maintaining the guaranteed pollutant emissions) Defective turbocharger check compactor shovel (missing power and power loss) whether entry edges are damaged by foreign bodies or whether formation of deposits in the compactor housing reduces output or whether runnertouches housing (clean compactor housing and runner). Check the turbine wheel for damage and free run. combustion air ratio not okay (motor correct leanox adjustment at running too lean), DIANE Part of the broken-off protective pipe in open the end cover and a manifold compensator is interrupting remove parts or replace the flow of the exhaust gases compensator.Inspect turbine wheel for damage. faulty insulation of exhaust collection attach new insulation of line (insulation is completely or partiall thickness and efficiency as worn down due to frequent dismantling original one or due to vibraiton mixture transporting parts after seal off compactor to throttle flap are not tight suction temperature too high(at >25°C) check whether ambient air reduction can be used acc. to ISO thermostat adjusted too high, 3046, except for other contractual the room venting not properly agreement planned or other vent stages do not turn on mixture temperature too high in spite of check mixture cooler, clean if TI 1000-

Keyword:

ENI Pakistan 1-10

Unit no.:

J F516/ J F662 - J F670

Module no.: ------

Module type :

JGS 312 GS-N.L.

Version:

C01

Engine no.: ------

Issued:

Doku./Pichler:

EN

4_1___B_DianeXT_EN.doc

Date: 2009-01 Page - No.: 8 / 104

Jenbacher

4.1 Checklist for alarm messages

Documentation

-

correct mixture cooling water admission temp. output display wrong; ignition not properly adjusted, orcombustion misfires by e.g. too large electrode distance or failure of cylinders due to defectat ignition system (e.g. defect ignition coil) throttle flap not fully opened,actuator stands at 100% contaminated air filter and hence great pressure loss before mixer flue gas counter pressure too

leakage at the flange connections of flue gas line

necessary (mixture and water part) or glycol ratio too high (check). check and correct error; make ignition check, measure ignition point, correct ignition adjustment and electrode distance, replace defective parts. correction of controller linkage adjustment actuator - throttle flap. measure pressure loss clean or replace the filter measure the counter pressure after high turboloader exit;clean oxikate and waste heat boiler if necessary. seal the line (replace sealings, tighten screws correctly) if necessaryrework flanges

0201, see maintenance see maintenance

see maintenance see maintenance

50

MOTOR OR SYSTEM MOTOR/GENERATOR RUNS IRREGULARLY OR UNSTABLE WITH LOAD

51

MOTOR VIBRATES STRONGLY failure of cylinder pendulum damper not okay motor adjustment not okay (ignition point) straps of motor add-on pieces not okay

check ignition, valves, check compression check and replace if necessary check and adjust

see maintenance see maintenance

check and remedy

52

MOTOR SHAKES (quick load fluctuations or great current and voltage fluctuations with little change of motor output) faulty ignition check ignition system see maintenance combustion air ratio not okay (motor check and adjust using the running too lean), pollutant measuring device water, humidity in spark plug chamber dry spark plug chamber, (after washing motor) clean plugs and connector.

53

ENGINE ROCKING biological gas: gas pressure control line not okay (e.g. water in the gas pressure controllers, stuck gas control valves)

check gas pressure with water column upstream of mixer. check gas pressure controller, repair if necessary

Keyword:

ENI Pakistan 1-10

Unit no.:

J F516/ J F662 - J F670

Module no.: ------

Module type :

JGS 312 GS-N.L.

Version:

C01

Engine no.: ------

Issued:

Doku./Pichler:

EN

4_1___B_DianeXT_EN.doc

Date: 2009-01 Page - No.: 9 / 104

Jenbacher

4.1 Checklist for alarm messages

Documentation

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misfires (motor adjusted too lean)

check and adjust using the pollutant measuring device

54

GENERATOR MOTOR ESCALATES (great current and voltage fluctuations at only little change in motor output) voltage controller at generator not okay adjust or repair description cos phi controller not okay check cables bad connection in circuit (cables) check that connector is firmly generator located

55

MOTOR ARCHIEVES NOT STABLE CONDITION (output swings slowly up and down) Non-optimal setting of Leanox-control optimise the controller parameters parameters at constant power Check control rods (ball heads worn / setpoint sluggish) Check gas pressure Check power control Check gas-quality fluctuations (landfill gas, possibly sewage gas) harmonization of leanoxcontroller harmonize time behavior output control not functioning leanox contr. to time behavior output control (decouple) control linkages not okay (too large check, if necessary repair or see dead center/to progressively adjusted, replace maintenance etc.) gas mixer not properly adjusted (e.g. lcheck, adjust characteristic not okay) gas pressure fluctuating check gas pressure TI 1000controller, check admission 0300 pressure quick fluctuation of the mixture check temp. in hot water Schematic temperature circulation diagram

56

ENGINE STOPS (individual cylinders) OR HAS AN EXHAUST GAS TEMPERATURE DEVIATING FROM THE CENTRAL VALUE Pre-combustion chamber gas pressure Eleminate cause! set too low Check spark plugs, ignition coils and ignition system defective ignition check see maintenance defective spark plug check voltage demand, see replace if necessary maintenance

57

PERIODIC FLUCTUATIONS IN PERFORMANCE continual switching on and off of the Conversion to thermostaticallyventilator(s) controlled, frequencyregulated ventilator

Keyword:

ENI Pakistan 1-10

Unit no.:

J F516/ J F662 - J F670

Module no.: ------

Module type :

JGS 312 GS-N.L.

Version:

C01

Engine no.: ------

Issued:

Doku./Pichler:

EN

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Jenbacher

4.1 Checklist for alarm messages

Documentation

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60

MOTOR KNOCKING output limitation faulty mixture cooling water temperature too high cooling water throughflow through the mixture cooler too low deposits in combustion chamber are butane and air mixed into the fuel gas? motor set too rich methane number of fuel gas too low combustion air ratio not okay ignition point not okay too early ignition point is set mixture temperature too high mixture cooler not okay

70

Eleminate cause! Eleminate cause!

Schematic diagram

Eleminate cause! check, remove deposits if any Eleminate cause! Eleminate cause! take gas sample and have it analyzed check, correct adjustment if necessary determine ignition point and adjust toward "late" Eleminate cause! check, remedy fault if any Eleminate cause!

TI 10000300 Schematic diagram

MISFIRING DETECTION RESPONDS, OR AT BR6 DEVIATION OF CYLINDER FLUE GAS TEMPERATURE TOO GREAT spigot nut at the line to gas inlet valve is retighten the screwing or seal loose or the cutting ring is loose (flue gas temperature is higher at misfire) defective output measurement (motor check the output output does not correspond to measurement (compare measured output) counter measurement with output measurement) wrong adjustment of misfire detector Eleminate cause! verdigris on ignition coil exit (connector clean carefully to make metal to ignition cable) shiny motor runs too lean due to defect of check motor adjustment mixer (or of the air bypass flap)or due to withmeasuring kit, if too lean, leanox control remedycause crack at end of thread torque too high replace spark plug and see (plug tightened without torque wrench or tightencorrectly with the right maintenance with defective tool, or tightened too torque much) missing or bad contact at highvoltage check contact screwing output of ignition coils or at ground ground contact at the ignition contact or ignition coil coil and retighten the connection defect at cable loom between ignition in case of loose contacts box and ignition coils (scraping spots, retighten screws, in all other ground contact, overheating and cases replace cable loom cracking at the insulation, loose contacts at the connections

Keyword:

ENI Pakistan 1-10

Unit no.:

J F516/ J F662 - J F670

Module no.: ------

Module type :

JGS 312 GS-N.L.

Version:

C01

Engine no.: ------

Issued:

Doku./Pichler:

EN

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Jenbacher

4.1 Checklist for alarm messages

Documentation

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interferences at the ignition pearl formation on electrodes due to overheating (e.g. knocking at times)

electrode distance too small (possibly only at site on one electrode) boost pressure transmitter defect or due to drift transmits too low value (to leanox controller or DIANE) causing too lean operation of motor spark plug shows blue or brown discoloring at steel part and shows electrode motor misfires because it is set too lean or due to defective ignition quick generator output change entry of dirt (shavings) or grease into the prechamber annulus, i.e. slits are partially blocked too large ignition voltage demand due to large electrode distance

spring in brass part of plug connector without voltage, or broken, bad contact to brass cap of plug (traces of smoke) consumption spark plug shows abnormal spark appearance or flashover at bottom of plug on oscilloscope

misfiring due to too low ignition voltage offer (defect at the ignition coil) breakage of ignition cable interior at the soldering at the brass part of the plug connector or at the bend of the rubber bush ceramic body at the spark plug on top, or inner part of plug, is soiled with electr. conductive grease or similar and causes spark discharge in this area; plug shows in lower range of brass part a low-out, thus spark discharge to plug shell is

check shield at the cables cannot be seen, metallic pearl may be caused by local melton between electrodes (remove with thickness gauge and check gap) correct electrode distance.

see maintenance

check boost pressure controller, i.e., compare boost pressure signal with manometer, in case of deviation replace transmitter spark plug was not tightened sufficiently and overheated check using an exhaust emmissions analyser and correct if necessary Eleminate cause! Wash the pre-chamber with petrol and blow out. re-adjustment of the electrode gap with the special tool, or replacement of the sparking plugs replace spark plug connector

see maintenance

plug daubed at the end side with electrically conductive gliding agent (when sprayed with Ultra-Therm not covered or too much spray used which dropped on electrodes when hot) check the coil at motor standstill with ignition voltage tester frequent pulling of the plug connector at the cable, the cable ruptures are not visible, replace plug and cable clean plug and connector or replace.check for proper seat of dust cap on top of the valve hoodBlow-out is usually very small, onlyvery small grey point is visible on spark

TI 14000111

Keyword:

ENI Pakistan 1-10

Unit no.:

J F516/ J F662 - J F670

Module no.: ------

Module type :

JGS 312 GS-N.L.

Version:

C01

Engine no.: ------

Issued:

Doku./Pichler:

EN

4_1___B_DianeXT_EN.doc

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Jenbacher

4.1 Checklist for alarm messages

Documentation

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created elastic seal ring inParker" valve of gas inlet valve destroyed

loose brass cap (traces of smoke on top of ceramic body) ball sticks to seat of gas inlet valve

90

OIL CONSUMPTION TOO HIGH carbonisation of the fire land through excessive idling or nonobservation of the limit values for used oil (TI 1000-0099B) leads to carbonisation of hard deposits on the piston top land. The upper rim pushes oil in front of it, more oil is burnt and the 1st ring receives too little oil and wears very repidly. (Ring carries to full height within 1000 op. hrs., darfk, cruty deposit in piston groove Piston runs crooked due to connecting rod parallelity tolerances being exceeded; similar effects to above with the same symptoms and can be clearly seen at the piston skirt on the pressure side, as well as at the fire land above the level of the bolts (one side clear, the other with hard oil carbonisation) (reduced gas access to 1st piston ring). turboloader throwing oil

100

TURBOCHARGER DEFECT

101

COMPACTOR THROWING OIL air filter resistance too great (dirty filter)

102

TURBINE THROWING OIL axial or radial play of runner

passage. replace plug suppresser if ball valve is too leaky, the pressure at theParker" valve is too high and the seal ring is destroyed tighten cap; if threading underneath of brass cap is loose, replace spark plug increase prechamber gas difference pressure; clean (wash valve, i.e. clean from lubricating oil which deposits in valve especially during start-up phase)

see maintenance

remove piston and clean replace first ring and break in motor

see point 0100

clean air filter, if required replace

see maintenance

measure, if exceeding admissible too great values

Keyword:

ENI Pakistan 1-10

Unit no.:

J F516/ J F662 - J F670

Module no.: ------

Module type :

JGS 312 GS-N.L.

Version:

C01

Engine no.: ------

Issued:

Doku./Pichler:

EN

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Date: 2009-01 Page - No.: 13 / 104

Jenbacher

4.1 Checklist for alarm messages

Documentation

-

oil sealing at turbine is defective

repair or replace check and repair

103

TURBOCHARGER EFFICIENCY NOT OKAY (flue gas turbocharger no longer archieves required load pressure) entrance shovels of compactorare check, search cause (foreign defective or damaged body?) and replace FGTL if necessary turbine shovels damaged check, search cause (foreign body?) and replace FGTL if necessary

104

COMPACTOR OR TURBINE WHEEL TOUCHED THE HOUSING defective axial sealing -axial play too measure, if exceeding great admissible too great values repair or replace

105

TURBOCHARGER VIBRATING turbine shovels (compactor shovels) defective (unbalanced)

110

WATER IN LUBRICATION OIL leaks at oil cooler craks or sinkholes at upper side of cylinder head between water storage and oil storage leaky O-rings at the cylinder liner leaky O-rings at the prechambers

replace wheel or turboloader

check and replace if necessary check, replace if necessary

replace O-rings replace O-rings

120

THE CONTRACTUALLY AGREED DEGREE OF EFFICIENCY IS NOT REACHED IN SPITE OF THE SALES TOLERANCE on site the sum of border conditions is measure values exactly and strongly negative in order to reach an convert to standard condition optimal efficiency (e.g. heating value of according to ISO 3046 depot gas extremely low, induction temperature >25°C, air pressure when in emergency off chain gas alarm --> linked

Eleminate cause!

Eleminate cause!

Eleminate cause!

TI 10000300

Eleminate cause!

TI 10000300

Eleminate cause!

GENERATOR OVERLOAD/SHORT CIRCUIT wrong adjustment or defective output Eleminate cause! controller overload in isolated operation

Keyword:

ENI Pakistan 1-10

Unit no.:

J F516/ J F662 - J F670

Module no.: ------

Module type :

JGS 312 GS-N.L.

Version:

C01

Engine no.: ------

Issued:

Doku./Pichler:

EN

4_1___B_DianeXT_EN.doc

Date: 2009-01 Page - No.: 16 / 104

Jenbacher

4.1 Checklist for alarm messages

Documentation

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short circuit wrong adjustment or defective output switch wrong adjustment or defective cos-phi controller wire breakage to PLC unbalanced load 1037

GENERATOR WINDING TEMPERATURE HIGH generator overload Eleminate cause! unbalanced load defective generator wrong cos-phi posistor or analogue input defective wire breakage to PLC ambient temperature too high wrong adjustment of fringe value

1038

GENERATOR REVERSE POWER generator power switch does not open 10% power switch point wrong adjustment output reduced too quickly defective output measurement (only variant with reverse current relay) wrong adjustment rev. current relay or defective DIANE wrong adjustment or defective defective current transmitter wire breakage to PLC short circuit or wire breakage in 20 mA current loop of output measuring transducer ignition failure (signal pickup/DISN failure)

1039

1040

SYNCHRONIZING FAILURE speed controller hunting throttle control rod loose synchronising unit faulty engine rough (ignition coil faulty) voltage balance circuit faulty engine idles too long gas pressure oscillating FUEL MIXTURE TEMPERATURE HIGH defective mixture cooling pump mixture cooler clogged, calcified, dirty hot water feedback temp. too high fresh water exchanger is clogged, calcified, dirty

Eleminate cause!

Eleminate cause!

Eleminate cause!

Keyword:

ENI Pakistan 1-10

Unit no.:

J F516/ J F662 - J F670

Module no.: ------

Module type :

JGS 312 GS-N.L.

Version:

C01

Engine no.: ------

Issued:

Doku./Pichler:

EN

4_1___B_DianeXT_EN.doc

Date: 2009-01 Page - No.: 17 / 104

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4.1 Checklist for alarm messages

Documentation

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defective PT100 water circulation of mixture cooling not vented cooling water amount of mixture too low wrong adjustment of fringe value 1041

1042

1043

1048

POWER SIGNAL MISSING wire breakage or short circuit of output signal wire breakage or short circuit of current transducer output measuring transducer defect defective current transducer defective output controller power setpoint too small (25°C) check whether ambient air reduction can be used acc. to ISO 3046, thermostat adjusted too high, the except for other contractual agreement room venting not properly planned or other vent stages do not turn on mixture temperature too high in spite of check mixture cooler, clean if TI 1000correct mixture cooling water admission necessary (mixture and water 0201, see temp. part) or glycol ratio too high maintenance (check).

Keyword:

ENI Pakistan 1-10

Unit no.:

J F516/ J F662 - J F670

Module no.: ------

Module type :

JGS 312 GS-N.L.

Version:

C01

Engine no.: ------

Issued:

Doku./Pichler:

EN

4_1___B_DianeXT_EN.doc

Date: 2009-01 Page - No.: 78 / 104

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4.1 Checklist for alarm messages

Documentation

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output display wrong; ignition not properly adjusted, orcombustion misfires by e.g. too large electrode distance or failure of cylinders due to defectat ignition system (e.g. defect ignition coil) throttle flap not fully opened,actuator stands at 100% contaminated air filter and hence great pressure loss before mixer flue gas counter pressure too

leakage at the flange connections of flue gas line

check and correct error; make ignition check, measure ignition point, correct ignition adjustment and electrode distance, replace defective parts. correction of controller linkage adjustment actuator - throttle flap. measure pressure loss clean or replace the filter measure the counter pressure after high turboloader exit;clean oxikate and waste heat boiler if necessary. seal the line (replace sealings, tighten screws correctly) if necessaryrework flanges

see maintenance

see maintenance see maintenance

50

MOTOR OR SYSTEM MOTOR/GENERATOR RUNS IRREGULARLY OR UNSTABLE WITH LOAD

51

MOTOR VIBRATES STRONGLY failure of cylinder pendulum damper not okay

check ignition, valves, check compression check and replace if necessary

motor adjustment not okay (ignition point) straps of motor add-on pieces not okay

check and adjust check and remedy

see maintenance see maintenance

52

MOTOR SHAKES (quick load fluctuations or great current and voltage fluctuations with little change of motor output) faulty ignition check ignition system see maintenance combustion air ratio not okay (motor running check and adjust using the too lean), pollutant measuring device water, humidity in spark plug chamber (after dry spark plug chamber, clean washing motor) plugs and connector.

53

ENGINE ROCKING biological gas: gas pressure control line not okay (e.g. water in the gas pressure controllers, stuck gas control valves) misfires (motor adjusted too lean)

check gas pressure with water column upstream of mixer. check gas pressure controller, repair if necessary check and adjust using the pollutant measuring device

Keyword:

ENI Pakistan 1-10

Unit no.:

J F516/ J F662 - J F670

Module no.: ------

Module type :

JGS 312 GS-N.L.

Version:

C01

Engine no.: ------

Issued:

Doku./Pichler:

EN

4_1___B_DianeXT_EN.doc

Date: 2009-01 Page - No.: 79 / 104

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4.1 Checklist for alarm messages

Documentation

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54

GENERATOR MOTOR ESCALATES (great current and voltage fluctuations at only little change in motor output) voltage controller at generator not okay adjust or repair description cos phi controller not okay check cables - generator bad connection in circuit (cables) check that connector is firmly located

55

MOTOR ARCHIEVES NOT STABLE CONDITION (output swings slowly up and down) Non-optimal setting of Leanox-control optimise the controller parameters parameters at constant power Check control rods (ball heads worn / setpoint sluggish) Check gas pressure Check power control Check gas-quality fluctuations (landfill gas, possibly sewage gas) harmonization of leanoxcontroller - output harmonize time behavior leanox control not functioning contr. to time behavior output control (decouple) control linkages not okay (too large dead check, if necessary repair or see center/to progressively adjusted, etc.) replace maintenance gas mixer not properly adjusted (e.g. lcheck, adjust characteristic not okay) gas pressure fluctuating check gas pressure controller, TI 1000check admission pressure 0300 quick fluctuation of the mixture temperature check temp. in hot water Schematic circulation diagram

56

ENGINE STOPS (individual cylinders) OR HAS AN EXHAUST GAS TEMPERATURE DEVIATING FROM THE CENTRAL VALUE Pre-combustion chamber gas pressure set Eleminate cause! too low Check spark plugs, ignition coils and ignition system defective ignition check see maintenance defective spark plug check voltage demand, replace if see necessary maintenance

57

PERIODIC FLUCTUATIONS IN PERFORMANCE continual switching on and off of the Conversion to thermostaticallyventilator(s) controlled, frequency-regulated ventilator

60

MOTOR KNOCKING output limitation faulty mixture cooling water temperature too high

Eleminate cause! Eleminate cause!

Schematic diagram

Keyword:

ENI Pakistan 1-10

Unit no.:

J F516/ J F662 - J F670

Module no.: ------

Module type :

JGS 312 GS-N.L.

Version:

C01

Engine no.: ------

Issued:

Doku./Pichler:

EN

4_1___B_DianeXT_EN.doc

Date: 2009-01 Page - No.: 80 / 104

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4.1 Checklist for alarm messages

Documentation

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cooling water throughflow through the mixture cooler too low deposits in combustion chamber are butane and air mixed into the fuel gas? motor set too rich methane number of fuel gas too low combustion air ratio not okay ignition point not okay too early ignition point is set mixture temperature too high mixture cooler not okay 70

Eleminate cause! check, remove deposits if any Eleminate cause! Eleminate cause! take gas sample and have it analyzed check, correct adjustment if necessary determine ignition point and adjust toward "late" Eleminate cause! check, remedy fault if any Eleminate cause!

TI 10000300 Schematic diagram

MISFIRING DETECTION RESPONDS, OR AT BR6 DEVIATION OF CYLINDER FLUE GAS TEMPERATURE TOO GREAT spigot nut at the line to gas inlet valve is retighten the screwing or seal loose or the cutting ring is loose (flue gas temperature is higher at misfire) defective output measurement (motor check the output measurement output does not correspond to measured (compare counter measurement output) with output measurement) wrong adjustment of misfire detector Eleminate cause! verdigris on ignition coil exit (connector to clean carefully to make metal ignition cable) shiny motor runs too lean due to defect of mixer check motor adjustment (or of the air bypass flap)or due to leanox withmeasuring kit, if too lean, control remedycause crack at end of thread torque too high (plug replace spark plug and see tightened without torque wrench or with tightencorrectly with the right maintenance defective tool, or tightened too much) torque missing or bad contact at highvoltage output check contact screwing ground of ignition coils or at ground contact or contact at the ignition coil and ignition coil retighten the connection defect at cable loom between ignition box in case of loose contacts and ignition coils (scraping spots, ground retighten screws, in all other contact, overheating and cracking at the cases replace cable loom insulation, loose contacts at the connections interferences at the ignition check shield at the cables pearl formation on electrodes due to cannot be seen, metallic pearl overheating (e.g. knocking at times) may be caused by local melt-on between electrodes (remove with thickness gauge and check gap) electrode distance too small (possibly only correct electrode distance. see at site on one electrode) maintenance

Keyword:

ENI Pakistan 1-10

Unit no.:

J F516/ J F662 - J F670

Module no.: ------

Module type :

JGS 312 GS-N.L.

Version:

C01

Engine no.: ------

Issued:

Doku./Pichler:

EN

4_1___B_DianeXT_EN.doc

Date: 2009-01 Page - No.: 81 / 104

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4.1 Checklist for alarm messages

Documentation

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boost pressure transmitter defect or due to drift transmits too low value (to leanox controller or DIANE) causing too lean operation of motor spark plug shows blue or brown discoloring at steel part and shows electrode motor misfires because it is set too lean or due to defective ignition quick generator output change entry of dirt (shavings) or grease into the prechamber annulus, i.e. slits are partially blocked too large ignition voltage demand due to large electrode distance

spring in brass part of plug connector without voltage, or broken, bad contact to brass cap of plug (traces of smoke) consumption spark plug shows abnormal spark appearance or flashover at bottom of plug on oscilloscope

misfiring due to too low ignition voltage offer (defect at the ignition coil) breakage of ignition cable interior at the soldering at the brass part of the plug connector or at the bend of the rubber bush ceramic body at the spark plug on top, or inner part of plug, is soiled with electr. conductive grease or similar and causes spark discharge in this area; plug shows in lower range of brass part a low-out, thus spark discharge to plug shell is created elastic seal ring inParker" valve of gas inlet valve destroyed

loose brass cap (traces of smoke on top of ceramic body)

check boost pressure controller, i.e., compare boost pressure signal with manometer, in case of deviation replace transmitter spark plug was not tightened sufficiently and overheated check using an exhaust emmissions analyser and correct if necessary Eleminate cause! Wash the pre-chamber with petrol and blow out. re-adjustment of the electrode gap with the special tool, or replacement of the sparking plugs replace spark plug connector

see maintenance

plug daubed at the end side with electrically conductive gliding agent (when sprayed with UltraTherm not covered or too much spray used which dropped on electrodes when hot) check the coil at motor standstill with ignition voltage tester frequent pulling of the plug connector at the cable, the cable ruptures are not visible, replace plug and cable clean plug and connector or replace.check for proper seat of dust cap on top of the valve hoodBlow-out is usually very small, onlyvery small grey point is visible on spark passage. replace plug suppresser if ball valve is too leaky, the pressure at theParker" valve is too high and the seal ring is destroyed tighten cap; if threading underneath of brass cap is loose, replace spark plug

TI 14000111

see maintenance

Keyword:

ENI Pakistan 1-10

Unit no.:

J F516/ J F662 - J F670

Module no.: ------

Module type :

JGS 312 GS-N.L.

Version:

C01

Engine no.: ------

Issued:

Doku./Pichler:

EN

4_1___B_DianeXT_EN.doc

Date: 2009-01 Page - No.: 82 / 104

Jenbacher

4.1 Checklist for alarm messages

Documentation

-

ball sticks to seat of gas inlet valve

90

OIL CONSUMPTION TOO HIGH carbonisation of the fire land through excessive idling or nonobservation of the limit values for used oil (TI 1000-0099B) leads to carbonisation of hard deposits on the piston top land. The upper rim pushes oil in front of it, more oil is burnt and the 1st ring receives too little oil and wears very repidly. (Ring carries to full height within 1000 op. hrs., darfk, cruty deposit in piston groove Piston runs crooked due to connecting rod parallelity tolerances being exceeded; similar effects to above with the same symptoms and can be clearly seen at the piston skirt on the pressure side, as well as at the fire land above the level of the bolts (one side clear, the other with hard oil carbonisation) (reduced gas access to 1st piston ring). turboloader throwing oil

100

TURBOCHARGER DEFECT

101

COMPACTOR THROWING OIL air filter resistance too great (dirty filter)

102

TURBINE THROWING OIL axial or radial play of runner

remove piston and clean replace first ring and break in motor

see point 0100

clean air filter, if required replace

see maintenance

measure, if exceeding admissible too great values repair or replace check and repair

oil sealing at turbine is defective 103

increase prechamber gas difference pressure; clean (wash valve, i.e. clean from lubricating oil which deposits in valve especially during start-up phase)

TURBOCHARGER EFFICIENCY NOT OKAY (flue gas turbocharger no longer archieves required load pressure) entrance shovels of compactorare defective check, search cause (foreign or damaged body?) and replace FGTL if necessary turbine shovels damaged check, search cause (foreign body?) and replace FGTL if necessary

Keyword:

ENI Pakistan 1-10

Unit no.:

J F516/ J F662 - J F670

Module no.: ------

Module type :

JGS 312 GS-N.L.

Version:

C01

Engine no.: ------

Issued:

Doku./Pichler:

EN

4_1___B_DianeXT_EN.doc

Date: 2009-01 Page - No.: 83 / 104

Jenbacher

4.1 Checklist for alarm messages

Documentation

-

104

COMPACTOR OR TURBINE WHEEL TOUCHED THE HOUSING defective axial sealing -axial play too great measure, if exceeding admissible too great values repair or replace

105

TURBOCHARGER VIBRATING turbine shovels (compactor shovels) defective (unbalanced)

110

WATER IN LUBRICATION OIL leaks at oil cooler craks or sinkholes at upper side of cylinder head between water storage and oil storage leaky O-rings at the cylinder liner leaky O-rings at the prechambers

replace wheel or turboloader

check and replace if necessary check, replace if necessary replace O-rings replace O-rings

120

THE CONTRACTUALLY AGREED DEGREE OF EFFICIENCY IS NOT REACHED IN SPITE OF THE SALES TOLERANCE on site the sum of border conditions is measure values exactly and strongly negative in order to reach an convert to standard condition according to ISO 3046 optimal efficiency (e.g. heating value of depot gas extremely low, induction temperature >25°C, air pressure when in emergency off chain gas alarm --> linked

Eleminate cause!

TI 10000300

Eleminate cause!

TI 10000300

Eleminate cause!

1036

GENERATOR OVERLOAD/SHORT CIRCUIT wrong adjustment or defective output Eleminate cause! controller overload in isolated operation short circuit wrong adjustment or defective output switch wrong adjustment or defective cos-phi controller wire breakage to PLC unbalanced load

1037

GENERATOR WINDING TEMPERATURE HIGH generator overload Eleminate cause! unbalanced load defective generator wrong cos-phi posistor or analogue input defective wire breakage to PLC ambient temperature too high wrong adjustment of fringe value

Keyword:

ENI Pakistan 1-10

Unit no.:

J F516/ J F662 - J F670

Module no.: ------

Module type :

JGS 312 GS-N.L.

Version:

C01

Engine no.: ------

Issued:

Doku./Pichler:

EN

4_1___B_DianeXT_EN.doc

Date: 2009-01 Page - No.: 86 / 104

Jenbacher

4.1 Checklist for alarm messages

Documentation

-

1038

1039

1040

1041

GENERATOR REVERSE POWER generator power switch does not open 10% power switch point wrong adjustment output reduced too quickly defective output measurement (only variant with reverse current relay) wrong adjustment rev. current relay or defective DIANE wrong adjustment or defective defective current transmitter wire breakage to PLC short circuit or wire breakage in 20 mA current loop of output measuring transducer ignition failure (signal pickup/DISN failure) SYNCHRONIZING FAILURE speed controller hunting throttle control rod loose synchronising unit faulty engine rough (ignition coil faulty) voltage balance circuit faulty engine idles too long gas pressure oscillating

Eleminate cause!

Eleminate cause!

FUEL MIXTURE TEMPERATURE HIGH defective mixture cooling pump mixture cooler clogged, calcified, dirty hot water feedback temp. too high fresh water exchanger is clogged, calcified, dirty defective PT100 water circulation of mixture cooling not vented cooling water amount of mixture too low wrong adjustment of fringe value POWER SIGNAL MISSING wire breakage or short circuit of output signal wire breakage or short circuit of current transducer output measuring transducer defect defective current transducer defective output controller power setpoint too small (