agenitor 406 Titelbild - web.vtc.eduweb.vtc.edu/users/zrn10240/manuals/genset/008_Troubleshooting.pdf · Troubleshooting . Troubleshooting. 2G-KWK ® Series - Biogas Combined Heat

Troubleshooting

Troubleshooting

2G-KWK ® Series - Biogas Combined Heat and Power Plants

2G-KWK-50BG

2G-KWK-64BG

2G-KWK-75BG

2G-KWK-100BG

2G-KWK-190BG

2G-KWK-250BG

2G-KWK-370BG

2G Energietechnik GmbH Benzstraße 3 D-48619 Heek

2 von 21 2G Energietechnik GmbH Benzstraße 3

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roubleshooting nergietechnik

Kap_008_agenitor_Störungsbeseitigung_En g 03.07.2012 Revision: 1.0

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Troubleshooting Contents

Contents

1 Preliminary notes regarding troubleshooting ...................................................... 5

2 Safety Information................................................................................................... 5

3 Fault messages ....................................................................................................... 7

4 Fault message history ............................................................................................ 8

5 Fault message list ................................................................................................. 10


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Troubleshooting nergietechnik

Troubleshooting Preliminary notes regarding troubleshooting/Safety Information


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1 Preliminary notes regarding troubleshooting

The following list of troubleshooting with regard to the various component groups describes possible basic faults and provide assistance in correcting them.

Observe the information in the documentation provided by the suppliers when working. Also make sure to observe the safety information provided there.

2 Safety Information

RISK

Risk to life and limb if a fault is corrected improperly! Despite all safety precautions, the operation of the combined heat and power plant poses risks to life and limb which cannot be avoided. Expertise with regard to handling and working with biogas, hazardous materials and electricity is a prerequisite for troubleshooting the combined heat and power plant.

The chapter in this manual must be read completely before beginning with troubleshooting. It must be made sure that personnel are familiar with the combined heat and power plant's hazards.

Malfunctions may only be corrected by qualified electricians and mechanics with the relevant training.

When working on components which are under voltage, the combined heat and power plant must first be deenergised on all poles. The grounding connection for electrical equipment must be checked. Secure the combined heat and power plant against unauthorized re-starting.

Applicable accident prevention regulations, the requirements of the responsible supervisory authority, instructions from chemical suppliers and the safety regulations explained in the operating manual must be observed when working.

Chemical resistant clothing and a chemical resistant face shield must be worn when working with chemicals.

Malfunctions may never be acknowledged remotely. For faults which cause a shutdown, a one-time or repeated acknowledgement without a correction of the cause can pose a significant risk of injury or damage to persons and machinery. The customer (and/or the party who performed the remote acknowledgement) bears the sole responsibility for damages resulting thereof.

Troubleshooting Safety Information


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If the EMERGENCY-STOP was actuated, the cause must always first be determined and corrected before the EMERGENCY-STOP is unlocked and the combined heat and power plant is restarted.

2G Energietechnik GmbH recommends a dialing alarm device which notifies the operator by phone call or SMS about the malfunction. This ensures that malfunctions are recognized early and that damage can be avoided.

In the event of faults for which the motor was automatically shutdown by the aggregate's monitor, the cause of the fault must be corrected before the aggregate is restarted!

Because serious damage or damage arising from wear can result and lead to the premature replacement of various components subject to wear, merely acknowledging the fault and restarting the motor is not permitted.

Complete operating data logging and a description of all unusual events are necessary. Merely recording the facts in writing is not sufficient. The data should be compared with the values at the time of commissioning and with the daily records in the operating diary and checked for plausibility. In the event of deviations from the ordinary, for example unusual noises etc., the cause must be determined and corrected. If this is unsuccessful, 2G Energietechnik customer service must be contacted immediately.

It is in the operator's own interest to maintain and log operating data (maintenance log, operating diary, data collection in the "Maintenance" folder). Properly maintained operating diaries and data collection sheets are important documents which enable relevant analyzes and remedial action in case faults arise.

These documents are also a basis of decision-making in questions of warranty claims. This is very important for the operator from an insurance perspective, because the ability to make a successful claim for machine damage depends on a carefully maintained operating diary.

The safety requirements and the operator guidelines must be observed. Applicable safety and accident prevention requirements prescribed by law must be observed. The operating company must make sure that the safety requirements applicable to the work being performed are complied with before beginning any work on the system. When carrying out work which may only be performed when the motor is at a standstill, the motor must be shut down in accordance with the operating manual and safeguarded against unauthorized restarting.


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Troubleshooting Fault messages

3 Fault messages The field with the name of the current screen will flash red if a fault appears: 1. Switch to the Alarms screen in

order to have the fault message displayed.

This screen shows all current messages which have not yet been displayed. Up to 2000 entries can be saved. All of the entries will be displayed when the filter is turned off. In the list of fault messages (Chapter 5), you can determine the cause and, depending on the fault, rectify the cause yourself or commission a specialised company with the troubleshooting. Once the malfunction has been rectified, mark the corresponding message and acknowledge it using the ACK button. The message will be removed from the message list.


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Troubleshooting Fault message history

4 Fault message history

In order to display the history, click on the History button in the message window.

All messages are shown according to date/time of day, and are sorted according to message no. and message text. Sort the messages by clicking on the Date/time, message no. or message text button. Use the buttons (arrows) on the right margin to move up and down in the list of messages. Clicking on Alarms will take you back to the entry screen.

Clicking on the filter options will shown only the selected messages (alarm, warning or message). Clicking on Off will show all of the entries.


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Troubleshooting Fault message history

Dark red = coming alarms

Light red = going alarms

“Going” means that the alarms have been acknowledged.

Dark yellow = coming warnings

Light yellow = going warnings

“Going” means that the warnings have been acknowledged.

Dark green = coming messages

Light green = going messages

“Going” means that the messages have been acknowledged.

The field will flash red in the event of an incoming alarm + yellow warning. Clicking on Alarms will take you back to the entry screen.

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Troubleshooting Fault message list

5 Fault message list

In the following table, fault messages are explained and remedial measures to correct the fault listed. Possible faults are listed below.

Some faults are only possible if the option they apply to is installed in your plant. It is also possible that some of the listed faults do not apply to your plant.

RISK

Risk to life and limb if a fault is corrected improperly! If the EMERGENCY-STOP was actuated, the cause must always first be determined and corrected before the EMERGENCY-STOP is unlocked and the combined heat and power plant is restarted.

Always contact 2G Energietechnik Service if you do not know exactly how to correct a fault.


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M0002 False start x x x M0003 Engine speed signal malfunctioning x x x M0009 Oil volume expansion minimum x x M0010 Oil volume expansion maximum x x x M0012 Engine oil level minimum x x x M0013 Engine oil level maximum x x x M0016 Timeout starting sequence x x x M0017 Timeout synchronisation x x x M0018 Timeout warm-up x M0019 Timeout closed loop A/F control activate x M0020 Timeout coastdown network x x x M0022 Oil change due x M0023 Maintenance due x M0024 Maintenance due x x x M0027 Gas magnet valve leaking x x x M0028 Gas magnet valve gas type 2 leaking x x x M0032 Auxiliary drive supply voltage failed x x x M0033 Auxiliary drive supply circuit breaker tripped x x x M0034 Network control voltage circuit breaker tripped x x x M0035 Generator control voltage circuit breaker tripped x x x M0036 Fault current circuit breaker tripped x x x M0037 Motor cooling circuit pump circuit breaker tripped x x x M0038 Heating pump circuit breaker tripped x x x M0039 Mixture cooling circuit pump circuit breaker tripped x x x M0040 Oil circulation pump circuit breaker tripped x x x M0041 Gas compressor circuit breaker tripped x x x M0042 Oil pump circuit breaker tripped x x x M0043 External circulator pump circuit breaker tripped x x M0044 Mixture cooler 1 circuit breaker tripped x x x M0045 Mixture cooler 2 circuit breaker tripped x x x M0047 Gas cooling circulator pump circuit breaker tripped x x x M0048 Emergency cooler 1 circuit breaker tripped x x M0049 Emergency cooler 2 circuit breaker tripped x x M0050 Emergency cooler 3 circuit breaker tripped x x M0051 Emergency cooler 4 circuit breaker tripped x x M0052 Room fan circuit breaker tripped x x x

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index M0053 M0054 M0055 M0056 M0057 M0058 M0059 M0060 M0061 M0062 M0063 M0065 M0066 M0067 M0068 M0069 M0070 M0075 M0076 M0077 M0079 M0080 M0081 M0082 M0083 M0085 M0086 M0090 M0091 M0093 M0094 M0095 M0096 M0097 M0098 M0099 M0104

message text Gas cooling circuit breaker tripped x x x Gas torch circuit breaker tripped x x Ignition and throttle valve circuit breaker tripped x x x Electric heater preheating circuit breaker x x Control voltage charger circuit breaker tripped x x x 24V control voltage circuit breaker tripped x x x Emergency cooler 5 circuit breaker tripped x x Emergency cooler 6 circuit breaker tripped x x Emergency cooler 7 circuit breaker tripped x x Emergency cooler 8 circuit breaker tripped x x Generator circuit breaker triggered x x x Generator thermistor triggered x x x Gas compressor thermistor triggered x x x Room fan thermistor triggered x x x Engine cooling circuit pump thermistor triggered x x x Heating pump thermistor triggered x x x Mixture cooling circuit pump thermistor triggered x x x Gas pre-alarm x x x Gas alarm x x x Smoke alarm x x x Air intake filter dirty x x x Maintenance switch actuated x x x Gas shut-off valve emergency stop switch actuated x x x Door emergency stop switch actuated x x x External emergency stop switch actuated x x x Electrical cabinet emergency stop switch actuated x x x CHP module emergency stop actuated x x x Emergency stop not acknowledged x x x Safety temperature limiter triggered x x x Gas line vacuum switch triggered x x x Gas holder vacuum switch triggered x x x Gas operating pressure switch triggered x x x Gas operating pressure switch gas type 2 triggered x x x Battery voltage too low x x CHP module auxiliary energy failed x x x Main cabinet auxiliary energy failed x x x Gas shut-off valve closed x x x


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M0105 Gas warning system malfunctioning x x x M0107 Electrical cabinet air conditioner malfunctioning x M0108 Gas cooling malfunctioning x x x M0109 Gas torch malfunctioning x M0110 Room fan speed controller malfunctioning x x x M0112 Ignition malfunctioning x x x M0113 Ignition: Trigger malfunction x x x M0114 Ignition: overspeed x x x M0115 Ignition: watchdog timer 1 x x x M0116 Ignition: watchdog timer 2 x x x M0117 Ignition: Processor error x x x M0118 Ignition: Low voltage x x x M0119 Ignition: Charging error x x x M0120 Ignition: Primary interruption x x x M0121 Ignition: Primary short circuit x x x M0122 Ignition: Secondary interruption x x x M0129 Ignition failure level 1 x M0130 Ignition failure level 2 x x M0131 Ignition failure level 3 x x x M0135 Knocking bank A x x M0136 Knocking bank A x x M0139 Knocking bank B x x M0140 Knocking bank B x x M0205 Charging pressure minimum x M0206 Charging pressure minimum x x x M0207 Charging pressure maximum x M0208 Charging pressure maximum x x x M0211 Gas pressure sensor minimum x x x M0214 Electrical cabinet temperature maximum x M0215 Module cabinet temperature maximum x M0216 Lambda value bank A minimum x x M0217 Lambda value bank A minimum x x x M0218 Lambda value bank A maximum x x M0219 Lambda value bank A maximum x x x M0221 Oil pressure minimum starting sequence x x x M0222 Oil pressure minimum level 1 x x x

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message text Oil pressure minimum level 2 x x x Engine coolant pressure minimum x Engine coolant pressure minimum x x x Engine coolant pressure maximum x Engine coolant pressure maximum x x x Mixture coolant pressure minimum x Mixture coolant pressure minimum x x x Mixture coolant pressure maximum x Mixture coolant pressure maximum x x x Heater water pressure minimum x Heater water pressure minimum x x x Heater water pressure maximum x Heater water pressure maximum x x x Engine coolant intake maximum x x Engine coolant intake maximum x x x Engine coolant discharge maximum x x Engine coolant discharge maximum x x x Engine coolant temperature spread maximum x x Engine coolant temperature spread maximum x x x Sulphur content maximum x Sulphur content maximum x x Heater return line temperature maximum x x Heater return line temperature maximum x x x Mixture temperature maximum x x Mixture temperature maximum x x x Mixture coolant temperature maximum x x Mixture coolant temperature maximum x x x Intake air temperature maximum x x Intake air temperature maximum x x x Room air temperature maximum x x Room air temperature maximum x x x Engine oil temperature maximum x x Engine oil temperature maximum x x x Generator bearing temperature A maximum x x Generator bearing temperature A maximum x x x Generator bearing temperature B maximum x x Generator bearing temperature B maximum x x x


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M0273 Exhaust temperature cylinder 1 minimum x M0274 Exhaust temperature cylinder 1 maximum x x M0275 Exhaust temperature cylinder 1 minimum x x x M0276 Exhaust temperature cylinder 1 maximum x x x M0277 Exhaust temperature cylinder 2 minimum x M0278 Exhaust temperature cylinder 2 maximum x x M0279 Exhaust temperature cylinder 2 minimum x x x M0280 Exhaust temperature cylinder 2 maximum x x x M0281 Exhaust temperature cylinder 3 minimum x M0282 Exhaust temperature cylinder 3 maximum x x M0283 Exhaust temperature cylinder 3 minimum x x x M0284 Exhaust temperature cylinder 3 maximum x x x M0285 Exhaust temperature cylinder 4 minimum x M0286 Exhaust temperature cylinder 4 maximum x x M0287 Exhaust temperature cylinder 4 minimum x x x M0288 Exhaust temperature cylinder 4 maximum x x x M0289 Exhaust temperature cylinder 5 minimum x M0290 Exhaust temperature cylinder 5 maximum x x M0291 Exhaust temperature cylinder 5 minimum x x x M0292 Exhaust temperature cylinder 5 maximum x x x M0293 Exhaust temperature cylinder 6 minimum x M0294 Exhaust temperature cylinder 6 maximum x x M0295 Exhaust temperature cylinder 6 minimum x x x M0296 Exhaust temperature cylinder 6 maximum x x x M0297 Exhaust temperature cylinder 7 minimum x M0298 Exhaust temperature cylinder 7 maximum x x M0299 Exhaust temperature cylinder 7 minimum x x x M0300 Exhaust temperature cylinder 7 maximum x x x M0301 Exhaust temperature cylinder 8 minimum x M0302 Exhaust temperature cylinder 8 maximum x x M0303 Exhaust temperature cylinder 8 minimum x x x M0304 Exhaust temperature cylinder 8 maximum x x x M0305 Exhaust temperature cylinder 9 minimum x M0306 Exhaust temperature cylinder 9 maximum x x M0307 Exhaust temperature cylinder 9 minimum x x x M0308 Exhaust temperature cylinder 9 maximum x x x

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index M0309 M0310 M0311 M0312 M0313 M0314 M0315 M0316 M0317 M0318 M0319 M0320 M0321 M0322 M0323 M0324 M0325 M0326 M0328 M0329 M0334 M0335 M0337 M0338 M0346 M0347

M0348

M0349 M0351 M0354 M0355 M0356 M0357

M0358

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message text Exhaust temperature cylinder 10 minimum x Exhaust temperature cylinder 10 maximum x x Exhaust temperature cylinder 10 minimum x x x Exhaust temperature cylinder 10 maximum x x x Exhaust temperature cylinder 11 minimum x Exhaust temperature cylinder 11 maximum x x Exhaust temperature cylinder 11 minimum x x x Exhaust temperature cylinder 11 maximum x x x Exhaust temperature cylinder 12 minimum x Exhaust temperature cylinder 12 maximum x x Exhaust temperature cylinder 12 minimum x x x Exhaust temperature cylinder 12 maximum x x x Exhaust temperature average minimum x Exhaust temperature average maximum x x Exhaust temperature average minimum x x x Exhaust temperature average maximum x x x Exhaust gas temperature bank A maximum x x Exhaust gas temperature bank A maximum x x x Exhaust gas temperature bank B maximum x x Exhaust gas temperature bank B maximum x x x Catalytic converter discharge maximum x x Catalytic converter discharge maximum x x x Catalytic converter temperature differential too low x Catalytic converter temperature differential too low x x Engine speed maximum starting sequence x Engine speed maximum x x x Difference between target power and actual power is too great x x x Power maximum x x x Lambda control deviation maximum x x x Measurement signal malfunction gas meter x x x Measurement signal malfunction gas pressure x x x Measurement signal malfunction intake air valve x x x Measurement signal malfunction exhaust air valve x x x Measurement signal malfunction external power requirement x x x Measurement signal malfunction methane CH4 x x x


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M0360 Measurement signal malfunction electrical cabinet temperature

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M0361

Measurement signal malfunction engine coolant circuit mixer

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M0362 Measurement signal malfunction heating circuit mixer x x x M0363 Measurement signal malfunction heating circuit pressure x x x M0364 Measurement signal malfunction wastegate x x x M0365 Measurement signal malfunction knock sensor bank A x x x M0366 Measurement signal malfunction knock sensor bank B x x x M0367 Measurement signal malfunction lambda bank A x x x M0368 Measurement signal malfunction lambda bank B x x x M0369 Measurement signal malfunction oil pressure x x x M0370 Measurement signal malfunction engine coolant pressure x x x M0371 Measurement signal malfunction mixture coolant pressure x x x M0372 Measurement signal malfunction charging pressure x x x

M0373 Measurement signal malfunction engine coolant intake temperature

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M0374 Measurement signal malfunction engine coolant discharge temperature

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M0375 Measurement signal malfunction heating circuit supply line temperature

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M0376 Measurement signal malfunction heating circuit return line temperature

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M0377 Measurement signal malfunction gas mixture temperature x x x

M0378 Measurement signal malfunction mixture coolant temperature

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M0379 Measurement signal malfunction intake air temperature x x x

M0380 Measurement signal malfunction heating circuit regulation temperature

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M0381 Measurement signal malfunction engine oil temperature x x x M0382 Measurement signal malfunction room air temperature x x x

M0383 Measurement signal malfunction generator bearing A temperature

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M0384 Measurement signal malfunction generator bearing B temperature

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M0387 Measurement signal malfunction exhaust temperature cylinder 1

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M0388 Measurement signal malfunction exhaust temperature x x x

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M0389

M0390

M0391

M0392

M0393

M0394

M0395

M0396

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M0398

M0399

M0400

M0402

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M0404 M0427 M0428 M0429 M0430 M0433 M0434 M0435 M0436 M0437

message text cylinder 2 Measurement signal malfunction exhaust temperature cylinder 3 x x x Measurement signal malfunction exhaust temperature cylinder 4 x x x Measurement signal malfunction exhaust temperature cylinder 5 x x x Measurement signal malfunction exhaust temperature cylinder 6 x x x Measurement signal malfunction exhaust temperature cylinder 7 x x x Measurement signal malfunction exhaust temperature cylinder 8 x x x Measurement signal malfunction exhaust temperature cylinder 9 x x x Measurement signal malfunction exhaust temperature cylinder 10 x x x Measurement signal malfunction exhaust temperature cylinder 11 x x x Measurement signal malfunction exhaust temperature cylinder 12 x x x Measurement signal malfunction exhaust temperature bank A x x x Measurement signal malfunction exhaust temperature bank B x x x Measurement signal malfunction catalytic converter discharge temperature x x Measurement signal malfunction module cabinet temperature x Measurement signal malfunction sulphur content x SPS restart x x Ignition communication malfunctioning x x Headquarters control technology malfunctioning x x x Network analysis communication malfunctioning x x x Generator reverse power level 1 x x x Generator reverse power level 2 x x x Res. Excess current level 1 x Excess current level 2 x x x


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M0438 Excess current level 3 x x x M0439 Excess current level 4 x x x M0440 Res. M0441 Res. M0442 Short circuit level 1 x x x M0443 Short circuit level 2 x x x M0444 Generator excess current level 1 x M0445 Generator excess current level 2 x x x M0446 Generator low voltage level 1 x M0447 Generator low voltage level 2 x x x M0448 Generator low voltage level 3 x x x M0449 Generator overfrequency level 1 x M0450 Generator overfrequency level 2 x x x M0451 Generator overfrequency level 3 x x x M0452 Generator underfrequency level 1 x M0453 Generator underfrequency level 2 x x x M0454 Generator underfrequency level 3 x x x M0455 Busbar overfrequency level 1 x x M0456 Busbar overfrequency level 2 x x M0457 Busbar overfrequency level 3 x x M0458 Busbar underfrequency level 1 x x M0459 Busbar underfrequency level 2 x x M0460 Busbar underfrequency level 3 x x M0461 Busbar underfrequency level 4 x x M0462 Busbar overfrequency level 1 x x M0463 Busbar overfrequency level 2 x x M0464 Busbar overfrequency level 3 x x M0465 Busbar underfrequency level 1 x x M0466 Busbar underfrequency level 2 x x M0467 Busbar underfrequency level 3 x x M0468 Busbar underfrequency level 4 x x M0469 Change of frequency (ROCOF) x x M0470 Vector jump x x M0471 Pos. seq. volt. low x x M0472 Generator overload level 1 x M0473 Generator overload level 2 x x x



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message text Generator overload level 3 x x x Generator overload level 4 x x x Generator overload level 5 x x x Generator current asymmetrical x x Generator voltage asymmetrical x x Idle power import x x Idle power export x x Synchronisation window x x x Synchronisation error generator switch x x x Res. Incorrect rotary field x x x Generator switch opening error x x x Generator switch closing error x x x Generator switch position error x x x Change of frequency (ROCOF) x Time-dependent low voltage 1 activated x Time-dependent low voltage 1 triggered x Time-dependent low voltage 2 activated x Time-dependent low voltage 2 triggered x Low voltage and idle power import 1 x Low voltage and idle power import 2 x Network analysis malfunctioning x x x Network protection 1 externally triggered x x x Network protection 2 externally triggered x x x Network slow-down time active x x x Excess current neutral conductor level 1 x x Excess current neutral conductor level 2 x x x Asymmetrical current level 1 x x Asymmetrical current level 2 x x x Asymmetrical voltage level 1 x x Asymmetrical voltage level 2 x x x Operational x Manual start x Start gas level x Start gas pressure x Start electric supply company external x External start x



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M0551 Start after false start x M0552 Start after network failure x M0558 Normal operation x M0559 Normal operation power reduction active x

M0560 Normal operation electric supply company external power reduction active

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M0561 Lambda control value not reached power reduction x M0570 Maximum number (3) power reduction / hour x M0571 Stop request manual x M0572 Stop request external x M0573 Stop request gas level x M0574 Stop request gas pressure x M0575 Electric supply company external shutdown x x

M0576 Electric supply company – external disconnection from network

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x

M0581 Refill engine oil x M0583 Waiting period starter x M0589 Synchronisation deactivated x M0590 Gas torch operation x M0591 Frost protection heating circuit active x M0592 Engine preheating active x M0593 Anti-condensation heater active x

Documents

agenitor 406 Titelbild - web.vtc.eduweb.vtc.edu/users/zrn10240/manuals/genset/008_Troubleshooting.pdf · Troubleshooting . Troubleshooting. 2G-KWK ® Series - Biogas Combined Heat