0% found this document useful (0 votes)

2K views1,058 pages

Description of Operation (J S889)

The document provides operation and maintenance instructions for a GE Jenbacher gas engine module. It includes sections on general conditions, operation of the plant, fault rectification, and descriptions of the basic engine and systems. Technical specifications, diagrams, and safety regulations are presented.

Uploaded by

chrisdaman2011

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

0% found this document useful (0 votes)

2K views1,058 pages

Description of Operation (J S889)

Uploaded by

chrisdaman2011

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

You are on page 1/ 1058

JGS 616 GS-N.

L
Description / Operation

Generator module

AB ENERGY 616 -31

J S889
Engine number: 1127180
Module number: 1127172

2015-06

© GE Jenbacher GmbH & Co OG

Achenseestr. 1-3
A-6200 Jenbach (Austria)
www.gejenbacher.com
Revision history
Index Date Description/Revision summary Creator
Auditor
1 17/06/2015 Delivery ➔ Footer
Huber

Original operating instructions

GE proprietary information: CONFIDENTIAL!

The information contained in this document is General Electric Company proprietary information and is disclosed in
confidence. It is the property of GE and may not be used, disclosed to others or reproduced without the express
written consent of GE. This includes, but is not limited to, use of the information to create, manufacture, develop or
derive any repairs, modifications, spare parts, designs or configuration changes, or to obtain government or
regulatory approval to do so. If consent is given for reproduction in whole or in part, this notice and the notice set
forth on each page of this document shall appear in any such reproduction in whole or in part.

© GE Jenbacher GmbH & Co OG, 2015-06

Table of contents

User Instructions .......................................................................................................................................................................... 1

Sections of the GE Jenbacher Product Documentation.................................................................................................................. 1.1
Key to Symbols ................................................................................................................................................................................................... 1.2
Type Plate and Type Designation of GE Jenbacher Products....................................................................................................... 1.3
Web portal ............................................................................................................................................................................................................ 1.4
Your Opinion Counts! ....................................................................................................................................................................................... 1.5
Service and Sales partners............................................................................................................................................................................ 1.6
Getting Started Guide...................................................................................................................................................................................... 1.7
Imprint .................................................................................................................................................................................................................... 1.8

General conditions ....................................................................................................................................................................... 2

Designated Use .................................................................................................................................................................................................. 2.1
REACH-Notification and Downstream User Communication for Substances in Articles ................................................ 2.2
Declaration of Conformity ....................................................................................................................................................................................
Securing GE Jenbacher modules during transport by truck................................................................................. TA 1000-0039
Boundary conditions for GE Jenbacher gas engines................................................................................................ TA 1100-0110
General conditions - Operation and Maintenance .................................................................................................... TA 1100-0111
Cleanliness During Service Work Involving Clean Oil Parts ................................................................................... TA 1100-0113
Installation of electrical equipment for GE Jenbacher generator sets............................................................. TA 1100-0114
Safety regulations ..................................................................................................................................................................... TA 2300-0005
Guidelines for using the LOTO kit ...................................................................................................................................... TA 2300-0010

Operation of the plant ................................................................................................................................................................. 3

Technical specification of the control system...................................................................................................................................... 3.1
Control box ........................................................................................................................................................................................................... 3.2
Dia.ne XT V3.4.............................................................................................................................................................................................. DIA.NE
Remote Data Transmission................................................................................................................................................................ Hermes

Fault rectification ......................................................................................................................................................................... 4

Failure Checklist ................................................................................................................................................................................................. 4.1

Description..................................................................................................................................................................................... 5
Basic engine......................................................................................................................................................................................................... 5.1
Description 5.1.1
Technical Data - Engine 5.1.2
Engine diagrams 5.1.3
Engine oil system 5.1.4
Cooling water system 5.1.5
Fuel gas system 5.1.6
System .................................................................................................................................................................................................................... 5.2
Technical data - Facility 5.2.1
Module drawings and Technical diagram 5.2.2
Gas train 5.2.3
MORIS ignition system 5.2.4
Flexible coupling 5.2.5
Control system.................................................................................................................................................................................................... 5.3
Leanox® controller 5.3.1
Speed controller 5.3.2
Power controller 5.3.3
Isolated operation controller 5.3.4

Consumables and Technical Instructions................................................................................................................................ 6

Operating Materials.......................................................................................................................................................................................... 6.1
Technical instructions...................................................................................................................................................................................... 6.2
Torque wrench........................................................................................................................................................................... TA 000-00-003
Preservation of GE Jenbacher modules.......................................................................................................................... TA 1000-0004
Requirements on the installation surface for GE Jenbacher plant .................................................................... TA 1000-0041
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Responsible: Release date: 18/06/2015
Index: 1 Page No.: 1/2
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Table of contents

Transporting and setting up GE Jenbacher switch cabinets ................................................................................ TA 1000-0043

Transport protection ................................................................................................................................................................ TA 1000-0044
Lifting, transporting and placing GE Jenbacher generating sets in engine rooms.................................... TA 1000-0046
Batteries (starter and storage)............................................................................................................................................. TA 1000-0050
TRIO-PS/3AC/24DC/40 battery charger.......................................................................................................................... TA 1000-0052
Approval procedure for various engine oils ............................................................................................................... TA 1000-0099A
Limit levels for used oil in GE Jenbacher gas engines........................................................................................... TA 1000-0099B
Procedure for testing the oil service life specific to the plant............................................................................ TA 1000-0099C
Determining the initial pH value (ipH) for used lube oil as defined in TI 1000-0099B............................. TA 1000-0099D
Aid to interpreting used oil analyses of engine lubricants .................................................................................. TA 1000-0099K
Storage and Handling of Fresh Oil for GEJ Gas Engines ....................................................................................... TA 1000-0099L
Taking lubricating oil samples / lubricating oil sampling protocol..................................................................... TA 1000-0112
Composition of cooling water in closed primary circuits........................................................................................ TA 1000-0200
Anti-freeze products and testing the coolant ............................................................................................................. TA 1000-0201
Corrosion protection products for cooling water for GE Jenbacher engines and testing the coolant
............................................................................................................................................................................................................ TA 1000-0204
Quality of circuit water in hot water and warm water heating systems......................................................... TA 1000-0206
Fuel gas requirements ............................................................................................................................................................ TA 1000-0300
Signs on the engine room door........................................................................................................................................... TA 1000-0330
EMC suited execution of cabling and ground connection to/and motor aggregates and control cabinet
............................................................................................................................................................................................................ TA 1000-0505
Handling of electronic components/modules ............................................................................................................. TA 1000-0510
Protective arrangements for setting up electrical installations .......................................................................... TA 1000-0515
Lubricating oil for type 2, 3, 4 and 6 GE Jenbacher engines ................................................................................. TA 1000-1109
Engine shut down...................................................................................................................................................................... TA 1100-0105
Installation of GE Jenbacher Units .................................................................................................................................... TA 1100-0112
Regulations for running in GE generating set engines ............................................................................................ TA 1400-0100
Pipings............................................................................................................................................................................................. TA 1400-0131
Spark plug adjustment tool for plugs with hook electrodes ................................................................................. TA 1400-0162
MORIS ignition ............................................................................................................................................................................. TA 1502-0068
MPM (MORIS Power Module)................................................................................................................................................. TA 1502-0069
SAFI (Sensor Actuator Function Interface) ..................................................................................................................... TA 1502-0071
SPA24 (SAFI-Pickup-Amplifier) ............................................................................................................................................. TA 1502-0072
Gas quantity controller (TecJet 110 and 50 plus) ....................................................................................................... TA 1510-0064
Dealing with exhaust condensate..................................................................................................................................... TA 1511-0069
Denso 301, 518 spark plugs ................................................................................................................................................. TA 1530-0191
Instructions for checking and mounting of waisted screws ................................................................................. TA 1902-0001
Tightening torques – J 6..GS-E/F................................................................................................................................... TA 1902-0228E/F
Check list for engine repairs and overhauls.................................................................................................................. TA 2102-0020
Isolated operation of spark ignition gas engines with DIA.NE (type 6 engines) ........................................... TA 2108-0026
Isolated operation - general................................................................................................................................................. TA 2108-0031
Employee protection................................................................................................................................................................ TA 2300-0001
Security tips when connecting GE Jenbacher Installations to the Internet ................................................... TA 2300-0006

Comments and supplements...................................................................................................................................................... 7

Comments and supplements....................................................................................................................................................................... 7.1

Appendix......................................................................................................................................................................................... 8
Generator .............................................................................................................................................................................................................. 8.1
SprungMarke!!!11250968331

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Responsible: Release date: 18/06/2015
Index: 1 Page No.: 2/2
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
1 User Instructions
1.1
Sections of the GE Jenbacher Product Documentation

Description – Operation
▪ Operation of the system
▪ Fault rectification
▪ Description of the engine and the system
▪ Choice of fuels
▪ Technical instructions

Maintenance
▪ What inspection work and maintenance work needs to be
carried out?
▪ When should the work be carried out?
▪ How should the work be carried out?
▪ Gathering operational data

Spare parts list

▪ Selecting the required spare part
▪ Ordering spare parts
▪ Allocating spare parts

SprungMarke!!!14215307

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 18/07/2013
Index: 1 Page No.: 1/1
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
1.2
Key to Symbols

The following symbols are used to highlight certain text passages in your GE Jenbacherproduct
documentation.

Caution
Follow these instructions to avoid risk of personal injury or risk of damaging engine or
system components.

Disassemble
Disassemble the component as described.

Assembling
Assemble the component as described.

Inspection
Inspect the components or operating materials as described.

Tightening torque
Tighten the nut or bolt to the specified tightening torque.

Clean
Clean the component as described.

Lubricate
Lubricate or grease the component as described.

Reference
Reference to a document or a section of the product documentation. Important
information or important note.

Info
Important information or important note.

SprungMarke!!!27021597778485003

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schatz Responsible: Dokumentation Release date: 22/08/2013
Index: 4 Page No.: 1/1
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
1.3
Type Plate and Type Designation of GE Jenbacher Products

1 Type plate

1.1 Engine type plate

The engine type plate is located on the crankcase.

Engine type plate

1.2 System type plate

The system type plate is located on the left-hand longitudinal member of the frame (viewed looking towards
the flywheel).

System type plate

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 31/03/2014
Index: 5 Page No.: 1/4
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
1.3
Type Plate and Type Designation of GE Jenbacher Products

Type Type Max. ambient Max. ambient temperature:

temperature
(intake air)
Serial No. Serial No. Rated frequency Rated frequency
Year of Year of manufacture Rated voltage Rated voltage
manufacture
Rated power Rated power Rated current Rated current
Rated power Rated power factor Mass Weight
factor
Maximum site Maximum installation site altitude Performance Performance class
altitude of class
installation

2 Type designation

2.1 Engine type designation

Term Designation code Key to abbreviation Example
Manufacturer J GE Jenbacher J 320 GS C05
Engine type 2 J 320 GS C05
3
4
6
9
No. of cylinders 8 8 cylinder in-line engine J 320 GS C05
12 12 cylinder V-engine
16 16 cylinder V-engine
20 20 cylinder V-engine
24 24 cylinder V-engine
Mode of operation (e.g.) GS Gas engine, turbocharged J 320 GS C05
GSH Gas engine, turbocharged
and hot cooled
Design A First design J 320 GS C05
B, C, D, E ... Modified designs
Version (e.g.) 02 Natural gas; ½ TA-Luft J 320 GS C05
05 Natural gas; TA-Luft
27 Biogas; TA-Luft

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 31/03/2014
Index: 5 Page No.: 2 / 4
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
1.3
Type Plate and Type Designation of GE Jenbacher Products

1 6

J 3 20 GS C 05
2

3
Engine type designation
① Manufacturer ④ Mode of operation
② Engine type ⑤ Design
③ No. of cylinders ⑥ Version

2.2 Module type designation

Term Designation code Key to abbreviation Example
Manufacturer J GE Jenbacher JMS 320 GS-N.LC
Unit type (e.g.) M Co-generation plant JMS 320 GS-N.LC
G Generator set
C Compressor set
Installation type S Stationary JMS 320 GS-N.LC
C In a container
Engine type 2 JMS 320 GS-N.LC
3
4
6
9
No. of cylinders 08 8 cylinder in-line engine JMS 320 GS-N.LC
12 12 cylinder V-engine
16 16 cylinder V-engine
20 20 cylinder V-engine
24 24 cylinder V-engine
Mode of operation (e.g.) GS Gas engine, turbocharged JMS 320 GS-N.LC
GSH Gas engine, turbocharged
and hot cooled

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 31/03/2014
Index: 5 Page No.: 3/4
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
1.3
Type Plate and Type Designation of GE Jenbacher Products

Term Designation code Key to abbreviation Example

Type of fuel gas N Natural gas JMS 320 GS-N.LC
B Bio gas
L Landfill gas
P Propane gas
S Special gas
N/B Natural gas /Bio gas (2-
gas operation)
Exhaust gas treatment L LEANOX engine JMS 320 GS-N.LC
LC LEANOX engine with
oxidation-type catalytic
converter
C 3-way catalytic converter

1 6

2 7

3 8

J M S 3 20 GS - N /B . LC
4
9
5
Plant type designation
① Installation type ⑥ Mode of operation
② Sort of unit ⑦ Type of fuel gas
③ Manufacturer ⑧ Alternative type of fuel gas
④ Engine type ⑨ To clean exhaust gas
SprungMarke!!!36028797033292555
⑤ No. of cylinders

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 31/03/2014
Index: 5 Page No.: 4 / 4
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
1.4
Web portal

The web portal contains the latest online information on our products, drawings, Service Bulletins, SPATSL (the
digital spare parts catalogue), background knowledge concerning gas engine technology etc. You can also
download interesting documents to your PC via the web portal. The web portal’s URL is:
http://information.jenbacher.com
When you first visit the web portal, you will find general information on GE Jenbacher. Since you are a GE
Jenbachercustomer, we are offering you the possibility of increased access rights for which you only need to
register online.

Registration:

Click on "registrieren" (Registration) and fill in the requested personal data. It is very important to also fill in your
regular GE Jenbachercontact person, as he or she is responsible for granting you the increased access rights.
Once you have registered, you will immediately be sent an e-mail containing the web portal link. You will then
be able to enter the required password. At this stage, you do not have increased access rights yet as your GE
Jenbacher contact person needs to confirm your application. This might take a few days.
Subsequently, you may change your password and personal data. Click on "know-how login" to enter your
personal profile, which you may edit yourself.
As soon as your increased access rights have been confirmed, you can enter the increased access web portal
below:

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Velik Responsible: VSB/Steinberger Release date: 22/08/2013
Index: 3 Page No.: 1/3
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
1.4
Web portal

Menu bullets – Tips:

"Produkte +Service" (Products and Service) menu -> "Produkte 50/60 Hz" (50/60 Hz products)
Viewing and downloading drawings and diagrams for various engine types and applications.
"Produkte + Service" (Products and Service) menu -> "Service" -> "Service Datenbank" (Service database)
Online access to all published Service Bulletins and therefore access to all service-related changes and
innovations.
"Expert know-how" menu
Comprehensive information on co-generation, fuel gas conditioning, exhaust gas treatment, etc.
For security reasons, you must change your password every 6 months. You will be sent an e-mail reminder
containing a link to your personal profile. To extend your increased access rights for another 6 months, just
overwrite your existing password in your "know-how profile", repeat the password and click on
"absenden" (send).

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Velik Responsible: VSB/Steinberger Release date: 22/08/2013
Index: 3 Page No.: 2 / 3
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
1.4
Web portal

After you have registered, you will receive a regular Newsletter. If you do not wish to receive it, click on
"Nein" (No).
If you have any questions, please contact your regular GE Jenbachercontact person.
SprungMarke!!!18014398524851339

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Velik Responsible: VSB/Steinberger Release date: 22/08/2013
Index: 3 Page No.: 3/3
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
1.5
Your Opinion Counts!

Dear readers,
The purpose of this product documentation is twofold. Firstly, it should ensure risk-free operation and
maintenance of your GE Jenbachersystem.
Secondly, this product documentation should serve as a reference manual covering technical data,
requirements and descriptions of engine and system components, and can also be used for troubleshooting
and training purposes.
Please help us to meet these aims by sharing your work experiences with us.
Subject: Rating Comments
How well do you think our documentation
is structured?

How easy is it to locate information?

What do you think about our technical

vocabulary?

Is the documentation comprehensive?

(Have all of the necessary topics been
covered to an appropriate extent?)

Any additional comments:

Rating: 1 = very good 2 = good 3 = satisfactory 4= adequate 5= inadequate

Please send the completed feedback form to: GE Jenbacher GmbH & Co OG
Documentation Department
Achenseestraße 1-3
A-6200 Jenbach (Austria)

+43 5244 600 566

SprungMarke!!!27021597779449995
[email protected]

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Velik Responsible: Documentation Release date: 22/08/2013
Index: 4 Page No.: 1/1
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
1.6
Service and Sales partners

GE Jenbacher GmbH & Co OG

Achenseestraße 1 - 3, A-6200 Jenbach
Tel.: +43 5244 600-0, Telefax: +43 5244 600 548
e-mail: [email protected]

GE Jenbacher
Servicecenter Wien
Am Concorde-Park 1/D2, A-2320 Schwechat
Tel.: +43 1 707 95 10, Telefax: +43 1 707 93 28
e-mail: [email protected]

GE Jenbacher
Hirschstrasse 40
9020 Klagenfurt
Tel.: +43 4242 431 124, Telefax: +43 4242 431 124 5
e-mail: [email protected]

Distributor/Service Provider
Intelligent Energy Generating Equipment LLC
(Orient Energy Systems Group Company)
Suite 808, Apricot Building, Dubai Silicon Oasis
P O Box 54652 Dubai, UAE
Tel.: +97 14 392 6207, Cellphone: +97 156 174 1186, Telefax: +97 14 392 6208
e-mail: [email protected]

Distributor/Service Provider
Jembas Assistencia Tecnica Lda
Lardo do Soweto Nr. 88, C.P. 10013 Luanda
Angola
Tel: 00244 222 637 000
e-mail: [email protected]
www: www.jembas.com

Industrias Juan F Secco SA

Juan Pablo II 5665
Av. Circunvalacion y Av. Urib
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 23/03/2015
Index: 25 Page No.: 1/22
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
1.6
Service and Sales partners

Santa Fe
2000 Rosario, Argentinia
Tel.: + 54-341 4094097
e-mail: [email protected]

CLARKE ENERGY AUSTRALIA Pty. Ltd.

Building 1, 2-4 Stirling Street
Thebarton SA 5031
Tel.: +61 (0)8 8290 2100, Telefax: +61 (0)8 8443 5848
e-mail: [email protected]
www: www.clarke-energy.com

Enerflex Service Pty. Ltd.

Eagle Farm, Schneider Road 115
4009 Brisbane, Queensland
Tel.: +61 (0)7 33189 000, Telefax: +61 (0)7 33189 099
e-mail: [email protected]
www: www.enerflex.com

Sales Representative
Ecogen Energy Systems bvba
Vaart Rechteroever 225
B-9800 Deinze
Tel.: +32 938 64860, Telefax: + +32 938 61134
e-mail: [email protected]

Filter EOOD
7, Iskarsko Shouse Blvd.,
Trade Center Europe
Building 6 Floor 1
PO 1528
Sofia, Bulgaria
Tel: +359 2 974 50 85
Fax: +359 2 974 50 87
e-mail: [email protected]
www: www.filter.bg

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 23/03/2015
Index: 25 Page No.: 2 / 22
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
1.6
Service and Sales partners

Distributor/Service Provider
Orient Energy Systems FZCO
Dubai Airport Free Zone, LIU, Warehouse No. G 06
DAFZA UAE
Tel: +971 4 2995300
Fax: +971 4 2995123
e-mail: [email protected]

Sales - Jenbacher gas engines

Rod. Jornalista Frco. Aguirre Proenca s/n Km 3,8 - Boa Vista
13064-654 Campinas-SP, Brazil
Tel.: +55 19 2104 6996, Telefax: +55 19 2104 6999
e-mail: [email protected]

Distributor/Service Provider
Filter SZAO
Logoisky Tract and MCAD Crossing, Minsky district,
Administrative Bldg., Office 501
223053 Minsk, Republic of Belarus
Tel.: +375 (172) 95 04 03, Telefax: +375 172 95 96 18
e-mail: [email protected]

Distributor/Service Provider
Gas Drive Global LP
4700 47 Street SE
Calgary, AB, T2B 3R1
CANADA
Tel: +1 403 387 6300
e-mail: [email protected]
www: www.gasdriveglobal.com

IWK Integrierte Wärme und Kraft AG (Sales)

Aspstrasse 11
CH-8472 Oberohringen / Seuzach, Schweiz

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 23/03/2015
Index: 25 Page No.: 3/22
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
1.6
Service and Sales partners

Tel.: + 41 52 320 00 00, Telefax: + 41 52 320 00 01

Tel. direct: +41 52 320 00 04, Mobil: +41 79 367 75 34
e-mail: [email protected]
www: www.iwk.ch

Distributor / Service Provider

Generadora Trasandina S.A. (GTSA)
Av. Apoquindo 5583, of 101, Las Condes
Santiago
Tel.: +56 2 952 4301, Mobile: +56 9 6570 0343
e-mail: [email protected]
www: www.generadoratrasandina.com

International Office & Packaging Operation

GE Energy (Hangzhou) Co. Ltd.
288 Hongxing Rd., South Bridge
Xiaoshan Economic & Tech. Development Zone
Hangzhou, 311231, P.R. China
Tel.: +86 571 8369 9888, Telefax: +86 571 8286 9107
e-mail: [email protected]

International Office
GE Energy
Jenbacher Sales China
18/F., Kerry Center , 1 Guanghua Road , Chaoyang District , Beijing 100020
Tel.: +8610 5822 3821, Telefax: +8610 8529 6283
e-mail: [email protected]

Distributor/Service Provider
Jebsen & Co. (China) Ltd.
30/F., Lee Garden Two, 28 Yun Ping Road,
Causeway Bay, Hong Kong, China
Tel.: +852 2923 8668, Telefax: +852 2882 1588
e-mail: [email protected]
Tel.: +852 2923 8718, Telefax: +852 2882 1588
e-mail: [email protected]
www: www.jebsen.com

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 23/03/2015
Index: 25 Page No.: 4 / 22
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
1.6
Service and Sales partners

Jebsen & Co Ltd.

Region: Hongkong and Macau
28/F., Lee Gardens Two,
28 Yun Ping Road,
Causeway Bay
Hong Kong
Tel: +852 2923 8883, Fax: +86 852 2882 1588
e-mail: [email protected]
www: www.jebsen.com

Distributor/Service
Shenyang WeiLiDa Engineering Equipment Co. Ltd.
Region: Liaoning, Jilin, Heilongjiang
Jiahuan Building No. 39, RM 1306, Heping nan street
Shenyang, Liaoning 110003
China
Tel.: +86 24 232 54 011, Fax: +86 24 832 51 066
e-mail: [email protected]

Distributor/Service provider
YUMON INTERNATIONAL TRADE (SHANGHAI) CO., LTD.
Region: Shandong, Jiangsu, Zhejiang, Anhui, Shanghai
Rm. 1001 ZhongRong International Building
No. 1088 Pudong S. Road,
Shanghai 200120, China
Telefone: +86-21-58781256
Fax: +86-21-58784945
e-mail: [email protected], [email protected]
www: www.solomon.com.tw

Distributor/Service provider
Guangzhou Shenfa M&E Industry Development Co. LTD
Region: Guangdong; Guangxi; Hunan; Jiangxi; Hainan
1708#, R&F Morgan Plaza, Huaqiang Rd.
Pearl River New Town
Guangzhou, P.R. China
Tel: +86 20 835 59 493
Fax: +86 20 835 63 252
Mobile: +86 13 924 219 065
e-mail: [email protected]
www: www.sf-power.com.cn

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 23/03/2015
Index: 25 Page No.: 5/22
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
1.6
Service and Sales partners

Distributor/Service Provider
Dongguan Camda Gererator Work Co. Ltd
Region: INNER MONGOLIA, HEBEI, SHAANXI, SHANXI, HENAN, HAINAN, CHONGQING
FOR COAL MINE GAS APPLICATIONS: Region China
Liaobu Town, Dongguan City, Guangdong Province 523407, P.R. China
Tel: +86-769-88996235; Fax: +86-769-88996282
e-mail: [email protected]
www: www.camda.cc, www.camdapower.com

Distributor/Service Provider
AB Energy SPA
Via Caduti del Lavoro, 13
250 Orzinuovi
Italy
Tel.: +39 0309947850
Email: [email protected]
www: www.gruppoab.at

JMP (Service)
Plynarenska 1, 65702 Brno
Tel.: +420 545 548 263, Telefax: +420 545 548 263
e-mail: [email protected]
www: www.jmpas.cz

Jenbacher GmbH
Carl-Benz-Straße 25
D-67227 Frankenthal (Pfalz)
Tel.: +49 (0) 6233 5110-0, Telefax: +49 (0) 6233 5110-170
Service Hotline: 07000 – 536 - 2224
e-mail: [email protected]

Sales Representative
Energas BHKW GmbH
Banneggstraße 90
D-88214 Ravensburg

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 23/03/2015
Index: 25 Page No.: 6 / 22
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
1.6
Service and Sales partners

Tel.: +49 751 88833330, Fax: +49 751 88833339

e-mail: [email protected]

GE Jenbacher Denmark
Samsøvej 10
DK-8382 Hinnerup
Tel.: +45 86966788, Telefax: +45 86967072
e-mail: [email protected]

Dominikanische Republik
Sales Representative / Service Provider
The Power Service Group, S.A.
Door Power Service S.A.
Calle Vicente Celestino Duarte 2
Zona Colonial , DN
Santo Domingo
Tel.: +1 809 285 0016, Telefax: +1 809 285 0017
e-mail: [email protected]

Algeria
Distributor / Service Provider
Amimer Energie SARL
za Adha Seddouk, 06500 W. Bejaia, Algeria
Tel.: 00 213 34323154, Telefax.: 00 213 34323135
e-mail: [email protected]

Clarke Energy France SAS

Z.A. de la Malle
RD 6
13320 Bouc Bel Air
Tel: +33 442 907575, Fax: +33 442 907576
e-mail: [email protected]
www: www.clarke-energy.com

AS Filter
Läike tee 9, Peetri küla, Rae vald

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 23/03/2015
Index: 25 Page No.: 7/22
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
1.6
Service and Sales partners

75312 Harjumaa
Tel.: +372 606 6666, Telefax: +372 606 6650
e-mail: [email protected]
www: www.filter-group.com

International Office
GE International Inc.
54 Lebanon Street,
El Mohandessin, Floor 13
Cairo
Tel.: + 20 2 3301 8000
e-mail: [email protected]

Sakr Power Systems

South Kattamyia, Sokhna old road, New Cairo
Third district, Block # 12
Tel.: +20 10 50 239 47, Telefax: +20 10 17 246 18
e-mail: [email protected]

Clarke Energy Ltd.

Power House, Senator Point, South Boundary Road,
Knowsley Industrial Park
Liverpool L33 7RR
Tel.: + 44 151 546 4446, Telefax: +44 151 545 5714
e-mail: [email protected]
www: www.clarke-energy.com

Distributed Power
GE Power & Water
Calle Josefa Varcarcel, 26
Edifcio Merrimack III
28027 Madrid
Spain
Tel.: +34 91 658 6800, Telefax: +34 91 652 2616
e-mail: [email protected]

GE Jenbacher Spain and Portugal

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 23/03/2015
Index: 25 Page No.: 8 / 22
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
1.6
Service and Sales partners

Ctra. de Hospitalet, 147-149 | Cityparc - Ed. Roma

E-08940 Cornellà de Llobregat (Barcelona)
Tel.: +34 93 475 1300, Telefax: +34 93 475 1301
e-mail: [email protected]

Höyrytys Oy
Palokorvenkatu 2
FIN-04261 Kerava
Tel.: +358 468 508 070, Telefax: +358 941 746 100
e-mail: [email protected]

Clarke Energy France SAS

Z.A. de la Malle
RD 6
13320 Bouc Bel Air
Frankreich
Tel.: +33 442 907 575, Telefax: +33 442 907 576
e-mail: [email protected]
www: www.clarke-energy.com

Distributor / Service Provider

GENELCO Power Systems Ltd.
2, Irinis Street
New Smymi Athens 17121
Tel: +30 210 934 69 94
Mobile: +30 6944 358 247
e-mail: mailto:[email protected]

International Office & Packaging Operation

GE Energy Jenbacher Hungary (Service)
Kisret ut1
H-2112 Veresegyhaz
Tel.: + 36 2858 7376 , Telefax: + 0036 2858 7491
e-mail: [email protected]

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 23/03/2015
Index: 25 Page No.: 9/22
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
1.6
Service and Sales partners

Distributor/Service Provider
AB Energy SPA
Via Caduti del Lavoro, 13
250 Orzinuovi
Italy
Tel.: +39 0309947850
Email: [email protected]
www: www.gruppoab.at

TZV Gredelj d.o.o. (Service)

Trnjanska Cesta 1, HR-10000 Zagreb
Tel.: +385 1 6111 311, Telefax: +385 1 6110 121
e-mail: [email protected]

Distributor/Service Provider
Navigat Energy Pte. Ltd.
Bank Rakyat Indonesia Building 8th,
Suite 810, Jendrak Sudiram Street 44-46
Jakarta 10210, Indonesia
Tel.: +62 21 572 4944, Telefax: +62 21 572 7614
e-mail: [email protected]
www: www.navigat.com

Distributor/Service Provider
Clarke Energy Ltd.
Power House, Senator Point, South Boundary Road,
Knowsley Industrial Park, Liverpool L33 7RR
Telephone: + 44 151 546 4446, Fax: + 44 151 545 5714
e-mail: [email protected]
www: www.clarke-energy.com

Distributor/Service Provider
Clarke Energy Ireland Ltd.
1 Stokes Place, St. Stephens Green, Dublin 2, Ireland
Tel.: +353 879 804002
e-mail: [email protected]
www: www.clarke-energy.com

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 23/03/2015
Index: 25 Page No.: 10 / 22
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
1.6
Service and Sales partners

Madei Taas Industrial Controls Ltd.

2 Hacharoshet st., Kfar-Saba 44641
Tel.: +972 9 7669903, Telefax: +972 9 7669904
e-mail: [email protected]
www: www.madeitaas.co.il

Clarke Energy India Private Limited

"Shivkiran", Lane no. 4, Dahanukar Colony, Kothrud
Pune 411 038
Tel.: +91 20 30241777
Telefax: +91 20 30241800
e-mail: [email protected]
www: www.clarke-energy-india.com

International Office
GE India Industrial Pvt. Ltd.
A-1, 2nd Floor, Golden Enclave
Corporate Towers, Airport Road
560 017 Bangalore
Tel.: +91 80 4150 1406, Telefax: +91 80 2520 3860
e-mail: [email protected]

Trinidad & Tobago

Distributor/Service Provider
Water Tech Limited
10 Nelson Road
Freeport
Trinidad, West Indies
Tel.: +868 673 5453, +868 673 2061, Telefax: +868 673 1620
e-mail: [email protected]

Distributor/Service Provider
Triveni Engineering & Industries Ltd.
Regions: KERALA, TAMIL NADU, KARNATAKA; ANDHRA PRADESH; ORISSA, MADHYA PRADESH, GOA,
LAKSHWADEEP, PONDICHERRY, ANDAMAN AND NICOBAR ISLANDS
12-A Peenya Industrial Area, Peenya, Bengaluru 560058, Karnataka
Tel.: +91 22 2282 4397, Fax: +86 21 5878 4945
e-mail: [email protected]
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 23/03/2015
Index: 25 Page No.: 11/22
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
1.6
Service and Sales partners

www: www.triveniturbines.com

Distributor/Service Provider
Navigat Energy Pte. Ltd.
139 Cecil Street, 04-02 Cecil House, Singapore 069539,
Rep. of Singapore, Indonesia
Tel.: +62 21 5724944, Telefax: +62 21 5727614
e-mail: [email protected]

GE Jenbacher
Via Staffali 1
37062 Dossobuono (Verona), Italy
Tel.: +39 045 6760211, Telefax: +39 045 6766322
e-mail: [email protected]

Sales Representative
NME s.r.L
Via Ferruccio Dell'Orto, 8
24126 Bergamo
Tel: +39 035 320030, Fax: +39 035 312022
e-mail: [email protected]
www: www.nmesrl.it

Distributor / Service Provider

Sakr Power Systems SAL
Kartaba Road, Industrial Area
Halata (Jbeil), Lebanon
Tel.: +961 9 444888, Telefax: +961 3 811108
e-mail: [email protected]
www: www.sakr.com

Hitachi Engineering & Services Co., Ldt.

2-2 Kandatacho Chiyoda-ku
Tokyo 101-0046
Tel.: +81 3 5297 0514, Telefax: +81 3 5297 0517
e-mail: [email protected]
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 23/03/2015
Index: 25 Page No.: 12 / 22
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
1.6
Service and Sales partners

Hitachi Engineering & Services Co., Ldt.

15-1, Higashionuma-cho, 1-chome
Hitachi-shi
Ibaraki-ken, 316-0023
Tel.: +81 294 36 7996, Telefax: +81 294 36 9637
e-mail: [email protected]

Osaka Gas Engineering Co., Ldt.

1-4-100, Hokuko, Konohana-Ku
Osaka 554-0033
Tel.: +81 6 4804 2600, Telefax: +81 6 4804 2601
e-mail: [email protected]

Distributor / Service Provider

Sakr Power Systems SAL
Kartaba Road, Industrial Area
Halata (Jbeil), Lebanon
Tel.: +961 9 444888, Telefax: +961 3 811108
e-mail: [email protected]
www: www.sakr.com

RNP Enterprise Ltd.

Room 301, Chung Won Bldg. 170-3
Bang - I - Dong
Song Pa-Ku, Seoul 138-050, Korea
Tel.: +82 2 412 3700, Telefax: +82 2 412 3044
e-mail: [email protected]

Turkuaz Machinery Ltd.

Rayimbek ave. 160A,
50016 Almaty
Tel.: +7 727 273 19 95, Telefax: +7 727 273 15 68
e-mail: [email protected]
www: turkuazmachinery.kz

Promelectronika-K TOO

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 23/03/2015
Index: 25 Page No.: 13/22
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
1.6
Service and Sales partners

Bogenbay batyra str 132, Office 113.105

050026 Almaty.
Tel.: +77 272 965560
Fax.: +77 272 721983
e-mail: [email protected]
www: www.intma.kz

Abdulaziz Abdulmoshin Al-Rashed Sons Co. WLL

Building No. 225-227, Block 2, next to Al-Watan TV,
Afdiya, Kuwait
Tel: 00965-24376740
Fax: 00965-24339291
Email: [email protected]
www: www.al-rashedholdings.com

Distributor / Service Provider

Sakr Power Systems SAL
Kartaba Road, Industrial Area
Halata (Jbeil)
Tel.: +961 9 444888, Telefax: +961 3 811108
e-mail: [email protected]
www: www.sakr.com

IWK Integrierte Wärme und Kraft AG (Sales)

Aspstrasse 11, CH-8472 Oberohringen / Seuzach, Schweiz
Tel.: + 41 52 320 00 00, Telefax: + 41 52 320 00 01
e-mail: [email protected]
www: www.iwk.ch

UAB Filter
Draugystes Str. 19, 3031 Kaunas
Tel.: +37 037 400 380, Telefax: +370 0872 1399
e-mail: [email protected]
www: www.filter.lt

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 23/03/2015
Index: 25 Page No.: 14 / 22
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
1.6
Service and Sales partners

ENERGOLUX S.A.
12, rue de Bitbourg, L-1273 Luxembourg-Hamm
Tel.: +352 43 42 43-1, Telefax: +352 43 68 33
e-mail: [email protected]

SIA Filter
21 Aizkraukles street, 1006 Riga
Tel.: + 371 7 556765, Telefax: + 371 70550224
e-mail: [email protected]
www: www.filter-group.com

Distributor & Service Provider

Smith Power Products
3065 West California Ave
Salt Lake City, UT 84104, USA
T: +52 3331641237
e-mail: [email protected]
www: www.smithpowerproducts.com

Distributor/Service Provider
Clarke Energy Nigeria Ltd.
13 B Obanta Street, Apapa, Lagos, Nigeria
Tel.: +234 181 56723
e-mail: [email protected]
www: www.clarke-energy.com

GE Jenbacher Netherlands
Kelvinring 58
NL-2952 BG ALBLASSERDAM
Tel.: +31 (0) 88 0019700, Telefax: +31 (0) 88 0019701
e-mail: [email protected]

ENTEC Services Limited

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 23/03/2015
Index: 25 Page No.: 15/22
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
1.6
Service and Sales partners

57G McLaughlins Road, Manukau City 2104

PO Box 76160, Manukau City 2241
Auckland, New Zealand
Tel:: +64 9 277 2211, Fax.: +64 9 277 2210
email: [email protected]
www: www.entec.co.nz

Distributor/Service Provider
Orient Energy Systems FZCO
Dubai Airport Free Zone, LIU, Warehouse No. G 06
DAFZA UAE
Tel: +971 4 2995300
Fax: +971 4 2995123
e-mail: [email protected]

Desco Incorporated
Laguna International Industrial Park
Lot 2 Block 3, Interstar Street
Barangay Mamplasan, City of Binan
Laguna, Philippines 4024
Tel.: +632 520 8149 to 50
www: www.deco.ph

KWE - Technika Energetyczna Sp.z o.o.

Ul. Miedziana 38
43-305 Bielsko-Biała, Polen
Tel.: +48 338 215 093, Telefax: +48 338 216 562
e-mail: [email protected]
www: www.kwe.pl

ECOPOWER – EQUIP. SERV. ENERGIA, UNIPESSOAL, LDA.

ATT: Raul Assunção
Carregado Park, Arm. D,
Lugar da Torre,
2580-512 Carregado
LISBOA – PORTUGAL
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 23/03/2015
Index: 25 Page No.: 16 / 22
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
1.6
Service and Sales partners

e-mail: [email protected]
www: www.ecopower.pt

Sales Representative (Greenhouse segment only)

Protermia
Praceta Joao Villaret, n°169, 4460-337 Sra. Da Hora
Tel: 351 229 579 130; Fax: 351 229 537 355
e-mail: [email protected]
www: www.prtermia.pt

SC Total Energy Business SA

55, Floreasca St., 6th Floor, 1st District
014453 Bucharest
Tel.: +40 21 569 84 45
Telefax: +40 21 456 84 45
e-mail: [email protected]
www: www.teb.com.ro

International Offices
GE Energy Russia
27, Electrozavodskaya Street, bld. 8, floor 5
107023 Moscow, Russia
Tel.: +7 495 937 11 11; +7 495 9 81 13 13, Telefax: +7 495 937 11 12
e-mail: [email protected]

ZAO Sigma Services (Service)

h. 15. bld. 33, M. Kaluzhskaya str.
117071 Moscow
Tel.: +7 095 935 7835, Telefax: +7 095 935 7888
e-mail: [email protected]

ZAO VADO International GUS (Sales)

Krasnaja Presnja 28
123022 Moskau - Russische Föderation
Tel.: +7 095 363 95 05, Telefax: +7 095 363 9509
e-mail: [email protected]
www: www.vado.biz

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 23/03/2015
Index: 25 Page No.: 17/22
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
1.6
Service and Sales partners

Focused on the North West Region

Distributor/Service Provider
Vapor CJSC
B. Moskovskaya 8/2 Letter A,
191002 Saint – Petersburg
T: + 7 812 448 00 70
Email: [email protected]
Web: www.vapor.ru

Focused on the South Ural and Volga Region

Distributor/Service Provider
Intma CJSC
Rabochaya Str.,93, Bld.2, Office 338
109544 Moscow
T: +7 495 974 12 95
Email: [email protected]
Web: www.intma.ru

Focused on the South and Central Region

Distributor/Service Provider
Max Motors LLC
19/4, Kurortniy prospect
354000 Sochi, RUSSIA
Tel.: +7(8622) 62-77-99(multichannel), Telefax: +7(8622) 62-61-16
Call center 8(800)505-77-99(calls are free of charge for Russian Federation customers!)
e-mail: [email protected]
www: www.max.motors.ru

GreenTech Energy LLC (Tumen and Kurgan Region)

Bld. IX, Begovaya str. 32
125284 Moscow
Phone: +7 495 970 1700
e-mail: [email protected]
URL: www.gte.su

Ali A. Tamimi Trading Company

2nd Industrial City
Al Baqaiq Street
Khobar, 31952
Tel.: +966 3 868 1037 ext. 100
Fax.: +966 3 868 2733
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 23/03/2015
Index: 25 Page No.: 18 / 22
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
1.6
Service and Sales partners

e-mail: [email protected]
www: www.al-tamimi.com

GE Jenbacher Denmark
Industrivej 19, DK-8881 Thorsø
Tel.: + 45 8 6966788, Telefax: + 45 8 6967072
e-mail: [email protected]

Sales Representative
IGF Gasprodukter
Årsta Park
Byängsgränd 14
S-120 40 Årsta
Tel. +46 -8 742 22 80, Fax: +46 87 44 44 50
e-mail: [email protected]
www: www.igfgasprodukter.se

Distributor/Service Provider
Navigat Energy Pte. Ltd.
105 Cecil Street # 15-02, the Octagon
Singapore 69534, Rep. of Singapore
Tel.: +65 653 88 808, Fax: +65 653 83 133
e-mail: [email protected]
www: www.navigat.com

TES d.o.o.
Gregorciceva 3, Maribor 2000
Tel.: +386 2 229 4726, Telefax: +386 2 229 4727
e-mail: [email protected] or [email protected]
www: www.tes.si

Distributor/Service Provider
Navigat Energy (Thailand) Ltd.
2/22 Chan Rd., K. Thungwatdorn;
Khet Sathorn
Bangkok 10120, Thailand

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 23/03/2015
Index: 25 Page No.: 19/22
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
1.6
Service and Sales partners

Tel.: +66 26785157, Fax: +66 26785158

e-mail: [email protected]
www: www.navigat.com

Topkapi Endüstri Mallari Ticaret A.S.

Pazartekke, Millet Cad. No.180-184
Topkapi
34104, Istanbul
Tel.: +90 212 534 04 10, Telefax: +90 212 524 58 46
e-mail: [email protected]
www: www.topkapigroup.com.tr

Distributor/Service Provider
Clarke Energy Tunisie SARL
Immeuble Sarra Bb Principle, Les Berges du Lac
Tunis
Tel.: +216 71 96 52 99, Fax: +216 25 39 04 90
e-mail: [email protected]
www: www.clarke-energy.com

Distributor/Service Provider
Clarke Energy Ltd.
Power House, Senator Point, South Boundary Road, Knowsley Industrial Park, Liverpool L33 7RR
T: +44 151 546 4446, Fax: +44 151 545 5714
e-mail: [email protected]
www: www.clarke-energy.com

Sinapse
7, Vanda Vasilevskaya Str.
03055 Kiev
Tel.: +38 044 238 0967 or +38 044 2380966, Telefax: +38 044 2380967 or +38 044 2380970
e-mail: [email protected], [email protected], www.sinapse.ua; www.cogeneration.com.ua

GE Energy

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 23/03/2015
Index: 25 Page No.: 20 / 22
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
1.6
Service and Sales partners

Jenbacher Sales and Service USA

5244 N. Sam Houston Parkway East,
Houston, TX 77032
Tel.: +1 832 295 5600
e-mail: [email protected]

Distributor/Service Provider
Northeast Energy Systems, a division of Penn Detroit Diesel Allison
(ME, VT, NH, MA, PA, NY, CT, DE, NJ, RI, OH) Corporate Headquater
8330 State Road, Philadelphia PA 19136
Telephone: +1 215 335 5010, Fax: +1 215 335 2163
e-mail: [email protected] or [email protected]
www: www.neesys.com

Northeast Energy Systems, a division of Penn Detroit Diesel Allison

(ME, VT, NH, MA, PA, NY, CT, DE, NJ, RI, OH)
86 Finnell Drive, Units 13 and 14
Weymouth, Massachusetts 02188
Telephone: + 1 781 340 9640, Fax: + 1 781 340 9649
e-mail: [email protected] or [email protected]
www: www.neesys.com

Distributor/Service Provider
Western Energy Systems, a division of Penn Detroit Diesel Allison
(AK, CA, HI, OR)
499 Nibus Street, Brea, California 92821
Telephone: +1 714 529 9700
e-mail: [email protected] or [email protected]

Inland Power Group. (MN, MI, WI, IA, IL, IN)

13015 W. Custer Avenue,
Butler, WI 53007
Tel.: +1 262 781 7100, Telefax: +1 262 783 8974
e-mail: [email protected] [email protected]
www: www.inlandpowergroup.com

Smith Power Products (WA, MT, ID, WY, NV, UT, AZ, CO, KS, MO, NE, NM, ND, OK, SD, TX)
3065 West California Ave.
Salt Lake City, UT 84104
Tel.: +1 801 415 5000, Telefax: +1 801 415 5700
e-mail: [email protected]

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 23/03/2015
Index: 25 Page No.: 21/22
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
1.6
Service and Sales partners

www: smithpowerproducts.com

GENEVA LLC, DBA Nixon Power Services Company

(AR, LA, MS, TN, AL, GA, KY, FL, SC, NC, VA, WV, MD)
5038 Thoroghbred Lane
Brentwood, TN 37027
Tel.: +1 615 309 5823
e-mail: [email protected]

Dome Trading and Contracting Company LTD

Villa Nr. 18, Street Nr. 38 (off Hadda Rd.)
Sana'a. PO Box 16187
YEMEN
Tel Office: +9671414023
Fax: +9671414044
e-mail: [email protected]
www: www.domeint.com

South Afrika/Botswana/Lesotho/Mozambique/Swaziland
Sales Representative/Service Provider
Agaricus Trading cc
P O Box 1535
Linkhills
3652
Kwazulu-Natal
South Africa
Tel.: + 27 31 7633222, Telefax: + 27 31 7633041
e-mail: [email protected]
www: www.agaricus.co.za
SprungMarke!!!216172782128219531

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 23/03/2015
Index: 25 Page No.: 22 / 22
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
1.7
Getting Started Guide

The Getting Started Guide should create awareness of certain preconditions which should be incorporated
before starting the engine. Non-compliance with those points can lead to severe engine damage. Also manual
and automatic starting procedure is shown in detail.

The Getting Started Guide consists of the following documents:

1 Poster (Din-A2) to display clearly visible in engine room

2 magnetic sheets (Din-A4) to display on control cabinet

Please find Getting Started Guide kit in original maintenance manual (1.7 Getting Started Guide)
SprungMarke!!!9007207511628555

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Pfister Responsible: Dokumentation Release date: 14/10/2014
Index: 2 Page No.: 1/1
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
1.8
Imprint

This GE Jenbacher Product Documentation consisting of :

▪ Description – Operation
▪ Maintenance
▪ spare parts list
was created by the Technical Documentation Department of GE Jenbacher.

If you have any questions, problems or suggestions regarding this Product Documentation, please contact us.
Address: GE Jenbacher GmbH & Co OG
A-6200 Jenbach | Austria
Telephone: +43 | 5244| 600-3064
Fax: +43 | 5244| 600-566
SprungMarke!!!27021597778924939
E-mail: [email protected]

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 22/08/2013
Index: 4 Page No.: 1/1
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
2 General conditions
2.1
Designated Use

1 Designated use.......................................................................................................................................... 1
2 Foreseeable misuse.................................................................................................................................. 1

1 Designated use
The designated use is the use of the engine which must be applied as described in the operating instructions.
GE Jenbacherco-generation plants and generator modules are designed for decentralised production of
electrical energy.
For this purpose a gas engine is used to power a high-voltage or low-voltage three-phase generator.
Co-generation plants also utilise the thermal energy from engine cooling water, engine oil, mixtures and
exhaust gases.
Any use not described in the operating or maintenance instructions is not considered a designated use. GE
Jenbacher accepts no liability for the consequences of any non-designated use.
GE Jenbacher systems are designed individually to the customer’s specifications. These specific requirements
also clearly define the designated use of the system and its proper operating conditions. Any subsequent
changes to the system must therefore always be approved by GE Jenbacher.

① Gas engine ③ Heat exchanger

② Generator

2 Foreseeable misuse
A reasonably foreseeable misuse is any use of the engine which may arise in a way not intended in the
operating instructions but can arise from easily foreseeable human behaviour.
In order to prevent a reasonably foreseeable misuse, GE Jenbacher has carried out a risk analysis as described
in EN ISO 12100.
The residual risks and possible misuses revealed in these analyses have been reduced to a minimum on the
basis of the PREVENT-PROTECT-WARN principle. For risks which cannot be constructively prevented, you will
find hazard signs on the plant and appropriate warnings in the operating instructions.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 16/10/2014
Index: 5 Page No.: 1/2
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
2.1
Designated Use

Misuses constitute a danger to operators, third parties and the plant itself.
You will find information on how to deal with the residual risks to prevent health and safety from being
compromised in the safety instructions TI 2300-0005, work instructions and your operating instructions.
Examples of residual risks include hot surfaces, electrical hazards (high voltage), poisonous gases, liquids under
pressure, heavy components, risk of trapping fingers, incorrect behaviour in the event of an alarm, fall from
height, danger of slipping, failure to follow lock-out/tag-out procedures and working on unsecured plant while
still running.
Unqualified staff are prohibited from operating or working on GE Jenbacher plants or entering the engine
room.
Familiarise yourself with the requirements in TI 2300-0001 “Employee protection”, TI 1100-0111 “General
conditions – Operation and maintenance”, official regulations on safety at work and the relevant parts of the
safety instructions.
Never operate GE Jenbacher plants outside their operational design constraints for and technical
specifications.
Familiarise yourself with the requirements in TI 1100-0110 “Boundary conditions for GE Jenbacher gas
engines”, the specified maintenance plan and the technical data recorded for your plant (e.g. performance, gas
quality, gas type, explosive environment, temperature, ventilation, monitoring, program and software versions,
etc.).
While the plant is operating, all safety devices and monitors specified by GE Jenbacher and official bodies must
be functional and should not be bypassed or removed.
Use only operating fluids, tools and spare parts approved by GE Jenbacher and official bodies for operation,
maintenance, servicing and cleaning. Familiarise yourself with the requirements in TI 1100-0111 "Operation
and maintenance", the official regulations and the approved operating fluids (engine oil, cooling-water
additives, lubricants, etc.) as stated in your operating instructions.
GE Jenbacher plants must be installed in accordance with GE Jenbacher specifications. Familiarise yourself
with the requirements in the arrangement plan, the technical diagram, the circuit diagram, the interface list,
the technical specification for the control system and information in the technical instructions for installation,
lifting and setting up.
Familiarise yourself with the disposal requirements and the special handling needed for hazardous materials or
materials subject to mandatory disposal.
You should also familiarise yourself with the requirements in safety guidelines TI 2300-0005, all statutory
regulations and the danger and disposal information on the product concerned.
SprungMarke!!!36028797033673611

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 16/10/2014
Index: 5 Page No.: 2 / 2
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
2.2
REACH-Notification and Downstream User Communication for Sub-
stances in Articles

Dear customer,
GE Jenbacher is committed to being a market leader in supplying products throughout the world. We have put
in place strong programs to comply with regulations in all countries in which we do business. Our approach to
REACH (Regulation 1907/2006 on the Registration, Evaluation, Authorization and Restriction of Chemicals
adopted by the European Union in December 2006) is being addressed in the same rigorous manner.
GE Jenbacher has been closely following the legislative development of REACH. We are working with our
suppliers to identify any potential implications of REACH on the availability of materials. The vast majority of GE
Jenbacher products including accessories and packaging are considered “articles” under REACH. The
candidate list pursuant to Article 59 of REACH has been published by ECHA at http://echa.europa.eu/
chem_data_en.asp
GE Jenbacher Based on a review GE Jenbacher has been informed that the following Candidate List Substance
is contained in the article supplied, above a concentration of 0.1% by weight of product inform you acc. Article
33 accordinglyt:
Part No. Description SvHC Name CAS No. EC No. concentr. Save use
612163 Flexible hose Alkanes, 85535-84-8 287-476-5 3.16% not applicable
C10-13, chloro
612563 Flexible hose Alkanes, 85535-84-8 287-476-5 3.16% not applicable
C10-13, chloro
629638 Flexible hose Alkanes, 85535-84-8 287-476-5 3.16% not applicable
C10-13, chloro
527170 Flexible hose Alkanes, 85535-84-8 287-476-5 2.84% not applicable
C10-13, chloro
382009 Flexible hose Alkanes, 85535-84-8 287-476-5 3.16% not applicable
C10-13, chloro
400596 Flexible hose Alkanes, 85535-84-8 287-476-5 2.97% not applicable
C10-13, chloro
165120 O-Ring Di (2-thylhexyl) 117-81-7 204-211-0 >0,1 Gew.-% Protective
phthalat gloves made of
nitrile or butyl
rubber
recommended
If you have a question regarding a specific product please do not hesitate to contact:

Roland Eitzinger
GE Energy
Technical Compliance Leader
Jenbacher Gas Engines
[email protected]
www.gejenbacher.com
Achenseestr. 1-3
A-6200 Jenbach, Österreich
GE Jenbacher GmbH & Co OG

SprungMarke!!!9007201671064971

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bilek Responsible: Eitzinger Roland Release date: 22/08/2013
Index: 2 Page No.: 1/1
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Declaration of Conformity

Declaration of Conformity - ORIGINAL

according with annex II, 1.A. of the machinery directive 2006/42/EC.
We,
GE Jenbacher GmbH & Co OG
Achenseestraße 1 – 3
A-6200 Jenbach
herewith declare, on our responsibility, that the
following equipment
Generator module : JGS 616 GS-N.L
Module number: 1127172

together with accessory electrical plant, lifting gear and all electrical and mechanical equipment supplied
and directly associated with it
to which this Declaration refers, conforms to the relevant fundamental safety objectives of CE Directives
2006/42/EC (Machinery Directive), 2004/108/EC (Electromagnetic Compatibility), 2006/95/EC (Low-Voltage
Directive - electrical units, to be used within specific voltage limits) and 97/23/EC (Pressure Equipment).
The following standards and technical specifications, among others, have been taken into account in order to
properly satisfy the requirements specified in the EC Directives:
EN ISO 12100:2010 Safety of machinery - General principles for design - Risk assessment and risk
reduction
EN 12601:2010 Reciprocating Internal Combustion Engine Driven Generating Sets - Safety
EN 60204-1:2006 Safety of Machinery - electric equipment of machines - Part 1: General
+A1:2009 +Cor.:2010 Requirements
EN 61439-2: 2011 Low-voltage switchgear and controlgear assemblies - Part 2: Power switchgear
and controlgear assemblies (IEC 61439-2:2011)
EN 61000-6-2:2005 Electromagnetic compatibility (EMC) – Part 6-2: Generic standards - Immunitiy for
+Cor.: 2005 industrial environments
EN 61000-6-4:2007 Electromagnetic compatibility (EMC) – Part 6-4: Generic standards - Emission
+A1:2011 standard for industrial environments

Dr. Andreas M. Lippert Documentation Officer: Country: CAN

General Manager Robert Pichler, Manager Documentation Datum: 2015-06
Technology GE Jenbacher GmbH & Co OG Language:
Achenseestraße 1-3, 6200 Jenbach,Austria
SprungMarke!!!54043195742536331
is authorised to compile technical documents

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 05/11/2014
Index: 7 Page No.: 1/1
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0039
Securing GE Jenbacher modules during transport by truck

NOTICE
Observance of the conditions of this Technical Instruction and performance of the
activities described therein is the basis of safe and efficient transport of the plant.
Non-observance of the conditions of this Technical Instruction and/or non-performance of the
prescribed activities or any departure from the prescribed activities shall result in the loss of
guarantee rights. This shall not be the case if the operator/carrier shows that although the
Technical Instruction was observed, defects already existed at the time of handover or
commissioning,
The activities and conditions defined in this Technical Instruction shall be performed and/or
observed by the plant operator. This shall not apply if this Technical Instruction is expressly
allocated to the area of responsibility of GE Jenbacher or a contractual agreement between the
operator/carrier and GE Jenbacherprovides for a different arrangement.

1 Scope
This Technical Instruction applies to all GE modules with Type 2, 3, 4 and 6 engines.

2 Purpose
This Technical Instruction expands the information in TA 1000-0042 and TA 1000-0046 by adding instructions
on securing GE Jenbacher modules during transport by truck.
It does not cover:
▪ transport in containers
▪ transport in crates, boxes or other rigid packing
Modules with Type 9 engines are treated separately and are subject to their own transport specifications.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Kecht S. Responsible: Wolf S. Release date: 29/08/2014
Index: 1 Page No.: 1/16
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0039
Securing GE Jenbacher modules during transport by truck

3 Relevant documents
The following documents must also be observed:
TA 1000-0042 Lifting and transporting GE Jenbacher modules and positioning them in engine rooms
TA 1000-0046 Lifting, transporting and placing GE Jenbacher generating sets in engine rooms. [⇨ TA
1000-0046, Page 1]
DIN EN 12195 Load restraining on road vehicles - Safety
VDI 2700 Securing of loads on road vehicles

4 Minimum requirements for the transport of modules (without accessories)

▪ Closed truck
Type 2 and 3 engines and generators:
▪ 12 lashing straps with at least LC 2,500 including edge protection
▪ 2 anti-slip mats of 200 mm x 6 000 mm x 12 mm
Type 4 engines:
▪ 10 lashing straps with at least LC 2 500 including edge protection
▪ 2 shackles with WLL 8,5 t pin, DM 28 mm, inside width 43 mm
▪ 2 anti-slip mats of 200 mm x 6 500 mm x 12 mm
Type 6 engines:
▪ 14 lashing straps with at least LC 2 500 including edge protection
▪ 4 shackles with WLL 8,5 t pin, DM 28 mm, inside width 43 mm
▪ 2 anti-slip mats of 200 mm x 7 000 mm x 12 mm
Type 624 engines:
▪ 8 lashing chains with at least LC 4 000 including edge protection
▪ 2 lashing straps with at least LC 2 500 including edge protection
▪ 4 shackles with WLL 8,5 t pin, DM 28 mm, inside width 43 mm
▪ 2 anti-slip mats of 200 mm x 9 800 mm x 12 mm

5 Loading

5.1 General
Loading must be carried out by an experienced and trained loader holding all the necessary training
certificates. The loader in this context is the person operating the lifting equipment used to load the truck,
regardless of whether they are an employee of GE Jenbacher or the carrier (truck driver or person responsible
for loading) The following are permissible for loading GE Jenbacher modules on to trucks:
▪ Forklift trucks with adequate lifting capacity, height and reach if permitted by the relevant TI for the engine
type.
▪ Mobile cranes
▪ Stationary cranes
When loading with this lifting equipment, all the work and safety instructions of the manufacturer of the lifting
equipment and those laid down by law must be observed. The loader must familiarise himself with these in
advance.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Kecht S. Responsible: Wolf S. Release date: 29/08/2014
Index: 1 Page No.: 2 / 16
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0039
Securing GE Jenbacher modules during transport by truck

5.2 Lifting, moving and setting down

The instructions in TA 1000-0046 for type 2, 3 and 4 engines and in TA 1000-0042 for Type 6 engines must
always be observed when lifting, moving and setting down. Modules must be lifted carefully, and the
permissible acceleration in the Z-direction of 0,2 g must not be exceeded. No movement in the X and Y
directions is permissible when lifting. The load must not be moved until lifting is completed.
When moving, pay strict attention to ensuring that no damage occurs to either the load or the truck, and that
no personal injury is suffered. The loader must make sure before the start of loading that the planned load path
is clear and there are no persons or objects obstructing the module and lifting gear; this must be continuously
checked during loading. If this not possible for technical reasons or reasons to do with the building, a loading
assistant must be called in to monitor the area out of the loader's field of view and to assist the loader by
means of optical or acoustic signals. The load must be moved carefully; jerky movements, speeds over 0,8 m/s
(3 km/h, half walking pace) and longitudinal and transverse accelerations of more than 0,1 g, e.g. when
negotiating bends, must be avoided at all costs.
Make sure before setting down that anti-slip measures have been taken where the module is to be placed.
Setting down itself must be carried out with extreme caution, and any impact on the module or transport
equipment must be avoided. The maximum permissible acceleration in the Z-direction is 0,2 g; horizontal
movement is inadmissible. It must also be ensured that once set down, the module frame sits flush on the
vehicle floor surface, and that the cargo cannot tip over and stands straight and has been positioned in
accordance with the instructions under "Positioning on the transport vehicle". If this is not the case, the loading
procedure (separated into horizontal and vertical procedures) must be repeated until the requirements are met
in full. The loader is responsible for compliance.

5.3 Positioning on the transport vehicle

The module must be positioned longitudinally in the middle of the load surface and parallel to the vehicle
longitudinal axis. The cargo must be positioned transversely on the vehicle so that the axle loads are as even
as possible; under no circumstances may the permissible individual axle or wheel loads be exceeded. Make
sure that there is sufficient clearance between the module and walls or tarpaulins so that no contact and
resulting damage to the module or the vehicle can occur during transport, and access to the lashing points on
the vehicle cargo floor is guaranteed.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Kecht S. Responsible: Wolf S. Release date: 29/08/2014
Index: 1 Page No.: 3/16
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0039
Securing GE Jenbacher modules during transport by truck

Fig. 1: Module positioning on the cargo floor viewed from the rear

Fig. 2: Module positioning on the cargo floor viewed from the left

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Kecht S. Responsible: Wolf S. Release date: 29/08/2014
Index: 1 Page No.: 4 / 16
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0039
Securing GE Jenbacher modules during transport by truck

6 Securing during transport

6.1 General
GE Jenbacher modules must be secured during
transport by truck in accordance with the regulations
and guidelines of EN 12195 and VDI 2700. Securing
using friction-locking alone and combined friction and
positive locking are both permissible. The carrier is
under an obligation to ensure that the driver given the
job is familiar with all the rules and regulations and
has been trained in them. The appropriate lashing
equipment must be provided by the carrier and
presented to the person responsible for despatch at
GE Jenbacher before loading is commenced. The
lashing equipment must be in good condition, be
completely undamaged and bear the manufacturer's
test notice.

Fig. 3: Test notice for lashing equipment as per EN

12195-2

Lashing equipment which is missing or does not comply with legal requirements will result in loading being
refused until the required equipment is presented. The complaint and resultant delay must be noted in the
delivery note. Any costs incurred by the delay or total refusal to load, including consequential costs, shall be
borne by the carrier. GE Jenbacher further reserves the right to claim against the carrier for any penalty
payments resulting from late delivery of the module to the customer, should a justified refusal to load for the
above reasons be the cause of the delayed delivery.

6.2 Anti-slip mats

To reduce the lashing forces it is required to use anti-slip mats according to VDI 2700 Part 15 for every single
transport. These will be provided by GE Jenbacher or its logistics partner, the firm of Geb. Weiss, to every carrier
before the start of loading.
The anti-slip mats must be positioned on the vehicle cargo floor (while observing the prohibition against
working under suspended loads) so that the two longitudinal beams of the module frame sit flush on the anti-
slip mats and no part of the module is in direct contact with the vehicle cargo floor.

6.3 Lashing straps

Heavy-duty lashing straps with the following properties are prescribed for lashing down GE Jenbacher
modules:

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Kecht S. Responsible: Wolf S. Release date: 29/08/2014
Index: 1 Page No.: 5/16
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0039
Securing GE Jenbacher modules during transport by truck

▪ Lashing strap according to EN 12195-2

▪ Width at least 50 mm
▪ at least LC 2 500 daN
▪ SHF 50 daN
▪ STF 300 daN
▪ Max. elongation 5%
▪ Carabiner or triangle hooks with safety latches (claw hooks only permissible after approval by the GE
Jenbacher person responsible for despatch, and if loosening or becoming undone during transport can be
ruled out)
or
▪ Lashing strap according to EN 12195-2
▪ Width at least 50 mm
▪ at least LC 5 000 daN
▪ SHF 50 daN
▪ STF 400 daN
▪ Max. elongation 5%
▪ Carabiner or triangle hook with safety latch

If a carabiner or triangle hook cannot be attached directly to the module, suitable aids or intermediate
equipment such as shackles or heavy-duty carabiners must be used.
Restraining chains must be used to secure GE Jenbacher modules with type J624 engines.

6.4 Lashing forces

The lashing provides a restraint against acceleration forces during transport. These generally result in tipping
around the longitudinal axis of the module-vehicle due to the narrow support triangle, and slipping in the
longitudinal direction.

Fig. 4: Support triangles in the longitudinal and transverse directions

The module must be restrained in principle as shown in Figs. 5 or 6. The number and position of the lashings
will depend on the weight of the module and the accessibility of the lashing points on the vehicle.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Kecht S. Responsible: Wolf S. Release date: 29/08/2014
Index: 1 Page No.: 6 / 16
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0039
Securing GE Jenbacher modules during transport by truck

Restraints must always run directly between the attachment point on the module and the load bearing point
on the vehicle, i.e. the lashing strap must run in a straight line between these two points without touching any
other components. In particular, it must be ensured that no other components are subjected to any forces from
the restraints which could deform or damage them, and that no components can deform during transport with
the result that the restraints can become loose or undone.

Fig. 5: Fastening lashings to the module, schematic, four-point fixing

① Module centre of gravity

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Kecht S. Responsible: Wolf S. Release date: 29/08/2014
Index: 1 Page No.: 7/16
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0039
Securing GE Jenbacher modules during transport by truck

Fig. 6: Fastening lashings to the module, schematic, six-point fixing

① Module centre of gravity

7 Attachment points on the module

Modules have different attachment points where the restraints have to be attached, depending on the engine
type and the scope of supply. The attachment points, their position on the module and the correct position of
the lashings for the individual engine types are shown in Figs. 7 to 25. The lashings must be checked before
transport is approved and started.

8 Restraining the module in the direction of travel

The fundamental rule is:
▪ The module must be restrained in backward direction (to prevent slipping forwards) with at least 60 % of
the weight of the load.
▪ The module must be restrained in forward direction (to prevent slipping backwards) with at least 40 % of
the weight of the load.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Kecht S. Responsible: Wolf S. Release date: 29/08/2014
Index: 1 Page No.: 8 / 16
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0039
Securing GE Jenbacher modules during transport by truck

9 Attachment points and restraints for Type 2 modules

Fig. 7: Position of the attachment points, Type 2, left

Fig. 8: Position of the attachment points, Type 2, right

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Kecht S. Responsible: Wolf S. Release date: 29/08/2014
Index: 1 Page No.: 9/16
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0039
Securing GE Jenbacher modules during transport by truck

Fig. 9: Detail of attachment point 1 Fig. 10: Detail of attachment point 2

Fig. 11: Detail of attachment point 3 Fig. 12: Detail of attachment point 4

10 Attachment points and restraints for Type 4 modules

Use a shackle when lashing down at the lifting lugs - see Fig. 16!

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Kecht S. Responsible: Wolf S. Release date: 29/08/2014
Index: 1 Page No.: 10 / 16
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0039
Securing GE Jenbacher modules during transport by truck

Fig. 13: Position of the attachment points, Type 4, left

Fig. 14: Position of the attachment points, Type 4, right

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Kecht S. Responsible: Wolf S. Release date: 29/08/2014
Index: 1 Page No.: 11/16
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0039
Securing GE Jenbacher modules during transport by truck

Fig. 15: Detail of attachment point 1 Fig. 16: Detail of attachment point 2

Fig. 17: Detail of attachment point 3, Type 4

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Kecht S. Responsible: Wolf S. Release date: 29/08/2014
Index: 1 Page No.: 12 / 16
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0039
Securing GE Jenbacher modules during transport by truck

11 Attachment points and restraints for Type J624 modules

Fig. 18: Position of the attachment points, Type J624, right

Fig. 19: Detail of attachment point 1, J624

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Kecht S. Responsible: Wolf S. Release date: 29/08/2014
Index: 1 Page No.: 13/16
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0039
Securing GE Jenbacher modules during transport by truck

Fig. 20: Detail of attachment point 2, J624

Fig. 22: Detail of attachment point 4, J624

Fig. 21: Detail of attachment point 3, J624

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Kecht S. Responsible: Wolf S. Release date: 29/08/2014
Index: 1 Page No.: 14 / 16
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0039
Securing GE Jenbacher modules during transport by truck

12 Generator attachment points and restraints

Fig. 23: Position of the generator attachment points, right

Fig. 24: Detail of generator attachment point 1 Fig. 25: Detail of generator attachment point 2

13 Checklist
The following checklist must be filled in completely before transport is commenced and question 17 must be
answered with YES before transport approval can be given by GE Jenbacher.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Kecht S. Responsible: Wolf S. Release date: 29/08/2014
Index: 1 Page No.: 15/16
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0039
Securing GE Jenbacher modules during transport by truck

Task description Person responsible Com Date and Signature

plet time
ed
(Y/N)
1 Transport order present, transport responsible
person, carrier and driver checked?
2 Cargo provided in accordance with transport
order?
3 Dimensions and exact weight of the cargo
known, checked and noted on the delivery note?
4 Vehicle suitable for transport as regards tonnage
and dimensions?
5 Carrier familiar with necessary regulations,
guidelines and GE Work Instructions?
6 Loader in possession of all necessary
qualification certificates and documents for
loading?
7 Vehicle cargo floor prepared as per VDI 2700?
8 Lashing equipment as per EN ISO 12195 present
and in perfect condition?
9 Anti-slip mats present and in perfect condition?
10 Cargo placed in the longitudinal and transverse
centre of the vehicle?
11 Cargo sitting flush on the anti-slip mats?
12 Enough lashing eyes in the vehicle cargo floor
and are they accessible?
13 Lashing carried out in accordance with
Technical Instruction?
14 Straps running in a straight line to the vehicle
cargo floor (no diversion caused by obstructing/
deformable module components)?
15 Straps clear (no danger of chafing), if not:
chafing protection fitted?
16 Straps tensioned crosswise to maximum manual
force (SHT value)?
SprungMarke!!!8458608011
17 Transport approval given?

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Kecht S. Responsible: Wolf S. Release date: 29/08/2014
Index: 1 Page No.: 16 / 16
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0110
Boundary conditions for GE Jenbacher gas engines

1 Scope ........................................................................................................................................................... 3
2 Purpose ....................................................................................................................................................... 3
3 Introduction ............................................................................................................................................... 3
4 Site documentation .................................................................................................................................. 3
5 Potentially explosive atmospheres........................................................................................................ 3
6 EMERGENCY STOP ..................................................................................................................................... 4
7 Minimum clearance around unit............................................................................................................ 4
8 Gas and smoke alarm system ................................................................................................................ 8
9 Fuel gas....................................................................................................................................................... 9
9.1 General ........................................................................................................................................................................... 9
9.2 Function lines in the fuel-gas system ............................................................................................................ 11
9.3 Condensate removal in the fuel-gas system.............................................................................................. 12
9.4 Minimum methane number................................................................................................................................ 13
10 Intake air .................................................................................................................................................. 14
10.1 General ......................................................................................................................................................................... 14
10.2 Condition of the intake air................................................................................................................................... 14
10.3 Air quality..................................................................................................................................................................... 14
10.4 Basis of ventilation design................................................................................................................................... 15
10.4.1 Temperatures 15
10.4.2 Pressurisation of engine room 16
10.4.3 Required air flow rate 17
10.4.4 Air recirculation 18
10.4.5 Air flow distribution and engine component temperatures 18
10.4.6 Noise reduction 19
10.5 Operation and control of engine room ventilation system.................................................................. 19
10.6 Design guidelines for the ventilation system ............................................................................................. 19
10.7 Cooling air for switchgear cabinets................................................................................................................ 22
11 Cooling water .......................................................................................................................................... 22
11.1 General ......................................................................................................................................................................... 22
11.2 Cooling water quality............................................................................................................................................. 23
11.3 Engine cooling circuit for JMS MODULES ..................................................................................................... 23
11.4 High-temperature circuit..................................................................................................................................... 24
11.5 Low temperature circuit (2nd stage mixture cooler) .............................................................................. 24
11.6 Exhaust gas heat exchanger ............................................................................................................................. 24
11.7 Cooling circuit operation...................................................................................................................................... 25
12 Lubricating oil.......................................................................................................................................... 25
13 Exhaust gas.............................................................................................................................................. 25
14 Electrical conditions ............................................................................................................................... 26
14.1 Electrical mains connection points ................................................................................................................. 26
14.2 Customer switchgear ............................................................................................................................................ 27
14.3 Generator circuit breaker .................................................................................................................................... 27
14.4 Module control panel............................................................................................................................................. 27
14.5 Power supply for auxiliaries................................................................................................................................ 28
15 Operation and maintenance................................................................................................................. 28
15.1 Safety regulations ................................................................................................................................................... 28
15.2 Minimum operation time ..................................................................................................................................... 29
15.3 Idling mode................................................................................................................................................................. 29
15.4 Partial load operation............................................................................................................................................ 29
15.5 Isolated operation ................................................................................................................................................... 29
15.6 Daily inspection ........................................................................................................................................................ 29
15.7 Inspection and maintenance............................................................................................................................. 29
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Madl W. Release date: 30/04/2015
Index: 16 Page No.: 1/33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0110
Boundary conditions for GE Jenbacher gas engines

15.8 Work on the container roof ................................................................................................................................ 30

16 Piping, thermal insulation and expansion joints............................................................................... 30
16.1 General design.......................................................................................................................................................... 30
16.2 Mechanical CONNECTION POINTS................................................................................................................... 31
16.3 Equipotential bonding ........................................................................................................................................... 31
16.4 Thermal insulation .................................................................................................................................................. 31

NOTICE
Observance of the conditions of this Technical Instruction and performance of the
activities described therein is the basis of safe and efficient plant operation.
Non-observance of the conditions of this Technical Instruction and/or non-performance of the
prescribed activities or any departure from the prescribed activities may result in the loss of
guarantee rights.
The activities and conditions defined in this Technical Instruction shall be performed and/or
observed by the plant operator. This shall not apply if this Technical Instruction is expressly
allocated to the area of responsibility of GE Jenbacher or a contractual agreement between the
operator and GE Jenbacherprovides for a different arrangement.

List of Abbreviations
JMS Jenbacher Module Set
JGC Jenbacher Generator Container
JMC GE Jenbacher Module Container
P&ID Piping and Instrumentation Diagram
PPE Personal Protective Equipment:
TI, TA Technical Instruction
TCA Turbo Charger and Auxiliaries

Glossary
CONNECTION POINT Terminal point where an interface is established with the customer system,
i.e. a piping flange or after an expansion bellow, electrical terminals, etc.
CUSTOMER Individual or entity with whom a GE Jenbacher supply / service contract is
signed.
ENGINE ROOM Any type of enclosure where a unit is installed, e.g. building, sound
enclosures, etc.
INTERFACE LIST Interface list of specific offer/order
HEAVY LOADS Loads weighing over 25 kg.
MODULE Engine, generator and TCA; includes everything that is mounted by GE
Jenbacher on the engine frame.
TECHNICAL INSTRUCTION Technical information and description of a defined scope and purpose of GE
Jenbacher products.
TECHNICAL DESCRIPTION Technical description of specific offer/order “TS_xxxxx”
TECHNICAL DIAGRAM Plant and Engine piping and instrumentation diagram of specific offer/order.
TECHNICAL SPECIFICATION OF Technical specification of control system for specific offer/order.
CONTROL SYSTEM
ZONE NE Hazardous area of negligible extent.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Madl W. Release date: 30/04/2015
Index: 16 Page No.: 2 / 33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0110
Boundary conditions for GE Jenbacher gas engines

1 Scope
This Technical Instruction applies to all GE Jenbacher modules and special products until such time as an
updated version of this document is issued.

2 Purpose
This TECHNICAL INSTRUCTION (TA) provides basic information about the installation of GE Jenbacher MODULES
and describes the boundary conditions required for their safe and efficient operation.

3 Introduction
The instructions within this TA are to be deemed as minimum technical requirements and do not cover any
local specific laws, regulations or guidelines.
Some design specifications outlined in this TA (e.g. minimum clearance data) are not applicable to
containerised versions of GE Jenbacher products (JMC and JGC).
The limit levels for harmful emissions guaranteed in the TECHNICAL DESCRIPTION are only valid for the load
range stated within ⇨ 15. Operation and maintenance [⇨ Page 28].

4 Site documentation
GE Jenbacher modules are modified to meet customers' specific needs and requirements. As a result of
individual and supplementary agreements, the site documentation may contain divergent information. In such
cases, GE Jenbacher must be contacted. However, certain parameters can be prioritised in advance.
The documents below have priority:
▪ for Technical Data: TECHNICAL DIAGRAM
▪ for Electrical Parameters: TECHNICAL SPECIFICATION OF CONTROL SYSTEM

5 Potentially explosive atmospheres

GE Jenbacher gas engines and products (including containerised versions) shall not be operated in zones 2, 1
or 0 (under IEC 60079-10-1:2008).
The CUSTOMER is responsible for ensuring that a ZONE NE (under IEC 60079-10-1:2008) is observed throughout
the entire period of operation (including engine starts and shut-downs) with adequate measures, e.g. forced-
draft (positive pressure) of the ENGINE ROOM
Proper ventilation of the ENGINE ROOM is essential to guarantee the safety of GE Jenbacher applications.
Therefore an engine start-up and operation is only permitted when a signal is sent in accordance with the
INTERFACE LIST to the GE Jenbacher control system, reporting that the ventilation system is working without
any issues (excluding black start situations).
Gas venting lines shall be planned and routed as described in ⇨ 9. Fuel gas [⇨ Page 9].
Minor leaks of both the pressurised gas and the gas-air-mixture paths on the engine have to be considered
when the explosion safety concept of the plant is established. The minimum recommended air changes to
ensure a ZONE NE in accordance with IEC 60079-10-1:2008 are as stated in ⇨ 10. Intake air [⇨ Page 14].
The fuel gas supply path, the main gas train and the pre-chamber gas train excluding the gas proportioning
valve (P.01-YCI-103) are considered permanently technically sealed under TRBS - Technical rules for safe
operation - 2152/1 Consequently, they do not create potentially explosive atmospheres. The optional pre-
chamber and main gas compressors cannot be considered permanently technically sealed under TRBS 2152/1.
The connection between the gas train and MODULE connection D “Fuel gas inlet“ and T “Fuel gas inlet (pre-
combustion chamber gas supply line)“ (refer to applicable TECHNICAL DIAGRAM), shall be designed to be
permanently technically sealed under TRBS 2152/1.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Madl W. Release date: 30/04/2015
Index: 16 Page No.: 3/33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0110
Boundary conditions for GE Jenbacher gas engines

6 EMERGENCY STOP
GE Jenbacher MODULES are equipped with manually operated EMERGENCY STOP buttons. The CUSTOMER shall
install additional emergency stop buttons in accordance with the information below:
1. Stationary engine
GE Jenbacher CUSTOMER
• 1 (one) emergency stop button on the module • Emergency stop button(s) inside and outside the
control panel ENGINE ROOM, hard-wired connected to the GE
• 1 (one) emergency stop button on the module Jenbacher control panel
interface panel • Quantity and positioning according to the
CUSTOMER’s risk assessment and local requirements

2. Container
GE Jenbacher CUSTOMER
• 1 (one) emergency stop button on the module • Emergency stop button(s) inside and outside the
control panel container, hard-wired connected to the GE
• 1 (one) emergency stop button on the module Jenbacher control panel
interface panel • Quantity and positioning according to CUSTOMER’s
• Emergency stop button in the container risk assessment and local requirements

The emergency stop buttons shall comply with the requirements of ISO 13850 and IEC 60947-5-5.
When the emergency stop button is actuated, the engine receives the emergency shutdown signal.

7 Minimum clearance around unit

The clearance around the MODULE assembly shall be determined by serviceability and emergency escape
route requirements.
The minimum clearance for maintenance work as detailed below shall be applied in the planning of the ENGINE
ROOM.
In the ENGINE ROOM a crane as detailed below shall be installed. The following minimum operability
requirements shall be applied for the crane:
▪ able to work with the specified loads (W);
▪ when installing equipment inside the engine room, the crane must be allowed to operate unobstructed
over the entire travel distance;
▪ minimum clearances must be observed over the entire travel distance (Y) , taking account of the crane
hook (C);
▪ able to access all heavy components, e.g. cylinder heads, turbo chargers and intercoolers;
▪ provision of a lay-down area to remove heavy components from the ENGINE ROOM.
The cranes in any ENGINE ROOM in which GE Jenbacher personnel work shall be inspected annually by an
authorised party, this being confirmed by valid inspection certificates.

ATTENTION
Removing the generator
It must be possible to remove the generator from the ENGINE ROOM. The minimum crane loads
(W) stated below do not include the generator.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Madl W. Release date: 30/04/2015
Index: 16 Page No.: 4 / 33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0110
Boundary conditions for GE Jenbacher gas engines

The stated minimum clearances (A, B, C, D and E) are the distances that have to be left around the MODULE in
order to allow installation, commissioning and maintenance work. This can include the removal of specific
heavy components, performed safely and according to the applicable regulations The minimum clearances
shall be measured from nearest point on the MODULE to to any obstacles, e.g. walls, plant piping, cabinets, etc.
The engine room components, equipment and piping shall be arranged in such a way that they do not obstruct
escape routes and exits or prevent staff from evacuating the premises. For this reason, special attention should
be paid to the electrical cabinets. Refer to applicable standards, e.g. IEC60634-7-729 and applicable local
regulations.

Minimum clearance around the MODULE without TCA

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Madl W. Release date: 30/04/2015
Index: 16 Page No.: 5/33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0110
Boundary conditions for GE Jenbacher gas engines

Minimum clearance around the MODULE with TCA

Legend
① TCA Y Minimum travel distance for crane along
the module width
② Engine
③ Generator
A Distance from back of assembly D Lateral distance
B Distance from front of assembly E Lateral distance
C Distance from crane hook W Crane - minimum load

Engine A [mm] B [mm] C [mm] D [mm] E [mm] W [kg] Y [mm]

Type 2 1,000 1,000 1,200 1,000 1,000 150 (1)
Type 3 1,000 1,000 1,200 1,000 1,000 500 1,600
Type 4 1,000 1,000 1,200 1,000 1,000 500 1,600
Type 6 E/F 1,500 1,000 1,500 1,000 1,000 1,000 1,600
Type 624 1,500 1,000 1,500 1,000 1,000 1,000 2,500
Type 9 (2) (2) (2) (2) (2) 2,000 (2)
(1) An overhead crane (trolley) with rails above the cylinder heads is recommended.
(2) For minimum clearances for type 9 engines, see the MODULE DRAWINGS.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Madl W. Release date: 30/04/2015
Index: 16 Page No.: 6 / 33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0110
Boundary conditions for GE Jenbacher gas engines

Additional room shall also be provided for the temporary storage, repair and overhaul of components.
Where other equipment has been installed in the ENGINE ROOM, such as an oxidation catalyst or exhaust gas
heat exchanger, additional clearances to perform maintenance work shall also be applied in accordance with
maintenance instructions, applicable standards and regulations.
In addition to the minimum clearance around the MODULE for maintenance work, all requirements relating to
emergency escape routes shall be applied in accordance with all applicable codes, standards, directives and
the plant safety risk assessment. For this purpose, the recommended standard to be followed is EN ISO 14122.
If a medium voltage generator is to be installed, a junction box (containing the surge protection to the
generator) can be installed beside the generator, within the minimum clearance around the MODULE. Access to
the generator and the surrounding area and maintenance work shall be possible at all times. The junction box
and respective cable and cable trays shall not create an obstruction to the maintenance of the MODULE or
block escape routes.
The clearance distances for maintenance on multiple engine installations should be defined allowing
maintenance operation of one unit at a time. It is therefore permissible to allow only one clearance distance for
maintenance between the MODULES (D, E) if the plant consists of several modules.
Any specified minimum clearance that cannot be maintained inside the ENGINE ROOM shall be accessible
through openings in the walls or roof.
As a minimum, the openings shall correspond to the areas ④ and ⑤ in the illustration below to permit
maintenance work to be carried out on the engine and disassembled parts to be fitted or removed.

Openings for MODULES without TCA

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Madl W. Release date: 30/04/2015
Index: 16 Page No.: 7/33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0110
Boundary conditions for GE Jenbacher gas engines

Openings for MODULES with TCA

① TCA ④ Lateral openings in the walls
② Engine ⑤ Roof opening
③ Generator

8 Gas and smoke alarm system

WARNING
Installing a gas and smoke alarm system
In order to guarantee the safe operation of GE Jenbacher modules, GE Jenbacher requires the
installation of a gas and smoke detection system with audible signal (alarm horn).

The objectives are as described below:

▪ The installation of the fuel gas sensors is intended to prevent explosive atmospheres from forming when
the engine is stopped and ventilation is not in operation (except for recirculation).
▪ Smoke sensors are intended to detect fire events.
▪ CO gas sensors are intended to prevent staff from being poisoned or asphyxiated.
It is the responsibility of the CUSTOMER to install a gas and smoke alarm system in the ENGINE ROOM that
satisfies the requirements of applicable laws, regulations, standards and the plant safety plan.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Madl W. Release date: 30/04/2015
Index: 16 Page No.: 8 / 33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0110
Boundary conditions for GE Jenbacher gas engines

The exact number and location of gas and smoke sensors shall be determined by the results of the
CUSTOMER's risk assessment. The following minimum requirements for the number and location of fuel gas
sensors shall be adhered to:

Fuel gas type

Natural gas
▪ at least one sensor per installed MODULE
▪ positioned above the gas train.
Non-natural gas
▪ at least two sensors per installed MODULE
▪ installed in an appropriate location at the vicinity of the gas train (several factors shall be considered e.g.
gas density and gas behaviour at ambient temperature, ventilation design, etc.).
For all fuel gases, if a pre-chamber gas compressor is installed, an additional dedicated gas sensor shall be
included.
The fuel gas sensors shall be designed for the gas-specific components (observed toxicity)! Record the results
from the gas analysis.

WARNING
Gas composition
Additional gas sensors shall be installed, depending on the gas composition and the toxicity of
the gas components. Special attention should be paid to special gases in accordance with TI
1000‑0300.

Where the fuel gas contains CO (carbon monoxide) and criterion 1, 2 or 3 has been met:
1. no odour compounds in the gas; CO content in the fuel gas > 0%;
2. the gas contains an odourant and the CO content of the fuel gas is >0.5%;
3. in areas where people circulate, particularly hazardous areas (in the vicinity of gas-carrying components);
the following minimum requirements for the CO gas sensors (number and location) shall be adhered to:
▪ at least two sensors per engine installed
▪ installed at a height between 1.5 m and 1.7 m
Specific gas sensors are mandatory for systems operating with special gases as defined in TI 1000-0300.
The location, number and type of suitable smoke sensors shall be defined in accordance with layout, ventilation
design and specific requirements from the safety risk assessment.
See also TI 2300-0005.

9 Fuel gas

9.1 General
The fuel gas system of GE Jenbacher engines is always designed on a project-specific basis to enable optimal
engine operation. The plant is designed according to the gas type, engine type, gas pressure and country-
specific standards.
The main criterion for dimensioning the gas train(s) is the gas pressure at the CONNECTION POINT. It is the
CUSTOMER's responsibility to observe the agreed limit values at the CONNECTION POINTS as specified in the
TECHNICAL DIAGRAM and/or TECHNICAL DESCRIPTION at all times.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Madl W. Release date: 30/04/2015
Index: 16 Page No.: 9/33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0110
Boundary conditions for GE Jenbacher gas engines

WARNING
Explosive mixture
The fuel gas provided by the CUSTOMER shall not be ignitable.

WARNING
Stop valve
According to good engineering practice a suitable stop valve (manual or automatic) must be
placed outside the ENGINE ROOM. The applicable standards, local technical and statutory
regulations and installation instructions shall be taken into account in the location and design of
this valve. The recommended location of the valve is at the point where the fuel pipes enter the
ENGINE ROOM. This means that the fuel gas supply to the plant can be cut off during repairs and
maintenance operations and the valve can also be actuated in case of emergencies. The
selected valve shall be provided with a suitable lockout device (LOTO), to prevent it from being
opened by unauthorised persons.

WARNING
Gas train
If the gas train is included in the GEJ scope of delivery, then this is also to be viewed as a unit.
Retroactive modifications by the CUSTOMER are not permitted.
Contact GE Jenbacher or GE Jenbacher service partner in the event that modifications to the gas
train become necessary.
This also applies to the prechamber gas trains (for series 6 and 9).

WARNING
Protection against weather effects
The gas pressure control system must be installed in the engine room or an enclosure that
provides protection against environmental and weather effects, especially corrosion, rain, icing,
humidity, UV radiation, poisonous or corrosive substances and harmful insects. A temperature
range from +5°C to +45°C must be maintained.

WARNING
CO content of fuel gas
If the CO content of the fuel gas is > 0.5%, a nitrogen flushing system shall be installed.

It is the CUSTOMER's responsibility to ensure that the fuel gas system is equipped with the necessary safety and
monitoring devices, does not leak and satisfies official requirements.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Madl W. Release date: 30/04/2015
Index: 16 Page No.: 10 / 33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0110
Boundary conditions for GE Jenbacher gas engines

9.2 Function lines in the fuel-gas system

Function lines are defined in DVGW G 491 as controller purge lines, vent lines from the leak tester and blow-off
lines from safety valves that have to be vented to atmosphere from the ENGINE ROOM. Purge, vent and blow-
off lines shall not be run into a common manifold. Function lines of the same kind may only be grouped
together if this does not adversely affect the operation of the individual items of equipment (follow the
manufacturers' instructions). The function line diameters shall be dimensioned in compliance with local
conditions and as a function of the pressure loss (piping, bends, etc.).

WARNING
Function lines
Function lines are not included in the GE Jenbacher scope of supply.
The installation of a permanently technically leakproof and well-made function line (e.g. to
TRBS2152, Part 2) is the responsibility of the CUSTOMER.

WARNING
Escaping gases
Gas escapes from around the outlet area of the function lines!

The escaping gases shall be conducted away safely. The function line outlets shall be situated at a safe
distance from ignition sources and protected against the ingress of foreign matter (e.g. rain, pests) that could
cause a blockage or adversely affect the operation of the equipment.
The areas around the function line outlets shall be evaluated and designed in accordance with current local
explosion protection and industrial safety regulations (e.g. 94/9/EG, IEC 60079, EN 1127-1).

Example of a high-pressure gas train (inlet gas pressure exceeding 499 mbar)
① High-pressure controller
② Safety blow-off valve
③ Safety shut-off valve
④ Function lines

The CONNECTION POINTS to which function lines should be attached are indicated in the TECHNICAL DIAGRAM.
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Madl W. Release date: 30/04/2015
Index: 16 Page No.: 11/33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0110
Boundary conditions for GE Jenbacher gas engines

Symbol used in the TECHNICAL DIAGRAM (as shown in E16287 - Key to the technical diagram and the module
views).

9.3 Condensate removal in the fuel-gas system

Cooling of gases in the fuel gas system can cause condensation, resulting in the accumulation of liquid. The
condensate shall be drained from the gas system under gas-tight conditions and disposed of in accordance
with its composition and local regulations (e.g. surface-water protection regulations, explosion protection).
The planning and construction of a gas-tight and well-made condensate drain line is the responsibility of the
CUSTOMER and shall comply with all local regulations regarding explosion protection and industrial safety. In
addition, the danger of freezing should be taken into account when draining condensate to atmosphere.

NOTICE
Gas-tight version of condensate drain line
Not all commercially available condensate drain lines are permanently gas-tight, and some lines
may leak due to dirt or vibration in the course of operation.
The suitability for use as a gas-tight condensate drain line for fuel gases and the conditions for
securing permanent gas-tightness must be expressly confirmed by the manufacturer/supplier
and observed accordingly.

Gases dissolved in the condensate may be liberated around the condensate drain as a result of pressure
release, which can lead to the formation of an explosive atmosphere in the condensate drain line.
The condensate drain line should have a direct vent to atmosphere.
The outlet of the condensate drain lines and the areas around the vent points shall be evaluated and designed
in accordance with current local explosion protection and industrial safety regulations (e.g. 94/9/EC, IEC 60079,
EN 1127-1). The arrangement of the condensate drain lines should also be inspected and approved by the site
safety officer and taken into account when drawing up the plant safety plan.
The schematic diagram below shows the principle of operation of the condensate drain, with a vent point to
atmosphere.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Madl W. Release date: 30/04/2015
Index: 16 Page No.: 12 / 33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0110
Boundary conditions for GE Jenbacher gas engines

U
4
3

6
Condensate drain for the fuel gas system
① Fuel gas + condensate source
② Vent point
③ Immediate environment
④ Gas-tight condensate discharge valve
⑤ Water trap
⑥ Condensate disposal

9.4 Minimum methane number

If the contractually agreed minimum methane number (refer to the TECHNICAL DESCRIPTION) is not reached,
the engine control system will automatically take the following steps to achieve knock-free operation and/or to
prevent knock damage:
▪ reduce the mixture temperature (if a controller has been installed and the ambient conditions are
conducive)
▪ set the ignition point to a later point in time, but still within the permissible range (followed by a decrease in
efficiency)
▪ reduce the engine load as specified in ⇨ Section 15. Operation and maintenance [⇨ Page 28]
▪ if these anti-knock measures prove to be insufficient, the knock-control system will shut down the engine
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Madl W. Release date: 30/04/2015
Index: 16 Page No.: 13/33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0110
Boundary conditions for GE Jenbacher gas engines

If the methane number repeatedly falls below the minimum, please contact GE Jenbacher for a system check-
up.

10 Intake air

10.1 General
The ventilation system supplies combustion air to the engine and dissipates the heat from the MODULE
(generator, engine, TCA) and auxiliary systems.
The engine-room shall be provided with forced-draught fans, which will result in positive pressure. Different
ventilation system designs shall be reviewed in advance with GE Jenbacher and shall require a CUSTOMER site-
specific assessment.
Additional constant ventilation shall be provided around the MODULE and auxiliary systems to prevent the
formation of potentially explosive atmospheres as a result of leaks.
All MODULES are designed to operate within specific temperature ranges. If these ranges are not adhered to,
the performance, reliability and service life of the engine could be affected.
The site conditions, ambient temperature and humidity shall be taken into account when planning the
ventilation system.
The ventilation system shall meet the noise requirements in compliance with applicable local regulations and
laws. For specific noise data, refer to the TECHNICAL DESCRIPTION.

10.2 Condition of the intake air

In order to avoid surge events in the turbochargers, the minimum combustion air temperature (T1) shall be
+10°C.
Engines with electrical starters are constrained by a permissible minimum ENGINE ROOM temperature of
+10°C, otherwise starting behaviour, starter motor power and starting battery capacity could be adversely
affected.

NOTICE
Preheating systems
GE Jenbacher MODULES are equipped with a cooling water preheating system. J920 systems are
equipped with an additional oil preheating system. Measures shall be taken to prevent heat
losses from the ENGINE ROOM when the preheating system is switched on.

The reference values as specified in ISO 3046 shall apply to air pressure, air intake temperature and air
humidity: 1,000 mbar, +25°C, 30% humidity. Where the above values differ from the values obtained at the
installation site, the specific engine performance will be reduced.
This corresponds to the standard constraints assumed by all engine manufacturers.
Other conditions shall be subject to agreement by GE Jenbacher. By modifying the pressure-charging system, it
will be possible to operate the system at full load even at higher intake temperatures. The conditions set out in
the TECHNICAL DESCRIPTION shall apply.

10.3 Air quality

The quality and condition of the intake (combustion) air have a significant effect on engine performance,
reliability and durability.
The intake air at the ENGINE ROOM (downstream ventilation intake filter) must not exceed the following limits:

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Madl W. Release date: 30/04/2015
Index: 16 Page No.: 14 / 33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0110
Boundary conditions for GE Jenbacher gas engines

Dust Type 2 to 6: purity class G3 as specified in EN779

J920: purity class M6 as specified in EN779 (formerly F6)
Humidity Generator cooling < 90% rel
Total sulphur < 1.0 mg/Nm³
Ammonia < 0.5 mg/Nm³
The combustion air is normally extracted from the ENGINE ROOM. To maintain the quality of the intake air
downstream of the air filter, the ENGINE ROOM cladding surfaces must be free of loose dust and fibres.
If systems containing refrigerants are installed in the ENGINE ROOM, the combustion air must be extracted
from outside the ENGINE ROOM. See also EN378-3.

WARNING
Intake air
The intake air shall not contain any flammable components.

10.4 Basis of ventilation design

The ventilation system shall be designed in accordance with the requirements outlined below.

10.4.1 Temperatures
The temperatures for ventilation design are specified as follows:

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Madl W. Release date: 30/04/2015
Index: 16 Page No.: 15/33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0110
Boundary conditions for GE Jenbacher gas engines

T1 – combustion/generator cooling air temperature

T2 – max. ENGINE ROOM temperature at outlet
T3 - ambient/intake temperature

10.4.2 Pressurisation of engine room

The ventilation system shall be designed to ensure that air in the ENGINE ROOM is pressurised, providing
positive pressure in the range 0.1 mbar < p < 0.5 mbar.
The effect of this positive pressure is that when the engine is at rest, particularly in multiple-engine systems,
there is always a defined air flow direction through the MODULE towards the exhaust chimney and no acidic
exhaust gas can be aspirated by the engine. This avoids corrosion and, in the event of a false start (which can
never be entirely ruled out), prevents unburned mixture from flowing back to the engine.
If the ENGINE ROOM has negative pressure, e.g. as in greenhouse applications, precautions shall be taken to
ensure that no exhaust from the exhaust gas system flows into the ENGINE ROOM. A safety risk assessment
shall be conducted on the operation of the ENGINE ROOM at negative pressure.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Madl W. Release date: 30/04/2015
Index: 16 Page No.: 16 / 33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0110
Boundary conditions for GE Jenbacher gas engines

10.4.3 Required air flow rate

The required air flow rate is determined by the following design criteria:
1. The radiation heat to be dissipated to comply with the maximum permissible engine room temperature.
2. The air flow is heated between the air intake and outlet. The differential temperature (∆T) between inlet and
outlet shall not exceed 10°C.
3. The engine room temperature shall not exceed the values specified in the table below at any time or in any
place. The fact that the air flow will be heated (by up to 10°C) as the radiant heat is removed shall be taken
into account.
4. In order to maintain the required air quality and avoid gas accumulations (see Section ⇨ 5. Potentially
Explosive Atmospheres [⇨ Page 3]), the minimum air change ratio must be observed (C). The calculation of
the minimum air exchange ratio is based on the formula below and is, for all GE Jenbacher MODULES, Cmin.
= 50h-1.
The required ventilation air flow rate is the maximum of these three values and must be maintained under all
operating and boundary conditions.
The air flow rates shall be calculated on the basis of the minimum values from the table below. The radiant
heat (Qst) is as stated in the TECHNICAL DESCRIPTION.
Engine type Max. engine-room temperature (T2 max)
Type 2 engine 47°C
Type 3 engine 47°C
Type 4 engine 45°C
Type 6 engine 47°C
Type 9 engine 47°C
The minimum air exchange ratio (C) is calculated according the following formula:

(Intake air – Combustion air)

Minimum air exchange ratio (C) = ────────────────────────────
Free volume in the room

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Madl W. Release date: 30/04/2015
Index: 16 Page No.: 17/33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0110
Boundary conditions for GE Jenbacher gas engines

✲ Combustion air
① Intake air – Combustion air ② Intake air
As the combustion air is usually drawn from the ENGINE ROOM, the combustion air demand (Vl) as stated in the
TECHNICAL DESCRIPTION shall be added to the design flow rate of the ventilation inlet system.

10.4.4 Air recirculation

Controlled air recirculation can be applied to raise the intake air temperature to meet combustion air and
ENGINE ROOM temperature requirements The risk of ignitable gas accumulation inside the ENGINE ROOM by
air recirculation shall be included by the CUSTOMER in the plant explosion safety plan. See also ⇨ Section 2.
Potentially explosive atmospheres [⇨ Page 3].

10.4.5 Air flow distribution and engine component temperatures

The air flow shall be distributed in the ENGINE ROOM in order to:
▪ ensure even ventilation (i.e. to prevent unwanted gas accumulations and heat pockets).
▪ maintain the combustion air temperature as specified in the TECHNICAL DESCRIPTION (at engine air filter,
T1).

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Madl W. Release date: 30/04/2015
Index: 16 Page No.: 18 / 33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0110
Boundary conditions for GE Jenbacher gas engines

▪ ensure that the surface temperatures of electrical components installed on the engine such as the ignition
system, ignition coils, ignition cable conduits, gas injection valves, knock controller and charge pressure
sensors, actuators, etc. do not exceed +70 °C. Otherwise the service life of these components will be
considerably reduced and the failure frequency will increase sharply. Damage and downtime caused by
such a situation are excluded from the warranty.
▪ ensure that the permissible temperature of the generator cooling air (T1) is not exceeded. For higher
temperatures, check whether the generator being used can be operated under the prevailing boundary
conditions.
▪ ensure that the air temperature in the vicinity of the switchgear cabinets mounted on the MODULE shall
not exceed +47°C. The switchgear cabinets are equipped with natural or forced draught ventilation,
depending on their internal thermal loads. If the ventilation design does not guarantee these values
(maximum ambient temperature at switchgear cabinets as stated in the above table), additional air-
conditioning units are available for the switchgear cabinets. GE Jenbacher can provide cooling system
designs that permit engine-room temperatures of ≤ 53 °C near the switch cabinets in special cases.
▪ It is the CUSTOMER's responsibility to ensure the necessary boundary conditions (T2 ≤ T2max).
▪ For type J920 engines, measures shall be taken to ensure that the temperature differential between the left
and right air intakes is less than 5°C.

10.4.6 Noise reduction

The air intake and outlet of the engine room ventilation system shall be fitted with suitable sound attenuation
components (silencers).

10.5 Operation and control of engine room ventilation system

A temperature sensor shall be positioned in front of the ventilation outlet to monitor the ENGINE ROOM
temperature (T2).

WARNING
Deflagrations
In order to prevent false starts and deflagrations of flammable gas accumulations, the
ventilation system shall be activated when requested by the module control panel via a specific
output contact (refer to INTERFACE LIST). This creates the controlled boundary conditions
required for the start-up and acceleration phase.

WARNING
Start-up conditions
The ventilation status (on/off) shall not be changed the during the start-up/synchronisation
phase. Any change in ENGINE ROOM pressure can influence the pre-pressure/zero pressure
controller and affect the speed stability, starting behaviour and synchronisation time of the
MODULE.

10.6 Design guidelines for the ventilation system

Generally, the incoming air should be drawn in at the generator end (refer to drawing below). This air is
intended to flow through the complete power set – generator, engine and turbocharger – in order to minimise
the impact of the thermal loads. Splitters or guides should directly feed the generator air inlet (suction) due
to high cooling air demand. In the case of type 6 and type 9 engines, the ventilation should be designed to
minimise temperature differences at the air inlets on Bank A and Bank B.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Madl W. Release date: 30/04/2015
Index: 16 Page No.: 19/33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0110
Boundary conditions for GE Jenbacher gas engines

Type 2, 3, 4 and 6 engines without TCA

G Generator M Engine
✲ Combustion air
① Intake air ② Discharged air

Guide values for air distribution

Type 2, 3, 4 and Half of the air required should be driven to the generator (G).
6 engines The other half should be driven to the combustion air intake (*) and the engine (M).

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Madl W. Release date: 30/04/2015
Index: 16 Page No.: 20 / 33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0110
Boundary conditions for GE Jenbacher gas engines

Type 624 engines

G Generator M Engine
T TCA
✲ Combustion air
① Intake air ② Discharged air

Guide values for air distribution

Type 624 Half of the air required should be driven to the generator (G).
engines The other half should be driven to the combustion air intake (*), the engine (M) and TCA (T).

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Madl W. Release date: 30/04/2015
Index: 16 Page No.: 21/33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0110
Boundary conditions for GE Jenbacher gas engines

Type 9 engines
G Generator M Engine
T TCA
✲ Combustion air
① Intake air ② Discharged air

Guide values for air distribution

Type 9 engines The air required should be divided equally for the TCA side (3) and generator side (1).
The required combustion air (*) shall be added to the air at the TCA side (3).

10.7 Cooling air for switchgear cabinets

Switchgear cabinets such as the module control cabinet (DIANE), power cubicles, station control cubicles, etc.
not mounted on the MODULE are intended for installation in a separate electrical switchgear room (⇨ Section
14. Electrical conditions [⇨ Page 26]).
The maximum permissible ambient temperature for these cabinets is 40°C.

11 Cooling water

11.1 General
The CONNECTION POINTS of the cooling cycle are represented in the TECHNICAL DIAGRAM The integration into
the heating/cooling system and the operating conditions shall be in accordance with the TECHNICAL DIAGRAM.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Madl W. Release date: 30/04/2015
Index: 16 Page No.: 22 / 33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0110
Boundary conditions for GE Jenbacher gas engines

The water return temperature must not exceed or drop below the specified figure, and the minimum flow rate
must be maintained. Deviations in the cooling water return temperature and water flow rate can cause a
shutdown of the MODULE. An additional emergency cooling circuit shall be installed if the heat cannot be
dissipated through the heating system.
The cooling circuit control system must be able to cope with a load change of up to 1% of rated power per
second. More rapid changes, or sudden reductions in cooling performance after trips caused by faults, can be
expected if the engine is running in island mode (as per TA 2108‑0031).
We advise the installation of a thermostatic control to achieve a constant return temperature at the intake of
the MODULE.
The three-way directional control valve and temperature measuring point must be positioned as near to the
engine as possible in order to prevent dead times. GE Jenbacher recommends using a PID controller in the
cooling water circuit and regulating the mixture temperature by means of a controller integrated in the module
control system.

WARNING
Liquid discharge at high pressure
The outlets from safety valves must be routed so that persons cannot be injured by the media
discharged when the safety valve is opened.

11.2 Cooling water quality

The cooling water quality shall comply with the following TECHNICAL INSTRUCTION.
Quality of cooling water in closed circuits 1000-0200
Anti-freeze products and testing the coolant 1000-0201
Corrosion protection products for cooling water for GE Jenbacher engines and testing the 1000-0204
coolant
Quality of circuit water in hot water and warm water heating systems 1000-0206
Quality of cooling water in open cooling circuits (optional) 1000-0208

The concentration of antifreeze shall be as specified in the TECHNICAL DESCRIPTION. The product-specific
minimum concentration requirements shall be observed.

WARNING
Antifreeze
The CUSTOMER shall specify the anti-freeze protection to take account of the local minimum
ambient temperature. The minimum concentration specified in the TECHNICAL DESCRIPTION
shall be observed in all cases.

GE Jenbacher recommends the installation of a dirt trap with mesh size ≤0.25 mm in the return water line to
the MODULE when a direct connection is made with the CUSTOMER's heating system or extensive cooling
systems.

11.3 Engine cooling circuit for JMS MODULES

The engine cooling water circuit is designated as E.04 (⇨ E16287 - Key to the TECHNICAL DIAGRAM and the
module views).

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Madl W. Release date: 30/04/2015
Index: 16 Page No.: 23/33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0110
Boundary conditions for GE Jenbacher gas engines

The pressure in the cooling water circuit shall comply with the limit values shown in the applicable TECHNICAL
DIAGRAM. These limit values are defined as the operating pressure for a fully heated cooling system. The
cooling water pressure shall be adjusted at the pressure regulator valve in accordance with the TECHNICAL
DIAGRAM.

11.4 High-temperature circuit

The high-temperature circuit is designated as E.06 with the CONNECTION POINTS A “Hot water inlet” and B “Hot
water outlet” (⇨ E16287 - Key to the Technical Diagram and the module views).
Appropriate measures shall be taken to ensure that the maximum pressure stated in the TECHNICAL
DESCRIPTION/TECHNICAL DIAGRAM is not exceeded, e.g. by installing safety valves
At the CONNECTION POINT, the cooling water inlet temperature (return water temperature) and pressure, flow
and content of antifreeze shall comply with the limit values stated in the TECHNICAL DIAGRAM and/or the
relevant TECHNICAL DESCRIPTION. In the event of discrepancies between the TECHNICAL DIAGRAM and
TECHNICAL DESCRIPTION, the values in the TECHNICAL DIAGRAM shall prevail.
The permissible temperature deviation at the water inlet from the CUSTOMER (CONNECTION POINT A “Hot
water inlet”) is: +0/‐5°C and is specified in the TECHNICAL DIAGRAM.
The permissible rate of change in the water inlet temperature shall not exceed 10°C per minute.
The pressure loss in the high-temperature circuit between CONNECTION POINTS A and B shall be as specified in
the TECHNICAL DIAGRAM.

11.5 Low temperature circuit (2nd stage mixture cooler)

The low-temperature circuit is designated as E.07 with CONNECTION POINTS M “Water inlet” and N “Water
outlet mixture/water heat exchanger stage 2”, (⇨ E16287 - Key to the TECHNICAL DIAGRAM and the module
views).
Appropriate measures shall be taken to ensure that the maximum pressure stated in the TECHNICAL
DESCRIPTION/TECHNICAL DIAGRAM is not exceeded, e.g. by installing safety valves
At the CONNECTION POINT, the cooling water inlet temperature (return water temperature) and pressure, flow
and content of antifreeze shall comply with the limit values stated in the TECHNICAL DIAGRAM and/or the
relevant TECHNICAL DESCRIPTION. In the event of discrepancies between the TECHNICAL DIAGRAM and
TECHNICAL DESCRIPTION, the values in the TECHNICAL DIAGRAM shall prevail.
GE Jenbacher recommends installing a thermostatic control to achieve a constant return temperature at the
MODULE intake. The cooling water temperature deviation shall not exceed ±2 °C.

ATTENTION
Cooling water temperature
If the cooling water temperature falls below the limit values, this can cause condensation in the
mixture cooler, resulting in fouling and corrosion of the heat exchanger.

The pressure loss in the low-temperature circuit between CONNECTION POINTS M and N shall be as specified in
the TECHNICAL DIAGRAM.

11.6 Exhaust gas heat exchanger

When using an exhaust gas heat exchanger, the minimum pressure requirements for the heating circuit shall
comply with TA 1000-0206.
In the event of discrepancies between the TECHNICAL DIAGRAM and TA 1000-0206, the higher pressures shall
prevail.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Madl W. Release date: 30/04/2015
Index: 16 Page No.: 24 / 33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0110
Boundary conditions for GE Jenbacher gas engines

ATTENTION
Minimum flow rate
The minimum flow rate of the cooling water through the exhaust gas heat exchanger shall be
maintained irrespective of whether the heat exchanger is in operation or bypassed. This ensures
that heat from minor exhaust gas leaks in the exhaust flap is dissipated.

11.7 Cooling circuit operation

The external cooling water circuit shall remain in operation for at least 5 minutes after engine stop to ensure
continued cooling.

12 Lubricating oil
It is recommended to locate the oil tanks inside the building or ENGINE ROOM to prevent condensation. If
outside, the oil tanks and distribution lines should be heated in order to allow the oil to flow properly.
The lubricating oil shall be selected in accordance with the following TECHNICAL INSTRUCTIONS:
Lubricating oil for GE Jenbacher type 9 engines 1000-1108
Lubricating oil for type 2, 3, 4 and 6 GE Jenbacher engines 1000-1109

Oil change in accordance with the following TECHNICAL INSTRUCTIONS:

Approval procedure for various engine oils 1000-0099A
Limit values for used oil on GE Jenbacher gas engines 1000-0099B
Procedure for testing plant-specific oil service life 1000-0099C
Determining the initial pH value (ipH) for waste lube oil as defined in TI 1000-0099B 1000-0099D

ATTENTION
Incorrect diagnoses possible due to the presence of copper!
Copper has a major oxidising effect on lubricating oil, especially at high temperatures, and
accelerates its ageing. An increased copper content in oil leads to incorrect diagnoses.
a) Pure copper shall not be used as a material for oil piping to the engine or valves or other
fittings.
b) Use copper-nickel alloys with a nickel content of ≥ 10 %. These alloys can also be used
instead of the steel piping normally used.

13 Exhaust gas
CONNECTION POINT C "Exhaust gas outlet" (⇨ E16287 - Key to the technical diagram and the module views).
The exhaust gas system comprises all piping, components and equipment from the MODULE exhaust gas
outlet up to the exhaust chimney outlet. The maximum permissible exhaust back pressure of the system is as
specified in the TECHNICAL DESCRIPTION.
Each component must be suitable for use in the exhaust system of a reciprocating engine and be able to
withstand the prevailing operating conditions. These include foreseeable pressure peaks that occasionally
occur when an unburned mixture ignites (deflagration) in the exhaust tract.
The maximum peak pressure to be expected in the exhaust system depends on a number of factors including,
but not limited to: gas type, mixture volume, Lambda value, system geometry, temperature etc. and cannot be
stated as a general value.
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Madl W. Release date: 30/04/2015
Index: 16 Page No.: 25/33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0110
Boundary conditions for GE Jenbacher gas engines

The design of the exhaust tract elements (e.g. silencers, exhaust gas heat exchangers, compensators) should
only be undertaken by specialists with the necessary expertise and experience in the design of exhaust
systems (including the selection of suitable wall thicknesses and support systems).
Safety aspects
A risk analysis is to be carried out for the exhaust system in accordance with ISO 12100:2010. Risks must be
considered at an individual component level as well as at an overall system level; all reasonable constructive
measures for minimising risks are to be implemented. Any residual risks shall be considered in the risk
assessment of the overall installation.
Where a pressure relief arrangement is required, this should be designed only by a specialist.

Further considerations
Further points which must be taken into consideration for the exhaust system include, but are not limited to:
Fast changes of flow velocity inside the exhaust duct can result in underpressure up to 200 mbar.
Chimneys shall conform to EN 13084.
The condensate from the heat-recovery boilers, silencers, exhaust manifold, etc. should be collected and
disposed of in accordance with local laws and guidelines.
Condensate lines should not be interconnected.

In the case of multi-engine systems, the exhaust gas systems may only be combined when:
▪ a double shut-off valve with intermediate ventilation is installed for each MODULE
▪ continuous underpressure exists (e.g. a continuous flow in the chimney) at the point where the systems are
combined.
The exhaust system is to be insulated externally for safety and acoustic reasons and to extend the service life
of the exhaust components by preventing condensate formation and thermal stress (see ⇨ section 16: Piping,
thermal insulation and expansion joints [⇨ Page 30]).
For special gas applications as described in TI 1000-0300, pressure relief valves are to be installed in the
exhaust gas system. The design, location, dimension and flame trap of the pressure relief valve shall be
specified on the basis of the exhaust gas system concerned.

14 Electrical conditions

14.1 Electrical mains connection points

Nominal mains voltage change: +/-10% of rated voltage*)
Max. permissible transient mains voltage changes: +/-19% of rated voltage*)
Nominal mains frequency deviation: max. +/- 2%
Minimum duration of micro interruptions (AWE): 200 ms**)
Make time of the synchronizing switch: 70 ms
Break time of the circuit breaker: 60 ms

*) The specified ranges relate to default voltages in accordance with IEC 60038/EN 50160. In the case of
countries with 415/240V, a maximum voltage tolerance of +6% applies because the related default voltage is
400/230V +/-10%.
**) Unless specific requirements are specified in the TECHNICAL DESCRIPTION, e.g. grid code requirements.
Transient overvoltage deflectors shall be installed to prevent external overvoltages from damaging the system.
The overvoltage protection at the mains voltage supply location is governed by the following standards:
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Madl W. Release date: 30/04/2015
Index: 16 Page No.: 26 / 33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0110
Boundary conditions for GE Jenbacher gas engines

Rated voltage ≤ 1000V: IEC 60364-4-44 overvoltage category II, Table 44.B;
Rated voltage > 1000V: EN/IEC 60099-5

WARNING
Overvoltage
It is essential to provide an additional overvoltage deflector to protect the generator. It is the
CUSTOMER's responsibility to assess overvoltage risks and plan suitable protective devices. For
details, see TA 1100-0112.

WARNING
Short circuit
The customer must confirm that the electrical distribution system and cables have been secured
to withstand short circuits. The short circuit current determined (e.g. in accordance with IEC
60909-0) must not exceed the maximum permissible current of the electrical distribution system.

14.2 Customer switchgear

CUSTOMER switchgear shall comply with the following standards:
Rated voltages ≤ 1 kV: IEC 61439-1, IEC 61439-2, IEC 60204-1, ISO 8528-4
Rated voltages > 1 kV: IEC 62271-200, IEC 60204-11, ISO 8528-4, metal enclosed and capable of withstanding
an internal arc fault and clearly marked to distinguish it from LV equipment.

14.3 Generator circuit breaker

Apart from the normal closing and shunt trip opening coils, the generator circuit breaker shall also be fitted
with a DC voltage under-voltage trip coil. This coil disconnects the generator CB in case of loss of control
voltage or wire breakage.

14.4 Module control panel

The module control panel consists of a completely enclosed floor-mounted sheet steel cubicle with front door
wired to terminals. The panel shall be supplied by GE Jenbacher, ready to operate. The cable entry is at the
bottom. Natural or forced ventilation shall be provided, depending on the design.
The module control panel shall be installed outside the ENGINE ROOM.
Design requirements for control panels are shown in the table below:
Protection class: External IP42 Internal IP20 (protection against
direct contact with live parts)
Design standards: EN 61439-2 / IEC 61439-2 and ISO 8528-4
Ambient conditions: 5 - 40 °C (41 - 104 °F) 70% relative humidity
Standard painting requirements: Panel - RAL 7035 Pedestal - RAL 7020
Dimensions: Width ≥ 1000 mm (other sizes available)
Height - 2000 mm + 200mm pedestal
Depth - 600 mm

The size of the control panel depends on the auxiliaries and is subject to change.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Madl W. Release date: 30/04/2015
Index: 16 Page No.: 27/33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0110
Boundary conditions for GE Jenbacher gas engines

The expected incoming and outgoing signals depend on the GE Jenbacher scope of supply (e.g. scope within
the MODULE).

14.5 Power supply for auxiliaries

The design of the power supply depends on the power consumption of the auxiliaries and is subject to change
(refer to WIRING DIAGRAM).
Fuse at CUSTOMER side:
Operating class gG
Rated breaking capacity 120kA
Standard IEC 60269

CUSTOMER surge protection device: Type 2, EN 61643‑11/Class II IEC 61643‑1, up to max. 2.5kV.
If voltage dip and voltage interruption requirements for the MODULE are applicable (Fault-Ride-Through,
FRT), EN 50160:2010 shall be used as a reference for selecting auxiliary components. The following
requirements are particularly relevant.
▪ Voltage dips: Performance criterion B* (EN 50160:2010, Annex B 4.2) shall be used for the evaluation of
auxiliary component performance for the voltage dips defined as follows:
– Residual voltage down to 5% for up to 1000ms
– Residual voltage down to 40% for up to 5000ms
▪ Voltage interruptions: Performance criterion B* (EN 50160:2010, Annex B 4.2) shall be used for the
evaluation of auxiliary component performance for the voltage interruptions with residual voltage 0% for a
duration of 5000ms.
(*) Performance Criterion B requires that the auxiliary component shall continue to operate automatically as
intended once the voltage recovers. No change of actual operating mode or stored data is allowed. For a full
specification, please refer to EN 50160:2010.
The voltage dip and voltage interruption tests as specified above shall be exclusively used to assess the ability
of the auxiliary components to support the MODULE during a mains failure.
Further detailed information can be found in the “INTERFACE LIST” and “TECHNICAL SPECIFICATION OF
CONTROL” (⇨ “Electrical Hardware” and ⇨ “Generator Switchgear”), that will be generated as part of site
documentation.

15 Operation and maintenance

Maintenance shall be carried out regularly and expertly as described in the applicable documents
(maintenance plans, etc.)
Further information to assist in troubleshooting is available on the GE Jenbacher Service page, and GE
Jenbacher Service can also be contacted.

15.1 Safety regulations

The safety of people, the environment and equipment on the site shall be regarded as the top priority. GE
Jenbacher will take all necessary measures to achieve its safety objectives in line with generally accepted
safety standards. Foreseeable residual risks which are unavoidable for technical reasons shall be highlighted
and displayed on appropriate warning signs. The CUSTOMER shall be responsible for providing communication
and training to prevent residual risks.
To this end, a risk assessment of conditions on site shall be carried out in accordance with applicable
standards and safety rules as well as local laws, regulations and guidelines.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Madl W. Release date: 30/04/2015
Index: 16 Page No.: 28 / 33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0110
Boundary conditions for GE Jenbacher gas engines

It is mandatory to wear personal protective equipment (PPE) on and around the site. The CUSTOMER shall
monitor compliance with the above.

15.2 Minimum operation time

12 hours per engine start, except when commissioning, carrying out maintenance work and during emergency
power operation.
Any deviations from the above minimum operation time may increase the amount of maintenance required.

15.3 Idling mode

The idle duration is limited by the module control unit, except for maintenance and initial setting for work. The
idling period shall be kept to a minimum.

15.4 Partial load operation

In principle, the goal is to achieve full-load operation.
The partial load limit for fuel gases is as specified in TI 1000-0300:
Type 2, 3 and 4 40% of rated bmep as specified in the TECHNICAL DESCRIPTION.
engines
Type 6 engines 50% of rated bmep as specified in the TECHNICAL DESCRIPTION.
Type 9 engines 40% of rated bmep as specified in the TECHNICAL DESCRIPTION.

Partial load limits for special gas applications as defined in TI 1000-0300 shall be determined by GE Jenbacher
on a project-specific basis.
The emission values quoted in the TECHNICAL DESCRIPTION are only applicable for the following loads:
▪ NOx emissions [mg/Nm³ at 5% O2, dry] or [ppm at 0% O2, dry] 50 -100% load
▪ NOx emissions [g/bhp_hr] 80 -100% load

15.5 Isolated operation

During isolated operation, the MODULE may be operated 6 times per year for 4 out of 24 hours at > 20% and <
40% of the rated load.

15.6 Daily inspection

The daily inspection round shall be performed in accordance with the applicable inspection and maintenance
instructions. At the same time, compliance with technical requirements and guidelines in this and other
applicable TAs should be checked on a continuous basis. The relevant engine parameter and measurement
data and the completion of maintenance work should be recorded in the maintenance log.

15.7 Inspection and maintenance

The regular inspection and maintenance of the system and system components is required to ensure the safe
and reliable operation of GE Jenbacher MODULES. The CUSTOMER shall be responsible for ensuring compliance
with the maintenance instructions set out in the maintenance plan which are applicable to the system. Details
of all work on the system shall be recorded and kept for use in the event of warranty claims.
An additional, root cause analysis shall be performed where unscheduled maintenance work is carried out as a
result of unforeseen faults and/or damage. This is intended to prevent future failures. Details of the
maintenance work, the results of the root cause analysis and the measures taken to prevent identical or similar
failures shall be recorded and kept for use in the event of warranty claims.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Madl W. Release date: 30/04/2015
Index: 16 Page No.: 29/33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0110
Boundary conditions for GE Jenbacher gas engines

Further up-to-date information to assist in troubleshooting is available on the GE Jenbacher Service page, and
the GE Jenbacher Service can also be contacted.

15.8 Work on the container roof

WARNING
Work on the container roof
Maintenance work on the container roof entails the risk of falling.
To ensure risk-free maintenance work, the container roof must be fitted with a safety railing or
scaffolding and safety steps for climbing up.
Additional requirements for wearing PPE shall be assessed and observed by the CUSTOMER.

GE Jenbacher Container products are not fitted with such fall-protection equipment as standard. Appropriate
fall-protection equipment can be ordered from GE Jenbacher.

Container fall-protection equipment

If the safety railing, scaffolding and safety steps are not ordered from GE Jenbacher, the CUSTOMER is
responsible for ensuring that corresponding safety equipment is obtained locally.

16 Piping, thermal insulation and expansion joints

16.1 General design

The piping shall be designed according the medium type, temperature and pressure and the permissible flow
velocity. The nominal pressure, permissible pressure losses, hydraulic and static forces have to be considered
when integrating GE Jenbacher engines and auxiliaries. The piping in direct proximity to the GE Jenbacher
engines and auxiliaries shall be designed and installed in accordance with maintenance requirements. For
further information, see ⇨ Section 16.2. CONNECTION POINTS for piping [⇨ Page 31].

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Madl W. Release date: 30/04/2015
Index: 16 Page No.: 30 / 33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0110
Boundary conditions for GE Jenbacher gas engines

The expansion joints for piping shall be selected on the basis of medium, operational ranges, material
compatibility, piping arrangement, piping supports and connection types. The displacements and distance
between CONNECTION POINTS shall be in line with the expansion joint design.
Any compensation of misalignments at flanges or welding points by creating torsion, excessive compression or
offset loads on the expansion joint is not allowed. In accordance with good constructional practice, a mating
flange in the piping system shall not be welded until the expansion joint has been bolted into position.
The sealing used for the piping shall be designed to take account of the nominal pressure, size of flanges,
medium type, temperature and piping material used.
The appropriate tightening torque shall be applied to bolted connections at the MODULE flanges and brackets.
All welding shall be executed, tested and documented in accordance with local standards, regulations and
laws.
The inner surfaces of all pipes, especially welded piping, shall be cleaned before assembly.
The documentation to be prepared in relation to manufacturing, installation, testing and inspection shall
comply with applicable standards, regulations and laws.
The CUSTOMER shall ensure that the latest standards and guidelines are applied.
TA 1400-0131: Piping - shall be followed.

16.2 Mechanical CONNECTION POINTS

For the GE Jenbacher piping interface data, i.e. flange type, nominal dimensions, nominal pressure, location of
the CONNECTION POINTS, flow temperatures and materials, please refer to the applicable drawing(s),
TECHNICAL DIAGRAM(s) and TECHNICAL INSTRUCTIONS.
In accordance with good engineering practice, the first pipe to be connected is the exhaust pipe behind the
turbocharger(s). Here a minimum of axial and lateral displacement of the expansion joint should be observed.
When this step has been completed, the remaining pipes can be connected. The installation of GE Jenbacher
engines has to be executed within the tolerance ranges of the CONNECTION POINTS. Please refer to the
standard tolerances specified in the engine drawing or – where no tolerances have been specified – DIN ISO
2768-1 (1991-06) – General tolerances for linear and angular dimensions.
All forces and moments resulting from pressure and flow of media in piping, static load of the piping, thermal
expansion and vibrations shall be avoided by decoupling the CONNECTION POINTS and supporting points for
GE Jenbacher piping. This statement applies to the engine(s) and all balance-of-plant equipment in the GE
Jenbacher scope of supply.

16.3 Equipotential bonding

Equipotential bonding shall be provided for all electrically conductive parts, including water, gas and exhaust
piping and components (valves, filters, etc.)
The equipotential bonding shall be provided by means of electrical connections between these parts and the
main earthing terminal. The design of the equipotential bonding shall comply with standards including
IEC60364-4-41 (refer to protective equipotential bonding) and IEC60634-5-54 (refer to types of protective
conductors.

16.4 Thermal insulation

The material and design of the thermal insulation for piping, integral components and balance-of-plant
equipment shall be carried out on the basis of the medium, permissible surface temperatures, ventilation
design, maintenance requirements, safety risks and applicable standards, regulations and laws.
The thickness of the insulation is a main constraint and shall be driven by touch protection, heat losses, noise
reduction and economic efficiency.
The insulation shall allow the thermal expansion and movement of the piping. All locations requiring
maintenance shall be provided with removable insulation only.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Madl W. Release date: 30/04/2015
Index: 16 Page No.: 31/33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0110
Boundary conditions for GE Jenbacher gas engines

If the exhaust system components (e.g. silencers) are not provided with thermal insulation, condensation may
form in the exhaust gas. This will lead to corrosion inside the plant, adversely affecting service life.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Madl W. Release date: 30/04/2015
Index: 16 Page No.: 32 / 33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0110
Boundary conditions for GE Jenbacher gas engines

SprungMarke!!!135107988859660427

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Madl W. Release date: 30/04/2015
Index: 16 Page No.: 33/33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0111
General conditions - Operation and Maintenance

NOTICE
Glossary and abbreviations
The glossary and abbreviations can be found in TI 1100-0110: Boundary conditions for GE
Jenbacher gas engines.

1 Scope
This Technical Instruction applies to all GE Jenbacher modules and special products until such time as an
updated version of this document is issued.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Mayer Markus Release date: 30/04/2015
Index: 8 Page No.: 1/9
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0111
General conditions - Operation and Maintenance

2 Purpose
This TECHNICAL INSTRUCTION (TI) contains basic information regarding the operation and maintenance of GE
Jenbacher MODULES and refers to other applicable TIs.

3 Basic conditions
The boundary conditions for GE Jenbacher gas engines as specified in Technical Instruction No. 1100-0110
must be observed. The work specified in the operational-data sheet must be carried out and this sheet must be
filled in correctly. All specified maintenance work must be performed regularly, expertly and on schedule and
knock-free operation must be ensured.

4 Cooler/heat exchanger (GE Jenbacher scope of supply)

When integrated into the hot water system, appropriate measures must be taken to prevent dirt or sediment
building up in the relevant components on the water side.
Refer to the TECHNICAL DIAGRAM and TECHNICAL INSTRUCTIONS for the relevant specifications.

5 CONNECTION POINTS
All conditions at CONNECTION POINTS must be observed and comply as per applicable TECHNICAL DIAGRAM
and/or TECHNICAL DESCRIPTION and the WIRING DIAGRAM, INTERFACE LIST and TECHNICAL SPECIFICATION OF
THE CONTROL SYSTEM. Failure to comply with these requirements may have an adverse effect on the
characteristics of the product and on its reliability of operation and, in the end, restrict or invalidate warranty
claims.

6 Maintenance staff
Work on the plant may only be carried out by specialist staff who have received relevant electrical and
mechanical training. It is possible to conclude service contracts with GE Jenbacher, GE Jenbacher subsidiaries
or authorised specialist contractors.

7 Safety instructions
The safety instructions in DESCRIPTION, OPERATION and MAINTENANCE must be observed. Statutory safety
regulations and accident prevention rules must be observed. Before performing any maintenance work on the
plant, the customer must make sure that the relevant safety instructions are being followed.
See also:
▪ TA 2300-0001: Employee protection [⇨ TA 2300-0001, Page 1]
▪ TA 2300-0005: Safety regulations [⇨ TA 2300-0005, Page 1]
For work which may only be carried out when the engine has been shut down, the system must be shut down
as specified in TI 1100-0105 and measures must be taken to ensure that it cannot be started accidentally.
See also:
▪ TA 1100-0105: Engine shut-down [⇨ TA 1100-0105, Page 1]
▪ Link to TI 2300-0010 Guidelines for using the LOTO kit [⇨ TA 2300-0010, Page 1]
The CUSTOMER is responsible for ensuring that the workplaces provided for service and maintenance purposes
are adequately lit. Additional mobile lighting must be provided if necessary.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Mayer Markus Release date: 30/04/2015
Index: 8 Page No.: 2 / 9
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0111
General conditions - Operation and Maintenance

8 Cleanliness when working on GE Jenbacher plants

▪ When working on GE Jenbacher engines, installations and components, always adhere to the strictest
standards of cleanliness.
▪ Thoroughly clean the working area before opening any engine components or parts, and remove all dirt
and deposits on the outside of the engine before opening the engine.
▪ Avoid the ingress of dirt from either outside or inside whenever any servicing or maintenance work is
carried out, e.g.
– deposits inside the engine or other plant components. Any gasket residues or deposits on engine
components must be thoroughly removed using suitable means.
– Dirty tools:
tools must be cleaned before use.
▪ Rotating metal brushes may not be used inside the engine room.
▪ Only clean, approved and undamaged tools may be used (as recommended in "TI 2300-0005: 8 Use of
tools [⇨ Page 8]").

ATTENTION
Contaminants
Components for use or installation on or in the engine should not be cleaned until immediately
before fitting.

▪ Make sure to select the right covers and means of protection for properly carrying out the work.
▪ When fitting components, ensure that all covers on the outside and inside of components and lines are
removed.

DANGER
Foreign bodies, dirt, loose screws or tools
Before recommissioning, ensure that all systems are free from foreign bodies, dirt, loose screws
or tools.
Failure to comply with this instruction can result in serious damage to components or systems or
to personal injury!

NOTICE
Maintenance and overhauling
Observe checklist TI 2102-0020 when carrying out maintenance work or overhauling engines.

9 Risk assessment
The CUSTOMER is responsible for observing and enforcing safety instructions to ensure the availability and safe
use of the plant and equipment. To this end, a risk assessment of conditions on site shall be carried out in
accordance with applicable standards and safety rules as well as local laws, regulations and guidelines.
The CUSTOMER must take the necessary measures to ensure that employees at the plant are only provided
with equipment which is suitable for the conditions pertaining at the workplace and guarantees their health
and safety if used properly.
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Mayer Markus Release date: 30/04/2015
Index: 8 Page No.: 3/9
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0111
General conditions - Operation and Maintenance

The risk assessment will cover approval, planning, assembly, commissioning, operation, maintenance,
servicing, decommissioning and disposal.
The risk assessment of the plant to be performed by the CUSTOMER in accordance with local conditions and
pursuant to local laws and guidelines may give rise to acceptance tests, inspections and maintenance
operations which are not included in the Maintenance Plan. The CUSTOMER is responsible for implementing
and enforcing these additional measures.

10 Start-up conditions
All GE Jenbacher engines are fitted with a preheating system for the engine cooling water. Only preheated
engines with a cooling water temperature of >55°C may be started, loaded and operated at full-load, otherwise
engine damage may result.

11 Failures
When the installation is operational, the engine management system will control the engine and also perform
engine-failure management. The engine-failure management system checks all system variables and will issue
a warning or switch off the installation if certain set values are exceeded or underrun.

ATTENTION
The cause of a TRIPPING fault MUST be rectified before the plant is restarted.
If a failure results in a WARNING being issued, the cause of the failure MUST be
rectified before the failure is reset.
Failure to do this may result in serious damage to the system and may also invalidate any
warranty claim.

Shut down the engine in accordance with TI 1100-0105 and secure it against unauthorised restarting in
accordance with TI 2300-0010.

Critical messages
If the system shuts down with a critical message, the cause of the failure must be rectified before the failure is
reset. The list of critical messages can be found in the “Failure Checklist” section in the DESCRIPTION /
OPERATION book. If one of these messages appears, contact GE Jenbacher of GE Jenbacher Servicepartner
immediately.

Remote acknowledgement
Based on the risk category selected by the CUSTOMER (0-4), failures resulting in the installation being switched
off can be reset using remote access to the visualisation system (max. 5 times every 6 hours' running under
load).
Failures: Diane No.: National Risk category
restrictions
MISFIRING 1047, 3005 - 3024 0
COOLING WATER TEMPERATURE MAXIMUM 1021 * 0
ENGINE ROOM TEMPERATURE MAXIMUM 1135 * 0
FAILURE OF AUXILIARY EQUIPMENT 1129 0
SYNCHRONISING FAILURE 1039 0
SUPPLY WATER TEMPERATURE MAXIMUM 1063 0
MISSING ENGINE RUNNING CONDITIONS 1025 1
STARTING FAILURE 1023 * 1
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Mayer Markus Release date: 30/04/2015
Index: 8 Page No.: 4 / 9
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0111
General conditions - Operation and Maintenance

Failures: Diane No.: National Risk category

restrictions
GAS PRESSURE MINIMUM CONTROLLED GAS SYSTEM 1 1028 * 1
GAS PRESSURE MINIMUM CONTROLLED GAS SYSTEM 2 1030 * 1
MIXTURE TEMPERATURE MAXIMUM 1040
OIL TEMPERATURE MAXIMUM 1043 1
ADMISSIBLE CONTROL DEVIATION OF LEANOX 1080 1
CONTROLLER EXCEEDED
ENGINE COOLING WATER PUMP FAILURE 1090 1
GENERATOR FREQUENCY TOO LOW 1110 1
ACTUAL VALUE MEASURING SIGNAL FAILURE 1113 1
ENGINE SPEED MEASURING SIGNAL FAILURE 1120 1
TECJET GAS QUANTITY JUMP 3099 1
ENGINE OIL LEVEL MINIMUM 1018 2
GENERATOR REVERSE POWER 1038 2
CYLINDER EXHAUST GAS TEMPERATURE DEVIATION 1044 2
FROM MAXIMUM AVERAGE VALUE
CYLINDER EXHAUST GAS TEMPERATURE MAXIMUM 1049 2
EXCESS OVER ABSOLUTE VALUE
COOLING WATER PRESSURE MAXIMUM 1050 2
MIXTURE TEMPERATURE FLUCTUATION SPEED MAXIMUM 1105 2
GENERATOR EXCITER FAILURE 1109 2
NEUTRAL CURRENT MAXIMUM 1112 2
CYLINDER EXHAUST GAS TEMPERATURE MAXIMUM 1049, 2001 – 2020 2
EXCESS OVER ABSOLUTE VALUE
COOLING WATER PRESSURE MAXIMUM 1050 2
CYLINDER 1 MAXIMUM EXCESS OVER ABSOLUTE VALUE 2001 2
CYLINDER X DEVIATION FROM AVERAGE VALUE, 2021 – 2040 2
MAXIMUM POSITIVE DEVIATION
CYLINDER X DEVIATION FROM AVERAGE VALUE, 2041 – 2060 2
MAXIMUM NEGATIVE DEVIATION
GAS PROPORTIONING VALVE CAN LINK FAILED 3093 2
OIL PRESSURE MINIMUM 1017 3
MISSING POWER SIGNAL 1041 3
OIL FILTER DIFFERENTIAL PRESSURE MAXIMUM 1059 3
GAS MIXER CONTROL FAULTY 1083 3
BACKFIRE PROTECTION 1128 3
ALL OTHER FAILURES NOT LISTED IN RISK CATEGORIES 0 4
– 3.
* Due to national restrictions, risks listed in category 0 and 1 may be promoted to category 4 risks.
Single or multiple resetting of all other trip-generating failures without remedying the cause first will result in a
considerable potential risk of injury or damage. The CUSTOMER (or the party responsible for the remote
resetting) will be entirely liable for such injury or damage.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Mayer Markus Release date: 30/04/2015
Index: 8 Page No.: 5/9
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0111
General conditions - Operation and Maintenance

12 Recording operational data, maintenance record sheet

It is mandatory for all operational data to be recorded and all out-of-the-ordinary events to be described.

ATTENTION
Interpretation and plausibility of data
It is not enough merely to record the facts in writing. The data should be compared with the
commissioning data and its plausibility verified. In case of deviations, abnormal noises etc. the
cause must be investigated and rectified. If you cannot find the cause, GE Jenbacher or GE
Jenbacher Servicepartner should be notified immediately.

It is in the CUSTOMER's best interests to maintain and record operational data (maintenance record sheet,
operational data journal, data recorded in the MAINTENANCE file). Properly maintained operational data
journals and data record sheets are important documents, enabling analysis and support in case of failures.
Moreover, these documents are also important when deciding on warranty claims.

13 Spare parts
Only original GE Jenbacher-spare parts (e.g. oil filters!) should be used. Warranty claims in respect of defects
and damage will be invalidated by the use of non-original spare parts.

NOTICE
Scheduling spare parts requirements
In order to avoid unscheduled downtimes due to maintenance work, it is strongly recommended
that a stock of spare parts be held.

14 Lubricating oil
GE Jenbacher does not guarantee any guaranteed fixed oil change intervals. The lubricating oil in GE
Jenbacher gas engines must be changed depending on its condition. It is the CUSTOMER's responsibility to take
all necessary measures to ensure the protection and safe operation of the plant and guarantee the plant's
availability.
The oil service life (depending on gas quality, mean pressure, engine type, oil consumption, oil temperature and
oil type) can be prolonged by fitting an additional oil tank. If premature wear is claimed, the results of the
lubricating oil analysis, subject to the limit levels laid down in Technical Instruction No. 1000-0099B, must be
presented in full, even after the warranty period has expired.

15 Spark plugs
No specific maintenance interval is specified for spark plugs. IW 0309 describes the inspection and
maintenance procedure.
Spark plug service life depends on the boundary conditions of the plant (e. g. type of spark plugs, gas type,
mean pressure, gas mixing temperature, ignition system, emission limits). It is the CUSTOMER's responsibility to
take all necessary measures to ensure the protection and safe operation of the plant and guarantee the plant's
availability.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Mayer Markus Release date: 30/04/2015
Index: 8 Page No.: 6 / 9
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0111
General conditions - Operation and Maintenance

16 Elastomer components
Elastomer components age and become brittle, even when engines are not operational. That is why the service
life of these components does not depend solely on the length of time for which the module has been in
service, the cooling water temperature and pressure, etc. With a normal running time of 5,000-6,000 Oh
annually and a maximum cooling water temperature of 90°C, all elastomer components are replaced at the
intervals specified in the maintenance plan. If this number of operating hours is not reached, the elastomer
components (e.g. O-rings at cylinder liners, elastic couplings etc.) should still be replaced as a precautionary
measure after a maximum of 5 years.

17 Decommissioning the plant

When prolonged scheduled or unscheduled downtimes occur, such as after the heating season in power
plants, the engine systems must be prepared (preserve, change old lubricating oil, close off the flue-gas
connection, etc.) for their downtime according to their geographical location (climate, proximity to the sea, gas
type, etc.)
As conditions can vary enormously, we recommend that you consult a suitable specialist firm concerning the
measures to be taken or contract it to carry out the work.
Before recommissioning the plant, you must make sure that it has been restored to its normal operational
condition.

18 Welding work on the module

ATTENTION
Damage to ignition rail caused by welding work
Before any welding work is carried out on the generating set, the ignition rail must be removed to
prevent any possible damage to it and it must be stored in a dry place. The ignition rail may not
be refitted and correctly connected until the welding work on the generating set has been
completed.

Always make sure to attach the negative pole as close as possible to the weld location when carrying out
welding work on the generating set – not on the mass connection (earth cable) though.
Only specifically qualified technical staff may perform welding work (regional regulations must be observed).
Furthermore, additional requirements and regulations must be observed for the welding of gas lines.

19 Components coming into contact with exhaust gas

All parts that come into contact with exhaust gas are state-of-the-art materials with a specified service life.
Due to the different operating modes and different fuel gas content (including traces of harmful substances),
no binding guarantee can be given on the service life of components such as the exhaust manifold, etc. Where
silencers are situated in the open air without external heat insulation, condensate (acid, water) can occur even
in installations without heat exchangers (hot exhaust gases) and shorten the service life. This also applies to
silencers with internal insulation, where the temperature in the rock wool insulation can fall below the dew
point.

20 Consumables
The service life and safe operation of the plant depend to a considerable extent on the consumables used. Only
use consumables such as fuel gas, engine cooling water, warm water, anti-freeze agent, anti-corrosive agent,
lubricating oil, etc. as specified in the respectiveGE Jenbacher Technical Instructions.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Mayer Markus Release date: 30/04/2015
Index: 8 Page No.: 7/9
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0111
General conditions - Operation and Maintenance

21 Fuel gas quality

The CUSTOMER is obliged to check the quality of the fuel gas in terms of thermal value, methane number and
content of harmful substances at regular intervals. If these values differ from the values stipulated in the
contract, immediate measures must be taken by agreement with GE Jenbacher or GE Jenbacher
Servicepartner. If the content of harmful substances increases (e.g. sewage gas, landfill gas) the lubricating oil
can become heavily acidified within a fraction of the normal oil change interval and acute or irreparable
damage and increased wear occur all of a sudden, for example on cylinder liners and bearings and/or oil
consumption increases.
If the methane number fluctuates downwards (within the range stipulated in the contract) the engine is
protected against harmful knock operation by the engine control system (automatic ignition point adjustment,
power reduction).

NOTICE
Optimum engine configuration
During the commissioning process the engine is adjusted to the optimum setting for the
methane number given at that time.
If the methane number increases after commissioning (for a prolonged period or a major part of
the plant's operating time) the engine setting should be adjusted so as to optimise operational
efficiency. This task must be carried out by GE Jenbacher or GE Jenbacher Servicepartner.

22 J624 TSTC turbocharger unit

ATTENTION
Turbocharger unit
Safety cannot be assured in the event of improper use.

This pressure equipment is part of the generating set and may only be used in the intended manner. The entire
engine and generating set documentation therefore applies in addition to these Instructions and must be taken
into account as well.
Use of the pressure equipment is only permissible if the stated limits are observed.
Information for use:
▪ The CUSTOMER must arrange for recurrent tests in accordance with local conditions and pursuant to local
laws and guidelines.
▪ The introduction of additional loads (lifting, pushing) is prohibited.
▪ No welding, heat treatment or metal-cutting machining may be carried out on the cast parts.
▪ The bolted joints between the cast parts must never be touched in any way, unless instructed in the
maintenance instructions.
Since these are open pressure equipment items, static overpressures are not possible. However, to avoid
exceeding the design pressures during engine operation, bypass valves and pressure sensors must be fitted.
They must be fully functional.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Mayer Markus Release date: 30/04/2015
Index: 8 Page No.: 8 / 9
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0111
General conditions - Operation and Maintenance

23 Maintenance Intervals
The intervals stated in the maintenance plan are average empirical values. Where there is a lack of proper
operation and maintenance (such as poor oil management, large accumulations of dust or other problematic
external influences), the intervals specified in the Maintenance Plan may not be reached and have to be carried
out at much shorter intervals.
The above can only be judged by the CUSTOMER. If irregularities are found during the daily inspection,
especially during the warranty period (abnormal sounds or noises, etc.), the operator must take action to
minimise any risk of damage (e.g. by immediately switching off the engine, investigating the cause of the
irregularity and rectifying it, and/or notifying the GE Jenbacher customer service department).

NOTICE
Scheduling of maintenance work
Upcoming maintenance work must be carried out before the maintenance interval is reached.
Maintenance work must be scheduled in advance and if necessary carried out before the
maintenance interval is reached to achieve fault-free operation or to avoid interruptions in
operation, for example, during the heating season.
Maintenance intervals may not be extended to avoid downtime during the heating season.

24 Documents from original equipment manufacturers

The customer documentation from GE Jenbacher contains documents from the original equipment
manufacturers for certain bought-in parts in addition to GE Jenbacher documents.
The following must be observed in relation to this:
▪ The appropriate information and documents from the original equipment manufacturer are taken into
account when drawing up GE Jenbacher documentation.
▪ In the event of discrepancies between GE Jenbacher documents and enclosed documentation from the
original equipment manufacturer, the GE Jenbacher documentation shall take priority (including any
appropriate Technical Instructions, maintenance plans and maintenance etc.)
▪ Any documents from the original equipment manufacturer that are provided are supplementary to the GE
SprungMarke!!!63050394822979979
Jenbacher documentation and should be observed in addition to this.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Mayer Markus Release date: 30/04/2015
Index: 8 Page No.: 9/9
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0113
Cleanliness During Service Work Involving Clean Oil Parts

1 Scope
This Technical Instruction applies to GE Jenbacher generating sets.

2 Purpose
This Technical Instruction tells you what to do during service work involving clean oil parts and work that could
have an effect on the clean oil circuit.

3 Note

NOTICE
Failure to observe this Technical Instruction could result in contamination which could
subsequently cause massive damage to the engine!

The Technical Instructions listed below must also be observed:

▪ General conditions – Operation and maintenance, TI 1100-0111 → Dealing with cleanliness.
▪ Checklist for engine repair and overhaul, TI 2102-0020 → Ensuring faultless work when carrying out deep
interventions - especially those relating to the clean oil circuit - on engines.
▪ Storage and handling of fresh oil for GE Jenbacher gas engines, TI 1000-0099L → handling engine oil.

4 Definition of clean oil circuit

The following areas/parts are in direct contact with clean oil:

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bilek F. Responsible: Anderson B. Release date: 06/11/2014
Index: 2 Page No.: 1/3
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0113
Cleanliness During Service Work Involving Clean Oil Parts

▪ Cylinder head
▪ Camshaft including camshaft bearings
▪ Crankcase bores
▪ Oil-carrying bores and ducts in various cover plates
▪ Oil bores and ducts in the crankcase
▪ Main bearings
▪ Big-end bearings
▪ Connecting rod
▪ Crankshaft
▪ Valve gear - tappets, push rods, rocker arms, etc.
▪ Oil supply lines
▪ Turbocharger assembly and console
▪ Oil filter and oil filter assembly
▪ Piston cooling nozzles

5 Handling newly supplied spare parts that affect the clean oil circuit
Parts that have a direct or indirect effect on the clean oil circuit must be handled with extreme care. Before
starting work on the engine, you should first check that the parts are in a good and usable condition and then
repack them properly to protect them until they are actually used. Before installing the parts, give them a visual
inspection (if necessary, using an endoscope) and where appropriate check them by feel.
Dirt, burrs and other possible contaminants could cause a malfunction. In such cases, you should always check
whether it is possible to rectify the situation. Otherwise, you should consult the GE Jenbacher Helpdesk
department. You should also always report defective shipments so that they can be improved in future.

6 Four-eyes principle
All work involving clean oil must be subject to the four-eyes principle in order to prevent defects or
contaminants from being overlooked.

7 Covers and protecting the clean oil circuit

All areas of the engine in which clean oil parts or clean oil zones are opened must be covered immediately.
Suitable plastic or rubber covers and residue-free adhesive tape can be used as coverings.
The crank pins on the crankshaft must be handled in a particularly sensitive way. They must be covered as
soon as they are removed from the connecting rod. You are recommended to use the official GE Jenbacher
plastic covers for this. If they are not available, use an alternative, fibre-free material.
Irrespective of the type of cover used, you must ensure that it has been cleaned to remove all residues.
Generally, rotating metal brushes should not be used in the engine room.
Other rotary cleaning methods are not permitted in the engine room as cleanliness cannot be guaranteed, due
to particles flying around. Where it is not possible to remove the component to be cleaned and taken to a
separate room and, at the same time, a different cleaning method is not possible, the utmost care must be
taken to cover it exactly to prevent dirt and foreign bodies from getting into the clean oil system. This rule does
not apply to rotating metal brushes.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bilek F. Responsible: Anderson B. Release date: 06/11/2014
Index: 2 Page No.: 2 / 3
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0113
Cleanliness During Service Work Involving Clean Oil Parts

8 Handling main and connecting rod bearing shells

Do not wear safety gloves when handling main and connecting rod bearings. You are exceptionally allowed
to take off your gloves, but only for the direct handling of these bearing shells. This includes inspecting,
lubricating and inserting the bearing shells.
You must put on the safety gloves again for all other work.

9 Cleaning material to be used

It is important to use the correct cleaning material. "Cleaning material" means direct cleaning material such as
cleaning cloths but also includes indirect cleaning material such as cup brushes, rotating metal brushes and
emery paper. Chemicals are not counted as cleaning material and are dealt with separately.
These materials must be available on site for work on the engine at 10,000 hour service intervals and for
repairs. Where these materials are not obtainable on site, you can order them from GE Jenbacher as part
number 1210145. They can be precisely those listed below or equivalent materials.
Qty. Unit Description Manufacturer Manufacturer code
1 Roll Cleaning paper 380x380 mm ALBW 11338-01
1 Roll Oil-absorbent roll 400x460 mm ALBW 80006-00
1 Box ZETPUTZ fleece cloth 33x35cm ALBW 10111-01
1 Each Back-up pad 75 mm - M14 ROLOC 3M 3M 784999
5 Each Buffing wheel 3M, 75 mm, 120 grain 3M 707529
5 Each Buffing wheel 3M, 75 mm, 80 grain 3M 707527
5 Each Surface grinder, 60x40x6 mm, 80 grain Bibielle RG0386
5 Each Surface grinder, 60x40x6 mm, 120 grain Pferd 44510126
5 Each Surface grinder, 30x20x6 mm, 80 grain Pferd 44412086
2 Each Cup brush, 125 mm Rial 487117
10 Each Abrasive fleece pad, 152x229 mm, fine, red 3M 762147
1 Each Abrasive cloth roll, 80 SIA 341584170080
1 Each Abrasive cloth roll, 120 SIA 341584170120
1 Each Abrasive cloth roll, 400 SIA 341584170400
SprungMarke!!!9007206124027787
1 Each End brushes for power drill, 23 mm Lessmann 453,161

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bilek F. Responsible: Anderson B. Release date: 06/11/2014
Index: 2 Page No.: 3/3
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0114
Installation of electrical equipment for GE Jenbacher generator sets

1 Area of application
This TECHNICAL INSTRUCTION (TI) applies to all GE Jenbacher generator sets and special products, unless a
modified version of this document is provided.

2 Purpose
This TI describes the technical requirements when installing electrical equipment for GE Jenbacher generator
sets. The content of this document can be used to assist in the design and construction of the systems
described, and in cases of damage can act as a basis for judging warranty claims.

3 Protective measures for installing high-voltage circuits

▪ TI 1000-0515: Protective measures for installation of high-voltage circuits [⇨ TA 1000-0515, Page 1]

4 Customer’s control power supply

Voltage: 24 VDC *
Ripple: Max. USS 2.4 V
* At least 22 V, maximal 30 V at GE Jenbacher–terminals inclusive of ripple

5 Starting system (Batteries)

Only applicable to engines with electric starter motors
▪ TI 1000-0050: Initial commissioning-up and maintenance of acid-filled lead storage batteries [⇨ TA
1000-0050, Page 1]
▪ Link to TI 1000-0052, TRIO-PS/3AC/24DC/40 battery charger [⇨ TA 1000-0052, Page 1]

6 EMC cabling and cable dimensions

▪ TI 1000-0505: EMC routing of wiring and earth connections to/between engine modules and control
cabinets [⇨ TA 1000-0505, Page 1]

7 Handling electronic components

▪ TI 1000-0510: Handling of electronic components/modules [⇨ TA 1000-0510, Page 1]

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Krainz G. Release date: 10/11/2014
Index: 1 Page No.: 1/7
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0114
Installation of electrical equipment for GE Jenbacher generator sets

8 Energy output cable at the generator

Generator power cable:
The diameter of the power cables must be determined or checked in accordance with VDE 298, Parts 1 - 4
(cabling method, bundled cables, etc.) or IEC 364-5-523 by the company carrying out the work. Generator
current: IN = ..... A, where cos phi = 0.8.
The connection guidelines laid down by the generator supplier must be observed.
When connecting the cable, make sure that no force is exerted on the generator terminals.
This also applies during assembly.
Sufficient free cable length must be provided between the generator and foundation / junction box to
compensate for the relative movement between the generator and foundation / junction box.

To enable insulation resistance tests at generator cables, these must be disconnected from the generator.

8.1 Low-voltage generators

The output cable must be laid horizontally on the specified side.

Under no circumstances should the output cable be run vertically upward through the terminal-box cover.
Output using cable:
Use flexible finely stranded copper conductors (no aluminium conductors).
The individual conductors must at least comply with Class 2 (Class 5 recommended) of IEC 60228/ CENELEC HD
383/ VDE 0295.
Cable terminal lugs:max. 45 mm wide (because of distance between connection bar holes).
Screwed cable glands: Nickel-plated brass Plastic glands may only be used in exceptional cases if highly-
flexible Class 5 rubber leads are used and it can be ensured that no static loads are applied to the gland, such
as the dead weight of the cable. (Plastic cable glands subjected to loads cannot withstand vibrational loads for
extended periods).
Output using bus bars:
To ensure that vibrations are not transmitted on and to compensate for any movements of the module, short
high-flexibility cable connections must be installed between the generator connection bars and the output
bars.
Note: compensators such as the wire mesh type have in practice been unable to withstand the vibrational
loadings in the long term.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Krainz G. Release date: 10/11/2014
Index: 1 Page No.: 2 / 7
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0114
Installation of electrical equipment for GE Jenbacher generator sets

8.2 Medium-voltage generators

1 4

Principle sketch: Energy output with cable sealing ends and strain-relief brackets
① Isolators ④ Threaded joint
② Sealing ends ⑤ Middle tension cable with free cable length
③ Depending on the generator type, strain-relief
brackets can also be mounted outside the
connection box.

In the case of elastically-mounted modules (see drawing) sufficient "free cable length" must be provided to
compensate for the movement of the module when starting, stopping and shutting off full load. In order to
ensure that no load is placed on the terminal clamps as a result of this movement, a cable fastening must be
introduced using the strain-relief brackets intended for that purpose. This cable fastening must be rigid and
should be linked to the moving generator set to prevent cable fastening movements with respect to the
terminal clamps (isolator).

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Krainz G. Release date: 10/11/2014
Index: 1 Page No.: 3/7
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0114
Installation of electrical equipment for GE Jenbacher generator sets

Medium-voltage cable:
Flexible, finely stranded single-core cabling must be used.
Conductor stranding: Class 5 in accordance with IEC 60228/ CENELEC HD 383/ VDE 0295.
Recommended cable for medium-voltage generators:
e.g.:
▪ FELTOFLEX NTMCWOEU (single-core cable),
manufacturer: Draka Industrial Cable GmbH http://www.draka.dk/cableteq/pdf/7_11.pdf
▪ PROTOLON NTMCGCWÖU (single-core cable),
http://www.prysmian.com
Cable sealing ends for generator connection >4.2 kV:
The available space between the terminal clamps (isolator) and the strain relief brackets is approx. 320 mm.
Consequently, only "short" sealing ends are involved.
Recommended sealing ends:
e.g.: - 3M QUICK TERM III (24kV)
Set 93-EP630-1 for 95 – 240 mm² Cu at 6 - 13.8 kV
(For more information: www.3M-elektro.de)
- Raychem (17.5 kV)
Set TFTI 4131 for 95 – 240 mm² Cu at 6 – 13.8 kV
(For more information: http://energy.tycoelectronics.com/countryselector.asp)
Generator connection without cable sealing ends for voltages <= 4.2 kV
Screened medium-voltage cables are not necessary for voltages < 4.2 kV Appropriate shrink tubing can be
used instead of sealing ends.
Connectable power cables:
Nominal voltage Rated current Connection cable / phase Connection cable / star
point
3.3 kV and 4.16 kV < 840 A 1 unscreened cable 1 unscreened cable
3.3 kV and 4.16 kV > 840 A 2 unscreened cables 1 unscreened cable
> 4.16 kV < 500 A 1 screened cable 1 screened cable
> 4.16 kV > 500 A 2 screened cables 1 screened cable

Cable terminal lugs:

These should be dimensioned in such a way that they are suitable for the powers (vibrations) occurring in the
generator.
Recommended (short) press cable sockets:
Nexans Company: Type KU-F-V (more information at www.nexans.com or www.gph.net)
Screwed cable glands: nickel-plated brass (no threaded plastic connections) or the built-in rubber glands.
Cable connection as per DIN 46200
Elastic components such as spring washers, dished washers, or aneroid diaphragms may be installed, but only
on one side of the clamped conductor. Washers may also need to be used. The other side is reserved for
conducting power, so only washers or safety plates made of a copper/zinc alloy (brass) can be used. Materials
which are at least equivalent in terms of electrical and mechanical properties are to be used.
When connecting lugs, the lugs must be protected with washers on both sides to prevent bending.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Krainz G. Release date: 10/11/2014
Index: 1 Page No.: 4 / 7
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0114
Installation of electrical equipment for GE Jenbacher generator sets

Tightening torques:
Insulated supports for indoor systems

Tightening torque M12

Tightening torque M16
Hexagonal head screw: steel 8.8

Capacitor-type terminal to DIN 46265

Tightening torque M12

Tightening torque M16
Connecting bolts: Ms
Connecting nuts: Ms

See also
• Key to Symbols [⇨ 1.2, Page 1]

9 Generator protection against transient surge voltages

High voltage transient surges caused by vacuum breaker switching operations or lightning strikes on power
lines can damage the insulation of generator windings and measuring equipment.
The provision of generator overvoltage protection is therefore an absolute necessity. Assessing the overvoltage
risks and designing adequate protective equipment is the responsibility of the design engineer for the plant.
Protection level: The impulse voltage withstand level of the main insulation and of the interturn insulation of
rotating AC machines is defined in the following standards:
- IEC 34-17 for low-voltage machines with wire windings
- IEC 34-15, IEC 71-1 and IEEE C62.21 for medium and high-voltage machines with bar windings
Overvoltage protection design for low-voltage generators with wire windings: The limit curve in Fig. 7 of
Section 9 in IEC 34-17 applies. The peak value of the voltage transients at the generator terminals with a rise
time less than or equal to 0.2 microseconds must be reduced to 1 kV, and that of those with a rise time of 0.8
microseconds, to 1.3 kV.
Overvoltage protection design for medium-voltage generators with bar windings: The peak value of the
voltage transients at the generator terminals with a rise time less than or equal to 0.2 microseconds must be
reduced to a value below the following:
Peak value in kV = 0.65 × (4 × U Ph-Ph + 5kV).
e.g. for an 11 kV generator: 0.65 × (4 × 11 + 5) = 31.8 kV
This can be achieved using a combination of capacitors and varistors/resistors.
Info: Although varistors limit the voltage peak value, they have no effect on the rise time of voltage transients
and therefore do not protect the interturn insulation. Capacitors, on the other hand, lengthen the rise time of
the voltage pulses so that the pulse voltage is spread over a greater portion of the winding which reduces the
individual interturn voltages.
The installation of separate interconnected capacitors and varistors or the use of combined elements is
therefore necessary.
Examples of combined high-frequency overvoltage surge suppressors:
- PROTEC Z from NTSA – Defined Power Protection http://www.ntsa.co.za/protecz.html or

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Krainz G. Release date: 10/11/2014
Index: 1 Page No.: 5/7
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0114
Installation of electrical equipment for GE Jenbacher generator sets

- ZORC from STRIKE technologies ltd. http://www.strike.co.za/Products_zorc.html

Place of installation: Surge suppressors provide the best protection against voltage surges and lightning
strikes when they are installed as close as possible to the generator in order to maintain the properties of the
capacitor. (Recommended: < 25 m). If the cables to the arrester are too long, its property of lengthening the
voltage pulse starts to decrease. Installation in the generator is not possible for vibrational reasons. A separate
earth cable with a resistance of less than 0.5 ohm must be run between the surge suppressor and the
generator housing.
The detailed design of adequate protective equipment, and specifying its installation location / distance from
the generator, are the responsibility of the plant designer.

10 Cabling for current transformers

Due to the danger of overvoltages, current transformers may not be operated with open secondary
terminals but only with these short-circuited or with a rated burden at the most.

Current transformer cores output:

The rated output on the rating plate (in VA) is the product of the rated burden (in ohms) and the square of the
secondary rated current (in A).
If the operating current is less than the rated current, the secondary output of the current transformer
decreases quadratically.
Example: On a current transformer with a rated output of 15 VA and a load of half the rated current, the output
decreases to one quarter, i.e. 3.75 VA.

Rated outputs of current transformers and maximum permissible burdens:

Rated output Max. permissible burden
10 VA 10 Ohm
15 VA 15 Ohm
20 VA 20 Ohm
30 VA 30 Ohm
Secondary rated current 1 A

Rated output Max. permissible burden

10 VA 0.4 Ohm
15 VA 0.6 Ohm
20 VA 0.8 Ohm
30 VA 1.2 Ohm
Secondary rated current 5 A

Taking into account the measuring and protective equipment connected by GE Jenbacher, the following
minimum cross-sections are necessary for the cabling between the current transformers and GE Jenbacher:
Current transformer rated Current transformer cabling Minimum cross section of current
output length transformer cabling
10 VA up to 100 m 2.5 mm2
15 VA up to 100 m 2.5 mm2
20 VA up to 100 m 2.5 mm2

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Krainz G. Release date: 10/11/2014
Index: 1 Page No.: 6 / 7
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0114
Installation of electrical equipment for GE Jenbacher generator sets

Current transformer rated Current transformer cabling Minimum cross section of current
output length transformer cabling
30 VA up to 100 m 2.5 mm2
Secondary rated current 1 A

Current transformer rated Current transformer cabling Minimum cross section of current
output length transformer cabling
up to 30m
10 VA up to 30 m 4 mm2
15 VA up to 30 m 2.5 mm2
20 VA up to 30 m 2.5 mm2
30 VA up to 30 m 2.5 mm2
up to 50m
10 VA up to 50 m 10 mm2 #)
2
15 VA up to 50 m 4 mm
20 VA up to 50 m 4 mm2
30 VA up to 50 m 2.5 mm2
up to 100m
10 VA up to 100 m 16 mm2 #)
15 VA up to 100 m 10 mm2 #)
2
20 VA up to 100 m 6 mm #)
2
30 VA up to 100 m 4 mm
Secondary rated current 5 A
#) these marked combinations should be avoided if at all possible.
SprungMarke!!!9335698187

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Krainz G. Release date: 10/11/2014
Index: 1 Page No.: 7/7
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0005
Safety regulations

1 Scope ........................................................................................................................................................... 1
2 Purpose ....................................................................................................................................................... 1
3 General ....................................................................................................................................................... 2
4 Safety signs hazard classification system ........................................................................................... 2
5 Health and safety during operation and maintenance ..................................................................... 3
6 What to do in the event of an alarm ..................................................................................................... 4
6.1 Evacuation alarm (gas alarm, fire alarm, CO alarm, gas pre-alarm) ................................................ 4
6.2 CO pre-alarm............................................................................................................................................................... 5
7 Personal protection .................................................................................................................................. 5
8 Use of tools................................................................................................................................................. 8
9 Transporting - lifting - installing............................................................................................................ 8
10 Shutdown procedure and making safe................................................................................................. 8
11 Engine room............................................................................................................................................. 12
12 Components............................................................................................................................................. 17
12.1 Exhaust gas system................................................................................................................................................ 17
12.2 turbocharger ............................................................................................................................................................. 18
12.3 Fuel gas system (gas and dual-fuel engines only) ................................................................................... 19
12.4 Diesel fuel system (diesel and dual-fuel engines only)........................................................................... 20
12.5 Cooling system ......................................................................................................................................................... 21
12.6 heat exchanger ........................................................................................................................................................ 23
12.7 Slam Valve .................................................................................................................................................................. 24
12.8 Lubrication system ................................................................................................................................................. 24
12.9 Control system.......................................................................................................................................................... 26
12.10 Ignition system ......................................................................................................................................................... 26
12.11 Cables and insulated wiring ............................................................................................................................... 27
12.12 Throttle valve............................................................................................................................................................. 27
12.13 Electrical connections ........................................................................................................................................... 27
12.14 Generator .................................................................................................................................................................... 28
12.15 Electrical cabinets ................................................................................................................................................... 29
12.16 Acoustic insulation (container; sound absorber hood) .......................................................................... 31
12.17 Battery .......................................................................................................................................................................... 31
12.18 Container/enclosure .............................................................................................................................................. 32
13 Maintenance and servicing................................................................................................................... 33
14 Cleaning.................................................................................................................................................... 35
15 Disposal requirements for waste electrical and electronic equipment ....................................... 36

1 Scope
This Technical Instruction applies to all Firmenname and GE Distributed Power plants.

2 Purpose
This Technical Instruction sets out the general safety regulations.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Hochrainer Responsible: Färber Jörg Release date: 22/07/2014
Index: 6 Page No.: 1/36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0005
Safety regulations

3 General
The operating and maintenance instructions contain basic safety signs,
requirements and directions which must be observed during the delivery,
setting-up, commissioning, operation and maintenance of machinery.GE
Jenbacher These documents must be read and understood by the user
before starting the machinery. The most recent edition of the operating
instructions must always be available at the machine.

The information contained in the safety instructions below is intended to provide you with an overview of
danger zones and possible causes of accidents.
Despite an inherently safe design and the use of technical and supplementary protective measures, residual
risks remain, which are referred to in this TI.
While the instructions below are intended for your safety, they cannot cover in detail the scope of all accident
risks posed by industrial machinery.

When operating this machinery it is your duty to comply with all current official and quasi-official safety rules
and codes applicable to your sector. You should also use your own powers of judgement to avoid hazards and
dangerous situations.
Most accidents are caused when people disregard simple, basic safety rules.

Any manipulation of the machine or its control cabinets which causes the machinery to operate outside of its
specified operating range (control range), is prohibited and could result in serious indirect damage.

Any modifications of the item supplied, including changes to the program and software, which are carried out
by the customer or third parties without GE Jenbacher prior consent will result in the lapse of any right to
damages or the exercise of a warranty claim against GE Jenbacher.

4 Safety signs hazard classification system

The pictograms with hazard classification used in this document are also used on GE Jenbacher products.
They refer to each of the hazards as described in this document.
DANGER (ISO DIS 3864-2)
denotes a high-risk hazard. If this hazard sign is
ignored, death or severe injury will follow as a direct
consequence.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Hochrainer Responsible: Färber Jörg Release date: 22/07/2014
Index: 6 Page No.: 2 / 36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0005
Safety regulations

WARNING (ISO DIS 3864-2)

denotes a medium-risk hazard. If this hazard sign is
ignored, death or severe injury may result.

CAUTION (ISO DIS 3864-2)

denotes a low-risk hazard. If this hazard sign is
ignored, minor or moderate injury may result.

NOTICE(similar to ANSI Z535.2)

denotes information directly or indirectly relating to
the safety of employees or measures to protect the
machinery. If this hazard sign is ignored, breakdowns
or material damage may result.

5 Health and safety during operation and maintenance

The customer will take all necessary precautions to ensure the safety of the contractors personnel at the site.
This includes provision of the safety instructions of the customer for review by the contractor, safety training by
the customer, proper safe handling and disposal of hazardous substances and the protection of the
contractors personnel from exposure to such substances, activation and deactivation of all power systems
(electrical, mechanical and hydraulic) using a safe and effective lock-out tag procedure, and conducting
periodic safety meetings.

The contractor will comply with reasonable health and safety requirements imposed from time to time by the
customer at the facility.

The contractor may conduct occasional safety audits to ensure that safe conditions exist and make
recommendations to the customer concerning such conditions. Neither the performance or non-performance
of safety audits nor the making of any recommendation by the contractor will relieve the customer of the
responsibility to provide a safe place to work. If the contractor's staff require medical attention, the customer's
local facilities will be made available to the contractors staff for as long as necessary.

If, in the contractors opinion, the safe performance of work at the site is or may be endangered by local
conditions, the contractor may remove some or all of its staff from the site and/or supervise performance of all
or any part of its work and/or evacuate its staff. The customer will assist with any such evacuation.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Hochrainer Responsible: Färber Jörg Release date: 22/07/2014
Index: 6 Page No.: 3/36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0005
Safety regulations

The operation of equipment at the site will be the responsibility of the customer. If the customer requires or
permits the contractor's staff to operate equipment at the site, the customer will indemnify the contractor, its
employees and agents for all costs and liability (including any reasonable attorney's fees) incurred by or
imposed upon the contractor, its employees and agents, based upon injury to persons (including death) or
damage to property resulting from the operation of equipment at the site by the contractors staff.

If the customer provides the contractors staff with any tools and equipment to perform work at the site, these
tools and equipment must be in a safe working condition (i.e. subject to inspections and preventive
maintenance). Tools must also conform to the GE Jenbacher standard.

If the contractor encounters any hazardous material at the site which requires special handling and/or
disposal, the customer will immediately take whatever precautions are required to legally eliminate such
hazardous conditions so that the work under contract may proceed safely. The customer must ensure that all
hazardous materials produced or generated in the course of the contractors work at the site are removed.

All decontamination necessary for the contractors work (including any repair work) will be performed by the
customer.

6 What to do in the event of an alarm

6.1 Evacuation alarm (gas alarm, fire alarm, CO alarm, gas pre-alarm)
Evacuation alarm as specified in ISO 8201/minimum duration 180 seconds.

Off

a b a b a c a

Cycle Time, s

a Phase a signal is "on" for 0,5 s ± 10%

b Phase b signal is "off" for 0.5 s ± 10%
c Phase c signal is "off" for 1.5 s ± 10% (c = a + 2b)
Cycle Length of cycle: 4 s ± 10%

▪ Leave the affected area immediately. Go out into the fresh air (outdoors) right away and congregate at
the designated assembly point.
▪ Shut off the diesel fuel supply and/or close the gas safety shut-off valve outside the engine room and
outside the danger zone and make sure that they cannot be opened unintentionally.
▪ Call the fire brigade.
▪ Do not re-enter the affected area.
▪ Wait for the fire brigade to arrive.
▪ Warn other people about the danger.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Hochrainer Responsible: Färber Jörg Release date: 22/07/2014
Index: 6 Page No.: 4 / 36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0005
Safety regulations

▪ Do not re-enter the affected area until the danger has been eliminated with the professional
assistance of the fire brigade, the fault or damage professionally rectified, all enclosed spaces
thoroughly ventilated and the area has been declared safe to re-enter.
Bear in mind that ambient and operating conditions differ from plant to plant and the general rule is that,
before work starts in plants using poisonous gases, the operator of the plant should draw up an
EMERGENCY PLAN which takes these specific conditions into account. The relevant statutory regulations must
also be taken into account. This emergency plan must be brought to the attention of all persons employed at
the plant, evidence of which must be available.

An emergency plan will generally consist of at least the following information:

▪ Emergency regulations (what to do, evacuation, escape routes, assembly point, etc.)
▪ Local emergency telephone numbers (rescue, emergency doctor, fire brigade)
▪ People to be notified in the event of an emergency
▪ Location of breathing apparatus independent of ambient air or an escape mask (gas mask with a suitable
filter)
▪ Other necessary safety information as laid down in statutory regulations, etc.

6.2 CO pre-alarm
Shut off the diesel fuel supply and/or close the gas safety shut-off valve outside the engine room and make
sure that they cannot be opened unintentionally. Leave the engine to run until it stops of its own accord due to
lack of fuel. The ventilation is set to maximum by the engine control system. Call in professionals to look for the
gas leak and initiate damage repair.

7 Personal protection
TI 2300-0001 – Employee protection
The operation of the plant or work on the plant may only be carried out by
specialist staff having relevant electrical and mechanical training.

Access to the machine room is restricted to persons (specialist staff) who

have read, understood and who observe the safety instructions.

Prohibition, hazard, mandatory and warning signs must be obeyed at all

times. Any failure to do so may result in injury and death or damage to the
machinery.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Hochrainer Responsible: Färber Jörg Release date: 22/07/2014
Index: 6 Page No.: 5/36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0005
Safety regulations

Wear personal protective equipment (PPE)!

Wear the personal protective equipment approved by the health and safety
organisations for body, head, eyes, ears and breathing. Never be in the
vicinity of an engine when wearing loose clothing, jewellery or long hair.
Always wear a bump cap except when working with suspended loads or if
the plant requires this. In this case, you must wear a hard hat.
According to NFPA70e, an electrician's helmet and other special equipment
may be required when carrying out electrical work. A GE version of
NFPA70e is available.

The standard equipment required for entering the engine room or

approaching and working on plant components, even outside the engine
room, consists of eye protection, protective clothing, hand protection and
safety footwear.
▪ Eye protection: must always be worn.
▪ Protective clothing: this must have long sleeves if surface temperatures
are likely to exceed 40°C in the work area.
▪ Safety footwear: Class S3 safety footwear must be worn when carrying
out servicing work.
Depending on the operational condition of the plant, the ambient
conditions, the type or location of the operation, use hearing protection,
safety helmet, fall prevention equipment, gas sensors, breathing mask or
other personal protective equipment, as appropriate.

You should also use your own powers of judgement to avoid hazards and
dangerous situations and wear the appropriate personal protective
equipment.

It is your duty to comply with all current official and quasi-official safety rules and codes applicable to your
sector.

Depending on the operating condition of the plant or the operation, hazards may arise which cause injury, so
wear the appropriate personal protective equipment. The examples below are not exhaustive:

Activities when plant is running:

▪ Hearing protection, eye protection, protective clothing, safety footwear, hand protection!

Assembly operations during maintenance and repair:

Caution: many plant and engine components are heavy. This gives rise to a risk of severe crushing and impact
injuries due to the heavy weight of the components.
▪ Safety footwear, protective clothing, hand protection!

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Hochrainer Responsible: Färber Jörg Release date: 22/07/2014
Index: 6 Page No.: 6 / 36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0005
Safety regulations

Installation, construction site, difficult access:

Danger of falling, tipping or flying objects, swinging loads and bumping into obstacles, which can cause severe
head injuries.
▪ Safety helmet, safety footwear!

Hot surfaces and liquids (oil, cooling water):

The engine, pipework, etc. can reach a surface temperature of up to 150°C.
▪ Thermal insulation gloves, protective clothing!

Pressurised pipes and containers:

Liquids such as engine coolant, lubricating oil and diesel fuel are hot and under pressure.
▪ Eye protection, protective clothing, thermal insulation gloves!

Working in dusty conditions:

Changing the air filter, cleaning operations, changing the active carbon, etc.
▪ Wear a breathing mask, eye protection, protective clothing and safety footwear!

Handling acids, starter battery, cleaning products, oil, anti-freeze and anti-corrosion products, chemicals:
▪ Acid- or chemical-resistant gloves and clothing, eye protection, safety footwear. Read the manufacturer's
instructions and make sure that you have the appropriate safety data sheets (MSDS) to hand!

Working at height (above 1.2 m):

Even falls from low heights can result in serious injury. When working at height
(from 1.2 m), where the provision of technical safeguards (e.g. handrails, work platforms, etc.) is either
impossible or impractical, you should use:
▪ personal fall arrest equipment consisting of harness and associated equipment (safety rope, karabiner
hook, damper, lanyard or height safety device)!

Use of poisonous gases, e.g.: CO, H2S, SO2, etc. (note the results of the gas analyses):
▪ CO sensors as personal protective equipment! Ensure personal protective equipment is regularly
maintained/calibrated.
People who are under the influence of alcohol and/or drugs represent a
danger to themselves and other people.
They must not be allowed to enter the engine room under any
circumstances.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Hochrainer Responsible: Färber Jörg Release date: 22/07/2014
Index: 6 Page No.: 7/36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0005
Safety regulations

Electrical work:
Electrical connections, defects or electrostatic charges may give rise to a risk of electric shock.
▪ Use "non-conductive" ladders to gain access (e.g.: fibreglass or plastic).
▪ Wear hand protection and protective clothing! Observe electrical instructions for tools and work to be
carried out!

8 Use of tools
Observe the following points before you use any tools:
▪ Every tool may only be used for its designated purpose.
▪ Check every tool for damage before and after use.
▪ The use of damaged tools is prohibited.
▪ Tools without a valid inspection document may not be used and must
be inspected.
▪ Always keep tools clean and dry as well as free from oil and grease.
▪ Check that your tools are complete before and after use.
▪ Make sure that you don't leave any tools or (damaged) tool parts
behind in the engine or engine components.

9 Transporting - lifting - installing

Take account of the Technical Instructions (TI 1000-0041, TI 1000-0042, TI
1000-0043, TI 1000-0044, TI 1000-0046, TI 1100-0100 and TI 1100-0112)
concerning the requirements for the arrangement surface, lifting, transport
safety pegs, transporting and positioning, installation of GE Jenbacher
modules, containers and switch cabinets, as well as the appropriate
background conditions.
Never use transport security shackles to lift components or modules. They
are only used to secure components or modules to the transport vehicle.

10 Shutdown procedure and making safe

Automatic machinery: liable to start without warning
If the operating mode selector switch is in "Aut" position, the module may
start without warning at any time.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Hochrainer Responsible: Färber Jörg Release date: 22/07/2014
Index: 6 Page No.: 8 / 36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0005
Safety regulations

Before commencing maintenance work, repairs, etc., shut down machinery as described below and secure
to prevent unauthorised start-up!
Shut down and secure
Engine switch-off:
Switch off the engine in accordance with Technical Instruction No.
1100-0105
and ensure that unauthorised persons cannot start the engine.

Isolate from power supply before starting work

Before starting work, isolate the machinery from the relevant circuits to
prevent it from being restarted and check to ensure that the system is
dead.

Dangerous voltage
If you see this warning near the mains isolating device, this means that
the mains isolating device does not switch off all electrical circuits. The
‘except for’ electrical circuits - i.e. the circuits not switched off - are shown
in the circuit diagram.
Despite having isolated the machinery, you should regard all components
as live.
Check that all components are disconnected!

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Hochrainer Responsible: Färber Jörg Release date: 22/07/2014
Index: 6 Page No.: 9/36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0005
Safety regulations

High-voltage ignition system – 40kV!

Improper use may be fatal!
The ignition system may cause electric shock.
Ignition systems may also produce extremely dangerous voltages when
the equipment is not operating. This applies to all ignition system
components, such as the cable, coil, connector, etc!

Hot surfaces

Risk of burns

Allow the engine cool down, wear personal protective equipment!

Wear thermal insulation gloves and protective clothing!

Danger from escaping liquids (hot and under pressure)

Liquids such as engine coolant, lubricating oil and diesel fuel are hot and
under pressure. Escaping liquids may cause serious injury.

Wear personal protective equipment.

Wear eye protection, thermal insulation gloves and protective clothing!

Allow the engine and coolant to cool down before removing pipes, seals and covers or opening components
that contain liquids. The pressure must first be reduced to zero. Only then, drain the coolant if necessary.
Liquids must be drained completely.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Hochrainer Responsible: Färber Jörg Release date: 22/07/2014
Index: 6 Page No.: 10 / 36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0005
Safety regulations

Risk of explosion

During charging, batteries produce hydrogen and oxygen which under

certain conditions may form an explosive mixture.
The battery is charged with 24 V DC even when the control system is
switched off. Sparks generated at the battery poles can ignite an explosive
atmosphere.

Check that the battery poles are firmly secured. No smoking, no naked lights, no sparks!

Poisonous gases

The air in the engine room may be severely polluted with evaporating oil,
cooling water, fuel gases or exhaust gases.

Ventilate the engine room thoroughly before starting work!

Ensure there is a fresh air supply when working in the engine room!
Wear personal protective equipment (gas sensors)!

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Hochrainer Responsible: Färber Jörg Release date: 22/07/2014
Index: 6 Page No.: 11/36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0005
Safety regulations

11 Engine room
No admittance for unauthorised persons!
Room contains electrical machinery
Admittance for authorised and trained personnel only (specialist staff)!

In principle, the engine room is an enclosed, protected room for the unmanned
operation of machinery.

Read the "Personal protection guidelines" in these safety instructions and wear the personal protective
equipment appropriate to the dangers concerned!

Noise

The noise produced when the machinery is operating or being started

may damage your hearing.

Wear hearing protection!

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Hochrainer Responsible: Färber Jörg Release date: 22/07/2014
Index: 6 Page No.: 12 / 36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0005
Safety regulations

No pacemakers

Because of the possibility of electromagnetic effects on pacemakers or

similar devices, people with such devices are prohibited from entering the
engine room.

No fire, naked flames or smoking

Install fire extinguishers

Fire extinguishers must be installed at places where they may be easily

reached in the event of a fire.

Risk of slipping

Wipe up any spilt oil, diesel fuel and coolant immediately and keep the
machinery clean.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Hochrainer Responsible: Färber Jörg Release date: 22/07/2014
Index: 6 Page No.: 13/36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0005
Safety regulations

Highly flammable materials

Keep oily rags in fire-proof containers. Never leave them lying on the
engine.

Do not store flammable liquids near engines.

Keep the machinery clean

Mark escape routes

Mark escape routes from the engine room and keep them clear of
obstructions.

Risk of escaping liquids (hot and under pressure)!

Avoid danger zones around safety valve and explosion protection valve
openings.
There are also danger zones around air filters.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Hochrainer Responsible: Färber Jörg Release date: 22/07/2014
Index: 6 Page No.: 14 / 36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0005
Safety regulations

Hot surfaces

Risk of burns

Allow the engine cool down, wear personal protective equipment!

Wear thermal insulation gloves and protective clothing!

Poisonous gases

Enclosed spaces must be well-ventilated to ensure a constant supply of

fresh air.
Rooms in which gas-consuming devices are operated must be ventilated.

In the event of unusual machine noise and unusual smells in the engine room, carry out a check. If you detect
a gas concentration in a building, you should always observe the following instructions:

If you fear that a hazard exists, actuate the emergency stop outside the engine room, close the gas safety
shut-off valve and/or shut off the diesel fuel supply outside the engine room and make sure that they cannot
be opened unintentionally.
Prevent any possibility of ignition and, if possible, break all the electrical circuits from outside the danger zone.
Evacuate all personnel from the danger zone.
Allow air into the affected parts of the building by opening windows and doors.
Call in professionals to look for the gas leak and its cause and initiate damage repair.

Toxic gases (e.g.: CO, H2S, etc.)!

Read the results of the fuel gas analyses!

Fuel gases may be poisonous and may result in death or damage to

health if inhaled.

Wear gas sensors as personal protective equipment (appropriate to the

poisonous gas components) and ensure proper ventilation!

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Hochrainer Responsible: Färber Jörg Release date: 22/07/2014
Index: 6 Page No.: 15/36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0005
Safety regulations

If the fuel gas contains carbon monoxide CO:

Carbon monoxide is a poisonous, odourless, colourless, highly flammable
gas, which is about as heavy as air.

Read the results of the fuel gas analyses!

Wear CO sensors as personal protective equipment when:

▪ the gas is odourless and the CO content of the fuel gas is>0% .
▪ the gas contains odours and the CO content of the fuel gas is >0.5%.

Observe these guide values if no other safety guidelines are available or

they are less stringent than the guide values. Country-specific thresholds/
guidelines ALWAYS have priority. Also ensure that personal protective
equipment is regularly maintained/calibrated.

CO concentration in the air and its effect if inhaled:

▪ 0.003 Vol% = 30 ppm no/minimal risk to health
▪ 0.010 Vol% = 100 ppm slight headache after several hours
▪ 0.050 Vol% = 500 ppm severe headache, dizziness, fainting after several
hours
▪ 0.1 Vol%-0.2 Vol% = 1000-2000 ppm death after 30 minutes
▪ 0.3 Vol%-0.5 Vol% = 3000-5000 ppm death after a few minutes
Other symptoms: vomiting and nausea, buzzing in the ears, light-headedness, convulsions, hyperventilation,
etc.

Risk of explosion

The air-gas mixture used as engine fuel is easily ignited and may explode.

Close and make secure the manual stop valve, ensure there are no sparks
or naked flames, impose a strict ban on smoking and provide adequate
ventilation!

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Hochrainer Responsible: Färber Jörg Release date: 22/07/2014
Index: 6 Page No.: 16 / 36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0005
Safety regulations

12 Components
Protective devices should not be removed while the machinery is in operation.
Repair or replace damaged protective devices immediately.
Before removing any protective device, secure the machinery to prevent unauthorised start-up.

Shut down and secure

Shut-down procedure and securing: Refer to section on "Shut-down

procedure and securing" in these safety instructions.

12.1 Exhaust gas system

Exhaust gases may be poisonous and may result in death or damage to health if inhaled.
Exhaust gases must always be discharged into the atmosphere.
The exhaust-gas system must be inspected regularly to ensure that it is gas-tight:

Visually Cracks, corrosion, faulty seals

Odour Exhaust smell

Locations at risk: Flange connections, seals, compensators, welded joints.

It is the operators responsibility to ensure that there are no leaks in the exhaust system.

Poisonous gases

Inhalation will result in damage to health or death.

Discharge exhaust gases into the atmosphere, check for leaks, provide
adequate ventilation.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Hochrainer Responsible: Färber Jörg Release date: 22/07/2014
Index: 6 Page No.: 17/36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0005
Safety regulations

Hot surfaces

Components which are not insulated and through which exhaust gas
passes are very hot and can cause severe burns.

Allow the engine cool down, wear personal protective equipment!

Wear thermal insulation gloves and protective clothing!

During commissioning, adjustment of engine operating parameters to suit different gas properties, or
diagnosing starting problems, there is an increased likelihood of backfire or deflagration in the exhaust system.
As a precaution, the operator should ensure that no persons are present in the vicinity of the exhaust system
during such operations.

12.2 turbocharger
As the turbocharger operates at high temperatures, flammable material must be kept at a distance.
Work on the turbocharger must only be carried out once the engine has been shut down and room
temperature has been reached, otherwise there is a risk of injury and fire.

Hot surfaces

Risk of burns

Allow the engine cool down, wear personal protective equipment!

Wear thermal insulation gloves and protective clothing!

Fire risk

Fire

Avoid contact with flammable material and keep the machinery clean!

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Hochrainer Responsible: Färber Jörg Release date: 22/07/2014
Index: 6 Page No.: 18 / 36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0005
Safety regulations

12.3 Fuel gas system (gas and dual-fuel engines only)

The engine is equipped for the fuel gas quality specified by the customer when the engine was ordered, and is
adjusted for this gas when it is first put into operation.

Notify GE JenbacherCustomer Service before you convert the system to another type of fuel gas and each time
the fuel gas quality is changed!

Note: The air-gas mixture used as engine fuel is easily ignited and may explode.
As soon as fuel gas is present in the pipes no welding work must be carried out in the engine room concerned.
No naked flames may be used and a strict ban on smoking must be observed.

The guidelines below must be read in conjunction with other mandatory requirements (arrangement plan,
Technical Instructions, statutory regulations, official directives, etc.) when assembling and operating the
plant:

The engine room ventilation must be so designed that gas concentrations are prevented and a slight
overpressure exists in the engine room. (See TA 1100-0110 [⇨ TA 1100-0110, Page 1])

Ensure that the pipes and components through which the fuel gas passes are fully leakproof.

A leak test as described in IW 8049 0 is required if a leak is detected or after repairs to pipes or components
carrying fuel gas and mixtures.

Install a flame trap (depending on the legal requirements of the country where the equipment is located) in the
gas supply line.

Align plant-side safety valves so that the outlet ports are in a protected area.

A manual stop valve must be provided outside the engine room for intentional shutdown of the plant (e.g. for
repair and maintenance and in emergencies), preferably at the point where the gas pipes enter the engine
room.
The manual stop valve must be designed to ensure that no unauthorised person can actuate it, i.e. open it
when in locked position.

It is the operator's responsibility to ensure that the fuel gas system is equipped with the necessary devices,
does not leak and satisfies official requirements.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Hochrainer Responsible: Färber Jörg Release date: 22/07/2014
Index: 6 Page No.: 19/36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0005
Safety regulations

Risk of explosion

The air-gas mixture used as engine fuel is easily ignited and may explode.
Gas being discharged could create a potentially explosive atmosphere.
No welding, no naked flames, strict ban on smoking, efficient
maintenance/inspection, leak tests, adequate ventilation gas alarm
system, manual stop valve closed and made safe!

Toxic gases (e.g.: CO, H2S, etc.)

Note the results of the gas analyses

Fuel gases may be poisonous and may result in death or damage to

health if inhaled.

Wear gas sensors as personal protective equipment (appropriate to the

poisonous gas components) and ensure proper ventilation!

You must also read the engine room guidelines in these safety
instructions!

Extreme care is required when carrying out maintenance or repair work on the gas train and the gas
pipes. These components contain quantities of residual gas which will escape when, for example, the gas
filter is being changed!

12.4 Diesel fuel system (diesel and dual-fuel engines only)

Danger from escaping liquids (diesel fuel is under high pressure)
Damaged piping, connections or other components in the diesel fuel
system must be replaced immediately.
Failure of any of these components will result in an escape of diesel fuel
under high pressure and therefore a danger of personal injury.
Wear personal protective equipment (safety glasses, protective clothing
and thermal insulation gloves). Keep away from pressure relief valves.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Hochrainer Responsible: Färber Jörg Release date: 22/07/2014
Index: 6 Page No.: 20 / 36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0005
Safety regulations

Hot surfaces
The components of the diesel fuel system (fuel pipes and filters, valves,
etc.) and the fuel itself are hot and can cause severe burns when working
on the fuel system (e.g. draining off the fuel, changing the fuel filters, ...).

Allow components to cool down, and wear personal protective equipment.

Wear thermal insulation gloves and protective clothing!

Fire risk
Leaks in the diesel fuel system must be scrupulously avoided as sprayed
or splashed diesel fuel may ignite on contact with hot engine components.

Keep the machinery clean and carry out maintenance/inspection as

instructed.

Rags dirty with diesel fuel must be disposed of as special waste.

12.5 Cooling system

When the engine is at operating temperature, the coolant is hot and pressurised.
Damaged or weathered pipes, seals, hoses and hose clips and other components must be replaced
immediately. If these components break or fracture, hot coolant could injure people and cause a fire.
Keep clear of pressure relief valves when operating the plant.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Hochrainer Responsible: Färber Jörg Release date: 22/07/2014
Index: 6 Page No.: 21/36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0005
Safety regulations

Risk of escaping liquids (hot and under pressure)

Depressurise these components accordingly before carrying out
maintenance work on them!
Fractured components allow hot coolant to escape, posing a risk of injury.
Regular maintenance/inspection of components. Wear personal
protective equipment (safety glasses, protective clothing and thermal
insulation gloves). Keep away from pressure relief valves.

Hot surfaces

Risk of burns

Allow the engine cool down, wear personal protective equipment!

Wear thermal insulation gloves and protective clothing!

To replace pipes and components

Shut down and secure

Shut-down procedure and securing → Refer to the "Shut-down

procedure and securing" section in these safety instructions.

Coolants are treated with anti-corrosive and anti-freeze products.

Anti-freeze and anti-corrosion products are usually classified as harmful
to health. Read the manufacturer's instructions and the safety data sheet
for the chemical concerned!

Wear personal protective equipment when handling anti-corrosion

products, anti-freeze products and coolant. Follow the manufacturer's
safety instructions!
Observe any disposal requirements.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Hochrainer Responsible: Färber Jörg Release date: 22/07/2014
Index: 6 Page No.: 22 / 36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0005
Safety regulations

12.6 heat exchanger

Heat exchangers are pressure vessels which are designed for specific pressure and temperature limits.

Operators must be made familiar with the specific design pressure and temperature.

Heat exchangers must be pressure-tested on a regular basis.

A visual inspection of the following points of risk must be carried out: Flange connections, seals, locks and
covers.

Any liquids escaping as the result of a leak may cause serious injury.

Keep clear of pressure relief valves when operating the plant.

Risk of escaping liquids (hot and under pressure)

The fracturing of components causes hot liquids to escape, thereby posing

a risk of injury.

Regular maintenance/inspection, regular pressure-testing. Wear personal

protective equipment (safety glasses, protective clothing and thermal
insulation gloves). Keep away from pressure relief valves! Reduce
pressure!

Hot surfaces

Risk of burns

Let the heat exchanger and pipes cool down, wear personal protective
equipment! Wear thermal insulation gloves and protective clothing!

Do not remove pipes, seals and covers from the cooling system until the components have cooled down, the
pressure has been reduced and all liquids have been fully drained off.

To replace pipes and components

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Hochrainer Responsible: Färber Jörg Release date: 22/07/2014
Index: 6 Page No.: 23/36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0005
Safety regulations

Shut down and secure

Shut-down procedure and securing: Refer to section on "Shut-down

procedure and securing" in these safety instructions.

12.7 Slam Valve

Avoid the danger zones around the valves as they could open at any time during operation. There is a risk of
injury due to hot operating materials under pressure.

Risk of escaping liquids (hot and under pressure)

The actuation of safety valves causes hot liquids to escape, thereby

posing a risk of injury.

Wear personal protective equipment (safety glasses, protective clothing

and thermal insulation gloves). Keep away from pressure relief valves.

12.8 Lubrication system

Risk of escaping liquids (during normal operation, lubricants are hot and
under pressure)

The actuation of safety valves causes hot liquids to escape, thereby

posing a risk of injury.

Wear personal protective equipment (safety glasses, protective clothing

and thermal insulation gloves). Keep away from pressure relief valves.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Hochrainer Responsible: Färber Jörg Release date: 22/07/2014
Index: 6 Page No.: 24 / 36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0005
Safety regulations

Hot surfaces

Components of the lubrication system (oil lines and filters, valves, etc.) and
the oil itself are hot and can cause severe burns when working on the lube
oil system (e.g. changing the oil or the oil filters).

Let components cool down, wear personal protective equipment. Wear

thermal insulation gloves and protective clothing!

Fire risk

Oil leaks must be scrupulously avoided as oil spray or splashes may ignite
on contact with hot engine components.

keep the machinery clean and carry out maintenance/inspection as

instructed!

Lubricating oils and oily rags must be disposed of as special waste.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Hochrainer Responsible: Färber Jörg Release date: 22/07/2014
Index: 6 Page No.: 25/36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0005
Safety regulations

12.9 Control system

The control rod assembly must not be obstructed while the machinery is
operating. Any unauthorised adjustment or bending of the control rod
assembly could cause the engine to race.

12.10 Ignition system

High-voltage ignition system – 40kV!
Improper use may be fatal!

The ignition system may cause electric shock.

Ignition systems may also produce extremely dangerous voltages when
the equipment is not operating.
Do not touch ignition system components such as the cable, coil,
connector, etc. while the engine is running. Do not pull ignition cables off
of coils! Ignition cables must not come into contact with other parts!

The spark plug ignites an air-gas mixture in the combustion chamber. As a

result, any air-gas mixture which has accumulated in the induction port,
exhaust system or turbocharger may ignite. Failures must not simply be
reset. Before restarting the module, you must first remedy the cause of the
failure! Please read the rules on this subject in Technical Instruction
1100-0111Technical Instruction 1100-0111.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Hochrainer Responsible: Färber Jörg Release date: 22/07/2014
Index: 6 Page No.: 26 / 36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0005
Safety regulations

Risk of explosion
Failures or incorrect operation (e.g. frequent unsuccessful attempts to
start, resetting the fault contrary to instructions, cause of the failure not
remedied, etc.) may cause an air-gas mixture to accumulate outside the
combustion chamber and explode thereby causing serious injury, death
and severe damage.

Remedy failures, operate machinery and carry out maintenance and

inspections in accordance with instructions!

12.11 Cables and insulated wiring

Dangerous electrical voltage

To protect you from the hazards posed by electrical energy, we would

point out that the use of cables and insulated wiring must comply with the
technical specifications issued by VDE, IEC, etc., in accordance with local
regulations and such work may only be performed by authorised
technicians (officially licensed electricians).
GE Jenbacher accepts no liability GE Jenbacherfor injury, loss or damage
due to improper installation.

12.12 Throttle valve

Do not obstruct or block the control rod assembly.
Do not attach objects to or suspend them from the control rod assembly.
Do not misuse the control rod assembly as a fixing point for fall prevention equipment.

12.13 Electrical connections

Dangerous electrical voltage

All electrical connections involve a risk of making a direct or indirect

electrical contact. Contact could result in a serious, and possibly fatal,
electric shock.

Connected components must be installed only by authorised experts

(officially licensed electricians) in accordance with local regulations.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Hochrainer Responsible: Färber Jörg Release date: 22/07/2014
Index: 6 Page No.: 27/36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0005
Safety regulations

12.14 Generator
Dangerous electrical voltage

The voltage produced by the generator is deadly.

Contact could result in a serious, and possibly fatal, electric shock.

Connected components must be installed only by authorised experts (officially licensed electricians) in
accordance with local regulations.
Make sure that the generator is earthed before it is operated for the first time.

Extreme caution is required if the generator or the area around it is damp or wet.

In the event of an accident caused by electric shock, shut the module down immediately by pressing the
emergency stop button.

If the victim is injured or unconscious, summon a first-aider or medical assistance immediately.

If the generator is shut down by a safety device, do not restart it until the cause of the accident has been
remedied.

During the commissioning of the generator, the supplier of the power supply cubicle must implement the
protective measures required under local regulations.
Ensure proper earthing

The machine must be properly earthed to prevent contact voltages and

electrostatic charging contrary to regulations.
Make sure that the engine is resting on non-conductive rubber bearings.

Following steps should be taken when working in close proximity with a generator:
1. As with all naturally aspirated generators a catastrophic event could lead to sparks exiting the generator.
Therefore, in order to re-enforce our commitment to safe working conditions we remind you of the
following practical steps that should be taken while working in close proximity of a running alternator:
Particulary we recommend, that
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Hochrainer Responsible: Färber Jörg Release date: 22/07/2014
Index: 6 Page No.: 28 / 36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0005
Safety regulations

a) A risk assessment is performed by the user/operating company to determine all personnel related risks
and the relevant personnel should be aware of these. Access to the power plant/generator set during oper-
ation should be restricted to personnel who have been trained.
b) personnel in the proximity of an operational generator should, at all times, wear suitable protective
clothing in accordance with the risks identified in para. 1.a. above, and with consideration to the following:
The following aspects in particular must be borne in mind:
Ear protection
Head and face protection
Safety footwear
Overalls that protect the lower arms and legs
2. Any work that is likely to require access to electrical conductors must be performed in compliance with all
local and national electrical safety procedures that are applicable to the site and to the voltage levels
involved as well as any site specific rules. In addition, all site-specific regulations must be observed.

12.15 Electrical cabinets

Dangerous electrical voltage

The voltage inside electrical cabinets is deadly.

Contact could result in a serious, and possibly fatal, electric shock.

Connected components must be installed only by authorised experts (officially licensed electricians) in
accordance with local regulations.

Make sure that the control cabinet is earthed before the plant is operated for the first time.

Extreme caution is required if the electrical cabinet or the area around it is damp or wet.

In the event of an accident caused by electric shock, shut the module down immediately by pressing the
emergency stop button.

If the victim is injured or unconscious, summon a first-aider or medical assistance immediately.

During the commissioning of the generator, the supplier of the power supply cubicle must implement the
protective measures required under local regulations.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Hochrainer Responsible: Färber Jörg Release date: 22/07/2014
Index: 6 Page No.: 29/36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0005
Safety regulations

Ensure proper earthing

The electrical cabinet must be properly earthed to prevent contact

voltages and electrostatic charging contrary to regulations.

Keep door closed

Proper operating conditions for electrical devices can only be achieved

with the cabinet door closed (e.g. weather exposure, heat, cold, dust, air-
conditioning in the cabinet, etc.)
This relates to all types of electrical cabinets, e.g. interface, control cabinet,
power cubicle, thermal reactor cabinet, etc.

Isolate from power supply before starting work

Caution: electrical cabinets can be supplied from a number of energy
sources!

Before starting work in electrical cabinets, isolate them from all energy
sources to prevent them from being reactivated and check to ensure that
the system is dead.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Hochrainer Responsible: Färber Jörg Release date: 22/07/2014
Index: 6 Page No.: 30 / 36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0005
Safety regulations

12.16 Acoustic insulation (container; sound absorber hood)

Fire risk

There is a risk of fire if loose insulation material comes into contact with
hot engine parts.

Check acoustic insulation for damage,

Keep the machinery clean and carry out maintenance/inspection as
instructed.
Acoustic insulation must not be soaked with chemicals!

12.17 Battery
Corrosive substances
The batteries used by GE Jenbacher are filled with dilute sulphuric acid,
which may cause serious corrosion.
Avoid contact with eyes and skin!
Wear personal protective equipment.
Wear acid-resistant gloves, protective clothing, safety glasses and safety
footwear when handling battery acid!

Risk of explosion
During charging, batteries produce hydrogen and oxygen which under
certain conditions may form an explosive mixture.
The battery is charged with 24 V DC even when the control system is
switched off. Sparks generated at the battery poles can ignite an explosive
atmosphere.
Check that the battery poles are firmly secured. No smoking, no naked
lights, no sparks!
The battery acid level must always be between the minimum and
maximum markings.
Proper maintenance according to the maintenance schedule is a
condition!
There is an acute explosion hazard under the following conditions:
▷ The battery's acid level is lower than the acid-level "min" mark.
▷ The battery is short-circuited or heavily overloaded (e.g. attempted
engine start when the engine is blocked).
▷ Excessive charge voltage (> 30 V).

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Hochrainer Responsible: Färber Jörg Release date: 22/07/2014
Index: 6 Page No.: 31/36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0005
Safety regulations

Battery acid may leak if batteries are damaged (e.g. during repair work), its
corrosive action causing damage to the environment and property. Acid
can also cause a chemical reaction with the lime in the concrete and
damage the floor.
Batteries, battery acid and rags contaminated with acid must be disposed
of as special waste.

See also
• Batteries (starter and storage) [⇨ TA 1000-0050, Page 1]

12.18 Container/enclosure
Extreme caution is required when carrying out maintenance and installation work on the roof. Ensure workers
are always safely harnessed to prevent a fall!
Wear safety harness / Risk of falling

Climbing on to the roof without a safety harness is extremely dangerous.

Secure the safety harness to suitable points provided on the roof!

Use personal fall arrest equipment consisting of harness and associated equipment (safety rope, karabiner
hook, damper, lanyard or height safety device)!

The container or enclosure housing the plant must be designed so that

the plant does not pose any risks in the accessible area.

No ladders should be permanently attached to freely accessible

containers or enclosures, so as to prevent unauthorised persons from
climbing on to the roof.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Hochrainer Responsible: Färber Jörg Release date: 22/07/2014
Index: 6 Page No.: 32 / 36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0005
Safety regulations

Where pipework, ducts, system components, etc. have to be laid or installed in the accessible area, they must
be positioned at such a height that they cannot be used for climbing or the system components installed within
the danger zone will also have to be enclosed.

If this is not possible, or if other dangers exist, the operator must secure the plant so as not to allow
unauthorised persons access to the danger zones.

Doors left open (e.g. during maintenance work) on the container, the
enclosure, the air intake, etc. can be slammed shut by a gust of wind. This
may result in hand or head injuries caused by crushing and impact.

Secure open doors with storm hooks (if available) or by other suitable
measures!

Keep door closed

All doors must be closed while the plant is operating! Proper operating
conditions can only be achieved with doors closed.

13 Maintenance and servicing

Note: The engine is liable to start without warning.

The customer must make sure that the relevant safety precautions have been taken before performing
any maintenance work on the engine.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Hochrainer Responsible: Färber Jörg Release date: 22/07/2014
Index: 6 Page No.: 33/36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0005
Safety regulations

See point 3 of these safety instructions, “Health and safety during operation and maintenance”.

Before commencing maintenance work, shut down the engine as described below and make sure that it
cannot be started inadvertently.

Shut down and secure

Shut-down procedure and securing: Refer to section on "Shut-down

procedure and securing" in these safety instructions.

Work on the installation may only be carried out by specialist staff having relevant electrical and mechanical
training. There may also be a service contract (maintenance or servicing contract), under which all servicing is
carried out by GE Jenbacher personnel.

Suitable safe lifting gear must be used when fitting or removing heavy components. Handling heavy
components gives rise to a risk of severe crushing and impact injuries due to the heavy weight of the
components. Wear personal protective equipment such as safety footwear, protective clothing, hand
protection and safety helmet.

Working at height (above 1.2 m):

When working at height (above 1.2 m), where the provision of technical safeguards (e.g. handrails, work
platforms, etc.) is either impossible or impractical, you should use personal fall arrest equipment consisting of a
harness and associated equipment (safety rope, carabiner hook, energy absorber, rope shortener or fall
arrester).

Poisonous gases in vessels below ground level, or in basins and pits.

Poisonous gases can accumulate in basins and pits, as well as in vessels

below ground level (e.g. condensate tanks).

Ensure proper ventilation or extraction to remove gas concentrations.

Check the maximum admissible work place values (gas concentration).

Wear gas sensors (appropriate to the poisonous gas components)

gas components)as personal protective equipment.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Hochrainer Responsible: Färber Jörg Release date: 22/07/2014
Index: 6 Page No.: 34 / 36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0005
Safety regulations

If the maximum admissible workplace values cannot be guaranteed, suitable breathing apparatus must be
worn.

Before carrying out any work on the plant, the customer has a duty to ensure that safety will not be
compromised.
Maintenance and repair work must be carried out with care. Temporary measures are not permitted:
▪ never "repair" fuses
▪ never deliberately ignore or re-use defective parts
▪ never place "drip catchers" under leaks
▪ never tighten bolts, which have a specified tightening torque, contrary to the instructions
▪ never make temporary repairs
▪ never implement unsystematic and unsuitable fault-finding procedures
Temporary repairs and makeshift arrangements may result in serious injury or damage the machinery.

Only repair methods specified in the engine documentation are allowed and may to be used.

DANGER
If the safety equipment for maintenance/servicing work has been dismantled or
rendered ineffective:
All the safety equipment must be restored to its original condition and its effectiveness checked.

14 Cleaning
Fire risk

Cleaning agents are usually highly flammable.

When carrying out cleaning operations, only use approved cleaning agents
in well ventilated areas. Under no circumstances use petrol, paint thinners
and other easily vaporising agents!
Keep cleaning agents and solvents away from flames and flying sparks!

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Hochrainer Responsible: Färber Jörg Release date: 22/07/2014
Index: 6 Page No.: 35/36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0005
Safety regulations

Poisonous gases

Avoid inhaling any gases as they may be fatal.

When carrying out cleaning operations, only use approved cleaning

agents in well ventilated areas!

Read the labels on all cleaning agent containers and follow the
instructions.

Never use unlabelled products.

Note disposal requirements.

15 Disposal requirements for waste electrical and electronic equipment

Electrical and electronic equipment can contain harmful substances which
can affect the environment and human health.
WEEE symbol (Waste of Electrical and Electronic Equipment):
the symbol for the separated disposal of electrical and electronic equipment
is a crossed-out waste bin on wheels (Directive 2002/96/EC Waste Electrical
and Electronic Equipment).
You must not dispose any electrical and electronic equipment marked with
this symbol (battery-operated electrical appliances, measurement equipment,
light-bulbs, etc.) in the domestic waste but dispose of these separately.
Always use the waste return and collection systems locally available and
contribute to the reuse, recycling and all other forms of use for waste
SprungMarke!!!54043195566186635
electrical and electronic equipment.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Hochrainer Responsible: Färber Jörg Release date: 22/07/2014
Index: 6 Page No.: 36 / 36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0010
Guidelines for using the LOTO kit

1 Purpose ....................................................................................................................................................... 1
2 LOTO Kit...................................................................................................................................................... 3
3 Incorrect applications.............................................................................................................................. 4
4 Shut-off valves........................................................................................................................................... 6
4.1 Main gas valve ............................................................................................................................................................ 6
4.2 Self-clamping ball valves ....................................................................................................................................... 7
5 Electrical components ............................................................................................................................. 9
5.1 Auxiliaries main breaker....................................................................................................................................... 10
5.2 Miniature circuit breakers.................................................................................................................................... 11
5.3 Motor protective circuit breaker....................................................................................................................... 14
5.4 Key-operated switches......................................................................................................................................... 14
5.5 Generator breaker - low-voltage ..................................................................................................................... 14
5.5.1 Non-withdrawable generator breaker 15
5.5.2 Withdrawable generator breaker 15
6 Affixing the marking ............................................................................................................................... 18
6.1 DANGER tag ............................................................................................................................................................... 19
6.2 CAUTION tag (transition tag) .............................................................................................................................. 19

The target recipients of this document are:

Distribution Partners, Service Partners, Commissioning Partners, Subsidiaries/Branches, Jenbach location
GE proprietary information: CONFIDENTIAL!
The information contained in this document is General Electric Company proprietary information and is
disclosed in confidence. It is the property of GE and may not be used, disclosed to others or reproduced
without the express written consent of GE. This includes, but is not limited to, use of the information to create,
manufacture, develop or derive any repairs, modifications, spare parts, designs or configuration changes, or to
obtain government or regulatory approval to do so. If consent is given for reproduction in whole or in part, this
notice and the notice set forth on each page of this document shall appear in any such reproduction in whole
or in part.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY

1 Purpose
This Technical Instruction describes the possible uses of the LockOut/TagOut locking system (LOTO Kit) on GE
Jenbacher systems.
It is not intended to list every individual application but simply to show by means of application examples how
to proceed when locking out. Since the conditions on any particular site may be completely different, the
lockout devices may need to be used in a different way to that shown in the photos in order to be effective.
Using LOTO strategies to secure equipment against accidental re-connection is only one of five steps in the
safety circuit (see safety rules below). The other four steps must also be followed to ensure safety at work.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: EHS / Csohany Release date: 02/07/2014
Index: 5 Page No.: 1/19
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0010
Guidelines for using the LOTO kit

WARNING
Danger of death due to electrical voltage!
When working on electrical systems, you must always follow the five safety rules for electrical
work as specified in EN 50110-1:
a) Disconnect completely
b) Secure against re-connection (LOTO)
c) Verify that the installation is dead
d) Carry out earthing and short-circuiting
e) Provide protection against adjacent live parts

Basic principles of LOTO applications

1. The LOTO lockout device is must always be secured by a personal red padlock.
2. The key to the personal LOTO padlock must never be made available to another person during the work.
3. The lockout must always be applied to whichever system securely prevents the plant part which is being
worked on from operating.
4. If more than one person is operating on the plant (including from outside firms), the LOTO device is fitted
with a hasp and each participant inserts his personal LOTO padlock in the hasp. The system cannot be
released until all the padlocks have been removed.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: EHS / Csohany Release date: 02/07/2014
Index: 5 Page No.: 2 / 19
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0010
Guidelines for using the LOTO kit

2 LOTO Kit

1 Miniature circuit breaker lockout - Tie-Bar (TB) 7 Universal cable lockout

2 Miniature circuit breaker lockout - Pin-In 8 Universal lockout
Standard (PIS)
3 Miniature circuit breaker lockout - Pin-Out 9 Cable lockout (addition to universal lockout)
Standard (POS)
4 Miniature circuit breaker lockout - Pin-Out 10 Additional arm for universal lockout
Wide (POW)
5 LOTO padlock 11 Large hasp
6 480 V breaker lockout 12 Small hasp
Read the safety and hazard advice in the safety instructions (TI 2300-0005) and wear the appropriate personal
protective equipment. GE personnel must also observe the information in the Safety Risk Assessment (SRA).
The LOTO kit must only be used by authorised persons. To obtain the "LOTO Authorised" qualification, a person
must complete the "Lockout / Tagout - Authorised Employee (Initial) [CEP-34] at http://mylearning.ge.com, pass
the associated test, and carry out a practical demonstration of a LOTO application in the presence of another
LOTO-authorised person. The on-line training must be refreshed every 2 years, and the practical demonstration
must be repeated annually.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: EHS / Csohany Release date: 02/07/2014
Index: 5 Page No.: 3/19
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0010
Guidelines for using the LOTO kit

If one of the LOTO components becomes defective or is lost, please contact your EHS officer so that he can
replace the defective component or complete the LOTO kit.

3 Incorrect applications

DANGER
Faulty locking
The following examples show the results of incorrectly-executed lockout procedures. Such
applications are equivalent to no lock at all!

Key not withdrawn!

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: EHS / Csohany Release date: 02/07/2014
Index: 5 Page No.: 4 / 19
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0010
Guidelines for using the LOTO kit

Lockout device locked with a normal combination

padlock (e.g. a toolbox padlock) instead of a lockout
padlock.

Lockout device only secured by a cable tie.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: EHS / Csohany Release date: 02/07/2014
Index: 5 Page No.: 5/19
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0010
Guidelines for using the LOTO kit

Unmarked padlock and no sign. One of the two

possible ways of marking (directly on the padlock /
separate tag) must be used.

4 Shut-off valves

4.1 Main gas valve

Main gas valve

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: EHS / Csohany Release date: 02/07/2014
Index: 5 Page No.: 6 / 19
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0010
Guidelines for using the LOTO kit

Main gas valve locked out with universal lockout and

additional arm

Main gas valve locked out with universal ball valve

cable lockout

4.2 Self-clamping ball valves

Ball valve locked with universal lockout: valve interlock
cannot be released

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: EHS / Csohany Release date: 02/07/2014
Index: 5 Page No.: 7/19
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0010
Guidelines for using the LOTO kit

Ball valve locked with universal lockout: valve interlock

cannot be released

Ball valve locked with universal cable lockout: ball

cannot be turned

Ball valve locked out with universal lockout and

additional arm: ball cannot be turned

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: EHS / Csohany Release date: 02/07/2014
Index: 5 Page No.: 8 / 19
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0010
Guidelines for using the LOTO kit

5 Electrical components

WARNING
Live electronic components
Dangerous voltages can be present at the outputs of electronic components (e.g. frequency
converters and soft starters) even when the input sides of these components are separated from
the mains or no start command is issued. That dangerous voltage is also present at any
connected individual consumers (e.g. pumps, fans, etc.).
a) That is why - before beginning any maintenance activities - you must always make
absolutely sure that all supply voltages to these electrical components and connected
consumers are safely disconnected.
b) Having disconnected the supply voltage, wait for at least 5 minutes before opening the
equipment to make sure that all capacitators have been discharged.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: EHS / Csohany Release date: 02/07/2014
Index: 5 Page No.: 9/19
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0010
Guidelines for using the LOTO kit

5.1 Auxiliaries main breaker

Auxiliaries main breaker - old version

Main / repair breakers can be locked out directly with
the lockout padlock.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: EHS / Csohany Release date: 02/07/2014
Index: 5 Page No.: 10 / 19
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0010
Guidelines for using the LOTO kit

Auxiliaries main breaker - current version

Turn wheel (1) until the openings (2) for the lockout
padlock are accessible. The main breaker has space
for 3 lockout padlocks.

WARNING
Equipment still live even after being switched off at the main breaker!
The main breaker on auxiliary equipment may disconnect only one of several power supplies.
a) The UPS main breaker disconnects the UPS and its voltage outputs.
b) For multiple power supplies (e.g. UPS systems) to be securely locked out (LOTO), the electrical
circuit (see the appropriate wiring diagram for the system) must be disconnected and locked
out.

5.2 Miniature circuit breakers

Items 1 to 4 in Fig. 1 are intended mainly for miniature circuit breakers.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: EHS / Csohany Release date: 02/07/2014
Index: 5 Page No.: 11/19
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0010
Guidelines for using the LOTO kit

Fit miniature circuit breaker lockouts (TB) between two

breakers, hook them in and screw them securely in
place.

Multiple circuit breakers locked out with TB lockout

and lockout padlock

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: EHS / Csohany Release date: 02/07/2014
Index: 5 Page No.: 12 / 19
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0010
Guidelines for using the LOTO kit

Multiple circuit breakers locked out with POS lockout

and lockout padlock.
Select the lockout type (TB, PIS, POS, POW) depending
on the space between the breakers.
Lockouts that grip from the inside (POS or PO) or the
top/bottom (TB) are suitable for circuit breakers which
are not mounted separately.

Circuit breaker locked out with a TB lockout, hasp and

more than one lockout padlocks when more than one
person is working on the plant.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: EHS / Csohany Release date: 02/07/2014
Index: 5 Page No.: 13/19
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0010
Guidelines for using the LOTO kit

5.3 Motor protective circuit breaker

Motor protective circuit breaker locked out with a
universal cable lockout.

5.4 Key-operated switches

480 V breaker lockout can also be used for key-
operated switches. The lockout covers the keyhole.
Only works if the locked-out switch cannot be turned
without the key!

5.5 Generator breaker - low-voltage

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: EHS / Csohany Release date: 02/07/2014
Index: 5 Page No.: 14 / 19
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0010
Guidelines for using the LOTO kit

5.5.1 Non-withdrawable generator breaker

Check that the generator breaker (2) is displayed as
being OPEN in the control system (screen 11.1).

Check that the main breaker is OFF in the mode

selection display (2).
Pull out the LOTO latch (1) and lock it with the LOTO
padlock.

5.5.2 Withdrawable generator breaker

1. Check that the generator breaker (2) is displayed as
being OPEN in the control system (screen 11.1).

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: EHS / Csohany Release date: 02/07/2014
Index: 5 Page No.: 15/19
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0010
Guidelines for using the LOTO kit

2. Check that the main breaker is OFF in the mode

selection display (1).

1 Mode selection display 4 Crank handle socket

2 Recessed folding crank handle 5 Crank interlock release
3 Breaker position display 6 LOTO latch

3. Take out the crank handle (2) and insert it in the

socket (4).

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: EHS / Csohany Release date: 02/07/2014
Index: 5 Page No.: 16 / 19
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0010
Guidelines for using the LOTO kit

4. Press the interlock release (5) and wind out the

generator breaker.

5. In the test position, the crank interlock release will

re-engage. Press the crank interlock release (5) again
until the breaker position display (3) is at the bottom
position "Released".

6. Pull out the LOTO latch (6) and lock it with the LOTO
padlock.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: EHS / Csohany Release date: 02/07/2014
Index: 5 Page No.: 17/19
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0010
Guidelines for using the LOTO kit

Generator breaker locked out

6 Affixing the marking

The marking can be affixed either directly to the padlock or to tags.

Minimum information:
▪ name of the person locking out (to be written on the padlock with a permanent marker)
▪ lockout date (with a non-permanent marker)
▪ Reason for lockout

Optional information:
▪ provisional release date
If not included in the LOTO kit, the "CAUTION" and "DANGER" tags can be ordered from any GE Jenbacher office
or directly from GE Jenbacher.

NOTICE
LOTO marking:
The LOTO markings must always be affixed directly to the padlock with a cable tie!

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: EHS / Csohany Release date: 02/07/2014
Index: 5 Page No.: 18 / 19
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0010
Guidelines for using the LOTO kit

6.1 DANGER tag

The name of the person working on the engine must
be written on the front (1) of the tag.

The current date must be written on the back (2). You

can also add any further information.

6.2 CAUTION tag (transition tag)

The following must be written on the back (2) of the
tag:
- the name of the person who affixed the transition tag
- the date it was affixed
- any other information

SprungMarke!!!36028797922688011

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: EHS / Csohany Release date: 02/07/2014
Index: 5 Page No.: 19/19
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
3 Operation of the plant
GE
Energy

TECHNICAL SPECIFICATION
OF THE CONTROL

1 x JGS 616 GS-N.L

AB Energy 616 - 31
J S889

Index: -
Vorbehaltlich techn. Änderungen!
Revision reserved!

© GE Jenbacher GmbH & Co OG

Achenseestr. 1-3
A-6200 Jenbach (Austria)
3.1
Technical specification of the control

1. Plant Short Description ______________________________________________________ 4

1.1 Plant Summary 4
1.2 Fuel Gas 4
1.3 Principal Drawing Electric 4
1.4 Heating Schematic 4
2. Auxiliaries _________________________________________________________________ 5
2.1 Starting Equipment 5
2.2 Control System Power Supply 5
2.3 Jacket Water Preheating M.04-W-002 5
2.4 Engine cooling water pump 6
2.5 Charge cooling water pump P.07-M-001[01] 6
2.10 Pre-Lube Oil Pumps 6
2.18 Scavenging fan | flap 6
2.19 Single circuit cooling 6
3. Function of the Cogeneration Plant ____________________________________________ 7
3.2 Customers request with customers power set point 7
3.6 Engine Control Functions 7
3.7 Generator Controller Functions 8
3.8 Procedure in case of mains failured 8
3.8.1 Island operation 9
4. Conditions ________________________________________________________________10
4.1 Parallel Operation 10
4.2 Grid Monitoring Unit 10
4.3 Safety Loop of the CHP 10
4.4 Requirement for Cabling performed by the Customer 10
4.5 Requirements for Customers Switchgear 11
5. Operation Modes of the CHP-plant ___________________________________________12
5.1 Automatic Operation 13
5.2 Manual CHP-Operation 14
5.3.1 Automatic Synchronizing through AB Energy (IFL 47 not activ) 16
5.3.2 Automatic Synchronizing Generator through GE Jenbacher (IFL 47 activ) 17
5.5 Standby Power Supply | Blackout operation 18
5.5.1 Standby Power Supply during Operation (island operation) 18
5.5.2 Island operation and engine standstill (black out start) 19
5.6 Synchronizing mains c.b.(resynchronizing) 20
5.6.1 Automatic Synchronizing through AB Energy (IFL 47 not activ) 20
5.6.2 Automatic Synchronizing through GE Jenbacher (IFL 47 is activ) 21
7. Electrical Hardware ________________________________________________________22
7.1 Module Control Cabinet per Module 22
7.2 Module Interface Cabinet 26
8. Remote Data-Transfer with DIA.NE XT - HERMES _______________________________26
8.1 General 26
8.2 Connections methods 26
8.3 Applications 27
8.4 Technical prerequisites 29

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Orgine: TPE | Gruber Robert Checked: Electrical Engineering Date: 08.05.2015

Index: - Page: 2 | 30
3.1
Technical specification of the control

Appendix : „ALARM LIST“

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Orgine: TPE | Gruber Robert Checked: Electrical Engineering Date: 08.05.2015

Index: - Page: 3 | 30
3.1
Technical specification of the control

Modification:

index datum ref. point comment name

1. Plant Short Description

1.1 Plant Summary

1 gas engine gensets

Fitted with 3 phase synchronous generator 4160 V  10 %, 60 Hz.
Total electric power: 2654 kW at pf. 1
3298 kVA at pf. 0,8
1.2 Fuel Gas

Natural gas

1.3 Principal Drawing Electric

See J S889 +U/page 5,6

1.4 Heating Schematic

Customer supply and GE Jenbacher hydraulic drawing J S889 00 03

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Orgine: TPE | Gruber Robert Checked: Electrical Engineering Date: 08.05.2015

Index: - Page: 4 | 30
3.1
Technical specification of the control

2. Auxiliaries

2.1 Starting Equipment

Starter batteries: lead/acid

24 V, 400 Ah per module.
Detailed description see TA-Nr. 1000-0050.

Charger:
24 V, 80 A
with integrated control system power supply 24 V =, 18 Ah. Used for module controller.

2.2 Control System Power Supply

24 V=, min. 22 - max. 30 V (inclusive of ripple) at GE Jenbacher terminal. max ripple Uss = 2,4 V.

2.2.1 Control voltage for module control cabinet

Control voltage for module control cabinet from starter batteries.

2.3 Jacket Water Preheating M.04-W-002

3x 480 V, 60 Hz, 2x 8,6 kW:
Thermostatically controlled between 55°C – 60°C.

Status Display (screen P_04.1)
"PREHEATING WATER CIRC. PUMP ON/OFF"
"PREHEATING ON/OFF"
The module will be preheated continuously whilst the service selector is in the manual or auto position.
When service selector switch is "OFF", preheating is switched off. (Electric heating elements, circulating pump,
thermostat).

2.3.1 Cooling water circulation pump M.04-M-002

240 V, 60 Hz, 370 W:
The pump operates during engine shutdown for cooling water preheating, and for another 30 minutes after
module stop for turbocharger cooling.
When the operating mode selector is set to "OFF", the cooling water circulation pump is switched off 30 min.
after module stop.
In case of loss of the supply voltage, the cooling water circulation pump will automatically switch over to a
battery supplied converter to ensure continued turbocharger cooling for 30 minutes.
The functioning is monitored using flow switches. Failures are displayed using the “PREHEATING PUMP
FAILURE“ warning.

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Orgine: TPE | Gruber Robert Checked: Electrical Engineering Date: 08.05.2015

Index: - Page: 5 | 30
3.1
Technical specification of the control

2.4 Engine cooling water pump

Jacket Water Circulating Pump 3x 480 V, 60 Hz, 7,5 kW:
The pump operates during module operation and during a 20-minute cool-down run of the turbocharger after
module stop.
In case of loss of the supply voltage during the cool-down run, the cooling water circulation pump will
automatically switch over to a battery supplied converter to ensure continued cooling.
As soon as the supply voltage returns, the engine cooling water pump will run for another 20 minutes.

2.5 Charge cooling water pump P.07-M-001[01], supplied by AB Energy

3x 480 V, 60 Hz, .. kW
The pump operates during module operation and during the 5-minute cool-down run.

2.10 Pre-Lube Oil Pumps

1x 3 phase 480 V, 60 Hz, 1,77 kW, M.03-M-002
1x 24 VDC, 1,5 kW, M.03-M-003
Controlled by module PLC.
Function: Both pumps operate for normal start. Only DC pump operates for black start.
Operating time of pumps > 1 minute before engine start. Once engine speed exceeds 800 rpm, pumps are
switched off.
After module stop, the AC pump continues to operate for 5 minutes in order to lubricate the turbochargers.
After module stop following a mains failure, only the DC pump operates.
 Additionally, the pumps can be manually controlled in order to preheat the lube oil.

manually activated oil preheating system.

2.18 Scavenging fan | flap

Fan: 3x 480 V, 60 Hz, 850 W M.02-M-001
Flap: 1x 24 VDC, 70 W, M.02-YCS-001
Is used to scavenge the exhaust gas duct from unburned fuel gas, with air before each normal- start. (not at
black out start) The flap is opened before each scavenging and the fan is started, after 1 minute the flap will be
closed again. The fan stays operating during the gas engine operation.

2.19 Single circuit cooling

Solenoid valve M.04-YCS-001: 1x 24 VDC, 22 W
At engine start with a jacket water temperature < 86°C  valve is open
At engine operation and jacket water temperature > 86°C  valve is closed. If the temperature decreases
below 84°C  valve is open
During the 20 minutes auxiliary cool down run is the valve open.

2.20 Transmission cooling water pump

3x 480 V, 60 Hz, 440 W, M.18-M-002
The pump operates during module operation and during a 5-minute cool-down run after module stop.

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Orgine: TPE | Gruber Robert Checked: Electrical Engineering Date: 08.05.2015

Index: - Page: 6 | 30
3.1
Technical specification of the control

3. Function of the Cogeneration Plant

The TI-No.. 1100-0110 „Boundary conditions for GE Jenbacher gas engines“ has to be followed.

3.2 Customers request with customers power set point

The module is requested into operation via a customer supplied potential free contact (interface No. 15).
Contact closed = Module operation
Contact opened = Module stop
The power control is performed via to a customer supplied potential free and linear mA signal
(0/4 - 20 mA = 50 - 100% nominal power interface No. 28)

3.6 Engine Control Functions

3.6.1 Knock control system:

All cylinders of the engine are fitted with analog knocking sensors (E.00-AI-101[xx]), the signals are pre-
processed by an analysis electronic and transmitted to the DIA.NE. If the knocking signal exceeds a certain
level and subsequently a knocking limit, the knocking control will be activated.

If the knocking signal exceeds a background noise level, the ignition point value is adjusted first. As an
additional measure (if applicable), the charge temperature is lowered and, finally, the engine power during
mains parallel operation is reduced by a specified time constant, until the knocking signal falls below the
background noise level. Once the knocking signal has fallen below the background noise level, the engine
power is returned to the rated power by increasing the time constant. If the engine power is reduced by the
knocking signal to 50% of rated power, the engine is shut down on safety grounds.
 Error message "KNOCKING FAILURE"
 Error message "KNOCKING FAILURE CYLINDER xx"

3.6.2 Power reduction due to charge temperature

If the charge temperature (E.08-TI-001) exceeds 51°C, the engine power will be reduced during mains parallel
operation by 4% per additional °C. If, however, the temperature exceeds 55°C, the engine is stopped and the
error message "CHARGE TEMPERATURE MAXIMUM" appears.

3.6.3 Power Reduction due to Misfiring

Every detected misfiring is displayed. The detection takes place according power surges. Every recognised
misfire event will be summarised with the misfire integrator. The increase and decrease speed of the integrator
is adjustable. If the integrator reaches a level of 50% the engine output will be reduced, at an integrator level of
100% the engine output will be reduced to 50% and subsequently the engine will be stopped. A misfiring alarm
will appear at a settable value of the integrator.
 Message "POWER REDUCTION - MISFIRE" (screen P_41.1)
If due to misfiring, the engine power must be reduced to 50% output then a module shutdown is performed
due to safety reasons.
 Failure Message "MISFIRING TROUBLE"

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Orgine: TPE | Gruber Robert Checked: Electrical Engineering Date: 08.05.2015

Index: - Page: 7 | 30
3.1
Technical specification of the control

3.7 Generator Controller Functions

3.7.1 Effective power reductions

To protect the generator, the effective power generated is reduced to certain limits.
A reduction takes effect in the case of:

- undervoltage (average voltage )


Message "POWER REDUCTION UNDERVOLTAGE”
- overvoltage (average voltage )
 Message "POWER REDUCTION OVERVOLTAGE”
- underfrequency
 Message “POWER REDUCTION UNDERFREQUENCY”
- overfrequency

Message "POWER REDUCTION OVERFREQUENCY”
- winding temperature too high (only if windings Pt100 assembled)
 Message "POWER REDUCTION WINDING TEMPERATURE”

3.7.2 Reactive energy reductions

- Limiting the reactive energy / cos phi at high winding temperatures

The highest of the 3 phase temperatures is taken as the actual value of the winding temperature. This
reduction is only activated if the assembled winding Pt100s are activated (not with PTC resistors).
 Message "REACTIVE POWER REDUCTION WINDING TEMPERATURE”

- Generator operation at the underexcited stability limit using pole wheel angle reduction
 Message "REACTIVE POWER REDUCTION POLAR WHEEL ANGLE”

3.7.3 Reactive power / cos phi control of the generator

 External setpoint(Customized):
The reactive power of the generator is adjusted depending on an external mA signal or is set according to
digital inputs with fixed setpoints.

3.8 Procedure in case of mains failure

Selection with Profibus Signal IFL 702

Signal “0“= No island operation active

Signal “1“= Island operation active

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Orgine: TPE | Gruber Robert Checked: Electrical Engineering Date: 08.05.2015

Index: - Page: 8 | 30
3.1
Technical specification of the control

3.8.1 Island operation

see point 5.5 for further description

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Orgine: TPE | Gruber Robert Checked: Electrical Engineering Date: 08.05.2015

Index: - Page: 9 | 30
3.1
Technical specification of the control

4. Conditions

4.1 Parallel Operation

The module operate in parallel with the mains. The relevant standards for parallel operation with the mains are
complied with.
The engine and exhaust heat are supplied to the customers heating circuit.
Terminal point electricity:

4.2 Grid Monitoring Unit

Settings of the grid protection relay see Wiring Diagram +U.
After response of the grid protection relay caused by a mains disturbance, the mains circuit breaker (MCB) will
be commanded open in case of island operatin selected
After response of the grid prodection relay caused by a mains disturbance, the generator circuit breaker
(Gen. C.B.) will be commanded open if no island operation is selected.
The maximum opening time of the MCB (Gen. C.B.) must not exceed 60 msec.

4.3 Safety Loop of the CHP

4.3.1 CHP Plant Safety Loop

For the total CHP plant, a current loop safety circuit for the following is provided.
- Emergency stop (contact external | GE Jenbacher)
- Gas alarm (contact external | GE Jenbacher)
- Fire alarm (contact external | GE Jenbacher)
Tripping of the safety loop produces an immediate shut down of the total CHP plant.

4.3.2 Gas Engine Safety Loop

For each engine | CHP module, a current loop safety circuit for the following is provided:
- Emergency stop
- Over speed
- Ignition monitoring
- Control of switchgear under voltage trip device for:
Generator reverse power
Shutdown fault
Missing power signal
Power signal overload
- Heating water temperature high (Temperature safety limit unit) (P.06-TS-001)
- Heating water pressure high (Pressure safety limit unit) (P.06-PS-001)
Tripping of the safety loop shuts down only the appropriate module | engine.

4.4 Requirement for Cabling performed by the Customer

Cable installation must comply with TA-Nr. 1000-0505.
The cross sectional areas for the power cables supplied by the installer must be in compliance with IEC 60204-
1 as well as IEC 60364-5-52 (methods of installation, grouping …).

4.4.1 Generator power cables:

See TA-Nr. 1100-0112 „Installation of GE Jenbacher Units”!

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Orgine: TPE | Gruber Robert Checked: Electrical Engineering Date: 08.05.2015

Index: - Page: 10 | 30
3.1
Technical specification of the control

Installed in such a manner as to reduce the risk of a short-circuit to a minimum, and not be placed close to
combustible material.

4.4.2 Only flexible cables are permitted.

4.5 Requirements for Customers Switchgear

Standards:
Rated voltages ≤ 1 kV: IEC 61439-2, IEC 60204-1, ISO 8528-4
Rated voltages > 1 kV: IEC 62271-200, IEC 60204-11, ISO 8528-4, metal enclosed and capable of withstanding
an internal arc fault, and clearly marked to distinguish it from LV equipment.

4.5.1 Generator switchgear:

Circuit breaker 3 pole drawout type with motor drive (24VDC), suitable for synchronizing and BLACK OUT Start
with de – excited generator (No generator voltage is available)
24 (110) VDC closing coil, closing time max. 70 msec. from GE Jenbacher interface until contacts of the
generator C.B. are closed, transmission time for the STATUS feedback signal max. 30msec.

24 (110) VDC shunt trip coil; trip time max. 60 msec. from GE Jenbacher interface until contacts of the
generator C.B. are opened, transmission time for the STATUS feedback signal max. 30msec.
24 (110) VDC under voltage trip coil

On | Off command from GE Jenbacher synchronizing only: Continuous contacts (1 NO and 1 NC)
with 24 VDC, 10 A (110VDC, 0,5A) load rating.
Over current and short circuit protection with primary or secondary relays.
Adjustment over current: to 1,1 times the rated generator current,
time characteristics acc. to IEC 60255-151: Very Inverse, time multiplier setting 0,6.
Adjustment short circuit: to 2,0 times generator nominal current with adjustable time delay
(300 msec).

1 earthing switch for MV/HV generators

3 x current transformer for measurement …./1A; 1FS5; 30VA

3 x current transformer for protection …./1A (or …./5A; see interfacelist) 10P10; 30VA for MV/HV generators
1 x cable transformer (for earth fault prot.) .../1A (or …./5A; see interfacelist) 10P10; 5VA for MV/HV generators
3 x fuses (and potential transformer …kV/1,73 : 100V/1,73 :100V/3 Class 0,5) for measurement / protection
3 x fuses (and potential transformer …kV/1,73 : 100V/1,73 :100V/3 Class 0,5) for measurement / protection at
the busbar side (1* per busbar)

Generator transient over voltage surge protection according TA-Nr. 1100-0112.

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Orgine: TPE | Gruber Robert Checked: Electrical Engineering Date: 08.05.2015

Index: - Page: 11 | 30
3.1
Technical specification of the control

5. Operation Modes of the CHP-plant

Functions of the service selector switch and the module demand selector-switch:

Service - Demand - Start Stop Set point for engine power

selector - selector - control
switch switch
STOP - - - -
MANUAL - START – key at STOP – key at DIA.NE XT internal
DIA.NE XT
AUTOMATIC OFF - Module demand -
cancelled
REMOTE Demand from Demand is cancelled by Variation: internal
customer or the customer or master
Variation: external from
master control control
customer or master control
ON Module is demanded internal

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Orgine: TPE | Gruber Robert Checked: Electrical Engineering Date: 08.05.2015

Index: - Page: 12 | 30
3.1
Technical specification of the control

5.1 Automatic Operation

According the CHP-functions for all available modules.
- with the demand selector-switch in pos. “REMOTE“
- with the demand selector-switch in pos. „ON“

Conditions for Automatic-start:

 Service selector switch in position "Automatic"
Safety chain is o.k.
No malfunction of the module (module specific)
Jacket water temperature (M.04-TI-001) > 40°C
Engine is not running
Visual signal "READY FOR AUTOMATIC START - ENGINE STOPPED"
Voltage free signal "ready for automatic start"
"Demand" from customer via interface no.701
- Contact closed: Engine starts up
- Contact opened: Engine stop's

The demand causes:

 Visual signal: "START PROGRAM RUNNING"
Scavenging of the exhaust duct system from unburned fuel gas with air:
The scavenging-flap (M.02-YCS-001) is opened before each scavenging, running time of the fan (M.02-M-001) is
1 minute,
after that the flap will be closed again.
Demand heating water circuit/heating water circulating pump (P.06-M-001)
- answer back signal heating water flow o.k. (P.06-FS-001)
Demand bypass flap (P.02-YCS-002) open
- answer back signal bypass flap (P.02-YCS-002) is opened

6 sec. after release for start:


Visual signal: "AUTOMATIC START IS RUNNING"
Starter (E.00-M-001[xx]) on, after 2 sec scavenging run, ignition on.
With answer back "Ignition operating", the gas valves (P.01-YCZ-xxx) are opened.

The engine ignites and powers up:

The starter (E.00-M-001[xx]) will be disengaged when the speed is higher start speed.

Visual signal: "START PROGRAM ENGINE RUNNING UP TO RATED SPEED"
Jacket water preheating (M.04-W-002) off.

If the engine doesn't ignite a 2nd attempt will follow.

If the 3rd attempt is also not successfully, a further start is blocked.
 Visual signal "START UP TROUBLE" and further start attempts are prevented.

Operational Messages:
10 seconds after engine start and power up, the lube oil pressure monitoring (M.03-PI-001) is activated.
 Visual signal "ENGINE IDLE OPERATION - ............"

Potential free contact "Operation | Engine is running" issued to master control and for the customer.

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Orgine: TPE | Gruber Robert Checked: Electrical Engineering Date: 08.05.2015

Index: - Page: 13 | 30
3.1
Technical specification of the control

 Visual signal " ENGINE IDLE OPERATION SYNCHRONIZE-/LOAD RELEASE".

Synchronizing:
 The synchronizing is performed automatically when synchronizing selector switch is in
automatic position.
 Visual signal "MAINS PARALLEL OPERATION".

Automatic Loading:
After the closure of generator C.B., the module power will be raised to its set point.

Shutdown during Automatic Operation

Reason: "Demand Module" signal from AB Energy (interface IFL 701)
is removed in pos. „REMOTE“ of the demand selector-switch or with the demand selector-switch in pos. „OFF“
 The load is reduced. Once load is less than 10% PN, the generator C.B. will be
opened by the breaker control.
Visual signal " STOP PROGRAM: ENGINE COOL DOWN RUN"
After one minute cool down run, the gas valves (P.01-YCZ-xxx) are closed.
Contact "operation | Engine is running" is removed.
Visual signal "STOP PROGRAM : ENGINE STOP SEQUENCE".
Ignition off and once engine speed is less than start speed
 Visual signal "READY FOR AUTOMATIC START ENGINE STOPPED"

Shut down check of gas train (leakage detection P.01-US-xxx)

Auxiliaries operate for 5 minutes (hot water circulating pump (P.06-M-001),…)

5.2 Manual CHP-Operation

 The CHP module can be operated manually by setting the service selector switch in
position "Manual". The load up/down of the module is thus manually operated.
The synchronizing function is automatic or manual (manually started auto synchronizing)
depending on synchronizer selector switch position.

Conditions for the Manual Start:

 Service selector switch in pos. manual.
Safety chain is o.k.
No module malfunction (module specific)
Engine is not running
 Visual signal: "READY FOR MANUAL START ENGINE STOPPED"
 Press start button for "start preparation"
The demand causes:
 Visual signal: "START PROGRAM RUNNING"
Scavenging of the exhaust duct system from unburned fuel gas with air.
The scavenging-flap (M.02-YCS-101) is opened before each scavenging, running time of the fan (M.02-M-101) is
1 minute, after that the flap will be closed again.
Demand heating water circuit (P.06-M-001)
- answer back signal heating water flow o.k. (P.06-FS-001)
Demand open exhaust bypass flap (P.02-YCS-002)

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Orgine: TPE | Gruber Robert Checked: Electrical Engineering Date: 08.05.2015

Index: - Page: 14 | 30
3.1
Technical specification of the control

- answer back signal bypass flap (P.02-YCS-002) is opened

If all conditions are o.k.:

 Visual signal "START ENGINE (PUSH START BUTTON) "
 Press start button

Starter (E.00-M-001[xx]) on, after 2 sec scavenging run, ignition on.

With answer back "Ignition operating", the gas valves (P.01-YCZ-xxx) are opened.
The engine ignites and starts up.
 Visual signal "START PROGRAM : ENGINE RUNNING UP TO RATED SPEED".
 Release start button
The starter (E.00-M-001[xx]) will be disengaged when the speed is higher than the start speed.
The cooling water preheating (M.04-W-002) is switched off.

Operation signals:
10 sec. after start and power up, lube oil monitoring (M.03-PI-001) is switched on
 Visual signal: "ENGINE IDLE OPERATION ................"
Voltage free signal: "Operation | Engine is running" to the customer

Synchronizing:
The synchronizing is possible in 2 modes: manual (manual initiated automatic
synchronization) and full automatic.
 Manual loading (load control):
With keys on the DIA.NE in the control panel.

Shut down in Manual Operation:

Before shutting down engine, decrease load using the DIA.NE.
 Synchronizing selector switch in position "Manual" or "Off"
 Switch off generator C.B. with  10 % engine power.
 Visual signal: "ENGINE IDLE OPERATION SYNCHRONIZE-/LOAD RELEASE"
 After 1 min. cool down run, stop engine with "Stop" button.
"Generator C.B. Release" is removed and the engine is shut down.
Afterwards the gas safety line will be checked (P.01-US-xxx).
 Visual signal: "READY FOR MANUAL START - ENGINE STOPPED"

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Orgine: TPE | Gruber Robert Checked: Electrical Engineering Date: 08.05.2015

Index: - Page: 15 | 30
3.1
Technical specification of the control

5.3.1 Automatic Synchronizing through AB Energy (IFL 47 not activ)

- engine in operation
- cooling water temperature (M.04-TI-001) above 55C
- Generator C.B. open
- Release Load and Synchronzing from engine control interface IFL 100

Demand synchronizing profibus signal interfac IFL 703

 Display "Synchronization selected"
- Select bus bar voltage
- Select generator voltage
- Select speed adjustment via interfaces IFL 104.1 and 104.2 by AB Energy

Automatic tuning of the generator voltage to the bus bar voltage.

Tuning of the generator frequency to the bus bar frequency by the synchronizing unit from AB Energy.
Closing command to the generator C.B. by the synchroniser AB Energy at the moment of synchronizing.
 Answer back "GENERATOR CIRCUIT-BREAKER CLOSED" .
 Status display "MAINS-PARALLEL OPERATION"

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Orgine: TPE | Gruber Robert Checked: Electrical Engineering Date: 08.05.2015

Index: - Page: 16 | 30
3.1
Technical specification of the control

5.3.2 Automatic Synchronizing Generator through GE Jenbacher (IFL 47 activ)

- engine in operation
- cooling water temperature (M.04-TI-001) above 55C
- Generator C.B. open
- Release Load and Synchronzing from engine control interface IFL 100

Demand synchronizing profibus signal interfac IFL 703

 Display "Synchronization selected"
- Select bus bar voltage
- Select generator voltage
- Preparation of the synchronizer
- Select generator C.B.
- Select speed adjustment

Automatic tuning of the generator voltage to the bus bar voltage.

Automatic tuning of the generator frequency to the bus bar frequency by the synchronizing unit.
Closing command to the generator C.B. by the synchroniser GeJ at the moment of synchronizing.(IFL 109)
 Answer back "GENERATOR CIRCUIT-BREAKER CLOSED" .
 Status display "MAINS-PARALLEL OPERATION"

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Orgine: TPE | Gruber Robert Checked: Electrical Engineering Date: 08.05.2015

Index: - Page: 17 | 30
3.1
Technical specification of the control

5.5 Standby Power Supply | Blackout operation

General:
- In every case of mains failure and transition from Mains-parallel operation to island operation the
customers load shedding equipment (preferably using relay control with direct contacts on the standby
loads) has to limit the standby load within 50 mSec after the mains C.B. is opened to the standby rating
of the module(s). It has to be ensured, that the load reduction at the transition from Mains-parallel
operation to island operation don‘t exceed 40% for Type 6 machines. This can be realized with a mains
import/export control for example. After a (further) module(s) is (are) connected to the standby
distribution system, the standby loads
can be added according the load adding diagram.
- Between load addings the engine needs approx. 1-2 minutes for thermal and control stabilizing specially
after a cold start.
- Dia.ne will ensure correct load sharing of the operating modules.
- Reactive power balance is performed through static adjustment of the generators.
In multiple module installations, the voltage adjustment of each generator must be identical.
- Power factor correction equipment must be disconnected during standby operation
to minimise the danger of over voltage and capacitive generator operation. The power
factor should be between cos φ = 1 and 0.8 (lagging).
- Module power range:
The modules are rated for 40% to 100% of nominal output for standby operation.
- Load adding diagram see TA-Nr. 2108-0025 for Type 3
TA-Nr. 2108-0029 for Type 4
TA-Nr. 2108-0026 for Type 6

5.5.1 Standby Power Supply during Operation (island operation)

Island operation activated through interface IFL 702

- Mains decoupling device dedects mains failure
- Mains C.B. will be opened.
- With feedback mains c.b open

Display "MAINS FAILURE"
- Module continues to operate
- Load shedding must reduce the consumer load to match the limits allowed by the operating module.
- Consumer loads connected in steps.
 Status display "ISLAND OPERATION"

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Orgine: TPE | Gruber Robert Checked: Electrical Engineering Date: 08.05.2015

Index: - Page: 18 | 30
3.1
Technical specification of the control

5.5.2 Island operation and engine standstill (black out start)

Black out start is released through profibus signal interface 702

Three versions for black out start are possible

1.) Black out start with open generator c.b.:

- engine not in operation mains c.b is opened

- interface IFL 702 release black out start is activated
- engine starts and speeds up
- AB Energy receives synchronizing and load release from GeJ ILF 100
- AB Energy is closing the generator c.b when speed and voltage are established
- generator is connected to busbar and consumers

2.) Black out start with open generator c.b. and deexcitation:

- engine not in operation mains c.b is opened

- interface IFL 702 release black out start is activated
- interface IFL 706 demand black out start with deexcitation is activated
- engine starts and speeds up
- deexcitation of generator is activated
- generator voltage decreases
- AB Energy receives synchronizing and load release from GeJ ILF 100
- AB Energy is closing the generator c.b
- deexcitation of generator is deselected
- generator voltage is rebuild
- generator is connected to busbar and consumers

3.) Black-OUT Start mit geschlossenem Generatorschalter:

- engine not in operation mains c.b is opened

- interface IFL 702 release black out start is activated
- interface IFL 705 demand black out start with gcb closed
activated
- AB Energy receives synchronizing and load release from GeJ ILF 100
- AB Energy is closing the generator c.b
- engine is starting
- generator is connected to busbar and consumers

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Orgine: TPE | Gruber Robert Checked: Electrical Engineering Date: 08.05.2015

Index: - Page: 19 | 30
3.1
Technical specification of the control

5.6 Synchronizing mains c.b.(resynchronizing)

5.6.1 Automatic Synchronizing through AB Energy (IFL 47 not activ)

Mains supply is o.k. Mains C.B. is opened
Mains C.B. is ready for closure
Generator C.B. is closed

Select synchronizing from AB Energy via Profibus IFL 704

 Status display " SYNCHRONIZING MAINS CB IS RUNNING"
- Selection mains voltage
- Selection busbar voltage (Generator)
- Preparation of the synchronizer
- Selection mains C.B.
- Select speed adjustment via interfaces IFL 104.1 and 104.2 by AB Energy

Automatic tuning of the generator frequency to the mains frequency.

Automatic tuning of the generator voltage to the mains voltage.
Automatic closing command to the mains C.B. at the moment of synchronizing.
 Answer back signal "MAINS C.B. IS CLOSED"
 Status display "MAINS-PARALLEL OPERATION"

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Orgine: TPE | Gruber Robert Checked: Electrical Engineering Date: 08.05.2015

Index: - Page: 20 | 30
3.1
Technical specification of the control

5.6.2 Automatic Synchronizing through GE Jenbacher (IFL 47 is activ)

Mains supply is o.k. Mains C.B. is opened
Mains C.B. is ready for closure
Generator C.B. is closed

Select synchronizing from AB Energy via Profibus IFL 704

Automatic tuning of the generator frequency to the mains frequency.

Automatic tuning of the generator voltage to the mains voltage.
Closing command to the generator C.B. by the synchroniser GeJ at the moment of synchronizing.(IFL 109)
 Answer back signal "MAINS C.B. IS CLOSED"
 Status display "MAINS-PARALLEL OPERATION"

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Orgine: TPE | Gruber Robert Checked: Electrical Engineering Date: 08.05.2015

Index: - Page: 21 | 30
3.1
Technical specification of the control

7. Electrical Hardware

Design of the enclosures:

All enclosed, steel, free standing cabinet with front opening door, rubber door seals,
completed to terminal strips for interconnection by customer via a cable channel
(double floor). Cable exit from underneath.

design according IEC 60439-1 | EN 60439-1 and ISO 8528-4.

ambient temperature 5°C - 40°C
Enclosures: Rittal, Type TS 8
colour RAL 7035

7.1 Module Control Cabinet per Module

Consisting of:
DIA.NE XT3 motor management system
System elements visualisation with central engine and module control

a) Visualisation:
Industrial control with 10,4“ colour graphics display.
10-key numeric keyboard for parameter input.
Keys for START, STOP, display selection keys and special functions.
Interfaces:
- Ethernet (twisted pair) for connection to DIA.NE WIN server
- CAN-Bus: bus connection to the intelligent sensors and actuators
- B&R bus connection to the control in- and outputs

OPTION: Interfacing with the customer’s plant management according to GE Jenbacher list of options
(PROFIBUS-DP Slave)

Protection class DIA.NE XT front: IP 65

Dimensions: W x H x D = approx. 323 x 358 x 105 (12,7 x 14,1 x 4,1 in)

A clear and functional graphic compilation of measured values is displayed on the screen. User prompts are by
means of direct-acting display selection keys and function keys.

Main displays:

 Generator interconnection, with electrically measured variables and display of

excitation voltage (generator winding temperature and generator bearing
temperature displays)
 Oil and engine cooling water circuits, with displays of oil pressure and temperature, and
cooling water pressure and temperature.
 Exhaust gas temperatures in a column graph which also displays the average
temperature.
 Main engine controller
 Module auxiliary controller

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Orgine: TPE | Gruber Robert Checked: Electrical Engineering Date: 08.05.2015

Index: - Page: 22 | 30
3.1
Technical specification of the control

 Auxiliary systems (status display)

 Operational data, i.e. operating hours, service hours, number of starts, active power
demand (kWh), reactive power demand (kVArh), and measured values for operational
logbook.
 System display, i.e. time, password, brightness, contrast, diagnostics.

Graphic trending display of up to 16 measured values:

 Long term trending (1 month at a storage interval of 30 sec.)

 Short term trending (20 min. at a storage interval of 1 sec.) - stopped and stored in the
event of a malfunction.

Recipe handling:
Setting, display and storage of all module parameters

Alarm management:
 Efficient diagnostic instrumentation listing all active fault messages both tabular and chronologically,
with the recorded time.

b) Central engine and module control:

A real-time, modular industrial control system which handles all jobs for module and engine-side sequencing
control (start preparation, start, stop, after-cooling, control of auxiliaries), as well as all control functions.

Interfaces:

Control functions:
- Speed control in idle mode and isolated operation
- Power output control in mains parallel operation, with respect to internal and external setpoint values
- LEANOX control system: the manifold pressure is controlled by the engine-driven air-gas mixer in
accordance with the generator terminal power and the charge temperature
- Knock control system: adjustment of ignition point, power output and (insofar as possible on site) the charge
temperature in the event that knocking is detected
- Active load sharing where several engines are running in isolated operation
- Linear reduction of power output in the event of excessive charge temperature and misfiring

 Interface relays as per the interface list

 Multi-transducer, to record the following electrically measured variables of the generator:
 Phase current (with slave pointer)
 Neutral conductor current
 Voltages Ph/Ph and Ph/N
 Active power (with slave pointer)
 Reactive power
 Apparent power
 Power factor

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Orgine: TPE | Gruber Robert Checked: Electrical Engineering Date: 08.05.2015

Index: - Page: 23 | 30
3.1
Technical specification of the control

 Frequency
An additional 0 (4) - 20 mA output is produced for active power, as well as a pulse output for active power
demand.

The following generator supervisions are integrated with the multi-transducer (max. 8 functions simultaneous):
- Overload/short-circuit [51], [50]
- Over voltage [59]
- Undervoltage [27]
- Asymmetric voltage [64], [59N]
- Unbalance current [46]
- Failure Exitation [40]
- Overfrequency [81>]
- Underfrequency [81<]

 Lockable service selector switch with the following positions:

 "Stop": No start up possible
If the engine runs and the switch is turned to "STOP" the engine stops immediately.
 "Manual": Full manual operation (start, stop) possible.
The module is not available for full automatic operation.
 "Automatic": Full automatic operation in case of request from the master
control or potential free contact.
- Automatic start
- Fully automatic operation with internal | external power command
- Shut down of module includes 1 minute engine cool down run and
5 minute cool down run for the auxiliaries.

 Module demand selector-switch with the settings:

 external demand not available. („OFF“)
 external demand. („REMOTE“)
 external demand contacts shorted. („ON“)

Supply disconnecting device for auxiliaries with lockable switch- disconnector

 STATUS MESSAGES
In the status bar of the GUI, the current operational status of the module will
be displayed. eg.
SERVICE SELECTOR SWITCH OFF
SERVICE SELECTOR SWITCH MANUAL NOT READY TO START
SERVICE SELECTOR SWITCH AUTOMATIC NOT READY TO START
READY FOR MANUAL START ENGINE STOPPED
READY FOR AUTOMATIC START ENGINE STOPPED
START PROGRAM RUNNING
START ENGINE (PUSH START BUTTON) (IN MANUAL OPERATION)
WAITING TIME BEFORE RELEASE OF NEXT MANUAL START (IN MANUAL OPERATION)
AUTOMATIC START IS RUNNING (IN AUTOMATIC OPERATION)
START PROGRAM: ENGINE RUNNING UP TO RATED SPEED
ENGINE IDLE OPERATION NO SYNCHRONIZE-/LOAD RELEASE

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Orgine: TPE | Gruber Robert Checked: Electrical Engineering Date: 08.05.2015

Index: - Page: 24 | 30
3.1
Technical specification of the control

ENGINE IDLE OPERATION SYNCHRONIZE-/LOAD RELEASE

SYNCHRONIZING IS RUNNING
MAINS-PARALLEL OPERATION
ISLAND OPERATION
RE-SYNCHRONIZING IS RUNNING
STOP PROGRAM: ENGINE COOL DOWN RUN
STOP PROGRAM: ENGINE STOP SEQUENCE
MODULE LOCKED OUT

 FAILURE MESSAGES MODULE CONTROL (ALARM MANAGEMENT):

see Appendix "ALARM LIST (STÖRMELDELISTE)"!

 Synchronizing unit - with frequency balance and following displays:

 Double voltmeter - for monitoring of bus bar and generator voltage
 Double frequency meter - for monitoring of bus bar and generator frequency
 Synchronouscope - for monitoring of the synchronizing function during synchronization
 Mains protection relay (f <>, V <>, ) .
 All required control, display and command devices

Synchronizing monitoring see Appendix "ALARM LIST”

Thermostatically controlled 41W cabinet ventilator.

Dimensions:
height = 2200 mm (incl. 200 mm pedestal)
width = 1000 mm
depth = 600 mm

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Orgine: TPE | Gruber Robert Checked: Electrical Engineering Date: 08.05.2015

Index: - Page: 25 | 30
3.1
Technical specification of the control

7.2 Module Interface Cabinet

All enclosed sheet steel cabinet with forward opening door (double doors as option), fitted with
rubber profile seals. Fitted to module skid and wired to the module auxiliaries and engine.
Painted in RAL 7035

Protection class: IP54 external.

Power supply from the starter battery charger.

Power distribution to the module mounted auxiliaries: (Power input from the supplier
of the auxiliaries power supply) .

comprising:
 terminal strip with cable entry from bottom
 decentral I/O system connected via an serial interface with the central engine control
system in the module control cabinet.
 measurement transducer for generator exciter voltage.
 relays, protection, motor contactors for auxiliary and valve control.
Thermostatically controlled 41W cabinet ventilator.

Module interface cabinet dimensions:

width = 1200mm
height = 1300mm
depth = 400mm

8. Remote Data-Transfer with DIA.NE XT - HERMES

8.1 General
HERMES is the remote data transfer solution for DIA.NE XT. HERMES is available via two connection methods
and applications.

8.2 Connections methods

8.2.1 Modem
Site-Customer connection via an analogue Modem.

Scope of supply
 DIA.NE WIN – Server (Industrial PC without display, keyboard or mouse, built into the control panel,
including operating system)
 Internal analogue modem.

Customer Requirements
 Analogue modem in the customers PC
 Public telephone connection with connection port for the DIA.NE WIN – Server (in the control panel)
including over-voltage protection corresponding to the local telecommunication regulations.
 Public telephone connection with connection port for the customer’s PC corresponding to the local
telecommunication regulations.

8.2.2 LAN
Site-Customer connection via a local network.

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Orgine: TPE | Gruber Robert Checked: Electrical Engineering Date: 08.05.2015

Index: - Page: 26 | 30
3.1
Technical specification of the control

Scope of supply
 DIA.NE WIN – Server (Industrial PC without display, keyboard or mouse, built into the control panel,
including operating system)
 Ethernet – Network card (10/100 BASE T)

Customer Requirements
 Ethernet – Network card (10/100 BASE T)
 Ethernet – Cabling between the DIA.NE WIN – Server the customers PC.

8.2.3 Internet (OPTION)

Site – Customer connection via secure Internet access

Scope of Supply
DIA.NE WIN – Server (Industrial PC without display, keyboard or mouse, built into the control panel, including
operating system)
Ethernet–Network card (10/100 BASE T)
Firewall–Appliance with connection feasibility to a customer network with a maximum of 10 Hosts (Installation
and service by GE Jenbacher; during warranty period included, afterwards as a service package with costs)
(built into the control panel)
Feature – service package (access monitoring, clock synchronization for server)

Customer Requirements
Broad band Internet access with at least two official IP addresses.
Connection feasibility for the Firewall–Appliance to the Internet–Router via Ethernet
(RJ45 Connector, Network Address Translation (NAT) is not permitted) or USB type A Connector.

8.3 Applications

8.3.1 DIA.NE WIN (OPTION)

DIA.NE WIN is the Windows based „man-machine interface“ for GE Jenbacher gas engines. The system offers
extensive facilities for commissioning, monitoring, servicing and analysis of the site. The option DIA.NE WIN
extends the visualisation of DIA.NE XT with respect to user friendliness, historical analysis and remote use.
Several service stations can be independently operated in parallel. The system consists of a central PC (DIA.NE
WIN – Server) which is built in to the control panel and one or more service stations (DIA.NE WIN – Clients). The
system runs on a Microsoft Internet Explorer platform.

Function
Service and monitoring, trend analysis, alarm management, parameter management, long-term data analysis,
multi-user system, remote control, OPC (OLE for process control), print and export functions, operating data
protocols, available in several languages.

Scope of supply
Software package DIA.NE WIN on the DIA.NE WIN – Server
DIA.NE WIN – Client Licence (Right to access of the user to the server on site)

Customer requirements
 Standard PC with keyboard, mouse and monitor (min. resolution 1024*768)
 230 V supply for the customers’ PC
 Operating system Windows 98, Windows NT, Windows 2000 or Windows XP
 Microsoft Internet Explorer (min. Version 6.0) including Java support

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Orgine: TPE | Gruber Robert Checked: Electrical Engineering Date: 08.05.2015

Index: - Page: 27 | 30
3.1
Technical specification of the control

8.3.2 DIA.NE RMC (OPTION)

DIA.NE RMC (Remote Message Control) is the automatic alarm system for DIA.NE XT. DIA.NE RMC can fully
automatically transmit essential operational information from the DIA.NE XT Alarm Management to a remote
station. The messages can be forwarded to an e-mail address, fax machine or mobile phone (SMS).
Furthermore the stored messages can be visualised at the remote station. The system consists of a central PC
(DIA.NE WIN – Server) which is built into the control panel and one or more customer remote stations.

Function
Automatic transfer of messages to the customer via email, fax or SMS. Display and printing of the messages
(also distributed via LAN). Automatic and manual transferral of messages, trend data and operating data
protocols.

Scope of supply
Software package DIA.NE message on the DIA.NE WIN – Server
Software package DIA.NE control and DIA.NE report on the remote station

Customer requirements
 Standard PC with keyboard, mouse and monitor (min. resolution 1024*768)
 230 V supply for the customers’ computer.
 Operating system Windows NT or Windows XP
 Internet connection (provider account) for the case that messages from the RMC should be
forwarded to an email receiver (incl. SMS for mobiles and pagers). (Mobiles and pagers to be provided by
the customer).
 Customer fax software for message forwarding via fax

OPTION:
8.3.2.1 DIA.NE message
DIA.NE message is installed on the modem servers of the plants. It is responsible for the transmission of
messages and data to DIA.NE control in the RDT control centers.

Message transmission:
The processing of alarm messages on the module visualization units is carried out by AMM (Alarm
Management) from DIA.NE. AMM records operational messages, warnings and malfunctions leading to
shutdowns (the latter two are also designated as alarm messages).

Prior to a transmission the messages generated by the modules are examined according to various criteria so
that the message transmission can be influenced in a specific way. The following criteria can be set:

Module, Message designation, Message number, Message type, Weekday, Time of the occurrence

If a message is classified as “to be transmitted”, it is then augmented with the plant code, plant number,
module designation and the module number and transmitted to the configured RDT control centers.

Data transmission:
The HTM (Historical Trend Management) function records measured values cyclically on the DIA.NE
visualization units and stores them in so-called log files.

OPTION:

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Orgine: TPE | Gruber Robert Checked: Electrical Engineering Date: 08.05.2015

Index: - Page: 28 | 30
3.1
Technical specification of the control

With the RPM (Report Management) function reports (e.g. operational logbook) can be automatically generated
which then are available as report files.

These files, which are stored in the modules, can be transferred manually or automatically to any desired RDT
control centers.

OPTION:
8.3.2.2 DIA.NE control
In the RDT control centers DIA.NE control regulates the reception and archiving of all incoming messages and
data. Additionally, the relaying of messages and reports via Fax and eMail (incl. SMS for cellular phones and
pagers) is organized for communication with service personnel.

Messages which are received from the plants are examined according to various criteria prior to being relayed
so that communication can be purposely influenced. The following criteria can be set:

Plant code, Plant number, Module, Message designation, Message number, Message type
Weekday, Time of the occurrence, Communication type (Fax, eMail, SMS)

For automatic protocolling, all recorded messages can be printed out daily. A connection check can be
activated to examine the RDT link between the modem servers and the RDT control centers. This ensures that a
check call is carried out on a daily basis.

OPTION:
8.3.2.3 DIA.NE report
With DIA.NE report one can display and print out messages received in an RDT control center on any number of
workstations (standard PCs). To do this, the PC must be linked via a LAN to the RDT control center. For the
message display one can select both the language and the desired plants.

For automatic protocoling all received messages can be printed out daily regarding specific plants. Through
DIA.NE report it is also possible to print out manually compiled protocols at any time.

OPTION:
8.3.3 Remote demand/blocking with HERMES
If the service selector switch at the module control panel is in pos."automatic" and the demand-selector switch
in pos."Remote", it is possible to enable (demanded) or disable (demand off) the module with a remote
controllable key at the visualisation.
Note:
With this option it makes no sense to have an additional clients demand (via hardware or data bus)
or a selfguidet operation (via GE Jenbacher master control, grid import /export etz.).

OPTION:
8.3.4 Remote - reset (see TA-Nr. 1100-0111 chapter 1.7)

8.4 Technical prerequisites

The customer has the responsibility to ensure that a telephone line with a separate number is available no later
than the start-up of operations. The connection must be installed in the module control cabinet in which the
modem server is installed. The telephone line must be operative and the number known. No charge (=tariff)
impulses may be applied to the line since they could interfere with data transmission. For the telephone line on

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Orgine: TPE | Gruber Robert Checked: Electrical Engineering Date: 08.05.2015

Index: - Page: 29 | 30
3.1
Technical specification of the control

the customers side an over voltage protection has to be provided which corresponds with local rules and
regulations of the telephone provider.

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Orgine: TPE | Gruber Robert Checked: Electrical Engineering Date: 08.05.2015

Index: - Page: 30 | 30
GE
Energy

Alarm List
STÖRMELDELISTE

1 x JGS 616 GS-N.L

AB Energy 616 - 31
J S889

Index: -
Revisions reserved!
Vorbehaltlich techn. Änderungen!

© GE Jenbacher GmbH & Co OG

Achenseestr. 1-3
A-6200 Jenbach (Austria)
3.1
Alarm list | Störmeldeliste

FAILURE MESSAGES MODULE CONTROL (TRIP) Message No.

Prior.
Index
STÖRMELDUNGEN MODULSTEUERSCHRANK MIT ABSTELLUNG Meldungs-Nr.

 FAILURE MESSAGES (ALARM MANAGEMENT)

Comments: OPT = OPTION
Only monitoring functions messages which are marked with a "X" are included.
CYLINDER xx = CYLINDER 1, 2, ...
CYLINDER xx/yy = CYLINDER 1/2, 3/4, ...

 STÖRMELDUNGEN (ALARM MANAGEMENT)

Anmerkung: OPT = OPTION
Es sind nur die mit "X" bezeichneten Überwachungen vorhanden.
Zylinder xx = Zylinder 1, 2, ...
Zylinder xx/yy = Zylinder 1/2, 3/4, ...

Prioritäten:
Priorität 1: Zündung aus,
Generatorschalter auf,
Magnetventile zu.
Priorität 2: Magnetventile zu,
Generatorschalter auf bei P < 10 % Pn, spätestens jedoch nach 1 Sekunde
Priorität 3: Anforderung aus,
normale Abstellung mit Kühllauf.

Priorities:
Priority 1: Ignition off,
Generator CB open,
Solenoid valves closed.
Priority 2: Solenoid valves closed,
Generator CB open at P < 10 % PN, but no later than after 1 second.
Priority 3: Demand off,
normal shutdown with cooling run.

OPT X Failure steam boiler 1001 2

Störung Dampfkessel
OPT X Heating circuit monitoring trip 1002 2
Heizkreisüberwachung ausgelöst
OPT X Exhaust gas temperature after 1003 3
Abgastemperatur nach Turbolader Maximum
OPT X Reserve failure 4 trip 1004 3
Generatorschalter Einschaltfehler nach Entregung
OPT Reserve failure 5 trip 1005
Reservestörung 5 abstellend
OPT Reserve failure 6 trip 1006
Reservestörung 6 abstellend
OPT Reserve failure 7 trip 1007
Reservestörung 7 abstellend
OPT Reserve failure 8 trip 1008
Reservestörung 8 abstellend

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Issued: TPE | Wagner Peter Checked: Electrical Engineering Date.: 18.06.2015

Index: - Page No.: 2 | 34
3.1
Alarm list | Störmeldeliste

FAILURE MESSAGES MODULE CONTROL (TRIP) Message No.

Prior.
Index
STÖRMELDUNGEN MODULSTEUERSCHRANK MIT ABSTELLUNG Meldungs-Nr.

OPT Reserve failure 9 trip 1009

Reservestörung 9 abstellend
OPT Reserve failure 10 trip 1010
Reservestörung 10 abstellend
OPT Reserve failure 11 trip 1011
Reservestörung 11 abstellend
OPT Reserve failure 12 trip 1012
Reservestörung 12 abstellend
OPT Reserve failure 13 trip 1013
Reservestörung 13 abstellend
OPT Reserve failure 14 trip 1014
Reservestörung 14 abstellend
OPT Reserve failure 15 trip 1015
Reservestörung 15 abstellend
OPT Reserve failure 16 trip 1016
Reservestörung 16 abstellend
X Oil pressure low 1017 2
Öldruck Minimum
X Engine oil level low 1018 3
Ölstand Motor Minimum
X Jacket water pressure low 1019 2
Kühlwasserdruck Minimum
OPT Jacket water level low 1020 2
Kühlwasserstand Minimum
X Jacket water temperature high 1021 3
Kühlwassertemperatur Maximum
OPT Overspeed (relay) 1022 1
Überdrehzahl (Relais)
X Start up failure 1023 3
Anlaufstörung
Reserve 1024
Reserve
Reserve 1025
Reserve
X Shutdown failure 1026 2
Abstellstörung
X Failure gas train 1 1027 3
Störung Gasstrecke 1
X Gas pressure low in gas train 1 1028 2
Gasdruck Minimum Gasstrecke 1
OPT Failure gas train 2 1029 3
Störung Gasstrecke 2
OPT Gas pressure low in gas train 2 1030 2
Gasdruck Minimum Gasstrecke 2
X Emergency stop / safety loop 1031 2
Not-Halt / Sicherheitsschleife

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Issued: TPE | Wagner Peter Checked: Electrical Engineering Date.: 18.06.2015

Index: - Page No.: 3 | 34
3.1
Alarm list | Störmeldeliste

FAILURE MESSAGES MODULE CONTROL (TRIP) Message No.

Prior.
Index
STÖRMELDUNGEN MODULSTEUERSCHRANK MIT ABSTELLUNG Meldungs-Nr.

OPT X Heating water flow low 1032 3

Heizwasserdurchfluss Minimum
OPT X Heating water temperature high 1033 2
Heizwassertemperatur Maximum
OPT Heating water pressure low 1034 2
Heizwasserdruck Minimum
OPT X Heating water pressure high 1035 2
Heizwasserdruck Maximum
X Generator overload/short circuit 1036 2
Generator Überlast/Kurzschluss
OPT Generator winding temperature high 1037 2
Generatorwicklungstemperatur Maximum
X Generator reverse power 1038 2
Generator Rückleistung
X Synchronizing failure 1039 2
Synchronisierstörung
X Charge temperature maximum 1040 2
Ladetemperatur Maximum
X Power signal missing 1041 2
Leistungssignal ausgefallen
X Power signal overload 1042 2
Leistungssignal Überlast
X Engine oil temperature high 1043 3
Öltemperatur Maximum
OPT X Cylinder exhaust gas temperature deviation from average value 1044 3
Abgastemperatur Zylinder Abweichung vom Mittelwert
Reserve 1045
Reserve
Reserve 1046
Reserve
X Misfiring failure 1047 3
Aussetzerstörung
OPT Knocking failure 1048 2
Klopfstörung
OPT X Cylinder exhaust gas temperature absolute value high 1049 3
Abgastemperatur Zylinder Maximum Überschreitung Absolutwert
X Jacket water pressure high 1050 3
Kühlwasserdruck Maximum
X Engine oil level high 1051 3
Ölstand Motor Maximum
X Gas pre-alarm 1052 2
Gasvoralarm
X Gas alarm 1053 2
Gasalarm
X Fire alarm 1054 2
Brandalarm

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Issued: TPE | Wagner Peter Checked: Electrical Engineering Date.: 18.06.2015

Index: - Page No.: 4 | 34
3.1
Alarm list | Störmeldeliste

FAILURE MESSAGES MODULE CONTROL (TRIP) Message No.

Prior.
Index
STÖRMELDUNGEN MODULSTEUERSCHRANK MIT ABSTELLUNG Meldungs-Nr.

Reserve 1055
Reserve
X Fail safe loop tripped 1056 2
Ruhestromschleife unterbrochen
OPT X High gas pressure in gas train 1 1057 3
Gasdruck Maximum Gasstrecke 1
OPT High gas pressure in gas train 2 1058 3
Gasdruck Maximum Gasstrecke 2
OPT Oil filter differential pressure high 1059 2
Ölfilterdifferenzdruck Maximum
OPT X Pre-lube pressure low 1060 2
Vorschmierdruck Minimum
OPT Ignition system failure 1061 1
Zündung gestört
Reserve 1062
Reserve
OPT X Heating water supply temperature high 1063 3
Vorlauftemperatur Maximum
X Overspeed (RPS-control system) 1064 1
Überdrehzahl (RPS)
Reserve 1065
Reserve
Reserve 1066
Reserve
Reserve 1067
Reserve
Reserve 1068
Reserve
Reserve 1069
Reserve
OPT Heating water return temperature measuring signal failure 1070 3
Messsignalstörung Rücklauftemperatur
OPT Heating water supply temperautre measuring signal failure 1071 3
Messsignalstörung Vorlauftemperatur
Reserve 1072
Reserve
X Multi measurement device: generator overload/short circuit 1073 2
Multimessumformer: Generator Überlast/Kurzschluss
Reserve 1074
Reserve
Reserve 1075
Reserve
Reserve 1076
Reserve
OPT X Boost pressure before throttle valve measuring signal failure 1077 2
Messsignalstörung Ladedruck vor Drosselklappe

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Issued: TPE | Wagner Peter Checked: Electrical Engineering Date.: 18.06.2015

Index: - Page No.: 5 | 34
3.1
Alarm list | Störmeldeliste

FAILURE MESSAGES MODULE CONTROL (TRIP) Message No.

Prior.
Index
STÖRMELDUNGEN MODULSTEUERSCHRANK MIT ABSTELLUNG Meldungs-Nr.

X Boost pressure measuring signal failure 1078 2

Messsignalstörung Ladedruckgeber
Reserve 1079
Reserve
X LEANOX control allowed deviation exceeded 1080 2
Leanoxregler zulässige Regeldifferenz überschritten
OPT Knock sensor measuring signal failure 1081 2
Messsignalstörung Klopfsensor
Reserve 1082
Reserve
OPT Control carburator defective 1083 2
Ansteuerung Gasmischer defekt
OPT Pre chamber gas pressure measuring signal failure 1084 2
Messsignalstörung Vorkammergasdruck
OPT Pre chamber gas pressure high 1085 2
Vorkammergasdruck Maximum
OPT CH4 content low 1086 2
CH4-Gehalt Minimum
OPT O2 content high 1087 2
O2-Gehalt Maximum
OPT O2 content measuring signal failure 1088 2
Messsignalstörung O2-Gehalt
Reserve 1089
Reserve
OPT X Malfunction of engine cooling water pump 1090 2
Störung Motorkühlwasserpumpe
Reserve 1091
Reserve
OPT X Scavenging flap failure 1092 2
Störung Spülluftklappe
Reserve 1093
Reserve
OPT Deflagration protection 1094 3
Verpuffungsschutz
OPT X Pre chamber gas pressure low 1095 3
Vorkammergasdruck Minimum
Reserve 1096
Reserve
Reserve 1097
Reserve
Reserve 1098
Reserve
OPT Comms failure with plant management system 1099 3
Ausfall Kommunikation mit zentraler Leittechnik
OPT X Water ingress into inlet manifold 1100 3
Wassereinbruch Ansaugleitung

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Issued: TPE | Wagner Peter Checked: Electrical Engineering Date.: 18.06.2015

Index: - Page No.: 6 | 34
3.1
Alarm list | Störmeldeliste

FAILURE MESSAGES MODULE CONTROL (TRIP) Message No.

Prior.
Index
STÖRMELDUNGEN MODULSTEUERSCHRANK MIT ABSTELLUNG Meldungs-Nr.

OPT X Transformer failure 1101 2

Störung Transformator
Reserve 1102
Reserve
Reserve 1103
Reserve
Reserve 1104
Reserve
X Charge temperature fluctuation speed maximum 1105 2
Änderungsgeschwindigkeit Ladetemperatur Maximum
Reserve 1106
Reserve
Reserve 1107
Reserve
Reserve 1108
Reserve
X Generator loss of excitation 1109 2
Generator Erregerausfall
X Generator frequency too low 1110 2
Generatorfrequenz zu nieder
X Generator frequency too high 1111 2
Generatorfrequenz zu hoch
X Neutral current maximum 1112 2
Nulleiterstrom Maximum
X Generator power measuring signal failure 1113 2
Messsignalstörung Istleistung
X Measuring signal failure charge temperature 1114 3
Messsignalstörung Ladetemperatur
Reserve 1115
Reserve
Reserve 1116
Reserve
Reserve 1117
Reserve
Reserve 1118
Reserve
Reserve 1119
Reserve
X Speed measuring signal failure 1120 2
Messsignalstörung Drehzahlmessung
OPT X Generator winding L1 temperature high 1121 2
Generatorwicklungstemperatur L1 Maximum
OPT X Generator winding L2 temperature high 1122 2
Generatorwicklungstemperatur L2 Maximum
OPT X Generator winding L3 temperature high 1123 2
Generatorwicklungstemperatur L3 Maximum

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Issued: TPE | Wagner Peter Checked: Electrical Engineering Date.: 18.06.2015

Index: - Page No.: 7 | 34
3.1
Alarm list | Störmeldeliste

FAILURE MESSAGES MODULE CONTROL (TRIP) Message No.

Prior.
Index
STÖRMELDUNGEN MODULSTEUERSCHRANK MIT ABSTELLUNG Meldungs-Nr.

OPT X Generator bearing drive end DE temperature maximum 1124 2

Generatorlagertemperatur Antriebsseite DE Maximum
OPT X Generator bearing non-drive end NDE temperature maximum 1125 2
Generatorlagertemperatur Nichtantriebsseite NDE Maximum
X Generator voltage low 1126 2
Generatorspannung zu nieder
X Generator voltage high 1127 2
Generatorspannung zu hoch
OPT Flame arrestors 1128 2
Flammrückschlagsicherung
X Failure auxiliaries 1129 2
Störung Hilfsbetriebe
Reserve 1130
Reserve
Reserve 1131
Reserve
OPT X Differential protection 1132 2
Differentialschutz
Reserve 1133
Reserve
OPT X Ground failure 1134 2
Erdschluss
OPT X Room temperature high 1135 3
Raumtemperatur Maximum
Reserve 1136
Reserve
OPT Mains starting device failure 1137 3
Störung Netzstartgerät
Reserve 1138
Reserve
Reserve 1139
Reserve
X Module interface panel circuit breaker tripped 1140 2
Sicherungsfall Modulinterfaceschrank
Reserve 1141
Reserve
Reserve 1142
Reserve
X Voltage negative sequence 1143 2
Spannungsasymmetrie
X Current negative sequence 1144 2
Stromasymmetrie
Reserve 2001
Reserve :
2060

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Issued: TPE | Wagner Peter Checked: Electrical Engineering Date.: 18.06.2015

Index: - Page No.: 8 | 34
3.1
Alarm list | Störmeldeliste

FAILURE MESSAGES MODULE CONTROL (TRIP) Message No.

Prior.
Index
STÖRMELDUNGEN MODULSTEUERSCHRANK MIT ABSTELLUNG Meldungs-Nr.

Reserve 2201
Reserve
Reserve 2202
Reserve
Reserve 2203
Reserve
Reserve 2204
Reserve
Reserve 2205
Reserve
Reserve 2206
Reserve
Reserve 2207
Reserve
Reserve 2208
Reserve
Reserve 2209
Reserve
Reserve 2210
Reserve
Reserve 2211
Reserve
Reserve 2212
Reserve
OPT Oil filter for turbocharger differential pressure maximum 2213 3
Ölfilter für Turbolader Differenzdruck Maximum
Reserve 2214
Reserve
Reserve 2215
Reserve
Reserve 2216
Reserve
Reserve 2217
Reserve
Reserve 2218
Reserve
Reserve 2219
Reserve
Reserve 2220
Reserve
OPT Measuring signal failure charge temperature before high-pressure turbocharger A 2221 3
Messsignalstörung Ladetemperatur vor Hochdruck-Turbolader A
OPT Measuring signal failure charge temperature before high-pressure turbocharger B 2222 3
Messsignalstörung Ladetemperatur vor Hochdruck-Turbolader B
OPT Charge temperature before high-pressure turbocharger maximum 2223 3
Ladetemperatur vor Hochdruck-Turbolader Maximum

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Issued: TPE | Wagner Peter Checked: Electrical Engineering Date.: 18.06.2015

Index: - Page No.: 9 | 34
3.1
Alarm list | Störmeldeliste

FAILURE MESSAGES MODULE CONTROL (TRIP) Message No.

Prior.
Index
STÖRMELDUNGEN MODULSTEUERSCHRANK MIT ABSTELLUNG Meldungs-Nr.

OPT Measuring signal failure pressure after turbocharger oil filter 2224 3
Messsignalstörung Druck nach Turbolader Ölfilter
OPT High-pressure turbocharger speed inclination maximum 2225 3
Hochdruck-Turbolader Drehzahlspreizung Maximum
OPT Low-pressure turbocharger speed inclination maximum 2226 3
Niederdruck-Turbolader Drehzahlspreizung Maximum
Reserve 2227
Reserve
Reserve 2228
Reserve
Reserve 2229
Reserve
Reserve 2230
Reserve
Reserve 2231
Reserve
Reserve 2232
Reserve
OPT Pressure after turbocharger oil filter maximum 2233 3
Druck nach Turbolader Ölfilter Maximum
OPT Pressure after turbocharger oil filter minimum 2234 2
Druck nach Turbolader Ölfilter Minimum
Reserve 2235
Reserve
Reserve 2236
Reserve
OPT High-pressure turbocharger speed maximum 2237 3
Hochdruck-Turbolader Drehzahl Maximum
OPT Turbocharger pre-lube pressure minimum 2238 2
Turbolader Vorschmierdruck Minimum
OPT Low-pressure turbocharger speed maximum 2239 3
Niederdruck-Turbolader Drehzahl Maximum
Reserve 2240
Reserve
Reserve 2241
Reserve
Reserve 2242
Reserve
Reserve 2243
Reserve
Reserve 2244
Reserve
Reserve 2245
Reserve
Reserve 2246
Reserve

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Issued: TPE | Wagner Peter Checked: Electrical Engineering Date.: 18.06.2015

Index: - Page No.: 10 | 34
3.1
Alarm list | Störmeldeliste

FAILURE MESSAGES MODULE CONTROL (TRIP) Message No.

Prior.
Index
STÖRMELDUNGEN MODULSTEUERSCHRANK MIT ABSTELLUNG Meldungs-Nr.

Reserve 2247
Reserve
Reserve 2248
Reserve
Reserve 2249
Reserve
Reserve 2250
Reserve
Reserve 2251
Reserve
Reserve 2252
Reserve
Reserve 2253
Reserve
Reserve 2254
Reserve
Reserve 2255
Reserve
Reserve 2256
Reserve
Reserve 2257
Reserve
OPT Measuring signal failure charge temperature t2 A 2258 3
Messsignalstörung Ladetemperatur t2 A
OPT Measuring signal failure charge temperature t2 B 2259 3
Messsignalstörung Ladetemperatur t2 B
Reserve 2260
Reserve
Reserve 2261
Reserve
Reserve 2262
Reserve
Reserve 2263
Reserve
Reserve 2264
Reserve
Reserve 2265
Reserve
Reserve 2266
Reserve
Reserve 2267
Reserve
Reserve 2268
Reserve
Reserve 2269
Reserve

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Issued: TPE | Wagner Peter Checked: Electrical Engineering Date.: 18.06.2015

Index: - Page No.: 11 | 34
3.1
Alarm list | Störmeldeliste

FAILURE MESSAGES MODULE CONTROL (TRIP) Message No.

Prior.
Index
STÖRMELDUNGEN MODULSTEUERSCHRANK MIT ABSTELLUNG Meldungs-Nr.

Reserve 2270
Reserve
Reserve 2271
Reserve
Reserve 2272
Reserve
Reserve 2273
Reserve
OPT Maximum positive deviation of average cylinder peak pressure 2274 1
Maximale positive Abweichung vom Zylinderspitzendruck Mittelwert
OPT Misfiring failure PBC 2275 2
Aussetzerstörung DMR
OPT NOx deviation 2276 2
NOx Abweichung
X Generator voltage low 2 2277 2
Generatorspannung zu nieder 2
OPT Turbocharger speed maximum 2278 3
Turbolader Drehzahl Maximum
OPT Turbocharger speed spread maximum 2279 3
Turbolader Drehzahlspreizung Maximum
OPT Measuring signal failure, charge temperature before high-pressure turbocharger 2280 3
Messsignalstörung Ladetemperatur vor Hochdruck-Turbolader
OPT Cylinder pressure sensor membrane burst 2281 2
Zylinderdrucksensor Membranbruch
OPT Average cylinder peak pressure maximum 2282 2
Zylinderspitzendruck Mittelwert Maximum
OPT Backfire prevention 2283 2
Rückzündschutz
OPT Oil pan filling level maximum 2284 3
Füllstand Ölauffangwanne Maximum
Reserve 2285
Reserve :
2300
Reserve 3001
Reserve
Reserve 3002
Reserve
X Measuring signal failure 3003 3
Messsignalstörung (2101 | 2102 | 2103 | 2104 | 3152 > 24h)
OPT X Pre chamber differential pressure low 3004 2
Vorkammerdifferenzdruck Minimum
Reserve 3005
Reserve :
3024
OPT Ignition trigger pickup missing 3025 2
Zündung Ausfall Trigger Pickup

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Issued: TPE | Wagner Peter Checked: Electrical Engineering Date.: 18.06.2015

Index: - Page No.: 12 | 34
3.1
Alarm list | Störmeldeliste

FAILURE MESSAGES MODULE CONTROL (TRIP) Message No.

Prior.
Index
STÖRMELDUNGEN MODULSTEUERSCHRANK MIT ABSTELLUNG Meldungs-Nr.

OPT Ignition reset pickup missing 3026 2

Zündung Ausfall Reset Pickup
OPT Ignition CAM pickup missing 3027 2
Zündung Ausfall CAM Pickup
OPT Ignition shutoff overspeed 3028 2
Zündung Überdrehzahlabstellung
OPT Ignition CPU failure 3029 2
Zündung CPU Fehler
OPT Ignition parameter failure 3030 3
Zündung Parameter Fehler
OPT Ignition CAN communication failure 3031 3
Zündung CAN Kopplung gestört
Reserve 3032
Reserve :
3051
OPT Wrong type of ignition system 3052 3
Falsches Zündsystem
Reserve 3053
Reserve :
3092
OPT X Gas proportioning valve CAN communication failure 3093 2
Gasdosierventil CAN Kopplung gestört
OPT X Gas proportioning valve wrong software 3094 3
Gasdosierventil falsche Software
OPT X Gas proportioning valve fuel gas temperature out of limits 3095 2
Gasdosierventil Gastemperatur nicht erfüllt
OPT X Gas proportioning valve fuel gas pre-pressure out of limits 3096 2
Gasdosierventil Gasvordruck nicht erfüllt
OPT X Gas proportioning valve internal failure 3097 2
Gasdosierventil interner Fehler
OPT X Gas proportioning valve mechanical malfunction 3098 2
Gasdosierventil mechanische Fehlfunktion
OPT X Step of fuel gas volume too high 3099 1
Gasmengensprung
Reserve 3100
Reserve
OPT Engine room purging cycle – Gas monitoring failure 3301 2
Maschinenraumluftspülung - Störung Gasüberwachung
OPT Engine room purging cycle not completed 3302 2
Maschinenraumluftspülung nicht abgeschlossen
Reserve 3303
Reserve
OPT X Oil pressure minimum transmission 3304 2
Öldruck Minimum Getriebe
OPT X Oil temperature maximum transmission 3305 3
Öltemperatur Maximum Getriebe

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Issued: TPE | Wagner Peter Checked: Electrical Engineering Date.: 18.06.2015

Index: - Page No.: 13 | 34
3.1
Alarm list | Störmeldeliste

FAILURE MESSAGES MODULE CONTROL (TRIP) Message No.

Prior.
Index
STÖRMELDUNGEN MODULSTEUERSCHRANK MIT ABSTELLUNG Meldungs-Nr.

OPT Thermal reactor: exhaust gas valve failure, middle position 3306 2
Thermoreaktor: Störung Abgasklappe Mittelstellung
OPT Safety loop thermal reactor 3307 2
Sicherheitsschleife Thermoreaktor
OPT Pressure of pre chamber gas compressor measuring signal failure 3308 2
Messsignalstörung Druck Vorkammergasverdichter
OPT Pressure of pre chamber gas compressor high 3309 2
Druck Vorkammergasverdichter Maximum
OPT Ignition output monitoring cylinder 3310 3
Zündung Ausgangsüberwachung Zylinder
X In/Out channel failure 3311 2
Fehler In/Out Kanäle
OPT Heating water return temperature after cooler measuring signal failure 3312 3
Messsignalstörung Rücklauftemperatur nach Kühler
OPT CO2 reactor temperature high 3313 2
CO2 Reaktortemperatur Maximum
OPT Failure CO2 flap 3314 2
Störung CO2 Klappe
OPT Pre chamber gas compressor oil level low 3315 3
Ölstand Vorkammergasverdichter Minimum
OPT Gas compressor failure 3316 2
Störung Gasverdichter
OPT Gas temperature high 3317 2
Gastemperatur Maximum
OPT Gas pressure low before gas compressor 3318 2
Gasdruck Minimum vor Gasverdichter
OPT Generator protection trip 3319 2
Generatorschutz ausgelöst
OPT Pressure of pre chamber gas train measuring signal failure 3320 3
Messsignalstörung Druck Vorkammergasstrecke
OPT Heating water return temperature before engine measuring signal failure 3321 3
Messsignalstörung Rücklauftemperatur vor Motor
OPT Crank case pressure high 3322 2
Kurbelgehäusedruck maximum
OPT Crank case pressure measuring signal failure 3323 2
Messsignalstörung Kurbelgehäusedruck
OPT Failure pre chamber gas compressor 3324 3
Störung Vorkammergasverdichter
OPT Gas pressure maximum – backfiring 3325 2
Gasdruck Maximum – Rückzündung
OPT Idling period gas compressor maximum 3326 3
Leerlaufzeit Gasverdichter Maximum
OPT Gas pressure before gas compressor measuring signal failure 3327 2
Messsignalstörung Gasdruck vor Gasverdichter
OPT Gas temperature measuring signal failure 3328 2
Messsignalstörung Gastemperatur

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Issued: TPE | Wagner Peter Checked: Electrical Engineering Date.: 18.06.2015

Index: - Page No.: 14 | 34
3.1
Alarm list | Störmeldeliste

FAILURE MESSAGES MODULE CONTROL (TRIP) Message No.

Prior.
Index
STÖRMELDUNGEN MODULSTEUERSCHRANK MIT ABSTELLUNG Meldungs-Nr.

OPT Earthing switch closed 3329 2

Erdungstrenner geschlossen
OPT X SAFI hardware failure 3330 1
SAFI Hardwarefehler
OPT X SAFI CAN communication failure 3331 3
SAFI CAN Kommunikation gestört
OPT X SAFI wrong type of software 3332 3
SAFI falsche Software
OPT X SAFI parameter failure 3333 3
SAFI Parameter Fehler
OPT Ignition point deviation too high 3334 3
Zündzeitpunktabweichung zu groß
OPT X SAFI shutoff overspeed 3335 1
SAFI Überdrehzahlabstellung
OPT X SAFI trigger pickup missing 3336 1
SAFI Ausfall Trigger Pickup
OPT X SAFI camshaft/reset pickup missing 3337 1
SAFI Ausfall Nockenwellen/Reset Pickup
OPT Ignition output failure 3338 2
Zündung Ausgangsfehler
OPT X Knocking failure 3339 2
Klopfstörung
OPT Misfiring failure 3340 3
Aussetzerstörung
OPT X Valve noise high 3341 2
Ventilgeräusch Maximum
OPT X Knock sensor measuring signal failure 3342 3
Messsignalstörung Klopfsensor
OPT X Ignition hardware failure 3343 2
Zündung Hardwarefehler
OPT X Ignition power supply failure 3344 1
Zündung Spannungsversorgung gestört
OPT X Ignition safety loop 3345 1
Zündung Sicherheitsschleife
OPT Ignition system 1 failure 3346 3
Zündung 1 gestört
OPT Ignition system 2 failure 3347 3
Zündung 2 gestört
OPT Glow ignition failure 3348 1
Störung Glühzünden
OPT N2 gas valves position failure 3349 2
Störung N2 Gasventilposition
OPT CO alarm 3350 2
CO Alarm
OPT Failure active filter 3351 2
Störung Aktivfilter

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Issued: TPE | Wagner Peter Checked: Electrical Engineering Date.: 18.06.2015

Index: - Page No.: 15 | 34
3.1
Alarm list | Störmeldeliste

FAILURE MESSAGES MODULE CONTROL (TRIP) Message No.

Prior.
Index
STÖRMELDUNGEN MODULSTEUERSCHRANK MIT ABSTELLUNG Meldungs-Nr.

OPT Disconnecting switch opened 3352 2

Trenner offen
OPT Gas pressure low in gas train 1 - line 2 3353 2
Gasdruck Minimum Gasstrecke 1 - Linie 2
OPT Gas pressure low in gas train 1 - line 3 3354 2
Gasdruck Minimum Gasstrecke 1 - Linie 3
OPT Gas pressure low in gas train 1 - line 4 3355 2
Gasdruck Minimum Gasstrecke 1 - Linie 4
OPT High gas pressure in gas train 1 - line 2 3356 3
Gasdruck Maximum Gasstrecke 1 - Linie 2
OPT High gas pressure in gas train 1 - line 3 3357 3
Gasdruck Maximum Gasstrecke 1 - Linie 3
OPT High gas pressure in gas train 1 - line 4 3358 3
Gasdruck Maximum Gasstrecke 1 - Linie 4
OPT Failure gas train 1 - line 2 3359 3
Störung Gasstrecke 1 - Linie 2
OPT Failure gas train 1 - line 3 3360 3
Störung Gasstrecke 1 - Linie 3
OPT Failure gas train 1 - line 4 3361 3
Störung Gasstrecke 1 - Linie 4
OPT Prechamber gas compressor suction maximum 3362 2
Saugdruck Vorkammergasverdichter Maximum
OPT Prechamber gas compressor gas outlet temperature maximum 3363 2
Gasaustrittstemperatur Vorkammergasverdichter Maximum
OPT Gas temperature after prechamber gas cooler maximum 3364 2
Gastemperatur nach Vorkammergaskühler Maximum
Reserve 3365
Reserve :
3396

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Issued: TPE | Wagner Peter Checked: Electrical Engineering Date.: 18.06.2015

Index: - Page No.: 16 | 34
3.1
Alarm list | Störmeldeliste

FAILURE MESSAGES MODULE CONTROL (WARNING) Message No.

Index
STÖRMELDUNGEN MODULSTEUERSCHRANK WARNEND Meldungs-Nr.

X Jacket water temperature low 1145

Kühlwassertemperatur Minimum
Reserve 1146
Reserve
OPT Comms failure with plant management system 1147
Ausfall Kommunikation mit zentraler Leittechnik
X Starter battery voltage low 1148
Starterbatteriespannung Minimum
Reserve 1149
Reserve
OPT Failure serial interface module 1150
Fehlermeldung von serieller Schnittstellenbaugruppe
OPT Data flow error serial interface module 1151
Unterbrechung Datenverkehr mit serieller Schnittstellenbaugruppe
Reserve 1152
Reserve
OPT Cylinder exhaust gas temperature measuring signal failure 1153
Messsignalstörung Abgastemperatur
OPT Generator winding L1 temperature high 1154
Generatorwicklungstemperatur L1 Maximum
OPT Generator winding L2 temperature high 1155
Generatorwicklungstemperatur L2 Maximum
OPT Generator winding L3 temperature high 1156
Generatorwicklungstemperatur L3 Maximum
OPT Generator bearing drive end DE temperature maximum 1157
Generatorlagertemperatur Antriebsseite DE Maximum
OPT Generator bearing non-drive end NDE temperature maximum 1158
Generatorlagertemperatur Nichtantriebsseite NDE Maximum
OPT Fresh oil tank level low 1159
Frischöltank Minimum
OPT Waste oil tank level high 1160
Altöltank Maximum
OPT Temperature before catalyst measuring signal failure 1161
Messsignalstörung Temperatur vor Katalysator
OPT Temperature after catalyst measuring signal failure 1162
Messsignalstörung Temperatur nach Katalysator
OPT Exhaust gas temperature after turbocharger measuring signal failure 1163
Messsignalstörung Abgastemperatur nach Turbolader
OPT Exhaust gas temperature after exhaust heat exchanger measuring signal failure 1164
Messsignalstörung Abgastemperatur nach Abgaswärmetauscher
OPT Scavenging fan failure 1165
Störung Spülluftventilator
OPT Oil supply failure 1166
Störung Ölversorgung

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Issued: TPE | Wagner Peter Checked: Electrical Engineering Date.: 18.06.2015

Index: - Page No.: 17 | 34
3.1
Alarm list | Störmeldeliste

FAILURE MESSAGES MODULE CONTROL (WARNING) Message No.

Index
STÖRMELDUNGEN MODULSTEUERSCHRANK WARNEND Meldungs-Nr.

OPT Heating water return temperature high 1167

Rücklauftemperatur Maximum
X Request for maintenance 1168
Wartungsanforderung
OPT Temperature before catalyst high 1169
Temperatur vor Katalysator Maximum
OPT Temperature after catalyst high 1170
Temperatur nach Katalysator Maximum
OPT Exhaust gas temperature after turbocharger high 1171
Abgastemperatur nach Turbolader Maximum
OPT Exhaust gas temperature after exhaust heat exchanger high 1172
Abgastemperatur nach Abgaswärmetauscher Maximum
Reserve 1173
Reserve
Reserve 1174
Reserve
OPT Mains failure 1175
Netzstörung
OPT Air inlet filter differential pressure high 1176
Zuluftfilterdifferenzdruck Maximum
OPT Reserve 1 - analogue measuring signal failure 1177
Messsignalstörung Reserveanalogwert 1
OPT Reserve 2 - analogue measuring signal failure 1178
Messsignalstörung Reserveanalogwert 2
OPT Reserve 3 - analogue measuring signal failure 1179
Messsignalstörung Reserveanalogwert 3
OPT Reserve 4 - analogue measuring signal failure 1180
Messsignalstörung Reserveanalogwert 4
OPT Reserve 5 - analogue measuring signal failure 1181
Messsignalstörung Reserveanalogwert 5
OPT Reserve 6 - analogue measuring signal failure 1182
Messsignalstörung Reserveanalogwert 6
OPT Reserve 7 - analogue measuring signal failure 1183
Messsignalstörung Reserveanalogwert 7
OPT Reserve 8 - analogue measuring signal failure 1184
Messsignalstörung Reserveanalogwert 8
OPT Generator winding temperature high 1185
Generatorwicklungstemperatur Maximum
OPT Heating water return temperature measuring signal failure 1186
Messsignalstörung Rücklauftemperatur
OPT Heating water supply temperature measuring signal failure 1187
Messsignalstörung Vorlauftemperatur
OPT Release from plant management system missing 1188
Freigabe aus zentraler Leittechnik fehlt
X Release from synchronizing missing 1189
Freigabe aus Synchronisierung fehlt

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Issued: TPE | Wagner Peter Checked: Electrical Engineering Date.: 18.06.2015

Index: - Page No.: 18 | 34
3.1
Alarm list | Störmeldeliste

FAILURE MESSAGES MODULE CONTROL (WARNING) Message No.

Index
STÖRMELDUNGEN MODULSTEUERSCHRANK WARNEND Meldungs-Nr.

Reserve 1190
Reserve
Reserve 1191
Reserve
OPT Throttle valve failure 1192
Störung Drosselklappe
OPT Reserve failure 1 warning 1193
Reservestörung 1 warnend
OPT Reserve failure 2 warning 1194
Reservestörung 2 warnend
OPT Reserve failure 3 warning 1195
Reservestörung 3 warnend
OPT Reserve failure 4 warning 1196
Reservestörung 4 warnend
OPT Reserve failure 5 warning 1197
Reservestörung 5 warnend
OPT Reserve failure 6 warning 1198
Reservestörung 6 warnend
OPT Reserve failure 7 warning 1199
Reservestörung 7 warnend
OPT Reserve failure 8 warning 1200
Reservestörung 8 warnend
OPT Reserve failure 9 warning 1201
Reservestörung 9 warnend
OPT Reserve failure 10 warning 1202
Reservestörung 10 warnend
OPT Reserve failure 11 warning 1203
Reservestörung 11 warnend
OPT Reserve failure 12 warning 1204
Reservestörung 12 warnend
OPT Reserve failure 13 warning 1205
Reservestörung 13 warnend
OPT Reserve failure 14 warning 1206
Reservestörung 14 warnend
OPT Reserve failure 15 warning 1207
Reservestörung 15 warnend
OPT Reserve failure 16 warning 1208
Reservestörung 16 warnend
OPT Mains CB status signal failure 1209
Netzschalter Stellungsrückmeldung gestört
OPT Mains CB opening failure 1210
Netzschalter Ausschaltstörung
OPT Mains CB closing failure 1211
Netzschalter Einschaltstörung
OPT Mains CB o-signal failure 1212
Störung 0-Signal Netzschalter

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Issued: TPE | Wagner Peter Checked: Electrical Engineering Date.: 18.06.2015

Index: - Page No.: 19 | 34
3.1
Alarm list | Störmeldeliste

FAILURE MESSAGES MODULE CONTROL (WARNING) Message No.

Index
STÖRMELDUNGEN MODULSTEUERSCHRANK WARNEND Meldungs-Nr.

OPT Mains CB 1-signal failure 1213

Störung 1-Signal Netzschalter
OPT Mains CB overload/short circuit 1214
Netzschalter Überlast/Kurzschluss
Reserve 1215
Reserve
X Bus bar voltage sensor failure 1216
Sammelschienenspannungswächter gestört
X Generator CB status signal failure 1217
Generatorschalter Stellungsrückmeldung gestört
X Generator CB opening failure 1218
Generatorschalter Ausschaltstörung
X Generator CB closing failure 1219
Generatorschalter Einschaltstörung
X Generator CB o-signal failure 1220
Störung 0-Signal Generatorschalter
X Generator CB 1-signal failure 1221
Störung 1-Signal Generatorschalter
OPT Generator manual-CB open 1222
Generatorschutzschalter Aus
Reserve 1223
Reserve
Reserve 1224
Reserve
OPT Cylinder xx exhaust gas temperature measuring signal failure 2061
(general message see No. 1153) :
Messsignalstörung Abgastemperatur Zylinder xx 2080
(Sammelmeldung siehe Nr. 1153)
Reserve 2081
Reserve
X Parameter missing 2082
Parameter fehlen
X RPS (control system) battery failure 2083
RPS (Regler) - Batterieausfall
X LEANOX algorithm failure 2084
Fehler bei der LOX - Geradenberechnung
Reserve 2085
Reserve
OPT Gasmixer position measuring signal failure 2086
Messsignalstörung Gasmischerposition
OPT Reserve failure 17 warning 2087
Reservestörung 17 warnend
OPT Reserve failure 18 warning 2088
Reservestörung 18 warnend
OPT Reserve failure 19 warning 2089
Reservestörung 19 warnend

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Issued: TPE | Wagner Peter Checked: Electrical Engineering Date.: 18.06.2015

Index: - Page No.: 20 | 34
3.1
Alarm list | Störmeldeliste

FAILURE MESSAGES MODULE CONTROL (WARNING) Message No.

Index
STÖRMELDUNGEN MODULSTEUERSCHRANK WARNEND Meldungs-Nr.

OPT Reserve failure 20 warning 2090

Reservestörung 20 warnend
OPT Reserve failure 21 warning 2091
Reservestörung 21 warnend
OPT Reserve failure 22 warning 2092
Reservestörung 22 warnend
OPT Reserve failure 23 warning 2093
Reservestörung 23 warnend
OPT Reserve failure 24 warning 2094
Reservestörung 24 warnend
OPT Reserve failure 25 warning 2095
Reservestörung 25 warnend
OPT Reserve failure 26 warning 2096
Reservestörung 26 warnend
X Deviation power setpoint to power present value maximum 2097
Leistungsistwertabweichung Maximum
OPT Exhaust gas valve failure 2098
Störung Abgasklappe
Reserve 2099
Reserve
OPT Differential protection relay failure 2100
Störung Differentialschutzgerät
X Jacket water temperature measuring signal failure 2101
Messsignalstörung Kühlwassertemperatur
X Engine oil temperature measuring signal failure 2102
Messsignalstörung Öltemperatur
X Engine oil pressure measuring signal failure 2103
Messsignalstörung Öldruck
X Jacket water pressure measuring signal failure 2104
Messsignalstörung Kühlwasserdruck
OPT Generator winding temperature measuring signal failure 2105
Messsignalstörung Generatorwicklungstemperatur
OPT Generator winding temperature L1 measuring signal failure 2106
Messsignalstörung Generatorwicklungstemperatur L1
OPT Generator winding temperature L2 measuring signal failure 2107
Messsignalstörung Generatorwicklungstemperatur L2
OPT Generator winding temperature L3 measuring signal failure 2108
Messsignalstörung Generatorwicklungstemperatur L3
OPT Generator bearing drive end DE temperature measuring signal failure 2109
Messsignalstörung Generatorlagertemperatur Antriebsseite DE
OPT Generator bearing non-drive end NDE temperature measuring signal failure 2110
Messsignalstörung Generatorlagertemperatur Nichtantriebsseite NDE
OPT Knock sensor measuring signal failure 2111
Messsignalstörung Klopfsensor
Reserve 2112
Reserve

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Issued: TPE | Wagner Peter Checked: Electrical Engineering Date.: 18.06.2015

Index: - Page No.: 21 | 34
3.1
Alarm list | Störmeldeliste

FAILURE MESSAGES MODULE CONTROL (WARNING) Message No.

Index
STÖRMELDUNGEN MODULSTEUERSCHRANK WARNEND Meldungs-Nr.

Reserve 2113
Reserve
OPT Preheating pump failure 2114
Störung Vorwärmpumpe
OPT Generator voltage regulator failure 2115
Störung Generatorspannungsregler
OPT Dump radiator failure 2116
Störung Kühler
OPT Charge cooler water pressure low 2117
Ladekühlwasserdruck Minimum
OPT Charge cooling water pump failure 2118
Störung Ladekühlwasserpumpe
OPT Charge cooler failure 2119
Störung Ladekühler
OPT Engine room ventilation failure 2120
Störung Raumluftventilatoren
OPT Generator rotating diode failure 2501
Generator Umlaufdioden Störung
Reserve 2502
Reserve
Reserve 2503
Reserve
Reserve 2504
Reserve
Reserve 2505
Reserve
Reserve 2506
Reserve
Reserve 2507
Reserve
Reserve 2508
Reserve
Reserve 2509
Reserve
Reserve 2510
Reserve
Reserve 2511
Reserve
Reserve 2512
Reserve
Reserve 2513
Reserve
OPT Failure throttle valve A1 2514
Störung Drosselklappe A1
Reserve 2515
Reserve

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Issued: TPE | Wagner Peter Checked: Electrical Engineering Date.: 18.06.2015

Index: - Page No.: 22 | 34
3.1
Alarm list | Störmeldeliste

FAILURE MESSAGES MODULE CONTROL (WARNING) Message No.

Index
STÖRMELDUNGEN MODULSTEUERSCHRANK WARNEND Meldungs-Nr.

OPT Failure throttle valve A2 2516

Störung Drosselklappe A2
Reserve 2517
Reserve
OPT Failure compressor bypass A1 2518
Störung Verdichterbypass A1
Reserve 2519
Reserve
OPT Failure compressor bypass B1 2520
Störung Verdichterbypass B1
Reserve 2521
Reserve
Reserve 2522
Reserve
Reserve 2523
Reserve
Reserve 2524
Reserve
Reserve 2525
Reserve
OPT High-pressure turbocharger speed maximum 2526
Hochdruck-Turbolader Drehzahl Maximum
OPT Low-pressure turbocharger speed maximum 2527
Niederdruck-Turbolader Drehzahl Maximum
OPT High-pressure turbocharger speed inclination maximum 2528
Hochdruck-Turbolader Drehzahlspreizung Maximum
OPT Low-pressure turbocharger speed inclination maximum 2529
Niederdruck-Turbolader Drehzahlspreizung Maximum
Reserve 2530
Reserve
OPT Charge temperature before high-pressure turbocharger minimum 2531
Ladetemperatur vor Hochdruck-Turbolader Minimum
OPT Charge temperature inclination before high-pressure turbocharger maximum 2532
Ladetemperaturspreizung vor Hochdruck-Turbolader Maximum
OPT Charge temperature before high-pressure turbocharger maximum 2533
Ladetemperatur vor Hochdruck-Turbolader Maximum
Reserve 2534
Reserve
Reserve 2535
Reserve
Reserve 2536
Reserve
Reserve 2537
Reserve
Reserve 2538
Reserve

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Issued: TPE | Wagner Peter Checked: Electrical Engineering Date.: 18.06.2015

Index: - Page No.: 23 | 34
3.1
Alarm list | Störmeldeliste

FAILURE MESSAGES MODULE CONTROL (WARNING) Message No.

Index
STÖRMELDUNGEN MODULSTEUERSCHRANK WARNEND Meldungs-Nr.

Reserve 2539
Reserve
Reserve 2540
Reserve
OPT Measuring signal failure charge pressure transducer p2 A 2541
Messsignalstörung Ladedruckgeber p2 A
Reserve 2542
Reserve
OPT Measuring signal failure charge pressure transducer p2 B 2543
Messsignalstörung Ladedruckgeber p2 B
Reserve 2544
Reserve
Reserve 2545
Reserve
OPT Exhaust gas temperature high after low pressure turbo charger A 2546
Abgastemperatur Maximum nach Niederdruck-Turbolader Bank A
OPT Exhaust gas temperature high after low pressure turbo charger B 2547
Abgastemperatur Maximum nach Niederdruck-Turbolader Bank B
Reserve 2548
Reserve
OPT Measuring signal failure exhaust gas temperature after low-pressure turbocharger A 2549
Messsignalstörung Abgastemperatur nach Niederdruck-Turbolader A
Reserve 2550
Reserve
OPT Measuring signal failure exhaust gas temperature after low-pressure turbocharger B 2551
Messsignalstörung Abgastemperatur nach Niederdruck-Turbolader B
Reserve 2552
Reserve
Reserve 2553
Reserve
OPT Pressure after turbocharger oil filter minimum 2554
Druck nach Turbolader Ölfilter Minimum
Reserve 2555
Reserve
Reserve 2556
Reserve
Reserve 2557
Reserve
Reserve 2558
Reserve
Reserve 2559
Reserve
Reserve 2560
Reserve
Reserve 2561
Reserve

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Issued: TPE | Wagner Peter Checked: Electrical Engineering Date.: 18.06.2015

Index: - Page No.: 24 | 34
3.1
Alarm list | Störmeldeliste

FAILURE MESSAGES MODULE CONTROL (WARNING) Message No.

Index
STÖRMELDUNGEN MODULSTEUERSCHRANK WARNEND Meldungs-Nr.

OPT Air humidity measuring signal failure 2562

Messsignalstörung Luftfeuchtigkeit
OPT Measuring signal failure speed high-pressure turbocharger A 2563
Messsignalstörung Drehzahl Hochdruck-Turbolader A
OPT Measuring signal failure speed high-pressure turbocharger B 2564
Messsignalstörung Drehzahl Hochdruck-Turbolader B
OPT Measuring signal failure speed low-pressure turbocharger A 2565
Messsignalstörung Drehzahl Niederdruck-Turbolader A
OPT Measuring signal failure speed low-pressure turbocharger B 2566
Messsignalstörung Drehzahl Niederdruck-Turbolader B
Reserve 2567
Reserve
Reserve 2568
Reserve
Reserve 2569
Reserve
Reserve 2570
Reserve
OPT Overvoltage protection auxiliaries supply failure 2571
Störung Überspannungsschutz Hilfsbetriebeversorgung
Reserve 2572
Reserve
OPT Overvoltage protection generator failure 2573
Störung Überspannungsschutz Generator
Reserve 2574
Reserve
Reserve 2575
Reserve
Reserve 2576
Reserve
Reserve 2577
Reserve
Reserve 2578
Reserve
Reserve 2579
Reserve
Reserve 2580
Reserve
Reserve 2581
Reserve
Reserve 2582
Reserve
Reserve 2583
Reserve
Reserve 2584
Reserve

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Issued: TPE | Wagner Peter Checked: Electrical Engineering Date.: 18.06.2015

Index: - Page No.: 25 | 34
3.1
Alarm list | Störmeldeliste

FAILURE MESSAGES MODULE CONTROL (WARNING) Message No.

Index
STÖRMELDUNGEN MODULSTEUERSCHRANK WARNEND Meldungs-Nr.

Reserve 2585
Reserve
Reserve 2586
Reserve
Reserve 2587
Reserve
Reserve 2588
Reserve
Reserve 2589
Reserve
Reserve 2590
Reserve
Reserve 2591
Reserve
Reserve 2592
Reserve
Reserve 2593
Reserve
Reserve 2594
Reserve
Reserve 2595
Reserve
Reserve 2596
Reserve
Reserve 2597
Reserve
Reserve 2598
Reserve
Reserve 2599
Reserve
Reserve 2600
Reserve
Reserve 2601
Reserve
Reserve 2602
Reserve
Reserve 2603
Reserve
Reserve 2604
Reserve
Reserve 2605
Reserve
Reserve 2606
Reserve
OPT NOx sensor 2 failure 2607
NOx Sensor 2 Störung

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Issued: TPE | Wagner Peter Checked: Electrical Engineering Date.: 18.06.2015

Index: - Page No.: 26 | 34
3.1
Alarm list | Störmeldeliste

FAILURE MESSAGES MODULE CONTROL (WARNING) Message No.

Index
STÖRMELDUNGEN MODULSTEUERSCHRANK WARNEND Meldungs-Nr.

OPT Engine AC prelubrication pump circuit breaker tripped 2608

Sicherungsfall AC Vorschmierpumpe Motor
OPT NOx sensor CANbus failure 2609
NOx Sensor CAN Störung
OPT NOx sensor 1 failure 2610
NOx Sensor 1 Störung
OPT Charge pressure before high pressure turbo charger measuring signal failure A 2611
Messsignalstörung Ladedruckgeber vor Hochdruck-Turbolader Bank A
OPT Charge pressure before high pressure turbo charger measuring signal failure B 2612
Messsignalstörung Ladedruckgeber vor Hochdruck-Turbolader Bank B
OPT Pressure after turbocharger oil filter maximum 2613
Druck nach Turbolader Ölfilter Maximum
OPT Turbocharger speed spread maximum 2614
Turbolader Drehzahlspreizung Maximum
OPT Measuring signal failure, turbocharger speed 2615
Messsignalstörung Drehzahl Turbolader
OPT Measuring signal failure, high-pressure turbocharger speed 2616
Messsignalstörung Drehzahl Hochdruck-Turbolader
OPT Measuring signal failure, low-pressure turbocharger speed 2617
Messsignalstörung Drehzahl Niederdruck-Turbolader
OPT Measuring signal failure, boost pressure transducer before high-pressure turbocharger 2618
Messsignalstörung Ladedruckgeber vor Hochdruck-Turbolader
OPT Measuring signal failure, charge temperature A 2619
Messsignalstörung Ladetemperatur A
OPT Measuring signal failure, charge temperature B 2620
Messsignalstörung Ladetemperatur B
OPT Measuring signal failure, air filter differential pressure 2621
Messsignalstörung Luftfilter Differenzdruck
OPT Exhaust gas temperature maximum after low-pressure turbocharger 2622
Abgastemperatur maximum nach Niederdruck-Turbolader
OPT Measuring signal failure, exhaust gas temperature after low-pressure turbocharger 2623
Messsignalstörung Abgastemperatur nach Niederdruck-Turbolader
Reserve 2624
Reserve :
2700
Reserve 3101
Reserve :
3151
OPT Engine room temperature measuring signal failure 3152
Messsignalstörung Raumtemperatur
OPT Release from gas plant missing 3153
Freigabe aus der Gasversorgung fehlt
OPT CH4 content low 3154
CH4-Gehalt Minimum
OPT CH4 content measuring signal failure 3155
Messsignalstörung CH4-Gehalt

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Issued: TPE | Wagner Peter Checked: Electrical Engineering Date.: 18.06.2015

Index: - Page No.: 27 | 34
3.1
Alarm list | Störmeldeliste

FAILURE MESSAGES MODULE CONTROL (WARNING) Message No.

Index
STÖRMELDUNGEN MODULSTEUERSCHRANK WARNEND Meldungs-Nr.

OPT Gas pressure measuring signal failure 3156

Messsignalstörung Gasdruck
OPT Suction pressure measuring signal failure 3157
Messsignalstörung Saugdruck
OPT O2 content measuring signal failure 3158
Messsignalstörung O2-Gehalt
OPT Gas temperature measuring signal failure 3159
Messsignalstörung Gastemperatur
OPT Gas volume measuring signal failure 3160
Messsignalstörung Gasdurchfluss
Reserve 3161
Reserve :
3180
OPT MONIC AIC offset failure cylinder xx 3181
MONIC AIC Offset Fehler Zylinder xx :
3200
OPT MONIC CAN communication failure 3201
MONIC CAN Kopplung gestört
OPT MONIC CPU failure 3202
MONIC CPU Fehler
OPT MONIC wiring failure 3203
MONIC Verdrahtungsfehler
Reserve 3204
Reserve
OPT MONIC firing voltage too low 3205
MONIC Zündspannung zu klein
OPT MONIC firing voltage too high 3206
MONIC Zündspannung zu groß
OPT MONIC average firing voltage too high 3207
MONIC Zündspannung Mittelwert zu groß
OPT MONIC firing voltage difference too high 3208
MONIC Zündspannung Differenz zu groß
OPT Ignition setting is forbidden during the engine is running 3209
Zündung Parametrierung derzeit verboten
Reserve 3210
Reserve
Reserve 3211
Reserve
OPT Fuel gas volume too high 3212
Gasmenge Obergrenze
OPT Gas proportioning valve fuel gas volume not reached 3213
Gasdosierventil Gasmenge nicht erreicht
Reserve 3214
Reserve
Reserve 3215
Reserve

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Issued: TPE | Wagner Peter Checked: Electrical Engineering Date.: 18.06.2015

Index: - Page No.: 28 | 34
3.1
Alarm list | Störmeldeliste

FAILURE MESSAGES MODULE CONTROL (WARNING) Message No.

Index
STÖRMELDUNGEN MODULSTEUERSCHRANK WARNEND Meldungs-Nr.

X Engine oil temperature high 3216

Öltemperatur Maximum
X Misfiring failure 3217
Aussetzerstörung
X Oil pressure low 3218
Öldruck Minimum
X Excitation voltage low 3219
Erregerspannung Minimum
X Jacket water temperature high 3220
Kühlwassertemperatur Maximum
OPT Gas pressure low in gas train 1 3221
Gasdruck Minimum Gasstrecke 1
OPT Gas pressure low in gas train 2 3222
Gasdruck Minimum Gasstrecke 2
X Intake air temperature measuring signal failure 3223
Messsignalstörung Ansauglufttemperatur
X Intake air temperature high 3224
Ansauglufttemperatur Maximum
OPT Engine oil level low 3401
Ölstand Motor Minimum
X Jacket water pressure low 3402
Kühlwasserdruck Minimum
OPT Jacket water level low 3403
Kühlwasserstand Minimum
OPT Water pressure cooler circuit installation low 3404
Wasserdruck Kühlerkreis Anlage Minimum
OPT Module control panel circuit breaker tripped 3405
Sicherungsfall Modulsteuerschrank
X Jacket water pressure high 3406
Kühlwasserdruck Maximum
OPT Measuring signal failure outdoor temperature 3407
Messsignalstörung Außentemperatur
OPT Cylinder exhaust gas temperature positive deviation from average value 3408
Abgastemperatur Zylinder positive Abweichung vom Mittelwert
OPT Cylinder exhaust gas temperature negative deviation from average value 3409
Abgastemperatur Zylinder negative Abweichung vom Mittelwert
OPT Ignition output monitoring cylinder 3410
Zündung Ausgangsüberwachung Zylinder
X Charge temperature maximum 3411
Ladetemperatur Maximum
OPT Mains monitoring device / generator protection relay failure 3412
Netzüberwachungsgerät / Generatorschutzrelais gestört
OPT Engine oil pressure before oil filter measuring signal failure 3413
Messsignalstörung Öldruck vor Ölfilter
OPT Oil filter achieves lifespan 3414
Ölfilter erreicht Lebensdauergrenze

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Issued: TPE | Wagner Peter Checked: Electrical Engineering Date.: 18.06.2015

Index: - Page No.: 29 | 34
3.1
Alarm list | Störmeldeliste

FAILURE MESSAGES MODULE CONTROL (WARNING) Message No.

Index
STÖRMELDUNGEN MODULSTEUERSCHRANK WARNEND Meldungs-Nr.

OPT Oil filter plugged - replace 3415

Ölfilter verstopft - Bitte wechseln
OPT Oil filter plugged - no engine start 3416
Ölfilter verstopft - Kein Motorstart
Reserve 3417
Reserve :
3496
X Failure in the safety loop 3497
Fehler in der Sicherheitsschleife
OPT Thermal reactor: sensor failure 3498
Thermoreaktor: Fühlerbruch
OPT Thermal reactor: compressed air supply failure 3499
Thermoreaktor: Störung Druckluftversorgung
OPT Thermal reactor: exhaust gas valve failure, end position 3500
Thermoreaktor: Störung Abgasklappe Endlage
OPT Thermal reactor: pre-heating time exceeded 3501
Thermoreaktor: Aufheizzeit überschritten
OPT Thermal reactor: control cabinet temperature high 3502
Thermoreaktor: Schaltschranktemperatur Maximum
OPT Thermal reactor: permissible difference of temperatures TK1/TK2 in excess of high 3503
Thermoreaktor: Zulässige Differenz von Temperaturen TK1/TK2 über Maximum
OPT Thermal reactor: temperature reaction chamber TK1/TK2 high 3504
Thermoreaktor: Temperatur Reaktionskammer TK1/TK2 Maximum
OPT Thermal reactor: temperature reaction chamber low 3505
Thermoreaktor: Temperatur Reaktionskammer Minimum
OPT Power reduction in isolated operation 3506
Leistungsreduktion im Inselbetrieb
OPT Oil pressure high 3507
Öldruck Maximum
OPT Heating water return temperature after cooler measuring signal failure 3508
Messsignalstörung Rücklauftemperatur nach Kühler
OPT Heating water return temperature after cooler high 3509
Rücklauftemperatur nach Kühler Maximum
OPT Failure CO2 fan 3510
Störung CO2 Ventilator
OPT Failure CO2 unit 3511
Störung CO2 Anlage
OPT Failure CO2 flap 3512
Störung CO2 Klappe
OPT Exhaust gas temperature after heat exchanger 1 measuring signal failure 3513
Messsignalstörung Abgastemperatur nach Abgaswärmetauscher 1
OPT Exhaust gas temperature after heat exchanger 2 measuring signal failure 3514
Messsignalstörung Abgastemperatur nach Abgaswärmetauscher 2
OPT Airconditioning unit failure in module interface cabinet 3515
Störung Klimagerät im Modulinterfaceschrank

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Issued: TPE | Wagner Peter Checked: Electrical Engineering Date.: 18.06.2015

Index: - Page No.: 30 | 34
3.1
Alarm list | Störmeldeliste

FAILURE MESSAGES MODULE CONTROL (WARNING) Message No.

Index
STÖRMELDUNGEN MODULSTEUERSCHRANK WARNEND Meldungs-Nr.

X Excitation voltage high 3516

Erregerspannung Maximum
X Communication to DIA.NE WIN server failed 3517
Kommunikation zum DIA.NE WIN Server ausgefallen
X Data registration in DIA.NE WIN server failed 3518
Datenaufzeichnung am DIA.NE WIN Server ausgefallen
OPT Heating water pump failure 3519
Störung Heizwasserpumpe
OPT Flare failure 3520
Störung Fackel
OPT Charge cooling water temperature maximum 3521
Ladekühlwassertemperatur Maximum
OPT Speed turbocharger A measuring signal failure 3522
Messsignalstörung Drehzahl Turbolader A
OPT Speed turbocharger B measuring signal failure 3523
Messsignalstörung Drehzahl Turbolader B
OPT Turbocharger speed high 3524
Turboladerdrehzahl Maximum
OPT Calorific value measuring signal failure 3525
Messsignalstörung Heizwert
OPT Heating water return temperature before engine measuring signal failure 3526
Messsignalstörung Rücklauftemperatur vor Motor
OPT Heating water return temperature before engine high 3527
Rücklauftemperatur vor Motor Maximum
OPT Exhaust gas backpressure high 3528
Abgasgegendruck Maximum
OPT Module blocked cool down special gas 3529
Blockierung Modul Abkühlung Sondergas
OPT SAFI CAN communication failure 3530
SAFI CAN Kommunikation gestört
OPT SAFI CAN errorrate too high 3531
SAFI CAN Fehlerrate zu hoch
OPT SAFI wrong type of software 3532
SAFI falsche Software
OPT SAFI software versions not identically 3533
SAFI Softwareversionen nicht identisch
OPT SAFI parameter failure 3534
SAFI Parameter Fehler
OPT SAFI setting ist forbidden during the engine is running 3535
SAFI Parametrierung im Motorbetrieb verboten
OPT SAFI camshaft/reset pickup missing 3536
SAFI Ausfall Nockenwellen/Reset Pickup
OPT SAFI trigger pickup missing 3537
SAFI Ausfall Trigger Pickup
OPT SAFI hardware failure 3538
SAFI Hardwarefehler

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Issued: TPE | Wagner Peter Checked: Electrical Engineering Date.: 18.06.2015

Index: - Page No.: 31 | 34
3.1
Alarm list | Störmeldeliste

FAILURE MESSAGES MODULE CONTROL (WARNING) Message No.

Index
STÖRMELDUNGEN MODULSTEUERSCHRANK WARNEND Meldungs-Nr.

OPT SAFI electronic temperature too high 3539

SAFI Elektroniktemperatur zu hoch
OPT Misfiring failure 3540
Aussetzerstörung
OPT Knock sensor measuring signal failure 3541
Messsignalstörung Klopfsensor
OPT Cylinder exhaust gas temperature measuring signal failure 3542
Messsignalstörung Abgastemperatur
OPT Ignition point deviation too high 3543
Zündzeitpunktabweichung zu groß
OPT Ignition hardware failure 3544
Zündung Hardwarefehler
OPT Ignition output failure 3545
Zündung Ausgangsfehler
OPT Ignition coil offset failure 3546
Zündspule Offset Fehler
OPT Spark plug voltage too low 3547
Zündspannung zu klein
OPT Spark plug voltage too high 3548
Zündspannung zu groß
OPT Average spark plug voltage too high 3549
Zündspannungsmittelwert zu groß
OPT Spark plug voltage difference too high 3550
Zündspannungsdifferenz zu groß
OPT Ignition power limitation active 3551
Zündung Leistungsbegrenzung aktiv
OPT Ignition power supply overload 3552
Zündung Spannungsversorgung überlastet
Reserve 3553
Reserve
Reserve 3554
Reserve
Reserve 3555
Reserve
Reserve 3556
Reserve
Reserve 3557
Reserve
Reserve 3558
Reserve
Reserve 3559
Reserve
Reserve 3560
Reserve
X Overspeed (RPS-control system) 3561
Überdrehzahl (RPS)

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Issued: TPE | Wagner Peter Checked: Electrical Engineering Date.: 18.06.2015

Index: - Page No.: 32 | 34
3.1
Alarm list | Störmeldeliste

FAILURE MESSAGES MODULE CONTROL (WARNING) Message No.

Index
STÖRMELDUNGEN MODULSTEUERSCHRANK WARNEND Meldungs-Nr.

X Charge temperature minimum 3562

Ladetemperatur Minimum
OPT Generator lubrication failure 3563
Störung Generatorschmierung
OPT Compressor bypass failure 3564
Störung Verdichterbypass
X Generator power setpoint measuring signal failure 3565
Messsignalstörung Generator Leistungssollwert
X Generator power factor setpoint measuring signal failure 3566
Messsignalstörung Generator Leistungsfaktorsollwert
OPT Gas compressor failure 3567
Störung Gasverdichter
OPT Gas temperature high 3568
Gastemperatur Maximum
OPT Gas pressure low before gas compressor 3569
Gasdruck Minimum vor Gasverdichter
OPT Gas pressure before gas compressor measuring signal failure 3570
Messsignalstörung Gasdruck vor Gasverdichter
OPT Module not released for start due to exhaust-gas scavenging 3571
Keine Startfreigabe Modul durch Abgasspülung
OPT Transformer failure 3572
Störung Transformator
OPT Generator lubeoil cooling system failure 3573
Störung Generator Schmieröl-Kühlung
OPT Failure active filter 3574
Störung Aktivfilter
OPT Mains failure GTE 2666 3575
Netzstörung GTE2666
OPT Mains failure TGS 3576
Netzstörung TGS
OPT Mains failure C13.100 3577
Netzstörung C13.100
OPT Failure auxiliaries 3578
Störung Hilfsbetriebe
OPT CO pre-alarm 3579
CO Voralarm
OPT N2 gas pressure low 3580
N2 Gasdruck Minimum
OPT N2 gas pressure high 3581
N2 Gasdruck Maximum
OPT Scavenging run failure 3582
Störung Spüllauf
OPT Cylinder exhaust gas temperature absolute value high 3583
Abgastemperatur Zylinder Maximum Überschreitung Absolutwert
OPT Cylinder exhaust gas temperature deviation from average value 3584
Abgastemperatur Zylinder Abweichung vom Mittelwert

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Issued: TPE | Wagner Peter Checked: Electrical Engineering Date.: 18.06.2015

Index: - Page No.: 33 | 34
3.1
Alarm list | Störmeldeliste

FAILURE MESSAGES MODULE CONTROL (WARNING) Message No.

Index
STÖRMELDUNGEN MODULSTEUERSCHRANK WARNEND Meldungs-Nr.

OPT Auto-ignition rate exceeded 3585

Glühzündrate überschritten
OPT Mains failure maintenance request 3586
Netzstörung Wartungsanforderung
OPT Water ingress into inlet manifold 3587
Wassereinbruch Ansaugleitung
OPT Inlet manifold fill sensor inactive 3588
Füllstandsensor Ansaugleitung inaktiv
OPT Power reduction exhaust temperature cylinder high 3589
Leistungsreduktion durch Abgastemperatur Zylinder hoch
OPT Measuring signal failure, intercooler water low temperature circuit 3590
Messsignalstörung Ladekühlwassertemperatur - Niedertemperaturkreis
OPT Power limitation by utility operator measuring signal failure 3591
Messsignalstörung Leistungsreduktion durch Netzbetreiber
OPT Power setpoint by utility operator measuring signal failure 3592
Messsignalstörung Leistungssollwert durch Netzbetreiber
OPT Power factor setpoint by utility operator measuring signal failure 3593
Messsignalstörung Leistungsfaktorsollwert durch Netzbetreiber
OPT Reactive power setpoint by utility operator measuring signal failure 3594
Messsignalstörung Blindleistungsollwert durch Netzbetreiber
OPT Reactive power limitation by utility operator measuring signal failure 3595
Messsignalstörung Blindleistungsbegrenzung durch Netzbetreiber
OPT Voltage setpoint by utility operator measuring signal failure 3596
Messsignalstörung Spannungsollwert durch Netzbetreiber

Keyword: AB Energy 616 - 31 Unit no.: J S889

Module type: 1 x JGS 616 GS-N.L

Issued: TPE | Wagner Peter Checked: Electrical Engineering Date.: 18.06.2015

Index: - Page No.: 34 | 34
3.2
Control box

1 Module control cabinet

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Provin Responsible: Doku./Provin Release date: 19/06/2013
Index: 9 Page No.: 1/2
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
3.2
Control box

2 Module interface cabinet

SprungMarke!!!72057594050777099

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Provin Responsible: Doku./Provin Release date: 19/06/2013
Index: 9 Page No.: 2 / 2
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

1 Information on the DIA.NE XT User Manual ......................................................................................... 3

2 DIA.NE XT3 is much more - a system description ............................................................................... 3
3 Components and hardware .................................................................................................................... 3
3.1 Components................................................................................................................................................................. 3
3.2 Hardware ...................................................................................................................................................................... 4
3.2.1 Power panel 6
3.2.2 I/O bus connection 6
3.2.3 I/O MODULES 7
4 Interfaces ................................................................................................................................................... 9
4.1 Interface with the DIA.NE WIN system ............................................................................................................ 9
4.2 Interfaces with inputs and outputs................................................................................................................... 9
4.3 Interface with the decentralised control components ............................................................................ 9
4.4 Interfaces with customer's higher-order control system ..................................................................... 10
5 Visualisation system .............................................................................................................................. 10
5.1 General visualisation.............................................................................................................................................. 10
5.2 Additional visualisation features ...................................................................................................................... 10
5.2.1 Parameter manager 10
5.2.2 Alarm management system 10
5.2.3 Online trends 10
5.2.4 Access protection 10
5.2.5 Activity recording 11
5.2.6 Multiple language capability 11
6 User interface .......................................................................................................................................... 11
6.1 Operation and navigation ................................................................................................................................... 11
6.1.1 Arrangement of keys 11
6.1.2 Key functionalities 12
6.2 Representation ......................................................................................................................................................... 17
6.2.1 Customer and expert view 17
6.2.2 Display in Customer View 17
6.2.3 Display in Expert View 21
6.2.4 Display elements 23
7 Visualisation screens ............................................................................................................................. 25
7.1 MAIN Plant Overview ............................................................................................................................................. 25
7.1.1 Overview (P_01.1) 26
7.1.2 Engine Startup Assistant (P_02.1) 31
7.1.3 Operational Data (P_02.1) 32
7.1.4 Auxiliaries 1 (P_04.1) 33
7.1.5 Auxiliaries 2 (P_04.2) 34
7.1.6 Operational Logbook 1 (P_05.1) 35
7.1.7 Operational Logbook 2 (P_05.2) 36
7.1.8 Humidity (P_06.1) 37
7.2 Electrical Diagram (ELE) ........................................................................................................................................ 39
7.2.1 Overview (P_11.1) 39
7.2.2 Generator Details 1 (P_12.1) 41
7.2.3 Synchronisation (P_13.1 42
7.2.4 Generator (P_14.1) 46
7.3 Hydraulic diagram (HYD)...................................................................................................................................... 47
7.3.1 Oil/Cooling Water screen (P_21.1) 47
7.4 Gas Supply (GAS) ...................................................................................................................................................... 49
7.4.1 Gas Details (P_31.1) 49
7.4.2 Special Gas (P_32.1) 52
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 1/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

7.4.3 Gas Mixture (P_33.1) 54

7.5 Engine controller (ENG) ......................................................................................................................................... 55
7.5.1 Engine Controller Overview (P_41.1) 55
7.5.2 Power Reduction 1 (P_41.2) 59
7.5.3 Power Reduction 2 (P_41.3) 60
7.5.4 LEANOX® Controller (P_42.1) 61
7.5.5 LEANOX® Controller Settings (P_42.2) 63
7.5.6 Speed, Power and Isolated Operation Controller (P_43.1) 64
7.5.7 Speed, Power and Isolated Operation Controller Settings (P_43.2) 66
7.5.8 Charge temperature controller (P_44.2) 67
7.5.9 Charge temperature controller autotune (P_44.3) 69
7.5.10 Knock Controller (P_45.1) 71
7.5.11 Ignition (P_46.1) 73
7.5.12 2-stage pressure-charging (P_47.1) 75
7.6 Cylinder information (CYL) ................................................................................................................................... 77
7.6.1 Cylinder Measured Values (P_51.1) 77
7.6.2 Cylinder Comparison (P_51.2) 79
7.6.3 Ignition Voltage Measurement (P_52.1) 80
7.6.4 Ignition Point Display (P_53.1) 81
7.6.5 Ignition Output Error (P_53.2) 85
7.6.6 Knock Integrator (P_54.1) 86
7.6.7 Knock Noise (P_54.2) 87
7.6.8 Valve Noise (P_54.3) 88
7.7 Exhaust system information (EXH)................................................................................................................... 89
7.7.1 Exhaust System Overview (P_61.1) 89
7.7.2 NOx overview (P_61.2) 91
7.7.3 Cylinder outlet exhaust temperature (P_62.1) 92
7.7.4 Turbocharger (P_63.1) 93
7.7.5 Thermal Reactor (P_61.1) 94
7.7.6 Codinox (P_66.1) 96
7.8 Plant controllers (CTR)............................................................................................................................................ 97
7.8.1 Plant Controller Overview (P_71.1) 97
7.8.2 Plant Controller Details (P_71.2) 99
7.8.3 Plant Controller Autotuning (P_71.3) 100
7.9 Customer Screens (CUSTOM) .......................................................................................................................... 102
7.9.1 Customer Screen (P_81.1) 102
7.10 System Information (SYS) .................................................................................................................................. 103
7.10.1 System Overview (P_91.1) 103
7.10.2 SAFI Hardware Details 1 (P_92.1) 105
7.10.3 SAFI Hardware Details 2 (P_92.2) 106
7.11 Parameter Manager (PARA) ............................................................................................................................. 106
7.11.1 Parameter Manager (P_Para1.1) 107
7.11.2 Parameter Manager (P_Para2.1) 107
7.12 User Management (USER)................................................................................................................................. 108
7.12.1 User Settings (P_U_1.1) 108
7.13 Alarm Management (ALARM) .......................................................................................................................... 110
7.13.1 Current Messages (P_A1.1) 110
7.13.2 Historical Messages (P_AI_2.1) 111
7.13.3 Primary trip (P_Al_3.1) 112
7.13.4 Measurements at Failure (P_Al_5.1) 113
7.13.5 Trending at Failure (P_Al_5.1) 114
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 2 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

7.14 Help System (HELP) .............................................................................................................................................. 115

7.14.1 Help for Alarm Management Entry (A_Help_XXX) 115

1 Information on the DIA.NE XT User Manual

Options
Not all of the pages or display and entry fields listed in this documentation are necessarily available for your
engines.
Depending on the number of engines, engine type, number of cylinders and module and control system
configurations, the DIA.NE XT3 system will only display the screens that are relevant to your engines.
If you have any questions concerning the configuration of your modules, please contact our Sales or Service
Department (www.gejenbacher.com).

Reference texts
[text]
The text in the screens is always in English. Where direct reference is made in a screen to a reference text, it will
be placed within square brackets and shown in bold and italics.

2 DIA.NE XT3 is much more - a system description

DIA.NE XT3 is the new generation of engine management system used by GE Jenbacher in all of its engine
types. It consists of a control unit, which includes a visualisation unit, in a single device.
The optional PC visualisation unit DIA.NE WIN provides a central and convenient means of operating the
Jenbacher modules, as well as a customer-specific coupling to a higher-order control system.
One of the main goals when developing DIA.NE XT3 was the perfect combination of powerful and flexible
control electronics on the one hand and a user-friendly operation concept on the other.
The innovative hardware concept is made up of state-of-the-art components and sets new standards in terms
of power, functionality and reliability of operation.
The innovative graphical information display makes DIA.NE XT3 a particularly user-friendly human-machine
interface, thereby making the plant much easier to handle for both the operator and the service and
maintenance staff.
Particular consideration has been given to customer specifications and requirements. For example, a specific
expert view containing large amounts of information has been generated for customers who are interested in
details. The customer view is ideal for those who require an interface reduced to the most important items.
A special detail of the new customer view consists of keys to the individual visualisation screens. This is a fast
and uncomplicated way of finding out what the various symbols mean.
The new help system is another milestone on the way to achieving a customer-friendly approach. For example,
online help facilities have been provided for the visualisation screens and for individual alarm entries.
The large 10.4" screen and a logical, simplified navigation system make DIA.NE XT3 an easy-to-operate human-
machine interface.

3 Components and hardware

3.1 Components
DIA.NE XT3 comprises the following units:
① Engine control and display unit based on a panel controller
② Decentralised I/O module for module control

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 3/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

③ Decentralised I/O module on the engine

④ Decentralised engine control/monitoring components (CAN bus)
⑤ Connection to DIA.NE WIN visualisation unit on client PC (Ethernet)
⑥ Connection to higher-order control system (RS232 / RS485)

The individual components are connected via interference-free industrial bus media. All measurement data are
communicated to the module itself by means of a decentralised I/O concept.
The consistent use of state-of-the-art technology therefore reduces the number of electrical connections to the
module to an absolute minimum.

3.2 Hardware

General
All of the control functions and substantial parts of the engine monitoring and control units on the engine
control system have been created using digital technology. The hardware used, known as a Power Panel, is a
combination of a programmable logic controller and a graphical used interface.
At the heart of this panel is a powerful standard CPU. The advantage of this is that these microprocessors
already provide a substantial bandwidth, which means that it will be possible to integrate ever more powerful
compatible motherboards into the system in future.
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 4 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

A separate communication module is used to copy the data required to map the CPU process from the I/O
modules. This copying process is performed in parallel with the actual computations in the CPU and does not
add to its load.
To keep the amount of cabling running to the module to an absolute minimum, a decentralised I/O concept has
been created for process connection. To this end, a module has been placed in the module interface cabinet to
combine all the engine measurement signals and control commands. It is connected to the engine controller in
the module control cabinet via a fast, interference-free bus connection.
A variety of modules are used at I/O level. The system allows the digital and analogue I/O modules to be flexibly
adjusted as required.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 5/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

3.2.1 Power panel

3.2.2 I/O bus connection

With 400 µs cycle time for a complete automation system, the I/O bus connection is the basis for very fast,
cyclical and strictly deterministic data traffic.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 6 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

3.2.3 I/O MODULES

The I/O hardware is a modular industrial automation system. The control philosophy is based on universal
scalability and full compatibility. In this way it is possible to achieve response times of less than 10 ms. The I/O
bus connection enables the system to be expanded without problems. Modular system design permits flexible
configurations at a granularity of 1 - -32 channels per module and the direct connection of sensors and
actuators.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 7/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 8 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

4 Interfaces

4.1 Interface with the DIA.NE WIN system

Control network [PLC NET]

The control network connects the engine and master controls to the DIA.NE WIN server. A second DIA.NE WIN
server is used in multi-engine plants with more than 4 engines. All participants within a single network are
arranged radially (Ethernet 10/100BaseT) with switches.
Plant network [PLANT NET]
In the case of multi-engine plants with more than 4 engines, the plant network interconnects the two DIA.NE
WIN servers. Once again, a radially arranged Ethernet network (Ethernet 100BaseT) is used.

4.2 Interfaces with inputs and outputs

The interface with the inputs and outputs of the engine control system is provided by a proprietary protocol.
This protocol ensures a high data rate and high reliability.
The individual modules communicate with each other along the common I/O bus backplane, whether they are
alongside each other on the top-hat rail, linked together in the same switchgear cabinet, or 100 m away in
other switchgear cabinets.

4.3 Interface with the decentralised control components

Decentralised control components are activated via a CAN bus connection.
Devices can be connected for:
control → ignition, gas proportioning valve (optional)

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 9/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

monitoring → KLS 98, SAFI (optional)

measurement → MONIC (optional)

4.4 Interfaces with customer's higher-order control system

The DIA.NE XT3 system makes it possible to provide data for a higher-order control system belonging to the
customer.
Several protocols are available. For example, serial protocols such as Modbus RTU (Slave) and Profibus DP
(Slave) are possible options.

5 Visualisation system

5.1 General visualisation

The visualisation system increases the operational reliability and provides an ease of use which meets the
highest expectations. The visualisation system handles all display and control functions. The use of a powerful
processor ensures that the system operates safely.
The display contains a clear and functional summary of the measured values. All values are presented
graphically. The system is operated using screen selection and function keys.
System messages and screen texts are all displayed in the language selected.
In addition to the usual process diagrams, the user is presented with tables showing the auxiliary equipment
and the most important measured values.

5.2 Additional visualisation features

5.2.1 Parameter manager

An easy-to-use parameter manager is provided in DIA.NE XT3 to display, adjust and store all engine and plant
parameters. To make the parameters easy to find, they have been structured into up to three levels.

5.2.2 Alarm management system

The DIA.NE XT3 alarm management provides the user with a powerful diagnostic tool. All error messages are
displayed in plain text and are arranged in tabulated form. The sequence of events can be clearly seen from
the time indication attached to the error messages. In addition, shutdown-related measured quantities are
displayed in a trending diagram.

5.2.3 Online trends

A multi-colour trend overview makes it possible to observe closely the real-time chronological trends of the
relevant measured values.

5.2.4 Access protection

When accessing the system, every user must log in using his own user name and user code. This enables user
identification and the release of specific functionalities and allows the user interface to be adapted to the
specific user group.
To protect against illegal access, the password entry is blocked for a specified period after three unsuccessful
login attempts.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 10 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

5.2.5 Activity recording

All user activities, e.g. login, logout, starting and stopping the module, etc. are recorded (activity logging).

5.2.6 Multiple language capability

The user interface is available in two languages and the user can switch between them. English is installed as
the default language on each DIA.NE XT system.
Additionally, one of the following languages can be displayed on the DIA.NE XT3 system:
Bulgarian, Chinese, Czech, German, Danish, Spanish, Estonian, Finnish, French, Greek, Croatian, Hungarian,
Lithuanian, Italian, Latvian, Dutch, Norwegian, Polish, Portuguese, Romanian, Russian, Swedish, Serbian, Slovak,
Slovene, Turkish;
The pressure and temperature display values can be changed between "bar", "psi" and "Pa" and between
"degrees Celsius" and "degrees Fahrenheit" respectively. All other units can be switched between the "ISO" and
the "US" system.

6 User interface

6.1 Operation and navigation

6.1.1 Arrangement of keys

The keyboard is divided into the following units:

① Screen selection keys
② Function keys
③ Tab key
④ Next screen/last screen
⑤ Help key
⑥ Engine start/stop
⑦ Control keys
⑧ Alarm management
⑨ Cursor keys
⑩ Numerical keys

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 11/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

6.1.2 Key functionalities

Screen selection keys

The screen selection keys are the highest level in the navigation system. Pressing one of the keys displays the
category in the relevant first screen (F1). You can select from the following 12 categories:

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 12 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

Main screens for the customer

Electrical diagram

Lube oil/cooling water schematic

Gas details

Engine controller

Cylinder measured values

Exhaust gas measurement data

Plant controllers

Spare screens for customer applications

System displays

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 13/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

Parameter manager

User settings

Alarm management system

The blue indicator lights in the top left-hand corner of the screen selection keys informs the user of the
category they have chosen to view.

Function keys
Function keys F1 to F7 are the second level of the navigation system.

Tab switching
The third and lowest navigation level is the tab switch key. By pressing the TAB key, you can alternate between
up to three different visualisation screens. As well as the screen itself, the lighting of the white indicator light
will tell you if other tabs are available.

Next screen/last screen

The NEXT and BACK screens allow you to navigate quickly between the current view and views you have
previously visited. You may already be familiar with this function from various web browsers. By pressing the
BACK key, you can browse back up to 10 views.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 14 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

Help key
Whenever a help page is available for a page or an alarm entry, the indicator light on the HELP key lights up.
Press this key to go to the appropriate help view.

Engine start/ stop

Press the START and STOP keys to start or stop the module in manual mode.

Function indicator light on START key

▪ Flashing: The module is in the start preparation phase. A manual or automatic start has been requested.
▪ Continuous light: The engine is running.
Function indicator light on STOP key
▪ Flashing: The module is in shutdown mode. Shutdown has been requested manually, automatically or due
to a failure.
▪ Continuous light: The engine is not running and is not ready for operation.

Control keys
You can allocate up to 6 keys for additional control commands, such as manual synchronisation, horn off, etc.
When a key has been allocated a function, this is shown by a labelling it.

Alarm management system

Press the ALARM key to go to the alarm management pages, as listed above.
The special feature of this key is the indicator light function. A flashing light means that an alarm has been
triggered. This flashing becomes a constant light as soon as you switch to a page in the alarm management
system. A fault can be displayed remotely if the screen saver has been activated.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 15/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

Pressing the RESET key resets warnings and failures. Trips can only be reset when the operating mode selector
is in OFF position.
When the white indicator light lights up this generally means that a reset is possible.

Cursor keys
The cursor keys are only used to navigate between the individual entry fields.
Warning: do not use them to select an option from a drop-down menu. Use the plus or minus keys (+/-) to
select from these menus.

Press the ENTER key to save entries and actuate pushbuttons.

Numerical keys
The numerical keys are used to enter numerical data.

The following keys are provided for entering negative (-) figures or figures with decimal places (,).

If you type in a figure incorrectly and you have not confirmed it by pressing ENTER, you can cancel the entry by
pressing the ESC key.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 16 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

The plus or minus keys (+/-) are active each time you enter figures. You can use them to change the last digit of
the figure. Save the value by pressing the ENTER key.
These keys are use to select the desired option in drop-down menus.

The ENTER key is used to complete entries and actuate software pushbuttons.

6.2 Representation

6.2.1 Customer and expert view

GE Jenbacher gas engines are highly efficient energy producers. A large number of measurements have to be
carried out to optimise the engine control system and perfect the plant control system. The resulting quantity
of displays is often irritating, as the values of interest to the plant operator are not explicitly displayed. Now,
with the advent of the DIA.NE XT3, a new approach has been adopted which is intended to assist the customer
to operate the engine.
The operator can decide how much data to visualise.
The full range of measured values is displayed in Expert View. In Customer View, displays are reduced to the
essential. In addition, symbols and labels should make the screens easier to understand.
You can switch views in the USER screen group.

6.2.2 Display in Customer View

The screen is divided as follows:
▪ Status indication
▪ Date and time
▪ Navigation
▪ Screen content

Status display
The status display consists of the following elements.

MAINS-PARALLEL OPERATION

The engine status is indicated by an animated circle. If the circle "rotates", the engine is turning.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 17/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

The circle only "stands still" when the engine stops running.

If a warning is active, the colour changes to yellow and a warning triangle appears.

If a trip occurs, a red symbol will make you aware of it.

Information on the engine running-up// status is given by the progress indicator. This allows you to see at a
glance whether the engine is running at the pre-selected operating point or not.

Module not activated

Module activated

Engine running up to speed//

Idling

Mains parallel or island operation

LEANOX® control active

The engine is delivering 95% or more of rated load for the current gas type.
The module status is displayed in plain language to the left of the progress indicator.

Netzparallelbetrieb
The monitor icon shows whether a user is on-line with DIA.NE WIN.

A user is connected to the engine control system with DIA.NE WIN.

The following indicators show whether a user has logged on to DIA.NE XT3.

No users are logged on.

A user has logged on.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 18 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

The electric power currently being produced is displayed both in figures and as a bar. The bar grows from left
to right. If the bar reaches the right-hand end, the engine has reached the rated power output for the current
gas type.

737 3997

A power reduction may be necessary for a variety of reasons, which are explained individually in the Power
Reduction screen. This operating condition is indicated by colour change of the power output bar to orange.

3097

Date and time

The current date and time are shown under the power output display.

Navigation
On the right-hand side, the labels on the function keys are displayed, depending on the main screen group
currently selected. The international abbreviations for the main screen group are shown at the top left of the
individual fields, with the title of the respective subscreen underneath in the centre.
To change to a subscreen, press the corresponding function key F1 to F7.
A change of colour and arrow direction indicates which screen is currently being displayed.

Overview

Engine start

Operating data

Auxillaries

Operating journal

The third navigation level is the tabs. Up to three screen tabs can be shown on a screen.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 19/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

ENG Motor Controller Power red. 1 Power red. 2 P_41.1

The international abbreviation for the main screen group is again shown at the left,

with the individual tab names in the middle of the tab bar. The selected tab has the same colour as the
background of the actual screen content. To change from one tab to another, pressing the TAB button.

Motor Controller Power red. 1 Power red. 2

The screen number is shown at the right-hand end of the tab bar.

The first character indicates the main screen selector group, while the second character indicates the selected
subscreen. The figure after the decimal point shows which tab is currently displayed.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 20 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

Screen content

The screen content consist of entries and displays, graphics and animations. The individual elements are
described in full in the Section "Display Elements".
A special feature in the Customer View is that a legend is displayed for each graphic. A number on the screen
refers to the corresponding entry in the legend, where the name of the corresponding plant part can be read. A
further simplification is a square symbol that indicates the status of the components.

6.2.3 Display in Expert View

The Expert View differs from the Customer View in the following respects:
▪ the status indication contains detailed information
▪ additional indications and inputs are displayed
▪ additional screens are displayed
▪ Keys are not displayed

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 21/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

Status indication

IDLE MODE - SYNCHRONIZE-/LOAD RELEASE

1231 Request module on

In expert mode, detailed text is displayed in the status indication. If a user has logged on at customer level or
higher, the last message entered in the alarm management system is also displayed.

Additional indications and measured values

measured values which are only of secondary importance for operating the plant are only displayed in Expert
View.
In the ELE overview screen, for example, the bus bar voltages are also displayed.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 22 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

Additional screens
Screens containing detailed information which is likewise not of primary importance for operating the plant is
only displayed in Expert View.
The Generator Details, Synchronization and Generator screens are additional displays in the ELE screen group.

ELE
Generator details

ELE
Synchronization

ELE
Generator

Keys
For reasons of space, no keys are displayed at all. The resulting blank areas are used to display additional
information.

6.2.4 Display elements

Numerical entry

Numerical values are displayed as black figures on a blue background. In addition to the measured value, the
units appears at the right, with an abbreviation of the measured quantity on the left if appropriate.

If an entry field has a grey background, this means that your current user authorisation level does not allow
you to adjust the value.

Focused entry:

A white background around a numerical value or a text display shows that the field is an entry field. A change
in the colour of the figures to white and the background to black means that the cursor has been focused on
this position.

Text / numerical display

Text and numerical displays are shown as white characters on a blue background.

Text selection

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 23/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

A status/option can be selected using text selection. This is indicated by a downward arrow. Press the ENTER
button to enter selection mode.

and then select the desired option using the "increase" and "decrease" buttons (+/-).

Press the "Enter" button to confirm the selection. To abort the selection process, press the ESC button or the
cursor buttons.

Action buttons

Buttons which initiate an action have black lettering against a white background. When the button is focused,
the letting colour changes from black to white and the background changes from white to dark grey.

If the lettering on a button is black and the background is greyed out, your current user authorisation level does
not allow you to adjust the value.

Animated graphical symbol

The colour or shape of the symbol can change according to the operating condition. In general, the colour
green indicates an active condition, and red a fault.

Legend
A legend is shown if Customer View is selected and the screen display is a schematic diagram.
The link between the diagram and legend texts is provided by numbers in ascending order.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 24 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

The pilot lights next to the texts give a overview of the status of the various elements. The different colours
LEDs have the following meanings:

grey: There is no electrical response from the key item

white: the element status is "off" or "open"

green: the element status is "on" or "closed"

red: a fault has been detected.

Trendings
Trending is provided on many screens as a support tool to optimise plant operation.
The trend curves cannot as a rule be edited, with the sole exception of the last shut-down trend. 4 curves out of
16 can be displayed.
The time axis can be varied in the User Settings screen (P_U_1.1).

The scales are shown to left and right of the graph display area, in the same colour as the trend curve.

7 Visualisation screens
All the screens that can be viewed by customers are described individually below. The description is based on
Expert View. Where Customer View not only contains a reduced number of indications but also deviates in
terms of display, the differences will be listed.
If engine parts are not displayed during visualisation, this means that it is an option. Where additional
indications relating to this documentation are available locally, it is a customer-specific add-on.
Note: The screenshots of the visualisation screens have been created using customer level (10).

7.1 MAIN Plant Overview

The MAIN screen group contains a summary of the most important information for the engine operator.
Electrical and hydraulic measurement data are displayed, as well as a number of counters.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 25/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

7.1.1 Overview (P_01.1)

The main overview screen is brought up by pressing the MAIN main screen selection button. This screen
presents an overview of the most important engine measurements and settings, and gives information about
the current operating and switching condition of the module.

① Gas mixer / Gas proportioning valve

This is where the gas mixer and the gas proportioning valve are displayed, depending on the engine type and
the design of the installation.

Gas mixer:
The gas mixer opening amount is displayed as percentage (see the illustration above).

Gas proportioning valve:

The lambda value is displayed at the gas proportioning valve.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 26 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

Display showing the gas type

The current gas type is shown for each mixer version as Gas type. The following displays are possible,
depending on the plant design:
Gas Description
type
1 Gas type 1
2 Gas type 2
3 Gas type 3
4 Gas type 4
1_2 Gas quality = interpolation between the gas 1 and gas 2 parameter sets
1_2/3 Gas type 1_2 (gas train1) mixed with gas type 3 (gas train 2)
1/3 Gas type 1 (gas train 1) mixed with gas type 3 (gas train 2)
Further details of the gas mixer are displayed in the Gas screen group
② Turbocharger bypass valve
Display showing the turbocharger bypass position (optional).
③ Waste heat boiler
Display showing the tube plate temperature (optional). The inlet and outlet temperatures are displayed in the
EXH screen group.
④ Catalytic converter
Display showing the catalytic converter temperature (optional). The inlet and outlet temperatures are displayed
in the EXH screen group.
⑤ Throttle valve
Display showing the throttle valve position.
⑥ Charge temperature and pressure
Display showing the charge temperature and pressure. The display showing boost pressure upstream of the
throttle valve (p2) is optional.
⑦ Return temperature
Display showing the return water temperature (optional).
⑧ Inlet water temperature
Display showing the supply water temperature (optional).
⑨ Power set point
It is necessary to have at least "Customer (10)" authorisation to adjust the power setpoint.
⑩ Average exhaust gas temperature / Turbocharger inlet temperature
Depending on the components on the engine, either the average exhaust gas temperature or the turbocharger
inlet temperature is displayed.
⑪ Engine cooling water
Display showing the cooling water temperature and pressure. Details are displayed in the HYD screen group.
⑫ Engine oil
Display showing the engine oil temperature and pressure. Details are displayed in the HYD screen group.
⑬ Speed
Display showing the engine speed.
⑭ Electrical diagram
The arrangement of the generator breaker, mains breaker and transformer varies and is
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 27/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

designed for each specific installation.

Status of generator and mains breakers:

Closed:

Open:

Mains status indication

In the event of mains failure, the mains status indication is white, otherwise it is green.
Mains OK:

Mains failure:

⑮ Electrical measurement data

Display showing electrical data for the generator. Details are displayed in the ELE screen group.
Abbreviation Designation Unit
P Active power [kilowatts]
Q Reactive power [Kilovolt amperes
reactive]
S Apparent power [Kilovolt amperes]
F Frequency [Hertz]
cos Φ Power factor [1]

⑯ Power set value and power reduction

The following types of power set values "P setpoint" are available:
Power set value Description
Internal The power set value is determined on the basis of the power setpoint
set by the operator. The power setpoint can be set in the Overview,
Engine Controller Overview, LEANOX Controller and Power Controller
screens.
External - analog The power set value is generated by an external analog signal
(4-20mA). See "Power / Scaling external power setpoint" parameter.
External - bus The power set value is created by a higher-order control system
connected to DIA.NE XT via an industrial bus connection.

The following types of power reduction "P reduction" are possible:

Power reduction Description
None No power reduction is in effect.
Knock The Knocking intensity has exceeded the limit value
for power reduction.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 28 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

Power reduction Description

Misfiring The number of Misfires has exceeded the limit value
for power reduction.
External - analog Power reduction due to an external analog signal.
This signal can be used for a variety of applications
(e.g. to control return water temperature). See
"Power / Scaling external power limitation"
parameter.
External - bus The power reduction is caused by a higher-order
control system connected to DIA.NE XT via an
industrial bus connection.
Charge temperature The charge temperature has exceeded the limit
value for power reduction. The power rating is
reduced linearly. See the "Power / Boost
temperature reduction" parameter.
Maximum power The pre-set power setpoint has exceeded the rated
power related to the gas type and is limited to the
latter. See "Power / Nominal values" parameter.
Minimum power The pre-set power setpoint has fallen below the
minimum permissible power setpoint and is limited
to the latter. See "Power / Nominal values /
Minimum power" parameter.
Exhaust gas temperature If the cylinder temperature ("Exhaust temp. positive/
negative deviation max.") deviates from the average
value for more than 30 seconds, a power reduction
is activated.
LEANOX The LEANOX controller deviation limit value has
been exceeded towards "lean". The power set point
is reduced linearly. If the LEANOX controller
deviation limit value is exceeded by than 20 percent
towards "rich", the engine is switched off. See
"LEANOX / Gas type x / Controller / Controller
deviation limit" parameter
intake temperature The intake temperature has exceeded the limit value
for power reduction. The power set point is reduced
linearly. See "Power / Intake air reduction"
parameter.
CH4 If the CH4 content of the gas is decreasing, the
power is reduced in accordance with an external
signal (4-20mA). See "Special gas / CH4 content"
parameter.
Gas pressure If the gas pressure is decreasing, the power is
reduced in accordance with an external signal
(4-20mA). See "Special gas / Gas pressure"
parameter.
Suction pressure If the suction pressure (compressor intake pressure,
e.g. on a landfill site) is decreasing, the power is
reduced in accordance with an external signal
(4-20mA). See "Special gas / Suction pressure"
parameter.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 29/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

Power reduction Description

Turbocharger speed If one of the two "switching point maximum speed"
limits (exhaust gas/turbocharger A or B) is exceeded,
the power is reduced accordingly depending on the
parameter "Value for P reduction" (power/
turbocharger speed reduction).
Undervoltage If the generator voltage drops below the adjustable
limit value of the nominal generator voltage, power
reduction begins.
Overvoltage If the generator voltage exceeds an adjustable limit
value of the nominal generator voltage, power
reduction begins.
Underfrequency If the generator voltage drops below an adjustable
limit value, power reduction begins.
Overfrequency If the generator frequency exceeds an adjustable
limit value of the nominal generator frequency,
power reduction begins. The power reduction only
ends when the deviation from the nominal
frequency is very small again (hysteresis window).
G. winding temperature If the generator winding temperature exceeds an
adjustable limit value, power reduction begins.
Cooling water temperature If the cooling water temperature rises, power is
reduced. See the "Power / Cooling water
temperature reduction" parameter.
Oil temperature If the oil temperature rises, power is reduced. See
"Power / Oil temperature reduction" parameter.
Return water temperature If the hot water return temperature rises, power is
reduced. See "Power / Return water temperature
reduction" parameter.
Pre-combustion chamber gas pressure If the pressure in the prechamber gas train
decreases, power is reduced. See "Power / Pressure
pre-chamber gas train reduction" parameter.
Utility operator The power is reduced in accordance with the set
parameters, or the engine is shut down, via 3 digital
inputs.
Charge temperature upstream of high-pressure If the maximum permissible charge air temperature
turbocharger upstream of the high-pressure turbocharger is
exceeded, the power is reduced.
DMR Power reduction due to various DMR safety
functions
The most effective power reduction is displayed. Further details are displayed in the "Engine controller Power
Reductions" screen.
In addition, a reactive power reduction can also take place. This is not displayed in this screen, however, but
only as an operational notification in the alarm management:
Reactive power reduction Description
G. winding temperature If the generator winding temperature
exceeds an adjustable limit value, reactive
power reduction begins.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 30 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

Reactive power reduction Description

Pole wheel angle If the capacitive reactive power exceeds a
certain value calculated on the basis of the
pole wheel angle, the reactive power is
limited.

7.1.2 Engine Startup Assistant (P_02.1)

The Engine Startup Assistant screen appears when you press the MAIN screen selection key, followed by F2.
The main measured and actuating variables for starting the gas engine are listed on this screen. A trend
analysis is also provide a better diagnosis of control processes.

① Speed data
This indication displays the current setpoint value for the speed controller, the manual setpoint value and the
measured actual value one below the other. The speed can only be adjusted in idle mode.
② Setpoint value for gas type
You can select the desired gas type from a text drop down menu.
③ Gas mixing
Either the setpoint values for gas mixers or gas proportioning valves are displayed here, depending on the
engine configuration.
In addition, you can press the button to switch gas mixing to manual in order to adjust the setpoint value
directly. If your authorisation level is "Customer (10)", you can already adjust the setpoint value in idle mode.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 31/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

④ Gas valve activation

The "open" command for the gas valves is visualised by a green indicator light.
⑤ Pre-combustion chamber gas differential pressure
Optionally, the pre-combustion chamber gas differential pressure is displayed here. If the differential pressure
is absent or too high, the engine is difficult or impossible to start.
⑥ Additional measured values
A series of additional measured values is displayed here, depending on the engine configuration. These
measured values can be used to diagnose startup problems.
⑦ Trending
The trend analysis is intended to show changes in the engine control system in graphical form. The speed,
throttle valve, boost pressure and gas mixing measurement data (% open or lambda) are displayed.

7.1.3 Operational Data (P_02.1)

The operating data screen is brought up by pressing the MAIN main screen selection button followed by F3 . It
is used to display general module data such as counter readings and various measurement values.

① Operating hours counter

Count of the number of hours for which the machine has been operating.
② Maintenance counter

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 32 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

A number of maintenance operations are required to keep the machine in good running order (e.g. oil change).
Four separate maintenance counters are used to generate warnings as a reminder that a maintenance
operation is due. The count is displayed in hours and is reduced by one hour after each hour of operation. The
counter is reset once maintenance has been completed. If the maintenance interval is for example 1000
operating hours, the number 1000 is entered.
③ Start counter
Counter that counts the number of starts.
④ Reserve counter
The four reserve counters can be supplied to customers as an option, for counting the total quantities specific
to their installation. They are prepared in the application for the specific order in question.
⑤ Active and reactive energy meter
The active energy meter is used to count the total the amount of active energy produced by the set and the
active energy imported from the mains.
The reactive energy meters count the total amount of reactive energy generated and imported. The generator
always attempts to calculate and set the optimum power factor (cos Phi).
⑥ LVRT events
The number of all detected LVRT events (low voltage ride through – grid code) are displayed here.

7.1.4 Auxiliaries 1 (P_04.1)

The Auxiliaries screen appears when you press the MAIN screen selection key, followed by F4. It is used to
visualise switching conditions and analogue measurement quantities of auxiliaries required for engine
operation.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 33/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

① Auxiliary equipment description

Depending on the configuration of the auxiliary equipment different screens can be shown here.
② Auxiliary equipment status screen
The condition of the individual auxiliaries is displayed here or shown as analogue values.

7.1.5 Auxiliaries 2 (P_04.2)

The Auxiliaries screen appears when you press the MAIN screen selection key, then F4, followed by the TAB
key. It is used to visualise other switching conditions and analogue measurement quantities of auxiliaries
required for engine operation.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 34 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

① Auxiliary equipment description

7.1.6 Operational Logbook 1 (P_05.1)

The Operational Data screen appears when you press the MAIN screen selection key, followed by F5. The
measurement data to be entered in the operational logbook are provided here in summarised form.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 35/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

① Description of record entry

Depending on the engine configuration, various indications can be activated here which are to be copied to the
operational logbook.
② Measurement data displays
The measurement data to be recorded can be read on the right of the plain text display.

7.1.7 Operational Logbook 2 (P_05.2)

The Operational Data screen appears when you press the MAIN screen selection key, then F5, followed by the
TAB key. The data to be entered in the operational logbook are provided here in summarised form.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 36 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

① Description of record entry

Depending on the engine configuration, various indications can be activated here which are to be copied to the
operational logbook.
② Data displays
The data to be recorded can be read on the right of the plain text display.

7.1.8 Humidity (P_06.1)

The intake air humidity screen is brought up by pressing the MAIN main screen selection button followed by
F6 . The measurement values required to determine the absolute intake air humidity are displayed here. An
optional charge temperature offset and the calculated maximum boost pressure are also displayed.
Note: This screen is only displayed if the optional humidity sensor is installed on the engine.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 37/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

① Relative humidity
The relative humidity of the intake air, as measured by the humidity sensor, is displayed here.
② Temperature
The intake air temperature, as measured by the humidity sensor, is displayed here.
③ Barometric pressure
The barometric ambient pressure is determined by the p2' sensor with the engine at rest.
④ Calculated absolute humidity
The absolute humidity is calculated from the three values (humidity, intake temp. & ambient pressure) shown
above.
⑤ Charge temperature offset
An offset can be added to the nominal charge air temperature to counter any condensation in the intake
system. However, for this to happen, it must be possible for the charge temperature to be controlled by the
engine control system.
⑥ Maximum boost pressure
The maximum possible boost pressure is calculated from "Relative humidity", "Intake temperature", "Barometric
pressure" and "t2". If the charge temperature has been exceeded, condensation will form in the intake system.
To prevent this, the engine output can be reduced automatically.
⑦ Current boost pressure (averaged)

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 38 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

The current boost pressure is displayed here to compare whether a reduction in output can be expected
because of the intake air humidity. The current boost pressure is averaged in order to prevent brief
fluctuations.

7.2 Electrical Diagram (ELE)

The ELE screen group contains a summary of information on the electrical system and in particular on the
generator. Details of electrical data, synchronisation, the generator control system and temperature measuring
points are displayed.
Note: Only the Overview (P_11.1) screen is displayed in Customer View.

7.2.1 Overview (P_11.1)

The main overview screen is brought up by pressing the ELE main screen selection button. This screen shows
an overview of the main electrical measured variables, together with the operating and switching conditions.
Note: The displays for the bus bar voltages ⑧ and ⑨ are not shown in the Customer View.

① Generator or engine indication

Ten seconds after starting speed is reached, the display changes colour from white to green.
② Generator breaker section
The switching condition of the generator breaker is displayed:

Open

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 39/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

Closed
An optional existing transformer can also be shown in the generator breaker section. This symbol is not
animated (no colour change).

Transformer
③ Mains section
The switching condition of the mains breaker is displayed:

Open

Closed
An optional existing transformer can also be shown in the mains section. This symbol is not animated (no
colour change).

Transformer

④ Bus bar status identification

If the voltage values of the bus bar are OK, a green mains symbol is displayed. In the event of a failure the
symbol appears black and white.

Bus bar voltage OK.

Bus bar voltage failure

⑤ Mains status indication
If the mains status is OK, a green mains symbol is displayed. In the event of a failure the symbol appears black
and white.

Mains voltage OK.

Mains voltage failure

⑥ Speed and power setpoint entry

Engine speed setpoint n

When the generator breaker is open, the entry field is visible and the engine speed setpoint value can
be altered. The engine speed setpoint value can be entered from User Level customer (10) upwards.

Power setpoint P
Here you can alter the power setpoint value, unless another type of power setting
has been installed. The power setpoint value can be entered from User Level customer (10) upwards.
⑦ Electrical measurement data
Display showing the most important electrical data for the generator.
Abbreviation Designation Unit
Im Average current value (3 phases) [Amperes]
Um Average voltage value (3 phases) [Volts]
P Active power [kilowatts]
Q Reactive power [Kilovolt amperes reactive]
S Apparent power [Kilovolt amperes]
f Frequency [Hertz]

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 40 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

Abbreviation Designation Unit

cos Φ Power factor [1]
⑧ Phase-to-phase bus bar voltage
The three phase-to-phase bus bar voltages L1-L2, L2-L3 and L3-L1 can be displayed as an option.
⑨ Bus-bar phase voltages
The three bus bar phase voltages between L1, L2 and L3 and the neutral conductor N can be displayed as an
option.

7.2.2 Generator Details 1 (P_12.1)

The "Generator Details 1" screen is brought up by pressing the ELE main screen selection button followed by
F2. This screen shows the electrical measurement values.
Note: This screen is only displayed in Customer View. Details of another measuring point can be brought up on
a second tab (P_12.2) as an option.

① Animated switching condition diagram

The explanations of the individual symbols are given in the overview screen (P_11.1).
② Generator phase-to-phase voltage
The three generator phase-to-phase voltages L1-L2, L2-L3 and L3-L1 are displayed.
③ Generator phase voltages
The three generator phase voltages between L1, L2 and L3 and the neutral conductor N are displayed.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 41/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

④ Dynamic pulsation amplitude of the phase currents and negative-phase sequence current as a
percentage.
The maximum value of the current pulsation amplitude is displayed as a percentage so that the smooth
running of the engine can be assessed while in mains-parallel operation. This peak-value memory has a
decaying time constant and should ideally display the lowest possible value.
The calculated negative-phase sequence current I unbal referred to the generator nominal current is displayed
as a measure of the unbalanced phase load.
⑤ Generator excitation voltage
The generator excitation voltage is displayed in volts.
⑥ Detailed display of electrical power output
The actual electrical power output is displayed in kilowatts. An additional display field is provided here for the
maximum value of this measurement. The value is always reset when the generator breaker is closed.
⑦ Phase currents detailed display
The three actual phase currents are shown in amperes. An additional separate display fields are provided here
for the current maximum values . The values are always reset when the generator breaker is actuated.
⑧ Neutral conductor current detailed display
The actual neutral conductor current is shown in amperes. An additional display field is provided here for the
maximum value of the neutral conductor current. The value is always reset when the generator breaker is
closed.

7.2.3 Synchronisation (P_13.1

The Synchronisation screen appears when you press the ELE screen selection key, followed by F3. A
synchronoscope, with all the measured values required for synchronisation, is displayed on this screen.
Note: This screen is only displayed in Customer View. Optionally, details of another synchronisation can be
shown on a second tab (P_13.2).

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 42 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

① Synchronoscope
The synchronoscope is used to display the changes in phase position during the synchronisation process. The
position of the pointer corresponds to the numerical value of Φ diff. The value is displayed from -180 to +180
degrees.
The synchronoscope pointer indicates the current phase position. The lower the differential frequency the more
slowly the pointer moves.

Permissible activation range

This activation condition is satisfied if the synchronisation pointer is within the permissible phase position.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 43/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

Engine speed deviation

The messages Too Fast and Too Slow are shown as an additional aid.
The display appears as soon as the permissible differential frequency is exceeded.

Synchronisation completed

Synchronisation will be finished upon receipt of the power switches response. This status is displayed using a
green disc. In this way, it is possible to check whether the control system is trying to close the switch.

Deviation from measured value in synchronised condition

Deviations may occur in the measured values because of errors in the measurement accuracy tolerance,
despite the fact that the systems are electrically linked.
② Voltage difference
The current voltage difference U diff between the two networks to be synchronised (U diff = U System 1 - U
System 2) is displayed.
③ Frequency difference
The current frequency difference f diff between the two networks to be synchronised (f diff = f System 1 - f
System 2) is displayed.
④ Comparing two electrical systems

Electrical System 1
The entry System 1 lists the current voltage and frequency of electrical system 1. System 1 is activated at the
X4 terminals of the multi-measurement converter. The voltage closer to the generator is displayed here during
the synchronisation procedure.
Examples:
The generator voltage is connected here during the synchronisation of the generator switch.
The bus bar voltage is connected here during the synchronisation of the mains switch.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 44 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

Electrical System 2
The entry System 2 lists the current voltage and frequency of electrical system 2. System 2 is activated at the
X6 terminals of the multi-measurement converter. The voltage closer to the mains is displayed here during the
synchronisation procedure.
Examples:
The bus bar or mains voltage is connected here during the synchronisation of the generator switch.
The mains voltage is connected here during the synchronisation of the mains switch.
⑤ Phase angle
The current phase angle between the networks to be synchronised Φ diff (-180° to +180°) is displayed.
⑥ Synchronisation mode
There are three ways in which synchronisation can be performed:
Inactive
No function has been selected or synchronisation has already been completed
Slip
The following applies to the generator and synchronisation voltage:
50% < U < 125% of rated voltage UN
80% < f < 110% of rated frequency fN
The generator voltage is adjusted to the synchronisation voltage in terms of amplitude and frequency. The
switch command is designed and executed in advance to take account of the parameterised phase angle, a
preset transformer connection circuit and the switch response time so that the main contacts of the power
switch are closed at the point of synchronisation.
Synchronisation takes place subject to the following conditions:
▪ The "Select synchronisation" command is set in the software
▪ The parameterised limit for voltage difference has been maintained (dUmax)
▪ The parameterised limits for frequency difference have been maintained (dfmax and dfmin)
▪ The parameterised limit for the phase angle (including transformer connection circuit) has been maintained
(dalpha)
If all the conditions have been satisfied, the activation output changes its condition from LOW to HIGH. When
the parameterised pulse period has ended, it switches back from HIGH to LOW.
Synchro Check
In this operating mode the device can be used as a synchronisation control.
The "Close LS" relay remains attached as long as the following conditions are satisfied:
▪ The "Start synchro check" command is set in the software
▪ The parameterised limit for voltage difference has been maintained (dUmax)
▪ The parameterised limits for frequency difference have been maintained (dfmax and dfmin)
▪ The parameterised limit for phase angle has been maintained (phimax)
The activation output remains set so long as all the conditions are satisfied.
Dead bus
The activation command for the power switch is issued without synchronisation if the following conditions are
satisfied:
▪ the "Start dead bus" command is set in the software
▪ The bus bar is dead (USS < 5% UN)
▪ The generator voltage and frequency can have any valid value.
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 45/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

If all the conditions have been satisfied, the activation output changes from LOW tot HIGH.

7.2.4 Generator (P_14.1)

The Generator screen appears when you press the main ELE screen selection key, followed by F4. Optionally,
the operating diagram of the synchronous generator and, optionally, its bearing and winding temperatures are
displayed.
Details of the function and setting of the generator controller can be found in Technical Instruction 1530-0182.

① Operating diagram of synchronous generator

The operating diagram of the synchronous generator shows the effective power and reactive energy. The blue
dot indicates the operating point. The current reactive energy (Q), the maximum permissible reactive energy (Q
LIMIT - orange line) and the exciter failure value (Q TRIP - red line)
Where the permissible reactive energy is reached and the generator control system is enabled, an operating
notification is issued and the control system is limited to this value.
Where the maximum reactive energy (exciter failure value) has been reached, the engine shuts down due to
exciter failure.
② Control type indication
The following control types are available for power factor control:
None only operating diagram displayed
Internal Setpoint value preset via parameter setting

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 46 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

External - Power factor setpoint preset via analogue signal

analogue
External - bus Power factor setpoint value preset via bus
③ Reactive energy indication
The following information on reactive energy is displayed:
Q current reactive energy
Q Limit Limit level for warning and control limit
Q Trip Limit level for shutdown due to exciter
failure
④ Generator winding temperature
Optionally, generator winding temperatures can be displayed in degrees Celsius, degrees Fahrenheit or in
Kelvin.
Depending on the generator type, either one or three measured values can be visualised.
⑤ Generator bearing temperature
Optionally, generator bearing temperatures can be displayed in degrees Celsius, degrees Fahrenheit or in
Kelvin.

7.3 Hydraulic diagram (HYD)

The HYD screen group contains information on the hydraulic system. Pressure and temperature data for the oil
and cooling water circuits are displayed.

7.3.1 Oil/Cooling Water screen (P_21.1)

The oil/cooling water screen is brought up by pressing the HYD main screen selection button . This screen
shows the main hydraulic measured variables, together with the operational conditions in the cooling circuits.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 47/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

① Oil circuit measured values

The current oil temperature and pressure are displayed. Depending on the plant design, additional temperature
measurements can be displayed here with plain language labelling.
② Oil pumps
Various oil pumps may be installed, depending on the engine type.

Main oil pump

Pre-lubricating pump (24 V)

Pre-lubricating pump (230 V)

Whether a pump is in operation or not is indicated by a change of colour from white to green.
③ Turbocharger oil pump
The operating status of the turbocharger oil pump can be shown here as an option. If the pump is in operation,
the colour changes to green.
④ Turbocharger lubrication pump manual start
If a turbocharger lubrication pump is fitted, it can be activated manually by pressing the start button.
⑤ Cooling water circuit measured values
The current cooling water temperature and pressure are displayed. Depending on the plant design, additional
temperature measurements can be displayed here with plain language labelling.
⑥ Cooling water pump
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 48 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

This shows the operating status of the cooling water pump. If the pump is in operation, this is represented by a
colour change to green.
⑦ Preheating system
The preheating operating status is displayed as an option. If the heating is in operation, this is represented by a
colour change to green.
⑧ Preheating pump
The preheating pump operating status is displayed as an option. If the pump is in operation, this is represented
by a colour change to green.
⑨ Preheating from external heating circuit
The preheating operating status is displayed as an option. If the heating is in operation, this is represented by a
colour change to green.
⑩ (Emergency) cooling system
The cooling water pump operating status is displayed as an option. If the cooling is in operation, this is
represented by a colour change to green.
⑪ Turbocharger oil pressure downstream of the control valve
The turbocharger oil pressure downstream of the control valve is displayed as an option.

7.4 Gas Supply (GAS)

The GAS screen group contains information on the gas supply to the engine. measured values and actuating
variables for the gas volume and quality are displayed.
Note: Only the Gas Details (P_31.1) screen is displayed in Customer View.

7.4.1 Gas Details (P_31.1)

The gas details screen is brought up by pressing the GAS main screen selection button. The most important
information on the gas train(s) and the gas supply quantity or quantities are displayed on this screen.
Note: The displays for the mixture details ⑨ are not shown in the Customer View.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 49/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

① Gas type selection

Use a drop-down list to select the desired gas type. Depending on the application, up to 4 gas types can be
selected here (gas 1, gas 2, gas 3 and gas 4). Optionally, a gas-quality-dependent gas type, (gas 1-2), or a
mixed operation between two gas trains (gas 1/3 and gas 1-2/3 ) can be selected. Entering Auto Gas activates
the automatic gas type switching system.
② Gas mixer setting

Mode of operation
Using the screen button Operation mode (automatic - manual) you can make the combo box for the setpoint
value editable The button is only available if the generator switch is deactivated. If the button has been
activated (manual mode of operation) and the generator switch is activated, the automatic mode of operation
is reactivated automatically. Moreover, switching is only possible if the user has logged in at a minimum of user
level customer (10).

Entering the setpoint value

At gas mixer rate set you can enter the setpoint value for the gas mixer position as a percentage. The entry
field is only visible as long as the generator switch is deactivated and the preset has been switched to manual.
In addition, the operator must have logged in at least as User Level Customer (10).

Current setpoint
At gas mixer rate the current setpoint value to be started by the control unit is displayed.
③ Gas quality screen

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 50 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

If the gas type is subject to strong quality fluctuations (CH4 content, calorific value), it is possible to interpolate
between two different parameter sets, depending on the measurement signal made available by the customer.
The current interpolation factor (equivalent to gas quality) is displayed as a percentage.
④ Gas train leak test
The gas train test is represented by the following 4 symbols:

No leak test request

Leak test active

Gas train is OK

Error during gas train leak test

⑤ Gas valve
The condition of the gas valve is represented by a colour change. If the valve is shown in green, the engine
control system activates the command.
⑥ Actual value signal for gas mixer
Actual values for individual gas mixers shown as an opening percentage. Up to four gas mixers (1 - 4) can be
installed on the engine, depending on the configuration.
⑦ Intake air temperature
The intake air temperature is displayed in degrees Celsius, Fahrenheit or Kelvin.
⑧ Alternative displays with gas proportioning valve
Depending on the engine configuration, gas proportioning valves may be installed instead of standard gas
mixers. The setpoint value for the mixture is specified by directly entering a desired lambda value. The
coefficient indicates the current air volume as opposed to the minimum air volume required for complete
combustion.

Alternative with a gas train:

Up to three gas proportioning valves control in parallel the mixture quantity of the fuel gas supplied to air. The
percentage indicated is the opening angle of the proportioning valve as a percentage.
The gas proportioning valves are number consecutively from top to bottom. This arrangement is reflected in
technical diagrams, distribution plans, alarm systems and parameter settings.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 51/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

Alternative with two gas trains:

In this configuration, the gas train with the lower-quality gas in terms of calorific value (e.g. biogas) can be
fitted with up to two gas proportioning valves and the gas train with the higher calorific value (e.g. natural gas)
can be fitted with one valve. The percentage indicated is the opening angle of the proportioning valve as a
percentage.
The gas proportioning valves are numbered consecutively, the valve right at the top being number 3, the
middle valve number 1 and the bottom valve number 2. This arrangement is reflected in technical diagrams,
distribution plans, alarm systems and parameter settings.
⑨ Gas proportioning valve details
The gas proportioning valve also provides measurement values which are only displayed in expert mode. Up to
3 columns can be displayed, depending on the engine configuration.

The following values are shown:

[λ] Lambda factor
[%] Gas proportioning valve
opening angle [%]
[°C], [°F], [K] Fuel gas temperature
[l/s], [ft3/s] Calculated flow rate
[bar], [psi], [kPa] Fuel gas pressure

7.4.2 Special Gas (P_32.1)

The Special Gas screen appears when you press the main GAS screen selection key, followed by F2.
Additionally, measured values for special gases are displayed on this screen.
Note: This screen is only displayed in Customer View and when at least one special gas measured value is to be
displayed.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 52 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

① Animated switching condition diagram

An explanation of the individual symbols can be seen in the Gas Details (P_31.1) screen.
② Gas type selection
You can select the desired gas type from a drop-down menu. Depending on the application, 4 gas types can be
selected (Gas 1, Gas 2, Gas 3 and Gas 4). Optionally, a quality-dependant gas type, (Gas 1-2), or a mixed
operation using two gas pressure control systems (Gas 1/3 and Gas 1-2/3) can also be selected. The Auto Gas
entry activates the automatic gas type switching system.
③ Gas mixer setting

Mode of operation
Using the Operation mode screen button (automatic – manual), you can make the entry field for the setpoint
value editable. The button is only available if the generator switch is deactivated. If the button has been
activated (manual mode of operation) and the generator switch is activated, the automatic mode of operation
is reactivated automatically. Moreover, switching is only possible if the user has logged in at User Level
Customer
(10) or higher.

Entering setpoint values

At Gas mixer rate set you can enter the setpoint value for the gas mixer position as a percentage. The entry
field is only visible while the generator switch is off and the setting has been switched to manual. In addition,
the operator must at least have logged in as User Level Customer (10).

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 53/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

Current setpoint value

Gas mixer rate displays the current setpoint value to be used by the control unit.
④ Gas quality indication
If the gas type is subject to strong quality fluctuations (CH4 content, calorific value), it is possible to interpolate
between two different parameter sets, depending on the measurement signal provided by the customer. The
current interpolation factor (i.e. gas quality) is displayed as a percentage.
⑤ Indication of special gas data
Optionally, the various measured values for special gases are displayed here.

7.4.3 Gas Mixture (P_33.1)

The Gas Mixture screen appears when you press the main GAS screen selection key, followed by F3.
Additionally, setpoint values for the gas mixture are displayed on this screen.
Note: This screen is only displayed in Customer View and when at least one gas mixture is provided for this
engine.

① Animated switching condition diagram

An explanation of the individual symbols can be seen in the Gas Details (P_31.1) screen.
② Gas type selection

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 54 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

You can select the desired gas type from a drop-down menu. Depending on the application, up to 4 gas types
can be selected (Gas 1, Gas 2, Gas 3 and Gas 4). Optionally, a quality-dependant gas type, (Gas 1-2), or a mixed
operation using two gas pressure control systems (Gas 1/3 and Gas 1-2/3) can also be selected. The Auto Gas
entry activates the automatic gas type switching system.
③ Gas mixer setting

Entering setpoint values

At Gas mixture rate set you can enter the setpoint value for the gas mixer position as a percentage. The entry
field is only visible while the generator switch is off and the setting has been switched to manual. In addition,
the operator must at least have logged in as User Level Customer (10).

Current setpoint value

Gas mixture rate displays the current setpoint value to be used by the control unit.
④ Current gas type indication
The currently available gas types are shown here. A mixture of these gas types (e.g. the related parameter sets)
produces the current, interpolated gas type.
⑤ Current gas quality indication
The ratio of gas quality interpolation between the Gas 1 parameters and Gas 2 parameters are displayed here.
⑥ Current mixture ratio indication
The mixture ratio for the gas change-over between gas type 1-2 and gas type 3 is shown here.
⑦ Automatic / manual setting change-over
Here you can set the gas quality or mixture ratio manually.

7.5 Engine controller (ENG)

The ENG screen group contains information on the active engine controller. The setpoint and actual values of
individual controllers are displayed. Trend analyses assist in diagnosing control changes on the engine.
Note: Only the Engine Controller Overview (P_41.1) screen and the Ignition (P_46.1) screen are displayed in
Customer View.

7.5.1 Engine Controller Overview (P_41.1)

The engine controller screen is brought up by pressing the ENG main screen selection button. This screen
displays an overview of the status, operating mode and control variables of all the engine controllers (LEANOX,
power, speed and island operation controller).

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 55/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

① Gas mixer / Gas proportioning valve

The gas mixer and the gas proportioning valve are displayed here, depending on the engine type and the
design of the installation.

Gas mixer:
The gas mixer opening amount is displayed as percentage (see the illustration above).

Gas proportioning valve:

The lambda value is displayed at the gas proportioning valve.

Display showing the gas type

For each mixer version also the current gas type Gas type is show. The following displays are possible,
depending on the plant design:

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 56 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

Gas type Description

1 Gas type 1
2 Gas type 2
3 Gas type 3
4 Gas type 4
1_2 Gas quality = interpolation between the gas 1 and gas 2 parameter sets
1_2/3 Gas type 1_2 (gas train 1) mixed with gas type 3 (gas train 2)
1/3 Gas type 1 (gas train 1) mixed with gas type 3 (gas train 2)
Further details of the gas mixer are displayed in the screen group Gas displayed.
② Turbocharger bypass valve
Display showing the turbocharger bypass position (optional).
③ Throttle valve
Display showing the default throttle valve position.
④ Boost pressure
Display showing the boost pressure.
⑤ Charge temperature
Display showing the charge temperature.
⑥ Engine speed
Display showing the engine speed.
⑦ Power output
Display showing the electrical power produced by the generator.
⑧ LEANOX controller

If the controller is in operation, the pilot light changes from white to green .
The controller mode (auto/manual) is displayed, as is the control deviation in mbar or mpsi.
⑨ Power controller

If the controller is in operation, the pilot light changes from white to green .
⑩ Speed controller

If the controller is in operation, the pilot light changes from white to green .
⑪Island operation controller

If the controller is in operation, the pilot light changes from white to green .
⑫ Power set value and power reduction

The following types of power set values "P setpoint" are available:
Power set value Description
Internal The power set value is determined on the basis of the power setpoint set by the
operator. The power setpoint can be set in the Overview, Engine Controller Overview,
LEANOX Controller and Power Controller screens.
External - analogue The power set value is generated by an external analogue signal (4-20 mA). See
"Power / Scaling external power setpoint" parameter.
External - bus The power set value is created by a higher-order control system connected to DIA.NE
XT via an industrial bus connection.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 57/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

⑬ The following types of power reduction "P reduction" are possible:

Power reduction Description
None No power reduction is in effect.
Knock The knocking intensity has exceeded the limit value for power reduction.
Misfiring The number of misfires has exceeded the limit value for power reduction.
External - analogue Power reduction due to an external analogue signal. This signal can be used for a
variety of applications (e.g. to control return water temperature). See "Power /
Scaling external power limitation" parameter.
External - bus The power reduction is caused by a higher-order control system connected to
DIA.NE XT via an industrial bus connection.
Charge temperature The charge temperature has exceeded the limit value for power reduction. The
power rating is reduced linearly. See the "Power / Boost temperature reduction"
parameter.
Maximum power The pre-set power setpoint has exceeded the rated power related to the gas type
and is limited to the latter. See "Power / Nominal values" parameter.
Minimum power The pre-set power setpoint has fallen below the minimum permissible power
setpoint and is limited to the latter. See "Power / Nominal values / Minimum
power" parameter.
Exhaust gas temperature If a cylinder temperature ("Exhaust temp. positive/negative deviation max.")
deviates from the average value for more than 30 seconds, a power reduction is
activated. The power is also reduced when the limit value (average value of
exhaust gas temperature > 40% Prated) is reached.
LEANOX The LEANOX controller deviation limit value has been exceeded towards "lean".
The power rating is reduced linearly. If the LEANOX controller deviation limit value
is exceeded by than 20 percent towards "rich", the engine is switched off. See
"LEANOX / Gas type x / Controller / Controller deviation limit" parameter
Intake temperature The intake temperature has exceeded the limit value for power reduction. The
power rating is reduced linearly. See "Power / Intake air reduction" parameter.
CH4 If the CH4 content of the gas is decreasing, the power is reduced in accordance
with an external signal (4-20 mA). See "Special gas / CH4 content" parameter.
Gas pressure If the gas pressure is decreasing, the power is reduced in accordance with an
external signal (4-20 mA). See "Special gas / Gas pressure" parameter.
Suction pressure If the suction pressure (compressor intake pressure, e.g. on a landfill site) is
decreasing, the power is reduced in accordance with an external signal (4-20 mA).
See "Special gas / Suction pressure" parameter.
Turbocharger speed If one of the two "switching point maximum speed" limits (exhaust gas/
turbocharger A or B) is exceeded, the power is reduced accordingly depending on
the parameter "Value for P reduction" (power/turbocharger speed reduction).
Undervoltage If the generator voltage drops below an adjustable limit value of the nominal
generator voltage, power reduction begins.
Overvoltage If the generator voltage exceeds an adjustable limit value of the nominal
generator voltage, power reduction begins.
Underfrequency If the generator frequency drops below an adjustable limit value of the nominal
generator frequency, power reduction begins.
Overfrequency If the generator frequency exceeds an adjustable limit value of the nominal
generator frequency, power reduction begins. The power reduction only ends
when the deviation from the nominal frequency is very small again (hysteresis
window).

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 58 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

Power reduction Description

Lim. winding temperature If the generator winding temperature exceeds an adjustable limit value, power
reduction begins.
Cooling water If the cooling water temperature rises, power is reduced. See "Power / Cooling
temperature water temperature reduction" parameter.
Oil temperature If the oil temperature rises, power is reduced. See "Power / Oil temperature
reduction" parameter.
Return water If the hot water return temperature rises, power is reduced. See "Power / Return
temperature water temperature reduction" parameter.
Pre-combustion chamber If the pressure in the pre-combustion chamber gas train decreases, power is
gas pressure reduced. See "Power / Pressure pre-chamber gas train reduction" parameter.
Utility operator The power is reduced in accordance with the set parameters, or the engine is shut
down, via 3 digital inputs.
Charge temperature If the maximum permissible charge air temperature upstream of the high-
upstream of high- pressure turbocharger is exceeded, the power is reduced.
pressure turbocharger
DMR Power reduction due to various DMR safety functions
Humidity The power is reduced when an intake air humidity limit is reached.
The most effective power reduction is displayed. Further details are displayed in the "Engine Controller
Reductions" screen.
In addition, a reactive power reduction can also take place. This is not displayed in this screen, however, but
only as an operational notification in the alarm management:
Reactive power reduction Description
Lim. winding temperature. If the generator winding temperature exceeds an adjustable limit value,
reactive power reduction begins.
Pole wheel angle If the capacitive reactive power exceeds a certain value calculated on
the basis of the pole wheel angle, the reactive power is limited.

7.5.2 Power Reduction 1 (P_41.2)

The Power Reduction 1 screen appears when you press the main ENG screen selection key and then the TAB
key. It shows the first part of an overview of the status of the power reductions envisaged for this engine.
Note: This screen is not displayed in Customer View.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 59/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

① Maximum power reduction

The protective measure for the engine showing the maximum reduction is displayed here.
② Reduction causes
The names of the reduction causes relevant to the plant configuration are displayed here using a dynamic list.
An explanation of the individual reductions can be seen in the Engine Controller Overview (P_31.1) screen.
③ Power reduction by cause
The admissible load limit by cause is listed here in kW.
④ Bar chart showing power reductions by cause
This overview is meant to speed up the identification of power reduction.
⑤ Highest reduction
The longest bar limits the maximum power.
⑥ Reduction
All shorter bars do not affect the maximum power.

7.5.3 Power Reduction 2 (P_41.3)

The screen "Power reduction 2" is brought up by pressing the ENG main screen selection button and then
pressing the TAB key.. Further status displays are shown as a continuation of the overview from the power
reduction 1 screen.
Note: This screen is not displayed in customer view.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 60 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

① Greatest power reduction

The protective measure for the engine which has the greatest reduction level is displayed here.
② Reduction causes
The names of the reduction causes relevant to the installation configuration are displayed here using a
dynamic list.
The explanations for the individual reductions are given in the engine controller overview screen (P_41.1).
③ Power reduction by cause
The permissible load limit by cause is listed here in kW.
④ Bar graph of power reduction by cause
This overview is meant to speed up power reduction identification.

7.5.4 LEANOX® Controller (P_42.1)

The LEANOX® controller screen is brought up by pressing the main screen selection button ENG followed by
F2 . This screen shows an overview of the most important control variables and a trending for emission control.
Note: This screen is only displayed in Customer View.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 61/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

① Controller input variables

The following input variables are shown:
Abbreviation Designation Unit
P Set Power setpoint [kW]
P curr. Actual power [kW]
p2’ Boost pressure [bar], [psi], [kPa]
t2’ Charge temperature [°C], [°F], [K]
② Leanox® controller

If the controller is in operation, the pilot light changes from white to green .
Click the Automatic button to toggle the operating mode of the LEANOX controller between "Automatic" and
"Manual". To do so when the engine is at a standstill, you will need to have at least "Customer (10)"
authorisation. The button is always enabled for higher authorisation levels.
The controller deviation box shows control deviation (boost pressure)
③ Controller output
The controller output is connected to the gas mixture actuator. Depending on the engine configuration, either a
percentage value for the gas mixer or the excess air ratio (lambda) for the gas proportioning valve can be
shown.
The enable for any change in the set point depends on the LEANOX controller mode. Adjustment is possible in
manual mode.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 62 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

④ Display showing the gas type

The gas type currently being used is displayed. The individual gas types are set out in the engine controller
overview screen (P_41.1).
⑤ Online trend
The following control variables are displayed as a trend:
Abbreviation Designation Line colour Unit
Power Power red [kW]
Boost pressure Current boost pressure blue [bar], [psi], [kPa]
Boost temperature Charge temperature green [°C], [°F], [K]
Controller deviation Controller deviation black [mbar], [mpsi], [Pa]
Gas mixer position Gas mixer set point orange [% opening], [λ Lambda]

7.5.5 LEANOX® Controller Settings (P_42.2)

The LEANOX® controller screen is brought up by pressing the ENG main screen selection button followed by F2
and finally the TAB button. This screen shows the most important settings and measured variables for
adjusting the LEANOX® controller including trending. Only trained customers are allowed to adjust the
controller. Please ask for information about the comprehensive training available from GE Jenbacher.
Note: This screen is only displayed in Customer View.

① Controller representation

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 63/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

The explanations of the individual symbols are identical to those in the LEANOX® controller (P_4.21). Only the
bottom two-thirds of the screen is different.
② Controller parameters
The controller parameters can be edited above the "Advanced Customer" password level. The following
settings are shown:
Abbreviation Designation Unit
GM kp Proportional component of [1]
controller
GM ki Integral component of [ms]
controller
Limit Max. boost pressure [mbar], [mpsi], [Pa]
deviation
Dead zone Controller dead zone [mbar], [mpsi], [Pa]
Y-max Max. gas mixer set point [% opening], [λ lambda]
Y-min Max. gas mixer set point [% opening], [λ lambda]
③ LEANOX® Parameter setting
The controller parameters can only be be edited by trained customers. The following settings are shown:
Abbreviation Designation Unit
P Electrical power [kW]
p2’ Boost pressure [mbar], [mpsi], [Pa]
t2’ Charge temperature [°C], [°F], [K]
n speed rpm
Two data points are displayed, which can be stored by advanced customers.
④ Additional measured values
A few additional measured values are shown here to assist in adjusting the controller.
Designation Unit
Max and average Φ exhaust temperature [°C], [°F], [K]
Misfire detection [%]
Max and average Φ knock integrator [%]

7.5.6 Speed, Power and Isolated Operation Controller (P_43.1)

The n, P, island controller screen is brought up by pressing the ENG main screen selection button followed by
F3. This screen shows an overview of the main electrical control variables and a trend display for the speed and
power output control.
Only trained customers are allowed to adjust the controller. Please ask for information about the
comprehensive training available from GE Jenbacher.
Note: This screen is only displayed in Customer View.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 64 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

① Controller input variables

The following input variables are shown:
Abbreviation Designation Unit
n Set Speed setpoint [rpm]
n curr. Actual speed [rpm]
P curr. Actual power [kW]
② Speed, power, island controllers

A change of the associated pilot light from white to green indicates which of the three controllers is in
operation.
In the event of a controller deviation the deviation for speed (rpm) and power 9kW) is shown.
③ Controller output
The controller output is connected to the throttle valve actuator and optionally to the turbocharger bypass
valve.
④ Online Trend
The following controlled variables are displayed as a trend:
Abbreviation Designation Line colour Unit
Speed speed red [rpm]
Power Power blue [kW]

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 65/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

Abbreviation Designation Line colour Unit

Throttle valve Throttle valve brown [% open]
Compressor bypass Compressor bypass valve orange [% open]

7.5.7 Speed, Power and Isolated Operation Controller Settings (P_43.2)

The n, P, Isolated Operation Controller Settings screen appears when you press the main ENG screen selection
key, then F3 and finally the TAB key. The main controller variables and a trend analysis of speed and power
control are summarised on this screen. Only customers who have received training are permitted to set the
controllers. Please obtain information on GE Jenbacher's extensive range of training courses.
Note: This screen is only displayed in Customer View.

① Controller display
The explanation of the individual symbols is identical to the Speed, Power and Isolated Operation Controller
(P_43.1) screen. Only the bottom two-thirds of the screen are different.
② Speed controller parameters
Only customers who have received training can edit the speed controller parameters. The following settings
are displayed:
Abbreviation Description Unit
kp Proportional component [1]
of controller

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 66 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

Abbreviation Description Unit

ki Integral component of [1]
controller
kd Differential component of [1]
controller
Y-max Maximum actuating [% opened]
variable
Y-min Minimum actuating [% opened]
variable
③ Power controller parameters
Only customers who have received training can edit the power controller parameters. The following settings
are displayed for the throttle valve and, optionally, also for the compressor bypass valve.
Abbreviation Description Unit
kp Proportional component [1]
of controller
ki Integral component of [1]
controller
kd Differential component of [1]
controller
Y-max Maximum actuating [% opened]
variable
Y-min Minimum actuating [% opened]
variable
④ Isolated operation controller parameters
Only customers who have received training can edit the isolated operation controller parameters. The following
settings are displayed for the throttle valve and, optionally, also for the compressor bypass valve.
Abbreviation Description Unit
kp Proportional component [1]
of controller
ki Integral component of [1]
controller
kd Differnetial component of [1]
controller
Y-max Maximum actuating [% opened]
variable
Y-min Minimum actuating [% opened]
variable

7.5.8 Charge temperature controller (P_44.2)

The charge temperature screen is brought up by pressing the ENG main screen selection button followed by F4
and finally the TAB button. This screen shows the main electrical control variables and a trending for the
selected charge temperature controller.
Only trained customers are allowed to adjust the controller. Please ask for information about the
comprehensive training available from GE Jenbacher.
Note: This screen is only an option and is only displayed in Customer View.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 67/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

① Controller information

This is the name of the controller. If the controller is in operation, the pilot light changes from white to green
.
② Controller mode
The controller can be switched between using an internal and external set point with the External button, if this
function is provided.
Click the Automatic button to switch the controller between "Automatic" and "Manual" modes. In manual
mode, the actuating variable [Y/OP] can be changed by hand.
③ Control variables
The controller set point W/SP, the actual value X-PV and the actuating signal Y/OP can be read off or edited in
this section, depending on access rights and operating mode.
④ Controller parameters
The controller parameters can only be be edited by trained customers. The following settings are shown:
Abbreviation Designation Unit
kp Proportional component of [1]
controller
ki Integral component of [ms]
controller

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 68 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

Abbreviation Designation Unit

kd Differential component of [ms]
controller
Y-max Maximum actuating [%]
variable
Y-min Minimum actuating [%]
variable
W-max Maximum set point value [°C], [°F], [K]
W-min Minimum set point value [°C], [°F], [K]
⑤ Online Trend
The following controlled variables are displayed as a trend:
Abbreviation Designation Line colour Unit
W/SP setpoint value blue [°C], [°F], [K]
x-PV actual value brown [°C], [°F], [K]
Y/OP Actuating orange [%]
variable

7.5.9 Charge temperature controller autotune (P_44.3)

The charge temperature autotune screen is brought up by pressing the ENG main screen selection button
followed by F4 and finally the TAB button twice. This screen shows an overview of the information for
initialising and using autotuning for the charge temperature controller.
Only trained customers are allowed to adjust the controller. Please ask for information about the
comprehensive training available from GE Jenbacher.
Note: This screen is only an option and is only displayed in Customer View.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 69/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

Note: Detailed information on the autotune controller can be found in TI 1000-0531.

The controller status is displayed in the plain text in the relevant language. The following texts can be
displayed:
▪ Autotuning active
▪ Autotuning parameters calculated
▪ Invalid value for P component
▪ Invalid value for I component
▪ Invalid value for D component
▪ Y-MAX is less than or equal to Y-MIN
▪ Error in calculation of controller parameters
▪ Maximum tuning time has been exceeded
▪ Invalid value for change to control variable dy-MAX
▪ Controlled variable X has left the permissible range
▪ Difference between W and X is too small to start the tuning process
▪ Error in calculating the increase in the controlled variable
▪ Y-MAX or Y-MIN was changed during the tuning process

① Control variables and parameters

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 70 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

The explanations of the individual values are given in the charge temperature controller screen (P_44.2).
② Tuning control
Click the [Start button to start the tuning process.
Click the Cancel button to stop the tuning process or reject the calculated parameters.
Click Accept to accept the calculated parameters.
Enter a time limit for tuning in Time-max. If this value is exceeded, the tuning process is aborted and a note to
that effect appears on the status display.
③ Tuning Quality
3 modes are available:
approx.: 1 vibration test over 3 periods
moderate : 2 vibration tests over 4 periods
fine : 3 vibration tests over 5 periods
④ Autotuning parameters

Calculated parameters:
The parameters which are used during or after the controller tuning process
are displayed here.
kp : Display of the calculated proportional component.
ki : Display of the calculated integral component.
kd : Display of the calculated differential component.
These parameters can be accepted for control purposes by pressing the Accept button.

Selecting the control mode:

The cross in the box next to the ki or kd parameters indicates whether control parameters should be
sought during the autotuning process for the part of the controller selected in this way.
If this calculation for a component is not required, this can be deselected in the appropriate box.

7.5.10 Knock Controller (P_45.1)

The knock controller screen is brought up by pressing the ENG main screen selection button followed by F5.
This screen shows the most important characteristics relating to knock control.
Note: This screen is only an option and is only displayed in Customer View.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 71/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

① Bar display for knock sensor signal 1

If the mA signal of a knock sensor Knock signal 1exceeds the preset control limit, the colour of the bar changes
from green to red.
① Bar display for knock sensor signal 2
If the mA signal of a knock sensor Knock signal 2exceeds the preset control limit, the colour of the bar changes
from green to red.
If SAFI or KLS98 has been installed on the engine as an option, the following optional screen content is brought
up:

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 72 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

The minimum (min) and maximum (max) values for knocking intensity (Knock intensity) and knocking noise
(Knock noise) for all cylinders are displayed.
In addition, the average value (Φ) for all the cylinders is displayed.
The permissible limit values for the individual variables are indicated by narrow red and blue bars under the
broad bars for the measured values, where the red bar is the maximum permitted value and the blue bar is the
minimum value.
If the measured value is within the permitted optimal zone the measured value bar is shown in green. If the
value exceeds or drops below the permitted zone, the bar changes to red or blue as appropriate.
③ Ignition point retardation
Display showing the nominal ignition timing point Nominal and the ignition point as adjusted (retarded) to
prevent knocking Reduced. The numerical display is given in crankshaft angle degrees.
100 percent of the corresponds to the maximum permissible adjustment.
④ Power reduction
Display showing the nominal power Nominal and the power as adjusted to prevent knocking Reduced. The
numerical display is given in kilowatt.
100 percent of the corresponds to the maximum permissible adjustment.
⑤ Charge temperature reduction
Display showing the set charge temperature Nominal and the temperature as adjusted to prevent knocking
Reduced. The temperatures are displayed in degrees Celsius, Fahrenheit or Kelvin.
100 percent of the corresponds to the maximum permissible adjustment.

7.5.11 Ignition (P_46.1)

The ignition screen is brought up by pressing the ENG main screen selection button followed by F6. This screen
shows the most important characteristics relating to knock control.
Note: Only item ① is displayed in Customer View in this screen.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 73/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

① Misfiring detection
The misfiring detection integrator is displayed here.
Power will be reduced if the engine misfires frequently. The misfire are counted by an integrator. This integrator
will slowly be scaled down again during any period in which there is no misfiring.

Power reduction is started when the integrator is at 50%. A power reduction to up to 50% is performed
proportionally until the misfiring integrator reaches 100%.
② Ignition point source
Up to three sources for the ignition point are available.
▪ Starting the engine
▪ mains parallel operation
▪ island operation
The source actually user is displayed at Source.
The global set point, i.e. valid for all cylinders, is shown under Ignition point setpoint.
③ Cylinder selection
Either one specific cylinder or an overview of all cylinders (average) can be selected with this graphical
selection tool. The selection is made using the cursor buttons.
④ Ignition point adjustment
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 74 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

The actual ignition point is composed from the following control interventions:
Knock control knock control offset
Power adaptation offset dependent the actual power
Cylinder balancing offset for cylinder equalisation
Cylinder selective adaptation offset for cylinder-selective operating point
optimisation

A change of the associated pilot light from white to green indicates which of the controllers is in
operation at any time.
Control interventions may need to be performed in parallel, indicated by more than one check box turning
green (= active).
The displays are selected for the respective cylinders using the cylinder selection tool in Section ③. If all the
cylinders are selected (All), the average for all the cylinders is displayed.
① Current ignition point
The current ignition point for one cylinder or the average is shown under the entry Ignition point current.
Selection of the cylinders is described in Section ③.
In addition, the ignition points of the cylinders with the minimum (min) and maximum (max) values are shown.

7.5.12 2-stage pressure-charging (P_47.1)

The 2-stage pressure charging screen is brought up by pressing the ENG main screen selection button followed
by F7. This screen shows the most important information about the 2-stage turbocharging.
Note: This screen is only displayed as an option.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 75/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

① Intake air temperature

This shows the temperature of the intake air.
② Turbocharger speed, bank A low pressure
This shows the speed of the low-pressure turbocharger for bank A.
③ Temperature upstream of exhaust gas turbocharger, high pressure
This shows the temperature upstream of the high pressure exhaust gas turbocharger.
④ Turbocharger speed, bank A high pressure
This shows the speed of the high-pressure turbocharger for bank A.
⑤ Turbocharger valve position displays, bank A
X1 Valve 1 actual value
W1 Valve 1 set point
X2 Valve 2 actual value (optional)
X2 Valve 2 set point (optional)
⑥ Charge temperature and pressure upstream of throttle valve
This shows the charge temperature and pressure upstream of the throttle valve.
⑦ Throttle valve position displays
X1 Valve 1 actual value
W1 Valve 1 set point

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 76 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

X2 Valve 2 actual value (optional)

X2 Valve 2 set point (optional)
⑧ Charge temperature t2' and boost pressure p2' after the throttle valve
This shows the charge temperature t2' and boost pressure p2' downstream of the throttle valve.
⑨ Waste gate
The set point W and actual value X for the wastegate position can be shown here as an option.
⑩ Turbocharger outlet temperature, low pressure
The temperature downstream of the low-pressure turbocharger is shown here.
⑪ Measurement displays and inputs for bank B.
The measurement displays and inputs shown for cylinder bank A are available for bank b in the same way.
⑫ Boost pressure upstream of the high-pressure turbocharger
The pressures upstream of the high-pressure turbochargers are shown here.

7.6 Cylinder information (CYL)

The CYL screen group contains information on the current status of the cylinders. Optionally, depending on the
engine configuration, this allows you to view the ignition voltage, ignition point, knock detection and exhaust
gas temperature.
Note: Only the Cylinder measured values (P_51.1) screen and, optionally depending on the engine
configuration, the Ignition Voltage (P_52.1) screen, is displayed in Customer View.

7.6.1 Cylinder Measured Values (P_51.1)

The Cylinder Measured Values screen appears when you press the CYL screen selection key. It shows an
overview of the status of the cylinder measured values.
Note: This screen is considerably reduced in Customer View and is therefore displayed extremely clearly (see
below).

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 77/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

① Numerical data display

Optionally, the value of a cylinder selected as described in ② (curr.), the minimum value (min), the average (Φ)
across all the cylinders and the maximum value (max) of all the cylinders are displayed for the following
measured values
Reference text Description Unit
Ignition voltage Ignition voltage [kV]
Ignition point Ignition point [°Crankshaft
angle]
Knock integrator Knock integrator [%]
Knock noise Knock noise [mV]
Valve noise Valve noise [mV]
Exhaust temperature Exhaust gas [°C], [°F], [K]
temperature
② Cylinder selection
You can use this graphical selection aid to select either a specific cylinder or an overview of all the cylinders
(average value). Use the cursor keys to make the selection.
If All is selected, only the maximum, minimum and average values will now be displayed.
③ Graphical data display
Optionally, in addition to the numerical display, the current measured values are displayed in a bar graph for
the cylinders selected at ②.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 78 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

The permissible limit values for individual variables are shown in narrow red and blue bars below the broad
measured value bar. The red bar is the maximum permissible value and the blue bar is the minimum value.
When the measured value moves within the permissible, optimum range, the measured value bar is shown in
green. If the values exceed or fall below this level, the bar changes to red or blue respectively.

Display in Customer View

In Customer View, the information is reduced to the essential. The values for the individual cylinders are no
longer displayed but the minimum, average and maximum values are shown.
"Traffic lights" are shown as a new display element. They provide an overview of the status of all the cylinders
in the engine.

The following status displays may be generated:

Green → everything OK. Each cylinder is operating with the tolerance range
set for this measured value.

Yellow → warning. At least one cylinder is not operating with the tolerance range
set for this measured value.

Red → shutdown. At least one cylinder is not operating with the tolerance range
set for this measured value. This may result in an engine shutdown immediately or in the near future.

7.6.2 Cylinder Comparison (P_51.2)

The Cylinder Comparison screen appears when you press the main CYL screen selection key, followed by TAB.
Depending on the engine configuration, up to 5 different measured values for each cylinder can be displayed in
parallel.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 79/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

Note: This screen is not displayed in Customer View.

① Cylinder selection
If there are 5 columns, one measured value available on the engine can be displayed for each cylinder. The
setting is saved when you change screens.

The following measured values can be selected:

Reference Description Unit
text
Exh. Temp. Exhaust gas [°C], [°F], [K]
temperature
Ignition p. Ignition point [°Crankshaft
angle]
High volt. Ignition voltage [kV]
Knock int. Knock integrator [%]
Knock signal Knock noise [mV]
Valve signal Valve noise [mV]

7.6.3 Ignition Voltage Measurement (P_52.1)

The Ignition Voltage Measurement screen appears when you press the main CYL screen selection key, followed
by F2. It shows an overview of the measured values for ignition voltages.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 80 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

Note: This screen is only displayed when the ignition voltage measurement option has been installed on the
engine.

① Graphical display of the ignition voltage

The ignition voltages of the individual cylinders are displayed in a bar graph.
The measured value bar is shown in green as long as it is within the tolerance range.
The tolerance range is visualised by means of two narrow bars in red and blue below the actual, broad
measured value bar.
The blue narrow bar represents the minimum permissible ignition voltage. If one of the ignition voltages falls
below this limit value, the colour of the bar will change from green to blue.
The red narrow bar represents the maximum permissible ignition voltage. If one of the ignition voltages
exceeds this limit value, the colour of the bar will change from green to red.
② Numerical display of the ignition voltage
The ignition voltages of the individual cylinders are displayed numerically in Kilovolts.
③ Minimum, maximum and average ignition voltage
The maximum value (max) and the minimum value (min) of all the cylinders and the average (Φ) across all the
cylinders are displayed here.

7.6.4 Ignition Point Display (P_53.1)

The ignition point screen is brought up by pressing the CYL main screen selection button followed by F3. It
shows an overview of the current ignition point settings for the individual cylinders.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 81/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

Note: This screen is only displayed in Expert View if an ignition system with selective ignition point adjustment is
installed on the engine.

① Graphical display of ignition points

The ignition point settings for the individual cylinders are displayed as a bar chart.
The bars are shown in green if the measured value is within the tolerance range.
The tolerance range is shown as two narrow bars in red and blue under the broad bar for the measured value.
A narrow blue bar represents the minimum permissible ignition point, while the red bar represents the
maximum permissible ignition point. Values above and below the tolerance cannot occur with this display.
The ignition points are displayed in crankshaft angle degrees before top dead centre.
The individual ignition points only vary if the individual knock control system has been activated by KLS/SAFI.
② Numerical display of ignition points
The ignition points are also displayed numerically in crankshaft angle degrees before top dead centre.
③ Minimum, maximum and average ignition voltage
The maximum (max) and minimum (min) values for all cylinders, and the average (Φ) for all cylinders, are shown
here.
④ Ignition energy
The ignition energy shown is the energy supplied to the ignition coils. 100% equals the maximum ignition
energy of the ignition system. This value is pre-set in the parameter management system.
This value is not displayed in the SAFI system.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 82 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

⑤ Ignition self-test
This button is only enabled when the operation mode selector switch is in "OFF" position and the user has
"Customer (10)" authorisation or higher.
Using the self-test function, you can test the ignition voltage supply of the ignition coils while the engine is at
standstill. The self test is automatically de-activated after 10 minutes.
In order to avoid any misfires due to the self-test, a scavenging start is carried out. The test sequence is started
by pressing the Start button.

Step 1: Warning that the engine will turn

Before any action is initiated on the set, a safety question is asked to make the user aware that the engine will
turn when the OK button is pressed as confirmation.
This warning is intended to prevent any physical injury or damage to the engine.

① Activation button
After confirmation of activation with the OK button, the self-test sequence is started.

② Cancel button
The entire preparatory sequence can be discontinued at any time with the Cancel button.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 83/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

Step 2: Prelubrication
Depending on the engine type it may require prelubrication before being turned by the starter motor.

Step 3: Scavenging
The next step is to turn the engine for a short period to scavenge the intake and exhaust systems.

Step 4: Waiting time

Before the procedure is completed, a brief waiting time elapses so that the engine can coast down.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 84 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

Step 5: Message that the self-test is active.

Once scavenging is completed the ignition system can be activated.

Step 6: Self-test active

The self-test is active for 10 minutes. It can be stopped prematurely with the STOP button.

7.6.5 Ignition Output Error (P_53.2)

The Ignition Output Error screen appears when you press the main CYL screen selection key, then F3, followed
by the TAB key. It shows an overview of the current ignition point settings for the individual cylinders, plus the
ignition deviation errors and ignition duration errors.
Note: This screen is only displayed in Expert View when a SAFI ignition system has been installed on the engine.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 85/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

① Display of ignition points

The ignition point settings of the individual cylinders are displayed in a bar graph and as a numerical value.
② Ignition delay errors
Display showing for each cylinder how often no ignition spark has been produced within the last ten engine
cycles.
③ Combustion time errors
Display showing for each cylinder how often the permissible combustion-time tolerance has been exceeded
and/or underrun within the last ten engine cycles.

7.6.6 Knock Integrator (P_54.1)

The knock Integrator screen is brought up by pressing the CYL main screen selection button followed by F4. It
shows an overview of the current knock control integrator values for the individual cylinders.
Note: This screen is only displayed in Expert View if a cylinder-selective knock monitoring system (SAFI/KLS98) is
installed on the engine.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 86 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

① Graphical display of knock integrators

The knock integrators are displayed as a percentage. Up to three knock prevention measures are set,
depending on the individual percentage values. When a first threshold value is reached (e.g. 10%), the knock
control system will retard the ignition point. When a second threshold value is reached (e.g .greater than 50%),
the power will be reduced. If, despite the ignition point adjustment and the reduction in the engine power, a
100 percent knocking intensity value is reached, the engine will be shut down. In addition, the charge
temperature will be lowered if the plant control system allows this.
① Numerical display of knock integrators
The knock integrators are also displayed numerically as a percentage.
③ Minimum, maximum and average integrator values
The maximum (max) and minimum (min) values for all cylinders, and the average (Φ) for all cylinders, are shown
here.

7.6.7 Knock Noise (P_54.2)

The Knock Noise screen appears when you press the main CYL screen selection key, then F4, followed by the
TAB key. It shows an overview of the current knock noise for the individual cylinders.
Note: This screen is only displayed in Expert View when a cylinder-selective knock monitoring system (SAFI/
KLS98) has been installed on the engine.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 87/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

① Graphical display of knock noise

The knock noise is displayed as a percentage. The knock noise is used as a basis for increasing or reducing the
knock integrator values.
② Numerical display of the knock noise
The knock noise is also displayed numerically in millivolts.
③ Minimum, maximum and average knock noise
The maximum value (max) and the minimum value (min) of all the cylinders and the average (Φ) across all the
cylinders are displayed here.

7.6.8 Valve Noise (P_54.3)

The Valve Noise screen appears when you press the main CYL screen selection key, then F4, followed by TAB
twice. It shows an overview of the current valve noise for the individual cylinders.
Note: This screen is only displayed in Expert View when a cylinder-selective knock monitoring system (SAFI/
KLS98) has been installed on the engine.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 88 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

① Graphical display of valve noise

The valve noise is displayed as mV. If a limit value (2000 mV) is exceeded, a trip warning (maximum valve noise)
will be generated in the alarm management system. Possible causes could include excessive valve play, valve
spring breakage, bearing damage, etc.
② Numerical display of the knock noise
The valve noise is also displayed numerically in millivolts.
③ Minimum, maximum and average valve noise
The maximum value (max) and the minimum value (min) of all the cylinders and the average (Φ) across all the
cylinders are displayed here.

7.7 Exhaust system information (EXH)

The EXH screen group contains information on the current measured values for the exhaust system. Optionally,
depending on the engine configuration, this allows you to view the exhaust gas collector temperatures, the
exhaust gas temperatures per cylinder, turbo speeds and exhaust gas treatment systems (thermal reactor,
CODINOX).
Note: Only the Exhaust System Overview (P_61.1) screen is displayed in Customer View.

7.7.1 Exhaust System Overview (P_61.1)

The Exhaust System Overview screen appears when you press the main EXH screen selection key. It shows an
overview of the status of the exhaust system.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 89/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

Note: This screen is considerably reduced in Customer View and is therefore displayed extremely clearly (see
below).
The measuring points listed below may be displayed, depending on the engine configuration.

① Cylinder selection
You can use this graphical selection aid to select a specific cylinder. Use the cursor keys to make the selection.
② Exhaust gas temperature at cylinder outlet
The current value (curr.), the maximum value (max) and the minimum value (min) of all the cylinders and the
average (Φ) across all the cylinders are displayed here.
③ Display showing the catalytic converter temperatures
The temperatures before, in and after the catalytic converter are displayed.
④ Display showing turbo temperatures
The temperatures before and after the turbocharger are visualised here.
⑤ Pipe plate temperature
The current pipe plate temperature is displayed here.
In addition, if you are authorised at user level "Customer" (10) or above, you can enter the limit values for
Warning and Trip.
⑥ Display showing temperatures at heat exchanger outlet
Depending on the plant, the heat exchanger outlet temperatures can be displayed here.
⑦ Status display for scavenging

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 90 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

The status of the scavenging air valve and the scavenging air fan are shown here.

Display in Customer View

In Customer View, the information is reduced to the essential. The values for the individual cylinders are no
longer displayed but the minimum, average and maximum values very probably will be.
"Traffic lights" are shown as a new display element. They provide an overview of the status of all the cylinders
in the engine.

The following status displays may be generated:

Green → everything OK. Each cylinder is operating with the tolerance range
set for this measured value.

Yellow → warning. At least one cylinder is not operating with the tolerance range
set for this measured value.

Red → shutdown. At least one cylinder is not operating with the tolerance range
set for this measured value. This may result in an engine shutdown immediately or in the near future.

7.7.2 NOx overview (P_61.2)

The NOx overview screen is brought up by pressing the EXH main screen selection button followed by TAB. It
shows an overview of the measured values for oxides of nitrogen and oxygen in the exhaust system.
Note: This screen is only displayed if the optional NOx sensor is installed on the engine.
Depending on the engine configuration, displays may be shown for the measuring points listed below.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 91/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

① Sensor 1 measurement display

The actual contents in the exhaust of oxides of nitrogen in ppm and oxygen as a % are displayed here for
sensor 1 numerically.
② Sensor 2 measurement display
The actual contents in the exhaust of oxides of nitrogen in ppm and oxygen as a % are displayed here for
sensor 2 numerically.
③ Average values display
The average values for both sensors of the measurements of oxides of nitrogen in mg referred to standard
cubic metres and x% oxygen content, and the average oxygen content as a %, are displayed here.

7.7.3 Cylinder outlet exhaust temperature (P_62.1)

The Cylinder Temperature screen appears when you press the main EXH screen selection key, followed by F2. It
shows an overview of the current exhaust gas temperature for the individual cylinders.
Note: This screen is only displayed in Expert View when a cylinder-selective exhaust gas measurement system
has been installed on the engine.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 92 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

① Graphical display of exhaust gas temperatures

Optionally, the current measured values for the exhaust gas temperatures are displayed here in addition to the
numerical display.
The permissible limit values for individual variables are shown in narrow red and blue bars below the broad
measured value bar. The red bar is the maximum permissible value and the blue bar is the minimum value.
When the measured value moves within the permissible, optimum range, the measured value bar is shown in
green. If the values exceed or fall below this level, the bar changes to red or blue respectively.
② Numerical display of the exhaust gas temperatures
You can choose to display the exhaust gas temperatures per cylinder in °C, °F or K.
③ Minimum, maximum and average cylinder temperature
The maximum value (max) and the minimum value (min) of all the cylinders and the average (Φ) across all the
cylinders are displayed here.

7.7.4 Turbocharger (P_63.1)

The turbocharger screen is brought up by pressing the EXH main screen selection button followed by F3. It
shows the turbocharger speeds.
Note: This screen is only displayed in Expert View if a turbocharger speed measurement system is installed on
the engine.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 93/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

① Turbocharger diagram
The turbocharger arrangement diagram is displayed here.
② Turbocharger speed
The speeds from the optional turbocharger speed sensors are displayed here in 1000 rpm. If two speeds are
shown, then one turbocharger speed sensor is installed for each cylinder bank (A + B).
③ Low-pressure turbocharger speed
The speeds from the optional low-pressure turbocharger speed sensors are displayed here in 1000 rpm. If two
speeds are shown, then one turbocharger speed sensor is installed for each cylinder bank (A + B).

7.7.5 Thermal Reactor (P_61.1)

The Thermal Reactor screen appears when you press the main EXH screen selection key, followed by F5. The
screen shows the status of cleaning as well as an overview of the measured values.
Note: This screen is only displayed in Expert View when an exhaust gas thermal reactor has been installed
downstream of the engine.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 94 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

① Thermal reactor
The reactor is displayed schematically. The average temperature of the active reactor is displayed at TK.
② Gas spray injection 1
The gas injection in Chamber 1 is shown using arrows in the direction of flow and by the valves changing
colour to green.
③ Gas spray injection 2
The gas injection in Chamber 2 is shown using arrows in the direction of flow and by the valves changing
colour to green.
④ Electric heating
The operation of the electric heating system is displayed by a colour change to green. The percentage value
indicates the heating's power setting.
⑤ Direction of flow
The direction of flow of the gas is shown using the shunt symbol and additional arrows.
⑥ Temperatures in Chamber 2
Two temperature measuring points (TK2_1 and TK2_2) per chamber are displayed in degrees Celsius, degrees
Fahrenheit or Kelvin.
⑦ Temperatures in Chamber 1
Two temperature measuring points (TK1_1 and TK1_2) per chamber are displayed in degrees Celsius, degrees
Fahrenheit or Kelvin.
⑧ Reference temperature
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 95/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

Display showing the ambient temperature as a reference measurement for the temperatures
(Tvgl) measured in the reactor in degrees Celsius, degrees Fahrenheit or Kelvin.

7.7.6 Codinox (P_66.1)

The Codinox screen appears when you press the main EXH screen selection key, followed by F6. The screen
shows the status of exhaust gas purification as well as an overview of the measured values.
Note: This screen is only displayed in Expert View when a Codinox exhaust gas purification system has been
installed downstream of the engine.

① engine operation
The operation of the engine is indicated by a colour change to green.
② Flushing fan
Depending on the engine type, the fan for flushing the exhaust gas system can be shown here. Before every
engine start the exhaust gas system is flushed to prevent unwanted misfiring. The operation is displayed by the
colour change to green.
③ Scavenging air valve
Depending on the engine type, the valve for flushing the exhaust gas system can be shown here. Before every
engine start the exhaust gas system is flushed to prevent unwanted misfiring. To this end the scavenging air
valve is opened. When the engine is in operation, this valve remains closed.
④ Oxibox
The Oxibox is not activated and does not provide any electrical responses.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 96 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

⑤ CODINOX reactor
If the CODINOX reactor is active, this is indicated by a change of colour to green.
⑥ CO2 valve
If the valve is opened, the exhaust gases are uses as a fertilizer. If the valve is closed, the exhaust gases are
released into the open air via the exhaust gas system. To indicate the direction of flow, arrows are shown after
the fan or above the exhaust gas stack symbol.
⑦ CO2 fan
When the CO2 valve is opened, the fan is in operation.
⑧ Temperature at waste heat boiler inlet
The exhaust gas temperature at the waste heat boiler inlet is displayed in degrees Celsius, degrees Fahrenheit
or Kelvin.
⑨ Temperature at catalytic converter inlet
The exhaust gas temperature at the waste catalytic converter inlet is displayed in degrees Celsius, degrees
Fahrenheit or Kelvin.
⑩ Temperature at heat exchanger outlet 1
The exhaust gas temperature at heat exchanger outlet 1 is displayed in degrees Celsius, degrees Fahrenheit or
Kelvin.
⑪ Temperature at heat exchanger outlet 2
The exhaust gas temperature at heat exchanger outlet 2 is displayed in degrees Celsius, degrees Fahrenheit or
Kelvin.

7.8 Plant controllers (CTR)

The CTR screen group contains information on the plant controllers. The individual controllers are displayed in
an overview and individually.
Note: Only the Controller Overview (P_71.1) screen and the Controller Details (P_71.2) screen are displayed in
Customer View.

7.8.1 Plant Controller Overview (P_71.1)

The plant controller overview screen is brought up by pressing the CTR main screen selection button. It shows
an overview of the status of all the plant controllers.
Note: The way the installed plant controllers are displayed depends on the particular engine configuration.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 97/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

① Controller status screen

If the controller is in operation, the pilot light changes from white to green . The controller attempts to
achieve its setpoint value.
② Plant controller selection
The focus can be positioned on a plant controller name using the cursor buttons. Changing from the overview
screen to the controller details screen with TAB brings up an display of information for the selected controller.
③ Set point and actual value numerically
The set point (set) and the actual value (curr.) are displayed, together with the units.
④ Set point and actual value as a bar chart
The set point and actual values are displayed as a bar chart showing 0 - 100% of the measurement range. This
representation shows quickly whether or not there is a substantial controller deviation.
⑤ Controller actuating signal
The output value of the actuating signal is shown as a percentage.
⑥ Scroll function
If more plant controllers are used on a generating set than can be simultaneously displayed on the overview
screen, a downwards arrow is shown for information. The arrow indicates that the rest of the controllers can be
displayed by moving downwards with the cursor buttons.
As soon as the first controller disappears at the top due to scrolling downwards, an upwards arrow appears at
the top to indicate that not all the controllers are being displayed.
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 98 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

7.8.2 Plant Controller Details (P_71.2)

The Plant Controller Details screen appears when you press the main CTR screen selection key, followed by
TAB. The main controller variables and a trend analysis for a plant controller are summarised on this screen.
Only customers who have received training are permitted to set the controllers. Please obtain information on
GE Jenbacher's extensive range of training courses.
Note: This screen is only displayed as an option.

① Controller information
The name of the controller is displayed here. If the controller is active, the indicator light changes from white
to green .
② Controller operating mode
Where this function is available, press the External key to toggle the controller between using the internal and
external setpoint.
Press the Automatic key to toggle the controller between "Automatic" and "Manual" modes. In manual mode,
you can change the actuating variable Y/OP by hand.
③ Controller variables
In this section, you can read off the setpoint value of the controller W/SP, the actual value X-PV and the
actuating signal Y/OP and, depending on your access rights and the operating mode, edit them.
④ Controller parameters
The controller parameters can be edited if you are at password level "Advanced Customer" or above. The
following settings are displayed:

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 99/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

Abbreviation Description Unit

kp Proportional component of [1]
controller
ki Integral component of [ms]
controller
kd Differential component of [ms]
controller
Y-max Maximum actuating [%]
variable
Y-min Minimum actuating [%]
variable
W-max Maximum setpoint value [free]
W-min Minimum setpoint value [free]
⑤ Online trends
The following controlled variables are displayed as a trend:
Abbreviation Description Line colour Unit
W/SP Setpoint value blue [free]
x-PV actual value brown [free]
Y/OP Actuating Orange [%]
variable

7.8.3 Plant Controller Autotuning (P_71.3)

The Autotuning screen appears when you press the main CTR screen selection key, select a plant controller
and then press TAB twice. Information on the initialisation and use of autotuning for the selected plant
controller is summarised on this screen.
Only customers who have received training are permitted to set the controllers. Please obtain information on
GE Jenbacher's extensive range of training courses.
Note: This screen is only displayed optionally and in Expert View.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 100 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

Note: Details on the autotuning controller can be found in TI 1000-0531.

The controller status is displayed in plain text and in the relevant language. The following text can be displayed:
▪ Autotuning active
▪ Autotuning parameters calculated
▪ Invalid value for P component
▪ Invalid value for I component
▪ Invalid value for D component
▪ Y-MAX is less than or equal to Y-MIN
▪ Error in calculation of controller parameters
▪ Maximum tuning time has been exceeded
▪ Invalid value for change to control variable dy-MAX
▪ Controlled variable X has left the permissible range
▪ Difference between W and X is too small to start the tuning process
▪ Error in calculating the increase in the controlled variable
▪ Y-MAX or Y-MIN was changed during the tuning process
① Control variables and controller parameters
An explanation of the individual values can be seen in the Plant Controller Details (P_71.2) screen.
② Tuning control

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 101/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

Press the Start button to start the tuning process.

Press the Cancel button to cancel the tuning process and discard the parameters calculated.
Use Accept to copy the parameters calculated.
Enter the time limit for tuning in the Time-max box. If this value is exceeded, the tuning process is aborted and
a note to that effect appears on the status display.
③ Tuning quality
Three modes are available:
approx.: 1 vibration test over 3 periods
moderate : 2 vibration tests over 4 periods (this is often the best choice)
fine : 3 vibration tests over 5 periods
④ Autotuning parameters

Calculated parameters:
Displayed here are the parameters which are used during or after the tuning process for
the controller.
kp : Display showing the calculated proportional component.
ki : Display showing the calculated integral component.
kd : Display showing the calculated differential component.
Press the Accept button to copy these parameters for the control system.

Selecting the controller type:

The cross in the check box next to the ki or kd parameter indicates whether it is advisable to search for
control parameters for the selected controller component during the autotuning process.
If you do not want to carry out the calculation for a component, you can uncheck the appropriate check box
.

7.9 Customer Screens (CUSTOM)

The CUSTOM screen group contains information ordered by the customer as a special requirement.
Up to 21 subscreens can be inserted in this menu.
Note: This screen is only displayed as an option.

7.9.1 Customer Screen (P_81.1)

The Cylinder Measured Values screen appears when you press the main CUSTOM screen selection key. The
screen content may vary from application to application.
Note: This screen is only displayed as an option.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 102 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

① Customer screen
This area can contain a customised screen.

7.10 System Information (SYS)

The SYS screen group contains information on the DIA.NE XT3 system and SAFI hardware.
Note: Only the System Overview (P_91.1) screen is displayed in Customer View.

7.10.1 System Overview (P_91.1)

The System Overview screen appears when you press the main SYS screen selection key. The most important
information on the DIA.NE XT3 system as well as the lamp test and timing adjustment are visualised on this
screen.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 103/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

① Plant identification screen

Engine type: The engine type or plant component type is displayed providing information on engine type and
number of cylinders or the plant component type.
The Application box contains the text that identifies the plant.
The engine number that appears on the type plate is shown at Engine number. This ensures that the engine is
clearly identified.
These details are used by GE Jenbacher for the administration of individual engine types, plants or individual
machines.
② Service active/inactive
In order to calculate availability, any servicing activities can be registered here. The button must be pressed as
soon as the servicing starts. The button text now switches to "Active". The button must be pressed again when
the servicing is finished. No more time is registered to Service and "Inactive" is displayed.
Should the mechanic forget to press the button when the servicing is finished, the switch from active to
inactive happens automatically following two hours of engine operation with a closed generator switch.
③ Activation of lamp test
When you press the Start button all the indicators are switched on for 15 seconds.
④ Time and date
Adjusts time and date display to DIA.NE XT and DIA.NE WIN. This function is only enabled for user level
customer (10) and above.
In the case of multi-engine plants equipped with DIA.NE WIN, system times are synchronised automatically.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 104 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

If a DIA.NE WIN Server is installed, date or time setting (in hours) can only be done through DIA.NE WIN. In this
case, the DIA.NE XT engine control system can only be used to adjust the time range in minutes or seconds.
Press the (Set) button to clear or copy the entry.
⑤ Software versions
The software version of the visualisation unit (VIS), the engine controller (RPS), the module control system (SPS),
and all CAN bus participants connected to the engine are displayed here.

7.10.2 SAFI Hardware Details 1 (P_92.1)

The SAFI Hardware Details 1 screen appears when you press the main SYS screen selection key, followed by F2.
The most important information on the SAFI system is displayed on this screen.
Note: This screen is only displayed as an option.

①
The hardware version for each device = cylinder pair is displayed.
② Firmware version
The firmware version for each device = cylinder pair is displayed.
③ Operating hours
The current operating hours for each device = cylinder pair is displayed.
④ Serial number
The serial number of the SAFI for each device = cylinder pair is displayed.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 105/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

⑤
The production date for each device = cylinder pair is displayed.

7.10.3 SAFI Hardware Details 2 (P_92.2)

The SAFI Hardware Details 2 screen appears when you press the main SYS screen selection key, then F2
followed by TAB. Further information on the SAFI system is displayed on this screen.
Note: This screen is only displayed as an option.

①
The electronics temperature for each device = cylinder pair is displayed.
② Tooth error
The tooth error shows any tooth on the flywheel ring gear on which a pickup error has been detected.
③ Filter version
The serial number of the knock filter for each device = cylinder pair is displayed.

7.11 Parameter Manager (PARA)

The parameter manager for the DIA.NE XT3 system is implemented in the PARA screen group. All the
parameters available for the relevant engine and authorisation level are displayed, and can be edited.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 106 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

7.11.1 Parameter Manager (P_Para1.1)

The parameter manager screen is brought up by pressing the PARA main screen selection button. The lists of
available parameter for the engine or the current authorisation level are shown on this screen. The desired list
can be selected from this screen.

① List navigation
All the parameter lists that can be viewed at the particular authorisation level are brought up. If a list entry (e.g.
Gas mixer) has a number of sub-entries (e.g. Gas type 1 and Gas type 2), these lists are shown in a second
column. If there are further sub-entries, these can be shown in a third level. The indication that an entry has
associated sub-entries is an arrow sign at the right-hand end of the selection field. Navigation between the
individual fields is done using the cursor buttons. To change to a submenu, press the right cursor button.
If the available space is not enough for the number of lists, further entries are displayed on extra tabs. The TAB
button is used to switch between tabs.
② List selection
After navigating to the desired list, the list can be displayed by pressing the Enter or the right cursor button.

7.11.2 Parameter Manager (P_Para2.1)

The Parameter Manager screen appears when you press the main PARA screen selection key and then select a
parameter list. The parameters from the selected list or the parameters available for the current authorisation
level are displayed on this screen.
If there is insufficient space available for the number of parameters, other entries are displayed on other tabs.
To switch between tabs, press the TAB key.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 107/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

① Parameter not editable

Some parameters are displayed for information purposes only. They cannot be edited at the current password
level. The grey background indicates that a value is not editable.
② Parameter selected
The selected parameter is displayed against a black background.
③ Parameter selectable
All selectable parameters are displayed against a white background. Use the cursor keys to navigate up and
down between the individual fields.

7.12 User Management (USER)

The USER screen group contains the user settings for the DIA.NE XT3 system.

7.12.1 User Settings (P_U_1.1)

The user settings screen is brought up by pressing the USER main screen selection button. It shows the
available user settings for the DIA.NE XT3 system.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 108 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

① Logging on as a user
To log on to the DIA.NE XT3 system with an individually-allocated password level, enter a user identification
number (User) and a personal code number (Code)
② Temporary identification
To obtain a higher password level for a short period, you can use this random number to generate a code
number (Temp ID).
The temporary identification is initiated by the Jenbacher service team (www.gejenbacher.com).
③ Logging off
Pressing the logout button (Logout) suspends access authorisation until the user logs on to the system again.
④ Authorisation level display
The current authorisation level is shown at Current authorisation.
⑤ Switching languages
Use the drop-down list to select the desired language. Texts customised for the customer are output in the
customer's national language and in English.
⑥ Switching between Expert and Customer Views
The large number of measuring points is of little interest for some customers. A separate view has been
created for these customers, which not only contains a reduced number of screens and information content
but also generates a better understanding of the screens by using symbols (such as traffic lights) and legends.
⑦ Switching between pressure units
The pressure units can be switched between bar, psi and kPa here.
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 109/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

⑧ Switching between temperature units

The temperature units can be switched between degrees centigrade, Fahrenheit and Kelvin here.
⑨ Switching between ISO and US units
The remaining units which are different in the ISO and American systems can be switched over with this
selection list.
⑩ Trend time axis scaling
The time axis for all tend displays on DIA.NE XT3 can be changed with this entry field. The sole exception is the
historical trend in the event of a shut-down.
One of the following time settings can be selected:
10 / 5 / 2.5 / 1 minutes
⑪ Default page selection
After a specific time, which can be set, the display can be switched to a different page, which is selected in
advance.
The page is identified by means of the page code, which can be seen at the top right-hand corner of the screen
content (e.g. P_11.1 for the electrical overview).
The desired page and the time to elapse after pressing the last button can be entered here.

7.13 Alarm Management (ALARM)

The ALARM screen group contains details of the current and historical message records including values
measured when a failure occurred.

7.13.1 Current Messages (P_A1.1)

The current messages screen is brought up by pressing the ALARM main screen selection button. This screen
shows the current alarms, warnings and operational messages in chronological order.
Note: Press the increment/decrement keys to scroll between the most recent and older messages.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 110 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

① Alarm
Alarms are messages that trip the engine and shut it down. They are indicated by a red background.
② Warning
Warnings are messages that do not trip the engine. They are intended to inform the user of a problem which
has arisen and which can result in a shut-down or engine damage in the future. Warnings are indicated by a
yellow background.
③ Operational message
Operational messages are purely information messages which should be displayed to the user and logged.
They are indicated by a white background.
④ Alarm cursor
A cursor is shown to assist when scrolling or selecting a message. Press the increment/decrement keys to scroll
between the most recent and older messages.

7.13.2 Historical Messages (P_AI_2.1)

The historic messages screen is brought up by pressing the ALARM main screen selection button followed by
F2. This screen shows the historic alarms, warnings and operational messages in chronological order.
Note: Press the increment/decrement keys to scroll between the most recent and older messages. The last
1000 entries are stored.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 111/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

① Historic messages
The last 1000 entries are displayed in chronological order.

7.13.3 Primary trip (P_Al_3.1)

The primary trip screen is brought up by pressing the ALARM main screen selection button followed by F3. This
screen shows the results of the primary trip evaluation.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 112 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

① Primary trip
This screen only shows messages that could probably result in a trip.
Fault pattern evaluation:
When the first trip fault occurs, both the first and all subsequent trip faults (alarm messages) are stored within
10 seconds of the first fault.
After this time has elapsed, the system searches for a known fault pattern.
If no pattern is detected, or no trip messages or only one, are active, an empty page is displayed here. Even if
the operation mode selector is switched to Stop during this 10-second period, nothing is entered on this page.

7.13.4 Measurements at Failure (P_Al_5.1)

The measurements at trip screen is brought up by pressing the ALARM main screen selection button followed
by F5. This screen displays selected measurements from the time of the last trip, and these are also available
on-line.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 113/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

① Cylinder exhaust temperatures at trip

The cylinder exhaust temperatures with a red background were logged when the trip occurred. They are
displayed in degrees centigrade, Fahrenheit or Kelvin.
② Actual cylinder exhaust temperatures
The actual cylinder exhaust temperatures are displayed with a blue background in degrees centigrade,
Fahrenheit or Kelvin.
③ Measurements display at trip
Selected measurements at trip are logged and displayed here, depending on the engine configuration.
④ Actual measurements display
The actual values are displayed here for comparison with the values at trip.

7.13.5 Trending at Failure (P_Al_5.1)

The trending at trip screen is brought up by pressing the ALARM main screen selection button followed by F6.
This screen displays selected measurements from the last trip in a trending.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 114 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

① Trend display
The following measurements can be displayed optionally:
▪ Gas mixer position / cooling water pressure / cylinder temperature / cooling water temperature
▪ Actual power / throttle valve position / turbocharger bypass valve position / boost pressure
▪ Actual speed / boost pressure / operating hours / oil pressure
▪ Oil temperature / return temperature / ignition point
2/3rds of the measurements shown are from before the trip, and 1/3rd after.
② Time stamp
The trip time is displayed for improved synchronisation with the alarm entries.
③ Line selection
A selection can be made from the lines displayed under ①. Up to 4 lines can always be displayed at the same
time.

7.14 Help System (HELP)

Help texts are provided for many alarm entries in the HELP system.

7.14.1 Help for Alarm Management Entry (A_Help_XXX)

The Help screen appears when an alarm management message has been selected for which a help text is
available in the relevant language. The LED on the Help key indicates whether a text is available.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 115/116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
DIA.NE
Dia.ne XT V3.4

① Message text
The message number and text generated by the alarm management system is displayed here.
② Causes
The well known causes that trigger this message are listed in plain text.
③ Corrective measures
Brief instructions for rectifying the problem are entered here.
④ Tip
Additional useful information is displayed in the Tip column.
SprungMarke!!!27021602613937675

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Thomas Weitzer Responsible: Elektronik Release date: 01/12/2014
Index: 4 Page No.: 116 / 116
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

1 General ....................................................................................................................................................... 1
1.1 Components................................................................................................................................................................. 2
2 Applications ............................................................................................................................................... 3
2.1 Remote control (operating and monitoring) with DIA.NE WIN ............................................................. 3
2.2 Automatic data and message transmission through DIA.NE remote message control.......... 4
2.3 DIA.NE control ............................................................................................................................................................. 5
2.3.1 Receiving messages and data 5
2.3.2 Notifying participants 6
2.3.3 Main screen 7
2.3.4 File menu 7
2.3.5 Help menu 13
2.4 DIA.NE report ............................................................................................................................................................. 13
2.4.1 Using the multi-user environment 13
2.4.2 Main screen 13
2.4.3 File menu 14
2.5 DIA.NE message ....................................................................................................................................................... 17
2.5.1 Transmission of messages 17
2.5.2 Failed connection to modules 18
2.5.3 File transmission 18
2.5.4 Main screen 18
2.5.5 File menu 19
2.5.6 Help menu 24
2.6 Installation instructions – configuration instructions............................................................................. 24
2.6.1 Configuring an RDT network connection between a DIA.NE WIN client and server (modem
option only) 24
2.6.2 Configuring a network connection between a DIA.NE WIN client and server (LAN option
only) 25
2.6.3 Configuring an Internet connection between a DIA.NE WIN client and server (Internet op-
tion only) 25
2.6.4 Configuring the DIA.NE WIN server 26
2.6.5 Installing/configuring the RDT control centre 27
3 Connections ............................................................................................................................................. 35
3.1 Modem.......................................................................................................................................................................... 35
3.2 Network (LAN)............................................................................................................................................................ 35
3.3 Internet......................................................................................................................................................................... 35
3.3.1 Components 36
3.3.2 General conditions 36
3.3.3 Preparation 37
3.3.4 Accessing the Jenbacher Remote Access Portal 38
3.3.5 Access to DIA.NE XT/WIN installations 41
3.3.6 Accessing DIA.NE installations 43
3.3.7 Troubleshooting, Tips & Tricks 45
3.3.8 Additional information 48

1 General
HERMES is the Remote Data Transmission program for DIA.NE XT / WIN. It provides both customers and
GE Jenbacher service engineers with a powerful tool for the remote control and maintenance of GE Jenbacher
engines and plants. When developing the program, the main design prerequisite was that HERMES should
comply with all functionalities of DIA.NE XT / WIN, the leading engine management system on the gas engine
market. Thanks to HERMES all on-site functionalities can now also be accessed through remote control. Apart
from that, DIA.NE remote message control (RMC) enables the automated transmission of messages and data
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 1/48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

to RDT (Remote Data Transmission) control centres. The concept ensures that the hierarchical information
compression approach upon which DIA.NE XT / WIN is based will be consistently followed in accordance with
the "automation pyramid".
HERMES therefore consists of:

2 applications
▪ DIA.NE WIN
▪ DIA.NE RMC (remote message control)

3 connection options
▪ Modem (analogue, ISDN, GSM)
▪ Network (LAN)
▪ Internet
which can be supplied in any combination customers may require.
However, at least 1 connection option and 1 application must be ordered.

1.1 Components
Each engine (module) is provided with a powerful control and visualisation unit
(DIA.NE XT), which is responsible for the direct control of the engine. All modules are linked through a network
connection using 100BaseT Ethernet. Up to 16 modules (+A1 through +A16) can be linked to a DIA.NE WIN
server (+Z1) via this network.
Any number of clients (DIA.NE WIN client, RDT control centre – but only up to a maximum of 5 clients at the
same time) can communicate with this computer, which is usually not equipped with a display, via various
connections. If required, a station control unit for the entire plant can be integrated into the network.
The following Figure shows the configuration.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 2 / 48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

2 Applications

2.1 Remote control (operating and monitoring) with DIA.NE WIN

The plant is remotely operated using a web-based application (DIA.NE WIN).
A separate set of online documentation has been written for DIA.NE WIN, describing both the operation and the
installation of the DIA.NE WIN client.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 3/48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

The configuration of the network connection between the DIA.NE WIN client and the DIA.NE WIN server via the
various connection options (modem, LAN, Internet) is described in the section entitled Installation instructions
– Configuration instructions.

2.2 Automatic data and message transmission through DIA.NE remote message control
The DIA.NE RMC software package contains an automated facility for transmitting data and messages from
DIA.NE WIN servers to RDT control centres and forwards them by fax, e-mail and SMS (via an e-mail SMS
gateway). The messages and data stored in an RDT control centre can be randomly accessed for processing by
any workstation connected to this unit via a LAN.
In line with the tasks described above, the DIA.NE RMC software package is divided into the following three
programs:

DIA.NE message
Once classified, the data on the individual modules generated in DIA.NE XT are transmitted to one or more RDT
control centres.

DIA.NE control
In the RDT control centre, all incoming messages are monitored and, following classification, they are
forwarded to an external communication participant.

DIA.NE report
The received data can also be accessed (View, Print) by all users via a network (LAN) connected to the RDT
control centre.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 4 / 48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

In an RDT control centre, PCs equipped with modem/LAN/Internet-as a standard are used to connect to any of
the DIA.NE WIN servers. The service engineers also have the option of forwarding the data and messages to
certain fax numbers and/or, using Internet access, to certain e-mail addresses. Messages can also be
forwarded to mobile phones and pagers via an e-mail SMS gateway.

2.3 DIA.NE control

In the RDT control centres, DIA.NE control takes care of receiving and archiving all incoming messages and
data. DIA.NE control also forwards messages and reports via fax and e-mail (incl. SMS for mobile phones and
pagers) to notify service staff.
The allocation of DIA.NE WIN servers to the RDT control centres is not pre-configured. In principle, any DIA.NE
WIN server can send messages and data to any RDT control centre.

2.3.1 Receiving messages and data

DIA.NE message places a call to the RDT control centre through an RAS connection object. Using Windows
terminology, the RDT control centre represents a Remote Access Server (RAS server). This service is pre-installed
in the Windows 2000 and Windows XP operating systems and only needs to be configured in accordance with
the installation instructions.
This way, DIA.NE message enters the messages originally generated by DIA.NE XT into a message database on
the RDT control centre. This database (MS Access) is used as a basis for data on the functions of the DIA.NE
control and DIA.NE report programs.
In addition, DIA.NE control can also receive the trend and logbook files recorded on the DIA.NE WIN server.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 5/48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

2.3.2 Notifying participants

In order to make notification as efficient as possible, the messages received from plants are checked on the
basis of various criteria before they are forwarded. The following criteria can be set:
▪ Plant password
▪ system number
▪ Module
▪ Message description
▪ Message number
▪ Message type
▪ Time at which the message is received
▪ Notification type (e-mail, SMS via e-mail, fax)

The messages are transmitted to the configured participant using the MAPI interface (Microsoft Message
Application Program Interface). The communication types available can be configured in the Microsoft mail
profile:

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 6 / 48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

▪ E-mail:
Connection to a mail server or dial-up line to Internet provider
▪ Fax:
Use of a MAPI-enabled fax server or the Microsoft Fax Service.
▪ Voice:
participants (and/or pagers) can be notified by selecting the fax function (without transmitting data)
▪ Text:
Messages can be forwarded to pagers and mobile phones through the e-mail SMS gateway. Gateway
services are provided by various mobile radio telephone suppliers or commercial service providers.

The messages are generated in two different types:

▪ Short (for SMS):
variable amount of message information
▪ Long (for e-mail and fax):
all message information

2.3.3 Main screen

Following the call by DIA.NE control, the main screen is displayed. It shows the configured customer data
("Customer name", "Address" and "Tel. No.") and the current status of the program. In this status field, all actions
executed by the program at the time are shown, e.g. reading in transmitted messages, notifying participants
etc.

Last actions
The Last actions table shows the activities of DIA.NE control.
The table items are always arranged in reverse chronological order. The most recent entries can be found at
the top of the table. The table is automatically updated.
The Main screen contains two menu commands, File to access the other menus and Help to access the online
help.

2.3.4 File menu

2.3.4.1 Caller
This table shows which DIA.NE WIN servers (DIA.NE message) have called this RDT control centre and displays
the connection control status.
When a connection between a new DIA.NE WIN server and the RDT control centre is established for the first
time, a new item is entered into this table containing the plant data.

Plant
Name of the plant whose DIA.NE WIN server has called.

Plant No.
Plant number of the caller.

Location
Contents of the DIA.NE message address field.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 7/48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

Last call
Date and time of last call during which messages were saved.

Last message matching

Date and time of last call during which "Non-Critical Messages" were transmitted (because of manual or
automatic database matching by DIA.NE message).

Last trend file matching

Date and time of last call during which trend files were transmitted.

Last report matching

Date and time of last call during which report files were transmitted.

Conn. Monitoring
If this check box is enabled, the entire line is displayed in red whenever connection monitoring is selected. This
will typically be the case if more than 24 hours have passed between the current date and the “Last call” date.
In that case, the Connection monitoring function in DIA.NE message should be enabled for this RDT control
centre (see DIA.NE message documentation).

2.3.4.2 Messages to be transmitted

This table contains all the messages which have not yet been used to notify participants.
In the table, certain messages can be excluded from notification by enabling the Already transmitted check
box. The Delay check box enables temporary delay of notification for specific messages.
Delay notification of participants
Enabling this check box will delay all notification of participants.

2.3.4.3 Export data

DIA.NE control continuously receives messages from the DIA.NE WIN servers and stores these in the message
database. This will increase the size of the database continuously, thus possibly adversely affecting the access
speed in the longer term. If so desired, the user of the RDT control centre can store the increasing amount of
data outside the current database.
To relocate the message data, the Export data dialogue box should be opened.

Database
Refers to current message database file.

Oldest entry
Date and time of oldest entry in this database.

Most recent entry

Date and time of most recent entry in this database.

Number of entries
The total number of entries in the message database.
The following three steps can be taken:

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 8 / 48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

▪ Export to database: The messages are exported to another Microsoft Access database in accordance with
the "Export from date" and "Export to date" specified. If the destination database is not yet available, it will
be created after the user has been prompted (in conformity with file path and name in the text field
concerned). If the database already exists, the messages to be exported will be added to it.
Exporting the messages will not erase the contents of the message database!
▪ Delete: The messages will be permanently deleted from the message database (for example, following a
prior export of data).
▪ Compact Database: Manually compresses the database.
All database clients (e.g. DIA.NE report) must be closed first.
This action is executed after clicking the OK button and acknowledging the warning.
The Cancel button closes the whole dialogue box again.

2.3.4.4 Message log book

This menu command is used to view and delete the DIA.NE control log book.
This log book contains DIA.NE control system entries.

2.3.4.5 Configuration
The DIA.NE control configuration window contains the following tabs:

2.3.4.5.1 RDT control centre

The customer data ("Customer name", "Address", "Tel. No.") of the RDT control centre are entered in this tab.

Message protocols
These settings enable automatic logging of all messages received in the last 24 hours. This will take place daily
at the pre-set time (e.g. “16:00”) on the pre-selected printer. The text in the Free text for automatic protocols field
will be printed in the heading of the message protocol. The printout contains all message information. Printout
format: A4, landscape.

Language (mandatory information!)

This field is used to select the language in which the message is to be printed (D, F, I, GB, etc.). This setting will
not affect the communication language setting.

Post office profile (mandatory information!)

The profile name should be entered in this field of the Microsoft mail profile which is to be used for
communication. The profile name can be found in the Mail entry in Control Panel.

TIP!
If Microsoft Outlook Express is used for sending messages (standard e-mail program), the entry in Post
office profile is irrelevant.

2.3.4.5.2 Standard messages

This tab contains the DIA.NE XT / WIN standard messages.
The entries in the table can be modified.
The data in the table are setup and maintained by GE Jenbacher. In combination with the Customer-specific
messages table, DIA.NE control adds a language-dependent text to the message numbers transmitted by the
DIA.NE WIN server (DIA.NE message).

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 9/48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

Msg. No.
Unique four-digit message number

Language
Language abbreviation (D, F, I, UK, etc.)

Msg. Type
Message type to which this message corresponds

Description
Text corresponding to this message number.

2.3.4.5.3 Customer specific Messages

The table contains customer-specific deviations from the standard message table. These deviations can arise if
certain customers (plants, modules) have allocated an entirely different meaning to a certain message number
than its standard meaning (typical cause of backup failures). In addition to the fields "Msg. No.", "Language",
"Msg. Type" and "Description" as already contained in the Standard messages table, two additional fields are
required for unique allocation to a module.

Plant
Number of the plant to which the exception applies.

modules
Number of the module to which the exception applies.
If the plant or module field is left blank, the exception applies to all plants and/or modules.

2.3.4.5.4 Notification
Using DIA.NE control it is possible to inform the participants of any messages received. The participants to be
notified are configured in this tab.

No. (mandatory information!)

Unique, freely selectable identification number.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 10 / 48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

Enabled
Enabled/Disabled communication participant

Description (mandatory information!)

Freely selectable description of the participant to be notified.

Address (mandatory information!)

E-mail or fax address of the participant to be notified (e-mail address or name of address book entry).

Type (mandatory information!)

There are four communication types:
▪ SMS (e-mail to Internet SMS Gateway)
Format: All message information can be freely configured and does not contain any special characters (see
section 3.5.5).
▪ E-mail
format: All available message information is transmitted. The message is a text file. The lines are followed
by CR+LF.
▪ FAX
Format: All available message information is transmitted. The message is a text file. The lines are followed
by CR+LF.
▪ Voice
Nothing more than a call is placed to the participants. If no contact can be established, no error message is
transmitted!
All other communication criteria are AND coupled (i.e. all conditions must be met). If a field is left blank, no
check will be made for this criterion.

Weekdays
This field is used to indicate the weekdays on which the participant notification mode should be active
(1=Monday, 2=Tuesday etc.). If you want to enter several days (e.g. "1, 2, 7"), these should be separated by
commas. If nothing is entered, there is no time limit.

Time from, Time to

Used to enter the time range during which the participant notification mode should be active. If nothing is
entered, there is no time limit.

Plant No.
If the plant number of the message received matches the plant number configured here, the message is
forwarded.

Module No.
If the module number of the message received matches the module number configured here, the message is
forwarded. If you want to enter several modules (e.g. "1, 3, 5"), these should be separated by commas.

Message No.
Used to enter the message number at which this participant should be notified.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 11/48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

Msg. Type
If the message type of the message received corresponds to the message type configured here, the message is
forwarded. If you want to enter several types (e.g. "A, W"), these should be separated by commas.

Language (mandatory information!)

Used to enter the language (as country identification code, see section 3.5.1) in which the participant should be
notified.

2.3.4.5.5 SMS format

This tab is used to configure the SMS format for the communication.
The information to be transmitted may consist of the following database entries:
▪ Date & time of the message (from AMM)
▪ Plant
▪ Module number
▪ Message type
▪ Message text
▪ Plant number
▪ Module name
▪ Message number
▪ Date and time of message (entry in message database)
▪ Free text
The contents of the Free text field are the "Subject" of the SMS message concerned.

2.3.4.6 Password protection

DIA.NE control is password protected to prevent unauthorised access to its configuration.

Logon
In order to be able to modify the configuration, the user has to log on. During the logon dialogue, the password
must be entered.

Logoff
Having modified the configuration, it is recommended that the user log off. This will protect the configuration
from unauthorised access by third parties.
Because the procedure for closing DIA.NE control is also password protected, the users have to log on before
they can close the program. This is not required when closing Windows.
During the password entry dialogue, the user has the option of changing the password.

ATTENTION!
Following installation, the default password in the configuration is "6020". This password should be changed
immediately when activating the program for the first time.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 12 / 48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

2.3.5 Help menu

2.3.5.1 Help
To help resolve any questions about DIA.NE control, you have an extensive Windows-type help function at your
disposal in which all program elements are described in detail.

2.3.5.2 About DIA.NE control

This dialogue box will give you the copyright information and the program version.

2.4 DIA.NE report

DIA.NE report can be used to display and print the messages received in an RDT control centre on any number
of processing stations (standard workstations). To that end, the workstations must be connected to the RDT
control centre via a LAN. Both the language and the plants selected can be pre-set for the message display.
In order to automate protocolling, all plant-specific messages received can be printed on a daily basis. Using
DIA.NE report, manually compiled protocols can be printed at any time.

2.4.1 Using the multi-user environment

To enable DIA.NE report to be individually configured on several workstations, you should add the hash mark
(#) and the workstation number to the DIA.NE report command line.
Example: for station 1: C:\Program Files\diane\DianeReport.exe #1
for station 2: C:\Program Files\diane\DianeReport.exe #2
for station 3: C:\Program Files\diane\DianeReport.exe #3
...

2.4.2 Main screen

Following the call by DIA.NE report, the main screen is displayed. This screen contains the configured customer
data (“Customer name”), filter criteria and table view of the message data.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 13/48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

Ingoing messages
The Ingoing messages table shows the messages that have been received from various DIA.NE WIN servers
(DIA.NE message) in the RDT control centre’s message database.
The table items are arranged in reverse chronological order. The order can be set using the Sort order field. The
most recent entries can be found at the top of the table. The table is automatically updated and/or can be
manually updated by pressing function key "F5" or choosing Refresh display from the File menu.

Resetting
New entries are displayed in bold type. Double-clicking on a line or pressing the Enter key will “quit” this
message changing it to non-bold type. At the same time, the Quit check box is enabled.
Once you have enabled “Quit”, you cannot disable it.

From date / To date

If so desired, the messages displayed can be chronologically filtered using the criteria From date and To date.
This filter uses the AMM date on the message.

No date limit
Clicking this box will cancel the date limit.

All messages
DIA.NE report distinguishes between "Critical Messages" which are automatically transmitted to the RDT control
centres on the basis of a pre-set condition in DIA.NE message, and "Non-Critical Messages", which are
transmitted to the RDT control centre based on automatic or manual database matching.
In general, DIA.NE report only displays "Critical Messages" in the Ingoing messages table. If the All messages
check box is enabled, the "Non-critical messages" are also displayed.

Plant filter
Selecting a specific plant reduces the message display to the selected plant.

Sort order
Select this to change the order in which messages are sorted.
AMM Date: Sorting based on the AMM date.
Chronological: Sorting based on order in which messages (Nos.) are received.
The Main screen contains two menu commands, File to access the other windows and Help to access the
online help.

2.4.3 File menu

2.4.3.1 Refresh display

This menu command is used to manually update the main screen display.

2.4.3.2 Print
This menu command is used to print all messages displayed on the main screen.
The Print options dialogue box contains the following tabs:

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 14 / 48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

Output
This tab is used to select the output type.
▪ Printer:
The Printer ... item is used to select the desired printer.
▪ File:
print output is converted into an ASCII file. The File ... item is used to select the desired path and file name.
▪ Print lines:
This item is used to print the entire contents of the Ingoing messages table, all the messages selected or
just the current message. The selection is made on the left side of the Ingoing messages table.
Print to preview window first:
If this check box is enabled, the item is displayed in the print preview window first before actually being sent to
the printer.

Print options
▪ Range:
This option makes it possible to limit the number of pages to be printed.
▪ Frame:
This option makes it possible to adjust the frame settings for the print layout.
Row multiple line:
Allows a hard return to entered in the output fields.

Columns
This tab allows you to select the message information to be used when printing.

Fonts
This item is used to select the font for headers and footers in order to modify the print layout.
Click the Print button to start printing.
If the Print to preview window first check box is enabled, a print preview window is opened before printing.

2.4.3.3 Caller
This table shows which DIA.NE WIN servers (DIA.NE message) have called this RDT control centre and displays
the connection control status.
When a connection between a new DIA.NE WIN server and the RDT control centre is established for the first
time, a new item is entered into this table containing the plant data.

Plant
Name of the plant whose DIA.NE WIN server has called.

Plant No.
Plant number of the caller.

Location
Contents of the DIA.NE message address field.

Last call
Date and time of last call during which messages were saved.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 15/48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

Last message matching

Date and time of last call during which "Non-Critical Messages" were transmitted (because of manual or
automatic database matching by DIA.NE message).

Last trend file matching

Date and time of last call during which trend files were transmitted.

Last report matching

Date and time of last call during which report files were transmitted.

Conn. Monitoring
If this check box is enabled, the entire line is displayed in red whenever connection monitoring is selected. This
will typically be the case if more than 24 hours have passed between the current date and the “Last call” date.
In that case, the Connection monitoring function in DIA.NE message should be activated for this RDT control
centre (see DIA.NE message documentation).

2.4.3.4 Configuration
Because a number of computers may be accessing the same message database using DIA.NE report, the
DIA.NE report configurations for every workstation are stored separately. This enables a user-defined DIA.NE
report environment for every workstation.

2.4.3.4.1 General

Number of days displayed (mandatory information)

This field limits the number of messages shown in the Ingoing messages table to a maximum number of days.
UNC path to database (mandatory information)
If DIA.NE report is to display the contents of a message database, its path (on the RDT control centre) should be
entered here.

Database local to computer

"<Drive>:\<DIA.NE RMC - program directory>" z.B.: C:\Program Files\diane

Database on network computer

"\\<Computername>\<Share>" e.g.: \\RDTCenter_1\diane

Message protocols
These settings enable automatic logging of all messages received in the last 24 hours. This will take place daily
at the pre-set time (e.g. “16:00”) on the pre-selected printer. The text in the Free text for automatic protocols
field will be printed in the heading of the message protocol. The printout contains all message information.
Printout format: A4, landscape.

Language (mandatory information!)

This field is used to select the language used for displaying or printing a message (D, F, I, GB, etc.).

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 16 / 48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

2.4.3.4.2 Display

Plants displayed
This table is used to enter the plants to be displayed. If the table is left empty, no messages will be displayed.
The plants to be displayed can be selected from the Plant combo box. This makes all known plants (plants
which are actually connected) available.

Visible fields
In these fields, the message information to be displayed in the Ingoing messages table of the main screen can
be selected. Information not visible in the main screen cannot be printed.

2.4.3.5 Help menu

2.4.3.6 Help
To help resolve any questions about DIA.NE report, you have an extensive Windows-type help function at your
disposal in which all program elements are described in detail.

2.4.3.7 About DIA.NE report

This dialogue box gives you the copyright information and the program version.

2.5 DIA.NE message

DIA.NE message is installed on the plant’s DIA.NE WIN servers. This program transmits messages and data to
DIA.NE control in the RDT control centres.

2.5.1 Transmission of messages

All the messages generated by the module are logged by a program on the DIA.NE WIN server (alarm logger).
These Operational messages (B), Warnings (W) and Trip messages (A) are written to files and further processed
by DIA.NE message.
In order to transmit the messages more efficiently, the messages on the modules are checked first against
various criteria before being transmitted.
The following criteria can be set:
▪ Module No. / Module name
▪ Message No. / Description
▪ Message type
▪ Weekdays
▪ Time of appearance
If a message is classified as being a “Critical message”, the plant name, plant number, module identification
and module number are added to it, after which the message is automatically transmitted to the RDT control
centres configured.

TIP!
Changing date and time on the modules and the DIA.NE WIN server can result in duplicated transmissions
or ‘gaps’ in the DIA.NE control database.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 17/48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

2.5.2 Failed connection to modules

If the messages logged by DIA.NE message cannot be loaded, DIA.NE message generates a special warning
message.
The warning message contains the following items:
▪ Description: Module inaccessible
▪ Message No.: 0001
▪ Message type: W

2.5.3 File transmission

Historical measurement data and logbook data are cyclically logged and stored in files on the DIA.NE WIN
servers.
The files stored on the modules can be transmitted both manually and automatically to any RDT control centre
by DIA.NE message.

2.5.4 Main screen

When DIA.NE message starts up, the main screen is displayed. It shows the configured plant data ("Customer
name", "Address", "Tel. No.", "Plant" and "Plant number") and the current status of the program. In this status
field, all actions executed by the program at the time are shown, e.g. checking the log files, transmitting
messages etc.

Last actions
The Last actions table shows the activities of DIA.NE message.
The table items are arranged in reverse chronological order. The most recent entries can be found at the top of
the table. The table is automatically updated.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 18 / 48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

From the Main screen access to the other windows is via the File menu item, and to the online help via the Help
menu item.

2.5.5 File menu

2.5.5.1 Database matching with RDT control centre

Database matching with RDT control centres is used to transmit all messages which have not been configured
for auto alarm activation ("Non-critical messages"). It can also be used to transmit trend and logbook files. In
addition to manual data matching, it is also possible to configure automatic data matching.
A combo box will appear from which the desired RDT control centre must be selected. Data matching can be
limited by using the From date and To date entry fields. Click the Select button to initiate the transfer.

Transmission to the following RDT control centre:

One specific centre can be selected from the list of all configured RDT control centres. RDT control centres are
defined using the identification and the RAS profile name.

From date / To date:

The date range for messages yet to be transmitted is automatically entered in these text boxes. If the date
range is extended, DIA.NE message will read out the required messages from the modules as well. Following
successful completion of this procedure, data transmission to the RDT control centre is started.

2.5.5.2 Message log book

This menu command is used to view and delete the DIA.NE message log book. This log book contains DIA.NE
control system entries.

2.5.5.3 Configuration
The DIA.NE message configuration window contains the following tabs:

2.5.5.4 Plant data

This item is used to enter the plant data ("Customer name", "Address", "Tel. No.", "Plant" and "Plant number") of
the DIA.NE WIN server ("Customer name" and "Plant number" are mandatory!).

Ring buffer capacity

This value indicates the length of time that “Non-critical messages“ are to remain stored in the DIA.NE message
database.

Scan interval for modules

The scan interval is used to determine the frequency with which DIA.NE message searches for new messages.
Zero means as quickly as possible.

Number of messages displayed

The value entered indicates the number of items in the Last actions table. A maximum of 200 items can be
displayed. If the pre-set number is exceeded, the oldest item is overwritten.

Language
This field is used to select the language in which message text is displayed (D, F, I, GB, etc.).

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 19/48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

Closing Interval

TIP!
This function only applies to modem servers with DIA.NE plants and must not be activated on DIA.NE WIN
servers!!!
Activating this field and indicating a time shuts down the program in a controlled manner. Together with the
Power off program installed on the modem server, this achieves a controlled re-boot of the modem server.
In the Days field, the shutdown procedure can be limited to specific days (1=Monday, 2=Tuesday, etc.). If you
want to enter several days (e.g. "1, 2, 7"), these should be separated by commas. If no specific day has been
entered, there is no limitation (= every day).

2.5.5.5 Modules
This item is used to enter the plant modules. The following fields can be filled for each of the modules:

Scan (mandatory information)

Clicking on this field will activate or deactivate the search for new messages per module.

Description (mandatory information!)

The engines are identified as follows:
Module M01 = JES_01
Module M02 = JES_02
etc

Module (mandatory information)

The module number corresponds to the engine number.

UNC path (mandatory information)

The UNC path indicates the directory structure through which DIA.NE message can reach the log files
e.g. DIA.NE WIN server for DIA.NE XT / WIN plants: "C:\log\M01"
modem server for DIA.NE plants: \\jes_01\c-drive\log

2.5.5.6 RDT control centres

This tab is used to enter all RDT control centres to be notified by DIA.NE message.

No.
The program will issue a running number.

Row
This item is used to indicate the sequence in which the RDT control centres are to be notified.

Backup only
If one of the RDT control centres cannot be reached, another RDT control centre (backup) to be notified can be
defined here.

Description (mandatory information!)

Free description of the RDT control centre.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 20 / 48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

Enabled (mandatory information)

If one of the RDT control centres cannot be reached temporarily, this item is used to deactivate the release. All
messages received in the meantime will be held back and will be transmitted after the release is reactivated.

RAS profile
Name of the RAS connection object through which the connection to the RDT control centre should be
established (Control Panel - Settings - Network and Dial-up connections). If the RDT control centre is directly
coupled to the DIA.NE WIN server via a LAN (LAN connection option), this field must be left blank.

Conn. Monitoring
If the connection control is activated, a special operating notification is transmitted to the RDT control centre
(watchdog). This message is transmitted when no message has been transmitted for the last 23 hours.
The operating notification contains the following items:
▪ Description: Connection Monitoring
▪ Message No.: 0000
▪ Message type: B
▪ Module number: 0

UNC path (mandatory information)

Path on the RDT control centre where the message database is stored.
This setting must match the setting on the RDT control centre.
Default: "\\<Workstation name>\<Share>" e.g. \\Computer_1\diane

Last status
Last status of the DIA.NE WIN server (communication with RDT control centre successful or unsuccessful). The
status is automatically updated when the window is opened.

Weekdays
Used to indicate the weekdays on which messages should be transmitted to an RDT control centre (1=Monday,
2=Tuesday, etc.). If nothing is entered, there is no time limit. If you want to enter several days (e.g. "1, 2, 7"),
these should be separated by commas.

Time from, Time to

Time within which the messages received should be transmitted to an RDT control centre. If nothing is entered,
there is no time limit. In order to activate a transmission, both a weekday and a time from/to should be entered

Backup 1
If it is not possible to transmit any messages, you can specify a backup centre here which is to be notified. The
figure indicated under Number should be entered (see first column).
This backup centre will not be used during manual or automatic data matching.

Backup 2
If messages cannot be transmitted to the first backup centre either, a second backup centre can be defined
here.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 21/48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

Data matching - Time

This field is used to enter the exact time at which the automated data matching with the RDT control centres
should be carried out.

Data matching - Days

The data matching operation defined under Time can be limited to certain weekdays (1=Monday, 2=Tuesday,
etc.). If you want to enter several days (e.g. "1, 2, 7"), these should be separated by commas.

2.5.5.7 Transmitted message

This tab is used to enter the criteria for those messages which are to be classified by DIA.NE message as
messages to be transmitted ("Critical Messages").
For a functional configuration, at least one module reference (“Description” or “Module number”) or one
message reference (“Message text”, “Message number” or “Message type”) must be entered!

Module No.
A combo box is used to enter information. Click the drop-down button to select the configured modules from a
list (see 3.3.2). If the module number of the received message matches the number entered here, the message
is classified as a message to be transmitted (“Critical Message”). If the box is left blank, no check will be made
for this criterion (meaning that for all plant modules the corresponding message will be transmitted if the
message type and message number match). When the drop-down button is used to make a selection, the
module name will be entered into the Module field automatically.

Mod. name
Name of the module selected in the Module No. field.

Description
A combo box is used to enter information. Click the drop-down button to select a specific message from the list.
The list is in sorted alphabetically. Selecting a text will automatically cause the “Msg. No." and “Msg. Type" to be
entered into the corresponding cells.

Msg. No.
If the message number matches the number indicated here, the message is classified as a message to be
forwarded (“Critical Message”). If the field is left blank, no check will be made for this criterion. A combo box is
used to enter information. Click the drop-down button to retrieve a specific message from the list. The list is
sorted numerically. Selecting a text will automatically cause the “Description" and “Msg. Type" to be entered
automatically in the corresponding cells.

Msg. Type
If the message type corresponds to the letters entered here (e.g. A = trip, W = warning, B = Operational ), the
message is classified as a message to be forwarded ("Critical Message”). If the field is left blank, no check will be
made for this criterion. If only the message type is entered without the message number, this means that all
messages of this type will be classified as messages to be forwarded. Multiple input in the “A, W” format is valid.

Weekdays
The message is checked for a weekday. The numbers 1 through 7, representing Monday through Sunday
respectively, can be entered (e.g. 1=Monday, 2=Tuesday, etc.) in this field. If the field is left blank, no check will
be made for this criterion. If you want to enter several weekdays (e.g. "1, 2, 7"), these should be separated by
commas. In order to have the message forwarded, the weekday requirement must be fulfilled.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 22 / 48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

Time from, Time to

If the time stamp of the message received falls within the pre-set “Time from / Time to” range, the message is
classified as a message to be forwarded ("Critical Message"). If a field is left blank, no check will be made for this
criterion. In order to have the message forwarded, the “Time from/Time to” requirement must be fulfilled.

2.5.5.8 Data matching

This tab is used to establish which files are to be transferred in the course of the automatic data matching
process.
The following data can be transferred.
▪ Messages:These are all messages which have not yet been transmitted ("Non-Critical Messages").
▪ Trends:These are files that contain historical measurement data. The file name may be freely selected and
can contain wildcards (*, ?) (e.g. *.mdb).
The files are stored at the RDT control centre in the directory ..\<Plant number>\<Module no>\LOG.
▪ Reports:These are files that contain log book data. The file name may be freely selected and can contain
wildcards (*, ?) (e.g. *.xml).
The files are stored at the RDT control centre in the directory ..\<Plant number>\<Module no>\REP.
RDT Centre No.
If you enter an RDT control centre in this field, the configuration line will be restricted to the specified RDT
control centre.

2.5.5.9 Messages registered

This table contains all the messages received from the modules which still must be transmitted to DIA.NE
control.

Delay transmission of messages to RDT control centres

Activating this option will stop transmission of all messages to the RDT control centres. All messages received
in the meantime will be stored and will be forwarded after the transmission is reactivated.

2.5.5.9.1 Password protection

DIA.NE control is password-protected to prevent unauthorised access to its configuration.

Logon:
In order to be able to modify the configuration, the user has to log on. During the logon dialogue, the password
must be entered.

Logoff:
Having modified the configuration, it is recommended that the user log off. This will protect the configuration
from unauthorised access by third parties.
Because the procedure for closing DIA.NE control is also password protected, the users have to log on before
they can close the program. This is not required when closing Windows.
During the password entry dialogue, the user has the option of changing the password.

ATTENTION!
Following installation, the default password in the configuration is "6020". This password should be changed
immediately when activating the program for the first time.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 23/48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

2.5.6 Help menu

2.5.6.1 Help
To help resolve any questions about DIA.NE message, you have an extensive Windows-type help function at
your disposal in which all program elements are described in detail.

2.5.6.2 About DIA.NE message

This dialogue box will give you the copyright information and the program version.

2.6 Installation instructions – configuration instructions

This section describes how to configure the network connection between the DIA.NE WIN client and the DIA.NE
WIN server to access the DIA.NE WIN application.
It also describes how to install and configure the DIA.NE RMC application on the server and client.

2.6.1 Configuring an RDT network connection between a DIA.NE WIN client and server (modem option
only)
An RDT network connection is used to establish a TCP/IP network connection between the DIA.NE WIN client
and DIA.NE WIN server through which data are transferred to the DIA.NE WIN application.

TIP!
To complete the following steps, users must have
LOCAL ADMINISTRATOR RIGHTS

Windows 2000
▪ Open the Network and Dial-up Connections folder in Control Panel
▪ Select Make New Connection and use the wizard to create a new connection
▪ After the welcome message, select Dial-up to private network in the Network Connection type dialogue box.
▪ In the next dialogue box, select the desired modem for incoming calls.
▪ In the Phone Number to Dial dialogue box, enter the telephone number of the desired DIA.NE WIN server.
▪ In the next dialogue box, you can choose whether to allow all users of this computer or only the current
user to use the RDT connection.
▪ In the last dialogue box, you can assign a name to the connection.
▪ Once the connection object has been created, double-click the object to open it.
▪ In the dialogue box that now appears, click the Properties button to go to the properties side of the
connection.
▪ Select the Options dialogue box and, in the Idle time before hanging up field, set the time after which the
RDT connection itself hangs up if no more data are transported.
▪ Go to the Networking dialogue box and select the Internet Protocol (TCP/IP) component.
▪ Click the Properties button to go to the properties side and click the Advanced... button to open the
advanced settings.
▪ Uncheck the Use default gateway on remote network check box.
▪ Close all dialogue boxes by clicking OK.

Windows XP
▪ Open the Network Connections folder in Control Panel
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 24 / 48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

▪ Select Create a new connection and use the wizard to create a new connection
▪ After the welcome message, select "Connect to the network at my workplace" in the Network Connection
Type dialogue box.
▪ In the next dialogue box, select Dial-up connection and continue with the wizard.
▪ Enter the desired name for the connection under Connection Name.
▪ In the Phone Number to Dial dialogue box, enter the telephone number of the desired DIA.NE WIN server
and click Finish in the wizard.
▪ Once the connection object has been created, double-click the object to open it.
▪ In the dialogue box that now appears, click the Properties button to go to the properties side of the
connection.
▪ Select the Options dialogue box and, in the "Idle time before hanging up" field, set the time after which the
RDT connection itself hangs up if no more data are transported.
▪ Go to the Networking dialogue box and select the Internet Protocol (TCP/IP) component.
▪ Click the Properties button to go to the properties side and click the Advanced... button to open the
advanced settings.
▪ Uncheck the Use default gateway on remote network check box.
▪ Close all dialogue boxes by clicking OK.
When you have established the RDT network connection, start the DIA.NE WIN client in accordance with DIA.NE
WIN Online Documentation.
When you have finished working on the DIA.NE WIN application, you should disconnect the RDT network
connection as soon as possible for cost reasons.
If you have any queries or problems, please contact the GE JenbacherCompetence Centre!

2.6.2 Configuring a network connection between a DIA.NE WIN client and server (LAN option only)
A GE Jenbacher service engineer will configure the network connection between the DIA.NE WIN client and the
DIA.NE WIN server when the plant is being commissioned.
Information required from the customer (desired configuration):
▪ IP address of the DIA.NE WIN server (default: 172.31.200.100)
▪ Subnet mask of the network (default: 255.255.0.0)
▪ Default Gateway of the network (default: 172.31.1.1)
▪ IP address of the customer‘s computer (suggestion: 172.31.1.1 / 255.255.0.0 / 172.31.200.100)

2.6.3 Configuring an Internet connection between a DIA.NE WIN client and server (Internet option only)
If the plant is to have an Internet connection, the DIA.NE WIN client computer must likewise have an Internet
connection. This can be either a dial-up or broadband connection (DSL) to the Internet service provider (ISP) or a
central Internet access point in any company network.
The Internet access point must provide at least the following services (protocols):
▪ http (web access)
▪ http (encrypted web access)
The actual configuration of the Internet access must be performed by the customer and cannot be supported
by
GE Jenbacher because of the wide variety of provider and network configurations.
The GE Jenbacher Competence Centre will be pleased to assist with any general questions on Internet access.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 25/48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

2.6.4 Configuring the DIA.NE WIN server

DIA.NE message is pre-installed as standard on every DIA.NE WIN server.
The program can be configured either by the GE Jenbacher Competence Centre or by the customer.
In order to carry out the configuration at the DIA.NE WIN server, the DIA.NE WIN server must be controlled
remotely by remote maintenance software.

2.6.4.1 Remote maintenance of the DIA.NE WIN server

To configure the DIA.NE WIN server, a network connection (TCP/IP) must be established with the DIA.NE WIN
server (via modem, LAN or the Internet).
A VNC Remote Control Session, which is used for the remote control of the DIA.NE WIN server, can be
established through this connection.
The VNC program (i.e. the VNC viewer) can be obtained from the manufacturer’s website http://
www.realvnc.org or from the GE Jenbacher web server http://www.jenbacher.com/dianewin/download.htm.
The VNC software is covered by the GNU General Public Licence and is therefore free of charge.
When the software starts, enter the IP address of the DIA.NE WIN server as the destination and a password.
The address will depend on the connection type selected and its configuration.
Default: via modem: 10.200.200.200
via LAN: 172.31.200.100
The password for the VNC connection must be requested from the GE Jenbacher Competence Centre.
If you have any queries or problems, please contact the GE JenbacherCompetence Centre!

2.6.4.2 Configuring DIA.NE message

▪ Open the dialogue box: Configuration
▪ The Plant Data form is displayed.
▪ Enter the data for the first form (minimum information: Plant, Plant number)
▪ Go to the Modules form
▪ Activate the desired modules by enabling the Scan check box and verify the UNC paths
▪ Go to the RDT control centres form
▪ Configure the RDT control centres (minimum information: “Row“, “Description“, “RAS profile“ (modem
connection only, the field remains blank for network connection!), “UNC path“, “User name“, “Password“,
“Enabled“ and “Conn. Monitoring”)
▪ Go to the Transmitted message form
▪ Configure the desired messages to be transmitted (minimum information: “Msg. No.“ or “Msg. Type”)
▪ Optional:Go to the Data matching form
▪ Optional:Configure the desired data for database matching
▪ Click the OK button to exit the configuration dialogue box
▪ If using the modem connection option: Configure the RDT network (see next point). The connection object
must have the same name as specified in the “RAS profile“ field in the RDT control centres configuration
dialogue box.
If you have any queries or problems, please contact the GE JenbacherCompetence Centre!

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 26 / 48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

2.6.4.3 Configuring the RDT network (modem option only)

An RDT network gives a computer access to enabled resources (drives) on a workstation (RDT control centre
with DIA.NE control database), even if it is not on the same network. In this case, the workstation you select
must be equipped with a modem and configured as an RAS server.

Set-up procedure
▪ Open the Network and Dial-up Connections folder in Control Panel
▪ Select “Dummy“ and make a copy of the connection using
Create Copy in the File menu
▪ Rename the new object using Rename in the File menu.
TIP The name of the connection object must be identical to the name of the “RAS profile” in the DIA.NE
message configuration!
▪ To change the connection object to the desired RDT control centre, double-click the object to open it.
▪ In the dialogue box that now appears, click the Properties button to go to the properties side of the
connection.
▪ Change the telephone number to the RDT control centre you want to select (Phone number field), and if
necessary select the modem to be used from the Connect using field. (ISDN, GSM, etc.)
▪ Confirm the configuration dialogue and click Cancel to close the connection object.

2.6.4.4 Configuring the network connection for the RDT control centre (LAN option only)
The configuration of the network connection from the DIA.NE WIN server to the customer’s computer (RDT
control centre or DIA.NE WIN client) must be carried out by a GE Jenbacher service engineer. This configuration
is identical to setting up the network connection to use the DIA.NE WIN client as described in the section on
Configuring a network connection between a DIA.NE WIN client and server (LAN option only)
.Information required from the customer (desired configuration):
▪ IP address of the DIA.NE WIN server (default: 172.31.200.100)
▪ Subnet mask of the network (default: 255.255.0.0)
▪ Default Gateway of the network (default: 172.31.1.1)
▪ IP address of the customer‘s computer (suggestion: 172.31.1.1 / 255.255.0.0 / 172.31.200.100)
TIP The IP address of the customer’s computer is derived from the UNC path in the DIA.NE message
configuration for this RDT control centre: \\<IP address>\<share>
(e. g. \\172.31.1.1\diane)

2.6.5 Installing/configuring the RDT control centre

TIP!
The software can only be installed if the user has
local Administrator Rights.
The user must also be familiar with the operation and maintenance of Windows 2000 / XP
and with the installation of software packages.
The customer must prepare the computer as follows for the installation of the RDT control centre (DIA.NE
control plus DIA.NE report):
▪ Windows 2000 Workstation or Windows XP Professional must be installed
▪ The most recent service packs including all the most recent patches must be installed
If, to divide the load, several modems are to be set up to answer incoming calls, Windows 2000 Server or
Windows Server 2003 will be required!

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 27/48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

If this is the case, please contact the GE Jenbacher Competence Centre!

If using the modem connection option:
▪ install the modem, including the connection to the telephone line
If using the LAN connection option:
▪ install the network card and configure the TCP/IP network between the DIA.NE WIN server and the DIA.NE
WIN client

Optional
▪ Install an additional network for the shared use of DIA.NE report
▪ Set up an e-mail account to forward messages by e-mail/SMS
The customer must prepare the computer as follows for the installation of a separate computer for DIA.NE
report:
▪ Windows NT 4.0, Windows 2000 Workstation or Windows XP must be installed
▪ The most recent service packs including all the most recent patches must be installed
▪ Network access to the RDT control centre must be provided (by installing the network card and configuring
the network)
The software installation can be broken down into the following steps:
▪ Installing the software
▪ Configuring the software:
▪ Creating the dial-in user
▪ If using the modem connection option: Configuring the dial-up services (Remote Access Services, RAS)
▪ Enabling the drive

2.6.5.1 Installing the DIA.NE control and DIA.NE report software

TIP!
To complete the following steps, users must have
LOCAL ADMINISTRATOR RIGHTS
The software is installed using the installation CD-ROM supplied. Insert the CD-ROM into the drive and run the
"Setup.exe" program.
Alternatively, all the installation software can be downloaded from the GE Jenbacher web server. Information
on the links to be used can be obtained from the GE Jenbacher Competence Centre.
The installation procedure is interactive.
The installation option RDT Control Centre installs the DIA.NE control and DIA.NE report programs.
Choose the Custom installation option to install a separate computer for DIA.NE report. This installs the DIA.NE
report program only.
You can cancel the installation at any time. You can also remove the software you have installed by
uninstalling the relevant program with the Add/Remove Programs function in Control Panel.
Please note that, following dia.ne control installation, the password is initialised using ‘6020’.

2.6.5.2 Configuring DIA.NE control

▪ Run the DIA.NE control program

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 28 / 48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

▪ Choose Login from the File menu to complete the login procedure.
Default password: 6020
(Otherwise, editing the configuration is not permitted!)
▪ Choose Configuration from the File menu to adjust any settings. Choose Notification to configure automatic
message forwarding by e-mail/text via e-mail/fax.
If you have any queries or problems, please contact the GE JenbacherCompetence Centre!

2.6.5.3 Configuring DIA.NE report

▪ Run DIA.NE report
▪ As soon as the program starts, a text box appears in which you have to type the path to the DIA.NE control
database.
- Database on local computer (RDT control centre):
<LW>:\<Installation directory> z.B.: c:\program files\diane
- database on a remote computer
\\<work station name>\<release name> e.g.: \\computer-1\diane
▪ Choose Configuration from the File menu to adjust any settings. Choose Display to select the plants which
are to be displayed.
If you have any queries or problems, please contact the GE JenbacherCompetence Centre!

2.6.5.4 Creating the dial-up user

A special user must be created to allow the DIA.NE WIN server (DIA.NE message) to access the RDT control
centre.

TIP!
To complete the following steps, users must have
LOCAL ADMINISTRATOR RIGHTS

Windows 2000
▪ Open the Users and Passwords dialogue box in Control Panel
▪ Click the Add... button and use the wizard to add a new user.
User name: hermesrmc
Full name: <any>
Description: <any>
Password: 041097
Access Level: Standard User (Power User)
▪ In the Users and Passwords dialogue box, go to the Advanced form and click the Advanced button in the
Advanced User Management section.
▪ Select Users and double-click the new user “hermesrmc“ to open it.
▪ Set the user properties as follows:
User must change password at next logon: DISABLED
User Cannot Change Password: ENABLED
Password never expires: ENABLED
Account is disabled: DISABLED
Account is locked out: DISABLED
▪ Confirm the dialogue and close all the dialogue boxes.

Windows XP
▪ Open the User Accounts dialogue box in Control Panel

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 29/48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

▪ Click the Create a new account button and use the wizard to add a new user.
Account name: hermesrmc
Account Type: Limited
▪ Select the new user to create the password.
▪ Choose the Create a password menu command and specify the following password: 041097
▪ Confirm the dialogue and close all the dialogue boxes.
▪ Open the Performance and Maintenance dialogue box in Control Panel
▪ Open Administrative Tools
▪ Open Computer Management
▪ Select the Users subgroup in Local Users and Groups and double-click the new user “hermesrmc“ to open it.
▪ Go to the Member Of configuration dialogue box.
▪ Click the Add... button to add the user to the Power Users group
(Add... – Advanced – Find now).
▪ Confirm the dialogue and close all the dialogue boxes.

TIP!
User names and passwords may only be changed in close consultation with GE Jenbacher, as any
unannounced change will result in data connection problems!

2.6.5.5 Configuring the Remote Access Service (RAS) (modem option only)
By configuring an RAS server you allow remote computers (DIA.NE WIN servers) to access resources ( file
releases; DIA.NE control database) in the local computer.

TIP!
To complete the following steps, users must have
LOCAL ADMINISTRATOR RIGHTS

Windows 2000
▪ Open the Network and Dial-up Connections folder in Control Panel
▪ Select Make New Connection and use the wizard to create a new connection
▪ After the welcome message, select Accept incoming connections in the Network Connection Type dialogue
box.
▪ In the next dialogue box, select the desired modem for incoming calls.
▪ In the Incoming Virtual Private Connection dialogue box, leave the Do not allow virtual private connections
option unchanged.
▪ Select the user “hermesrmc“ in the next dialogue box, Allowed Users.
If this user does not appear in the selection, cancel the wizard and perform the previous step “Creating
the dial-up user”!
▪ In the next dialogue box, “Networking Components”, the following components must be enabled:
– Internet Protocol (TCP/IP)
– File and Printer Sharing for Microsoft Networks
– Client for Microsoft Networks
▪ Select Internet Protocol (TCP/IP), go to Properties and enable the following setting:

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 30 / 48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

▪ In the last dialogue box, you can assign a name to the connection.

Windows XP
▪ Open the Network Connections folder in Control Panel
▪ Select Create a new connection and use the wizard to create a new connection
▪ After the welcome message, select Set up an advanced connection in the Network Connection Type
dialogue box.
▪ In the Advanced Connection Options dialogue box, select Accept incoming connections.
▪ In the next dialogue box, select the desired modem for incoming calls.
▪ In the Incoming Virtual Private Network (VPN) Connection dialogue box, leave the Do not allow virtual private
connections option unchanged.
▪ Select the user “hermesrmc“ in the next dialogue box, User Permissions.
If this user does not appear in the selection, cancel the wizard and perform the previous step “Creating
the dial-up user”!
▪ In the next dialogue box, Networking Software, the following components must be enabled:
– Internet Protocol (TCP/IP)
– File and Printer Sharing for Microsoft Networks
– Client for Microsoft Networks
▪ Select Internet Protocol (TCP/IP), go to Properties and enable the following setting:

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 31/48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

▪ Close the wizard.

As soon as the connection is created, the RAS service is active and accepts incoming modem connections.

2.6.5.6 Enabling the drive

To be able to access the drives of a workstation which is configured as an RAS server, you must enable the
relevant drive or directory.

TIP!
To complete the following steps, users must have
LOCAL ADMINISTRATOR RIGHTS

Windows 2000
▪ Open Explorer and go to the folder containing the DIA.NE control program directory (default:(e.g. “C:
\Program Files“)
▪ Select the program folder and choose Sharing ... from the File menu.
▪ Select Share this folder in the dialogue box.
▪ Click the Permissions button to set the access rights.
▪ In the dialogue box that now appears, click the Remove button to remove the group “Everyone“.
▪ Click the Add... button to add the DIA.NE dial-up user “hermesrmc“.
▪ In Permissions, give the user the right to “Change“.
▪ Confirm and close all dialogue boxes.

Windows XP
▪ Open Explorer
▪ Choose Folder Options... from the Tools menu.
▪ Go to the View configuration dialogue box and disable the Use simple file sharing (Recommended) option in
Advanced Settings.
▪ Close the dialogue box.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 32 / 48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

▪ Go to the folder containing the DIA.NE control program directory (default: "diane“) (e.g. “C:\Program Files“)
▪ Select the program folder and choose Sharing and Security ... from the File menu.
▪ Select Share this folder in the dialogue box.
▪ Click the Permissions button to set the access rights.
▪ In the dialogue box that now appears, click the Remove button to remove the group Everyone.
▪ Click the Add... button to add the DIA.NE dial-up user “hermesrmc“. (Add... – Advanced – Find now)
▪ In Permissions, give the user the right to “Change“.
▪ Confirm and close all dialogue boxes.
After you re-boot the PC, the DIA.NE WIN server (DIA.NE message) is authorised to access the DIA.NE control
database.

2.6.5.7 Automatic start-up of DIA.NE control

To enable DIA.NE control to automatically start up when re-booting or logging off/on, there must be a shortcut
to DIA.NE control in the All Programs - Startup folder.

2.6.5.8 Automatic login to the RDT control centre when re-booting

Follow the steps below to ensure you can log in automatically after the RDT control centre has been re-booted.

TIP!
To complete the following steps, users must have
LOCAL ADMINISTRATOR RIGHTS

Windows 2000
▪ Open the Users and Passwords folder in Control Panel
▪ Select the desired auto-login user from the user list.
(To do this, the check box Users must enter a user name and password to use this computer must be
enabled.)
▪ Disable the check box Users must enter a user name and password to use this computer.
▪ Click the OK button to close the dialogue box. Confirm the next password request by typing the password
in twice.

Windows XP
▪ Open the Users and Passwords folder in Control Panel
▪ Select the desired auto-login user from the user list.
(To do this, the check box Users must enter a user name and password to use this computer must be
enabled.)
▪ Disable the check box Users must enter a user name and password to use this computer.
▪ Click the OK button to close the dialogue box. Confirm the next password request by typing the password
in twice.

2.6.5.9 Configuring the Windows Firewall (only Windows XP Service Pack 2 and higher)
▪ Start the "Windows Firewall" entry in the system control panel.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 33/48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

▪ Deactivate the "Don’t allow exceptions" checkbox!

▪ Select the second tab, i.e. "Exceptions".

▪ Activate the "File and Printer Sharing" checkbox.

▪ Having selected this entry, select the "Edit" button and subsequently select the "Change scope ..." button in
the dialogue box that follows.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 34 / 48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

▪ Select the lowest entry, i.e. "Custom list:" and enter the "Incoming Connections" IP address range in the text
field.

TIP!
This IP address range has been stated in section 2.6.5.5. Configuring the Remote Access Service (RAS) and is
the default setting: 10.200.200.100 to 10.200.200.105.
The resulting network to be freed is: 10.200.200.0/255.255.255.0
If another IP address range is used for the "Incoming Connections", you must use this address range.
▪ Close all open dialogue boxes by clicking on "OK".

3 Connections

3.1 Modem
A telephone line via the public telephone system is used as the medium for connecting the plant to the
customer.
The connection from the customer (client) to the DIA.NE WIN server (server) is established for the “remote
control” application. The reverse applies in the case of the “automatic data and message transmission“
application.
By default, an analogue modem to the internationally approved V90/V92 standard is used in the plant.
Customers can use any commercially available analogue modem.
Maximum attainable connection speed: 56 KBit/s
An alternative option would be to fit the plant with an ISDN adapter or a GSM modem (dual band 900/1800).

3.2 Network (LAN)

An Ethernet network connection is used as the connection medium between the plant and the customer.
Cabling: Twisted Pair (TP) cables (at least CAT 5)
Maximum cable length:100 m (extension by means of additional on-site network components (repeater, hub,
etc.) is possible)
Network protocol: TCP/IP
Maximum attainable connection speed: 100 MBit/s

3.3 Internet
A permanent Internet connection is used as the connection medium between the plant and the customer.
Because of the high risks involved in connecting the plant to the Internet, a security plan has been drawn up
which satisfies the most stringent security criteria in the IT sector.
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 35/48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

TIP!
A direction connection to the Internet is
not permitted under any circumstances due to the high safety risk (criminals, hackers, etc.) and will result
in the loss of guarantee and warranty rights.
In this respect, see also the following Technical Instruction 2300-0006 (Security tips when connecting GE
JenbacherInstallations)

3.3.1 Components

3.3.2 General conditions

This connection option requires a permanent Internet access point in the plant and additional security devices
(firewall).
Descriptions of the exact scope of supply and the exact on-site services are available from the GE Jenbacher
Sales Department or the GE JenbacherCompetence Centre.
▪ Internet access to the customer’s computer
▪ DIA.NE XT/WIN: Installed DIA.NE WIN client
(see Remote control (operating and monitoring) using DIA.NE WIN)
▪ DIA.NE: Installed software "Symantec pcANYWHERE"

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 36 / 48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

3.3.3 Preparation

3.3.3.1 Installing the Windows Update Pack (only Windows XP Service Pack 2 and higher)
Due to a security flaw in Service Pack 2 for Windows XP you must implement the following Microsoft Update
(only once per computer).
http://www.microsoft.com/downloads/details.aspx?amp;displaylang=en&familyid=17D997D2-5034-4BBB-
B74D-AD8430A1F7C8&displaylang=en
More information on this update can be found on the following website:
http://support.microsoft.com/default.aspx?scid=kb;[LN];884020

3.3.3.2 Configuring the Microsoft Internet Explorer security settings

Add the hermes-plants.jenbacher.com domain (internal domain for GE Jenbacher installations) to the "Trusted
sites" of Microsoft Internet Explorer.
Follow the instructions in "Adding the website to the Trusted sites" of the DIA.NE WIN clients installation
manual.
▪ Activate Microsoft Internet Explorer and select the "Internet Options..." menu item in the "Tools" menu.
▪ Then select the "Security" tab and subsequently the "Trusted Sites" symbol.

▪ Click the [Sites...] button to activate the dialogue box for adding websites to the Trusted sites zone.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 37/48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

▪ Click [Add] to add the Jenbacher installations domain *.hermes-plants.jenbacher.com to the trusted sites.
ATTENTION!
The [Require server verification (https:) for all sites in this zone] option must be deactivated in order for the
domain to be added!
Make sure to add "*." to the beginning of the domain name.

3.3.4 Accessing the Jenbacher Remote Access Portal

Activate Microsoft Internet Explorer and select the Jenbacher Remote Access Portal:
http://hermes.jenbacher.com

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 38 / 48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

TIP!
Please contact the GE Jenbacher Competence Centre for user information for clients with DIA.NE installations
and modem server.
If the login data are used for "Plant Access" (user name starts with the number 2 or 3), always add the
installation number (UZ number, J number). When doing so, the 2 numbers must be separated using
"_" (underscore) (e.g. 211111_A123).
If the login data are used for "Group Access" (user name starts with the number 5 or 6), always add the user
name to the Group access number. When doing so, the 2 numbers must be separated using "_" (underscore)
(e.g. 512345_54321).
Following the login, the following customer-specific interface appears:

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 39/48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

TIP!
When activating the Remote Access Portal for the first time, a dialogue box appears asking you to install an
ActiveX component by NOKIA Inc. This request must be answered positively as failure to do so will result in a
component required for accessing the installation (Nokia Application Forwarding) not being installed.

This programme will be activated automatically in future every time the Jenbacher Remote Access Portal is
accessed and appears as a separate programme or menu bar icon.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 40 / 48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

If this is not the case, you must activate the component manually via the portal link "Launch HTTP Proxy" (lower
section "Local Web Proxy") before access is sought to Jenbacher installations for the first time.

TIP!
To safely end the access to the Jenbacher Remote Access Portal, we recommend using the "Sign off" menu
item!

3.3.5 Access to DIA.NE XT/WIN installations

You can activate the following functions after you have logged into the Jenbacher Remote Access Portal:

3.3.5.1 Starting the DIA.NE WIN application

Activate the desired link in the "Web" section (e.g. web_b505_HKW_Rosenheim)
The DIA.NE WIN application appears with the login page.

TIP!
All incoming and outgoing data are displayed in the "Activity" section of the "Nokia Application Forwarding"
programme display.
You can return to the start-up page of the Remote Access Portal by:
▪ using the Previous function of Microsoft Internet Explorer until you arrive at the Remote Access Portal;
▪ using the "Extend Session" button of the Nokia Application Forwarding component and subsequently
selecting the "Go To Portal" link in the Remote Access Portal.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 41/48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

3.3.5.2 Downloading files from the DIA.NE WIN server

Activate the link in the "File" section (e.g. ftp_b505_HKW_Rosenheim)
A login dialog box appears to which the user must login using his/her FTP user information.
A file browser interface now appears enabling the user to take several actions (upload, download, delete, ...); the
access level is user-specific.

3.3.5.3 Starting Port Forwarding for remote maintenance of the DIA.NE WIN server using VNC software
Activating the link in the "Port Forwarding" section (e.g. pfw_a889_Agro_Care_45)
Now the following information on the activated connection possibilities appears:

Resource Name: Name of port connection

Local Address: IP address used to access the remote computer.
Listen Port: Port used to access the remote computer.
Destination Server: Full remote computer name.

You must enter the "Destination Server" or the "Local Address" in the programmes (e.g. VNC) you use!

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 42 / 48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

ATTENTION!
The VNC host service must not be active when Port Forwarding is started!

TIP!
All incoming and outgoing data are displayed in the "Activity" section of the "Nokia Application Forwarding"
programme display.
VNC requires 1 Port (TCP 5800) per connection.

3.3.6 Accessing DIA.NE installations

You can activate the following functions after you have logged into the Jenbacher Remote Access Portal:

3.3.6.1 Starting Port Forwarding for remote maintenance of the modem server using "Symantec
pcANYWHERE" software
Activating the link in the "Port Forwarding" section (e.g. pfw_a889_Agro_Care_45)
Now the following information on the activated connection possibilities appears:

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 43/48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

Resource Name: Name of port connection

Local Address: IP address used to access the remote computer.
Listen Port: Port used to access the remote computer.
Destination Server: Full remote computer name.
The Symantec pcANYWHERE Remote Control Object must be configured as follows:
▪ Connection info – Device List: TCP/IP
▪ Settings – Network host to control or IP address: „Destination Server“ or „Local Address“

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 44 / 48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

ATTENTION!
The Symantec pcANYWHERE host mode must not be active when Port Forwarding is started!

TIP!
All incoming and outgoing data are displayed in the "Activity" section of the "Nokia Application Forwarding"
programme display.
Because Symantec pcANYWHERE requires 2 ports per connection (TCP 5631 and UDP 5632), two entries are
displayed per connection.

3.3.7 Troubleshooting, Tips & Tricks

3.3.7.1 Help system

The Jenbacher Remote Access Portal features an Online help function, which can be activated via:
https://hermes.jenbacher.com/_nsas.int_/help/en_US/wwhelp/wwhimpl/js/html/wwhelp.htm
or the help link on the portal site.

3.3.7.2 Error when activating the Nokia Application Forwarding component

▪ The Microsoft Internet Explorer security settings do not allow the ActiveX components to be downloaded/
started.
⇨ Add the page : hermes.jenbacher.com to the "Trusted Sites" zone. (This zone allows activating ActiveX
components for the DIA.NE WIN application).
⇨ Check all other security software possibly installed (pop-up blockers, firewall, ...)

3.3.7.3 Error messages when activating the DIA.NE WIN application

▪ Check whether the Nokia Application Forwarding component has been activated successfully:

⇨ If the status is not "Connected", the maximum connection time was exceeded or an error occurred when
establishing the connection.
The connection can be re-established, using the "Extend session" button.
If other error messages appear, please close Microsoft Internet Explorer and reboot.
▪ Check whether the *.hermes-plants.jenbacher.com domain is part of the "Trusted sites":
If the setting is correct, the "Trusted sites" symbol must be displayed in the lower Microsoft Internet Explorer
status bar whenever the DIA.NE WIN application is activated.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 45/48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

⇨ Check the setting according to the above section Configuring the Microsoft Internet Explorer safety
settings
▪ If the "Trusted Sites" symbol is displayed correctly, please check whether the security settings for the
"Trusted sites" zone comply with the DIA.NE WIN client installation manual.

3.3.7.4 VNC error message "unable to resolve host by name: …“

This error message appears when the VNC server service has been activated on the client computer.
This service must be deactivated before Port Forwarding is started!

3.3.7.5 Setting the user-specific default language

At the bottom of the login page, the user can directly change the language setting:

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 46 / 48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

The default language can also be set in the Remote Access Portal, using the "Preferences" submenu on the
main page.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 47/48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Hermes
Remote Data Transmission

3.3.8 Additional information

3.3.8.1 Information on the Remote Access Portal used

Nokia Secure Access System: http://www.nokia.com/nokia/0,8764,43098,00.html

3.3.8.2 Information on the installation firewall used

Check Point VPN-1 EDGE: http://www.checkpoint.com/products/vpn-1_edge/index.htm
SprungMarke!!!9007199279074315

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner, Überegger Responsible: Engineering Release date: 13/11/2013
Index: 2 Page No.: 48 / 48
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
4 Fault rectification
4.1
Failure Checklist

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

ATTENTION
The cause of a TRIPPING fault MUST be rectified before the plant is restarted.
If a failure results in a WARNING being issued, the cause of the failure MUST BE
rectified first before the failure is reset.
Failure to do this may result in serious damage to the system and may also invalidate any
warranty claim.

Shut down the engine in accordance with TI 1100-0105 and secure it against unauthorised restarting in
accordance with TI 2300-0010.

Critical Messages
If the system shuts down with a critical message, the cause of the failure should be rectified first before the
failure is reset.
If one of the following error messages appears, contact your GE service partner immediately. (Service and Sales
partners [⇨ 1.6, Page 1])
1017 OIL PRESSURE AT MINIMUM

1019 COOLING WATER PRESSURE MINIMUM

1048 KNOCKING

1049 CYLINDER EXHAUST GAS TEMPERATURE MAXIMUM EXCESS OVER ABSOLUTE VALUE

1050 COOLING WATER PRESSURE MAXIMUM

1051 ENGINE OIL LEVEL MAXIMUM

1060 PRELUBRICATION PRESSURE MINIMUM

1080 ADMISSIBLE CONTROL DEVIATION OF LEANOX CONTROLLER EXCEEDED

1094 DEFLAGRATION PROTECTION

2117 MIXTURE COOLING WATER PRESSURE MINIMUM

3322 CRANK CASE PRESSURE HIGH

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 1/40
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
4.1
Failure Checklist

3341 MAXIMUM VALVE NOISE

3368 RAMP-DOWN TIME TOO SHORT

3406 COOLING WATER PRESSURE MAXIMUM

3414 END OF OIL FILTER SERVICE LIFE

3415 OIL FILTER CLOGGED - PLEASE CHANGE

3416 OIL FILTER CLOGGED - ENGINE WILL NOT START

3507 OIL PRESSURE AT MAXIMUM

Index
10 START CONDITIONS MISSING
12 OF AGGREGATE
13 PLANT-SIDED
20 MOTOR WON'T START
30 MOTOR SAWING IN IDLE RUN (can't be synchronized)
40 MOTOR DOES NOT REACH FULL LOAD (while maintaining the guaranteed pollutant emissions)
50 MOTOR OR SYSTEM MOTOR/GENERATOR RUNS IRREGULARLY OR UNSTABLE WITH LOAD
51 MOTOR VIBRATES STRONGLY
52 MOTOR SHAKES (quick load fluctuations or great current and voltage fluctuations with little change
of motor output)
53 ENGINE ROCKING
54 GENERATOR MOTOR ESCALATES (great current and voltage fluctuations at only little change in
motor output)
55 MOTOR ARCHIEVES NOT STABLE CONDITION (output swings slowly up and down)
56 ENGINE STOPS (individual cylinders) OR HAS AN EXHAUST GAS TEMPERATURE DEVIATING FROM THE
CENTRAL VALUE
57 PERIODIC FLUCTUATIONS IN PERFORMANCE
60 MOTOR KNOCKING
70 MISFIRING DETECTION RESPONDS, OR AT BR6 DEVIATION OF CYLINDER FLUE GAS TEMPERATURE
TOO GREAT
90 OIL CONSUMPTION TOO HIGH
100 TURBOCHARGER DEFECT
101 COMPACTOR THROWING OIL
102 TURBINE THROWING OIL
103 TURBOCHARGER EFFICIENCY NOT OKAY (flue gas turbocharger no longer archieves required load
pressure)
104 COMPACTOR OR TURBINE WHEEL TOUCHED THE HOUSING
105 TURBOCHARGER VIBRATING

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 2 / 40
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
4.1
Failure Checklist

110 WATER IN LUBRICATION OIL

120 THE CONTRACTUALLY AGREED DEGREE OF EFFICIENCY IS NOT REACHED IN SPITE OF THE SALES
TOLERANCE
1001 FAILURE STEAM BOILER
1002 HEATING CIRCUIT CONTROL SYSTEM ACTIVATED
1003 TEMPERATURE BEFORE EXHAUST HEAT EXCHANGER HIGH
1004 GENERATOR CIRCUIT BREAKER CLOSING FAILURE AFTER DEEXCITATION
1017 OIL PRESSURE LOW
1018 ENGINE OIL LEVEL LOW
1019 JACKET WATER PRESSURE LOW
1021 JACKET WATER TEMPERATURE HIGH
1023 START UP FAILURE
1026 SHUTDOWN FAILURE
1027 FAILURE GAS TRAIN 1
1028 GAS PRESSURE LOW IN GAS TRAIN 1
1031 EMERGENCY STOP/SAFETY LOOP
1032 HEATING WATER FLOW LOW
1033 HEATING WATER TEMPERATURE HIGH
1035 HEATING WATER PRESSURE HIGH
1036 GENERATOR OVERLOAD/SHORT CIRCUIT
1038 GENERATOR REVERSE POWER
1039 SYNCHRONIZING FAILURE
1040 FUEL MIXTURE TEMPERATURE HIGH
1041 POWER SIGNAL MISSING
1042 POWER SIGNAL OVERLOAD
1043 ENGINE OIL TEMPERATURE HIGH
1044 CYLINDER EXHAUST GAS TEMPERATURE DEVIATION FROM AVERAGED VALUE
1047 MISFIRING FAILURE
1049 CYLINDER EXHAUST GAS TEMPERATURE HIGH ABSOLUTE VALUE
1050 JACKET WATER PRESSURE HIGH
1051 ENGINE OIL LEVEL HIGH
1052 GAS PRE-ALARM
1053 GAS ALARM
1054 FIRE ALARM
1056 FAIL SAFE LOOP TRIPPED
1057 HIGH GAS PRESSURE IN GAS TRAIN 1
1060 PRE-LUBE PRESSURE LOW
1063 HEATING WATER SUPPLY TEMPERATURE HIGH
1064 OVERSPEED (RPS-CONTROL SYSTEM)
1073 MULTI MEASUREMENT DEVICE: GENERATOR OVERLOAD/SHORT CIRCUIT
1077 BOOST PRESSURE BEFORE THROTTLE VALVE MEASURING SIGNAL FAILURE
1078 BOOST PRESSURE MEASURING SIGNAL FAILURE
1080 LEANOX CONTROL ALLOWED DEVIATION EXCEEDED

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 3/40
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
4.1
Failure Checklist

1090 ENGINE COOLING WATER PUMP FAILURE

1092 SCAVENGING AIR VALVE FAILURE
1095 PRE CHAMBER GAS PRESSURE LOW
1100 WATER PRESENT IN FUEL/AIR SYSTEM
1101 TRANSFORMER FAILURE
1105 SPEED OF TEMPERATURE CHANGE MIXTURE TEMPERATURE MAXIMUM
1109 GENERATOR LOSS OF EXCITATION
1110 GENERATOR FREQUENCY TOO LOW
1111 GENERATOR FREQUENCY TOO HIGH
1112 NEUTRAL CURRENT MAXIMUM
1113 GENERATOR POWER MEASURING SIGNAL FAILURE
1114 FUEL MIXTURE TEMPERATURE MEASURING SIGNAL FAILURE
1120 SPEED MEASURING SIGNAL FAILURE
1121 GENERATOR WINDING (L1) TEMPERATURE HIGH
1122 GENERATOR WINDING (L2) TEMPERATURE HIGH
1123 GENERATOR WINDING (L3) TEMPERATURE HIGH
1124 GENERATOR BEARING (A) TEMPERATURE HIGH
1125 GENERATOR BEARING (B) TEMPERATURE HIGH
1126 GENERATOR VOLTAGE LOW
1127 GENERATOR VOLTAGE HIGH
1129 FAILURE WITH AUXILIARIES
1132 DIFFERENTIAL PROTECTION
1134 GROUND FAILURE
1135 ROOM TEMPERATURE HIGH
1140 MODULE INTERFACE PANEL CIRCUIT BREAKER TRIPPED
1143 VOLTAGE NEGATIVE SEQUENCE
1144 CURRENT NEGATIVE SEQUENCE
1145 JACKET WATER TEMPERATURE LOW
1148 STARTER BATTERY VOLTAGE LOW
1168 REQUEST FOR MAINTENANCE
1189 RELEASE FROM SYNCHRONIZING MISSING
1216 BUS BAR VOLTAGE SENSOR FAILURE
1217 GENERATOR CB STATUS SIGNAL FAILURE
1218 GENERATOR CB OPENING FAILURE
1219 GENERATOR CB CLOSING FAILURE
1220 GENERATOR CB O-SIGNAL FAILURE
1221 GENERATOR CB 1-SIGNAL FAILURE
2082 PARAMETER(S) MISSING
2083 RPS (CONTROL SYSTEM) BATTERY FAILURE
2084 LEANOX ALGORITHM FAILURE
2097 DEVIATION POWER SETPOINT TO POWER PRESENT VALUE MAXIMUM
2101 JACKET WATER TEMPERATURE MEASURING SIGNAL FAILURE
2102 ENGINE OIL TEMPERATURE MEASURING SIGNAL FAILURE

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 4 / 40
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
4.1
Failure Checklist

2103 JACKET WATER PRESSURE MEASURING SIGNAL FAILURE

2104 JACKET WATER PRESSURE MEASURING SIGNAL FAILURE
2277 Generator voltage too low 2
3003 MEASURING SIGNAL FAILURE
3004 PRE CHAMBER DIFFERENTIAL PRESSURE LOW
3093 GAS PROPORTIONING VALVE CAN COMMUNICATION FAILURE
3094 INCORRECT TECJET SOFTEWARE
3095 TECJET GAS TEMPERATURE NOT REACHED
3096 TECJET GAS PRE-PRESSURE NOT REACHED
3097 TECJET INTERNAL ERROR
3098 TECJET MECHANICAL MALFUNCTION
3099 TECJET GAS VOLUME CHANGE
3216 ENGINE OIL TEMPERATURE HIGH
3217 MISFIRING FAILURE
3218 OIL PRESSURE LOW
3219 EXCITATION VOLTAGE LOW
3220 JACKET WATER TEMPERATURE HIGH
3223 INTAKE AIR TEMPERATURE HIGH
3224 INTAKE AIR TEMPERATURE MEASURING SIGNAL FAILURE
3304 GEARBOX OIL PRESSURE LOW
3305 GEARBOX OIL TEMPERATURE HIGH
3311 IN/OUT CHANNEL FAILURE
3330 SAFI HARDWARE FAILURE
3331 SAFI CAN COMMUNICATION FAILURE
3332 SAFI WRONG TYPE OF SOFTWARE
3333 SAFI PARAMETER FAILURE
3335 SAFI SHUTOFF OVERSPEED
3336 SAFI TRIGGER PICKUP MISSING
3337 SAFI CAMSHAFT/RESET PICKUP MISSING
3339 KNOCKING FAILURE
3341 VALVE NOISE HIGH
3342 KNOCK SENSOR MEASURING SIGNAL FAILURE
3343 IGNITION HARDWARE FAILURE
3344 IGNITION POWER SUPPLY FAILURE
3345 IGNITION SAFETY LOOP
3402 JACKET WATER PRESSURE LOW
3406 JACKET WATER PRESSURE HIGH
3411 FUEL MIXTURE TEMPERATURE HIGH
3497 Failure in the safety loop
3516 EXITATION VOLTAGE HIGH
3517 COMMUNICATION TO DIA.NE WIN SERVER FAILED
3518 DATA REGISTRATION IN DIA.NE WIN SERVER FAILED
3561 OVERSPEED (RPS-CONTROL SYSTEM)

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 5/40
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
4.1
Failure Checklist

3562 FUEL MIXTURE TEMPERATURE LOW

3565 GENERATOR POWER SETPOINT MEASURING SIGNAL FAILURE
3566 GENERATOR POWER FACTOR SETPOINT MEASURING SIGNAL FAILURE

10 START CONDITIONS MISSING

Measuring signal interrupted Check the cabling, check scale of
measurement range

12 OF AGGREGATE
e.g. min. gas pressure closed current loop not remove cause or complain at
released trader;remove loose contact or wire
breakage, or replace defect
monitoring device

13 PLANT-SIDED
no release through auxiliary operation 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.

20 MOTOR WON'T START

Unsuitable Impco or Jenbacher mixer 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.
throttle flap won't open 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 (<12 VDC); short circuit at
the lines to the actuator or
overtemperature (> 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.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 6 / 40
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
4.1
Failure Checklist

Ignition defective check following points (partly with

Ignition spark missing stroboscope).mains supply of DISN-
unit (relay 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
electrode distance too smallat all spark plugs when changing plugs by sets to non - see
JENBACHER tested models, electrode maintenanc
distance is often too small, needs e
greater distance.
throttle flap opens and closes quickly during cwrong pick-up adjustment and quite
start procedure often must be positioned closer to
toothed wheel of starter according to
adjustment instructions
gas pressure too low or too high or gas pressure gas pressure prior to gas pressure TA
fluctuations controller line does not correspond to 1000-0300
listings in techn. scheme.
gas pressure in front of zero-pressure controller 1) higher values lead to excessive TA
too high enriching of motor at start; 1000-0300
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.
wrong mixer adjustment check programming of start opening
membrane of gas pressure controller defective check membrane for ruptures
gas pressure controller stuck check for easy movement
gas magnet valve is defective check whether gas magnet valves
open
no inflammable mixture forms check whether the slot at the mixer
cone at the Jenbacher-mixer
corresponds to the %o-position
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)

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 7/40
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
4.1
Failure Checklist

start or idle run position of mixer or gas or air unsuited gas pressure controller
bypass flap incorrect 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.

30 MOTOR SAWING IN IDLE RUN (can't be synchronized)

throttle flap slightly bent following detonation in remove throttle flap and align, check see
intake line and does not fully close anymore (idle for easy functioning maintenanc
speed partially too high) e
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
Heinzmann actuator driver not optimally check the 0% position of the actuator
adjusted
as a result of a pulsating draught in the exhaust fit flap with a solenoid valve at the
flue while still warm foot of the flue.
Heinzmann actuator defective (damaged) replace
speed controller not optimally adjusted
the control linkage adjusted too progressively in correct adjustment and make sure
idle run that the flap can fully close.
sluggish control lines, or throttle flap relube the joints, or disassemble the see
throttle flap bearing and replace; maintenanc
replace bearing bushing. e
Gas-pressure fluctuations use manometer or water columnto
Check the control rods (ball heads worn / measure where the gas pressure
sluggish) fluctuations appear, i.e., upstream of
mixer, upstream of gas pressure
Mixture too lean / too rich controller or downstream of
Check speed controller setting customergas admission controller; if
controller unsuited, replace it, or call
supplier (of admission pressure
controller).
idle run position at gas or air bypass valve not better adjust idle run position by trial
optimally adjusted or no optimal programming in or program differently
DIANE
damaged joint cones of control line replace joint cones see
maintenanc
e

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 8 / 40
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
4.1
Failure Checklist

40 MOTOR DOES NOT REACH FULL LOAD (while maintaining the guaranteed pollutant emissions)
throttle flap not fully opened,actuator stands at correction of controller linkage see
100% adjustment actuator - throttle flap. maintenanc
e
faulty insulation of exhaust collection line attach new insulation of thickness
(insulation is completely or partiall worn down and efficiency as original one
due to frequent dismantling or due to vibraiton
leakage at the flange connections of flue gas line seal the line (replace sealings, tighten
screws correctly) if necessaryrework
flanges
mixture transporting parts after compactor to seal off
throttle flap are not tight
Defective turbocharger check compactor shovel whether
(missing power and power loss) 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.
flue gas counter pressure too measure the counter pressure after
high turboloader exit;clean oxikate
and waste heat boiler if necessary.
suction temperature too high(at >25°C) reduction check whether ambient air
can be used acc. to ISO 3046, except for other thermostat adjusted too high, the
contractual agreement room venting not properly planned or
other vent stages do not turn on
output display wrong; ignition not properly check and correct error; see
adjusted, orcombustion misfires by e.g. too large make ignition check, maintenanc
electrode distance or failure of cylinders due to e
defectat ignition system (e.g. defect ignition coil) measure ignition point,
correct ignition adjustment and
electrode distance,
replace defective parts.
contaminated air filter and hence great pressure measure pressure loss see
loss before mixer clean or replace the filter maintenanc
e
combustion air ratio not okay (motor running too correct leanox adjustment at DIANE
lean),
Part of the broken-off protective pipe in a open the end cover and remove parts
manifold compensator is interrupting the flow of or replace compensator.Inspect
the exhaust gases turbine wheel for damage.
mixture temperature too high in spite of correct check mixture cooler, clean if TI
mixture cooling water admission temp. necessary (mixture and water part) or 1000-0201,
glycol ratio too high (check). see
maintenanc
e

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 9/40
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
4.1
Failure Checklist

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

51 MOTOR VIBRATES STRONGLY

pendulum damper not okay check and replace if necessary see
maintenanc
e
failure of cylinder check ignition, valves, check see
compression maintenanc
e
motor adjustment not okay (ignition point) check and adjust
straps of motor add-on pieces not okay 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
maintenanc
e
water, humidity in spark plug chamber (after dry spark plug chamber, clean plugs
washing motor) and connector.
combustion air ratio not okay (motor running too check and adjust using the pollutant
lean), measuring device

53 ENGINE ROCKING
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 generator

bad connection in circuit (cables) check that connector is firmly located

55 MOTOR ARCHIEVES NOT STABLE CONDITION (output swings slowly up and down)
gas pressure fluctuating check gas pressure controller, check TA
admission pressure 1000-0300
quick fluctuation of the mixture temperature check temp. in hot water circulation Schematic
diagram
control linkages not okay (too large dead center/ check, if necessary repair or replace see
to progressively adjusted, etc.) maintenanc
e
gas mixer not properly adjusted (e.g. l- check, adjust
characteristic not okay)

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 10 / 40
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
4.1
Failure Checklist

Non-optimal setting of Leanox-control optimise the controller parameters at

parameters constant power setpoint
Check control rods (ball heads worn / 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)

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

57 PERIODIC FLUCTUATIONS IN PERFORMANCE

continual switching on and off of the ventilator(s) Conversion to thermostatically-
controlled, frequency-regulated
ventilator

60 MOTOR KNOCKING
mixture cooling water temperature too high Eleminate cause! Schematic
diagram
combustion air ratio not okay check, correct adjustment if Schematic
necessary diagram
cooling water throughflow through the mixture Eleminate cause!
cooler too low
deposits in combustion chamber check, remove deposits if any
are butane and air mixed into the fuel gas? Eleminate cause!
methane number of fuel gas too low take gas sample and have it analyzed TA
1000-0300
output limitation faulty Eleminate cause!
mixture temperature too high check, remedy fault if any
too early ignition point is set Eleminate cause!
motor set too rich Eleminate cause!
mixture cooler not okay Eleminate cause!

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 11/40
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
4.1
Failure Checklist

ignition point not okay determine ignition point and adjust

toward "late"

70 MISFIRING DETECTION RESPONDS, OR AT BR6 DEVIATION OF CYLINDER FLUE GAS TEMPERATURE

TOO GREAT
crack at end of thread torque too high (plug replace spark plug and see
tightened without torque wrench or with tightencorrectly with the right torque maintenanc
defective tool, or tightened too much) e
verdigris on ignition coil exit (connector to clean carefully to make metal shiny
ignition cable)
electrode distance too small (possibly only at site correct electrode distance. see
on one electrode) maintenanc
e
pearl formation on electrodes due to cannot be seen, metallic pearl may
overheating (e.g. knocking at times) be caused by local melt-on between
electrodes (remove with thickness
gauge and check gap)
spigot nut at the line to gas inlet valve is loose or retighten the screwing or seal
the cutting ring is loose (flue gas temperature is
higher at misfire)
interferences at the ignition check shield at the cables
defective output measurement (motor output check the output measurement
does not correspond to measured output) (compare counter measurement with
output measurement)
missing or bad contact at highvoltage output of check contact screwing ground
ignition coils or at ground contact or ignition coil contact at the ignition coil and
retighten the connection
motor runs too lean due to defect of mixer (or of check motor adjustment
the air bypass flap)or due to leanox control withmeasuring kit, if too lean,
remedycause
boost pressure transmitter defect or due to drift check boost pressure controller, i.e.,
transmits too low value (to leanox controller or compare boost pressure signal with
DIANE) causing too lean operation of motor manometer, in case of deviation
replace transmitter
too large ignition voltage demand due to large re-adjustment of the electrode gap see
electrode distance with the special tool, or replacement maintenanc
of the sparking plugs e
spring in brass part of plug connector without replace spark plug connector
voltage, or broken, bad contact to brass cap of
plug (traces of smoke)
defect at cable loom between ignition box and in case of loose contacts retighten
ignition coils (scraping spots, ground contact, screws, in all other cases replace
overheating and cracking at the insulation, loose cable loom
contacts at the connections
motor misfires because it is set too lean or due check using an exhaust emmissions
to defective ignition analyser and correct if necessary
elastic seal ring inParker" valve of gas inlet valve if ball valve is too leaky, the pressure
destroyed at theParker" valve is too high and
the seal ring is destroyed

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 12 / 40
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
4.1
Failure Checklist

ceramic body at the spark plug on top, or inner clean plug and connector or
part of plug, is soiled with electr. conductive replace.check for proper seat of dust
grease or similar and causes spark discharge in cap on top of the valve hoodBlow-out
this area; plug shows in lower range of brass is usually very small, onlyvery small
part a low-out, thus spark discharge to plug shell grey point is visible on spark passage.
is created replace plug suppresser
breakage of ignition cable interior at the frequent pulling of the plug connector
soldering at the brass part of the plug connector at the cable, the cable ruptures are
or at the bend of the rubber bush not visible, replace plug and cable
misfiring due to too low ignition voltage offer check the coil at motor standstill with
(defect at the ignition coil) ignition voltage tester
spark plug shows blue or brown discoloring at spark plug was not tightened
steel part and shows electrode sufficiently and overheated
entry of dirt (shavings) or grease into the Wash the pre-chamber with petrol
prechamber annulus, i.e. slits are partially and blow out.
blocked
ball sticks to seat of gas inlet valve increase prechamber gas difference
pressure;
clean (wash valve, i.e. clean from
lubricating oil which deposits in valve
especially during start-up phase)
wrong adjustment of misfire detector Eleminate cause!
quick generator output change Eleminate cause!
consumption spark plug shows abnormal spark plug daubed at the end side with TI
appearance or flashover at bottom of plug on electrically conductive gliding agent 1400-0111
oscilloscope (when sprayed with Ultra-Therm not
covered or too much spray used
which dropped on electrodes when
hot)
loose brass cap (traces of smoke on top of tighten cap; if threading underneath see
ceramic body) of brass cap is loose, replace spark maintenanc
plug e

90 OIL CONSUMPTION TOO HIGH

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 13/40
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
4.1
Failure Checklist

carbonisation of the fire land through excessive remove piston and clean replace first
idling or nonobservation of the limit values for ring and break in motor
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 see point 0100

100 TURBOCHARGER DEFECT

101 COMPACTOR THROWING OIL

air filter resistance too great (dirty filter) clean air filter, if required replace see
maintenanc
e

102 TURBINE THROWING OIL

oil sealing at turbine is defective check and repair
axial or radial play of runner measure, if exceeding admissible too
great values repair or replace

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

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

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 14 / 40
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
4.1
Failure Checklist

turbine shovels (compactor shovels) defective replace wheel or turboloader

(unbalanced)

110 WATER IN LUBRICATION OIL

leaks at oil cooler check and replace if necessary
leaky O-rings at the cylinder liner replace O-rings
leaky O-rings at the prechambers replace O-rings
craks or sinkholes at upper side of cylinder head check, replace if necessary
between water storage and oil storage

120 THE CONTRACTUALLY AGREED DEGREE OF EFFICIENCY IS NOT REACHED IN SPITE OF THE SALES
TOLERANCE
on site the sum of border conditions is strongly measure values exactly and convert
negative in order to reach an optimal efficiency to standard condition according to
(e.g. heating value of depot gas extremely low, ISO 3046
induction temperature >25°C, air pressure <1000
mbar)
induction vacuum before compactor too high clean air filter see
due to dirty air filter maintenanc
e
flue gas counter pressure too high due to dirty clean boiler
waste heat boiler

1001 FAILURE STEAM BOILER

See steam boiler supplier handbooks for
description of Maintenance and Fault alarms

1002 HEATING CIRCUIT CONTROL SYSTEM ACTIVATED

Group alarm of failures 1033-1035 Monitoring Check monitoring equipment in
equipment in heating circuit activated heating water circuit Remedy the
failure as is described for No.
1033-1035

1003 TEMPERATURE BEFORE EXHAUST HEAT EXCHANGER HIGH

Firing point is too late Eleminate cause!
Overload
Mixture is too rich
Thermoelement or evaluation equipment is out
of order
Intake air filter is dirty
Exhaust gas back pressure is too high
Maximum value has been set incorrectly

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 15/40
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
4.1
Failure Checklist

1004 GENERATOR CIRCUIT BREAKER CLOSING FAILURE AFTER DEEXCITATION

Wire breakage, cabling fault, faulty sensor, Check wiring/cabling, inspect sensor,
scaling incorrect check scaling

1017 OIL PRESSURE LOW

leak in the oil lines or the oilpan clogged oil Eleminate cause!
cooler, oil filter or oil line
uncontrolled switching off (killing) of engine too
low speed
oil level below "min. oil level"
defective oil pressure transmitter
engine switch-off by closed current loop (defect
monitoring)
wrong adjustment of fringe value

1018 ENGINE OIL LEVEL LOW

leakage in oil lines or oilpan Eleminate cause!
defective solenoid valve "fill oil" (won't open)
defective oil level sensor or evaluation device
empty fresh oil tank
slide at oil pump station is closed
three-way cock in wrong position
oil level measurerer not adjusted (with analog
measuring)
"sag" in pressure-equalization line (venting)
wrong adjustment of fringe value

1019 JACKET WATER PRESSURE LOW

leak in cooling water system Eleminate cause!
defective pressure transmitter of cooling water
leaking safety valve
damaged membrane in pressure
wrong adjustment of fringe value
crack in inlet or outlet duct of cylinder head

1021 JACKET WATER TEMPERATURE HIGH

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 16 / 40
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
4.1
Failure Checklist

hot water feedback temp. too high Eleminate cause!

cooler clogged, calcified, dirty
return temperature control incorrectly adjusted
emergency cooler clogged calcified, dirty
fresh water missing
cool. wat. pump defect
defect. cool. water temp. transmission
heat circulation pump defective
heat circ. slide, fresh - water slide closed
ambient temp. too high (with table cooler)
throughflow amount too small (primary/
secondary)
follow-up heating when shut off
water circulations not vented
motor output too high
glycool amount too high
defective short-circuit thermostat
wrong adjustment of fringe value
water circulation not vented

1023 START UP FAILURE

3 unsuccessful starting attempts no gas Eleminate cause!
defective ignition
wrong gas mixer valve start position
wrong adjustment of gas pressure
safety automation in motor terminal strip is off
starter won't start

1026 SHUTDOWN FAILURE

leaky or defective gas valves Eleminate cause!
speed limit wrongly adjusted

1027 FAILURE GAS TRAIN 1

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 17/40
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
4.1
Failure Checklist

leaky gas valves Eleminate cause! TA

gas valve closed 1000-0300

defective gas tightness coantroller

clogged gas filter
too low gas pressure
dirty filter in supply line to tightness controller
condensate in the supply line to tightness
controller
vibrations of tightness controller device

1028 GAS PRESSURE LOW IN GAS TRAIN 1

gas valve closed Eleminate cause! TA
wrong adjustment or defective gas pressure 1000-0300
controller
missing gas supply (line breakage) pressure
fluctuations by other user defective pressure
switch
no gas present (sewer gas)
wire breakage to PLC
dirty filter in supply line

1031 EMERGENCY STOP/SAFETY LOOP

emergency off button enabled Eleminate cause!
wire breakage
safety loop
belt alarm --> when in emergency off chain
gas alarm --> linked

1032 HEATING WATER FLOW LOW

Leakage in the heating water system Eleminate cause!
Obstruction in the heating water system
Heating water pump defective (protective motor
switch triggered)
Slide closed
Heating water flow control switch incorrectly set
or defective
Wire break to the SPC

1033 HEATING WATER TEMPERATURE HIGH

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 18 / 40
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
4.1
Failure Checklist

heat. water pump defective Eleminate cause!

wrong adjustment of or defective heating water
controls
slide closed
wrong adjustment of or defective heating water
temp. switch feedback return temperature too
high (no heating demand)
wire breakage to PLC

1035 HEATING WATER PRESSURE HIGH

clogged heating cooling system Eleminate cause!
slide closed
slide for water filling open
safety valve defective
wrong adjustment or defective cooling water
pressure valve
wire breakage to PLC

1036 GENERATOR OVERLOAD/SHORT CIRCUIT

wrong adjustment or defective output controller Eleminate cause!
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

1038 GENERATOR REVERSE POWER

generator power switch does not open Eleminate cause!
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)

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 19/40
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
4.1
Failure Checklist

1039 SYNCHRONIZING FAILURE

speed controller hunting Eleminate cause!
throttle control rod loose
synchronising unit faulty
engine rough (ignition coil faulty)
voltage balance circuit faulty
engine idles too long
gas pressure oscillating

1040 FUEL MIXTURE TEMPERATURE HIGH

defective mixture cooling pump Eleminate cause!
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

1041 POWER SIGNAL MISSING

wire breakage or short circuit of output signal Eleminate cause!
wire breakage or short circuit of current
transducer
output measuring transducer defect
defective current transducer
defective output controller
power setpoint too small (<10% Pnenn)

1042 POWER SIGNAL OVERLOAD

overload isolated operation Eleminate cause!
output controller wrong adjusted or defective
input of wrong measuring transducer or wrong
output switch point
defective output measuring transducer defective
current transducer defective output controller

1043 ENGINE OIL TEMPERATURE HIGH

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 20 / 40
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
4.1
Failure Checklist

oil cooler clogged, dirty Eleminate cause!

hot water feedback temp. is too high
defective cooling water pump
cooling water heat exchanger chocked dirty
return remperature control incorrectly adjusted
fresh water heat exchanger chocked, dirty
table cooler too small
ambient temp. to high (with table cooler)
throughflow amount too low (primary/second.)
limit value adjusted incorrectly

1044 CYLINDER EXHAUST GAS TEMPERATURE DEVIATION FROM AVERAGED VALUE

pre chamber gas valve faulty Eleminate cause!
Ignition breakdown (glow plug, ignition coil)
thermoelement defect
limit value adjusted incorrectly
cylinder knocks

1047 MISFIRING FAILURE

Wrong distance of electrodes Eleminate cause!
Wrong A/F ration
Failure in ignition system (sparkovers, break of
insulators)
Too late ignition point
Misvire detection incorrectly adjusted or
defective
Ignition defective
Ignition coil defective

1049 CYLINDER EXHAUST GAS TEMPERATURE HIGH ABSOLUTE VALUE

Ignition point not okay Eleminate cause!
Limite value wrongly adjusted
cylinder knocks fase engine adjustment
Overload

1050 JACKET WATER PRESSURE HIGH

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 21/40
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
4.1
Failure Checklist

slide for filling cooling water is open Eleminate cause!

leaking plug sleeve
defective cooling water pressure transmitter
defect. cool. water temp. measurement and
overheated motor
pressure expansion container too small
filling pressure too high
wrong adjustment of fringe value

1051 ENGINE OIL LEVEL HIGH

defective solenoid valve "fill oil" Eleminate cause!
defective oil level sensor or evaluator
oil level measurerer is not adjusted (with analog
measuring)
wrong adjustment of fringe value

1052 GAS PRE-ALARM

leak in gas line system Eleminate cause!
solvent, cleaning agent in container
transmitter defective
wrong adjustment or defective evaluator

1053 GAS ALARM

leak in gas line system Eleminate cause!
solvent, cleaning agent in container
transmitter defective
wrong adjustment or defective evaluator

1054 FIRE ALARM

fire Eleminate cause!
smoke
solvent, cleaning agent in container
transmitter defect
evaluator defect

1056 FAIL SAFE LOOP TRIPPED

24V supply missing Eleminate cause!
safety loop monitoring tripped
emergency stop

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 22 / 40
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
4.1
Failure Checklist

1057 HIGH GAS PRESSURE IN GAS TRAIN 1

Gas pressure controlle wrong adjustment or Eleminate cause!
defective
Pressure switch defect
wire breakage to PLC

1060 PRE-LUBE PRESSURE LOW

Air pocket in oil pipe work Eleminate cause!
Motor circuit breaker
Prelubricating pump faulty
Oil temperature too low
Oil pressure analogue sensor faulty

1063 HEATING WATER SUPPLY TEMPERATURE HIGH

heat. water pump defective Eleminate cause!
wrong adjustment of or defective heating water
controls
slide closed
wrong adjustment of or defective heating water
temp. switch feedback return temperature too
high (no heating demand)
wire breakage to PLC

1064 OVERSPEED (RPS-CONTROL SYSTEM)

speed overshoot afte mains failure Eleminate cause!
speed limit wrongly adjusted

1073 MULTI MEASUREMENT DEVICE: GENERATOR OVERLOAD/SHORT CIRCUIT

1077 BOOST PRESSURE BEFORE THROTTLE VALVE MEASURING SIGNAL FAILURE

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 23/40
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
4.1
Failure Checklist

24V supply to boost pressure transducer faulty secure interfaces

transducer cables faulty repair cables
transducer range exceeded wrong transducer
tranduce faulty change transducer
analogue input card faulty

1078 BOOST PRESSURE MEASURING SIGNAL FAILURE

24V supply to boost pressure transducer faulty secure interfaces
transducer cables faulty repair cables
transducer range exceeded wrong transducer
tranduce faulty change transducer
analogue input card faulty

1080 LEANOX CONTROL ALLOWED DEVIATION EXCEEDED

measuring signal fault - actual power see fault No. 1113
Measuring signal fault - mixture Temperature see fault No. 1114
Measuring signal fault - boost pressure see fault No. 1078
Gas mixer control defective see fault No. 1083

1090 ENGINE COOLING WATER PUMP FAILURE

Faulty water pump Check water pump and electric
Cable to PLC defect motor.

Engine emergency circuit breaker set incorrectly Compare the engine emergency
circuit breaker setting and the current
Incorrectly set minimum current collection relay setting with the actual current
control relay collection of the motor.

1092 SCAVENGING AIR VALVE FAILURE

Signal from client Check the valve
Compare the engine emergency
circuit breaker setting with the actual
current collection of the drive motor.
Check the tightness of the valve while
the gas engine is running. Readjust
the CLOSE (ZU) torque switch if the
valve is leaking.

1095 PRE CHAMBER GAS PRESSURE LOW

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 24 / 40
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
4.1
Failure Checklist

wire breakage Eleminate cause!

short circuit
defective PT100
defective PT100 measuring transformer
defective safety device measuring transformer
current supply
Analogue input card faulty

1100 WATER PRESENT IN FUEL/AIR SYSTEM

Charge cooler leaks Remove leaks Replace failure level
Level sensor failure sensor Check wiring

Wire breakage

1101 TRANSFORMER FAILURE

Transformer overload Eleminate cause!
Transformer out of balance
Faulty transformer cooling
Wire breakage to PLC

1105 SPEED OF TEMPERATURE CHANGE MIXTURE TEMPERATURE MAXIMUM

Inform the GE-JENBACHER customer
service department

1109 GENERATOR LOSS OF EXCITATION

Voltage controller faulty change controller
Excitation voltage protection has been tripped Close protection switch
Faulty rotating diodes Check/replace the diodes
defective cos-phi controller

1110 GENERATOR FREQUENCY TOO LOW

Speed governor has been set incorrectly Eleminate cause!
Speed governor is out of order
Error in speed governor circuit

1111 GENERATOR FREQUENCY TOO HIGH

Speed governor has been set incorrectly Eleminate cause!
Speed governor is out of order
Error in speed governor circuit

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 25/40
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
4.1
Failure Checklist

1112 NEUTRAL CURRENT MAXIMUM

Out-of-balance load in isolated operation. Eleminate cause!
Non-symmetrical mains supply causing
compensating currents.
Inadmissible 3rd (upper) harmonic wave (150 Hz).
Earth fault

1113 GENERATOR POWER MEASURING SIGNAL FAILURE

Mult - transducer faulty Change multi-transducer
Cables for multi-transducer faulty Check cables
Analogue input card faulty Change analogue input card
wrong adjustment of fringe value

1114 FUEL MIXTURE TEMPERATURE MEASURING SIGNAL FAILURE

PT100 faulty change PT100
PT100 cables faulty Check cables
Analogue input card faulty

1120 SPEED MEASURING SIGNAL FAILURE

Speed pick-up wrongly adjusted Gap from 1 revolution of gear rim.
24V supply failure to pickup Check interface
Pickup cable fault Check cable

1121 GENERATOR WINDING (L1) TEMPERATURE HIGH

1122 GENERATOR WINDING (L2) TEMPERATURE HIGH

generator overload Check main switch for trace heating
unbalanced load system in accordance with
manufacturer's instructions Check
defective generator the measuring sequence of the
wrong cos-phi response switch in accordance with
the wiring diagram and
PT100 sensore defective
manufacturer's instructions for the
ambient temperature too high installed components
wrong adjustment of fringe value
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 26 / 40
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
4.1
Failure Checklist

1123 GENERATOR WINDING (L3) TEMPERATURE HIGH

1124 GENERATOR BEARING (A) TEMPERATURE HIGH

bearing defective Eleminate cause!
PT100 sensor defective
cable break to PLC
ambient temperature too high
wrong adjustment of fringe value

1125 GENERATOR BEARING (B) TEMPERATURE HIGH

bearing defective Eleminate cause!
PT100 sensor defective
cable break to PLC
ambient temperature too high
wrong adjustment of fringe value

1126 GENERATOR VOLTAGE LOW

voltage controller fault change controller
Excitation voltage protection has been tripped Close protection switch
Blown fuse Check fuse

1127 GENERATOR VOLTAGE HIGH

voltage controller fault change controller
voltage controller measurement circuit is Check measurement circuit
disturbed

1129 FAILURE WITH AUXILIARIES

supply circuit breaker tripped by check wiring
overload check adjustment
short circuit circuit breaker

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 27/40
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
4.1
Failure Checklist

1132 DIFFERENTIAL PROTECTION

stator earth fault Eleminate cause!
Winding fault

1134 GROUND FAILURE

generator earth fault Eleminate cause!
limiting value on evaluation instrument
incorrectly adjusted
trigger device defective
defective current transformer in generator
incorrect current transformer
current transformer connections exchanged

1135 ROOM TEMPERATURE HIGH

room vent failure check the frequency controller
wrong adjustment or defective thermostat
exterior temperatur too high
unfavorable placing of thermostat

1140 MODULE INTERFACE PANEL CIRCUIT BREAKER TRIPPED

Circuit breaker or engine circuit breaker in Eleminate cause!
module control cabinet has tripped
Power circuit breaker or engine circuit breaker in
module control cabinet is off
Wire breakage
Loose terminal on SPC input card
Loose terminal on circuit breaker's or engine
circuit breaker's auxiliary contacts

1143 VOLTAGE NEGATIVE SEQUENCE

fuse blown in measurement circuit check fuses
Generator earth fault Fault checks
Generator winding fault
Armature fault
Mains voltage assymetry

1144 CURRENT NEGATIVE SEQUENCE

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 28 / 40
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
4.1
Failure Checklist

current transformer circuit interuption check CT circuits

Mains voltage assymetry Check faults
Unbalanced load in Island operation
Earth fault

1145 JACKET WATER TEMPERATURE LOW

failure cooling water preheating Eleminate cause!
return temperature control incorrectly adjusted
defective cooling water temp. transmitter
heat-up process not finished
wrong adjustment of fringe value

1148 STARTER BATTERY VOLTAGE LOW

loader defect (fuse) check battery charging
not enough battery acid in battery
defective battery
too strong loads
frequent starts
wire breakage to PLC

1168 REQUEST FOR MAINTENANCE

Service counter has reached zero (operating hrs) reset service counter after According to
from preselected limit completion of service customer
setting

1189 RELEASE FROM SYNCHRONIZING MISSING

a) Synchronization's control logic is not issuing a) Check prerequisites for logical
release due to unfulfilled prerequisites release from synchronization
(prerequisites relating to specific
order according to control
b) Signal error in SPC output chain in description)
synchronization/coupling relays/wiring/coupling
relays/SPC input in module control
b) Eliminate cause !

1216 BUS BAR VOLTAGE SENSOR FAILURE

measuring voltage missing Eleminate cause!
busbars voltage-detector defective
wire breakage SPG-OK message to PLC
PLC-input defective

1217 GENERATOR CB STATUS SIGNAL FAILURE

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 29/40
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
4.1
Failure Checklist

wire breakage check cables/connections

switch return messages check auxiliary contacts/answerback
circuit breaker or contactor defective of breaker or contactor

(return message/auxiliary contacts) check auxiliari contacts

relay for switch return message defective check/change relay

PLC-input defective check PLC input (performed by GE-

JENBACHER)

1218 GENERATOR CB OPENING FAILURE

ground contacts welded (with circuit breaker/ change/check contactor
contactor combination) change/check breaker
circuit breaker defective change/check relay
relay for switch-off order is defective check breaker position signal
wrong position of retun message switch check/change breaker position
PLC-output defective answerback relay
check PLC output (performed by GE-
JENBACHER)

1219 GENERATOR CB CLOSING FAILURE

relay for switch-on order defective check/change relay
line breakage to circuit breaker/contactor check cabels/connections
circuit breaker defective check/change breaker
PLC output defective check PLC output

1220 GENERATOR CB O-SIGNAL FAILURE

wire breakage to PLC output monitoring check cables/connections
PLC input defective check PLC input (performed by GE-
PLC output defective JENBACHER)
check PLC output (performed by GE-
JENBACHER)

1221 GENERATOR CB 1-SIGNAL FAILURE

wire breakage to PLC output monitoring check cables/connections
PLC input defective check PLC input (performed by GE-
PLC output defective JENBACHER)
check PLC output (performed by GE-
JENBACHER)

2082 PARAMETER(S) MISSING

Some parameters required for the operation of Transmitting the most recent and
the machine are missing. No, insufficient or complete parameter set (*.par file)
wrong parameters transmitted. using e.g. DIA.NE WIN.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 30 / 40
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
4.1
Failure Checklist

2083 RPS (CONTROL SYSTEM) BATTERY FAILURE

NiCd battery for CPU2005 is flat (Battery LED lit) change NiCd battery
Lithium battery for the user memory is flat Lithium battery
(Battery LED flashing)

2084 LEANOX ALGORITHM FAILURE

two identical operating point for Lox memory repeat Lox setup procedure
have been used

2097 DEVIATION POWER SETPOINT TO POWER PRESENT VALUE MAXIMUM

2101 JACKET WATER TEMPERATURE MEASURING SIGNAL FAILURE

wire breakage Eleminate cause!
short circuit
defective PT100
defective PT100 measuring transformer
defective safety device measuring transformer
current supply
Analogue input card faulty

2102 ENGINE OIL TEMPERATURE MEASURING SIGNAL FAILURE

wire breakage Eleminate cause!
short circuit
defective PT100
defective PT100 measuring transformer
defective safety device measuring transformer
current supply
Analogue input card faulty

2103 JACKET WATER PRESSURE MEASURING SIGNAL FAILURE

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 31/40
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
4.1
Failure Checklist

2104 JACKET WATER PRESSURE MEASURING SIGNAL FAILURE

2277 Generator voltage too low 2

voltage controller fault change controller
Excitation voltage protection has been tripped Close protection switch
Blown fuse Check fuse

3003 MEASURING SIGNAL FAILURE

Signal from client Eliminate cause!

3004 PRE CHAMBER DIFFERENTIAL PRESSURE LOW

defective prechamber pressure keeping valve Eleminate cause!
defective pressure switch
wrong adjustment of fringe value

3093 GAS PROPORTIONING VALVE CAN COMMUNICATION FAILURE

CAN connection between Tecjet and dia.ne Check CAN bus wiring
interrupted Check resistance load at CAN bus

3094 INCORRECT TECJET SOFTEWARE

TJ software version not dia.ne compatible or not Execute software download from
latest version dia.ne (by JENBACHER mechanic)

3095 TECJET GAS TEMPERATURE NOT REACHED

Gas temperature too high or too low Check the gas temperature

3096 TECJET GAS PRE-PRESSURE NOT REACHED

Gas pre-pressure too high or too low Check engine gas pre-pressure
Check module gas pre-pressure
Check pre-pressure controller setting

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 32 / 40
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
4.1
Failure Checklist

3097 TECJET INTERNAL ERROR

Defective internal electronics Check power supply and wiring
Replace equipment

3098 TECJET MECHANICAL MALFUNCTION

Piston jammed or position sensors covered with Piston jammed or position sensors
condensate (moisture) covered with
condensate (moisture )check for
visible metal chips
Remove condensate (moisture) by
wiping off or using hot air

3099 TECJET GAS VOLUME CHANGE

Inadmissably large gas-volume change Check engine operating conditions
Check charge pressure sensor

3216 ENGINE OIL TEMPERATURE HIGH

oil cooler clogged, dirty Eleminate cause!
hot water feedback temp. is too high
defective cooling water pump
cooling water heat exchanger chocked dirty
return remperature control incorrectly adjusted
fresh water heat exchanger chocked, dirty
table cooler too small
ambient temp. to high (with table cooler)
throughflow amount too low (primary/second.)
limit value adjusted incorrectly

3217 MISFIRING FAILURE

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 33/40
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
4.1
Failure Checklist

3218 OIL PRESSURE LOW

3219 EXCITATION VOLTAGE LOW

Voltage controller faulty change controller
Excitation voltage protection has been tripped Close protection switch

3220 JACKET WATER TEMPERATURE HIGH

hot water feedback temp. too high Eleminate cause!
cooler clogged, calcified, dirty
return temperature control incorrectly adjusted
emergency cooler clogged calcified, dirty
fresh water missing
cool. wat. pump defect
defect. cool. water temp. transmission
heat circulation pump defective
heat circ. slide, fresh - water slide closed
ambient temp. too high (with table cooler)
throughflow amount too small (primary/
secondary)
follow-up heating when shut off
water circulations not vented
motor output too high
glycool amount too high
defective short-circuit thermostat
wrong adjustment of fringe value
water circulation not vented

3223 INTAKE AIR TEMPERATURE HIGH

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 34 / 40
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
4.1
Failure Checklist

Defective fuse Eleminate cause!

Wire breakage on PLC
Defective analog input card
Customer signal not present

3224 INTAKE AIR TEMPERATURE MEASURING SIGNAL FAILURE

Exceeding the intake temperature for which full This warning should be regarded as
engine output was agreed. An output reduction an indication, no further action is
caused by [too high] an intake temperature is required. The reasons for the output
possible. reduction are physical in nature.
Cleaning the exhaust-gas
turbochargers will result in higher
power reserves.

3304 GEARBOX OIL PRESSURE LOW

see gearbox description Eleminate cause!

3305 GEARBOX OIL TEMPERATURE HIGH

see gearbox description Eleminate cause!

3311 IN/OUT CHANNEL FAILURE

Regulation fault Eleminate cause!
MSF fault
Converter adjustment!

3330 SAFI HARDWARE FAILURE

see
TI 1502-0068 - MORIS ignition
TI 1502-0069 - MPM (MORIS Power Modul)
TI 1502-0071 - SAFI (Sensor-Actor-Function-
Interface)
TI 1502-0072 - SPA24 (SAFI-Pickup-Amplifier)

3331 SAFI CAN COMMUNICATION FAILURE

see
TI 1502-0068 - MORIS ignition
TI 1502-0069 - MPM (MORIS Power Modul)
TI 1502-0071 - SAFI (Sensor-Actor-Function-
Interface)
TI 1502-0072 - SPA24 (SAFI-Pickup-Amplifier)

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 35/40
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
4.1
Failure Checklist

3332 SAFI WRONG TYPE OF SOFTWARE

see
TI 1502-0068 - MORIS ignition
TI 1502-0069 - MPM (MORIS Power Modul)
TI 1502-0071 - SAFI (Sensor-Actor-Function-
Interface)
TI 1502-0072 - SPA24 (SAFI-Pickup-Amplifier)

3333 SAFI PARAMETER FAILURE

see
TI 1502-0068 - MORIS ignition
TI 1502-0069 - MPM (MORIS Power Modul)
TI 1502-0071 - SAFI (Sensor-Actor-Function-
Interface)
TI 1502-0072 - SPA24 (SAFI-Pickup-Amplifier)

3335 SAFI SHUTOFF OVERSPEED

see
TI 1502-0068 - MORIS ignition
TI 1502-0069 - MPM (MORIS Power Modul)
TI 1502-0071 - SAFI (Sensor-Actor-Function-
Interface)
TI 1502-0072 - SPA24 (SAFI-Pickup-Amplifier)

3336 SAFI TRIGGER PICKUP MISSING

see
TI 1502-0068 - MORIS ignition
TI 1502-0069 - MPM (MORIS Power Modul)
TI 1502-0071 - SAFI (Sensor-Actor-Function-
Interface)
TI 1502-0072 - SPA24 (SAFI-Pickup-Amplifier)

3337 SAFI CAMSHAFT/RESET PICKUP MISSING

see
TI 1502-0068 - MORIS ignition
TI 1502-0069 - MPM (MORIS Power Modul)
TI 1502-0071 - SAFI (Sensor-Actor-Function-
Interface)
TI 1502-0072 - SPA24 (SAFI-Pickup-Amplifier)

3339 KNOCKING FAILURE

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 36 / 40
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
4.1
Failure Checklist

see
TI 1502-0068 - MORIS ignition
TI 1502-0069 - MPM (MORIS Power Modul)
TI 1502-0071 - SAFI (Sensor-Actor-Function-
Interface)
TI 1502-0072 - SPA24 (SAFI-Pickup-Amplifier)

3341 VALVE NOISE HIGH

see
TI 1502-0068 - MORIS ignition
TI 1502-0069 - MPM (MORIS Power Modul)
TI 1502-0071 - SAFI (Sensor-Actor-Function-
Interface)
TI 1502-0072 - SPA24 (SAFI-Pickup-Amplifier)

3342 KNOCK SENSOR MEASURING SIGNAL FAILURE

see
TI 1502-0068 - MORIS ignition
TI 1502-0069 - MPM (MORIS Power Modul)
TI 1502-0071 - SAFI (Sensor-Actor-Function-
Interface)
TI 1502-0072 - SPA24 (SAFI-Pickup-Amplifier)

3343 IGNITION HARDWARE FAILURE

see
TI 1502-0068 - MORIS ignition
TI 1502-0069 - MPM (MORIS Power Modul)
TI 1502-0071 - SAFI (Sensor-Actor-Function-
Interface)
TI 1502-0072 - SPA24 (SAFI-Pickup-Amplifier)

3344 IGNITION POWER SUPPLY FAILURE

see
TI 1502-0068 - MORIS ignition
TI 1502-0069 - MPM (MORIS Power Modul)
TI 1502-0071 - SAFI (Sensor-Actor-Function-
Interface)
TI 1502-0072 - SPA24 (SAFI-Pickup-Amplifier)

3345 IGNITION SAFETY LOOP

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 37/40
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
4.1
Failure Checklist

see
TI 1502-0068 - MORIS ignition
TI 1502-0069 - MPM (MORIS Power Modul)
TI 1502-0071 - SAFI (Sensor-Actor-Function-
Interface)
TI 1502-0072 - SPA24 (SAFI-Pickup-Amplifier)

3402 JACKET WATER PRESSURE LOW

Leakage in emergency cooling water system Eleminate cause!
Faulty emergency cooling water pressure sensor
Leaking safety valve
Faulty membrane in pressure compensation
reservoir
Incorrectly preset limiting value
Wire breakage to PLC

3406 JACKET WATER PRESSURE HIGH

Registration by customer

3411 FUEL MIXTURE TEMPERATURE HIGH

3497 Failure in the safety loop

When the closed-current circuit is activated by Have all closed-current circuit relays
an EMERGENCY STOP or by the heating circuit checked by a GE Jenbacher service
control system, not all closed-current circuit mechanic or by a mechanic from a
relays report the drop-out position to the control specialized company authorised to
system. do so by GE Jenbacher. The error
message can only be reset when the
EMERGENCY STOP switch is pressed.
To that end, all closed-current circuit
relays must report the drop-out
position to the control system.

3516 EXITATION VOLTAGE HIGH

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 38 / 40
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
4.1
Failure Checklist

Wire breakage Eleminate cause!

Short-circuit
Rotating rectifier diode error
Excitation protection switch activated
Excitation current relais failure
Cos phi / voltage regulator error

3517 COMMUNICATION TO DIA.NE WIN SERVER FAILED

Connection between DIA.NE XT and DIA.NE WIN Check connection, plug in network
server interrupted cable, check functionality of network
DIA.NE WIN server has failed or is defective components (cables, DIA.NE WIN
server network card, HUB, DIA.NE XT
HUB failure network components), replace
Software technical problem at DIA.NE WIN server network components.

Check and repair voltage supply,

contact competence centre, replace
DIA.NE WIN server hard disc, replace
DIA.NE WIN server.

Check and repair voltage supply,

contact competence centre, replace
HUB.

Contact competence centre, replace

DIA.NE WIN server hard disc

3518 DATA REGISTRATION IN DIA.NE WIN SERVER FAILED

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 39/40
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
4.1
Failure Checklist

Communication to DIA.NE WIN server has failed Check connection, plug in network
DIA.NE WIN server has failed or is defective cable, check functionality of network
components (cables, DIA.NE WIN
HUB failure server network card, HUB, DIA.NE XT
Software technical problem at DIA.NE WIN server network components), replace
network components.

Check and repair voltage supply,

contact competence centre, replace
DIA.NE WIN server hard disc, replace
DIA.NE WIN server.

Check and repair voltage supply,

contact competence centre, replace
HUB.

Contact competence centre, replace

DIA.NE WIN server hard disc

3561 OVERSPEED (RPS-CONTROL SYSTEM)

speed overshoot afte mains failure Eleminate cause!
speed limit wrongly adjusted

3562 FUEL MIXTURE TEMPERATURE LOW

Electrical control valve in the mixture cooling Check control valve, check controller
circuit Thermostatic control valve in the mixture setting Check control valve, check
cooling circuit control valve interior

3565 GENERATOR POWER SETPOINT MEASURING SIGNAL FAILURE

wire breakage to PLC output monitoring check cables/connections
PLC input defective check PLC input (performed by GE-
PLC output defective JENBACHER)
check PLC output (performed by GE-
JENBACHER)

3566 GENERATOR POWER FACTOR SETPOINT MEASURING SIGNAL FAILURE

wire breakage to PLC output monitoring check cables/connections
PLC input defective check PLC input (performed by GE-
PLC output defective JENBACHER)
check PLC output (performed by GE-
SprungMarke!!!11251080203
JENBACHER)

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 40 / 40
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5 Description
5.1.1
Description

1 General ....................................................................................................................................................... 1
2 Engine principle......................................................................................................................................... 1
3 Crankcase housing ................................................................................................................................... 1
4 Oil pan......................................................................................................................................................... 1
5 Cylinder liners............................................................................................................................................ 1
6 Cylinder heads........................................................................................................................................... 2
7 Crankshaft.................................................................................................................................................. 3
8 Connecting rod.......................................................................................................................................... 4
9 Vibration damper...................................................................................................................................... 5
10 Main and connecting rod bearing shells: ............................................................................................. 5
11 Piston .......................................................................................................................................................... 6
12 Gear train ................................................................................................................................................... 6
13 Valve timing gear...................................................................................................................................... 7
14 Exhaust gas turbocharger ...................................................................................................................... 9
15 Engine oil pump......................................................................................................................................... 9
16 Engine cooling water pump .................................................................................................................. 11
17 Starter ....................................................................................................................................................... 11
18 Gas quantity controller.......................................................................................................................... 11
18.1 Static mixer................................................................................................................................................................. 12

1 General
The GE Jenbacher gas engine works on the 4-stroke principle and is a water-cooled 16 12-cylinder V-engine
(60°) with an exhaust gas turbocharger for pressure charging the intake mixture.

2 Engine principle
GE Jenbachergas engines use the LEANOX method, which is a further development of the lean-mix engine
principle.
Lean-mix engines are supplied with a gas mixture with an air surplus to minimise emissions already during the
combustion stage.

3 Crankcase housing
The spheroidal graphite housing features side crankcase covers that provide easy access during assembly/
disassembly.
On the flywheel-side, the crankcase is sealed off (oil tight and dust proof) by the gearbox and on the opposite
side by the crankcase cover.

4 Oil pan
The oil pan is made out of welded steel plate and closes off the bottom of the crankcase.

5 Cylinder liners
The cylinder liners are wet and can be replaced individually. They are spun cast and are inserted into the
cylinder block from above.
As they heat up, they are free to expand downwards.
The water room and the power module are separated by O-rings on the outside of the cylinder liners.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 27/06/2013
Index: 10 Page No.: 1/12
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.1.1
Description

1 4

Type 6 cylinder liner

① O-ring ④ Water room
② Scraper ring ⑤ engine oil duct (piston cooling nozzle)
③ Cylinder head gasket ⑥ Power module

6 Cylinder heads
The water-cooled cylinder heads - which can be replaced separately - are all equipped with two inlet and
exhaust valves, a pre-combustion chamber with a pre-combustion chamber gas valve and a spark plug each.
The intake and exhaust valves feature a valve rotation device (Rotocaps). The pressed valve seat rings can be
replaced.

5 6

4 7 8
Cylinder head section, type 6, right
① valve guide ⑥ valve spring
② Exhaust gas ⑦ Intake valve
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 27/06/2013
Index: 10 Page No.: 2 / 12
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.1.1
Description

③ Water room ⑧ valve seat

④ Exhaust valve ⑨ Mixture
⑤ Rotocap

Cylinder head section, types 6 and 624, left front

① Spark plug ④ Water room
② Mixture ⑤ Exhaust gas
③ Precombustion chamber ⑥ Pre-combustion chamber gas valve

7 Crankshaft
The drop-forged crankshaft runs on 9 bearings, is statically and dynamically balanced and has bolted-on
counterweights. All bearing journals have been surface hardened and polished.
One of the main bearings is designed as a guide bearing and takes up the axial forces exerted by the
crankshaft.
The crankshaft main bearings are lubricated via oil ducts in the crankcase.
The crankshaft is fitted at one end with a balanced flywheel with the ring gear for starting, and a vibration
damper at the other end.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 27/06/2013
Index: 10 Page No.: 3/12
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.1.1
Description

1 2 3

4 5
Crankshaft section, types 6 and 624
① Connecting rod bearings ④ Crankshaft toothed gear
② Oil ducts ⑤ counterweight
③ Main bearing

8 Connecting rod
The connecting rods are drop-forged and quenched and tempered. They are separated diagonally across the
big-end and have serrated joins. The cross-section is designed as an I-profile to provide maximum stability of
the connecting rods.
The big-end bearing shells are replaceable plain bearings. The small-end bushings are pressed in. The big-end
bearings are lubricated via oil ducts in the crankshaft.
The gudgeon pins are supplied with oil from the piston cooling nozzles.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 27/06/2013
Index: 10 Page No.: 4 / 12
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.1.1
Description

Connecting rod

9 Vibration damper
A viscous damper is used to reduce rotational vibrations of the crankshaft.
The viscous damper is a fully closed housing containing a flywheel. The cavities between the housing and the
flywheel are filled with silicone oil.
2

Vibration damper section

① Cavities ③ Housing
② Flywheel mass

10 Main and connecting rod bearing shells:

Two-part, replaceable crankshaft main bearings and connecting rod bearings.
Sputter bearing Grooved ball bearing 3-metal bearing
Connecting rod upper bearing shell x
bearings
lower bearing shell x
Main bearing upper bearing shell x
lower bearing shell x

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 27/06/2013
Index: 10 Page No.: 5/12
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.1.1
Description

11 Piston
The light metal alloy pistons with cooling duct are equipped with a plain compression ring, a taper face
compression ring and an oil control ring with expander.
Cooling oil is supplied via fixed spray nozzles mounted in the crankcase.
1

Types 612, 616 and 620 piston section

① Oil control ring with expander ⑤ Piston
② Plain compression ring ⑥ Piston pin
③ Cooling oil duct ⑦ Injection nozzle
④ Taper face compression ring

12 Gear train
The gear driving the engine oil pump and the camshaft can be found on the flywheel side. The crankshaft
toothed gear, the intermediate gears and the camshaft timing gear all have timing marks to ensure that the
timing is correctly adjusted.
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 27/06/2013
Index: 10 Page No.: 6 / 12
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.1.1
Description

Gear train (flywheel end)

Type 6 and 624 gear train diagram

① Camshaft timing gear ③ Driving gear of engine oil pump
② Intermediate gear ④ Crankshaft toothed gear

13 Valve timing gear

The camshaft runs on 9 bearings in replaceable bearing bushes and is driven by the crankshaft via
intermediate gears. The rocker arms on the intake and exhaust valves are operated by the camshaft by means
of tappets and push rods. An adjustment bolt on each rocker arm is used for accurate adjustment of the tappet
clearance. Pressurised oil is used to lubricate the tappets and the rocker arm mountings. The oil is supplied to
each rocker arm through a bore in the push rod. The other moving parts in the cylinder head are lubricated by
the spray oil emerging at the rocker arm mountings.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 27/06/2013
Index: 10 Page No.: 7/12
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.1.1
Description

Type 6 valve timing gear, Fig. 1

① Adjustment bolt (valve play) ③ Exhaust valve
② Valve stems ④ Rocker arm bracket

Type 6 valve timing gear, Fig. 2

① Adjustment bolt ③ Rocker arm (inlet)
② Rocker arm (exhaust) ④ Push rod

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 27/06/2013
Index: 10 Page No.: 8 / 12
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.1.1
Description

14 Exhaust gas turbocharger

The exhaust gases entering the turbine housing drive the turbine wheel, and therefore also the compressor
impeller which sits on the same shaft as the turbine wheel. The compressor impeller draws in the gas/air
mixture from the gas/air mixer and pushes it into the engine intake chamber via the mixture cooler (mixture/
water heat exchanger) and the throttle valve.
The exhaust gas turbocharger is lubricated by the engine lubricating system.

Types 6 and 624 turbocharger

① Compressor impeller ④ Engine oil
② Mixture ⑤ Exhaust gas
③ Plain bearing ⑥ Turbine wheel

15 Engine oil pump

GE Jenbacher engines are equipped with a forced feed lubrication system.
A mechanical toothed gear pump is used as the engine oil pump.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 27/06/2013
Index: 10 Page No.: 9/12
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.1.1
Description

Types 612, 616 and 620 engine oil pump

① Driving gear ③ Oil pump gear wheel
② O-ring

Types 6 and 624 engine oil pump

① Engine oil (to the oil cooler) ③ Engine oil (from the oil pan)
② Control oil

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 27/06/2013
Index: 10 Page No.: 10 / 12
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.1.1
Description

16 Engine cooling water pump

The electrical pump provides for cooling-water circulation in the closed engine cooling water system.

17 Starter
One or more electric sliding gear starter motors.

18 Gas quantity controller

The gas volume controller is an active gas proportioning valve and is part of the LEANOX system.
To create a combustible air-gas mixture, fuel gas is added to the intake air through the gas proportioning
valve.
(4x for blast furnace bas [BFG], 1x coke gas [COG], 1x natural [NG])
To change the air ratio λ, the required gas amount is entered via the CAN bus (dia.ne).
Actual air charge supplied for combustion
Air ratio λ = ————————————————————————
Stoichiometrically required air charge

Gas quantity controller

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 27/06/2013
Index: 10 Page No.: 11/12
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.1.1
Description

18.1 Static mixer

Gas mixer [624TSTC]

① air ④ Blowby
② to the exhaust gas turbocharger ⑤ Bypass flow
③ Main gas mixture
In the gas mixer, a fuel gas is added to the intake air via a gas aperture in order to create a combustible air-gas
mixture. The gas mixer is used to achieve an optimal fuel gas/intake air mixture (intake air, blast furnace gas
[BFG] and admixture of natural gas [NG] and coke gas [COG]).
SprungMarke!!!81064793307798027

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 27/06/2013
Index: 10 Page No.: 12 / 12
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.1.2
Technical Data - Engine

Build data:
Method of operation of 4-stroke spark ignition engine
mixture pressure-charging with exhaust gas turbocharger
Direction of rotation viewed towards flywheel anti-clockwise
Cylinder arrangement cylinder V-engine (60°)
Number of cylinders 16
Bore mm 190
Stroke mm 220
Total displacement l 99,8
Compression ratio Epsilon 12,0

Standard reference conditions:

Air pressure mbar 1000*)
Air temperature °C 25
Relative humidity % 30
*) or 100 m above mean sea level
Loss of engine performance:
Altitude: 0,7 % for every additional 100m above 500 m
Temperature: 2 % for every additional 1°C over 30 °C

Operational data:
Nominal revolutions rpm 1500
Average piston speed at nominal engine speed m/s 11
Lubricating oil operating pressure bar ca. 6
Lubricating oil minimum pressure 1) bar 2-4
Cooling water outlet temperature at full load °C 95
Lubricating oil consumption (average at full load) g/kWh 0,3
1) The minimum lubricating oil pressure depends on engine oil temperature and engine speed and lies in the 2
– 4 bar range.
Weight/dimensions:
Engine weight (dry) kg 10000
Engine weight (operative) kg 10700
Length mm 3950
width mm 1680
height mm 2605

Capacities:
Engine lubricating oil: l 530
Engine Cooling water l 270

Field emissions:
(Electromagnetic radiation)

All GE Jenbacher engines satisfy the requirements specified in the standards:

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Konrad Schartner Responsible: Dokumentation Release date: 27/06/2013
Index: 6 Page No.: 1/2
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.1.2
Technical Data - Engine

▪ DIN EN 61000-6-1: Electromagnetic Compatibility (EMC) - Part 6-1:

Generic Standards – immunity for residential, commercial and light industrial environments.
▪ DIN EN 61000-6-4: Electromagnetic compatibility (EMC) – Part 6-4:
Generic Standards: interference emission for industrial environments.

Example showing the result of an EMC measurement on a GE Jenbacher engine

① Statutory limit ③ background interference level
② Engine interference level

Type 616 engine diagram

All data refer to an engine running at full load under the given temperature conditions.
The operating materials and system peripherals must conform to TI 1100-0110 "Requirements for GE
Jenbacher Gas Engines".
SprungMarke!!!45035996289463179

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Konrad Schartner Responsible: Dokumentation Release date: 27/06/2013
Index: 6 Page No.: 2 / 2
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.1.3
Engine diagrams

1 Key to engine diagrams:

In order to improve the clarity of the diagrams, any media entering or exiting the engine are indicated by an
arrow.

Different letters are used to identify different media (e.g. = fuel gas inlet). In some cases, a digit is added to
the letter to give even more detailed information.
The tip of the arrow indicates the flow direction of the media.

Fuel gas:
Fuel gas entry

Intake air:
Intake air

Air-gas mixture
Air-gas mixture

Water:
Engine cooling water, engine cooling water entering

Engine cooling water exiting

Water entering (mixture/water heat exchanger stage 1)

Water exiting (mixture/water heat exchanger stage 1)

Water entering (mixture/water heat exchanger stage 2)

Water exiting (mixture/water heat exchanger stage 2)

Engine oil :
Engine oil outlet (to engine oil/water heat exchanger)

Engine oil outlet (to engine oil/water heat exchanger)

Exhaust gas:
Exhaust gas outlet

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Konrad Schartner Responsible: Dokumentation Release date: 27/06/2013
Index: 6 Page No.: 1/7
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.1.3
Engine diagrams

2 Engine diagrams

D 1

DV
5

11
C
12

① Engine cooling water return line ⑫ Piston

② Pre-combustion chamber gas supply line ⑬ Piston pin
③ Camshaft ⑭ Cylinder liner
④ Roller tappet ⑮ Connecting rod
⑤ Push rod ⑯ Right-hand engine cooling water duct
⑥ Rocker arm (exhaust valve) ⑰ Right-hand main engine oil duct
⑦ Rocker arm (intake valve) ⑱ Piston cooling nozzle
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Konrad Schartner Responsible: Dokumentation Release date: 27/06/2013
Index: 6 Page No.: 2 / 7
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.1.3
Engine diagrams

⑧ Valve stems ⑲ Crankshaft with counterweight

⑨ Engine oil duct ⑳ Crankcase housing
⑩ Spark plug Ⓐ Engine oil pan
⑪ Intake chamber

C W3 C
7
W2
W1 8

3 W
N M 9

6 O
10
W W
11

① Mixture reservoir ⑦ Exhaust gas turbocharger

② Heat exchanger mixture/water (1st and 2nd ⑧ Actuator
stage)
③ Insulated exhaust gas manifold ⑨ Starter
④ Exhaust gas turbocharger bypass ⑩ Vibration damper with protective cage
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Konrad Schartner Responsible: Dokumentation Release date: 27/06/2013
Index: 6 Page No.: 3/7
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.1.3
Engine diagrams

⑤ Engine oil pump ⑪ Engine oil pan

⑥ Engine oil filter

V V

8
3

① Intake air filter ⑥ Crankcase ventilation

② Rocker cover ⑦ Motorölversorgungsleitung (Abgasturbolader)
③ Cylinder head ⑧ Insulated exhaust gas manifold
④ Starter ⑨ Engine oil pump
⑤ Engine oil pan ⑩ Toothed flywheel

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Konrad Schartner Responsible: Dokumentation Release date: 27/06/2013
Index: 6 Page No.: 4 / 7
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.1.3
Engine diagrams

8
V

9
1

4 10

12
D
13

C O
14

W1 15

① Intake air filter ⑨ Starter

② Ignition coil ⑩ Engine oil pan
③ Rocker cover ⑪ Crankcase cover
④ Gas mixer ⑫ Crankcase housing
⑤ Engine cooling water return line ⑬ Insulated exhaust gas manifold
⑥ Exhaust gas turbocharger ⑭ Engine oil filter
⑦ Mixture reservoir ⑮ Heat exchanger mixture/water (1st and 2nd
stage)

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Konrad Schartner Responsible: Dokumentation Release date: 27/06/2013
Index: 6 Page No.: 5/7
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.1.3
Engine diagrams

⑧ Crankcase ventilation

C O 10
3

4 12

5 13

6 14

① Heat exchanger mixture/water (1st and 2nd ⑨ Exhaust gas turbocharger bypass
stage)
② Mixture reservoir ⑩ Engine oil filter
③ Exhaust gas turbocharger ⑪ Engine oil pan
④ Gas mixer ⑫ Crankcase cover
⑤ Ignition coil ⑬ Crankcase housing
⑥ Rocker cover ⑭ Engine oil pump

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Konrad Schartner Responsible: Dokumentation Release date: 27/06/2013
Index: 6 Page No.: 6 / 7
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.1.3
Engine diagrams

⑦ Engine cooling water return line ⑮ Insulated exhaust gas manifold

⑧ Intake air filter ⑯ Crankcase ventilation

SprungMarke!!!45035996292656651

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Konrad Schartner Responsible: Dokumentation Release date: 27/06/2013
Index: 6 Page No.: 7/7
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.1.4
Engine oil system

1 Engine oil system ...................................................................................................................................... 1

1.1 Crankcase engine oil circuit ................................................................................................................................. 2
1.2 Engine oil supply to exhaust gas turbocharger .......................................................................................... 3
2 Automatic topping up of engine oil ....................................................................................................... 3

1 Engine oil system

The mechanical gear pump (engine oil pump) sucks engine oil from the engine oil pan and passes it under
pressure through an external line to the engine oil cooler.
In the engine oil cooler (engine oil/water heat exchanger) the thermal energy of the engine oil is transferred to
the water circuit.
After the oil has passed through the oil cooler, it is cleaned in the oil filter, from where it is then passed on to the
lubricating points.
The engine lubricating oil pump is flow-controlled using a pressure regulator in order to supply the correct
engine lubricating oil pressure. The pressure regulator in turn is controlled via a control oil line from the right
main engine oil duct.
Engine oil :
Engine oil outlet (to engine oil/water heat exchanger)

Engine oil outlet (to engine oil/water heat exchanger)

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 27/06/2013
Index: 5 Page No.: 1/4
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.1.4
Engine oil system

E.03-P-001 Mechanical engine oil pump | pump (engine lubricating oil)

E.03-YPC-003
M.03-M-002 Engine oil pump - AC preliminary lubrication + continued cooling | engine (lubricating oil
for set)
M.03-P-002 Engine oil pump - AC preliminary lubrication + continued cooling | pump (lubricating oil for
set)
M.03-M-003 Engine oil pump - AC preliminary lubrication + continued cooling | engine (lubricating oil
for set)
M.03-P-003 Engine oil pump - AC preliminary lubrication + continued cooling | pump (lubricating oil for
set)
E.08-VT-001 Exhaust gas turbocharger | compressor (air/fuel gas mixture engine)
E.08-VT-002
E.08-F-001 Engine oil filter |filter (lubricating oil for set)
1 Non-return valve 3 Engine oil pan
2 Right-hand main engine oil gallery

1.1 Crankcase engine oil circuit

The cooled and cleaned engine oil is fed to the left and right main engine oil ducts in the crankcase via a duct
in the casing cover (damper side).
The crankshaft main bearings are supplied with engine oil through bores in the crankcase via the left main
engine oil duct.
Engine oil is then distributed from the crankshaft main bearings to the big-end bearings via bores in the
crankshaft.
Two engine oil ducts are arranged parallel to the camshaft, and they are supplied with oil from the main engine
oil duct via a duct in the gearbox. These two ducts are designed to supply engine oil to the camshaft and the
timing gear.
Oil is supplied to the piston cooling nozzles via both main engine oil ducts.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 27/06/2013
Index: 5 Page No.: 2 / 4
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.1.4
Engine oil system

1 Right main engine oil duct 2 Piston cooling nozzle

1.2 Engine oil supply to exhaust gas turbocharger

The exhaust gas turbochargers are supplied with engine oil via external lines.

2 Automatic topping up of engine oil

The oil pan engine oil level can be read off at the inspection glass for engine oil level monitoring. If the oil level
drops below a fixed minimum value, then the solenoid valve opens and fresh oil flows from the fresh oil tank
into the oil pan. The solenoid valve closes when the oil level reaches a fixed upper limit.
Engine oil :
Engine oil drain (connection to used oil tank)

Engine oil refill (connection to fresh oil tank)

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 27/06/2013
Index: 5 Page No.: 3/4
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.1.4
Engine oil system

M.03-LI-001 Engine oil level in the oil pan | level sensor (lubricating oil for set)
M.03-YCS-001 Solenoid valve - automatic engine top-up | valve open/shut (lubricating oil for set)
1 inspection glass 4 Connection to engine oil pan
2 3-way cock 5 Crankcase venting line
3 ball valve
SprungMarke!!!36028797041112843

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 27/06/2013
Index: 5 Page No.: 4 / 4
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.1.5
Cooling water system

1 Engine cooling water circuit ................................................................................................................... 1

2 mixture cooling circuit ............................................................................................................................. 1
3 Engine cooling water preheating........................................................................................................... 2

1 Engine cooling water circuit

The electrical pump pumps engine cooling water through the two main water ducts in the engine block, and
from there through the cylinder block cooling jacket.
The cylinder heads are supplied with cooling water via vertical bores. Water flows through the cylinder heads,
cools them and is then fed back to the pump via the engine cooling water return line.

Key to Figure:
Engine cooling water, engine cooling water entering

Engine cooling water exiting

2 mixture cooling circuit

In engines of this performance class, the air-gas mixture must be cooled to a maximum temperature of 50 °C.
The mixture cooler is designed with 2 stages, with the 2nd stage being cooled with cold water of approx. 40 °C.

Key to Figure:
Water entering (mixture/water heat exchanger stage 2)

Water exiting (mixture/water heat exchanger stage 2)

Water entering (mixture/water heat exchanger stage 1)

Water exiting (mixture/water heat exchanger stage 1)

N M

On engine version C21 (biogas), the low-temperature mixture cooling circuit (stage 2) is not required).

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 27/06/2013
Index: 3 Page No.: 1/2
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.1.5
Cooling water system

3 Engine cooling water preheating

Pre-heating the engine cooling water allows the engine to be put under load immediately after the engine is
started.

The engine cooling water is heated to approx. 60 °C.

This can be achieved either by an electric heater unit or a heat exchanger (hot water or vapour).
An electric pump is used to ensure that the warm cooling water is circulated around the engine’s water rooms.

Key to Figure:
Engine cooling water, engine cooling water entering

Engine cooling water exiting

The cooling water pre-heating system is not an alternative to antifreeze additive in the cooling water!
SprungMarke!!!18014398532067723

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 27/06/2013
Index: 3 Page No.: 2 / 2
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.1.6
Fuel gas system

1 General description
Fuel gas enters the air-gas mixer vertically, where it is mixed with air and then passed on through a pipe to the
exhaust gas turbochargers. After the exhaust gas turbochargers, the compressed air-gas mixture is collected
again, and then it flows through the air-gas mixture cooler (air-gas mixture/water heat exchanger).
After the mixture cooler, the air-gas mixture flows past the throttle valve which, depending on its setting,
controls the amount of throughput into the intake chamber in the crankcase. The mixture is then distributed
from the intake chamber to the individual cylinders.

2 Exhaust gas turbocharger bypass

The exhaust gas turbocharger bypass connects the pressure side and the suction side of the intake pressure
charging system (exhaust gas turbocharger). Throughput is controlled by electrically operated valves.
The exhaust gas turbocharger bypass has two functions. Firstly, it is designed to protect the exhaust gas
turbocharger against the effects of pumping, and secondly it is used to control the power output during
operation, as a result of which the level of control can be significantly improved.

3 Pre-combustion chamber gas system

In order to achieve even burning of the mixture, GE Jenbacher engines use the prechamber principle. The gas
pressure control line supplies the pre-combustion chamber gas valves with fuel gas via the pre-combustion
chamber distribution line. The spark plug initiates combustion in the pre-combustion chamber, which then
propagates evenly throughout the combustion chamber.

Key to Figure:
Fuel gas:
Fuel gas inlet (pre-combustion chamber gas supply line)

Fuel gas entering (pre-combustion chamber gas

supply line)

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 27/06/2013
Index: 9 Page No.: 1/3
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.1.6
Fuel gas system

Prechamber gas valve

Prechamber

4 Schematic diagram – fuel gas system

Fuel gas:
Fuel gas entry

Fuel gas inlet (pre-combustion chamber gas supply line)

Number Description
E.01-YVD-001 Fuel gas controller (fuel gas - engine)
E.01-YVD-002
E.08-YCI-002 Throttle valve (air/fuel gas mixture - engine)
E.05-F-001 Intake air filter (air - engine)

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 27/06/2013
Index: 9 Page No.: 2 / 3
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.1.6
Fuel gas system

Number Description
E.08-VT-001 Exhaust gas turbocharger (air/fuel gas mixture - engine)
E.08-VT-002
E.08-W-001 Heat exchanger - mixture/water (air/fuel gas mixture - engine)
E.08-W-002
E.08-YCI-001 Throttle valve (air/fuel gas mixture - engine)
1 Intake line
2 Pre-combustion chamber gas supply line
3 Pre-combustion chamber gas valve

SprungMarke!!!72057594058523403

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 27/06/2013
Index: 9 Page No.: 3/3
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.2.1
Technical data - Facility

1 Power and degrees of efficiency

Qzu/Qm Energy supplied/mechanical ±5% kWh/kWh 2,18
pme Effective mean pressure bar 22,0
Pm Mechanical power kW 2745
Blocked ISO standard power ICFN according to ISO 3046
Pel Electric power output at cos phi = 1 kW 2654
ηel Electrical efficiency % 44,46
ηtherm Therm. efficiency % 44,46
ηges Total efficiency % ---

2 Standard reference conditions

Air pressure mbar 1000*)
Air temperature °C 25
Relative humidity % 30
*) or 100 m above mean sea level

3 Exhaust system
Maf Exhaust gas flow, moist --- kg/h 14548
LP Residual sound pressure level when operating a module dB (A) at 10m ..
distance
NOx Nitrogen oxides mg/m3 2) 500
CO Carbon monoxide mg/m3 2) -
1) 3
NMHC Non-methane hydrocarbons mg/m 2) -
1)
at a total installation emission of > 3 kg/h.
The exhaust gas emission values refer to dry exhaust gas with 5% O2, in standard reference conditions,
during which the gas engine should, at the very least, be operated at half load.
2)
Exhaust gas emission values expressed in mg/m3 for dry exhaust gas, in standard reference conditions, with
5% O2.

4 Fuel gas system

Mz Methane number 94|80
3
Hu Calorific value kWh/m 9,5
3
Vgas Fuel gas volume --- m /h 628

5 Water circuit
Vww Cooling Water --- m3/h 65,9
3
Vgk Mixture cooling water --- m /h 30

6 Intake air
Vl Combustion air --- m3/h 10938

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Huber Responsible: Dokumenation Release date: 25/02/2015
Index: 5 Page No.: 1/3
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.2.1
Technical data - Facility

7 Energy balances
Ambient temperature 30 °C --- °C
Qag Heat exchanger exhaust gas/water - °C ±8% kW 0 ---
Qgk1 Heat exchanger mixture / water (1st stage) ±8% kW 690 ---
Qgk2 Heat exchanger mixture / water (2nd stage) ±8% kW 212 ---
Qgetr Transmission --- kW --- ---
QkW Engine cooling-water/water heat exchanger ±8% kW 413 ---
Qoel Engine-oil/water heat exchanger ±8% kW 267 ---
Qre Residual heat --- kW --- ---
Qst Radiant heat (engine and generator) --- kW 202 ---
Qww Total usable thermal output ±8% kW 1370 ---

8 Temperatures
Hot water return temperature +0 °C 75,0
(technical diagram A) -5
Hot water inlet temperature + --- °C 95,0
(technical diagram B) - ---
Inlet temperature + --- °C 40,0
(heat exchanger mixture / water, stage 2) - ---
(Technical diagram M)
Outlet temperature + --- °C 46,8
(heat exchanger mixture / water, stage 2) - ---
(Technical diagram N)

9 Weight
Mges tr Total weight, dry (module container) kg 30900
Mges gf Total weight, filled (module container) kg 32300
MMot tr Engine weight dry kg 13900
Mges gf Engine weight filled kg ---
1)
MAggr Module weight kg ---
MGen + Getr Weight of generator and transmission kg ---
MGen Generator weight kg 8700
1)
In standard series 6 engines (version E), the generator is mounted on a separate frame. Its weight is therefore
not included in this value.

10 Dimensions
Length mm ~10200
Width mm ~2000
Height mm ~3900

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Huber Responsible: Dokumenation Release date: 25/02/2015
Index: 5 Page No.: 2 / 3
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.2.1
Technical data - Facility

11 Lacquer coat
LMot Engine RAL No. 6018
LGen Generator RAL No. 6018
LFra Frame RAL No. 6018
LCon Container RAL No. ---
LSch Switch cabinet RAL No. 7035

The operating materials and system peripherals must conform to TI 1100-0110 "Requirements for GE
Jenbacher Gas Engines".
SprungMarke!!!36028797034667275

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Huber Responsible: Dokumenation Release date: 25/02/2015
Index: 5 Page No.: 3/3
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.2.2
Module drawings and Technical diagram

1 Key to module drawings and technical diagram ................................................................................ 1

1.1 Standards and technical specifications.......................................................................................................... 1
1.2 Connections ................................................................................................................................................................. 1
1.3 Key to lines and components .............................................................................................................................. 4
1.3.1 Key to components 4
1.3.2 Key to lines 6
1.4 GE Jenbacher - Tag number ................................................................................................................................ 7
1.4.1 System 7
1.4.2 Circuit 7
1.4.3 Type 8
1.4.4 Number 10
1.4.5 Part 10
1.4.6 Engine identifier 10
1.5 Component identification.................................................................................................................................... 10
1.5.1 Equipment, valves 10
1.5.2 Fittings 10
1.6 Process functions .................................................................................................................................................... 11
1.7 Installation components ...................................................................................................................................... 12

1 Key to module drawings and technical diagram

1.1 Standards and technical specifications

The following standards and technical specifications, among others, have been taken into account for the
representations in technical diagrams and installation diagrams
DIN 2429-1 Symbolic representation of pipework components for use on engineering
drawings; basic requirements
DIN 2429-2 Symbolic representation of pipework components for use on engineering
drawings; functional representation
DIN 2481: Thermal power plants; graphical symbols
DIN 19227: Graphical symbols and identifying letters for process control engineering: symbolic
representation for functions
DIN ISO 16016 Technical product documentation - Protection notices for restricting the use of
documents and products
DIN EN ISO 10628 Flow diagrams for process plants - General rules (ISO 10628:1997), German version
EN ISO 10628:2000
IEC PAS 62424 Representation of process control engineering requests in P&I diagrams and data
exchange to PCE-CAE tools
EN 60079-10 Electrical equipment for potentially explosive gas atmospheres
Part 10: Zoning of hazardous explosive areas

1.2 Connections

D
Different letters are used to identify different media (e.g. = fuel gas entry). In some cases a digit is added to
the letter to give even more detailed information.
The same systematics are used in the technical diagram to indicate any media entering or exiting.
Fuel gas: Fuel gas inlet
D

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 1/20
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.2.2
Module drawings and Technical diagram

Fuel gas entering (pre-combustion chamber gas supply line)

Exhaust, breather and air-bleed lines in the fuel gas

Ex-zone breather line

Ex-zone safety shut-off valve

Ex-zone safety blow-off valve

Exhaust line (gas pressure control system)

Washing connection (to the intercooler)

Washing connection (from the intercooler)

Fuel: Diesel fuel inlet

Diesel feed
Y1

Diesel derivation
Y2

Intake air: Intake air

Intake air, bank A

Intake air, bank B

Exhaust gas tract scavenging air

Compresse Compressed air (starting equipment)

K1
d air:
Compressed air (Control air)
K2

Compressed air (service)

Water: Hot water inlet (high-temperature)

Hot water outlet (high-temperature)

Discharge
E

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 2 / 20
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.2.2
Module drawings and Technical diagram

Condensation drain
F

Safety valve (engine cooling water circuit or mixture cooling water circuit)
G

Safety valve (hot water circuit)

Filling connection (engine cooling water circuit or mixture cooling water circuit)
L

Warm water enters (low temperature, mixture/water heat exchanger, 2nd stage)
M

Warm water enters (low temperature, mixture/water heat exchanger, 2nd stage)
N

Water inlet (fuel gas preheating)

Water outlet (fuel gas preheating)

Raw water inlet

Raw water outlet

Engine cooling water inlet

Engine cooling water outlet

Water entering (mixture/water heat exchanger 1st stage)

Water outlet (mixture/water heat exchanger 1st stage)

Engine cooling water (draining/topping-up)

Engine oil: Engine oil topping up (connection to fresh oil tank)

Engine oil drain (connection to used oil tank)

Engine oil outlet (to engine oil/water heat exchanger)

Engine oil inlet (from engine oil/water heat exchanger)

Lubricating Lubricating oil (from generator kit)

X1
oil:
Lubricating oil (to generator kit)
X2

Lubricating oil (from generator kit)

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 3/20
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.2.2
Module drawings and Technical diagram

Lubricating oil (from generator kit)

Exhaust Exhaust gas outlet

C
gas:
Exhaust gas inlet
C2

1.3 Key to lines and components

The following list contains a selection of the symbols used in the technical diagram. In addition, the symbolic
representations are accordance with DIN 2481 and DIN 19227-1 apply.

1.3.1 Key to components

processed on-site, on the module

processed in the local control system

processed in the GEJ control system

Control function (incorporated in the local control system)

Control function (incorporated in the GEJ control system)

Non-return valve

Ball valve

Compensator

3-way valve

JENBACHER Interface
GE Jenbacher limit of supply, and/or GE Jenbacher scope of supply
Pressure expansion vessel

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 4 / 20
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.2.2
Module drawings and Technical diagram

Oil reservoir

Pressure vessel, gas

Piston

Catalytic converter

Codibox

Single-circuit table cooler

Dual-circuit table cooler

Thermal reactor

Air-cooled compressor

Condensate separator

Cooling tower

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 5/20
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.2.2
Module drawings and Technical diagram

Chimney

5-way valve

4-way valve

Explosion protection valve

Biogas cooler

1.3.2 Key to lines

Air

Fuel gas

Exhaust gas

Crankcase ventilation

Engine cooling water / hot water

Raw water

Engine oil

Control oil

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 6 / 20
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.2.2
Module drawings and Technical diagram

Control impulse

1.4 GE Jenbacher - Tag number

The GE Jenbacher tag numbers are based on a logical combination of alphanumeric blocks. This number
provides general information on the component's position and function. More detailed information can be
found in the technical diagram and circuit diagram.
The GE Jenbacher tag number consists of a total of 4 blocks and 2 optional identifiers.

6 1 4 5

01 E . 02 - TI - 001 [01]
2 3

① System ④ Number
② Circuit ⑤ optional: Part
③ Type ⑥ optional: Engine identifier

1.4.1 System
Letters Description
E Engine
M Module
O ORC
P System
G Generator

1.4.2 Circuit
Sign Designation
00 Engine block
01 Fuel gas
02 Exhaust gas
03 Lubricating oil / fresh oil / waste oil
04 Engine cooling water
05 Intake air
06 High temperature circuit
07 Low temperature circuit
08 Air/Fuel-gas mixture
09 Emergency cooling
10 Customised

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 7/20
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.2.2
Module drawings and Technical diagram

Sign Designation
11 Thermo oil
12 ORC high-temperature circuit
13 ORC low-temperature circuit
14 Pre-combustion chamber gas system
15 Nitrogen purging installation
16 Thermal reactor
17 Ventilation system
18 Transmission+accessories
19 Activated carbon
20 TSA
21 Water (external source)
22 Generator rotor
23 Generator stator
24 Chemicals
25 Steam
26 Waste water
27 Cooling tower circuit
28 Hot water
29 Urea solution
30 Secondary High-temperature circuit
31 Starter air
32 Control air
33 Service air
34 ...
35 Water/oil mixture
36 Dirty water
37 Cooling circuit
50 Diesel

1.4.3 Type
Sign Designation
A Generator
AI Vibration sensor
B Container
DS Steam boiler
DV Consumer (customer)
EI Ignition Control
F Filter
FC Frequency converter
FI Flow indicator
FL Flow limiter
FQ Flow meter
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 8 / 20
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.2.2
Module drawings and Technical diagram

Sign Designation
FS Flow switch
GL Inspection glass
IP I/P converter
JI Analysis equipment
KH Ball valve
KHF Ball valve with spring return
LI Level sensor
LS Level switch
M Engine
NS Engine On/Off
NC Engine frequency controlled
P Pump
PDS Differential-pressure switch
PI Pressure indicator
PID Differential pressure sensor
PS Pressure switch
QC Volumeter
QQ Calorimeter
S Switch
SI Pickup
TC Temperature control
TI Temperature indicator
TS Temperature switch
US Leak testing
USZ Ignition
VB Fan
VT Compressor
W Heat exchanger
XCO Compensator
XFH Hose
XSA Silencer
XWI Exhaust gas heat exchanger water injection
Y Driving motor (piston machine)
YCI Valve with position controller
YCS Valve Open/Closed
YCZ Valve Open/Closed safety relevant
YFA Flame disruption protection
YFC Bundle control valve/Shut-off valve
YPC Filling valve
YPS Safety valve
YRC Non-return valve
YTC Temperature control valve

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 9/20
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.2.2
Module drawings and Technical diagram

Sign Designation
YVD Fuel gas regulator

1.4.4 Number
The 3-digit number is used to identify clearly the component on the installation.
Numbers after 600 are reserved for customer-specific requirements.

1.4.5 Part
Components that are installed more than once are considered parts. This guarantees their identity on the
installations.

1.4.6 Engine identifier

On multiple-engine power plants, components are clearly allocated to a particular engine by the use of the
engine identifier. The engine part number link can be seen on the technical diagram.

1.5 Component identification

All components are identified as per the diagram. For purposes of identification, two methods are used.

1.5.1 Equipment, valves

Marking on the component itself. The Tag number is written in a line.

P.02-XSA-001

Example: Exhaust silencer marking P.02-XSA-001

P System (installation)
02 Circuit (exhaust gas)
XSA Type (silencer)
001 Number

1.5.2 Fittings
Marking of fittings in bubbles on the component. The first line describes component type and function. The
second line contains information on position and identity.
M

YCI

E.08.001

Example: Shut-off valve marking E.08-YCI-001

E System (engine)
08 Circuit (air/fuel-gas mixture)
YCI Type (valve with position controller)
001 Number

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 10 / 20
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.2.2
Module drawings and Technical diagram

1.6 Process functions

The letters H and L as a PCE process function designate the upper or lower limits and are used in combination
with A, S or Z. S or Z designate an automatic process. A is used for an operator action when a set limit is
reached. Each level (e.g. H, HH, HHH) can be combined with an alarm and a switching function (e.g. AS or AZ).
The switching point positions are next to the respective bubbles.

LLL or HHH ➔ Level 3

LL or HH ➔ Level 2
L or H ➔ Level 1

A ➔ Issues a warning or alarm message

AZ ➔ Triggers a safety-relevant action and trips the safety circuit (Emergency Stop)
AS ➔ Describes a switching point with a controlled sequence

Example: Pressure measurement with High Alarm and Low and Low-Low alarms with switching points
If a pressure of 5.2 bar is exceeded, a warning
PI 5,2bar AH message appears on the DIANE control system.
3,2bar AL If the pressure drops below 3.2 bar, a warning
M.03.001 3,0bar ASLL message appears on the DIANE control system.
If the pressure drops below 3.0 bar an alarm is given
and the engine is shut down.
All pressures stated are relative pressures unless otherwise specified.

Example: Temperature measurement with signal input and five switching points

97°C ASHHH The operating point of the engine cooling water

60°C SHH temperature is designed to be 95°C.
TI 55°C SH If the temperature drops below 37°C the control
M.04.001 56°C SL system issues a warning message "Engine Cooling
37°C ASLL Water Temperature Minimum" and automatic starting
95°C
is blocked.
At 56°C SL (falling), the preheating is switched on. At
55°C SH (rising), the load release is given for starting
the engine. When the switching point of 60°C is
reached, preheating is switched off. A shut-down and
an alarm in the control system occur at the 97°C
ASHHH switching point. If additional signals are
included in a measurement, they are added to the
temperature measuring point or the bubble via a
signal line.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 11/20
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.2.2
Module drawings and Technical diagram

Example: Thermostatic temperature control valve

B This temperature control valve is controlled by a
temperature sensor. The set temperature is 70°C.
AB A If a value of 72°C AH is reached, an alarm is given on
DIANE.

TI 72°C AH
P.06.012

70°C

1.7 Installation components

The components installed in this installation are shown in the Technical Diagram and the installation diagrams,
which are numbered using the GE Jenbacher TAG system. The purpose of this table is to describe these
components and provide the link to the schematic diagram.
Abbreviation Circuit diagram Description Remark
Secti Pa P el.
on ge at designatio
h n

E.00-AI-101 Vibration sensor (Engine block - Knock sensor

[01] Engine)
E.00-AI-101 Vibration sensor (Engine block - Knock sensor
[02] Engine)
E.00-AI-101 Vibration sensor (Engine block - Knock sensor
[03] Engine)
E.00-AI-101 Vibration sensor (Engine block - Knock sensor
[04] Engine)
E.00-AI-101 Vibration sensor (Engine block - Knock sensor
[05] Engine)
E.00-AI-101 Vibration sensor (Engine block - Knock sensor
[06] Engine)
E.00-AI-101 Vibration sensor (Engine block - Knock sensor
[07] Engine)
E.00-AI-101 Vibration sensor (Engine block - Knock sensor
[08] Engine)
E.00-AI-101 Vibration sensor (Engine block - Knock sensor
[09] Engine)
E.00-AI-101 Vibration sensor (Engine block - Knock sensor
[10] Engine)
E.00-AI-101 Vibration sensor (Engine block - Knock sensor
[11] Engine)
E.00-AI-101 Vibration sensor (Engine block - Knock sensor
[12] Engine)

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 12 / 20
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.2.2
Module drawings and Technical diagram

Abbreviation Circuit diagram Description Remark

Secti Pa P el.
on ge at designatio
h n
E.00-AI-101 Vibration sensor (Engine block - Knock sensor
[13] Engine)
E.00-AI-101 Vibration sensor (Engine block - Knock sensor
[14] Engine)
E.00-AI-101 Vibration sensor (Engine block - Knock sensor
[15] Engine)
E.00-AI-101 Vibration sensor (Engine block - Knock sensor
[16] Engine)
E.00-M-001 Engine (Engine block - Engine)
E.00-NS-001 Engine On/Off (Engine block -
Engine)
E.00-PI-025 +M1 52 3 +E1-52B1 Pressure control (Engine block - Crank shaft casing
Engine)
E.00-SI-001 +M1 73 3 +E1-73B2 Pickup (Engine block - Engine) Crankshaft
E.00-SI-002 +M1 73 5 +E1-73B3 Pickup (Engine block - Engine) Crankshaft (Reset)
E.00-SI-005 +M1 73 2 +E1-73B1 Pickup (Engine block - Engine) Camshaft
E.00-USZ-001 +M1 75 0 +E1-75K1 Ignition (Engine block - Engine) MORIS
E.00-USZ-001 +M1 76 0 +E1-76K1 Ignition (Engine block - Engine) MORIS
E.00-USZ-004 Ignition (Engine block - Engine) Antiknock control
E.00-Y-001 Driving motor (piston machine)
(Engine block - Engine)
E.02-TI-001 [01] Temperature control (Exhaust Exhaust gas outlet cylinder head
gas - Engine)
E.02-TI-001 [02] Temperature control (Exhaust Exhaust gas outlet cylinder head
gas - Engine)
E.02-TI-001 [03] Temperature control (Exhaust Exhaust gas outlet cylinder head
gas - Engine)
E.02-TI-001 [04] Temperature control (Exhaust Exhaust gas outlet cylinder head
gas - Engine)
E.02-TI-001 [05] Temperature control (Exhaust Exhaust gas outlet cylinder head
gas - Engine)
E.02-TI-001 [06] Temperature control (Exhaust Exhaust gas outlet cylinder head
gas - Engine)
E.02-TI-001 [07] Temperature control (Exhaust Exhaust gas outlet cylinder head
gas - Engine)
E.02-TI-001 [08] Temperature control (Exhaust Exhaust gas outlet cylinder head
gas - Engine)
E.02-TI-001 [09] Temperature control (Exhaust Exhaust gas outlet cylinder head
gas - Engine)
E.02-TI-001 [10] Temperature control (Exhaust Exhaust gas outlet cylinder head
gas - Engine)
E.02-TI-001 [11] Temperature control (Exhaust Exhaust gas outlet cylinder head
gas - Engine)

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 13/20
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.2.2
Module drawings and Technical diagram

Abbreviation Circuit diagram Description Remark

Secti Pa P el.
on ge at designatio
h n
E.02-TI-001 [12] Temperature control (Exhaust Exhaust gas outlet cylinder head
gas - Engine)
E.02-TI-001 [13] Temperature control (Exhaust Exhaust gas outlet cylinder head
gas - Engine)
E.02-TI-001 [14] Temperature control (Exhaust Exhaust gas outlet cylinder head
gas - Engine)
E.02-TI-001 [15] Temperature control (Exhaust Exhaust gas outlet cylinder head
gas - Engine)
E.02-TI-001 [16] Temperature control (Exhaust Exhaust gas outlet cylinder head
gas - Engine)
E.02-Y-001 Driving motor (piston machine) Turbocharger (exhaust gas side)
(Exhaust gas - Engine)
E.02-Y-002 Driving motor (piston machine) Turbocharger (exhaust gas side)
(Exhaust gas - Engine)
E.03-F-001 Filter (Lubricating oil / fresh oil / Engine oil filter
waste oil - Engine)
E.03-P-001 Pump (Lubricating oil / fresh oil / Mechanical engine oil pump
waste oil - Engine)
E.03-YPC-001 Filling valve (Lubricating oil / fresh
oil / waste oil - Engine)
E.05-F-001 Filter (Combustion Air - Engine) Intake air filter
E.08-F-001 Filter (Air/Fuel-gas mixture - Crankcase ventilation
Engine)
E.08-LI-001 +M1 55 7 +E1-55B4 Level sensor (Air/Fuel-gas Type 6 engine intake line filling
mixture - Engine) limit sensor
E.08-PI-001 +M1 51 3 +E1-51B3 Pressure control (Air/Fuel-gas Charge pressure (mixture
mixture - Engine) pressure p2')
E.08-PI-002 +M1 52 4 +E1-52B2 Pressure control (Air/Fuel-gas Charge pressure before the
mixture - Engine) throttle valve (mixture pressure
p2)
E.08-TI-001 +M1 53 2 +E1-53B1 Temperature control (Air/Fuel- Mixture temperature t2'
gas mixture - Engine)
E.08-VT-001 Compressor (Air/Fuel-gas mixture Exhaust-gas turbocharger
- Engine)
E.08-VT-002 Compressor (Air/Fuel-gas mixture Exhaust-gas turbocharger
- Engine)
E.08-W-001 Heat exchanger (Air/Fuel-gas Heat exchanger (mixture/water)
mixture - Engine)
E.08-W-002 Heat exchanger (Air/Fuel-gas Heat exchanger (mixture/water)
mixture - Engine)
E.08-YCI-001 Valve with position controller (Air/ Throttle valve
Fuel-gas mixture - Engine)
E.08-YCI-101 +M1 68 0 +E1-68M1 Valve with position controller (Air/ Electrical control valve - Exhaust-
Fuel-gas mixture - Engine) gas turbocharger bypass system

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 14 / 20
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.2.2
Module drawings and Technical diagram

Abbreviation Circuit diagram Description Remark

Secti Pa P el.
on ge at designatio
h n
E.08-YCI-102 +M1 68 2 +E1-68M2 Valve with position controller (Air/ Electrical control valve - Exhaust-
Fuel-gas mixture - Engine) gas turbocharger bypass system
E.14-PI-001 +M1 51 4 +E1-51B4 Pressure control (Pre-combustion Pre-chamber gas
chamber gas system - Engine)
G.00-A-001 +G1 5 0 +G1-5G1 Generator (Engine block -
Generator)
M.02-M-001 +M1 13 5 +E1-13M2 Engine (Exhaust gas - Module) Flushing the Exhaust gas
manifold
M.02-NS-001 Engine On/Off (Exhaust gas -
Module)
M.02-PS-001 +M1 55 1 +E1-55B1 Pressure switch (Exhaust gas - Exhaust-gas back pressure
Module)
M.02-TI-001 +M1 36 5 +E1-36B1 Temperature control (Exhaust After exhaust-gas turbocharger
gas - Module)
M.02-TI-002 +M1 36 6 +E1-36B2 Temperature control (Exhaust After exhaust-gas turbocharger
gas - Module)
M.02-TS-001 +M1 16 7 +E1-16B1 Temperature switch (Exhaust gas Flushing the Exhaust gas
- Module) manifold
M.02-VB-001 Fan (Exhaust gas - Module) Flushing the Exhaust gas
manifold
M.02-YCS-001 +M1 16 0 +E1-16M1 Valve Open/Closed (Exhaust gas - Exhaust-gas valve - Flushing the
Module) Exhaust gas manifold
M.03-KHF-001 Ball valve with spring return
(Lubricating oil / fresh oil / waste
oil - Module)
M.03-LI-001 +M1 54 1 +E1-54B1 Level sensor (Lubricating oil / Engine oil level in engine oil pan
fresh oil / waste oil - Module)
M.03-M-002 +M1 12 1 +E1-12M1 Engine (Lubricating oil / fresh oil / Engine oil pump - AC
waste oil - Module) prelubrication + continued
cooling
M.03-M-002 +V1 8 3 +E1-8M1 Engine (Lubricating oil / fresh oil / Engine oil pump - AC
waste oil - Module) prelubrication + continued
cooling
M.03-M-003 Engine (Lubricating oil / fresh oil / Engine oil pump - DC
waste oil - Module) prelubrication + continued
cooling
M.03-NS-002 Engine On/Off (Lubricating oil /
fresh oil / waste oil - Module)
M.03-NS-003 Engine On/Off (Lubricating oil /
fresh oil / waste oil - Module)
M.03-P-002 Pump (Lubricating oil / fresh oil / Engine oil pump - AC
waste oil - Module) prelubrication + continued
cooling

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 15/20
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.2.2
Module drawings and Technical diagram

Abbreviation Circuit diagram Description Remark

Secti Pa P el.
on ge at designatio
h n
M.03-P-003 Pump (Lubricating oil / fresh oil / Engine oil pump - DC
waste oil - Module) prelubrication + continued
cooling
M.03-PI-001 +M1 51 0 +E1-51B1 Pressure control (Lubricating oil / Engine oil pressure
fresh oil / waste oil - Module)
M.03-PI-002 +M1 52 5 +E1-52B3 Pressure control (Lubricating oil / Engine oil pressure - before
fresh oil / waste oil - Module) engine oil filter
M.03-TI-001 +M1 53 3 +E1-53B2 Temperature control (Lubricating
oil / fresh oil / waste oil - Module)
M.03-W-001 Heat exchanger (Lubricating oil / oil / water - Engine oil
fresh oil / waste oil - Module)
M.03-YCS-001 +M1 54 3 +E1-54M1 Valve Open/Closed (Lubricating Solenoid valve - Automatic
oil / fresh oil / waste oil - Module) topping up of engine oil
M.03-YPC-002 Filling valve (Lubricating oil / fresh Pressure relief valve - engine oil
oil / waste oil - Module) circuit
M.03-YPC-003 Filling valve (Lubricating oil / fresh
oil / waste oil - Module)
M.04-B-001 Container (Engine cooling water - Pressure compensation tank
Module)
M.04-B-002 Container (Engine cooling water - Pressure compensation tank
Module)
M.04-FS-001 +M1 55 4 +E1-55B3 Flow switch (Engine cooling Turbocharger pressure
water - Module)
M.04-M-001 +M1 13 1 +E1-13M1 Engine (Engine cooling water - Electric engine cooling water
Module) pump (applies to type 2, 312D, 4
and 6 engines)
M.04-M-002 +M1 15 3 +E1-15M1 Engine (Engine cooling water - Engine cooling water preheating
Module)
M.04-NS-001 Engine On/Off (Engine cooling
water - Module)
M.04-NS-002 Engine On/Off (Engine cooling
water - Module)
M.04-P-001 Pump (Engine cooling water - Electric engine cooling water
Module) pump (applies to type 2, 312D, 4
and 6 engines)
M.04-P-002 Pump (Engine cooling water - Engine cooling water preheating
Module)
M.04-PI-001 +M1 51 1 +E1-51B2 Pressure control (Engine cooling Engine cooling-water pressure
water - Module)
M.04-PI-002 Pressure control (Engine cooling
water - Module)
M.04-TI-001 +M1 53 4 +E1-53B3 Temperature control (Engine Engine cooling water
cooling water - Module) temperature
M.04-TS-001 Temperature switch (Engine Engine cooling water preheating
[01] cooling water - Module)

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 16 / 20
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.2.2
Module drawings and Technical diagram

Abbreviation Circuit diagram Description Remark

Secti Pa P el.
on ge at designatio
h n
M.04-TS-001 Temperature switch (Engine Engine cooling water preheating
[02] cooling water - Module)
M.04-W-002 Heat exchanger (Engine cooling Heating unit
water - Module)
M.04-YCS-001 +M1 10 6 +E1-10M1 Valve Open/Closed (Engine Solenoid valve - Auxiliary engine
cooling water - Module) cooling water pump (bypass)
M.04-YFC-002 Bundle control valve/Shut-off
valve (Engine cooling water -
Module)
M.04-YPC-001 Filling valve (Engine cooling water
- Module)
M.04-YPS-001 Safety valve (Engine cooling Filling connection (engine cooling
water - Module) water circuit or mixture cooling
water circuit)
M.05-PID-001 Differential pressure sensor
(Combustion Air - Module)
M.05-TI-001 +M1 53 6 +E1-53B4 Temperature control Intake air temperature
(Combustion Air - Module)
M.06-TI-001 +M1 60 1 +E1-60B1 Temperature control (High Return temperature (before
temperature circuit - Module) engine)
M.06-TI-014 +M1 60 4 +E1-60B2 Temperature control (High Inlet temperature after engine-
temperature circuit - Module) cooling water heat exchanger
M.07-TS-001 +M1 55 3 +E1-55B2 Temperature switch (Low Return temperature
temperature circuit - Module)
M.18-F-001 Filter (Transmission+accessories -
Module)
M.18-M-002 +M1 13 7 +E1-13M3 Engine (Transmission Transmission cooling water
+accessories - Module) pump
M.18-NS-002 Engine On/Off (Transmission
+accessories - Module)
M.18-P-001 Pump (Transmission+accessories Engine oil pump - Transmission
- Module) oil
M.18-P-002 Pump (Transmission+accessories Transmission cooling water
- Module) pump
M.18-PI-001 Pressure control (Transmission Transmission oil
+accessories - Module)
M.18-PS-001 +M1 57 2 +E1-57B1 Pressure switch (Transmission Transmission oil
+accessories - Module)
M.18-TS-001 +M1 57 3 +E1-57B2 Temperature switch Transmission oil
(Transmission+accessories -
Module)
M.18-W-001 Heat exchanger (Transmission oil / water - Transmission oil
+accessories - Module)
M.18-YPC-001 Filling valve (Transmission
+accessories - Module)

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 17/20
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.2.2
Module drawings and Technical diagram

Abbreviation Circuit diagram Description Remark

Secti Pa P el.
on ge at designatio
h n
P.01-F-101 Filter (Fuel gas - System) Condensate separator - Gas
pressure control system 1
P.01-F-102 Filter (Fuel gas - System) Gas filter - Gas pressure control
system 1
P.01-PI-101 Pressure control (Fuel gas - upstream of safety shut-off valve
System) - Gas pressure control system 1
P.01-PI-102 Pressure control (Fuel gas - Gas pressure control system 1
System)
P.01-PS-101 +M1 56 1 +P1-56B1 Pressure switch (Fuel gas - Gas pressure min. - Gas pressure
System) control system 1
P.01-PS-103 +M1 56 2 +P1-56B2 Pressure switch (Fuel gas - Gas pressure max. - Gas
System) pressure control system 1
P.01-US-101 +M1 64 1 +P1-64K1 Leak testing (Fuel gas - System) Gas pressure control system 1
P.01-US-600 Leak testing (Fuel gas - System)
P.01-US-601 Leak testing (Fuel gas - System)
P.01-YCI-101 Valve with position controller Pressure regulator - Gas pressure
(Fuel gas - System) control system 1
P.01-YCI-103 +M1 71 0 +E1-71M1 Valve with position controller Fuel gas regulator - Gas pressure
(Fuel gas - System) control system 1
P.01-YCZ-101 Valve Open/Closed safety Safety shut-off valve - Gas
relevant (Fuel gas - System) pressure control system 1
P.01-YCZ-102 Valve Open/Closed safety Safety shut-off valve - Gas
relevant (Fuel gas - System) pressure control system 1
P.01-YCZ-103 Valve Open/Closed safety Solenoid valve - Gas valve gas
relevant (Fuel gas - System) pressure control system 1
P.01-YCZ-110 +M1 65 6 +P1-SSL49 Valve Open/Closed safety Solenoid valve - Main gas valve
relevant (Fuel gas - System) before gas pressure control
system 1
P.02-A-001 Generator (Exhaust gas - System)
P.02-B-001 Container (Exhaust gas - System) Condensate drain of water
supply
P.02-B-002 Container (Exhaust gas - System) Condensate drain of water
supply
P.04-TC-012 Temperature control (Engine
cooling water - System)
P.04-W-001 Heat exchanger (Engine cooling
water - System)
P.04-YTC-001 Temperature control valve Return temperature boosting -
(Engine cooling water - System) engine cooling water circuit
(single circuit)
P.07-B-001 Container (Low temperature Pressure compensation tank
circuit - System)
P.07-M-003 Engine (Low temperature circuit - Water pump - Low-temperature
System) circuit (pump 2)

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 18 / 20
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.2.2
Module drawings and Technical diagram

Abbreviation Circuit diagram Description Remark

Secti Pa P el.
on ge at designatio
h n
P.07-NS-003 Engine On/Off (Low temperature
circuit - System)
P.07-P-003 Pump (Low temperature circuit - Water pump - Low-temperature
System) circuit (pump 2)
P.07-PI-001 Pressure control (Low
temperature circuit - System)
P.07-PI-002 Pressure control (Low
temperature circuit - System)
P.07-PI-003 Pressure control (Low
temperature circuit - System)
P.07-PS-001 +A1 50 1 +P1- Pressure switch (Low
SSL54.1 temperature circuit - System)
P.07-TC-003 Temperature control (Low
temperature circuit - System)
P.07-W-002 Heat exchanger (Low
temperature circuit - System)
P.07-YPC-001 Filling valve (Low temperature
circuit - System)
P.07-YPS-001 Safety valve (Low temperature
circuit - System)
P.07-YTC-001 Temperature control valve (Low Return temperature boosting -
temperature circuit - System) low-temperature circuit
P.14-B-001 Container (Pre-combustion Pressure vessel
chamber gas system - System)
P.14-F-002 Filter (Pre-combustion chamber
gas system - System)
P.14-F-006 Filter (Pre-combustion chamber
gas system - System)
P.14-F-101 Filter (Pre-combustion chamber
gas system - System)
P.14-M-001 Engine (Pre-combustion chamber Heat exchanger fan (fuel gas/air)
gas system - System)
P.14-M-010 Engine (Pre-combustion chamber Fuel-gas compressor
gas system - System)
P.14-NS-001 Engine On/Off (Pre-combustion
chamber gas system - System)
P.14-NS-010 Engine On/Off (Pre-combustion
chamber gas system - System)
P.14-PI-001 Pressure control (Pre-combustion
chamber gas system - System)
P.14-PI-002 Pressure control (Pre-combustion
chamber gas system - System)
P.14-PI-101 Pressure control (Pre-combustion
chamber gas system - System)

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 19/20
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.2.2
Module drawings and Technical diagram

Abbreviation Circuit diagram Description Remark

Secti Pa P el.
on ge at designatio
h n
P.14-PI-130 Pressure control (Pre-combustion Pressure indicator
chamber gas system - System)
P.14-PI-131 Pressure control (Pre-combustion Pressure indicator
chamber gas system - System)
P.14-PS-101 +M1 56 3 +P1-56B3 Pressure switch (Pre-combustion Suction pressure too low
chamber gas system - System)
P.14-TI-005 Temperature control (Pre-
combustion chamber gas system
- System)
P.14-TI-006 Temperature control (Pre-
combustion chamber gas system
- System)
P.14-VT-010 Compressor (Pre-combustion Fuel-gas compressor
chamber gas system - System)
P.14-W-001 Heat exchanger (Pre-combustion fuel gas / air
chamber gas system - System)
P.14-YCI-001 Valve with position controller Pre-combustion chamber gas
(Pre-combustion chamber gas compressor
system - System)
P.14-YCI-101 Valve with position controller Pressure regulator - Pre-
(Pre-combustion chamber gas chamber gas
system - System)
P.14-YCS-001 Valve Open/Closed (Pre- Solenoid valve - Start-up relief
combustion chamber gas system valve fuel-gas compressor
- System)
P.14-YCS-007 Valve Open/Closed (Pre- Solenoid valve - Before fuel-gas
combustion chamber gas system compressor
- System)
P.14-YCZ-030 Valve Open/Closed safety Solenoid valve - Main gas valve
relevant (Pre-combustion for pre-combustion chamber
chamber gas system - System) controlled gas system
P.14-YCZ-101 +M1 65 3 +P1-65M2 Valve Open/Closed safety Solenoid valve - Pre-combustion
relevant (Pre-combustion chamber gas line
chamber gas system - System)
P.14-YCZ-102 +M1 65 4 +P1-65M3 Valve Open/Closed safety Solenoid valve - Pre-combustion
relevant (Pre-combustion chamber gas line
chamber gas system - System)
P.14-YPS-001 Safety valve (Pre-combustion
chamber gas system - System)
P.14-YPS-002 Safety valve (Pre-combustion
SprungMarke!!!11251689099
chamber gas system - System)

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Huber Responsible: Doku./Huber Release date: 18/06/2015
Index: 1 Page No.: 20 / 20
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.2.3
Gas train

1 Gas piping
Technical Information 1400-0131.

2 Gas train
F Filter
KH Ball valve
PI Pressure monitoring
PS pressure switch
US Leak testing
YCI Valve with position controller
YCS Valve Open/Closed
YCZ Valve Open/Closed safety relevant

Main gas trains

Prechamber gas trains

SprungMarke!!!81064793472112011

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin Responsible: Dokumentation Release date: 29/09/2014
Index: 10 Page No.: 1/1
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.2.4
MORIS ignition system

1 General
The combustion of the fuel gas in the gas engine is initialised by a modulated, decentralised high-voltage
capacitor ignition system. The ignition energy, the ignition point and other parameters of the ignition system
are pre-set by the engine control system via the CAN bus. Comprehensive diagnostic systems make it possible
to make a very detailed analysis of the status of the ignition system.

2 Construction of the MORIS ignition system

Basic construction of the MORIS ignition system based on the example of an 8-cylinder V engine:

ZK ZK ZK ZK

MS SAFI MS MS SAFI MS

CAN A
A-M ZM B-M ZM E-M
24 V

B
1 SPA24
A-M ZM B-M ZM E-M

24 V MPM
MS SAFI MS MS SAFI MS

ZK ZK ZK ZK

① Trigger, Reset and CAM Signal MPM MORIS Power Modul

A Bank A M-S MORIS ignition coil
B Bank B SAFI Sensor Actor Function Interface
A-M A module SPA24 SAFI Pick-up Amplifier
B-M B module ZM ZM Ignition module
E-M E module ZK Spark plug
CAN CAN

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TCD/Kraus, Gschirr, Kröll Responsible: Controls Release date: 02/09/2013
Index: 2 Page No.: 1/3
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.2.4
MORIS ignition system

The modular construction makes it possible to fit the widest possible range of engines with the modules
described.

2.1 MPM (MORIS Power Module)

The MPM generates a voltage of 185 V from the 24 V battery voltage to supply the ignition system with energy.
If more energy is required because of a high number of cylinders or a very high energy demand from the
ignition system, it is possible to fit two MPMs per engine.
Detailed information on the MPM can be found in TI 1502-0069.

2.2 SPA24 (SAFI Pickup Amplifier):

SPA24 conditions the engine's three pickup signals for processing on the SAFI, and SPA24 is powered by the 24
V battery voltage. The three pickup signals are:

▪ ring gear signal on the flywheel

▪ reset signal on the flywheel
▪ Camshaft signal

Detailed information on the SPA24 can be found in TI 1502-0072.

2.3 MORIS (MOdular Rail Ignition System):

MORIS consists of an aluminium section into which a connection module, an intermediate module and an end
module have been inserted. The ignition modules are fitted between these inserted modules. The ignition
module contains the output stage of the ignition system, which controls the ignition coils for two cylinders.
Detailed information on the MORIS can be found in TI 1502-0068.

2.4 SAFI (Sensor Actor Function Interface):

The ignition system is controlled by SAFI. SAFI calculates the angle position of the crankshaft and camshaft
based on pickup signals and subsequently the ignition point, which is specified by the engine control system. In
addition to the ignition point, the ignition energy, ignition spark characteristics, the commands for the misfire
control system and information on the monitoring of the ignition process are transmitted via the CAN bus by
the engine control system. Information on the status of the ignition system is reported back to the engine
control system by SAFI via the CAN bus. The ignition output stage is regulated by SAFI to ensure that the
preselected spark characteristics are set.
As well as controlling the ignition system, SAFI's functions include detecting the condition of the spark plug,
measuring the engine speed, monitoring knocking and valve noise, analysing the combustion process and
measuring the exhaust gas temperature.
SAFI is mounted on the MORIS in the centre of the ignition modules between the two ignition coils.
Detailed information on the SAFI can be found in TI 1502-0071.

2.5 M coil (MORIS ignition coil)

Each ignition output stage powers two M coils, which are mounted to the left and right of SAFI. The M coils
produce the high voltage. The high voltage is measured by a capacitor divider, the signal being amplified and
analysed in SAFI.
Detailed information on the MORIS can be found in TI 1502-0068.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TCD/Kraus, Gschirr, Kröll Responsible: Controls Release date: 02/09/2013
Index: 2 Page No.: 2 / 3
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.2.4
MORIS ignition system

2.6 spark plug connector

The ignition energy is transferred to the spark plug via the spark plug connector.

3 Ignition characteristics:
In the MORIS ignition system the current in the ignition spark is kept to the preset characteristics. The
conversion is therefore mostly independent of the condition of the spark plug, provided that the system's high-
voltage supply is not exceeded.
If the ignition spark is extinguished, the MORIS ignition spark is restored automatically.
The diagram below illustrates the working principle of the MORIS ignition system.

Control of MORIS
by SAFI (energy feed and
current set point)

Implementation as ignition sparks (voltage and

current)

Ph1 Firing up
Ph2 Igniting
Ph3 Initialising for re-ignition
ZZP Ignition timing point
STROM Current
HS High voltage
SprungMarke!!!9007199274690059
Isek I second

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TCD/Kraus, Gschirr, Kröll Responsible: Controls Release date: 02/09/2013
Index: 2 Page No.: 3/3
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.2.5
Flexible coupling

1 Function of the flexible coupling............................................................................................................ 1

2 Tightening torques ................................................................................................................................... 1
3 Components of the flexible coupling..................................................................................................... 1
3.1 Engine end .................................................................................................................................................................... 1
3.2 Generator end............................................................................................................................................................. 1

1 Function of the flexible coupling

The generator housing and the gearbox (engine) are rigidly bolted together via the coupling housing.
The gear on the coupling element (generator) engages with the one on the coupling flange (engine), and power
is transferred from the engine to the generator by positive locking.
The flexible coupling is designed to transmit power up to a certain rated torque. If this rated torque is exceeded
by a factor of about 5 – 6, then the external teeth (rubber disc) slip to protect the engine and the generator
against temporary overloading.
Temporary overloading can be caused by incorrect synchronisation or a short circuit.

2 Tightening torques
See Inspection/Maintenance work IW 8071 A0

3 Components of the flexible coupling

3.1 Engine end

The internal-geared coupling flange (light metal ring) is bolted onto the flywheel.

3.2 Generator end

The coupling hub is mounted onto the generator shaft using a feather key and a set screw.
The coupling element, which consists of a steel disc onto which a rubber disc has been vulcanised, is bolted to
the coupling hub.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Provin Responsible: Dokumentation Release date: 21/04/2015
Index: 58 Page No.: 1/2
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.2.5
Flexible coupling

SprungMarke!!!513410357540003595

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Provin Responsible: Dokumentation Release date: 21/04/2015
Index: 58 Page No.: 2 / 2
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.3.1
Leanox® controller

1 Leanox® controller................................................................................................................................... 1
2 Pollutant emissions as a function of the air ratio λ ........................................................................... 1
3 Schematic diagram of the controlled system...................................................................................... 3

1 Leanox® controller
GE Jenbacher The operation of gas engines has been optimised to ensure that lowest exhaust emission values
are achieved under full-load operation.
These optimised exhaust emissions can be achieved only by operating lean-mix engines with the correct air
excess ratio λ (air ratio). This principle exploits the direct link between NOx-emissions and the air excess ratio to
achieve minimum exhaust emission values. The patented LEANOX control system is based on the linear
relationship between the air excess ratio λ and the quantities power, boost pressure and air-gas mixture
temperature. A control system based on these principles has the great advantage that all these quantities can
be measured easily and reliably, and that the air ratio λ can be calculated exactly. The system eliminates the
need for measuring probes in the exhaust system, which can be subject to ageing. This means that the
emissions targets can be met reliably.

The task of the LEANOX controller is to calculate and set the optimum boost pressure, based on the current
power output and the current air-gas mixture temperature. The linear relationship between these quantities is
calculated automatically by dia.ne after two of the operating points have been stored to memory.

The LEANOX controller switches itself on automatically once the actual power output exceeds a threshold value
(approx. 30% of the total power output). The program provides four sets of parameters for different types of
fuel gas.

The LEANOX controller is always active during mains-parallel operation, but can also be switched on during
island operation (depending on the system-specific design).

A PI-controller is used for the actual control.

2 Pollutant emissions as a function of the air ratio λ

NOX/CO NMHC
[mg/Nm3], [mg/Nm3],
at 5% O2 at 5% O2

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 02/07/2013
Index: 3 Page No.: 1/4
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.3.1
Leanox® controller

12000 240

11000 CO 220

10000
NOx
200

9000 180

8000 160
150

7000 140

6000 120 2
NMHC
5000 100

4000 80

3000 60

2000 40

1000 20
650
500

0,9 1,0 1,1 1,2 1,3 1,4 1,5 1,6 1,7 λ

LEANOX
1
Leanox Diagram
NOx -> TA Luft limit value common operating range until now
CO -> TA Luft limit value ① Lean-burn operation
NMHC -> TA Luft limit value ② Misfiring range
SCR procedure λ Air ratio Lambda
NSCR method (λ-1 concept)

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 02/07/2013
Index: 3 Page No.: 2 / 4
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.3.1
Leanox® controller

3 Schematic diagram of the controlled system

Exhaust gas outlet

Intake air

Fuel gas entry

dia.ne (SAM)

2 P soll /nsoll
PIST

p2’

t2’

ST
C

G D
M

V
M
3 NVG
NCG NVD
NSG

NVA
Leanox control system diagram

Controlled variable Final control element

p2' (boost pressure) Gas mixer drive (gas aperture)
t2' (mixture
temperature)
PIST (power)
① Leanox controller
② P controller/ nP controller
③ Gas engine
G Generator
SI Pickup
VT Compressor

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 02/07/2013
Index: 3 Page No.: 3/4
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.3.1
Leanox® controller

Controlled variable Final control element

YCI Valve with position controller
YVD Fuel gas controller
SprungMarke!!!18014398529540747
W heat exchanger

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 02/07/2013
Index: 3 Page No.: 4 / 4
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.3.2
Speed controller

Speed controller:
After the engine has been started up, the electronic speed controller adjusts the engine speed to a setpoint
value. The actual engine speed is compared to the setpoint engine speed, and is then matched to it by altering
the setting of the throttle valve.
Controlled variable Final control element
n (speed) Throttle valve

n-R

G Generator
M Engine
N Power grid
P Electrical power
n Speed
n-R Speed controller
V Consumer
SprungMarke!!!9007199274813323
Z Engine idle

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: TCC/Hirzinger Release date: 02/07/2013
Index: 2 Page No.: 1/1
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.3.3
Power controller

1 Power controller
In mains parallel operation, the engine is controlled by a power output controller in order to strictly maintain
the setpoint output. The current power output of the generator is compared to the set point and then varied
accordingly by adjusting the throttle valve and electrically-operated valves in the mixture bypass system
(turbocharger bypass).
The electrically operated valves in the turbocharger bypass system work together with the throttle valve to
ensure an optimum level of control over the system.
Controlled variable actuator
P (power) Turbocharger bypass throttle valve

V
P

P
P

3
G M
Power controller diagram
① Mains parallel operation M Engine
② Power controller G Generator
③ Mains P Electrical power
SprungMarke!!!18014398530226059
V Consumer

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Schartner Responsible: Dokumentation Release date: 02/07/2013
Index: 3 Page No.: 1/1
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
5.3.4
Isolated operation controller

Isolated-operation controller
In island operation, a constant engine speed is required even when loads are switched on and off. This function
is also carried out by the governor in a specific adaptation.

When several generating set modules operate in parallel in an isolated grid (e.g. emergency power operation),
the required power output has to be distributed optimally over the modules available.
There are two power distribution methods available which meet these requirements.

Power distribution via an equalising line

The average value of the individual power outputs of the engines is calculated and made available via the
equalising line to the controller which uses it as a target value. When operating via an equalising line the power
distribution is accurate and the grid frequency is held exactly.

Power distribution using offset coefficient control: (dia.ne and other engine management systems)
A power distribution system that uses offset coefficient control lowers the desired engine speed as the power
output increases. If every engine responds in the same way, then a stable operating point sets in at which all
engines deliver the same power.
Controlled variable Final control element
n (speed) Turbocharger bypass
Throttle valve
P (power) Turbocharger bypass
Throttle valve

V
P

3
G M
Island operation controller diagram
① Island operation M Engine
② Island-operation controller G Generator
③ Mains P Electrical power
SprungMarke!!!18014398530247819
V Consumer

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Velik Responsible: TCC Hirzinger Release date: 02/07/2013
Index: 3 Page No.: 1/1
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
6 Consumables and Technical Instructions
6.1
Operating Materials

1 Engine oil .................................................................................................................................................... 1

1.1 Functions....................................................................................................................................................................... 1
1.2 Influencing factors .................................................................................................................................................... 2
1.2.1 General factors influencing the condition of the used oil 2
1.2.2 The sulphate ash content as a factor influencing engine operation 2
1.3 Technical Directive (requirements).................................................................................................................... 2
2 Cooling Water............................................................................................................................................ 3
2.1 Functions....................................................................................................................................................................... 3
2.2 Technical Directive (requirements).................................................................................................................... 3
3 Fuel gas....................................................................................................................................................... 3
3.1 Functions....................................................................................................................................................................... 3
3.2 Determining the methane number ................................................................................................................... 4
3.3 Technical Directive (requirements).................................................................................................................... 4

1 Engine oil

1.1 Functions
In addition to the lubrication of bearings and moving engine parts, the engine oil is used in the cooling, sealing
and cleaning processes in the engine.

▪ Lubrication of bearings (crankshaft main bearings; big-end bearings; camshaft bearings; gear train
bearings...) and moving engine parts (pistons/cylinder liners; tappets; rocker arms; valves....).
▪ Cooling of pistons (cooling duct on piston crown) and exhaust gas turbocharger. The engine oil absorbs
thermal energy from hot engine components and transfers it to the cooling water in the oil cooler (engine
oil/water heat exchanger).
▪ Sealing effect between piston rings and cylinder liners.
▪ Cleaning and preservation to prevent deposits in the engine. Deposits caused by combustion and wear
(ash; metal abrasion...) are picked up by the engine oil. Some of these deposits are filtered out in the engine
oil filter, the rest remain suspended in the engine oil.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Velik Responsible: Dokumentation Release date: 30/04/2015
Index: 7 Page No.: 1/4
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
6.1
Operating Materials

1.2 Influencing factors

1.2.1 General factors influencing the condition of the used oil

1.2.2 The sulphate ash content as a factor influencing engine operation

Although engine oils with a high sulphate ash content increase the oil service life time, they also increase the
amount of deposits in the combustion chamber.
A minimum ash content in the engine is required, however, to achieve a "dry-lubrication effect".

1.3 Technical Directive (requirements)

It is obvious from this variety of requirements why engine oil plays such a decisive role in the satisfactory
operation of the engine.
The following Technical Instructions apply and should be used for selecting an engine oil type, for determining
the engine oil service life and also for interpreting used oil analyses.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Velik Responsible: Dokumentation Release date: 30/04/2015
Index: 7 Page No.: 2 / 4
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
6.1
Operating Materials

Engine oil / engine lubricants:

Lubricating oil for type 2, 3, 4 and 6 GE Jenbacher engines 1000-1109
Approval procedure for various engine oils 1000-0099A
Limit values for used oil on GE Jenbacher gas engines 1000-0099B
Procedure for testing plant-specific oil service life 1000-0099C
Determining the initial pH value (ipH) for waste lube oil as defined in TI 1000-0099B 1000-0099D
Aid to interpreting used oil analyses of engine lubricants 1000-0099K
Taking lubricating oil samples / lubricating oil sampling protocol 1000-0112

2 Cooling Water

2.1 Functions
The function of the cooling water in the primary circuit (engine cooling water circuit) and the heating water
circuit is to carry thermal energy. The cooling water in the primary circuit takes thermal energy from the engine
and transfers it via heat exchangers to the heating water circuit.

2.2 Technical Directive (requirements)

Natural water is either acidic (pH value less than 7) or alkaline (pH value more than 7). The quality of the water
is also affected by the type and quantity of dissolved substances and the type and quantity of suspended
particles:
▪ Acidic water attacks iron and copper components.
▪ Alkaline water attacks aluminium components. Alkaline water is also usually hard and encourages the
formation of stones.
Locally available water should always be analysed before deciding whether it can be used as cooling water in a
GE Jenbacher system.
If the analysed water does not meet the specified requirements (Technical Instructions), then it needs to be
treated accordingly. Antifreeze additive should be added to the water in accordance with Technical Directive
1000-0201 based on the local geographical and climatic conditions.
The following technical Directives apply and should help you to assess and prepare cooling water.

Cooling water:
Quality of cooling water in closed circuits 1000-0200
Anti-freeze products and testing the coolant 1000-0201
Corrosion protection products for cooling water for GE Jenbacher engines and testing the 1000-0204
coolant
Quality of circuit water in hot water and warm water heating systems 1000-0206

3 Fuel gas

3.1 Functions
A combustible mixture of gas and air is required for combustion in the cylinder. In this process the fuel gas is
the source of energy and the air is the source of oxygen.
The methane number and the calorific value are the key characteristics of the fuel gas. The methane number
shows the knock-resistance of the gas and hence determines the basic engine design.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Velik Responsible: Dokumentation Release date: 30/04/2015
Index: 7 Page No.: 3/4
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
6.1
Operating Materials

The fuel gas composition is decisive for engine design and equipment and has enormous influence over
running characteristics, susceptibility to faults and durability of the gas engine.

3.2 Determining the methane number

Determining the methane number

3.3 Technical Directive (requirements)

The engine is equipped for the fuel gas quality specified by the customer when the engine was ordered, and is
optimised for this gas when it is first taken into operation.
For this reason it is essential that the customer service department at GE Jenbacher is notified if the fuel quality
is changed.
The following Technical Directives apply and can be used to help you assess your fuel gas.

Fuel gas:

SprungMarke!!!54043195590080395
Fuel-gas quality of natural, associated petroleum, biogas and landfill gas 1000-0300

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Velik Responsible: Dokumentation Release date: 30/04/2015
Index: 7 Page No.: 4 / 4
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
6.2
Technical instructions

1 Operation
Switching off the engine 1100-0105
Regulations for running in GE generating set engines 1400-0100
Check list for engine repairs and overhauls 2102-0020

2 Tightening torque
Torque wrench 000-00-003
Instructions for fitting and testing reduced-shaft bolts 1902-0001
Tightening torques – J 6..GS-E/F 1902-0228E/F

3 Mechanical engine and system components

Transport protection 1000-0044
Pipework 1400-0131
Spark plug adjustment tool for plugs with hook electrodes 1400-0162

4 Electrical engine and system components

Batteries (starter and storage) 1000-0050
TRIO-PS/3AC/24DC/40 battery charger 1000-0052
EMC approved routing of wiring and earth connections to/between engine modules and 1000-0505
control cabinets
Handling of electronic components/modules 1000-0510
Protective measures for installing high-voltage circuits 1000-0515
Gas quantity controller (TecJet 110 and 50 plus) 1510-0064
Isolated operation of spark-ignition gas engines with dia.ne (Type 6 engines) 2108-0026
Isolated operation - general 2108-0031

5 Basic conditions
Preservation of Jenbacher modules 1000-0004
Requirements on the installation surface for GE Jenbacher plant 1000-0041
Transporting and setting up GE Jenbacher control cabinets 1000-0043
Lifting and transporting GE Jenbacher modules and positioning them in engine rooms 1000-0046
Signage on the engine room door 1000-0330
Installation of GE Jenbacher modules 1100-0112
Employee protection 2300-0001
Security tips when connecting GE Jenbacher Installations to the Internet 2300-0006

6 ignition
MORIS ignition 1502-0068
MPM (MORIS Power Module) 1502-0069

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Velik Responsible: Dokumentation Release date: 25/04/2013
Index: 9 Page No.: 1/2
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
6.2
Technical instructions

SAFI (Sensor Actuator Function Interface) 1502-0071

SprungMarke!!!72057594061542027
SPA24 (SAFI pickup amplifier) 1502-0072

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Velik Responsible: Dokumentation Release date: 25/04/2013
Index: 9 Page No.: 2 / 2
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 000-00-003
Torque wrench

1 Adjusting the torque wrench .................................................................................................................. 1

2 Assembly instructions.............................................................................................................................. 1
3 Loosening of reduced-shaft bolts (torque-to-yield bolts) ................................................................. 1
4 Calibrating torque wrenches.................................................................................................................. 2

1 Adjusting the torque wrench

1.1 Set the prescribed tightening torque in accordance with the manufacturer's instructions.

2 Assembly instructions
2.1 Clean the threads of bolts and nuts as well as contact surfaces. Do not re-use reduced-shank bolts (torque-to-
yield bolts) damaged by corrosion, notching etc. If the pistons or bearings are damaged, new reduced-shank
bolts must be used unless existing test facilities show the bolts are in perfect condition.

2.2 Oil the threads and contact surfaces lightly with fresh engine oil.

2.3 Always pull smoothly and evenly on the torque wrench. Always pull smoothly and evenly (no jerks), keeping the
direction of pull at right angles to the wrench. Stop tightening immediately when the wrench releases.

2.4 Do not turn bolts on parts sitting on seals or gaskets through more than 60° to 90° in one turn, and then turn
the next bolt through the same angle. After turning and tightening each bolt through the same angle, repeat
this procedure until the wrench releases If tightening is carried out correctly, the each opposite bolt or screw
should make the torque wrench release at the same angle when tightened.
If a greater angle should be found necessary on the second bolt, this shows that tightening has not been
carried out symmetrically. In that case, slacken the first bolt until the releasing clicks of the torque wrench can
all be heard for all screws at the same angle.
Always tighten crosswise, changing frequently from one bolt to another.

2.5 When tightening parts without seals or gaskets, moving from one bolt to another before reaching the
tightening torque is advisable, as is crosswise tightening After tightening the bolts, apply short hard blows to
the bolt head or work piece (with a light alloy or plastic mallet). Then retighten. If retightening is possible, the
procedure must be repeated.

2.6 Note that it is still possible to continue tightening after the torque wrench has released. You must therefore
stop tightening immediately when the torque wrench releases.

2.7 Warning! Components connected by a locking element (cannular spring-locking elements) must not be treated
as described in Section 2.5 after being tightened using a torque wrench. If a blow with a mallet is applied to the
thrust piece which transmits the preloading of the bolts to the locking rings, the friction of the element will be
overcome and the component will be displaced. Such a blow would exert an additional load on the component,
for which it is not designed, and which is therefore not permissible. The procedure mentioned in Section 2.5 (i.e.
repeated retightening) could lead to a so-called ‘cold welding’ of parts and components, as a result of which it
may be impossible to undo them again.

3 Loosening of reduced-shaft bolts (torque-to-yield bolts)

Bolts positioned opposite to each other must be loosened alternately in several sequences. Never loosen one
bolt fully before loosening the other. If several bolts are involved (along a circumference), these must be
loosened in a crosswise pattern in several sequences (bolt by bolt).
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: TPA Release date: 01/12/2011
Index: 3 Page No.: 1/2
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 000-00-003
Torque wrench

This loosening procedure will prevent the bolt seizing.

First loosen the bolts 1/4 turn only until the tightening torque is eliminated and the screws, bolts or nuts can be
easily removed.

3.1 Important:
Never loosen reduced-shaft bolts when they are at operating temperature:
If disassembly becomes necessary immediately after engine shutdown, immediately open all crankcase covers
to ensure a quicker engine cool-down. The reduced-shaft bolts to be loosened – in particular the cylinder head
bolts – may not be loosened until they have cooled down to the point where they can be touched continuously
(below 40 °C to 45 °C).

4 Calibrating torque wrenches

The torque wrench must be calibrated annually. It must also be calibrated whenever it is subjected to an
overload or if incorrectly handled, which can affect its measuring uncertainty.
SprungMarke!!!18014398533592715

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: TPA Release date: 01/12/2011
Index: 3 Page No.: 2 / 2
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0004
Preservation of GE Jenbacher modules

1 Scope
The Technical Instruction applies to new engines/modules, overhauled or repaired engines, and all engines that
have already been commissioned but whose operation has been interrupted for a prolonged period (more than
3 months). See also TI 1000-0026.

2 Purpose
This Technical Instruction describes the preservation/represervation and depreservation of modules held in
temporary storage for up to 12 months (before commissioning). For longer storage periods, the following
preservation must be checked and repeated (see the "Represervation" section) every 12 months at the latest.
This preservation must also be carried out when commissioned engines are taken out of operation for
prolonged periods (more than 3 months).
There are 2 kinds of preservation:

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Kecht S. Responsible: Wolf S. Release date: 26/05/2015
Index: 6 Page No.: 1/17
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0004
Preservation of GE Jenbacher modules

▪ European preservation
Engines are not shipped by sea freight and remain within the central European climate zone (temperate
continental climate).
▪ Overseas preservation
Engines are shipped as sea freight or through tropical/subtropical zones and/or are operated in tropical/
subtropical zones.

3 Relevant documents
The following documents also be observed:
TI 1000-0044 Transport protection [⇨ TA 1000-0044, Page 1] [Transport protection]
TI 1000-0050 Batteries (starter and storage) [⇨ TA 1000-0050, Page 1] [Batteries (Starter and buffer
batteries)]
TI 1000-0204 Corrosion protection products for cooling water for GE Jenbacher engines and testing the
coolant [⇨ TA 1000-0204, Page 1] [Corrosion-protection products for cooling water for GE
Jenbacher engines and for checking the coolant]
IW 8071 A0 Transmission [Gearbox]

4 Responsibilities
The following applies as regards monitoring and implementing the rules in these TIs:
▪ So long as the product is at Jenbach or a despatch warehouse managed by GSCM, GSCM (Assembly or
Shipping) shall be responsible.
▪ When delivered to the customer/end customer/partner, risk and responsibility pass to the customer/end
customer/partner.
After a period of storage longer than 1 year from the last preservation (as from the Jenbach "ready for
despatch" notification), the customer/end customer/partner must represerve the product thoroughly and
completely in accordance with this TI 1000-0004, and send the respective project manager a report as
proof that it has been carried out. The number of the engine in question must be quoted in the report. The
"Customer check list" in the Appendix is provided for use as a report.

5 Corrosion protection and packaging products

In order to ensure the optimum service life and safe operation of the GE Jenbacher module, only the corrosion
protection and packing products mentioned in this TI may be used for preservation and packing.
Materials / Products Remarks
Spray gun Commercially available compressed-air or electric spray
gun.
When preserving the cylinder liner, use a spraying hose
to prevent the cylinder running surface from becoming
damaged.

Cooling water anti-corrosion additive DREW AMEROID - Maxigard

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Kecht S. Responsible: Wolf S. Release date: 26/05/2015
Index: 6 Page No.: 2 / 17
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0004
Preservation of GE Jenbacher modules

Materials / Products Remarks

Anti-corrosion oil
(part no.: 298843)

Avilub Metacorin 832

Lubricating grease Commercially available lubricating grease
Preservation wax
(part no.: 400296)

Dinitrol 81
Surface protection
(part no.: 197268)

BRANO®tect corrosion protection spray

Oil paper
(wood-free paper impregnated with wax, paraffin or
ceresin – impermeable to water and corrosion-
inhibiting)

Adhesive tape (incl. dispenser)

Corrosion inhibitor sponge

(part no.: 285878)

Fleece foil Packaging foam, 3 mm

(part no.: 337858)
Foil Commercially available construction foil (thickness ~0.2
mm)

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Kecht S. Responsible: Wolf S. Release date: 26/05/2015
Index: 6 Page No.: 3/17
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0004
Preservation of GE Jenbacher modules

Materials / Products Remarks

VCI paper Branorost
VCI foil Corrosion protection foil

6 Conservation

6.1 General
Preservation means preservation for the first time by GE Jenbacher before delivery, and also before prolonged
interruptions to operation or storage of a module by the customer.

6.2 Internal preservation of engines

▪ Cooling water system / water spaces:
Only initial preservation in Jenbach:
The engine is run on the test stand with a premixed 60/40 mixture of water and antifreeze (Havoline
ethylene glycol-based antifreeze concentrate) containing an elevated proportion of corrosion inhibitors.
As from July 2015, all piping and passages carrying cooling water (all cooling circuits) will be purged with
nitrogen (see the see the section on Nitrogen Purging).

The following applies for customers:

Represervation of the cooling water zones of stored uncommissioned engines is carried out by purging all
piping and passages carrying cooling water with nitrogen (see the section on Nitrogen Purging).
The following applies to longer shut-downs (more than 3 months) of engines in operation:
The entire cooling water system must be flushed with antifreeze with an anti-corrosion additive (as per TI
1000-0204).
Drain off the cooling water completely from the engine while still warm after operation and open the water
inlets and outlets immediately to allow vapour to escape. All the water spaces must always be fully drained
due to the risk of freezing.
Do not close the openings and drain and vent valves until the engine is fully cooled down (≤ 40 °C).
Additional preservation of all cooling water piping and jackets as described in the section on Nitrogen
Purging.
▪ Crankcase and oil spaces:
After the test run, completely drain off all the lubricating oil from the engine while still warm.
Do not close all openings and drain valves until the engine is fully cooled down.
No additional preservation is necessary for the oil spaces, as the engine oil used for the test run at Jenbach
exhibits an adequate preventive action against corrosion, including in the long term.

The following applies for customers:

Change the oil before taking engines out of operation.
Then run the engine for a at least an hour so that the fresh oil can be distributed around the engine.
▪ Cylinder liners/Combustion chamber:
For Type 3 engines:
Remove the spark plugs and spray anti-corrosion oil (Avilub Metacorin 832) into the cylinders with a spray
gun so that a thin protective coating is applied all round the cylinder liners.
Then refit the spark plugs.

For Types 4, 6 and 9 engines:

Using a spray gun, spray the anti-corrosion oil in at the indicator locking bolt.

Description of the spraying procedure:

Carry out the spraying procedure twice and move the spray lance up and down in the cylinder during
spraying so that the entire interior and also the underside of the cylinder head is wetted with anti-corrosion

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Kecht S. Responsible: Wolf S. Release date: 26/05/2015
Index: 6 Page No.: 4 / 17
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0004
Preservation of GE Jenbacher modules

oil.
When doing this for the first time, bring no. 1 cylinder to TDC and then spray in anti-corrosion oil for the
prescribed time (see the "Spraying Times" table).
The second time, bring the cylinder in question to TDC (see the "Cylinder Position" table) and repeat the
spray procedure as described above.

Spraying Times table (per spraying procedure):

Engine type Spraying time [seconds]
2 2
3 2
4 2
6 3
9 4

Cylinder position table - 2nd time:

Engine Cylinder at TDC
J208 2
J312, J412 10
J316, J416 7
J320, J420 between 3/19
J612 10
J616 2
J620 between 12/2
J624 between 16/21
J920 between 2/3

6.3 Nitrogen purging

Nitrogen purging is understood as blowing out the air from a closed space by displacing it by nitrogen. The
nitrogen can be provided from a gas bottle using a pressure reducer.
Ideally, the vent points and drain points of the cooling water circuit in question should be used for nitrogen
purging.
The vent points on Type 6 engines are marked with the following symbol:

To do this, connect the hose to a vent point near the inlet side and open a vent point near the outlet side to
ensure that the entire cooling water system is purged with nitrogen.
The nitrogen inlet pressure must not exceed 300 mbar!
When the system is closed off, a slight overpressure of 100 mbar to a maximum of 300 mbar should still be
present in the cooling water circuit.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Kecht S. Responsible: Wolf S. Release date: 26/05/2015
Index: 6 Page No.: 5/17
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0004
Preservation of GE Jenbacher modules

ATTENTION
Systems may be pressurized!
Take care when opening water and oil circuits.
a) Open such systems slowly and release the pressure slowly if necessary.

Minimum purge time – Table:

Engine type Engine cooling water High-temperature circuit Low-temperature circuit
circuit [min] [min] [min]
2 5 5 2
3 10 10 4
4 10 10 4
6 15 15 5
9 (engine) 15 - -
9 (TCA) 15 15 10

6.4 Closing all openings

Close all openings (such as cooling water connections,
intake line, exhaust-gas manifold, exhaust gas outlet,
fuel inlet before mixer or openings or oil connections)
using blanking covers with counter flanges.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Kecht S. Responsible: Wolf S. Release date: 26/05/2015
Index: 6 Page No.: 6 / 17
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0004
Preservation of GE Jenbacher modules

6.5 Outside engine preservation / preservation of electrical/mechanical module parts

▪ Bright parts:
spray with BRANOtect corrosion protection spray.
For larger surfaces e.g. on Type 6 engines where
the generator is not coupled to the engine, spray
Dinitrol 81 preservation wax over the entire
flywheel face so that it is fully covered.
Preserve the bright generator coupling flange in
the same way.

▪ Turning gear:
① Grease

▪ Knock sensors (if fitted):

Wrap these in oil paper.

▪ Platen-type heat exchanger: no preservation

measures required.

▪ Table cooler (if installed):

Since these cannot be reliably drained completely,
table coolers must be flushed with antifreeze
(premixed antifreeze from the supplier).

▪ Exhaust gas manifold cladding: no preservation

measures required.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Kecht S. Responsible: Wolf S. Release date: 26/05/2015
Index: 6 Page No.: 7/17
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0004
Preservation of GE Jenbacher modules

▪ Air filters:
seal using oil paper.

Overseas and European preservation:

Overseas preservation
▪ Generator:
Affix 3 corrosion inhibitor sponges inside the
terminal boxes.
Overseas preservation:
Seal any cooling-air openings and other openings
of the terminal box using oil paper.

European preservation: no measures.

▪ On all generators (apart from the LSA56, TD125 and Type 9 generators), the generator shaft must be
rotated every two months so that the rolling elements change position (at least 2 revolutions).
This must be entered in the customer check list.

Do not turn the generator by its fan, but use the engine flywheel instead.
Remove any transport safety pegs first (see TI 1000-0044). Refit the transport safety pegs after
rotating the shaft.

▪ Gearbox (optional):
Fill with gear oil in accordance with IW 8071 A0.
Seal off the gearbox so that is airtight.
Since condensation can occur inside the gearbox housing during extended standstill periods (> 18 months),

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Kecht S. Responsible: Wolf S. Release date: 26/05/2015
Index: 6 Page No.: 8 / 17
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0004
Preservation of GE Jenbacher modules

especially if sealed airtight, change the gearbox oil in accordance with IW 8071 A0 before commissioning.
Caution: water, even in minute quantities, can cause pitting!
Spray bright parts (e.g. the shaft) with corrosion protection oil (BRANOtect anti-corrosion spray, part no.
197268).
Affix a warning sign:
Attention: This gearbox has been given long-term preservation and must not be opened!
When the generator is out of service for a prolonged period of time, the gearbox shaft must be rotated
every two months to ensure that the rolling elements change position (at least 2 rotations).
This must be entered in the customer check list!

▪ Ignition box, interface:

Affix a corrosion inhibitor sponge inside each of the above.
▪ Various switchgear cabinets:
Affix 2 corrosion inhibitor sponges inside each of
these.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Kecht S. Responsible: Wolf S. Release date: 26/05/2015
Index: 6 Page No.: 9/17
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0004
Preservation of GE Jenbacher modules

European preservation:
wrap the cabinet in normal commercially-
available construction foil/stretch wrap.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Kecht S. Responsible: Wolf S. Release date: 26/05/2015
Index: 6 Page No.: 10 / 17
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0004
Preservation of GE Jenbacher modules

Overseas preservation:
Wrap the cabinet in fleece foil as well.

▪ Actuator: no preservation measures required.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Kecht S. Responsible: Wolf S. Release date: 26/05/2015
Index: 6 Page No.: 11/17
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0004
Preservation of GE Jenbacher modules

▪ Control rod linkage:

Grease pivot points using a grease gun at the grease nipple. Remove the
excess grease and apply a grease film to the left and right-hand side of
the bearing gap to protect against dust.

▪ Battery: see TI 1000-0050.

6.6 Entire module

Cover with foil.

7 Represervation
Represervation must be carried out 12 months after the initial preservation.
Represervation must also be carried out after work on the engine during which parts were removed and
refitted/replaced, or the cooling water circuits were opened.
Particular attention must be paid to the following points when doing this:
▪ renewing the preservation inside the combustion chambers (spraying with Avilub Metacovin 832)
▪ Represervation of internal preservation inside the cooling water jackets (see the "Nitrogen Purging" section)
▪ checking and if necessary renewing the surface preservation of the flywheel and other bare bright surfaces
(spray with BRANOtect anti-corrosion spray)
▪ checking and if necessary lubricating the turning gear and control rod assembly pivot points
▪ checking and if necessary renewing the seals and covers

8 Storage and transport

The modules must be stored in such a way that these are never subjected to
▪ direct adverse weather conditions (rain, snow, dew, mist and spray),
▪ adverse conditions due to drift sand, aggressive gases, hygroscopic substances and
harmful animals/insects.

Minimum requirements:
▪ roofed enclosed dry space
▪ stowed horizontally
▪ no stacking of packing units or components
▪ protection against other parts that may fall
▪ protection against falling over
▪ protection against direct solar radiation
▪ protective cover (foil) against dirt contamination, inside ventilated to prevent condensate formation
▪ no unauthorised access to parts/components

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Kecht S. Responsible: Wolf S. Release date: 26/05/2015
Index: 6 Page No.: 12 / 17
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0004
Preservation of GE Jenbacher modules

If stored in exposed climatic zones (long-term air humidity > 70%, short-term temperature fluctuations >20°C),
additional protective measures typical for the locality should be considered.

The above-mentioned points must also be observed before transporting the module/engine or plant
components.
Transport must be effected using a suitable vehicle or container with adequate weather protection to ensure
that the item being transported does not come into contact with water. The company in charge of the
transport must ensure that the item being transported reaches the customer's site undamaged, clean and free
of corrosion.

9 Depreservation

Note:
Preserved GE Jenbacher modules must be depreserved before commissioning or recommissioning.

Depreservation before commissioning

1. Remove foil and blanking covers.
2. Remove corrosion inhibitor sponges.
3. Prepare the engine for commissioning.

Notes for commissioning

Commission the engine as per the commissioning check list.

10 Diesel fuel system

At the end of the test run, the engine is operated with special diesel (free of biological additives) until the entire
system is filled with special diesel.
No other measures are necessary.

11 Type 9 engines
For preservation of Type 9 modules, the following points must be observed in addition to the measures
described above:
▪ Close off the engine-TCA connecting pipes and check them before refitting, and clean if necessary.
▪ Lightly spray the inside of the main fuel gas pipe and prechamber gas pipe on the engine with Avilub 832.

11.1 Preservative engine packing

After completely conditioning the engine to ambient temperature (room temperature, +15 to +25 °C) and
carrying out and checking the corrosion protection measures covered in separate instructions, wrap the
component completely with VCI corrosion protection film so that it is as airtight as possible, and secure the film
in a suitable way. In particular, make sure that the film does not damage the corrosion protection applied, and
that the foil is not itself damaged during transport. Apply suitable foam or bubble wrap edge protection at
exposed locations. Penetrations in the VCI film for transport safety pegs and lifting lugs must be sealed up
immediately. The corrosion protection must be applied and vented, and the VCI film wrapping carried out, in
reasonably quick succession (max. 24 hours after applying the corrosion protection), in the same room at a
temperature difference of no more than 5 °C.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Kecht S. Responsible: Wolf S. Release date: 26/05/2015
Index: 6 Page No.: 13/17
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0004
Preservation of GE Jenbacher modules

11.2 TCA module

Preservation of oil and cooling water circuits

▪ TCA module was not put on the test stand: General preservation of the oil and cooling water circuits by
means of nitrogen purging (see the section on Nitrogen Purging).
▪ TCA module was put on the test stand (only applies to oil circuits): no additional preservation is necessary
for the oil circuit.

Preheating module
▪ Conservation the same as for the switchgear cabinet

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Kecht S. Responsible: Wolf S. Release date: 26/05/2015
Index: 6 Page No.: 14 / 17
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0004
Preservation of GE Jenbacher modules

12 Check lists

12.1 Initial conservation check list

Unit number (J XXX):__________ Yes No Date Done by
Internal preservation
Cooling water system water spaces preserved
Crankcase space and oil space drained and drain valves
shut
Cylinder liners sprayed with anti-corrosion oil
Rocker cover space sprayed with anti-corrosion oil
Closing all openings
All openings closed off with blanking covers
External preservation
Bright parts sprayed with BRANOtect corrosion protection
spray
Turning device and control rod assembly greased
Knock sensor, air filters, generator (only for overseas)
sealed with oil paper
Corrosion inhibitor sponges glued in the ignition box,
switchgear cabinets and generator
Flat-bed cooler (optional) flushed with antifreeze
Switchgear cabinet packed in accordance with European
preservation
Switchgear cabinet packed in accordance with overseas
preservation
Gearbox (optional)
(change the gearbox oil as per IW 8071 A0 before commissioning)
Filled with gear oil according to IW 8071 A0
Gearbox closed and sealed airtight
Complete module enclosed in construction foil
Preservation carried out according to TI 1000-0004

Name: Date :

Signature :____________

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Kecht S. Responsible: Wolf S. Release date: 26/05/2015
Index: 6 Page No.: 15/17
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0004
Preservation of GE Jenbacher modules

12.2 Customer check list

Unit number (J XXX):__________ Yes No Date Done by
Photodocumentation sent to GE Jenbacher X X
Preservation carried out according to TI 1000-0004
Visual inspection of preservation foil (engine wrapping)
Preservation foil available on site X X
Foil in good condition without cracks X X
Generator visual inspection
Generator rotor turned after 2 months
(every 2 months)
after 4 months
after 6 months
after 8 months
after 10 months
after 12 months
Engine inspection
Combustion chambers in as-new condition X X
Corrosion marks visible; if yes, additional photos sent to GE
Jenbacher
Combustion chambers in bad condition X X
Cooling water pump for Type 4/6 engines
(new set of gaskets must be fitted at commissioning)
Gasket set available on site X X
Gearbox (optional)
(change the gearbox oil as per IW 8071 A0 before commissioning)
Filled with gear oil according to IW 8071 A0 X X
Gearbox closed and sealed airtight X X
Gearbox shaft turned after 2 months
(every 2 months)
after 4 months
after 6 months
after 8 months
after 10 months
after 12 months

Name: Date :

Signature :____________

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Kecht S. Responsible: Wolf S. Release date: 26/05/2015
Index: 6 Page No.: 16 / 17
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0004
Preservation of GE Jenbacher modules

12.3 Storage and transport check list

Interval
Requirement Monthly Every 2 Before
months commissioning /
storage for longer
than 1 year
Storage and transport conditions
Temperature -15 °C to +50 °C – if this cannot be X
maintained, the grease must be
replaced
Air humidity < 75% (if water has formed the anti- X
condensation heating must be
switched on at commissioning)
Cleanliness Visual inspection: dust, corrosion, X
water formation
Vibration load Check for stability and vibration-free Once per storage location
foundation
Generator storage and transport conditions
Condensation Activate anti-condensation heating X
protection
Generator surface Check the protective coating and X
renew as necessary
Cleaning Clean the cooling openings and X
blow them out with dry air
Roller bearing
Shaft rotation Rotate the generator rotor through X*)
at least 2 revolutions
Grease lubrication Exchange/replace the lubricant X
Plain bearing
Oil lubrication Replace the oil X
Electrical check
Polarisation index Measure the polarisation index (only X**)
for medium- and high-voltage
generators)
Insulation resistance Measure the insulation resistance X**)
*) more than every 2 months after despatch/transport
**) at every commissioning
SprungMarke!!!45035996313955339

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Kecht S. Responsible: Wolf S. Release date: 26/05/2015
Index: 6 Page No.: 17/17
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0041
Requirements on the installation surface for GE Jenbacher plant

1 Purpose
This Technical Instruction describes the requirements for the arrangement surface of GE Jenbacher plants in
terms of flatness, dimensions and load-bearing capacity.

2 General
The particular advantages of our basic engine conception are the high speed and the special balance of the
moved masses. Based on these characteristics, the requirements in terms of the static and dynamic load-
bearing capacity of the arrangement surface are minimal.
However, because of the specially designed frame construction of our elastic module bearings (engine and
generator), very strict requirements have been laid down in terms of the flatness of the arrangement surface.

3 Arrangement surface

3.1 Load-bearing capacity of the arrangement surface

The arrangement surface must be capable of withstanding the static and dynamic loads of GE Jenbacher
plants.
Static load = Plant weight
Dynamic load = ≤3% of plant weight

3.2 Size of the arrangement surface

The arrangement surface can be either a pedestal, a paved surface or the engine-room floor.

3.2.1 Modules
The standard size of the arrangement surface is (frame length +200 mm [7,874 in]) x (frame width +200mm
[7,874 in]).
If an oil collection tray is used as an option, make sure that the dimensions of the arrangement surface at least
match those of the oil collection tray.

3.2.2 Container trailer

The standard size of the arrangement surface is (trailer length +200 mm) x (trailer width +200 mm).
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Beck Responsible: Maderböck M. Release date: 14/05/2012
Index: 3 Page No.: 1/2
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0041
Requirements on the installation surface for GE Jenbacher plant

3.2.3 Container
The container arrangement surface can be either a strip or a slab foundation.
The surface dimensions are contained in the foundation plan or the a base-frame drawing.

3.3 Flatness requirements for the arrangement surface

3.3.1 Modules
Contrary to the standards formulated and valid at this time, it has been agreed that the flatness requirement
for the arrangement surface of the installation will be increased to ± 1.5mm measured across the entire
arrangement surface.

3.3.2 Container trailer

The trailer is installed horizontally (check using a spirit level). Use shims if necessary.

3.3.3 Container
The containers are normally supplied with support plates to enable the container to be arranged horizontally.

3.3.4 If the contractor intends to use a grouting compound to meet the flatness criteria, the following
minimum requirements should be met
1. Swelling ≤ 0,1%
2. Volume stability
3. Strength
Pressure resistance must be at least 25 N/mm² after 24 hours. After 56 and 90 days respectively, there should
be no noticeable reduction in the resistance to pressure.
Any remaining unevenness can be compensated by inserting plates between the module arrangement surface
and the Sylomer strips.
The shim plate thickness must correspond to the deviation (between the plant arrangement surface and the
Sylomer strips) plus ~ 2 mm.

3.4 Surface treatment of the arrangement surface

It is advisable to make the arrangement surface oil- and water-resistant by applying a protective coating.
Many grout products are already water- and oil-resistant, in which case a protective coating is not required.
SprungMarke!!!18014398535958027

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Beck Responsible: Maderböck M. Release date: 14/05/2012
Index: 3 Page No.: 2 / 2
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0043
Transporting and setting up GE Jenbacher switch cabinets

1 Scope
This Instruction applies to GE Jenbacher switchgear cabinets.

2 Purpose
This Instruction describes the transport or movement of GE Jenbacher switchgear cabinets.

3 Corrosion protection and packaging products

Material / Products Remarks
Adhesive tape (incl. dispenser)

Anti-corrosive sponge
part no.: 285878)

Non-woven film Packaging foam, 3mm

part no.: 337858)
Film

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Kecht S. Responsible: Krainz Günter Release date: 16/12/2013
Index: 2 Page No.: 1/5
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0043
Transporting and setting up GE Jenbacher switch cabinets

4 transport
Two anti-corrosive sponges are attached to the inside
of each switchgear cabinet.

Electrical switchgear cabinets are transported upright and film-wrapped:

On disposable pallets:
the base of the cabinet is screwed to the pallet by four
screws inside the switchgear cabinet.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Kecht S. Responsible: Krainz Günter Release date: 16/12/2013
Index: 2 Page No.: 2 / 5
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0043
Transporting and setting up GE Jenbacher switch cabinets

▪ Transport within Europe:

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Kecht S. Responsible: Krainz Günter Release date: 16/12/2013
Index: 2 Page No.: 3/5
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0043
Transporting and setting up GE Jenbacher switch cabinets

▪ Transport overseas:
the cabinet is additionally wrapped in non-woven
film.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Kecht S. Responsible: Krainz Günter Release date: 16/12/2013
Index: 2 Page No.: 4 / 5
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0043
Transporting and setting up GE Jenbacher switch cabinets

In a container:
the switchgear cabinet is secured without pallets.

5 Setting up switchgear cabinets

Always use the lifting lugs mounted on top of the
switchgear cabinet (see the Figure) when setting up or
transporting it. Make sure that you always use the four
lifting lugs when using a crane to transport the
cabinet.
Alternatively, once set up, the switchgear cabinet can
be moved on a transport pallet by means of a suitable
fork-lift device.
The risk of slipping and tipping must be prevented by
securing the cabinet with retaining straps.

SprungMarke!!!9007199281482891

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Kecht S. Responsible: Krainz Günter Release date: 16/12/2013
Index: 2 Page No.: 5/5
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0044
Transport protection

1 Tips
▪ The marked transport pegs protect the engine, the elastic engine and generator bearings from being
damaged on the way to their destination.
▪ Any documents and instruction plates from the original equipment manufacturer that are provided are
supplementary to the GE Jenbacher Technical Instruction and must be observed in addition to it!
Always remove all transport safety pegs before initial commissioning begins!

2 Location of transport safety pegs

2.1 Type 3 engines

In the gear wheel housing to secure the crankshaft
Above the starter Next to the engine turning gear

Remove spacer sleeve, nut and bolt

Between the frame and the engine (on the elastic bearing)

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Wolf Sven Release date: 05/11/2013
Index: 4 Page No.: 1/15
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0044
Transport protection

Remove bolt, filler ring and nut Remove bolt, nut, filler ring and stop square

2.2 Type 4 engines

on the timing cover
to lock the crankshaft
On both engine sides (Starter - Engine turning gear!

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Wolf Sven Release date: 05/11/2013
Index: 4 Page No.: 2 / 15
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0044
Transport protection

Remove spacer sleeve, nut and bolt

Between the frame and the engine (on the elastic Between the frame and the generator (at the elastic
bearing) bearing)

Remove bolt, filler ring, nut and spacer sleeve

2.3 J 612/616/620
Between the frame and the engine (on the elastic Between the frame and the generator (at the elastic
bearing) bearing)

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Wolf Sven Release date: 05/11/2013
Index: 4 Page No.: 3/15
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0044
Transport protection

Remove bolt, filler ring, nut and spacer sleeve

Between the frame and the engine (at the elastic bearing) - generator-sided

Remove bolt, filler ring, nut and intermediate ring (do not remove spacer sleeve)

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Wolf Sven Release date: 05/11/2013
Index: 4 Page No.: 4 / 15
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0044
Transport protection

On transmission housings (optional)

Remove clamping rings, copper plates, bolts, nuts, filler rings and set screws

2.4 J 624
Between the frame and the engine (on the elastic bearing)

Remove the bolt and washer

Between the frame and the generator (at the elastic

bearing)

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Wolf Sven Release date: 05/11/2013
Index: 4 Page No.: 5/15
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0044
Transport protection

Remove bolt, filler ring, nut and spacer sleeve

2.5 Type 9 engines

2.5.1 TCA module

2.5.1.1 Frame reinforcements

NOTICE
Transport safety pegs!
Make sure that all yellow items are always removed before operation and returned to GE
Jenbacher.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Wolf Sven Release date: 05/11/2013
Index: 4 Page No.: 6 / 15
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0044
Transport protection

Engine-side frame reinforcements

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Wolf Sven Release date: 05/11/2013
Index: 4 Page No.: 7/15
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0044
Transport protection

Operator-side frame reinforcements

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Wolf Sven Release date: 05/11/2013
Index: 4 Page No.: 8 / 15
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0044
Transport protection

2.5.1.2 Bridging of suspension

Position of the transport safety pegs (overview)

Position of the transport safety pegs

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Wolf Sven Release date: 05/11/2013
Index: 4 Page No.: 9/15
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0044
Transport protection

Detail view of transport safety pegs

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Wolf Sven Release date: 05/11/2013
Index: 4 Page No.: 10 / 15
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0044
Transport protection

2.5.1.3 Attaching and removing the transport safety pegs

Attachment (on both sides)

Transport safety pegs on intercooler

1. Screw plates TL9008256 (2) using screw TL660760 (3) to intercooler housing TL9002533 (1) (already pre-
mounted on intercooler housing).
2. Screw bolts (15) with nuts (25) in the stops on the TCA module frame.
3. Bolt clamping pieces (5) to support slats (8) and (9) using bolts (30).
4. Insert guide bolt (22) with washer (24) through clamping pieces (5) and screw into mounting bracket on TCA
module frame but do not tighten.
5. Tension clamping pieces (5) (including support slats (8) and (9)) against plates TL9008256 on the intercooler
housing using bolts (15) and lock them using nuts (25).
6. Use spacer plates (6) with screws (23).
7. Tighten screws (23) as per TI so that the intercooler console is lying across the plates TL9008256 on the
intercooler and the support slats (9) are fixed securely to the crossbeam on the TCA module frame.
8. Screw side stop bolts (21) into the strips on the TCA module frame, tension against the intercooler console
and lock them using nuts (25).
9. Use bolts/washers/nuts (32), (33), (34) and (35) to affix the TCA module frame struts to the TCA module
frame.

Removal (on both sides)

1) Remove TCA module frame struts (1) and (2).
2) Turn side stop bolts (21) back to zero position and remove.
3) Remove screws (23) and spacer plates (6).
4) Return clamping pieces (5) and bolts (15) to zero position and secure with guide bolts (22).

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Wolf Sven Release date: 05/11/2013
Index: 4 Page No.: 11/15
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0044
Transport protection

Transport condition

Operating condition

2.6 Generators
Remove all the transport safety pegs below before commissioning and keep them for possible future transport!
Between the frame and the generator (at the flexible mounting)

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Wolf Sven Release date: 05/11/2013
Index: 4 Page No.: 12 / 15
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0044
Transport protection

Type 4, 612, 616 and 620 engines 624

Remove bolt, filler ring, nut and spacer sleeve

Read instruction plates and manufacturer's instructions carefully as additional transport safety pegs still
may be fitted depending on the generator type, as shown in the example below for Leroy Somer type
LSA53, LSA54, LSA56, DIG142 and Toyo Denki generators:
Rotor anti-rotation device - driven end

Rotor anti-rotation device - Leroy Somer Rotor anti-rotation device - Toyo Denki
Rotor anti-rotation device - non-driven end for Leroy Somer generators

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Wolf Sven Release date: 05/11/2013
Index: 4 Page No.: 13/15
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0044
Transport protection

View of the rotor anti-rotation device ④ with cover ② removed.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Wolf Sven Release date: 05/11/2013
Index: 4 Page No.: 14 / 15
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0044
Transport protection

Arrangement of rotor anti-rotation device - side view

Arrangement of rotor anti-rotation device - plan view

① Information plate on generator terminal box

② Cover Observe the tightening torque specified in the
manufacturer's instructions!
③ Information plate on the rotor tied on with cables.
④ Rotor anti-rotation device Observe the tightening torque specified in the
manufacturer's instructions!
SprungMarke!!!27021597790972811
⑤ Cable

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Wolf Sven Release date: 05/11/2013
Index: 4 Page No.: 15/15
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0046
Lifting, transporting and placing GE Jenbacher generating sets in en-
gine rooms.

1 Scope
This Technical Instruction applies to all GE Jenbacher modules with Type 4 and 6 engines.

2 Purpose
This Technical Instruction describes how to lift GE Jenbacher modules, transport them on transport vehicles
and position them in engine rooms. It also describes the correct use and maintenance of the load suspension
device (lifting equipment, chains, ropes, etc.).
The module arrangement surface must comply with the requirements specified in Technical Instruction
1000-0041.

3 Relevant documents
The following documents must also be observed:

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bacher A. Responsible: Wolf S. Release date: 07/05/2015
Index: 10 Page No.: 1/33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0046
Lifting, transporting and placing GE Jenbacher generating sets in en-
gine rooms.

TA 1000-0039 Securing GE Jenbacher modules during transport by truck [⇨ TA 1000-0039, Page 1]

TA 1000-0041 Requirements on the installation surface for GE Jenbacher plant [⇨ TA 1000-0041, Page
1]
TA 1000-0044 Transport protection [⇨ TA 1000-0044, Page 1]
IW 8071 A0 Transmission
IW 8079 A4 Elastically screwed coupling housing
IW 8079 A6 Flexibly-mounted coupling housing

4 General instructions:
Normal operating conditions
These load suspension devices are designed to lift Jenbacher modules in accordance with the relevant
European and national standards, subject to the operating restrictions listed below.

Guidelines for use

Make sure that the load suspension device is only used by a trained operative. During every use, it should be
borne in mind that the load suspension device:
▪ should not have suffered damage that may have an adverse effect on safety and functioning (e.g.
fractures, notches, cracks, cuts, wear, distortion, damage as a result of heat impact, etc.),
▪ should not have suffered bending or torsion,
▪ is not moved across sharp edges without appropriate measures being taken,
▪ is not overloaded due to jolting,
▪ is not used to lift loads in excess of its lifting capacity as specified on the plate (lifting capacity plate, type
plate, label),
▪ is not loaded asymmetrically without the necessary precautions being taken,
▪ is properly used and loaded if it needs to be shortened.
Failing to observe these rules or improper use may result in injury or damage.

Maintenance
Make sure that the load suspension device is checked by an expert at least once a year for external damage,
distortions, wear and corrosion, cracks and breaks and rejected if the defects found are in excess of tolerance
values. No changes may be made during the maintenance that have an adverse effect on the functioning and
lifting capacity of the load suspension device.

Operating restrictions
The load suspension device must not be used in such a way that the load may unintentionally become
detached.

5 Lifting engines and generating sets

Please read and follow the instructions on the stickers affixed to engine and lifting equipment!

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bacher A. Responsible: Wolf S. Release date: 07/05/2015
Index: 10 Page No.: 2 / 33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0046
Lifting, transporting and placing GE Jenbacher generating sets in en-
gine rooms.

Sticker on the frame

Type 4 engine with split frame

Caution: Modules with type 4 engines with split frame should only be lifted without the generator! The engine
frame and generator frame remain in assembled condition for transport.

J 412 with continuous frame and generator LSA 52.2 M60

Caution: Modules with type 4 engines with continuous frame and generator type LSA 52.2 M60 should only be
lifted without the generator!

J 416/420 with continuous frame

Caution: In the case of modules with type 4 engines with continuous frame and a generator with a total weight
exceeding 5,000 kg, the generator must be removed for transport.
Before lifting, check the weight on the generator type plate.
Sticker on engine frame: Sticker on lifting device:

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bacher A. Responsible: Wolf S. Release date: 07/05/2015
Index: 10 Page No.: 3/33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0046
Lifting, transporting and placing GE Jenbacher generating sets in en-
gine rooms.

Diagram for J 412-420 and J 612-620E/F/X Diagram for J 412-420 and J 612-620E/F/X

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bacher A. Responsible: Wolf S. Release date: 07/05/2015
Index: 10 Page No.: 4 / 33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0046
Lifting, transporting and placing GE Jenbacher generating sets in en-
gine rooms.

Diagram for J 624G

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bacher A. Responsible: Wolf S. Release date: 07/05/2015
Index: 10 Page No.: 5/33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0046
Lifting, transporting and placing GE Jenbacher generating sets in en-
gine rooms.

Diagram for J 624H

Diagram showing angle of inclination ▪ When hoisting the module, always ensure that its
maximum permissible angle of inclination in
longitudinal direction does not exceed 5°. If the
angle exceeds 5°, stop the hoisting procedure
immediately!
▪ Before hoisting the module again, first adjust the
hook-in points on the lifting device so that the
permissible angle of inclination is not exceeded.
The hook-in points shown on the lifting device
sticker are for guidance only!
▪ Ensure that the lifting device used (crane, etc.) has
a guaranteed minimum lifting capacity (see type
plate for the engine/module weight).
Make sure that the yellow transport safety pegs are correctly installed when lifting an engine, module or
generator - TI 1000-0044.
Arrangement of the lifting lugs on the engine:
Cylinder number 1 is located on the left side of the engine when facing the flywheel.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bacher A. Responsible: Wolf S. Release date: 07/05/2015
Index: 10 Page No.: 6 / 33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0046
Lifting, transporting and placing GE Jenbacher generating sets in en-
gine rooms.

Cylinder number
① Engine flywheel

Tightening sequence and torques for lifting lugs with hexagonal sleeves and hexagon head bolts:
Tighten the hexagonal sleeve ① on the cylinder head
bolt to be fixed to the specified torque (see table
below).
Place the lifting lug ② on the hexagonal sleeve.
Screw the hexagon head bolt ③ into the hexagonal
sleeve and tighten to the specified torque (see Table
below).

Diagram showing lifting lug with hexagonal sleeve and

hexagon head bolt

Engine type Engine version Part no. Lifting lug To be fitted between cylinder Nm Nm
heads ① ③
J 412 B 1/2 3/4 7/8 9/10 150 150
J 416 B 403246 1/2 3/4 9/10 11/12 150 150
J 420 B/C 2/3 4/5 12/13 14/15 150 150
J 612 E/F 330639 / 393573 4/5 5/6 10/11 11/12 650 650
J 616 E/F 304636 5/6 6/7 13/14 14/15 650 650
J 616 X 9019165 5/6 6/7 13/14 14/15 650 650
J 620 E/F 304636 4/5 8/9 14/15 18/19 650 650
Correct mounting of the special lifting lug for J 616 X (diesel)
Caution: be sure not to damage the high-pressure fuel lines! When fitting the lifting lugs, make sure that no
bolts have to be tightened under the short end of the high-pressure fuel line.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bacher A. Responsible: Wolf S. Release date: 07/05/2015
Index: 10 Page No.: 7/33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0046
Lifting, transporting and placing GE Jenbacher generating sets in en-
gine rooms.

Cylinder bank A Cylinder bank B

Arrangement of the lifting lugs on the mixture cooler unit:

Engine type Engine version Part no. Lifting lug For mounting For mounting Nm Nm
on the mixture between ① ③
cooler unit cylinder heads
J 624 G/H 574980 For positioning, 7/8 9/10 650 650
see drawing
below

J624 Version G:
Use only an ISATEC lifting device (Part No.: 623826).

Cylinder number
① Engine flywheel

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bacher A. Responsible: Wolf S. Release date: 07/05/2015
Index: 10 Page No.: 8 / 33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0046
Lifting, transporting and placing GE Jenbacher generating sets in en-
gine rooms.

J624 Version H:
Use only an ISATEC lifting device (Part No.: 623826).

Cylinder number
① Engine flywheel

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bacher A. Responsible: Wolf S. Release date: 07/05/2015
Index: 10 Page No.: 9/33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0046
Lifting, transporting and placing GE Jenbacher generating sets in en-
gine rooms.

Attach the lifting equipment to the lifting lugs and hoist

the module with a crane or mobile crane.
Make sure when attaching the lifting equipment that
the angle of force is consistent with the V-angle of the
engine (see table below).

Engine type Engine V-angle Part no. Part no. Ideal chain length1) Note
version Lifting Lifting lug [mm]
device
J 412 / J 416 B 70° 301287 403246 798 -
J 420 B/C 70° 301287 403246 798 -
J 612 E/F 60° 301287 330639 715 Standard lug
393573 565 Special lug (long)
J 616 / J 620 E/F 60° 301287 304636 800 -
J 616 X 60° 301287 9019165 727 Special lug for diesel
engines
J 624 G 60° 6238262) 574980 1180 Engine end
505734 751 Generator end
3)
521344 574980 929 Engine end
505734 813 Generator end
2)
J 624 H 60° 623826 574890 1180 Engine end
647283 2045 Generator end
1)
Measure out a length of chain and apply it rounded off to a whole element (same length for both ends), if
necessary using variable stops (intermediate or suspension shackles). Pay attention to operating instructions
and load capacity!
2)
Use lifting device from version K06 only (see type plate)!
3)
Alternative lifting device, single-stage, for 624 only!

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bacher A. Responsible: Wolf S. Release date: 07/05/2015
Index: 10 Page No.: 10 / 33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0046
Lifting, transporting and placing GE Jenbacher generating sets in en-
gine rooms.

The lifting device can be ordered from GE Jenbacher.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bacher A. Responsible: Wolf S. Release date: 07/05/2015
Index: 10 Page No.: 11/33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0046
Lifting, transporting and placing GE Jenbacher generating sets in en-
gine rooms.

6 Lifting generators / generator frames with generator and gearbox

WARNING
Danger to life from using unsuitable lifting points!
Do not lift generators by their transport / lashing lugs, but only by the lifting points provided for
the purpose!

Observe any instruction plates and manufacturer's instructions, as different lifting lugs may be mounted
depending on the generator type. The example below refers to a generator manufactured by Toyo Denki!
Generator - Toyo Denki WD195

① Transport / lashing lugs ③ Lifting points

② Rotor transport
protection

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bacher A. Responsible: Wolf S. Release date: 07/05/2015
Index: 10 Page No.: 12 / 33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0046
Lifting, transporting and placing GE Jenbacher generating sets in en-
gine rooms.

WARNING
Danger to life from using unsuitable lifting points!
The lugs on the generator and gearbox should not under any circumstances be used to lift the
complete generating set.
These lugs should only be used to move the generator frame containing the generator and
gearbox.

Lifting lugs on the Type DIG... generator from Cummins

With gearbox (from September 2014)

Make sure when attaching the lifting equipment to the frame that the spread angle of the longitudinal axis of
all sling chains to the vertical does not exceed 45°.

Lifting lugs on the generator and on the frame

With gearbox (until September 2014)

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bacher A. Responsible: Wolf S. Release date: 07/05/2015
Index: 10 Page No.: 13/33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0046
Lifting, transporting and placing GE Jenbacher generating sets in en-
gine rooms.

Make sure when attaching the lifting equipment to the gearbox that the force angle is the same as the angle of
the lifting lugs.

Lifting lugs on the gearbox

7 Transport on transport vehicles

7.1 General instructions:

Transport safety pegs must be fitted as described in TI 1000-0044.
This applies to lifting modules, transporting them on transport vehicles and positioning them in engine rooms.
Transporting on transport vehicles:
See also TI 1000-0039!
Prevent the risk of slipping and tipping by properly securing the module with retaining straps.
The lashing lugs are not designed to lift modules but only to secure the modules on transport vehicles!

Do not lift the engine by the yellow lashing lugs!

Lifting the motor by the lashing lugs with result in the
lugs breaking off and the engine being seriously
damaged.
Caution! Extreme danger!
Only lift by the lifting lugs provided for the purpose!

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bacher A. Responsible: Wolf S. Release date: 07/05/2015
Index: 10 Page No.: 14 / 33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0046
Lifting, transporting and placing GE Jenbacher generating sets in en-
gine rooms.

① Lifting lug ③ "Lifting prohibited!" sticker

② Lashing lug

7.2 Rail transport

If possible, railway trucks must not be used for transport purposes as rail transport often involves frequent and
hard bumping. Bumping can result in damage to the generator’s roller bearings, also referred to as "false
brinelling" in the technical literature. There is also the risk during shunting of railway trucks being bumped an
pushed away, possibly damaging the engine sliding bearings, and especially the thrust bearings. Cold welding
has been known to be caused by railway trucks being bumped and pushed away resulting in very high axial
accelerations.
If, due to local conditions rail transport cannot be avoided, sylomer strips or other damping elements must be
placed under the module frame (this does not apply to container versions as these are automatically provided
with damping elements). The shipping company must also guarantee that the railway truck carrying the
engine/module will NOT be bumped and pushed away during shunting.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bacher A. Responsible: Wolf S. Release date: 07/05/2015
Index: 10 Page No.: 15/33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0046
Lifting, transporting and placing GE Jenbacher generating sets in en-
gine rooms.

8 Positioning in the engine room

8.1 Positioning Type 6 E/F and J 624 GS engine and Type 4 module
Lifting 2.

Transport on transport
vehicles 3.

YES Crane reaches NO

installation area

Position Sylomer
strips
YES NO
unit with base
Position unit with
crane
YES NO YES NO
Oil drip pan Oil drip pan

Lowering onto Lowering onto Lowering onto

rollers 5.1/a rollers 5.1/b rollers 5.1/c Lowering onto
rollers 5.1/d
Moving on Moving on Moving on
rollers 5.2 rollers 5.2 rollers 5.2 Moving on
rollers 5.2
Transfering onto steel Transfering onto Transfering onto steel
pipes/rollers 5.3 rollers 5.4 pipes/rollers 5.3 Inserting Sylomer
strips 5.5
Inserting Sylomer Inserting Sylomer Inserting Sylomer
strips 5.5 strips 5.5 strips 5.5

Checking Sylomer
strips 5.6

YES NO
Sylomer OK

Inserting plate 5.7

Removing transport
quards TI 1000-0044

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bacher A. Responsible: Wolf S. Release date: 07/05/2015
Index: 10 Page No.: 16 / 33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0046
Lifting, transporting and placing GE Jenbacher generating sets in en-
gine rooms.

8.2 Positioning a generator

Lifting 2.3

Transport on transport
vehicles 3.

YES NO
Crane reaches
installation area

YES NO
unit with base

Lowering onto Lowering onto

rollers 6.1/a rollers 6.1/b

Moving on Moving on
rollers 6.2 rollers 6.2

Transfering onto
rollers 6.3

Connect the generator

and engine 7.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bacher A. Responsible: Wolf S. Release date: 07/05/2015
Index: 10 Page No.: 17/33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0046
Lifting, transporting and placing GE Jenbacher generating sets in en-
gine rooms.

9 Engines and modules cannot be put into place using a crane

9.1 Lowering on to rollers

DANGER
Danger of tipping over!
Do not under any circumstances stand close to the left or right of the module while the module is
stationary on the rollers and/or being moved on rollers.

Position the transport rollers at a distance from the frame I-beams, placing wooden spacer blocks (square
timbers) on the transport rollers, if required.
5.1/a Height of spacer blocks h = min. pedestal height + height of oil collection tray
5.1/b Height of spacer blocks h = min. pedestal height
5.1/c Height of spacer blocks h = min. height of oil collection tray
5.1/d No spacer blocks are required! (The frame can be lowered directly on to the transport
rollers.)

Use a crane to lift the module as far as possible into the building.

① Transport rollers

Position the frame side-member on transport rollers with wooden spacer blocks on top.
The engine should now be positioned almost horizontally on the transport rollers.
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bacher A. Responsible: Wolf S. Release date: 07/05/2015
Index: 10 Page No.: 18 / 33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0046
Lifting, transporting and placing GE Jenbacher generating sets in en-
gine rooms.

9.2 Moving on rollers

There are various options for moving the module on transport rollers.

Diagram of type 4 engine (transport roller positions)

Diagram of J 424 (transport roller positions)

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bacher A. Responsible: Wolf S. Release date: 07/05/2015
Index: 10 Page No.: 19/33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0046
Lifting, transporting and placing GE Jenbacher generating sets in en-
gine rooms.

Diagram of type 6 engine, E/F/X Version (transport roller positions)

Diagram of J 624, G Version (transport roller positions)

9.2.1 Pulling with a forklift or a cable winch

Attach a chain, bar or cable to the module frame cross-member with a textile loop.

9.2.2 Using a forklift truck

If the engine is to be moved using a forklift truck, a protective square timber should be placed at the engine
face between forklift truck and engine. The engine can now be moved by positioning the forklift forks against
this square timber.
Experience has shown that three or four strong people are capable of moving a module. This operation
requires a level floor. Alternatively, steel plates must be laid to make the floor level.
Bear the following in mind in order to prevent damage.
Under no circumstances must force be applied to plant components such as module interfaces, ignition box,
etc.
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bacher A. Responsible: Wolf S. Release date: 07/05/2015
Index: 10 Page No.: 20 / 33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0046
Lifting, transporting and placing GE Jenbacher generating sets in en-
gine rooms.

9.3 Transferring on to steel rollers/tubes

In this case, steel tubes/rollers must be used which are not wider than the oil collection tray and protrude over
the upper edge so that the module frame need only be lifted slightly.
Move the module directly by the oil collection tray.
Install hydraulic jacks at the lifting points.

① Lifting point

As the amount of space available is limited, especially if the engine is equipped with an engine oil pan, bear in
mind the following advice relating to the dimensions of the hydraulic jacks.

Roll suitable steel tubes/rollers in the oil collection tray under the frame and remove the front pair of transport
rollers.
Lower the module on to the steel tubes/rollers.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bacher A. Responsible: Wolf S. Release date: 07/05/2015
Index: 10 Page No.: 21/33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0046
Lifting, transporting and placing GE Jenbacher generating sets in en-
gine rooms.

① Steel tube

Transfer the second pair of transport rollers in the same way.

9.4 Transferring onto rollers

Move the engine directly by its pedestal.
Install hydraulic jacks at the lifting points. Remove the wooden spacer blocks, lift the transport rollers on to the
pedestal and place the module frame on to them.

Diagram of J 616 (transferring the transport rollers)

Transfer the second pair of transport rollers in the same way.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bacher A. Responsible: Wolf S. Release date: 07/05/2015
Index: 10 Page No.: 22 / 33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0046
Lifting, transporting and placing GE Jenbacher generating sets in en-
gine rooms.

Diagram of J 616 (transferring the second transport roller pair)

9.5 Place sylomer strips underneath the generator.

Procedure for the J 624 GS engine - G version:
Place a square timber under one end of the frame. At the other end, the module frame is lifted using hydraulic
jacks.
For reasons of safety, place the module frame on a square timber to prevent it from sagging.
Remove the transport rollers and lay the sylomer strips up to square timber.
If four (4) hydraulic jacks are available, the module can be lifted at both ends to lay and align the sylomer strips
in a single operation.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bacher A. Responsible: Wolf S. Release date: 07/05/2015
Index: 10 Page No.: 23/33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0046
Lifting, transporting and placing GE Jenbacher generating sets in en-
gine rooms.

Diagram of J616 GS (placing sylomer strips underneath the module and aligning them)

Lift the module frame at the other end and remove the square timber.
Lay sylomer strips over the entire length and arrange so that the sylomer strip protrudes evenly all round under
the frame side-members.
Trim the sylomer strips flush with the frame side-members.

Diagram of J616 GS (placing sylomer strips and aligning them)

Procedure for the J 624 TSTC engine - H version:

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bacher A. Responsible: Wolf S. Release date: 07/05/2015
Index: 10 Page No.: 24 / 33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0046
Lifting, transporting and placing GE Jenbacher generating sets in en-
gine rooms.

Lift the module using eight (8) hydraulic jacks to lay and align the sylomer strips in a single operation.

Lay sylomer strips over the entire length and arrange so that the sylomer strip protrudes evenly all round under
the frame side-members.
Lower the module frame evenly and remove the hydraulic jacks.
Trim the sylomer strips flush with the frame side-members.

9.6 Checking the sylomer strips

The module frame must be evenly spread over the entire length of the sylomer strips.
It must not be possible to move the sylomer strips at any point under the frame side-member.

9.7 Inserting shims

If the sylomer strips are unevenly loaded, shim plates must be inserted (under the sylomer strips) at any points
where the sylomer strips can be moved.
The thickness of the inserted plate must correspond to the deviation (between module installation surface and
sylomer strips) plus ~ 2 mm [0.079 in].

10 The generator cannot be put into place using a crane

10.1 Lowering on to rollers

Position the transport rollers at a distance from the frame I-sections, placing spacer blocks on the transport
rollers, if required.
6.1/a Height of spacer blocks h = min. pedestal height
6.1/d No spacer blocks are required! (The frame can be lowered directly on to the transport rollers.)

Position the generator on transport rollers using a crane or forklift truck.

The generator should now be positioned almost horizontally on the transport rollers.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bacher A. Responsible: Wolf S. Release date: 07/05/2015
Index: 10 Page No.: 25/33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0046
Lifting, transporting and placing GE Jenbacher generating sets in en-
gine rooms.

10.2 Moving on rollers

There are various options for moving the generator on transport rollers.

10.2.1 Pulling with a forklift or a cable winch

Attach a chain, bar or cable to the generator frame cross-member with a textile loop.

10.2.2 Pushing with a forklift or manpower

If the generator is to be moved using a forklift truck, a protective piece of squared wood should be placed at
the face between the forklift truck and the frame. The generator can now be moved by positioning the forklift
forks against this piece of squared wood.
Experience has shown that two strong people are capable of moving a generator with no difficulty. This
operation requires a level floor. Alternatively, steel plates must be laid to make the floor level.

10.3 Transferring onto rollers

Move the generator directly by its pedestal.
Install hydraulic jacks at the lifting points. Remove the wooden spacer blocks, lift the transport rollers on to the
pedestal and place the generator frame on them.

Transfer the second pair of transport rollers in the same way.

11 Coupling the generator and engine to each other

11.1 With non-elastic coupling housing

Lift (using a crane) or roll the generator towards the module which was already aligned on the sylomer strips.
Stop the movement when the measuring gauge touches the frame cross-member on the flywheel side.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bacher A. Responsible: Wolf S. Release date: 07/05/2015
Index: 10 Page No.: 26 / 33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0046
Lifting, transporting and placing GE Jenbacher generating sets in en-
gine rooms.

① Measuring gauge ② Frame cross-member at flywheel end

Lift generator using hydraulic lifting equipment. Place sylomer strips underneath the generator. Place sylomer
strips on the engine side underneath the generator (both in longitudinal direction and crosswise).
The generator frame must be evenly spread over the entire length of the sylomer strips.
It must not be possible to move the sylomer strips at any point under the frame side-member.
If an engine oil pan is fitted, the difference in frame height between module and generator must be adequately
compensated for (e.g. all-welded shaped tube frame).

① All-welded shaped tube frame ('shaped tube ② Removing the yellow transport safety pegs
package')
The construction of the generator frame guarantees that the module frame rises above the generator frame
(by approx. 5 mm). This difference is equalised by inserting distance plates.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bacher A. Responsible: Wolf S. Release date: 07/05/2015
Index: 10 Page No.: 27/33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0046
Lifting, transporting and placing GE Jenbacher generating sets in en-
gine rooms.

To insert these plates, the generator should be lifted hydraulically or mechanically using four (4) jacking bolts
(inserted into the fine screw-thread inserts on the generator pedestal).

① Fine screw-thread inserts at the generator ② Install distance plates

frame.

Insert two threaded rods (M16 x 370) opposite to the flywheel casing and pull the generator smoothly towards
the engine by tightening the hexagonal nuts.

① Hexagonal nut ② Threaded rod (M16 x 370)

You should now be able to slide the coupling element (rubber band) into the coupling flange without exerting
too much force.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bacher A. Responsible: Wolf S. Release date: 07/05/2015
Index: 10 Page No.: 28 / 33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0046
Lifting, transporting and placing GE Jenbacher generating sets in en-
gine rooms.

The flange facing of the flywheel casing and coupling housing must be in perfect parallel alignment. Any
deviations should be compensated for by installing distance plates between the generator frame and the
elastic generator bearing.

Radial: max. 2 mm Axial: max. 3 mm Where item A is not accessible,

measure at a point as close as
possible to item A.

Use hexagonal bolts (M16 x ..*) with hardened-steel washers to connect the engine and generator.
*) The length of the bolt differs from one generator type to another.
Tighten the hexagonal bolts using a tightening torque of 190 Nm and then secure them using Loctite 242.

11.2 Type 6 engine with flexibly-mounted coupling housing

▪ Check the module assembly location for evenness.
▪ Install the engine frame and place the sylomer strips underneath the frame.
▪ Fit the coupling collar (aluminium splines)
Tightening torque: 420 Nm (310 lb ft) with LOCTITE® 242®

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bacher A. Responsible: Wolf S. Release date: 07/05/2015
Index: 10 Page No.: 29/33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0046
Lifting, transporting and placing GE Jenbacher generating sets in en-
gine rooms.

Fitting the coupling collar

Remove the transport safety pegs between the frame and the engine (at the flexible mountings). – TI
1000-0044
▪ Remove the bolts from the split frames.

Symbols
① Bolts at the split in the frame

▪ Push the generator completely to the rear within the generator frame (elongated slots in frame).
▪ Lift (slide) the generator frame against the engine frame.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bacher A. Responsible: Wolf S. Release date: 07/05/2015
Index: 10 Page No.: 30 / 33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0046
Lifting, transporting and placing GE Jenbacher generating sets in en-
gine rooms.

▪ Lift the generator frame on side and position the sylomer strips.

▪ Align the height of the generator and engine frames and bolt both frames together tightly.
▪ Remove the transport safety pegs between the frame and the generator (at the flexible mountings). – TI
1000-0044
▪ Slide the generator together with the rubber rails towards the engine (the area between the steel plates
vulcanised on to the rubber rails and the generator frame is greased during assembly in Jenbach to make
sliding the rubber rails easier).
Caution: When sliding the generator using hydraulically powered tools, always position these tools at the
lower steel plate of the rubber rails. Never position them on the generator without first lifting it, as this can
damage the rubber rails.
The generator shaft will probably have to be turned a little in order to introduce the rubber coupling splines
into the aluminium splines on the engine. If necessary, you can adjust the generator height using shim
plates.
▪ Check whether the bolt holes of the flexibly-mounted coupling housing and the threaded holes in the
engine flange are exactly aligned.
Check also whether both connection flanges are parallel to each other.
Further height adjustments (fine adjustments) can be made by removing or adding shim plates. The shim
plates are included in the GE Jenbacher scope of supply.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bacher A. Responsible: Wolf S. Release date: 07/05/2015
Index: 10 Page No.: 31/33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0046
Lifting, transporting and placing GE Jenbacher generating sets in en-
gine rooms.

Checking the bolt holes are aligned for height

Adjusting the height with shim plates Removing or adding shim plates

▪ After aligning the generator, slide the rubber rails as far as possible towards the engine and tighten the
coupling bolts between engine and generator to a tightening torque of 190 Nm, applying Loctite®242 ® to
the threads..

Bolting the coupling between the engine and generator

▪ Finally, check the axial clearance of the flexibly-mounted coupling housing as per IW 8079 A6.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bacher A. Responsible: Wolf S. Release date: 07/05/2015
Index: 10 Page No.: 32 / 33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0046
Lifting, transporting and placing GE Jenbacher generating sets in en-
gine rooms.

11.3 Type 4 engine with flexibly-mounted coupling housing

Measure the axial clearance of the flexibly--mounted coupling housing as per IW 8079 A4.

12 Erection of sets with gearboxes

12.1 Set-up
When handling multiple engines with gearboxes, make sure that the generator and engine frames are
correctly assigned.

① Markings on generator frame ② Markings on engine frame

See IW 8071 A0 when aligning gearboxes and couplings!

Remove the lashing lugs before commissioning.

Fit the knock sensors using the indicated tightening
torques.

SprungMarke!!!81064793319432843

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bacher A. Responsible: Wolf S. Release date: 07/05/2015
Index: 10 Page No.: 33/33
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0050
Batteries (starter and storage)

1 Scope
This Technical Instruction applies to all GE Jenbacher generating sets.

2 Purpose
This Technical Instruction describes how to handle the starter motor batteries and buffer batteries.

3 Safety information

3.1 General safety instructions

ATTENTION
Please observe the safety and hazard information in the safety instructions (TI
2300-0005) and wear the appropriate personal protective equipment (PPE).
Remove electrically-conductive (metal) jewellery and watches before working on electrical
equipment.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Fahringer A. Release date: 13/03/2015
Index: 11 Page No.: 1/15
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0050
Batteries (starter and storage)

WARNING
Acid-filled batteries
a) Do not smoke or strike any naked lights or sparks in the vicinity of batteries.
b) Do not touch the terminals with metallic objects or lay metal tools down on them.
c) Do not overcharge the batteries; the battery temperature must not exceed 50 °C.
d) When charging the batteries, make sure the room is well ventilated.
e) Check regularly that the electrical connections are firmly seated.

WARNING
Touchable voltage / current sources
To avoid short circuits between the battery poles, protect the battery posts against physical
contact with post caps and a battery cover.

3.2 Battery acid

WARNING
Dilute battery acid
Dilute sulphuric acid can cause severe irritation and burns
a) remove contaminated, wet clothing immediately
b) in the event of contact with skin, flush with copious amounts of water
c) after inhaling acid vapours, inhale fresh air immediately and inform a doctor
d) in the event of contact with eyes, flush under running water for several minutes and inform a
doctor
e) in the event of swallowing immediately drink copious amounts of water, swallow activated
carbon and inform a doctor
f) Mop up spilt acid with a binding agent (e.g. sand), neutralise with chalk/soda and then
dispose of these in accordance with local regulations.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Fahringer A. Release date: 13/03/2015
Index: 11 Page No.: 2 / 15
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0050
Batteries (starter and storage)

DANGER
Explosion hazard
There is an acute explosion hazard under the following conditions:
ü The acid level is below its minimum marking.
ü The battery has been short-circuited or seriously overloaded (e.g. by a starting attempt with
a locked motor)
ü The charging voltage is too high (> 30 V)
a) If the acid level is low, top it up with distilled water up to the mark
b) Rectify the cause of the short-circuit or overload.
c) Check the charger

3.3 Lead-acid batteries

DANGER
Explosive mixture
During charging, lead-acid batteries produce hydrogen and oxygen which under certain
conditions may form an explosive mixture.
a) When charging the batteries, make sure the room is well ventilated.

ATTENTION
Lead-acid battery
Do not stand on the battery!

ATTENTION
Mixing different batteries
Starter motor and storage batteries of different makes and types must not be mixed together.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Fahringer A. Release date: 13/03/2015
Index: 11 Page No.: 3/15
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0050
Batteries (starter and storage)

WARNING
Post grease
Wear protective gloves when handling
Wash skin with soap and water in the event of skin contact

4 Specification of the batteries

Engine type Number of Capacity Internal Cold start Note
batteries resistance Ri current CCA [A]
[mOhm]
208 2 batt. 160 Ah < 2.5 1050
312 2 batt. 200 Ah < 2.5 1150
316 2 batt. 200 Ah < 2.5 1150
320 2 batt. 200 Ah < 2.5 1150
412 2 batt. 200 Ah < 2.5 1150
416 2 batt. 200 Ah < 2.5 1150
416 4 batt. 200 Ah < 2.5 1150 with medium-
voltage
generator
420 4 batt. 160 Ah < 2.5 1050 oil-cooled
turbocharger
420 4 batt. 200 Ah < 2.5 1150 water-cooled
turbocharger
424 4 batt. 160 Ah < 2.5 1050
612 4 batt. 200 Ah < 2.5 1150
616 4 batt. 200 Ah < 2.5 1150
620 4 batt. 200 Ah < 2.5 1150
624 6 batt. 200 Ah < 2.5 1150 Single-stage
turbocharger
624 6 batt. 200 Ah < 2.5 1150

5 Starter motor battery

5.1 Commissioning new starter motor batteries

The batteries used by GE Jenbacher are fully charged and ready for use after the battery has been filled with
dilute sulphuric acid.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Fahringer A. Release date: 13/03/2015
Index: 11 Page No.: 4 / 15
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0050
Batteries (starter and storage)

ATTENTION
Filling the battery entails handling acid.
a) Wear suitable personal protective equipment when handling acid (protective gloves, rubber
apron, safety glasses)
b) Washing facilities (wash basin, hose) must be within reach
c) Provide filled eyewash bottles directly at the filling location.

5.1.1 Tips
When filling, both the battery and the acid must have a minimum temperature of +10°C.
Fill the battery with acid just before it is installed (initial commissioning).
Fill the unfilled and charged battery with electrolyte (dilute sulphuric acid) at a density as specified in the
Section "Dilute Sulphuric Acid". The battery is then immediately ready for use.
GE Jenbacher does not supply battery acid!

5.1.2 Dilute sulphuric acid

In order to achieve the best possible efficiency and maximum service life, the following limit values must be
observed for the chemical composition of the dilute sulphuric acid:
Constituent Unit Value Tolerance
1
H2SO4 kg/l 1.270 ± 0.0050
Cl ppm max. 6.0
Fe ppm max. 30.0
NH4 ppm max. 50.0
organic substances ppm max. 50.0
1
The density of the dilute sulphuric acid used depends on climatic conditions at the installation site.
In temperate climate zones, an acid density between 1.270 and 1.280 kg/l should be used (at an acid
temperature of T = 25°C).
In hot climate zones, an acid density between 1.250 and 1.260 kg/l should be used (at an acid temperature of T
= 25°C).

NOTICE
Density as a function of temperature
The density of dilute sulphuric acid varies with temperature. The values given refer to an acid
temperature of 25°C. Any temperature deviations when filling must be taken into account.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Fahringer A. Release date: 13/03/2015
Index: 11 Page No.: 5/15
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0050
Batteries (starter and storage)

5.1.3 Filling procedure

NOTICE
Protection during storage and transport
The battery may be fitted by the manufacturer with additional equipment for protection during
storage and transport. Remove this equipment in accordance with the manufacturer's
instructions.

▪ Unscrew the battery caps. Remove any adhesive strips or sealing washers and discard these.
▪ Fill the battery cells with diluted sulphuric acid up to the top acid level mark (MAX mark).
▪ Allow the battery to stand for 30 - 60 minutes. Then lift the battery at the corners (shake it) to ensure the
acid is thoroughly mixed, and lower it again without damaging it.
Correct the acid level if necessary.

NOTICE
Check the acid level.
When initially filled and also when first charged, the acid level may drop significantly because the
battery acid diffuses into the plates and the level drops as a result. The level also drops during
the actual charging.
Check the level before connecting the battery to the module and correct as necessary.

▪ Screw on the battery caps hand-tight.

The battery is now ready for use and to be installed in the generating set .

NOTICE
Observe the manufacturer's information
The manufacturer's instructions for the various battery types must be observed.

First charge:
After being filled with sulphuric acid, the starter motor battery should be charged with a special charger until it
gases. Make sure the battery is well ventilated for this.
A first charge continued up to gassing increases the battery service life.

Vibration-damped mounting:
The starter motor battery should be mounted on a vibration-damping base. This increases the service life of the
starter motor battery.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Fahringer A. Release date: 13/03/2015
Index: 11 Page No.: 6 / 15
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0050
Batteries (starter and storage)

Mechanical protection of the battery by a base plate and cover:

The battery must be protected against mechanical damage by a cover. The battery should also be mounted on
a tray to prevent damage from sharp objects on the engine room floor.

5.2 Removal / installation of batteries

WARNING
Danger from unauthorised restarting!
a) Shut down the engine in accordance with Technical Instruction No. 1100-0105.
b) Secure the engine against unauthorised restarting in accordance with Technical Instruction
no. 2300-0010.

The following work may only be carried out by specialist staff having the relevant electrical training.

5.2.1 Removal
Before starting to remove the starter batteries, a few safety precautions must be taken (see also DIN EN
50272-2:2001 Section 10.4):
Allow sufficient clear space around the working area.
Keep an escape route > 600 mm wide in case of an evacuation.
Switch the main fuses for the buffer and starter
batteries to OFF.
Switch off the main fuse(s) for battery chargers or
switch off the main breaker for auxiliary equipment.
See the plant circuit diagram.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Fahringer A. Release date: 13/03/2015
Index: 11 Page No.: 7/15
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0050
Batteries (starter and storage)

Secure the main fuses against being switched back on.

Check that there is no current.

This can be tested at the starter motor battery leads
with a clip-on ammeter for direct current.

For Type 6 engines: remove the tread plate.

Avoid situations where people can trip over expanding

anchors or other fastenings.

Remove the battery covers.

Version without starter terminal box

Disconnect the negative terminal of the batteries from
the module frame, insulate the detached terminal
cable and place it on the floor

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Fahringer A. Release date: 13/03/2015
Index: 11 Page No.: 8 / 15
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0050
Batteries (starter and storage)

Version with starter terminal box

Disconnect the negative contact in the starter terminal
box

Version with starter connecting bars

Lift off the acrylic cover.

Remove the contact at the copper bar using an

insulated open-ended wrench.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Fahringer A. Release date: 13/03/2015
Index: 11 Page No.: 9/15
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0050
Batteries (starter and storage)

Remove the connections to the batteries using an

insulated open-ended wrench.
1. Disconnect the negative terminal
2. Disconnect the positive terminal
Insulate the battery terminal posts with post caps or
suitable self-adhesive tape.
Remove the batteries and stow them securely:
▪ do not stack them
▪ a battery carelessly placed somewhere represents
a hazard that can trip somebody over

Lifting heavy loads

Manual lifting of heavy loads can result in physical injury.
Starter motor batteries may only be lifted by two people (for loads up to 50 kg), or with the aid
of a suitable hoist with a load capacity greater than 70 kg.
Loads over 50 kg may only be moved with the aid of a suitable hoist.
⇨ Weight of the batteries used: see the section "Lead-Acid Batteries".

5.2.2 Installation
Grease the battery pole posts with post grease.
1. Place the cable on the negative terminal.
2. Place the cable on the positive terminal.
Secure the terminals with an insulated open-ended
wrench.

Version without battery terminal box

Connect the negative terminal of the batteries to the
module frame

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Fahringer A. Release date: 13/03/2015
Index: 11 Page No.: 10 / 15
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0050
Batteries (starter and storage)

Version with starter terminal box

Connect the negative contact in the starter terminal
box.

Version with starter connecting bars

Connect the contact at the copper bar.
Check that all the connections are tight and intact.

Refit the acrylic cover.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Fahringer A. Release date: 13/03/2015
Index: 11 Page No.: 11/15
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0050
Batteries (starter and storage)

Refit the battery covers.

For Type 6 engines: fit the tread plate and connect it

to the foundation.

Check that all the work in the hazardous areas has

been completed and that there is no danger to people
or machinery.
Remove the LOTO locks.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Fahringer A. Release date: 13/03/2015
Index: 11 Page No.: 12 / 15
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0050
Batteries (starter and storage)

Switch the main fuses for the buffer and starter

batteries to ON.

5.2.3 Connecting the starter motors

5.2.3.1 Connecting the battery cable to the starter motors

The bolts on the positive and negative terminals on the starter motors are copper or brass. It is essential to
observe the specified tightening torques for the pole nuts.
Cable terminals may only be connected and disconnected at the starter motor if the battery has been
disconnected and the fuse switched off.
The tightening torques can be found in the technical instructions for the specific engine in question:
▪ TI 1902-0212: Screwing and tightening torques for type 2 and 3 engines
▪ TI 1902-0213: Screwing and tightening torques for type 4 engines
▪ TI 1902-0212: Screwing and tightening torques for type 4 version D engines
▪ TA 1902-0228 C: Screwing and tightening torques for type 6 version C engines
▪ TI 1902-0228 E/F: Screwing and tightening torques for type 6 version E/F engines [⇨ TA 1902-0228E/F,
Page 1]
▪ TI 1902-0228 G/H: Screwing and tightening torques for type J 624 version G/H engines
▪ TI 1902-0228 DS: Tightening torques J 6..DS

5.2.3.2 Protection against accidental contact for the starter motor system
The electrical contacts of the batteries must be protected against possible short circuits. Contact covers
complying with the degree of protection IP 20 must be used for this.
Starter motor battery poles, battery cable, battery bus bars and starter motor terminals are protected against
accidental contact to protection class IP2X or IPXXB (protection against insertion of fingers).

5.3 Maintenance instructions

Repairing the battery is not permitted. Modifying the battery in any way may cause it to explode.
Keep to the maintenance interval specified in the maintenance plan. If the water consumption increases,
reduce the maintenance interval accordingly.
When working on batteries, make sure that washing facilities are present in the immediate vicinity.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Fahringer A. Release date: 13/03/2015
Index: 11 Page No.: 13/15
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0050
Batteries (starter and storage)

Please observe the safety and hazard signs in the safety instructions
(TI 2300-0005) and wear the appropriate personal protective equipment.
Always keep the battery dry and clean. Protect the battery poles by applying battery pole grease or pure
vaseline.
A carefully maintained and completely charged battery is your best guarantee for trouble-free starting.
An increase in the battery water consumption is a sure sign of battery overcharging causing a strong reduction
of the battery service life. Check the battery charge condition and, in the event of malfunction, inform GE
Jenbacher immediately.
An increased ambient temperature can also affect battery water consumption. If this is the case, the inspection
interval must be reduced accordingly as described in the maintenance plan.

5.3.1 Visual inspection

Check the battery housing for damage. Check the battery poles for defects caused by short circuits or damage
of a mechanical nature. If necessary, replace the battery.
The battery cover must always be fitted to the battery during operation. The cover may only be removed for
maintenance work.
Do not step on the cover.

The cover over the battery connections must always be fitted.

5.3.2 Acid condition/density

DANGER
Explosion hazard
There is an acute explosion hazard under the following conditions:
ü The acid level is below its minimum marking.
ü The battery has been short-circuited or seriously overloaded (e.g. by a starting attempt with
a locked motor)
ü The charging voltage is too high (> 30 V).
a) If the acid level is low, top it up with distilled water up to the mark
b) Rectify the cause of the short-circuit or overload.
c) Check the charger

If the acid level falls to near or below the minimum level, the appropriate amount of distilled water should be
added (never use tap water or acid) to bring the level up to maximum.
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Fahringer A. Release date: 13/03/2015
Index: 11 Page No.: 14 / 15
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0050
Batteries (starter and storage)

The acid density level is indicative for the charge condition of the battery. The acid density level is measured
using an acid tester. When testing, make sure to sample acid from every battery cell.
With a fully-charged battery and the correct acid level, the acid density value should comply with the
values in the section "Dilute Sulphuric Acid".
ü If the acid density is too low in a large number of cells (<= 1.20 kg/l), insufficient charging is probably the
cause.
a) Disconnect the battery from the charger, set the no-load voltage of the charger to 27.2V and reconnect the
battery.
ð The acid density must be > 1.20 kg/l after one hour.
ð If it is not, replace the battery.
If one or some of the battery cells show an abnormally low acid density level (> 0.015 kg/l), it may be assumed
that the battery plates are short-circuiting. Gassing usually occurs in faulty cells during charging. If this occurs,
discontinue charging at once and replace the battery.

5.3.3 Storage
Storing unfilled batteries
Unfilled batteries are maintenance-free.
The storage room must be dry.
Storing filled batteries
Charge disconnected batteries approx. every 4 weeks.

5.4 Cabling
Only use suitable battery terminals, such as those supplied by GEJ. The battery terminals supplied by GEJ with
a cross-section of 120 mm² can take a cable cross-section up to 150 mm².
The battery cables between each battery and the electrical connection to the motor must all be of the same
length.

6 Storage batteries
Storage batteries are supplied filled and charged. They are ready for operation immediately after installation
and are maintenance-free.
Storage batteries must be replaced after expiry of their service life in order to ensure proper storage battery
function. The necessary replacement interval can be taken from the maintenance plan.

7 Disposal
Observe local regulations when disposing of batteries.
In Europe: Directive 2006/66/EC ("Battery Directive")
SprungMarke!!!90071992574273163

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Fahringer A. Release date: 13/03/2015
Index: 11 Page No.: 15/15
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0052
TRIO-PS/3AC/24DC/40 battery charger

1 Components............................................................................................................................................... 1
2 Signals......................................................................................................................................................... 1
3 Adjustment instructions .......................................................................................................................... 2
3.1 Charger for Phoenix 1 x 40 A battery for starter motor / control unit.............................................. 2
3.2 Charger for Phoenix 2 x 40 A battery for starter motor / control unit.............................................. 2
3.3 Charger for Phoenix 3 x 40 A battery for starter motor / control unit.............................................. 2

Please observe the safety and hazard signs in the safety instructions
(TI 2300-0005) and wear the appropriate personal protective equipment.
The charger is set to the required operation in the factory and does not require further operation.

1 Components

TRIO charger
① AC input ④ LED "DC OK"
② DC output ⑤ Assembly rails adapter
③ Potentiometer 22.5 V DC ... 29,5 V DC ⑥ Opening for cable ties

2 Signals
Condition 1 Condition 2
LED "DC OK" lights up off
Cause Output voltage Output voltage < 21.5 V or no output voltage
> 21.5 V

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Boxleitner Responsible: TKE/Grain Release date: 24/10/2011
Index: 1 Page No.: 1/2
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0052
TRIO-PS/3AC/24DC/40 battery charger

Condition 1 Condition 2
Meaning Output voltage and The TRIO POWER is operational but there is a
output current are "OK". consumer malfunction. The current consumption
exceeds IN or the output is short circuited.
The TRIO POWER is not operational because there
is no mains supply voltage, the primary-side fuse
has been activated or the charger is defective.

3 Adjustment instructions

3.1 Charger for Phoenix 1 x 40 A battery for starter motor / control unit
Parameters Value Remarks
Trickle charge voltage 26.8 V Adjust during no-load operation with the
"adjust" potentiometer.
Static current limitation approx. 1.15 x 40 A = 46 A Can be ascertained immediately after a
number of starting operations.

3.2 Charger for Phoenix 2 x 40 A battery for starter motor / control unit
Parameters Value Remarks
Trickle charge voltage 26.8 V Adjust during no-load operation with the
"adjust" potentiometer.
2 chargers connected in parallel : Set the chargers individually to 26.8 V.
When operating 2 chargers in parallel with a minimum charger load of 50%
(as found immediately after several starting operations), check the correct
current distribution with a clamp-on ammeter (permissible difference 10%).
Measured current at charger 1 ............A
Measured current at charger 2 ............A
Static current limitation approx. 2 x 1.15 x 40 A = 92 A

3.3 Charger for Phoenix 3 x 40 A battery for starter motor / control unit
Parameters Value Remarks
Trickle charge voltage 26.8 V Adjust during no-load operation with the
"adjust" potentiometer.
3 chargers connected in parallel : Set the chargers individually to 26.8 V.
When operating 3 chargers in parallel with a minimum charger load of 50%
(as found immediately after several starting operations), check the correct
current distribution with a clamp-on ammeter (permissible difference 10%).
Measured current at charger 1 ............A
Measured current at charger 2 ............A
Measured current at charger 3 ............A
SprungMarke!!!1148429067
Static current limitation approx. 3 x 1.15 x 40 A = 138 A

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Boxleitner Responsible: TKE/Grain Release date: 24/10/2011
Index: 1 Page No.: 2 / 2
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0099A
Approval procedure for various engine oils

1 Scope
This Technical Instruction applies to Jenbacher gas engines.

2 Purpose
This Technical Instruction gives directions on how to carry out a lubricating oil approval procedure for GE
Jenbacher on application by an external party.
It sets out all the requirements, conditions and actions necessary for the approval to be granted.

3 General
An approval procedure is usually requested by a lubricating oil manufacturer, but additive manufacturers,
service partners and partnerships consisting of a number of parties can have an interest in the approval of a
lubricating oil.
The party interested in the oil approval procedure is referred to below as the "supplier".
The party ultimately responsible for the engine and its operation is referred to as the "customer".
If all the requirements and conditions set out in the Technical Instruction are met and the product has passed
an approval procedure, it will be included in the appropriate class in the list of recommended lubricants.
Discussions on the continued presence of the product in the list of selected oils will be held no later than 4
years after the product approval. The continued presence in the list of selected oils depends on the technical
requirements of the engine, traceability of the product, constancy of the product specifications and positive
field experiences.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bilek F. Responsible: Nota F. Release date: 26/05/2015
Index: 7 Page No.: 1/4
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0099A
Approval procedure for various engine oils

The suitability of a lubricating oil is determined by means of a field test on a customer's engine. A field test can
only be carried out with the knowledge and approval of the customer and with his support. A contract to this
effect will be concluded between the supplier and the customer laying down the procedure of the field test and
the responsibilities of the contracting parties.
Use of a non-approved lubricating oil is basically the responsibility of the customer. GE Jenbacher will therefore
ask the supplier to guarantee in writing that they will indemnify the customer against any damage due to use
of the lubricating oil. Damage due to use of the lubricating oil includes not only breakage of engine
components, but also increased wear and deposits and any resulting down times, additional maintenance
work and loss of profit.
Any costs incurred by GE Jenbacher in connection with the oil approval will be borne by the supplier.
GE Jenbacher reserves the right to decline or delay an oil approval procedure, despite a suitable product
specification, for organisational reasons.
GE Jenbacher reserves the right not to approve a lubricating oil. Reasons for this can include:
▪ the results of the field test show a lack of suitability for use in GE Jenbacher engines
▪ the record of the field test is inadequate (e.g. insufficient oil analyses, or the oil consumption, filter service
lives or incidents relevant to the lubricating oil were not properly documented).
▪ the field test was not representative (e.g. it was conducted under reduced load, incidents occurred or
lubricated parts suffered damage so that the findings cannot be properly classified, etc.)
Technical Instructions applicable as part of an oil approval procedure:
TI 1000-0099B - Analysis program and limit values for used oil
TI 1000-0099C - Testing the site-specific oil service life
TI 1000-0099D - Analysis of the ipH value
TI 1000-0300 - Fuel gas quality
TI 1000-0112 - Sampling lubricating oil

4 Conducting oil approval procedures

4.1 Application
The supplier must apply to GE Jenbacher for consent to carry out an oil approval procedure for a defined test
candidate in a specific engine type and for a specific fuel gas class.

4.2 Product specification and laboratory screening tests

The supplier shall provide the specifications and the results of the laboratory screening tests in accordance
with the appopriate form (GE Jenbacher Requirements for Lube Oils). If the use of different production plants
means that different base oils may be used in the product, the specifications of all the qualities used must be
provided and laboratory screening tests be carried out.
GE Jenbacher will then decide on the basis of this data whether an engine test may be carried out with the test
candidate.

4.3 Engine test

The engine test will take place on customers' engines. In order for a lubricating oil to be approved, a field test
must be carried out on 2 engines in different plants. Discussions must be held with GE Jenbacher before the
start of the test as to which engines are suitable for an approval test. If a lubricating oil is to be tested for fuel
gas class B or C, the gas at the test plant must be of poor quality but still just acceptable under TI 1000-0300.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bilek F. Responsible: Nota F. Release date: 26/05/2015
Index: 7 Page No.: 2 / 4
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0099A
Approval procedure for various engine oils

The supplier shall identify possible test engines and provide the engine numbers or plant identification
numbers. GE Jenbacher can then decide on the basis of this data whether that engine is suitable for an oil test.
A test engine must be of the latest technical version.
An oil test should be conducted on a new engine immediately after commissioning if at all possible.
If an oil test has to be carried out on an engine already in operation, the following preconditions must be met:
▪ The engine must be suitable for an oil test in principle on the basis of its technical condition, its version and
the operating hours it has already accumulated.
▪ All incidents relevant to lubricating oil must be known.
▪ The oil history in accordance with TI 1000-0099 B and C must be continuous with no gaps and nothing
unusual.
▪ 4 cylinder units will be replaced before the test start.
▪ All the combustion chambers will be cleaned before the test start.
▪ The oil filters will be replaced again after the running-in programme.
▪ An oil counter will be installed.

4.4 Test contract

After the test engines have been identified, the supplier will conclude a test contract with the customer. This
contract shall set out the responsibility of the oil manufacturer as regards any possible damage and
consequential damage due to the lubricating oil. Consequential damage shall include increased wear and
deposits, and any resulting unexpected downtime, additional maintenance work and loss of earnings. It is
advantageous to document the test procedure and the necessary activities in detail, in particular who has to
carry out which activities.

4.5 Test start and conduct

New oil filters will be fitted at the start of the test.
An oil counter will be fitted at the start of the test. This can be ordered from GE Jenbacher under the part
number 581384.
During the first oil interval, oil samples will be taken every 150 hours for fuel gas class A or every 75 hours for
fuel gas classes B and C. On all other oil intervals, the sampling interval can be extended to 300 and 150 hours
respectively. An oil sample should be taken approximately 2 hours after the start of the test and approximately
2 hours after an oil change.
Used oil analyses shall be carried out at a GE Jenbacher partner laboratory in compliance with TI 1000-0099 B.
The supplier must order part no. 510132 (starter package) and part no. 506604 (top-up package) from GE
Jenbacher for this.
If an oil parameter limit value under TI 1000-0099 B is reached or exceeded, the oil must be changed.
Premature oil changes can falsity the findings and are therefore only allowed with the express permission of GE
Jenbacher. This shall not apply to any necessary repairs which entail an oil change, or to premature oil
changes due to public or staff holidays. Falsified results can lead to refusal of the approval.
Daily oil consumption measurements must be carried out, and the oil counter reading and active power
demand must be recorded. Oil consumption data must be provided to GE Jenbacher no later than the same
time as the used oil data.

Do not include the oil volume required for the oil change (bypass the oil counter).
Care must be taken to ensure that an uninterrupted operational logbook is kept.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bilek F. Responsible: Nota F. Release date: 26/05/2015
Index: 7 Page No.: 3/4
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0099A
Approval procedure for various engine oils

4.6 Test duration

The test duration for each engine shall be at least 6,000 operating hours. No modifications may be made to the
lubricating oil during this time. The engine operating conditions must be held as constant as possible.
GE Jenbacher cannot guarantee that the field test will finish as soon as the minimum duration has elapsed.
Delays may be incurred for organisational reasons, e.g. at times when the engine cannot be shut down. This
requires a certain amount of flexibility of the part of the customer and the supplier.

4.7 Examination of the engine

The engine examination shall place after a minimum of 6,000 engine operating hours. The examination shall be
conducted by a specialist from GE Jenbacher and must be requested from the GE Jenbacher headquarters.
The following part numbers can be ordered as a complete oil examination package. These are the flat-rate
costs that cover all outgoings such as materials, examination, mechanics, examiners, travel costs, etc.
Engine type Part number (part no.)
Type 3 engines Part no. 658916
Type 4 engines Part no. 658917
Type 6 engines Part no. 658918

The engine examination includes endoscopy of the combustion chambers, and engine dismantling. An
examination generally requires an engine shut-down of approximately 3 days. The examination timing shall be
established by agreement between GE Jenbacher, the customer and the supplier. However, GE Jenbacher
cannot guarantee that GE Jenbacher technicians will be available at a time requested by a customer.
The examination shall be carried out in accordance with GE Jenbacher guidelines.

4.8 Rebrand approvals

Rebrand products are engine lubricating oils which are not being used for the first time in a GE Jenbacher
product (new product), but are being used within a new business context (different supplier). The following
conditions apply for including such a product in TI 1000-1109 under a new name:
▪ The original product must hold a GE Jenbacher approval.
▪ Confirmation or declaration of consent from the original manufacturer and a request by the rebrand
manufacturer for a rebrand approval.
▪ Renewal of the confirmation or declaration of consent from the original manufacturer at 2-yearly intervals.
Responsibility for the product lies with the oil supplier.
A rebrand approval can be ordered under the following part numbers:
Engine type Part number (part no.)
Type 3 engines Part no. 658974
Type 4 engines Part no. 658975
SprungMarke!!!54043195551824651
Type 6 engines Part no. 658976

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bilek F. Responsible: Nota F. Release date: 26/05/2015
Index: 7 Page No.: 4 / 4
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0099B
Limit levels for used oil in GE Jenbacher gas engines

1 Application ................................................................................................................................................. 1
1.1 Brief Instruction .......................................................................................................................................................... 2
2 Analysis programme - limit / alarm values ......................................................................................... 2
2.1 Oil condition ................................................................................................................................................................. 2
2.2 Contaminants.............................................................................................................................................................. 3
2.3 Metallic elements....................................................................................................................................................... 3
2.4 Oil additive elements ............................................................................................................................................... 4
3 Interpretation of used oil values and measures based on them ..................................................... 4
3.1 Oil condition characteristics ................................................................................................................................ 4
3.2 Impurities....................................................................................................................................................................... 5
3.3 Metallic elements....................................................................................................................................................... 6
3.4 Additive elements...................................................................................................................................................... 6
4 Used oil reports ......................................................................................................................................... 6
5 Documentation for used oil analyses ................................................................................................... 6

1 Application
This Technical Instruction gives directions on the oil care for GE Jenbacher gas engines.
Other applicable Technical Instructions: 1000-0099C (analysis intervals)
1000-0099D (determination of the ipH value)
1000-0112 (sampling)

GE Jenbacher oil monitoring programme

The scope of the analysis and the assessment and evaluation of the used oil analyses can only be guaranteed
to have been carried out in accordance with GE Jenbacher guidelines if the GE Jenbacher analysis system is
used (part number 510132).
The special GE Jenbacher colour code allows simple decisions to be taken about necessary measures (Caution:
only applicable to GE Jenbacher partner laboratories)
Green No action necessary before the next sample
Yellow Change the oil before the next sample
Red Contact your Technical Service Hotline

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Entwicklung/Chvatal S. Responsible: Entwicklung Release date: 26/05/2015
Index: 6 Page No.: 1/7
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0099B
Limit levels for used oil in GE Jenbacher gas engines

Caution
The GE Jenbacher colour code and the actions derived from it only apply to the GE Jenbacher oil monitoring
programme. Third-party laboratories may possibly use the same traffic light colours but not the same derived
necessary actions. The use of third-party laboratories is allowed. However, the scope of the analysis, evaluation
of the data and the measures based on these recommended by third party laboratories do not necessarily
comply with the GE Jenbacher guidelines.
Evaluation of the used oil analysis data and measures based on it must be done by the responsible person in
accordance with theGE Jenbacher guidelines (see Sections 2 and 3).

1.1 Brief Instruction

▪ Lubricating oil in internal combustion engines changes and ages as a function of the operating conditions..
▪ The lubricating oil in GE Jenbacher Gagas engines must be changed depending on its condition. GE
Jenbacher does not issue any guaranteed fixed oil change intervals.
▪ Lubricating oil must be tested for serviceability on a regular basis. (See TI 1000-0099C) for the analysis
interval).
▪ The analysis programme must be carried out in its entirety (see Section 2).
▪ The limit and alarm values must be observed (see Section 2).
▪ The analysis reports must be documented and kept by the customer, and submitted to GE Jenbacher
suitable form on request.
▪ The analysis reports must show a trend. At least 5 analysis reports (see Section 5 for an example).
▪ See Section 3 for the interpretation of the analysis data, and for measures to be taken.
▪ The customer is responsible for ensuring that samples are sent to the laboratory immediately after they are
taken. The time between a sample being taken and its arrival at the laboratory must not exceed 5 days.
▪ If a change is made to another brand of lubricating oil, the products must not be mixed in the storage tank
or oil pan. The amount of residual oil held in the engine and storage tank must be kept as low as possible. If
oils are mixed, the various oil characteristics can no longer be correctly interpreted.

2 Analysis programme - limit / alarm values

Parameters and limit values only apply for lubricants approved for GE Jenbacher engines in accordance with TI
1000-1109.
Parameters and alarm levels apply to wear and corrosion products. These alarm levels are not applicable when
bypass filters are used.

2.1 Oil condition

Information
Programme Unit Limit level Guideline Oil Engine Gas
point
Viscosity at 100°C mm²/sec, cSt ≥ fresh oil +3 and ≥ DIN 51562 x
17≥16.9 *)
Viscosity at 40°C mm²/sec, cSt ≥ fresh oil +25% DIN 51562 x

Base number BN mg KOH/g ≤ 50% of the fresh oil DIN ISO 3771 x
(TBN) ≤ 2.5 *)
Acid number AN mg KOH/g ≥ fresh oil value +2.5 DIN ISO 3771 x
(TAN) ≥ fresh oil value +3 *)

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Entwicklung/Chvatal S. Responsible: Entwicklung Release date: 26/05/2015
Index: 6 Page No.: 2 / 7
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0099B
Limit levels for used oil in GE Jenbacher gas engines

Information
Programme Unit Limit level Guideline Oil Engine Gas
point
ipH value - ≤ 4.0 GE Jenbacher TA 1000-099D x
method
≤ 4.5 Mobil method
Ageing (oxidation) ABS/cm ≥ 20 IR spectroscopy x
≥ 30 *)
IR nitration ABS/cm ≥ 20 IR spectroscopy x
≥ 30 *)
Soot % ≥2 IR spectroscopy x
*) for Mobil Pegasus 1005 only

2.2 Contaminants
Information
Programme Unit Limit level Guideline Oil Engine Gas
point
Sodium (Na) ppm, mg/kg 20 DIN 51396/3 x
Potassium (Ka) ppm, mg/kg 5 DIN 51396/3 x
Chlorine (Cl) ppm, mg/kg - DIN 51396/3 x
Glycol % 0.02 x
Water % 0.2 x x
Silicon (Si) ppm, mg/kg 20 DIN 51396/3 x
(Class A)
Silicon (Si) ppm, mg/kg 200 DIN 51396/3 x
(Class B, C)
Sulphur (S) ppm, mg/kg - DIN 51396/3 x x

2.3 Metallic elements

Information
Programme Unit Alarm levels Guideline Oil Engine Gas
point
Iron (Fe) ppm, mg/kg 20 DIN 51396/3 x
Aluminium (Al) ppm, mg/kg 15 DIN 51396/3 x
Chromium (Cr) ppm, mg/kg 5 DIN 51396/3 x
Copper (Cu) ppm, mg/kg 15 DIN 51396/3 x
Tin (Sn) ppm, mg/kg 5 DIN 51396/3 x
Lead (Pb) ppm, mg/kg 20 DIN 51396/3 x

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Entwicklung/Chvatal S. Responsible: Entwicklung Release date: 26/05/2015
Index: 6 Page No.: 3/7
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0099B
Limit levels for used oil in GE Jenbacher gas engines

2.4 Oil additive elements

Information
Programme Unit Limit values Guideline Oil Engine Gas
point
Calcium (Ca) ppm, mg/kg - DIN 51396/3 x
Zinc (Zn) ppm, mg/kg - DIN 51396/3 x
Phosphorus (Ph) ppm, mg/kg - DIN 51396/3 x
Boron (B) ppm, mg/kg - DIN 51396/3 x
Molybdenum (Mb) ppm, mg/kg - DIN 51396/3 x

3 Interpretation of used oil values and measures based on them

It is quite normal for the properties of lubricating oil to change (through ageing) in the course of operation. The
lubricating oil must therefore be changed in good time, in other words before it becomes unserviceable. The
lubricating oil can be prevented from becoming unserviceable if it is changed when the limit values of an
analysis variable are reached.

3.1 Oil condition characteristics

Viscosity ➢ If the limit value has been reached, the oil must be changed.
Viscosity is a measure of the fluidity of lubricating oil and is temperature-dependent. Viscosity increases as a
result of thermal loading and ageing of the oil.

Oxidation ➢ If the limit value has been reached, the oil must be changed.
Ageing
Oil oxidation is due to the lubricating oil reacting with oxidised combustion products. Oxidation increases
during usage. Oxidation products can contribute to the formation of organic acids, so that corrosion cannot be
ruled out.

Nitration ➢ If the limit value has been reached, the oil must be changed.
Oil nitration is due to the lubricating oil reacting with oxides of nitrogen. Nitration increases during usage. There
is a danger of the formation of corrosive reaction products.

Base number ➢ If the limit value has been reached, the oil must be changed.
The base number (BN, TBN) denotes the alkaline reserve of the lubricating oil, and characterises its chemical
neutralising capacity. The alkaline reserve of the lubricating oil is constantly reduced with continued usage due
to its reaction with acids. A rapid reduction in the total base number is to be expected when operating with
contaminated fuel gases (biogases, sludge gases or landfill gases).

Acid number ➢ If the limit value has been reached, the oil must be changed.
TAN, AN
Oxidation and nitration processes can lead to the formation of weak organic acids which are only partially
neutralised by the basic reserve of the lubricating oil. The TAN increases during usage. A sharp increase in the
acid number is to be expected when operating with contaminated fuel gases (biogases, sludge gases or landfill
gases).

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Entwicklung/Chvatal S. Responsible: Entwicklung Release date: 26/05/2015
Index: 6 Page No.: 4 / 7
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0099B
Limit levels for used oil in GE Jenbacher gas engines

ipH value ➢ If the limit value has been reached, the oil must be changed.
Determination of the ipH value is absolutely essential when using non-natural gas fuels. The presence of acids
in these fuel gases before combustion cannot be ruled out, even if the BN value has not yet reached its limit.
The ipH value decreases steadily during usage.

Soot ➢ If the limit value has been reached, the oil must be changed.
Experience has shown that gas engines do not form soot. However, soot formation cannot be ruled out on
more recent engine versions. The soot content of the oil must therefore be routinely checked.

3.2 Impurities

Sodium ➢ If the limit value has been reached, the oil must be changed and the cooling system checked for
leaks.
Sodium is a typical element in cooling water corrosion protection additives. An increase in the sodium content
of used oil indicates contamination with cooling water. In many instances no water can be proved in the oil
despite a high sodium content.

Potassium ➢ If the limit value has been reached, the oil must be changed and the cooling system checked
for leaks.
Potassium is a typical element in cooling water corrosion protection additives. An increase in the potassium
content of used oil indicates contamination with cooling water.
Potassium is a possible impurity in wood gas, which is sometimes used as a fuel. If potassium is suspected in
the fuel gas, no limit value applies.

Chlorine ➢ Pay particular attention to the BN, AN and ipH values

Chlorine in small quantities in oil may be an additive element. Chlorine is known as an impurity in biogas,
special gas or landfill gas if these used as fuel. Chlorine can exist in lubricating oil in a various compounds,
some of which can cause severe corrosion. The chlorine content itself has no limit.

Glycol ➢ If the limit value has been reached, the oil must be changed and the cooling system checked for
leaks.
If coolants with antifreeze products are used, glycol is an indicator of cooling water leaks. Glycol is
incompatible with mineral oil and reacts with the additives in lubricating oil to form sludge. This severely
impairs the lubricity of the oil.

Water ➢ If the limit value has been reached, the oil must be changed and the cooling system checked for
leaks.
Check for leaks. It is essential to check whether uncontrolled condensation processes are occurring in the
lubricating oil system or whether the oil is being incorrectly stored.
Water contained in the oil of a gas engine generally leads to the formation of an emulsion, which reduces the
overall usefulness of the oil. Water in the oil leads in particular to increased wear and corrosion.

Silicon (fuel gas classes A, B and C) ➢ If the limit value has been reached, the oil must be changed and the
air filters inspected or replaced.
▪ Fuel gas classes A and B ➢ dust:
If class A or B fuel gas B is used, silicon in the oil is due to dust in the combustion air. Dust consists of relatively
large silicon particles and causes severe wear.
▪ Fuel gas class C ➢ siloxanes:

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Entwicklung/Chvatal S. Responsible: Entwicklung Release date: 26/05/2015
Index: 6 Page No.: 5/7
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0099B
Limit levels for used oil in GE Jenbacher gas engines

Siloxanes are organic compounds produced when Class C fuel gases are used. The increased silicon content in
the gas results in heavier deposits in the combustion chamber which in turn can cause increased wear to
pistons, rings and liners. Increase exhaust gas wear is also known as a consequence of the silicon content of
the fuel gas. It is possible to establish whether the silicon found in the oil will cause damage in a particular case
by determining the operational value, SiB, as described in TI 1000-0300.
The SiB value must be regularly calculated and documented. A regular inspection of the combustion chamber
with an endoscope is recommended. Any increase in abrasive metals such as iron, chromium and aluminium
must be carefully noted. Increased attention must also be paid to the correct valve play adjustment.
▪ Anti-foaming agents
The silicon content for steady-state gas engines is generally between 4 and 7 ppm and is not critical for engine
operation.
An analytical determination of the origin of the silicon in the used oil is not possible.

Sulphur ➢ Pay particular attention to the BN, AN and ipH values

Sulphur is a major component of the lubricating oil. The sulphur in the lubricating oil is not a problem for engine
operation, but gives information about the quality of the lubricating oil. Sulphur is known as an impurity in class
B and C fuel gases. Sulphur from the fuel gas produces acidic compounds in the lubrication oil, thereby
increasing the danger of corrosion. The sulphur content itself has no limit.

3.3 Metallic elements

➢ If the alarm level is reached, contact your Technical Service Hotline.

3.4 Additive elements

No limits are in operation. Most additive elements remain relatively stable over the service life of the oil.
Determination of the additive elements supports the product control.

4 Used oil reports

Used oil reports must include the following data:
▪ Customer: ▪ GEJ ZU number:
▪ Engine type: ▪ Sample date:
▪ Fuel gas: ▪ Engine operating hours:
▪ Lubricating oil product: ▪ Oil operating hours:

5 Documentation for used oil analyses

Example of suitable documentation for used oil analyses:
Customer: Plant data:
Name: BioPower Engine type: JMS 420 GS-B.L
Address: Grünwalden Fuel gas: Biogas
Contact: Mr. A.N. Other Lubricating oil: Product name:
----------------------
Engine number: XXXXXXX
GE J ID number: J XXXX
Sample number 29 30 31 32 33 34

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Entwicklung/Chvatal S. Responsible: Entwicklung Release date: 26/05/2015
Index: 6 Page No.: 6 / 7
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0099B
Limit levels for used oil in GE Jenbacher gas engines

Sample date 12/10/201 20/10/201 29/10/201 16/11/10 23/11/2010 03/12/2010

0 0 0
Analysis date 17/10/201 27/10/201 05/11/201 24/11/201 30/11/2010 08/12/2010
0 0 0 0
Oil operating hours 602 803 1004 202 417 613
Engine operating hours 11615 11816 12017 12351 12566 12762
Unit
Viscosity at 40°C cSt 158 165 172 149 157 162
Viscosity at 100°C cSt 15.4 15.9 16.3 14.9 15.5 15.8
Oxidation/Ageing ABS/cm 13 15 18 7 12 15
Nitration ABS/cm >1 >1 >1 2 >1 >1
TAN mgKOH/g 2.14 2.56 3.08 2.02 2.17 2.56
TBN mgKOH/g 3.6 3 2.8 4.1 3.6 3.1
IPH --- 6.83 5.96 5.48 7.29 6.71 5.74
Silicon ppm 1 2 2 2 2 2
Sodium ppm 2 2 2 2 2 2
Boron ppm 1 1 1 1 1 1
Sulphur ppm 7800 7700 7700 8500 8500 8400
Chlorine ppm <50 <50 <50 <50 <50 <50
Glycol % by <0.01 <0.01 <0.01 <0.01 <0.01 <0.01
weight
Water % by <0.05 <0.05 <0.05 <0.016 <0.05 <0.01
weight
Potassium ppm <1 <1 <1 <1 <1 <1
Iron ppm 4 4 5 2 2 5
Chromium ppm <1 <1 <1 1 <1 <1
Molybdenum ppm <1 <1 <1 <1 <1 <1
Aluminium ppm 1 2 1 1 1 2
Copper ppm <1 <1 <1 <1 <1 <1
Lead ppm <1 <1 <1 <1 <1 <1
Tin ppm <1 <1 <1 <1 <1 <1
Nickel ppm <1 <1 <1 <1 <1 <1
Magnesium % by 0.0004 0.0004 0.0005 0.0005 0.0005 0.0006
weight
Calcium % by 0.1290 0.1373 0.1459 0.1252 0.1325 0.1214
weight
Phosphorus % by 0.0273 0.0287 0.0317 0.0287 0.0305 0.0360
weight
Zinc % by 0.0293 0.0336 0.0359 0.0309 0.0350 0.0399
SprungMarke!!!45035996297007243
weight

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Entwicklung/Chvatal S. Responsible: Entwicklung Release date: 26/05/2015
Index: 6 Page No.: 7/7
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0099C
Procedure for testing the oil service life specific to the plant

1 Scope of application ................................................................................................................................. 1

2 Brief Instruction ........................................................................................................................................ 1
2.1 Oil interval (after commissioning or major overhaul of the engine, and engine upgrades).......
1
2.2 Oil intervals and all other ....................................................................................................................................... 2
3 Notes ........................................................................................................................................................... 3

1 Scope of application
GE Jenbacher - gas engines
Other applicable Technical Instructions:
▪ TI 1000-0099B: Limit values for used oil in GE Jenbacher gas engines [⇨ TA 1000-0099B, Page 1]
▪ TI 1000-0112 Taking lubricating oil samples / lubricating oil sampling protocol [⇨ TA 1000-0112, Page 1]

2 Brief Instruction
GE Jenbach does not guarantee any guaranteed fixed oil change intervals. The lubricating oil in GE
Jenbacher gas engines must be changed depending on its condition.

2.1 Oil interval (after commissioning or major overhaul of the engine, and engine upgrades)
Fuel gas class A: Oil samples every 150 operating hours
Fuel gas classes B and C: Oil samples every 75 operating hours

The oil must be changed if any measured value has reached its limits under Section 2.1 of TI 1000-0099B.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Konstruktion, Problemanalyse Release date: 26/05/2015
Index: 6 Page No.: 1/3
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0099C
Procedure for testing the oil service life specific to the plant

Y 1
150 300 450

75 150 225

① Service life ③ Analysis results in each case

② Numerical value of relevant analysis results - ④ forecastable end of the service life of an oil
here, only one filling
test interval (approx.150 Oh with natural gas, 75 Oh with landfill gas and biogas)
Limit value as per TI 1000-0099B

2.2 Oil intervals and all other

oil samples must be taken at approx. 20%
approx. 70%
approx. 100% of the expected oil service life.

BUT:
No unmonitored period of use of the oil may exceed:
fuel gas class A: 500 operating hours
fuel gas classes B and C: 250 operating hours

ATTENTION
After commissioning or carrying out maintenance work on the engine, particular attention must be paid to
impurities and abrasives in the lubricating oil. If a warning value is reached, contact the technical service
hotline.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Konstruktion, Problemanalyse Release date: 26/05/2015
Index: 6 Page No.: 2 / 3
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0099C
Procedure for testing the oil service life specific to the plant

▪ See TI 1000-0110, section 2.2 for impurities.

▪ See TI 1000-0110, section 2.3 for abrasives.

3 Notes

Oil service life

Lubricating oil in internal combustion engines changes and ages as a function of the operating conditions. The
lubricating oil must be changed before it becomes unserviceable.
The service life of a single filling of lubricating oil depends on different factors. The following have a major
influence on the oil service life:
▪ oil consumption
▪ thermal load on the oil
▪ mechanical load on the oil
▪ oil circulation quantity
▪ composition of the fuel gas
▪ brand of lubricant
In non-natural gas operation (fuel gas classes Band C) the oil service life can be expected to be considerably
shorter for a given fuel gas quality compared to natural gas operation (fuel gas class A).

Oil change
When changing oil, make sure that the oil residues in the engine are kept to a minimum, i.e. by changing the oil
filters, draining the oil cooler, etc.
If a change is made to a different brand of lubricating oil, the amount of residual oil held in the engine and
storage tank must be kept as low as possible. If oils are mixed, the various oil characteristics can no longer be
correctly interpreted.

Oil analyses
The analysis reports must be documented and kept by the customer, and made available to GE Jenbacher on
request.

Auxiliary tank
If the oil service life is unsatisfactory, it can be prolonged by increasing the engine oil capacity by adding an
auxiliary tank

Changes in the analysis results trend

If a value (e.g. "X" in Fig. 1) suddenly exhibits change trends compared to previous analyses, this must be
considered an alarm signal, even if the limit has not yet been reached as shown in example "Y" (curve ).
If you have any questions or require assistance in evaluating the analysis results, call the technical service
hotline.
SprungMarke!!!45035996296926475

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Konstruktion, Problemanalyse Release date: 26/05/2015
Index: 6 Page No.: 3/3
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0099D
Determining the initial pH value (ipH) for used lube oil as defined in TI
1000-0099B

Purpose:
To standardise the method for determining the ipH value in the individual analytical laboratories in order to
ensure comparability between the individual values and with our limit level.

Method: GE Jenbacher
Reference: ASTM D 664, 7.15 - TITRATION SOLVENT

Requirement:
▪ Buffer parent solution A**
▪ Titration solvent
▪ pH glass electrodes manufactured by METROHM AG, HERISAU

Recipe:
Titration solvent: Toluol, water and isopropyl alcohol as described in ASTM D 664
Buffer parent solution A**:
Weigh in 24.2 +/- 0.1 g of 2, 4, 6-TRIMETHYL PYRIDINE into a 1-litre flask filled with 100 ml of isopropyl alcohol.
Add 750 +/- 5 ml of 0, 2 normal alcoholic hydrochloric acid and fill with isopropanol up to 1000 ml.
The solution can be kept for 2 weeks at room temperature and 4 weeks at approx. 8°C (refrigerator).
Procedure:
The used-oil sample is heated to 60 +/- 5°C in its original container and shaken thoroughly so that all sediments
are evenly distributed throughout the used oil.
5 g of the used-oil sample is dissolved in 125 ml of the (above-mentioned) titration solvent.
The electrodes are dipped into a non-aqueous buffer solution
(= 10 ml of buffer parent solution A** and 100 ml titration solvent) in accordance with the relevant operating
instructions, or are agitated in the buffer solution for
approx. 5 minutes and the millivoltmeter is set to pH = 4.
The electrodes are then placed in the titration solution (see above: i.e. 5 g of used oil + 125 ml of titration
solvent), agitated for approx. 5 minutes and then the initial pH value is read

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Dokumentation Release date: 26/05/2015
Index: 4 Page No.: 1/2
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0099D
Determining the initial pH value (ipH) for used lube oil as defined in TI
1000-0099B

Method: Mobil

Procedure:
The pH meter must be calibrated before the pH value is measured. In order to do so, aqueous buffer solutions
with a pH value of 4.0 and 2.0 are measured consecutively. If the calibration is performed using two points of
reference, the relative rate-of-rise of the measuring chain can be determined. If this determination results in a
value below 95%, the set-up of the measuring instruments must be checked to ascertain the source of the
problem!
To determine the pH value of a used oil sample, 3.6 g of the sample is first mixed with 90 ml of solvent. To
produce one litre of solvent, 500 ml toluol, 495 ml isopropanol and 5 ml of demineralised water are mixed
thoroughly. This mixture corresponds to the solvent described in ASTM D664 (Standard Test Method for Acid
Number Determination)l. The degree of purity described in this standard for the chemicals used must be
adhered to in each case.
Once the weighed-in oil sample has been thoroughly mixed with the solvent, the pH value can be measured
without further stirring. On completion of the measurement, the electrode should be cleaned with pure i-pH
solvent. Oil residues must be removed completely. During the intervals between measurements, the electrode
should be stored in slightly acidified (pH 3-4) demineralised water In our experience, insufficient cleaning of the
measuring electrode is the most frequent cause of faulty measurements.
SprungMarke!!!27021597787423755

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Dokumentation Release date: 26/05/2015
Index: 4 Page No.: 2 / 2
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0099K
Aid to interpreting used oil analyses of engine lubricants

1 Tips .............................................................................................................................................................. 1
2 Used oil test result .................................................................................................................................... 2
2.1 Water present in oil .................................................................................................................................................. 2
2.2 High insoluble content ............................................................................................................................................ 2
2.3 Increased viscosity.................................................................................................................................................... 3
2.4 Reduced viscosity/general.................................................................................................................................... 4
2.5 Reduced viscosity/diesel engines and hydraulically controlled two-stroke gas engines ....... 4
2.6 Higher than normal trace metal count detected by spectro analysis or atomic absorption
analysis........................................................................................................................................................................... 5
2.7 Low alkaline reserve................................................................................................................................................. 6
2.8 Infrared analysis (gas engines) shows increased absorption at 5.8 μm (1,710 Hz).................... 6
2.9 Infrared analysis (gas engines) shows increased absorption at 6.1 μm (1,630 Hz).................... 6
3 Overview of factors affecting engine oil condition............................................................................. 6
4 Overview of natural oil ageing, which occasionally proceeds too rapidly due to overloading .....
8
5 Additional evaluation of the concentration of harmful substances in fuel gases by means of
regular lube oil analyses ......................................................................................................................... 8
5.1 Requirement ................................................................................................................................................................ 8
5.2 Procedure...................................................................................................................................................................... 9
5.3 Rating.............................................................................................................................................................................. 9

1 Tips
For limit levels of lubricating oils, please refer to TI 1000-0099B, TI 1000-0099C and TI 1000-0099D.
It is quite normal for the properties of lubricating oil to change (through ageing or depletion) in the course of
operation. Where the lubricating oil is ageing at a steady rate, but unusually quickly, this often means that the
additive package is unsuitable for the operational requirements (e.g. fuel, mode of running, etc.) or that the
engine is malfunctioning e.g. because of an incorrect setting.
Where the lubricating oil becomes depleted all at once, this often indicates a sudden change in the engine
operating mode (e.g. engine damage, change of fuel type/quality, harmful substances in the environment, etc.).
Very often there is an interaction between excessive oil ageing and an unnoticed change in the engine
condition. This means that excessively aged oil causes engine damage and engine damage places greater
demands on the oil.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Dokumentation Release date: 26/05/2015
Index: 4 Page No.: 1/9
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0099K
Aid to interpreting used oil analyses of engine lubricants

2 Used oil test result

2.1 Water present in oil

Primary cause Specific factors Engine and oil conditions
responsible
Condensation Low-temperature operation Stop-go operation.
Low coolant temperature. Excessive
engine idling.
Flow-back of condensate from Inadequate crankcase ventilation.
crankcase breather Weather-related condensation in
the crankcase ventilation pipe
combined with an unfavourable
pipe layout which allows
condensate to run back into the
engine.
Coolant leakage Cylinder head gasket leaky (water Gasket defective or burnt through,
passage) or gasket incorrectly installed.
Leaky O-rings on wet cylinder liners Incorrect installation. Defective O-
ring. Seating surface corroded.
Engine block, cylinder head or Coolant frozen.
water-cooled exhaust manifold Overheating during operation, or
often leaky, as well as waste heat lack of coolant in cooling system.
boiler
High blow-by Piston ring area Worn piston rings or cylinder liners.
Stuck or broken rings.
Choking in exhaust system Blockages in exhaust manifold,
exhaust pipe, silencer, turbocharger
or waste heat boiler.
Faulty cleaning Machine not cleaned properly For example, washing with water
can allow water into the lube oil
system.
Improper oil storage System topped up with oil that Oil drums (even originally sealed
contains water ones) are left out in the rain.
Ingress of rainwater Ingress via end of exhaust pipe Extreme weather conditions, poor
when engine at a standstill layout of exhaust system.
Ingress of water via fuel supply Not only atomised condensate in Biologically or pyrolitically produced
fuel gas supply gases have not been allowed to dry
properly

2.2 High insoluble content

Primary cause Specific factors Engine and oil conditions
responsible
Fuel soot or fuel additives Rich operation Overgreasing, restricted air intake.
Worn piston rings or cylinder liners Poor mechanical condition of
engine or of shaft sealing ring on
turbocharger.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Dokumentation Release date: 26/05/2015
Index: 4 Page No.: 2 / 9
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0099K
Aid to interpreting used oil analyses of engine lubricants

Primary cause Specific factors Engine and oil conditions

responsible
Fuel soot Defective injectors Poor spray pattern.
Dripping nozzles. Delivery starts too
soon (i.e. so-called "spraying beyond
the piston edge" while exhaust gas
is noticeably soot-free).
Oil breaking down Operating temperature too high Operating too long at maximum
power.
Engine settings incorrect or engine
in poor mechanical condition or
exhaust gas entering the oil system
via the turbocharger.
Oil cooler blocked with sludge.
Oil change intervals beyond Improper preventive maintenance
permissible limit practices.
Different brands of oil mixed High crankcase oil level.
Worn bearings, guides and rings
Dirt and dust Inadequate air filter maintenance Improper or poor preventive
maintenance practices.
Air leaks in intake system Poor mechanical condition.
Metal engine parts Wear, corrosion or failed or Refer to notes in section 2.6.
damaged parts
Lack of air in diesel engine Choking on intake side, leaks on Intake air filter dirty, turbocharger
boost pressure side defective, boost air cooler dirty.
Leaks in intake or exhaust system
between engine and turbocharger.
Combustion failure in diesel engines Poor combustion Insufficient cooling of boost air, fault
in injection system (e.g. concerning
start of fuel delivery or equalisation
of pumps).

2.3 Increased viscosity

Primary cause Specific factors Engine and oil conditions
responsible
Fouling, Fuel soot Refer to notes in section 2.2 (fuel
soot or fuel additives).
Water Refer to notes in section 2.1.
Oxidation and/or nitration Operating temperature too high All engines:
Oil change intervals often excessive,
inadequate cooling, operating too
long at maximum power.
Gas engines:
Fuel gas mixture too lean.
Ignition point setting too early.
Higher-viscosity oil used Wrong oil used Wrong product used for first fill or
top-up.
Lube oil instructions not followed.
"Viscosity improver" additives used.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Dokumentation Release date: 26/05/2015
Index: 4 Page No.: 3/9
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0099K
Aid to interpreting used oil analyses of engine lubricants

2.4 Reduced viscosity/general

Primary cause Specific factors Engine and oil conditions
responsible
Lower-viscosity oil used Wrong oil used Wrong product used for first fill or
top-up.
Lube oil instructions not followed.

2.5 Reduced viscosity/diesel engines and hydraulically controlled two-stroke gas engines
Primary cause Specific factors Engine and oil conditions
responsible
Fuel dilution Fuel injection too rich Oversize injectors.
Dripping nozzles.
Blockage in the fuel return line
or leakage oil line.
Poor combustion Piston rings broken or seized.
Dripping injection nozzles. Poor
spray pattern. Worn piston rings or
cylinder liners. Constriction of air
supply or exhaust line
Cracked or broken connections in Relates to machines (engines) with
fuel lines fuel lines routed on inside.
Lines kinked due to inattention.
Unsuccessful starting attempts All reasons for false starts.
Internal leakage in injection or feed Plunger wear or defective sealing
pumps elements allow fuel to enter the
pump or engine oil space

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Dokumentation Release date: 26/05/2015
Index: 4 Page No.: 4 / 9
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0099K
Aid to interpreting used oil analyses of engine lubricants

2.6 Higher than normal trace metal count detected by spectro analysis or atomic absorption analysis
Primary cause Specific factors Engine and oil conditions
responsible
External contamination, coolant. Metals found in used engine oil Source of metals in used engine oil.
Engine metals due to abrasion and Aluminium *) Piston, bearings and cylinder liners:
corrosion dirt and dust contamination
Barium Oil additives, diesel fuel additives.
Boron *) Cooling water conditioners.
Calcium Oil additives (primary).
Dirt and dust contamination
(secondary).
Chromium *) Piston rings, cylinder liners, plated
rocker arms, inlet and exhaust
valves or crankshaft.
Cooling water conditioners.
Chlorine *) Unauthorised addition to fuel or
(i.e. all four halogens) combustion air.
Important, because it has an
extremely detrimental effect on the
alkalinity of the oil but it cannot
always be recognised as described
in section 2.7.
Copper *) Bearings, bushings, joint rings, air
filter mesh, oil cooling tubes.
Iron *) Engine parts.
Lead *) Abrasions from bearing running-in
layers,
Magnesium Oil additives (primary).
Sea-water contamination
(secondary).
Phosphorus Oil additives.
Silicon *) Contamination caused by sand and
dust or as a result of organic silicon
compounds in landfill and sewage
gases.
Wear and tear of aluminium engine
parts (secondary) or due to previous
machine maintenance work which
included abrading or honing
operations.
Sodium *) Contamination due to use of non-
distilled (or non-condensed) water,
cooling water conditioners,
contamination due to dust.
Tin *) Tin-plated bearings.
Zinc Oil additives (primary), bearings
(secondary).

*) Refers to metals which must be carefully monitored when sampling and/or changing oil.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Dokumentation Release date: 26/05/2015
Index: 4 Page No.: 5/9
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0099K
Aid to interpreting used oil analyses of engine lubricants

2.7 Low alkaline reserve

Primary cause Specific factors Engine and oil conditions
responsible
Contamination by combustion acids High-sulphur fuel Oil's TBN not high enough. Over-
extended oil change intervals.
Excessive blow-by (nitrate Poor combustion due to incorrect
development) settings or defective parts. Poor
mechanical condition of engine.
Acid-forming vapours drawn in with Refrigerants such as Freon or NH3.
intake air
Oil oxidation Excessive operating temperature Operating at excessive peak load.
Poor mechanical condition of
engine.
Poor engine settings.
Faulty oil purification Excessive oil residues in oil filter, oil Strong acids not removed.
pan, oil cooler, etc. during oil Cleaning intervals not adhered to.
change

2.8 Infrared analysis (gas engines) shows increased absorption at 5.8 μm (1,710 Hz)
Primary cause Specific factors Engine and oil conditions
responsible
Oil oxidation Excessive operating temperatures High piston and cylinder
temperatures.
High fuel oil temperatures and
engine hot spots.
Refer also to comments in section
2.7 (Oil oxidation).

2.9 Infrared analysis (gas engines) shows increased absorption at 6.1 μm (1,630 Hz)
Primary cause Specific factors Engine and oil conditions
responsible
Nitrogen fixation (Nitration) Poor combustion Inappropriate and/or poor
operating practices, such as:
poor combustion, engine overload,
faulty crankcase ventilation,
defective ignition timing, excessive
blow-by (piston, cylinder).
Refer also to comments in section
2.7 (Excessive blow-by (nitrate
development)).

3 Overview of factors affecting engine oil condition

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Dokumentation Release date: 26/05/2015
Index: 4 Page No.: 6 / 9
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0099K
Aid to interpreting used oil analyses of engine lubricants

Predictable and unpredictable

operation-related contaminants
(e. g. dust, residues, abrasion, water)

Chemical ageing Physical ageing

of oil of oil

Engine type Condition of oil Service life

Oil consumption
Fresh oil supply
and loss

Extraction rate of filtration system

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Dokumentation Release date: 26/05/2015
Index: 4 Page No.: 7/9
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0099K
Aid to interpreting used oil analyses of engine lubricants

4 Overview of natural oil ageing, which occasionally proceeds too rapidly due to overloading

Atmospheric nitrogen N

Nitrogen oxides Nox

Wet
Dry

Oxidising/nitrifying effect Acidifying effect

Oil ageing/oil nitrification Oil acidification

Viscosity increase Decomposition of paper filters

(refer to section 2.3 on corrosive effects in oil circuit, wear
high temp. operation) and tear on bearings due to corrosion
(refer to section 2.7 on excessive blow-by
(nitrate development) and 2.9 on
poor combustion)

5 Additional evaluation of the concentration of harmful substances in fuel gases by means of

regular lube oil analyses

5.1 Requirement
▪ Use of lube oil in accordance with specifications (refer to the relevant Technical Instruction)
▪ Adherence to all characteristic values and limits which indicate the chemical ageing of used oil (ipH, TBN, IR
5,8 my, IR 6,1 my, etc.)
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Dokumentation Release date: 26/05/2015
Index: 4 Page No.: 8 / 9
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0099K
Aid to interpreting used oil analyses of engine lubricants

5.2 Procedure

1
2

x At

① Oil service life (Oh) ③ Developing a parameter

② Time gap ④ NN parameter
Limit as per TI 1000-0099B

5.3 Rating
shortest period found
More than 300 Oh..... Oil change is still effective; there is not Caution
much risk that the engine will be
damaged by harmful substances
200 to 300 Oh... The harmful substances are still (at State of alarm
least to a certain extent) neutralised by
an oil change
Less than 200 Oh...... The harmful substances can no longer Maximum state of alarm
SprungMarke!!!27021597787322251
be neutralised by an oil change

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Dokumentation Release date: 26/05/2015
Index: 4 Page No.: 9/9
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0099L
Storage and Handling of Fresh Oil for GEJ Gas Engines

1 Scope
This Technical Instruction applies to GE Jenbacher gas engines.

2 Purpose
This concerns the storage of fresh oil in individual containers in order to preserve its lubricating properties.
This does not concern constructional measures and requirements relating to environmental protection or
proper handling by technical staff. These details, instructions and requirements can be found in the safety data
sheet for the product used.
This does not concern the storage and disposal of waste oil. The relevant requirements can be found in the
safety data sheet.

3 Regulations
In addition to the relevant safety data sheets, you must also observe all applicable statutory regulations.

4 Purchasing engine lubricating oil

You are strongly recommended to purchase lubricating oil only from accredited dealers authorised by the
relevant oil manufacturer. This ensures that you will be using the product whose name is shown on the
containers. You will find details of accredited dealers on the home page of the oil manufacturer concerned.
Contact details of accredited dealers can also be obtained from GE Jenbacher.
The party authorised to supply the lubricating oil will bear sole responsibility for the purchase and use of
lubricating oil from non-accredited dealers. This includes liability for loss or damage of any kind, e.g. direct loss
or damage, consequential loss or damage or indirect loss or damage, as well as liability for any increased
maintenance costs.

5 Storage
The proper place to store lubricating oil is inside buildings:
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bilek F. Responsible: Anderson B. Release date: 26/05/2015
Index: 4 Page No.: 1/2
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0099L
Storage and Handling of Fresh Oil for GEJ Gas Engines

▪ The store room must be kept clean and dry.

▪ This room must be kept at an even temperature. High temperatures (>60°C) must be avoided as high
temperature ages the oil prematurely.
▪ Humidity must be maintained at a constant level. Severe temperature fluctuations can cause condensation
to form.
▪ Once opened, containers must be properly resealed immediately after use to ensure that neither water nor
other contaminants can enter.

The storage of lubricating oil in the open air must be avoided at all costs as rain, condensation and frost
damage the oil.
If storing the oil in the open air is unavoidable, please observe the following points:
▪ Containers must not be stored in direct sunlight.
▪ Containers must not be stored below temperatures of "pour point plus 10°C", e.g. if pour point is -15°C →
storage temperature must not be below -5°C. Containers must be protected from snow and rain.
▪ Drums must not be stored upright, but horizontally with the bung hole facing downwards.
▪ Where containers have been opened or partially emptied, you must ensure that neither water nor other
contaminants can get into the oil. In case of doubt, do not use this oil batch again.
▪ Containers must be resealed immediately after use.
▪ If stored properly in their original containers, most lubricating oils have a shelf life of several years. You can
obtain accurate information on shelf life from your lubricating oil supplier.
▪ It is recommended that, if they are stored for a prolonged period, drums should be rolled carefully at
regular intervals, but not more than two months, to mix the oil effectively.

6 Filling engines
▪ Clean the top of the drum before opening it.
▪ Then clean the connectors.
▪ Intake ports must be kept clean at all times and protected from dust from the ambient air, e.g. by keeping
the intake ports in suitable plastic bags.
▪ Hoses must be kept clean. If in doubt, use new hoses.
▪ If it is necessary during maintenance work to drain off some or all of the oil, it must not be re-used (this
does not affect type 9 engines).

7 Oil tanks
Dimension the fresh oil tank so that the planned oil change interfaces can be achieved.
The entire volume (oil pan & fresh oil tank) is to be observed for the dimensioning of the used oil tank.
In order to achieve a gravity-powered filling, the fresh oil tank must be aligned no less than 1m and no more
than 10m above the oil connection on the generating set. If gravity-powered filling is not possible, then a pump
must be provided.
Separate pumps must be provided for fresh and used oil.
SprungMarke!!!27021604626767883

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bilek F. Responsible: Anderson B. Release date: 26/05/2015
Index: 4 Page No.: 2 / 2
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0112
Taking lubricating oil samples / lubricating oil sampling protocol

1 Scope
This instruction is intended for Jenbacher stationary engines.
Depending on the engine type and condition of use that can be expected, GE Jenbacher operating instructions
will include any lubricating-oil instructions provided for that particular use.
These lubricating-oil instructions are mandatory.

Refer to the TIs listed below:

TI No.: 1000-0099B Scope of analysis and limiting values for used oil analyses
TI No.: 1000-0099C Testing the site-specific oil service life
TI No.: 1000-0099K Aid to interpreting used oil analyses of engine lubricants
DIN 51574 Sampling of lubricating oils from internal combustion engines

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bilek F. Responsible: Nota F. Release date: 27/05/2015
Index: 8 Page No.: 1/13
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0112
Taking lubricating oil samples / lubricating oil sampling protocol

2 Analysis kits

The starter pack contains:

Part Number Description
510132 Hard plastic case with 20 sample containers,
including sample labels and mailing pouches
506605 3 m sampling hose
506606 Sampling pump
460134 Sampling hose with adapter
300 ml sample container

Refill packs can be ordered from GE Jenbacherquoting the following part numbers:
Part Number Description
506605 3 m sampling hose
506606 Sampling pump
506602 Refill pack with 5 sample containers
506603 Refill pack with 10 sample containers
506604 Refill pack with 20 sample containers

3 Oil change interval

The possible operating conditions (e.g. load spectrum and fuel quality) and the performance standards of the
different permissible oil types are so many and varied that GE Jenbacher purposely does not specify an oil
change schedule.
If, when discussing the matter, a GE Jenbacher employee mentions an oil change interval, this will be either
an actual number of hours relating to the case in question
or
an anticipated number of hours given without obligation.
It will never be a mandatory scheduled oil change interval.
GE Jenbacher mandatory instructions are that the oil is to be changed at variable intervals in accordance with
known limit values based on used-oil analyses.
If for specific organisational reasons an operator cannot have "too variable" oil change intervals, he will still be
obliged to perform systematic used-oil analyses on a recurring basis but he can organise the timing of oil
changes by carrying out early changes on oil fills which are still usable.

4 Procedure for taking oil samples

4.1 General instructions:

▪ Oil samples should never be filled into containers of any kind as both the material of which the container is
made and residues of its previous contents may result in an incorrect diagnosis.
▪ Oil samples must be taken when the when the engine is running completely normally.
▪ Taking oil samples when the engine is at standstill is only allowed when the engine has not been provided
with an oil sampling location.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bilek F. Responsible: Nota F. Release date: 27/05/2015
Index: 8 Page No.: 2 / 13
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0112
Taking lubricating oil samples / lubricating oil sampling protocol

▪ Only up-to-the-minute oil analyses can help to prevent problems. It is therefore recommended that oil
samples be despatched by express mail. Spectro®/Jet-Care® guarantees to complete the analysis,
prepare the analysis report and send the report to a specified e-mail address within 48 hours of receipt of
the oil sample.

4.2 Taking oil samples with the engine running

Note: to obtain a representative oil sample, approx. 0.3 litres of oil must be drawn off before the actual sample
is taken.

① Threaded connection Oil samples are taken by screwing the sampling line
into the threaded connection (TI no. 460134).

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bilek F. Responsible: Nota F. Release date: 27/05/2015
Index: 8 Page No.: 3/13
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0112
Taking lubricating oil samples / lubricating oil sampling protocol

4.2.1 Mechanical Drive

Oil samples are taken from Mechanical Drive engines
at a threaded connection in the pressure oil line
upstream of the oil filter.

4.2.2 Type 2 and 3 engines

Oil samples are taken from Type 2 and 3 engines with
at a threaded connection in the pressure oil line
upstream of the oil filter.

4.2.3 Type 4 engine

Oil samples are taken from a type 4 engine at a
threaded connection in the pressure oil line upstream
of the oil filter.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bilek F. Responsible: Nota F. Release date: 27/05/2015
Index: 8 Page No.: 4 / 13
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0112
Taking lubricating oil samples / lubricating oil sampling protocol

4.2.4 Type 6 engine

Oil samples are taken from a type 6 engine at a
threaded connection in the pressure oil line upstream
of the oil filter.

Oil samples are taken from a type 624 TSTC engine at

an oil sampling cock at the lowest point in the
pressure oil line

4.2.5 Type 9 engine

Oil samples are preferably taken from Type 9 engines with the engine running; if this is not possible, then within
20 minutes of shutting the engine down, as the continued cooling is in operation during this period and oil is
still being pumped and circulated.

Position of the oil sampling point

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bilek F. Responsible: Nota F. Release date: 27/05/2015
Index: 8 Page No.: 5/13
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0112
Taking lubricating oil samples / lubricating oil sampling protocol

Oil sampling point under the AMOT valve

Oil sampling

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bilek F. Responsible: Nota F. Release date: 27/05/2015
Index: 8 Page No.: 6 / 13
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0112
Taking lubricating oil samples / lubricating oil sampling protocol

4.3 Taking oil samples with the engine at a standstill

When the engine is at a standstill the oil sample is taken using a clean hose inserted into the dip stick opening.
Tip: the hose must not be longer than the dip stick to ensure that the sample is not adulterated by sludge and
sediment.
If a hose section is re-used, the hose must be flushed by being pumped through 3 times.

5 Operator's obligation
Generally, oil analysis reports reflect a condition that no longer exists when the report becomes available. The
operator therefore has to decide on the basis of a trend assessment of the individual analysis reports when a
particular filling of oil should be replaced without the limit levels referred to in TI 1000-0099B actually being
exceeded.

6 Completing the sample report sheet

Only sample report sheets completed correctly and in full will ensure that the analysis is clearly allocated to the
right engine.
The following is mandatory information to be included on the sample report sheet:
Data Comment Where to find
Site name Project name, address Supplied by the operator
engine number 7-digit number On the system type plate – see
appendix. The system type plate is
located on the frame of the
module.
UZ number (design J XXXX On the cover sheet of the site
number, ID number documentation – see Apendix.
GE / Spectro ID number Supplied by the customer
Module type JMS XXX GS – X.X On the system type plate – see
appendix. The system type plate is
located on the frame of the
module.
Engine operating hours Total operating hours since commissioning On the DIA.NE display
Operating hours since last Must be recorded in operational
oil change data sheet E0101 – refer to
maintenance manual for site
concerned.
Brand of lubricating oil Consists of the name of the oil Oil drum
manufacturer and the name of the specific
product,
e.g. Mobil Pegasus 705
Top up since last oil In operator's own records
change
Sample date

7 Registering plants and engines

It is essential to register plants and engines for used oil analyses, preferably at the time of commissioning the
engines. The procedure is necessary so that the laboratory can allocate the sample to the correct system.
Below, how to register with Spectro/Jetcare:

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bilek F. Responsible: Nota F. Release date: 27/05/2015
Index: 8 Page No.: 7/13
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0112
Taking lubricating oil samples / lubricating oil sampling protocol

Step 1:
After opening Internet Explorer, go to the Spectro or (North America) Jet-Care address http://www.spectro-
oil.com/gej or http://www.jet-care.com/gej. The first page of our used oil analysis website will appear.

① Click on "Register Site".

Step 2:
Registering the plant:

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bilek F. Responsible: Nota F. Release date: 27/05/2015
Index: 8 Page No.: 8 / 13
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0112
Taking lubricating oil samples / lubricating oil sampling protocol

① Submit button

This page asks you to enter the plant address and the address where the analysis reports are to be sent. After
this data has been received, a password is generated and sent back to the first e-mail address (Report E-Mail
1). The password will ensure complete access and allow engine data to be entered.
Reports can be sent either as .pdf files or as ECHO® data files. ECHO® data files can be read with the ECHOTM
program, which can be downloaded from this website under "Program". "Reporting method" can be either by E-
mail or by downloading the password-protected data.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bilek F. Responsible: Nota F. Release date: 27/05/2015
Index: 8 Page No.: 9/13
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0112
Taking lubricating oil samples / lubricating oil sampling protocol

Fill in all the data and click on "Submit".

Step 3:
After receipt of this, a username and password will be generated and sent to "Report E-mail 1". Enter this data
on the start page and click "Log in".

Step 4:
The next page that appears gives complete access to the database and in particular allows the engines of the
plant for which the password was generated to be registered .
Click “Register Engine”.

① Register Engine

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bilek F. Responsible: Nota F. Release date: 27/05/2015
Index: 8 Page No.: 10 / 13
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0112
Taking lubricating oil samples / lubricating oil sampling protocol

Step 5:
The registration form must be completed in full for each engine at the plant. After filling in the data for the first
engine, press "Submit" and confirmation will appear for the first engine. The remaining engines at the plant
can now be registered, pressing "Submit" after each engine until all of them have been registered. After that the
samples can be sent off, properly labelled.

① Program button
② Submit button

Instructions on using the "ECHO Reporting Program" can be found in the menu bar under “Program” as a .pdf
file entitled "How to use the Echo reporting program.pdf".

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bilek F. Responsible: Nota F. Release date: 27/05/2015
Index: 8 Page No.: 11/13
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0112
Taking lubricating oil samples / lubricating oil sampling protocol

8 Appendix:

Oil sampling accompanying certificate

System type plate

Engine description cover sheet

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bilek F. Responsible: Nota F. Release date: 27/05/2015
Index: 8 Page No.: 12 / 13
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0112
Taking lubricating oil samples / lubricating oil sampling protocol

① Plant name ⑦ Operating hours since last oil change

② Engine number ⑧ Name of lubricating oil
③ UZ number (design number, ID number) ⑨ Oil quantity filled into the engine
④ Module type ⑩ Top up since last oil change
⑤ GE / Spectro ID number ⑪ Sample date
⑥ Engine operating hours

Spectro addresses
SprungMarke!!!63050394806092555

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bilek F. Responsible: Nota F. Release date: 27/05/2015
Index: 8 Page No.: 13/13
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0200
Composition of cooling water in closed primary circuits

1 General
An aqueous solution is used as the coolant in GE Jenbacher engines. Corrosion inhibitors and anti-freeze
products need to be added to the cooling circuits of GE Jenbacher engines.

2 Validity
This Technical Instruction applies to all GE Jenbacher engines with closed primary cooling circuits (engine
cooling circuit, low-temperature circuit)
ATTENTION
This does not apply to heating circuits (see TI 1000-0206)

3 Water quality
The following water quality is necessary for mixing with anti-freeze products and corrosion inhibitors.
Analysis value Unit Permissible range
Appearance - clear, free of sediment and suspended matter
Odour - neutral
pH value at 25°C - 6.5 - 7.5
Total Hardness (CaCO3) °dH < 15
ppm < 250
Calcium mg/l < 100
Sulphates mg/l < 100
Chlorides mg/l < 80
Iron mg/l < 0.2
Zinc mg/l < 0.1
Fluorides mg/l < 20
Electrical conductivity µS/cm <500
Rainwater, brackish water, sea water and condensate do not possess the required properties without
appropriate treatment

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Dokumentation Release date: 27/05/2015
Index: 5 Page No.: 1/2
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0200
Composition of cooling water in closed primary circuits

Both the water analyses and professional sampling must be carried out by a suitable firm.
The water quality tests, which are required for mixing with anti-freeze and corrosion protection products, must
be carried out at least once a year. The analysis reports must be documented and kept by the customer, and
made available to GE Jenbacher on request.

4 Information
If water with the properties demanded in the table is mixed with anti-freeze or corrosion inhibitor, the pH,
hardness and conductivity values will automatically change.
SprungMarke!!!36028797046823051

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Dokumentation Release date: 27/05/2015
Index: 5 Page No.: 2 / 2
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0201
Anti-freeze products and testing the coolant

ATTENTION
Anti-freeze products already contain corrosion inhibitors. To ensure that sufficient corrosion inhibitor is present,
the minimum anti-freeze concentration laid down by the manufacturer must be observed. The necessary
minimum concentration is given in the product description. A concentration lower than the specified minimum
will lead to corrosion.
The permissible maximum concentration of anti-freeze product depends on the design of the cooling circuits
and can be taken from the "Heat Recovery" section in the Technical Description.
Depending on the technology used in the corrosion inhibitors, the product manufacturers recommend
changing the coolant after 2 to 5 years. These are only general recommendations. Due to the wide range of
applications and operating conditions under which GE Jenbacher engines are used, it may be necessary to
change the coolant earlier. If the corrosion inhibitors in the coolant are used up, this indicates a significantly
increased danger of corrosion rather than an absence of corrosion protection.
The coolant must therefore be tested regularly to check that the anti-freeze protection and corrosion inhibition
are adequate and that the water quality is suitable.

2 Testing the coolant

▪ Testing the anti-freeze protection with a refractometer: at least quarterly .
If the glycol content is in the specified range, adequate corrosion inhibitor is also present.
▪ Testing the quality of the water to which the anti-freeze is added: annually (see TI 1000-0200 for the limit
values)
▪ If premixed products are used, the water quality check can be omitted.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: TED/Chvatal Susanne Release date: 27/05/2015
Index: 6 Page No.: 1/3
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0201
Anti-freeze products and testing the coolant

3 Coolant change
▪ Change coolants with corrosion protection products based on OAT technology every 5 years at the latest.
▪ Change coolants with mineral corrosion protection products every 2 years at the latest
▪ If anti-freeze protection will definitely not be needed in the coolant, corrosion protection alone may be
added to the coolant. (See TI 1000-0204 for products)

4 Information on filling the cooling circuit

Always clean the entire cooling system thoroughly by flushing with water and check the system for any leaks
before adding the anti-freeze.
Pour the required amount of anti-freeze into the cooling system and top up the system with water, as
described in TI 1000-0200.
Run the engine for 30 minutes afterwards.
Always bleed the cooling system because corrosion may form in spots where air has collected.

5 Selection overview
Selection overview
Havoline XLC 40/60 Antifreeze NF
Havoline XLC

Havoline XLC 40/60 Coolant Plus

Havoline XLC

Coolelf CHP Deicer Deicer E

Coolelf CHP Supra

Glysantin Protect Plus G48 Fricofin

Antifreeze Extra Härtol Frostox W206

Antifreeze Extra BF6

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: TED/Chvatal Susanne Release date: 27/05/2015
Index: 6 Page No.: 2 / 3
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0201
Anti-freeze products and testing the coolant

Products not or no longer mentioned in this Technical Instruction are not necessarily unsuitable for GE
Jenbacher engines. However, the data or test methods necessary to assess their suitability are not available.
Use of such products is under operator's own responsibility.
SprungMarke!!!45035996301577099

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: TED/Chvatal Susanne Release date: 27/05/2015
Index: 6 Page No.: 3/3
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0204
Corrosion protection products for cooling water for GE Jenbacher en-
gines and testing the coolant

1 General
An aqueous solution is used as the coolant in GE Jenbacher engines. Corrosion inhibitors and anti-freeze
products need to be added to the cooling circuits of GE Jenbacher engines.
Anti-freeze products are available both as concentrates and as premixed solutions ready to use.
Depending on the technology used in the corrosion inhibitors, the product manufacturers recommend
changing the coolant after 2 to 5 years. These are only general recommendations. Due to the wide range of
applications and operating conditions under which GE Jenbacher engines are used, it may be necessary to
change the coolant earlier.
If the corrosion inhibitors in the coolant are used up, the danger of corrosion is significantly higher than with
pure water.
The coolant must therefore be tested regularly to check that the anti-freeze protection and corrosion inhibition
are adequate and that the water quality is suitable.
Comment:
Since checking the required concentration of anti-freeze products can be done very easily on site with a
refractometer, GE Jenbacher recommends the addition of an anti-freeze product to the cooling water even if
frost protection is not necessary. However, check whether the design of the cooing circuits allows the addition
of anti-freeze; this can be taken from the "Heat Recovery" section of the technical description. See TI 1000-0201
for further information on using anti-freeze products.

2 Testing the coolant

▪ Due to the different technologies and different concentrations of corrosion inhibitors used, no generally
applicable tests or limit values can be given for monitoring the coolant.
▪ If the control range and limit values are not attached in the Appendix, the product descriptions of all the
products named in this Technical Instruction explain how the coolant is to be tested, or else the information
is deposited with GE Jenbacher.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Pichler Responsible: TST/Chvatal Release date: 27/05/2015
Index: 7 Page No.: 1/4
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0204
Corrosion protection products for cooling water for GE Jenbacher en-
gines and testing the coolant

▪ The following applies to all the products named in this Technical Instruction:
During the first 5 months after commissioning the engine, the coolant must be tested monthly. If the
coolant data is stable within its specifications, the interval can be extended to 2000 engine operating
hours.
If the coolant data is outside the specified range, then according to the coolant manufacturer the product
must be brought within the specified range.
The analyses must be documented by the customer and presented on request by GE Jenbacher.
▪ Testing the quality of the water to which the corrosion protection is to be added:
Once per year (see TI 1000-0200 for the limit values).
The analyses must be documented by the customer and presented on request by GE Jenbacher.

3 Information on filling the cooling circuit

Always clean the entire cooling system thoroughly by flushing with water and check the system for any leaks
before adding corrosion inhibitors.
Pour the required amount of corrosion protection into the cooling system and top up the system with water, as
described in TI 1000-0200.
Run the engine for 30 minutes afterwards.
Always bleed the cooling system because corrosion may form in spots where air has collected.

4 Selection overview
Company Product name Concentration %
Corrshield NT4201 0.6 to 1

Havoline XLI 5 to 10

Nalco2000 3 to 4

Maxigard 1.6 to 2

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Pichler Responsible: TST/Chvatal Release date: 27/05/2015
Index: 7 Page No.: 2 / 4
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0204
Corrosion protection products for cooling water for GE Jenbacher en-
gines and testing the coolant

Company Product name Concentration %

BL1 4 to 6
BL6 3 to 6

5 Appendix

5.1 Scope of analysis and admissible range for coolants with Corrshield NT4201, Nalco2000 and Maxigard
corrosion inhibitors.
Corrshield NT4201 Nalcool 2000 Maxigard
Interval Test Unit Limit values Limit values Limit values
annually Corrosion ‰ per year < 1 low-carbon steel < 1 low-carbon steel < 1 low-carbon
< 0.1 copper/brass < 0.1 copper/brass steel
< 0.1 copper/brass
annually microbiologi colony-forming < 10³ < 10³ < 10³
cal units per mm
annually Iron ppm Fe <3 <3 <3
annually copper ppm Cu < 0.2 < 0.2 < 0.2
each sample pH - 8.0 – 9.5 11.0 – 12.0 9 – 10
each sample nitrite ppm NO2 1000 - 1200 1000 - 1200 700 - 900
each sample nitrate ppm NO3 document document document
each sample ammonia ppm NH3 <3 <3 <3
each sample electrical µS/cm document document document
conductivity
each sample Total ppm CaCO3 < 20 < 20 < 20
hardness
each sample chloride ppm Cl < 150 < 150 < 150
each sample sulphate ppm SO4 < 150 < 150 < 150
each sample quartz ppm SiO2 < 200 < 200 < 200

5.2 Test standards for coolants with Corrshield NT4201, Nalco2000 and Maxigard corrosion inhibitors.
conductivity EN 27888(C8)
pH DIN 38404-C5
chloride [ppm] EPA Method 9056A EN ISO 10304-1
nitrite [ppm] EPA Methode 9056A EN ISO 10304-1
phosphate [ppm] EPA Methode 9056A EN ISO 10304-1
nitrate [ppm] EPA Method 9056A EN ISO 10304-1
iron [ppm] EPA 200.8 EN ISO 11885 (E22)
calcium [ppm] EPA 200.8 EN ISO 11885 (E22)

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Pichler Responsible: TST/Chvatal Release date: 27/05/2015
Index: 7 Page No.: 3/4
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0204
Corrosion protection products for cooling water for GE Jenbacher en-
gines and testing the coolant

silicon [ppm] EPA 200.8 EN ISO 11885 (E22)

boron [ppm] EPA 200.8 EN ISO 11885 (E22)
aluminium [ppm] EPA 200.8 EN ISO 11885 (E22)
copper [ppm] EPA 200.8 EN ISO 11885 (E22)
magnesium EPA 200.8 EN ISO 11885 (E22)
SprungMarke!!!54043195556324619
sulphate EPA Method 9056A EN ISO 10304-1

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Pichler Responsible: TST/Chvatal Release date: 27/05/2015
Index: 7 Page No.: 4 / 4
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0206
Quality of circuit water in hot water and warm water heating systems

1 Scope
This instruction applies to the composition of circuit water in hot water (permissible flow temperature above
100°C) and warm water heating systems.
It does not apply to the engine cooling water circuit (Refer to TI 1000-0200)!

2 Quality of circuit water

Non-saline water
Appearance Clear and odourless, no deposits or suspended solids
pH value (25°C) 9 - 10.5
Electr. conductivity µS/cm < 100
(at 25°C)
Oxygen O2 content mg/l < 0.05
2+ 2+
Alkaline earths Ca , Mg mmol/l < 0.02
Total hardness °dH < 0.1
Chlorides Cl - mg/l < 20
4
Phosphate PO mg/l 5 - 10

3 Important
3.1 If there is a risk of below-zero temperatures (freezing), make sure to contact a specialist firm to determine the
type of cooling agent required. Always comply with the specifications of the waste-heat boiler .

3.2 You should always check the water quality after filling up larger quantities of make-up water, but at least every
four years using a water-analysis procedure.

3.3 If the values in the table (section 2) are not achieved, the customer should contact a specialist outside firm
familiar with water treatment.

3.4 Always use trisodium phosphate for the basic alkalinisation of the filling and make-up water.

3.5 Minimum filling pressure:

In the case of plants that use exhaust gas heat and operate on a water/glycol mixture,
please observe the following minimum filling pressure values depending on the inlet temperature.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Dokumentation Responsible: Entwicklung Release date: 13/12/2012
Index: 2 Page No.: 1/2
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0206
Quality of circuit water in hot water and warm water heating systems

Inlet temperature Minimum filling

°C pressure required
bar

90 2.0
95 2.5
100 3.0
105 3.5
110 4.0

4 Water analysis
Always take the following points into account when performing water analyses:

4.1 Sampling should be done properly, as the analysis results can be easily distorted
Always use clean glass or plastic sample containers.
Always rinse the sample containers thoroughly (3 to 5 times) with the water to be tested before taking the
actual sample. In the case of water temperatures in excess of 25 °C, you must take the sample via a cooler
which cools down the water to be examined to a temperature of 25 °C.

4.2 You should determine the temperature, pH value, oxygen or carbon dioxide content immediately following
sample taking on site.

4.3 You must carry out the analytical tests according to the analysis instructions for the water quality concerned.

4.4 Because of the minute quantities of substances in the water, with an order of magnitude of less than 0.1% and
in some cases even less than 0.01%, a water analysis is similar to a chemical trace analysis and therefore
requires very sensitive detection methods.

4.5 Always use uniform units of measure to indicate the concentrations of substances in the water.
The most common units are "mg/l" or "g/l" or "µg/l".
Sometimes "mol/m³" or "val/kg" are also used.

4.6 A one-off water analysis will never guarantee the actual water quality of the water present in the systems over
a longer period of time. You should therefore always use average analysis results to assess the water quality.
SprungMarke!!!9007199282647435

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Dokumentation Responsible: Entwicklung Release date: 13/12/2012
Index: 2 Page No.: 2 / 2
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0300
Fuel gas requirements

1 Scope
This Technical Instruction (TI) applies to GE Jenbacher engines that are designed to be used with gaseous fuels.

2 Purpose
The purpose of this Technical Instruction is to illustrate the requirements and the limits that apply to the use of
fuel gas in combustion engines. Specifically, these relate to the limit values and requirements placed on the gas
composition, the trace elements and accompanying substances, and the oil, condensate and particles that the
fuel gas may contain.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin, D. Responsible: Madl, W. Release date: 30/04/2015
Index: 7 Page No.: 1/19
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0300
Fuel gas requirements

3 General
GE Jenbacher engine systems make use of a broad range of gaseous fuels as fuel gas. In contrast to petrol and
diesel fuels, gaseous fuels generally do not have to comply with strict specifications or classifications. Be that
as it may, the fuel gas is still subject to specific requirements and limit values. In principle, all gaseous fuels that
can be used in combustion engines can be classified as "fuel gases".
The physical and chemical characteristics of gaseous fuels can vary enormously. However, from the point of
view of construction and operating processes, the engines are designed to function within a very strict range of
characteristics and are often very sensitive to changes to these characteristics.
The engine system is optimally geared to the fuel gas composition for which it was sold. In case of obvious
changes, particularly where the fuel gas-related limit values are exceeded, the engine operation is affected.
This may mean that the safety of the plant and its operation can no longer be guaranteed.
Lubricating oil can lose its corrosion protection characteristics due to impurities in the fuel gas. The
results of regular lubricating oil analyses are indicative of fuel gas impurities. Refer as well to the following
Technical Instructions:
▪ TI 1000-0099B: Limit values for used oil in GE Jenbacher gas engines [⇨ TA 1000-0099B, Page 1]
▪ TI 1000-0099C Procedure for testing the oil service life specific to the plant [⇨ TA 1000-0099C, Page 1]
▪ TI 1000-0112 Taking lubricating oil samples / lubricating oil sampling protocol [⇨ TA 1000-0112, Page 1]
▪ TI 1000-1109: Lubricating oil for type 2, 3, 4 and 6 GE Jenbacher engines [⇨ TA 1000-1109, Page 1]
▪ TI 1000-1108: Lubricating oils for type 9 engines

ATTENTION
Environment, health & safety
Fuel gases and their preparation, together with their use in combustion engines, can result in
exposure to substances that can be harmful to the environment and/or injurious to health. The
handling of fuel gases, deposits and condensates therefore requires that the relevant health and
safety instructions are observed and that the necessary precautionary measures are taken.

4 Gas types
The fuel gases used in GE Jenbacher engines can be divided into the main categories listed below. GE
Jenbacher gas engines are not confined to these main categories. Solutions for other gas types can be
developed in conjunction with GE Jenbacher.

4.1 Natural gas

Natural gas is characterised by its high methane (CH4) content and is very pure. Its methane content is between
65 and 100 vol%.

4.2 Associated gas

This category of fuel gas is characterised by its medium to high methane content. Its methane content can lie
between 35 and 90 vol%. Of the other constituents, nitrogen (N2) or carbon dioxide (CO2) can occur in high
concentrations of up to 45 vol% and an increased proportion of higher-value hydrocarbons.

4.3 Biogas, sludge gas, landfill gas

These fuel gases are produced by the conversion of liquid or solid organic substances by micro-organisms. Like
associated gas, they are characterised by a medium to high methane content and the constituents N2 and CO2.
However, as this gas emanates from highly heterogeneous substances, special care must be taken with regard
to trace elements and accompanying substances.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin, D. Responsible: Madl, W. Release date: 30/04/2015
Index: 7 Page No.: 2 / 19
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0300
Fuel gas requirements

4.4 Mine gas

This fuel gas is recovered from mines and is characterised by very wide fluctuations in its methane content,
which can lie between 25 and 95 vol%. Of the other constituents, N2 can exist in a concentration of up to 65 vol
%, CO2 up to 15 vol% or oxygen (O2) up to 15 vol%. This gas is frequently associated with a certain amount of
dust loading, which necessitates a pre-separation stage.

4.5 Gases from thermal gasification processes

These gases are produced through the targeted gasification of biomass (e.g. wood), waste material, coal, etc.,
and typically exhibit high levels of hydrogen (H2) and carbon monoxide (CO). As this gas emanates from highly
heterogeneous substances, special care must be taken with regard to trace elements and accompanying
substances. This type of gas is also referred to as synthesis gas.

4.6 Process gases

Process gases arise in the steel industry and are hence also referred to as steel gas. These gases fall into the
following main groups:
Gas description Main components Origin
Coke-oven gas H2/CH4/N2/CO Coking process
Blast furnace gas N2/CO/CO2/H2 Process gas from steel production
Converter gas CO/N2/CO2/H2 Process gas produced during the
manufacture of steel, e.g. LD gas
(Linz-Donawitz process)

4.7 Liquid gas, propane gas

The most distinctive feature of liquid gases is that they are transported and stored in a liquid state. They are
then evaporated before being used.
Liquid natural gas (LNG) consists initially of natural gas, which is liquefied by cooling it to -161°C. However,
"fractionation" can occur during the evaporation process, resulting in possible deviations and fluctuations in
the gas composition, such as an increase in the concentration of longer-chain hydrocarbons.
Propane gas is already in a liquid state under relatively low pressures and normal temperatures. Its main
constituent is propane (C3H8), which is present in concentrations of 60 to 100 vol%. It may also contain high
concentrations of butane (C4H10 - up to 10 vol%), ethane (C2H6 - up to 20 vol%) or methane (up to 40 vol%).

5 Requirements and limit values

Fuel gases are composed of various individual components. These include their main components, trace
elements and accompanying substances, plus oil, condensate and particles.
To guarantee faultless engine operation and the specified maintenance intervals, the specified fuel gas
requirements must be permanently maintained at the GE Jenbacher interface. A summary of the requirements
and limit values, together with any other special requirements, can be found in the Appendix.
GE Jenbacher cannot honour warranty claims relating to problems caused by exceeding one or more of the
limit values specified in this TI.

5.1 Physical fuel gas properties, main components and thermodynamic requirements
The main components determine the relevant fuel gas characteristics for physical engine operation (e.g.
calorific value, combustion air ratio, combustion temperature, laminar flame propagation speed, ignition limits,
knock resistance). They are normally expressed as vol% and must be specified in the form of a comprehensive
gas analysis (see Appendix: Checklist for fuel gas quality information).

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin, D. Responsible: Madl, W. Release date: 30/04/2015
Index: 7 Page No.: 3/19
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0300
Fuel gas requirements

Apart from a number of limiting conditions stipulated on the data sheet, the technical specifications also show
the type of fuel gas.
In cases where the available fuel gas does not conform to what is stated in the standard product range, a
special - client-specific - solution can be arranged, taking into account all technical and efficiency-related
options.
It is normal for the composition of some gas types to vary substantially. In Leanox-controlled engine operation
(under load), these fluctuations can to a large extent be compensated for by the engine management system.
In order to guarantee a satisfactory starting behaviour, however, a certain fluctuation range is necessary and
the engine management must be provided with suitable/usable information (e.g.: calorific value, CH4 content)
on the current gas quality.
Physical properties, main components and thermodynamic requirements
Gas pressure Fluctuation ≤ 10 mbar/s
Gas temperature Min. 10 °C Higher temperatures should be
Max. 40 °C checked in all cases!
Relative gas Max. 80 % rel. Must be guaranteed at any
humidity temperature and supply pressure! 1)
Max. 50 % rel. When using a GE Jenbacher active
carbon filter at the intake of the active
carbon system. Higher temperatures
should be checked in all cases!
Lower calorific Fluctuation ≤4 %/min
value
Methane number Speed of change ≤ 10 MN/min According to standard calculation
method (AVL)
Hydrogen H2 Speed of change ≤4 vol%/min Particularly with process gases
Ignitability The gas must not be ignitable. Observe regulatory
requirements and limit values!
1)
The limit values quoted in sections 5.4 and 5.5 apply if a pre-chamber gas compressor is being used for the
pre-chamber gas system, or if the system is installed in tropical zone countries.

5.2 Limit values for trace elements and accompanying substances, oil, condensate and particles
Trace elements and accompanying substances usually enter the gas during the gas formation process. They
are usually impurities in the ppm range. In contrast to the effects of main components, the effects of trace
elements or accompanying substances do not become noticeable until the engine has been operational for a
certain time (cumulative effect). The same applies to oil, condensate and particles. As these effects are
predominantly harmful, the fuel gases should be as free as possible of trace elements and accompanying
substances. If the accompanying substance content is very high, suitable fuel gas cleaning may, under certain
circumstances, be the best method of ensuring economic utilisation of the fuel gas.
To determine the suitability of a fuel gas for use in combustion engines, comprehensive knowledge of the gas
analysis is required. Field experience shows that even results that were obtained under the same operating
conditions can vary substantially. The effect of trace elements can therefore only be predicted to a certain
extent, as very complex interrelations and cause/effect relations are often involved. In principle, the effects of
trace elements are proportional to the quantity fed into the engine while it was operating. When using a fuel
gas with a high calorific value, the gas flow to the engine is smaller compared with a gas with a low calorific
value. As a result, the amount of trace elements fed into the engine - and therefore their effect - differs even if
there are identical concentrations of trace elements in the fuel gas. In order to be able to compare various
gases, the trace element concentration values must be relative to a certain fuel gas energy amount (the fuel
gas performance required to generate a certain engine output is very similar for all gas types).
GE Jenbacher has therefore set the energy content of one standard cubic metre of methane to 10 kWh
(rounded off).
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin, D. Responsible: Madl, W. Release date: 30/04/2015
Index: 7 Page No.: 4 / 19
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0300
Fuel gas requirements

Additional trace elements or impurities not explicitly mentioned in this Technical Instruction can change the
properties of the fuel gas. GE Jenbacher does not accept responsibility for reduced output, reduced efficiency,
reduced availability or possible engine damage resulting from such additional trace elements or impurities. In
such cases GE Jenbacher is also relieved of any and all warranty obligations.
Limit values for trace elements and accompanying substances 2)
Total sulphur S ≤ 700 mg/10 kWh Note effect on oil service life 3)
≤ 1200 mg/10 kWh With limited warranty 4)
Halogen compounds Total Cl + 2 * F ≤ 100 mg/10 kWh Note partial load operation 5)
≤ 400 mg/10 kWh With limited warranty 4)
Ammonia NH3 ≤ 50 mg/10 kWh Higher NH3 values in the fuel gas may
result in the NOx values for the engine
exhaust gas stated in the specification
being exceeded.
VOSC as total silicon Total silicon as SiOL ≤ 0.02 Precise silicon operational value SiO 6) to
(silicon operational be determined by oil analysis
limit value)
Highly flammable Acetylene (C2H2) ≤ 0.2 vol% These substances can cause
components Carbonyl sulphide ≤ 0.2 vol% uncontrolled spontaneous combustion
(COS) in the system!
2)
The limit values quoted in the following sections apply if GE Jenbacher fuel gas or exhaust gas treatment
systems are being used, or if engines are being used with a pre-chamber gas system, or if the system is
installed in tropical zone countries.
3)
The oil service life is noticeably reduced above a total sulphur content of approx. 50 mg/10 kWh and/or a
total halogen content of approx. 20 mg/10 kWh (refer to TI 1000-0099 B and C). If desulphurisation units are
being used, note that extremely high concentrations of sulphur can enter and damage the engine very quickly
when a fault occurs in such units.
This category also includes the limit values for hydrofluoric acid (HF) and hydrochloric acid (HCl). Refer to the
sample calculation for converter gas in the Appendix.
4)
The limits can be increased if one is prepared to accept higher maintenance costs and a reduction in the
service life of all the engine and plant components that come into contact with the fuel gas, engine oil or
exhaust gas. In order to achieve a satisfactory minimum oil service life (approx. 500 Oh) a suitably large
additional lubricating oil tank must be fitted, as designed by GE Jenbacher.
5)
For installations using heat recovery, care must be taken to ensure that the acid dew point in the heat
recovery boiler - taking partial load operation into account - does not fall below its minimum value.
6)
When using a fuel gas with traces of volatile oxidisable silicon compounds, no fuel gas limit values can be
quoted due to the wide fluctuations and difficulty in carrying out an analysis. The operational value SiO is the
determining value for the amount of silicon fed to the engine, and is determined from the results of two oil
analyses. This must not exceed the operational limit value SiOL. The calculation is explained in the Appendix.
Limit values for oil, condensate and particles
Particles A filter in the gas train protects the system against particles.
The filter in the gas train is not used as a work filter 7)
Total oil content ≤ 0.2 mg/10 kWh
Tar CxHyRz No tar Where gases (particularly wood gas)
in the contain tar, the gas train must be
intake fitted with a trace heating system
system and thermal insulation! 8)

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin, D. Responsible: Madl, W. Release date: 30/04/2015
Index: 7 Page No.: 5/19
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0300
Fuel gas requirements

Limit values for oil, condensate and particles

Condensate or No condensate and no sublimation of water or tars in
sublimate components that come into contact with gas and/or
mixture! 9)
7)
If the filter service life as stated in the maintenance plan is not achieved or the filter service life is found to be
unacceptable or the operation of the gas train is compromised, measures must be taken by the customer to
improve the situation.
If a work filter is necessary, it must have a filtration efficiency of at least 99.99% for particle diameters greater
than 3 µm.
8)
In mixtures or gases in which the hydrocarbons form solid, liquid or highly viscous products when the mixture
or gas cools to below the dew point, the condensation or sublimation products are described as tar. This
affects all hydrocarbons (CxHyRz) with 6 or more carbon atoms and a molar mass (M) ≥ benzene (78.11 g/mol)
with every possible substitution group (Rz).
When condensing out, tars can cause problems in the gas or mixture-side intake tract.
If tars condense or sublimate in components that are in contact with the gas or mixture, some of the problems
that may arise are as follows:
▪ Clogging of fittings (filters, pressure regulators, solenoid valves, etc.) in the gas train
▪ Clogging of the gas mixer and compressor impeller on the exhaust gas turbocharger
▪ Clogging of the intercooler
When gases containing tar are mixed with cold combustion air, the mixture temperature must not fall below
the tar dew point. In such situations, the tar dew point of the fuel gas must be correspondingly lower in order to
prevent the tar condensing and/or sublimating in components that are in contact with the gas or mixture!

ATTENTION
Condensed and/or sublimated tars
Besides shortening the service life of components, increasing maintenance costs and restricting
engine operation, condensed and/or sublimated tars can also adversely affect the safety of the
gas train!

9)
Condensate or sublimate in the area where gas and air are mixed (gas mixer) can sometimes also be caused
by combustion air which is too cold. In this case, the problem can be remedied if the customer takes measures
to preheat the combustion air, for example by recirculating the room ventilation!
The absolute quantity of elements which have entered the engine is decisive for determining the trace element
content. The quoted limit values assume that the combustion air is free of accompanying substances.
The limits can, with the prior agreement of GE Jenbacher, be increased if one is prepared to accept higher
maintenance costs and a reduction in the service life of all the engine and system components that come into
contact with the fuel gas, engine oil or exhaust gas. Moreover, additional measures, such as the design and
attachment by GE Jenbacher of a supplementary lubricating oil reservoir, can help increase the minimum
service life of the oil.

5.3 Additional requirements when using GE Jenbacher fuel gas or exhaust gas treatment systems
For engines, GE Jenbacher offers a wide range of in-house developed fuel gas and exhaust gas treatment
systems. The additional requirements set out in the table below apply to the system as a whole if the engine is
equipped with one of these treatment systems.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin, D. Responsible: Madl, W. Release date: 30/04/2015
Index: 7 Page No.: 6 / 19
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0300
Fuel gas requirements

Additional requirements when using GE Jenbacher fuel gas or exhaust gas treatment systems
Total sulphur S ≤ 500 mg/10 kWh When using GEJ active carbon
≤ 200 mg/10 kWh system
≤ 20 mg/10 kWh When using GEJ CO catalyst 10)
When using GEJ formaldehyde
catalyst 10)
Halogen compounds Total Cl + 2 * F ≤ 200 mg/10 kWh When using GEJ active carbon
≤ 200 mg/10 kWh system
≤ 20 mg/10 kWh When using GEJ CIAir system
When using GEJ CO catalyst or GEJ
formaldehyde catalyst
VOSC as total silicon Total silicon as SiOT ≤ 0.0005 When using GEJ CO catalyst or GEJ
formaldehyde catalyst
Total trace elements The metals and heavy metals listed as examples have the effect of deactivating the
when catalytic catalytic converter. This reduces its service life accordingly.
converter is used ▪ Sulphur, phosphorus, lead, mercury, arsenic, antimony, zinc, copper, tin, iron, nickel,
chromium, etc.
▪ The warranty will cease to apply if the cumulative volume of these elements exceeds
350g/Nm3 of the honeycomb catalytic converter. The evidence will be provided by
quantitative analysis of a used sample. The exhaust gas must, in all cases, be free of
silicon compounds, such as siloxanes.
10)
SO2 is converted to SO3 in the catalytic converter. As condensate forms, sulphurous or sulphuric acid is
produced. Consequently, heat recovery boilers, catalytic converters and exhaust gas systems for exhaust gas
temperatures < 180°C are covered by a limited warranty in the event of damage.

5.4 Additional requirements for engines with a pre-chamber gas system

The following limit values apply to engines with a pre-chamber gas system.
Additional requirements for engines with a pre-chamber gas system
Total sulphur S ≤ 200 mg/10
kWh

Engines equipped with a pre-chamber gas system require fuel gas at a higher pressure. When the pressure
level changes, condensation and sublimation of trace elements can occur in the fuel gas. The additional
requirements set out below apply if a compressor is being used to increase the pressure level.
Additional requirements when using a pre-chamber gas compressor for the pre-chamber system
Gas temperature at pre-chamber Min. 10 °C Higher temperatures should be checked in all
gas compressor inlet Max. 40 °C cases! If the engine room temperature is below
30°C, trace heating and insulation of the entire
gas train can be carried out to reliably avoid
condensation and sublimation.
Relative gas humidity at the pre- Max. 15 % rel. No condensate in the gas train up to the pre-
chamber gas compressor inlet chamber gas valve!

5.5 Additional requirements for applications using mine gas in tropical zone countries
Special requirements exist for mine gas applications in tropical zone countries located between latitudes 30°
north and 30° south. Areas affected include Central America (including Mexico), South America (with the
exception of Uruguay, Argentina and Chile), Africa, the Arabian Peninsula (including Israel), the Indian
subcontinent (Pakistan, Bangladesh, India, Sri Lanka), the whole of South-East Asia (including China), Australia

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin, D. Responsible: Madl, W. Release date: 30/04/2015
Index: 7 Page No.: 7/19
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0300
Fuel gas requirements

(north of 30° latitude) and Oceania. To prevent condensation in the components conveying fuel gas and the
mixture, the following requirements apply in these countries to the operation of GE Jenbacher engine systems
with mine gas.
Additional requirements in tropical zone countries located between latitudes 30° north and 30° south
Relative gas humidity of mine gas Max. 50 % rel. No condensate in the gas train up to
the gas mixer!

5.6 Requirements regarding freedom from condensate of fuel gas

In addition to water vapour, many types of gas also contain other condensable substances that demand
special attention. Condensation processes can adversely affect engine operation. This is particularly true in the
case of gases from gasification processes, which, depending on the process and the gas treatment system,
may contain condensable organic components such as tar and water-soluble naphthalene, not to mention
many others. This can have potentially negative consequences, especially for the components conveying the
fuel gas.

NOTICE
Danger of engine damage
Experience shows that an insufficiently dry gas initially mostly causes malfunctions in the valves,
devices and piping outside the engine itself. If the cause is not rectified, however, damage to the
engine cannot be ruled out.

Malfunctions that occur because the fuel gases supplied are insufficiently free from condensate are not
covered by our warranty. This warranty exclusion does not apply if the contractual scope of supply of GE
Jenbacher expressly includes a specific fuel gas drier.
Additional information relating to freedom from condensate can be found in the Appendix.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin, D. Responsible: Madl, W. Release date: 30/04/2015
Index: 7 Page No.: 8 / 19
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0300
Fuel gas requirements

6 Appendix

6.1 Overview of the requirements and limit values

Description Supplement Limitation Unit Remark
Physical properties, main components and thermodynamic requirements
Gas pressure Fluctuation ≤ 10 mbar/s
Gas temperature Min. 10 °C Higher temperatures should be
Max. 40 °C checked in all cases!
Relative gas Max. 80 % Must be guaranteed at any
humidity temperature and supply pressure!
Lower calorific Fluctuation ≤4 %/min
value
Methane number Speed of change ≤ 10 MN/min According to standard calculation
method (AVL)
Hydrogen H2 Speed of change ≤4 vol%/min Particularly with process gases
Ignitability The gas must not be ignitable. Observe regulatory requirements
and limit values!
Limit values for trace elements and accompanying substances
Total sulphur S ≤ 700 mg/10 kWh Note effect on oil service life
≤ 1200 mg/10 kWh With limited warranty
Halogen Total Cl + 2 * F ≤ 100 mg/10 kWh Note partial load operation
compounds ≤ 400 mg/10 kWh With limited warranty
Ammonia NH3 ≤ 50 mg/10 kWh Higher NH3 values in the fuel gas may
result in the NOx values for the
engine exhaust gas stated in the
specification being exceeded.
VOSC as total Total silicon as SiOL ≤ 0.02 Precise silicon operational value SiO to
silicon (silicon operational limit be determined by oil analysis
value)
Highly flammable Acetylene (C2H2) ≤ 0.2 vol% These substances can cause
components Carbonyl sulphide (COS) ≤ 0.2 vol% uncontrolled spontaneous
combustion in the system!
Limit values for oil, condensate and particles
Particles - A filter in the gas train protects the
system against particles. The filter in
the gas train is not used as a work
filter
Total oil content ≤ 0.2 mg/10 kWh
Tar CxHyRz No tar in Where gases (particularly wood gas)
components contain tar, the gas train must be
that are in fitted with a trace heating system
contact with and thermal insulation!
the gas or
mixture

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin, D. Responsible: Madl, W. Release date: 30/04/2015
Index: 7 Page No.: 9/19
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0300
Fuel gas requirements

Description Supplement Limitation Unit Remark

Condensate or - No condensate and no sublimation of
sublimate water or tars in components that
come into contact with gas and/or
mixture!
The above table is just an extract. Details can be found in the individual chapters.

6.2 Overview of the additional requirements

Description Supplement Limitation Unit Remark
Additional requirements when using GE Jenbacher fuel gas or exhaust gas treatment systems
Total sulphur S ≤ 500 mg/10 kWh When using GEJ active carbon
≤ 200 mg/10 kWh system
≤ 20 mg/10 kWh When using GEJ CO catalyst
When using GEJ formaldehyde
catalyst
Halogen compounds Total Cl + 2 * F ≤ 200 mg/10 kWh When using GEJ active carbon
≤ 200 mg/10 kWh system
≤ 20 mg/10 kWh When using GEJ CIAir system
When using GEJ CO catalyst or GEJ
formaldehyde catalyst
VOSC as total silicon Total silicon as SiOL ≤ 0.0005 When using GEJ CO catalyst or GEJ
formaldehyde catalyst
Total trace elements The metals and heavy metals listed as examples have the effect of deactivating the
when catalytic catalytic converter. This reduces its service life accordingly.
converter is used ▪ Sulphur, phosphorus, lead, mercury, arsenic, antimony, zinc, copper, tin, iron, nickel,
chromium, etc.
▪ The warranty will cease to apply if the cumulative volume of these elements
exceeds 350g/m3 of catalytic converter. The evidence will be provided by
quantitative analysis of a used sample. The exhaust gas must, in all cases, be free
of silicon compounds, such as siloxanes.

Additional requirements for engines with a pre-chamber system

Total sulphur S ≤ 200 mg/10
kWh
Additional requirements when using a pre-chamber gas compressor for the pre-chamber system
Gas temperature in pre-chamber Min. 10 °C Higher temperatures should be checked in all
gas compressor Max. 40 °C cases! If the engine room temperature is below
30°C, trace heating and insulation of the entire
gas train can be carried out to reliably avoid
condensation and sublimation.
Relative gas humidity at the pre- Max. 15 % rel. No condensate in the gas train up to the pre-
chamber gas compressor inlet chamber gas valve!
Additional requirements for mine gas applications in tropical zone countries between latitudes 30° north
and 30° south
This additional requirement for mine gas applications typically applies to the countries of Central America (incl.
Mexico), South America (with the exception of Uruguay, Argentina and Chile), Africa, the Arabian peninsula (incl.
Israel), the Indian subcontinent (Pakistan, Bangladesh, India, Sri Lanka), the whole of South-East Asia (incl.
China), Australia (north of 30° latitude) and Oceania.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin, D. Responsible: Madl, W. Release date: 30/04/2015
Index: 7 Page No.: 10 / 19
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0300
Fuel gas requirements

Relative gas humidity of mine gas Max. 50 % rel. No condensate in the gas train up to the gas
mixer!
The above tables are just an extract. Details can be found in the individual chapters.

6.3 Explanation of freedom from condensate

To adhere to this TI, no condensate should form in any components conveying fuel gas or the mixture. Should
condensation nevertheless occur, the following explanations may prove helpful.

The most common types of condensate formation

Gas Condensate structure Most common consequences for engines
Biogas, sludge gas and Acidic water, also as an Corrosion (→ wear)
landfill gas emulsion with the TAN concentration or pH reduction in lubricating oil
lubricating oil in the gas
Carbon deposited on valves, piston ring grooves
compressor
and slots
Associated gas Higher hydrocarbon Film of lubricating oil washed off (seizing)
compounds in liquid form Knocking combustion
Edges burnt off
Higher hydrocarbon Carbon deposits on: valves, piston ring grooves and
compounds in liquid form slots
and/or crude oil
Liquid gas, propane gas Liquid propane/butane Film of lubricating oil washed off (seizing)
Knocking combustion
Edges burnt off
Gas from gasification Same as all other gases Same as all other gases
processes, process gases

Influence on engine operation

④
⑦

⑤ ⑥
② ③ ⑦ ⑧
①

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin, D. Responsible: Madl, W. Release date: 30/04/2015
Index: 7 Page No.: 11/19
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0300
Fuel gas requirements

Component Effect Solution Detection

No. ① Fouling of the gas filter, swelling Clean or replace affected Visual inspection after
Gas train of diaphragms, deposits of parts as per maintenance 10,000 operating hours (Oh)
condensate or sublimate instruction or in the event of a fault
No. ② No known consequences
Gas mixer
No. ③ Deposits on compressor wheel or Clean as per maintenance Difficulty reaching full load /
Turbocharger diffuser schedule after 10,000 Oh or power reduction
as required
No. ④ Clogged by tar deposits; in worst Clean using solvent. Can be Visual inspection after
Turbocharger case, failure of the valve cleaned at the same time as 10,000 Oh or in the event of
bypass valve the intercooler (10,000 Oh) a fault
No. ⑤ No known consequences
Intercooler 1st
stage
No. ⑥ Clogged with tar deposits and Clean with intercooler Large fall in pressure can
Intercooler 2nd condensate; possible power cleaning device be equalised to a certain
stage reduction as a result of extent using turbocharger
increasing pressure loss reserves; indication:
increase in boost pressure
No. ⑦ Clogged by tar deposits; possible Mechanical cleaning. Can be Large fall in pressure can
Flame trap power reduction cleaned at the same time as be equalised to a certain
the intercooler (10,000 Oh) extent using turbocharger
reserves; indication:
increase in boost pressure
Component temperature
greater than e.g. intercooler
temperature (~80-90°C)
No. ⑧ Clogged by tar deposits; in worst Clean using solvent. Can be Visual inspection after
Throttle valve case, failure of the throttle valve cleaned at the same time as 10,000 Oh or in the event of
the intercooler (10,000 Oh) a fault
No. ⑨ - - -
Engine

How to avoid malfunctions resulting from condensate in the fuel gas

▪ In general, the technical project execution department at GE Jenbacher should be contacted if
condensation occurs.
▪ Condensation of the vapour by cooling and/or expansion.
▪ Mechanical separation (e.g. cyclone or separation filter) and by gas-tight discharge of the condensate.
▪ The fuel gas line leading to the engine must be designed not to allow the gas to continue to cool down (and
also not to be expanded by resistance or downstream pressure reducers). If necessary, the fuel gas line
must be insulated or provided with a trace heating system.
▪ In spite of the freedom from condensate found at the condensate test points, a certain amount of
condensate can find its way into the engine. It is therefore very important to ensure that the condensate is
as free from acid-forming components as possible. To verify this, the pH-value of the aqueous extract
taken from the condensate separators must be checked. The stronger the acid, the more powerful the
adverse effect is, even with condensate quantities that can hardly be verified.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin, D. Responsible: Madl, W. Release date: 30/04/2015
Index: 7 Page No.: 12 / 19
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0300
Fuel gas requirements

ATTENTION
Skin hazards from chemical substances! Corrosive condensate
The safety instructions must be observed when draining condensate from the gas system. Wear
acid-resistant gloves when handling condensate.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin, D. Responsible: Madl, W. Release date: 30/04/2015
Index: 7 Page No.: 13/19
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0300
Fuel gas requirements

6.4 Check list for fuel gas quality information

General information
Name of the project or the plant
Location (country and/or city) of the plant
Name of the contact person
Telephone number
Origin of the gas
Gas type classification:
Natural gas (NG)
Associated gas (APG)
Biogas, sludge gas, landfill gas (BG)
Mine gas (CMG)
Gases from gasification processes (GG)
Process gases (PG)
Liquid gas, propane gas (LG)

Physical properties
Gas pressure (from – to) - mbar(o)
Gas temperature (from – to) - °C
Gas relative humidity (from – to) - %
Atmospheric pressure (from – to) - mbar

Main components Relevant for the Vol% Measurement method

following gas types *
N A B C G P L
G P G M G G G
G G
Methane CH4 X X X X X X X
Ethane C2H6 X X X
Propane C3H8 X X X X
Butane C4H10 X X X
Pentane C5H12 X X X
Hexane C6H14 X X X
Carbon monoxide CO X X X
Hydrogen H2 X X
Carbon dioxide CO2 X X X X X
Nitrogen N2 X X X X X
Oxygen O2 X X X X
Miscellaneous X X X X X X X

Trace elements and Relevant for the Qty. mg/10 Measurement method
accompanying following gas types * kWh
substances
N A B C G P L
G P G M G G G
G G
Ammonia NH3 X X X
Total chlorine X X X

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin, D. Responsible: Madl, W. Release date: 30/04/2015
Index: 7 Page No.: 14 / 19
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0300
Fuel gas requirements

Trace elements and Relevant for the Qty. mg/10 Measurement method
accompanying following gas types * kWh
substances
Total fluoride X X X
Prussic acid HCN X
Hydrogen sulphide H2S X X X X
Total organosilicon X
compounds
Total sulphur X X X X
Acetylene C2H2 X X
Carbonyl sulphide COS X X
Tar Benzene X X
Naphthalene X X
Tar dew point X X Temperature °C
Miscellaneous X X X X X X X

Particles
< 3 µm X X X
> 3 µm X X X
Miscellaneous X X X X X X X

* The individual positions are relevant if this component is (or can be) present in the gas. Positions allocated to
a gas type are marked "X" and are required in each case.
Other information:

GE Jenbacher recommends that you only use analysis institutes with which it is familiar.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin, D. Responsible: Madl, W. Release date: 30/04/2015
Index: 7 Page No.: 15/19
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0300
Fuel gas requirements

6.5 Organosilicon compounds in biogas, sludge gas and landfill gas

Organosilicon compounds
Organosilicon compounds are found in fuel gases from landfills, water purification plants and biogas
installations (depending on the source of the biomass). When using these fuel gases in combustion engines,
silicon oxide is produced (quartz particles), which may result in increased maintenance of the machinery and, in
certain cases, in the deactivation of an exhaust gas catalytic converter.
Siloxanes, silanes and silanoles all belong to the organosilicon compound group. Siloxanes are increasingly
used in cosmetics, detergents and as anti-foaming agents in industry. The other substances enter the fuel gas
primarily as siloxane decomposition products. These are combustible and very volatile substances that
originate from watery systems (sludge, fermenters, landfill leach water).
An assessment of the levels of organosilicon compounds in fuel gas should be carried out in the following
applications:
▪ Gases from landfills
▪ Gases from sewage plants that mainly process domestic waste water
▪ Gases from biogas installations, depending on the origin of the biomass
▪ Gases from landfills where intermediate products from silicon chemical processes or other silicon-
containing products are dumped, and gases from sewage plants into which silicon-containing effluent is
discharged
While the tried and tested GE Jenbacher renewable active carbon system effectively removes these
organosilicon compounds from sludge gas and biogas, any decision to use this cleaning technique for landfill
gas should be taken on a case-by-case basis.

Determining levels of organosilicon compounds

The total of the organosilicon compounds contained in the fuel gas is used to calculate the total silicon atoms
contained in the fuel gas in [mg/Nm³]. Given the the methane value, this value can be converted into the
content of silicon atoms from organosilicon compounds in [mg/10 kWh].
Particularly in the case of fuel gases from landfill sites, GE Jenbacher's advice is to analyse the organosilicon
compounds in the preparatory project phase in order to estimate the expected level of maintenance
operations. The analysis results also provide GE Jenbacher with a framework on which to base its advice for
the best gas-cleaning method, taking into account feasibility and efficiency aspects.
The sampling and analysis of organosilicon compounds in the typically occurring concentrations do not reflect
the generally accepted state-of-the-art. GE Jenbacher offers its customers a tried and tested analysis
technique which the company has developed itself. The sampling should only be performed by trained
specialist GE Jenbacher staff.
During operation, the silicon load is determined from the silicon content of the oil. Strict maintenance of this
limit value forms the basis for the validity of a service contract. This limit value does not indicate the current
silicon load value, but shows the amount of silicon accumulated during the period between two oil analyses.

Requirements for sampling and the selection of the sampling location

Identifying the organosilicon compounds in fuel gas is always a reflection of the current situation at the time
the sample was taken. Sample taking can only yield suitable results if the fuel gas source to be sampled meets
the following criteria:
1. The sample location must be a part of the gas line with a constant gas flow and must be free of
condensate. Up or downward pipe sections are well suited for this purpose. In case of horizontal pipe
sections, the sample location must branch off upward, otherwise condensate will collect in the branches.
This also falsifies the sample if the condensate has been drained off and the gas is visually dry.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin, D. Responsible: Madl, W. Release date: 30/04/2015
Index: 7 Page No.: 16 / 19
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0300
Fuel gas requirements

2. The fuel gas supply must have been up and running without interruption for at least three (3) hours. The
gas volume flow must be at least 75% of the operational gas flow that would be needed at full-load
condition of the projected gas engine installation. With gas lines having a reduced flow during sampling,
there is the risk of a faulty measurement when trace components condense on cold surfaces and/or when
organosilicon compounds are absorbed into other condensed trace components.
3. The sampling location should preferably be in the pressurised part of the fuel gas line upstream of the
projected engine is reached. However, sample taking in negative pressure lines is also possible.
4. During this period, landfill gas installations require the suction pressure to be approximately the same as
the suction pressure during the projected full-load operation. Landfills which produce no gas flows in the
volumes required for the projected engine operation cannot be sampled satisfactorily. In the case of
landfills, suitable samples can only be taken in a gas collecting line. Sample taking from individual sources
will not yield results that can be used as described in this Technical Instruction.
5. In order to achieve a fuel gas trace element load that is as constant as possible, none of the settings of the
operational gas installation should be modified during sample taking.

6.6 Sample calculations

Sample calculation trace element concentration SC

Measured concentration [mg/Nm3]
SC = ──────────────────────────────── X 10
Calorific value [kWh/Nm3]
Concentrations are frequently indicated in volume-related quantities e.g. ppm (parts per million), which must be
converted in an intermediate step to mg/Nm3 using the density under normal conditions: i.e.
SC' [mg/Nm3] = Measured concentration [ppm] x element density [kg/Nm3]
Remark: expressing the quantity as ppm ( = 10-6) and conversion from kg to mg (10+6) cancel each other out.
Sample calculation
CO2 40%
CH4 60%
H2S 260 ppm (at normal density condition = 1.52 kg/Nm3)
Lower calorific value 6 kWh/Nm3 ( = 60% of 100% CH4 = 10 kWh/Nm3)

Step 1: conversion of measured value in ppm to mg/Nm3, in relation to H2S

SC'1 [mg/Nm3]= 260 [ppm] x 1.52 [kg/Nm3] SC'1= 395 mg/Nm3

Step 2: conversion of the value in relation to H2S to the limited sulphur value in mg/Nm3
Sulphur molar mass 32
3
SC' [mg/Nm ]= ───────────────── x SC’1 SC' [mg/Nm ]= ─── x 395 [mg/Nm3]
3

Molar mass of H2S 34

SC'= 372 mg/Nm3

Step 3: conversion of measured value in mg/Nm3 to comparison value (mg/10 kWh).

372 [mg/Nm3]

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin, D. Responsible: Madl, W. Release date: 30/04/2015
Index: 7 Page No.: 17/19
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0300
Fuel gas requirements

SC= ──────────── x10 ⇨ SC= 620 mg/10 kWh actual value

6 [kWh/Nm3]

Without catalytic converter ⇨ SC T = 700 mg/10 kWh SC < SC G ⇨ OK

In principle, this sample calculation also applies to all limit values expressed as mg/10 kWh.

Sample calculation for converter gas

Main gas components Value Unit
Acetylene C2H2 < 0.1 vol%
Higher-value HC (> C5H12) < 0.2 vol%
CO 67.75 vol%
N2 13.21 vol%
CO2 16.22 vol%
H2O 2.52 vol%

Trace elements and accompanying substances Value Unit

H2S 80 ppm
HF 7.1 mg/10 kWh
HCl 4.0 mg/10 kWh

Gas characteristics Value Unit

Lower calorific value 2.38 kWh/Nm3

Hydrofluoric and hydrochloric acid

Step 1: calculation of the total quantity of chlorine
Chlorine molar mass 35.4
Cl [mg/10 kWh] = ─────────────── x Cl’ Cl [mg/10 kWh] = ──── x 4 [mg/10kWh]
HCl molar mass 36.4

Cl = 3.9 [mg/10 kWh]

Step 2: calculation of the total quantity of fluoride

Fluorine molar mass 19
F [mg/10 kWh] = ─────────────── x F' F [mg/10 kWh] = ──── x 7.1 [mg/10kWh]
HF molar mass 20

F = 6.7 [mg/10 kWh]

Step 3: calculation of the total quantity of halogens

Hal [mg/10 kWh] = Cl + 2 x F Hal [mg/10 kWh] = 3.9 [mg/10 kWh] + 2 x 6.7 [mg/10 kWh]

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin, D. Responsible: Madl, W. Release date: 30/04/2015
Index: 7 Page No.: 18 / 19
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0300
Fuel gas requirements

Hal = 17.3 [mg/10 kWh]

Step 4: comparison of actual and setpoint value

Without catalytic ➔ HalT = 100 mg/10 kWh Hal < HalT ➔ OK
converter

In principle, these sample calculations apply to all limit values indicated in mg/10 kWh.

Sample calculation of silicon operational value SiO

Determined using two oil analyses:
∆ Si content in engine oil: the increase of the Si content in the engine oil in ppm between two analyses, and
∆ oil operation time: the operating time in hours between the two oil analyses.
∆ Si content in engine oil [ppm] x total operating oil volume (l)
Si Operational value [SiO] = ───────────────────────────────────────────── x 1.1
Average engine power output [kW] x ∆ oil operation time (h)

The total operating oil volume equals the oil volume in the oil pan plus the oil volume of any additional oil tanks,
if installed.
Refilling volume is definitely excluded.
Sample calculation
Increase in the Si content of the engine oil between 40 ppm
two oil samples
Total operating oil volume 500 l
Engine power output 2000 kW
Operational oil life between the analyses 600 h

40 ppm x 500 l
SiO = ─────────────── x 1.1
2000 kW x 600 h

SiO = 0.018 actual value

SprungMarke!!!54043195551952907
SiOT = 0.02 SiO < SiOT ⇨ OK

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin, D. Responsible: Madl, W. Release date: 30/04/2015
Index: 7 Page No.: 19/19
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0330
Signs on the engine room door

1 Scope
This TI specifies the type of safety signs to be affixed to the engine room door and their location. You must also
comply with any relevant official instructions regarding signage.

2 Operating area sign/safety signage

The pictograms are explained in full in the safety instructions.
If the fuel gas contains CO, the following pictogram
must also be affixed.
Refer to the results of the gas analyses!

DANGER
CO

(( CO))

ISO 3864, ÖNORM Z1000, ANSI Z535 JWN 080 080 / 400743

The signage can be ordered from GE Jenbacher.

3 Affixing
All doors leading to the engine room must be identified with an operating area sign or provided with a safety
sign.
The signs must be affixed to the top half of the engine room door.
In exceptional cases, they may be located at the same height and within an area extending 80 cm from the
opening side of the engine room door.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Dokumentation Release date: 26/05/2010
Index: 1 Page No.: 1/2
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0330
Signs on the engine room door

80 cm

Signed area
SprungMarke!!!28134923

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Dokumentation Release date: 26/05/2010
Index: 1 Page No.: 2 / 2
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0505
EMC suited execution of cabling and ground connection to/and motor
aggregates and control cabinet

1 Importance of measures for ensuring Electromagnetic Compatibility (EMC) ............................... 1

2 Anti-interference measures.................................................................................................................... 1
3 Earthing/shielding treatment on the shielding guide........................................................................ 6

1 Importance of measures for ensuring Electromagnetic Compatibility (EMC)

Importance of measures for ensuring Electromagnetic Compatibility (EMC)

The cabling and the earthing principles are the elements of a system that are mainly responsible for decoupling
sufficiently the existing interference sources from potentially susceptible devices.

For this reason, any measures taken to eliminate interference must principally involve the cabling and the
earthing principles.

2 Anti-interference measures

Earthing of inactive metal parts

Proper earthing is a major factor in ensuring interference-free assembly.
"Earthing" means the conductive connection of all inactive metal parts (VDE 0160).
The principle of surface earthing must be generally applied.
All conductive inactive metal parts must be earthed!

The following must be observed when earthing:

All earth connections must be low-impedance.

Large surface areas of all metal parts must be connected.

Always use especially wide earthing strips to make the connection. It is not only the cross-section of earth
connections that is of key importance but also their surface.
(As a rule, do not use aluminium as there is a danger of oxidation!)

Screwed connections must always be made with split washers or serrated lock washers.

Shielding of equipment
Cabinets and housings are included in order to shield the control system. Please read the following tips.

Overlapping cabinet covers, including side sections, rear walls, roof and ground sheets must be earthed at
regular intervals.

Doors must additionally be connected to the cabinet earth by way of earthing measures. Use several earthing
strips for this.

Lines exiting from the shielding housing must be shielded or led through a filter.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Elektrokonstruktion Responsible: TCG/Thaler Release date: 11/08/2010
Index: 2 Page No.: 1/9
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0505
EMC suited execution of cabling and ground connection to/and motor
aggregates and control cabinet

If there are sources of strong interference in the cabinet, they must be isolated from sensitive electronic parts
with sheets. These sheets must be screwed to the cabinet earth in several places to produce a low-impedance.

The interference voltages which are coupled into the automation device via signal and supply lines are
deflected to the central earthing point (standard mounting rail).

The central earthing point must be connected to the PE bus (earthing bar) with low-resistance and with as
short a Cu-conductor as possible (≥ 10 mm²).

Shielding of lines
Cables with braided shields must be used!
As a rule, shielded lines must always be connected to both sides of the cabinet potential to ensure good
conductivity. Proper interference suppression of all coupled frequencies can only be achieved with shielding on
both sides. Place the shielding over a large area on the shielding guide and then lead it to the modules.

The interference currents on cable shielding will be deflected to earth at PLCs via the shielding guide and then
via the equipotential bonding conductors. To make sure that these deflected currents do not become sources
of interference themselves, the interference currents must be earthed via a low-resistance and low-impedance
path, as follows:

Tighten the mounting bolts of cable connectors, modules and equipotential bonding conductors.

Protect contact surfaces of equipotential bonding conductors from corrosion.

Lay equipotential bonding conductors over as short a distance as possible and following a direct route.

Cableways
Wiring arrangement inside cabinets
When cabling a cabinet, the arrangement of the lines is very important to ensure the interference immunity
(electromagnetic compatibility) of the system
The lines are divided into three wiring groups:

Wiring Groups
Wiring group 1:
▪ shielded data lines (data bus cables, etc.)
▪ shielded analogue lines
▪ unshielded lines for DC and AC ≤ 60 V
▪ unshielded lines for DC and AC ≤ 230 V

Wiring group 2:
▪ unshielded lines for DC and AC > 60 V and ≤ 230 kV

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Elektrokonstruktion Responsible: TCG/Thaler Release date: 11/08/2010
Index: 2 Page No.: 2 / 9
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0505
EMC suited execution of cabling and ground connection to/and motor
aggregates and control cabinet

Wiring group 3:
▪ unshielded lines for DC and AC > 230 V and ≤ 1 kV
▪ (generator power cable, lines for three-phase current controls, etc.)

Cableways
All wiring groups must be laid separately in the cabinet. The wiring arrangement means laying wires in
separate cable ducts
separate cable bundles.

Information
Maintain a minimum distance of 10 cm between signal lines and power cables with ≥ 115/230 VAC.
When laying shielded lines, place the shield at the cabinet entrance on the shield reception bus.

Wiring arrangement outside cabinets

Outside cabinets (but inside buildings) lay the lines on metal cable trays. The joints of the cable trays should be
galvanically connected to each other and must be locally earthed every 20 to 30 m.

As a rule, shielded cables must be used for analogue signal lines!

Wiring Groups
Wiring group 1 (LG1):
▪ shielded analogue lines
▪ unshielded lines for DC and AC ≤ 60 V
▪ unshielded lines for DC and AC ≤ 230 V
Wiring group 2 (LG2):
▪ unshielded lines for DC and AC > 60 V and ≤ 230 V
Wiring group 3 (LG3):
▪ unshielded lines for DC and AC > 230 V and ≤ 1 kV.
(generator power cable, lines for three-phase current controls, etc.)

Cableways
Each cable group should be laid in separate cable trays (cable runs, cableways, cable ducts, underground cable
conduits).

Cables of different wiring groups must be laid at least 10 cm apart (when placing AEG-MODICON PLCs the WG1
cable must be laid at least 50 cm from the WG3 cables), except if they are laid in separate conduits or ducts or
separated from each other by special rigid sleeves.
Minimum distances must also be observed at crossovers and points of proximity.

Cables sensitive to electromagnetic interference must be installed at least one metre from possible sources of
interference (contactors, transformers, motors, electric welders, electric starters, etc.).

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Elektrokonstruktion Responsible: TCG/Thaler Release date: 11/08/2010
Index: 2 Page No.: 3/9
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0505
EMC suited execution of cabling and ground connection to/and motor
aggregates and control cabinet

Cables sensitive to interference are:

▪ data bus cables
▪ video cables
▪ keyboard cables
▪ printer cables
▪ analogue signal cables

Where two control components are connected by more than one signal cable, ensure that the distance
between the cables is as short as possible.

Lay the signal cable and relevant equipotential bonding conductor as close together as possible. Lay the signal
cable and equipotential bonding conductor via the shortest possible cabling route.

Lay individual cables with similar signals (supply and return lines, power supply cables) as close together as
possible, if necessary twisting them together.

Lay all cables close to earth connections.

Avoid extending cables via terminals or similar devices.

Additional instructions for laying data transfer cables. (The cables below are always supplied and
connected by GE Jenbacher):

ET100 – data bus cable

a) Lay separately from all other cables.
b) Minimum distance from LG3 cables ≥ 10 cm.
c) Earth as close as possible to the cabinet entrance (earth clip). Continue the shielding as far as the interface
connector without earthing again. (c) will be carried out by GE Jenbacher!)

SINEC data bus cable:

a) Lay separately from all other cables.
b) Minimum distance from LG3 cables ≥ 10 cm.

REMOTE I/O cable for dia.ne:

a) Lay separately from all other cables.
b) Minimum distance from LG2 and LG3 cables ≥ 10 cm.
c) Earth as close as possible to the cabinet entrance (earth clip). Continue the shielding as far as the interface
connector without earthing again. (c) will be carried out by GE Jenbacher!)

Video, keyboard and printer cables:

a) Lay separately from all other cables.
b) Minimum distance from LG3 cables ≥ 10 cm (> 50 cm for AEG MODICON PLCs).

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Elektrokonstruktion Responsible: TCG/Thaler Release date: 11/08/2010
Index: 2 Page No.: 4 / 9
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0505
EMC suited execution of cabling and ground connection to/and motor
aggregates and control cabinet

c) Strain relief in the control cabinet with the aid of the earth clips provided. (c) will be carried out by GE
Jenbacher).

General shielded lines:

a) Minimum distance from LG3 cables ≥ 10 cm (> 50 cm for AEG MODICON PLCs).
b) Strain relief in the control cabinet in the sections provided.
c) Shielding to be earthed as close as possible to the cabinet entrance (shielding guide) with the aid of the earth
clips provided. (b) and c) will be carried out by GE Jenbacher!)

General wiring guidelines:

Generator power cable:
The diameter of the power cables must be determined or checked in accordance with VDE 298, Parts 1-4
(cabling method, bundled cables, etc.) or ÖVE L-20 or IEC 364-5-523 by the company carrying out the work.
Rated generator current: IN = ..... A, where cos phi = 0.8.

Only flexible cables are permitted.

The cables used must conform to current harmonised and national standards. The cables to be laid must be
suitable for their intended purpose and the laying method used; they must be capable of withstanding specific
local conditions.

Use only metal cable trays (also in existing concrete cable channels ). All the assembly materials (including
screws) must be properly protected against corrosion.

The cables must be numbered in accordance with the cable list.

Pay attention to the curving radius of the cables.

Cable entries must counter tensile forces. Where twisted nipples are used, additional strain relief should be
provided. Use only one cable per screw fixing.
The protection class of each device to be connected must be complied with.
All screw connections on the generator must be suitable for the power cable used.

Where cables are to be laid on a cable tray or cableway, they must be adjusted, secured, relieved of stress and
if necessary covered by a protective plate. Once laid, single-wire high-voltage cables (NYY-E YY) must be
secured so as to withstand short-circuits.

Third party cabling requirements for GE Jenbacher electrical distribution systems

Generator power cable:

The diameter of the power cables must be determined or checked in accordance with VDE 298, Parts 1-4
(cabling method, bundled cables, etc.) or ÖVE L-20 or IEC 364-5-523 by the company carrying out the work.
Rated generator current: IN = ..... A, where cos phi = 0.8.
(Recommended cable for medium-voltage generators: SIEMENS PROTOLON, type: NTMCGCWÖU).

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Elektrokonstruktion Responsible: TCG/Thaler Release date: 11/08/2010
Index: 2 Page No.: 5/9
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0505
EMC suited execution of cabling and ground connection to/and motor
aggregates and control cabinet

L1 L3 L2 PEN

L3 L2 L2 L1 L1 L3 PEN PEN

2 cm 2D 2D 2D 2D 2D 2D 2D 2 cm

L1 L2 L3 L2 L3 L1 L3 L1 L2 PEN PEN PEN

2 cm 3D 2D 3D 2D 3D 2D 3D 2 cm
D = Diameter of cable

The risk of fire inside cable ducts and, in the case of bundled cables, inside buildings will be reduced by
choosing a suitable cabling method and by taking preventive measures to minimise the spread and
consequences of fire.

An insulation test must be carried out on completion of the work.

Insulation resistance tests in accordance with EN / IEC 60204-1 (Section 18.3) and HD 60364-6 / IEC 60364-6
and local regulations.
A report must be drawn up on the tests carried out, containing the required test results including information
on the measuring instruments used.
This test port must be handed over to the customer.
Generator cables must be disconnected from the generator before their insulation resistance is tested.
The same applies to frequency converters.

The work must be carried out strictly in accordance with the relevant regulations and standards.

The company carrying out the work must be present during the testing and commissioning of the plant so that
any problems arising can be rectified immediately.

The company is liable for the satisfactory completion of its work, i.e. it undertakes to rectify any defects free of
charge.

All components of the electrical system supplied by GE Jenbacher must be installed and secured in a suitable
manner according to the plant layout plan, i.e. the control cabinets must be positioned and screwed together
and the batteries and chargers must be installed.

3 Earthing/shielding treatment on the shielding guide

Earthing/shielding treatment on the shielding guide:
Earthing
Ensure that the earth connection is electrically sound with a split washer or serrated lock washer (anti-
corrosion treatment) ①.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Elektrokonstruktion Responsible: TCG/Thaler Release date: 11/08/2010
Index: 2 Page No.: 6 / 9
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0505
EMC suited execution of cabling and ground connection to/and motor
aggregates and control cabinet

Lay earthing lines by the shortest route.

Partitioning with separating plates is necessary for the part of the cabinet in which the inductors (especially
transformers, valves and connectors) have been fitted.

Partition plates must be connected to the cabinet (earth) and electrically sound.

If powerful interference sources (EMC) have been installed in the cabinet (e. g. frequency converter, etc.), their
shielding housings must be connected separately to the central earthing point (> = 10 mm2).

Shielding treatment on the shielding guide

Lay shields so that they are spread out as far as possible and use suitable shield clamps.
Connect shielding guide to assembly plate or cabinet housing so that it is properly conductive.
Pull the braiding back over the cable insulation ②.
Twist relevant signal feed and return lines ③.
Keep the shield connection as short as possible ④.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Elektrokonstruktion Responsible: TCG/Thaler Release date: 11/08/2010
Index: 2 Page No.: 7/9
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0505
EMC suited execution of cabling and ground connection to/and motor
aggregates and control cabinet

3 4

1
E 5

6
<5cm
3

2 2 7

⑤ terminal strip ⑨ Cable ties - strain relief

⑥ to PLC BG ⑩ Cable with braiding
⑦ Earth clip ⑪ Cable duct
⑧ Shielding guide

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Elektrokonstruktion Responsible: TCG/Thaler Release date: 11/08/2010
Index: 2 Page No.: 8 / 9
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0505
EMC suited execution of cabling and ground connection to/and motor
aggregates and control cabinet

7 2

<5cm 3

1
E 5

6
<5cm 3

2 2
7

④ Cable duct ⑧ Shielding guide

⑤ terminal strip ⑨ Cable ties - strain relief
⑥ to PLC BG ⑩ Cable with braiding
SprungMarke!!!9007199282725899
⑦ Earth clip

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Elektrokonstruktion Responsible: TCG/Thaler Release date: 11/08/2010
Index: 2 Page No.: 9/9
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0510
Handling of electronic components/modules

1 General
Very low-powered electronic components are particularly susceptible to external influences, e.g. electrostatic
charges, magnetic fields, mechanical stresses, etc.

2 Replacement of modules
Modules must never be connected or disconnected when they are live, i.e. modules may only be installed or
removed when the supply voltage for the central unit and the signal transmitters has been switched off.
When replacing modules or using them for the first time, always check the following:
▪ that it is the correct module type (stock number/supply voltage)
▪ that it is in the correct slot (documentation)
▪ that it has been assembled correctly (e.g. EPROMs)
▪ that bridges and coding circuits have been correctly adjusted (documentation)
▪ that the version of software is appropriate and up-to-date

3 Commissioning
If you bring an electronic module into the service room from a cooler environment, you will have to wait,
depending on the difference in temperature, until any condensation has dried up before commissioning it.

4 Handling of electrostatic sensitive devices (ESD)

4.1 Definition of terms

Electrostatic sensitive devices (ESD) are all electronic semiconductors and devices and modules consisting of
semiconductors which are not protected against electrostatic charges by suitable housings.

4.2 Basic rules for protecting against electrostatics

a) All electrostatic sensitive devices must only be handled in a workplace which is protected against
electrostatics!
b) They must only be stored and transported in protected packing and transportation materials!
c) Suppliers must also observe these rules, i.e. ESDs received from suppliers in packing units inadequately
protected against electrostatic charging must be returned to the supplier immediately.

4.3 Labelling
ESDs can be packed for transport in electrostatically conductive protective packs and identified as ESDs by
means of clearly visible stickers e.g.
Caution: Electrostatic sensitive devices (ESD)
Parts packed and marked in this way must only be opened and handled by suitably trained personnel in
a workplace protected against electrostatics.

4.4 Measures to protect against electrostatic charging

In order to protect a workplace against electrostatics, you must prevent electrostatic charging occurring and
dissipate existing charges quickly and safely.
This is achieved by special conductive protection mats (connected to earth) on the work surface (panel/base of
switchgear cabinet) and by wrist bands worn by staff (1 MOhm-safety resistance connected to earth).
SprungMarke!!!28259339

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Elektrokonstruktion Release date: 26/05/2010
Index: 1 Page No.: 1/1
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0515
Protective arrangements for setting up electrical installations

1 Purpose
To test the protection against shock currents (protective arrangements) when installing electrical equipment
with nominal voltages of up to ~ 1000 V.

2 General
Each plant must be inspected and tested during and/or on completion of installation before it is commissioned
by the user and measurements must be carried out.
The protective arrangements must be checked before the plant is first commissioned (original inspection) and
before re-commissioning.
It is stressed that all regulations governing the protective arrangements (hitherto specific to each country) must
be adhered to.
All those companies or operatives engaged in the setting up or installation of the above systems, who are
subject to legislation other than that of Austria, must of course act strictly in accordance with the regulations
by which they are bound.
Furthermore, it is emphasised that the first electrical commissioning, especially the protective arrangements
check, may only be carried out by specialist staff who have received appropriate training.

3 Protective arrangements - classification and use

The protective arrangements are classified as those which offer protection against direct contact (basic
protection) and those which offer protection against indirect contact (fault protection) and additional
protection.

3.1 Protection against direct contact

In the case of normal electrical equipment, protection against live parts is achieved by combining protection by
insulation and protection by covering. It must only be possible to open or remove covers using a tool or key,
unless either the equipment is shut down before the covers are opened or removed, or there are additional
suitable barriers inside.

3.2 Protection in the case of indirect contact

This form of protection, which is intended to prevent dangerous voltages from coming into contact with parts
which should not normally carry operational voltages but which have been made live through damage to the
basic insulation, may be classified as follows:

Protective arrangements without earth-protection conductor:

▪ Protective insulation
▪ Protective low voltage (Functional low voltage)
▪ Protective isolation of one or more pieces of equipment using equipotential bonding conductors

Protective arrangements with earth-protection conductor:

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Endprüfung Release date: 26/05/2010
Index: 1 Page No.: 1/2
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-0515
Protective arrangements for setting up electrical installations

▪ Protective earth
▪ Protective multiple earthing, neutralisation
▪ Current-operated earth-leakage circuit-breaker system
▪ Protective conductor system

Systems supplied by GE Jenbacher are always provided with protective arrangements in the form of protective
conductors. The choice of fault protection is determined by the local conditions. The on-site power supply in
particular is a deciding factor in the choice of protective arrangements which may be used in the case of
indirect contact. In relation to neutralisation, this situation must be emphasised, especially, because the
neutralisation conditions in the distribution network and the consumer unit also have to conform to the
regulations. Only the local electricity supply company can decide whether this is the case in the distribution
network and neutralisation may be used.
If specific types of electrical equipment or electrical operating areas are subject to additional or more stringent
rules or exceptions under the applicable regulations, they will take precedence over the general regulations in
this regard.

4 Reference sources
▪ ÖVE-EN 1 Part 1/1989, Part 1a/1992, Part 1b/10.95
▪ VDE 0100 Part 410/01.97
▪ VDE 0100 Part 610/04.94
▪ EN 60 439 Part 1
▪ Reference book: "Schutz gegen gefährliche Körperströme und gegen Überspannungen" [Protection against
SprungMarke!!!28428683
shock currents and overvoltages] - Bieglmeier/Mörx - seventh edition

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Endprüfung Release date: 26/05/2010
Index: 1 Page No.: 2 / 2
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-1109
Lubricating oil for type 2, 3, 4 and 6 GE Jenbacher engines

1 Scope
This Technical Instruction applies to all Type 2, 3, 4 and 6 GE Jenbacher gas engines.

2 General
When selecting a lubricating oil suitable for use in GE Jenbacher gas engines, account must be taken of the
engine’s requirements and the requirements related to the fuel gas and - possibly - the exhaust gas treatment
unit.

3 Effects on the lubricating oil and the oil service life

Fuel gases contain trace and accompanying elements which can cause deposits in the combustion chamber,
acid attack of components and wear.

Experience shows that the following harmful substances have the greatest effects on the lubricating oil and the
oil service life:

Chlorine, fluoride and sulphur cause the lubricating oil to acidify.

Organic silicon compounds cause wear.

Accordingly, fuel gases can be divided in the following classes:

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bilek F. Responsible: Nota F. Release date: 27/05/2015
Index: 14 Page No.: 1/9
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-1109
Lubricating oil for type 2, 3, 4 and 6 GE Jenbacher engines

▪ Class A: natural gas and gases that permanently comply with the restrictions regarding trace and
accompanying elements in acc. with TI 1000-0300, TI 1000-0301 and TI 1000-0302
Natural gas, associated petroleum gas, mine gas, biogas (sulphur < 200 mg/10 kWh), special gases
(thermoselect and steel plant gases).
▪ Class B: gases containing acid-forming trace elements or trace elements that primarily affect the oil
condition
Biogas, sludge gas, wood gas and/or pyrolysis gases.
▪ Class C: Gases containing acid-forming trace elements and additional trace elements causing wear
Landfill gas
Lubricating oil can lose its corrosion protection characteristics due to impurities in the fuel gas. The results of
regular lubricating oil analyses are indicative of fuel gas impurities. In this respect, see also the following
Technical Instructions:
TI 1000-0112
TI 1000-0099 A, B, C, D.

4 Lubricating oil requirements for GE Jenbacher engines

SAE 40
Additives suitable for four-stroke spark-ignition gas operation.
Release procedure successfully completed in acc. with TI 1000-0099A.

5 Lubricating oil tables – selection overview:

5.1 Note
▪ Product names (in boldface)* are suitable for prolonged oil change intervals in GE Jenbacher gas engines
using class A fuel.
▪ Mobil Pegasus 1005** can be assessed using increased oil limit values (see TI 1000-0099B).
▪ A, B, C: fuel gas classes
▪ CAT: if an oxidation catalytic converter is included in the GE Jenbacher scope of supply

5.2 Lubricating oil table for Type 2 and 3 GE Jenbacher engines

Firma Produktname A B C CAT

Mobil Pegasus 705 X X
Pegasus 805 X
Pegasus 610 X
Pegasus 710 X
Pegasus 1005** X
Castrol Duratec L X X X
Duratec MX X X

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bilek F. Responsible: Nota F. Release date: 27/05/2015
Index: 14 Page No.: 2 / 9
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-1109
Lubricating oil for type 2, 3, 4 and 6 GE Jenbacher engines

Firma Produktname A B C CAT

Shell Mysella S3N X X
Mysella S3S X X
Mysella S5S X X
Mysella S5N X X
Petro Canada Sentron LD 5000* X X
Sentron LD 8000* X
Sentron CG 40 Plus X X
Sentron CG 40 X X
Texaco Chevron Caltex Geotex LA 40 X
Geotex LF 40 X
HDAX 5500 LFG Gas Engine Oil 40 X X
HDAX 5200 Low Ash Gas Engine Oil 40 X X
HDAX 6500 LFG Gas Engine Oil 40 X X
HDAX 7200 Low Ash Gas Engine Oil 40 X
Total Nateria MH 40 X X
Nateria ML 406 X
Nateria MJ 40 X
Nateria MP 40 X
Fuchs Titan Ganymet LA X X
Titan Ganymet X
Titan Ganymet Plus X
Titan Ganymet Ultra* X X X
Cepsa Troncoil Gas 40 X
Troncoil Gas LD 40 X
Troncoil Gas JGC 40 X X
OMV Gas LEG 40 X
Gas XDI 40 X
Gas HD 40 X X
LUKOIL Efforse 4004 X
Efforse XDI 4004 X
Efforse HD 4009 X X
Q8 Mahler G4 X X
Mahler G5 X X X X
Mahler G8 X X
Mahler HA X X
Roloil Mogas G4 X X
Mogas G5 X X X X
Mogas G8 X X
Mogas AC-40 X X

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bilek F. Responsible: Nota F. Release date: 27/05/2015
Index: 14 Page No.: 3/9
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-1109
Lubricating oil for type 2, 3, 4 and 6 GE Jenbacher engines

Firma Produktname A B C CAT

PEAK Navitus G4 X X
Navitus G5 X X X X
Navitus G8 X X
Navitus HA 40 X X
Addinol MG Extra LA X X
MG Extra Synth* X X
MG Extra Plus X X
Gas Engine Oil LG 40 X X
Gas Engine Oil NG 401 X X
Repsol Long Life Gas 4005* X
Long Life Biogas 4005 X X
Super Motor Gas 4005 X
Valvoline GEO Plus LA Engine Oil SAE 40 X X
Mol GMO MA X
Eneos NOC 440 (M) X
SRS Mihagrun LAX 40 X X
Mihagrun X 40 X X
Cenex NGEO 2500 MA X

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bilek F. Responsible: Nota F. Release date: 27/05/2015
Index: 14 Page No.: 4 / 9
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-1109
Lubricating oil for type 2, 3, 4 and 6 GE Jenbacher engines

5.3 Lubricating oil table for Type 4 GE Jenbacher engines (versions A and B)
Firma Produktname A B C CAT
Mobil Pegasus 705 X X X
Pegasus 805 X
Pegasus 1005** X
Pegasus SR X
Castrol Duratec L X X X X
Shell Mysella S3N X X X X
Mysella S5N* X X
Mysella S5S X X
Petro Canada Sentron LD 5000* X X
Sentron LD 8000* X
Sentron CG 40 Plus X X
Texaco Chevron HDAX 5200 Low Ash Gas Engine Oil 40 X X
Caltex HDAX 6500 LFG Gas Engine Oil 40 X X
HDAX 7200 Low Ash Gas Engine Oil 40 X
Total Nateria MH 40 X X X X
Nateria MP 40 X
Fuchs Titan Ganymet LA X X
Titan Ganymet Ultra* X X
Cepsa Troncoil Gas LD 40 X
Troncoil Gas JGC 40 X X X X
OMV Gas LEG SAE 40 X
Gas XDI SAE 40 X
LUKOIL Efforse 4004 X
Efforse XDI 4004 X
Q8 Mahler G4 X X X
Mahler G5 X X X X
Roloil Mogas G4 X X
Mogas G5 X X X X
PEAK Navitus G4 X X
Navitus G5 X X X X
Addinol MG Extra LA X X
MG 40 Extra Synth* X X
Gas Engine Oil LG 40 X X
Gas Engine Oil NG 40 X X
Repsol Long Life Gas 4005* X
Long Life Biogas 4005 X X
Super Motor Gas 4005 X
Valvoline GEO Plus LA Engine Oil SAE 40 X X
Eneos NOC 440 (M) X
SRS Mihagrun LAX 40 X X
Mihagrun X 40 X X

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bilek F. Responsible: Nota F. Release date: 27/05/2015
Index: 14 Page No.: 5/9
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-1109
Lubricating oil for type 2, 3, 4 and 6 GE Jenbacher engines

Firma Produktname A B C CAT

MOL GMO Long Life X X

5.4 Lubricating oil table for Type 4 GE Jenbacher engines (as from version C)

Firma Produktname A B C CAT

Mobil Pegasus 705 X X X X
Pegasus 805 X X X
Shell Mysella S5N* X X X X

Petro Canada Sentron LD 5000* X X X X

Sentron LD 8000* X
Texaco HDAX 5200 Low Ash Gas Engine Oil X X X X
Chevron
Caltex
Repsol Long Life Gas 4005* X X X
Galp GN LX4005 X X X X

5.5 Lubricating oil table for Type 6 GE Jenbacher engines (versions C and E)
Firma Produktname A B C CAT
Mobil Pegasus SR X
Pegasus 605 X
Pegasus 705 X X X
Pegasus 805 X X
Pegasus 1005* X
Castrol Duratec L X X X X
Shell Mysella S3N X X X X
Mysella S5N* X X
Mysella S5S X X
Petro Canada Sentron LD 5000* X X
Sentron LD 8000 X
Sentron CG 40 Plus X X
Texaco Chevron HDAX 5200 Low Ash Gas Engine Oil 40 X X
Caltex HDAX 6500 LFG Gas Engine Oil 40 X X
HDAX 7200 Low Ash Gas Engine Oil 40 X
Total Nateria MH 40 X X X X
Nateria MP 40 X
Fuchs Titan Ganymet LA X X
Titan Ganymet Ultra* X X
Cepsa Troncoil Gas LD 40 X
Troncoil Gas JGC 40 X X X X

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bilek F. Responsible: Nota F. Release date: 27/05/2015
Index: 14 Page No.: 6 / 9
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-1109
Lubricating oil for type 2, 3, 4 and 6 GE Jenbacher engines

Firma Produktname A B C CAT

OMV Gas LEG 40 X
Gas XDI 40 X
LUKOIL Efforse 4004 X
Efforse XDI 4004 X
Q8 Mahler G4 X X
Mahler G5 X X X X
Roloil Mogas G4 X X
Mogas G5 X X X X
PEAK Navitus G4 X X
Navitus G5 X X X X
Addinol MG Extra Synth* X X
Gas Engine Oil LG 40 X X
Gas Engine Oil NG 40 X X
Repsol Long Life Gas 4005* X
Long Life Biogas Gas 4005 X X
Super Motor Gas 4005 X
Valvoline GEO Plus LA Engine Oil 40 X X
Eneos NOC 440 (M) X
SRS Mihagrun LAX 40 X X
Mihagrun X 40 X X
MOL GMO Long Life X X

5.6 Lubricating oil table for Type 6 GE Jenbacher engines (as from version F)

Firma Produktname A B C CAT

Mobil Pegasus 705 X X X X
Pegasus 805 X X X
Shell Mysella S5N* X X X X
Petro Canada Sentron LD 5000* X X X X
Texaco Chevron HDAX 5200 Low Ash Gas Engine Oil 40 X X X X
Caltex
Repsol Long Life Gas 4005* X X X
Galp GN LX 4005 X X X X
Q8 Oils Mahler G5 X X
Roloil Mogas G5 X X
PEAK Navitus G5 X X

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bilek F. Responsible: Nota F. Release date: 27/05/2015
Index: 14 Page No.: 7/9
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-1109
Lubricating oil for type 2, 3, 4 and 6 GE Jenbacher engines

5.7 Other products can be used for Type 2 and 3 engines, Type 4 engines (versions A and B) and Type 6
engines (versions C and E)
Firma Produktname A B C CAT
Aral Degasol NGL X X X
Avia Gasmotorenöl LA SAE 40 X X
Bellini S.p.A THG OILEXTRA SAE 40 X X
Brad Penn Lubricants Supreme DDO Low Ash Stat. GEO 40 X
CITGO Pacemaker LFG LA Gas Engine Oil X X
Compagnia Italiana Vanguard Astra JM 40 X X
Lubrificanti
D.A Lubricant Company Blue Flame J 40 X X
De Oliebron Tor GEO BG/LF 40 X X
Engen GEO LL 40 X
GEO N X X
GEO BL - 40 X X
Exol Taurus GEO G240 X X
Galp GNLX 4005 X X
Gazpromneft G-Profi PSN 40 X X
Gulf Oil Gulfco LFG 40 X X
Lotos Ibis NGO Super LA SAE 40 X X
Matrix GE LA Oil X X
Morris Lubricant GEO Ultra 40 X X
GEO Ultra G-LF 40 X X
Nils Burian Light SAE 40 X X
Burian Plus SAE 40 X X
North Sea Lubricants Tidal Power LA 40 X X
Ori-Tecoil Gas Engine Oil 40 C X X
Orlen Delgas L 40 X X
Delgas Premium L 40 X X
Pakelo Geoterm LA EVO SAE 40 X X
Paramo Mogulgas B X X
PAZ Lubricants Biogas 40 X X
Petromin Petrogas Plus 40 X X
Rymco Frya Gas LA Plus X X
Sasol Gas Engine Oil LA X X
Tectrol Methaflexx NG X X
Methaflexx HC Premium* X X X
TNB Gas Engine Oil LA X X
Wameco S.R.L. NGE OILEXTRA SAE 40 X X
77 Lubricants Gas Engine Oil LA 40 X X
Nachstehende Produkte sind nur für Baureihe 2 und 3 Motoren anwendbar
Agip AUTOL BGJ 40 X
Aral Degasol LFM X X

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bilek F. Responsible: Nota F. Release date: 27/05/2015
Index: 14 Page No.: 8 / 9
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1000-1109
Lubricating oil for type 2, 3, 4 and 6 GE Jenbacher engines

Firma Produktname A B C CAT

Avia Gasmotorenöl HA SAE 40 X X
Gasmotorenöl S40 SAE 40 X X
Eurolube Gasmotorenöl HGM Plus X X
Nils Burian SAE 40 X
Oilfino Famagas HA 40 X
Pakelo Geoterm MA SAE 40 X
Phi Oil Gas Engine Oil MA 40 X
Tectrol Methaflexx HC Plus X
Methaflexx GE-M X X
Zeller+Gmelin Divinol Spezial Typ 4 SAE 40 X
Divinol SpezialHA SAE 40 X X
SprungMarke!!!117093590401419787

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Bilek F. Responsible: Nota F. Release date: 27/05/2015
Index: 14 Page No.: 9/9
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0105
Engine shut down

Other applicable Technical Instructions

▪ TI 2300-0001 Employee protection
▪ TI 2300-0005 Safety Instructions
▪ TI 2300-0010 Lockout / Tagout (LOTO)
▪ TI 2108-0027 (J208 with SAM)
▪ TI 2108-0028 (J212 with SAM)

WARNING
When an engine is shut down for service and maintenance work, the central lines
(compressed air starter, gas valves, diesel fuel valves, starter motor battery) must
be secured using Lockout/Tagout (LOTO) in accordance with TI 2300-0010.
Consequences

1 Scope
This Technical Instruction applies to all GE Distributed Power modules with Type 2, 3, 4, 6 and 9 engines, unless
a modified version of this document is provided.

2 Purpose
This Technical Instruction describes how to shut down the engine correctly.

3 Type 2, 3, 4 and 6 engines up to DIA.NE XT V3.x

3.1 Mode of operation - MANUAL

for a normal engine shutdown up to step 8, for an engine shutdown for service/maintenance up to step 13
1. Turn the operation mode selector switch to the position MANUAL
2. Reduce the power output to approx. 10 %
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Boxleitner Responsible: Dokumentation Release date: 24/11/2014
Index: 4 Page No.: 1/7
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0105
Engine shut down

3. Turn the generator switch to the position OFF

4. Turn the synchronisation selector switch to the position "Zero" and lock it
5. Engine after-cooling: Let the engine cool down in idling operation for a minute
6. Press the Stop button after the after-cooling phase is completed
7. After-running of auxiliaries: up to 40 min
8. Turn the mode selector switch to the STOP position, shut the engine down and take out the key
Normal engine shutdown now completed!
9. Close the gas valve at the gas train inlet
10. Attach a warning sign to the switch cabinet to prevent unauthorised restarting!
11. Once all the auxiliaries have been automatically switched off, remove the negative battery terminal from
the module frame, place the detached terminal cable on the ground and secure it against inadvertent
reconnection.
12. Isolate the main circuit for the auxiliaries, lock it in accordance with TI 2300-0010 (LOTO) and check that it
is dead!
13. Check to ensure that all components are dead and sufficiently cooled off. Attention: Overpressure!

3.2 AUTOMATC operating mode

for a normal engine shutdown up to step 4, for an engine shutdown for service/maintenance up to step 9
1. Turn the activation mode selector to the position OFF
2. The engine will automatically shed its load and shut down.
3. After-running of auxiliaries: up to 40 min
4. Turn the mode selector switch to the STOP position, shut the engine down and take out the key
Normal engine shutdown now completed!
5. Close the gas valve at the gas train inlet
6. Attach a warning sign to the switch cabinet to prevent unauthorised restarting!
7. Once all the auxiliaries have been automatically switched off, remove the negative battery terminal from
the module frame, place the detached terminal cable on the ground and secure it against inadvertent
reconnection.
8. Isolate the main circuit for the auxiliaries, lock it in accordance with TI 2300-0010 (LOTO) and check that it
is dead!
9. Check to ensure that all components are dead and sufficiently cooled off. Attention: Overpressure!

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Boxleitner Responsible: Dokumentation Release date: 24/11/2014
Index: 4 Page No.: 2 / 7
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0105
Engine shut down

4 Type 2, 3, 4 and 6 engines as from to DIA.NE XT4 V4.x

4.1 MANUAL operating mode

for a normal engine shutdown up to step 8, for an engine shutdown for service/maintenance up to step 13
As from DIA.NE XT4, the operating mode, operation of the generator switch, synchronisation and activation are
selected on the touch display at the panel, and prior logging on to DIA.NE XT4 is necessary

1. Select MANUAL mode

2. Reduce the power output to approx. 10 %
3. Set the synchronization selector switch to the position OFF
4. Set the generator switch to the position OFF
5. Engine after-cooling: Let the engine cool down in idling operation for a minute
6. Press the Stop button after the after-cooling phase is completed
7. After-running of auxiliaries: up to 40 min
8. Set the operating mode to the OFF position, lock it with a password and make a note of the password
Normal engine shutdown now completed!
9. Close the gas valve at the gas train inlet (on gas engines)
10. Attach a warning sign to the switch cabinet to prevent unauthorised restarting!
11. Once all the auxiliaries have been automatically switched off, remove the negative battery terminal from
the module frame, place the detached terminal cable on the ground and secure it against inadvertent
reconnection.
12. Isolate the main circuit for the auxiliaries, lock it in accordance with TI 2300-0010 (LOTO) and check that it
is dead!
13. Check to ensure that all components are dead and sufficiently cooled off. Attention: Overpressure!

4.2 AUTOMATIC operating mode

for a normal engine shutdown up to step 4, for an engine shutdown for service/maintenance up to step 9
1. Set the activation selector switch to the position OFF
2. The engine will automatically shed its load and shut down.
3. After-running of auxiliaries: up to 40 min
4. Set the operating mode to the OFF position, lock it with a password and make a note of the password
Normal engine shutdown now completed!
5. Close the gas valve at the gas train inlet (on gas engines)
6. Attach a warning sign to the switch cabinet to prevent unauthorised restarting!
7. Once all the auxiliaries have been automatically switched off, remove the negative battery terminal from
the module frame, place the detached terminal cable on the ground and secure it against inadvertent
reconnection.
8. Isolate the main circuit for the auxiliaries, lock it in accordance with TI 2300-0010 (LOTO) and check that it
is dead!
9. Check to ensure that all components are dead and sufficiently cooled off. Attention: Overpressure!

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Boxleitner Responsible: Dokumentation Release date: 24/11/2014
Index: 4 Page No.: 3/7
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0105
Engine shut down

5 Engines with prelubrication:

5.1 Mode of operation - MANUAL

for a normal engine shutdown up to step 7, for an engine shutdown for service/maintenance up to step 13
1. Select MANUAL operating mode
2. Reduce the power output to approx. 10 %
3. Turn off the generator switch (OFF position)
4. Engine after-cooling: Let the engine cool down in idling operation for a minute
5. Press the Stop button after the after-cooling phase is completed
6. After-running of auxiliaries: up to 40 min
7. Select STOP operating mode
Normal engine shutdown now completed!
8. Close the gas valve at the gas train inlet
9. Attach a warning sign to the switch cabinet to prevent unauthorised restarting!
10. Once all the auxiliaries have been automatically switched off, remove the negative battery terminal from
the module frame, place the detached terminal cable on the ground and secure it against inadvertent
reconnection.
11. Press the Emergency Stop button and remove the key
12. Isolate the main circuit for the auxiliaries, lock it in accordance with TI 2300-0010 (LOTO) and check that it
is dead!
13. Check to ensure that all components are dead and sufficiently cooled off. Attention: Overpressure!

5.2 AUTOMATC operating mode

for a normal engine shutdown up to step 4, for an engine shutdown for service/maintenance up to step 10
1. Turn the activation mode selector to the position OFF
2. The engine will automatically shed its load and shut down.
3. After-running of auxiliaries: up to 40 min
4. Select STOP operating mode
Normal engine shutdown now completed!
5. Close the gas valve at the gas train inlet
6. Attach a warning sign to the switch cabinet to prevent unauthorised restarting!
7. Once all the auxiliaries have been automatically switched off, remove the negative battery terminal from
the module frame, place the detached terminal cable on the ground and secure it against inadvertent
reconnection.
8. Press the Emergency Stop button and remove the key
9. Isolate the main circuit for the auxiliaries, lock it in accordance with TI 2300-0010 (LOTO) and check that it
is dead!
10. Check to ensure that all components are dead and sufficiently cooled off. Attention: Overpressure!

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Boxleitner Responsible: Dokumentation Release date: 24/11/2014
Index: 4 Page No.: 4 / 7
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0105
Engine shut down

6 Type 9 engines up to DIA.NE XT V3.x

6.1 Mode of operation - MANUAL

for a normal engine shutdown up to step 8, for an engine shutdown for service/maintenance up to step 13

1. Turn the operation mode selector switch to the position MANUAL

2. Reduce the power output to approx. 10 %
3. Turn the generator switch to the "OFF" position
4. Turn the synchronisation selector switch to the position "Zero" and lock it
5. Engine after-cooling: Let the engine cool down in idling operation for a minute
6. Press the Stop button after the after-cooling phase is completed
7. After-running of auxiliaries: up to 40 min
8. Turn the mode selector switch to the STOP position, shut the engine down and take out the key
Normal engine shutdown now completed!
9. Close the gas valve at the gas train inlet
10. Attach a warning sign to the switch cabinet to prevent unauthorised restarting!
11. Close the compressed air supply valve to the starter motor and secure it against inadvertent opening in
accordance with TI 2300-0010 (LOTO)!
12. Isolate the main circuit for the auxiliaries, lock it in accordance with TI 2300-0010 (LOTO) and check that it
is dead!
13. Check to ensure that all components are dead and sufficiently cooled off. Attention: Overpressure!

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Boxleitner Responsible: Dokumentation Release date: 24/11/2014
Index: 4 Page No.: 5/7
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0105
Engine shut down

6.2 AUTOMATC operating mode

for a normal engine shutdown up to step 4, for an engine shutdown for service/maintenance up to step 9

1. Turn the activation mode selector to the position OFF

2. The engine will automatically shed its load and shut down.
3. After-running of auxiliaries: up to 40 min
4. Turn the mode selector switch to the STOP position, shut the engine down and take out the key
Normal engine shutdown now completed!
5. Close the gas valve at the gas train inlet
6. Attach a warning sign to the switch cabinet to prevent unauthorised restarting!
7. Close the compressed air supply valve to the starter motor and secure it against inadvertent opening in
accordance with TI 2300-0010 (LOTO)!
8. Isolate the main circuit for the auxiliaries, lock it in accordance with TI 2300-0010 (LOTO) and check that it
is dead!
9. Check to ensure that all components are dead and sufficiently cooled off. Attention: Overpressure!

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Boxleitner Responsible: Dokumentation Release date: 24/11/2014
Index: 4 Page No.: 6 / 7
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0105
Engine shut down

SprungMarke!!!27021597792886923

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Boxleitner Responsible: Dokumentation Release date: 24/11/2014
Index: 4 Page No.: 7/7
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0112
Installation of GE Jenbacher Units

1 Area of application ................................................................................................................................... 1

2 Purpose ....................................................................................................................................................... 1
3 General conditions ................................................................................................................................... 1
4 Planning...................................................................................................................................................... 1
4.1 Safety and employee protection........................................................................................................................ 2
4.2 Transport and installation ..................................................................................................................................... 2
4.3 Fuel gas.......................................................................................................................................................................... 2
4.4 Lubricating oil.............................................................................................................................................................. 2
4.5 Exhaust gas.................................................................................................................................................................. 3
4.6 Engine-cooling, warm and hot water .............................................................................................................. 3
4.7 Ventilation..................................................................................................................................................................... 3
4.8 Electrics .......................................................................................................................................................................... 3
4.9 Installation documentation .................................................................................................................................. 3

1 Area of application
This Technical Instruction applies to all GE Jenbacher generator sets and special products, unless a modified
version of this document is provided.

2 Purpose
This TECHNICAL INSTRUCTION (TI) describes the requirements to be taken into account when installing GE
Jenbacher generator sets, and refers to other TIs that contain detailed information on each requirement. This
document therefore represents an entry point for persons entrusted with the planning of a plant.

3 General conditions
The boundary conditions for GE Jenbacher gas engines as specified in TI 1100-0110 must be observed.
The general conditions for operation and maintenance in accordance with TI 1100-0111 also apply to the
installation of GE Jenbacher generator sets.

4 Planning
The following list contains systems and activities which must normally be taken into account when installing GE
Jenbacher generator sets. The TIs and drawings listed must be observed when designing and planning these
generator sets.
Additional standards and local technical and statutory rules and regulations must be assessed and observed
by the CUSTOMER.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku / Boxleitner Responsible: Mayer Markus Release date: 29/05/2015
Index: 12 Page No.: 1/4
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0112
Installation of GE Jenbacher Units

4.1 Safety and employee protection

Activities on GE Jenbacher plants may entail hazards for persons and machinery. Reference is made at the
appropriate location (as part of the activity description) to all foreseeable unavoidable hazards that occur in the
course of activities demanded by GE Jenbacher.
When selecting the maintenance staff, it must therefore be ensured that only specialist personnel with the
appropriate training are engaged, and that the applicable safety regulations for the work being carried out are
observed.
Protective regulations by GE Jenbacher that must be observed generally can be found in:
▪ TA 2300-0001: Employee protection [⇨ TA 2300-0001, Page 1]
▪ TA 2300-0005: Safety regulations [⇨ TA 2300-0005, Page 1]

4.2 Transport and installation

Due to the nature of GE Jenbacher generator sets, great care must be exercised when transporting them. The
CUSTOMER is responsible for checking in advance whether transport and installation are feasible.
The following TIs must always be observed in this respect:
▪ TA 1000-0041: Requirements on the installation surface for GE Jenbacher plant [⇨ TA 1000-0041, Page 1]
▪ TA 1000-0042: Lifting and transporting GE Jenbacher modules and positioning them in engine rooms
▪ TA 1000-0043: Transporting and setting up GE Jenbacher control cabinets [⇨ TA 1000-0043, Page 1]
▪ TA 1000-0044: Transport protection [⇨ TA 1000-0044, Page 1]

4.3 Fuel gas

Special mechanical, design and chemical properties are to be taken into account for fuel gas and for
components that carry fuel gas.
In mechanical terms, take care to ensure that the interface between generating set (gas entry at engine) and
gas line (gas train) is installed as a flexible connection.
The following design considerations apply:
▪ The gas piping must be dimensioned in such a way that the requisite gas prepressure is reached (at the
inlet to the gas train),
▪ the zero pressure controller and the TecJet must be positioned for technical control reasons with the
flexible connection upstream of the engine gas intake on the gas mixer and
▪ the clearance between the controller and the engine connection must not exceed a particular length:
Zero pressure 2m max. (including hose)
controller
TecJet: 1.3m max. (including hose)

In chemical terms, the pipework must be resistant to the gas components.

Additional important information from GE Jenbacher can be found in the following TIs and elsewhere;
▪ TA 1000-0300: Fuel gas requirements [⇨ TA 1000-0300, Page 1]
▪ TA 1100-0110: Boundary conditions for GE Jenbacher gas engines
▪ TA 1510-0064: Gas Quantity Controller TecJet 110 and 50 Plus

4.4 Lubricating oil

The following TIs contain information on handling lubricating oil and on the design and construction of the
lubricating oil system:

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku / Boxleitner Responsible: Mayer Markus Release date: 29/05/2015
Index: 12 Page No.: 2 / 4
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0112
Installation of GE Jenbacher Units

▪ TA 1000-0099A: Approval procedure for various engine oils [⇨ TA 1000-0099A, Page 1]

▪ TA 1000-0099B: Limit values for used oil on GE Jenbacher gas engines [⇨ TA 1000-0099B, Page 1]
▪ TA 1000-0099C: Procedure for testing the oil service life specific to the plant [⇨ TA 1000-0099C, Page 1]
▪ TA 1000-0099D: Determining the initial pH value (ipH) for used lube oil as defined in TA 1000-0099B [⇨ TA
1000-0099D, Page 1]
▪ TA 1000-0099K: Aid to interpreting used oil analyses of engine lubricants [⇨ TA 1000-0099K, Page 1]
▪ TI 1000-0099L: Storage and handling of fresh oil for GEJ gas engines [⇨ TA 1000-0099L, Page 1]
▪ TA 1400-0131: Pipelines [⇨ TA 1400-0131, Page 1]

4.5 Exhaust gas

Important information on the dimensioning and design and construction of the exhaust gas system can be
found in:
▪ TA 1100-0110: Boundary conditions for GE Jenbacher gas engines

4.6 Engine-cooling, warm and hot water

The following TIs contain information on handling engine cooling water, hot water and heating water, and on
the design and construction of the water circuits:
▪ TA 1000-0200: Quality of cooling water in closed circuits [⇨ TA 1000-0200, Page 1]
▪ TA 1000-0201: Antifreeze additive [⇨ TA 1000-0201, Page 1]
▪ TA 1000-0204: Cooling water anti-corrosion additive [⇨ TA 1000-0204, Page 1]
▪ TA 1000-0206: Quality of circuit water in hot water and warm water heating systems [⇨ TA 1000-0206,
Page 1]
▪ TA 1000-0208: Quality of cooling water in open cooling circuits
▪ TA 1400-0131: Pipelines [⇨ TA 1400-0131, Page 1]

4.7 Ventilation
Important information on the technical equipment for ventilating the engine room, generator and engine can
be found in:
▪ TA 1100-0110: Boundary conditions for GE Jenbacher gas engines

4.8 Electrics
Information on general protective measures when constructing electrical high-voltage plants, requirements for
the customer's control power supply, cabling, cable dimensioning, routing, and handling of electronic
components can be found in:
▪ TA 1100-0110: Boundary conditions for GE Jenbacher gas engines
▪ TA 1100-0114: Installation of electrical fixtures for GE Jenbacher generating sets [⇨ TA 1100-0114, Page 1]

4.9 Installation documentation

Other technical documents are drawn up on a plant-specific basis and only become available in the course of
project implementation. These include:
▪ Technical Diagram
▪ Arrangement plan / terminal diagram
▪ View of generator set
▪ Circuit diagram
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku / Boxleitner Responsible: Mayer Markus Release date: 29/05/2015
Index: 12 Page No.: 3/4
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1100-0112
Installation of GE Jenbacher Units

▪ Cable list
▪ Interface list
▪ Technical specification of the control system
▪ Description - Operation
▪ Maintenance
▪ Spare parts catalogue
These technical documents are always binding! GE Jenbacher or GE Jenbacher partners can be contacted for
information needed before completion of any relevant document.
SprungMarke!!!99079191862043915

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku / Boxleitner Responsible: Mayer Markus Release date: 29/05/2015
Index: 12 Page No.: 4 / 4
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1400-0100
Regulations for running in GE generating set engines

1 Tips
This Technical Instruction describes the running-in procedure for Type 2, 3, 4, 6 and 9 gas engines with a
generator coupled (also applies to 60 Hz rated frequency).
The running-in procedure must be carried out at the appropriate rated engine speed (apart from Type 9
engines).
The purpose of carrying out the running-in procedure according to the instructions is:
▪ to be able to observe the engine’s operating behaviour closely after repair or maintenance to ensure that
the work has been carried out correctly, and to minimise any risk to subsequent normal operation;
▪ to achieve the required running-in wear of new engine components (cylinder linings, pistons, piston rings,
plain bearings etc.).
▪ All new modules leaving the GE Jenbacher production plant are subjected to a mandatory running-in
procedure on the factory test stand and a functional test.
▪ All repaired modules leaving the production plant are subjected to a mandatory running-in procedure on
the factory test stand and a functional test.
▪ New engines which are coupled to the module at the installation site must be run in and tested on site.
▪ Modules which are repaired on site must be run in and tested on site.

2 Procedure
Before carrying out the engine running-in programme, follow the Inspection work - Daily inspection
procedure.
Initial commissioning of new engines
Having finished the engine running-in programme according to procedure (as described in section 3), carry out
Maintenance following initial commissioning.

3 Engine running-in programme

Make sure that, if required, engine operation can be stopped immediately by pressing the EMERGENCY
STOP button!
You must therefore ensure that the EMERGENCY STOP button is freely accessible at all times!
Look out for any unusual sounds, vibrations and temperature phenomena during the running-in
procedure.

Type 2,3,4 and 6 engines:

The purpose of the running-in stages (5 minutes each) is to check the mixture setting using the exhaust gas
emission measurement. NOx emissions must not exceed 1,000 mg NOx/m3N (or 5% O2 in the exhaust gas).

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin, Daniel Responsible: Anderson, Barry Release date: 17/07/2013
Index: 6 Page No.: 1/4
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1400-0100
Regulations for running in GE generating set engines

Type 9 engine:
The first running-in stage, with the engine delivering power, is to check the mixture setting using the exhaust
gas emission measurement. NOx emissions must not exceed 1,000 mg NOx/m3N (or 5% O2 in the exhaust gas).

3.1 Running-in programme for type 2, 3 and 4 gas engines:

Carry out the running-in stages subsequently. When reaching rated load, this load setting should be
maintained for 30 minutes after which the running-in procedure can be ended.
be continued for 30 minutes' running, at the end of which running-in is finished. Do not overload!

Type J 424 engine:

Prior to starting the engine the following steps must be adhered:
1. The pre-lubrication pump shall be operated for 5-10 minutes to flush engine oil galleries and bearings.
2. During the flushing period with the pre-lube pump still operating, the crankshaft shall complete a minimum
of 2 revolutions using manual method.
ELECTRICALPOWER
Running-in Stage running J 208 J 212 J 216/ J 316/ J 320/ J 420 J 424
stage time J 312 J 412 J 416
Min. kW kW kW kW kW kW kW
1 10 0 0 0 0 0 0 0
2 5 35 50 65 90 120 150 180
3 5 85 130 160 220 290 360 430
4 10 130 205 250 350 470 580 700
5 10 200 305 380 520 700 870 1050
6 10 265 410 510 700 930 1160 1400
7 30 Rated Rated Rated Rated Rated Rated Rated
power power power power power power power

3.2 Running-in programme for type 6 gas engines:

Complete the running-in stages in sequence until rated power is reached. Then run the engine for 30 minutes
at rated power and finish the running-in procedure. Do not overload!
ELECTRICALPOWER
Running-in Stage running J 612 J 616 J 620 J 624
stage time
Min. kW kW kW kW
1 10 0 0 0 0
2 5 200 240 300 400
3 10 500 400 760 1000
4 10 750 900 1140 1500
5 10 1000 1200 1520 2000
6 10 1250 1520 1900 2500
7 10 1500 1800 2400 2900
8 10 1750 2100 2900 3500
9 30 Rated Rated Rated Rated
power power power power

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin, Daniel Responsible: Anderson, Barry Release date: 17/07/2013
Index: 6 Page No.: 2 / 4
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1400-0100
Regulations for running in GE generating set engines

3.3 Running-in programme for type J424 & J624 gas engines with Miba 69 lead free bearings installed
Miba 69 Syntec + Sputter berings are characterised by the dark grey apprearance of syntec overlay and
indentified as Miba 69 by the part marking on side wall.
Prior to starting the engine the following steps must be adhered:
1. The pre-lubrication pump shall be operated for 5-10 minutes to flush engine oil galleries and bearings.
2. During the flushing period with the pre-lube pump still operating, the crankshaft shall complete a minimum
of 2 revolutions using manual method.
3. Complete the running-in stages in sequence until rated power is reached. Then run the engine for 60
minutes at rated power and finish the running-in procedure.
Do not overload!

NOTICE
Island operation
For engines operating in Island mode, load control is not always possible and as such step 3
cannot be completed.
Step 1 and 2 are still mandatory and shall be completed prior to engine start.

ELECTRICALPOWER
Running-in Stage running J 424 J 624
stage time
Min. kW kW
1 5 0 0
2 10 180 400
3 20 430 1000
4 20 700 1500
5 20 1050 2000
6 20 1400 2500
7 20 - 2900
8 20 - 3500
9 60 Rated power Rated power

3.4 Running-in programme for type 9 gas engines:

Complete the running-in stages in sequence until rated power is reached. Then run the engine for 30 minutes
at rated power and finish the running-in procedure. Do not overload!

Running-in programme for new engines, or after replacing the main or conrod bearings
Running-in Stage running Electrical Speed
stage time power
Min kW rpm
1 10 0 500
2 10 0 800
3 5 0 1000
4 10 1200 1000
5 15 2100 1000

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin, Daniel Responsible: Anderson, Barry Release date: 17/07/2013
Index: 6 Page No.: 3/4
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1400-0100
Regulations for running in GE generating set engines

6 15 2900 1000
7 15 3800 1000
8 60 4800 1000
9 60 5700 1000
10 30 6700 1000
11 30 7600 1000
12 30 8600 1000
13 60 Rated power 1000

Running-in programme after repairs or maintenance (apart from replacing the main or conrod bearings)
Running-in Stage running Electrical Speed
stage time power
Min. kW rpm
1 5 0 500
2 5 0 1000
3 10 2000 1000
4 10 3000 1000
5 10 4000 1000
6 10 5000 1000
7 10 6000 1000
8 15 7000 1000
9 15 8000 1000
10 30 9000 1000
11 30 9500 1000

4 Additional guidance for first start-up

Any kind of work on an engine or generator could potentially result in risk. Except to conduct absolutely
necessary work, nobody shall be in the engine room when the engine is started for the FIRST time after
performing relevant service jobs until full load has been reached and stabilized for 15 minutes. After this period
of time the engine room can be entered again. The affected service jobs could involve either the commissioning
of new and overhauled units or the repair/replacement of rotating/oscillating parts.
SprungMarke!!!45035996303076235

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin, Daniel Responsible: Anderson, Barry Release date: 17/07/2013
Index: 6 Page No.: 4 / 4
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1400-0131
Pipings

1 Purpose
This Technical Instruction describes the pickling and preservation of steel pipes.

2 General
Pipes on which welding operations are carried out or which are subject to scaling due to other effects of heat
must be cleaned by pickling.
Secure all piping against vibration. Pipes must be connected to the engine using flexible connecting pieces.
A test certificate as specified in DIN 8560, Test Group RII, is required before welding work can be carried out on
gas pipes.
Pressure and impermeability checks must be carried out in accordance with specific national or local
regulations.
Seal gas-carrying threaded pipe connections with DIN-DVGW registered screw thread sealing tape or DIN-
DVGW registered "Wevoplast F" (DIN-DVGW Reg. No. 74.01 e 130) together with hemp (flax).

3 Pickling pipes
Use a mixture of sodium bisulphate and water or hydrochloric acid and water as the pickling agent.

Mixing ratio of water to acid:

Hydrochloric acid 1:1
Sodium bisulphate 1:20 Use the mixing ratios specified by the manufacturer of the
pickling agent!

Close the pipe at one end and fill with pickling agent or, if possible, lay it in a pickling bath.
Follow the manufacturer's instructions with regard to temperature!

Pickling agent exposure time:

Hydrochloric acid/water approx. 1 hour
Sodium bisulphate/water approx. 10 hours

At the end of the exposure time, empty the pipe or remove it from the pickling bath and rinse thoroughly with a
cold cleansing agent.
Ensure that the pipe is has been properly cleaned.

Dispose of pickling agent correctly!

4 Preservation of pickled pipes

Preserve pipes with a suitable agent after pickling.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Dokumentation Release date: 26/05/2010
Index: 1 Page No.: 1/2
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1400-0131
Pipings

e.g. oil line - engine oil, cooling water lines - coolant.

SprungMarke!!!30083467

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Dokumentation Release date: 26/05/2010
Index: 1 Page No.: 2 / 2
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1400-0162
Spark plug adjustment tool for plugs with hook electrodes

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Bilek Responsible: TET/Kraus Markus Release date: 22/01/2015
Index: 3 Page No.: 1/6
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1400-0162
Spark plug adjustment tool for plugs with hook electrodes

1 Scope
This Technical Instruction applies to all spark plugs with hook electrodes used in GE Jenbacher Type 6 and 9
engines (e.g. P603 or Denso 518).

Ⓐ P603 spark plug Ⓑ 518 spark plug

2 Purpose
This Technical Instruction describes how to correctly adjust spark plugs with hook electrodes.

3 Personal protective equipment

Wear your personal protective equipment when adjusting spark plugs. This includes:
▪ safety glasses
▪ safety shoes
▪ gloves

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Bilek Responsible: TET/Kraus Markus Release date: 22/01/2015
Index: 3 Page No.: 2 / 6
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1400-0162
Spark plug adjustment tool for plugs with hook electrodes

4 Tool design

Spark plug adjustment tool part no. 9011882

① Hand wheel for securing the tool ④ Hand wheel for adjusting the electrode gap
② Clamp for the tool base ⑤ Adjustment pin
③ Tool base ⑥ Recess for spark plug hexagon

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Bilek Responsible: TET/Kraus Markus Release date: 22/01/2015
Index: 3 Page No.: 3/6
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1400-0162
Spark plug adjustment tool for plugs with hook electrodes

5 Operation

5.1 Preparing the tool

The tool must be securely mounted on a bench or other stable work surface before being used to adjust spark
plugs. If the spark plug has to be adjusted in situ on the engine, the Type 6 is fitted with a upper step plate near
the cylinder heads.
To secure the tool to a stable work surface, first undo the clamp ② with the hand wheel ① until the clamp can
fit over the work surface. As soon as the tool base ③ is seated and stable on the work surface, secure the tool
with the hand wheel ①.

5.2 Adjusting the electrode gap

5.2.1 Preparing the spark plug

Before placing the spark plug in the tool, remove the joint ring on the plug.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Bilek Responsible: TET/Kraus Markus Release date: 22/01/2015
Index: 3 Page No.: 4 / 6
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1400-0162
Spark plug adjustment tool for plugs with hook electrodes

5.2.2 Placing the spark plug in the tool

Before the spark plug is placed in the tool, check whether it is damaged in any way and whether enough
precious metal remains to allow continued use. If there is any damage or insufficient electrode material,
dispose of the spark plug.
To place the spark plug in the tool, first retract the adjustment pin ⑤ by turning the hand wheel ④
anticlockwise until the spark plug can be carefully placed in the recess for the hexagon ⑥. Do not damage the
ceramic body of the spark plug. The electrodes of the spark plug will be pointing towards the adjustment pin
and the electrode gap must remain easily accessible. Hold the spark plug with a magnet from underneath to
prevent it tilting.

5.2.3 Adjusting the electrode gap

Slide a feeler gauge with a 0.28 mm gap between the electrode and turn the hand wheel ④ clockwise until the
feeler gauge jams. The important point here is to hold the feeler gauge so that this pressure on it can be felt,
which is best done by moving the feeler gauge slightly. Then turn the hand wheel back slightly to relieve the
load on the electrode carrier and check the adjusted electrode gap. This should be between 0.28 mm and 0.32
mm.
If the electrode gap is still incorrectly set, repeat the adjustment process.
Never exert any uncontrolled pressure on the centre electrode, as excessive force will damage the spark
plug.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Bilek Responsible: TET/Kraus Markus Release date: 22/01/2015
Index: 3 Page No.: 5/6
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1400-0162
Spark plug adjustment tool for plugs with hook electrodes

5.2.4 Removing the spark plug from the tool

To remove the spark plug retract the adjustment pin ⑤ by turning the hand wheel anticlockwise until the plug
can be removed from the tool. Take care to ensure that the ceramic body of the spark plug is not damaged.

5.2.5 Fitting a new joint ring

Fit a new joint ring to the spark plug immediately after setting the electrode gap. Do not forget this under any
circumstances.
SprungMarke!!!18014400901078027

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Bilek Responsible: TET/Kraus Markus Release date: 22/01/2015
Index: 3 Page No.: 6 / 6
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0068
MORIS ignition

1 Safety information.................................................................................................................................... 2
1.1 General ........................................................................................................................................................................... 2
1.2 Ignition module........................................................................................................................................................... 3
2 Description................................................................................................................................................. 4
2.1 General description of MORIS.............................................................................................................................. 4
2.2 General description of MORIS2 ........................................................................................................................... 4
2.3 Construction of MORIS ........................................................................................................................................... 5
2.4 Construction of MORIS2 ......................................................................................................................................... 7
3 Technical data ........................................................................................................................................... 8
3.1 Protection class .......................................................................................................................................................... 8
3.2 Ambient conditions................................................................................................................................................... 8
3.3 Chemical resistance................................................................................................................................................. 8
3.4 Mechanical data ........................................................................................................................................................ 8
3.4.1 Vibration resistance 8
3.4.2 Rail dimensions 9
3.4.3 Tightening torques 9
3.5 Electrical data ............................................................................................................................................................. 9
3.5.1 24 V power supply 9
3.5.2 185 V power supply 10
3.5.3 Pickup signal amplifier SPA24 10
3.5.4 SAFI 10
4 Installation ............................................................................................................................................... 11
4.1 Mounting the ignition system on the engine.............................................................................................. 11
4.2 Earthing the ignition system .............................................................................................................................. 11
4.3 Mounting and adjusting the pickups on the engine ............................................................................... 11
4.4 Replacing components......................................................................................................................................... 12
4.4.1 spark plug connector 12
4.4.2 Thermocouple 12
4.4.3 M coil 12
4.4.4 SAFI 13
4.4.5 Ignition modules 14
4.4.6 Connection and end modules 15
4.4.7 Link modules 16
4.4.8 Setting the cylinder coding 17
5 Operation ................................................................................................................................................. 17
5.1 Ignition control system ......................................................................................................................................... 18
5.1.1 Phase 1 – Producing the ignition spark 19
5.1.2 Phase 2 – Regulating the current in the ignition spark 19
5.1.3 Phase 3 – De-energising and synchronising for possible re-ignition after spark interruption
21
5.1.4 Pickup signals 21
5.1.5 Visual displays on the SAFI 21
5.1.6 Identifying the cylinder arrangement in the engine 21
5.1.7 Adjusting the reset position 22
5.1.8 High-voltage measurement 22
5.1.9 Port Injection 22
5.2 Control and visualisation ..................................................................................................................................... 22
5.2.1 Parameter setting 22
5.2.2 Displays 23
5.2.3 Monitoring functions 24
5.2.4 Possibility of diagnosis by self-test 25
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus/Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 2 Page No.: 1/36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0068
MORIS ignition

5.2.5 Safety plan 26

6 Diagnosis and troubleshooting............................................................................................................ 28
6.1 ignition.......................................................................................................................................................................... 28
6.1.1 Operating notification (Bxxxx) 28
6.1.2 Warnings (Wxxxx) 28
6.1.3 Error messages (Axxxx) 29
6.2 High-voltage measurement ............................................................................................................................... 30
6.2.1 Operating notification (Bxxxx) 30
6.2.2 Warnings (Wxxxx) 31
6.3 Port Injection.............................................................................................................................................................. 32
6.3.1 Operational message (Bxxxx) 32
6.3.2 Warnings (Wxxxx) 32
6.3.3 Error messages (Axxxx) 33
7 Cylinder coding........................................................................................................................................ 33
8 Terminal designation ............................................................................................................................. 35
8.1 Ignition module......................................................................................................................................................... 35
8.2 Connection module ................................................................................................................................................ 36
8.3 End module ................................................................................................................................................................ 36

1 Safety information

1.1 General

NOTICE
All work on the engine is governed in all respects by the guidelines in Technical Instruction "TI
2300-0005 Safety instructions" and in particular the guidelines for ignition systems.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus/Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 2 Page No.: 2 / 36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0068
MORIS ignition

ATTENTION
Before starting the ignition system, make sure that all parts of the ignition unit have been
installed and connected in accordance with the instructions.

WARNING
Magnetic fields
People wearing a pacemaker are not permitted to enter the engine room and carry out work on
the ignition system.

DANGER
Danger to life from high voltages
Extremely dangerous voltages can be produced during the self-test and engine operation
(primary power supply of 185 V to the ignition coil and high voltage in excess of 40 kV on the
secondary side). Currents of up to 100 A occur during operation. Improper use may result in a risk
of injury or death due to electric shock!
a) Before assembly or repair work on the ignition system, the engine must be shut down and
secured to prevent unauthorised starting and the self-test disabled.
b) Before working on the ignition system, you must disconnect the power supply to MORIS and
check to ensure that the system is dead.

1.2 Ignition module

WARNING
High voltage
Touching the M-coil connection sockets or replacing the ignition module while the 185 V power
supply is live, as indicated by the red LEDs, is prohibited.

When working on the ignition rail system, read the instructions displayed there.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus/Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 2 Page No.: 3/36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0068
MORIS ignition

① red LED
Before replacing MORIS components, disconnect the 24 V und 185 V power supplies to the rail and check to
ensure that the system is dead. To do so, remove both connector plugs from the connection module for the
power supply to the MORIS rail and check the LED located underneath an M coil to ensure that the 185 V
voltage is dead.
The ignition modules are identical apart from the expansion of the port injection actuation.

2 Description

2.1 General description of MORIS

The name MORIS is derived from the term "Modular Rail Ignition System" and describes the design
configuration of the ignition system. With this modular concept, every cylinder or engine configuration can be
put together using individual modules. The output stage of the ignition system, the ignition module, has been
integrated in the cabling rail. One ignition module contains the power electronics for two cylinders.
The SAFI (Sensor Actor Functional Interface ) is a further development of the KLS98 (knock sensor system). The
SAFI is a DSP-based device into which the ignition control and monitoring system have been integrated as well
as comprehensive monitoring functions (knocking, exhaust-gas temperatures, etc.). The SAFI calculates the
speed and crankshaft angle position for the ignition pulses from pick-up signals from the camshaft and the
crankshaft which are processed by the SPA 24 (SAFI Pick-up Amplifier). The SAFI and the engine controller
communicate via the CAN bus.
Power is supplied to the MORIS by the 24 V grid and the MPM (MORIS Power Module).

2.2 General description of MORIS2

The MORIS2 was developed for Type 9 engines and is a development of the original MORIS. The only addition is
the power electronics for actuating the main chamber gas valve PI (port injection) and the prechamber gas
valve PCI/PCS (Pre-Chamber Injection). This modular concept also means that any desired cylinder or engine
configuration can be assembled from individual modules.
The SAFI2 (Sensor Actuator Functional Interface 2) is a further development of the SAFI by the addition of the PI
and PCI/PCS actuation. SAFI(1) and MORIS2 consequently cannot be combined, as the SAFI(1) does not support
actuation of the gas valves.
Another new development for the Type 9 is the PBC (pressure-based engine control). This function is necessary
for the control concept of the Type 9 and for a some special gas applications of the Type 6.
The SAFI2 calculates the speed and crankshaft angle position for the pressure data detection and ignition
pulses from pick-up signals from the camshaft and the crankshaft which are processed by the SPA 24 (SAFI
Pick-up Amplifier). The SAFI2 and the engine controller communicate via the CAN bus.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus/Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 2 Page No.: 4 / 36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0068
MORIS ignition

Power is also supplied to the MORIS by the 24 V grid and the MPM (MORIS Power Module). The increased power
output from the additional actuation of the gas valves means that four MPMs are needed for one J920, one to
supply each closed MORIS rail.
The following Technical Instructions are referred to in this document:
▪ TI 1502-0069 - MPM (MORIS Power Module)
▪ TI 1502-0071 - SAFI (Sensor Actor Functional Interface)
▪ TI 1502-0072 - SPA24 (SAFI Pick-up Amplifier)
You will need these Technical Instructions to obtain a complete understanding of the MORIS functions.

2.3 Construction of MORIS

An aluminium rail is used for each row of cylinders. The rail connected to cylinder 1 is designated as Bank A and
the rail for the second row of cylinders as Bank B.

MORIS with holder, M coils and SAFI for J612 engine

① Aluminium rails Part nos. 487209 to 487211

Part nos. 487804 to 487805
② Connection module for power supplies, signal and Bank A: Part no. 487195
CAN bus connections Bank B: Part no. 487346
③ Ignition module Part no. 487207
④ End module Bank A: Part no. 487198
Bank B: Part no. 487347
⑤ Gasket between the individual modules Part no. 487213
⑥ M coil Part no. 487181
Part No. 487883 (CSA version)
⑦ SAFI Part nos. 411880, 433525, 435624

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus/Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 2 Page No.: 5/36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0068
MORIS ignition

⑧ Link module Type 4 engines: Part no. 487208

Type 6 engines: Part no. 487803

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus/Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 2 Page No.: 6 / 36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0068
MORIS ignition

2.4 Construction of MORIS2

One aluminium rail is used for each row of cylinders. The rail connected to cylinder 1 is designated as Bank A
and the rail for the second row of cylinders as Bank B.
1 Aluminium rails Part no. 649570 (MORIS2 basic rail
for 20-cylinder J920 - Part 1)
Part no. 649571 (MORIS2 expanded
rail for 20-cylinder J920 - Part 2)
2 Connection module for power Bank A: Part. no. 649 485
supplies, signal and CAN bus Bank B: Part no. 649486
connections
3 Ignition and gas control module Part no. 649472 (PI/PCS)
Part no. 675091 (PI/PCS)
4 End module Bank A: Part no. 649474
Bank B: Part no. 649476
5 Gasket between the individual Part no. 487213
modules
6 M coil Part no. 487181
Part No. 487883 (CSA version)

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus/Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 2 Page No.: 7/36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0068
MORIS ignition

7 SAFI 2 KLS: Part no. 652092

Type 9 engine PBC: Part no. 652438
Type 6 engine PBC: Part no. 652439
8 MORIS J920 link module Part no. 649489

The three-pole plug connectors for the active prechamber gas valves must be provided with orifices, as the
series configuration allows for passive prechamber gas valves.

3 Technical data

3.1 Protection class

When assembled, the MORIS ignition system with all components mounted on it complies with Protection Class
IP54.

3.2 Ambient conditions

Temperature limits Storage -25 ... + 70 ℃
In operation -25 ... + 85 °C

Relative humidity Storage 90 %, no dew

In operation 85 %, no dew

Air pressure up to 2,000 m above sea

level

3.3 Chemical resistance

MORIS has been developed to meet GE Jenbacher's specific requirements for chemical resistance to the
antifreeze (glycol) in the engine cooling water, sulphurous acid, engine oil and UV radiation.

In general, the following limit levels for atmospheric pollution apply:

Sulphur dioxide (SO2) 0.030 ppm
Hydrogen sulphide (H2S) 0.010 ppm
Nitrous oxide gases (NOx) 0.030 ppm
Chlorine (C12) 0.010 ppm
Hydrogen fluoride (HF) 0.010 ppm
Ammonia (NH2) 0.500 ppm
Ozone (O3) 0.005 ppm

3.4 Mechanical data

3.4.1 Vibration resistance

MORIS is designed for vibration loads to an effective value of max. 20 mm/s at 10 - 300 Hz.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus/Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 2 Page No.: 8 / 36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0068
MORIS ignition

3.4.2 Rail dimensions

The length of the rail depends on the engine type in use. Two J612 rails per cylinder row are used for the J624.
part number Engine type Length
487 209 Rail J412 1,557 mm
487 210 Rail J416 2,017 mm
487 211 Rail J420 2,477 mm
487 804 Rail J612 1,933 mm
487 805 Rail J616 2,581 mm
487 806 Rail J620 3,229 mm

3.4.3 Tightening torques

Bolt type Dimension Position Tightening torque
Hexagonal socket bolt M6 x 35 mm SAFI top left 3.4 Nm | 30 lb in
Hexagonal socket bolt M6 x 30 mm SAFI bottom right 3.4 Nm | 30 lb in
Special hexagonal socket bolt M6 x 40 mm M coil 3.4 Nm | 30 lb in
Countersunk bolt M5 x 12 mm Ignition module 2.3 Nm | 20 lb in
Countersunk bolt M4 x 9 mm with Connecting module, type 6 engine 1.7 Nm | 15 lb in
8-32 X 3/8 SEAL FT coupling and end modules
HD joint ring
Hexagonal head bolt M6 x 12 mm Earthing bolt on connection and 3.4 Nm | 30 lb in
end modules
Hexagonal head bolt M5 x 12 mm Mounting 2.3 Nm | 20 lb in
Special hexagonal head bolt M10 x 15 mm Thermocouple 15 Nm | 133 lb in
Hexagonal head bolt M8 x 25 mm Knock sensor 20 Nm | 177 lb in

3.5 Electrical data

The terminal designations of all MORIS components are listed in Section Terminal designation [⇨ Page 35].

See also
• Terminal designation [⇨ Page 35]

3.5.1 24 V power supply

MORIS is powered by a battery with a nominal voltage of 24 V DC. The battery voltage may fluctuate within a
range from 18 V to 32 V.
The battery voltage must not fall below 15 V during the start-up process, otherwise the SAFI and the MPM may
fail.
The 24 V power supply for MORIS is protected by a 16.5 x 11 x 3.8 mm violet-coloured 3 A MINI automotive fuse
in the connection module. Replacement of the fuse is described in Connection and end modules [⇨ Page 15].

See also
• Connection and end modules [⇨ Page 15]

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus/Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 2 Page No.: 9/36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0068
MORIS ignition

3.5.2 185 V power supply

MPM (MORIS Power Module) is a DC-DC converter and supplies the MORIS with a DC current at 185 V from the
24 V grid. The voltage output is activated via a digital input A safety contact reports the output of the MORIS
power supply to the control system.
The MPM supplies 2.5 A rms at a nominal input voltage of 24 V with an 80% efficiency.
Nominal input voltage 24 V DC
Maximum power consumption at rated voltage 24.1 A
Nominal output voltage 185 V DC
Maximum output current 2.5 A rms
Operating temperature range -20°C to + 75°C

Number of MPMs:
Due to the power output of 462 W per MPM, it is necessary to fit more MPMs on some engine configurations in
order have the required power available. On Type 4 and 6 engines with more than 20 cylinders, a second MPM
must be fitted. Because the port Injection valves on the Type 9 are actuated from the 185 V circuit, the
additional power required for all port injection applications must be ensured by means of the number of MPMs.
Further information on the MPM can be found in the relevant Technical Instruction TI 1502-0069.

3.5.3 Pickup signal amplifier SPA24

SPA24 (SAFI Pick-up Amplifier 24V), is a pick-up amplifier which processes the camshaft, reset and ring gear
signals into the form required for the SAFI.
A voltage of at least 3 V is required to identify passive pick-up signals.
Rated power consumption 170 mA
Nominal input voltage DC 24 V
Operating temperature range 0°C to + 70°C
Max. power per output 100 mA
Further information on the SPA24 can be found in the relevant Technical Instruction, TI 1502-0072.

3.5.4 SAFI
The SAFI power supply may fluctuate within a range from 18 V to 32 V ±10% residual ripple.
Rated power consumption 175 mA
Nominal input voltage DC 24 V
Operating temperature range -25°C to 85°C
Input voltage range for signals 15 – 32 V DC
Further information on the SAFI can be found in the relevant Technical Instruction, TI 1502-0071.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus/Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 2 Page No.: 10 / 36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0068
MORIS ignition

4 Installation

4.1 Mounting the ignition system on the engine

Example of a mounting on the Type 4 engine

① M5 x 20 bolt ③ T-groove slide nut
② Washer ④ Metal cushion-type damper

Metal cushion-type dampers are used to protect the structure of the MORIS rails from vibration.
The rails are secured to the mounting on the engine by means of M5 x 20 mm T-groove slide nuts, M5 x 12 mm
mounting bolts and dished washers.

4.2 Earthing the ignition system

Connect the MORIS rails to the engine earth using an earthing cable with a cross-section of least 2.5 mm².
One M6 x 12 mm bolt is provided at each connection and end module to connect the earthing cable to the rail.

4.3 Mounting and adjusting the pickups on the engine

NOTICE
The mounting and adjustment of pick-ups is described in TI 1502-0072 – SPA24.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus/Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 2 Page No.: 11/36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0068
MORIS ignition

4.4 Replacing components

ATTENTION
Please read the guidelines and safety instructions in Section "Safety Information [⇨ Page 2]"
before replacing any MORIS component.

NOTICE
Each time you fit or remove a MORIS component, inspect the gaskets for damage and replace if
necessary. This is the only way to guarantee that the system as a whole remains permanently
watertight (IP54).

See also
• Safety information [⇨ Page 2]

4.4.1 spark plug connector

To replace the spark plug connector, loosen the union nut on the coil terminal and the two M8 nuts of the
double-end studs on the valve cover.
Each time you remove a spark plug connector, inspect the area of the adapter between the cylinder-head
cover and the spark plug sleeve for oil leaks and if necessary replace defective O-rings.

4.4.2 Thermocouple
Tighten the assembly sleeves for the thermocouples using a 30 Nm tightening torque. The exhaust gas
thermocouples must be manually tightened on SAFI and on the engine block using a 15 Nm torque. Connect
the thermocouple for the left cylinder to the left-hand connector and the thermocouple for the right cylinder to
the right-hand connector for the SAFI.

4.4.3 M coil
The M coil is fastened to the ignition module with four special M6 x 40 hexagonal socket bolts (refer to Section
Tightening torques [⇨ Page 9]).
The first time a coil is fitted or replaced, the self-adhesive 3 mm NBR gasket supplied must be affixed to the M
coil.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus/Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 2 Page No.: 12 / 36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0068
MORIS ignition

① 3 mm self-adhesive NBR gasket

② M6 x 40 hexagonal socket bolt

Before disassembling, loosen the coil terminal on the spark plug connector. After fitting the M coil, reconnect
the coil terminal on the spark plug connector and hand-tighten.

See also
• Tightening torques [⇨ Page 9]

4.4.4 SAFI
SAFI is fitted with two hexagonal socket bolts (M6 x 60 bottom right / M6 x 35 top left) (see Section Tightening
torques [⇨ Page 9]). The 3 mm thick NBR gasket supplied must be attached when fitting the SAFI.

① M6 x 35 hexagon socket bolt

② M6 x 30 hexagon socket bolt
③ Connections for thermocouples
④ 3 mm NBR gasket
⑤ M8 x 25 hexagon-head bolt

Loosen the thermocouples and the knock sensors before removing the SAFI. After fitting the SAFI, connect the
thermocouples and tighten the knock sensors with the required tightening torque (refer to Section Tightening
torques [⇨ Page 9]).
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus/Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 2 Page No.: 13/36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0068
MORIS ignition

See also
• Tightening torques [⇨ Page 9]

4.4.5 Ignition modules

Remove the M coils and the SAFI before disassembling the ignition module. Next, loosen the eight M5 x 12 mm
countersunk bolts and pull the ignition module off the rail using two M6 bolts.

① M5 x 12 countersunk bolt (qty. 8)

② M6 bolts for the ignition module extension

NOTICE
Nature and source of the hazard
Never use a screwdriver under any circumstances to lever the ignition module out of the rail.
Otherwise, you will damage the O-ring packing cord and the system will no longer be
guaranteed watertight.
Before fitting, check all the gaskets on the ignition module.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus/Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 2 Page No.: 14 / 36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0068
MORIS ignition

① Guide pin

Using the guide pins to keep it as parallel as possible to the rail, push the ignition module carefully and without
exerting excessive force into the rail. If excessive force is required, you should check for damage around the
gaskets, around the plug-in connectors both on the ignition module (bent off pin in 15-pole ODU connector
block) and on the sockets on the rail (15-pole socket terminal strip).
After fitting the ignition module, tighten the M5 x 12 mm mounting bolts with the appropriate tightening torque
(refer to Section Tightening torques [⇨ Page 9]).

See also
• Tightening torques [⇨ Page 9]

4.4.6 Connection and end modules

To replace a connection or end module, detach the rail from the engine.
The next step is to remove the adjacent ignition module (see the instructions in Section Ignition modules [⇨
Page 14]).
Then remove the end cover with the four M4 x 9 mm bolts, loosen the four M4 x 9 mm bolts on the cover of the
connection or end module, remove the gasket and push the module out of the rail.
Mount the new module in reverse order. When installing the module, ensure that it is mounted exactly flush
with the end of the rail. Incorrect positioning can cause problems when you come to plug in the ignition
module.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus/Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 2 Page No.: 15/36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0068
MORIS ignition

NOTICE
Before re-installing the ignition module, ensure that the coding switch is adjusted to the same
setting as with the replaced module and secure it with sealing varnish. The coding switch setting
is described in Sections "Setting the cylinder coding [⇨ Page 17]", "Identifying the cylinder
arrangement in the engine [⇨ Page 21]" and "Cylinder coding [⇨ Page 33]".
The 24 V power supply for MORIS is protected by a violet-coloured 3 A MINI automotive fuse 16.5
x 11 x 3.8 mm in size in the connection module. To replace the fuse, remove the front and side
cover panels of the connection module and use flat-nose pliers to change the fuse. When
reassembling, make sure the gaskets at the MIL plugs and the front and side cover panels are
correctly positioned.

See also
• Ignition modules [⇨ Page 14]
• Setting the cylinder coding [⇨ Page 17]
• Identifying the cylinder arrangement in the engine [⇨ Page 21]
• Cylinder coding [⇨ Page 33]

4.4.7 Link modules

1. To replace a link module, detach the rail from the engine.
2. Remove the adjacent ignition module (see the instructions in Section "Ignition modules [⇨ Page 14]") either
towards the connection module or towards the end module, depending on the number of modules to be
removed.
3. Remove the link or end modules (Section "Connection and end modules [⇨ Page 15])".
Before removing the link modules you should note down the current position of the individual modules so
that you don't have to change the coding of the modules during the subsequent re-assembly process.
4. Remove the gaskets and push the individual link modules out of the rail. In the case of Type 6 engine link
modules, the M4 x 9 assembly bolts must be loosened beforehand.
5. Set the same coding on the replacement link module as on the original link module (see Sections "Setting
the cylinder coding [⇨ Page 17]", "Identifying the cylinder arrangement in the engine [⇨ Page 21]" and
"Cylinder coding [⇨ Page 33]").
6. To reassemble, push the link modules into the rail so that Pin 15 in the socket terminal strip is positioned
level with the connection or end module.
7. Fit the link or end module.
Insert the gasket before screwing down the link or end module (see Section "Connection and end modules
[⇨ Page 15]").
8. Plug in the individual ignition modules and do not forget the gaskets.
9. Once all the modules have been positioned and mounted, tighten the M5 x 12 mm and M4 x 9 mm
mounting bolts (with O-ring) on the ignition modules and link modules (Type 6 engine only).
10. Fit the end cover. Check the gasket and replace as necessary.

See also
• Ignition modules [⇨ Page 14]
• Connection and end modules [⇨ Page 15]
• Setting the cylinder coding [⇨ Page 17]
• Identifying the cylinder arrangement in the engine [⇨ Page 21]
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus/Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 2 Page No.: 16 / 36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0068
MORIS ignition

• Cylinder coding [⇨ Page 33]

4.4.8 Setting the cylinder coding

The coding signal is required so that the SAFI can be allocated to the cylinder position. In the case of the
MORIS, a hexadecimal rotary selector switch is used to set the coding. The SAFI receives two bits of code (2nd
and 4th bit) from the right side of the ignition module, and two from the left side (1st and 3rd bits).

Coding switch for Type 4 engine link module

① Pin 15 of the socket terminal strip.
② Hexadecimal coding switch

The coding on the connecting, coupling and end modules must be set as shown in the table in Section "Cylinder
coding [⇨ Page 33]".
Check: The current coding is displayed on a flashing CAN LED while the SAFI is booting up. A precise description
of this SAFI function can be found in Section "Identifying the cylinder arrangement in the engine [⇨ Page 21]".

See also
• Identifying the cylinder arrangement in the engine [⇨ Page 21]
• Cylinder coding [⇨ Page 33]

5 Operation
The MORIS is operated and controlled via the dia.ne XT visualisation system and regulated by means of the
SAFI (refer to the Technical Instruction for SAFI – TI 1502-0071).

The general diagram below shows in schematic form the structure of the control and regulation circuit of the
MORIS ignition system.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus/Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 2 Page No.: 17/36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0068
MORIS ignition

① Pick-up signals
② Ignition control system
③ Ignition feedback
Voltage supply
Cylinder coding
④ MORIS fail-safe loop
⑤ CAN
⑥ Analogue signals

5.1 Ignition control system

The ignition functions are enabled when SAFI is operated in combination with the MORIS ignition system. SAFI
triggers the ignition, adjusts the ignition sparks in accordance with the set parameters and monitors the
electrical ignition process.
MORIS operates in 3 phases.
Phase 1 – Producing the ignition spark
Phase 2 – Regulating the current in the ignition spark
Phase 3 – De-energising and synchronising for possible re-ignition after spark interruption

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus/Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 2 Page No.: 18 / 36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0068
MORIS ignition

HV Voltage at the spark plug Ph1…3 Phases 1 to 3

Isec Current in the high-voltage circuit t Time

5.1.1 Phase 1 – Producing the ignition spark

At the ignition point, SAFI switches the energy supplied by MPM and stored in the output stage to the ignition
coil. The first pulse, which is determined by the characteristics of the ignition coil, produces the ignition spark.
After a specified time, a response must be received from MORIS to indicate that the current flow has been
established in the secondary circuit. If this response is not received, the error message "MORIS hardware error"
is displayed and the ignition process aborted.
The ignition system also transmits a conditioned voltage signal to display the high voltage. SAFI analyses the
peak value of this signal and transmits the ignition voltage value averaged over 10 cycles.

5.1.2 Phase 2 – Regulating the current in the ignition spark

Once the ignition spark has been produced, MORIS adjusts the current in the ignition spark to the specified set
point value which is determined by the ignition current flow. If the current in the ignition spark too low, more
electrical energy is supplied to the ignition coil and when the set point value has been reached the energy
supply to the ignition coil is disconnected.
The following curves can be selected for the ignition current flow:
Ignition current flow - 0 Ignition current flow 1: Constant

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus/Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 2 Page No.: 19/36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0068
MORIS ignition

Parameters can be set for ignition current flow - 0,

which is used for trial purposes.

Ignition current flow 2: Steep rise Ignition current flow 3: Flat rise

Ignition current flow 4: Rib Ignition current flow 5: Straight line with tail

Ignition current flow 6: Rise with straight line Ignition current flow 7: Needle

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus/Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 2 Page No.: 20 / 36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0068
MORIS ignition

5.1.3 Phase 3 – De-energising and synchronising for possible re-ignition after spark interruption
If the system is overloaded, the MORIS is de-energised by disconnecting the energy supply to the ignition coil
and prepared for re-ignition as soon as conditions in the ignition system permit. The time for the re-ignition is
calculated by SAFI from the conditions in MORIS and Phase 1 - producing the spark - is initiated.
The ignition system issues a response. SAFI uses this response to check the function of the ignition system and
generates messages accordingly.

5.1.4 Pickup signals

SAFI requires two digital signals to detect the engine running conditions. The three analogue pickup signals are
converted to two digital signals by the SPA24 (refer to TI 1502-0071 – SAFI and TI 1502-0072 - SPA24).

5.1.5 Visual displays on the SAFI

The device has five LED displays, of which the "STATUS" LED is in three colours.

Description Colour Meaning

POWER Green Power supply
STATUS Green Firing up
Red Error
Yellow Booting up
CAM Yellow Synthetic camshaft/reset impulse
TRIGGER Yellow Trigger impulse
CAN Yellow CAN bus activity

5.1.6 Identifying the cylinder arrangement in the engine

In each cabling rail, the position of SAFI on the engine is identified by the cylinder coding (see Section "Setting
the cylinder coding [⇨ Page 17]"). SAFI's detection and verification operations are described in Technical
Instruction TI 1502-0071.

See also
• Setting the cylinder coding [⇨ Page 17]
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus/Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 2 Page No.: 21/36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0068
MORIS ignition

5.1.7 Adjusting the reset position

After the engine has been started, an ignition timing strobe must be used to compare the ignition point on the
flywheel with the ignition point value shown on the engine control system.
If the value displayed does not match the actual value on the flywheel, the engine must be shut down, the
value for the reset signal corrected and the value rechecked (for the exact procedure, refer to TI 15020071 –
SAFI).
The engine should not be put under load until the current ignition point matches the ignition point displayed on
the dia.ne XT.

5.1.8 High-voltage measurement

It is possible to use the high-voltage measurement system on the M coil to measure the SAFI ignition voltage
and communicate this to the engine control system via the CAN bus.
When doing this, the SAFI sends the engine control system the average value from 10 measurement cycles.
In the ignition self-test, the dia.ne XT determines the maximum values of the individual cylinders in order to
facilitate diagnosis of the high-voltage supply from the M coils.
The high-voltage measurement system does not generate trip error messages.

5.1.9 Port Injection

The Port Injection function consists of selective cylinder control of the gas quantity by means of solenoid valves.
Activation and monitoring of these solenoid valves, also referred to as Port Injection valves, is implemented in
SAFI2 and MORIS2.
MORIS2 and SAFI2 are further developments of the MORIS/SAFI system, expanded by the addition of an
activation and monitoring function for selective cylinder gas metering (Port Injection).
In the first version only the selection of the Port Injection valve was implemented in the DIANE, and the
electronic prechamber gas valve (PCI) and prechamber gas safety valve (PCS) were not supported.
A feedback signal corresponding to the actual current signal through the PI valve is evaluated by SAFI2 to
diagnose the function of the PI valve.
More detailed information on the port injection generally can be found in the Technical Instruction: TI
1502-0071 SAFI (Sensor-Actuator-Function-Interface).

5.2 Control and visualisation

5.2.1 Parameter setting

General ignition parameters

The following parameters have been saved in the Ignition parameter list.

▪ Ignition point for gas types 1 - 4

These settings lie between the value for the earliest and the latest ignition point:

▪ Earliest possible ignition point

▪ Latest possible ignition point
▪ Overspeed
▪ Misfire control

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus/Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 2 Page No.: 22 / 36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0068
MORIS ignition

MORIS system parameters

The following parameters have been saved in the Ignition – MORIS parameter list.
▪ Settings
▪ combustion duration
▪ Maximum ignition current
▪ ignition current flow
▪ Coil type
▪ Power unit output for MORIS

▪ Monitoring functions
▪ Ignition error rates
▪ Tolerance for combustion time deviation

Parameters for MORIS hardware

The coil type determines the hardware design of the MORIS ignition coil. The necessary parameters are
permanently stored in the Task.

The ignition current flow determines the spark characteristics. The necessary parameters are permanently
stored in the Task.

Coil type 0 and ignition current flow 0 can be configured using the parameters in this menu and are used for
testing new hardware designs. The parameters in this menu can be viewed and changed by User Level 45 and
upwards.

Displays

5.2.2 Displays
In the CYL menus on the dia.ne XT you can switch between the screens for ignition point, ignition voltage,
maximum ignition voltage and ignition output error.
The displays are always visible, irrespective of the user level.

Ignition point
The set point values of the ignition points of all the cylinders are displayed on this screen in bar and digital
form.

Ignition voltage
The ignition voltages of all the cylinders are displayed in bar and digital form on this screen while the engine is
running and during the self-test.

Maximum ignition voltage

The maximum values of the ignition voltages of all the cylinders are displayed in bar and digital form on this
screen during the self-test. If the self-test is disabled, this screen is also disabled.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus/Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 2 Page No.: 23/36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0068
MORIS ignition

Ignition output errors

The bar indication shows the current output error rates, where the maximum value, 10, denotes a complete
failure of the cylinder concerned.
The digital values represent the maximum values which have occurred for error rates, and the error rates can
be reset to 0 on the click of a button by User Level 10 and upwards.

5.2.3 Monitoring functions

CAN communication
SAFI communication with the engine control system is monitored as follows:
▪ All SAFIs must be communicating with the control system before the engine is started.
▪ When at a standstill, the engine is prevented from starting after 25 seconds of interrupted communication
with at least one SAFI.
▪ When in operation, the engine is shut down after 2 seconds of interrupted communication with at least one
SAFI.

Voltage supply failure

The ignition end stages of MORIS are powered by the MPM power units. The 185 V power supply is switched
with engine start preparation and in the self-test.
The output voltage of the MPM power units for the MORIS output stages is monitored and displays the status
via digital outputs. If these digital outputs become inoperative while the engine is running or if the 185 V power
supply is not activated within 10 seconds when requested by the power unit, the message Ignition power
supply failed is displayed and the gas valves are closed during engine operation.

Ignition running and gas valves opening

The message "Ignition on" is generated when all the SAFIs display the message "Output firing". The gas valves
must not be opened until it is certain that the state of all the SAFIs is 'Firing'.
The gas valves close if the message 'Output firing' is not available for all the cylinders. In this case, the message
Ignition off is generated (refer to Section 5.2.5 – Safety plan).
In the event of a shut-down, the ignition is deselected via the CAN bus and at the same time the 185 V power
supply for the ignition is switched off and the gas valves closed.

Output error
The combustion time of the ignition spark is measured and compared with the pre-set set point value. If the
measured combustion time is outside the tolerance, this is analysed by SAFI as an error.
If the number of errors over 10 ignition pulses exceeds the value for permissible error rates, SAFI issues the
message "Error rates for ignition time exceeded" and from this generates a warning or the trip-producing error
message Ignition output error.
The permissible deviation and the error rate over 10 ignition pulses are adjustable, where the value 0 disables
the monitoring system.

Warning
If the SAFI error messages "Error rate for combustion time exceeded" is displayed on a maximum of one
cylinder, the warning "Output error" is displayed with the operating notification for the cylinder.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus/Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 2 Page No.: 24 / 36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0068
MORIS ignition

Error message
The engine controller monitors all the cylinders and as soon as more than one cylinder is displaying the
message 'Error rate for combustion time exceeded' at the same time, the error message 'Ignition output error'
is generated with the operating notification for the cylinder concerned.
The error message with the operating notification for the cylinder is also displayed when the SAFI message
'Output firing is missing' from any cylinder when the engine is running.

Ignition hardware error

If the ignition coil is defective or no spark plug connector is present at the ignition coil output or no spark plug is
connected, the message 'Ignition hardware error' is displayed.

Monitoring the port Injection valves

The diagnosis is divided into three main areas:
▪ Open detection
The rise in the pull-in current is evaluated. It detects whether the valve opens, whether a valve is connected
(there is a current flow), and whether the wiring is correct (no cable breakage or short-circuit).
▪ Open Point Detection
Evaluation of the pull-in current curve shows whether and when the valve opens.
▪ Close Detection
Close Detection checks whether the valve has closed correctly after the normal opening sequences (gas
injection event) but before the start of ignition.

5.2.4 Possibility of diagnosis by self-test

The self-test is best activated from the screen Detail – Ignition – Current ignition voltage and Ignition voltage.
If the engine starts to turn while the ignition system is in self-test mode, SAFI automatically switches off the
self-test function.
The self-test is automatically de-activated after 10 minutes.
The current ignition voltage values during the self-test are displayed on the screen Detail – Ignition – Current
Ignition voltage and maximum values of the ignition voltages of all the cylinders are displayed in bar and digital
form on this screen Detail – Ignition – Maximum ignition voltage (maximum value memory).

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus/Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 2 Page No.: 25/36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0068
MORIS ignition

5.2.5 Safety plan

Overview
Module Interface MORIS
Engine Safety Line

Gas Values Control

Connection Module
Rail Bank A

Ignition Modules

End Module
MORIS Safety Loop and MPM Safety Contacts
+24VDC Line

Fuse SAFI SAFI SAFI

Current
Limiter
MORIS Safety Loop
Gas valve request
Safety line

MORIS Safety Line

End Module
Connection Module

Ignition Modules
Rail Bank B

SAFI SAFI SAFI

Current
Limiter
MORIS Safety Loop

Relais

24VDC MORIS Power Supply

GND

MPM MPM
DC/DC DC/DC

Relais

24VDC
GND
Relais

24VDC
PLC GND

Relais

24VDC Gas
GND Valves

MORIS fail-safe loop

The safety plan for MORIS is based on a fail-safe loop which covers the entire MORIS.
The MORIS fail-safe loop is supplied with 24 V DC and is based on the closed-circuit principle.
Each time the engine stops, the function of every contact integrated into the MORIS fail-safe loop is checked. If
an error arises an alarm message is displayed and the engine is prevented from starting.
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus/Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 2 Page No.: 26 / 36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0068
MORIS ignition

A self-resetting overload protection system (PTC) of 250 mA at an ambient temperature of 20°C is integrated
into each connection module in the MORIS as overcurrent protection. The constant current of the MORIS fail-
safe loop must not exceed 120 mA.
The MORIS fail-safe loop is closed when all the SAFIs switch to "Firing" mode and opened when a SAFI de-
activates the "Firing" mode or reaches the set overspeed.
Optocouplers are used to integrate the SAFI safety contacts into the MORIS fail-safe loop.

MPM safety contact:

The ignition end stages only work at a voltage exceeding 125 V. The MPM power supply is activated during the
start preparation phase and the MPM safety contact is closed 2 seconds after an output voltage of 130 V has
been reached at the MPM.
If the MPM output voltage falls below 130 V, the safety contact is opened without delay.

Emergency stop fail-safe loop:

If the emergency stop fail-safe loop in the engine control system, the MORIS fail-safe loop or an MPM safety
contact is opened, the start-up process is stopped and the gas valves closed.
The MORIS fail-safe loop is integrated into the engine control system's emergency stop fail-safe loop in series
with one or two MPM safety contacts depending on the ignition power required for the engine. The engine
control system's emergency stop fail-safe loop must be closed so that the engine can be started and operated.
The MORIS fail-safe loop or the MPM safety contacts can only open the engine control system's emergency
stop fail-safe loop if the gas valves have already been opened.
The engine control system's emergency stop fail-safe loop is opened by the MORIS emergency stop fail-safe
loop when the gas valves have been activated and the following conditions apply:
▪ a SAFI de-activates the "Firing" mode (e.g. due to a faulty pick-up signal) or
▪ the pre-set overspeed point is reached
▪ SAFI loses its power supply or the processor freezes
The engine control system's emergency stop fail-safe loop is opened by an MPM safety contact when the gas
valves have been activated and the following conditions apply:
▪ the output voltage falls below 130 V

Emergency shut-down of ignition system

The engine control system's emergency stop fail-safe loop shuts down the engine. In this case, not only are the
gas valves closed when the emergency stop fail-safe loop is released, but the MPM is also de-activated and the
energy supply to the ignition system interrupted within 80 ms.
The way the MORIS fail-safe loop and the MPM are integrated into the module control system is shown in the
schematic diagram of the plant concerned.

Controlling the gas valves

The MORIS fail-safe loop and the MPM safety contacts are integrated directly into the control system for the
gas valves. The gas valves are de-activated when the MORIS fail-safe loop or an MPM safety contact has been
opened.
The gas valves are activated from the engine control system. The engine control system opens the gas valves
when it has a response indicating that all the SAFIs are in "Firing" mode and the MPMs have an output voltage
of over 130 V, no error is detected and the operating condition of the engine permits it (e.g. time-delayed in the
event of a purge start).

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus/Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 2 Page No.: 27/36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0068
MORIS ignition

6 Diagnosis and troubleshooting

Only ignition-related messages are dealt with below.

Detailed information and descriptions of monitoring functions, operational, warning and error messages and
setting parameters for the SAFI and dia.ne XT can be found in Technical Instruction TI 1502-0071 – SAFI.
When replacing components, always read the instructions in Section "Replacing components [⇨ Page 12]" or in
the technical instruction for the device concerned.

See also
• Replacing components [⇨ Page 12]

6.1 ignition

6.1.1 Operating notification (Bxxxx)

Message Message Description/Troubleshooting
number
B3225 Ignition On All the cylinders are firing
B3226 Ignition Off At least one cylinder is not firing
B3294 Ignition power reduction active Cylinder Display shows cylinder with power reduction
xx
B3278 Ignition output error Cylinder xx Display shows cylinder with output error
B3283 Ignition hardware error Cylinder xx Display shows cylinder with hardware error

6.1.2 Warnings (Wxxxx)

Message Message Description/Troubleshooting
number
W3544 Ignition hardware error No ignition current could be measured. Either no spark could be built
up or no ignition coil has been fitted.
If the parameters set are OK, the problem may be caused by an
excessive ignition-voltage requirement or a hardware defect in the
coil, the ignition module or the SAFI. A self-test of the ignition system
is useful for fault-finding.
Corrective measures:
Check the air gaps of the spark plugs.
Replace the defective ignition coil, the ignition module or the SAFI.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus/Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 2 Page No.: 28 / 36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0068
MORIS ignition

Message Message Description/Troubleshooting

number
W3545 Ignition output errors A cylinder has an output error caused by exceeding the preset
tolerance for combustion time deviation, which is assessed by means
of an error rate.
The error is displayed when no spark is produced or the spark
combustion time deviates from the preset tolerance value. There may
be a hardware defect in the spark plug, the spark plug connector, the
ignition coil, the ignition module or the SAFI. A self-test of the ignition
system is useful for fault-finding.
Corrective measures:
Check the air gaps of the spark plugs.
Check that the spark plug connector and its forward resistance (< 2.5
kOhm) have been fitted correctly.
Replace the defective spark plug, the spark plug connector, the
ignition coil, the ignition module or the SAFI.
Check that the parameters for the combustion time deviation and
error rate have been set.
W3551 Ignition power reduction The ignition process had to be aborted before the set combustion
active time was reached as the power absorbed by the ignition system
exceeded the maximum output of the power supply.
If the parameters set are OK, the problem may be caused by an
excessive ignition-voltage requirement or a defective coil.
Corrective measures:
Check the air gaps of the spark plugs.
Replace the ignition coil.
W3552 Ignition power supply When the engine is running, this error message is displayed
overloaded immediately after the failure of the safety contact for the MPM power
supply (WARNING OUT). The cause of the fault may be incorrectly set
parameters for combustion time and ignition current setpoint. If the
parameters set are OK, the problem may be caused by an excessive
ignition-voltage requirement due to excessive turbulence at the spark
plug or an incorrect type of spark plug has been installed or a defect
has occurred in the MPM.
Corrective measures:
Check the parameters set for ignition current, combustion time and
general power settings.
Check the type of spark plug installed.
Replace the MPM.

6.1.3 Error messages (Axxxx)

Message Message Description / troubleshooting
number
A3338 Ignition output errors The error is displayed when no spark is produced in more than one
cylinder or the spark combustion time deviates from the pre-set
tolerance (for corrective measures, see W3545).

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus/Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 2 Page No.: 29/36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0068
MORIS ignition

Message Message Description / troubleshooting

number
A3344 Ignition power supply When the engine is running, this error message is displayed
failed immediately after the failure of the safety contact for the MPM power
supply (REPLY OUT) and the engine is shut down.
The MPM power supply is activated with start preparation. The error
message is generated when a response is not received within 5
seconds from the MPM safety contact (REPLY OUT) indicating
successful activation.
Corrective measure:
The power unit output parameter for the power units must match the
output of the installed power units.
Check the LEDs on the MPM for the 24 V power supply (POWER), the
request (REQUEST), the response (WARNING) and the safety contact
(REPLY).
Check the cabling to the rail and the wiring to the control system
including the relay function.
Replace the MPM as described in TI 1502-0069.
A3343 Ignition hardware error There is a hardware defect or the hardware components, e.g. SAFI,
MORIS, M coil and the spark plug connector have not been fitted
correctly.
Corrective measure:
Find the defective component and replace it as described in TI
1502-0069 for the MPM or in Section 4.4 Replacing components.
A3345 Ignition fail-safe loop SAFI opens the fail-safe loop in the event of overspeed, a SAFI
hardware error, a pick-up error or an "Ignition off" command from the
control system.
Corrective measure:
If no additional message is displayed, check the cabling in the fail-
safe loop including all installed switching elements and if necessary
replace defective devices (see also Section 4.4 - Replacing
components).
Otherwise, depending on any additional error message, inspect the
devices concerned and if necessary adjust or replace them.

6.2 High-voltage measurement

6.2.1 Operating notification (Bxxxx)

Message Message Description / troubleshooting
number
B3286 Ignition coil offset error Cylinder xx Display shows cylinder position of SAFI with offset
error.
B3287 Ignition voltage too low Cylinder xx Display shows cylinder position of SAFI with excessively
low ignition voltage.
B3288 Ignition voltage too high in cylinder xx Display shows cylinder position of SAFI with excessive
ignition voltage.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus/Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 2 Page No.: 30 / 36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0068
MORIS ignition

Message Message Description / troubleshooting

number
B3289 Average ignition voltage too high Display of cylinder position of SAFI with excessive
Cylinder xx average ignition voltage.
B3290 Ignition voltage difference too high Display shows cylinder position of SAFI with excessive
Cylinder xx ignition voltage difference.

6.2.2 Warnings (Wxxxx)

Message Message Description / troubleshooting
number
W3546 Ignition coil offset error There is no offset voltage in the coil.
If this error affects one cylinder, the line connecting the ignition
coil and SAFI may be damaged or the measuring device on the
ignition coil may be defective.
Corrective measure:
To effect a diagnosis, you can also measure the offset voltage on
the relevant pin of the SAFI connector plug while the engine is at a
standstill (see "Terminal designation" in Section 8.1 – Ignition
module).
Replace the defective ignition coil, the SAFI or the ignition module.
W3547 Ignition voltage too low The ignition voltage is too low, which can cause misfires. Possible
causes are thread on the spark plug electrodes, the air gaps are
too small, defect in the ignition coil or high-voltage sensor. Check
the ignition system with the self-test function.
Corrective measure:
Check the parameters in the section on SAFI – HV measurement.
Check the air gaps of the spark plugs and look out for thread.
Replace the ignition coil.
W3548 Ignition voltage too high The ignition voltage is too high, which may result in damage to the
high-voltage cables and the ignition coil. The ignition voltage could
be so high that no spark is formed on the electrode, thereby
causing misfires.
Corrective measure:
Check the parameters in the section on SAFI – HV measurement.
The air gap in the spark plug electrodes may be too big and must
be checked.
An interruption in the high-voltage circuit between the ignition coil
and the spark plug may also result in an excessive ignition voltage.
Check the forward resistance of the spark plug connector (< 2.5
kOhm) and the spark plug.
Defective high-voltage sensor in the ignition coil. Replace the
ignition coil.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus/Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 2 Page No.: 31/36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0068
MORIS ignition

Message Message Description / troubleshooting

number
W3549 Average ignition voltage too The average value of all ignition voltages calculated in the DIANE
high is too high.
Corrective measure:
Check the parameters in the section on SAFI – HV measurement.
Check the air gaps of the spark plugs.
W3550 Ignition voltage difference The difference between the cylinders with the highest and lowest
too high ignition voltage is too great.
Corrective measure:
Check the parameters in the section on SAFI – HV measurement.
Check the air gaps of the spark plugs.

6.3 Port Injection

6.3.1 Operational message (Bxxxx)

Message number Message Description
B2814 Maximum PI opening Shows cylinder position of SAFI with maximum
duration opening duration
B2815 Minimum PI opening Shows cylinder position of SAFI with minimum
duration opening duration
B2816 PI On Shows activation of Port Injection valves
B2817 PI Off Shows deactivation of Port Injection valves
B2818 PI fault in Shows cylinder position of SAFI with maximum
detection failure opening duration.
B2819 PI fault in Shows cylinder position of SAFI with faulty opening
opening point detection duration
B2820 PI valve failure when Shows cylinder position of SAFI with maximum
closing cylinder opening duration
B2823 PI deactivates cylinder Shows cylinder position of SAFI with deactivated
Port Injection

6.3.2 Warnings (Wxxxx)

Message number Message Description
W2585 PI fault in The warning is generated by the first opening
opening detection failure detection failure. If the faults are detected
consecutively equivalent to the set parameter "PI
open detection failure rate", an alarm message is
generated.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus/Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 2 Page No.: 32 / 36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0068
MORIS ignition

6.3.3 Error messages (Axxxx)

Message number Message Description/Solution
A2254 PI opening detection failure A Port Injection failure in opening detection is
detected by SAFI2 if no current signal or an
incorrect current signal to the Port Injection valve is
measured.
The main reason for this failure is a short circuit or
cable breakage between the Port Injection driver
and valve, or a valve which is not connected.
A2255 PI fault in opening point If no valve opening or delayed opening is detected,
detection this alarm message is generated and the engine is
shut down.
A2256 PI valve failure when closing The PI valve remains open when de-energised,
which can allow an uncontrolled quantity of gas to
be metered.
SAFI2 suppresses the ignition pulses immediately
after the error and opens the "Ignition safety loop",
which has the effect of
deactivating the power supply to the ignition and
the PI valves.
When troubleshooting check whether the valve is
damaged or blocked mechanically.

7 Cylinder coding
8 cylinders Coding 12 cylinders Coding
Bank Module DEC HEX Module DEC HEX
Bank A Connection module 0 0 Connection module 0 0
A A
Link module 1 0 0 Link module 1 0 0
Link module 2 3 3 Link module 2 3 3
Link module 3 2 2 End module A 0 0
End module A 1 1
Bank B Connection module 1 1
B
Link module 1 6 6
Link module 2 5 5
End module B 0 0
16 cylinders Coding 20 cylinders Coding
Bank Module DEC HEX Module DEC HEX
Bank A Connection module 0 0 Connection module 0 0
A A
Link module 1 0 0 Link module 1 0 0
Link module 2 3 3 Link module 2 3 3
Link module 3 2 2 Link module 3 2 2
End module A 1 1 Link module 4 1 1
End module A 4 4

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus/Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 2 Page No.: 33/36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0068
MORIS ignition

Bank B Connection module 4 4 Connection module 5 5

B B
Link module 1 5 5 Link module 1 4 4
Link module 2 4 4 Link module 2 7 7
Link module 3 7 7 Link module 3 2 2
End module B 2 2 Link module 4 9 9
End module B 8 8
Type 6-MD 12- Coding Type 6-MD 16- Coding
cylinder engine cylinder engine
Bank Module DEC HEX Module DEC HEX
Bank A Connection module 0 0 Connection module 0 0
A A
Link module 1 0 0 Link module 1 0 0
Link module 2 3 3 Link module 2 3 3
End module A 0 0 Link module 3 2 2
End module A 1 1
Bank B Connection module 1 1 Connection module 4 4
B B
Link module 1 6 6 Link module 1 5 5
Link module 2 5 5 Link module 2 4 4
End module B 0 0 Link module 3 7 7
End module B 2 2

24-cylinder bank A Coding 24-cylinder bank B Coding

Bank Module DEC HEX Bank Module DEC HEX
Bank Connection module 0 0 Bank Connection module 4 4
A-A A B-A B
Link module 1 0 0 Link module 1 7 7
Link module 2 3 3 Link module 2 2 2
End module A 0 0 End module B 8 8
Bank End module B 2 2 Bank End module A 1 1
A-B Link module 1 1 1 B-B Link module 1 8 8
Link module 2 4 4 Link module 2 11 B
Connection module 5 5 Connection module 10 A
B A
20-cylinder Type 9 engine, Coding 20-cylinder Type 9 engine, Coding
bank A bank B
Bank Module DEC HEX Bank Module DEC HEX
Bank Connection module 0 0 Bank Connection module 5 5
A-A A B-A B
Link module 1 0 0 Link module 1 4 4
Link module 2 3 3 Link module 2 7 7
End module A 0 0 End module B 2 2

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus/Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 2 Page No.: 34 / 36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0068
MORIS ignition

Bank End module B 2 2 Bank End module A 0 0

A-B Link module 1 1 1 B-B Link module 1 9 9
Connection module 4 4 Connection module 8 8
B A

8 Terminal designation

8.1 Ignition module

25-pole Sub-D connection socket for SAFI:
Pin Designation Description
1 HS2 High-voltage measurement signal from right ignition coil
2 HS1 High-voltage measurement signal from left ignition coil
3 STROM Ignition current setpoint for left and right ignition output stage
4 IP1 Trigger signal for the left ignition output stage
5 CODE 4 Third bit of SAFI code for position sensing
6 CODE 1 First bit of SAFI code for position sensing
7 CODE 2 Second bit of SAFI code for position sensing
8 CAN-Low CAN-Low
9 CAN-High CAN-High
10 OFF Emergency shutdown
11 CAM Signal from the camshaft pickup
12 GND Ground
13 +24 V Power supply for SAFI
14 GND Ground
15 GND Ground
16 IP2 Trigger signal for the right ignition output stage
17 RM1 Response from the left ignition end stage
18 GND Ground
19 CODE 8 Fourth bit of SAFI code for position sensing
20 RM2 Response from the right ignition end stage
21 CAN-GND CAN-GND
22 n.c. Unallocated
23 TRIGGER Signal from ring gear
24 GND Ground
25 n.c. Unallocated

7w2 Sub-D socket for M coil:

Pin Designation Description
A1 185 V 185 V power supply for M coil
A2 IGBT Switch contact for output stage
1 HV Sensor Output for high-voltage sensor
out

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus/Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 2 Page No.: 35/36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0068
MORIS ignition

Pin Designation Description

2 Isec Electrical response signal
3 GND Ground
4 +24V Power supply for high-voltage sensor
5 n.c. Unallocated

8.2 Connection module

5-pole MIL connector plug for 185 V power supply for MORIS:
Pin Designation Description
A +185V 185 V power supply for MORIS output stages
B GND Ground/earth for 185V power supply
C SC-A, SC-B Bank A or B safety contact for MPM (GND potential)
D GND Ground/earth for 185V power supply
E +185V 185 V power supply for MORIS output stages

10-pole MIL connector plug for 24V power supply, signal lines and CAN bus:
Pin Designation Description
A +24V Power supply for output stage and SAFI
B GND 24V ground/earth
C n.c. Unallocated
D CAM CAM/RESET signal from SPA24
E TRIGGER TRIGGER signal from SPA24
F CAN-LOW CAN BUS low-level line
G CAN-HIGH CAN BUS high-level line
H CAN-GND CAN bus ground/earth line
I SAFETY MORIS fail-safe loop with SAFI safety contacts
LOOP
Y n.c. Unallocated

8.3 End module

4-pole MIL connector plug for CAN bus and fail-safe loop connection line:
Pin Designation Description
A CAN-LOW CAN BUS low-level line
B CAN-HIGH CAN BUS high-level line
C CAN-GND CAN bus ground/earth line
D SAFETY MORIS fail-safe loop with SAFI safety contacts
SprungMarke!!!9007199286491403
LOOP

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus/Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 2 Page No.: 36 / 36
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0069
MPM (MORIS Power Module)

1 Safety information

NOTICE
All work on the engine is governed in all respects by the guidelines in Technical Instruction "TI
2300-0005 Safety instructions" and in particular the guidelines for ignition systems.

ATTENTION
Before starting the ignition system, make sure that all parts of the ignition unit have been
installed and connected in accordance with the instructions.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus / Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 3 Page No.: 1/13
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0069
MPM (MORIS Power Module)

WARNING
Magnetic fields
People wearing a pacemaker are not permitted to enter the engine room and carry out work on
the ignition system.

DANGER
Danger to life from high voltages
Extremely dangerous voltages can be produced during the self-test and engine operation
(primary power supply of 185 V to the ignition coil and high voltage in excess of 40 kV on the
secondary side). Currents of up to 100 A occur during operation. The capacitors in the MORIS rail
are charged to 185 V during operation. A reverse voltage of up to 185 V may therefore occur at
the 185 V connector plug.
Improper use may result in a risk of injury or death due to electric shock!
a) Before assembly or repair work on the ignition system, the engine must be shut down and
secured to prevent unauthorised starting and the self-test disabled.
b) Before working on the ignition system, you must disconnect the power supply to MORIS and
check to ensure that the system is dead.

The plug-in connector (J1) of the MPM 24 V power supply must be locked.
Before starting the ignition system, make sure that all parts of the ignition unit have been installed and
connected in accordance with the instructions.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus / Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 3 Page No.: 2 / 13
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0069
MPM (MORIS Power Module)

2 Description

Picture of the MPM

2.1 General
MPM (MORIS Power Module) is a DC-DC converter and supplies the MORIS (MOdular Rail Ignition System) with
DC at 185 V from the 24 V grid.
One or more MPMs may be needed, depending on the engine application and the ignition output this requires.
Control and monitoring are provided by the engine control system, which indicates the status of the MPM by
generating operational, warning and alarm messages (refer to TI 1502-0071 SAFI and TI 1502-0068 MORIS).
MPM has a safety contact which is integrated into the emergency stop fail-safe loop and the gas valve control
system and is opened if a fault develops.
The following Technical Instructions are referred to in this document:
▪ TI 1502-0068 – MORIS (Modular Rail Ignition System)
▪ TI 1502-0071 – SAFI (Sensor Actor Functional Interface)
You will need these Technical Instructions to obtain a complete understanding of the MORIS functions.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus / Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 3 Page No.: 3/13
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0069
MPM (MORIS Power Module)

3 Technical data

3.1 Protection class

MPM conforms to Protection Class IP21.

3.2 Ambient conditions

Temperature limits Storage -25 ... + 70 ℃
In operation -25 ... + 75 ℃

Relative humidity Storage 90 %, no dew

In operation 85 %, no dew

Air pressure up to 2,000 m above sea level

3.3 Chemical resistance

MPMS has been developed to meet the specific GE Jenbacher requirements for chemical resistance to the
antifreeze (glycol) in the engine cooling water, sulphurous acid, engine oil and UV radiation.
In general, the following limit levels for atmospheric pollution apply:
● Sulphur dioxide (SO2) 0.030 ppm
● Hydrogen sulphide (H2S) 0.010 ppm
● Nitrous oxide gases (NOx) 0.030 ppm
● Chlorine (C12) 0.010 ppm
● Hydrogen fluoride (HF) 0.010 ppm
● Ammonia (NH2) 0.500 ppm
● Ozone (O3) 0.005 ppm

3.4 Mechanical data

3.4.1 Vibration resistance

MPM is designed for vibration loads to an effective value of max. 20 mm/s at 10 - 300 Hz.

3.4.2 Dimensions
Dimensions of the housing (length x height x depth):
▪ without connector plug and top hat rail support: 220 x 108 x 45 mm
▪ including connector plug and top hat rail support: 260 x 108 x 56 mm

The minimum space required for the mounting, connection and ventilation of the power unit is 350 x 160 mm
(refer to Section 4 Installation).

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus / Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 3 Page No.: 4 / 13
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0069
MPM (MORIS Power Module)

3.5 Electrical data

3.5.1 Rated data

● Nominal input voltage: 24 V DC
● Input voltage range: 15 – 32 V DC
● Maximum power consumption at rated voltage: 24.1 A rms
● Starting current consumption: 45 A peak
● Nominal output voltage: 185 V DC
● Maximum output current: 2.5 A rms
● Efficiency: > 80%
● Operating temperature range: - 25 °C to + 75 °C
● Voltage range at inputs and outputs: 15 - 32 V DC
● Maximum permissible current for outputs: 120 mA

3.5.2 Terminal designation

Connector plug J1 – 24V IN
Pin Designation Description
1 24 V 24V power supply for MPM
2 24V GND Earth for the 24V power supply
3 GROUND earth connection

Connector plug J2 - Interface

Pin Designation Description
5 WARNING-OUT Response contact warning for 185V output voltage
4 REPLY-OUT Response contact error for 185V output voltage
3 24V FOR REPLY Input for the 24V power supply to the response and safety
contact
2 REQUEST-OUT 24V earth for the request signal
1 REQUEST-IN +24V request signal from the control system

Connector plug J3 – 185V OUTPUT

Pin Designation Description
1 185V-OUT-A +185V output voltage for MORIS Bank A
2 185V-GND-A 185V earth for MORIS Bank A
3 SC-A Safety contact for MORIS Bank A
4 185V-OUT-B +185V output voltage for MORIS Bank B
5 185-GND-B 185V earth for MORIS Bank B
6 SC-B Safety contact for MORIS Bank B

3.5.3 Safeguards
The MPM is protected internally on the 24 V input side by a 30 A fuse against overloading and short-circuiting.
Replacement of the fuse is described in Replacing the fuse [⇨ Page 7].

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus / Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 3 Page No.: 5/13
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0069
MPM (MORIS Power Module)

The safety and response contacts (REPLY-OUT and WARNING-OUT) are protected from overload current and
short circuits by a PTC with 120 mA (250 mA at 20°C).

See also
• Replacing the fuse [⇨ Page 7]

3.5.4 Earthing
The MPM is earthed via the earth contact of connector plug J1 – Pin 3 and the earth line must have a cross-
section of at least 2.5 mm².

3.5.5 Minimum diameter for 24 V power supply line:

The 24V supply line must have a minimum diameter of 4 mm² .

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus / Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 3 Page No.: 6 / 13
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0069
MPM (MORIS Power Module)

4 Installation

4.1 Components
The MPM is mounted in the module interface. Sufficient air circulation must be provided around the fan outlet
to ventilate the power unit properly.

Photograph: Unit mounted in the module interface of the type 4 engine Min. space required: 350 x 160 mm
① J1 latch

4.2 Replacing the fuse

To replace the 30 A fuse, cut the power to the MPM and disconnect all the connector plugs.
Then push the orange-coloured latches downwards slightly and push them out.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus / Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 3 Page No.: 7/13
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0069
MPM (MORIS Power Module)

① Press the latch downwards

② Push the latch outwards
Next, loosen the 4 retaining bolts on the housing and remove the side panel.

You can now replace the fuse with the aid of flat-nose pliers.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus / Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 3 Page No.: 8 / 13
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0069
MPM (MORIS Power Module)

5 Operation

5.1 Displays on the MPM

The status of the MPM is displayed on 5 LEDs:
Designation Colour Meaning
POWER Green 24 V power supply voltage present
REPLY Green 185 V output voltage present
Response via REPLY-OUT safety contact
REQUEST Green Control system request is available
24 V at the REQUEST-IN input
WARNING Yellow 185 V output voltage below 170 V for t > 2 seconds
Warning: W3552 "Ignition power supply overloaded"
FAULT Red 185 V output voltage is below 130 V
Error: A3344 "Ignition power supply failed"

5.2 Control and monitoring

Control and monitoring of the MPM are provided by the engine control system.

5.2.1 Parameter setting

The MORIS controller needs details of the power unit output(s) to calculate the maximum ignition spark output.
The value for the total installed power unit output is indicated in the parameter manager on the screen Ignition
– MORIS by the "power unit output" parameter in watts.

5.2.2 Control system

During engine start preparation or in the self-test, the MPM is activated via the REQUEST-IN input by setting a
digital control output.
Der Rückmeldekontakt REPLY-OUT meldet die Ausgabe der 185V-Versorgungsspannung an die Steuerung.

5.2.3 Monitoring
The MPM has a SC-A and SC-B safety contact (Safety Contact Bank A and B) for each 185 V output. The safety
contacts are laid in the cabling system to the MORIS rail and earthed in the connection module.
If only one output is used, connect the second safety contact to 185V-GND directly on the connector plug.
If this contact is opened due to disconnection of cabling or by a break in the line, the 185V outlet voltage is shut
off immediately.
If the outlet voltage falls below 170V for more than 2 seconds, the warning is displayed via the WARNING-OUT
contact. As soon as the nominal voltage of 185V is restored the warning is automatically reset. The warning
containing is displayed by the alarm management system with the message "W3552 Ignition power supply
overloaded".
If the output voltage falls below 130V, the 185V output voltage is shut off and the error message with the
REPLY-OUT safety contact is reported to the control system. The shutdown is displayed by the alarm
management system with the message "A3344 Ignition power supply failed".

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus / Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 3 Page No.: 9/13
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0069
MPM (MORIS Power Module)

5.3 Safety plan

5.3.1 Outline
Module Interface MORIS
Gas Valves Control
Engine Safety Line

Connection Module

End Module
MORIS Safety Loop and MPM Safety Contacts

Ignition Modules
Rail Bank A
+24VDC Line

Fuse SAFI SAFI SAFI

Current
Limiter
Gas valve request

MORIS Safety Loop

Safety line

MORIS Safety Line

Ignition Modules
Connection Module

End Module
Rail Bank B

SAFI SAFI SAFI

Current
Limiter
MORIS Safety Loop

Relais

24VDC MORIS Power Supply

GND

MPM MPM
DC/DC DC/DC

Relais

24VDC
GND
Relais

24VDC
PLC GND

Relais

24VDC Gas
GND Valves

The REPLY-OUT safety contact reports the output of the 185V power supply to the control system and at the
same time is integrated into the emergency stop fail-safe loop and the gas valve control system. The gas
valves can only be opened with the MPM safety contacts closed. The gas valves are closed immediately if the
MPM safety contacts fail.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus / Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 3 Page No.: 10 / 13
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0069
MPM (MORIS Power Module)

The MORIS fail-safe loop is integrated into the engine control system's emergency stop fail-safe loop in series
with one or two MPM safety contacts depending on the ignition power required for the engine. The engine
control system's emergency stop fail-safe loop must be closed so that the engine can be started and operated.
The engine control system's emergency stop fail-safe loop is opened by an MPM safety contact when the gas
valves have been activated and the output voltage of 130V has not been reached.
The structure of the MORIS safety plan is described in greater detail in TI 1502-0068 – MORIS and in
TI 1502-0071 – SAFI.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus / Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 3 Page No.: 11/13
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0069
MPM (MORIS Power Module)

6 Diagnosis and troubleshooting

6.1 Warnings (Wxxxx)

Message Message Description / troubleshooting
number
W3552 Ignition power supply When the engine is running, this error message is displayed
overloaded immediately after the failure of the safety contact for the MPM power
supply (WARNING OUT). The cause of the fault may be incorrectly-set
parameters for the ignition or port injection. If the parameters set are
OK, the problem may be caused by an excessive ignition voltage
requirement due to excessive turbulence at the spark plug or an
incorrect type of spark plug has been installed or a defect has
occurred in the MPM.
Corrective measure:
Measure the MPM output voltage, taking the information in the
Section into account. Monitoring [⇨ Page 9]
Check the parameters set for ignition current and combustion time.
Check the type of spark plug installed.
Replace the MPM.

6.2 Error messages (Axxxx)

Message Message Description / troubleshooting
number
A3344 Ignition power supply When the engine is running, this error message is displayed
failed immediately after the failure of the safety contact for the MPM power
supply (REPLY OUT) and the engine is shut down.
The MPM power supply is activated with start preparation. The error
message is generated when a response is not received within 5
seconds from the MPM safety contact (REPLY OUT) indicating
successful activation.
Corrective measure:
The power unit output parameter for the power units must match the
output of the installed power units.
Check the LEDs on the MPM for the 24 V power supply (POWER), the
request (REQUEST), the response (WARNING) and the safety contact
(REPLY).
Check the cabling to the rail and the wiring to the control system
including the relay function.
Replace the MPM as described in TI 1502-0069.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus / Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 3 Page No.: 12 / 13
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0069
MPM (MORIS Power Module)

Message Message Description / troubleshooting

number
A3345 Ignition fail-safe loop SAFI opens the fail-safe loop in the event of overspeed, a SAFI
hardware error, a pick-up error or an "Ignition off" command from the
control system.
Corrective measure:
If no additional message is displayed, check the cabling in the fail-
safe loop including all installed switching elements and if necessary
replace defective devices.
Otherwise, depending on any additional error message, inspect the
SprungMarke!!!18014398542181771
devices concerned and if necessary adjust or replace them.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE / Kraus / Kröll Responsible: Elektronik Release date: 27/06/2014
Index: 3 Page No.: 13/13
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

1 Safety information.................................................................................................................................... 3
2 Description of the concept...................................................................................................................... 4
2.1 Parts/design................................................................................................................................................................. 4
2.2 Basic function.............................................................................................................................................................. 4
3 Technical data ........................................................................................................................................... 6
3.1 Protection class .......................................................................................................................................................... 6
3.2 Ambient conditions................................................................................................................................................... 6
3.3 Mechanical data ........................................................................................................................................................ 6
3.3.1 Vibration 6
3.3.2 Chemical requirements 6
3.4 Electrical data ............................................................................................................................................................. 6
3.5 Exhaust-gas temperature measurement ...................................................................................................... 7
3.6 High-voltage measurement ................................................................................................................................. 7
3.7 First-generation SAFI connections and displays ........................................................................................ 7
3.8 Connections and displays from SAFI 2 ............................................................................................................ 9
3.8.1 Terminal designations 10
3.8.2 Displays on the device 12
3.9 Firmware ..................................................................................................................................................................... 12
4 Components............................................................................................................................................. 14
4.1 Installation of the sensors ................................................................................................................................... 14
4.1.1 Knock sensors 14
4.1.2 Thermocouples 14
4.2 Identifying the cylinder arrangement in the engine ............................................................................... 15
5 Pickup signals .......................................................................................................................................... 16
5.1 Camshafts/reset signal......................................................................................................................................... 16
5.2 Flywheel signal (trigger signal) .......................................................................................................................... 16
6 Implementation in the engine control system .................................................................................. 17
6.1 Parameter manager .............................................................................................................................................. 17
6.2 Alarm accompanying values ............................................................................................................................. 18
7 Functions .................................................................................................................................................. 19
7.1 General function ...................................................................................................................................................... 19
7.1.1 Description of general functions 19
7.1.2 Parameter setting 20
7.1.3 Displays 22
7.1.4 Trend display 22
7.1.5 Operating notifications: 22
7.1.6 Warnings 23
7.1.7 Error messages 24
7.2 KLS function ............................................................................................................................................................... 26
7.2.1 Description of the function 26
7.2.2 Parameter setting 26
7.2.3 Displays 28
7.2.4 Trend display 28
7.2.5 Operating notification 28
7.2.6 Warnings 29
7.2.7 Error messages 29
7.3 DMR function ............................................................................................................................................................ 30
7.3.1 Description of the function 30
7.3.2 Parameter setting 30
7.3.3 Displays 30
7.3.4 Trend display 31
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 1/52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

7.3.5 Operational messages: 33

7.3.6 Warnings 34
7.3.7 Error messages 34
7.4 Port Injection function........................................................................................................................................... 35
7.4.1 Description of the function 35
7.4.2 Parameter setting 35
7.4.3 Displays 36
7.4.4 Trend display 36
7.4.5 Operational messages: 38
7.4.6 Warnings 39
7.4.7 Error messages 39
7.5 Ignition function ....................................................................................................................................................... 40
7.5.1 Description of the function 40
7.5.2 Parameter setting 40
7.5.3 Displays 42
7.5.4 Trend display 42
7.5.5 Operating notification 42
7.5.6 Warnings 43
7.5.7 Error messages 44
7.6 Ignition voltage measurement function ....................................................................................................... 45
7.6.1 Description of the function 45
7.6.2 Displays 45
7.6.3 Trend display 45
7.6.4 Parameter setting 45
7.6.5 Operating notification 47
7.6.6 Warnings 47
7.6.7 Error messages 48
7.7 Exhaust gas temperature measurement function .................................................................................. 49
7.8 Speed measurement function........................................................................................................................... 50
7.8.1 Description of the function 50
7.8.2 Displays 50
7.8.3 Operating notification 50
7.8.4 Warnings 50
7.8.5 Error messages 50
8 Appendix 1: Engine Restart after trip „Knocking Failure A3339“ as a result of mechanical
causes ....................................................................................................................................................... 51

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 2 / 52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

1 Safety information

ATTENTION
Please observe the safety and hazard signs in the safety instructions
(TI 2300-0005) and wear the appropriate personal protective equipment.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 3/52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

2 Description of the concept

SAFI is fitted between two cylinders and performs a variety of measuring and monitoring functions depending
on hardware design and software configuration, and controls and monitors the ignition system for both
cylinders. SAFI stands for Sensor Actor Function Interface SAFI is a further development of the KLS98, with a
substantially increased range of functions.
The following functionalities are included in SAFI:
▪ KLS: knock detection and valve-noise control limit
▪ DMR: combustion analysis (knocking, misfires, etc.) by measuring the combustion pressure curve
▪ Port Injection: controlling and monitoring the cylinder-specific injection into the inlet manifold Port Injection
▪ Ignition: activation and control of the MORIS ignition system
▪ Ignition voltage measurement: ignition voltage requirement of the spark plugs
▪ Exhaust-gas temperature measurement
▪ Speed measurement

2.1 Parts/design
The designation SAFI is used in general in this document for the first-generation SAFI, and SAFI 2 for the further
development. Where a description refers exclusively to the first-generation SAFI or to SAFI 2, this will be stated
in the description.
SAFI (1st generation) SAFI 2
SAFI with KLS function 411880 652092
1200176
SAI with DMR function 665426 652439
435624 652438
Thermocouple

2.2 Basic function

SAFI boots up when the power supply is connected, after which all the parameters in SAFI are deleted and
must be sent by the engine control system. The individual functions can only be activated via the CAN bus.
SAFI has a digital output that sends signals to indicate that the ignition is operating and therefore ignition
signals are being emitted. If the CAN communication fails during operation, the ignition system operation can
be derived from the level of this output and appropriate responses carried out.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 4 / 52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

Sensors Sensors
Ignition Ignition
① Pick-up signals
② Ignition control system
③ Ignition feedback
Voltage supply
Cylinder coding
④ MORIS
Safety circuit
⑤ CAN
⑥ Analogue signals

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 5/52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

3 Technical data

3.1 Protection class

When fitted, SAFI achieves protection class IP54.

3.2 Ambient conditions

Temperature limits Storage -25 ... + 70 ℃
In operation -25 ... + 85 °C
Rel. humidity Storage 90 %, no dew
In operation 85 %, no dew
Air pressure up to 2,000 m above sea level

3.3 Mechanical data

3.3.1 Vibration
SAFI must be protected from engine vibration when fitted. The supports designed for MORIS should be used.
SAFI is designed for vibration loads to an effective value of max. 20 mm/s at 10-300 Hz.

3.3.2 Chemical requirements

SAFI has been developed to meet the specific GE Jenbacher requirements for chemical resistance to the
antifreeze (glycol) in the engine cooling water, sulphurous acid, engine oil and UV radiation.
In general, the following limit levels for atmospheric pollution apply:
● Sulphur dioxide (SO2) 0.030 ppm
● Hydrogen sulphide (H2S) 0.010 ppm
● Oxides of nitrogen (NOx) 0.030 ppm
● Chlorine (Cl2) 0.010 ppm
● Hydrogen fluoride (HF) 0.010 ppm
● Ammonia (NH2) 0.500 ppm
● Ozone (O3) 0.005 ppm
If pollution levels are higher, they must be approved separately by GE Jenbacher.

3.4 Electrical data

Voltage supply
SAFI is powered by a battery with a nominal voltage of 24 V. The battery voltage may fluctuate in a range from
15 V to 32 V ± 10% residual ripple.

Power consumption
The maximum power consumption of a first-generation SAFI is 175 mA.
The maximum power consumption of a SAFI2 is 130 mA.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 6 / 52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

3.5 Exhaust-gas temperature measurement

The exhaust gas temperature of each cylinder is measured by SAFI using type K NiCrNi thermocouples, for
which SAFI is provided with cold junction compensation. The measurement accuracy corresponds to Class 2 for
type K thermocouples as specified in EN 60584-2.
Temperature range: Tolerance
0 °C to 333 °C ±2.5 K
333 °C to 900 °C ± 0.75%

Brief additional deviations of ± 5 K will occur in the event of rapid changes in SAFI's ambient temperature.

3.6 High-voltage measurement

High-voltage is measured over the entire range from 0 kV to 50 kV to an accuracy of ± 1 kV.

3.7 First-generation SAFI connections and displays

① LEDs ③ Knock sensors

② Exhaust gas thermocouples

Terminal allocations
Sub D connector plug
PIN Designation Meaning
1 HV 2 High-voltage measurement signal from right ignition coil
2 HV 1 High-voltage measurement signal from left ignition coil
3 POWER Ignition current setpoint for left and right ignition end stage
4 IP 1 Trigger signal for the left ignition end stage
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 7/52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

PIN Designation Meaning

5 CODE 4 Third bit of SAFI code for position sensing
6 CODE 1 First bit of SAFI code for position sensing
7 CODE 2 Second bit of SAFI code for position sensing
8 CAN low CAN low
9 CAN high CAN high
10 OFF Emergency shutdown
11 CAM Signal from the camshaft pickup
12 GND Ground/earth
13 +24 V Power supply for SAFI
14 GND Ground/earth
15 GND Ground/earth
16 ZZP2 Trigger signal for the right ignition end stage
17 RM1 Feedback from the left ignition output stage
18 GND Ground/earth
19 CODE 8 Fourth bit of SAFI code for position sensing
20 RM2 Feedback from the right ignition output stage
21 CAN-GND CAN-GND
22 n.c. Unallocated
23 TRIGGER Signal from ring gear
24 GND Ground/earth
25 n.c. Unallocated

Exhaust gas thermocouples

Number Designat Meaning
ion
1 + + thermocouple connection
2 GND Connection for shielding
3 - - connection for thermocouple

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 8 / 52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

3.8 Connections and displays from SAFI 2

① Exhaust gas thermocouples ③ LEADs

② Knock sensors

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 9/52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

3.8.1 Terminal designations

Sub D connector plug
PIN Designation Meaning
1 HS R High-voltage measurement signal from right ignition coil
2 HS L High-voltage measurement signal from left ignition coil
3 POWER Ignition current setpoint for left and right ignition end stage
4 ZZP L (IP L) Trigger signal for the left ignition end stage
5 CODE 4 Third bit of SAFI code for position sensing
6 CODE 1 First bit of SAFI code for position sensing
7 CODE 2 Second bit of SAFI code for position sensing
8 CAN low CAN low
9 CAN high CAN high
10 SC Emergency shutdown
11 CAM Signal from the camshaft pickup
12 GND Ground/earth
13 +24 V Power supply for SAFI
14 PI R Trigger signal for the right Port Injection driver output stage
15 PCI R Trigger signal for the right prechamber gas valve driver output stage
16 ZZP R (IP R) Trigger signal for the right ignition end stage
17 RM1 Feedback from the left ignition output stage
18 PCI L Trigger signal for the left prechamber gas valve driver output stage
19 CODE 8 Fourth bit of SAFI code for position sensing
20 RM2 Feedback from the right ignition output stage
21 CAN-GND CAN-GND
22 PI RM R Feedback for the right Port Injection and prechamber gas valve driver output stage
23 TRIGGER Signal from ring gear
24 PI RM L Feedback for the left Port Injection and prechamber gas valve driver output stage
25 PI L Trigger signal for the left Port Injection driver output stage

Exhaust gas thermocouples, knock sensors and cylinder pressure sensors

On the SAFI2 the exhaust gas thermocouples, knock sensors and cylinder pressure sensors are connected
directly inside the housing. To do this, undo the 5 connection screws and remove the cover to reveal the
connector.
To connect the sensors, remove the 12-pole connector block from the socket with pointed pliers. Push the
connector, with the sensors connected to it, into the socket and fit the strain reliever. Make sure that the gasket
is correctly fitted to ensure the sealing effect.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 10 / 52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

① Connector block for the sensors ⑤ Left cylinder exhaust gas thermocouple
② Strain reliever ⑥ Right cylinder knock sensor
③ Seal ⑦ Right cylinder exhaust gas thermocouple
④ Left cylinder knock sensor
On the SAFI2 with the KLS function (part number 652092), connect the knock sensors, and on the SAFI2 with the
DMR function (part number 652439), connect the connection cable for the pressure sensors.

Terminal designation for the SAFI2 with the KLS function

PIN Designation colour Meaning
1 Piezo / Pressure L+ Yellow + input to left cylinder knock sensor
2 Piezo / Pressure L - Black - input to left cylinder knock sensor
3 +24V L not used
4 GND not used
5 TC L+ Green + input to left cylinder exhaust gas thermocouple
6 TC L- White - input to left cylinder exhaust gas thermocouple
7 Piezo / Pressure L+ Yellow + input to right cylinder knock sensor
8 Piezo / Pressure L - Black - input to right cylinder knock sensor
9 +24V L not used
10 GND not used
11 TC L+ Green + input to right cylinder exhaust gas thermocouple
12 TC L- White - input to right cylinder exhaust gas thermocouple

Terminal designation for the SAFI2 with DMR function

PIN Designation colour Meaning
1 Piezo / Pressure L+ Blue + input to left cylinder pressure sensor
2 Piezo / Pressure L - Black - input to left cylinder pressure sensor
3 +24V L White 24 V power supply to left cylinder pressure sensor
4 GND - Jumper to pin 2
5 TC L+ Green + input to left cylinder exhaust gas thermocouple
6 TC L- White - input to left cylinder exhaust gas thermocouple
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 11/52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

PIN Designation colour Meaning

7 Piezo / Pressure L+ Blue + input to right cylinder pressure sensor
8 Piezo / Pressure L - Black - input to right cylinder pressure sensor
9 +24V L White 24 V power supply to right cylinder pressure
sensor
10 GND - not used
11 TC L+ Green + input to right cylinder exhaust gas thermocouple
12 TC L- White - input to right cylinder exhaust gas thermocouple

Shielding for the thermocouples and cylinder pressure sensors is not included in SAFI2, as the sensors
themselves are already earthed.

3.8.2 Displays on the device

The device has five LED displays, of which the "STATUS" LED is in three colours.
Designation Colour Meaning
POWER Green Power supply
STATUS Green Ignition or ignition self-test / port injection or port injection self-test
Red Error
Yellow Booting up
CAM Yellow Synthetic camshaft/reset pulse
TRIGGER Yellow Trigger pulse
CAN Yellow CAN bus activity

3.9 Firmware
SAFI is operated using firmware version 7.xx. Firmware versions with the same figure before the decimal point
are compatible, making it possible to operate an engine with different firmware versions of SAFI.
Reserved firmware numbers:
Reserved firmware range First version
SAFI (1st generation) 7.00 - 7.40
SAFI DMR (2nd generation) 7.40 - 7.59 7.44
SAFI KLS (2nd generation) 7.60 – 7.99 7.64
SAFI1 DMR 7.53
SAFI KLS filter version 1.00 - 1.99 1.01
SAFI DMR filter version 2.00 - 2.99 2.01

The numerals before the decimal point indicate the functional scope, the numerals after the decimal point
indicate the firmware version.
Higher numerals after the decimal point represent improved versions without any increase in
functionality.
If the code does not match the above-mentioned engine positions or if a firmware problem arises, on the first-
generation SAFI the CAM and TRIGGER LEDs will flash alternately after the boot-up, and on SAFI2 the STATUS
LED will light up red.
If firmware problems arise, download the firmware again or replace SAFI.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 12 / 52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

Firmware update
You can update the firmware via DIA.NE XT. The need for a firmware update and the exact procedure must be
discussed with the Competence Centre in Jenbach.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 13/52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

4 Components
First-generation SAFIs are supplied with one M6 x 30 and M6 x 35 hexagonal socket head screw and one
gasket.
The SAFI2 is supplied with two M6 x 35 hexagonal socket head screws and one gasket.
The bolts must be tightened to 3.4 Nm.

① Exhaust gas thermocouples ③ Seal

② Knock sensors

4.1 Installation of the sensors

4.1.1 Knock sensors

Each of the two knock sensors is fastened by a mounting bolt (M8x25) to the adapter nut on the rear cylinder
head bolts of the neighbouring cylinder heads, without crossing cables, using a tightening torque of 20 Nm.
Ensure that the surface is even and clean. Filler rings are not permitted. Tighten the adapter nuts to the cylinder
head bolts using a 60 Nm tightening torque.

4.1.2 Thermocouples
Tighten the thermocouple sleeves to a torque of 30 Nm. The exhaust gas thermocouples must be tightened to
the first-generation SAFIs by hand and to the engine block with a torque of 15 Nm. Connect the thermocouple
for the left cylinder to the left-hand connector and the thermocouple for the right cylinder to the right-hand
connector.
The exhaust gas thermocouples are connected to the SAFI2 by the connector block and tightened on the
engine block with a torque of 15 Nm.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 14 / 52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

4.2 Identifying the cylinder arrangement in the engine

The SAFIs boot up when the power supply is connected. During the boot-up SAFI detects the installation
position on the engine by means of a code in the MORIS rail. This is displayed visually by the number of times
the CAN LED flashes as shown in the table below. The STATUS LED flashes orange.
SAFI installed between LED CAN flashes
Cylinders 1 and 2 once
Cylinders 3 and 4 twice
Cylinders 5 and 6 3 times
cylinders 7 and 8 4 times
cylinders 9 and 10 5 times
cylinders 11 and 12 6 times
cylinders 13 and 14 7 times
cylinders 15 and 16 8 times
cylinders 17 and 18 9 times
cylinders 19 and 20 10 times
cylinders 21 and 22 11 times
cylinders 23 and 24 12 times

If an engine position is duplicated in the event of an engine fault, the incorrect position will be highlighted on
the DIA.NE system by the message "SAFI CAN communication error". The duplicate must be found by checking
all the positions by connecting and disconnecting each individual device.
If the code does not match the above-mentioned engine positions or if a firmware problem arises, on the first-
generation SAFI the CAM and TRIGGER LEDs will flash alternately after the boot-up, and on SAFI2 the STATUS
LED will light up red.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 15/52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

5 Pickup signals
SAFI requires two digital signals to detect the engine running conditions. The three analogue pickup signals are
converted to two digital signals by the SPA24.

NOTICE
The settings for the pickup signals are documented in TI 1502-0072 – SPA24.

5.1 Camshafts/reset signal

The camshafts/reset signal is a synthetic signal generated by the SPA24 from the signal from the camshaft
pickup and the reset signal from the crankshaft.
A significant factor for calculating the crankshaft position is the negative edge of this digital signal, which
matches the crossover of the analogue reset signal. The position of this edge is set relative to the top dead
centre of the first cylinder in the parameter manager and, as is usual in ignition systems, positive values
indicate the range before the top dead centre and negative values the range after the top dead centre of the
cylinder.
The negative edge of the input is indicated visually by the CAM LED on SAFI lighting up briefly.

Adjusting the reset position

GE Jenbacher engines normally have a reset position in the range 45 – 95 °CA before top dead centre. The
exact position of this signal must be communicated to SAFI via the parameter reset position in the SAFI
parameter list. The possible adjustment range is from -360 °CA to 360 °CA
When the engine is started for the first time or conversions are made that alter the position of the reset pickup,
an ignition timing strobe must be used to compare the ignition point on the engine with the ignition point value
on the engine control system. If the value displayed does not match the actual value on the flywheel, the
engine must be shut down, the value for the reset signal corrected and the ignition point rechecked.

NOTICE
The engine must not be switched to operation under load until the ignition point has been
checked!

5.2 Flywheel signal (trigger signal)

SAFIs require between 50 and 500 impulses per rotation (trigger signal) to be able to calculate the speed and
the exact angle position of the cylinders.
The positive edge of the input is visualised by the TRIGGER LED on SAFI lighting up briefly.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 16 / 52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

6 Implementation in the engine control system

Depending on the function, many shutdowns and warnings are assigned an operating notification containing
information on the cylinder or SAFI. Once a shutdown has occurred or a warning has appeared, the assigned
operational messages are entered one after the other in time intervals of a few seconds.
Only the operational message from the last cylinder is listed in the current alarm management system. The
operating notifications from all the cylinders can be viewed in the alarm history.

6.1 Parameter manager

SAFI affects the following parameter lists:

SAFI:
▪ Function activation
▪ Reset position
▪ Ignition point monitoring

Exhaust gas:
▪ Activation of the monitoring system
▪ Limit values

Engine Data:
▪ SAFI activation

Ignition voltage measurement:

▪ Activation of the monitoring system
▪ Limit values

Anti-knock:
▪ Knock controller activation and setting
▪ Knock detection setting
▪ Valve noise detection setting
▪ Mechanical noise setting
▪ Individual cylinder enable
▪ General ignition point adjustment

Ignition
▪ Activation of the misfire control system
▪ Overspeed limit value
▪ Ignition point limit values
▪ MORIS energy setting
▪ MORIS output monitoring
▪ MORIS coil type
▪ MORIS power supply unit output

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 17/52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

6.2 Alarm accompanying values

In all cylinder-specific error messages and warnings the cylinders concerned are displayed in an additional
operating notification, which are designated as an alarm accompanying value.
The current alarm list displays the error message or warning and, in addition, an operating notification. In the
historic alarm list, all the cylinders concerned are each displayed in their own operating notification. In the
DIA.NE XT system the cylinder number appears next to the operating notification and in the DIA.NE WIN system
the cylinder number is displayed by double-clicking the relevant operating notification.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 18 / 52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

7 Functions

7.1 General function

7.1.1 Description of general functions

Any functionalities which are required to operate and monitor SAFIs, irrespective of the assigned task, are
described as general functions.

7.1.1.1 Pickup monitoring

SAFI generates the current position of the crankshaft and camshaft from the pickup signals to an accuracy of
0.1 °CA In order to avoid incorrect positions being detected by incorrect pickup signals, these signals are
monitored
▪ for the presence of the trigger and the synthetic camshaft/reset signal
▪ to count the number of teeth between two synthetic camshafts/reset pulses
▪ to ascertain the time from one tooth to the next in order to detect missing teeth and interference signals.

To make troubleshooting easier when a pickup error occurs, the number of teeth detected between the last
synthetic camshafts/reset pulse and the defective pickup pulse is displayed SAFI System screen. Make sure that
the value displayed relates to the crankshaft which is rotated twice per engine cycle.
You can find the defective tooth by counting the teeth on the ring gear, starting with the reset.
Interference pulses from the ignition system can also cause the false detection of pickup signals as a result of
faults in the high-voltage circuit. The crankshaft angle position relative to top dead centre of the first cylinder
can be calculated using the formula below and the firing order of the engine concerned.
360° CA
(Number of teeth on failure x —————————— - Reset Position )
number of teeth on
engine

7.1.1.2 Hardware monitoring

If the attached hardware does not support the selected function or the device has an internal malfunction, this
error will be displayed.

7.1.1.3 CAN communication

All SAFIs must be communicating with the control system before the engine is started. Failure of CAN
communication will generate an alarm message after 25 seconds and the engine will be shut down.
SAFI monitors the signals on the CAN bus. The warning "High CAN error rate" is available to identify CAN bus
problems at an early stage. This message indicates an above-average number of defective protocols on the
CAN bus.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 19/52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

NOTICE
Although SAFI detects defective protocols, the cause of these defective protocols may also rest
with other participants!

7.1.1.4 Software monitoring

The current software status of the individual devices is displayed on the System - SAFI screen.
An alarm message is generated if the software on at least one SAFI is not compatible with the software in the
engine control system.
If SAFIs are connected to an engine with a different software version, this is indicated by a warning. Although
different but compatible software versions can be run together on the engine, we recommend that you update
to the same software version. Consult GE Jenbacher to decide which software is to be updated.

7.1.1.5 Monitoring the temperature of the electronics

SAFI measures the internal temperature of the electronics which may exceed the temperature of the housing
by up to 10 K. If the internal temperature exceeds 95°C, this means that the maximum permissible ambient
temperature is exceeded and a warning is generated.

NOTICE
If the maximum ambient temperature is exceeded, this will cause the SAFI to fail during
prolonged operation, which is a situation that should therefore be avoided!

The current temperatures of the electronics of all the cylinders are displayed on the System – SAFI screen and
recorded in a long-term trend.

7.1.1.6 Parameter monitoring

Irrespective of the functionality set, SAFI detects the presence of plausible parameters. A trip alarm is
generated if parameters are not plausible or fall outside the value range, or if the parameters have not yet
been transmitted.
If parameters on the SAFI parameter list are changed while the engine is running, the new value is not
accepted in order to protect the engine. The user is alerted by the SAFI warning "Setting parameters during
operation prohibited" to the fact that the change has not been effected. The new value will not become active
until the next engine start-up.

7.1.2 Parameter setting

7.1.2.1 Engine data parameter list

SAFI

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 20 / 52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

Use this parameter to activate the SAFI option. When you activate it, the SAFI parameter list and the System –
System data – SAFI screen are displayed.
Default value: On

7.1.2.2 SAFI parameter list

Ignition
Choose the ignition option to activate SAFI as an ignition control system combined with an ignition output
stage.
Default value: On

Ignition voltage
Choose the ignition voltage measurement option to activate SAFI as an ignition voltage measurement system
and the SAFI ignition voltage parameter list is displayed.
Default value: On

Exhaust gas temperature

Choose the exhaust gas measurement option to activate SAFI as an instrument for measuring the exhaust gas
temperature.
Default value: On

Knock
Choose this option to activate SAFI as a knock detection system. This option requires SAFI to be used with
knock sensors.
Default value: On

OCA
The OCA function (optical misfiring detection) is not enabled for SAFI.
Default value: Out

Reset position
Set this parameter on the engine as described in TI 1502-0072 – SPA24.
Default value: 50.0 °CA
J624 default value: 48.5 °CA

Check ignition point tolerance

Where this parameter has been activated, SAFI measures the difference in the ignition point between SAFI and
the ignition system. As SAFI controls the ignition in its current configuration, this parameter is currently
disabled.
Default value: Out

Ignition point tolerance

This parameter indicates the tolerance for the deviation of the ignition point of the ignition system from SAFI. As
SAFI controls the ignition in its current configuration, this parameter is currently disabled.
Default value: 50.0 °CA

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 21/52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

7.1.3 Displays
The SAFI screen in System visualises the system data for all SAFIs.
The system data consists of:
▪ Hardware version
The hardware version contains information on the version (numeral before the decimal point) and the type of
hardware (numerals after the decimal point). The numeral before the decimal point is incremented on each
redesign. The figure after the decimal point indicates the different SAFI versions equipped with the KLS or DMR
functions.
The table below shows the allocation of the numerals after the decimal point to the component assembly.
Hardware version Component assembly
x.064 SAFI with the KLS function and thermocouple sensors
x.192 SAFI with the DMR function and thermocouple sensors
x.080 SAFI with the KLS function, thermocouple sensors and PI control *)
x.208 SAFI with the DMR function, thermocouple sensors and PI control *)
*) PI control is required for the J920 engine
If the parameter setting activates a function that SAFI does not support, the alarm message "SAFI hardware
error" is displayed.
▪ Firmware version
▪ Op hrs
▪ serial number
▪ Production date
▪ Temperature of electronics
▪ Tooth error
To make troubleshooting easier when a pickup error occurs, the number of teeth detected between the last
synthetic camshafts/reset pulse and the defective pickup pulse is displayed.
▪ Filter version
The filter version is the version of the filter implemented in the firmware for the Piezo sensors.

7.1.4 Trend display

The temperatures of the electronics are recorded in the SAFI long-term trend over 12 months with a resolution
of 0.5 h.

7.1.5 Operating notifications:

Message Message Quality Form Description
number
B3270 SAFI hardware error at Display of cylinder position of SAFI with hardware error
cylinder
B3271 SAFI CAN communication Display of cylinder position of SAFI without CAN communication
failure at cylinder
B3272 SAFI wrong software at Display of cylinder position of SAFI with incompatible software
cylinder
B3273 SAFI parameter error at Display of cylinder position of SAFI with parameter error
cylinder

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 22 / 52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

Message Message Quality Form Description

number
B3276 SAFI trigger pickup cylinder Display of cylinder position of SAFI with trigger pickup failure
failure
B3277 SAFI camshaft/reset pickup Display of cylinder position of SAFI with camshaft/reset pickup
cylinder failure failure
B3284 SAFI software versions not Display of cylinder position of SAFI with different software
identical at cylinder version. At least two SAFIs are always displayed as the engine
control system cannot decide which is the correct one.
B3291 SAFI setting parameters Display of cylinder position of SAFI for which parameter setting is
during operation prohibited prohibited.
for cylinder
B3292 SAFI CAN error rate too high Display of cylinder position of SAFI with excessive CAN error rate
at cylinder
B3293 SAFI electronics temperature Display of the SAFI cylinder position with excessive electronics
too high at cylinder temperature

7.1.6 Warnings
Message Message Description/Solution
number
W3531 SAFI CAN error rate too high The message is displayed when an above-average number of
error frames has been recorded on the CAN bus. Error frames
are failed communication attempts which must be repeated,
thereby increasing the utilisation of the CAN bus.
As analysis of error rates is not included in each device in the
CAN bus circuit, it is possible that the error frames are also
being produced by another device.
Error frames are caused by electromagnetic disturbances,
defective cabling (e.g. cable too long, wrong cable, poor
terminators, bypasses) or a faulty device.
Detailed information on the CAN bus and troubleshooting can be
obtained from TI 1531-0012 "CAN bus on the GE Jenbacher
engine".
W3533 SAFI software versions not The software statuses of the individual SAFIs are not identical
identical but they are compatible.
Updating to identical software statuses is recommended.
Consult GE Jenbacher node:1801439856539610710081007 to
decide which software is to be updated.
W3535 SAFI parameter setting during If parameters on the SAFI parameter list are changed while the
engine operation prohibited engine is running, the new value is not accepted in order to
protect the engine. This warning alerts the user to the fact that
the change has not been effected.
The engine must be shut down. The changes will take effect the
next time the engine is started.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 23/52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

Message Message Description/Solution

number
W3539 SAFI electronics temperature If the housing and therefore the ambient temperature exceeds
too high 85 °C, this means that the maximum permissible ambient
temperature is exceeded and this warning is generated.
The internal temperatures of all SAFI devices are listed on the
System – SAFI screen. On the SAFI 1 the warning is output at an
electronics temperature of 86 °C. On the SAFI 2, the warning is
output at a temperature of 102 °C due to the higher temperature
generated by the electronics.
If the ambient temperature reaches 95 °C, the SAFI is switched
off with a SAFI hardware error and the safety loop is opened.
Where the temperature of the electronics in one SAFI is too high,
check the area around the SAFI for any heat sources (leaky
exhaust gas lines, turbocharger, etc.) and rectify the cause of the
problem.
Where electronics temperatures in the engine as a whole are
found to be high or excessive, optimise the ventilation system or
provide additional ventilation for SAFI.

7.1.7 Error messages

Message Message Description/Solution
number
A3330 SAFI hardware error The hardware is either incompatible with the parameters set for
the engine control system or defective.
Compare the parameters on the SAFI parameter list with the
devices actually installed.
If the parameters are OK, replace the device.
A3331 SAFI CAN communication This error message is generated when there has been no
failure communication with one or more SAFIs for more than 25 seconds.
The cause may be a faulty device, faulty CAN bus cabling or a
power failure to the SAFI.
Detailed information on the CAN bus and troubleshooting can be
obtained from TI 1531-0012 CAN bus on the GE Jenbacher node:
1801439856539610710081007.
A3332 SAFI wrong software The software versions in the engine control system and SAFI are
not compatible.
If the hardware is compatible (see Hardware error), compatibility
can be restored by updating the SAFI software or the engine
control software.
A3333 SAFI parameter error A parameter error is generated if parameters are not plausible or
outside the value range, or if the parameters have not yet been
transmitted.
Check all SAFI parameters.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 24 / 52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

Message Message Description/Solution

number
A3336 SAFI trigger pickup failure A problem with the trigger signal has been detected.
Adjust the pickups as described in TI 1502-0072 – SPA24.
A TRIGGER LED on each SAFI and SPA24 flashes when a pickup
signal is detected. These displays are helpful for checking whether
a signal has failed in the event of an error.
A3337 SAFI camshaft/reset pickup A problem with the synthetic camshaft/reset signal has been
failure detected.
Adjust the pickups as described in TI 1502-0072 – SPA24.
A CAM LED on each SAFI and SPA24 flashes when a pickup signal
is detected. These displays are helpful for checking whether a
signal has failed in the event of an error.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 25/52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

7.2 KLS function

7.2.1 Description of the function

The information on knock and valve noise generated by the Piezo sensors is described as the KLS function.
The KLS function is based on the proven principle of the KLS98 and the parameter names used are the same as
for the KLS98. However, the limit levels may differ if there is a different frequency response in the input circuit.
The KLS function consists of the windowing of the engine cycle into different measurement ranges in which on
the one hand combustion noise is evaluated for knock noise and on the other hand mechanical noise is
evaluated for defects in the valve operating mechanism.

Differences from the KLS98

If a higher-quality digital signal processor is used, the valve noise will be higher with SAFI than with the KLS98.
This is because SAFI has a more linear frequency curve than KLS98 and therefore displays the high frequencies
of valve noise. This property is taken into account when determining the limit levels.
At lower frequencies of knock noise the differences are negligible, with the knock noise on SAFI corresponding
to the knock noise measured on the KLS98.

7.2.2 Parameter setting

General knock parameters

All the parameters have been saved in the Antiknock – KLS98/SAFI parameter list.

KLS98 Reset pulse position

This position of the reset pulse is only used with KLS98, while the position of the reset pulse in the SAFI
parameter list is set for SAFI.
Default value for type 4 engines: -123 °CA
Default value for type 6 engines: -144 °CA

Angle window at start of knock noise

This parameter indicates the beginning of the combustion analysis relative to the top dead centre of the
cylinder concerned.
Default value: 0 °CA

Angle window width of knock noise

This parameter indicates the duration of the combustion analysis starting with the "Angle window at start of
knock noise" parameter.
Default value for type 4 engines: 50 °CA
Default value for type 6 engines: 45 °CA

Angle window at start of valve noise

This parameter indicates the beginning of the valve noise analysis relative to the top dead centre of the
cylinder concerned.
The parameter must be selected so that there is no overlap with the angle window for the knock noise relative
to the combustion cycle.
Default value for type 4 engines: 70 °CA
Default value for type 6 engines: 60 °CA

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 26 / 52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

Angle window width of valve noise

This parameter indicates the duration of the mechanical noise analysis starting with the "Angle window at start
of valve noise" parameter.
The parameter must be selected so that there is no overlap with the angle window for the knock noise relative
to the combustion cycle.
Default value for type 4 engines: 630 °CA
Default value for type 6 engines: 660 °CA

Angle window at start of mechanical noise

This parameter is provided to split the valve noise into separate systems for monitoring the inlet and exhaust
valves. The function is not active.
Default value for type 4 engines: 80 °CA
Default value for type 6 engines: 50 °CA

Angle window width of mechanical noise

Limit level for measurement signal failure

When the engine is running at half-load or more, all the measured values for valve noise must have exceeded
this value, otherwise the measurement signal from SAFI will not be recorded correctly.
Default value for type 4 engines: 50 mV
Default value for type 6 engines: 30 mV

Filter function for knocking

This parameter is used to select the digital filter function for the knock signals.
Default value for type 4 engines: 1
Default value for type 6 engines: 4

Limit level for knocking

The parameter indicates the level from which combustion is considered knocking combustion. The engine
control system optimises the engine control on the basis of this limit level, and generates a shutdown if there is
danger of damage to the engine.
Default value for type 4 engines: 1,200 mV
Default value for type 6 engines: 500 mV

Limit level for valve noise

The limit level indicates the maximum permissible valve noise during operation. If this limit is exceeded, this
means that there is a defect and the engine shuts down.
Default value for type 4 engines: 10,000 mV
Default value for type 6 engines: 8,000 mV

Limit level for mechanical noise

This limit level is provided to split the valve noise. This function is not active.
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 27/52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

Default value: 8,000 mV

General ignition point adjustment

If general active ignition point adjustment is enabled, the entire engine has is set to the same ignition point. The
cylinder with the latest ignition point determines the ignition point for the engine as a whole.
Default value: Out

Options for releasing cylinders 1-24

These parameters are used to set the release of each cylinder monitor individually. You can choose from the
following settings:
▪ 0 – Piezo off: The KLS functions are deactivated.
▪ 1 – Piezo on: The KLS functions are activated.
Default value: 1 up to the number of cylinders on the engine / 0 for cylinders above the number of cylinders.

NOTICE
If the Piezo function is disabled, the knock and valve noise monitor for this cylinder is inactive,
although the measured values are displayed!

7.2.3 Displays
The values for combustion noise output measured by SAFI are displayed on the Engine controller – Antiknock –
Knock noise screen and the knock intensities calculated by the engine control system from the measured
values are displayed on the Engine controller – Antiknock – Knock intensity screen.
The measured values for mechanical noise generated by SAFI are displayed in the Details – Valve noise screen.

7.2.4 Trend display

In the "knocking intensities" and "knocking intensities at trips" trends, the knocking intensities are recorded in a
short-term trend over 1 hour with a resolution of 1 second.

7.2.5 Operating notification

Message Message Quality Form Description
number
B3279 Knock failure at cylinder Display of cylinder position of SAFI with knocking
B3281 Maximum valve noise at Display of cylinder position of SAFI with shutdown due to
cylinder excessive valve noise
B3282 Knock sensor measurement Display of cylinder position of SAFI with measurement signal
signal failure at cylinder failure

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 28 / 52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

7.2.6 Warnings
Message Message Description
number
W3541 Measurement signal failure Once engine half load has been exceeded, a check is carried out
Knock sensor to ascertain whether the measured values for valve noise have
exceeded the value parameterised for measurement signal
failure. This message is generated if the value is not exceeded
within 3 seconds.
The Piezo sensor has not been installed correctly or the device is
defective (e.g. break in sensor cable).

7.2.7 Error messages

Message Message Description
number
A3339 Knocking failure The engine control system detects a dangerous condition for the
engine due to knock noise or mechanical issues. A shut down
prevents mechanical damage due to knocking combustion.
This is a complex shut down and may be caused by mechanical
damage, poor mixture composition, auto-ignition, misfires or
ignition problems.
Whenever this trip occurs, the cause of the trip must be
investigated and remedied first before the engine is restarted
again. Please respect additional information in Appendix 1 of
this document.
A3341 Maximum valve noise The limit level for valve noise has been exceeded. Usually, this
shut down points to a mechanical problem in the cylinder head
(valves, bearings, etc.).
Whenever this trip occurs, the cause of the trip must be
investigated and remedied first before the engine is restarted
again. Please respect additional information in Appendix 1 of
this document.
If the root cause is not clear inspect all cylinders with a bore
scope.
A3342 Measurement signal failure Once engine half load has been exceeded, a check is carried out
Knock sensor to ascertain whether the measured values for valve noise have
exceeded the value parameterised for measurement signal
failure. This message is generated if the value is not exceeded in
more than 50% of the installed devices within 3 seconds.
The Piezo sensor has not been installed correctly or the device is
defective (e.g. break in sensor cable).

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 29/52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

7.3 DMR function

7.3.1 Description of the function

The DMR function (pressure-based engine control system) is the term use to describe a control system based
on information generated by cylinder pressure sensors from the pressure curve.
The basis of the DMR function is the evaluation of defined areas of the pressure curve during the ignition event.
The algorithms implemented in the SAFI allow different evaluations to be carried out in parallel. The facilities
offered by the DMR function are significantly greater than the KLS function, since the pressure curve is
evaluated in each cycle and the control system can respond to variations in the pressure changes.
The DMR function currently consists of the following algorithms:
▪ knock
▪ maximum pressure
▪ auto-ignition
▪ misfiring
▪ sensor faults
▪ IMEP
▪ AI50%
Detailed information on the cylinder pressure sensors for DMR is included in the maintenance instructions IW
8058 A0.

7.3.2 Parameter setting

The DMR function is activated/deactivated in the Parameters - SAFI - DMR screen.

General DMR parameters

Start of the pressure window
The start of the window for evaluating the pressure curve is defined by a parameter.
Default value: 310 °CA
High-pressure window
The actual evaluation is performed using the values from the high-pressure window. This is fixed at a length of
100 °CA and contains 1000 values, which results in a resolution of 0.1 °CA

Limit level for knocking

General ignition point adjustment
If general ignition point adjustment is made, the entire engine is set to the same ignition point. The cylinder with
the latest ignition point determines the ignition point for the engine as a whole.
Local ignition point adjustment
In different control methods of the DMR, the ignition point is controlled selectively for individual cylinders.
Detailed information on the parameterisation can be found in the TI - Pressure-based engine control.

7.3.3 Displays
The values for combustion noise measured by SAFI are displayed in the Engine Controller - Antiknock - Knock
Noise screen.
The knock strengths calculated by SAFI from the measurements are displayed in the Engine Controller -
Antiknock - Knock Noise screen.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 30 / 52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

The ignition points given by the engine control system are displayed in the Engine Controller - Antiknock - IP
screen.
The mean effective pressures calculated by SAFI from the measurements are displayed in the Engine Controller
- Antiknock - IMEP screen.
The peak pressures calculated by SAFI from the measurements are displayed in the Engine Controller -
Antiknock - p-max screen.

7.3.4 Trend display

In the "knocking intensities" and "knocking intensities at trips" trends, the knocking intensities are recorded in a
short-term trend over 1 hour with a resolution of 1 second.
In the "Pmax" trends, the peak pressures are recorded in a short-term trend over 1 hour with a resolution of 1
second.
A long-term trend over 1 month is also stored, with a resolution of 30 seconds.
In the "IMEP" trends, the peak pressures are recorded in a short-term trend over 1 hour with a resolution of 1
second.
A long-term trend over 1 month is also stored, with a resolution of 30 seconds.
In the "Knock integrator" trends, the data from the knock integrator are recorded in a short-term trend over 1
hour with a resolution of 1 second.
In the "Al_var" trends, the values at a defined conversion point are recorded in a short-term trend over 1 hour
with a resolution of 1 second.
A long-term trend over 1 month is also stored, with a resolution of 30 seconds.
In the "PowerActUnfilt" trends, the active power is recorded in a short-term trend over 1 hour with a resolution
of 1 second.
A long-term trend over 1 month is also stored, with a resolution of 30 seconds.
In the "PressBoostUnfilt" trends, the boost pressure is recorded in a short-term trend over 1 hour with a
resolution of 1 second.
A long-term trend over 1 month is also stored, with a resolution of 30 seconds.
In the "IPCyl" trends, the controlled ignition point is recorded in a short-term trend over 1 hour with a resolution
of 1 second.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 31/52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

Display in DIA.NE WIN

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 32 / 52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

Display in DIA.NE XT3 / 3.2

7.3.5 Operational messages:

Message Message Quality Form Description
number
B3279 Knock failure at cylinder Display of cylinder position of SAFI with knocking
B2802 Measuring signal failure Display of cylinder position of SAFI with measurement
cylinder pressure sensor signal failure
B2151 DMR safety power reduction Display of cylinder position with reduction in safety power
B2146 DMR power reduction Display of cylinder position with power reduction
B2808 Maximum positive deviation Display of cylinder position with the maximum positive
from average peak cylinder deviation from the average peak cylinder pressure
pressure
B2145 Ignition point reduction by DMR Display of cylinder position with ignition point reduction due
to a DMR measurement
B2825 Maximum cylinder peak Display of cylinder position with maximum peak pressure
pressure
B2826 Maximum cylinder peak Display of cylinder position with maximum peak pressure
pressure

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 33/52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

7.3.6 Warnings
Message Message Description
number
W2577 Measurement signal failure Once engine half-load has been exceeded, a check is
Knock sensor carried out to ascertain whether the measured values for
peak pressure have exceeded the value parameterised for
measurement signal failure. This message is generated if
the value is not exceeded within 3 seconds.
The cylinder pressure sensor has not been installed
correctly or the device is defective (e.g. break in sensor
cable)
W2588 Maximum cylinder peak Once engine half-load has been exceeded, a check is
pressure carried out to ascertain whether the measured values for
the p-max signal have exceeded the value parameterised
for measurement signal failure. This message is generated
if the value does not drop back below the parameterised
value within 3 seconds.

7.3.7 Error messages

Message Message Description
number
A3339 Knocking failure The engine control system detects a dangerous condition
for the engine due to knock noise or mechanical issues.. A
shut down prevents mechanical damage due to knocking
combustion.
This is a complex shut down and may be caused by
mechanical damage, poor mixture composition, auto-
ignition, misfires or ignition problems.
Whenever this trip occurs, the cause of the trip must be
investigated and remedied first before the engine is
restarted again. Please respect additional information in
Appendix 1 of this document.
A2262 Maximum cylinder peak The engine control system detects that the parameterised
pressure maximum peak pressure has been exceeded and the
engine is in a dangerous state. A shut down prevents
mechanical damage due to incorrect combustion.
A2214 Measuring signal failure SAFI detects a measuring signal failure and generates the
cylinder pressure sensor operational and error messages described. If more than
half the cylinders in question are affected by a measuring
signal failure, the engine is shut down.
The cylinder pressure sensor has not been installed
correctly or the device is defective (e.g. break in sensor
cable).
A2274 Maximum positive deviation This check detects the maximum deviation between the
from cylinder peak pressure peak pressure signals. If a threshold is exceeded, the
engine is shut down for safety reasons.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 34 / 52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

7.4 Port Injection function

The Port Injection function consists of selective cylinder control of the gas quantity by means of solenoid valves.
Activation and monitoring of these solenoid valves, also referred to as Port Injection valves, is implemented in
SAFI2 and MORIS 2.
MORIS 2 and SAFI2 are further developments of the MORIS/SAFI system, expanded by the addition of an
activation and monitoring function for selective cylinder gas metering (Port Injection).
In the first version only the selection of the Port Injection valve was implemented in the DIANE, and the
electronic prechamber gas valve (PCI) and prechamber gas safety valve (PCS) were not supported.
A feedback signal corresponding to the actual current signal through the PI valve is evaluated by SAFI2 to
diagnose the function of the PI valve.

7.4.1 Description of the function

The diagnosis is divided into three main areas:

Open Detection
The rise in the pull-in current is evaluated. It detects whether a valve is connected (there is a current flow), and
whether the wiring is correct (no cable breakage or short-circuit).

Open Point Detection

Evaluation of the pull-in current curve shows whether and when the valve opens. Not activated in series usage.

Close Detection
Close Detection checks whether the valve has closed correctly after the normal opening sequences (gas
injection event) but before the start of ignition. A brief current signal is sent to the valve, on the basis of which
an incorrectly-open valve can be detected.
If an open valve is detected, the ignition pulse is suppressed by SAFI2 and the safety loop is opened, which
triggers a priority 1 shutdown.

7.4.2 Parameter setting

7.4.2.1 Setting the valve control parameters

The valve parameters are grouped together in specific parameter packages for each valve.
If valve type "1" is selected by the user, all values of the sub-variables are loaded under valve type 1, and if
valve type "2" is selected, all the values of the sub-variables under valve type 2 are selected. The data
structures of valve types "1" and "2" remain unchanged, and only the values change.

Contents:
Variable Value (adjustable)
Name: PI_config_file
Version x.xx
Date 23/06/2011
Valve type 1-10

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 35/52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

7.4.2.2 Setting the valve monitoring parameters

Valve closed detection

Activates/deactivates the Close Detection function
In SAFI2 Close Detection is activated by the variable "PI close detection"

Error rates for valve opening point detection

Open Point detection is deactivated if the variable "PI open point detection failure rate" is set to a value of 0.
Setting this variable to a parameter value between 1 and 10 gives different sensitivities.

Error rates for valve opening detection

The pull-in current detection, also known as open detection, is deactivated if the variable "PI open detection
failure rate" is set to a value of 0.
Setting this variable to a parameter value between 1 and 10 gives different sensitivities.

7.4.3 Displays
The values for the opening point output measured by SAFI are displayed in the Engine Controller - Port Injection
- Opening Point screen.
The values for the opening duration output measured by SAFI are displayed in the Engine Controller - Port
Injection - Opening Duration screen.
The values for the Close Detection gradient output measured by SAFI are displayed in the Engine Controller -
Port Injection - Close Detection Slope screen.
A Close Detection signal is generated cyclically on all cylinders in the self-test to check whether the PI valves
are closed. The measured values are shown in the Engine Controller - Port Injection - Close Detection Slope
screen in bar and digital form. In the self-test, the average, maximum and minimum values are shown. The
current values are average values from the last ten ignition events, and the maximum and minimum values are
the highest/lowest values which have occurred.
These displays are only visible if the function in question has been activated.

7.4.4 Trend display

No trend display is provided in the current version.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 36 / 52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

Display in DIA.NE WIN

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 37/52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

Display in DIA.NE XT3

7.4.5 Operational messages:

Message number Message Description
B2814 Maximum PI opening Shows cylinder position of SAFI with maximum
duration opening duration
B2815 Minimum PI opening Shows cylinder position of SAFI with minimum
duration opening duration
B2816 PI On Shows activation of Port Injection valves
B2817 PI Off Shows deactivation of Port Injection valves
B2818 PI fault in opening detection Shows cylinder position of SAFI with maximum
opening duration.
B2819 PI fault in opening point Shows cylinder position of SAFI with faulty opening
detection duration
B2820 PI valve failure when closing Shows cylinder position of SAFI with maximum
cylinder opening duration.
B2823 PI deactivates cylinder Shows cylinder position of SAFI with deactivated
Port Injection

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 38 / 52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

7.4.6 Warnings
Message number Message Description/Solution
W2585 PI opening detection failure The warning is generated by the first opening
detection failure. If the faults are detected
consecutively equivalent to the set parameter "PI
open detection failure rate", an alarm message is
generated.

7.4.7 Error messages

Message number Message Description/Solution
A2254 PI opening detection failure A Port Injection failure in opening detection is
detected by SAFI2 if no current signal or an
incorrect current signal to the Port Injection valve is
measured.
The main reason for this failure is a short circuit or
cable breakage between the Port Injection driver
and valve, or a valve which is not connected.
A2255 PI fault in opening point If no valve opening or delayed opening is detected,
detection this alarm message is generated and the engine is
shut down.
A2256 PI valve closing failure The PI valve remains open when de-energised,
which allows an uncontrolled quantity of gas to be
metered.
SAFI2 suppresses the ignition pulses immediately
after the failure and opens the "Ignition safety loop",
which deactivates the power supply to the ignition
and the PI valves.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 39/52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

7.5 Ignition function

7.5.1 Description of the function

The ignition functions are enabled when SAFI is operated in combination with MORIS ignition system. SAFI
triggers the ignition, adjusts the ignition sparks in accordance with the set parameters and monitors the
electrical ignition process.
A detailed description of the function can be found in TI 1502-0068.

7.5.2 Parameter setting

7.5.2.1 Ignition parameters

The following parameters have been saved in the Ignition parameter list.

Setting the ignition points

Ignition points are set for different modes of operation independently of the ignition system.

NOTICE
The default values given here depend on the gas composition and application; changes in the
ignition point may only be made by authorised personnel or after consultation with GE
Jenbacher!

Default values for type 4 engines:

IP without knock monitoring for gas types 1-4: 20 °CA
IP with knock monitoring for gas types 1-4, mains parallel 24 °CA
mode:
IP with knock monitoring for gas types 1-4, island mode: 18 °CA
IP minimum gas types 1-4: 14 °CA

Default values for type 6 engines:

IP without knock monitoring for gas types 1-4: 18 °CA
IP with knock monitoring for gas types 1-4, mains parallel 20 °CA
mode:
IP with knock monitoring for gas types 1-4, island mode: 18 °CA
IP minimum gas types 1-4: 14 °CA

Default values for type 9 engines:

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 40 / 52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

Earliest possible ignition point

The ignition point is limited to this value. SAFI will not accept an earlier ignition point.
Default value for type 4 engines: 27 °CA
Default value for type J612, J616, J620 engines ... 25 °CA
J624 default value: 27 °CA

Latest possible ignition point

The ignition point is limited to this value. SAFI will not accept a later ignition point.
Default value: 10 °CA

Overspeed
This parameter sets the speed for the overspeed trip which opens the safety contact and switching off the
ignition.
Default value at rated speed of 1200 rpm: 1440 rpm
Default value at rated speed of 1500 rpm: 1800 rpm
Default value at rated speed of 1800 rpm: 2150 rpm

Misfire control
This parameter is used to enable the misfire control system to selectively shut down cylinders if the speed is too
high.
Default value for type 4 engines: On
Default value for type 6 engines: Out

7.5.2.2 MORIS
The following parameters have been saved in the Ignition – MORIS parameter list.

Combustion time
You can set the duration of the ignition spark. Prolonging the spark duration has a positive effect on the misfire
limit but also means an increased power requirement.
Type 4 engines with a default value of 500 mg/Nm³ NOX: 500 µs
Type 4 engines with a default value of 250 mg/Nm³ NOX: 700 µs
Default value for type 6 engines: 250 µs

Ignition current level

You can specify the maximum ignition current for the ignition spark. The ignition current level scales the set
ignition current flow and indicates its maximum value. Increasing the ignition current has a positive effect on
the misfire limit but also means an increased power requirement.
Default value: 40 %

Ignition current flow

This parameter is used to adjust the ignition current flows specified in TI 1502-0068 MORIS.
Default value for type 4 engines: 5
Default value for type 6 engines: 1

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 41/52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

Coil type
As the electrical characteristics of the ignition coil affect the ignition control system, the set coil type must
always match the installed coil type.
Default value: 1

Power unit output

This is the parameter for the total output of the 185 V MPM power units. The maximum permissible ignition
output is calculated and limited on the basis of this parameter.
Default value for type 4 engines: 462 W
Default value for type 6 engines: 924 W

Minimum triggering level for varying the spark duration

This level indicates the number of tolerable misfires per ten engine cycles, above which a warning is generated.
Monitoring is disabled when the parameter is set to 0.
Default value: 3

Spark duration tolerance

The spark duration tolerance indicates the extent to which the measured spark duration can deviate from the
set spark duration.
Default value: 80%

7.5.3 Displays
You can switch between the ignition point and ignition voltage screens on the Details – Ignition screen and the
ignition self-test can be activated when the mode selector switch is in the "Off" position.

Ignition output errors

Ignition output errors are displayed as digital values on the Details – Ignition screen, where a distinction is
made between combustion time tolerance and ignition delay in order to improve diagnosis. The displayed
value is a relative value which indicates the number of failed ignition attempts per ten ignition events.

Ignition point
The ignition points of all the cylinders and the global, minimum, maximum and average ignition point across
the engine as a whole are displayed on the Details – Ignition point screen.

7.5.4 Trend display

No trends are recorded for MORIS.

7.5.5 Operating notification

Message Message Description
number
B3225 Ignition On All the cylinders are firing
B3226 Ignition Off At least one cylinder is not firing
B3294 Ignition power reduction active Display shows cylinder with power reduction
- cylinders
B3278 Ignition output error at cylinder Display shows cylinder with output error

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 42 / 52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

Message Message Description

number
B3283 Ignition hardware error at Display shows cylinder with hardware error
cylinder

7.5.6 Warnings
Message Message Description/Solution
number
W3545 Ignition output errors This warning is generated when repeated combustion time
deviations are measured.
To carry out a diagnosis, check the "Combustion time tolerance"
and "Minimum triggering level for combustion time deviation"
parameters. The error rates for combustion time deviations are
displayed on the Ignition – Output errors screen.
W3551 Ignition power reduction active The ignition process had to be aborted before the set
combustion time was reached as the power absorbed by the
ignition system exceeded the maximum output of the MPM
power supply.
If the parameters set are OK, the problem may be caused by an
excessive ignition voltage requirement.
Check the spark plug air gaps.
The coil, ignition module or SAFI may have a hardware defect.
If the installed MPM power unit is unable to provide the required
output, install an additional unit.
W3552 Ignition power supply The voltage level of the MPM power supply falls below 180 V at
overloaded 185 V nominal for 2 seconds. This overloads the MPM, which
results in a reduced service life.
The power supply unit output parameter for MORIS must match
the total of the outputs of all the power supply units.
A detailed description of the original error can be found in TI
MPM/MORIS.
W3544 Ignition hardware error If SAFI does not receive any feedback from MORIS during the
build-up of the ignition spark, the current ignition attempt is
aborted and the warning is output.
Ignition coil-related error rates have been parameterised.
Check the setting of the ignition coil parameter.
Check the hardware components, i.e. SAFI, MORIS, MPM, spark
plug or spark plug sleeve.
The error rates for hardware errors per ten combustion cycles
are displayed on the Ignition – Output errors screen.
Carry out the ignition self-test when troubleshooting to check
the high-voltage supply from the coils. If the voltage is less than
40 kV at any cylinder, change the associated coil.
If 3 or more cylinders are affected, the trip "A3433 Ignition
hardware failure" is triggered.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 43/52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

7.5.7 Error messages

Message Message Description/Solution
number
A3343 Ignition hardware error If SAFI does not receive any feedback from MORIS during the
build-up of the ignition spark, the ignition attempt is aborted
and the engine shut down.
Ignition coil-related error rates have been parameterised.
Check the setting of the ignition coil parameter.
Check the hardware components, i.e. SAFI, MORIS, MPM, spark
plug or spark plug sleeve.
The error rates for hardware errors per ten combustion cycles
are displayed on the Ignition – Output errors screen.
Carry out the ignition self-test when troubleshooting to check
the high-voltage supply from the coils. If the voltage is less than
40 kV at any cylinder, change the associated coil.
A3344 Ignition power supply failed When the engine is running, this error message is displayed
immediately after the failed response of the MPM power supply
and the engine is shut down.
The MPM power supplies are activated during start preparation.
The error message is displayed if a successful activation has not
been reported within 5 seconds.
The power unit output parameter for MORIS must match the
output of the power units.
A detailed description of the original error can be found in TI
1502-0068 MPM.
A3345 Ignition fail-safe loop Each SAFI reports the transmission of ignition signals via a
contact. If a SAFI opens the contact while gas valves are open,
the gas valves are closed immediately and this error message is
displayed. Details of the event that triggered the opening of the
SAFI contact are displayed in an additional message if there has
been no CAN bus failure or cabling error.
If no additional message is present, check the wiring, MORIS
and SAFI for a hardware error by replacing the MORIS and SAFI
modules to narrow down the fault to a single module.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 44 / 52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

7.6 Ignition voltage measurement function

7.6.1 Description of the function

If ignition coils with an active measurement output are available on the engine, it is possible to measure the
SAFI ignition voltage and communicate this to the engine control system via the CAN bus.
In doing so, SAFI communicates the average value from 10 measurement cycles to the engine control system.

7.6.2 Displays
You can switch between the ignition point and ignition voltage screens on the Details – Ignition screen.
The ignition voltages of all the cylinders are displayed in bar and digital form on the Ignition – Details screen
while the engine is running and during the self-test. In the self-test it is possible to switch between the current
and maximum values. The current values are average values from the last ten ignition events and the
maximum value is the highest value which has occurred since you switched to the maximum value display.

7.6.3 Trend display

The measured values are recorded in the "Ignition voltages" long-term trend over 12 months with a resolution
of 0.5 h.

7.6.4 Parameter setting

The following parameters have been saved in the Ignition voltage measurement parameter list.

Monitoring active from

The limit monitor starts when the average ignition voltage exceeds this limit level.
Default value for type 4 engines: 15 kV
Default value for type 6 engines: 12 kV

Monitoring the hysteresis

The limit monitor is deactivated as soon as the voltage falls below the "Monitoring active from" limit level minus
this value.
Default value: 2 kV

Minimum ignition voltage monitoring active

Activates the monitor as soon as the voltage falls below the minimum ignition voltage.
Default value: On

Ignition voltage minimum

Indicates the lower limit level when monitoring the minimum ignition voltage.
Default value for type 4 engines: 12 kV
Default value for type J612, J616, J620 engines ... 6 kV
J624 default value: 8 kV

Ignition voltage minimum delay

The voltage must drop below the minimum limit level at least for this period so that a warning can be
generated.
Default value: 30 s

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 45/52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

Maximum ignition voltage monitor active

Activates monitoring as soon as the voltage exceeds the maximum ignition voltage.
Default value: On

Ignition voltage maximum

Indicates the upper limit level when monitoring the ignition voltage.
Default value for type 4 engines: 33 kV
Default value for type 6 engines: 35 kV

Ignition voltage maximum delay

The voltage must exceed the maximum limit level at least for this period so that a warning can be generated.
Default value: 10 s

Average ignition voltage monitoring active

Activates monitoring as soon as the voltage exceeds the average ignition voltage.
Default value: Out

Maximum average ignition voltage

Indicates the limit level for monitoring as soon as the voltage exceeds the average of all ignition voltages.
Default value: 30 kV

Average ignition voltage maximum delay

The voltage must exceed the maximum permissible average ignition voltage at least for this period so that a
warning can be generated.
Default value: 30 s

Ignition voltage differential monitoring active

Activates the voltage differential monitoring from the highest to the lowest ignition voltage value.
Default value: On
J624 default value: Out

Ignition voltage differential

Indicates the limit level for the monitor as soon as the voltage exceeds the maximum ignition voltage
differential.
Default value for type 6 engines: 10 kV
Default value for type 4 engines: 6 kV
J624 default value: 6 kV

Ignition voltage difference delay

The voltage must exceed the ignition voltage difference at least for this time so that a warning can be
generated.
Default value: 30 s

Trigger voltage
This parameter is used for the MONIC only, is not enabled for SAFI and does not affect the function.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 46 / 52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

Default value: 5 kV

7.6.5 Operating notification

Message Message Description
number
B3286 Ignition coil offset error at Display of cylinder position of SAFI with offset error
cylinder
B3287 Ignition voltage too low at Display of cylinder position of SAFI with excessively low ignition
cylinder voltage
B3288 Ignition voltage too high at Display of cylinder position of SAFI with excessive ignition
cylinder voltage
B3289 Average ignition voltage too Display of cylinder position of SAFI with excessive average
high at cylinder ignition voltage
B3290 Ignition voltage difference too Display of cylinder position of SAFI with excessive ignition
high at cylinder voltage difference

7.6.6 Warnings
Message Message Description/Solution
number
W3546 Every MORIS ignition coil produces an offset voltage of 2 V
Ignition coil offset error when connected to the power supply. This error message is
generated if this offset voltage is not present. The
Check for the presence of the offset voltage during start
preparation.
If this error affects one cylinder, the line connecting the ignition
coil and the SAFI may be damaged or the measuring device on
the ignition coil may be defective.
If the fault is present on all cylinders, the ignition coil power
supply has failed.
To effect a diagnosis, measure the offset voltage on the
relevant pin of the SAFI connector plug while the engine is at
standstill. It can also be measured with SAFI disconnected.
W3547 Ignition voltage too low The ignition voltage is too low, which means the ignition
energy is too low, which in turn can cause misfires.
The air gaps may be too small and must be checked.
Check the ignition system by means of a self-test.
W3548 Ignition voltage too high The ignition voltage is too high, which may result in damage to
the high-voltage cables and the ignition coil. The ignition
voltage could be so high that no flash-over occurs at the
electrode, thereby causing misfires.
The air gap may be too big and must be checked.
An interruption in the high-voltage circuit between the ignition
coil and the spark plug may also result in an excessive ignition
voltage.
W3549 Average ignition voltage too The average value of all ignition voltages calculated in the
high engine control system is too high.
Check the air gaps of the spark plugs.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 47/52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

Message Message Description/Solution

number
W3550 Ignition voltage difference too The difference between the cylinders with the highest and
high lowest ignition voltage is too great.
Check the air gaps.

7.6.7 Error messages

The ignition voltage measuring system does not generate trip-producing error messages.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 48 / 52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

7.7 Exhaust gas temperature measurement function

SAFI measures the exhaust gas temperature and transmits the measured values for each cylinder to the
engine control system. The engine control system processes, displays and analyses the measured values.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 49/52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

7.8 Speed measurement function

7.8.1 Description of the function

SAFI calculates the speed from the ring gear pulses. From this, DIA.NE produces an average value which enters
the engine controller as the engine speed. The speed is monitored for the set value in the Ignition parameter
list. If the value is exceeded the fail-safe loop is opened, the ignition system disabled and an error message
generated.

7.8.2 Displays
The current engine speed is available on a number of screens. The way the speed is displayed is not affected
irrespective of whether the speed is determined by SAFI or another measuring device.

7.8.3 Operating notification

Message Message Description/Solution
number
B3275 SAFI overspeed trip at cylinder Display of cylinder position of SAFI with shutdown due to
overspeed.

7.8.4 Warnings
The speed measurement system does not generate any warnings.

7.8.5 Error messages

Message Message Description/Solution
number
A3335 SAFI shutdown due to overspeed The engine speed exceeds the set value.
At the same time as it is sending the message, SAFI opens a
hardware contact which triggers closure of the gas valves
and with it the shutdown of the engine.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 50 / 52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

8 Appendix 1: Engine Restart after trip „Knocking Failure A3339“ as a result of mechanical
causes
Whenever an engine is automatically tripped off by the module control system due to an alarm, the cause of
the trip must be remedied first before the module is restarted again in accordance with TI 1100-0111 ("Faults"
section).

Description of the facts

After a trip event it is not permitted simply to reset a failure and then restart the engine, as critical or wear-
induced damage could possibly result in premature replacement of various components.
In single case events we have been informed of consequential damages on the engine due to restart after trip
due to ‘Knocking failure A3339’.
In light of the above, we have issued this Service Bulletin to highlight the correct actions to be taken after
engine shut down. This can be caused by either the engine control system detecting a dangerous condition for
the engine due to the knocking noise or by poor mixture composition, auto-ignition, misfires or ignition
problem. The former is considered more important and must be checked first rather than assuming the latter.

Required action
In case of engine shut down due to ’Knocking failure A3339’ all cylinder temperatures at trip must be checked.
Fig. 1: How to show the Alarm messages on the DIA.NE
XT3
1. Press ‘ALARM‘

Fig. 2: Alarm messages showing ’Knocking failure

A3339’
2. Press ‘Alarms and warnings‘
① Alarm messages showing ’Knocking failure A3339’

Check the cylinder temperature trending.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 51/52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0071
SAFI (Sensor Actuator Function Interface)

Fig. 3: Cylinder temperature trending

3. Press ‘Trending ‘
4. Select ‘Cyl. Temp.'
② Cylinder temperature at trip increased

Check all the cylinder temperatures at the trip and compare them with the average cylinder temperatures. If
the difference at the trip between the temperature of one cylinder and the average temperature of all the
cylinders is greater than 25°C, the engine may not be restarted. Inform the service staff member responsible
for engine inspections and ascertain the cause of the trip.
The average cylinder temperature should be calculated as follows:
TCyl.Av. = (TCyl.1 + TCyl.2 + …) / No.Cyl.
TCyl.Av. …average cylinder temperature at trip
TCyl.1 …temperature of cylinder 1 at trip
TCyl.2 …temperature of cylinder 2 at trip
No.Cyl. Total number of cylinders (12, 16, 20 or 24)

Cylinder temperatures at trip (the numbers shown

above are only for display purposes)
5. Press ‘Measurements at trip ‘
③ Check all cylinder temperatures at trip

Relevant documents
The relevant regulations are all part of the plant documentation given to every customer when receiving an
engine. In addition, the latest versions of the Technical Instructions referred to here can be downloaded from
the Jenbacher web portal (http://information.jenbacher.com) under the heading ’Technical Knowledge Base’.
▪ Technical Instruction TI 2300-0005 Safety regulations
▪ Technical Instruction TA 1100-0111, General conditions – Operation and maintenance
SprungMarke!!!54043195561875339
▪ Service Bulletin SB-077, Exhaust gas temperature deviations

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku/Boxleitner Responsible: Fahringer Release date: 02/07/2014
Index: 7 Page No.: 52 / 52
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0072
SPA24 (SAFI-Pickup-Amplifier)

1 Description................................................................................................................................................. 2
1.1 General .......................................................................................................................................................................... 2
1.2 Basic information ..................................................................................................................................................... 3
1.2.1 SPA24 block diagram 3
1.2.2 Input signals 3
1.2.3 Output signals 3
1.3 Displays/indications on the device.................................................................................................................... 4
1.4 TRIGGER signal............................................................................................................................................................ 5
1.4.1 Signal generation 5
1.4.2 Engine signal shape 6
1.5 RESET signal ................................................................................................................................................................. 7
1.5.1 Signal generation 7
1.5.2 Engine signal shape 8
1.6 CAM/RESET signal...................................................................................................................................................... 9
1.6.1 Signal generation 9
1.6.2 Engine signal shape 10
1.7 Monitoring systems ................................................................................................................................................ 10
1.7.1 Polarity RESET input signal 10
1.7.2 Chronological overlap of TRIGGER and RESET input signals 12
2 Safety information.................................................................................................................................. 14
3 Technical data ......................................................................................................................................... 15
3.1 Protection class ........................................................................................................................................................ 15
3.2 Ambient conditions................................................................................................................................................. 15
3.3 Mechanical data ...................................................................................................................................................... 15
3.3.1 Vibration 15
3.3.2 Dimensions 15
3.3.3 Assembly 15
3.4 Electrical data ........................................................................................................................................................... 15
3.4.1 Voltage supply 15
3.4.2 Power consumption 15
3.5 Connections and displays.................................................................................................................................... 15
3.5.1 Terminal designation 15
3.5.2 Displays on the device 17
4 Installation ............................................................................................................................................... 17
4.1 SPA24 assembly....................................................................................................................................................... 17
4.2 Pickup adjustment at the engine ..................................................................................................................... 18
4.2.1 CAM camshaft signal 18
4.2.2 Crankshaft RESET signal 18
4.2.3 TRIGGER pickup signal (flywheel) 18
4.2.4 Assembly of the active camshaft pickup 18
4.2.5 Assembly of passive RESET and TRIGGER pickups for the flywheel and reset signals 19
5 Diagnosis and troubleshooting............................................................................................................ 21
5.1 Operating notifications: ........................................................................................................................................ 21
5.2 Error messages......................................................................................................................................................... 22

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Controls/Greuter Rainer Responsible: Controls Release date: 08/11/2010
Index: 2 Page No.: 1/22
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0072
SPA24 (SAFI-Pickup-Amplifier)

1 Description

1.1 General
SPA24 stands for SAFI-Pickup-Amplifier with 24 V DC supply voltage.
GE Jenbacher part No.: 495854
SPA24 is a pickup amplifier with internal logic which generates all three engine pickup signals - camshaft signal
(CAM), reset signal (RESET) and ring-gear signal (TRIGGER) - in the digital form required for SAFI.
The SPA24 is supplied with power from the +24 V DC circuit.
The following Technical Instructions are referred to in this document:
▪ TI 1502-0071 - SAFI (Sensor Actor Functional Interface)
▪ TI 1502-0068 - MORIS (Modular Rail Ignition System)

The following functionalities are included in SPA24:

▪ internal logical linking of all three analogue engine pickup signals
▪ providing suitable, accurately timed, amplified, digital output signals for SAFI
which are accurate to 0.1 crankshaft angle degree
▪ providing the digital generated TRIGGER pickup signal for SAFI
▪ (cylinder banks A and B)

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Controls/Greuter Rainer Responsible: Controls Release date: 08/11/2010
Index: 2 Page No.: 2 / 22
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0072
SPA24 (SAFI-Pickup-Amplifier)

▪ providing the digital, logically linked CAMshaft / RESET pickup signal for SAFI
(cylinder banks A and B)
▪ providing the generated RESET pickup signal (cylinder banks A and B)
▪ monitoring the correct polarity of the analogue RESET and TRIGGER pickup input signals
▪ control voltage output +24V DC (twice).

1.2 Basic information

1.2.1 SPA24 block diagram

1.2.2 Input signals

The input values are all three engine pickup signals, i.e. TRIGGER (ring-gear signal), RESET (ring-gear reset
signal), CAM (camshaft signal), and the +24 V DC supply voltage. TRIGGER and RESET are passive pickups
without their own + 24V DC voltage supply. CAM is generated by an active pickup which is supplied with + 24 V
DC by the SPA24. The TRIGGER ring-gear signal has a repetition rate which is equal to the flywheel’s number of
teeth (in the range of 50 to 500 teeth), the RESET signal repeats itself once every crankshaft rotation and the
CAM signal every two crankshaft rotations (flywheel). The CAM signal is generated once every engine cycle, i.e.
once every camshaft rotation.

1.2.3 Output signals

The SPA24 provides accurately timed signal outputs for an engine speed range between 0 and 2500 rpm. The
output signal level values are either "0 V" or "+14 V" DC, depending on the operational condition. The SPA24
amplifies the pickup input signals and produces suitable digital output signals. The output consists of a
logically-linked digital CAM/RESET output signal which is generated from CAM and RESET input - and the
generated digital TRIGGER output signal. The digital RESET output signal is provided for monitoring purposes.
The generation of the digital output signals will be explained in more detail in sections 1.4 to 1.6. The duplicated
+24V DC voltage outputs can be used to supply the electronics to be controlled (e.g. SAFI). The output signals
are duplicated.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Controls/Greuter Rainer Responsible: Controls Release date: 08/11/2010
Index: 2 Page No.: 3/22
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0072
SPA24 (SAFI-Pickup-Amplifier)

The release of the digital SPA24 output signals is defined with an engine speed of >50 rpm-1 and a pickup input
signal of > ±3 V. The engine speed of 50 rpm is detected by the SPA24 by independently and internally
measuring the input frequencies of the RESET and TRIGGER signal. If two input signal pulses are chronologically
too far apart, the output signals are not released if the 50 rpm limit value is underrun. This results in a more
accurate signal analysis. If both conditions for the RESET or TRIGGER signal have not been met, the output
concerned is set to a 0V DC output level and optically indicated using orange LED "L" (e.g. when engine is idling
out or at standstill). The LED indication "L" refers to "Low Speed", i.e. the engine speed is too low and underruns
the defined digital output signal’s release speed of 50 rpm. If the above conditions are met, the output signals
generated for engine start and engine operation are available. During engine operation (≥50 rpm-1) LED "L" is
deactivated and a check is made to ensure that the pickup distances are set correctly. The ± 3 V switch
threshold of the pickup input signals is reached at a pre-defined pickup default setting of ¾ to 1¼ turns at 50
to 90 rpm.
During engine standstill, all SPA24 digital signal outputs have a 0 V DC signal value. The double +24V DC
outputs are continuously active, independently of the digital signal output’s release speed monitoring.

1.3 Displays/indications on the device

On the SPA24, the operating conditions of the input signals and various controls are indicated using light-
emitting diodes (LEDs).
The three green LEDs "T", "C" and "R" indicate that the relevant pickup input signals TRIGGER, CAM and RESET
are available. The LEDs always flash at the rising edge of the positive edge of the pickup signal concerned.
The presence of the supply voltage is indicated by a green LED "P".
The red alarm LED "K" lights up when the zero-voltage level crossover of the falling edges of the RESET and
TRIGGER input signal are within 20 microseconds of each other (see 1.7.2 – Chronological overlap of TRIGGER
and RESET input signals).
The orange "POL" LED indicates the incorrect polarity of the RESET input signal (see 1.7.1 – Polarity RESET input
signal).
The orange "L" LED indicates that the SPA24 output signals are blocked due to an engine speed which is too
low (see 1.2.3 – Output signals). Therefore, LED "L" lights up at engine standstill and turns off at engine start-up.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Controls/Greuter Rainer Responsible: Controls Release date: 08/11/2010
Index: 2 Page No.: 4 / 22
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0072
SPA24 (SAFI-Pickup-Amplifier)

1.4 TRIGGER signal

1.4.1 Signal generation

LED T LED T
TRIGGER Input

Pre-Trigger-Level Trigger-Level

+3V

0V
TIME
TRIGGER Output

0V
TIME
The TRIGGER input signal (ring-gear signal) is generated by a passive pickup.
The TRIGGER input signal is pre-triggered at a +3V signal level to detect the positive, rising edge of the
analogue sinus-shaped pickup signal, while at the same time the TRIGGER output signal is activated at the
digital +14V High level. The chronologically later 0V Low signal level (= zero-voltage level crossover) of the same
TRIGGER input signal pulse is the trigger point which resets the TRIGGER output signal to the 0V Low signal
level.
The "T" LED (= TRIGGER input signal) lights up when the input signal level exceeds the +3V pre-trigger level, and
turns off when the +3V pre-trigger level is underrun.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Controls/Greuter Rainer Responsible: Controls Release date: 08/11/2010
Index: 2 Page No.: 5/22
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0072
SPA24 (SAFI-Pickup-Amplifier)

1.4.2 Engine signal shape

CH4: SPA24 TRIGGER input signal

CH3: SPA24 digital TRIGGER output signal for SAFI

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Controls/Greuter Rainer Responsible: Controls Release date: 08/11/2010
Index: 2 Page No.: 6 / 22
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0072
SPA24 (SAFI-Pickup-Amplifier)

1.5 RESET signal

1.5.1 Signal generation

LED R LED R
RESET Input

Pre-Trigger-Level Trigger-Level

+3V

0V
TIME
RESET Output

0V
TIME
The RESET input signal (= ring-gear reset signal) is generated by a passive pickup.
The RESET input signal is pre-triggered at a +3V signal level to detect the positive, rising edge of the analogue
pickup signal, while at the same time the RESET output signal is activated at the digital +14V High level. The
chronologically later 0V Low signal level (= zero-voltage level crossover) of the same RESET input signal pulse is
the trigger point which resets the RESET output signal to the 0V Low signal level.
At every engine rotation, the RESET output signal is set to High and subsequently reset to Low.
The "R" LED (= RESET input signal) lights up every engine rotation by a short 25 ms impulse when the input
signal level reaches the +3V pre-trigger level.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Controls/Greuter Rainer Responsible: Controls Release date: 08/11/2010
Index: 2 Page No.: 7/22
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0072
SPA24 (SAFI-Pickup-Amplifier)

1.5.2 Engine signal shape

CH1: SPA24 RESET input signal

CH2: digitally linked SPA24 CAM/RESET output signal for SAFI
CH3: digital SPA24 RESET output signal

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Controls/Greuter Rainer Responsible: Controls Release date: 08/11/2010
Index: 2 Page No.: 8 / 22
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0072
SPA24 (SAFI-Pickup-Amplifier)

1.6 CAM/RESET signal

1.6.1 Signal generation

LED R
CAM Input

Trigger-Level

+3V

0V
TIME
RESET Input

LED R
Pre-Trigger-Level

+3V Trigger-Level

0V
TIME
CAM - RESET Output

0V
TIME

The CAM input signal (= camshaft signal) is generated by an active pickup with a + 24V DC voltage supply.
The RESET input signal (= ring-gear reset signal) is generated by a passive pickup.
The CAM input signal is pre-triggered at a +3V signal level to detect the positive, rising edge of the digital
rectangular pickup signal, while at the same time the logically linked CAM/RESET output signal is activated at
the digital +14V High level. The next RESET input signal - which is chronologically in the same engine cycle - is

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Controls/Greuter Rainer Responsible: Controls Release date: 08/11/2010
Index: 2 Page No.: 9/22
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0072
SPA24 (SAFI-Pickup-Amplifier)

also pre-triggered at a +3V signal level to detect the positive, rising edge. The chronologically later zero-voltage
level crossover of the RESET input signal pulse is the trigger point which resets the logically linked CAM/RESET
output signal to the 0V Low signal level. At every second engine rotation, the logically linked CAM/RESET output
signal is therefore set to High and subsequently reset to Low (see 1.2.3 – Output signals / 1.7.1 – Polarity of the
RESET input signal).
LED "C" (= CAM input signal) lights up every two engine rotations when the input signal level exceeds the +3V
pre-trigger level, and turns off when the +3V pre-trigger level is underrun.
LED "R" (= RESET input signal) lights up every engine rotation by a short 25 ms impulse when the input signal
level exceeds the +3V pre-trigger level.

1.6.2 Engine signal shape

CH4: SPA24 CAM input signal

CH1: SPA24 RESET input signal
CH2: digital logic SPA24 CAM/RESET output signal for SAFI
CH3: digital SPA24 RESET output signal (for control measuring purposes)

1.7 Monitoring systems

1.7.1 Polarity RESET input signal

The RESET input signal (= ring-gear reset signal) is generated by a passive pickup.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Controls/Greuter Rainer Responsible: Controls Release date: 08/11/2010
Index: 2 Page No.: 10 / 22
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0072
SPA24 (SAFI-Pickup-Amplifier)

An incorrect polarity of the RESET input signal is automatically corrected by the SPA24.
The polarity is detected by the SPA24 by pre-triggering the positive and negative signals. If the polarity is
incorrect, the input signal is inverted by the SPA24 software for further internal processing resulting in a
functional correct signal transmission of the logically linked CAM/RESET and RESET output signals. The diagram
below shows the internal inversion by the SPA24 in the case of an incorrectly polarised RESET input signal.
Pole reversal of the RESET input signal at the SPA24 terminals results in the correct polarity therefore
preventing the "POL" LED from lighting up. This condition should be reached after the engine is started up!

The polarity of the RESET pickup signal should be corrected only at engine standstill.

Internal polarity reversal of the RESET signal

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Controls/Greuter Rainer Responsible: Controls Release date: 08/11/2010
Index: 2 Page No.: 11/22
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0072
SPA24 (SAFI-Pickup-Amplifier)

1.7.2 Chronological overlap of TRIGGER and RESET input signals

The TRIGGER input signal (ring-gear signal) and the RESET input signal (= ring-gear reset signal) are generated
by a passive pickup.
Under certain unfavourable conditions, the RESET and TRIGGER pickup signals may chronologically overlap at
the zero-voltage level crossover. As a consequence, a trouble-free operation of the ignition cannot be
guaranteed.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Controls/Greuter Rainer Responsible: Controls Release date: 08/11/2010
Index: 2 Page No.: 12 / 22
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0072
SPA24 (SAFI-Pickup-Amplifier)

The RESET and TRIGGER input signals are triggered by the chronologically later zero-voltage level crossover "0
V signal level" at the positive falling flank of the relevant signal. If the zero-voltage level crossovers of the RESET
and TRIGGER input signals overlap, there is a common trigger time and the RESET and TRIGGER input signals
coincide. According to the definition, a trigger point chronologically overlaps whenever the trigger times of both
signal and zero-voltage level crossovers fall within a 20 ms timeframe.
The red alarm LED "K" lights up at every ‘trigger point collision’ for 2 seconds and then turns off automatically.
Red alarm LED "K" does not light up if the trigger times of both signal and zero-voltage level crossovers fall
outside the 20 ms timeframe.

If this situation arises, the polarity of the TRIGGER signal at the equipment input terminals must be reversed
during engine standstill.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Controls/Greuter Rainer Responsible: Controls Release date: 08/11/2010
Index: 2 Page No.: 13/22
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0072
SPA24 (SAFI-Pickup-Amplifier)

LED R T LED R T
K K
RESET Input

falling edge

TIME
TRIGGER Input

falling edge rising edge

0V TIME

< 20 microseconds
Reset / Trigger - collision
The diagram below illustrates the definition of a ‘chronological trigger point overlap’ at different TRIGGER input
signal polarities.

2 Safety information
Please observe the safety and hazard signs in the safety instructions
(TI 2300-0005) and wear the appropriate personal protective equipment.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Controls/Greuter Rainer Responsible: Controls Release date: 08/11/2010
Index: 2 Page No.: 14 / 22
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0072
SPA24 (SAFI-Pickup-Amplifier)

3 Technical data

3.1 Protection class

When fitted, SPA24 has protection class IP20.

3.2 Ambient conditions

Temperature limits Storage -40 ... + 70 °C
In operation -25 ... + 70 °C

Relative humidity Storage 90 %, no dew

In operation 85 %, no dew

3.3 Mechanical data

3.3.1 Vibration
SPA24 is installed in the module interface cabinet and assembled vibration-free onto the engine frame using
rubber buffers.

3.3.2 Dimensions
Housing: width x height x depth = 35 mm x 100 mm x 115 mm.

3.3.3 Assembly
For reasons of easy access, the SPA24 housing is assembled into the module interface cabinet using a top-hat
rail, type TS 35/15 mm.

3.4 Electrical data

3.4.1 Voltage supply

SPA24 is powered by a battery with a nominal voltage of 24 V DC. The battery voltage may fluctuate in a range
from 15 V to 32 V ± 10% residual ripple.

3.4.2 Power consumption

The maximum power consumption of the SPA24 is approx. 170 mA with maximum 12 SAFIs without additional
load at both voltage outputs (output connectors J5 and J6) at a +24 V DC supply voltage.

3.5 Connections and displays

3.5.1 Terminal designation

All four 3-fold input junctions of the SPA24 are located on top of the housing and are coded. An incorrect plug
connection is therefore not possible.
Input junction Pin Description
J1 24V + 24 V DC supply voltage for SPA24
J1 G supply voltage, earth

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Controls/Greuter Rainer Responsible: Controls Release date: 08/11/2010
Index: 2 Page No.: 15/22
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0072
SPA24 (SAFI-Pickup-Amplifier)

Input junction Pin Description

J1
J2 24V + 24V DC supply voltage, camshaft pickup
J2 G camshaft pickup, earth
J2 CAM camshaft pickup signal
J3 + RES RESET pickup signal
J3
J3 - RES RESET pickup signal
J4 + TRG TRIGGER pickup signal
J4
J4 - TRG TRIGGER pickup signal

All four 3-fold output junctions of the SPA24 are located on the bottom of the housing and are coded to
prevent using incorrect plug connections.
The output signals are always duplicated. Plug connections serving functionally equal signals both have a
similar coding to facilitate faultfinding when on-site.

Output junction Pin Description

J5 24V +24V DC control voltage output
J5 G control voltage, earth
J5 R RESET output signal – cylinder bank A
J6 24V +24V DC control voltage output
J6 G control voltage, earth
J6 R RESET output signal – cylinder bank B
J7 T TRIGGER output signal – cylinder bank A
J7 G Weight
J7 C/R combined CAM/RESET output signal – cylinder bank A
J8 T TRIGGER output signal – cylinder bank B
J8 G Weight
J8 C/R combined CAM/RESET output signal – cylinder bank B

Coding of the connector plugs

Inputs
Input Pin SPA24 socket Plug coding
junction coding
J1 24V No Yes
J1 G Yes No
J1 No Yes
J2 24V Yes No
J2 G Yes No
J2 CAM No Yes
J3 + RES Yes No
J3 No Yes

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Controls/Greuter Rainer Responsible: Controls Release date: 08/11/2010
Index: 2 Page No.: 16 / 22
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0072
SPA24 (SAFI-Pickup-Amplifier)

Input Pin SPA24 socket Plug coding

junction coding
J3 - RES Yes No
J4 + TRG No Yes
J4 Yes No
J4 - TRG Yes No

Inputs
Output Pin SPA24 socket Plug coding
junction coding
J5 24V Yes No
J5 G No Yes
J5 R No Yes
J6 24V Yes No
J6 G No Yes
J6 R No Yes
J7 T No Yes
J7 G No Yes
J7 C/R Yes No
J8 T No Yes
J8 G No Yes
J8 C/R Yes No

3.5.2 Displays on the device

The device has seven LED to indicate the operating conditions and various monitoring activities.
Description Colour Meaning
P Green Supply voltage SPA24
T Green Signal from ring-gear TRIGGER pickup
C Green Signal from CAM pickup
R Green Signal from crankshaft RESET pickup
POL Yellow Incorrect polarity of RESET pickup signal
→ The RESET signal is automatically inverted internally.
K Red If the zero point of the falling edge of the RESET and TRIGGER signal falls
within a 20 µs timeframe pole reversal of the TRIGGER signal!
L Yellow The SPA24 does not transmit any signals because the speed has fallen
below 50 rpm or the pickup input signal voltage is below 3 V. The LED
lights up at engine standstill and turns off at engine start-up! (L stands for
Low Speed)

4 Installation

4.1 SPA24 assembly

The SPA24 is assembled into the module interface cabinet using a TS35/15 mm top-hat rail.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Controls/Greuter Rainer Responsible: Controls Release date: 08/11/2010
Index: 2 Page No.: 17/22
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0072
SPA24 (SAFI-Pickup-Amplifier)

4.2 Pickup adjustment at the engine

4.2.1 CAM camshaft signal

Four-stroke engines require information about the angle of rotation of the camshaft in order to distinguish
between the compression stroke and the gas-exchange stroke. As the signal equals the camshaft speed and
has a smaller angle speed, an active pickup must be used.

4.2.2 Crankshaft RESET signal

To be able to accurately determine the crankshaft position during the working cycle, a crankshaft reset signal
in connection with the camshaft signal is required.
The RESET position is approximated by mechanically measuring the crankshaft angle (CA) position before the
top dead centre (BTDC) of the first cylinder.
The exact reset position must be checked following every engine adjustment which may influence the reset
position using a strobe light and adjusted in the ignition using the RESET POSITION parameter (see the technical
instructions for SAFI - TI 1502-0071).

4.2.3 TRIGGER pickup signal (flywheel)

The flywheel requires at least 50 (at most 500) impulses per revolution (TRIGGER signal).

4.2.4 Assembly of the active camshaft pickup

The distance between signal transmitter and pickup must be between 0.75 und 1.25 mm. The M12 x 1 pickup
originally supplied by GE Jenbacher must therefore be adjusted to ¾ to 1¼ turns. Despite reduced accuracy,
pickups with a 5/8" UNF thread must be set to a gap of ¾ to 1¼ turns.
Default setting: 1 turn = 1 mm

1 mm

The camshaft signal must occur before the crankshaft reset signal and must be between 110 ° and 200° CA
BTDC in the ignition cycle.
When adjusting, ensure that the pickup is reset to the maximum elevation. Especially when using a screw head
as trigger source, e.g. in type 6 engines, an incorrect adjustment can lead to mechanical triggering and
destruction of the pickup.
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Controls/Greuter Rainer Responsible: Controls Release date: 08/11/2010
Index: 2 Page No.: 18 / 22
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0072
SPA24 (SAFI-Pickup-Amplifier)

4.2.5 Assembly of passive RESET and TRIGGER pickups for the flywheel and reset signals
Magnetic (passive) pickups should be carefully adjusted to a distance between 1.0 and 1.8 mm between the
pickup and the tooth or trigger source. Accordingly, a genuine GE Jenbacher pickup with a 5/8" UNF thread
should be adjusted to ¾ - 1¼ turns.
When adjusting, ensure that the pickup is set to the highest elevation. Especially when using a screw head as
trigger source, e.g. in type 6 engines, an incorrect adjustment can lead to mechanical triggering and
destruction of the pickup.
Default setting: 1 turn = 1.4 mm

1,4 mm

Ensure that the pickup cannot receive any other signals besides the reset or ring-gear signals (e.g. holes,
markings or elevations). This risk occurs, for example, if the head of the hexagonal bolt is too close to the ring
gear or other failure sources are nearby. The amplitude of the interference signals increases with the speed.
If the failure source cannot be eliminated, increase the distance between the pickup and the trigger source to
such an extent that any interference signal peak voltages remain below 1.5 V and therefore below the SPA24
trigger limit value. The SPA24 requires a peak voltage from the pickup of at least ±3 V, which is reached at an
engine speed of 50 to 90 rpm depending on the pickup distance set (¾ to 1¼ turns). If the voltage is lower than
± 3V, the SPA24 does not emit any output signals as a result of which no ignition signals are emitted by the
SAFI.
The distance should therefore be selected in such a way that a sufficient amplitude is available for the regular
reset signal or ring-gear signal during the starting procedure and at the same time sufficient protection is
guaranteed against any interference signals while at rated engine speed. In general, a distance of 1 to 1¼
turns will prove to be optimal.
In the following two photographs, examples of possible failure sources are shown.
Examples of an interference source based on a type 4 engine flywheel disk

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Controls/Greuter Rainer Responsible: Controls Release date: 08/11/2010
Index: 2 Page No.: 19/22
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0072
SPA24 (SAFI-Pickup-Amplifier)

① Error: Protruding rivets on the marking plate for determining TDC.

② Error: Excessively-deep punch marks to mark the cylinders can also cause interference signals.
③ Drilled hole as reset trigger source
④ Ring gear
⑤ Error: Reset pick-up position too near to the teeth for the torsion measurement or ring gear.

In the Figure , the reset pickup has been adjusted to an excessive distance (1½ turns) while the trigger pickup
has been adjusted to the default setting of 1 turn. A reset signal level of only +/‑ 2.95 V is achieved at start-up,
which is too low for a functional correctly generated digital CAM/RESET output.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Controls/Greuter Rainer Responsible: Controls Release date: 08/11/2010
Index: 2 Page No.: 20 / 22
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0072
SPA24 (SAFI-Pickup-Amplifier)

① Voltage below 3 V trigger level!

CH1: RESET input signal +/- 2.9V (1V/div) / pickup distance 1½ turns
CH2: TRIGGER input signal (attention 2V/div) / pickup distance 1 turn

5 Diagnosis and troubleshooting

Only SPA24-related messages are dealt with below.

Detailed information and descriptions of monitoring functions, operational, warning and error messages and
setting parameters for the SAFI and DIA.NE XT can be found in Technical Instruction TI 1502-0071 – SAFI.

5.1 Operating notifications:

Message Message Description
number
B3276 SAFI trigger pickup Display shows cylinder position of SAFI with trigger pickup failure
cylinder failure
B3277 SAFI camshaft/reset Display shows cylinder position of SAFI with camshaft/reset pickup
pickup cylinder failure failure

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Controls/Greuter Rainer Responsible: Controls Release date: 08/11/2010
Index: 2 Page No.: 21/22
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1502-0072
SPA24 (SAFI-Pickup-Amplifier)

5.2 Error messages

Message Message Description/Solution
number
A3336 SAFI trigger pickup A problem with the trigger signal has been detected.
failure = SPA24 TRIGGER output signal.
Check SPA24 and SAFI supply voltage!
→ Every SPA24 and SAFI is provided with a POWER LED!
Check SPA24 TRIGGER input signal and SPA24 TRIGGER-output
signal (= SAFI input signal).
→ A TRIGGER LED on SPA24 and each SAFI flashes when a pickup
input signal is detected. These displays are helpful for checking
whether a signal has failed in the event of an error.
→ Check pickup for contamination (e.g. metal chippings)
→ The error message during engine start-up can be caused by an
incorrect pickup setting.
Check the pickup setting acc. to SPA24 TI 1502-0072 (section 4).
A3337 SAFI camshaft/reset A problem with the logical camshaft/reset signal has been
pickup failure detected,
= i.e. linked SPA24 CAM/RESET output signal.
Check SPA24 and SAFI supply voltage!
→ Every SPA24 and SAFI is provided with a POWER LED!
Check SPA24 CAM and RESET input signal and SPA24 logic output
signal (= SAFI input signal).
→ On SPA24 the CAM and RESET LEDs flash when a pickup input
signal is detected, and on SAFI a CAM LED. These displays are
helpful for checking whether a signal has failed in the event of an
error.
→ Check pickup for contamination (e.g. metal chippings)
→ The error message during engine start-up can be caused by an
incorrect pickup setting. Check the
SprungMarke!!!9007199288561803
pickup setting acc. to SPA24 TI 1502-0072 (section 4).

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Controls/Greuter Rainer Responsible: Controls Release date: 08/11/2010
Index: 2 Page No.: 22 / 22
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1510-0064
Gas quantity controller (TecJet 110 and 50 plus)

1 Introduction ............................................................................................................................................... 1
2 Description of the system ....................................................................................................................... 2
2.1 Mechanical assembly of the device.................................................................................................................. 2
2.2 Gas pressure/gas quality requirements ......................................................................................................... 3
2.3 Electrical connection................................................................................................................................................ 4
2.3.1 Device connector 4
2.3.2 Relevant connecting cable 4
2.3.3 Power supply 4
2.3.4 CAN – linking 5
2.3.5 Coding / release of the device 5
3 Commissioning.......................................................................................................................................... 5
3.1 Parameter setting ..................................................................................................................................................... 5
3.1.1 Indicative values for the GAS PROPORTIONING VALVE/TECJET RECIPE 5
3.1.2 LEANOX recipe 8
3.1.3 ENGINE DATA recipe 8
3.2 DIA.NE visualisation screens ................................................................................................................................ 8
3.2.1 LEANOX 8
3.2.2 DETAILS - GAS 9
3.2.3 SYSTEM 9
4 Troubleshooting ........................................................................................................................................ 9
4.1 Error messages........................................................................................................................................................... 9
4.1.1 Tripping 9
4.1.2 Warning 10
4.2 Troubleshooting ....................................................................................................................................................... 11
4.2.1 Power supply problems (voltage supply, CAN bus) 11
4.3 Mechanical problems (gas quality and pressure)..................................................................................... 11
4.4 Electronic problems (internal errors) .............................................................................................................. 11

1 Introduction
Using the TecJet gas proportioning valve you can specify a desired gas volume, thus dispensing with the gas
mixer used until now. Doing so allows you to actively intervene to make mixtures more lean or rich and to
directly preset the fuel mixture lambda value. The fuel mixture lambda value is the ratio between the actual
combustion air volume and the stoichiometrically required air volume. That is why stoichiometric combustion
equals lambda = 1, resulting in improved behaviour while starting and during isolated operation. A zero
controller pressure is no longer required. This type of gas proportioning valve can be used in combination with
both natural gas and special gases.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Hirzinger Responsible: Elektronik Release date: 27/05/2010
Index: 1 Page No.: 1/11
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1510-0064
Gas quantity controller (TecJet 110 and 50 plus)

2 Description of the system

① Sensor box ③ Actuator electronics

② Actuator

The actuator drive with integrated electronics is located on the side of the valve housing. The connector plug is
located on the face of the housing. A mechanical pointer is located on the opposite side, indicating the current
valve position. The direction of flow is indicated using an arrow on the cast iron housing. On top of the valve is a
metal housing containing the device sensors (sensor box).

2.1 Mechanical assembly of the device

The TecJet should be assembled so as to protect it from engine vibrations. In view of control requirements
(dead volume) use a flexible hose (approx. 0.5 m) making sure that the maximum admissible distance from the
engine connection point does not exceed 1.3 m.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Hirzinger Responsible: Elektronik Release date: 27/05/2010
Index: 1 Page No.: 2 / 11
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1510-0064
Gas quantity controller (TecJet 110 and 50 plus)

As a guideline, a distance of up to 2 m (at least 6x the rated diameter) between TecJet and the solenoid valves
must be maintained to provide a damping system. This should already be taken into account by the
manufacturer in the design of the gas train. The manufacturer advises maintaining an intake-side damping
distance of 6x the rated device diameter and an output-side damping distance of 2x the rated device diameter
and assembling the device according to ANSI/ISA-S75.02 to prevent sensitivity losses. By observing the above
distances, these requirements are fulfilled.
The device is mounted horizontally with the sensor box on top. The direction of flow is indicated by means of an
arrow on the cast iron housing.

See the Figure below for the position of the individual gas train components.

max. 1,3 m max. 5 m

DK
1

PDS SO V PS

PI PI

M PCV
SO V SO V
3 3

8 7 6 5 1
4 3 2

① ball valve ⑤ TecJet gas proportioning valve

② Micro filter ⑥ Flexible hose
③ Pre-pressure controller ⑦ Engine connection point
④ Solenoid valves with leak test ⑧ To engine

Whenever several fuel gases need to be mixed, this arrangement is implemented for each individual fuel gas.
Once they have passed the gas proportioning valves, the gases are combined and fed to the gas mixer housing
or a shared piece of tubing leading to the turbocompressor/compressor intake.

2.2 Gas pressure/gas quality requirements

The differential pressure across the device must be in the 10 – 500 mbar range. The intake-sided pressure must
be in the 0.4 barabs and 1.6 barabs range. The required gas prepressure at the customer interface follows from
the required gas volume, the calorific value, the engine efficiency and pressure losses along the gas pressure
control system. When determining the required gas prepressure at the customer interface, the relevant
guidelines must be taken into account (the Jenbacher Anlagenkonstruktion and Projektierung departments can
help you).
The zero pressure controller is no longer required. The prepressure controller is a standard feature as in
practice there is no guarantee that TI 1000-0300/0301 or -0302 will actually be complied with.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Hirzinger Responsible: Elektronik Release date: 27/05/2010
Index: 1 Page No.: 3/11
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1510-0064
Gas quantity controller (TecJet 110 and 50 plus)

Ensure that a relative gas-moisture content percentage of 80 % is not exceeded (in accordance with
TI 1000-0300-0301 or -0302) and that measures are taken to prevent condensate from forming (in accordance
with TI 1400-0091).

2.3 Electrical connection

2.3.1 Device connector

The TecJet is integrated into the DIA.NE system using a connector. The connector contains both the power
supply and the CAN bus. The pin sequence is indicated in the table below.
Meaning Pin
Power supply + W
Power supply - Z
CAN – ID1 H
CAN – ID2 G
CAN – High In R
CAN – Low In S
CAN – High Out T
CAN – Low Out U
CAN – Gnd V
CAN - Shield X

The device earthing (according to CE) is provided by fitting a braided cable which is as short as possible (< 1 m)
and has a minimum cable diameter of 2.5 mm² between the relevant connection screw and the engine earth.

2.3.2 Relevant connecting cable

A power supply cable with the following colour/number codes and pin sequence is used to establish the
electrical connection.
Description Colour (number) Pin
Power supply + 1 W
Power supply - 2 Z
CAN – ID1 4 H
CAN – ID2 3 G
CAN – High IN Blue R
CAN – Low IN White / blue S
CAN – High OUT White / orange T
CAN – Low OUT Orange U

2.3.3 Power supply

The supply voltage must be in the 18 - 32 VDC (24 VDC nominal) range and is pole-error protected. The device is
also over-voltage protected up to 80 VDC. During operation 65 Watt (250 Watt peak) for TecJet50PLUS and 100
Watt (315 Watt peak) for TecJet110 are required.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Hirzinger Responsible: Elektronik Release date: 27/05/2010
Index: 1 Page No.: 4 / 11
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1510-0064
Gas quantity controller (TecJet 110 and 50 plus)

2.3.4 CAN – linking

The CAN bus is contained in the connecting cable. The bus lines are linked to the device, also providing for
return lines. Using the pins for CAN ID1 and CAN ID2, the node number can be set, resulting in the CAN bus
identification.
Device CAN ID1 CAN ID2 Device CAN node
1 Open Open 1 6
2 Minus Open 2 7
3 Open Minus 3 8
4 Minus Minus 4 9
In the case of mixed gas applications, devices 1 and 3 are selected for the lower calorific value fuel gas, and
device 2 for the higher calorific value fuel gas with a more constant fuel gas quality. See also the relevant TI.

2.3.5 Coding / release of the device

As there is no release pin, the device is put into active mode by sending an amount of gas >0 nl/s through the
CAN bus.

3 Commissioning

3.1 Parameter setting

The device requires no settings. Some recipe entries in the DIA.NE system may need to be changed, though.

3.1.1 Indicative values for the GAS PROPORTIONING VALVE/TECJET RECIPE

The indicative values below are established using a type 4 engine running on natural gas. The parameters are
indicative for a new Leanox controller with an oil temperature dependent starting procedure and a stationary
operation lambda controller.
Description Default value Unit
Characteristic restricted by oil temperature minimum 30 °C
Characteristic restricted by oil temperature maximum 70 °C
Volumetric efficiency 0.85 ---
Oil temperature point 1 30 °C
Lambda point 1 1.4 ---
Oil temperature point 2 70 °C
Lambda point 2 1.4
Lambda offset for mains parallel operation 0.3 ---
Lambda offset for isolated operation 0.3 ---
Calorific value 9.971 kWh/Nm3
Minimum air requirement 9.54 l/l
Standard gas density 720 g/m3
Delay after start-up 4 s
Delay after mains parallel or isolated operation 10 S
P part -3
I part -20 (as from RPS 7.31 +
20)
Throttle valve setpoint position 4 %
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Hirzinger Responsible: Elektronik Release date: 27/05/2010
Index: 1 Page No.: 5/11
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1510-0064
Gas quantity controller (TecJet 110 and 50 plus)

Description Default value Unit

Lambda control range 0.1 ---

These settings are input according to the number and nature of the different gas types. The lambda setting
range runs from 1 to 2.5.
Value = 1 means very rich
Value = 2 means very lean

The volumetric efficiency parameter represents the volumetric engine efficiency according to the relevant
engine configuration (values to be influenced are of a mechanical nature, e.g. camshaft type). A typical value
for type 4 engines with non-Miller camshafts would be 0.85 and 0.73 for engines with Miller camshafts. These
values must, however, be determined on a case-by-case basis; the correct default values are preset.

The lambda point 1 and 2 set values correspond to the mixture lambda values at the relevant points on the oil
temperature dependent start-up characteristic.

When switching over from stationary operation to mains parallel or isolated operation, the lambda offset
mains parallel and isolated operation parameters are added to the fuel mixture lambda value.

The calorific value corresponds to the energy content of one cubic metre of fuel gas under standard conditions
(to be calculated using the software).

The minimum air requirement corresponds to the air quantity that must be added per fuel gas quantity in order
to obtain stoichiometric combustion (Lambda=1) (to be calculated using the software).

Before commissioning (at least in the case of special gas-fuelled installations), a recent gas analysis must be
available and/or the CH4 content must be determined using a gas analysis device. Ideally, also other
components such as CO2, O2 and N2 could be established. We would recommend, however, that you calibrate
such devices on a weekly basis or have this done.

If the gas analysis is carried out online and is used to determine the gas type interpolation, the following items
must receive special attention: the detection time (ideally less than one second), the position of the
measurement location in view of the flow times in the piping system (ideally just ahead of TecJet), the reaction
time of the analysis devices (ideally in seconds), and the measurement results themselves (verification using a
reference measurement device).

The parameters must be set as follows (the tables are indicative only). You can use the software on the service
laptop for accurate calculations in the case of complex gas compositions.
You can find the program at https://information.jenbacher.com under the menu item: " Produkte+Service -->
Service Datenbank --> Service Bulletins".

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Hirzinger Responsible: Elektronik Release date: 27/05/2010
Index: 1 Page No.: 6 / 11
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1510-0064
Gas quantity controller (TecJet 110 and 50 plus)

Calorific value:Reduce this parameter in accordance with the CH4 content if the remaining volume parts are
complemented using ambient air only (e.g. mine gas application).
CH4 content [%] Calorific value [kWh/Nm3]
100 9.9
50 4.95
30 2.97

Otherwise, the following guide values apply:

Gas Calorific value [kWh/
Nm3]
Natural gas, dry 9.8 – 11.7
Landfill gas 6–5
Landfill gas, drawn in 3–5
Mine gas, active 3–5
Mine gas, passive 5.5 – 7.7
Biogas 4-6

Standard gas density:

Gas Density [g/m3]
Natural gas, dry 720 - 860
Landfill gas 1220 – 1350
Landfill gas, drawn in 1200 - 1280
Mine gas, active 1000 - 1180

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Hirzinger Responsible: Elektronik Release date: 27/05/2010
Index: 1 Page No.: 7/11
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1510-0064
Gas quantity controller (TecJet 110 and 50 plus)

Gas Density [g/m3]

Mine gas, passive 880 – 950
Biogas 1200 - 1500

Minimum air requirement: Describes the air volume required for λ =1 combustion and can be set in
accordance with the CH4 content if the remaining volume parts are complemented using ambient air only (e.g.
mine gas application).

Indicative values:
CH4 content [%] Air requirement [l/l]
100 9.54
50 4.77
30 2.86

Otherwise, the following guide values apply:

Gas Air requirement [g/m3]
Natural gas, dry 9.5 – 11.1
Landfill gas 4.8 – 5.7
Landfill gas, drawn in 2.5 – 4.5
Mine gas, active 2.1 – 4.2
Mine gas, passive 5.7 – 7.6
Biogas 3.8 – 5.3

3.1.2 LEANOX recipe

Settings as usual. Because the gas proportioning valve reacts faster than the gas mixer in the case of incorrect
settings, we advise against manually adjusting the Leanox characteristic parameters (without making a Leanox
calculation using dia.ne).

3.1.3 ENGINE DATA recipe

This recipe is used to clear the TecJet gas proportioning valve for the visualisation unit and to set the number of
gas proportioning valves (important for mixed gas applications).

3.2 DIA.NE visualisation screens

3.2.1 LEANOX
The device is manually operated by entering the fuel mixture lambda value indicated as LAMBDA in the DIA.NE
visualisation system.

If the air requirement and gas density are correctly set, the following applies:
TECJET – value in the range [1.0 ... 1.3] Very rich mixture
TECJET – value in the range [1.3 ... 1.8] Lean mixture
TECJET – value in the range [1.8 ... 2.0] Very lean mixture

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Hirzinger Responsible: Elektronik Release date: 27/05/2010
Index: 1 Page No.: 8 / 11
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1510-0064
Gas quantity controller (TecJet 110 and 50 plus)

Manual adjustments must take place in 0.05 increments maximum.

3.2.2 DETAILS - GAS

Measurement values indicated include gas pressure, gas temperature, differential gas pressure across the
device and throttle valve position. These data are only available using dia.ne XT/WIN.

3.2.3 SYSTEM
Apart from the known version numbers, the system screen shows the gas proportioning valve programme
version (2.02 or higher required).

4 Troubleshooting

4.1 Error messages

4.1.1 Tripping
Message text and number Error Solution
TJ CAN KOPPLUNG DEFEKT CAN messages could not be sent. Check the CAN bus connection.
TJ CAN LINK FAILURE The CAN bus connection must not
3093 – Priority 1 be interrupted. Check CAN bus
terminators and wiring.
As of DIANE XT 2.10 the additional See CAN bus 1531-0012 Technical
operating notification 3241 is Instruction
displayed indicating the device
concerned.
TJ FALSCHE SOFTWARE TJ software version not DIA.NE Install device using correct software
TJ WRONG SOFTWARE compatible and/or not up-to-date. and/or have GE Jenbacher
mechanic install correct software
3094 – Priority 3
(version > 2.02).
As of DIANE XT 2.10 the additional
operating notification 3242 is
displayed indicating the device
concerned.
TJ GASTEMPERATUR NICHT Gas temperature too high or too Check the gas temperature.
ERFUELLT low; normally, the temperature
TJ FUEL GAS TEMPERATURE OUT OF must be in the –40 to 80 °C range.
LIMITS
3095 – Priority 1
As of DIANE XT 2.10 the additional
operating notification 3243 is
displayed indicating the device
concerned.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Hirzinger Responsible: Elektronik Release date: 27/05/2010
Index: 1 Page No.: 9/11
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1510-0064
Gas quantity controller (TecJet 110 and 50 plus)

Message text and number Error Solution

TJ GASVORDRUCK NICHT ERFUELLT Gas temperature or differential Check the prepressure controller
TJ FUEL GAS PRESSURE OUT OF pressure too high or too low; settings; check the pipe system for
LIMITS normally, the prepressure must be frozen condensate.
in the 500 to 1600 mbar abs range.
3096 – Priority 1
The differential pressure across the
As of DIANE XT 2.10 the additional device must be between 10 and
operating notification 3244 is 500 mbar.
displayed indicating the device
concerned.
TJ INTERNER FEHLER Defective integrated electronics. Check the voltage supply and the
TJ INTERNAL FAILURE wiring. Replace the device if the
error message cannot be reset.
3097 – Priority 1
As of DIANE XT 2.10 the additional
operating notification 3245 is
displayed indicating the device
concerned.
TJ MECHANISCHE FEHLFUNKTION Mechanical damage, valve stuck, Visually check for damage.
TJ MECHANICAL MALFUNCTION broken shaft.

3098 – Priority 1
As of DIANE XT 2.10 the additional
operating notification 3246 is
displayed indicating the device
concerned.
GASMENGENSPRUNG Excessive gas volume change. Inadmissible operating conditions,
GAS AMOUNT STEP TOO HIGH e.g. erratic engine behaviour, rpm
variations, sudden charge pressure
3099 – Priority 1 increases, sudden fuel mixture
As of DIANE XT 2.10 the additional temperature increases.
operating notification 3247 is
displayed indicating the device
concerned.

4.1.2 Warning
Message text and number Error Solution
GASMENGE OBERGRENZE Calorific value drop towards the Check the fuel gas requirements,
FUEL GAS AMOUNT TOO HIGH ‚insufficient’ range, charge pressure check the gas/calorific value, check
increase, overspeed. the engine requirements.
3212
As of DIANE XT 2.10 the additional
operating notification 3248 is
displayed indicating the device
concerned.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Hirzinger Responsible: Elektronik Release date: 27/05/2010
Index: 1 Page No.: 10 / 11
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1510-0064
Gas quantity controller (TecJet 110 and 50 plus)

Message text and number Error Solution

TJ GASMENGE NICHT ERREICHT Prepressure too low, solenoid valves Check and/or adjust the
TJ FUEL GAS AMOUNT NOT are not opening. prepressure controller, check
REACHED 3213 whether the solenoid valves work
properly.
As of DIANE XT 2.10 the additional
operating notification 3249 is
displayed indicating the device
concerned.

4.2 Troubleshooting

4.2.1 Power supply problems (voltage supply, CAN bus)

Symptoms Error Solution
No TecJet data present on No voltage supply Check the 24 V voltage supply in the
visualisation unit. interface cabinet for a blown fuse.
Otherwise, check the TecJet
connection plug.
No TecJet data present on CAN bus wiring not OK, incorrect Check signal circuit at CAN bus
visualisation unit, CAN error node number. (terminators 120 Ω, forward
messages. resistance CAN-Low → CAN-High).
Connect the TecJet to the CAN bus
before the ignition. If the remaining
devices at the CAN bus are OK,
check the connecting plug at the
TecJet.

4.3 Mechanical problems (gas quality and pressure)

Symptoms Error Solution
Unstable engine running behaviour, Condensate in sensor Disassemble TecJet, open gas flow
excessive richness, excessive gas compensation line (possibly frozen). system and dry using hot air.
moisture (>80 %).
Unstable engine running, Excessive gas prepressure Check the prepressure controller,
insufficient gas pressure. fluctuations or gas prepressure too check the gas train for pressure
high/low. loss.
Unstable engine running, ‚Lox Limit‘ Significant gas quality fluctuations. Check on gas supply, current gas
engine tripping. analysis and volume of gas actually
supplied.

4.4 Electronic problems (internal errors)

Symptoms Error Solution
SprungMarke!!!35667595
Internal device error. Defective electronics. Replace device.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Hirzinger Responsible: Elektronik Release date: 27/05/2010
Index: 1 Page No.: 11/11
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1511-0069
Dealing with exhaust condensate

1 Scope
This Technical Instruction (TA) applies to GE Jenbacher lean-burn gas engines.

2 Purpose
This TA gives information on dealing with exhaust condensate produced during the operation of lean-burn
engines, and describes its chemical composition, pH value and guidelines for handling and disposing of it.

3 Composition of exhaust condensate

In addition to water, exhaust condensate usually contains traces of acids (resulting from CO2, nitrous and
sulphuric acid components; in some cases chlorine, fluorine and other constituents, depending on the nature of
the fuel), solid organic and inorganic combustion residues and under some circumstances unburnt lubricating
oil. The condensate constituents have their origins in the fuel gas, combustion air, lubricating oil and
combustion process.
The pH value has been shown to lie generally in the range between: 1,5 < pH < 4.

4 Handling and dealing with exhaust condensate

Due the exhaust gas composition, the adequate safety precautions must be be taken in order to deal with
exhaust condensate:
▪ The exhaust condensate must be collected.
▪ The condensate lines from various subsystems such as the exhaust silencer, catalytic converter, heat
exchanger, chimney and other connecting pipes must not be run to a common header. The condensate
from each subsystem must be drained off and collected separately.
▪ To comply with EN 10226, the inside diameter of condensate piping must be at least
– R 1½“ (R 2” on J920 engines) for exhaust silencers
– DN50 for exhaust gas heat exchangers.
▪ The above design reduces the risk of obstructions caused by sludge formed from the condensate
constituents.
In addition, the exhaust back pressure must be taken into account when designing the piping and
collectors for each subsystem.
▪ Neutralisation must be carried out in accordance with the specifications of local legislation and
regulations.
▪ Regulations and standards on environmental protection, safe handling and the disposal of exhaust
condensate must be observed and implemented in accordance with local legislation and regulations.

5 Calculating the amount of condensate produced

The amount of condensate produced during a cold start can be calculated approximately using the following
formula:
Pm [kW] mechanical power output
VC [l] expected condensate quantity
1 [l] =1 [litres] =0.001 [m3]
SprungMarke!!!8288852363

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin D. Responsible: Release date: 25/08/2014
Index: 1 Page No.: 1/1
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1530-0191
Denso 301, 518 spark plugs

Shut down the engine in accordance with TI 1100-0105 and secure it against unauthorised restarting in
accordance with TI 2300-0010.
Please observe the safety and hazard signs in the safety instructions
(TI 2300-0005) and wear the appropriate personal protective equipment.

1 Area of application
This Technical Instruction applies to all GE Jenbacher engines using Denso 301 or 518 spark plugs.

2 Purpose
This Technical Instruction describes the use of Denso 301 and 518 spark plugs.

3 Setting values for spark plugs

Reference to IW 0309 M0

ATTENTION
Maximum ignition voltage requirement
The ignition voltage requirement stated below must (at full load) not be exceeded under any
circumstances.

Spark-plug type Engine NOx [mg/ Gas type Ignition Spark plug Spark plug
type Nm³] voltage setting tightening torque in
requirement guideline value: cylinder head
[< kV] Electrode gap [Nm]
[mm]
Denso 301 Type 6 to 250 - 500 landfill gas 35 0.3 30
version C natural gas
sludge gas
Denso 301 Type 6 250 - 500 Special 35 0.3 30
on request engine - all gases apart
versions from wood
gas
Denso 518 Type 6 as 250 - 500 landfill gas 35 0.3 30
from natural gas
version E, sludge gas
Type 9 all wood gas
versions

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin, D. Responsible: Spreitzer, K. Release date: 12/06/2015
Index: 1 Page No.: 1/6
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1530-0191
Denso 301, 518 spark plugs

left: Denso 301, right: Denso 518

4 Adjustment tool (the only possible tool)

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin, D. Responsible: Spreitzer, K. Release date: 12/06/2015
Index: 1 Page No.: 2 / 6
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1530-0191
Denso 301, 518 spark plugs

5 Wear signs, and adjusting the spark plugs

ATTENTION
Breaking of spark-plug insulator nose
Do not leave the feeler gauge between the spark plug electrodes when adjusting the electrode
distance, as the pressure could be transferred to the central electrode and may cause the nose
of the spark-plug insulator to break.
Only use the feeler gauge for checking the electrode distance.
When adjusting the electrodes, always use the adjusting tool from the GE Jenbacher scope of
supply and nothing else.

Signs of wear
The noble metal plates at the central and earth electrodes are seriously eroded. There is, however, enough
material left for further operation. Make sure that the earth electrode carrier (see the illustrations below) still
has enough material to prevent auto-ignition. On spark plugs operated at up to 35 kV, the electrode carrier is
often so worn that it tapers to a point or there is so little noble metal stock left that adjustment will result in
severe knocking or very short service intervals.

Adjustment
Use the adjustment tool to set the spark plug to the optimal electrode gap (guideline value 0.3 mm).

5.1 Denso 518 spark plug

5.2 Signs of wear

Earth electrode

Central electrode

1: Denso 518 - can be adjusted

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin, D. Responsible: Spreitzer, K. Release date: 12/06/2015
Index: 1 Page No.: 3/6
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1530-0191
Denso 301, 518 spark plugs

2: Denso 518 - adjustment not recommended due to the danger of auto-ignition

In the case of Fig. 2, it is recommended to operate the Denso 518 up to a maximum ignition voltage of 35 kV
and thereafter replace it by new spark plugs or adjust it if enough electrode material is present.
To adjust the Denso 518 spark plug, use adjustment tool no. 9011882 as described in TI 1400-0162, Operating
Instructions for the adjustment tool for spark plugs with hook electrodes.

6 Service models for the Denso 518

Since spark plugs for engines with prechamber ignition display very different erosion behaviour, particular
attention must be paid to the maintenance strategy. Since the operational demands on spark plugs are
different, several different service models are presented below.

6.1 Model 1: Optimal spark plug loading

This model is based on the assumption that every spark plug will be replaced once the maximum voltage of 35
kV has been reached. Due to the high maintenance outlay, the service costs for this model are correspondingly
high. A service engineer needs to on site quickly to be able to replace every spark plug as soon as the
maximum voltage is reached. Furthermore, the spark plugs should not be adjusted and should be disposed of.
Only those spark plugs that have reached 35 kV are to be replaced, and all the other spark plugs remain
untouched.

6.2 Model 2: Minimum service life multiplied by 1.5

In order to avoid unnecessary servicing work, all spark plugs whose ignition voltage is greater than 26 kV are
replaced as soon as the first spark plug reaches the maximum voltage of 35 kV. Spark plugs that have not yet
reached this voltage are not replaced. The next spark plug service must be carried out as soon as one spark
plug reaches the maximum voltage again. The time between services generally corresponds to the minimum
service life multiplied by 1.5.
The Figure below shows the application example of the 2nd model. Both the maximum voltage of 35 kV and
the replacement limit of 26 kV are plotted on this graph. Spark plug 1-1 (ZK 1-1) has the lowest expected
service life. According to the rules of model 2, all the spark plugs that are between the 26 kV and 35 kV lines
must be replaced. In this example, spark plug 2 would have to be replaced as well. No service activity is
required for any of the others. The next spark plug to reach the maximum voltage is spark plug 3-1. At that
service spark plug 4 would have to be replaced as well, as it is in the replacement area. The initiator of the third
service is spark plug 1, which has again reached the maximum voltage of 35 kV. In this instance, spark plug 5
would have to be replaced as well. Adjustment would also be possible in the case of this spark plug, as the
ignition voltage is only slightly above 26 kV. After the third service, a new cycle begins. In theory, the periods
between services are similar to the first cycle.
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin, D. Responsible: Spreitzer, K. Release date: 12/06/2015
Index: 1 Page No.: 4 / 6
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1530-0191
Denso 301, 518 spark plugs

Ignition voltage requirement

1. Service

2. Service

3. Service
New cycle

Operating hours

Application example for service model 2

6.3 Model 3: Minimum service life multiplied by 2

In this model, all the spark plugs in the area between the shortest service life and double the shortest service
life are replaced. Those spark plugs not in this area will then be replaced as soon as the next cylinder reaches
the end of its service life. The Figure below shows the application example of the 3rd model. All the spark plugs
in the area between the minimum service life and double the service life that have reached the maximum
voltage of 35 kV must be replaced by new spark plugs. As the customer cannot see the expected operating
hours, he has to be guided by the ignition voltages. This means that all spark plugs that exhibit an ignition
voltage between 22 kV and 35 kV must be replaced when the first plug reaches the end of its service life. In the
example shown below, the spark plugs in cylinders nos. 9, 14 and 17 must be replaced. The spark plug in no. 2
cylinder does not have to be replaced, as its ignition voltage is under 22 kV.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin, D. Responsible: Spreitzer, K. Release date: 12/06/2015
Index: 1 Page No.: 5/6
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1530-0191
Denso 301, 518 spark plugs

Upper limit

Replace spark plugs

in this area
High voltage [kV]

Lower limit

Double service life

Operating hours [h]

Application example for service model 3

SprungMarke!!!10891954315

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin, D. Responsible: Spreitzer, K. Release date: 12/06/2015
Index: 1 Page No.: 6 / 6
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1902-0001
Instructions for checking and mounting of waisted screws

1 Instructions on torque values ................................................................................................................ 1

2 Instructions for testing and replacing reduced-shaft bolts ............................................................. 1

1 Instructions on torque values

1.1 For a table of torque values, refer to TI 1902-.... in the respective Operator's Manual.
1.2 All screws, bolts and/or nuts listed in TI 1902-.... must only be tightened using the specified tightening torque
(and angular displacement) and only using a suitable torque wrench. During tightening, fresh engine lubricating
oil must be used as a lubricant (never use molybdenum-based grease!). Apply this oil to the clean thread and to
the bolt or screw head and nut contact surface.
Always follow the instructions in TI 000-00-003!
Never use screws, bolts, nuts or washers which show defects (even slight ones) e.g. on thread or contact faces.
When using a thread locking liquid, use only LOCTITE 243.

2 Instructions for testing and replacing reduced-shaft bolts

After the engine has been dismantled, all reduced-shaft bolts must be tested to ensure that they are in
absolutely perfect condition In the absence of suitable testing equipment or adequate specialist knowledge,
especially when the cost of testing is greater than the value of the bolts, they should be replaced.
These also include reduced-shaft bolts that are not usually removed during a general overhaul of the engine
(e.g. counterbalance bolts, flywheel bolts, etc.).
2.1 The contact faces of the bolt head, the transitional points and the shaft surfaces must be free of notches,
frictional corrosion or rust formation.
The cross-grinding or phosphatisation of the bolt-head contact surfaces must be undamaged.
2.2 The contact faces must be at right angles to the thread.
2.3 Check reduced-shaft bolts for cracks.
2.4 The thread must be free of defects, such as cracks, frictional corrosion, distortions, etc.
2.5 If the criteria set out in sections 2.1 - 2.4 have not been satisfied, new bolts must be used.
Whenever new bolts are to be used, replace the entire set of bolts.
2.6 In the event of damage to con-rods, main bearings or pistons, replace all the bolts in the "surrounding area"
and all bolts that work together as a set.
SprungMarke!!!37502859

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: Konstruktion Release date: 27/05/2010
Index: 1 Page No.: 1/1
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Author: Doku./Bilek
Module type: JGS 616 GS-N.L
Identification: AB ENERGY 616 -31
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.

1 Tightening torques
Index: 9
Responsible: TEK/Stauder Kurt
Engine version: F 01
Device number: J S889

Make sure to drip some fresh engine lubricating oil on the screw thread and sealing faces of screws and bolts which are not secured using
Loctite!
Technical Instruction no.: 000-00-003 must be followed
Designation Drawing Threa Screw-in Tightening Comment Graphical representation Associated

Technical Instruction: TA 1902-0228E/F

No. d torque (stud) torque maintenance
Part No. Nm lbf.ft Nm lbf.ft work
1 Connecting-rod bolt J 0702 M16x1 100/9 mounted using
202 02 07 .5 0° angular displacement

Tightening torques – J 6..GS-E/F

184310 method.

2 Balance weight bolt J 0767 03 M24x1 190/6 mounted using

01 06 .5 0° angular displacement
216192 method.
secured using Loctite
243
3 Cap screw with collar for J 0759 03 M24x1 190/6 mounted using
balance weight 01 06 .5 0° angular displacement
Release date: 16/10/2012

method.
Module number: 1127172

304063
secured using Loctite
243
Page No.: 1/23
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.

5 Vibration damper mounting J 0759 M16x1 290

bolt (J620) 203 00 05 .5
229243
Index: 9
Responsible: TEK/Stauder Kurt
Engine version: F 01
Device number: J S889

6 Hexagonal head bolt with J 0759 M16x1 290

collar for vibration damper 203 00 09 .5
mounting (J620) 304741

Technical Instruction: TA 1902-0228E/F

Tightening torques – J 6..GS-E/F
7 Cap screw for vibration J 0614 M16x1 420
damper mounting (J612 303 01 06 .5
and J616) 181603

8 Cap screw with collar for J 0757 M18x1 420

vibration damper mounting 603 00 09 .5
(J612 and J616) 304035
Release date: 16/10/2012

Module number: 1127172

Page No.: 2/23
Author: Doku./Bilek
Module type: JGS 616 GS-N.L
Identification: AB ENERGY 616 -31
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.

Designation Drawing Threa Screw-in Tightening Comment Graphical representation Associated

No. d torque (stud) torque maintenance
Part No. Nm lbf.ft Nm lbf.ft work
9 Flywheel mounting bolt 115053 M18x1 420 secured using Loctite
.5 243

10 Flywheel mounting bolt with J 0759 M18x1 420 secured using Loctite
collar 103 00 05 .5 243
309657
Index: 9
Responsible: TEK/Stauder Kurt
Engine version: F 01
Device number: J S889

11 Flywheel ring gear bolt 100475 M12 80 secured using Loctite

243

Technical Instruction: TA 1902-0228E/F

Tightening torques – J 6..GS-E/F
12 Main bearing bolt J 0759 05 M33x2 800 Material 10.9
01 05
229865
13 J 0758 Material 12.9
705 01 05
351504
Release date: 16/10/2012

Module number: 1127172

Page No.: 3/23
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.

Author: Doku./Bilek
Module type: JGS 616 GS-N.L
Identification: AB ENERGY 616 -31
Designation Drawing Threa Screw-in Tightening Comment Graphical representation Associated
No. d torque (stud) torque maintenance
Part No. Nm lbf.ft Nm lbf.ft work
14 Nut for main bearing bolt J 0759 05 M33
01 06
229867
Hydraulic torque wrench 133456 For material 12.9:
1095 bar/
bolt elongation: 1.30
mm.
permanent strain:
0.95-1.00 mm
Index: 9
Responsible: TEK/Stauder Kurt
Engine version: F 01
Device number: J S889

For material 10.9:

779 bar/
bolt elongation: 0.76
mm permanent
strain:
0.58-0.62 mm
313226 For material 12.9:

Technical Instruction: TA 1902-0228E/F

645 bar/ bolt
elongation: 1.30 mm
permanent strain:
0.95-1.00 mm

Tightening torques – J 6..GS-E/F

For material 10.9:
459 bar/
bolt elongation: 0.76
mm.
permanent strain:
0.58-0.62 mm
Mfr. ITH For material 12.9:
1189 bar/ bolt
elongation: 1.30 mm
Release date: 16/10/2012

Module number: 1127172

permanent strain:
0.95-1.00 mm
Page No.: 4/23

For material 10.9:

846 bar/
bolt elongation: 0.76
mm permanent
strain:
0.58-0.62 mm
Author: Doku./Bilek
Module type: JGS 616 GS-N.L
Identification: AB ENERGY 616 -31
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.

Designation Drawing Threa Screw-in Tightening Comment Graphical representation Associated

No. d torque (stud) torque maintenance
Part No. Nm lbf.ft Nm lbf.ft work
15 Cylinder-head nut J 0702 05 M30
01 06
119730
Hydraulic torque wrench 133456 M30 622 bar
Mfr. ITH 675 bar

16 Cap screw with collar J 0759 M27x2 200/9 Assembled using

(lateral tie bolt) 605 01 07 0 angular displacement
method
Index: 9
Responsible: TEK/Stauder Kurt
Engine version: F 01
Device number: J S889

304055

17 Hexagonal head bolt with J 0758 M27x2 400/1 Assembled using

collar (lateral tie bolt) 705 01 07 20° angular displacement
351505 method

Technical Instruction: TA 1902-0228E/F

Tightening torques – J 6..GS-E/F
18 Double-end stud for rocker J 0702 06 M16 105 secured using Loctite
support 00 28 243
119726
19 J 0759
706 00 16
301923

20 Double-end stud for J 0752 M10 12

prechamber retaining 106 01 10
bracket 122482
Release date: 16/10/2012

Module number: 1127172

Page No.: 5/23
Technical Instruction: TA 1902-0228E/F
Tightening torques – J 6..GS-E/F
maintenance
Graphical representation Associated

work

sprayed with
Ultratherm
Comment

lbf.ft
Tightening
torque (stud) torque

900
Nm
40

80
lbf.ft
Threa Screw-in

J 0759 11 M30x2
M10

J 0759 06 M16
d
Drawing

Part No.
21 Nut for double-end stud for 101817

256744

285657
01 41

00 09
No.

22 Sealing pin for endoscopy

23 Engine lifting equipment

prechamber retaining
Designation

bracket

sleeve
bore
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: TEK/Stauder Kurt Release date: 16/10/2012
Index: 9 Page No.: 6/23
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1902-0228E/F
Tightening torques – J 6..GS-E/F
maintenance
Graphical representation Associated

work

secured using Loctite

Comment

222
lbf.ft
Tightening
torque (stud) torque

900

140
Nm
lbf.ft
Threa Screw-in

Nm
M30x2

M16

M16
d
Drawing

Part No.
194194

101615

26 Nut for double-end stud for 101829

No.

25 Cap screw for rocker arm

24 Engine lifting equipment

rocker support
Designation

(inlet)
bolt
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: TEK/Stauder Kurt Release date: 16/10/2012
Index: 9 Page No.: 7/23
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1902-0228E/F
Tightening torques – J 6..GS-E/F
maintenance
Graphical representation Associated

work

secured using Loctite

Comment

243

243
lbf.ft
Tightening
torque (stud) torque

110
Nm
40

65
lbf.ft
Threa Screw-in

Nm
M12

M12

M10
d
Drawing

Part No.
27 Bolt for cylinder-head cover 101610

28 Camshaft wearing ring bolt 100473

195472

30 Bolts for split-type camshaft 115245

No.

29 Camshaft gear bolt

Designation
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: TEK/Stauder Kurt Release date: 16/10/2012
Index: 9 Page No.: 8/23
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1902-0228E/F
Tightening torques – J 6..GS-E/F
maintenance
Graphical representation Associated

work
secured using Loctite
Comment

243
lbf.ft
Tightening
torque (stud) torque

1300

1800
750
Nm
lbf.ft
Threa Screw-in

Nm
195330/1 M30

J 0759 10 M30

M30
d

J 0759 10

J 0759 10
Drawing

Part No.

234831

361570

361573

361634

234832
95331

00 11

00 09

00 81
No.

Hexagonal head bolt with

collar for mounting block
32 Cap screw with collar for
31 Intermediate flange bolt

35 Mounting-block bolt
intermediate flange
Designation

34
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: TEK/Stauder Kurt Release date: 16/10/2012
Index: 9 Page No.: 9/23
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.

Author: Doku./Bilek
Module type: JGS 616 GS-N.L
Identification: AB ENERGY 616 -31
Designation Drawing Threa Screw-in Tightening Comment Graphical representation Associated
No. d torque (stud) torque maintenance
Part No. Nm lbf.ft Nm lbf.ft work
36 J 0759 10 M30 150/6 mounted using
00 83 0° angular displacement
361574 method.

37 Slotted nut for intermediate 195478 M80x2 550 tightened using claw
gear 1 wrench I (TL.472697)
Index: 9
Responsible: TEK/Stauder Kurt
Engine version: F 01
Device number: J S889

(gear train)

38 Slotted nut for intermediate 110963 M45x1 400 Tightened using claw
gear 2 .5 wrench II (part no.

Technical Instruction: TA 1902-0228E/F

(gear train) 472698)

Tightening torques – J 6..GS-E/F

39 Oil pan bolts 100309 M12 80
40 111249 110

41 Exhaust-gas turbocharger / 188136 M16 150 Bolt and nut in

exhaust manifold bolt material 1.4828
42 328972/3 M16-T 190 Bolt and nut in
Release date: 16/10/2012

Module number: 1127172

56682 material 1.4980,

Increased flank
Page No.: 10/23

clearance
Author: Doku./Bilek
Module type: JGS 616 GS-N.L
Identification: AB ENERGY 616 -31
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.

Designation Drawing Threa Screw-in Tightening Comment Graphical representation Associated

No. d torque (stud) torque maintenance
Part No. Nm lbf.ft Nm lbf.ft work
43 Bolt for 2-part exhaust 226242 M12 28 Bolt and nut in
manifold DN200 material 1.4828
44 340755 M12-T 100 Bolt and nut in
material 1.4980,
Increased flank
clearance
45 Nut for double-end stud for 101822 M12 80
exhaust-gas line
Index: 9
Responsible: TEK/Stauder Kurt
Engine version: F 01
Device number: J S889

46 Double-end stud for 236878 M20 190

exhaust-gas turbocharger
bracket

Technical Instruction: TA 1902-0228E/F

47 Nut for double-end stud for 236879 M20 530

Tightening torques – J 6..GS-E/F

exhaust-gas turbocharger
bracket

48 Hexagonal head bolt with J 0759 M20 160/9 Assembled using

collar for exhaust-gas 322 00 08 0° angular displacement
turbocharger bracket 314950 method.
Release date: 16/10/2012

Module number: 1127172

Page No.: 11/23
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.

Author: Doku./Bilek
Module type: JGS 616 GS-N.L
Identification: AB ENERGY 616 -31
Designation Drawing Threa Screw-in Tightening Comment Graphical representation Associated
No. d torque (stud) torque maintenance
Part No. Nm lbf.ft Nm lbf.ft work
49 Cap screw for aftercooler 101249 M12 60/80 Following
pretensioning using a
tightening torque of
60 Nm, tighten to a
torque of 80 Nm
working crosswise
from the centre.
50 Cap screw for aftercooler 408809/1 M12 60/12 Following
15253/ 0 pretensioning using a
101605/4 tightening torque of
Index: 9
Responsible: TEK/Stauder Kurt
Engine version: F 01
Device number: J S889

09702 60 Nm, tighten to a

torque of 120 Nm
working crosswise
from the centre.
51 prechamber gas valve 433894/3 M12x1 30
34976/38 .5
9588
321631 20

Technical Instruction: TA 1902-0228E/F

Tightening torques – J 6..GS-E/F
52 Bolt for fitting the exhaust 236906 M20 380
53 gas turbocharger to the 261958
exhaust gas turbocharger
bracket

54 Bolt with collar for fitting the 360862 M20 240/9 assembled using
exhaust gas turbocharger 0° angular displacement
Release date: 16/10/2012

Module number: 1127172

55 to the exhaust gas 361236 method

turbocharger bracket
Page No.: 12/23
Author: Doku./Bilek
Module type: JGS 616 GS-N.L
Identification: AB ENERGY 616 -31
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.

Designation Drawing Threa Screw-in Tightening Comment Graphical representation Associated

No. d torque (stud) torque maintenance
Part No. Nm lbf.ft Nm lbf.ft work
56 Double-end stud for 398510/3 M20 30 1100 bar
mounting the exhaust-gas 98516
turbocharger to the
exhaust-gas turbocharger
bracket
Hydraulic torque spanner Znr.
33.02361
Mfr. ITH
57 Bolt for mounting the 577152 M20 560
exhaust-gas turbocharger
Index: 9
Responsible: TEK/Stauder Kurt
Engine version: F 01
Device number: J S889

297624
to the exhaust-gas
turbocharger bracket
ABB: A135

58 Bolt for mounting the 527366 M24 540/9 Assembled using

exhaust-gas turbocharger 300822 0° angular displacement

Technical Instruction: TA 1902-0228E/F

to the exhaust-gas method
turbocharger bracket
ABB: A140

Tightening torques – J 6..GS-E/F

59 V-belt for compressor and M12 60 Wet screw thread
turbine housing; and inside of profile
ABB: TPS52 and TPS57 using high-
temperature resistant
lubricant
60 Bolt for mounting the 70
compressor to the bearing
housing; ABB: TPS52
Release date: 16/10/2012

Module number: 1127172

Page No.: 13/23
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.

62 Bolt for mounting the 105

compressor to the bearing
housing; ABB: TPS57
Index: 9
Responsible: TEK/Stauder Kurt
Engine version: F 01
Device number: J S889

63 Bolt for mounting the 75

turbine to the bearing
housing; ABB: TPS57

Technical Instruction: TA 1902-0228E/F

64 bolt for mounting the 34

Tightening torques – J 6..GS-E/F

compressor to the bearing
housing; PBS: NR17 and
NR20

65 bolt for mounting the 34 Moisten screw thread

turbine to the bearing using universal high-
housing; PBS: NR17 and temperature resistant
NR20 lubricant.
Release date: 16/10/2012

Module number: 1127172

Page No.: 14/23
Technical Instruction: TA 1902-0228E/F
Tightening torques – J 6..GS-E/F
maintenance
Graphical representation Associated

work

Check the position of

flange relative to the

turbine housing.
the gas exhaust
Comment

lbf.ft
Tightening
torque (stud) torque
Nm
15

40
lbf.ft
Threa Screw-in

M10-
Tx45
d
Drawing

Part No.

370899
No.

67 Nut for fitting the turbine

ABB: TPS52 and TPS57

exhaust; ABB: TPS52

66 Speed sensor
Designation
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: TEK/Stauder Kurt Release date: 16/10/2012
Index: 9 Page No.: 15/23
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.

Author: Doku./Bilek
Module type: JGS 616 GS-N.L
Identification: AB ENERGY 616 -31
Designation Drawing Threa Screw-in Tightening Comment Graphical representation Associated
No. d torque (stud) torque maintenance
Part No. Nm lbf.ft Nm lbf.ft work
68 Nut for fitting the turbine 370900 M12- 65 Check the position of
exhaust; ABB: TPS57 Tx50 the gas exhaust
flange relative to the
turbine housing.
Index: 9
Responsible: TEK/Stauder Kurt
Engine version: F 01
Device number: J S889

V-belt for turbine exhaust 12 Moisten screw thread

PBS: NR17/S and NR20/S and inside of profile
using high-

Technical Instruction: TA 1902-0228E/F

temperature resistant
lubricant
70 Spark plug in cylinder head 289383/3 M18x1 30 Sprayed with Never
38159 .5 Seeze

Tightening torques – J 6..GS-E/F

71 Bolt to knock sensor 100418 M8 20 Do not use a filler ring
Release date: 16/10/2012

Module number: 1127172

Page No.: 16/23
Technical Instruction: TA 1902-0228E/F
Tightening torques – J 6..GS-E/F
maintenance
Graphical representation Associated

work
Comment

lbf.ft
Tightening
torque (stud) torque
Nm
40
lbf.ft
Threa Screw-in

Nm
d
Drawing

Part No.
No.

73 Cooling water pressure

72 Boost pressure sensor

74 Oil pressure sensors

Designation

sensor
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: TEK/Stauder Kurt Release date: 16/10/2012
Index: 9 Page No.: 17/23
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1902-0228E/F
Tightening torques – J 6..GS-E/F
maintenance
Graphical representation Associated

work
Comment

lbf.ft
Tightening
torque (stud) torque

18-24

12-18
Nm

5.8

15
lbf.ft
Threa Screw-in

M12

M10

M10
M6
d

1201866
Drawing

Part No.
No.

with parallel starter relays)

(multi-starter applications
75 Iskra starter, type AZG:
Nut for securing the +

Nut for securing the

Hexagonal nut for

negative terminal

connection 50

connection 45
Designation

terminal
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: TEK/Stauder Kurt Release date: 16/10/2012
Index: 9 Page No.: 18/23
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Author: Doku./Bilek
Module type: JGS 616 GS-N.L
Identification: AB ENERGY 616 -31
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.

Designation Drawing Threa Screw-in Tightening Comment Graphical representation Associated

No. d torque (stud) torque maintenance
Part No. Nm lbf.ft Nm lbf.ft work
76 Hexagonal nut for valve 113793 M12x1 80
adjustment bolt inlet valve .5

77 Hexagonal nut (at valve 113798 M14x1 80

push rod) for valve .5
adjustment bolt inlet valve
Index: 9
Responsible: TEK/Stauder Kurt
Engine version: F 01
Device number: J S889

78 Hexagonal nut for valve 113798 M14x1 80

adjustment bolt – outlet .5
valve

Technical Instruction: TA 1902-0228E/F

Tightening torques – J 6..GS-E/F
79 Nut and lock nut for 370897 M10 40
securing the diffuser at the
turbine outlet; ABB: TPS52
Release date: 16/10/2012

Module number: 1127172

Page No.: 19/23
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.

Author: Doku./Bilek
Module type: JGS 616 GS-N.L
Identification: AB ENERGY 616 -31
Designation Drawing Threa Screw-in Tightening Comment Graphical representation Associated
No. d torque (stud) torque maintenance
Part No. Nm lbf.ft Nm lbf.ft work
80 Nut and lock nut for 370898 M12 65
securing the diffuser at the
turbine outlet; ABB: TPS52
Index: 9
Responsible: TEK/Stauder Kurt
Engine version: F 01
Device number: J S889

81 Tensioners for securing the Mfr. P&S Main thread sprayed

exhaust gas turbo-charger; with Ultratherm.
ABB: A140 Tighten the tensioner

Technical Instruction: TA 1902-0228E/F

in accordance with
maintenance
instructions for
exhaust gas

Tightening torques – J 6..GS-E/F

turbocharger (W8026
M6).
82 Cylinder pressure sensor in 548302/5 25
the combustion chamber 81263
Release date: 16/10/2012

Module number: 1127172

Page No.: 20/23
Technical Instruction: TA 1902-0228E/F
Tightening torques – J 6..GS-E/F
maintenance
Graphical representation Associated

work
Comment

lbf.ft
Tightening
torque (stud) torque

22-30

20-28
4-4.5

30±3
Nm
lbf.ft
Threa Screw-in

M 12
M12

M12
M6
d
Drawing

Part No.
120345

460867
No.

83 Bosch-starter, type TB(R)

84 Bosch-starter, type HEP:

Nut for securing the +

Nut for securing the

negative terminal
Nut on starter
Designation

terminal
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: TEK/Stauder Kurt Release date: 16/10/2012
Index: 9 Page No.: 21/23
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1902-0228E/F
Tightening torques – J 6..GS-E/F
maintenance
Graphical representation Associated

work
Comment

lbf.ft
Tightening
torque (stud) torque

25/45°

110

190
Nm
lbf.ft
Threa Screw-in

Nm
M10

M10

M12

M16
d

1214629

1214629
Drawing

Part No.

100474

100495
No.

mounting bolt for gear train

87 Hexagon head bolts for

88 Hexagon head bolts for

85 Hexagon-head gear

86 Hexagon-head gear
Designation

gear train

gear train
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: TEK/Stauder Kurt Release date: 16/10/2012
Index: 9 Page No.: 22/23
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 1902-0228E/F
Tightening torques – J 6..GS-E/F
maintenance
Graphical representation Associated

work
Comment

lbf.ft
Tightening
torque (stud) torque
Nm
30
lbf.ft
Threa Screw-in

Nm
M18x1
.5
d
Drawing

Part No.
408895
No.

ventingIntercooler
89 Ball valve for
Designation

SprungMarke!!!72057594075456651
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Bilek Responsible: TEK/Stauder Kurt Release date: 16/10/2012
Index: 9 Page No.: 23/23
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2102-0020
Check list for engine repairs and overhauls

1 Purpose of this instruction...................................................................................................................... 1

2 Scope ........................................................................................................................................................... 1
3 Check list for engine repairs and overhauls ........................................................................................ 2
4 Appendix: Measured values: ................................................................................................................... 3
5 Appendix: Assembly protocol ................................................................................................................. 4
6 Appendix: Hand-over protocol ............................................................................................................... 5

1 Purpose of this instruction

This check list is intended to assist in repairing and overhauling GE Jenbacher engines correctly if the oil system
has to be opened in the course of these repairs and overhauls.

2 Scope
This check list can be used for all engine types without restriction.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Provin Responsible: Nota F. Release date: 16/10/2013
Index: 2 Page No.: 1/5
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2102-0020
Check list for engine repairs and overhauls

3 Check list for engine repairs and overhauls

Generator No.: Engine No.:

No. Description ☑
1 Shut down the engine in accordance with Technical Instruction No. 1100-0105 and protect against ❑
unauthorised persons starting the engine in accordance with Technical Instruction No. 2300-0010.
2 Read the safety and hazard advice in the safety instructions (TI 2300-0005) and wear the appropriate ❑
personal protective equipment.
3 Check the scope of the work to be carried out and make sure that all the necessary materials and ❑
tools are ready.
4 Only use clean, valid and accurate tools as claimed in ⇨ TA 2300-0005: 6.1 Use of tools [⇨ Page 8]. ❑
5 Make sure that the engine room is as clean as possible. ❑
6 Check whether the engine room ventilation can be shut down. (not possible if other engines are in ❑
operation). Prepare tarpaulins or plastic covers to cover the engine.
7 As soon as the engine is opened up, make sure that the openings are covered or sealed off as quickly ❑
as possible to prevent contamination by dirt, dust or the like.
8 If clean oil bores, galleries, pipes etc. are opened, make sure that they are covered or sealed off ❑
immediately (!). This is especially important for crankshafts. Crankpin journals must be covered at
once. The best way of doing this is to clean them, wrap them in cleaning paper and secure the paper
with self-adhesive tape.
9 For longer pauses (e.g. overnight) cover the entire engine to avoid any possible dirt contamination. ❑
10 Make 100% sure that no machinery such as angle grinders or other rotating machinery with grinding ❑
wheels, brushes etc. are used in the engine room. Experience has shown that brush wires or parts of
other rotating tools can contaminate the entire engine room.
11 Avoid using compressed air in the engine room. ❑
12 When rebuilding the engine, only ever use clean engine oil from a closed oil can. Do not use open oil ❑
cans with brushes or the like, as these are very likely to be contaminated with dirt. Dirt contamination
of the oil can damage every kind of bearing.
13 When replacing big-end or main bearings, makes sure in advance that you have the correct size and ❑
type of bearing ready. Engines can have crankpin and main bearing journal sizes that differ from
standard. Make sure when using oversized conrods that you have the matching bearings ready. The
conrods are marked with their diameters.
Important: Always check the dimensions, not the part numbers. Fill in the additional Appendix No. 1.
14 Make sure when replacing pistons, piston rings, cylinder liners (which may be oversized) that you have ❑
the correct parts ready and that these parts fit together (e.g. liner diameter, scraper ring height to
piston, etc.).
15 Follow all the applicable Technical Instructions and Maintenance Instructions when rebuilding the ❑
engine.
Fill in the protocol in Appendix 2.
16 Only use the correct standard and special tools approved by GE Jenbacher. ❑
17 Make sure that all parts are properly cleaned before assembly. ❑
18 Before closing all the crankcase covers, make sure that nothing has been left inside the engine: ❑
▪ Check completeness of tools.
▪ Ensure that no tools or broken parts have been left inside the engine or engine components.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Provin Responsible: Nota F. Release date: 16/10/2013
Index: 2 Page No.: 2 / 5
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2102-0020
Check list for engine repairs and overhauls

Date Signature Steps carried out

Team Leader

Technician 1

Technician 2

Technician 3

Technician 4

Technician 5

4 Appendix: Measured values:

Diameter in mm
Crankpin journal diameter
Main bearing journal diameter

Old bearing part New bearing part Bearing Crankpin journal

numbers numbers specification diameter
marking (diameter) (measured)
Main bearings
Big-end bearings

Comment: Remember that bearings may be marked as "Std." but oversized or undersized bearings will also be
marked with the diameter. Any such additional marking must match the specific diameter of the crankpin
journal or main bearing journal.
Oversized and undersized bearings will not be marked as "Std.", but the respective diameters will have been
marked on the bearing.
Oversized conrods are always marked with the German word "Uebermass" (Oversize) and/or the diameter, e.g.
"D 107.25".
Remember that the part numbers may be different. This is due to the fact that bearing sets of the new type of
Synthec bearing have different part numbers for the bottom shells compared to other bearing sets. The
diameters are more important than the part numbers.

Name, signature and date of comparison and

measurement

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Provin Responsible: Nota F. Release date: 16/10/2013
Index: 2 Page No.: 3/5
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2102-0020
Check list for engine repairs and overhauls

5 Appendix: Assembly protocol

Task Torque and angle used Name, signature
Hydraulic pressure, if applicable
Main bearing bolts

Main bearing bracket tie bolts

Fitting the pistons

Connecting rod bearing bolts

Cylinder head nuts

Rocker bolts and nuts

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Provin Responsible: Nota F. Release date: 16/10/2013
Index: 2 Page No.: 4 / 5
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2102-0020
Check list for engine repairs and overhauls

6 Appendix: Hand-over protocol

By whom (name, To whom (name, Date/ Which work has already Open tasks to be carried
signature, reason) signature) Time been carried out out next

SprungMarke!!!9007202038616587

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Doku./Provin Responsible: Nota F. Release date: 16/10/2013
Index: 2 Page No.: 5/5
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2108-0026
Isolated operation of spark ignition gas engines with DIA.NE (type 6 en-
gines)

1 Scope
This Technical Instruction (TI) applies to all Type 6 engines equipped with the "Island Mode" option.
The illustrations in this TI refer to engines warmed up to operating temperature.

2 Purpose
The diagrams included in this TI above provide information on the permissible, switchable effective electrical
power block load (both positive and negative) plotted on the y axis as a function of the current effective power
"base load" on the x axis for each individual class as specified in ISO 8528.
The specified power outputs are shown as a percentage of the rated power (after allowing for given
reductions), rated frequency and cosφ=1 of the engine version concerned, in accordance with the product
range.

3 General
See Technical Instruction 2108-0031 for general instructions and explanations on island mode operation of GE
Jenbacher gas engines.
The generating set needs about 15 seconds between load increases within the classes (including allowing for
the settling time), and about 30 seconds for load increases outside the classes, for the control system to
stabilise. It is essential to adhere to this, especially when starting engines that are already at operating
temperature.
The maximum possible load jump (addition or shedding) without observing the standard ISO 8582 Part 5 is
marked in the load shift diagrams with "LIMIT". If this category is not given in a diagram, the limit corresponds
to the lowest class given.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin, D. Responsible: Spreitzer, K. Release date: 13/02/2014
Index: 4 Page No.: 1/11
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2108-0026
Isolated operation of spark ignition gas engines with DIA.NE (type 6 en-
gines)

4 Power shift diagrams type 6 engines in compliance with ISO 8528, Part 5

4.1 Power shift diagrams Version E

4.1.1 Taking frequency difference and adjustment time into account

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin, D. Responsible: Spreitzer, K. Release date: 13/02/2014
Index: 4 Page No.: 2 / 11
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2108-0026
Isolated operation of spark ignition gas engines with DIA.NE (type 6 en-
gines)

-5

-10
Block Load [%Nominal Load]

-15

-20

-25

-30

-35

-40 CLASS 1

-45

-50
0 20 40 60 80 100
Base Load [%Nominal Load]

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin, D. Responsible: Spreitzer, K. Release date: 13/02/2014
Index: 4 Page No.: 3/11
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2108-0026
Isolated operation of spark ignition gas engines with DIA.NE (type 6 en-
gines)

4.2 Power shift diagrams type 6 engines Version F

4.2.1 Taking frequency difference and adjustment time into account

45
Block Load [%Nominal Load]

40 LIMIT

15 CLASS 1
CLASS 2
10
CLASS 3
5

0
0 20 40 60 80 100
Base Load [%Nominal Load]

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin, D. Responsible: Spreitzer, K. Release date: 13/02/2014
Index: 4 Page No.: 4 / 11
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2108-0026
Isolated operation of spark ignition gas engines with DIA.NE (type 6 en-
gines)

-5

-10 CLASS 3
Block Load [%Nominal Load]

-15

-20 CLASS 2

-25

-30

-35

-40 CLASS 1

-45

-50
0 20 40 60 80 100
Base Load [%Nominal Load]

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin, D. Responsible: Spreitzer, K. Release date: 13/02/2014
Index: 4 Page No.: 5/11
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2108-0026
Isolated operation of spark ignition gas engines with DIA.NE (type 6 en-
gines)

4.2.2 Taking frequency difference into account without adjustment time

0
CLASS 3
GEJ
-5

-10

-15
Block Load [% Nominal Load]

-20

-25

-30

-35

-40

-45

-50
0 10 20 30 40 50 60 70 80 90 100
Base Load [% Nominal Load]

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin, D. Responsible: Spreitzer, K. Release date: 13/02/2014
Index: 4 Page No.: 6 / 11
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2108-0026
Isolated operation of spark ignition gas engines with DIA.NE (type 6 en-
gines)

4.3 Power shift diagrams Type 6 Version G engines

4.3.1 Allowing for frequency and voltage deviations with the settling time

Positive Load Diagram - Settling Time Criteria

J624 G101 MN94 Pnom 4MW BMEP 22bar @ 50Hz
40

Classification
Allowable Load Increase at Rated Power [%]

35 according to
ISO8528-5:2005

30 Limit

20 Class 1

10 Class 2

0
0 10 20 30 40 50 60 70 80 90 100

Basis Load at Rated Power [%]

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin, D. Responsible: Spreitzer, K. Release date: 13/02/2014
Index: 4 Page No.: 7/11
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2108-0026
Isolated operation of spark ignition gas engines with DIA.NE (type 6 en-
gines)

4.3.2 Allowing for frequency and voltage deviations without the settling time
Positive Load Diagram - Maximal Dynamic Deviation Criteria
J624 G101 MN94 Pnom 4MW BMEP 22bar @ 50Hz
40

35
Allowable Load Increase at Rated Power [%]

25 Limit

Class 1

20 Class 2

15 Class 3

0
0 10 20 30 40 50 60 70 80 90 100

Basis Load at Rated Power [%]

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin, D. Responsible: Spreitzer, K. Release date: 13/02/2014
Index: 4 Page No.: 8 / 11
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2108-0026
Isolated operation of spark ignition gas engines with DIA.NE (type 6 en-
gines)

Negative Load Diagram - Maximal Dynamic Deviation Criteria

J624 G101 MN94 Pnom 4MW BMEP 22bar @ 50Hz
0

-10

-20
Allowable Load Increase at Rated Power [%]

-30 Class 3

Class 2
-40

Class 1
-50 Limit

-60

-70

-80

-90

-100
0 10 20 30 40 50 60 70 80 90 100
Basis Load at Rated Power [%]

4.4 Power shift diagrams for Type 6 Version H engines

This evaluation is based on test bed measurements with the following engine configuration:
▪ versions H5, H6, H11, H12, H111 and H112.
The engine designs allow the following graphs to be used for all Type 6 Version H engines.
▪ LSA56 generator
▪ Software revision for PP2014 (volumetric flow characteristic diagram and new lambda modification for
island operation active).
The measured data evaluation is based on a BMEP of 24 bar.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin, D. Responsible: Spreitzer, K. Release date: 13/02/2014
Index: 4 Page No.: 9/11
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2108-0026
Isolated operation of spark ignition gas engines with DIA.NE (type 6 en-
gines)

4.4.1 Allowing for frequency and voltage deviations with the settling time:

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin, D. Responsible: Spreitzer, K. Release date: 13/02/2014
Index: 4 Page No.: 10 / 11
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2108-0026
Isolated operation of spark ignition gas engines with DIA.NE (type 6 en-
gines)

4.4.2 Allowing for frequency and voltage deviations without the settling time:

SprungMarke!!!27021597801812619

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Provin, D. Responsible: Spreitzer, K. Release date: 13/02/2014
Index: 4 Page No.: 11/11
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2108-0031
Isolated operation - general

1 Definition .................................................................................................................................................... 1
2 Categories of isolated operation ........................................................................................................... 3
3 Factors influencing isolated operation................................................................................................. 3
3.1 Load application ........................................................................................................................................................ 3
3.2 Load shedding ............................................................................................................................................................ 4
4 Factors influencing locals mains systems (multi-engine plants)..................................................... 4
5 Assessment of isolated operation performance................................................................................. 4
6 Power shift diagrams for isolated operation....................................................................................... 5
6.1 Power shift diagrams............................................................................................................................................... 5
6.2 Load shedding ............................................................................................................................................................ 7
7 Planning and technical features ............................................................................................................ 7
7.1 Supplying power to installations with an uninterruptible power supply (UPS installations) ......
8
7.2 Parallel operation with UPS systems................................................................................................................ 8
7.3 Automatic backup time of 15 s in conformity with DIN VDE 0100, Part 710 and/or 718........ 9
7.4 Soft magnetisation of transformers ................................................................................................................. 9
7.5 Black start ..................................................................................................................................................................... 9
7.6 Several generating sets operating in parallel .............................................................................................. 9
7.6.1 Offset coefficient 9
7.6.2 Load distribution 9
7.6.3 Load management 10
7.7 Points requiring special attention.................................................................................................................... 10
7.7.1 Information on operational condition from switch conditions – delay times 10
7.7.2 Unknown customer load ratios – capacitive loads 10
7.7.3 System interconnection control system 10
7.7.4 Auxiliaries 10
8 Constraints............................................................................................................................................... 10
8.1 Rated engine load ................................................................................................................................................... 10
8.2 Emissions..................................................................................................................................................................... 11
8.3 Mixture cooling water temperature, mixture temperature ................................................................. 11
8.4 Ignition timing point ............................................................................................................................................... 11
8.5 Intake temperature................................................................................................................................................. 11
8.6 exhaust-gas back pressure ................................................................................................................................ 11
8.7 Isolated operation with biogas, landfill gas and sludge gas............................................................... 11
8.8 Gas supply .................................................................................................................................................................. 11
8.9 Generator .................................................................................................................................................................... 12
9 Appendix A. Isolated Operation Performance Assessment Characteristics................................ 13

1 Definition
Gas engines are said to be in isolated/emergency power/standby operation when the plant is required to
maintain the power supply to the consumers in the absence of the public power grid (see Figure 1). As soon as
this occurs, the bus bar frequency and voltage must be maintained within defined limits.
Mains parallel operation Local mains system Primary isolated operation

L L DS L L DS L L DS

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TCC/Sarmiento Responsible: Controls Release date: 05/03/2012
Index: 3 Page No.: 1/16
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2108-0031
Isolated operation - general

Mains parallel operation Local mains system Primary isolated operation

Local mains (A)

L: Load
L

Local mains (B)

L: Load
L DS DG: Distributed generation

Mains

If the consumers are supplied with energy by a generator driven by a reciprocating internal combustion engine,
referred to below as the generating set, the frequency is regulated by the engine speed and voltage control is
effected by the automatic voltage regulator - AVR - incorporated as an integral part of the generator.

ωm/θm AVR P/Q

Us/Is

Ug/Ig
ωref R u E Tmot K Tgen G ωe/θe
L
Figure 2. Isolation operation
E GE Jenbacher Engine L Load
K Coupling AVR Automatic Voltage Regulator
R Controller G Generator
u Controlled variable Us/Is Excitation voltage/current
ωe/θe Generator electrical speed/angle position Ug/Ig Generator voltage/current
ωe/θe Generator mechanical speed/angle position Tgen Generator torque
ωref Set point value Tengine Engine torque
P/Q Active / reactive power

In plants with more than one engine or with generating sets from other manufacturers in a local mains system,
the frequency and voltage are regulated by one part or by all the generating sets. The active and reactive
power must then be controlled by the load management system. A small proportion in terms of power can be
power-controlled in this local system. In must be ensured here that variations in output can be called up
quickly, and as a result high dynamic properties are necessary.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TCC/Sarmiento Responsible: Controls Release date: 05/03/2012
Index: 3 Page No.: 2 / 16
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2108-0031
Isolated operation - general

2 Categories of isolated operation

Stand-by operation Isolated operation of the gas engine is only required as a stand-by solution
for the mains supply, and is not designed for continuous operation.
Primary operation Isolated operation of the gas engine is used as the primary energy source for
(100% isolated) the consumers. Diesel sets or the mains can be available as stand-by energy
sources.
Emergency power operation This is the same as stand-by operation, but with far higher demands on the
start-up time (e.g. 15 seconds start-up time, black start) and maximum
availability.
Supplying local mains systems The gas engine operates as part of a local mains system which is not
connected to the public mains system. This operation presents particular
requirements regarding short interruptions, loading and load shedding, and
redundant operation (n-1).
Greenhouse applications Very gentle power shifts due to relatively small loads combined with
extensive load management for power shifts, transition from mains to
isolated operation. The gas engine is generally operated at 100% of its rated
load, since suitable small load stages are available.
Fire pump systems The gas engine is designed to supply fire pumps. Special requirements are
placed on the engine regarding the time until the load can be applied. The
gas engine must have the maximum possible availability (even if suffering
from faults) and must not be shut down without valid reasons during
operation in support of firefighting operations.

3 Factors influencing isolated operation

The dynamics of a generating set are affected by a large number of factors. The step response is determined
by both mechanical and electrical phenomena. In order to state the frequency and voltage behaviour of a
generating set under load changes, the maximum load application and rejection capabilities must be
ascertained. Attention must be paid to the following, among other things:
▪ coincidence factor of the consumers
▪ intermittent output in the course of operation
The required generating set rated power can only be laid down if the electrical consumers to be supplied are
known. This entails above all taking note of the occurring load surges when consumers are switched on, e.g.
lifts. pumps, fans, lighting and non-linear consumers. Once the consumer profile is known, the following must
be taken into account:

3.1 Load application

The load assumption capability of the generating set depends primarily on the mean effective pressure (BMEP)
of the engine at the rated frequency and power, the pressure-charging dynamics (dynamics of the exhaust gas
turbocharger), and characteristics and settings of the AVR, and the total engine-generator moment of inertia.
Since the function of all the influences cannot be expressed in terms of values, recommended mean values for
load application should be given, taking a maximum permissible frequency dip as the criterion.
Due to the high mean effective pressure, the load must be applied in stages (see ISO 8528-2:2005). Since the
times between the individual power stages depend on the BMEP as well as the effective moment of inertia of
the generating set, these may need to be agreed with the plant operator as necessary. If the load must be
applied in a number of stages, the need for the appropriate circuitry for this must be taken into account. The
permissible values for the dynamic frequency and voltage fluctuations at load changes can be taken as the
criterion.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TCC/Sarmiento Responsible: Controls Release date: 05/03/2012
Index: 3 Page No.: 3/16
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2108-0031
Isolated operation - general

The generating set requires approx. 15 seconds between load applications for the control system to stabilise
itself, and approx. 30 seconds to stabilise itself thermally. This must be adhered to, especially when the engines
have not yet reached their operating temperature.
In order to prevent overloads and the consequential failure of the generating set, it must be ensured that at the
moment when the load is applied, the existing power requirements of the consumer equipment at the time
does not exceed the power output of the particular generating set and engine type.

3.2 Load shedding

The response of the generating set after load shedding depends on the actuator and gas dynamics. On some
engines with pressure-charging, a load-shedding limit is laid down to avoid the risk of turbocharger pumping or
deflagrations.
The limits for load shedding are specified separately for each engine type (see TI-2108-002, Load-shedding
capability). Further information can be found in Section 6.2.

4 Factors influencing locals mains systems (multi-engine plants)

The following can influence parallel operational behaviour:
▪ load distribution
▪ speed droop of the speed controller
▪ dynamic behaviour of the engine in question
▪ AVR droop
▪ dynamic behaviour of the generator taking into account the damping characteristics of the mains system
in question .
More detailed information about the factors influencing the distribution of active and reactive power in
accordance with ISO 8528-5:2005 can be found in TI 1530-0182.
Where different energy generators are being used in combination (generating sets from different
manufacturers or different types of energy generators), other options besides a load distribution line or the
standard speed-drop control are provided by a higher-order load management system, but these options
should be checked first for each specific project. Further information can be found in Section 7.5.

5 Assessment of isolated operation performance

The operational behaviour of a generating set powered by a reciprocating internal combustion engine is
assessed in compliance with ISO 8528, Part -5. This Standard replaces DIN 6280, which is no longer valid.
Depending on the specific application, different design classes ranging from G1 to G4 will apply. The figures
given in Table 1 for the respective design classes are permissible limit values, which unless otherwise stated
may not be exceeded in the course of operation (see ISO 8528-5:2005 Table 4 - Performance Class Operating
Limit Values). The limit values below refer to external-ignition gas engines under load.
The respective design class always applies to a power generation plant if all the limits laid down to this design
class have been met. If customers request deviations from the limit values in terms of higher quality, these
must be agreed in writing. The design classes do not change in this case.
Class G4 is freely definable - in accordance with customer-specific requirements (CSR) and is specifically
stipulated for GE Jenbacher at ± 7% for the dynamic frequency and voltage difference, disregarding the control
stabilisation time. Other limit levels can be defined and displayed to take account of application-specific issues.
If an emergency power supply is provided for hospitals or communal facilities (in compliance with DIN VDE
0100, Part 710 and Part 718 respectively), operational behaviour is assessed in accordance with ISO
8528-12:2005. In both cases, special attention must be paid to the required interruption times/transition times.
The assessment criteria laid down in ISO 8528-12 are equivalent to those laid down in ISO 8528-5.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TCC/Sarmiento Responsible: Controls Release date: 05/03/2012
Index: 3 Page No.: 4 / 16
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2108-0031
Isolated operation - general

Parameters Icon Unit Limit values

Class 1 Class 2 Class 3 Class 4
Frequency deviation αf % 3.5 2 2 CSR
bandwidth
Steady-state frequency βƒ % ≤2.5 ≤1.5 ≤0,5 CSR
bandwidths
Dynamic frequency δ-dyn % ≤-25 ≤-20 ≤-15 CSR
deviation after a load
application
Dynamic frequency δ+dyn % ≤+18 ≤+12 ≤+10 CSR
deviation after load
rejection
Frequency control settling tf,app s ≤10 ≤5 ≤3 CSR
time after load application
Frequency control settling tf,shed s ≤10 ≤5 ≤3 CSR
time after load rejection
Static voltage difference δUst % ≤±5 ≤±2.5 ≤±1 CSR
-
Dynamic voltage deviation δU dyn % ≤-25 ≤-20 ≤-15 CSR
after a load application
Dynamic voltage deviation δU+dyn % ≤+35 ≤+25 ≤+20 CSR
after load rejection
Voltage control settling tU,app s ≤10 ≤5 ≤5 CSR
time after load application
Voltage control settling tU,shed s ≤10 ≤5 ≤5 CSR
time after load rejection
The parameters set out in Table 1 are described in Table 2 and illustrated in Figures 8 and 9.

6 Power shift diagrams for isolated operation

The power shift diagrams of the respective engine types are available in the following Technical Instructions:
▪ Type 2 engine - J208 with DIANE XT TI 2108 - 0030
▪ Type 3 engine with DIANE XT TI 2108 - 0025
▪ Type 4 engine with DIANE XT TI 2108 - 0029
▪ Type 6 engine with DIANE XT TI 2108 - 0026
The diagrams listed above provide information on the permissible, switchable effective electrical power block
load (both positive and negative) plotted on the y axis as a function of the current effective power "base load"
on the x axis for each individual class as specified in ISO 8528.
The specified power outputs are shown as a percentage of the rated power (after allowing for given
reductions), rated frequency and cosφ=1 of the engine version concerned, in accordance with the product
range.

6.1 Power shift diagrams

The diagrams in the Technical Instructions for each of the engine types apply to engines at operating
temperature.
The diagrams show design classes G1 to G4 and the limit outputs (the outputs at which load can still be
applied, taking all limit values - minimum and maximum frequency and voltage - into account (see Figures 3
and 4). The lines show the maximum load that can be applied or shed, as the respective limit values correspond

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TCC/Sarmiento Responsible: Controls Release date: 05/03/2012
Index: 3 Page No.: 5/16
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2108-0031
Isolated operation - general

to the design class. Where special requirements have been specified for loads to be added or shed, suitable
concepts (choice of shedding stages, mains interconnection control unit, load management system) must be
drawn up.
The specific TI for the various engine types each include two (2) diagrams for load application and shedding.
One is shown in accordance with ISO 8528-5:2005, and one disregarding the frequency and voltage control
settling time. The second form takes the criterion of maximum frequency dip into account (see Appendix A). The
x axis describes the starting load (base load) and the y axis the switching load (block load), each as a
percentage [%] of the rated power.
50

40
Block Load [% Nominal Load]

30 Limit

25 Class 1

20 Class 2

15 Class 3

10
Class 4
5

0
0 10 20 30 40 50 60 70 80 90 100
Base Load [% Nominal Load]
Figure 3. Load application diagram

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TCC/Sarmiento Responsible: Controls Release date: 05/03/2012
Index: 3 Page No.: 6 / 16
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2108-0031
Isolated operation - general

-10

-20
Block Load [% Nominal Load]

Class 3
-30

-40
Class 3
-50

-60 Class 2

-70

-80 Class 1

-90 Limit

-100
0 10 20 30 40 50 60 70 80 90 100
Base Load [% Nominal Load]
Figure 4. Load-shedding diagram

6.2 Load shedding

Normally, load reduction on the gas engine will occur during the transition from mains parallel operation to
isolated operation or during isolated operation. Because of the design of the turbocharger, this can cause
"pumping behaviour" in the turbocharger. No limitations on the load shedding behaviour are required for type
2, 3 and 4 engines.
Currently, type 6 engines are subject to individual limit levels for load-shedding capability (see TI 2108-0026,
load-shedding capability).

7 Planning and technical features

The classification into one of the design classes described in Section 5 depends on the consumers to be
supplied during isolated operation and must therefore be determined by the customer. This therefore results in
the maximum possible power shift. Careful coordination with the customer during the tender and planning
stage is therefore essential. The size and type of the electrical consumers and their starting and operational
characteristics must be known by this stage. In the case of electric motors the magnitude of the effective
starting power is relevant, as this determines the effective torque at the motor shaft. The torque depends on
the type of electric motor and the starting conditions (star-delta starting, soft start, thyristor-controlled drives,
heavy starting, etc.).

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TCC/Sarmiento Responsible: Controls Release date: 05/03/2012
Index: 3 Page No.: 7/16
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2108-0031
Isolated operation - general

MN
3

nN n
Figure 5. Torque profile for an electric motor start
① Direct start
② Star-delta starting
③ Soft start

You must take into account that during isolated operation, the power consumption by single "rotating"
consumers with comparatively high moments of inertia J (large fans, pumps, etc.) must not exceed approx.
40% of the rated power of the generating set. In addition, remember that the starting current of electric motors
is several multiples of the nominal value. This percentage is based on empirical data and indicates the point
from which dynamic interactions between the generating set and the consumer can occur. Cases like this
require special measures, which can be determined by means of simulations. Power flow analyses are used for
this.
In isolated operation with several engines, it is the case that the first module must already supply consumers
while the other modules are synchronised to it. In such cases, you must ensure that only very limited load
fluctuations (max. 2% of the rated module load) occur during the synchronisation process. The more frequent
such load fluctuations are, the longer the synchronising procedure will take.
Since the current and cos(ϕ) curve of consumers define the engine dynamics, these must be specifically
obtained from the customer and passed on.

7.1 Supplying power to installations with an uninterruptible power supply (UPS installations)
When supplying power to UPS installations, it is essential to use their interaction features (e.g. staggered
switching in, ramp-shaped loads). This will reduce the effect of added loads and result in a generally more
efficient use of the module. Normally, strict tolerances apply to the maximum admissible voltage and
frequency deviations on the input side of UPS systems. It is absolutely essential that this fact is taken into
account.

7.2 Parallel operation with UPS systems

Because of the differing voltage forms and dynamic characteristics (frequency control of a generating set is
based on "rotating masses", while in UPS systems the frequency control is inertia-free using power electronics),
parallel operation with standard software is not possible. Clarification for the specific project in question is
necessary.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TCC/Sarmiento Responsible: Controls Release date: 05/03/2012
Index: 3 Page No.: 8 / 16
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2108-0031
Isolated operation - general

7.3 Automatic backup time of 15 s in conformity with DIN VDE 0100, Part 710 and/or 718
Supplying emergency power consumers in conformity with the above standard within a 15 s timeframe is not
currently possible for type 2, 3 and 4 GE Jenbacher gas engines. Due to the design of the auxiliary equipment
on type 6 engines, emergency power can only be supplied to emergency consumers after clarification for the
specific project.

7.4 Soft magnetisation of transformers

Where transformers have to be accelerated in self-contained start mode, the acceleration power must be
monitored to ensure that the module is not overloaded. By way of guidance, transformers with a nominal
power of 2 or more times nominal generator power can be accelerated. However, the method described below
should be used as standard.
In the case of very large isolated operation loads, e.g. large transformers, which cannot be added directly
because of excessive starting currents, it is possible to soft-magnetise them. The module is started, the
generator de-energised, the generator switch activated and the generator energised again.

7.5 Black start

In a black start, the plant is completely disconnected from the public power grid. The GEJ product (generating
set, module, ...) is the prime mover and must start with a 24 V DC power supply and close the generator breaker
at rated speed in order to supply the plant with AC power.
A black start can take place on an engine that was previously not in operation (cold start) or an engine that has
been shut-down (hot start).

7.6 Several generating sets operating in parallel

With regard to the generators used, please bear in mind that a specific reactive-load distribution using voltage
droop takes place as well as an identical voltage reduction using a voltage knee. You should also take into
account the pitch factor of the winding if the generator star points are connected. If this is not identical, star-
point throttles must be used.
During parallel operation of GE Jenbacher generating sets, what is referred to as a load distribution line is
normally used. This process is required in order to ensure the desired load distribution between the various
generating sets. The use of measuring transducers should be considered if the load distribution line is subject
to different loads.

7.6.1 Offset coefficient

In this case, the engine speed is changed by means of a preset power gradient (speed drop) in order to produce
a desired percentage of the nominal load as the isolated load. By varying the gradient it is possible to increase
the load on more heavy-duty engines (e.g. diesel modules or gas engines with low mean pressure). Make sure
here that the speed drop setting does not adversely affect the plant dynamics (frequency and voltage) in any
way.

7.6.2 Load distribution

In this case, the power generated from each module is transmitted by a mA output signal and the average
engine power loaded by a mA input. Both signals have been scaled as standard to the range 0… 100% of the
nominal power of the module concerned, corresponding to 4… 16 mA. Unlike the speed droop load distribution,
the rated speed is not changed for control purposes and can therefore be held constant. The distribution
percentages between engines can be adjusted (the standard distribution is equal percentages). When
switching individual engines in and out, load application and shedding is effected using a ramp.
The sometimes different scales and input resistors from different manufacturers as well as different engine
control systems and their implementation of this concept must be taken into account.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TCC/Sarmiento Responsible: Controls Release date: 05/03/2012
Index: 3 Page No.: 9/16
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2108-0031
Isolated operation - general

7.6.3 Load management

If a mains system is operated using different types of energy generators (gas engine, diesel engine, gas turbine,
solar power, wind turbine, water power) or at least several energy generators of the same type, this is
described as a micro- or mini-grid. In such cases, grid simulations are essential and energy storage estimates
helpful. Where specific projects are in the analysis phase, the inertia of the subsystems and the transfer
functions for engines, controllers and generators must be regarded as essential system input values. On this
basis it is possible to select and simulate the above or other combined load estimates. In the case of
particularly stable basic energy generators, it is possible to switch less rigid systems in a power-controlled form
to rigid systems in isolated operation.
The rule of thumb for this eventuality is to apply a ratio of module inertias of about 2:1. If the plant has to meet
high technical demands, the dimensioning must be tested and validated by simulations.

7.7 Points requiring special attention

7.7.1 Information on operational condition from switch conditions – delay times

The operational condition of the engine is assigned on the basis of responses from the generator switch and
the mains switch There are essential transition points in operating conditions at which a rapid response from
the switch is required in order to activate the corresponding controller functions.
In some field systems, it is precisely this immediate response that is causing difficulties. There are the non-
reducible switch times (permitted up to < 60 ms). If these responses are additionally transmitted via relays or
even station control systems (software), further undesirable delay times are added. For example, even a
doubling of the time can result in engine shutdowns due to "overspeed" on the transition from mains-parallel
operation to isolated operation at low load.

7.7.2 Unknown customer load ratios – capacitive loads

If the ratio of capacitive to inductive loads (e.g. in the lower load range, when all the compensators have been
added) is very large, this can result in unexpectedly large generator loads, pole slip and generator damage. It is
therefore essential to ensure that the generator is always operated in the inductive range. Worst-case
scenarios can be simulated using grid stability analysis.

7.7.3 System interconnection control system

If the currently required power for the operation to be supplied is recorded at the point of supply, a mains
interconnection control unit may be sensible from a financial and technical point of view. The recorded power
is produced by the gas engine up to a certain necessary difference and because of this the transition from
network to isolated operation results in a particularly clean transition behaviour.

7.7.4 Auxiliaries
The exhaust gas system is not purged for emergency power operation.
As a result, due to the prelubrication the maximum time from emergency power activation to the engine start
(when the engine turns) is 60 seconds for an engine previously not in operation.

8 Constraints

8.1 Rated engine load

The relevant rated load for each engine version can be found in the product range and adjusted in accordance
with the appropriate reduction diagrams. These produce the actual 100% rated load which is used as a
reference value in the load diagrams.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TCC/Sarmiento Responsible: Controls Release date: 05/03/2012
Index: 3 Page No.: 10 / 16
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2108-0031
Isolated operation - general

Increased-load versions are operated in isolated operation at their original rated load. Furthermore, only the
rated loads corresponding to the gas type used are permissible for generating sets with multiple or mixed gas
operation.

8.2 Emissions
Isolated operation is subject to active emission control at a defined exhaust gas emission level of 500 mg/Nm3
@ 5% O2 NOx irrespective of the emissions required in mains-parallel operation. Parameters in the engine
control system make it possible to ensure that during transition to isolated operation, the control automatically
switches to higher emission values. To a certain extent, this will improve the control quality in the overall
control range as well as increasing the load-adding capabilities and availability. The switch can be
parameterised but this is not obligatory.
If the emissions are kept below the value stated above, e.g. 250 mg/Nm 3 @5%O2 NOx, special approval will be
needed.

8.3 Mixture cooling water temperature, mixture temperature

The power shift diagrams apply to a mixture temperature corresponding to the product range. In this case too,
the reduction of the mixture temperature results in an increased load-adding capability and therefore an
increase in availability.

8.4 Ignition timing point

The power shift diagrams apply when the ignition point matches the default parameter values. Any change in
the ignition point to the "retarded" setting will improve the load-adding capability.

8.5 Intake temperature

The power shift diagrams apply to intake temperatures corresponding to the product range. Any reduction in
the intake temperature will improve the load-adding capability.

8.6 exhaust-gas back pressure

The power shift diagrams apply up to a maximum exhaust-gas back pressure of 60 mbar. Reducing the
exhaust-gas back pressure improves load-adding behaviour.

8.7 Isolated operation with biogas, landfill gas and sludge gas
The use of biogas, landfill gas and sludge gas does not require special approval for the isolated operation of
type 2, 3 and 4 engines. Modules in dual-gas operation require project-specific clarification due to the energy
content of the gas. Mixed-gas operation and switching gas types during isolated operation both need special
approval.
When changing over from mains-parallel operation to isolated operation, particular care must be taken to
ensure that the requirements for constant gas pressure and quality are met (TI 1000-0300).
The gas supply to the gas compressor must be guaranteed for black-out start capability.
The use of gas engines in isolated operation with non-natural gas in life-preserving systems is not permitted
due to the uncertainty of the gas supply!

8.8 Gas supply

To ensure appropriate operational behaviour of the modules, the fuel gas must be of consistent quality and at
constant supply pressure (TI 1000-0300).

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TCC/Sarmiento Responsible: Controls Release date: 05/03/2012
Index: 3 Page No.: 11/16
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2108-0031
Isolated operation - general

The module's black-start capabilities can only be deduced subject to the proviso that there is suitable gas
quality and sufficient gas pressure. Type 6 engines with prechambers are approved for black starts in the
product range (as from 2012), as they require prelubrication and a drive for the prelubrication pump.
In the case of multi-gas operation, this gas should therefore have the best possible availability for island
operation

8.9 Generator
To keep the speed drop within the limit levels permitted for the control class in the event of added loads, the
generator voltage is reduced selectively and dynamically by the "generator voltage knee point". In the case of
multi-engine systems, special care must be taken to ensure that these settings are identical on all modules.
The setting of the generator voltage knee (starting point and steepness) is laid down in accordance with the ISO
8528-5:2005 standard. The following setting points for GE Jenbacher are used for.
Standard settings based on two generating sets with different rated speeds.
1500 rpm genset 1800 min-1 genset
1500 – 1470 rpm 1800 -1764 min-1 Rated voltage
1370 rpm 1644 rpm 0.9 x nominal voltage

The diagram below shows the voltage knee point.

105

100
1
95
U [%]

90 2

75
80 85 90 95 100 105 110 115 120

f [%]
Figure 6. Frequency/voltage characteristic
U [%] Voltage (% rated value) ① Voltage knee
f [%] Frequency (% rated value) ② pitch

In order to increase engine stability, it is possible to set the voltage knee point to more than 100% of the
nominal speed (broken line) by coordinating the consumers.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TCC/Sarmiento Responsible: Controls Release date: 05/03/2012
Index: 3 Page No.: 12 / 16
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2108-0031
Isolated operation - general

UG
1

100% 2
5

95%

90%

5%
3 4

IQ IQ
100% 75% 50% 25% 25% 50% 75% 100%
Figure 7. Reactive-load distribution:
① Underexcitation ② Overexcitation
③ Load assumption ④ Load discharge
UG Generator voltage

The reactive load required by the consumers is shown in the case of multi-engine systems by means of an
equal distribution to the generators running in combination. The distribution is achieved by adjusting the
voltage droop. The essential point in this regard is that all the generators must have the same settings for rated
voltage, voltage statics (typically 3%), voltage knee point (trip point, gradient, dwell) and AVR reaction times.
Different settings may result in pole slip and therefore damage to the generator.

9 Appendix A. Isolated Operation Performance Assessment Characteristics

A.1. Generator frequency

If synchronous generators are used, the static frequency characteristics are dependent on the engine speed
controller. The dynamic characteristics are influenced by the complete control system (engine control, AVR,
mass moment of inertia, etc.).
Figure 8 shows the relevant parameters for assessing the steady-state and transient frequency behaviour of a
generating set in accordance with ISO 8528-5:2005. The characteristics can be taken from Table 2 (see ISO
8528-5:2005 Table 1 - Symbols, Terms and Definitions)

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TCC/Sarmiento Responsible: Controls Release date: 05/03/2012
Index: 3 Page No.: 13/16
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2108-0031
Isolated operation - general

fd,max

+
d fdyn
Df 2
[Hz]
Frequenzf [Hz]

t f,zu

fr
Df
1 t f,ab
-
Entlastung d fdyn

fd,min
t [s]

Figure 8. Frequency stabilisation behaviour

f Frequency t Time
① Load reduction ② Load adding

Parameters Icon Unit Description

Frequency deviation αf % Frequency band around the equilibrium frequency
bandwidth for determining where the frequency settles permanently within a
the stabilisation time specified stabilisation time after switching power on or
off , expressed as a percentage of the rated frequency.
Df
af = ´ 100
fr

Steady-state frequency βf % Zone of a frequency fluctuation occurring around a

bandwidths stationary mean value at constant power output,
expressed as a percentage of rated frequency.
Undershoot frequency fd,min Hz Minimum permissible frequency deviation after a sudden
load application.
Overshoot frequency fd,max Hz Maximum permissible frequency deviation after a
sudden load rejection.
Dynamic (temporary) δf-dyn % Temporary frequency difference between the
frequency deviation (from the undershoot frequency and the rated frequency,
mains frequency) after a load occurring during the stabilisation process after a sudden
application load application and expressed as a percentage of the
rated frequency.
The dynamic frequency deviation must not exceed the
permissible frequency tolerance.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TCC/Sarmiento Responsible: Controls Release date: 05/03/2012
Index: 3 Page No.: 14 / 16
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2108-0031
Isolated operation - general

Dynamic (temporary) δf+dyn % Temporary frequency difference between the overshoot

frequency deviation (from the frequency and the rated frequency, occurring during the
mains frequency) after a load stabilisation process after a sudden load rejection and
rejection. expressed as a percentage of the rated frequency
The dynamic frequency deviation must not exceed the
permissible frequency tolerance.
Frequency control settling tf,app s Time between the sudden load application and the
time after load application frequency permanently settling in the stationary
tolerance band.
Frequency control settling tf,shed s Time between the sudden load rejection and the
time after load rejection frequency permanently settling in the stationary
tolerance band.

A.2. Generator voltage

The voltage behaviour of the generating set is influenced mainly the voltage behaviour of the generator and
possibly the voltage controller. The static and dynamic frequency behaviour of the generating set also
influences the static and especially the dynamic behaviour in the rated zone. This also depends on the
individual design of the generating set. Figure 9 shows the voltage limits after a load step change.

Ud,max

+
d Udyn
DU 2

t U,zu
[V]
uenzU[Hz]

ur
Freq

DU
1 t U,ab
-
Entlastung d Udyn

Ud,min

t [s]

Figure 9. Voltage stabilisation behaviour

U Voltage t Time
① Load reduction ② Load reduction

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TCC/Sarmiento Responsible: Controls Release date: 05/03/2012
Index: 3 Page No.: 15/16
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2108-0031
Isolated operation - general

Voltage deviation bandwidth ΔU V Frequency band around the equilibrium voltage, where the
for determining the terminal voltage settles permanently within a specified
stabilisation time stabilisation time after switching power on or off ,
expressed in volts.
Ur
D U = 2dUst ´
100
Static voltage difference δUst % Maximum deviation by the voltage from rated voltage after
the decay of dynamic processes in the zone between no-
load and rated power output, taking into account the
heating effect and the frequency behaviour of the
generating set.
The static voltage deviation is expressed as as percentage
of the rated voltage
U st, max - Ust ,m in
dU st = ± ´ 100
2U r
Undershoot voltage Ud,min V Minimum permissible voltage deviation after a sudden load
application.
Overshoot voltage Ud,max V Maximum permissible voltage deviation after a sudden load
rejection.
Dynamic (temporary) voltage δU-dyn % Difference between the minimum peak value of the
deviation (after a load terminal voltage after a sudden load application and the
application) rated voltage peak value, referred to the rated voltage peak
value and expressed as a percentage of rated voltage.
Dynamic (temporary) voltage δU+dyn % Difference between the minimum peak value of the
deviation (after a load terminal voltage after a sudden load rejection and the rated
rejection) voltage peak value, referred to the rated voltage peak value
and expressed as a percentage of rated voltage.
Voltage control settling time tU,app s Time between a sudden load application and the terminal
after load application voltage returning permanently to the within the static
voltage deviation, taking the frequency stabilisation time
into account.
Note: The magnitude and change over the time of the
dynamic speed variation of the engine are the influencing
factors.
Voltage control settling time tU,shed s Time between a sudden load rejection and the terminal
after load rejection voltage returning permanently to the within the static
voltage deviation, taking the frequency stabilisation time
into account.
Note: The magnitude and change over the time of the
dynamic speed variation of the engine are the influencing
SprungMarke!!!18014398548941835
factors.

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TCC/Sarmiento Responsible: Controls Release date: 05/03/2012
Index: 3 Page No.: 16 / 16
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0001
Employee protection

1 General

1.1 Employer's duties

Employers are required to assume responsibility for the safety and health of employees in all aspects of their
work. Employers have to take any measures required to protect life, health and standards, including measures
to prevent work-related dangers, to provide information and instruction and to provide a suitable organisation
and the required resources.
First and foremost, companies contracted to carry out work must comply with all applicable country-specific
regulations.

1.2 Employee's duties

Employees are legally required to apply the measures to protect life, health and standards as laid down in
statutory legislation and official regulations and in accordance with their training and their employer's
instructions. They have to behave in such a way that avoids causing danger wherever possible.

1.3 Safety of machines and associated electrical equipment

After proper assembly/installation and completion of commissioning, GE Jenbacher machines and the
associated electrical equipment comply with all applicable EU directives and therefore European safety and
health requirements (Machinery, Electro-Magnetic Compatibility and Low-Voltage Directives).

2 Specialist field - electrical engineering

2.1 Definition of terms

Electrical specialist
The electrical specialist must (and can) recognise potential dangers and take responsibility for assessing the
work given to him/her.
▪ Technical qualification achieved by successful completion of a specialist training course
(e.g. electrical engineer, master electrician, qualified electrician).
– Similarly, several years of work experience – on-the-job-training - in a particular field of electrical
engineering can impart the required knowledge and skills, and form the basis for qualification as a
skilled electrician for limited ranges of tasks
(e.g. staff who repair plants and carry out minor modifications).

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TCS/Thaler Josef Responsible: Endprüfung Release date: 26/05/2010
Index: 1 Page No.: 1/5
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0001
Employee protection

▪ Special knowledge in the field of "electrical plants based on block heating/power station technology using
gas combustion engines".
▪ Knowledge of the applicable electrical engineering regulations and employee protection regulations
( e.g. EN 50110-1 + EN 50110-2-x, BGV A3, ÖVE/ÖNORM E 8001-1, VDE 0100-410, HD 60364-4-41, IEC
60364-4-41, ÖVE/ÖNORM E 8001-6-61, VDE 0100-600, HD 60364 6, IEC 60364-6).

A person instructed in electrical engineering is someone who has been instructed and if necessary trained by
an electrical specialist for the tasks allotted to him/her and on the potential dangers arising from incorrect
behaviour, as well as in terms of the protective measures required.
A person instructed in electrical engineering is not allowed to assemble, alter or maintain electrical plant and
equipment on his/her own. This may only be done under the direction and supervision of an electrical
specialist.

Operation of electrical plants

Covers all activities (operating and working) on and in electrical plants, as well as on and with electrical
equipment.

Working on electrical plants

This includes the manufacture, assembly, modification, maintenance and repair of electrical plants and
equipment (also, for example, clearing faults).

Operating electrical plants and equipment

In principle this can be any work performed on setting, switching and controlling devices
(e.g. switching a power switch, replacing a plug fuse).

EN 50110-1 + EN 50110-2-x Operation of electrical installations:

This standard covers the operation of and all work on, with or in the vicinity of electrical installations. This
includes electrical installations of all voltage levels from low voltage to high voltage.

Initial start-up
An electrical plant may only be started up for the first time when a test has proved that the equipment
conforms, electrically and mechanically, to the safety requirements specified in
▪ accident prevention regulations, and
▪ electrical engineering rules.
The same applies to restarting after a repair (in particular, testing the measures to protect against accidental
contact).

Employee protection regulations

As the terms are generally understood, national provisions (laws and orders) and accident prevention
regulations issued, for example, by professional associations, are deemed to be employee protection
regulations.
The legal status of an accident prevention regulation must be inferred from the law or from the individual
regulations (e.g. BGV A3 is legally binding in Germany).

Electrical engineering rules/provisions

This is "generally" accepted engineering practice contained, for example, in the IEC, CENELEC EN, CENACLE HD
VDE, and ÖVE provisions (accepted = the majority of the experts are convinced of their correctness). Legislators
and regulators refer to the "(Generally) recognised rules of the trade" and their legal status therefore follows
from this.
Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TCS/Thaler Josef Responsible: Endprüfung Release date: 26/05/2010
Index: 1 Page No.: 2 / 5
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0001
Employee protection

ÖVE Austrian Electrotechnical Association

VDE German Association for Electrical, Electronic & Information
Technologies
CENELEC European Committee for Electrotechnical Standardisation
IEC International Electrotechnical Commission

2.2 Spheres of activity and required qualifications

Work on electrical plants

Exclusively by electrical specialists
or carried out under their direction and supervision
▪ Limited in space and time, direction and supervision relate to a clear-cut task or a defined job (it must not
mean in every case that the electrical specialist is required to be permanently "on site"). The electrical
specialist's "responsibility for direction and supervision" covers, in particular:
– Induction (introduction, training)
– Instructing about possible dangers and safe behaviour (as well as regular or continuous supervision)
– Introduction and employment of some supervisory staff to whom, after relevant instruction by the
electrical specialist, supervisory duties can be assigned to assist the electrical specialist.
– Monitoring to ensure that the work is carried out properly.

Operating electrical plants and equipment

▪ These duties must be carried out by a person who is at least instructed in electrical engineering.
– For the following examples, an employee must be at least qualified as an instructed person:
– Cleaning electrical plants
– Working close to electrically live parts
– Determining zero voltage
– Activation of final control elements which are required for the safety or functioning of an electrical
plant or electrical equipment.

Initial start-up
▪ Must be carried out by an electrical specialist

2.3 Complying and dealing with necessary technical informational materials

2.3.1 Information materials

In our case, the general term "informational materials" includes

General provisions for employee protection.

▪ Laws and statutory regulations

Accident prevention regulations, such as

▪ Electrical plant and equipment (BGV A3) - Germany
▪ Operation of electrical high-voltage plant, basic regulations EN 50110-1 + EN 50110-2-x

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TCS/Thaler Josef Responsible: Endprüfung Release date: 26/05/2010
Index: 1 Page No.: 3/5
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0001
Employee protection

Electrical engineering provisions

"Generally accepted engineering practice" (e.g. IEC, CENELEC EN, CENELEC HD and VDE regulations or
standards) covers, for example, the following subjects:
▪ Assembly of electrical high-power plant with nominal voltage up to 1000V and = 1500V
– Definitions and protection against hazardous shock currents, ÖVE/ÖNORM E 8001-1
– Electrical equipment, ÖVE EN 1 Part 2, ÖVE/ÖNORM E 8001-2-x
– Quality and use of wiring and cables, ÖVE-EN 1 part 3, ÖVE/ÖNORM E 8001-3-41
▪ Electrical high-voltage plant and emergency power supply in structural works for communal facilities, ÖVE/
ÖNORM E 8002-x, VDE 0100-718
▪ Electrical high-power plant in hospitals and in premises used for medical purposes outside hospitals, ÖVE
EN 7, VDE 0100-710
▪ Assembly of electrical high-power plant with nominal voltages up to 1000 V - DIN-VDE 0100
– Protective measures - Group 400 (part 410, 470)
– Selection and assembly of electrical equipment - Group 500
– Tests - Group 600 (part 600 - initial tests)
▪ Low-voltage switchgear and control gear assemblies - type-tested and partially type-tested assemblies,
EN / IEC 60439-1
▪ Safety of machinery - Electrical equipment of machines - General Requirements, EN / IEC 60204-1
▪

2.3.2 Hand-over and handling (duty to instruct)

Information materials
▪ To be handed over to foremen and other supervisors as well as other people who work under their own
responsibility.
▪ Other employees who work on electrical equipment or electrical plants must be given the opportunity to
read these materials (e.g. by creating a reading area or posting them on notice boards).
The workforce must be informed of the rules and operating regulations applicable to their work and have
them explained, and make it their duty to follow them. This must be repeated at suitable intervals as
dictated by the operational conditions.
People who only work temporarily in and on plants, or are only involved in specific jobs, must be informed
of the dangers and the protective measures associated with these jobs and warned to be careful.
For all work as defined in the provision on the "Operation of electrical high-power plant", a suitable person who
is familiar with the necessary safety measures must be appointed as the person immediately responsible.
If you adhere to the "generally accepted engineering practice" it is unlikely that you will give the appearance of
having acted negligently. You are therefore strongly urged to follow the "generally accepted engineering
practice".

2.3.3 Sources of information

▪ Laws or electrical engineering laws and statutory regulations arising from them
▪ Professional organisations ➨ Accident prevention regulations VBG 4
▪ Trade associations (or committees) ➨ ÖVE or VDE rules
▪ Standards institutes, e.g. DIN and ÖNORM
▪ European Committee for Electrotechnical Standardisation ( CENELEC ) EN Standards, HD (Harmonisation
Documents)

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TCS/Thaler Josef Responsible: Endprüfung Release date: 26/05/2010
Index: 1 Page No.: 4 / 5
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0001
Employee protection

▪ International Electrotechnical Commission (IEC) ➨ IEC publications (international standard).

2.4 Concluding explanatory note

The contents of the above sections are based on current Austrian and German regulations. Basically, this
section provides a path which, if converted into appropriate action, achieves a sufficiently high level of safety in
terms of protecting human life and equipment. All those companies or operatives engaged in the setting up or
installation of the above systems, who are subject to legislation other than that of Austria, must of course act
strictly in accordance with the regulations by which they are bound. The above guidelines are intended, above
all, to focus attention on the basic issues and call on those in executive positions to take considered action.
The subject of "commissioning" is only dealt with at a basic level because the commissioning of GE Jenbacher
combined power/heat systems or electrical power generation systems demands more extensive and
specialised training. GE Jenbacher does not consider technical training in electrical engineering alone to be
sufficient for this task.
SprungMarke!!!37625611

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TCS/Thaler Josef Responsible: Endprüfung Release date: 26/05/2010
Index: 1 Page No.: 5/5
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0006
Security tips when connecting GE Jenbacher Installations to the Inter-
net

1 General
The GE Jenbacher HMI (Human Machine Interface) provides customer connectivity via network connections.
Using this connection, the customer is able to access GE Jenbacher’s DIA.NE WIN® application and thus
control the plant remotely.

This network connection was EXCLUSIVELY planned by GE Jenbacher for connections to local customer
networks (customer LANs).

By the use of today’s technologies and because of widespread Internet connectivity, the network connections
referred to offer a possibility for connecting the plant to the Internet. Customers often use a network router
with port-forwarding for this application.

This technical instruction explains the risk associated with this solution and shows the appropriate solution
from a security standpoint provided by GE Jenbacher.

2 Safety risks / danger

Using such routers with port-forwarding contains a wide range of serious security issues!
Some examples:
▪ Unencrypted transmission of data over the Internet
– Detection of transmitted unencrypted passwords by HACKERS!
– Possibility for HACKERS to start a Man-In-The-Middle attack (Online-modification of transmitted data,
e.g. setpoint values, parameters, ...).
▪ Using correctly configured routers (correct port limitations): Possibility of direct access to the Web server
installed at the DIA.NE(r) WIN-server
– No protection against web server directed viruses, worms, Denial of Service (DoS) and exploit attacks
(e.g. Code Red)!
– Little protection against password cracking attacks by HACKERS (Finding out of passwords)!
▪ Using mismanaged routers or using outdated router firmware (Security updates not installed): Direct
access to the server’s operating system
– No protection against all sorts of viruses, worms, trojan and Denial of Service (DoS) attacks (e.g. Blaster,
Sasser, Spybot, Beagle, ...)!
– Password protection can be bypassed by HACKERS at all levels!
▪ No access control and access logging by the GE Jenbacher Remote Access Portal
(dual Layer authentication)

These serious security problems cause direct danger for customer and plant:

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner Nikolaus Responsible: Entwicklung Release date: 26/05/2010
Index: 1 Page No.: 1/3
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0006
Security tips when connecting GE Jenbacher Installations to the Inter-
net

▪ Access to the plant using inappropriately obtained passwords or Man-In-The-Middle attacks by

unauthorised persons:
This means that such persons have full access to all setpoint values, plant parameters, historical data
including modification and deletion.
▪ Take-over of full control of the server by unauthorised persons:
– Bypassing all security restrictions provided by the operation system and consequently full access to all
the application’s setpoint values, plant parameters and historical data.
– Unauthorised use of the server’s hardware and the Internet connection for criminal activities (spam
mailing, DoS attacks, ...).
▪ Damage to the DIA.NE® WIN server:
Total loss of the server (data, accessibility, hardware) due to deletion of the server’s hard disk by HACKER
intervention or by a VIRUS.
These manipulations can cause catastrophic damage to the plant
and can be life threatening!

3 Solution based on GE Jenbacher Firewall

To solve these problems, GE Jenbacher has developed a specific solution for accessing plants over Internet.

This solution uses an onsite Firewall to protect the plant which can handle a highly secured, encrypted
connection to a central Firewall at GE Jenbacher (Virtual Private Network, VPN). These connections and all
devices involved are directly controlled and maintained by GE Jenbacher specialists, who ensure a very fast
response to system-based security problems (updates) or HACKER activities (proactive and reactive).

Using the firewall and VPN connections prevents the plant from being accessed directly. Only authenticated
users gain access to the plant over GE Jenbacher Remote Access Portal.

4 Warning
STRICTLY PROHIBITED!
Unsafe Safe

Router with port forwarding: GE Jenbacher Firewall solution:

direct access to DIA.NE® WIN with unencrypted login access to DIA.NE® WIN only via GEJ Remote Access
via the DIA.NE® password. Portal ( 1. encrypted authentication at the portal, 2.
encrypted login with the DIA.NE® password)

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner Nikolaus Responsible: Entwicklung Release date: 26/05/2010
Index: 1 Page No.: 2 / 3
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
Technical Instruction: TA 2300-0006
Security tips when connecting GE Jenbacher Installations to the Inter-
net

GE Jenbacher is not liable for any damage or defects resulting from port forwarding or direct connection to the
GE Jenbacher DIA.NE® WIN server. Such damage or defects are not covered by the GE Jenbacher warranty.
SprungMarke!!!38162059

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: TEE/Brunner Nikolaus Responsible: Entwicklung Release date: 26/05/2010
Index: 1 Page No.: 3/3
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
7 Comments and supplements
7.1
Comments and supplements

SprungMarke!!!12972427

Identification: AB ENERGY 616 -31 Device number: J S889 Module number: 1127172
Module type: JGS 616 GS-N.L Engine version: F 01
Author: Responsible: Release date: 31/05/2010
Index: 1 Page No.: 1/1
GE Proprietary Information: CONFIDENTIAL! Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or on the first page.
8 Appendix
2327 en – 11.2011 / o

ALTERNATOR
Service & Operating Manual
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS

TABLE OF CONTENTS

2.3.3 Maintenance of antifriction bearings

1. GENERAL INFORMATION a) General points
b) Lubricant
c) Cleaning bearings
1.1 INTRODUCTION 2.3.4 Servicing the antifriction bearings
1.1.0 General points a) General points
1.1.1 Safety notes b) Removing the bearings
1.1.2 Conditions of use c) Bearing reassembly
a) Generalities 2.3.5 Antifriction bearing protection devices
b) Vibratory analysis 2.3.9 Antifriction bearing installation drawing

1.2 GENERAL DESCRIPTION 2.4 SLEEVE BEARINGS (Plain)

1.2.1 Generator 2.4.0 Description of horizontal Sleeve bearings
1.2.2 Excitation system a) Physical description
b) Operating description of Self-lubricating
2. DESCRIPTION OF SUB-ASSEMBLIES bearing
c) Operating description of Oil circulation bearing
2.4.1 Electrical insulation of Sleeve bearings
2.1 STATOR a) Illustration diagram of the insulating film
2.1.1 Electric machine armature b) Insulation check
a) Mechanical description 2.4.2 Storage of Sleeve bearings machine
2.1.2 Excitation field winding a) General points
2.1.3 Stator protection b) Short term storage
a) Heating resistor c) Long term storage
b) Stator winding temperature sensor 2.4.3 Oil circulation installation
c) Stator air sensor 2.4.4 Start-up of Sleeve bearings
d) Stator vibration sensor a) General check before start up
b) Self-lubricating bearings start up data
c) Water cooled bearing (type EFW..) start up
2.2 ROTOR
data
2.2.1 Revolving field-coil
d) Oil circulation bearing with non-accurate oil
2.2.2 Excitation armature
flow (+0% ; -40%)
2.2.3 Fan (machines: IC 0 A1)
e) Oil circulation bearing with accurate oil flow
2.2.4 Rotating diode bridge
(+5% ; -10%)
a) General points
f) Inspection of Sleeve bearings at the end of
b) Tightening torque for the rotating diode
start-up
fastening screws
2.4.5 Maintenance of Sleeve bearings
c) Rotating rectifier test
a) Verification of oil-level
2.2.5 Balancing
b) Temperature verification
2.2.6 Rotor vibration sensor
c) Oil draining
d) Pressure measurement of a Sleeve bearing
2.3 ANTI FRICTION-BEARINGS housing
(rolling bearing) e) Oil for sleeve bearing
2.3.0 Description of antifriction bearings f) Oil sump capacity
2.3.1 Start-up of antifriction bearings g) Sealing Compound
2.3.2 Storage of machine with anti friction
bearings

3
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS
2.4.6 Dismantling
a) Tools and equipment
b) Lifting equipment 2.7 COOLER
c) Dismantling of the shaft seal type 10 (outboard 2.7.0 Description of the cooler
side) a) General points
d) Dismantling of the shaft seal type 20 (outboard b) Description of AIR-AIR coolers
side) c) Description of AIR-WATER DOUBLE TUBE
e) Dismantling of the top half of the housing EXCHANGER
f) Removal of the top half of the shell d) Description of AIR / WATER SINGLE TUBE
g) Dismantling of the loose oil ring EXCHANGER
h) Dismantling the machine side shaft seal 2.7.1 Water Cooler operating condition
i) Removal of the bottom half of the shell a) Water Cooler installation
j) Dismantling of the machine seal b) "Standard" operation with water
2.4.7 Cleaning and checking c) "Emergency" operation without water
a) Cleaning 2.7.2 Start-up of the water cooler
b) Wear checking a) General points
c) Insulation checking (only for insulated bearing) 2.7.3 Maintenance of the water-cooler
2.4.8 Assembly of the Bearing a) General points
a) Fitting in the bottom half of the shell b) Cleaning
b) Assembly of the shaft seal machine-side c) Leak detection for a double-tube exchanger
c) Installation of the loose oil ring 2.7.4 Servicing the water-cooler
d) Fitting in the top half of the shell a) Cooler removal
e) Closing of the bearing b) Cooler re-assembly
f) Assembly of the type 10 Outboard Side Seals 2.7.5 Cooler protection devices
g) Assembly of the type 20 Outboard Side Seals a) Leak detection (float system)
h) Assembly of the RD-thrust pads ; bearing type b) Water temperature sensor
E...A c) Water filtering
2.4.9 Oil-leakage trouble-shooting
a) Self-lubricating bearing
b) Oil circulation bearing 2.8 AIR FILTERS
2.4.10 Sleeve bearing protection devices 2.8.0 General
a) Sight-level glass 2.8.1 Cleaning
b) Oil thermometer a) Air filter cleaning period
c) Thermostat or sensor b) Air filter cleaning procedure
d) Pre lub pump
e) Oil filtering and pollution 2.18 TERMINAL BOX
2.18.0 Description
2.6 OIL CIRCULATION LUBRICATING UNIT 2.18.1 Electric panel
2.6.0 General points a) Compounding panel ( if compound regulator)
2.6.1 Oil circulation by gravity return b) Booster plate ( if shunt regulator)
a) General points 2.18.2 Automatic voltage regulator
b) Supply line 2.18.3 Electrical contact tightening
c) gravity oil return
2.6.2 Oil cooling unit Air/Oil exchanger 2.19 PROTECTION DEVICES
2.6.3 Oil cooling unit Water/Oil exchanger 2.19.1 Stator protection devices
2.19.2 Bearing protection devices
2.19.3 Cooler protection devices

2.20 NAMEPLATES
2.20.1 Main nameplate
2.20.2 Lubrication nameplate
2.20.3 Rotation direction nameplate

4
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS

3. VOLTAGE REGULATOR AND EXTERNAL 5. START-UP

AUXILIARIES
5.0 START-UP SEQUENCE
4. INSTALLATION 5.0.1 Static checks
5.0.2 Rotating checks
a) Rotating checks not excited
4.1 TRANSPORT AND STORAGE b) Rotating checks at no load excited
4.1.1 Transport c) Generator and site safeties
4.1.2 Storage warehouse d) Rotating checks at full load
4.1.3 Maritime packing 5.0.3 Generator Start Up check list
4.1.4 Unpacking and installation
4.1.5 Storage measures of a site machine
5.1 ELECTRICAL START-UP INSPECTION
5.1.0 General points
4.2 INSTALLATION OF THE MACHINE 5.1.1 Windings Insulation
4.2.1 Fitting the coupling (double-bearing 5.1.2 Electrical connections
machine only) 5.1.3 Parallel operation
4.2.2 Fitting the stator a) Definition of parallel operation
b) Possibility of parallel operation
c) Parallel coupling
4.3 ELECTRIC MACHINE ALIGNMENT
4.3.1 Various alignment characteristics
a) General points 5.2 MECHANICAL START-UP INSPECTION
b) Axis height Thermal elevation 5.2.0 General points
c) Sleeve bearing shaft elevation a) Alignment; fixing; prime mover
d) Antifriction bearing shaft elevation b) Cooling
4.3.2 Two bearings machine alignment c) Lubrication
a) machines without axial end play (standard) 5.2.1 Vibrations
b) machines with axial end play
4.3.3 Single bearing machine alignment 6. PREVENTIVE MAINTENANCE
a) General points
b) Single bearing machine
4.3.4 Alignment procedure 6.1 MAINTENANCE SCHEDULE
a) Checking "Double concentricity" alignment
method
6.2 MECHANICAL MAINTENANCE
6.2.1 Air gap check
4.4 ELECTRICAL CONNECTIONS a) General points
4.4.0 General points b) Double bearing machine
4.4.1 Phase-sequence c) Single bearing machine
a) standard machine.IEC 34-8 6.2.2 Bolts tightening
b) if wanted, NEMA. 6.2.3 Cleanliness
4.4.2 Insulating distances
4.4.3 Added products in the terminal box 6.3 ELECTRICAL MAINTENANCE
6.3.1 Measuring instruments
a) Instruments used
b) Identification of ohmmeter polarity
6.3.2 Insulation check of the winding
a) General
b) Armature insulation measure
c) Field insulation measurement
d) Exciter insulation measurement
e) Polarisation index

5
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS

7. SERVICING

7.1 GENERAL SERVICING

7.2 TROUBLE SHOOTING

7.2.0 General points
7.2.1 Regulator trouble-shooting procedure

7.3 ELECTRICAL TESTS

7.3.1 Stator winding test
7.3.2 Rotor winding test
7.3.3 Excitation armature winding test
7.3.4 Excitation field winding test
7.3.5 Rotating diode bridge test
7.3.6 Electric panel test

7.4 CLEANING THE WINDINGS

7.4.0 General points
7.4.1 Coil-cleaning product
a) general
b) Cleaning products
7.4.2 Cleaning the stator, rotor, excitation and
diodes
a) using specific chemical product
b) Rinsing using soft water

7.5 DRYING THE WINDING

7.5.0 General points
7.5.1 Drying method
a) General points
b) Drying generator stop
c) Drying generator in rotation

7.6 RE-VARNISHING

10. FOLDOUT

6
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS

1. GENERAL INFORMATION 1.1.2 Conditions of use

a) Generalities
1.1 INTRODUCTION A machine must only be installed, operated, by qualified
and trained persons.
1.1.0 General points Any technical engineer operating, maintaining this machine
This manual provides installation, operating and must be allowed to practice in regard with local working
maintenance instructions for synchronous machines. It laws (eg: to be certified to operate on high voltage
devices…)
also describes the basic construction of these machines.
This manual is general ; it applies to an entire group of A machine can only be operated for the duty foreseen by
synchronous generators. Additionally, in order to make its original tender.
information-finding easier, Section 1, "Characteristics and The main data of this machine are summarized in "Section
Performance", has been included, describing the machine 1" of this manual
completely (type of construction, type of bearing, Any operating condition other than those specified by the
protection index, and so forth...); this will enable you to original tender must receive a Leroy Somer agreement
determine exactly the chapters which apply to your
Any modification of the machine structure must receive a
machine.
Leroy Somer agreement
This synchronous machine has been designed for a
maximum length of service. To achieve this, it is necessary b) Vibratory analysis
to pay special attention to the chapter concerning the It is the responsibility of the gen set manufacturer to
periodic maintenance schedule for the machines. ensure that the different assembled system will be
vibratory compatible.(ISO 8528-9 and BS5000-3)
1.1.1 Safety notes It is the responsibility of the gen set manufacturer to
ensure that the shaft line torsional analysis has been done
The warnings "DANGER, CAUTION, NOTE" are used to
and accepted by the different parties (ISO 3046)
draw the user’s attention to different points:
CAUTION :
DANGER :
EXCEEDING THE VIBRATORY LEVEL ALLOWED BY
THIS WARNING IS USED WHEN AN OPERATION,
THE STANDARD ISO 8528-9 & BS5000-3 MAY CREATE
PROCEDURE, OR USE MAY CAUSE PERSONAL
HEAVY DAMAGES (BEARING DAMAGE, STRUCURE
INJURY OR LOSS OF LIFE
CRACKS …).
EXCEEDING THE TORSIONAL VIBRATORY LEVEL OF
CAUTION : THE SHAFT LINE (ex: ABS, LLOYD …) MAY CREATE
THIS WARNING IS USED WHEN AN OPERATION, HEAVY DAMAGES (CRANKSHAFT FAILURE ,
PROCEDURE, OR USE MAY CAUSE DAMAGE TO OR GENERATOR SHAFT FAILURE, …)
DESTRUCTION OF EQUIPMENT
Refer to chapter 2.1.3 for further information about the
NOTE : accepted vibration level of the standard ISO 8528-9 and
This warning is used when an operation, procedure, or BS5000-3
delicate installation requires clarification.

7
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS

1.2 GENERAL DESCRIPTION

1.2.1 Generator
The synchronous generator is an alternating-current
machine, without rings or brushes. The machine is cooled
by the flow of air through the machine.
For a better comprehension, use the drawings of chapter
10.

1.2.2 Excitation system

The excitation system is mounted on the side opposite the
coupling.
The excitation system comprises two assemblies:
The excitation armature, generating a three-phase current,
coupled with the three-phase rectifier bridge (comprised of
six diodes) supplies the excitation current to the generator
revolving field. The excitation armature and the rectifier
bridge are mounted on the synchronous generator rotor
shaft and are interconnected electrically with the revolving
field of the machine.
The excitation field winding (stator) is supplied by the
control (in direct current)

5 1
3
4 2

1- Excitation field winding

2- Excitation armature
3- Rotating diode bridge
4- Revolving field
5- Machine stator

8
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS
To improve the machine protection the alarm set point may
2. DESCRIPTION OF SUB-ASSEMBLIES be reduced following effective site information:
Alarm temperature (*) = Highest recorded temp + 10°K
Trip temperature (*) = Alarm temperature + 5 °K
2.1 STATOR (*) do not pass over the values of the previous chart.
(*)Highest recorded temp: Temperature measured at
2.1.1 Electric machine armature the site in the worst temperature condition at the stator
temperature sensor
a) Mechanical description
The machine stator comprises low-loss steel laminations, E.g. : a class B machine reached 110°C during a facto ry
assembled under pressure. The steel laminations are heat run test. Set the alarm temperature to 120°C in stead
blocked axially by a welded ring. The stator coils are of 130°C as indicated in the previous chart. Set the
inserted and blocked in the slots, then impregnated with emergency shutdown to 115°C instead of 135°C as
varnish, and polymerised to ensure maximum resistance to indicated in the previous chart.
mould, excellent dielectric rigidity and perfect mechanical
linking. c) Stator air sensor
As an option an RTD or thermostat can measure the stator
air inlet temperature (cold air)
2.1.2 Excitation field winding
The excitation field winding comprises a solid element and Stator air inlet temperature; Alarm points and shutdown:
a winding. • alarm Nominal air inlet stator + 5 K
• shutdown 80°C
The excitation is flanged on the rear end shield of the
machine. Stator air outlet temperature; Alarm points and shutdown:
• alarm Nominal air inlet stator + 35K
The winding is made of enamelled copper wires. • shutdown Nominal air inlet stator + 40K
NOTE :
2.1.3 Stator protection For an open drip proof machine the nominal air
temperature entering the stator corresponds to the ambiant
a) Heating resistor
temperature
The heating element avoids internal condensation during Inhibit the stator air sensor safety "alarm" for few seconds
the shutdown periods. It is connected to the main terminal during the machine start up;
box strip. The heating resistor is switched on as soon as
the machine is shut down. It is located at the back end of NOTE:
the machine. For a water cooled machine (CACW) the nominal air
entering the stator may be approximated as following:
The electrical characteristics are provided in Section 1 Tair entering stator = Twater entering cooler + 15°K
"Technical Characteristics".

b) Stator winding temperature sensor

The temperature sensors are located in the active part of
the stack. They are located in the zone assumed to be the
hottest part of the machine. The sensors are connected to
a terminal box.
Depending on the temperature rise of the machine, the
temperature of the sensors should not exceed a maximum
of :
TEMP. RISE ALARM TRIP
class
Power (KVA) < 5000 > 5000 < 5000 > 5000
B 130 °C 125 °C 135 °C 130 °C
F 155 °C 150 °C 160 °C 155 °C
H 175 °C 170 °C 180 °C 175 °C

9
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS
The aluminium plates (E) are pressed against the winding,
d) Stator vibration sensor acting as a heat dissipator and ensure excellent clamping
This chapter concerns the setting of seismic probes. For of these coils.
setting of proximity probes refer to the rotor
Support bars (C) on each pole protect the end windings
The vibration level of the machines is directly linked to the against the centrifugal force.
duty and to the site characteristics.
The revolving field-coil is heated and shrunk onto the shaft.
We propose the following adjustment:
Vibration Alarm (*) = Site Highest Vibration level + 50%
Vibration Trip = Vibration Alarm + 50%
(*) do not pass over the values of the following chart
The machines are engineered to be able to withstand the
vibration level specified by the standard ISO8528-9 and
BS5000-3
Maximum levels for : reciprocating Internal combustion
engines
Nominal speed kVA Generator vibration level 2.2.2 Excitation armature
(rpm) (nominal conditions) The excitation armature is constructed by stacking
magnetic steel laminations. These steel laminations are
Overall Any harmonics held in place by rivets.
(mm/s rms)
(2–1000 Hz) The excitation coil is keyed and heat-shrunk onto the shaft.
1300 à 2199 > 250 < 20 The windings are enamelled copper wires, class "F"
< 0.5 mm ; pp insulation (or "H", depending on the customer's request or
721 à 1299 ≥ 250 < 20 (5 – 8 Hz) size of the machine).
> < 18
1250 2.2.3 Fan (machines: IC 0 A1)
< 9 mm/s ; rm
≤ 720 > < 15 (8 – 200 Hz) The synchronous machine is characterized by a self-
1250 ventilation system. A centrifugal fan is mounted between
the revolving field coil and the front bearing.
< 10 (*)
Air intake is at the rear of the machine and the exhaust on
(*) generator on concrete base the drive end side.
The fan consists of a hub, which is keyed and heat-shrunk
Maximum levels for : Turbines onto the shaft. The flange is made of welded steel,
attached to the hub with hexagonal head-cap screws. The
Turbines Max advised : 4.5 ventilation effect is obtained through, inclined blades. The
(hydraulic ; gaz ; steam) (overall ; mm/s rms)
air is exhausted by centrifugation. The air inlet and outlet
must remains free during operation
2.2 ROTOR
2.2.4 Rotating diode bridge
2.2.1 Revolving field-coil a) General points
The revolving field coil comprises a stack of steel The rectifier bridge, comprising six diodes, is placed at the
laminations, stamped and cut to reproduce the indentation rear of the machine. The rotating bridge is made of glass
of the projecting poles. fibre with a printed circuit to connect the diodes together.
The steel lamination stack-up is terminated at each end This bridge is supplied with alternating current by the
with high-conductivity electrical plates. excitation armature and supplies direct current to the
revolving field-coil. The diodes are protected against over
To enable parallel operation between machines, and in voltage by rotating resistors, or by varistors. These
order to ensure stability, high electrical conductivity bars resistors (or varistors) are mounted in parallel with the
are inserted in holes crossing the poles from one side to revolving field-coil.
the other. These bars are welded with the stack end
laminations in order to obtain a complete cage winding (or
LEBLANC dampening cage).
The winding (B) is placed around the pole (A) and is
impregnated with epoxy resin (class F machine insulation)
or with varnish (class H machine insulation).
The winding is made of insulated flattened copper with
high electrical conductivity.

10
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS

2 c) Rotating rectifier test

Carry out the test using a D.C. source as indicated below.
1 + 3 A diode in good condition should allow the current to flow
only in the anode-to-cathode direction.
Disconnect the diodes before the test.
3 ... 48 volts

- - +
1 - Field 1 2
2 - Rotating resistors
3 - Exciter armature

The inner and outer rings are connected to the revolving

field-coil 1 - Anode
2 - Cathode
1
Diode type Positive Negative
SKR diode housing diode wire
2
SKN diode wire diode housing

When reassembling ensure that the diodes are be

tightened to the correct torque

1 - Outer ring 2.2.5 Balancing

2 - Inner ring The entire rotor has been balanced according to ISO8221
The diode fastening screws must be tightened to the standard in order to obtain a residual imbalance less than :
correct torque. Gen set : Class G2.5
Turbine : Class G1
b) Tightening torque for the rotating diode fastening The balancing is carried out at two levels. The first is that
screws of the fan. It is recommended, when the fan is refitted
(after servicing) to respect the initial indexing.
CAUTION :
THE ROTATING DIODE FASTENING SCREWS MUST The second is that of the shaft end. The shaft end is cold-
BE TIGHTENED USING A TORQUE WRENCH stamped to indicate the type of balancing.
CALIBRATED TO THE RECOMMENDED TORQUE. H : balancing with Half-key carried out as
standard
Diode Tightening torque F : balancing with Full key
N : balancing without key (None)
SKR 100/.. 1.5 m.daN
The coupling must be balanced to fit the generator rotor
SKR 130/.. 1.5 m.daN balancing.
SKN 240/.. 3 m.daN
2.2.6 Rotor vibration sensor
This chapter concerns the setting of proximity probes. For
setting of seismic probes refer to the stator chapter
The vibration level of the machines is directly linked to the
duty and to the site characteristics.
We propose the following adjustment:
Vibration Alarm (*) = 50% of the Bearing shell gap
Vibration Trip = 75% of the Bearing shell gap

11
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS

2.3.3 Maintenance of antifriction bearings

2.3 ANTI FRICTION-BEARINGS
a) General points
2.3.0 Description of antifriction bearings Antifriction bearings or ball bearings do not require special
The bearings are installed at each end of the machine. maintenance.
They can be replaced. They must be lubricated regularly with the same type of
The bearings are protected from external dust by labyrinth grease as used in the factory. For information concerning
seals. the lubrication quantity and interval, refer to Section 1 :
The bearings must be lubricated regularly. The old grease "Characteristics and Performance".
is forced out at the lower part of the bearings by the force CAUTION :
of the new grease being injected.
LUBRICATION MUST BE CARRIED OUT AT LEAST
EVERY 6 MONTHS
2.3.1 Start-up of antifriction bearings
The bearings are pre-lubricated in the factory, but before CAUTION :
they are put into service, it is necessary to complete this IT MUST BE DANGEROUS TO MIX GREASES WHICH
lubrication. HAVE DIFFERENT SOAP BASE. IT IS NECESSARY TO
GET THE GREASE SUPPLIER APPROVAL OR TO
CAUTION CLEAN THE BEARING BEFORE TO PROCEED
UPON START-UP, GREASE THE MACHINE WHILE IT IS
RUNNING SO AS TO FILL ALL THE FREE SPACES IN
THE GREASING DEVICE
NOTE:
Record the temperature of the bearings during the initial After a regreasing the bearing temperature may increase
operating hours. Poor lubrication can cause abnormal of 10 to 20°C
heating. This temporary temperature increase may stay few tens of
hours
If the bearing hisses, lubricate it immediately. Some
bearings may make a clattering noise if they do not
NOTE:
operate at normal temperature. This may occur if the
For re greasing period lower than 2000 hours we
weather is very cold or when the machine is operating
recommend to install a continuous greasing system to limit
under abnormal temperature conditions (start-up phase,
the maintenance operators visit
for example). The bearings will become quieter after
These type of system must be disable during machine stop
having reached their normal operating temperature.
The grease contained in these systems must not be stored
over a period of 1 year
2.3.2 Storage of machine with anti friction bearings
This chapter must be taken in consideration if a machine is b) Lubricant
stopped more than 6 months. Recommended lubricant:
Grease the bearings , machine stopped , inject two time SKF LGWA2
the grease volume used for a standard maintenance. SHELL GADUS S3 V220C (lithium complex base).
Every 6 months turn the the machine shaft line of few SHELL RETINAX LX2 (lithium complex base).
turns. Then inject a standard grease volume CASTROL LMX NLGI2
TOTAL Multis complex EP2
Recommendation for a grease choice ::
Mineral oil or PAO (SHC)
Base (soap ) grade NLGI 2
Lithium complex base
Base oil viscosity at 40°C: 100 to 200 mm2/s
Dye penetration test (DIN 51817) : 2% minimum
Use of grease which do not fit to the recomended figure
(substitution grease) :
Mineral oil or PAO (SHC)
Base (soap ) grade NLGI 2 or NLGI 3
Lithium base
Base oil viscosity at 40°C: 100 to 200 mm2/s
Dye penetration test (DIN 51817) : 2% minimum

CAUTION :
THE USE OF A SUBSTITUTION GREASE CONDUCE TO
REDUCE THE RE GREASING PERIOD OF 30%

12
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS
NOTE:
Lithium and complex lithium soap can be mixed
Lithium complex and calcium lithium soap can be mixed
In case of change of grease brand it is recommended to
proceed to a massive greasing to waste the previous
grease.

c) Cleaning bearings
This note is applicable when the type of grease is
changed.
c) Bearing re-assembly
Dismantle the machine in order to get to the bearing
A bearing can be refitted if it is known to be in perfect
Remove the old grease with a palette knife. condition As far as possible we recommend to use a new
Clean the lubricator and the grease removal tube. bearing
For greater cleaning efficiency, use a brush with solvent. Before refitting a bearing, carefully clean the surface of the
bearing and the other parts of the bearing.
NOTE:
The most widely-used solvent is gasoline : white spirit is Measure the shaft diameter to check it is within the
acceptable. recommended tolerances.
In any cases national environmental and sanitary To install the bearing on the shaft, it is necessary to heat
regulation must be fulfilled. the bearing. The heat source may be an oven or a space
heater (the use of oil baths is strongly discouraged). The
DANGER: use of an induction bearing heater is recommended.
THE PROHIBITED SOLVENTS ARE:
CHLORINATED SOLVENT CAUTION:
(TRICHLORETHYLENE,TRICHLOROETHANE) WHICH NEVER HEAT A BEARING TO MORE THAN 125°C
BECOMES ACID (257°F)
FUEL-OIL (EVAPORATES TOO SLOWLY) Push the bearing up to the shaft shoulder, and check after
GASOLINE CONTAINING LEAD cooling that the inner ring is still in contact with the
BENZINE (TOXIC) shoulder. Lubricate using the recommended grease.
Blow compressed air onto the bearings to evaporate the
excess solvent. 2.3.5 Antifriction bearing protection devices
Fill the bearing with the new grease. As an option, the bearing may be protected from over-
heating by RTD or PTC sensors (customer’s choice)..
Re-assemble the cage and the parts, which have been
For special use in warm surroundings where the
dismantled, filling them with grease.
temperature of the bearings exceeds the authorised limit
Use a grease pump to complete the bearing lubrication (for a bearing known to be in good condition), contact us.
(while machine running)
Bearing; Alarm points and shutdown:
• alarm 90°C (194°F)
2.3.4 Servicing the antifriction bearings • shutdown 95°C (203°F)

a) General points
To improve the machine protection the alarm set point may
CAUTION: be reduced following site effective information:
CLEANLINESS IS IMPERATIVE Alarm temperature (*) = Highest recorded temp + 15°K
(*) do not pass over the values of the previous chart.
b) Removing the bearings
E.g. : At site the common bearing temperature is 60°C . Set
The inner bearing race is mounted, shrunk onto the shaft. the alarm temperature to 75°C instead of 90°C as
The outer bearing race is free, or slightly tightened, on the indicated in the previous chart
hub (depending on the type of bearing). To remove the
bearing from the shaft, it is necessary to use a dedicated
hub-puller to avoid damaging the surface of the shaft.

NOTE:
Heat the bearing during the pulling operation makes the
operation easier and prevent the shaft from scratch.

13
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS

2.3.9 Anti friction bearing installation drawing

Machine type A50

Drive end Non drive end

1 End shield 5 O-Ring
2 End cover 6 Non drive end shield
3 Ball bearing 6226 C3 7 End cover
4 End cover fixing screw 8 Ball bearing 6226 C3
9 Bearing pre load washer
10 End cover fixing screw

14
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS

2.3.9 Anti friction bearing installation drawing (following)

Machine type A52.2; Two bearings

Bearing assembly "Power plant"

Drive end Non Drive end
1 End cover 5 End shield
2 End cover fixing screw 6 End cover fixing screw
3 Ball bearing 6232 MC3 7 End cover
4 End shield 8 Roller bearing NU 1028 MC3
Bearing assembly " Marine "
Drive end Non Drive end
1 9 End shield
2 same as à "power plant" 10 End cover
3 11 End cover fixing screw
4 12 Bearing pre load spring
13 Ball bearing 6226 C3
14 O-Ring

15
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS

2.3.9 Anti friction bearing installation drawing (following)

Machines A53 and A54 :

Drive end side (2 bearing machine) Non drive end side

1 – End shield 1 – End shield
2 – M12 stud 2 – M12 stud
3 – End cover 3 – End cover
4 - Shaft 4 – Shaft
5 – Ball bearing 6232 MC3 5 – Ball bearing 6328 MC3
6 – Spring

16
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS

2.3.9 Anti friction bearing installation drawing (following)

Machine type A56 ; Power plant (6 poles and more)

1
2
4 7
5 8 (6248 MC3) 7 1
(NU 232) 8 2
6 4
5
3
Ø440J6

Ø290K6
Tr240x4

Ø240n6
-0,1

-0,1

Ø155 ±0,1
-0,1

Ø158 -0,1
Ø160n5
0

0
0

0
Ø235

Ø180
Ø260

1 – Bearing carrier 3 – Snap ring 5 - Rotating deflector 7 - Inside bearing cover

2 - Outside bearing cover 4 - Fixed deflector 6 - Nut 8 – Anti friction bearing

Machine type A56 ; Power plant (4 poles only)

7 1
2
(NU 232) 8
4
5
6
Ø290K6
O 380 J6

O 180 n5

-0.1
-0.1

0
0

-0,1

Ø155 ±0,1

-0,1
Ø160n5
0
O 220

0
O 175

Ø158
Ø180

1 – Bearing carrier 3 – Snap ring 5 - Rotating deflector 7 - Inside bearing cover

2 - Outside bearing cover 4 - Fixed deflector 6 - Nut 8 – Anti friction bearing

17
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS

c) Operating description of Oil circulation bearing

2.4 SLEEVE BEARINGS Proceed as for the self-lubricated bearings.
Note : For vertical machines refer to the attached specific For special duty of high speed machine or high loaded
bearing notice. bearing it might be necessary to have an oil circulation
Refer to the attached cut view in "chapter 10" for an easier system (external device which ensure the cooling and the
understanding circulation of the oil)
The oil warmed by the bearing losses is externally cooled
2.4.0 Description of horizontal Sleeve bearings and is returned directly to the shell. To obtain efficient
cooling the oil flow must be correct (refer to section 1).
a) Physical description
Rotation of the machine rotor is guided by Sleeve 2.4.1 Electrical insulation of Sleeve bearings
bearings.
The bearing housing is constructed in two ribbed parts a) Illustration diagram of the insulating film
providing considerable heat extraction potential. Following the used technology shaft circulating current
may occurs. When necessary, ACEO insulates the Non
The sleeve bearing comprises two half-shells with an Drive End bearing to avoid shaft-circulating current.
external spherical shape. This allows self-alignment. The
guiding surfaces of the sleeve bearing are covered with tin- An insulating film is applied to the bearing housing
based anti-friction metal. spherical seat.
The spherical seat of the housing of the electrically
insulated bearings is covered with an insulating coating.
The positioning pin of the sleeve bearing in the housing is
also insulated with an insulating bush.
The lubrication ring, mounted free on the shaft, is made of
brass. In order to simplify dismantling, the ring is cut in two
parts, assembled using screws.
A guide for the lubrication ring (synthetic materials) is
attached to the upper bearing half-shell (for marine
applications only).
1 – Electrical insulation
The floating labyrinth seals are cut in two parts, held
together by an expandable ring. These seals are inserted CAUTION:
in a support. A seal-positioning pin rests in the support to WHEN INSULATED BEARING IS USED THE
block it during rotation. ACCESSORIES IN CONTACT WITH THE SHELL MUST
The upper part of the housing is closed by means of a BE ELECTRICALLY INSULATED (TEMPERATURE
glass plug allowing observation of the rotation of the SENSOR …)
lubrication ring. A threaded metal plug allows the bearing
to be filled with oil.
The lower housing may be equipped with an oil-level sight
indicator, a thermometer and a temperature sensor.

b) Operating description of Self-lubricating bearing

Upon stopping, the shaft rests on the lower bearing; there
is metal-to-metal contact.
During the start-up phase, the shaft rubs against the anti-
friction metal of the bearing. Oil lubrication is used.
After having reached its transition speed, the shaft creates
its oil film. At this point there is no further contact between
the shaft and bearing.

CAUTION:
PROLONGED OPERATION AT EXTREMELY SLOW
ROTATION SPEEDS (SEVERAL rpm) WITHOUT
LUBRICATION COULD SERIOUSLY DAMAGE THE
SERVICE LIFE OF THE BEARING.

18
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS

b) Insulation check c) Long term storage

Single bearing machine: When a sleeve bearing machine has to be stopped for
Maintain the rotor at the drive end side to insulate it from more than one year:
the earth (disconnect the coupling if not done). Measure Drain the bearing. Place a "Silicagel" gag inside the
the insulating resistance between the shaft and the bearing oil sump (it is necessary to open the bearing
ground. The insulation should be better than 0.1 MΩ. housing to proceed)
measured under 500 V DC
Place an adhesive strip along the parting lines of the
housing.
1 Pour the recommended protecting agent through the oil
filling hole of the bearing (around 50 cc). Turn the shaft
4 2 several times in order to spread the product evenly
throughout the bearing.
3
CAUTION:
5 A VISIT OF THE BEARING (research of corrosion
marks) MUST BE DONE AT LEAST ONCE PER YEAR

CAUTION:
1 - Bearing shell
2- Insulating film BEFORE START UP IT WILL BE NECESSARY TO
3 - Bearing housing REMOVE THE "SILICAGEL" BAG AND TAPES
4 - Rotor
5 - Insulating wedging
2.4.3 Oil circulation installation
Double bearing machine: Refer to chapter 2.6
Maintain the rotor at the drive end side to insulate it from
the earth (disconnects the coupling; Dismount the drive
end bearing if not done). Measure the insulating resistance 2.4.4 Start-up of Sleeve bearings
between the shaft and the ground. The insulation should
a) General check before start up
be better than 0.1 MΩ. measured under 500 V DC
To identify your bearing characteristics refer to section 1
Installed shell accessories (e.g: RTD) must fit 0.1 MΩ.
measured under 500 V DC This verification must be carried out upon the first start-up,
during periodic inspection of the bearing, or as soon as
any part of the bearing alignment is changed (coupling ...).
2.4.2 Storage of Sleeve bearings machine
After a long shutdown period, proceed following the used
a) General points storage procedure (refer to chapter 2.4.2)
CAUTION: Check that the shaft has not corroded (onto journal
FOR MINERAL OIL WE RECOMMEND THE USE OF surface; thrust faces and seals surfaces)
TECTYL PRODUCTS FROM "VALVOLINE GmbH" SUCH Fill the bearing oil cavities with oil.
AS TYPE "511 M"
FOR SYNTHETIC OIL WE RECOMMEND THE USE OF CAUTION:
"JELT 003400" SPRAY FROM "ITW SPRAYTEC" THE BEARINGS ARE DELIVERED WITHOUT OIL

NOTE : Clean the external parts of the bearing. Dust and dirt
It is possible to start the machine up without removing the impede the radiation of the heat
recommended protection agent. Check if the temperature monitoring equipment works.

b) Short term storage

When a sleeve bearing machine has to be stopped for
more than one month and less than one year:
Do not drain the bearing
Pour the recommended protecting agent through the oil
filling hole of the bearing (around 50 cc). Turn the shaft
several times in order to spread the product evenly
throughout the bearing.

19
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS

b) Self-lubricating bearings start up data d) Oil circulation bearing with non accurate oil flow
To identify your bearing characteristics refer to section 1 (+0% ; -40%)
Fill the bearing with the recommended oil. The oil must be To identify your bearing characteristics refer to section 1
new, absolutely free of any traces of dust or water. This chapter typically applies for standard bearings (as for
bearing types E..Z.K ; E..Z.Q).
The oil level limits are as follows:
minimum oil level: bottom of the oil sight glass The oil circulating bearings (without Leroy Somer
maximum oil level: 2/3 the top of the oil sight glass lubricating system) are delivered with:
a breather
NOTE: It is recommended to filter the oil before filling the an oil inlet flow regulating system.
bearing. The "oil flow regulating system" consists of :
an adjustable pressure reducing valve "A"
CAUTION: a diaphragm.
NOT ENOUGH LUBRICANT LEADS TO TEMPERATURE
RISES AND THUS TO DAMAGE TO THE BEARING. NOTE: The breather can be removed if it is proved that the
TOO MUCH LUBRICANT LEADS TO LEAKAGES. bearing casing is in depressure regarding the atmosphere.
Fit a plug tin place of the breather
Retighten the split line and flange screws (12) by using the
following torque values: The oil flow adjustment does not request high accuracy.
Do not feed the bearing with an oil flow higher than this
Bearing Size 14 18 22 28 one indicated in section 1.
Torque [Nm] 170 330 570 1150 Ensure that the complete oil supply and return lines have
(lightly oiled) been rinsed as instructed in the chapter.2.4.3
Ensure that the installation instructions have been followed
Check the firm position of the top sight glass (5). (refer to chapter.2.4.3 ) such as filtering unit, return line
Check the firm position of the oil sight glass (23). properly inclined etc.
If a temperature sensor or thermometer is used check they Proceed as for the self-lubricated bearings and then
are correctly fixed. start the oil supply system (pump etc.).

Retighten all screw plugs in the connection holes (4), (22), To adjust the oil flow as recommended in section 1:
Machine stopped, adjust the pressure reducing valve "A" to
(24) (27) by using the necessary torque values:
get the bearing oil level at the middle of the glass. And
Plugs threads G 3/8 G 1/2 G 3/4 G1 then run the generator
Machine running and oil at the operating temperature the
Torque [Nm] 30 40 60 110
oil sight glass level should be within 1/3 and ½ of the
glass. If necessary readjust the pressure reducing valve
"A"
Plugs threads G 1 1/4 G 1 1/2 G2 G 2 1/2
Torque [Nm] 160 230 320 500
Check the operation of the temperature monitoring
equipment. A
During the start-up period, check the temperature of the
bearings. The temperature should stay below 95°C an d
then drop down to the temperature normally recommended
(refer to the technical characteristics for Sleeve bearings in
Section 1.)
In case of oil oozing retighten the bearing fixing screws
and the plugs to the recommended torque.
During generator operation the oil level in the bearing must
c) Water cooled bearing (type EFW..) start up data comply with the indications in Chapter 2.4.5.
To identify your bearing characteristics refer to section 1
Proceed as for the self-lubricated bearings and
check the water flow of the cooler. (refer to the data
contained in section 1)
Water has to be filtered as per chapter 2.7.5

20
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS

e) Oil circulation bearing with accurate oil flow

2.4.5 Maintenance of Sleeve bearings
(+5% ; -10%)
To identify your bearing characteristics refer to section 1 a) Verification of oil-level
This chapter typically applies for bearings engineered for Check the oil level at regular intervals.
heavy thrust (tilting pads as for bearing types E..Z.A). The oil level limits are as follows:
minimum oil level: bottom of the oil sight glass
CAUTION:
maximum oil level: 2/3 the top of the oil sight glass
THE OIL FLOW MUST BE CARREFULLY ADJUSTED TO
THE REQUESTED VALUE
Maximum admissible oil level
The oil circulating bearings are delivered with: Optimum top oil level
a breather Optimum bottom oil level
an oil inlet flow regulating system. 2/3
1/2 1/3
The "oil inlet regulating system" consists of : Minimum admissible oil level
an adjustable pressure reducing valve "A" b) Temperature verification
a diaphragm.
Check the bearing temperature and record it. A bearing
NOTE: The breather can be removed if it is proved that the temperature, which suddenly varies without any obvious
bearing casing is in depressure regarding the atmosphere reason (change of ambient temperature etc.), indicates
abnormal operation. It is then necessary to inspect the
Ensure that the complete oil supply and return lines have bearing.
been rinsed as instructed in the chapter.2.4.3
c) Oil draining
Ensure that the installation instructions have been followed
(refer to chapter.2.4.3) such as filtering unit, return line NOTE:
properly inclined etc. Risk of pollution! Please observe the instructions for the
Proceed as for the self-lubricated bearings and then use of the lubricating oil. The manufacturer can provide
start the oil supply system (pump etc.). The oil flow must information on waste oil disposal
be strictly adjusted within the requested value using a flow
It is recommended to drain the oil at intervals of
meter. Run the generator.
8000 hours of operation in dirty environment (eg :
Machine running and oil at the operating temperature the gen set application)
oil sight glass level should be within 1/3 and 2/3 of the 16000 hours of operation in clean environment (eg :
glass. If the level reach the top of the oil sight glass hydro power plant)
investigate for the oil return line design.
A yearly inspection of the oil sump is recommended. Have
f) Inspection of Sleeve bearings at the end of start-up a special attention to water contamination.
Supervise the bearing during the trial run ( 5-10 operating It is possible to decide the oil change only after making an
hours ). analysis and not at fixed period. In such practice the oil
analysis report must fulfill pollution recommendation of
Pay special attention to:
chapter "2.4.10-e":
- oil level
- bearing temperature Shut down the installation and secured it against
- sliding noises of the shaft seals unintended operation.
- tightness of the sump plugs Take all necessary measures to collect all of the lubricating
- tightness of the bearing accessories oil.
- occurrence of vibrations.
Release the lubricating oil while it is still warm. Impurities
CAUTION : and residues will thus be removed.
IF THE BEARING TEMPERATURE EXCEEDS THE Unscrew the oil drain plug (27). Release the lubricating oil
CALCULATED VALUE OF 15 k STOP THE MACHINE and collect it.
IMMEDIATELY. INSPECT THE BEARING AND
DETERMINE THE CAUSES. NOTE:
If the lubricating oil contains unusual residues or is visibly
In case of oil oozing retighten the bearing fixing screws changed, eliminate the causes. If necessary, carry out an
and plugs to the recommended torque
inspection.

Tighten the oil drain plug (27) using the following torque
values:
Bearing size 14 18 22 28
Torque [Nm] 30 40 60 60
Remove the screw plugs from the oil filler hole (4).

21
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS
NOTE: Field pressure measure :
Make sure that no impurities get into the bearing.
Using a transparent tube as water column manometer.
Use a lubricant with the viscosity indicated on the bearing
type plate. Fill the lubricant through the oil filler hole (4) up Connect a flexible transparent tube to the upper part of the
bearing. Connect a pressure tap corresponding to the
to the middle point of the oil sight glass (23).
flexible tube used.
The oil level limits are as follows:
Install the pressure tap in place of the filling plug located
minimum oil level: bottom of the oil sight glass on the top of the bearing housing.
maximum oil level: 2/3 the top of the oil sight glass
Partially fill the pipe with water.
NOTE:
Insufficient lubricant leads to temperature rises and thus to NOTE:
Be careful not to cause water to enter the bearing
damage to the bearing.
Too much lubricant leads to leakage. In the case of Measure the pressure (or depression) in millimeters of
bearings lubricated by a loose oil ring, too much lubricant water column.
could break the oil ring, thus leading to damage to the NOTE:
bearing. Given the low pressures measured, to make the reading
easier it is advised to incline the water column manometer
Tighten the screw plug into the oil filler hole (4) using the
by 5.7° (diagram below). A reading amplification of "10" is
following torque values:
thus obtained.
Bearing size 14 18 22 28
50 mm
Torque [Nm] 30 40 60 60

5 mm
d) Pressure measurement of a Sleeve bearing housing
The external environment of the electric machine may
5,7°
cause pressurizing or depressurizing of the Sleeve bearing
and lead to oil leakage. 10 mm 100 mm
Example: The oil return line (of a circulation bearing)
99mm 5,7°
opening directly into a diesel motor lower sump and
allowing the housing back-pressure to return to the
bearing.
Example: A vacuum generated by a coupling located too e) Oil for sleeve bearing
close the Sleeve bearing and acting as a fan. We do not have any special recommendation regarding
The relative depression (or pressure) during operation any mineral oil manufacturer.
must remain less than 5 mm of water column. The relative The used oil must comply with the requested viscosity
pressure is the pressure difference existing between the (refer to Section 1).
bearing oil sump and the bearing outside (measured close
to the seals). For frequent cold starting (lower than -15°C) witho ut oil
sump heater please contact us. A new oil viscosity may be
Pe : external pressure advised.
close to the seal Pi
Use a non-foaming mineral oil, without additives. If an oil
Pi : bearing oil sump containing additives has to be used, make sure that the
pressure supplier confirms the chemical compatibility of the oil and
Pm : machine the lead anti-friction properties.
expansion chamber
(gain access as CAUTION:
indicated by the SYNTHETIC OILS MAY BE USED ONLY IF USED
arrow) LUBRICANT ARE ISSUED FROM THE FOLLOWING
Pe
LIST
∆ (Pe - Pi) < 50Pa
∆ (Pm - Pi) < 50Pa Pm Since the synthetic lubricants are not standardized, no
guarantee can be given regarding their chemical and
Note: 50Pa=5mmWC mechanical behavior. Some synthetic lubricant may
become acid and destroys bearing parts (white metal, oil
ring, sight indicator..) in a short time
If synthetic oil has to be used; during the first 2000 hours
of use the lubricant should be checked at short intervals.

22
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS
Viscosity data (for information) : Few examples of mineral oil:
x y viscosity viscosity Type
ISO (cSt ; 40°C)
850 42
775 40 ARAL VG 32 32 Vitam GF 32
700 38 VG 46 46 Degol CL46
680
625 36 VG 68 68 Degol CL 68
550 34
500
BP VG 32 31,5 Energol CS 32
140 32
450 460
VG 46 46 Energol CS 46
30
VG 68 68 Energol CS 68
400 28
365 26 CHEVRON VG 32 30,1 Mechanism LPS 32
315 320 24 VG 46 43,8 Mechanism LPS 46
280 22 VG 68 61,9 Mechanism LPS 68
240 20
205 220 90 50 ESSO VG 32 30 TERESSO 32
18
175 16
VG 46 43 TERESSO 46
140 150 40 14
VG 68 64 TERESSO 68
115 85 12 MOBIL VG 32 30 D.T.E. Oil Light
100 30
85 10 VG 46 43 D.T.E. Oil Medium
60 68 80
20 8 VG 68 64 D.T.E. Oil Heavy Medium
40 46 6
32 75 10W SHELL VG 32 32 Tellus Oil 32
20 22 4
10 0W & 5W 2 VG 46 46 Tellus Oil 46
VG 68 68 Tellus Oil 68
A B C
x - CST at 40°C
y - CST at 100°C The only synthetic lubricant allowed are those one issued
from the following list
A - ISO (VG)
B - SAE J306c Transmissions viscosité Type
C - SAE J300d motors (cSt ; 40°C)

KLUBER 32 Summit SH 32
44 Summit SH 46
62 Summit SH 68
81 Summit SH 100
MOBIL 31 SHC 624
65 SHC 626
SHELL 32 Madrella Oil AS 32
48 Madrella Oil AS 46
68 Madrella Oil AS 68

f) Oil sump capacity (liters)

Bearing EFxxx 14 18 22 28
Volume (l) 8 13 21 34

23
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS

g) Sealing Compound
2.4.6 Dismantling
Mineral oil.
On split surfaces it is possible to use following compounds a) Tools and equipment
(never dry): The following tools and equipment are necessary:
Loctite 128068 - Allan key set
"Hylomar M ; Marton-Domsel" - Wrenching key set
"Universal-Dichtmasse 200 PU ; Reinz-Dichtungs-gmbh" - Open-jaw spanner set
- Feeler gauges (up 0.05mm)
On split surfaces only (do not use on floating labyrinth
- Caliper gauge
seals) it is possible to use following compounds :
- Emery paper, Sleeve scraper
Terostat-9140 ; Teroson
- Lifting equipment
Blue silicone RTV n°6 ; Loctite
- Permanent sealing compound (refer to chapter 2.4.5)
Blue RTV 6B ; Permatex
- Clean cloth
Hi-Temp RTV FAG 26B ; Permatex
- Oil with the viscosity indicated (see bearing type plate)
NOTE: - Detergents
We do not recommend the use of sealing compound onto - Liquid screw locking compound (e.g. LOCTITE 242)
the floating labyrinth seals. - Liquid sealing compound and Teflon tape.
However for certain leakage type , the use of "Curyl T" may
DANGER
help to solve the encountered issue.
BEFORE TRANSPORTING OR LIFTING CHECK IF THE
EYE BOLTS ARE TIGHT! INSECURE EYE BOLTS
CAUTION
COULD RESULT IN THE BEARING BECOMING LOOSE.
COMPOUND WITH SILICONE BASE CAN POLLUTE
BEFORE MOVING THE BEARING BY THE EYE BOLTS
THE SYNTHETIC OIL BATH. THE USE OF SILICONE
MAKE SURE THAT THE SPLIT LINE SCREWS ARE
BASE COMPOUND CAN BE DONE ONLY AFTER
TIGHTENED, OTHERWISE THE BOTTOM HALF OF THE
CHECKING COMPATIBILITY WITH OIL
BEARING COULD BECOME DETACHED.
MANUFACTURER.
MAKE SURE THAT THE EYE BOLTS ARE NOT EX
POSED TO BENDING STRESS, OTHERWISE THE
BOLTS COULD BREAK.

Follow exactly the instructions for the use of the lifting

equipment.

NOTE:
Make sure that the work place is clean. Contamination and
damage to the bearing, especially of the running surfaces,
have a negative influence on the operating quality and
could lead to premature damage.

Shut down the installation and ensure that any unintended

operation is prevented.
Interrupt the cooling water supply (EFW.. bearing only).
Remove all thermo sensors from the connection holes.
Take all necessary measures to collect the lubricating oil.
Unscrew the oil drain plug (27) and collect the lubricating
oil (refer to chapter 2.4.5.c)

b) Lifting equipment
The following steps are to be observed before using the
lifting equipment:
To transport the complete bearing unit
Check if the split line screws are tight (12):
Check if the eye bolts are tight (6).
Connect the lifting equipment to the eye bolts (6).

24
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS
To transport the top half of the housing f) Removal of the top half of the shell
Check if the eye bolts are tight (6).
Unscrew the split line screws (19) and lift the top half of the
Connect the lifting equipment to the eye bolts (6). shell (11).
To transport the bottom half of the housing
CAUTION:
Screw 2 eye bolts (6) with suitable threads tight into the tap
holes (17) marked with a cross. DO NOT DAMAGE THE THRUST AND RADIAL
RUNNING SURFACES.
Bearing size 14 18 22 28
g) Dismantling of the loose oil ring
Tap hole M 16 M 20 M 24 M 30
Open both split lines of the loose oil ring (44) by
Connect the lifting equipment to the eye bolts (6). untightening and removing the screws (47). Separate both
To transport the Bearing shells halves of the loose oil ring (44) carefully without using any
tools or other devices.
Screw 2 eye bolts or screw hooks with suitable threads
tight into the tap holes (9):
Bearing size 14 18 22 28
Tap hole M 8 M 12 M 12 M 16
Connect the lifting equipment to the screw hooks.

c) Dismantling of the shaft seal type 10 (outboard side)

Loosen all screws (55) and turn them off.
Remove simultaneously in axial direction both top half (48)
and bottom half (51) of the seal carrier from the housing.
Shift the top half of the seal (53) a little (about 20 mm ). Tilt
it over carefully until the hook spring (49) unbends.

DANGER:
DURING DISMANTLING OF THE FLOATING
LABYRINTH SEAL HOLD TIGHT THE HOOK SPRING
(38). THIS IS UNDER TENSION AND COULD SPRING
BACK AND LEAD TO INJURY.

Open the hook spring (49) and remove the bottom half of
the seal (52) from the shaft.

d) Dismantling of the shaft seal type 20 (outboard side) Illustration 1 : Opening of the loose oil ring
Untight all seals fixing screw (49) and remove them. To check the geometry of the loose oil ring put it together
Simultaneously remove in axial direction both top and as follows:
bottom (48) ,(52) halves of the rigid labyrinth seal. Press the positioning pin (45) into the holes (46).
- Remove the split line screws (50). Adjust both halves of the loose oil ring till the split lines
- Separate the top half of the rigid labyrinth seal (59) from match each other.
the bottom half (63). Tighten the screws (47).
e) Dismantling of the top half of the housing
Remove the flange screws (8).
Remove the split line screws (12).
Lift the top part of the housing (1) until the top part of the
housing can be moved in axial line over the bearing shell,
without touching it.

25
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS

h) Dismantling the machine side shaft seal

2.4.7 Cleaning and checking
Shift the top half of the seal (53) a little (about 20 mm). Tilt
it over carefully until the hook spring (49) unbends. a) Cleaning

DANGER: CAUTION:
DURING DISMANTLING OF THE FLOATING USE ONLY NON-AGGRESSIVE DETERGENTS SUCH
LABYRINTH SEAL HOLD TIGHT THE HOOK SPRING AS FOR INSTANCE
(38). THIS IS UNDER TENSION AND COULD SPRING · VALVOLINE 150
BACK AND LEAD TO INJURY. · ALKALINE CLEANING COMPOUNDS (PH-VALUE 6 TO
9, SHORT REACTION TIME).
Open the hook spring (49) and turn the bottom half of the
seal (52) in the opposite direction to the anti-rotation pin DANGER:
out of the integrated seal groove of the bottom half of the PLEASE OBSERVE THE INSTRUCTIONS FOR THE USE
housing.
OF THE DETERGENTS.
i) Removal of the bottom half of the shell
CAUTION:
CAUTION: NEVER USE CLEANING WOOL OR CLOTH. RESIDUES
MAKE SURE THAT ALL BEARINGS MOUNTED ON A OF SUCH MATERIALS LEFT IN THE BEARING COULD
SHAFT LINE ARE OPENED. LOOSEN THE SPLIT LINE LEAD TO EXCESSIVE TEMPERATURES.
SCREWS OF THE HOUSINGS.
Clean the following parts thoroughly :
CAUTION: top half of the housing (1)
THE LIFTING EQUIPMENT SHOULD NOT COME IN bottom half of the housing (21)
TOUCH WITH THE SEAL AND RUNNING SURFACES top half of the shell (11)
bottom half of the shell (13)
OF THE SHAFT.
sealing surfaces of the top half (48) and bottom half (51)
Lift the shaft up to the point where shaft and bottom half of of the seal carrier or of the rigid labyrinth seal
the shell (13) do not touch each other any more. Protect loose oil ring (44).
the shaft against unintended movement. Water cooler cleaning (bearing type EFW.. only)
Turn the bottom half of the shell (13) out of the bottom half Check the condition of the oil cooler (26).
of the housing (21) and remove it from the shaft. In case the oil cooler (26) is encrusted with oil sludge:
j) Dismantling of the machine seal Dismantle the oil cooler. Remove the encrustation by using
Usually it is not necessary to dismantle the machine seal for instance a wire brush.
(10) if maintenance works are carried out. Install the oil cooler (26) into the bearing.
If due to certain reasons the split machine seal must be
dismantled please observe that this operation can be
carried out only from the inner part of the machine. Loosen
the split line screws of the machine seal and remove the
flange screws (7).
Non-split machine seals can be dismantled only after
dismantling the machine shield or the shaft completely.
In the case the machine seal is equipped with a hamp
packing, some visible changes can be noticed, such as :
tallow excess, black color of the seal due to temperature
development. Even in such cases it is not necessary to
renew the hamp packing. Color changes will appear with a
new hamp packing too, until the seal clearance adjusts
during operation.

26
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS

b) Wear checking
2.4.8 Assembly of the Bearing
Carry out a visual check of the wear condition of all bearing
parts. The following graph provides information on the CAUTION:
parts that must be replaced in case of wear. The right REMOVE ALL IMPURITIES OR OTHER OBJECTS SUCH
evaluation of the wear condition, especially of the running AS SCREWS, NUTS, ETC. FROM INSIDE THE
surfaces of the bearing shell, implies a lot of experience. If BEARING. IF LEFT INSIDE THEY COULD LEAD TO
in doubt, replace the worn part with new ones. DAMAGE OF THE BEARING. COVER UP THE OPENED
Part Wear condition Maintenance proceedings BEARING DURING BREAKS.
Shell Scoring Bearing temperature before
inspection: CAUTION:
· not increased no new CARRY OUT ALL ASSEMBLY OPERATIONS WITHOUT
shells MAKING USE OF FORCE.
· increased new shells
White metal New shell CAUTION:
lining damaged USE A LIQUID SCREW LOCKING COMPOUND (E.G.
LOCTITE 242) FOR ALL HOUSING, SPLIT LINE AND
Bow wave ridges New shells
FLANGE SCREWS.
Shaft Baffles broken or New shaft seal
seal damaged a) Fitting in the bottom half of the shell
Loose Geometrical form New loose oil ring Apply some lubricant on the spherical seating (14) in the
oil ring (roundness, bottom half of the housing (21) and on the running
flatness ) visibly surfaces of the shaft. Use the same type of lubricant as
changed indicated for bearing operation ( see type plate ).
Place the bottom half of the shell (13) on the running
surface of the shaft. Turn the bottom half of the shell (13)
c) Insulation checking (only for insulated bearing) into the bottom half of the housing (21) with the split line
Check the insulating layer of the spherical seating (14) of surfaces of both halves in true alignment.
the top half (1) and bottom half (21) of the housing. In case In case the bottom half of the shell does not turn in easily,
of damage contact Leroy Somer; département ACEO check the position of the shaft and the alignment of the
factory. bearing housing

CAUTION:
(ONLY FOR BEARINGS EF..K)
THESE OPERATIONS SHOULD BE CARRIED OUT
MOST CAREFULLY. THE THRUST PARTS OF THE
BOTTOM SHELL SHOULD NOT BE DAMAGED.

Lower down the shaft till it sits on the bottom half of the
shell (13).

b) Assembly of the shaft seal machine-side

The machine-side shaft seal is standard-wise a floating
labyrinth seal. The integrated seal groove is in the top and
bottom halves of the housing.

DANGER:
DURING ASSEMBLY HOLD THE HOOK SPRING ENDS
SECURELY TO AVOID THEM SUDDENLY RELEASING
AND CAUSING POSSIBLE INJURY!

Check the movement of the floating labyrinth seal on the

shaft in the seal area outside the housing:
Put the hook spring (49) around the shaft and hook both
ends into each other.
Put both halves of the seal (52), (53) in their place on the
shaft.
Put the hook spring (49) into the spring groove (50).
Turn the floating labyrinth seal on the shaft.

27
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS
Remove the rest of the sealing compound.
CAUTION:
THE FLOATING LABYRINTH SEAL SHOULD TURN Push the spring hook into the integrated seal groove
EASILY ON THE SHAFT. A JAMMED SEAL COULD between the bottom half of the housing and the seal until
LEAD TO OVERHEATING DURING OPERATION AND both ends jut out from the split line.
EVEN TO SHAFT WEAR. Place the top half of the seal with the cam facing the inside
of the bearing on the bottom half of the seal.
If the floating labyrinth seal jams, dismantle it from the
shaft. Remove the worn parts of the seal carefully, by Stretch the hook spring until both ends can be hooked.
using emery paper or a Sleeve scraper.
c) Installation of the loose oil ring
Dismantle the floating labyrinth seal. Open both split lines of the loose oil ring (44) by
untightening and removing the screws (47). Separate both
NOTE: halves of the loose oil ring (44) carefully without using any
We do not recommend the use of sealing compound onto tools or other devices.
the floating labyrinth seals.
However for certain leakage type , the use of "Curyl T" may
help to solve the encountered issue.

Apply sealing compound on the guide surfaces of the

integrated seal groove in the bottom half of the housing.

Illustration 2: Coating of sealing compound on the

integrated seal groove
Apply a uniform layer of sealing compound on the seal
surfaces and on the split line surfaces of both halves of the
seal (52), (53).

Illustration 4 : Opening of the loose oil ring

Place both halves of the loose oil ring into the shell groove
(13) encircling the shaft. Press the positioning pin (45) of
each split line into the corresponding hole (46).

Illustration 3 : Coating of sealing compound on the floating

labyrinth seal
Place the bottom half of the seal (52) with the labyrinths
onto the shaft.
The oil return holes at the bearing side must be opened.
Turn the seal in the opposite direction to the anti-rotation
pin into the groove of the housing until the split lines of the
bottom half of the housing and the bottom half of the seal
match each other.

28
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS
Adjust both halves of the loose oil ring until the split lines
e) Closing of the bearing
match each other.
Check the true alignment of the shell (11), (13) and bottom
half (21) of the housing.
The positioning pin (3) in the top half of the housing fits in
the corresponding positioning pin hole (2). The bearing
shell is thus placed into its right position.
Check if the engraved numbers (20) on the top and bottom
halves of the housing correspond.
Clean the split line surfaces of the top and bottom halves
(1), (21) of the housing.
Apply sealing compound over the whole surface of the split
line of the bottom half (21) of the housing.
Illustration 5 : Installation of the loose oil ring
Place the top half of the housing carefully into the machine
Tighten the screws (47) by using the following torque shield, without touching the seals or the bearing shell.
values:
Bearing size 14 18 22 28
Torque [Nm] 1,4 2,7 2,7 2,7

d) Fitting in the top half of the shell

Apply some lubricant on the running surfaces of the shaft.
Use the same type of lubricant as indicated for bearing
operation (see type plate).
Check if the engraved numbers (15) on the bottom and top
halves of the shell correspond.
Place the top half of the shell (11) on the shaft; both
engraved numbers (15) should be on the same side.

CAUTION :
AN INCORRECTLY PLACED SHELL COULD JAM THE
SHAFT THUS LEADING TO THE DAMAGE OF BOTH
SHAFT AND BEARING.

CAUTION : (FOR BEARINGS TYPE EF..K ONLY)

PLACE THE TOP HALF OF THE SHELL CAREFULLY
ON THE SHAFT. THE THRUST PARTS OF THE TOP
HALF OF THE SHELL SHOULD NOT BE DAMAGED.

Tighten up the split line screws (19) by using the following

torque values:
Bearing size 14 18 22 28
Torque [Nm] 20 69 69 170
Check the split line of the bearing shell by using a feeler
gauge. The split line gap should be less than 0.05 mm. If
the split line is greater than this, dismantle both top and
bottom (11), (13) halves of the shell.
Check the mobility of the loose oil ring (44).
Marine bearing only:
A guide bush in the top half of the shell secures the
function of the loose oil ring.
Check the mobility of the loose oil ring (44) in the guide
bush.

29
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS
Lower the top half of the housing (1) vertically on the
bottom half of the housing (21). Lower the top half of the
housing (1) until the split line of the housing is not visible
any more.
Gently hit the bottom half of the housing (21) with a nylon
hammer, thus ensuring the alignment of the spherical
seating.
Insert the split line screws (12). Tighten them hand-tight.
Insert the flange screws (8). Tighten them using the
following torque values:
Bearing size 14 18 22 28
Illustration 6 : Application of sealing compound on the
Torque [Nm] 170 330 570 1150 floating labyrinth seal

Tighten the split line screws (12) of the housing crosswise Press the bottom half of the seal (52) against the shaft.
using the same torque values Place the top half of the seal (53) on the shaft and align
both halves of the seal to each other.
f) Assembly of the type 10 Outboard Side Seals Place the hook spring (49) into the spring groove (50) and
stretch until both ends can be hooked.
DANGER: 43 42 1

DURING ASSEMBLY HOLD THE HOOK SPRING ENDS

38 41 21

(49) SECURELY TO AVOID THEM SUDDENLY

RELEASING AND CAUSING POSSIBLE INJURY!

Check the movement of the floating labyrinth seal on the

shaft in the seal area outside the housing.
Place the hook spring (49) around the shaft and hook both
ends into each other.
Locate both halves of the seal (52), (53) in their place on
the shaft.
Locate the hook spring (49) in the spring groove (50).
Turn the floating labyrinth seal on the shaft.

CAUTION:
THE FLOATING LABYRINTH SEAL SHOULD TURN
EASILY ON THE SHAFT. A JAMMED SEAL COULD
LEAD TO OVERHEATING DURING OPERATION AND
EVEN TO SHAFT WEAR.

If the floating labyrinth seal jams, dismantle it from the

shaft. Remove the worn parts of the seal carefully, by Illustration 7 : Assembly of the floating labyrinth seal
using emery paper or a Sleeve scraper. Align the split line of the floating labyrinth seal and the split
line of the seal carrier.
Dismantle the floating labyrinth seal.
Check that both engraved numbers (56)and(58) on top and
NOTE: bottom halves of the seal carrier (48), (51) correspond.
We do not recommend the use of sealing compound onto Clean the following:
the floating labyrinth seals. the seal surfaces of the top (48) and bottom (51) half of the
However for certain leakage type , the use of "Curyl T" may seal parts: carrier (the groove of the floating labyrinth seal,
help to solve the encountered issue. the flange surfaces)
the split line surfaces of the top (48) and bottom (51) half
of the carrier
the flange surfaces of the housing.
Apply a uniform layer of sealing compound on the seal
surfaces and on the split line surfaces of both halves of the
seal (52), (53).

30
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS
Apply a uniform layer of sealing compound on:
the lateral surfaces of the groove at the top (48) and g) Assembly of the type 20 Outboard Side Seals
bottom (51) half of the seal carrier Check if the engraved numbers on the bottom half (63)
the flange surfaces of the top (48) and bottom (51) half of and top half (59) of the rigid labyrinth seal correspond.
the seal carrier Clean the flange surfaces of
the split line surfaces of the bottom half of the seal carrier the top half and bottom half (63) of the rigid labyrinth seal
(51). the split line surfaces of the top half and bottom half (63) of
the rigid labyrinth seal
the flange surfaces of the housing.
Apply a uniform layer of sealing compound on the following
parts:
the flange surfaces of the top (59) and bottom half (63) of
the rigid labyrinth seal
the split lines of the bottom half (63) of the rigid labyrinth
seal.

Illustration 8 : Application of sealing compound on the seal

carrier
Place the top half of the seal carrier (48) on the top half of
the seal (53). Press the bottom half (51) of the seal carrier
against it. Push the shaft seal completely into the housing.

Illustration 10: Application of sealing compound on the rigid

labyrinth seal

Illustration 9 : Assembly of the seal carrier

Align the split lines of the seal carrier and the housing.
Tighten up the screws (55) by using the torque values:
Bearing size 14 18 22 28
Torque [Nm] 8 20 20 20

31
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS
Place the top half (59) of the rigid labyrinth seal on the
shaft and press slightly the bottom half (63) of the rigid
labyrinth seal from below against it. Lightly push the rigid
labyrinth seal completely into the housing.
Tighten the split line screws (61).
Place in parallel alignment the split line of the rigid
labyrinth seal and the split line of the housing.

CAUTION:
PRESS THE RIGID LABYRINTH SEAL FROM BELOW
AGAINST THE SHAFT

Adjust the rigid labyrinth seal in such a way that the

clearance "f" between the shaft and the rigid labyrinth seal
at both split lines has the same figure. Illustration 1: Assembly of the RD-thrust pads
Place the top half of the shroud ring (39) into the top half of
the shell (6) by inserting the anti-rotation pin (43) into the
location hole (38). Match the split line of the top half of the
shell (6) with the split line of the top half of the shroud ring
(39) in true alignment.

Illustration 11: Alignment of the rigid labyrinth seal

Tighten the screws (60) by using the following torque
values:
Bearing size 14 18 22 28
Torque [N.m] 8 20 20 20

h) Assembly of the RD-thrust pads ; bearing type E...A

Clean both top and bottom halves of the shroud ring and
all RD-thrust pads..
Check if the parts show any visible damage. Illustration 2: Assembly of the shroud ring
Carry out the assembly of both thrust parts of the top Tighten the screws (40) by using the following torque
(6) and bottom (27) half of the shell according to the values:
following instructions:
Bearing size 14 18 22 28
An RD-thrust pad on both sides of the top half of the shell
has a bore for the insertion of a thermo sensor ( thrust part Tap hole M5 M6 M8 M10
temperature measurement).
Torque [N.m] 2,7 8 20 40
To mount the RD-thrust pad into the correct position
proceed as follows: Place the bottom half of the shroud ring (41) into the
- Find the position of the location hole (38) on the top half bottom half of the shell (27). Match the corresponding
of the shroud ring (39).Insert the RD-thrust pad (42) with split lines in true alignment. Tighten the screws (40)
the anti-rotation pin (43) into the corresponding thrust pad with the same torque value as valid for the top half of
location hole (37).
the shell (6).
Insert all other RD-thrust pads (42) into the corresponding
Check the mobility of all RD-thrust pads (42).
thrust pad holes (37)
If the RD-thrust pads jam, realign the top (39) and bottom
of the top and bottom half of the shell (6),(27).
half (41) of the shroud ring.

CAUTION
INSUFFICIENT MOBILITY OF THE RD-THRUST PADS
WILL CAUSE DAMAGE OF THE BEARING.

Both top and bottom halves of the shells are prepared

for assembly.

32
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS

c) Thermostat or sensor (optional)

2.4.9 Oil-leakage trouble-shooting
The recorded oil sump temperature must stay below 85°C
A bearing loss more than 4 drops of oil per day can be in normal condition.
considered as a leakage
Below this quantity this phenomenon is named oozing and The shell temperature must stay below 90°C in norma l
is inherent to sleeve bearing technology. An oil oozing condition.
need a periodic cleaning done by the end user without Shell metal ; Alarm points and shutdown:
necessary corrective action • alarm 95°C (203°F)
Oil leakage can occur in the Sleeve bearings if certain • shutdown 100°C (212°F)
measures are not taken. Oil sump ; Alarm points and shutdown:
• alarm 85°C (185°F)
a) Self-lubricating bearing • shutdown 90°C (194°F)
- Is the oil level correct? (see chapter 2.4.5.a )
To improve the bearing protection the temperature set
- Is the Sleeve bearing in decompression? (see chapter points can reduced following the effective site condition
2.4.5.d ). If the depression level is abnormal, add a
protective screen. Alarm temperature (*) = Highest recorded temp + 5°K
Trip temperature (*) = Alarm temperature + 5 °K
- Is the leakage occurring around the parting line? Clean (*)Highest recorded temp: Temperature measured at
the parting lines carefully with a solvent. Apply a sealing the site in the worst temperature
compound (refer to chapter 2.4.5) upon reassembly (see
chapter 2.4.6) Eg: A bearing reach 80°C in the worst site condition
Adjust the alarm set point to 85°C instead of 95°C a s
b) Oil circulation bearing previously recommended.
- All information and instructions concerning the "self- Adjust the trip set point to 90°C instead of 100°C a s
lubricating bearings" apply. previously recommended.

- Is the bearing oil flow correct (for data refer to section 1)? d) Pre lub pump (optional)
To adjust the oil flow refer to chapter 2.4.4 A pump takes up the oil from the bearing oil sump and
-Is the Sleeve bearing under pressure? pours it over the bearing shell.
To measure refer to chapter 2.4.5 . This pressure most This pump ensures bearing lubrication, increasing the
certainly comes from the oil-return circuit. Check the oil- greasing effect during operation at very low speed and
return circuit (refer to chapter 2.4.3 ). The back-pressure start up period
can often be eliminated by inserting a siphon-effect on the
oil-return line (then make sure that the circuit modification Check the electrical connection of the pump motor to be
does not disturb the oil-return flow). sure of the rotation direction (the rotation direction is
indicated on the pump).

2.4.10 Sleeve bearing protection devices The pump has to be run few seconds before the
synchronous machine starting (pre lub effect) and stopped
a) Sight-level glass as soon as the main shaft line pass over200 rpm
A sight-level gauge is placed on each bearing housing (on For application having a long stop period (time over 5
the left or the right). The level control method is described minutes; eg: Steam Turbine, hydro turbine) the pump has
in chapter 2.4.5 a to be run as soon as the speed pass below 200 rpm
b) Oil thermometer (optional) The pump has to be run continuously during barring period
(eg: engine maintenance)
The thermometer gives the oil sump temperature.
The recorded oil sump temperature must stay below 85°C
in normal condition.

33
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS

e) Oil filtering and pollution

Following indication are related to the maximum 2.6 OIL CIRCULATION LUBRICATING UNIT
acceptable oil pollution level and to the oil filtering level
(filter efficiency) which has to be installed to obtain a clean 2.6.0 General points
oil Oil circulating bearing are noticeable by the third digit of
Refer to Section 1 to get data about the used bearing their code. Letters "Z" ; "X" ; "U" indicate the use of an oil
The viscosity change must remains within +/- 10% of a circulating bearing
fresh oil lubricant Example of oil circulating bearing :
Acidity change must remains (TAN) +/- 0.5 mg KOH/g of a EFZLK ; ERXLA …..
fresh oil lubricant For engineering reason (need of cooling, need of
Humidity ratio must remains below 0.05 % lubrication) an external oil supply can be requested.
This paragraph applies to bearings designed for high axial Following the machine engineering the lubricating oil can
thrust (tilting pads technology as used in bearings type come from different sources :
.....A).
• Oil from the drive engine (System with gravity return)
Maximum acceptable pollution:
following ISO 4406 : 17/15/12 • Oil lubricating unit (System with gravity return)
following NAS 1638 classe 7
• Unit heater
Filtering level to ensure :
following ISO 16889 : β 10 ( c ) = 100 (filtering 10µ) 2.6.1 Oil circulation by gravity return
a) General
This paragraph applies to standard bearings with low axial This chapter applies for bearings, which need an oil
thrust , self lub or oil circulation (as types E..Z.K ; E..Z.Q). circulation system
Maximum acceptable pollution: The operating condition (sequences of operation,
following ISO 4406 : 18/16/13 maintenance …) are given by a specific notice attached to
following NAS 1638 class 9 the present one.
Filtering level to ensure (oil circulation bearing):
following ISO 16889 : β 25 ( c ) = 100 (filtering 25µ)
1 7
3 6

4 5

1 – Oil inlet
2 – Oil sight level indicator
3 – Exhaust elbow
4 – Immediate slope
5 – Following ducts
6 – Return oil sump
7 - Breather
Correct oil flow is obtained by regulating the pressure at
the bearing inlet. (item 1)

34
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS

b) Supply line
To avoid excessive difficulties of cleaning, and to allow an
easy ducting, it is necessary to use pipes requested for 200 mm
mini
hydraulic duty

"H" > 200 mm

mini : 300mm
After installation of the oil lines, rinse the entire oil circuit in
order to avoid dirt or impurities entering inside the bearing
and its connections. Rinse with washing oil. It is important 15°
to remove the instrumentation (for example, pressure
60°
gauge, flow-meter ...) during the rinsing operation to avoid mini
any pollution.
NOTE: Min Average slope: 150 mm / m
Never leave the Sleeve bearing on the rinsing circuit, as
insoluble particles could enter the bearing and damage it.
Install a breather as close as possible of the bearing output
The oil circulating bearings are equipped with an oil inlet The breather should be to a minimum of 200 mm above
pressure regulating system (item 1) the highest point of the bearing.
The delivered oil pressure has to be reduced by the The breather line should be linked to the top side of the
bearing system before entering the bearing to get the main oil line
correct oil flow, refer to chapter 2.4.4 for start up). It is imperative to quickly go down after the bearing output:
Install an elbow (minimum 60°) immediately after th e
A filtering unit must be installed on the supply system.
bearing exhaust.(item 3)
Refer to chapter 2.4.10. Pipe with a Minimum slope of 15° (so: a difference of 25
cm for 100cm long) minimum 300 mm high
c) gravity oil return
The difference of level between return oil sump and
CAUTION: bearing exhaust must be strictly higher than "H"=200 mm
REMEMBER THAT THE OIL EXHAUSTED FROM THE The average slope of the return line must be strictly higher
BEARING GOES BACK TO THE TANK ONLY BY than 15 cm per meter of ground line. The average slope is
GRAVITY EFFECT based on the difference of level between bearing exhaust
and return sump oil level.
CAUTION: The oil return line must no be exposed to counter current
NOT TO FOLLOW THESE RULES MAY CAUSE HEAVY air flow (air which should went from the oil return sump and
LEAKS BY BEARING SUMP OVERFLOW. go toward the bearing).
Eg: a return line which should exhaust above the oil level
CAUTION: inside an engine oil sump should receive a crankcase back
ADVISES AND REQUEST DONE IN THIS CHAPTER DO pressure which should have a real negative effect.
NOT ALLOW THE INSTALLATOR TO COMPLETE BY NOTE : The requested oil flow is indicated in section 1
ITS OWN CALCULATIONS NEEDED FOR A CORRECT Oil return line size :
OPERATION OF ITS SYSTEM.
Flange Thread Ø inter Oil flow ; max
Some bearing may have two exhaust. In this case the both (mm) (l/min)
exhaust lies must be connected ISO VG 32 ISO VG 68
Because of the requested engineering rules the return ISO VG46 ISO VG100
ducts frequently have big size. Their manufacturing is DIN DN32 G 1 ¼" 33 7,5 5,5
frequently done by welding. It will be necessary to clean
the welds and to rinse the oil lines before use. DIN DN40 G 1 ½" 40 11 9
DIN DN50 G 2" 50 17 16
DIN DN65 G 2 ½" 66 30 25
DIN DN80 G 3" 80 45 40

35
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS
Connection in "Y" shape:
It is acceptable to join the return lines of two bearings. In 2.6.2 Oil cooling unit Air/Oil exchanger
this case it is necessary to maintain a constant oil speed This system does not apply to high thrust capability
(Pipe section after = sum of the both pipes section) bearings (bearings noticeable by the fifth digit of their
code). Example : cannot be used for a bearing EFZLA
The "cooling unit" is a compact system totally fitted on the
S2 machine, close to the bearing
S1 S1 + S2 The oil is pumped from the bearing sump, passes through
an Air to Oil cooler, and is then routed back to the bearing
shell. A fan ensure the cooling of the unit using the
ambient air
The oil circulates under low pressure
The oil flow is fixed at the factory without any possible
adjustment.
The pump and the fan must run permanently as long as
the synchronous machine will rotate
No specific maintenance is required (except vibration
dampers)

CAUTION:
IN CASE THE SYSTEM INSTALLED WITH VIBRATION
DAMPERS, THE DAMPERS MUST BE PERIODICALLY
CHECKED AND CHANGED EACH FIVE YEARS.

In case of failure of the "cooling unit" the synchronous

machine :
Remains able to operate safely during a certain time (few
minutes)
The machine can be started without the cooling system
In such event, the bearing temperature will slowly increase
permitting the bearing temperature sensors to detect
overheating, trigger the alarm and protect the bearing by
stopping the machine

36
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS

2.6.3 Oil cooling unit Water/Oil exchanger

2.7 COOLER
This system does not apply to high thrust capability
bearings (bearings noticeable by the fifth digit of their
code). Example : cannot be used for a bearing EFZLA 2.7.0 Description of the cooler

The "cooling unit" is a compact system totally fitted on the a) General points
machine, close to the bearing The purpose of the cooler is to remove machine heat
The oil is pumped from the bearing sump, passes through losses (mechanical, ohmic etc). The exchanger is located
an Water to Oil cooler, and is then routed back to the on the top of the machine.
bearing shell. The water flow is ensured by the electrical Normal operation:
machine The internal air goes through the exchanger, transferring
The oil circulates under low pressure the heat and then goes back to the machine.
The oil flow is fixed at the factory without any possible CAUTION:
adjustment. IN CASE THE HOUSING INSTALLED WITH VIBRATION
The pump must run permanently as long as the DAMPERS, THE DAMPERS MUST BE PERIODICALLY
synchronous machine will rotate. The Water flow must be CHECKED AND CHANGED EACH FIVE YEARS.
ensured as far as the pump is operating.
No specific maintenance is required (except vibration CAUTION:
dampers) THE COOLER MUST BE FULLY OPERATIONAL AS
SOON AS THE MACHINE IS ROTATING (EVEN IF THE
CAUTION: MACHINE IS RUN AT NO LOAD !)
IN CASE THE SYSTEM INSTALLED WITH VIBRATION
DAMPERS, THE DAMPERS MUST BE PERIODICALLY b) Description of Air/Air coolers
CHECKED AND CHANGED EACH FIVE YEARS.
The internal air flow is moved by a fan fixed on the
In case of failure of the "cooling unit" the synchronous machine shaft. The internal cooling air circulates through
machine : the machine and through the air-cooler in a closed circuit.
Remains able to operate safely during a certain time (few The External air circulation can be created through natural
minutes) ventilation (machine class IC 6 A1 A1) or through separate
The machine can be started without the cooling system ventilation(machine class IC 6 A1 A6).
In such event, the bearing temperature will slowly increase
permitting the bearing temperature sensors to detect
overheating, trigger the alarm and protect the bearing by 1
stopping the machine. air 3 air
Water has to be filtered as per chapter 2.7.5
air
Water 2

1 - Air to Air cooler

2 - Ambient air
3 - Internal air
The air-cooler comprises a main housing containing the
tubes and an end housing which act as an air guide

Oil
~

37
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS

c) Description Air/Water double tube exchanger d) Description of Air/Water single tube exchanger
The internal air flow is moved by a fan fixed on the The internal air flow is moved by a fan fixed on the
machine shaft. The internal cooling air circulates through machine shaft. The internal cooling air circulates through
the machine and through the air-cooler in a closed circuit. the machine and through the air-cooler in a closed circuit.
The internal air circulation can be created through natural The internal air circulation can be created through natural
ventilation (machine class IC 8 A1 W7) or through ventilation (machine class IC 8 A1 W7) or through
separate ventilation (machine class IC 8 A6 W7). separate ventilation(machine class IC 8 A6 W7).
Eg : machine class IC 8 A1 W7 An exchanger comprises a fin-tube block containing
1 air • a steel frame
air
• a fin-tube block crimped mechanically onto the tubes.
• The • tube bundle is roll-expanded in the end plates
The water distribution in the tubes is provided by two water
air boxes. One water box is equipped with collars for fitting the
inlet and outlet water lines. Neoprene seals provide
watertightness between the water boxes and the end
plates.

1 – Air to Water cooler A 1

The double-tube technique keeps the cooling circuit from
being affected by possible water leakage. The double tube
provides a high safety level. In case of leakage, the water
goes from the inside of the internal tube to the coaxial
B
space between the two tubes. The water is drained axially
to a leakage chamber where it may activate a sensor.
An exchanger comprises a fin-tube block containing :
• a steel frame. 2 3
• a fin-tube block crimped mechanically to the tubes.
1 - Tube with fins
The tube bundle is roll-expanded in the end plates (parts 3 2 - End plate
and 4) 3 - Water bar
The water distribution in the tubes is provided by two A - Air B – Water
removable water boxes (part 5). A water box is equipped
with collars for fitting the inlet and outlet lines. Neoprene
seals ensure watertightness between the water boxes and
the end plates.

A
B 1
2

3 5
6 4

1 - Single internal tube

2 - External tube with internal grooving and with External
fins
3 - Internal plate
4 - External plate
5 - Outside wall of the pressure tank
6 - Flow of water or liquid leaks
A - Air B - Leakage C - Water

38
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS

c) "Emergency" operation without water

2.7.1 Water Cooler operating condition
As an option the machines can be engineered to be able to
a) Water Cooler installation operate in an "Emergency" mode without water flow
Assembly example: Only machines engineered for this operation case can
1 Outlet flange operate without water flow.
2 Inlet flange
3 Water cooler CAUTION :
4 Connecting flange THIS OPERATING CONDITION CORRESPOND TO A
5 Tap POWER DERATED OPERATING MODE
6 Flexible junction
7 Pipe In such case the machine operate in "open drip proof"
8 Draining and de aeration mode (cooling ensured by ambient air, with a protection
9 Water leakage detector level IP23)
The air inlet and outlet flaps located at the non drive end
and drive end side of the machine must be open
(concerned openings are marked by specific labels) before
running the shaft line

2.7.2 Start-up of the water cooler

a) General points
If the cooler has been stocked for more than 6 months,
recheck the correct tightening of the water boxes .The
st
tightening must be done in 4 steps (1 step , tightening at
nd
¼ of the nominal torque ; 2 step , tightening at 1/2 of the
rd
nominal torque ; 3 step , tightening at 3/4 of the nominal
torque ; final step ; tightening at 4/4 of the nominal torque).
The tightening must be done "diagonally" using a torque
wrench
Bolt M10 M12 M16
Water pipes must be connected stress free
Water pipes must be able to expand without restraint Nominal torque [Nm] 46 79 193

CAUTION:
FOR MACHINE SUPPORTING A VIBRATION LEVEL "diagonally" tightening principle :
HIGHER THAN 5 MM/S RMS WE RECOMMEND THE
USE OF HYDRAULIC FLEXIBLE JUNCTION

A pressure limit or must be installed on the system to

protect the complete assembly against abnormal over
pressure

b) "Standard" operation with water Make sure that the safety devices are operating.
CAUTION: Connect the supply and return lines.
WATER SUPPLY MUST BE EFFECTIVE AS SOON AS Fill with water, whilst carefully draining the circuit.
THE GENERATOR IS ROTATING UP TO THE
COMPLETE SHAFT LINE STOP CAUTION: (machine with motorized fan only)
WE RECOMMEND THAT THE FREE OPERATION OF
CAUTION: THE FAN BE CHECKED (NO FRICTION, NO
WATER SUPPLY MUST BE STOPPED AS SOON AS BLOCKING).
THE GENERATOR IS STOPPED TO AVOID IMPORTANT
CONDENSATION INTO THE GENERATOR CAUTION:
BEFORE START-UP, CHECK THE CLEANLINESS OF
THE COOLER FINS.

Start up the installation (if the other sub-assemblies allow

this).
Load the machine (KVA); adjust the water flow-rate to
obtain the rated flow-rate (refer to Section 1).
Check the water tightness of the lines and of the
exchanger.

39
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS
Check that the temperatures comply with the
recommended temperatures. 2.7.4 Servicing the water-cooler
a) Cooler removal
2.7.3 Maintenance of the water-cooler
The cooler unit is slid into its housing. It is possible to
a) General points remove the cooler from the housing without removing the
water boxes. The cooler is fastened to the housing via a
A regular cooler clogging will have the result to a regular series of screws on the housing.
winding temperature increasing
Remove the supply and return pipes.
The cooler cleaning period is mainly function of the water
purity Provide two supports to hold the cooler when it comes out
of its housing.
In case of used of non recirculated water with risk (eg: river
water with algae passing trough the cooler) we recommend Remove the cooler using slings that can be attached to the
a tubes visit after one year of operation. The following visit connecting flanges.
should be forecasted following the observed dust level.
b) Cooler re-assembly
b) Cleaning Carry out the operations of the "Cooler Removal" chapter
Stop the machine. in the reverse order. Be careful to push the cooler
completely into its housing before tightening the fastening
Cut off the power supply by isolating the inlet and outlet
screws of the cooler to the casing.
lines, and drain the water.
Disconnect the leak sensor (option with double-tube
2.7.5 Cooler protection devices
cooler), and make sure that there are no leaks.
Remove the water boxes on each side of the machine. a) Leak detection (float system)
Rinse and brush each water box. A magnet float activates a switch located in the float
guiding rod
NOTE:
Do not use a hard wire brush as this will remove the
protective oxidation layer which has formed on the A
surfaces of the water boxes. Clean each tube with a metal x
scraper. Rinse in soft water. 1
y
Keep the leakage chamber dry (double-tube water-cooler
only) z
Proceed to a gasket change 2
c) Leak detection for a double-tube exchanger
If a leak is detected, it is necessary to ascertain its origin
1 - Guide rod
immediately and repair it.
2 - Magnetic float
Remove the two water boxes, apply a slight positive
A – No potential contacts
pressure in the leakage chamber and thus between the
x - Blue y - Brown z – Black
two tubes (only concerns double-tube coolers).
If a tube is damaged plug it at BOTH ends. Use a tapered b) Water temperature sensor (optional)
plug. The plug should preferably be made of salt-water A temperature sensor may be installed into the water inlet
resistant aluminum bronze or of a synthetic material. flow of the cooler.
Proposal of adjustment of the water inlet sensor :
Alarm temperature (*) = Water site temp max + 5 °K
Trip temperature (*) = Alarm temperature + 5 °K

c) Water filtering
Water filtering is not ensured by Leroy Somer.
Water filtering must be better than 300 µ

40
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS

2.8 AIR FILTERS 2.18 TERMINAL BOX

2.8.0. General 2.18.0 Description

Only use approved filters. Any filter not correctly Use the attached Terminal box drawing
engineered may conduce to air flow restriction and then to The main terminal box of the machine is located on the top
abnormal generator cooling or to dust entering the of the machine.
generator
The neutral and phase wires are connected to the
terminals, one terminal per phase and one terminal per
2.8.1. Cleaning neutral line. See "Terminal Box" diagram.
a) Air filter cleaning period The openings provide access to the terminals.
The cleaning period depends of the site conditions and can The gland plates are made of non-magnetic materials in
change order to avoid circulating currents.
The cleaning of the filter is requested if the record of the The connection of accessories is achieved by terminal
stator winding temperature (using the stator winding strips. Use a 5 mm maximum screwdriver to work on the
sensors) indicates an abnormal increase in temperature. blocking screws. See the "Machine Protection Devices"
diagram.
b) Air filter, cleaning procedure
The filter element (flat or cylindrical) is immersed in a tank If products have to be added in the terminal box (CT’s,
of cold or warm water (temperature less than 50°C). Use VT’s, Shunt ex) refer to chapter.4.4.3
water with detergent added.
Shake the filter gently to ensure that the water flows 2.18.1 Electric panel
through the filter in both directions. a) Compounding panel (if compound regulator)
When the filter is clean, rinse it with clear water. The compounding panel is located in the terminal box
Drain the filter properly (there must be no more formation The three current transformers (TI 01, TI 02, TI 03), fitted
of droplets) in the terminal box on three power supply conductors,
Refit the filter on the machine. supply the compounding panel.
Rectifier bridges (CR 01, CR 02) rectify the alternating
CAUTION: current coming from these three transformers.
DO NOT USE WATER WITH A TEMPERATURE HIGHER
An RC circuit (R 01, C 01) acts as a filter; CR 03 protects
THAN 50°C, DO NOT USE SOLVENTS.
the system from high voltage spikes.
NOTE : R 02 is an assembly of two adjustable resistors (adjusted
Do not clean the filter using compressed air. This at the factory). Refer to the regulator manual.
procedure would reduce filter efficiency. L 01 is an adjustable self-inducting coil comprising three
coils. The different positions of the jumpers are shown on a
plate attached to the self-inducting coil. L 01 is adjusted to
supply excitation with no load. Refer to the regulator
manual.

b) Booster plate ( if shunt + booster regulator)

The booster plate is located in the terminal box.
The three current transformers TI 01, TI 02, TI 03, fitted to
three power supply conductors, supply the booster plate.
Rectifier bridges (CR 01, CR 02) rectify the alternating
current from these three transformers.
An RC circuit (R 01, C 01) acts as a filter. CR 03 protects
the system from high voltage spikes.
R 02 is an assembly of two adjustable resistors (adjusted
in the factory). Refer to the regulator manual, section
"Principle of Excitation-Regulation".

41
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS

2.18.2 Automatic voltage regulator 3. VOLTAGE REGULATOR AND EXTERNAL

When the automatic voltage regulator is located in the AUXILIARIES
terminal box, it is fitted on a separate plate, insulated from
vibration by means of dampening pads. The operation of The regulator instruction manual may be considered as an
the regulator is explained in chapter 3. independent manual, included in the machine instruction
manual.
CAUTION :
THE DAMPENING PADS MUST BE CHECKED
PERIODICALLY AND REPLACED EVERY FIVE YEARS

2.18.3 Electrical contact tightening

Applicable for brass thread
Thread M5 M6 M8 M10 M12 M14 M16
Torque 2.5 4 8 20 35 57 87
[Nm]

2.19 PROTECTION DEVICES

2.19.1 Stator protection devices

See "Stator protection" in chapter 2.1.3.

2.19.2 Bearing protection devices

See "Bearing protection" in chapter 2.3.5 or chapter 2.4.9

2.19.3 Cooler protection devices

See "Cooler safety" in chapter 2.7.5

2.20 NAMEPLATES

2.20.1. Main nameplate

The main nameplate is fitted to the stator. It gives the
manufacturer's electrical characteristics, the type of
machine and its serial number. The serial number is
necessary for any contact with the factory
For machines with anti-friction bearings, the quantity of
grease, the type and frequency of lubrication are
stipulated.

2.20.2. Lubrication nameplate

The machines with Sleeve bearings have a lubrication
plate attached to the bearing, giving:
Oil change frequency; Oil capacity of bearing; Oil viscosity.
The machines with anti-friction bearings have a lubrication
plate fixed on the stator, giving :
Type of bearing; Grease-change frequency; Quantity of
grease.

2.20.3. Rotation direction nameplate

An arrow on the drive end bearing indicates the rotation
direction.

42
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS

4. INSTALLATION
4.1.4 Unpacking and installation

4.1 TRANSPORT AND STORAGE DANGER :

THE FOUR LIFTING HOOKS MUST BE USED TO LIFT
4.1.1 Transport THE MACHINE WITH SLINGS (ONE HOOK AT EACH
During the transport the intermittent shocks level applied to CORNER OF THE MACHINE)
the machines must remains below 30 m/s
2 Rotors of machines with Sleeve bearings and single-
bearing machines, are blocked during transportation so as
Machines equipped with roller bearing must have their to avoid any movement. Withdraw the retaining bars. The
rotor locked during the transport to avoid "false brineling" retaining bar is screwed to the end of the shaft and to the
problem front support.
Machine temperature must remains within the range -20°C
CAUTION :
to +70°C. Stay down to -40°C during few hours is adm itted.
ALL THE LOCKING DEVICES PAINTED RED OR WITH
The machine must be protected against bad weather RED STICKER MUST BE REMOVED.
conditions and condensation.
Machines must not be handled at temperature below -20°C The end of the shaft is protected from corrosion. Clean it
before coupling.
4.1.2 Storage warehouse
4.1.5 Storage measures of a site machine
The machine must be stored in clean and dry premises
which are not subject to abrupt changes in temperature or Before stopping the machine for a long period (several
months), it is essential to take several precautionary
to high humidity (75% maximum)
measures:
The heating resistor must be switched on at all times
Refer to chapter 2.3.2 (anti friction machine) or chapter
Storage at an ambient temperature of +5 to +45° C is 2.4.2 (sleeve bearing machine)
recommended.
The heating resistor must be switched on at all times.
The machine must not be subject to vibrations higher than
For water-coolers, the water flow must be shut off. If the
1mm/s rms
water is not treated and if there is likelihood of freezing, the
exchanger must be drained.
4.1.3 Maritime packing
For an open machine, it is recommended that the air inlet
The synchronous machine is carefully packed in a wooden and outlet be closed.
crate, then hermetically sealed.
Before starting the machine up again, it will be necessary
Standard maritime packing (For long term storage) as, to carry out a start-up inspection.
seaworthy packing with fully watertight sealed film and
dessicant (silicagel bags) according Category 4C of SEI
standard. 4.2 INSTALLATION OF THE MACHINE
Optional maritime packing (In case of extended storage
period), with a special design with double sealing can be 4.2.1 Fitting the coupling (double-bearing machine
used. This packing enable access to the shaft in order to only)
perform the periodic shaft rotation recommended for The coupling must be balanced separately before
assembly on the machine shaft. Refer to the balancing
antifriction bearings (refer to chapter 2.3.2). This packing
instructions in chapter 2.2.5.
provides access to the dessicant for periodic change
(every 18 months) The shrinking of the half coupling onto the electrical
machine shaft end must be choose, by the gen-set
Breaking the hermetic protective film discharges Leroy manufacturer, in such way as it should be removable for
Somer of its long-duration storage guarantee. maintenance (e.g.: bearing change).

43
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS

c) Sleeve bearing shaft elevation

The calculated displacement is given in " section 1"
4.2.2 Fitting the stator
Four plates on the frame enable the unit to be fitted to a Exact Sleeve bearing elevation due to the oil film :
skid. The machine goes from point "1" to point "2".
The fixing bolts must support the forces created by the
static and dynamic loads. -X X

The machine may be positioned by means of 4 dowel pins.

The dowel pins make later realignment easier. (The use of Y Y
pins is optional).
The machine may be aligned through the use of 4 jacking-
screws. These jacking-screws allow the machine to be β
positioned according to the various axes.
Horaire Stop Anti horaire
Clock Wise Counter Clock Wise
4.3 ELECTRIC MACHINE ALIGNMENT
2 2
4.3.1 Alignment general points
1 1
a) General points
The alignment consist to obtain the driving shaft and the Clear : diametrical clearance
driven shaft coaxial when operating at the nominal Oil film : oil film thickness
conditions (machine rotating ; at its operating temperature) β : Attitude angle
The machine must be aligned according to the ACEO
 Clear. 
standard and adhere to the manufacturer's alignment X= − Oil film  . Sin ( β )
standard for the drive machine.  2 
When heating the machine has its shaft line which grow  Clear   Clear 
up. Between stop and rotation the shaft axis location inside Y = −  − Oil film  . Cos ( β )
its bearing is different. The total axis height elevation is  2   2 
composed of the thermal elevation and of the bearing
elevation. d)Anti-friction bearing shaft elevation
Caused by thermal growth of the anti friction bearing.
CAUTION: "2"
THE ALIGNMENT MUST BE DONE TAKING IN
CONSIDERATION THE SHAFT MOVEMENT Y ° 0,01 mm
CORRECTION

The correct locating of the parts must be obtained by

"1"
inserting shims under the machine pads..
The double-bearing machines are mounted with bearings 1 - cold, in rotation, or stopped
(ball or roller) or Sleeve bearings. The axial clearance of 2 - hot, in rotation, or stopped
the bearings (if the machine has Sleeve bearings) must be
distributed as well as possible, taking into account the axial
thermal expansion. The Anti friction-bearing machines with
a positioning bearing (standard machine) do not have axial
play.
The machines are delivered with the rotor mechanically
centered (axially and radially) in relation to the stator.

CAUTION :
THE ALIGNMENT STANDARDS OF MANUFACTURERS
OF DRIVE MACHINES ARE FREQUENTLY MORE
PRECISE THAN THOSE OF THE A.C.E.O

b) Axis height Thermal elevation

∆ H (mm) =λ (°K -1) . H(m) . ∆T(°K)
H(m) = Height of the machine axis
∆T= frame temperature elevation = 30°C
λ = Coefficient of steel elongation = 0.012 °K-1

44
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS

4.3.2 Two bearings machine alignment 4.3.3 Single bearing machine alignment
a) machines without axial end play (standard) a) General points
The alignment must take the tolerances of the coupling The alignment consist also to get the rotor of the
into account. A misalignment, acceptable by the coupling, synchronous machine coaxial to its stator
must not create an excess load on the bearing subsequent
to the axial and radial stresses outside the tolerances of
said bearing.
Shafts alignment limits to follow:

Angular error

0.01 mm

0.08 mm 100 mm
parallelism error
"A" et "B" give the shaft line alignment
"D" et "E" give the alignment of the stator regarding the
To check the alignment, there are different methods: the rotor.
"double concentricity" method is described in the Because of the engineering of the synchronous machine
"alignment procedure" chapter 4.3.4. the only requested adjustment is "C".
For generators type A60 and A62 "E" can be adjusted
b) machines with axial end play (refer to 6.2.1)
The alignment must be performed using the same method
as for a machine having no axial end play. b) Single bearing machine
It is imperative to position the rotor axially in relation to the
CAUTION: stator in order to achieve correct magnetic centering of the
THE ROTOR AXIAL LOCATION MUST BE CHECKED TO rotor in the stator.
AVOID ANY MAGNETIC OFFSET
Single-bearing machines are delivered by the ACEO
factory with the rotor centered mechanically (axially and
CAUTION: radially) in relation to the stator.
THE FAN THRUST OF THE ELECTRICAL MACHINE
MUST BE HELD THROUGH THE COUPLING. L
A “C”
A needle fitted on the drive end side bearing must face a
groove machined on the shaft. If the needle is missing the
L
distance "A" (distance from the groove up to the first
bearing part) is stamped on the shaft enabling checking.
Example for a sleeve bearing machine : B

1
Two half-shells (B parts) mounted on the front flange act
as a front bearing for the transportation and installation.
The outside of the centring half-shells face a groove
machined on the shaft.
"A" The half-shells have "L = L" construction symmetry
The length "A" shown on the diagram is stamped on the
shaft end (allowing alignment in case of absence of item
"B" rings or in case of absence of groove on the shaft)
The length "L" shown on the diagram is stamped on the
shaft end.
The side "C" represents the machined side of the bearing.
Remove the centring upper half-shell (upper "B" part).
Fit the electric machine to the drive system centering.

45
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS
Remove the centering lower half-shell (lower "B" part).
Carry out the alignment by moving the machine assembly 4.3.4 Alignment procedure
by means of lifting-screws mounted on the brackets (see a) Checking "Double concentricity" alignment method
alignment procedure below). Use shims in order to obtain
This method is not sensitive to axial movements.(the
proper alignment.
alignment methods using axial measure may often be
The centering of the rotor in relation to the stator should be perturbed by small axial movement of the rotor)
checked by measuring the concentricity of the shaft in
It is possible to check the alignment with the coupling
relation to the bearing. After having tightened the fastening
installed.
screws completely, the rotor-stator alignment must be
better than 0.05 mm axis-to-axis (that is 0.1 mm reading). Equipment required :
Two rigid brackets. The rigidity of the two brackets is very
Shafts alignment limits (regarding the drive):
important.
Two micrometers
Angular error Implementation :
During the measures, both shafts must turn simultaneously
0.01 mm in the same direction. (For example : the coupling installed
0.02 mm 100 mm with its screws untightened). By turning both shafts
parallelism error simultaneously, the measurement is not affected by the
error resulting from run out of the two shaft ends.
Check the axial positioning of the rotor in relation to the
stator. For this verification, use an upturned half-shell ("B"
part) (use of the symmetry of the "L = L" part) as shim. The C1
outside of the shim ("B" part) must be facing the groove
machined on the shaft to within +/- 1 mm.
12h B
Mount the cover plates by replacing the transportation half-
shells (delivered separate with the machine) to avoid
9h
foreign matter entering in the machine. Make sure the
closing plates are correctly centered in relation to the shaft. A
3h

6h C2

The "C1" and "C2" micrometers are located at an angular

difference of 180°.
More the distance "L" is long better should be the
sensitivity to detect the angular error
The reading should be performed 4 times for the "C1" and
"C2" micrometers : at 12h, 3h, 6h, 9h
It is recommended to record the results and draw the axes
for better evaluation, as explained below. Interpretation of
measurements by means of an example.
Values given in millimeters. The reading is considered
positive (+) when the micrometer stylus is pushed inwards.

46
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS
MEASUREMENTS
+ 1.34
4.4 ELECTRICAL CONNECTIONS
C1 C2

+ 0.90 4.4.0. General points

+ 0.70 The installation must comply with the electrical diagrams.
12h B
Refer to the attached the electrical diagrams.
+ 0.164 Check that all the protection devices are correctly
connected and in good working order.
9h 3h
+ 0.86 A The assembler has the responsibility to mechanically and
+ 1.04
+ 0.102 electrically protect the generator within the best practice
rules and to secure any operation over the defined tender
6h L=400
(respect of capability curve ; overspeed …)
+ 1.00 For low-voltage machines, power supply cables must be
Measurements referring to the vertical plane: connected directly to the machine terminals (without
Considering the vertical plane "C1" : The vertical action adding washers etc)
towards the top of shaft "A" on the micrometer is dominant. For high-voltage machines, power supply cables should be
In the plane "C1" the axis "A" is higher than axis "B” connected to separate terminals or to current transformer
( 0.9 – 0.1 ) / 2 = - 0.05 mm terminals.
In the vertical plane "C2", the vertical action towards the NOTE:
top of shaft "B" on the micrometer is greater. THE GLAND PLATE IS MADE OF NON MAGNETIC
In the plane "C2" the axis "B" is higher than axis "A" MATERIAL.
( 0.134 – 0.102 ) / 2 = 0.16 mm
The respective position of the axes is as follows: CAUTION
DO NOT ADD WASHERS TO THE POWER SUPPLY
C1 CABLE TERMINALS OTHER THAN THOSE USED BY
B THE MANUFACTURER OF THE ELECTRIC MACHINE
A
Check that the lugs are tightened.
0.16
CAUTION
C2
0.05 ALL CURRENT TRANSFORMERS MUST BE
CONNECTED OR SHUNTED
Regarding the vertical plane the angular alignment error is:
( 0.16 + 0.05 ) *100 / 400 = 0.0525 mm/100mm (not CAUTION
acceptable) THE VOLTAGE TRANSFORMER MUST NEVER BE
Measurements referring to the horizontal axis: SHUNTED
In the plane "C1" the axis "B" is further to the right than "A”
( 0.104 – 0.86 ) / 2 = 0.09 mm CAUTION
In the plane "C2" the axis "B" is further to the left than "A” THE INSTALLED POWER CABLES MUST BE FIXED
( 0.70 - 1.64 ) / 2 = - 0.47 mm AND SUPPORTED IN SUCH A WAY AS TO BE ABLE TO
WITHSTAND THE VIBRATION LEVEL REACHED BY
The representation of the shafts is as follows: THE GENERATOR IN OPERATION (refer to Vibration
C1 chapter)
B
The power cables must not stress (push, pull, bend ...) the
A generator terminals
0.47

C2
0.09

Regarding the horizontal plane the angular error is:

( 0.47 + 0.09 ) *100/ 400 = 0.14 mm/100mm (not
acceptable)
In the both planes the parallelism error is:
52 + 9 2 = 0.103mm or 16 2 + 47 2 = 0.496 mm (not
acceptable)

47
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS

b) On request ; NEMA
4.4.1. Phase-sequence
An arrow located on the front bearing indicates the
a) Standard units ; IEC 34-8 direction of rotation.
Except by special request of the customer, the phase- In the terminal box a specific marking plate indicates the
sequence is carried out using the IEC 34-8 standard. An specific generator phase sequence.
arrow located on the front bearing indicates the direction of
rotation.
In the terminal box a specific marking plate indicates the Counter clockwise rotation Clockwise rotation viewed
specific generator phase sequence. viewed from the stator from the stator connection
connection (NEMA) (NEMA)
(Clockwise rotation viewed (Counter clockwise
Clockwise rotation viewed Counter clockwise rotation from the shaft drive end rotation viewed from the
from the shaft drive end viewed from the shaft following IEC) shaft drive end following
drive end IEC)
The phases are marked: The phases are marked: The cables are marked: The cables are marked:
U1, V1, W1. U1, V1, W1. U1, V1, W1. U1, V1, W1.
Viewed from the front of Viewed from the front of The terminals are marked The terminals are marked
the terminal box the the terminal box the : :
terminals are : terminals are : T3, T2, T1 T3, T2, T1
U1, V1, W1 U1, V1, W1
Viewed from the front of Viewed from the front of
The installer connects : The installer connects : the terminal box the the terminal box the
L1 --> U1 L3 --> U1 cables are : cables are :
L2 --> V1 L2 --> V1 U1, V1, W1 U1, V1, W1
L3 --> W1 L1 --> W1 The installer connects : The installer connects :
L1 --> (U1) T3 L3 --> (U1) T3
L2 --> (V1) T2 L2 --> (V1) T2
L3 --> (W1) T1 L1 --> (W1) T1

U2 V2 W2 U2 V2 W2

T6 T5 T4 T6 T5 T4

U1 V1 W1 U1 V1 W1
U1 V1 W1 U1 V1 W1
1
T3 T2 T1 T3 T2 T1
L1 L2 L3 L3 L2 L1

L1 L2 L3 L3 L2 L1

48
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS

4.4.2 Insulating distances 5. START-UP

Products not delivered by ACEO and then installed in the
terminal box must meet the electrical insulating distances.
5.0 START-UP SEQUENCE
This applies to power cables and lugs, and to added
transformers, etc. The generator start up (commissioning) must follow the
following sequences:
Nominal Voltage 500 V 1 KV 2 KV 3 KV
Phase-Phase in 25 30 40 60 5.0.1 Static checks
the air (mm) Machine fixing as per chapter 5.2
Phase-Earth in the 25 30 40 60 Alignment as per chapter 5.2
air (mm) Cooling as per chapter 5.2
Bearing lubrication as per chapter 5.2
Phase-Phase 25 30 40 70
Electrical connections as per chapter 5.1.0 and chapter
Creeping (mm)
5.1.2
Phase-Earth 25 30 40 70
Winding insulation as per chapter 6.3.2
Creeping (mm)

5.0.2 Rotating checks

Nominal Voltage 5 KV 7,5KV 12,5KV 15 KV
a) Rotating checks not excited
Phase-Phase in 120 180 190 190 Run the generator without excitation by steps to verify the
the air (mm) bearings temperature as per chapter 5.2
Phase-Earth in the 90 120 125 125 At the nominal speed (not excited) measure the vibrations.
air (mm) Check that the vibration level is in accordance with the
generator (as per chapter 5.2.1) and duty request.
Phase-Phase 120 180 190 190
Creeping (mm) b) Rotating checks at no load excited
Phase-Earth 120 180 190 190 In AVR manual mode; Voltage adjustment; check the
Creeping (mm) excitation current value (refer to AVR manual and to the
generator test report)
4.4.3 Added products in the terminal box In AVR automatic mode; Voltage adjustments; Voltage
This may apply to site added customer CTs ; VTs etc. range; check the excitation current value (refer to AVR
manual and to the generator test report)
ACEO must be informed if some appliances have to be
installed in the generator terminal box. At the nominal speed (excited) measure the vibrations.
Check that the vibration level is in accordance with the
The products not delivered by ACEO and then installed in generator (as per chapter 5.2.1) and duty request.
the terminal box must meet the electrical insulating
distances. Refer to chapter 4.4.2. c) Generator and site safeties
The installed appliances must be able to withstand Proceed to the site safeties adjustment (over voltage relay,
vibration. over current relay, differential protection; negative
sequence relay...). The setting points are not under our
responsibility.
Check the synchronizer setting following chapter 5.1.3
For any operation at a speed exceeding the nominal range
(generally the main frequency +3%) the generator
excitation must be shut off (refer to the electrical diagram)

d) Rotating checks at full load

Operating In parallel with the mains
Adjust the Power Factor
Load the generator step by step. :
Check the excitation current at 25%of the rated load
Check the excitation current at 100%of the rated load
At the nominal speed (full load) measure the vibrations.
Check that the vibration level is in accordance with the
generator (as per chapter 5.2.1) and duty request.

49
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS

5.0.3 GENERATOR START UP CHECK LIST

TYPE SERIAL N°

Voltage V Frequency Hz Speed rpm

Output Power kVA Power Factor

STATIC CHECKS

Mechanical checks
• Direction of Rotation Clock Wise or Anti-clock Wise
• Mechanical Fixing of the generator ______________________________________________________
• Coupling - Alignment to the engine ______________________________________________________
• Cooling : Coolant flow and level ______________________________________________________
• Air inlet and exhaust free ______________________________________________________
• Bearing lubrication : Sleeve Bearings Lubrication (flow ; level ; oil type) ________________________
or Anti-friction Bearings Greasing
Temperature sensors (correct readings) _______________________________
• Space Heaters ____________________________________________________________________

Type of AVR : 1F 2F 3F

Electrical connections between alternator, AVR and main panel :

• Output power cables connections following phase order ___________________________________________
• Terminal box connections ___________________________________________
• AVR detection voltage ___________________________________________
• Supply power and excitation terminals ___________________________________________
• Network detection (3F only) ___________________________________________
• Command signals (equalisation and synchronisation for 2F and 3F) _________________________________
• Excitation polarity and booster ___________________________________________
• Protective devices : (Bearing oil level fault detectors; Temperature sensors, etc) __________________
• External accessories (e.g.. remote potentiometer) ___________________________________________

ALL CURRENT TRANSFORMERS MUST BE CONNECTED

Windings insulation
• Insulation test of the : Stator Rotor Exciter armature Exciter field
Measured values in MOhms :

All works must be carried out by a qualified and authorized person.

For more information, please refer to the service manual

Tested by : Date & Signature :

50
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS
ROTATING CHECKS

WITH EXCITATION - AT NO LOAD CONDITIONS

• Verification of the bearings temperature °C _________________________

• In manual mode : Voltage adjustment ___________________________________

Excitation current check ___________________________________

• In automatic mode : Voltage Setting (referring to nominal voltage) ________________________

Excitation current check ___________________________________

• Parallel coupling : Adjustment to parallel operation (3F) ________________________

A FAULTY SYNCHRONISING CAN BE THE ORIGIN OF DAMAGES (HIGH MECHANICAL OVER-

TORQUE)
• Maximum acceptable values for synchronisation to the mains :
Maximum frequency shift 0,1 Hz _________________________
Maximum Phase offset 10 ° _________________________
Maximum voltage (P.N.) difference 5% of Un _________________________

Control / Adjustment of the site safeties

• Over-voltage, _________________________________________________________________
• Over-current (by short-circuit on stator in separate excitation mode), _________________________
• Negative sequence relay, _________________________________________________________________
• Over-speed, __________________________________________________________________
• Differential protection (in static conditions), _____________________________________
• Other protective device. __________________________________________________________________

CHECK THAT ALL SAFETY EQUIPMENT OPERATES CORRECTLY

WITH EXCITATION - LOADED

• Voltage stability __________________________________________________________________

• Adjustment of the Power Factor ____________________________________
• Verification of the excitation current versus load from 25% to full load at rated PF. _______________
• Maximum load value kVA PF

• Vibrations measurements in : mm/s RMS. or other unit

At nominal speed measure the vibrations
Drive End H V A
Non Drive End H V A

All works must be carried out by a qualified and authorized person.

For more information, please refer to the service manual

Tested by : Date & Signature :

51
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS

c) Parallel coupling
5.1 ELECTRICAL START-UP INSPECTION CAUTION:
AN IMPROPER COUPLING CAN BE THE ORIGIN OF
5.1.0 General points DAMAGES (HIGH MECHANICAL OVERTORQUE AND
Electrical connections (auxiliaries, safeties and power OVER CURRENT)
connections) must comply with the diagrams provided.
Refer to chapter 4 At the coupling the following values must not be overpass:
Max frequency shift : 0,1 Hz
DANGER:
Max phase offset : 10° (electrical angle)
CHECK THAT ALL SAFETY EQUIPMENT OPERATES
CORRECTLY. Max voltage (phase - neutral) between machines :
(at phase offset =0) 5 % of the nominal voltage
In case of faulty coupling, of mains fugitive disappearing
5.1.1 Winding Insulation inducing a faulty coupling over what it is acceptable by the
The insulation and the polarization index must be generator, ACEO cannot be considered as responsible of
measured on start up and then each year the damages.
To measure the insulation refer to the chapter.6.3.2

5.2 MECHANICAL START-UP INSPECTION

5.1.2 Electrical connections
The phases must be connected directly to the machine 5.2.0 General points
links (with no spacers or washers, etc).
Make sure that the lugs are sufficiently tightened. a) Alignment ; fixing ; prime mover
The installation must comply with the manufacturer’s
CAUTION: installation rules for drive machine (alignment, mounting).
ALL CURRENT TRANSFORMERS MUST BE An arrow at the drive end, end shield, indicates the
CONNECTED direction of rotation.

b) Cooling
5.1.3 Parallel operation
The air inlet and exhaust must be unobstructed.
a) Definition of parallel operation The cooling auxiliaries (water circulation in the cooler, etc)
• Between machines must be operating.
Parallel operation is possible if the power ratio between the c) Lubrication
smallest machine and the largest machine is less than or
equal to 10. Lubrication must be carried out :
- anti friction bearings, refer to chapter 2.3
• With the mains - Sleeve bearings, refer to chapter 2.4
The "mains" is defined as a source of power greater than
or equal to ten times the output of the machine with which 5.2.1 Vibrations
it will be coupled. The vibration measurement must be taken on each
b) Possibility of parallel operation bearing in the three directions. The measured levels must
be lower than the specified values indicated in the chapter
Parallel operation, if planned at the outset, does not cause 2.1.3
any problems if several basic rules are followed.
Adjust the sensor as per chapter 2.1.3

53
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS

6. PREVENTIVE MAINTENANCE

6.1 MAINTENANCE SCHEDULE

The purpose of the general maintenance schedule below is to help establish the maintenance schedule particular to the
installation. The suggestions and recommendations are to be followed as closely as possible in order to maintain the machine
efficiency and in order not to reduce the service life of the machine.
The maintenance operations are detailed in the chapters relative to the subjects concerned (Example: bearing, see chapter 2).
LUBRICATION AND PREVENTIVE MAINTENANCE SCHEDULE
Frequency of maintenance
Days Hours Comments

STATOR
Winding temperature 1 Refer to 2.1.3
Bolts tightening 8000 (*1) Refer to 6.2.2
Cleaning air inlet and outlet 1000 Refer to 6.2.3
Insulation 8000 (*1) Refer to 6.3.2
Polarisation index 8000 (*1) Refer to 6.3.2

ROTOR
Insulation 8000 (*1) Refer to 6.3.2
Cleaning diodes 8000 (*1) Refer to 7.4
Diodes tightening 8000 (*1) Refer to 2.2.4
Polarisation index 8000 (*1) Refer to 6.3.2

TERMINAL BOX
Cleaning 8000 (*1)
Regulator assembly 8000 (*1) Applicable if mounted in the terminal box
Bolts tightening 8000 (*1) Refer to 6.2.2

Following technical specification in "Section 1"

SLEEVE BEARINGS
Oil leak 1 Refer to 2.4.9
Oil temperature 1 Refer to 2.4.10
Oil level 1 Refer to 2.4.5
Oil drain 8000/16000 Following environment cleanness; Refer to 2.4.5
Bolts tightening 8000 (*1) Refer to 2.4

Following technical specification in "Section 1"

ANTI FRICTION BEARINGS
Re greasing Refer to 2.3.3 ; See lub plate; grease at least every 6 months
Bearing temperature 1 Refer to 2.3.5

(*1) : Or once a year

54
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS

LUBRICATION AND PREVENTIVE MAINTENANCE SCHEDULE (following)

Days Hours Comments

Following technical specification in "Section 1"

COOLER
Leakage level 1 Refer to 2.7.5
Water temperature 1 Refer to 2.7.5
Cleaning Refer to 2.7.3 ; following site condition

8000 Voir 2.6.2 ; 2.6.3 ; 2.7.0.a ; 2.18.2 ;

VIBRATION DAMPERS

Following technical specification in "Section 1"

FILTERS
Cleaning 1000 Refer to 2.8 & following " Section 1"
Following technical specification in "Section 1"
FAN-MOTOR
Bearing Re greasing Refer to motor lub plate ; following" Section 1"
8000 (*1) Refer to 2.19 et "Section 1 ; (sensors, , ….)
PROTECTION DEVICES

(*1) : Or once a year

55
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS

Bolt : Steel / Steel

6.2 MECHANICAL MAINTENANCE (greasy thread)
To obtain additional information on the maintenance of Ø nominal Torque Ø nominal Torque
sub-assemblies, refer to the chapters dealing with the sub- (mm) (mN) (mm) (mN)
assemblies concerned.
3 1,0 18 222
4 2,3 20 313
6.2.1 Air gap check
5 4.6 22 430
a) General points 6 7.9 24 540
The direct air gap check is not allways possible because of 8 19.2 27 798
a lack of access. When the air gap can be reached the 10 37.7 30 1083
measure can be fastidious because of paint and resin 12 64.9 33 1467
coating on the checked surfaces 14 103 36 1890
To make the measure more reliable and easy the air gap 16 160
check will be done onto the exciter :
Air gap < 1 mm max offset : 0.1 mm
1 mm ≤ Air gap max offset 10% of air gap

b) Double bearing machine

Verification of the air gap is not necessary. The rotor is
mechanically centered by its construction. Even after
dismantling and reassembling the machine, the rotor will
return to its position without verification of the air gap.
The exciter air gap of generators type A60 and A62 are
site adjustable.

c) Single bearing machine

When the machine is delivered, the rotor is mechanically
centered in the stator (see chapter on alignment). After
dismantling the machine, it will be necessary to center the
rotor in the stator, by using the two half-shells (delivered
with the machine) as explained in the chapter 4.3.3.
If you do not have 1/2 shells, use a dial indicator to check
the concentricity between the shaft (machined surface)
and the front bearing (machined surface).

6.2.2 Bolts tightening

Check the tightening of the sleeve bearing fixing bolts
(refer to chapter 2.4)
Check the tightening of the rotating diodes (refer to chapter
2.2.4)
Check the tightening of the terminal box accessories (refer
to chapter 2.18)
If no torque value is specified into the concerned chapter
the following values can be used

57
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS

b) Identification of ohmmeter polarity

Steel and copper alloy Plugs In many testing procedures, the ohmmeter polarity is
(greasy thread) important (diode test, etc) and must be known. As a
second instrument, you must use a voltmeter in the "direct
Ø nominal Torque Ø nominal Torque
current" position, in order to check the polarity of the
(inches) (mN) (inches) (mN)
ohmmeter connections. Proceed as explained below :
G3/8 30 G1 ¼ 160
G1/2 40 G1 ½ 230

8
G3/4 60 G2 320 0 Volts 10 Ohms 0

G1 110 G2 ½ 500

DC ž

6.2.3 Cleanliness
The whole machine must be kept clean.

CAUTION :
ALL THE CLEANING PERIODS INDICATED IN THIS
MANUAL MAY BE CHANGED (INCREASED OR
DECREASED) ACCORDING TO SITE CONDITIONS
6.3.2 Insulation check of the winding
The air inlet and air outlet surfaces must be maintained
a) General
clean (Louvers can be cleaned as per the filters) refer to
chapter 2.8. The insulation resistance enables the status of the
machine insulating to be verified.
CAUTION :
The following measurements can be taken at any time
DIRT ENTERING THE MACHINE MAY POLLUTE AND
without any damage to machine insulating material.
THUS REDUCE THE ELECTRICAL INSULATION
The insulation check must be done :
The rotating diodes must be keep clean. The rotating Before the start up
diodes cover has to be clean. Refer to chapter 7.4 After a long standstill
As soon as an abnormal operation occurs.
6.3 ELECTRICAL MAINTENANCE If the measurement indicates a poor result we advise
contacting our Service department.
6.3.1 MEASURING INSTRUMENTS To perform the measurement the generator must be
stopped.
a) Instruments used
- AC voltmeter 0-600 Volts If the insulation resistance is less than that required, it is
necessary, to clean and to dry the machine (refer to
- DC voltmeter 0-150 Volts chapter 7.5).
- Ohmmeter 10E-3 to 10 ohms
DANGER :
- Megohmmeter 1 to 100 MOhms / 500 Volts BEFORE ANY WORK THE RULES CONCERNING THE
- AC Ammeter 0- 4500 A SAFETY OF MATERIALS AND PERSONS MUST BE
APPLIED (TOTAL LOCKING OF THE GENERATOR
- DC Ammeter 0-150 A
FUNCTIONS, GROUNDING OF THE PHASES …)
- Frequency meter 0-80 Hz
Low resistance can be measured by means of an b) Armature insulation measure
appropriate ohmmeter or by using a Kelvin or Wheatstone Disconnect the three phases at the generator terminals.
bridge.
CAUTION
NOTE :
ALL ACCESSORIES MUST BE DISCONNECTED (AVR ,
The identification of the equipment polarity may differ from
EMC FILTER ;;;)
one ammeter to another.
REFER TO THE ELECTRICAL DIAGRAM TO IDENTIFY
THE ACCESSORIES TO DISCONNECT

58
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS
The measurement has to be taken between one phase and e) Polarization index
the earth.
The polarization index enables the status of the machine
Machine nominal voltage insulating to be verified and gives an indication of the
pollution of the winding.
Un ≤ 2400 V Un > 2400 V
A poor polarization index may be corrected by a cleaning
Applied test 500 V DC 1000 V DC and drying of the winding
voltage (DC) The following measurements can be taken at any time
without any damage to the machine insulating material.
[3 (U n + 1)] MΩ
The measured value at 25°C must be over
CAUTION
where Un (the nominal voltage) is in Kilovolts. (e.g. : a ALL ACCESSORIES MUST BE DISCONNECTED (AVR ,
generator of 6.6 KV must have an insulation resistance EMC FILTER ;;;)
greater than 22.8 MΩ). REFER TO THE ELECTRICAL DIAGRAM TO IDENTIFY
If the minimum insulation level is not reached, dry the THE ACCESSORIES TO DISCONNECT
windings (refer to chapter 7.5)
NOTE:
c) Field insulation measurement It must be done using a stable DC source.
Disconnect the two ends of the field at the rotating diodes Use a specific polarization index appliance under 500 or
bridge 1000 DC volts (refer to" insulation of the winding" chapter
The measurement should be taken between one end of the for the correct applied voltage)
field winding and the earth.
Open the winding star point
The applied test voltage must be of 500 V DC.
Disconnect AVR cables from the stator terminals
The measured value must be over 20 MΩ.
If the minimum insulation level is not reached, dry the
windings (refer to chapter 7.5)

d) Exciter insulation measurement

CAUTION
ALL ACCESSORIES MUST BE DISCONNECTED (AVR ,
EMC FILTER ;;;)
REFER TO THE ELECTRICAL DIAGRAM TO IDENTIFY
THE ACCESSORIES TO DISCONNECT

To measure the exciter field insulation disconnect the two

ends of the exciter field at the terminals located on the top Apply the requested voltage
of the exciter.
After 1 minute record the Insulating resistance
To measure the exciter armature insulation disconnect the
two ends of the exciter armature at the rotating diodes After 10 minutes record the Insulating resistance
bridge
The measurement should be taken between one end of the
field winding and the earth.
The applied test voltage must be of 500 V DC. The polarization index must be higher than 2.
The measured value must be over 20 MΩ. Proceed for each phase
If the minimum insulation level is reached, dry the windings
(refer to chapter 7.5)

59
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS

7. SERVICING 7.4 CLEANING THE WINDINGS

7.1 GENERAL SERVICING 7.4.0 General points

The cleaning of the winding is an heavy service operation
DANGER : which has to be engaged only if necessary.
BEFORE WORKING ON THE GENERATOR, MAKE
SURE THAT THE START-UP CANNOT BE ACTIVATED The cleaning of the windings become necessary as soon
as the insulation resistance and/or the polarization index
BY ANY MANUAL OR AUTOMATIC SIGNAL
are not satisfactory (refer to chapter 6.3.2)

DANGER:
BEFORE WORKING ON THE MACHINE, MAKE SURE 7.4.1 Coil-cleaning product
THAT YOU HAVE UNDERSTOOD THE OPERATING a) General
PRINCIPLES OF THE SYSTEM. IF NECESSARY, REFER A long term efficient cleaning can only be done in a work
TO THE APPROPRIATE CHAPTERS IN THIS MANUAL. floor if equipped with specialized devices. A site cleaning,
because less efficient, can be considered only for a
CAUTION: transient period.
GIVEN THE POWER FACTOR APPLIED TO THE
MACHINE, A VOLTMETER OR KILOWATT METER CAUTION:
DOES NOT NECESSARILY SHOW THE KVA LOAD OF SOLVENTS, WHICH ARE HIGHLY CHLORINATED AND
THE MACHINE. SUBJECT TO HYDROLYSIS IN DAMP ATMOSPHERES
ARE PROHIBITED. THEY QUICKLY BECOME
ACIDIFIED, PRODUCING CORROSIVE AND
CONDUCTIVE HYDROCHLORIC ACID.
7.2 TROUBLESHOOTING
CAUTION:
7.2.0 General points
DO NOT USE TRICHLORETHYLENE,
When a defective part is replaced with a spare part, make PERCHLORETHYLENE, OR TRICHLORETHANE
sure that it is in good condition.
Avoid mixtures sold under various trademarks which often
7.2.1 Regulator trouble-shooting procedure contain white spirit (which evaporates too slowly) or
Refer to the enclosed regulator manual. chlorinated products (which are likely to become acidified).

CAUTION:
DO NOT USE ALKALINE PRODUCTS. THEY ARE
7.3 ELECTRICAL TESTS
DIFFICULT TO RINSE AND CAUSE REDUCTION OF
INSULATION RESISTANCE BY FIXING THE HUMIDITY
7.3.1 Stator winding test
See chapter 6.3 b) Cleaning products
Use pure de-greasing and volatile agents which are well-
7.3.2 Rotor winding test defined such as :
See chapter 6.3 Gasoline (without additives)
Toluene (slightly toxic ) ; inflammable
7.3.3 Excitation armature winding test Benzene or benzine (toxic ; inflammable)
See chapter 6.3 Ciclohexaire (non-toxic; inflammable)
Soft water

7.3.4 Excitation field winding test

See chapter 6.3

7.3.5 Rotating diode bridge test

See chapter 2.2

7.3.6 Electric panel test

Use electrical diagrams for assistance.

60
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS

7.4.2 Cleaning the stator, rotor, excitation system and

diodes
7.5 DRYING THE WINDING
a) using specific chemical product 7.5.0 General points
The insulation and the impregnation system are not All electric machines must be stored under dry conditions.
damaged by solvents (see the list of authorized products If a machine is placed in damp surroundings, it must be
above). dried before it is put into service. Units operating
intermittently or placed in areas with high temperature
It is essential to avoid entry of cleaning agents into the variations, are exposed to dampness and must be dried
slots. Apply the product with a brush, sponging frequently very thoroughly if necessary.
in order to avoid accumulation in the housing. Dry the
winding with a dry cloth. Allow the traces to evaporate
7.5.1 Drying method
before reassembling the machine.
a) General points
CAUTION:
During the drying operation measure the winding insulation
AFTER CLEANING THE GENERATOR, DRYING IS and the polarization index each 4 hours.
IMPERATIVE TO RECOVER THE CORRECT WINDING
INSULATION To survey the insulation progress, record the measured
values and plot the obtained progress function of the time.
b) Rinsing using soft water When the insulation value becomes constant, the machine
can be considered as dry.
Hot soft water (less than 80°C) used under pressure (less
than 20 bars) can be used. When the resistance is constant, it may be assumed that
the machine is dry. This operation may take up to 24
CAUTION: hours, depending on the size of the machine and on the
AFTER CLEANING THE GENERATOR, DRYING IS degree of dampness. This may even take up to 72 hours.
IMPERATIVE TO RECOVER THE CORRECT WINDING
INSULATION CAUTION:
TAKE FIRE-PREVENTION MEASURES DURING THE
DRYING OF THE MACHINE.
ALL THE CONNECTIONS MUST BE TIGHTENED.

b) Drying generator stop

The procedure " Drying generator in rotation" should be
preferred to the following one if it is possible to run the
generator at its nominal speed
Several thermometers must be positioned onto the winding
and the temperature must not exceed 75°C (167°F). I f one
of the thermometers exceeds this value, immediately
reduce the heating effect.
Dry by using an external source of heat, for example,
heaters or lamps.
Leave an opening for an exhaust for the damp air.

c) Drying generator in rotation

Disconnect the machine from the mains
Short circuit the machine stator at the machine terminals
Disconnect the Voltage regulator and short-circuit the
booster.
Install an amp meter on the short-circuited winding.
Run the machine at its nominal speed (to air cool the
machine)
Energized the machine (exciter field) using an separate ex
citation source. Use a DC source (batteries ...)
Adjust the excitation current to get the nominal current at
the stator (machine armature).
Warm up during 4 hours, stop and leave it to cool down
(winding temperature < 50°C)

61
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS
Check the winding insulation and the polarization index
If necessary conduce an other drying period...

U1
C
U2
V1 A B
V2
W1
W2

+ -

A - Stator
B - Rotor
C - Exciter

7.6 RE-VARNISHING
CAUTION:
RE VARNISHING MUST ONLY BE CONSIDERED IF
ABSOLUTLY NECESSARY. A RE VARNISHING
OPERATION DONE ON A WINDING STILL DIRTY OR
NOT PERFECTLY DRY MAY CONDUCE TO A
DEFINITIVE LOSS OF INSULATION

62
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS

10. TYPICAL CUT VIEWS

10.1 MACHINE CUT VIEWS

10.1.1 Machine type A52

1 Rotor 10 Polar wheel
2 Bearing (drive end) 11 Balancing disc
3 Fan hub 12 Exciter field
4 Drive end shield 13 Exciter armature
5 Fan 14 Non drive end shield
6 Fan screen 15 Bearing (non drive end)
7 Stator winding 16 Rotating resistances
8 Stator ribs 17 Rotating diodes
9 Stator lamination 18 Diode bridge cover

4 5 6 7 8 9 10 11 12 13 14

2
17
1

4 5 6 7 8 9 10 11 12 13 14

2
17
1

63
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS

10.1.2 Machine type A53 ; A54

64
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS

10.1.3 Machine type A56 ; A58

4 5 6 7 8 9 10 11 12 13 14

3 15

2 16

1 17

65
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS

10.2 FLANGED SLEEVE BEARING

10.2.1 Self lubricating bearing

1 Top half of the housing 15 Engraved number - bearing shell
2 Positioning pin hole 16 Recess
3 Positioning pin 17 Tap hole
4 Oil filler hole 18 Screw
5 Top sight glass 19 Split line screw - bearing shell
6 Eye bolt 20 Engraved numbers - bearing housing
7 Screw 21 Bottom half of the housing
8 Screw 22 Connection hole for temperature measurement of the journal
9 Tap hole ( in the top and bottom halves of the shell, up size part
14 ) 23 Oil sight glass
10 Machine seal 24 Connection hole for the oil sump temperature measurement
11 Top half of the shell 25 Out/Inlet cooling water (Type ExW xx)
12 Split line screw - bearing housing 26 Oil cooler ( Type ExW xx)
13 Bottom half of the shell 27 Oil drain plug
14 Spherical seating

66
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o

ALTERNATORS

10.2.2 Oil circulation bearing

1 Top half of the housing 16 Recess
2 Positioning pin hole 17 Tap hole
3 Positioning pin 18 Screw
4 Connection hole for the thrust part oil supply (optional) 19 Split line screw - bearing shell
5 Top sight glass 20 Engraved numbers - bearing housing
6 Eye bolt 21 Bottom half of the housing
7 Screw 22 Connection hole for temperature measurement of the journal
8 Screw part
9 Tap hole ( in the top and bottom halves of the shell, up size 23 Oil inlet connection hole
14 ) 24 Connection hole for the oil sump temperature measurement
10 Machine seal 25 Out/Inlet cooling water (Type ExW xx)
11 Top half of the shell 26 Oil cooler ( Type ExW xx)
12 Split line screw - bearing housing 27 Oil drain plug
13 Bottom half of the shell 28 Metal tabs ( optional for EFZLx )
14 Spherical seating 29 Oil outlet connection hole
15 Engraved number - bearing shell 30 Oil outlet pipe
31 Marking

J316V05 en
No ratings yet
J316V05 en
4 pages
Jenbacher: Build Data: Operational Data
No ratings yet
Jenbacher: Build Data: Operational Data
1 page
Amjad Textile JH827 - 2196246 - 258
No ratings yet
Amjad Textile JH827 - 2196246 - 258
279 pages
W 0700m6 - Gas Mixer PDF
No ratings yet
W 0700m6 - Gas Mixer PDF
5 pages
W 0200m0 - Control Rod Assembly Throttle Valveactuator PDF
No ratings yet
W 0200m0 - Control Rod Assembly Throttle Valveactuator PDF
6 pages
TS JGC320 D805 480V 35C 500NOx 01-Feb-18 Preliminary
100% (1)
TS JGC320 D805 480V 35C 500NOx 01-Feb-18 Preliminary
47 pages
DianeWIN V2-5-0 Benutzerhandbuch EN
100% (1)
DianeWIN V2-5-0 Benutzerhandbuch EN
99 pages
Knock Control System (For Type 6 Engines) - Commissioning: Technical Instruction
No ratings yet
Knock Control System (For Type 6 Engines) - Commissioning: Technical Instruction
24 pages
Schaltplan JGS420 - SO#36824 JY108 - 7458609 - 258
No ratings yet
Schaltplan JGS420 - SO#36824 JY108 - 7458609 - 258
249 pages
ST-156 Compatibility Between DIA - NE WIN and DIA - NE XT PDF
No ratings yet
ST-156 Compatibility Between DIA - NE WIN and DIA - NE XT PDF
6 pages
GE DIANE Internet Fire Wall
100% (1)
GE DIANE Internet Fire Wall
46 pages
J 6..GS-C Tightening Torques: Technical Instruction
No ratings yet
J 6..GS-C Tightening Torques: Technical Instruction
16 pages
1000-0046 - EN Transportation of Type 6
No ratings yet
1000-0046 - EN Transportation of Type 6
22 pages
ST 183 612-620-624 Descriere Senzori PDF
100% (1)
ST 183 612-620-624 Descriere Senzori PDF
38 pages
GE Jenbacher Engine Running-In Guide
No ratings yet
GE Jenbacher Engine Running-In Guide
3 pages
Diagrama de Control Jenbacher
No ratings yet
Diagrama de Control Jenbacher
35 pages
Fuel System
50% (2)
Fuel System
1 page
Checklist For Alarm Messages
No ratings yet
Checklist For Alarm Messages
43 pages
Industrial Spark Plug for Jenbacher
No ratings yet
Industrial Spark Plug for Jenbacher
2 pages
Emissions Monitoring: Technical Instruction
No ratings yet
Emissions Monitoring: Technical Instruction
16 pages
Critical Alarm Management in DIA.NE
100% (2)
Critical Alarm Management in DIA.NE
4 pages
Jenbacher: 1100-0105 Engine Shut-Down
No ratings yet
Jenbacher: 1100-0105 Engine Shut-Down
1 page
Gas Mixer
67% (3)
Gas Mixer
38 pages
5 1 1 B J320C en
67% (3)
5 1 1 B J320C en
12 pages
Technical Diagram en
100% (3)
Technical Diagram en
4 pages
Checklist For Alarm Messages
No ratings yet
Checklist For Alarm Messages
38 pages
624 JGS-NL-electric Wiring Diagram PDF
No ratings yet
624 JGS-NL-electric Wiring Diagram PDF
617 pages
TA 1400-0100 Procedura de Rodaj A Motoarelor (TIMPI) PDF
No ratings yet
TA 1400-0100 Procedura de Rodaj A Motoarelor (TIMPI) PDF
10 pages
320
No ratings yet
320
61 pages
Jenbacher: 1. Replacing The Cylinder Head
No ratings yet
Jenbacher: 1. Replacing The Cylinder Head
2 pages
DIA - NE XT4 CTR 4.08 HMI 2.9 R5 - en
100% (1)
DIA - NE XT4 CTR 4.08 HMI 2.9 R5 - en
222 pages
1502-0068 Moris
No ratings yet
1502-0068 Moris
52 pages
Spare Parts Catalogue J Y962: Engine Number: 1422528 Module Number: 1422527
No ratings yet
Spare Parts Catalogue J Y962: Engine Number: 1422528 Module Number: 1422527
368 pages
1902-0212 en
100% (2)
1902-0212 en
26 pages
Spax (Safi Pickup Amplifier Extended) : Technical Instruction
No ratings yet
Spax (Safi Pickup Amplifier Extended) : Technical Instruction
26 pages
Disassembly:: W 0704 M0 Gas-Mixer
No ratings yet
Disassembly:: W 0704 M0 Gas-Mixer
4 pages
Boundary Conditions Engines Installation 1100-0110 en
50% (2)
Boundary Conditions Engines Installation 1100-0110 en
19 pages
Diane Win
100% (2)
Diane Win
15 pages
Component Overview
0% (1)
Component Overview
20 pages
Jenbacher DIA.NE XT Guide
100% (1)
Jenbacher DIA.NE XT Guide
87 pages
Instructions On Nox Measurements and Leanox Settings: Technical Instruction
No ratings yet
Instructions On Nox Measurements and Leanox Settings: Technical Instruction
16 pages
JGS 420 GS-S.L: Low Methane - Coal Mine Methane
No ratings yet
JGS 420 GS-S.L: Low Methane - Coal Mine Methane
34 pages
ST-108 Lenox Seting PDF
No ratings yet
ST-108 Lenox Seting PDF
4 pages
Gas Qualtiy TA1000-0300 - en
No ratings yet
Gas Qualtiy TA1000-0300 - en
30 pages
Cylinder Head: Maintenance Instruction
100% (1)
Cylinder Head: Maintenance Instruction
12 pages
Schedle Maintenance Jenbacher
0% (1)
Schedle Maintenance Jenbacher
3 pages
GERMANY - Engineering JGS620
100% (1)
GERMANY - Engineering JGS620
40 pages
1000-0505 en
100% (1)
1000-0505 en
8 pages
Extended DIA - Ne XT - Access
33% (3)
Extended DIA - Ne XT - Access
2 pages
1000-1109 - Index 17 GE Jenbacher Gas Engines
No ratings yet
1000-1109 - Index 17 GE Jenbacher Gas Engines
14 pages
GE - 200802 - Technical Specs Jenbacher Type 6 PDF
No ratings yet
GE - 200802 - Technical Specs Jenbacher Type 6 PDF
2 pages
Jenbacher: 1100-0110 Boundary Conditions For GE Jenbacher Gas Engines
100% (1)
Jenbacher: 1100-0110 Boundary Conditions For GE Jenbacher Gas Engines
12 pages
Maintenance (J S889)
No ratings yet
Maintenance (J S889)
444 pages
6 2 B Br6e en
No ratings yet
6 2 B Br6e en
1 page
GE Jenbacher Standard Technical Specifications
100% (1)
GE Jenbacher Standard Technical Specifications
19 pages
Jenbacher: Considerations For Use 1
No ratings yet
Jenbacher: Considerations For Use 1
1 page
Generator Safety & Maintenance Manual
No ratings yet
Generator Safety & Maintenance Manual
54 pages
Manual Gesan
82% (11)
Manual Gesan
70 pages
JMS 208 GS-N.L: Technical Specification
No ratings yet
JMS 208 GS-N.L: Technical Specification
4 pages
J208V06 en
No ratings yet
J208V06 en
4 pages
Introduction to Industrial Hydraulics
No ratings yet
Introduction to Industrial Hydraulics
25 pages
Hydraulic Notes
No ratings yet
Hydraulic Notes
1 page
NCB-E - Installation Manual - 03.03.2020 ENG
No ratings yet
NCB-E - Installation Manual - 03.03.2020 ENG
91 pages
Sec2 2
No ratings yet
Sec2 2
34 pages
Thermodynamics
No ratings yet
Thermodynamics
86 pages
BS EN 292-1991 Safety of Machinery
No ratings yet
BS EN 292-1991 Safety of Machinery
90 pages
FEE Module 2 Short Notes-1
No ratings yet
FEE Module 2 Short Notes-1
10 pages
IGGL Recruitment 2024: Apply Online
No ratings yet
IGGL Recruitment 2024: Apply Online
5 pages
Business Energy Bill Summary
No ratings yet
Business Energy Bill Summary
3 pages
Principles of Classical Mechanics Describe Gyroscopic Effects
No ratings yet
Principles of Classical Mechanics Describe Gyroscopic Effects
4 pages
Documents - Pub Eco Solution Manual
100% (1)
Documents - Pub Eco Solution Manual
71 pages
READING (Skill) Eng - VN - Khoa R
No ratings yet
READING (Skill) Eng - VN - Khoa R
38 pages
Self Cleaning Evaporator Driven by MVR - The Way To Go - Shachi - 2021
No ratings yet
Self Cleaning Evaporator Driven by MVR - The Way To Go - Shachi - 2021
3 pages
Lecture Notes Kirchhoff
No ratings yet
Lecture Notes Kirchhoff
9 pages
Gravity Light Project
No ratings yet
Gravity Light Project
16 pages
Application Note Siddique Ice Factory Islamabad
No ratings yet
Application Note Siddique Ice Factory Islamabad
2 pages
JC2 Physics H2 2018 Yishun
No ratings yet
JC2 Physics H2 2018 Yishun
80 pages
Powering Pakistans Future A PLEXOS Based Study 2024 505e0b080f
No ratings yet
Powering Pakistans Future A PLEXOS Based Study 2024 505e0b080f
63 pages
Earthing Systems Conference 2019
No ratings yet
Earthing Systems Conference 2019
4 pages
FLUS 06/ FLS 09: Flame Detector
100% (2)
FLUS 06/ FLS 09: Flame Detector
18 pages
CAE Use of English Part 2, Test 5 - The Light Bulb
No ratings yet
CAE Use of English Part 2, Test 5 - The Light Bulb
2 pages
Dexter explosion rebunk
No ratings yet
Dexter explosion rebunk
5 pages
PSM0004
No ratings yet
PSM0004
3 pages
Ws - World Wind Speed
No ratings yet
Ws - World Wind Speed
1 page
GT24/GT26 Operation Training Lesson: Electro Hydraulic Safety System
No ratings yet
GT24/GT26 Operation Training Lesson: Electro Hydraulic Safety System
42 pages
G10 Q2 M3 Practice Test
No ratings yet
G10 Q2 M3 Practice Test
4 pages
Mẫu Phiếu Thao Tác Cô Lập Tc Ra Sửa Chữa
No ratings yet
Mẫu Phiếu Thao Tác Cô Lập Tc Ra Sửa Chữa
4 pages
Instruction Manual: Compact Switching Power Supply
No ratings yet
Instruction Manual: Compact Switching Power Supply
2 pages
Continuum Mechanics
No ratings yet
Continuum Mechanics
589 pages
Generator Motoring: Impacts & Protection
100% (1)
Generator Motoring: Impacts & Protection
14 pages
DT Theory Revision
No ratings yet
DT Theory Revision
21 pages
Bw216d4-101583-Service Manual
100% (6)
Bw216d4-101583-Service Manual
974 pages
The Update of IEC 61400-24 Lightning Protection of Wind Turbines
No ratings yet
The Update of IEC 61400-24 Lightning Protection of Wind Turbines
17 pages
Numerical Investigation of Hydrogen Combustion in Gas Turbine Combustor - Rev.C
No ratings yet
Numerical Investigation of Hydrogen Combustion in Gas Turbine Combustor - Rev.C
16 pages